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Suzuki DL650/AK7DL650/AK8 Service Manual

Summary of DL650/AK7DL650/AK8

  • Page 1

    Group index general information 1 periodic maintenance 2 engine 3 fi system diagnosis 4 fuel system and throttle body 5 cooling and lubrication system 6 chassis 7 electrical system 8 servicing information 9 10 foreword this manual contains an introductory description on the suzuki dl650 and procedur...

  • Page 2: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 3: Supplements

    11 12 13 supplements dl650k5 ('05- model) dl650k6 ('06- model) dl650/ak7 ('07- model) 14 15 dl650/ak9 (’09-model) dl650/ak8 ('08- model) 16 wiring diagram partshark.Com 877-999-5686.

  • Page 4: How To Use This Manual

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

  • Page 5: Partshark.Com

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply thread loc...

  • Page 6: Abbreviations Used In This

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

  • Page 7: Partshark.Com

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

  • Page 8: Sae-to-Former Suzuki Term

    Sae-to-former suzuki term this table lists sae (society of automotive engineers) j1930 terms and abbreviations which may be used in this manual in compliance with sae recommendations, as well as their former suzuki names. Sae term former suzuki term full term abbreviation a air cleaner b barometric ...

  • Page 9: Partshark.Com

    Sae term former suzuki term full term abbreviation i idle speed control ignition control ignition control module intake air temperature m malfunction indicator lamp manifold absolute pressure mass air flow o on-board diagnostic open loop p programmable read only memory pulsed secondary air injection...

  • Page 10: Partshark.Com

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

  • Page 11: General Information

    General information 1-1 1 general information contents warning/caution/note .........................................................................1- 2 general precautions...........................................................................1- 2 suzuki dl650k4 (’04-model) .......................

  • Page 12: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ! Indicat...

  • Page 13: Partshark.Com

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

  • Page 14: Suzuki Dl650K4 (’04-Model)

    1-4 general information suzuki dl650k4 (’04-model) • difference between photographs and actual motorcycles depends on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head. The engine serial number 2 ...

  • Page 15: Partshark.Com

    General information 1-5 engine oil (for usa) suzuki recommends the use of suzuki performance 4 motor oil or an oil which is rated sf or sg under the api (american petroleum institute) service classification. The recommended viscosity is sae 10w-40. If an sae 10w-40 oil is not available, select and a...

  • Page 16: Break-In Procedures

    1-6 general information anti-freeze/engine coolant the engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends...

  • Page 17: Cylinder Identification

    General information 1-7 cylinder identification the two cylinders of this engine are identified as no.1 and no.2 cylinder, as viewed from front to rear . *5 *4 no.2 no.1 partshark.Com 877-999-5686.

  • Page 18: Information Labels

    1-8 general information information labels a: attached *1: for e-28 (french) *2: except for e-28 *3: for e-28 *4: these labels are attached on the right frame. *5: this label is attached on the up side of chain cover. Dl650 dl650ue 1 noise label a (for e-03, 24, 33) 2 information label a (for e-03, ...

  • Page 19: Specifications

    General information 1-9 specifications dimensions and dry mass overall length ................................................................ 2 290 mm (90.2 in) overall width ................................................................. 840 mm (33.1 in) overall height .............................

  • Page 20: Partshark.Com

    1-10 general information chassis front suspension .......................................................... Telescopic, coil spring, oil damped rear suspension ........................................................... Link type, coil spring, oil damped front fork stroke..............................

  • Page 21: Country And Area Codes

    General information 1-11 country and area codes the following codes stand for the applicable country (-ies) and area (-s). Model code country or area dl650 e-02 e-03 e-19 e-24 e-28 e-33 u.K. U.S.A. (except for california) eu australia canada california (u.S.A.) dl650-ue e-19 eu partshark.Com 877-999...

  • Page 22: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 23: Periodic Maintenance

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

  • Page 24: Partshark.Com

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your conve...

  • Page 25: Partshark.Com

    Periodic maintenance 2-3 note: i=inspect and clean, adjust, replace or lubricate as necessary; r=replace; t=tighten interval item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 brake fluid — i i i i replace every 2 years. Tires — i i i i steering i — i —...

  • Page 26: Partshark.Com

    2-4 periodic maintenance lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 27: Maintenance and Tune-Up Pro-

    Periodic maintenance 2-5 maintenance and tune-up pro- cedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • remove the seat. ( ! 7-4) • remove the fuel tank. ( ! 5-7) • remove the air cleaner box cap 1 . • remove the air cleaner...

  • Page 28: Partshark.Com

    2-6 periodic maintenance note: when cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug. Spark plug no.1 (front) spark plug removal • remove the cowling. ( ! 7-5). • remove the radiator mounting bolt 1 . • move the radiator lower side to forward. • remove th...

  • Page 29: Partshark.Com

    Periodic maintenance 2-7 no.2 (rear) spark plug removal • remove the seat. ( ! 7-4) • lift and support the fuel tank. ( ! 5-7) • remove the spark plug cap. • remove the spark plug with the special tool. $09930-10121: spark plug socket wrench set heat range • check to see the heat range of the plug. ...

  • Page 30: Partshark.Com

    2-8 periodic maintenance spark plug and plug cap installation " • install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque. & spark plug: 11 n·m (1.1 kgf-m, 8.0 lb-ft) note: when fitting the spark plug caps, front and rear, face the triangle mark a...

  • Page 32: Partshark.Com

    2-10 periodic maintenance valve clearance adjustment the clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • remove the intake or exhaust camshafts. ( ! 3-21, 23) • remove the tappet and shim by fingers or magnetic hand. • check the figures printed on the shim...

  • Page 33: Partshark.Com

    Periodic maintenance 2-11 (intake side) measured t appet clearance (mm) suffix no . 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 present shim size (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 0.00...

  • Page 34: Partshark.Com

    2-12 periodic maintenance (exhaust side) measured t appet clearance (mm) suffix no . 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 present shim size (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1.2...

  • Page 35: Partshark.Com

    Periodic maintenance 2-13 fuel line • lift and support the fuel tank. ( ! 5-7) • inspect the fuel feed hose a for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. Engine oil and oil filter oil should be changed while the engine is warm. Oil filter replacement at th...

  • Page 36: Partshark.Com

    2-14 periodic maintenance • start up the engine and allow it to run for several minutes at idling speed. • turn off the engine and wait about one minute, then check the oil level through the inspection window a . If the level is below mark “l”, add oil to “f” level. If the level is above mark “f”, d...

  • Page 37: Partshark.Com

    Periodic maintenance 2-15 engine idle speed note: make this adjustment when the engine is hot. • start up the engine and set its idle speed to the specified range by turning the throttle stop screw 1 . % engine idle speed: 1 300 ± 100 r/min throttle cable play adjust the throttle cable play a with t...

  • Page 38: Partshark.Com

    2-16 periodic maintenance major adjustment • remove the fuel tank. ( ! 5-7) • remove the air cleaner box. ( ! 5-15) • loosen the lock-nut 1 of the throttle returning cable. • turn the returning cable adjuster 2 to obtain proper cable play. • loosen the lock-nut 3 of the throttle pulling cable. • tur...

  • Page 39: Partshark.Com

    Periodic maintenance 2-17 clutch • loosen the lock-nut 1 and turn the adjuster 2 all the way into the clutch lever assembly. • remove the engine sprocket cover. • loosen the lock-nut 3 and turn out the adjusting screw 4 two or three rotations. • from that position, slowly turn the adjuster screw 3 i...

  • Page 40: Partshark.Com

    2-18 periodic maintenance cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank. A full line b lower line • if the level is below the lower line, add engine coolant to the ful...

  • Page 41: Partshark.Com

    Periodic maintenance 2-19 air bleeding the cooling circuit • add engine coolant up to the radiator inlet. • support the motorcycle upright. • slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • add engine coolant up to the radiator inlet. • start up the en...

  • Page 42: Partshark.Com

    2-20 periodic maintenance radiator hoses • remove the cowling. ( ! 7-5) • check to see the radiator hoses for crack, damage or engine coolant leakage. • if any defects are found, replace the radiator hoses with new ones. Drive chain visually check the drive chain for the possible defects listed belo...

  • Page 43: Partshark.Com

    Periodic maintenance 2-21 • count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. % drive chain 20-pitch length service limit: 319.4 mm (12.57 in) adjusting • loosen or tighten both chain ad...

  • Page 44: Partshark.Com

    2-22 periodic maintenance cleaning and lubricating • wash the chain with kerosene. If the chain tends to rust quickly, the intervals must be shortened. " • after washing and drying the chain, oil it with a heavy-weight motor oil. " brake brake fluid level check • keep the motorcycle upright and plac...

  • Page 45: Partshark.Com

    Periodic maintenance 2-23 # # brake pads • remove the brake caliper. (front) • the extent of brake pad wear can be checked by observing the grooved limit a on the pad. When the wear exceeds the grooved limit, replace the pads with the new ones. ( ! 7-59 and - 69) " the brake system of this motorcycl...

  • Page 46: Partshark.Com

    2-24 periodic maintenance brake pedal height • loosen the lock-nut 1 and rotate the push rod 2 to locate brake pedal 20 – 30 mm (0.59 – 0.98 in) a below the top face of the footrest. • retighten the lock-nut 1 to secure the push rod 2 in the proper position. % brake pedal height a: 20 – 30 mm (0.79 ...

  • Page 47: Partshark.Com

    Periodic maintenance 2-25 air bleeding the brake fluid circuit air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of air is indic...

  • Page 48: Partshark.Com

    2-26 periodic maintenance tire tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification...

  • Page 49: Partshark.Com

    Periodic maintenance 2-27 front fork inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( ! 7-17) rear suspension inspect the damper for oil leakage and the spring unit for dam- age. Check that there is no...

  • Page 50: Partshark.Com

    2-28 periodic maintenance chassis bolt and nut check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-29 for the loca- tions of the following nuts and bolts on the motorcycle.) tighten initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles...

  • Page 51: Partshark.Com

    Periodic maintenance 2-29 partshark.Com 877-999-5686.

  • Page 52: Compression Pressure Check

    2-30 periodic maintenance compression pressure check the compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compressi...

  • Page 53: Oil Pressure Check

    Periodic maintenance 2-31 oil pressure check check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pressure * clog...

  • Page 54: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 55: Engine

    Engine 3-1 engine contents 3 engine components removable with the engine in place ....3- 2 engine removal and installation...................................................3- 3 engine removal ................................................................................3- 3 engine installation......

  • Page 56: Partshark.Com

    3-2 engine engine components removable with the engine in place engine components which can be removed while the engine is installed on the chassis are listed below. For the installing and removing procedures, refer to respective paragraphs describing each component. Engine left side engine right si...

  • Page 57: Partshark.Com

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • drain the engine oil. ( ! 2-13) • dr...

  • Page 58: Partshark.Com

    3-4 engine • remove the throttle body. ( ! 5-16) • disconnect the spark plug caps. • remove the left side frame cover. ( ! 7-5) • disconnect the gear position switch lead wire coupler 1 . • disconnect the generator lead wire coupler 2 and ckp sen- sor lead wire coupler 3 . • remove the ect sensor le...

  • Page 59: Partshark.Com

    Engine 3-5 • remove the gearshift lever 1 . • remove the engine sprocket cover 2 . • remove the clutch release assembly 3 , its support plate 4 and spring 5 . • remove the clutch push rod 6 . • remove the clutch cable from the generator cover. Note: if it is necessary to replace the clutch cable or ...

  • Page 60: Partshark.Com

    3-6 engine • remove the cotter pin. (for e-03, 28, 33) • loosen the rear axle nut 1 . • loosen the chain adjusters 2 . • remove the engine sprocket 3 . • disconnect the engine ground lead wire 4 . • disconnect the ho2 sensor lead wire coupler 5 and release the ho2 sensor lead wire from the clamp 6 ....

  • Page 61: Partshark.Com

    Engine 3-7 • remove the muffler mounting bolt 1 . • loosen the front exhaust pipe mounting bolts 2 . • remove the front exhaust pipe 3 . • loosen the rear exhaust pipe mounting bolts. • remove the muffler. • remove the right footrest bracket mounting bolts. • remove the oil cooler 4 . Partshark.Com ...

  • Page 62: Partshark.Com

    3-8 engine • disconnect the starter motor lead wire 1 and oil pressure switch lead wire 2 . • support the engine with an engine jack. • remove the engine mounting nut 3 and bolt 4 . • loosen the engine mounting thrust adjuster lock-nut with the special tool. " 09940-14990: engine mounting thrust adj...

  • Page 63: Partshark.Com

    Engine 3-9 • remove the left engine mounting bracket 1 . • disconnect the ignition coil lead wires 2 . • disconnect the water hose clamp 3 . • remove the engine mounting nut. • loosen the engine mounting thrust adjuster lock-nut. " 09940-14990: engine mounting thrust adjuster socket wrench • loosen ...

  • Page 64: Partshark.Com

    3-10 engine • loosen the pinch bolt 1 . • gradually lower the engine assembly by removing the bolt 2 , 3 . # be careful not to damage the frame and engine when removing the engine from the frame. Partshark.Com 877-999-5686.

  • Page 65: Partshark.Com

    Engine 3-11 engine installation remount the engine in the reverse order of engine removal. Pay attention to the following points: note: * the engine mounting nuts are self-locking. * once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the spec...

  • Page 66: Partshark.Com

    3-12 engine • before installing the engine assembly, install the spacer a , collar b and engine thrust adjuster c . • install the collar 1 onto the crankcase properly as shown. • install the left engine mounting bracket 2 . • apply thread lock to the engine mounting bracket bolts. • tighten the engi...

  • Page 67: Partshark.Com

    Engine 3-13 • put the drive chain on the driveshaft. • gradually raise the engine assembly and align all the bolt holes. • install the engine mounting bolts and tighten them tempo- rarily. • tighten the engine mounting thrust adjusters to the specified torque. $ engine mounting thrust adjuster: 12 n...

  • Page 68: Partshark.Com

    3-14 engine • install the washers and tighten the union bolt to the specified torque. $ oil cooler union bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • install the new gaskets. • apply thread lock to the muffler mounting bolt. % 99000-32050: thread lock “1342” partshark.Com 877-999-5686.

  • Page 69: Partshark.Com

    Engine 3-15 $ • adjust the brake pedal height. & brake pedal height a standard: 20 – 30 mm (0.79 – 1.18 in) • install the gearshift arm as shown. & gearshift arm angle a: approx. 63.6 ° apply parmatex 1372 apply parmatex 1372 item n·m kgf-m lb-ft abcd 23 2.3 16.5 63.6 ˚ partshark.Com 877-999-5686.

  • Page 70: Partshark.Com

    3-16 engine • adjust the gearshift lever as shown. & gearshift lever height a standard: 20 – 30 mm (0.79 – 1.18 in) • install the engine sprocket. • install the engine sprocket and the washer. • apply a small quantity of thread lock to the drive shaft thread portion. % 99000-32050: thread lock “1342...

  • Page 71: Partshark.Com

    Engine 3-17 • install the clutch cable to the generator cover temporarily. • apply suzuki moly paste to the clutch release. ( 99000-25140: suzuki moly paste \ • assemble the clutch release so that the lever arm a will be angle of 80 degree with axle b . • adjust the clutch cable play. ( ! 2-17) note...

  • Page 72: Partshark.Com

    3-18 engine • after installing the engine, route the wire harness, cables and hoses properly. ( ! 9-16) • adjust the following items. * engine oil ( ! 2-14) * engine coolant ( ! 2-19) * engine idle speed ( ! 2-15) * throttle cable play ( ! 2-15) * clutch cable play ( ! 2-17) * throttle body synchron...

  • Page 73: Engine Disassembly

    Engine 3-19 engine disassembly engine top side # • remove the spark plugs. ( ! 2-6) • disconnect the crankcase breather hoses 1 . • disconnect the pair hoses 2 . • remove the thermostat case 3 along with the hoses 4 . Note: refer to the section 6 for their servicing. • remove the water unions 5 and ...

  • Page 74: Partshark.Com

    3-20 engine • remove the oil cooler bracket 7 . • remove the rear exhaust pipe 8 and gasket. • remove the valve timing inspection plug 9 and generator cover plug 0 . Cylinder head cover • remove the front cylinder head cover 1 . • remove the dowel pin 2 and o-ring 3 . Partshark.Com 877-999-5686.

  • Page 75: Partshark.Com

    Engine 3-21 • remove the rear cylinder head cover 4 . • remove the dowel pin 5 and o-ring 6 . Front camshafts • turn the crankshaft to bring the “ f” line a on generator rotor to the index mark b of the valve inspection hole and also to bring the cams to the position as shown in illustration. Note: ...

  • Page 76: Partshark.Com

    3-22 engine • remove the spring holder bolt 2 , spring and gasket. • remove the cam chain tension adjuster 3 . • remove the intake camshaft journal holder 4 . • remove the exhaust camshaft journal holder 5 . Note: mark the cylinder location as “f” to the camshaft journal holders. • remove the dowel ...

  • Page 77: Partshark.Com

    Engine 3-23 • remove the cylinder head gasket 5 , dowel pins 6 and cam chain guide 7 . Front cylinder • remove the cylinder nuts 1 . • remove the cylinder 2 . • remove the cylinder base gasket 3 and dowel pins 4 . Note: make sure that the oil jet is inserted in the crankcase. Front piston • place a ...

  • Page 78: Partshark.Com

    3-24 engine note: * at the above condition, the rear cylinder is at atdc 90 ° on expansion stroke. * before removing the camshafts, inspect the valve clearance. ( ! 2-8) • remove the cam chain guide 1 . • remove the cam chain tension adjuster cap bolt 2 , spring and gasket. • remove the cam chain te...

  • Page 79: Partshark.Com

    Engine 3-25 rear cylinder head • remove the cylinder head bolt (m6) 1 . • remove the cylinder bolts (m6) 2 . • remove the cylinder head bolts 3 and washers. Note: when loosening the cylinder head bolts, loosen each bolt little by little diagonally. • remove the cylinder head 4 . • remove the cylinde...

  • Page 80: Partshark.Com

    3-26 engine rear piston • place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. • remove the piston pin circlip 1 . • remove the piston 2 by driving out the piston pin. Note: scribe the cylinder number on the head of the piston. Starter motor • remove ...

  • Page 81: Partshark.Com

    Engine 3-27 clutch cover • remove the clutch cover 1 . • remove the dowel pins 2 and gasket 3 . Clutch • hold the generator rotor 1 with the special tool. " 09930-44530: rotor holder • remove the clutch springs. Note: loosen the clutch spring set bolts little by little and diagonally. • remove the p...

  • Page 82: Partshark.Com

    3-28 engine • remove the clutch push rod 6 . Note: if it is difficult to pull out the push rod 6 , use a magnetic hand or a wire. • remove the clutch drive plates and driven plates. • remove the spring washer 7 and spring washer seat 8 . • flatten the clutch sleeve hub nut lock washer. • hold the cl...

  • Page 83: Partshark.Com

    Engine 3-29 • remove the lock washer 9 . • remove the clutch sleeve hub 0 . • remove the thrust washer a . • remove the primary driven gear assembly b . • remove the spacer c . Oil pump • remove the snap ring 1 . • remove the oil pump driven gear 2 . Note: do not drop the snap ring 1 into the crankc...

  • Page 84: Partshark.Com

    3-30 engine • remove the oil pump 5 . Gearshift system • remove the snap ring 1 and washer 2 . • remove the gearshift shaft assembly 3 and washer 4 . • remove the gearshift cam plate bolt 5 . • remove the gearshift cam plate 6 . • remove the gearshift cam stopper 7 . Partshark.Com 877-999-5686.

  • Page 85: Partshark.Com

    Engine 3-31 • remove the following parts. 8 gearshift cam stopper bolt 9 gearshift cam stopper spring 0 washer oil pipe • remove the oil pipe stopper 1 . • remove the oil pipe 2 . Primary drive gear • hold the generator rotor with the special tool. " 09930-44530: rotor holder • remove the primary dr...

  • Page 86: Partshark.Com

    3-32 engine • remove the water pump drive gear 1 and primary drive gear 2 . Rear cam chain • remove the cam chain tensioner 1 . Note: do not drop the washer 2 into the crankcase. • remove the rear cam chain 3 and cam chain drive sprocket 4 . Generator rotor • hold the generator rotor with the specia...

  • Page 87: Partshark.Com

    Engine 3-33 • remove the key 2 . • remove the starter driven gear 3 . Front cam chain • remove the cam chain tensioner 1 . Note: do not drop the washer 2 into the crankcase. • remove the front cam chain 3 . Gear position switch • remove the driveshaft oil seal retainer 1 . • remove the gear position...

  • Page 88: Partshark.Com

    3-34 engine • remove the o-ring 3 . • remove the switch contacts 4 and springs 5 . Crankcase • remove the oil plate 1 . • remove the crankcase bolts and clamp 2 . Note: loosen the crankcase bolts diagonally and smaller sizes first. • separate the crankcase into 2 parts, right and left with the speci...

  • Page 89: Partshark.Com

    Engine 3-35 • remove the o-rings 3 and dowel pins 4 . Crankshaft • remove the crankshaft 1 . Transmission • remove the gearshift fork shafts 1 . • remove the gearshift cam 2 . • remove the gear shift forks 3 . • remove the driveshaft assembly 4 and countershaft assem- bly 5 . • remove the engine spr...

  • Page 90: And Servicing

    3-36 engine engine components inspection and servicing cylinder head cover disassembly # • remove the pair reed valve cover 1 . Inspection inspect the pair reed valve for damage and the carbon deposit. If any damage or the carbon deposit is found in the reed valve, replace it with a new one. Reassem...

  • Page 91: Partshark.Com

    Engine 3-37 • apply thread lock to the bolts and then install the pair reed valve cover. % 99000-32050: thread lock “1342” note: the inlet pipe of the pair reed valve cover must face left side of the engine. Camshaft/camshaft journal # camshaft • all camshafts should be checked for runout and also f...

  • Page 92: Partshark.Com

    3-38 engine cam wear worn-down cams are often the cause of mistimed valve opera- tion resulting in reduced power output. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height h , which is to be measured with a micrometer. Replace camshaft if it wears worn down to...

  • Page 93: Partshark.Com

    Engine 3-39 if the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification. & journal holder i.D. S...

  • Page 94: Partshark.Com

    3-40 engine cam chain guide check the contacting surface of the cam chain guide. If it is worn or damaged, replace it with a new one. Cylinder head valve and valve spring disassembly • remove the tappets 1 and shims 2 by fingers or magnetic hand. # • using special tools, compress the valve springs a...

  • Page 95: Partshark.Com

    Engine 3-41 • pull out the valve from the other side. • remove the oil seals 6 and spring seats 7 . # cylinder head distortion decarbonize the combustion chambers. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at se...

  • Page 96: Partshark.Com

    3-42 engine valve head radial runout place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. If it measures more than the service limit, replace the valve. & valve head radial runout service limit: 0.03 mm (0.001 in) " 09900-20607: dial gauge (1/100 mm)...

  • Page 97: Partshark.Com

    Engine 3-43 valve guide servicing • using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. " 09916-43210: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement part...

  • Page 98: Partshark.Com

    3-44 engine valve seat width inspection visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. • coat the valve seat with prussian blue and set the valve in place.Rotate the valve with light pressure. • check that the transferred blue on the...

  • Page 99: Partshark.Com

    Engine 3-45 initial seat cut • using the 45 ° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • measure the valve seat width w after every cut. Note: cut only the minimum amount necessary from the seat to pre- vent the possibility of the valve stem becoming too close to th...

  • Page 100: Partshark.Com

    3-46 engine final seat cut • if the contact area w is too low or too narrow, use the 45 ° cutter to raise and widen the contact area. Note: * after cutting the 15 °, 30 ° and 60 ° angles, it is possible that the valve seat (45 °) is too narrow. If so, re-cut the valve seat to the correct width. * co...

  • Page 101: Partshark.Com

    Engine 3-47 valve stem end condition • check the valve stem end face for pitting and wear. Valve spring the force of the coil springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • ...

  • Page 102: Partshark.Com

    3-48 engine valve and valve spring installation • install the valve spring seats 1 . • apply engine oil to each oil seal 2 . • install the oil seal. # • insert the valves, with their stems coated with molybde- num oil solution all around and along the full stem length without any break. # * molybden...

  • Page 103: Partshark.Com

    Engine 3-49 • install the tappet shim and the tappet to their original position. Note: * before installing them, apply engine oil to the shims and tap- pets all over, also to the tappet chambers on the cylinder head. * when seating the tappet shim, be sure the figure printed sur- face faces the tapp...

  • Page 104: Partshark.Com

    3-50 engine cylinder cylinder distortion check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. &...

  • Page 105: Partshark.Com

    Engine 3-51 piston and piston ring piston diameter • using a micrometer, measure the piston outside diameter at 20 mm (0.79 in) a from the piston skirt end. If the measurement is less than the limit, replace the piston. & piston diameter service limit: 80.88 mm (3.184 in) at 20 mm (0.79 in) from the...

  • Page 106: Partshark.Com

    3-52 engine & piston ring groove width standard (1st) : 1.21 – 1.23 mm (0.0476 – 0.0484 in) (2nd): 1.01 – 1.03 mm (0.0398 – 0.0406 in) (oil) : 2.01 – 2.03 mm (0.0791 – 0.0799 in) & piston ring thickness standard (1st) : 1.17 – 1.19 mm (0.0461 – 0.0469 in) (2nd): 0.97 – 0.99 mm (0.0382 – 0.0390 in) "...

  • Page 107: Partshark.Com

    Engine 3-53 oversize oil ring the following two types of oversize oil rings are available as optional parts. They bear the following identification marks. • measure the outside diameter to identify the size. 1 oil ring spacer a paint piston pins and pin bore measure the piston pin bore inside diamet...

  • Page 108: Partshark.Com

    3-54 engine conrod big end side clearance check the conrod side clearance by using a thickness gauge. If the clearance exceeds the limit, replace conrod or crankshaft. & conrod big end side clearance service limit: 0.50 mm (0.020 in) " 09900-20803: thickness gauge conrod big end width check the conr...

  • Page 109: Partshark.Com

    Engine 3-55 conrod-crank pin bearing selection • place the plastigauge axially along the crank pin, avoiding the oil hole, at tdc or bdc side as shown. " 09900-22301: plastigauge 09900-22302: plastigauge • tighten the conrod cap bolts to the specified torque, in two stages. ( ! 3-57) # • remove the ...

  • Page 110: Partshark.Com

    3-56 engine & conrod i.D. & crank pin o.D. " 09900-20202: micrometer (25 – 50 mm) & bearing thickness # a color code conrod and bearing reassembly • when fitting the bearings to the bearing cap and conrod, be sure to fix the stopper part a first and press in the other end. # • apply molybdenum oil s...

  • Page 111: Partshark.Com

    Engine 3-57 • when fitting the conrods on the crankshaft, make sure that i.D. Codes a of the conrods face each cylinder intake valve sides. • apply engine oil to the thread and flange of the bearing cap bolts. • tighten the bearing cap bolt as following two steps. $ conrod bearing cap bolt (initial)...

  • Page 112: Partshark.Com

    3-58 engine oil pressure switch • remove the oil pressure switch 1 . • inspect the oil pressure switch. ( ! 8-34) • apply suzuki bond to the thread part of the oil pressure switch 1 and tighten it to the specified torque. + 99104-31140: suzuki bond “1207b” (usa) 99000-31140: suzuki bond “1207b” (oth...

  • Page 113: Partshark.Com

    Engine 3-59 • install the oil strainer 3 . Note: fit the projection a of the oil strainer 3 in the concave portion of the crankcase. • install the oil strainer plate 2 and tighten the oil starainer plate screw to the specified torque. $ oil strainer plate screw: 10 n·m (1.0 kgf-m, 7.0 lb-ft) oil jet...

  • Page 114: Partshark.Com

    3-60 engine inspection and cleaning • check the oil jets for clogging. • if they are clogged, clean their oil passage with a proper wire and compressed air. 1 piston cooling oil jet (#13) 2 oil jet (#14) (for transmission) 3 oil jet (#14) (for each cylinder head) installation • fit the new o-rings t...

  • Page 115: Partshark.Com

    Engine 3-61 crankshaft journal bearing inspection • inspect the crankshaft journal bearings for any damage. • if any, replace them with a specified set of bearings. Selection • inspect the crankshaft journal for any damage. • measure the crankshaft journal o.D. With the special tool. & crankshaft jo...

  • Page 116: Partshark.Com

    3-62 engine & bearing thickness # a color code replacement use the special tool to replace the crankshaft journal bearings. The replacement procedure is as follows. • set the special tool as shown to remove the crankshaft journal bearings with the special tool. " 09913-60221: journal bearing remover...

  • Page 117: Partshark.Com

    Engine 3-63 • gradually press out the bearing with the special tool by using the hand-press. # 1 hand-press 2 crankcase 3 bearing note: using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following s...

  • Page 118: Partshark.Com

    3-64 engine • tighten the special tool bolts to the specified torque. $ special tool bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) # • set the bearings installed in the special tool to the crankcase half as shown. # note: install the bearing from inside to outside of each crankcase halves. Before installing ...

  • Page 119: Partshark.Com

    Engine 3-65 • apply enough engine oil to the special tool and the bearings and then set the special tool carefully. • gradually press 1 in the bearing 2 into the main journal bore by using the hand-press until the special tool 3 contacts the special tool 4 . Note: using the hand-press is recommended...

  • Page 120: Partshark.Com

    3-66 engine crankcase bearing and oil seal inspection rotate the bearing inner race by finger to inspect for abnormal play a , noise and smooth rotation while the bearings are in the crankcase. Replace the bearing with new ones, if there is anything unusual. Inspect the oil seals for any damage. Rem...

  • Page 121: Partshark.Com

    Engine 3-67 • remove the crankcase bearings by with the special tool. " 09921-20240: bearing remover set note: select the suitable size attachment as following illustration. Bearing remover attachment 1 - 25 mm 2 - 17 mm 3 - 20 mm a left crankcase b right crankcase partshark.Com 877-999-5686.

  • Page 122: Partshark.Com

    3-68 engine installation • install the crankcase bearings and oil seals with the special tool. " 09913-70210: bearing installer set note: select the suitable size attachment as following illustration. Bearing installer attachment • apply suzuki super grease to the oil seal lip. ' 99000-25030: suzuki...

  • Page 123: Partshark.Com

    Engine 3-69 clutch clutch drive plates note: wipe off engine oil from the clutch drive plates with a clean rag. • measure the thickness of drive plates with a vernier calipers. • if each drive plate is not within the standard range, replace it with a new one. & drive plate thickness standard: 2.92 –...

  • Page 124: Partshark.Com

    3-70 engine clutch bearing inspection smooth engagement and disengagement of the clutch depends on the condition of this bearing. Inspect the clutch release bearing for any abnormality, particu- larly cracks, to decide whether it can be reused or should be replaced. Clutch sleeve hub/primary driven ...

  • Page 125: Partshark.Com

    Engine 3-71 • install the snap ring 2 . Gearshift shaft/gearshift arm disassembly • remove the following parts from the gearshift shaft/gearshift arm. 1 washer 5 washer 2 snap ring 6 plate return spring 3 gearshift shaft return spring 7 gearshift cam drive plate 4 snap ring inspection check the gear...

  • Page 126: Partshark.Com

    3-72 engine transmission countershaft disassembly # • remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2 . • remove the concaved washer 3 and o-ring 4 . • slide the 6th 5 and 2nd drive gears 6 toward the 3rd/4th drive gears 7 , then remove the 2nd dr...

  • Page 127: Partshark.Com

    Engine 3-73 • remove the 5th drive gear bushing d . Driveshaft disassembly • remove the washer 1 and 1st driven gear 2 . • remove the 1st driven gear bushing 3 , washer 4 and 5th driven gear 5 . • remove the snap ring 6 , washer 7 and 4th driven gear 8 . • remove the 4th driven gear bushing 9 , lock...

  • Page 128: Partshark.Com

    3-74 engine • remove the 3rd driven gear bushing b and washer c . • remove the snap ring d and 6th driven gear e . • remove the snap ring f and 2nd driven gear bushing g . • remove the 2nd driven gear h . Inspection inspect the each gear and bushing for wear and damage. If they are found to be damag...

  • Page 129: Partshark.Com

    Engine 3-75 reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: • before installing the gears, lightly coat moly paste or engine oil to the driveshaft and countershaft. ( 99000-25140: suzuki moly paste • before installing th...

  • Page 130: Partshark.Com

    3-76 engine \ # 1 6th drive gear bushing 2 3rd driven gear bushing 3 4th driven gear bushing • after installing the 3rd driven gear 4 onto the driveshaft, install lock washer no.2 5 onto the driveshaft, and position it so it fits into the groove. • then, fit lock washer no.1 6 into lock washer no.2 ...

  • Page 131: Partshark.Com

    Engine 3-77 1 1st (low) drive gear/countershaft 7 5th driven gear 2 5th drive gear 8 4th driven gear 3 3rd/4th drive gear 9 3rd driven gear 4 6th (top) drive gear 0 6th (top) driven gear 5 2nd drive gear a 2nd driven gear 6 1st (low) driven gear a 145 n·m (14.5 kgf·m, 105 lb-ft) partshark.Com 877-99...

  • Page 132: Partshark.Com

    3-78 engine gearshift fork to groove clearance using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. & shift fork to groove clearance service limi...

  • Page 133: Partshark.Com

    Engine 3-79 starter clutch inspection install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns in one direction only. If a large resistance is felt for rotation, inspect the starter clutch or ...

  • Page 134: Partshark.Com

    3-80 engine • be sure to seat the flange a of the one way clutch 3 to the guide 4 . • install the guide 5 to the generator rotor with the arrow mark b faced upward. • apply thread lock super to the bolts and tighten them to the specified torque. , 99000-32030: thread lock super “1303” $ starter clut...

  • Page 135: Partshark.Com

    Engine 3-81 oil pump inspection rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly. # clutch release inspection • check the teeth of clutch release for any damage and wear. * do not attempt to disassemble the oil pump assem- bly....

  • Page 136: Engine Reassembly

    3-82 engine engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Engine bottom side transmission • install t...

  • Page 137: Partshark.Com

    Engine 3-83 crankshaft • coat lightly molybdenum oil solution to the crankshaft journal bearings. * molybdenum oil solution • install the crankshaft into the left crankcase half. # crankcase • clean the mating surfaces of the left and right crankcase halves. • install the o-rings 1 , 2 and dowel pin...

  • Page 138: Partshark.Com

    3-84 engine • when securing the right and left crankcase halves, tighten each bolt a little at a time to equalize the pressure. Tighten all the securing bolts to the specified torque values. $ crankcase bolt: (m8) 26 n·m (2.6 kgf-m, 19.0 lb-ft) (m6) 11 n·m (1.1 kgf-m, 8.0 lb-ft) # note: * after the ...

  • Page 139: Partshark.Com

    Engine 3-85 gear position switch • install the gear position switch contacts 1 and springs. • apply suzuki super grease to the o-ring 2 and then install it onto the gear position switch. ' 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the gear pos...

  • Page 140: Partshark.Com

    3-86 engine generator rotor • install the starter driven gear 1 . • apply engine oil to the bushing of the starter driven gear. • degrease the tapered portions a of the generator rotor assembly and the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these sur...

  • Page 141: Partshark.Com

    Engine 3-87 rear cam chain • install the rear cam chain 1 . • install the cam chain tensioner 2 , washer 3 and cam chain tensioner bolt 4 . • tighten the cam chain tensioner bolt 4 to the specified torque. $ cam chain tensioner bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) note: the front and rear cam chain t...

  • Page 142: Partshark.Com

    3-88 engine oil pipe • install the oil pipe 1 . • tighten the oil pipe stopper screw 2 to the specified torque. $ oil pipe stopper screw: 8 n·m (0.8 kgf-m, 6.0 lb-ft) note: align the projection a of the oil pipe with the groove b of its stopper. Gearshift system • install the gearshift cam stopper 1...

  • Page 143: Partshark.Com

    Engine 3-89 • apply a small quantity of thread lock to the gearshift cam stopper plate bolt and tighten it to the specified torque. % 99000-32050: thread lock “1342” $ gearshift cam stopper plate bolt: 13 n·m (1.3 kgf-m, 9.5 lb-ft) • install the gearshift shaft/gearshift arm 7 with the washer 8 as s...

  • Page 144: Partshark.Com

    3-90 engine • install the washer 1 and pin 2 . • install the oil pump driven gear 3 . • install the snap ring 4 . Clutch • install the spacer 1 and apply engine oil to it. • install the primary driven gear assembly 2 onto the counter- shaft. Note: be sure to engage the oil pump drive and driven gear...

  • Page 145: Partshark.Com

    Engine 3-91 • hold the clutch sleeve hub with the special tool. " 09920-53740: clutch sleeve hub holder • tighten the clutch sleeve hub nut to the specified torque. $ clutch sleeve hub nut: 50 n·m (5.0 kgf-m, 36.0 lb-ft) • bend the lock washer to lock the nut securely. • install the spring washer se...

  • Page 146: Partshark.Com

    3-92 engine • install the clutch push rod b into the countershaft. • install the clutch push piece c , the bearing d and thrust washer e to the countershaft. Note: thrust washer e is located between the pressure plate and bearing d . • hold the generator rotor (crankshaft) with the special tool. " 0...

  • Page 147: Partshark.Com

    Engine 3-93 • install the clutch cover. Generator cover • apply molybdenum oil solution to both ends of the shaft 1 . * molybdenum oil solution • install the starter idle gear 2 and shaft 1 . • install the dowel pins 3 and gasket 4 . # • install the generator cover. $ generator cover bolt: 10 n·m (1...

  • Page 148: Partshark.Com

    3-94 engine starter motor • install the new o-ring to the starter motor. # • apply suzuki super grease to the o-ring. ' 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the starter motor 1 . • tighten the starter motor mounting bolts with the clamp 2...

  • Page 149: Partshark.Com

    Engine 3-95 • 1st ring 5 and 2nd ring 6 have letters “t” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. • position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located. A 2nd ring an...

  • Page 150: Partshark.Com

    3-96 engine oil jet • apply suzuki super grease to the new o-rings. ' 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • apply engine oil to the oil jet holes on the crankcase. • install each of the oil jet (#14) to the left and right crankcase, as shown in th...

  • Page 151: Partshark.Com

    Engine 3-97 • apply engine oil to the sliding surface of the cylinders. Note: the front and rear cylinders can be distinguished by the embossed-letters a . “front” : front cylinder “rear” : rear cylinder • hold the piston rings in proper position, and insert each of the piston into the respective cy...

  • Page 152: Partshark.Com

    3-98 engine • fit the dowel pins 2 and new cylinder head gasket 3 to the cylinder. # • install the washers 4 to the cylinder head bolts (m10) 5 as shown. • apply engine oil to the washers and thread portion of the bolts before installing the cylinder head bolts. • place the rear cylinder head on the...

  • Page 153: Partshark.Com

    Engine 3-99 • install the front cylinder head in same manner as the rear cyl- inder head installation. Cam shaft • the cam shafts are identified by the embossed letters. Inf : no.1 (front) intake camshaft 1 exf : no.1 (front) exhaust camshaft 2 inr : no.2 (rear) intake camshaft 3 exr : no.2 (rear) e...

  • Page 154: Partshark.Com

    3-100 engine • the other arrow mark “2” on the exhaust camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark “2” count out 16 roller pins (from the exhaust camshaft side going towards the intake camshaft side). Engage the 16 roller p...

  • Page 155: Partshark.Com

    Engine 3-101 • tighten the camshaft journal holder bolts to the specified torque. $ camshaft journal holder bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) # • recheck the front camshaft positions, intake and exhaust. Cam chain tension adjuster • with the spring holder bolt and spring removed from the cam chain...

  • Page 156: Partshark.Com

    3-102 engine • install the cam chain guide 7 . No.2 (rear) camshafts • from the position where the front camshafts have now been installed, rotate the generator rotor 360 degrees (1 turn) coun- terclockwise and align the “ f” line a on the generator rotor with the index mark b of the valve timing in...

  • Page 157: Partshark.Com

    Engine 3-103 • the other arrow mark “2” on the intake camshaft sprocket should now be pointing straight up. Starting from the roller pin that is directly above the arrow mark “2” count out 16 roller pins (from the intake camshaft side going towards the exhaust camshaft side). Engage the 16th roller ...

  • Page 158: Partshark.Com

    3-104 engine • apply engine oil to the camshaft journal holders. • install the camshaft journal holders, intake and exhaust. • fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. Note: * align the flange e of the camshafts with the ...

  • Page 159: Partshark.Com

    Engine 3-105 no.1 (front) cylinde tdc of compression stroke 1 cam chain guide 2 cam chain guide a forward 2 1r 3 1f 2 1r 3 1f 2 1r 3 1f 2 1r 3 1f partshark.Com 877-999-5686.

  • Page 160: Partshark.Com

    3-106 engine cylinder head cover • pour engine oil in each oil pocket in the front and rear cylinder heads. Note: be sure to check the valve clearance. ( ! 2-8) • install the dowel pins 1 and o-rings 2 . • install the new gaskets to each cylinder head cover. • apply suzuki bond to the cam end caps o...

  • Page 161: Partshark.Com

    Engine 3-107 exhaust pipe • tighten the exhaust pipe bolts 1 to the specified torque. $ exhaust pipe bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) # water union • install the o-ring to the water union. # • when installing the water union, apply engine coolant to the o-ring. / engine coolant intake pipe • app...

  • Page 162: Partshark.Com

    3-108 engine generator cover plug • apply engine oil to the o-ring of the generator cover plug. • tighten the valve timing inspection plug 1 and generator cover plug 2 to the specified torque. $ valve timing inspection plug: 23 n·m (2.3 kgf-m, 16.3 lb-ft) generator cover plug: 11 n·m (1.1 kgf-m, 8.0...

  • Page 163: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 164: Fi System Diagnosis

    Fi system diagnosis contents precautions in servicing.................................................................... 4- 2 electrical parts............................................................................. 4- 2 fuse ........................................................................

  • Page 165: Partshark.Com

    Fi system diagnosis 4-1 4 sensors ......................................................................................................4-49 ckp sensor inspection ..................................................................4-49 ckp sensor removal and installation .................................

  • Page 166: Precautions In Servicing

    4-2 fi system diagnosis precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock type ...

  • Page 167: Partshark.Com

    Fi system diagnosis 4-3 • when connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- mi...

  • Page 168: Partshark.Com

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

  • Page 169: Partshark.Com

    Fi system diagnosis 4-5 electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are as...

  • Page 170: Partshark.Com

    4-6 fi system diagnosis continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c . 1 ecm • disconnect the coupler b and measure resistance between couplers a and b . I...

  • Page 171: Partshark.Com

    Fi system diagnosis 4-7 short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/couple...

  • Page 172: Partshark.Com

    4-8 fi system diagnosis using testers • use the suzuki multi-circuit tester set (09990-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of the tester to burn...

  • Page 173: Fi System Technical Features

    Fi system diagnosis 4-9 fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These...

  • Page 174: Partshark.Com

    4-10 fi system diagnosis compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant tempe...

  • Page 175: Partshark.Com

    Fi system diagnosis 4-11 fi system parts location a speedometer f fuel injector, no.1 b ckp sensor g fuel injector, no.2 c tp sensor h ignition coil, no.1 d gear position sensor i stva e stp sensor j to sensor ecm a i f g c e j h b d partshark.Com 877-999-5686.

  • Page 176: Partshark.Com

    4-12 fi system diagnosis k iap sensor n fuel pump relay l iat sensor o ignition coil, no.2 m ect sensor p pair control valve k l m n o p ecm partshark.Com 877-999-5686.

  • Page 177: Partshark.Com

    Fi system diagnosis 4-13 fi system wiring diagram ig 2 ig 1 o/g b/y w/bl b b/bl br gr/w gr/b b/r r/b dg r p/w b/br w/b w/g y p w b/w w/r g/b br/b b/g b/w b/w y/b br/w o/r mode selection switch speedometer int ake air pressure sensor p air solenoid contr ol v al ve side- st and switch gear position s...

  • Page 178: Self-Diagnosis Function

    4-14 fi system diagnosis self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi light). To check the function of the individual fi system devices, ...

  • Page 179: Partshark.Com

    Fi system diagnosis 4-15 dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. ( " 4-20) the memorized malfunction code is displayed on lcd (display) panel. Malfunc- tion means that the ecm does not receive signal from ...

  • Page 180: Partshark.Com

    4-16 fi system diagnosis in the lcd (display) panel, the malfunction code is indicated from small code to large code. Tps adjustment 1. Warm up the engine and adjust the engine idle speed to 1 300 ± 100 rpm. ( " 2-15) 2. Stop the engine. 3. Connect the special tool (mode select switch) and select th...

  • Page 181: Fail-Safe Function

    Fi system diagnosis 4-17 fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from each ...

  • Page 182: Fi System Troubleshooting

    4-18 fi system diagnosis fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper...

  • Page 183: Partshark.Com

    Fi system diagnosis 4-19 note: * the above form is a standard sample. It should be modified according to conditions characteristic of each market. Motorcycle/environmental condition when problem occurs environmental condition weather temperature frequency fair cloudy rain snow always other hot warm ...

  • Page 184: Partshark.Com

    4-20 fi system diagnosis self-diagnostic procedures don’t disconnect couplers from ecm, battery cable from battery, ecm ground wire harness from engine or main fuse before con- firming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase memorized informati...

  • Page 185: Partshark.Com

    Fi system diagnosis 4-21 malfunction code and defective condition malfunction code detected item detected failure condition check for c00 no fault ––––––––––– c12 crankshaft position sensor the signal does not reach ecm for 3 sec. And more, after receiving the iap signal. The crankshaft position sen...

  • Page 186: Partshark.Com

    4-22 fi system diagnosis malfunction code detected item detected failure condition check for c28 secondary throttle valve actuator when no actuator control signal is supplied from the ecm or communication signal does not reach ecm or operation voltage does not reach stva motor, c28 is indicated. Stv...

  • Page 187: Partshark.Com

    Fi system diagnosis 4-23 “c12” ckp sensor circuit malfunction inspection step1 1) turn the ignition switch off. 2) check the ckp sensor coupler 1 for loose or poor contacts. If ok, then measure the ckp sensor resistance. 3) disconnect the ckp sensor coupler and measure the resis- tance. % ckp sensor...

  • Page 188: Partshark.Com

    4-24 fi system diagnosis step2 1) disconnect the ckp sensor coupler. 2) crank the engine a few seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. % ckp sensor peak voltage: 3.7 v and more ( + white – - green) 3) repeat the above test procedure a few times and mea...

  • Page 189: Partshark.Com

    Fi system diagnosis 4-25 “c13” iap sensor circuit malfunction inspection step 1 1) lift and support the fuel tank. ( " 5-7) 2) turn the ignition switch off. 3) check the iap sensor coupler for loose or poor contacts. If ok, then measure the iap sensor input voltage. 4) disconnect the iap sensor coup...

  • Page 190: Partshark.Com

    4-26 fi system diagnosis step 2 1) connect the iap sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) start the engine at idle speed. 4) measure the iap sensor output voltage at the wire side cou- pler (between g/b and b/br wires). % iap sensor output voltage: approx. 2...

  • Page 191: Partshark.Com

    Fi system diagnosis 4-27 output voltage (vcc voltage 4.5 v, ambient temp. 25 °c, 77 °f) altitude (reference) atmospheric pressure output voltage (ft) (m) (mmhg) kpa (v) 0 2 000 0 610 760 707 100 94 approx. 3.3 – 3.6 2 001 5 000 611 1 524 707 634 94 85 approx. 3.0 – 3.3 5 001 8 000 1 525 2 438 634 56...

  • Page 192: Partshark.Com

    4-28 fi system diagnosis “c14” tp sensor circuit malfunction inspection step 1 1) remove the fuel tank ( " 5-7). 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage. 4) disconnect the tp sensor coupler. 5) turn t...

  • Page 193: Partshark.Com

    Fi system diagnosis 4-29 step 2 1) remove the air cleaner box. ( " 5-15) 2) turn the ignition switch off. 3) disconnect the tp sensor coupler. 4) check the continuity between a and ground. % tp sensor continuity: ∞ Ω (infinity) ( a – ground) 5) if ok, then measure the tp sensor resistance (between a...

  • Page 194: Partshark.Com

    4-30 fi system diagnosis step 3 1) connect the tp sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. Measure the tp sensor output voltage at the coupler (between + p/w and - b/br) by turning the throttle grip. % tp sensor output voltage thro...

  • Page 195: Partshark.Com

    Fi system diagnosis 4-31 “c15” ect sensor circuit malfunction inspection step 1 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at the wire side coupler. 3) disconnect the coupler and turn the ignition switch on....

  • Page 196: Partshark.Com

    4-32 fi system diagnosis step 2 1) turn the ignition switch off. 2) measure the ect sensor resistance. (refer to page 6-10 for details.) % ect sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal) ! 09900-25008: multi circuit tester set & tester knob indication: resistance (Ω) i...

  • Page 197: Partshark.Com

    Fi system diagnosis 4-33 “c21” iat sensor circuit malfunction inspection step 1 1) lift and support the fuel tank. ( " 5-7) 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor voltage at the wire side coupler. 4) disconnect ...

  • Page 198: Partshark.Com

    4-34 fi system diagnosis step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. % iat sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal) ! 09900-25008: multi circuit tester set & tester knob indication: resistance (Ω) is the resistance ok? Note: iat sen...

  • Page 199: Partshark.Com

    Fi system diagnosis 4-35 “c23” to sensor circuit malfunction inspection step 1 1) remove the seat. ( " 7-4) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) remove the to sensor. 5) measure the resistance bet...

  • Page 200: Partshark.Com

    4-36 fi system diagnosis step 2 1) connect the to sensor coupler. 2) insert the needle pointed probe to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between br/w and b/br wires of the to sensor at horizontal. % to sensor voltage: 0.4 – 1.4 v ...

  • Page 201: Partshark.Com

    Fi system diagnosis 4-37 “c28” stv actuator circuit malfunction inspection step 1 1) remove the fuel tank and air cleaner box. ( " 5-15) 2) turn the ignition switch off. 3) check the stva coupler for loose or poor contacts. 4) turn the ignition switch on to check the stv operation. Stv operating ord...

  • Page 202: Partshark.Com

    4-38 fi system diagnosis “c29” stp sensor circuit malfunction inspection step 1 1) remove the air cleaner box. ( " 5-15) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage. 4) disconnect the stp sensor coupler...

  • Page 203: Partshark.Com

    Fi system diagnosis 4-39 step 2 1) turn the ignition switch off. 2) disconnect the stp sensor coupler. 3) check the continuity between yellow wire and ground. % stp sensor continuity: ∞ Ω (infinity) (yellow – ground) 4) if ok, then measure the stp sensor resistance at the coupler (between yellow and...

  • Page 204: Partshark.Com

    4-40 fi system diagnosis step 3 1) turn the ignition switch off. 2) connect the stp sensor coupler. 3) insert the needle pointed probes to the stp sensor coupler. 4) disconnect the stva coupler. 5) turn the ignition switch on. 6) measure the stp sensor output voltage at the coupler (between + yellow...

  • Page 205: Partshark.Com

    Fi system diagnosis 4-41 “c31” gear position (gp) switch circuit malfunction inspection step 1 1) remove the left frame cover. ( " 7-5) 2) turn the ignition switch off. 3) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp switch voltage. 4) support the motorcycle wit...

  • Page 206: Partshark.Com

    4-42 fi system diagnosis “c32” or “c33” fuel injector circuit malfunction inspection step 1 1) remove the air cleaner box. ( " 5-15) 2) turn the ignition switch off. 3) check the injector couplers for loose or poor contacts. If ok, then measure the injector resistance. 4) disconnect the injector cou...

  • Page 207: Partshark.Com

    Fi system diagnosis 4-43 step 2 1) disconnect the injector couplers. 2) turn the ignition switch on. 3) measure the injector voltage between y/r wire (no.1 injector coupler and no.2 injector coupler) and ground. % injector voltage: battery voltage ( + y/r – - ground) note: injector voltage can be de...

  • Page 208: Partshark.Com

    4-44 fi system diagnosis “c41” fp relay circuit malfunction inspection step 1 1) remove the seat. ( " 7-4) 2) turn the ignition switch off. 3) check the fp relay coupler for loose or poor contacts. If ok, then check the insulation and continuity. Refer to page 5-10 for details. Is the fp relay ok? N...

  • Page 209: Partshark.Com

    Fi system diagnosis 4-45 “c49” pair control solenoid valve circuit malfunction inspection step 1 1) remove the fuel tank. ( " 5-7) 2) turn the ignition switch off. 3) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure the pair control solenoid valve resis- ...

  • Page 210: Partshark.Com

    4-46 fi system diagnosis step 2 1) connect the pair control solenoid valve coupler. 2) turn the ignition switch on. 3) insert the needle pointed probes to the pair control solenoid valve coupler. 4) measure the voltage at the wire side coupler between brown wire and ground. % pair control solenoid v...

  • Page 211: Partshark.Com

    Fi system diagnosis 4-47 “c44” ho2 sensor (ho2s) circuit malfunction (e-02, 19) inspection step 1 1) lift and support the fuel tank. ( " 5-7) 2) turn the ignition switch off. 3) check the ho2 sensor coupler for loose or poor contacts. 4) insert the needle pointed probes to the ho2 sensor coupler. 5)...

  • Page 212: Partshark.Com

    4-48 fi system diagnosis step 2 1) warm up the engine enough. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) measure the ho2 sensor output voltage at the coupler (between w/g and b/br wires) when idling condition. 4) also, measure the ho2 sensor output voltage while holding the en...

  • Page 213: Sensors

    Fi system diagnosis 4-49 sensors ckp sensor inspection the crankshaft position sensor is installed in the generator cover. ( " 4-23) ckp sensor removal and installa- tion • remove the generator cover. ( " 3-26) • install the generator cover in the reverse order of removal. Iap sensor inspection the ...

  • Page 214: Partshark.Com

    4-50 fi system diagnosis iat sensor inspection the intake air temperature sensor is installed on the right side of the air cleaner box. ( " 4-33) iat sensor removal and installa- tion • lift and support the fuel tank. ( " 5-7) • remove the iat sensor from the air cleaner box. • install the iat senso...

  • Page 215: Partshark.Com

    Fuel system and throttle body 5-1 5 fuel system and throttle body contents fuel system ..............................................................................................5- 2 fuel delivery system.....................................................................5- 2 fuel pump .............

  • Page 216: Fuel System

    5-2 fuel system and throttle body fuel system fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped...

  • Page 217: Partshark.Com

    Fuel system and throttle body 5-3 fuel pump the electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. The ecm controls its on/off operation as controlled under the fuel pump control system. When electrical...

  • Page 218: Partshark.Com

    5-4 fuel system and throttle body when the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction. This process continuously takes place causing fuel pressure to be built up. The ...

  • Page 219: Partshark.Com

    Fuel system and throttle body 5-5 fuel pressure regulator the fuel pressure regulator consists of the spring and valve. It keeps absolute fuel pressure of 300 kpa (3.0 kgf/cm 2 , 43 psi) to be applied to the injector at all times. When the fuel pressure rises more than 300 kpa (3.0 kgf/cm 2 , 43 psi...

  • Page 220: Partshark.Com

    5-6 fuel system and throttle body fuel pump control system when the ignition switch is turned on, current from the battery flows to the fuel pump motor through the side- stand relay and the fuel pump relay causing the motor to turn. Since the ecm has a timer function, the fuel pump motor stops turni...

  • Page 221: Fuel System

    Fuel system and throttle body 5-7 fuel system fuel tank lift-up • remove the seat. ( ! 7-4) • remove the cowring. ( ! 7-5) • remove the fuel tank mounting bolt and fuel tank mount stay 1 . • lift and support the fuel tank with the fuel tank mount stay. Fuel tank removal • lift and support the fuel t...

  • Page 222: Partshark.Com

    5-8 fuel system and throttle body fuel pressure inspection • lift and support the fuel tank. ( ! 5-7) • place a rag under the fuel feed hose. • remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. $ 09940-40211: fuel pressure gauge adaptor 09940-40220...

  • Page 223: Partshark.Com

    Fuel system and throttle body 5-9 fuel pump inspection turn the ignition switch on and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. Fuel discharge amount i...

  • Page 224: Partshark.Com

    5-10 fuel system and throttle body fuel pump relay inspection fuel pump relay is located behind the ecm. • remove the seat. ( ! 7-4) • remove the fuel pump relay. First, check the insulation between 1 and 2 terminals with pocket tester. Then apply 12 volts to 3 and 4 terminals, + to 3 and - to 4 , a...

  • Page 225: Partshark.Com

    Fuel system and throttle body 5-11 • remove the screws. • remove the fuel pump assy 4 from the fuel pump plate 5 . • remove the fuel pump holder 6 . • remove the fuel mesh filter 7 . • remove the fuel pressure regulator holder 8 and the fuel pressure regulator 9 . Partshark.Com 877-999-5686.

  • Page 226: Partshark.Com

    5-12 fuel system and throttle body fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. Note: if the fuel mesh filter is clogged with many sed...

  • Page 227: Partshark.Com

    Fuel system and throttle body 5-13 • install the new o-ring and apply suzuki super grease to it. # & 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • when installing the fuel pump assembly, first tighten all the fuel pump assembly mounting bolts lightly in t...

  • Page 228: Partshark.Com

    5-14 fuel system and throttle body throttle body and stv actuator construction *1 1 tp sensor a stp sensor mounting screw 2 stp sensor b tp sensor mounting screw ' 3 stva c fuel delivery pipe mounting screw item n·m kgf-m lb-ft a 2.0 0.2 1.5 4 fuel delivery pipe *1 do not turn the screw. B 3.5 0.35 ...

  • Page 229: Partshark.Com

    Fuel system and throttle body 5-15 air cleaner and throttle body removal air cleaner box • remove the fuel tank. ( ! 5-7) • disconnect the iat sensor coupler 1 . • remove the iap sensor vacuum hose 2 . • disconnect the iap sensor coupler 3 . • loosen the throttle body clamp screws. • disconnect the ...

  • Page 230: Partshark.Com

    5-16 fuel system and throttle body throttle body • remove the fuel tank. ( ! 5-7) • remove the air cleaner box. ( ! 5-15) • disconnect the various lead wire couplers. 1 tp sensor 2 stp sensor 3 stva motor • remove the injector lead wire coupler. • disconnect the idle stop screw. • loosen the throttl...

  • Page 231: Partshark.Com

    Fuel system and throttle body 5-17 • disconnect the throttle cables from their drum. • dismount the throttle body assembly. " * be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly. * after disconnecting the throttle cables...

  • Page 232: Partshark.Com

    5-18 fuel system and throttle body throttle body disassembly " • remove the iap sensor vacuum damper and its hose. • disconnect the fuel feed hose 1 . • remove the throttle link rod 2 and secondary throttle link rod 3 . Note: the throttle link rod 2 is longer than the secondary throttle link rod 3 ....

  • Page 233: Partshark.Com

    Fuel system and throttle body 5-19 • remove the tps 5 and stps 6 with the special tool. $ 09930-11950: torx wrench (th 25) 09930-11960: torx wrench (th 20) note: prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. • remove the oil seals 7 . ...

  • Page 234: Partshark.Com

    5-20 fuel system and throttle body • remove the throttle stop screw 9 . Note: measure the length a for accurate reinstallation. " " never loosen the throttle stop screw b on the no.2 throt- tle body. Never remove the throttle valve and secondary throttle valve. Partshark.Com 877-999-5686.

  • Page 235: Partshark.Com

    Fuel system and throttle body 5-21 " • remove the fast idle link lever 0 . • remove the spring a . • remove the spring b , bushing c and plastic washer d . Never remove the throttle body link plates. Partshark.Com 877-999-5686.

  • Page 236: Partshark.Com

    5-22 fuel system and throttle body throttle body cleaning # • clean all passageways with a spray type carburetor cleaner and blow dry with compressed air. " throttle body inspection • check following items for any damage or clogging. * o-ring * secondary throttle valve * throttle shaft bushing and s...

  • Page 237: Partshark.Com

    Fuel system and throttle body 5-23 throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • apply suzuki super grease to the throttle stop screw tip and the both ends of a spring. & 99000-25030: suzuki super grease “a” (usa...

  • Page 238: Partshark.Com

    5-24 fuel system and throttle body • install the spring 4 and fast idle link lever 5 . Note: make sure that the spring ends are hooked correctly. • install the washers 5 , 6 , spring washer 7 and nut 8 . Note: the washer 5 is inserting in the axis certainly. • apply suzuki super grease to the seal l...

  • Page 239: Partshark.Com

    Fuel system and throttle body 5-25 note: make sure the throttle valve open or close smoothly. • align the boss a of the stp sensor with the groove b of the st valve shaft. • install the stp sensor. • tighten the stp sensor mounting screws. $ 09930-11960: torx wrench ' stp sensor mounting screw: 2.0 ...

  • Page 240: Partshark.Com

    5-26 fuel system and throttle body • install the fuel injectors by pushing them straight to each throt- tle body. " • install the fuel delivery pipe assembly to the throttle body assembly. " • tighten the fuel delivery pipe mounting screws. ' fuel delivery pipe mounting screw: 5.0 n·m (0.5 kgf-m, 3....

  • Page 241: Partshark.Com

    Fuel system and throttle body 5-27 stv synchronization • install the throttle body. ( ! 5-27) • turn the ignition switch off, if stv synchronization is per- formed on the vehicle. • turn the stva shaft with a finger so that the throttle valve height a will be same as b . " note: measure the throttle...

  • Page 242: Partshark.Com

    5-28 fuel system and throttle body • connect the fuel injector couplers to the fuel injectors. Note: * the fuel injector coupler no.1 (front) can be distinguished from that of the no.2 (rear) by the “f” mark a . * adjust the throttle cable play with the cable adjusters. Refer to page 2-15 for detail...

  • Page 243: Partshark.Com

    Fuel system and throttle body 5-29 tp sensor adjustment after checking or adjusting the throttle valve synchronization, adjust the tp sensor positioning as follows: • after warming up engine, adjust the idling speed to 1 300 rpm. • stop the warmed-up engine and connect the special tool to the dealer...

  • Page 244: Partshark.Com

    5-30 fuel system and throttle body fast idle inspection the fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engi...

  • Page 245: Partshark.Com

    Fuel system and throttle body 5-31 fast idle adjustment • remove the fuel tank. ( ! 5-7) • remove the air cleaner box. ( ! 5-15) • disconnect the stva lead wire coupler and turn the ignition switch on. • open the stv fully with a finger. Measure the output voltage of the tp sensor. " • if the tp sen...

  • Page 246: Partshark.Com

    5-32 fuel system and throttle body throttle valve synchronization check and adjust the throttle valve synchronization between two cylinders. Calibrating each gauge (for vacuum balancer gauge) • start up the engine and run it in idling condition for warming up. • stop the warmed-up engine. • remove t...

  • Page 247: Partshark.Com

    Fuel system and throttle body 5-33 • turn the air screw 4 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6 . Note: the vacuum gauge is positioned approx. 30 ° from the horizon- tal level. • after making sure that the steel b...

  • Page 248: Partshark.Com

    5-34 fuel system and throttle body • connect a tachometer and start up the engine. • bring the engine rpm to 1 300 rpm by the throttle step screw. • check the vacuum of the two cylinders and balance the two throttle valves with the synchronizing screw 2 on the no.2 throttle body. Note: * during bala...

  • Page 249: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 250: Partshark.Com

    Cooling and lubrication system contents cooling and lubrication system engine coolant....................................................................................... 6- 2 cooling circuit....................................................................................... 6- 3 cooling circui...

  • Page 251: Partshark.Com

    Cooling and lubrication system 6-1 6 oil pump................................................................................................6-20 oil pressure switch .......................................................................6-20 oil cooler ..................................................

  • Page 252: Engine Coolant

    6-2 cooling and lubrication system engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the c...

  • Page 253: Cooling Circuit

    Cooling and lubrication system 6-3 cooling circuit 1 thermostat 2 reserve tank 3 radiator 4 no.1 cylinder head 5 no.1 cylinder 6 no.2 cylinder 7 no.2 cylinder head 8 water pump cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for ti...

  • Page 254: Radiator

    6-4 cooling and lubrication system radiator removal • remove the cowling. ( # 7-5) • drain the engine coolant. ( # 2-18) • disconnect the right and left radiator hoses from the radiator. • disconnect the siphon hose 1 from the radiator. • disconnect the horn lead wire coupler 2 . Partshark.Com 877-9...

  • Page 255: Partshark.Com

    Cooling and lubrication system 6-5 • remove the radiator lower mounting bolt. • disconnect the cooling fan motor and thermo-switch lead wire coupler 3 . • remove the radiator upper mounting bolt. • disconnect the speed sensor lead wire from the clamp 4 . • with the hooks a unlocked, remove the radia...

  • Page 256: Partshark.Com

    6-6 cooling and lubrication system inspection and cleaning road dirt or trash stuck to the fins must be removed. Use of compressed air is recommended for this cleaning. Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Installation • install the ra...

  • Page 257: Radiator Cap

    Cooling and lubrication system 6-7 radiator cap inspection • remove the radiator cap. ( # 6-3) • fit the cap 1 to the radiator cap tester 2 . • build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95 – 125 kpa (0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) and that...

  • Page 258: Cooling Fan

    6-8 cooling and lubrication system cooling fan inspection • remove the cowling. ( # 7-5) • disconnect the cooling fan motor and thermo-switch lead wire coupler 1 . Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration. The voltmeter is for making sure t...

  • Page 259: Cooling Fan Thermo-Switch

    Cooling and lubrication system 6-9 cooling fan thermo-switch removal • remove the cowling. ( # 7-5) • drain the engine coolant. ( # 2-18) • disconnect the cooling fan thermo-switch lead wire coupler 1 . • remove the cooling fan thermo-switch 2 . Inspection • check the thermo-switch closing or openin...

  • Page 260: Ect Sensor

    6-10 cooling and lubrication system ect sensor removal • drain the engine coolant. ( # 2-18) • disconnect the ect sensor lead wire coupler. • place a rag under the ect sensor and remove the ect sen- sor 1 . Inspection • check the ect sensor by testing it at the bench as shown in the figure. Connect ...

  • Page 261: Partshark.Com

    Cooling and lubrication system 6-11 installation • install a new sealing washer 1 . • tighten the ect sensor to the specified torque. $ ect sensor: 19 n·m (1.9 kgf-m, 13.5 lb-ft) ! • pour engine coolant. ( # 2-18) • bleed air from the cooling circuit. ( # 2-19) take special care when handling the ec...

  • Page 262: Thermostat Case Assembly

    6-12 cooling and lubrication system thermostat case assembly removal • drain the engine coolant. ( # 2-18) • place a rag under the thermostat case. • remove the thermostat case cap 1 . • remove the thermostat 2 . Inspection inspect the thermostat pellet for signs of cracking. Test the thermostat at ...

  • Page 263: Partshark.Com

    Cooling and lubrication system 6-13 • keep on heating the water to raise its temperature. • just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8.0 mm (0.31 in). % thermostat valve lift standard: over 8.0 mm at 100 °c (over 0.31 in at 212 °f) ...

  • Page 264: Water Pump

    6-14 cooling and lubrication system water pump removal and disassembly • drain the engine coolant. ( # 2-18) • drain the engine oil. ( # 2-13) • disconnect the water hoses 1 , 2 . • remove the water pump case and clutch cover. ( # 3-27) note: before draining engine oil and engine coolant, inspect en...

  • Page 265: Partshark.Com

    Cooling and lubrication system 6-15 • remove the water pump 6 from the clutch cover. • remove the screws and separate the water pump. • remove the o-rings 7 . • remove the e-ring from the impeller shaft. • remove the impeller from the other side. • remove the mechanical seal ring 5 and rubber seal 6...

  • Page 266: Partshark.Com

    6-16 cooling and lubrication system • remove the bearings with the special tool. & 09921-20240: bearing remover set (10 mm) note: if there is no abnormal noise, bearings removal is not neces- sary. ! • remove the mechanical seal and oil seal with the special tool. & 09913-70210: bearing installer se...

  • Page 267: Partshark.Com

    Cooling and lubrication system 6-17 oil seal visually inspect the oil seal for damage, with particular attention given to the lip. Replace the oil seal that shows indications of oil leakage. Bearing case visually inspect the bearing case for damage. Replace the water pump body if necessary. Reassemb...

  • Page 268: Partshark.Com

    6-18 cooling and lubrication system • install the new mechanical seal with the special tool. & 09913-70210: bearing installer set () 25 mm) • install the new bearings with the special tool. & 09913-70210: bearing installer set () 25 mm) note: the stamped mark on the bearing faces to the crankcase si...

  • Page 269: Partshark.Com

    Cooling and lubrication system 6-19 • apply engine coolant to the o-ring 4 . • install a new o-ring. ! • connect the water hoses. • pour engine coolant. ( # 2-18) • pour engine oil. ( # 2-14) use a new o-ring to prevent engine coolant leakage. 4.5 n·m (0.45 kgf-m, 3.3 lb-ft) partshark.Com 877-999-56...

  • Page 270: Lubrication System

    6-20 cooling and lubrication system lubrication system oil pressure # 2-31 oil filter # 2-14 oil pressure regulator # 3-57 oil strainer # 3-58 oil jet # 3-49, -59, -60 and -96 oil pump # 3-81 and -89 oil pressure switch # 3-58 and 8-34 partshark.Com 877-999-5686.

  • Page 271: Oil Cooler

    Cooling and lubrication system 6-21 oil cooler removal • drain the engine oil. ( # 2-13) • disconnect the oil cooler hoses. • remove the oil cooler. • remove the oil cooler fin guard net 1 . • remove the oil hoses 2 . Inspection and cleaning inspect the oil cooler and hose joints for oil leakage. If...

  • Page 272: Partshark.Com

    6-22 cooling and lubrication system fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Installation • install the new gasket washers 1 . ! • connect the oil hoses. • install the oil cooler. $ oil cooler mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) •...

  • Page 273: Oil Pan

    Cooling and lubrication system 6-23 engine lubrication flow chart oil pan oil strainer clutch plates clutch push peace oil pressure regulator oil pump oil filter oil gallery right side crankshaft journal bearing left side crankshaft journal bearing oil pressure switch driven gear and bushing driven ...

  • Page 274: Engine Lubrication Circuit

    6-24 cooling and lubrication system engine lubrication circuit front cylinder / partshark.Com 877-999-5686.

  • Page 275: Partshark.Com

    Cooling and lubrication system 6-25 rear cylinder partshark.Com 877-999-5686.

  • Page 276: Chassis

    Chassis contents exterior parts .......................................................................................7- 2 construction ...................................................................................7- 2 removal ......................................................................

  • Page 277: Partshark.Com

    Chassis 7-1 7 remounting ....................................................................................... 7-56 final inspection and adjustment ............................................ 7-57 front brake ...........................................................................................

  • Page 278: Exterior Parts

    7-2 chassis exterior parts construction 1 wind screen cover 6 cowling body 2 wind screen 7 combination meter panel 3 wind screen brace 8 cowling inner cover ! 4 cowling brace 9 left cowling item n·m kgf-m lb-ft 5 right cowling a cowling brace mounting bolt a 35 3.5 25.5 partshark.Com 877-999-5686.

  • Page 279: Partshark.Com

    Chassis 7-3 1 seat rail 4 mud guard ! 2 rear fender no.1 5 frame cover item n·m kgf-m lb-ft 3 rear fender no.2 a seat rail mounting bolt a 50 5.0 36.0 partshark.Com 877-999-5686.

  • Page 280: Partshark.Com

    7-4 chassis removal seat • remove the seat with the ignition key 1 . Fuel tank side cover • remove the seat. ( " 7-4) • remove the fuel tank side covers 1 . Note: “ ✩ ” indicates hook location. Carrier • remove the seat. ( " 7-4) • remove the carrier 1 . Partshark.Com 877-999-5686.

  • Page 281: Partshark.Com

    Chassis 7-5 frame cover • remove the seat. ( " 7-4) • remove the carrier. ( " 7-4) • remove the fuel tank side cover. ( " 7-4) • remove the frame covers 1 . Note: “ ✩ ” indicates hook location. Rear fender • remove the seat. ( " 7-4) • remove the carrier. ( " 7-4) • remove the bolts 1 . • disconnect...

  • Page 282: Partshark.Com

    7-6 chassis • remove the wind screen 2 . • remove the fuel tank top cover 3 . • remove the combination meter panel mounting screws 4 . • remove the combination meter panel 5 . Note: “ ✩ ” indicates hook location. • disconnect the speedometer lead wire coupler 6 . • remove the cowling inner cover 7 b...

  • Page 283: Partshark.Com

    Chassis 7-7 • remove the left cowling 8 . • remove the right cowling 9 . • remove the wind screen brace 0 . • disconnect the turn signal light lead wire couplers a . • remove the screws b . • remove the cowling body c . Note: “ ✩ ” indicates hook location. Partshark.Com 877-999-5686.

  • Page 284: Partshark.Com

    7-8 chassis • disconnect the coupler d . • remove the cowling blace e . • remove the combination meter. ( " 8-29) installation install the exterior parts in the reverse order of removal. Pay attention to the following points: • install the wind screen brace 1 as shown in the photograph. Note: instal...

  • Page 285: Front Wheel

    Chassis 7-9 front wheel construction 1 brake disc 5 front wheel ! 2 dust seal 6 tire valve item n·m kgf-m lb-ft 3 bearing a front axle a 65 6.5 47.0 4 center spacer b brake disc bolt b 23 2.3 16.5 partshark.Com 877-999-5686.

  • Page 286: Partshark.Com

    7-10 chassis removal • remove the right and left brake calipers. ( " 7-59) • loosen the axle pinch bolt 1 on the right front fork leg. # • slightly loosen the front axle with the special tool. $ 09900-18710: hexagon bit 12 mm • raise the front wheel off the ground and support the motorcy- cle with a...

  • Page 287: Partshark.Com

    Chassis 7-11 • remove the dust seal with the special tool. $ 09913-50121: oil seal remover ! # front axle using a dial gauge, check the front axle for runout and replace it if the runout exceeds the limit. $ 09900-20607: dial gauge (1/100) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm...

  • Page 288: Partshark.Com

    7-12 chassis reassembly and remounting reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: a left b right 39 n·m 3.9 kgf-m 28.0 lb-ft ( ) 23 n·m 2.3 kgf-m 16.5 lb-ft ( ) 39 n·m 3.9 kgf-m 28.0 lb-ft ( ) 23 n·m 2.3 kgf-m 16.5 l...

  • Page 289: Partshark.Com

    Chassis 7-13 wheel bearing • apply suzuki super grease to the wheel bearings. ' 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • first install the left wheel bearing, then install the right wheel bearing and spacer with the special tools and used bearing. $ ...

  • Page 290: Partshark.Com

    7-14 chassis brake disc make sure that the brake disc is clean and free of any greasy matter. • apply thread lock to the disc mounting bolts and tighten them to the specified torque. Note: the stamped mark a on the brake disc should face to the out- side. ! Brake disc bolt: 23 n·m (2.3 kgf-m, 16.5 l...

  • Page 291: Partshark.Com

    Chassis 7-15 note: before tightening the axle pinch bolt on the right front fork leg, move the front fork up and down 4 or 5 times without applying front brake. • tighten the axle pinch bolt 1 on the right front fork leg to the specified torque. ! Front axle pinch bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft...

  • Page 292: Front Fork

    7-16 chassis front fork construction 1 spring adjuster b oil seal 2 o-ring c oil seal retainer 3 washer d guide metal 4 spacer e oil lock piece 5 spring f outer tube 6 rebound spring g cylinder 7 inner tube h washer ! 8 slide metal a front fork cap bolt item n·m kgf-m lb-ft 9 gasket b front axle pin...

  • Page 293: Partshark.Com

    Chassis 7-17 removal and disassembly • remove the front wheel. ( " 7-10) • remove the speedometer lead wire mounting bolts 1 . • remove the front fender bolts and brake hose bolts. • remove the front fender 2 . • loosen the front fork upper clamp bolts 3 . Note: slightly loosen the front fork cap bo...

  • Page 294: Partshark.Com

    7-18 chassis • invert the fork and drain the fork oil out of the fork by stroking. • hold the fork inverted for a few minutes to drain the fork oil. • remove the front axle pinch bolt. (for right front fork reg) • remove the damper rod bolt with the special tools. • remove the damper rod. $ 09940-34...

  • Page 295: Partshark.Com

    Chassis 7-19 • remove the oil seal stopper ring. • pull the inner tube out of the outer tube. Note: be careful not to damage the inner tube. # • remove the following parts. A oil seal b oil seal retainer c guide metal d slide metal e oil lock piece • remove the pin f . • remove the washer g . • remo...

  • Page 296: Partshark.Com

    7-20 chassis inspection inner and outer tubes inspect the inner tube outer surface and the outer tube inner sur- face for scratches. If any defects are found, replace them with the new ones. Fork spring measure the fork spring free length. If it is shorter than the ser- vice limit, replace it with a...

  • Page 297: Partshark.Com

    Chassis 7-21 reassembly and remounting reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: metals and seals • hold the inner tube vertically and clean the metal groove and install the guide metal by hand as shown. # • assemble...

  • Page 298: Partshark.Com

    7-22 chassis • install the oil seal stopper ring 6 and the dust seal 7 . A dust seal b oil seal stopper ring c oil seal d oil seal retainer e guide metal cylinder • install the rebound spring 1 to the cylinder 2 . • apply fork oil to the cylinder ring. • install the cylinder into the front fork. • a...

  • Page 299: Partshark.Com

    Chassis 7-23 fork oil • place the front fork vertically without spring. • compress the front fork fully. • pour the specified front fork oil into the front fork. + 99000-99001-ss8: suzuki fork oil ss-08 % front fork oil capacity (each leg): 524 ml (17.7/18.5 us/imp oz) • move the inner tube up and d...

  • Page 300: Partshark.Com

    7-24 chassis fork spring • install the fork spring 1 into the front fork. • install the washer 2 and spacer 3 . Note: the smaller spring pitch end a must face downward. • apply fork oil lightly to the o-ring. # • install the spring adjuster to the front fork cap bolt. • apply fork oil lightly to the...

  • Page 301: Partshark.Com

    Chassis 7-25 • tighten the front fork cap bolt 4 to the specified torque. ! Front fork cap bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • loosen the front fork lower clamp bolt. • align the top of the inner tube to the upper surface of the steering stem upper bracket. • tighten the front fork upper and lowe...

  • Page 302: Steering and Handlebar

    7-26 chassis steering and handlebar construction 1 handlebars 0 spacer 2 steering stem upper bracket a washer 3 dust seal b expander ! 4 bearing upper a handlebar clamp bolt item n·m kgf-m lb-ft 5 bearing lower b steering stem head nut a 23 2.3 16.5 6 steering stem lower bracket c front fork upper c...

  • Page 303: Partshark.Com

    Chassis 7-27 removal handlebars • remove the handlebar balancers 1 . • remove the rear view mirrors 2 . Note: do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. • remov...

  • Page 304: Partshark.Com

    7-28 chassis • remove the handlebars by removing the handlebar clamp bolts. • remove the clutch lever holder b . Steering stem • remove the front forks. ( " 7-17) • remove the handlebars. ( " 7-27) • remove the guides 1 . • remove the brake hose guide 2 . • remove the ignition switch 3 with the spec...

  • Page 305: Partshark.Com

    Chassis 7-29 • remove the steering stem upper bracket by removing the steering stem head nut. • remove the steering stem lock-nut with the special tools. $ 09940-14911: steering stem nut wrench 09940-14960: steering stem nut wrench socket • remove the washer 4 . • remove the steering stem nut with t...

  • Page 306: Partshark.Com

    7-30 chassis • remove the steering stem upper bearing 7 . • remove the steering stem lower bearing 8 . Inspection and disassembly inspect the removed parts for the following abnormalities. * distortion of the steering stem * bearing wear or damage * abnormal bearing noise * handlebars distriction * ...

  • Page 307: Partshark.Com

    Chassis 7-31 reassembly and remounting reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points: outer races • press in the upper and lower outer races with the special tool. $ 09941-34513: steering outer race installer 09913-702...

  • Page 308: Partshark.Com

    7-32 chassis • install the washer. Note: when installing the washer, align the stopper lug to the groove of the steering stem. • install the steering stem lock-nut and tighten it to the specified torque with the special tools. $ 09940-14911: steering stem nut wrench 09940-14960: steering stem nut wr...

  • Page 309: Partshark.Com

    Chassis 7-33 • set the punch mark c on the handlebar clamp forward. • tighten the handlebar clamp bolts to the specified torque. ! Handlebar clamp bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) note: when tightening the handlebar clamp bolts, first tighten the bolt 1 and then tighten the bolt 2 . Handlebar sw...

  • Page 310: Partshark.Com

    7-34 chassis • install the left handlebar switch box to the handlebars by engaging the stopper 3 with the handlebars hole 4 . • install the clutch master cylinder with the proper clutch hose routing. • install the handlebar balancers and the rear view mirrors. (handlebar balancer installation: " 9-3...

  • Page 311: Rear Wheel

    Chassis 7-35 rear wheel construction 1 rear axle a retainer 2 dust seal b sprocket mounting drum 3 brake disc c rear sprocket 4 collar d bearing 5 bearing e dust seal 6 rear wheel f collar ! 7 tire valve a brake disc bolt item n·m kgf-m lb-ft 8 damper b rear sprocket nut a 23 2.3 16.5 9 spacer c rea...

  • Page 312: Partshark.Com

    7-36 chassis removal • remove the cotter pin. (for e-03, 28, 33) • loosen the rear axle nut. • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the axle nut and draw out the rear axle. # • remove the collars 1 , 2 . • remove the rear sprocket mou...

  • Page 313: Partshark.Com

    Chassis 7-37 • remove the rear sprocket 6 from the rear sprocket mounting drum. • remove the brake disc 7 . Inspection and disassembly tire: ( "7-79) wheel: ( "7-11 and 7-79) rear axle using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. % axle ...

  • Page 314: Partshark.Com

    7-38 chassis sprocket inspect the rear sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set. A normal wear b excessive wear dust seal • inspect the wheel dust seal lip and sprocket mounting drum dust seal lips for wear or damage. If ...

  • Page 315: Partshark.Com

    Chassis 7-39 bearing inspect the play of the wheel and sprocket mounting drum bear- ings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. • remove the sprocket mounting dru...

  • Page 316: Partshark.Com

    7-40 chassis reassembly and remounting reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: a left b right 60 n·m 6.0 kgf-m 43.5 lb-ft ( ) 23 n·m 2.3 kgf-m 16.5 lb-ft ( ) 100 n·m 10.0 kgf-m 72.5 lb-ft e-03, 28, 33 ( ) partshark...

  • Page 317: Partshark.Com

    Chassis 7-41 bearing • apply suzuki super grease to the bearings before installing. ' 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) • install the new bearing to the sprocket mounting drum with the special tool. $ 09913-70210: bearing installer set (& 62) no...

  • Page 318: Partshark.Com

    7-42 chassis dust seal • install the new dust seals with the special tool. $ 09913-70210: bearing installer set ( 1 & 62) ( 2 & 47) note: when installing the dust seals, the stamped mark of dust seal must face the special tool. • apply suzuki super grease to the dust seal lips before assembling rear...

  • Page 319: Partshark.Com

    Chassis 7-43 • install the rear sprocket mounting drum assembly to the rear wheel hub. • tighten the sprocket mounting nuts to the specified torque. ! Rear sprocket nut: 60 n·m (6.0 kgf-m, 43.5 lb-ft) • install the collar. Rear axle • remount the rear wheel and rear axle, install the washer and rear...

  • Page 320: Rear Shock Absorber

    7-44 chassis rear shock absorber construction 1 rear shock absorber b rear shock absorber lower mounting nut ! Item n·m kgf-m lb-ft a rear shock absorber upper mount- ing nut a 50 5.0 36.0 b 50 5.0 36.0 partshark.Com 877-999-5686.

  • Page 321: Partshark.Com

    Chassis 7-45 removal • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the pre-load adjuster 1 . • remove the cushion lever rod bolts/nuts and the cushion rods 2 . • disconnect the pre-load adjuster hose from the clamp 3 . • remove the rear shoc...

  • Page 322: Partshark.Com

    7-46 chassis inspection inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. # rear shock absorber disposal ) gas pressure release • mark the drill hole at a , shown in the illustration, with a center punch. • co...

  • Page 323: Partshark.Com

    Chassis 7-47 remounting remount the rear shock absorbers in the reverse order of removal. Pay attention to the following points: • install the rear shock absorber and tighten the rear shock absorber upper/lower mounting nuts. ! Rear shock absorber lower mounting nut: 50 n·m (5.0 kgf-m, 36.0 lb-ft) r...

  • Page 324: Partshark.Com

    7-48 chassis suspension setting after installing the rear suspension, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment the pre-load is adjusted by turning the pre-load adjuster knob without tool. Position “0” provides the softest spring pre-load. Position “5” provi...

  • Page 325: Rear Swingarm

    Chassis 7-49 rear swingarm construction 1 rear shock absorber 0 swingarm 2 rear cushion rod a center spacer 3 rear cushion lever a rear shock absorber upper mounting nut ! Item n·m kgf-m lb-ft 4 spacer b cushion lever nut a 50 5.0 36.0 5 bearing c cushion rod nut b 78 7.8 56.5 6 washer d swingarm pi...

  • Page 326: Partshark.Com

    7-50 chassis removal • remove the exhaust pipe and exhaust muffler. ( " 3-6) • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the rear wheel. ( " 7-36) • remove the rear brake hose guides 1 . • remove the cushion rods 2 . • remove the shock abs...

  • Page 327: Partshark.Com

    Chassis 7-51 • remove the mud guard 8 . • remove the chain buffer 9 . Inspection and disassembly spacer • remove the spacers 1 from swingarm and cushion lever. • inspect the spacers for any flaws or other damage. If any defect is found, replace the spacers with the new ones. Chain buffer inspect the...

  • Page 328: Partshark.Com

    7-52 chassis swingarm bearing insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • remove the swingarm pivot bearings and spacer with the special tool. $ 09921-20240: bearing remover set (25 mm) # • re...

  • Page 329: Partshark.Com

    Chassis 7-53 • remove the cushion lever bearings with the special tool. $ 09921-20240: bearing remover set (20 mm and 17 mm) # cushion rod inspect the cushion rods for damage and distortion. The removed bearings must be replaced with the new ones. Partshark.Com 877-999-5686.

  • Page 330: Partshark.Com

    7-54 chassis reassembly reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: 1 frame 2 rear shock absorber 3 washer 4 cushion lever 5 cushion rod 6 swingarm a left b right 50 n·m 5.0 kgf-m 36.0 lb-ft ( ) 50 n·m 5.0 kgf-m 36.0 lb-ft ( ) 90 n·...

  • Page 331: Partshark.Com

    Chassis 7-55 swingarm bearing • install the bearings and spacer into the swingarm pivot all together with the special tools. $ 09941-34513: steering race installer 09913-70210: bearing installer set ( & 32) note: when installing the bearing, the stamped mark on the bearing must face the special tool...

  • Page 332: Partshark.Com

    7-56 chassis remounting remount the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: swingarm • insert the swingarm pivot shaft and tighten it to the specified torque with the special tool. ! Swingarm pivot shaft: 15 n·m (1.5 kgf-m, 11.0 lb-ft) $ 09944...

  • Page 333: Partshark.Com

    Chassis 7-57 cushion lever and cushion rod • install the washers 1 and cushion lever 2 . Note: insert the cushion lever mounting bolt from the left side. ( " 7-54) • install the cushion rod and rear shock absorber. Note: insert the cushion rod mounting bolts and rear shock absorber mounting bolts fr...

  • Page 334: Front Brake

    7-58 chassis front brake construction 1 diaphragm 0 dust seal 2 dust boot a piston 3 piston/cup set b caliper holder 4 brake hose c caliper 5 pin a front brake master cylinder mounting bolt ! Item n·m kgf-m lb-ft 6 pad mounting pin b brake hose union bolt a 10 1.0 7.0 7 brake pad spring c air bleede...

  • Page 335: Partshark.Com

    Chassis 7-59 ) # brake pad replacement • remove the caliper. # • remove the pin 1 . • remove the brake pads by removing the pad mounting pin 2 . • clean up the caliper especially around the caliper pistons. • install the outer pad with the detent a of pad fitted to the detent b on the caliper holder...

  • Page 336: Partshark.Com

    7-60 chassis • install the inner pad so that the inner pad will be seated on the hatched part c . • install the pad mounting pin 3 . • install the pin 4 securely. • install the caliper. • tighten the caliper mounting bolts to the specified torque. ! Front brake caliper mounting bolt: 39 n·m (3.9 kgf...

  • Page 337: Partshark.Com

    Chassis 7-61 # caliper removal and disassembly • drain the brake fluid. ( " 7-60) • remove the brake pads. ( " 7-59) • disconnect the brake hoses by removing the brake hose union bolts. Note: place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. • remove the brak...

  • Page 338: Partshark.Com

    7-62 chassis • place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air. # • remove the dust seals 3 and piston seals 4 . # caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any ...

  • Page 339: Partshark.Com

    Chassis 7-63 rubber parts inspect the rubber parts for damage. If any damage is found, replace them with the new ones. Caliper reassembly and remounting reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: • wash the caliper bores...

  • Page 340: Partshark.Com

    7-64 chassis caliper holder • apply suzuki silicone grease to the caliper holder pin. - 99000-25100: suzuki silicone grease • install the caliper holder to the caliper. • install the pad spring 1 . Note: when installing the pad spring, seated on the lug of pad spring to concaved part of brake calipe...

  • Page 341: Partshark.Com

    Chassis 7-65 brake disc inspection visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. % front disc thickness: service limit: 4.5 mm (0.18 in) $ 09900-20205: micrometer (0...

  • Page 342: Partshark.Com

    7-66 chassis • remove the brake lever 3 and brake switch 4 . • pull out the dust boot 5 and remove the snap ring 6 . • remove the piston and return spring. 7 piston 8 secondary cup 9 primary cup 0 return spring master cylinder inspection inspect the master cylinder bore for any scratches or other da...

  • Page 343: Partshark.Com

    Chassis 7-67 master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: # , specification and classification: dot 4 • apply brake fluid to the piston and cups. • install the following pa...

  • Page 344: Rear Brake

    7-68 chassis rear brake construction 1 brake hose c brake pad spring 2 diaphragm d caliper bracket 3 reservoir tank hose e caliper 4 piston/cup set a brake hose union bolt 5 push rod b rear brake master cylinder mounting bolt ! Item n·m kgf-m lb-ft 6 dust boot c rear brake master cylinder rod lock-n...

  • Page 345: Partshark.Com

    Chassis 7-69 ) # brake pad replacement • remove the plug 1 . • loosen the pad mounting pin 2 . • remove the caliper bracket bolt 3 . # • remove the pad mounting pin and brake pads with the rear caliper pivoted up. • clean up the caliper especially around the caliper pistons. * this brake system is f...

  • Page 346: Partshark.Com

    7-70 chassis • assemble the insulator 4 and shim 5 to the new brake pad 6 . # • install the new brake pads. Note: make sure that the detent of the pad is seated onto the retainer on the caliper bracket. • tighten the caliper mounting bolt 7 and pad mounting pin 8 to the specified torque. ! Rear brak...

  • Page 347: Partshark.Com

    Chassis 7-71 brake fluid replacement • remove the right frame cover. ( " 7-5) • remove the brake fluid reservoir cap. • replace the brake fluid in the same manner as the front brake. ( " 7-60) , specification and classification: dot 4 # caliper removal and disassembly • drain the brake fluid. ( " 7-...

  • Page 348: Partshark.Com

    7-72 chassis • pivot the caliper up and remove the caliper from the caliper bracket 2 . • remove the pad spring 3 . • remove the spacer 4 and boot 5 from the caliper. • remove the brake caliper sliding pin 6 . • place a rag over the piston to prevent it from popping out and then force out the piston...

  • Page 349: Partshark.Com

    Chassis 7-73 • remove the dust seal 7 and piston seal 8 . # caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. Brake caliper piston inspect the brake caliper piston surface for an...

  • Page 350: Partshark.Com

    7-74 chassis brake disc inspection inspect the rear brake disc in the same manner as the front brake disc. ( " 7-65) % service limit rear disc thickness: 5 mm (0.20 in) rear disc runout: 0.30 mm (0.012 in) * brake disc removal ( "7-37) * brake disc installation ( "7-42) caliper reassembly and remoun...

  • Page 351: Partshark.Com

    Chassis 7-75 • tighten the brake caliper sliding pin 3 to the specified torque. ! Brake caliper sliding pin: 27 n·m (2.7 kgf-m, 19.5 lb-ft) • apply suzuki silicone grease to the brake caliper slid- ing pin. - 99000-25100: suzuki silicone grease • install the caliper to the caliper bracket 4 . • set ...

  • Page 352: Partshark.Com

    7-76 chassis • loosen the lock-nut 2 . • remove the master cylinder mounting bolts 3 . • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 4 and disconnect the brake hose. # • remove the master cylinder by turning the master cyl...

  • Page 353: Partshark.Com

    Chassis 7-77 master cylinder inspection cylinder, piston and cup set inspect the cylinder bore wall for any scratches or other dam- age. Inspect the cup set and each rubber part for damage. Master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse order of r...

  • Page 354: Partshark.Com

    7-78 chassis • install the master cylinder. • tighten the lock-nut 9 . ! Rear brake master cylinder rod lock-nut: 18 n·m (1.8 kgf-m, 13.0 lb-ft) • install the reservoir tank. (rear brake hose routing: " 9-27) • temporarily install the master cylinder to the frame. • connect the brake hose to the mas...

  • Page 355: Tire and Wheel

    Chassis 7-79 tire and wheel tire removal the most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For...

  • Page 356: Partshark.Com

    7-80 chassis valve • inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal rubber is peeling or has damage. • inspect the valve core. If the seal 1 has abnormal deforma- tion, replace the valve with a new one. Valve installation • any dust or rust aro...

  • Page 357: Partshark.Com

    Chassis 7-81 tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. # • when installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the t...

  • Page 358: Partshark.Com

    7-82 chassis • in this condition, check the “rim line” a cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line a and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire co...

  • Page 359: Drive Chain

    Chassis 7-83 drive chain use the special tool in the following procedures, to cut and rejoin the drive chain. $ 09922-22711: drive chain cutting and joining tool set note: when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Drive chain cutting • s...

  • Page 360: Partshark.Com

    7-84 chassis • place the drive chain link being disjointed on the holder part 8 of the tool. • turn in both the adjuster bolt 6 and pressure bolt “a” 3 so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” 3 with the bar. • turn in the pressure bolt “...

  • Page 361: Partshark.Com

    Chassis 7-85 • apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0 . Note: when positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 t...

  • Page 362: Partshark.Com

    7-86 chassis • stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “a” 3 with the bar until the pin end diameter becomes the specified dimension. % pin end diameter specification d # • adjust the drive chain, after connecting it. ( " 2-21) did 5.5 – 5.8 mm (0.217 – 0.228 in) * ...

  • Page 363: Electrical System

    Electrical system 8-1 8 electrical system contents cautions in servicing ...........................................................................8- 2 connector .........................................................................................8- 2 coupler ......................................

  • Page 364: Cautions In Servicing

    8-2 electrical system cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock before disconnecting it ...

  • Page 365: Partshark.Com

    Electrical system 8-3 semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as a ecm. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • the mf battery used in this mot...

  • Page 366: Partshark.Com

    8-4 electrical system using the multi circuit tester • properly use the multi circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 367: Partshark.Com

    Electrical system 8-5 location of electrical components 1 horn 2 fuel injector ( ! 4-42) 3 stp sensor ( ! 4-38) 4 tp sensor ( ! 4-28) 5 stv actuator ( ! 4-37) 6 fuel pump ( ! 5-9) 7 speed sensor ( ! 8-35) 8 ignition coil (no.1) 9 ckp sensor ( ! 4-23) 0 generator ( ! 8-10) a gear position switch ( ! ...

  • Page 368: Partshark.Com

    8-6 electrical system 1 to sensor ( ! 4-35) 2 fuel pump relay ( ! 5-10) 3 ecm (engine control module) 4 fuse box 5 turn signal/side-stand relay ( ! 8-37) 6 starter relay ( ! 8-19) 7 battery 8 iap sensor ( ! 4-25) 9 iat sensor ( ! 4-33) 0 pair control valve ( ! 10-7) a regulator/rectifier ( ! 8-11) b...

  • Page 369: Charging System

    Electrical system 8-7 charging system 1 generator 2 regulator/rectifier 3 ignition switch 4 main fuse 5 battery 6 load trouble shooting battery runs down quickly step1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step2 1) check the battery for cur...

  • Page 370: Partshark.Com

    8-8 electrical system step4 1) measure the continuity of the generator coil. ( ! 8-10) is the resistance of generator coil ok? Step5 1) measure the generator no-load voltage. ( ! 8-10) is generator no-load performance ok? Step6 1) inspect the regulator/rectifier. ( ! 8-11) is the regulator/rectifier...

  • Page 371: Partshark.Com

    Electrical system 8-9 inspection battery current leakage • remove the seat. ( ! 7-4) • turn the ignition switch to the off position. • disconnect the battery - lead wire. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester. If the reading excee...

  • Page 372: Partshark.Com

    8-10 electrical system generator coil resistance • remove the right cowling. ( ! 7-5) • disconnect the generator coupler 1 . Measure the resistance between the three lead wires. If the resistance is out of the specified value, replace the stator with a new one. Also, check that the generator core is...

  • Page 373: Partshark.Com

    Electrical system 8-11 regulator/rectifier • remove the right cowling. ( ! 7-5) • disconnect the regulator/rectifier couplers 1 . • remove the regulator/rectifier 2 . Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not wit...

  • Page 374: System

    8-12 electrical system starter system and side-stand/ignition interlock system 1 starter motor 2 starter relay 3 clutch switch 4 starter button 5 engine stop switch 6 turn signal/side-stand relay 7 ignition switch 8 fuse 9 side-stand switch 0 gear position switch a battery a to ecm and ignition coil...

  • Page 375: Partshark.Com

    Electrical system 8-13 step3 1) measure the starter relay voltage at the starter relay connectors (between b/y and y/g) when the starter button is pushed. Is a voltage ok? Step4 1) inspect the starter relay. ( ! 8-19) is the starter relay ok? Step5 the starter motor runs when the transmission is neu...

  • Page 376: Partshark.Com

    8-14 electrical system starter motor removal and disassembly • remove the starter motor and disconnect the starter motor lead wire 1 . • disassemble the starter motor as shown in the illustration. 1 housing end (rear bracket) 6 armature a thrust stopper 2 brush spring (2 pcs) 7 starter motor case b ...

  • Page 377: Partshark.Com

    Electrical system 8-15 starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damage is found, replace the brush assembly with a new one. Commutator inspect the commutator for discoloration, abnormal wear or undercut a . If abno...

  • Page 378: Partshark.Com

    8-16 electrical system starter motor reassembly reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: " • apply suzuki super grease to the lip of the oil seal. - 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (othe...

  • Page 379: Partshark.Com

    Electrical system 8-17 • install the washers 2 (12 × 6.5 × 2), washer 3 (16 × 6.5 × 1), washer 4 (14 × 6.5 × 1) and nut 5 . " • install the washers 6 . Note: the number of washer 6 varies according to individual. • install the seal rings 8 to starter motor case 7 . • when install the rear bracket to...

  • Page 380: Partshark.Com

    8-18 electrical system • apply suzuki super grease to the starter motor o-rings. - 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) " • tighten the starter motor housing bolts to the specified torque. / starter motor housing bolt: 3.5 n·m (0.4 kgf-m 2.45 lb-ft...

  • Page 381: Partshark.Com

    Electrical system 8-19 starter relay inspection • remove the seat. ( ! 7-4) • disconnect the battery - lead wire from the battery. • remove the starter relay cover 1 . • disconnect the starter relay coupler 2 . • disconnect the starter motor lead wire 3 and battery lead wire 4 . • remove the starter...

  • Page 382: Partshark.Com

    8-20 electrical system side-stand/ignition interlock system parts inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-s...

  • Page 383: Partshark.Com

    Electrical system 8-21 • connect the gear position switch coupler to the wiring har- ness. • turn the ignition switch to “on” position and side-stand to upright position. • insert the needle pointed probes to the gear position switch coupler. Measure the voltage between pink and b/w lead wires using...

  • Page 384: Partshark.Com

    8-22 electrical system side-stand relay inspection first check the insulation between d and e terminals with the tester. Then apply 12 v to terminals d and c ( + to d and - to c ) and check the continuity between d and e . If there is no continuity, replace the turn signal/side-stand relay with a ne...

  • Page 385: Ignition System

    Electrical system 8-23 ignition system 1 ckp sensor 2 ecm 3 wave form arrangement circuit 4 power source circuit 5 cpu 6 tp sensor 7 ect sensor 8 gear position switch 9 engine stop switch 0 ignition coil #1 a spark plug #1 b ignition coil #2 c spark plug #2 d side-stand relay e fuse f ignition switc...

  • Page 386: Partshark.Com

    8-24 electrical system step3 1) measure the ignition coil primary peak voltage. ( ! 8-25) note: the ignition coil peak voltage inspection method is applicable only with the multi circuit tester and peak volt adaptor. Is the peak voltage ok? Step4 1) inspect the spark plug. ( ! 2-6) is the spark plug...

  • Page 387: Partshark.Com

    Electrical system 8-25 inspection ignition coil primary peak voltage • lift and support the fuel tank. ( ! 5-7) • remove the radiator lower mounting bolt and move the radia- tor lower side to forward. • disconnect the two spark plug caps. • connect the new two spark plugs to each spark plug cap and ...

  • Page 388: Partshark.Com

    8-26 electrical system • repeat the above procedure a few times and measure the highest ignition coil primary peak voltage. ' tester knob indication: voltage (&) $ ignition coil primary peak voltage: 150 v and more 0 • if the peak voltage is lower than the specified values, inspect the ignition coil...

  • Page 389: Partshark.Com

    Electrical system 8-27 ckp sensor peak voltage • remove the seat. ( ! 7-4) • disconnect the ecm coupler. Note: make sure that all of the couplers are connected properly and the battery used is in fully-charged condition. Measure the ckp sensor peak voltage in the following proce- dures. • connect th...

  • Page 390: Partshark.Com

    8-28 electrical system if the peak voltage on the ckp sensor lead wire coupler is ok but on the ecm coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specification, the ckp sensor must be replaced and re-checked. 5 ckp sensor 6 ckp sensor coupler 7 ...

  • Page 391: Combination Meter

    Electrical system 8-29 combination meter removal and disassembly • disconnect the battery - lead wire. • remove the combination meter panel. ( ! 7-6). • remove the combination meter 1 . " • disassemble the combination meter as follows. " when disconnecting and connecting the combination meter couple...

  • Page 392: Partshark.Com

    8-30 electrical system inspection led (light emitting diode) check that the led lights immediately after turning the ignition switch on. If the led fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler. Stepping motor check that the pointer c...

  • Page 393: Partshark.Com

    Electrical system 8-31 odometer the odometer indicates “------” when the odometer is faulty. Replace the combination meter unit with a new one. Trip meter the trip meter indicates “----.-” when the trip meter is faulty. In case the odometer works normaly, perform the trip meter reset. If the trip me...

  • Page 394: Partshark.Com

    8-32 electrical system indicators engine coolant temperature meter inspection • disconnect the ect sensor coupler 1 . " • connect the variable resistor a between the terminals. • turn the ignition switch “on”. • check the display of engine coolant temperature meter as shown below. If any abnormality...

  • Page 395: Partshark.Com

    Electrical system 8-33 fuel level gauge inspection • remove the fuel tank. ( ! 5-7) • remove the fuel pump. ( ! 5-10) measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. # 09900-25008: multi circuit tester set (...

  • Page 396: Partshark.Com

    8-34 electrical system fuel level meter inspection • remove the fuel tank left side cover. ( ! 7-4) • disconnect the fuel pump lead wire coupler. • connect the each resistor between the yellow/black and black/white lead wires at the wire harness. • turn the ignition switch “on” position and wait for...

  • Page 397: Partshark.Com

    Electrical system 8-35 speedometer and speed sensor if the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and connection of coupler 1 . If the speed sensor and connection are all right, replace the meter with a new one. Speed sensor removal and installation ...

  • Page 398: Lamps

    8-36 electrical system lamps headlight, brake light/taillight and turn signal light headlight 12 v 60/55 w 12 v 60/55 w + 5 w a only e-02, 19 brake light/tail light 12 v 21/5 w turn signal light 12 v 21 w headlight beam adjustment • adjust the headlight beam, both vertical and horizontal. A : vertic...

  • Page 399: Relays

    Electrical system 8-37 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not i...

  • Page 400: Partshark.Com

    8-38 electrical system switches ignition switch removal • remove the fuel tank. ( ! 5-7) • remove the air cleaner box. ( ! 5-15) • disconnect the ignition switch coupler 1 . • remove the ignition switch mounting bolts with the special tools. # 09930-11920: torx bit jt40h 09930-11940: bit holder " 1 ...

  • Page 401: Partshark.Com

    Electrical system 8-39 inspection inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. G/y ground on (engine is stopped) off (engine is running) color position b/y b/y off on color position o w/b off on color position ...

  • Page 402: Battery

    8-40 electrical system battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a . Note: wh...

  • Page 403: Partshark.Com

    Electrical system 8-41 note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 404: Partshark.Com

    8-42 electrical system servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 405: Servicing Information

    Servicing information 9-1 9 servicing information contents troubleshooting ...................................................................................9- 2 malfunction code and defective condition ........................9- 2 engine ...............................................................

  • Page 406: Troubleshooting

    9-2 servicing information troubleshooting malfunction code and defective condition malfunction code detected item detected failure condition check for c00 no fault ––––––––––– c12 crankshaft position sensor the signal does not reach ecm for 3 sec. And more, after receiving the iap signal. The cranks...

  • Page 407: Partshark.Com

    Servicing information 9-3 malfunction code detected item detected failure condition check for c28 secondary throttle valve actuator when no actuator control signal is supplied from the ecm or communication signal does not reach ecm or operation voltage does not reach stva motor, c28 is indicated. St...

  • Page 408: Partshark.Com

    9-4 servicing information engine engine will not start or is hard to start symptom, possible causes and remedy 1) compression too low • valve clearance out of adjustment. • worn valve guides or poor seating of valves. • mistimed valves. • excessively worn piston rings. • worn-down cylinder bores. • ...

  • Page 409: Partshark.Com

    Servicing information 9-5 engine idles poorly engine stalls often symptom, possible causes and remedy • valve clearance out of adjustment. • poor seating of valves. • defective valve guides. • worn down camshafts. • too wide spark plug gaps. • defective ignition coils. • defective ckp sensor. • defe...

  • Page 410: Partshark.Com

    9-6 servicing information noisy engine symptom, possible causes and remedy 1) excessive valve chatter • too large valve clearance. • weakened or broken valve springs. • worn tappet or cam surface. • worn and burnt camshaft journal. 2) noise seems to come from piston • worn down pistons or cylinders....

  • Page 411: Partshark.Com

    Servicing information 9-7 engine runs poorly in high speed range symptom, possible causes and remedy 1) defective engine internal/electrical parts • weakened valve springs. • worn camshafts. • valve timing out of adjustment. • too narrow spark plug gaps. • ignition not advanced sufficiently due to p...

  • Page 412: Partshark.Com

    9-8 servicing information engine lacks power symptom, possible causes and remedy 1) defective engine internal/electrical parts • loss of valve clearance. • weakened valve springs. • valve timing out of adjustment. • worn piston rings or cylinders. • poor seating of valves. • fouled spark plugs. • in...

  • Page 413: Partshark.Com

    Servicing information 9-9 engine overheats dirty or heavy exhaust smoke slipping clutch dragging clutch transmission will not shift symptom, possible causes and remedy 1) defective engine internal parts • heavy carbon deposit on piston crowns. • not enough oil in the engine. • defective oil pump or ...

  • Page 414: Partshark.Com

    9-10 servicing information transmission will not shift back transmission jumps out of gear radiator (cooling system) engine overheats engine overcools symptom, possible causes and remedy • broken return spring on shift shaft. • rubbing or sticky shift shaft. • distorted or worn gearshift forks. Repl...

  • Page 415: Partshark.Com

    Servicing information 9-11 chassis heavy steering wobbly handlebars wobbly front wheel front suspension too soft front suspension too stiff noisy front suspension wobbly rear wheel symptom, possible causes and remedy • overtightened steering stem nut. • broken bearing in steering stem. • distorted s...

  • Page 416: Partshark.Com

    9-12 servicing information rear suspension too soft rear suspension too stiff noisy rear suspension brakes insufficient brake power brake squeaking excessive brake lever stroke leakage of brake fluid symptom, possible causes and remedy • weakened spring of shock absorber. • leakage of oil from shock...

  • Page 417: Partshark.Com

    Servicing information 9-13 brake drags electrical no sparking or poor sparking spark plug soon become fouled with carbon spark plug become fouled too soon spark plug electrodes overheat or burn generator does not charge symptom, possible causes and remedy • rusty part. • insufficient brake lever or ...

  • Page 418: Partshark.Com

    9-14 servicing information generator does charge, but charging rate is below the specification generator overcharges unstable charging starter button is not effective symptom, possible causes and remedy • lead wires tend to get short- or open-circuited or loosely connected at terminals. • grounded o...

  • Page 419: Partshark.Com

    Servicing information 9-15 battery “sulfation”, acidic white powdery substance or spots on surface of cell plates battery runs down quickly battery “sulfation” symptom, possible causes and remedy • cracked battery case. • battery has been left in a run-down condition for a long time. Replace the bat...

  • Page 420: Partshark.Com

    9-16 servicing information wire harness, cable and hose routing wire harness routing *1 *2 clamp wiring harness clamp starter motor wiring harness clamp gear position switch wiring harness side-stand switch generator 1 iat sensor lead wire *1 insert the protruded section each on the handle- bar swit...

  • Page 421: Partshark.Com

    Servicing information 9-17 *1 *3 *4 *5 *6 *2 1 wiring harness no.2 *3 triangle mark of each spark plug cap must be brought to the exhaust side. 2 magneto lead wire *4 cut the clamp end. 3 ignition coil no.2 *5 do not slack the lead wire. *1 clamp the turn signal light read wire. *6 pass through the ...

  • Page 422: Partshark.Com

    9-18 servicing information heated oxygen sensor (ho2s) wire routing (for e-02, 19) *1 *2 1 ho2 sensor (for e-02, 19) *1 route the ho2 sensor lead wire along the fuel tank drain hose. 2 ho2 sensor lead wire *2 pass through the ho2 sensor lead wire forward the swingarm. 3 wiring harness partshark.Com ...

  • Page 423: Partshark.Com

    Servicing information 9-19 engine electrical parts set-up 90 ˚ 90 ˚ *1 *2 bolt gear position switch lead wire generator lead wire clamp starter motor lead wire *1 battery ground lead wire generator cover a starter motor lead wire mounting nut *1 45 ° and less ! Item n·m kgf-m lb-ft b ckp sensor set ...

  • Page 424: Partshark.Com

    9-20 servicing information speed sensor lead wire routing 20 mm (0.79 in) *1 *2 *3 20 mm (0.79 in) 1 speed sensor lead wire *1 cut the clamp end. 2 clamp *2 route speed sensor lead wire to come outside the brake hose guide. 3 brake hose *3 route speed sensor lead wire on inside of front fork outer t...

  • Page 425: Partshark.Com

    Servicing information 9-21 throttle cable routing 1 throttle cable no.1 4 wiring harness 2 throttle cable no.2 *1 fit the cable boots securely. 3 front brake hose 0 mm (0 in) 0 mm (0 in) *1 partshark.Com 877-999-5686.

  • Page 426: Partshark.Com

    9-22 servicing information clutch cable routing \ b – b *2 *1 *3 *4 c – c d – d e – e b b c c e e d d 1 throttle cable (pull) 7 reserve tank bracket 2 throttle cable (return) *1 route left handle switch wiring harness in the groove of radiator shroud. 3 handle switch wiring harness *2 route left han...

  • Page 427: Partshark.Com

    Servicing information 9-23 throttle body installation/hose routing \ 15 ˚ ~ 25 ˚ *4 *1 *2 *3 *5 *6 *6 view a *6 40 ˚ ~ 50 ˚ 2 ~ 5 mm (0.08 ~ 0.20 in) 15 ˚ ~ 25 ˚ a 1 iat sensor 9 intake pipe clamp 2 vacuum damper *1 to canister (for e-33) 3 throttle body assembly *2 pass through the vacuum hose insi...

  • Page 428: Partshark.Com

    9-24 servicing information cooling system hose routing \ *1 *6 *6 *3 *2 *7 *7 *4 *5 1 clamp *3 matching mark (yellow) 2 wiring harness *4 clamp the water drain hose and oil pressure switch lead wire. 3 oil pressure switch *5 fill the bearing with engine oil until engine oil comes out from the hole o...

  • Page 429: Partshark.Com

    Servicing information 9-25 \ *1 *2 *3 *4 *5 *1 *6 *1 0 ~ 90 ˚ 90 ˚ marking position installation point 90 ˚ 90 ˚ 1 clamp *2 matching mark (white) 2 jiggle valve *3 marking (yellow) 3 union *4 clamp bolt head must face downward. 4 radiator hose *5 clamp bolt head must face left side. *1 marking *6 le...

  • Page 430: Partshark.Com

    9-26 servicing information front brake hose routing \ throttle cables stopper 21 ˚ 21 ˚ stopper brake hose guide *4 *2 *1 *5 *3 *5 *1 brake hose clamp stopper stopper *1 stopper 21 ˚ brake hose 42 ˚ *1 after the brake hose union has contacted the stopper, tighten the union bolt. *4 assemble the brak...

  • Page 431: Partshark.Com

    Servicing information 9-27 rear brake hose routing \ u p p e r lower 35 ˚ *1 *1 *3 *3 *2 *4 42 ˚ a – a 35 ˚ a a 1 frame *1 clamp ends should face forward. 2 stopper *2 white paint faces outside. 3 brake hose *3 after the brake hose union has contacted the stopper, tighten the union bolt. 4 brake hos...

  • Page 432: Partshark.Com

    9-28 servicing information fuel tank drain hose routing *1 *3 *2 *1 route fuel tank drain hose so that its curve faces forward. *3 make sure to position the clamp in the specified direction. *2 route fuel tank drain hose to come inside (left side) gear position sensor wiring harness. Partshark.Com 8...

  • Page 433: Partshark.Com

    Servicing information 9-29 fuel tank installation 1 ~ 2 mm (0.04 ~ 0.08 in) 27 mm (1.06 in) *1 1 fuel tank center shield *1 align the front end of fuel tank center shield with this position. 2 fuel tank side cushion partshark.Com 877-999-5686.

  • Page 434: Partshark.Com

    9-30 servicing information pair (air supply) system hose routing *1 1 matching mark (white) *1 pass the pair hose between the cylinder head cover and intake pipe. 2 matching mark (yellow) partshark.Com 877-999-5686.

  • Page 435: Partshark.Com

    Servicing information 9-31 seat lock cable routing head lamp set-up 1 seat lock cable view of left view of top *1 *2 *3 *1 adhere cushion along the ridge line of lens. *3 right and left cushions shall be attached sym- metrically. *2 start to adhere cushion from the corner of lens. Partshark.Com 877-...

  • Page 436: Partshark.Com

    9-32 servicing information absorber hose routing battery cushion installation 1 absorber hose 3 rear fender (front) 2 clamp *1 *1 front view of left 12 battery protector *1 adhere battery protector at the upper end. Partshark.Com 877-999-5686.

  • Page 437: Partshark.Com

    Servicing information 9-33 side-stand set-up brake pedal/footrest set-up ! Item n·m kgf-m lb-ft a 40 4.0 29.0 b 50 5.0 36.0 c 100 10.0 72.5 1 pin 3 footrest 2 e-ring 4 brake light switch a – a a a partshark.Com 877-999-5686.

  • Page 438: Partshark.Com

    9-34 servicing information engine cap installation *1 view of right view of left 1 engine cap *1 push the center of cap so as to thoroughly remove looseness. Partshark.Com 877-999-5686.

  • Page 439: Partshark.Com

    Servicing information 9-35 footrest set-up handlebar balancer installation note: after installing the rh balancer weight, check that throttle grip rotate smoothly by turning it. ! Item n·m kgf-m lb-ft a 5.5 0.55 4 partshark.Com 877-999-5686.

  • Page 440: Partshark.Com

    9-36 servicing information special tools 09900-18710 hexagon bit 12 mm 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20204 micrometer (75 – 100 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20508 cylinder gauge set 09900-20602 dial gauge (1/1000 mm, 1 mm) 09900-20...

  • Page 441: Partshark.Com

    Servicing information 9-37 09913-60221 journal bearing remover/installer 09913-70210 bearing installer set 09915-40610 oil filter wrench 09915-64512 compression gauge 09915-74511 oil pressure gauge set 09915-74521 oil pressure gauge hose 09915-74532 oil pressure gauge attachment 09915-77331 meter (f...

  • Page 442: Partshark.Com

    9-38 servicing information 09917-47011 vacuum pump gauge 09920-13120 crankcase separating tool 09920-53740 clutch sleeve hub holder 09921-20240 bearing remover set 09924-84510 bearing installer set 09925-18011 steering bearing installer 09930-10121 spark plug socket wrench set 09930-11920 torx bit j...

  • Page 443: Partshark.Com

    Servicing information 9-39 note: when order the special tool, please confirm whether it is available or not. 09940-40211 fuel pressure gauge adaptor 09940-40220 fuel pressure gauge hose attachment 09940-52861 front fork oil seal installer 09940-92720 spring scale 09941-34513 bearing/steering race in...

  • Page 444: Tightening Torque

    9-40 servicing information tightening torque engine item n·m kgf-m lb-ft cylinder head cover bolt 14 1.4 10.0 spark plug 11 1.1 8.0 camshaft journal holder bolt 10 1.0 7.0 cam chain tension adjuster cap bolt 8 0.8 5.7 cam chain tension adjuster mounting bolt 10 1.0 7.0 cylinder head bolt [m: 10] ini...

  • Page 445: Partshark.Com

    Servicing information 9-41 fi system parts item n·m kgf-m lb-ft exhaust pipe bolt/nut 23 2.3 16.5 muffler mounting bolt/nut 23 2.3 16.5 oil pipe stopper screw 8 0.8 6.0 engine sprocket nut 145 14.5 105 engine mounting bolt/nut 55 5.5 40.0 engine mounting nut [center] 93 9.3 67.5 engine mounting thru...

  • Page 446: Partshark.Com

    9-42 servicing information chassis item n·m kgf-m lb-ft steering stem head nut 90 9.0 65.0 steering stem lock-nut 80 8.0 58.0 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork cylinder bolt 20 2.0 14.5 front axle 65 6.5 47.0 fr...

  • Page 447: Partshark.Com

    Servicing information 9-43 tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 ...

  • Page 448: Service Data

    9-44 servicing information service data valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.000...

  • Page 449: Partshark.Com

    Servicing information 9-45 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft jour...

  • Page 450: Partshark.Com

    9-46 servicing information cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure compression pressure difference ---- piston to cylinder clearance 0.055 – 0.065 (0.0022 – 0.0026) 0.120 (0.0047) cylinder bore 81.000 – 81.015 (3.1890 – 3.1896) nicks or scratches piston...

  • Page 451: Partshark.Com

    Servicing information 9-47 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – ...

  • Page 452: Partshark.Com

    9-48 servicing information transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (...

  • Page 453: Partshark.Com

    Servicing information 9-49 thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) ...

  • Page 454: Partshark.Com

    9-50 servicing information fi sensors+ secondary throttle valve actuator throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed + g...

  • Page 455: Partshark.Com

    Servicing information 9-51 electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 2 – 5 Ω +...

  • Page 456: Partshark.Com

    9-52 servicing information wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator lig...

  • Page 457: Partshark.Com

    Servicing information 9-53 brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 15.870 – 15.913 (0.6248 – 0.6265) ---- r...

  • Page 458: Partshark.Com

    9-54 servicing information tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kp...

  • Page 459: Partshark.Com

    Servicing information 9-55 fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane ( ) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriat...

  • Page 460: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 461: Emission Control Information

    10 emission control information 10-1 contents emission control information emission control systems ..............................................................10- 2 fuel injection system .................................................................10- 2 crankcase emission control system ........

  • Page 462: Emission Control Systems

    10-2 emission control information emission control systems fuel injection system dl650 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 fuel f...

  • Page 463: Partshark.Com

    Emission control information 10-3 crankcase emission control system the engine is equipped with a pcv system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body. 1 pair reed valve a ...

  • Page 464: Partshark.Com

    10-4 emission control information exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and three-way catalyst sys- tem. (except for e-03, -24 and-28) the fresh air is drawn into the exhaust port with the pair solenoid valve and pair reed va...

  • Page 465: Partshark.Com

    Emission control information 10-5 noise emission control system tampering with the noise control system prohibited: federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, o...

  • Page 466: Partshark.Com

    10-6 emission control information (for e-33: k7) pair (air supply) system inspection hoses • inspect the hoses for wear or damage. • inspect that the hoses are securely connected. Pair reed valve • remove the pair reed valve cover. ( 3-36) • inspect the reed valve for the carbon deposit. • if the ca...

  • Page 467: Partshark.Com

    Emission control information 10-7 pair control solenoid valve • remove the air cleaner box. ( ! 5-15) • remove the pair control solenoid valve 1 . • check that air flows through the air inlet port to the air outlet port. • if air does not flow out, replace the pair control solenoid valve with a new ...

  • Page 468: Partshark.Com

    10-8 emission control information pair (air supply) system hose routing ! 9-30 heated oxygen sensor (ho2s) wire routing (e-02, 19) ! 9-18 partshark.Com 877-999-5686.

  • Page 469: Inspection (E-02, 19)

    Emission control information 10-9 heated oxygen sensor (ho2s) inspection (e-02, 19) • remove the seat. ( ! 7-4) • disconnect the ho2 sensor coupler. • remove the ho2 sensor unit. % & • inspect the ho2 sensor and its circuit referring to flow table of the malfunction code (c44). • disconnect the ho2 ...

  • Page 470: (Only For E-33)

    10-10 emission control information evaporative emission control system inspection (only for e-33) • remove the frame cover. ( ! 7-5) • lift and support the fuel tank with its prop stay. ( ! 5-7) hoses inspect the hoses for wear or damage. Make sure that the hoses are securely connected. Evap caniste...

  • Page 471: Partshark.Com

    Emission control information 10-11 evap canister hose routing (only for e-33) *6 *5 *3 *2 *4 *1 1 purge hose *2 clamp ends should face outside. 2 wiring harness *3 white paint mark should face top side. 3 evap canister *4 pass through the purge hose between the frame and wiring harness. 4 frame *5 t...

  • Page 472: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 473: Dl650K5 ('05- Model)

    Note: the specifications and service data are the same as k4-model. Contents dl650k5 ('05- model) dl650k5 ('05 model) 11 11- 1 service data.......................................................................................11- 3 specifications.........................................................

  • Page 474: Specifications

    – 2 – specifications dimensions and dry mass overall length ...................................................................................... 2 290 mm (90.2 in) overall width........................................................................................ 840 mm (33.1 in) overall height ...

  • Page 475: Service Data

    – 3 – service data 4 stroke valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0.0019) ...

  • Page 476: Partshark.Com

    – 4 – camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. &...

  • Page 477: Partshark.Com

    – 5 – cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm², 185 – 242 psi) 1 100 kpa (11 kgf/cm², 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm², 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 – 0.0026...

  • Page 478: Partshark.Com

    – 6 – conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pin...

  • Page 479: Partshark.Com

    – 7 – transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.851...

  • Page 480: Partshark.Com

    – 8 – thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ----...

  • Page 481: Partshark.Com

    – 9 – fi sensors+ secondary throttle valve actuator throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed + g/b – - b/br tp sensor...

  • Page 482: Partshark.Com

    – 10 – electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 2 – 5 Ω + tap – - tap seconda...

  • Page 483: Partshark.Com

    – 11 – wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam i...

  • Page 484: Partshark.Com

    – 12 – brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 15.870 – 15.913 (0.6248 – 0.6265) ---- rear 14.000 – 14.043 ...

  • Page 485: Partshark.Com

    – 13 – tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 ...

  • Page 486: Partshark.Com

    – 14 – fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents...

  • Page 487: Partshark.Com

    – 15 – exhaust pipe/muffler installation ! Starter button inspection information inspect switch for continuity with a tester. If any abnormality is found, replace the respective switch assembies with new ones. Wire color o/r: orange with red tracer o/w: orange with white tracer y/g: yellow with blac...

  • Page 488: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 489: Dl650K6 ('06- Model)

    Note: asterisk mark (*) indicates the new k6-model service data.. K5 ('05 model). Note: Ø any differences between dl650k5 ('05 model) and dl650k6 ('06 model) in specifications and service data are clearly indicated with the asterisk marks (*). Ø contents dl650k6 ('06- model) dl650k6 ('06 model) 12 1...

  • Page 490: Specifications

    – 2 – specifications dimensions and dry mass overall length ...................................................................................... 2 290 mm (90.2 in) overall width ....................................................................................... 840 mm (33.1 in) overall height ...

  • Page 491: Service Data

    – 3 – service data 4 stroke valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0.0019) ...

  • Page 492: Partshark.Com

    – 4 – camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. &...

  • Page 493: Partshark.Com

    – 5 – cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm², 185 – 242 psi) 1 100 kpa (11 kgf/cm², 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm², 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 – 0.0026...

  • Page 494: Partshark.Com

    – 6 – conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pin...

  • Page 495: Partshark.Com

    – 7 – transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.851...

  • Page 496: Partshark.Com

    – 8 – thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ----...

  • Page 497: Partshark.Com

    – 9 – fi sensors+ secondary throttle valve actuator throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.7 v at idle speed + g/b – - b/br tp sensor...

  • Page 498: Partshark.Com

    – 10 – electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 2 – 5 Ω + tap – - tap seconda...

  • Page 499: Partshark.Com

    – 11 – wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam i...

  • Page 500: Partshark.Com

    – 12 – brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 15.870 – 15.913 (0.6248 – 0.6265) ---- rear 14.000 – 14.043 ...

  • Page 501: Partshark.Com

    – 13 – tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 ...

  • Page 502: Partshark.Com

    – 14 – fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents...

  • Page 503: Emission Control System

    – 15 – emission control system exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and three-way catalyst sys- tem. The fresh air is drawn into the exhaust port with the pair solenoid valve and pair reed valve. The pair solenoid valve is o...

  • Page 504: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 505: Dl650K7/ak7 (’07-Model)

    Contents dl650k7/ak7 (’07-model) this manual describes service data, service specifications, servicing procedures abs and ser- vicing procedures which differ from those of the dl650k6 (’06-model). Note: • any differences between the dl650k6 (’06-model) and dl650k7 (’07-model) in specifi- cations and...

  • Page 506: Dl650K7/ak7 (’07-Model)

    Dl650k7/ak7 (’07-model) contents country and area codes the following codes stand for the applicable country(-ies) and area(-s). Model code country or area effective frame no. Dl650 e-02 e-03 e-19 e-24 e-28 e-33 u.K. U.S.A. (except for california) e.U. Australia canada california (u.S.A.) js1b111120...

  • Page 507: Manual

    Abbreviations used in this manual a abdc : after bottom dead center abs : anti-lock brake system ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center a/f : air fuel mixture b bbdc : before bottom dead center btdc : before top dea...

  • Page 508: Partshark.Com

    N nox : nitrogen oxides o ohc : over head camshaft ops : oil pressure switch p pair : pulsed secondary air injection pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae : society of automotive engineers sds : suzuki diagnosis system stc system : s...

  • Page 509: Sae-to-Former Suzuki Term

    Sae-to-former suzuki term this table lists sae (society of automotive engineers) j1930 terms and abbreviations which may be used in this manual in compliance with sae recommendations, as well as their former suzuki names. Sae term former suzuki term full term abbreviation a anti-lock brake system ab...

  • Page 510: Partshark.Com

    Sae term former suzuki term full term abbreviation i idle speed control isc –––– idle speed control valve –––– isc valve ignition control ic electronic spark advance (esa) ignition control module icm –––– intake air temperature iat intake air temperature (iat), air tempera- ture m malfunction indica...

  • Page 511: Specifications (Dl650K7)

    Specifications (dl650k7) dimensions and dry mass overall length ...................................................... 2 290 mm (90.2 in) overall width ....................................................... 840 mm (33.1 in) overall height ...................................................... 1 390...

  • Page 512: Partshark.Com

    Chassis front suspension ................................................. Telescopic, coil spring, oil damped rear suspension .................................................. Link type, coil spring, oil damped front fork stroke ................................................... 150 mm (5.9 in) r...

  • Page 513: Specifications (Dl650Ak7)

    Specifications (dl650ak7) dimensions and dry mass overall length ...................................................... 2 290 mm (90.2 in) overall width ....................................................... 840 mm (33.1 in) overall height ...................................................... 1 39...

  • Page 514: Partshark.Com

    Chassis front suspension ................................................. Telescopic, coil spring, oil damped rear suspension .................................................. Link type, coil spring, oil damped front fork stroke ................................................... 150 mm (5.9 in) r...

  • Page 515: Partshark.Com

    Periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. Important: the pe...

  • Page 516: Maintenance And Tune-Up

    Maintenance and tune-up procedures this section describes the servicing procedures for each peri- odic maintenance item which differ from those of the dl650k6 (’06-model). For details other than the following items, refer to the dl650 service manual. Spark plug no.1 (front) spark plug removal • remo...

  • Page 517: Partshark.Com

    No.2 (rear) spark plug removal • lift and support the fuel tank. ( ! Dl650k4 5-7) • remove the spark plug caps. • remove the spark plugs with the special tool. # 09930-10121: spark plug socket wrench set heat range • check to see the heat range of the plug. Carbon deposit • check to see if there are...

  • Page 518: Partshark.Com

    Spark plug and plug cap installation % • install the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque. & spark plug: 11 n·m (1.1 kgf-m, 8.0 lb-ft) note: when fitting the spark plug caps, front and rear of cylinder head cover side, face the triangle mar...

  • Page 519: Fi System Diagnosis

    Fi system diagnosis ecm terminal terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) h — 2 iat sensor signal (iat) i ect sensor signal (ect) 3 iap sensor signal #1 (iap. F) j to sensor signal (tos) 4 stp sensor signal (stp) k tp sensor signal (tp) 5 power source for sensors (vcc) l iap...

  • Page 520: Partshark.Com

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

  • Page 521: Partshark.Com

    Dtc table and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 (p0335) ckp sensor the signal does not reach ecm for 2 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical parts ckp sensor, lead wir...

  • Page 522: Partshark.Com

    Dtc no. Detected item detected failure condition check for c23 (p1651) to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v in other than the above value, c23 (p1651) is indicated. To sensor, lead wire/coupler connection p1651 h sens...

  • Page 523: Partshark.Com

    Dtc no. Detected item detected failure condition check for c32 (p0201)/ c33 (p0202) fuel injector ckp sensor (pickup coil) signal is pro- duced, but fuel injector signal is inter- rupted several times (front 50 times, rear 25 times) or more continuously. In this case, the code c32 (p0201) or c33 (p0...

  • Page 524: Partshark.Com

    Dtc troubleshooting “c12” (p0335) ckp sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the dl650 service manual 4-23 for details. “c13” (p1750...

  • Page 525: Partshark.Com

    3) check the iap sensor coupler (front cylinder side 1 or rear cylinder side 2 ) for loose or poor contacts. If ok, then measure the iap sensor input voltage. 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the red wire 3 and ground. 7) also, measure t...

  • Page 526: Partshark.Com

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

  • Page 527: Partshark.Com

    “c14” (p0120-h/l) tp sensor circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( ! Dl650k4 5-7) 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the t...

  • Page 528: Partshark.Com

    6) measure the voltage at the red wire b and ground. 7) also, measure the voltage at the red wire b and b/br wire c . $ tp sensor input voltage: 4.5 – 5.5 v ( + red – - ground) ( + red – - b/br) # 09900-25008: multi-circuit tester set ' tester knob indication: voltage ( ( ) is the voltage ok? Step 2...

  • Page 529: Partshark.Com

    “c15” (p0115-h/l) ect sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the dl650 service manual 4-31 for details. “c21” (p0110-h/l) iat sensor...

  • Page 530: Partshark.Com

    5) measure the voltage between dg wire terminal and ground. 6) also, measure the voltage between dg wire terminal and b/br wire terminal. $ iat sensor input voltage: 4.5 – 5.5 v ( + dg – - ground) ( + dg – - b/br) # 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set ' tester...

  • Page 531: Partshark.Com

    “c23” (p1651-h/l) to sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the dl650 service manual 4-35 for details. “c24” (p0351) or “c25” (p0352...

  • Page 532: Partshark.Com

    “c28” (p1655) stv actuator circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( ! Dl650k4 5-7) 3) check the stva coupler for loose or poor contacts. 4) turn the ignition switch on ...

  • Page 533: Partshark.Com

    Step 2 1) turn the ignition switch off. 2) disconnect the stva coupler. 3) remove the throttle body. ( ! Page 52) 4) check the continuity between each terminal and ground. $ stva continuity: ∞ Ω (infinity) (terminal – ground) 5) if ok, then measure the stva resistance (between terminal a and termina...

  • Page 534: Partshark.Com

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

  • Page 535: Partshark.Com

    “c29” (p1654-h/l) stp sensor circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank. ( ! Dl650k4 5-7) 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the...

  • Page 536: Partshark.Com

    Step 2 1) turn the ignition switch off. 2) remove the air cleaner box. ( ! Page 51) 3) connect the stp sensor coupler. 4) insert the needle pointed probes to the stp sensor coupler. 5) disconnect the stva lead wire coupler. 6) turn the ignition switch on. 7) measure the stp sensor output voltage at ...

  • Page 537: Partshark.Com

    “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 (when indicating c32/p0201 for fuel injector #1) (when indicating c33/p0202 for fuel injector #2) 1) turn the ignition switch off. 2) remove the air cle...

  • Page 538: Partshark.Com

    5) if ok, then check the continuity between each terminal and ground. $ stp sensor continuity: ∞ Ω (infinity) # 09900-25008: multi-circuit tester set ) tester knob indication: resistance ( Ω ) are the resistance and continuity ok? Step 2 1) turn the ignition switch on. 2) measure the injector voltag...

  • Page 539: Partshark.Com

    “c40” (p0505 or p0506 and p0507) isc valve circuit malfunction % inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) remove the air cleaner box. ( ! Page 51) 3) check the isc valve coupler for loose or poor contacts. If ok, then chec...

  • Page 540: Partshark.Com

    4) disconnect the isc valve coupler and ecm coupler. 5) check the continuity between terminals a and i , terminals b and 0 , terminals c and g , terminals d and \ , terminals e and 0 , and terminals f and ^ . % $ isc valve wire continuity: continuity ( * ) # 09900-25008: multi-circuit tester set 099...

  • Page 541: Partshark.Com

    Active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” 1 . 5) check that the “spec” 2 is idle speed 1 300 ± 100 rpm. 6) che...

  • Page 542: Partshark.Com

    Check 3 1) click the button 1 and increase the “spec” 2 to 1 400 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2 . Also, check that the number of steps 4 in the isc valve position increases . Check 4 1) increase the “spec” 1 to 1 800 rpm. 2) check that the “desir...

  • Page 543: Partshark.Com

    “c41” (p0230) fp relay circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the dl650 service manual 4-44 for details. “c42” (p01650) ig switch circuit m...

  • Page 544: Partshark.Com

    “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24, 41) inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 (when indicating c44/p0130:) 1) turn the ignition switch off. 2) remove the seat. ( ! Dl650k4 7-4) 3) check the ho2 sensor for loose or ...

  • Page 545: Partshark.Com

    7) disconnect the ecm coupler. 8) check the continuity between w/g wire a and terminal 6 . 9) also, check the continuity between b/br wire b and terminal b . % $ ho2 sensor lead wire continuity: continuity ( * ) # 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set + tester k...

  • Page 546: Partshark.Com

    Is the voltage ok? Step 1 (when indicating c44/p0135:) 1) turn the ignition switch off. 2) remove the seat. ( ! Dl650k4 7-4) 3) check the ho2 sensor for loose or poor contacts. If ok, then measure the ho2 sensor resistance. 4) disconnect the ho2 sensor coupler and measure the resis- tance between te...

  • Page 547: Partshark.Com

    Step 2 (when indicating c44/p0135:) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w/b wire and ground. 4) if the tester voltage indicates the battery voltage, it is good conditio...

  • Page 548: Fuel Pump

    Fuel pump fuel discharge amount inspection " • lift and support the fuel tank. ( ! Dl650k4 5-7) • disconnect the fuel feed hose 1 from the fuel tank. • connect a proper fuel hose 2 to the fuel pump. • place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • disconnect...

  • Page 549: Partshark.Com

    Fuel pump construction 1 fuel level gauge 5 fuel pump 2 o-ring 6 fuel mesh filter & 3 fuel pressure regulator 7 o-ring item n·m kgf-m lb-ft 4 o-ring a fuel pump mounting bolt a 10 1.0 7.0 dl650k7/ak7 (’07-model) 13-45 partshark.Com 877-999-5686.

  • Page 550: Partshark.Com

    Fuel pump removal and disassembly removal • remove the fuel tank. ( ! Dl650k4 5-7) • remove the fuel pump assembly by removing its mounting bolts diagonally. " disassembly • remove the screws. • disconnect the terminals and • remove the fuel level gauge 1 . • remove the fuel pressure regulator holde...

  • Page 551: Partshark.Com

    • remove the fuel pressure regulator 3 . • remove the o-ring 4 and fuel pump holder 5 . • remove the fuel mesh filter 6 . • remove the fuel pump 7 . • remove the fuel joint pipe 8 . Dl650k7/ak7 (’07-model) 13-47 partshark.Com 877-999-5686.

  • Page 552: Partshark.Com

    Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. Note: if the fuel mesh filter is clogged with many sediment or rust, replace the fuel fil...

  • Page 553: Partshark.Com

    • install a new o-ring and apply suzuki super grease to it. " , 99000-25010: suzuki super grease “a” (or equivalent grease) • when installing the fuel pump assembly, first tighten all the fuel pump assembly mounting bolts lightly in the ascending order of numbers, and then tighten them to the specif...

  • Page 554: Throttle Body

    Throttle body construction only for e-33 1 stp sensor 8 secondary throttle link rod 2 tp sensor 9 throttle link rod 3 o-ring 0 stva & 4 fuel delivery pipe/hose a stp sensor mounting screw item n·m kgf-m lb-ft 5 fuel injector b tp sensor mounting screw a 3.5 0.35 2.5 6 o-ring c fuel delivery pipe mou...

  • Page 555: Partshark.Com

    Air cleaner and throttle body removal air cleaner box • remove the fuel tank. ( ! Dl650k4 . 5-7) • remove the iap sensor vacuum hoses ( 1 , 2 ). • disconnect the iap sensor (r) coupler 3 . • remove the clamp and disconnect the iap sensor (f) coupler 4 . • loosen the throttle body clamp screws. • dis...

  • Page 556: Partshark.Com

    Throttle body • disconnect the various lead wire couplers. 1 tp sensor 2 stp sensor 3 stva • remove the injector lead wire couplers. • disconnect the isc valve hoses. • loosen the throttle body clamp screws. 13-52 dl650k7/ak7 (’07-model) partshark.Com 877-999-5686.

  • Page 557: Partshark.Com

    • disconnect the throttle cables from their drum. • dismount the throttle body assembly. % throttle body disassembly % • remove the vacuum hoses ( 1 , 2 ). • disconnect the fuel feed hose 3 . • remove the throttle link rod 4 and secondary throttle link rod 5 . Note: the throttle link rod 4 is longer...

  • Page 558: Partshark.Com

    • remove the fuel injectors. • remove the tp sensor 7 and stp sensor 8 with the special tool. # 09930-11950: torx wrench note: prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. % % never remove the stva 9 and throttle body link plates 0 . ...

  • Page 559: Partshark.Com

    % throttle body cleaning " • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. % inspection check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose * delivery pipe/hose * injector cushion seal nev...

  • Page 560: Partshark.Com

    Throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • with the stv fully closed, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Note: * apply thin coat of the engine oil to th...

  • Page 561: Partshark.Com

    • apply thin coat of the engine oil to the new cushion seal 3 , and the o-ring 4 . % • install the fuel injector 5 by pushing it straight to the delivery pipe 6 . Note: align the coupler e of injector with boss f of the delivery pipe. % • install the fuel delivery pipe/hose 7 to the throttle body as...

  • Page 562: Partshark.Com

    Air cleaner box and throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the throttle pulling cable 1 and throttle returning cable 2 to the throttle cable drum. • loosen each throttle cable lock-nut. • turn in each throttle cabl...

  • Page 563: Partshark.Com

    Stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor out put voltage and adjust the stp sensor position as follows: • remove the air cleaner box. ( ! Page 51) • disconnect the stva coupler. ( ! Page 28) • insert the needle pointed probes to the stp sensor lead wire cou...

  • Page 564: Partshark.Com

    Tp sensor adjustment after all adjustments are completed, check or adjust the tps setting condition. 1. Warm up the engine and check the engine idle r/min. 2. Remove the seat. ( ! Dl650k4 7-4) 3. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. ( ! Page...

  • Page 565: Partshark.Com

    Throttle valve synchronization use of sds tool check and adjust the throttle valve synchronization between two cylinders. Step 1 • lift and support the fuel tank. ( ! Dl650k4 5-7) • remove the rubber caps 1 from each vacuum nipple on the throttle body. • connect the vacuum tester hoses 2 to each vac...

  • Page 566: Partshark.Com

    • click “active control”. • click “isc air volume control” 3 . • click “on” bottom 4 to fix the isc air volume between two cylinders. Note: when making this synchronization, be sure that the water tem- perature is within 80 – 100 °c (176 – 212 °f). A engine speed: approx. 1 300 rpm b isc valve posit...

  • Page 567: Partshark.Com

    Isc valve removal • remove the air cleaner box. ( ! Page 51) • disconnect the isc valve coupler 1 . % • disconnect the hoses and remove the isc valve 2 . Installation install the isc valve in the reverse order of removal. Note: when removing or replacing the isc valve, must be set the isc valve to t...

  • Page 568: Partshark.Com

    13-64 dl650k7/ak7 (’07-model) isc valve pre-set when removing or replac ing the isc valve, set the isc valv e using the following procedure: procedure 1) turn the ignition switch to the off position. 2) remove the seat. ( 7-4) 3) connect the special tool to the dealer mode coupler and turn its switc...

  • Page 569: Ignition System

    Ignition system inspection ignition coil primary peak voltage • disconnect all the spark plug caps. ( ! Page 12) • connect new spark plugs to each spark plug cap and ground them on the cylinder. Note: be sure that all the spark plugs are connected properly and the battery used is in fully-charged co...

  • Page 570: Partshark.Com

    • shift the transmission into neutral, turn the ignition switch to the “on” position and grasp the clutch lever. • press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage. • repeat the above procedure a few times and measure t...

  • Page 571: Combination Meter

    Combination meter fuel level gauge inspection ! Dl650k4 8-33 fuel level meter inspection • remove the fuel tank left side cover. ( ! Dl650k4 7-4) • disconnect the fuel pump lead wire coupler. • connect the each resistor between the yellow/black and black/white lead wires at the wire harness. • turn ...

  • Page 572: Partshark.Com

    Introduction of abs (for dl650a) front and rear wheel speed sensors wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2 . Abs control unit abs control unit calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels ...

  • Page 573: Partshark.Com

    Abs control unit calculating process the abs controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the abs control unit calculating process. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlle...

  • Page 574: Partshark.Com

    Hydraulic unit (hu) the hydraulic unit operates the solenoid valves based upon the signal which is output from the abs control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by operating separate components for t...

  • Page 575: Partshark.Com

    Dl650k7/ak7 (’07-model) 13-71 fail-safe function if malfunction occurs in the abs electric system, this sets valve relay off. Consequently, motor relay will be set off and the indicator light on, and no current will be applied to motor solenoid valve inactivating abs and turning abs indicator light ...

  • Page 576: Cautions In Servicing

    Cautions in servicing abs wiring • the abs parts are connected to various lead wires. The cou- pler and lead wire connections, as well as the lead wire and wire harness routing must be done correctly. Make sure that the proper clamps are used and positioned correctly. Note: if all of the connections...

  • Page 577: Partshark.Com

    Battery • only use a fully charged battery. • in order to prevent damage to the abs control unit etc., be sure to connect the battery properly. • never disconnect the battery or any other lead wires while the engine is running. Note: for battery and battery connection precautions. ( ! Dl650k4 4-4 an...

  • Page 578: Partshark.Com

    Abs information " • be sure to route the brake hoses correctly. • the abs does not shorten the motorcycle’s braking distance. When riding down slopes or on wet or bumpy roads the braking distance is lengthened as compared to a motorcycle without abs. In addition, braking distance increases the more ...

  • Page 579: Abs Components

    Abs components abs components location 1 abs indicator light 4 abs control unit/hu 2 front wheel speed sensor rotor 5 rear wheel speed sensor rotor 3 front wheel speed sensor 6 rear wheel speed sensor dl650k7/ak7 (’07-model) 13-75 partshark.Com 877-999-5686.

  • Page 580: Partshark.Com

    13-76 dl650k7/ak7 (’07-model) abs coupler connection diagram speedometer fuse bo x abs mo t or fuse fr ont wheel speed sensor ignition switch mode select switch rear wheel speed sensor abs contr ol unit abs v al ve fuse wire harness (wire har ness no .2) (wire har ness no .1) (har ness side) 10a 15a...

  • Page 581: Partshark.Com

    Abs wiring diagram r o b/r o o b/y o/y w/r bl gr/r w/y b/r b/w r/b r b o/y o o/g b/r b/w b b/y w/y b/r w/r b w b w o b/w r r r r r r r/b bi o/g bl o/g bl o/g on off lock p ignition switch battery 1: main 30 a starter relay 1 fuse box 1. Head hi 2. Head lo 3. Fuel 4. Ignition 5. Signal 6. Fan 15 a 15...

  • Page 582: Partshark.Com

    Abs unit system diagram pump motor motor rela y v alv e rela y rear wheel speed sensor f ront wheel speed sensor abs indicator light 25 11 16 5 7 19 4 13 2 12 18 43 2 1 15 14 13 12 11 10 9 8 7 6 5 26 25 24 23 22 21 20 19 18 17 16 1 f ront inlet v alv e 2 f ront outlet v alv e 3 rear inlet v alv e 4 ...

  • Page 583: Abs Troubleshooting

    Abs troubleshooting abs troubleshooting description many of the abs malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the abs. Before beginning any repairs, thor...

  • Page 584: Partshark.Com

    Troubleshooting procedure troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. ( ! Page 82) 2. Perform the pre-diagnosis inspection. ( ! Page 83) 3. Inspect the abs indicator li...

  • Page 585: Partshark.Com

    Basic troubleshooting diagram 1. Gather information from the customer. ( : page 82) 2. Perform the pre-diagnosis inspection. ( : page 83) 3. Inspect the abs indicator light. ( : page 86) 6. Inspect the abs components. ( : page 119) 4. Output the dtcs stored in the abs control unit. ( : page 89) 7. D...

  • Page 586: Partshark.Com

    Information gathering to properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without duplicating the malfunction, even...

  • Page 587: Partshark.Com

    Pre-diagnosis inspection the mechanical and hydraulic components of the brake system should be inspected prior to performing any electrical checks. These inspections may find problems that the abs could not detect; thus, shortening repair time. Brake brake fluid level check ( ! Dl650k4 2-22) brake p...

  • Page 588: Partshark.Com

    Abs component wheel speed sensor – sensor rotor clearance • inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thickness gauge 09900-20806: thick...

  • Page 589: Partshark.Com

    • check for continuity between 1 terminal of coupler and bat- tery - terminal, also 4 terminal of coupler and battery - ter- minal. # 09900-25008: multi-circuit tester set + tester knob indication: continuity ( * ) if there are no continuity, repair the coupler or wire harness. Abs control unit coup...

  • Page 590: Partshark.Com

    Abs indicator light inspection step 1 1) check if the abs indicator light lights up when turning the ignition switch to on. Note: if the abs indicator light flashes, there may be a short-circuit existing in the mode select switch wire. Does the abs indicator light up? The abs indicator light lights ...

  • Page 591: Partshark.Com

    Step 4 1) turn the ignition switch to off. 2) disconnect the abs control unit coupler. ( ! Page 84) 3) turn the ignition switch to on with the abs control unit cou- pler disconnected, measure the voltage between b terminal and 4 terminal at the coupler. $ normal value: 7.5 – 9.5 v and more # 09900-2...

  • Page 592: Partshark.Com

    Step 7 1) turn the ignition switch to off and disconnect the abs con- trol unit coupler. ( ! Page 84) 2) turn the ignition switch to on with the abs control unit cou- pler disconnected, measure the voltage between h terminal and 4 terminal at the coupler. $ normal value: battery voltage (12.0 v and ...

  • Page 593: Partshark.Com

    Dl650k7/ak7 (’07-model) 13-89 dtc (diagnostic trouble code) output connect the special tool to the mode select coupler to output the memorized dtcs on the abs indicator light. • turn the ignition switch to off. • remove the seat. ( 7-4) • connect the special tool to the mode select coupler 1 (orange...

  • Page 594: Partshark.Com

    Understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the abs indicator light. A number between 1 and 9 is represented by the number of times that the abs indicator light lights up in interval of 0.4 seconds and the separation between the tens and o...

  • Page 595: Partshark.Com

    Dl650k7/ak7 (’07-model) 13-91 dtc deleting and abs operation check dtc deleting • connect the special tool to the mode select coupler (o – b/w) and output the dtcs. \ 09930-82710: mode select switch • while the dtcs are being output, set the special tool to off. • in the dtc deletion mode, switch th...

  • Page 596: Partshark.Com

    Abs operation check after deleting the dtcs, repeat the code output procedure and make sure that no dtcs remain (the abs indicator light no longer flashes). If any dtcs remain, perform the appropriate procedures, then delete the codes. If dtcs are left stored, con- fusion may occur and unnecessary r...

  • Page 597: Partshark.Com

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

  • Page 598: Partshark.Com

    Use of sds diagnostic procedures * don’t disconnect couplers from abs hu, the battery cable from the battery, abs hu ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such discon- nection will erase the memorized ...

  • Page 599: Partshark.Com

    Use of sds diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • click the abs button 1 . • click the “dtc inspection” button 2 . • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the abs hu. Therefore, er...

  • Page 600: Partshark.Com

    • follow the displayed instructions. • check that both “current dtc” 4 and “past dtc” 5 are deleted (nil). 13-96 dl650k7/ak7 (’07-model) partshark.Com 877-999-5686.

  • Page 601: Partshark.Com

    Active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “abs” 1 . 4) click “active control” 2 . 5) click “abs hu operating” 3 . Dl650k7/ak7 (’07-model) 13-97 partshark.Com 877-999-5686.

  • Page 602: Partshark.Com

    6) it progresses to the next according to the following indication of screens. Return next cancel help return next cancel help 13-98 dl650k7/ak7 (’07-model) partshark.Com 877-999-5686.

  • Page 603: Partshark.Com

    Note: * if the front wheel is selected, lift the front wheel off the ground using a jack. * two operators are needed in this work; one should apply a rotational force to the front wheel. Return next cancel help return next cancel help dl650k7/ak7 (’07-model) 13-99 partshark.Com 877-999-5686.

  • Page 604: Partshark.Com

    Note: * in normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the abs hu operating sound will be heard. * the abs hu motor operates for 6 seconds and then stops automatically. Note: * inspect the rear brake as the same manner of fr...

  • Page 605: Partshark.Com

    Dtc table of abs *1 it goes off after running at more than 5 km/h (3.1 mile/h). *2 the wheel speed sensor lead wire is connected to the abs control unit, but a short-circuit or faulty conti- nuity inside the abs control unit caused this dtc to appear, therefore, the abs control unit/hu assembly must...

  • Page 606: Partshark.Com

    Dtc troubleshooting dtc “25” (c1625): wheel speed sensor related malfunction step 1 1) check that the specified tires are installed. Tire type: front: bridgestone tw101 j 110/80r19m/c 59h rear: bridgestone tw152 f 150/70r17m/c 69h are the tires ok? Step 2 1) make sure the tire pressure for each tire...

  • Page 607: Partshark.Com

    Step 4 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thickness gauge 09900-20806: thickness gauge are the clearances ok? Yes replace the abs ...

  • Page 608: Partshark.Com

    Dtc “35” (c1635): abs motor malfunction step 1 1) inspect if the pump motor makes turning noise by setting the ignition switch to on from off when the vehicle stands still. Does the pump motor make any turning noise? Step 2 1) remove the seat. ( ! Dl650k4 7-4) 2) inspect the abs motor fuse. Abs moto...

  • Page 609: Partshark.Com

    Dtc “41” (c1641): wheel speed sensor signal malfunction (f) step 1 1) inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thickness gauge 09900-20806: thic...

  • Page 610: Partshark.Com

    Dtc “42” (c1642): wheel speed sensor circuit open (f) step 1 1) turn the ignition switch to off. 2) remove the air cleaner box cap. ( ! Dl650k4 2-5) 3) remove the abs control unit/hu cover. ( ! Page 84) 4) check the abs control unit coupler and front wheel speed sensor coupler for loose or poor cont...

  • Page 611: Partshark.Com

    Step 4 1) measure the resistance between 5 terminal and ground at the abs control unit coupler. $ normal value: ∞ Ω (infinity) ) tester knob indication: resistance ( Ω ) is the resistance between 5 and ground ok? Step 5 1) measure the resistance between 1 terminal and ground at the front wheel speed...

  • Page 612: Partshark.Com

    Step 8 1) connect the front wheel speed sensor coupler. 2) connect three 1.5 v dry cells a in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between + dry cell terminal and f ter- minal on the abs control unit coupler. $ normal value: 5.9 – 16.8 ma / t...

  • Page 613: Partshark.Com

    Dtc “44” (c1644): wheel speed sensor signal malfunction (r) step 1 1) inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thickness gauge 09900-20806: thick...

  • Page 614: Partshark.Com

    Dtc “45” (c1645): wheel speed sensor circuit open (r) step 1 1) turn the ignition switch to off. 2) remove the seat. ( ! Dl650k4 7-4) 3) remove the abs control unit/hu cover. ( ! Page 84) 4) check the abs control unit coupler and rear wheel speed sensor coupler for loose or poor contacts. If ok, the...

  • Page 615: Partshark.Com

    Step 4 1) measure the resistance between i terminal and ground at the abs control unit coupler. $ normal value: ∞ Ω (infinity) ) tester knob indication: resistance ( Ω ) is the resistance between i and ground ok? Step 5 1) measure the resistance between 1 terminal and ground at the rear wheel speed ...

  • Page 616: Partshark.Com

    Step 8 1) connect the rear wheel speed sensor coupler. 2) connect three 1.5 v dry cells a in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between + dry cell terminal and 7 ter- minal on the abs control unit coupler. $ normal value: 5.9 – 16.8 ma # 09...

  • Page 617: Partshark.Com

    Dtc “47” (c1647): supply voltage (increased) note: when the voltage resumes the normal level, the abs indicator light will go off. Step 1 1) turn the ignition switch to off. 2) remove the seat. ( ! Dl650k4 7-4) 3) measure the voltage between the + and - battery terminals using the multi-circuit test...

  • Page 618: Partshark.Com

    Step 3 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( ! Page 84) 3) check the abs control unit coupler for loose or poor con- tacts. If ok, then disconnect the abs control unit coupler. 4) run the engine at 5 000 r/min with the dimmer switch set to hi. 5) measure the ...

  • Page 619: Partshark.Com

    Dtc “48” (c1648): supply voltage (decreased) note: when the voltage resumes the normal level, the abs indicator light will go off. Step 1 1) turn the ignition switch to off. 2) remove the seat. ( ! Dl650k4 7-4) 3) measure the voltage between the + and - battery terminals using the multi-circuit test...

  • Page 620: Partshark.Com

    Step 3 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( ! Page 84) 3) check the abs control unit coupler for loose or poor con- tacts. If ok, then disconnect the abs control unit coupler. 4) run the engine at 5 000 r/min with the dimmer switch set to hi. 5) measure the ...

  • Page 621: Partshark.Com

    Dtc “55” (c1655): abs control unit malfunction step 1 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thickness gauge 09900-20806: thickness ga...

  • Page 622: Partshark.Com

    Dtc “61” (c1661): abs solenoid malfunction step 1 1) turn the ignition switch to off. 2) remove the seat. ( ! Dl650k4 7-4) 3) open the fuse box and inspect the abs valve fuse 1 . Abs valve fuse: 25 a is the abs valve fuse ok? % step 2 1) remove the abs control unit/hu cover. ( ! Page 84) 2) check th...

  • Page 623: Partshark.Com

    Abs component removal, inspection and installation front wheel speed sensor/sensor rotor removal % • raise the front wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the front wheel speed sensor by removing the mounting bolt. • remove the front wheel assembly. ...

  • Page 624: Partshark.Com

    • remove the fuel tank. ( ! Dl650k4 5-7) • remove the air cleaner box cap. ( ! Dl650k4 2-5) • disconnect the sensor coupler and remove the front wheel speed sensor. ( ! Page 133) inspection • inspect the wheel speed sensor for damage. • clean the sensor if any metal particle or foreign material stuc...

  • Page 625: Partshark.Com

    • align the recess a on the speed sensor bracket with the stop- per b on the right front fork. • check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) # 09900-20803: thicknes...

  • Page 626: Partshark.Com

    Front wheel speed sensor installation front wheel speed sensor right left 0.3 – 1.5 mm (0.012 – 0.059 in) 13-122 dl650k7/ak7 (’07-model) partshark.Com 877-999-5686.

  • Page 627: Partshark.Com

    Rear wheel speed sensor/sensor rotor removal % • raise the front wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the rear wheel speed sensor by removing the mount- ing bolt. • remove the rear wheel assembly. ( ! Dl650k4 7-36) " • remove the rear wheel speed se...

  • Page 628: Partshark.Com

    Inspection • inspect the wheel speed sensor for damage. • clean the sensor if any metal particle or foreign material stuck on it. • check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. Installation installation is in the reverse or...

  • Page 629: Partshark.Com

    Rear wheel speed sensor installation for e-03, 28, 33 right left 0.3 – 1.5 mm (0.012 – 0.059 in) rear wheel speed sensor dl650k7/ak7 (’07-model) 13-125 partshark.Com 877-999-5686.

  • Page 630: Partshark.Com

    Abs control unit/hu removal " % • remove the seat. ( ! Dl650k4 7-4) • remove the battery. • drain the brake fluid. ( ! Dl650k4 7-71) • disconnect the following parts from the battery case 1 . 2 fuse box and turn signal/side-stand relay 3 starter relay 4 fuel pump relay 5 abs valve relay fuse 6 abs m...

  • Page 631: Partshark.Com

    • loosen the flare nuts 9 and disconnect the brake pipes. • disconnect the abs control unit coupler 0 . • remove the abs control unit/hu by removing the mounting bolts. Installation installation is in the reverse order of removal. Pay attention to the following points. • tighten the brake pipe flare...

  • Page 632: Partshark.Com

    Wire harness, hose routing and sensor installation wire harness routing *1 clamp end should face upward. *3 pass through the harness under the cowling boss. *2 cut the tip of clamp after clamp. *4 triangle mark of each spark plug cap must be brought to the exhaust side. Wiring harness ig coil couple...

  • Page 633: Partshark.Com

    *1 triangle mark of each spark plug cap must be brought to the exhaust side. *4 do not slack the lead wire. *2 cut the tip of clamp after clamping. *5 pass through the pair reed valve wire between the frame and pair control solenoid valve. *3 clamp the high-tension cord. *6 pass through the licence ...

  • Page 634: Partshark.Com

    Front brake hose routing (for dl650) 1 brake hose *2 after positioning the brake hose junction with the stopper, tighten the bolt. 2 brake hose guide *3 after positioning the clamp with the stopper, tighten the clamp bolt. 3 brake hose clamp *4 assemble the brake hose firmly. 4 throttle cables *5 cl...

  • Page 635: Partshark.Com

    Front brake hose routing (for dl650a) 1 brake hose 7 abs control unit/hu 2 throttle cable (return) *1 after the brake hose union has contacted the stopper, tighten the union bolt. 3 throttle cable (pull) *2 clamp the brake hose firmly. 4 clutch cable *3 set the white painted marking side of the hose...

  • Page 636: Partshark.Com

    Rear brake hose routing (for dl650a) 1 abs control unit *3 white paint outside. 2 guide *4 insert the reservoir hose into union to the root. 3 wheel speed sensor lead wire *5 pass through the reservoir hose outside of the seat rail. 4 brake hose *6 clamp ends should face forward. *1 after the brake ...

  • Page 637: Partshark.Com

    Front wheel speed sensor installation (for dl650a) note: cut the tip of clamp after clamping. *1 hold the wheel speed sensor lead wire with clamp on the top of the radiator. *8 pass through the wheel speed sensor lead wire in front of the brake hose. Make clearance between the wheel speed sensor lea...

  • Page 638: Partshark.Com

    Rear wheel speed sensor installation (for dl650a) 1 guide *1 clamp the sensor lead wire to the brake hose at white painted marking. 2 wheel speed sensor lead wire *2 pass through the sensor lead wire inside of brake hose guide. 3 brake hose *3 letters should face outside. *3 *2 *1 13-134 dl650k7/ak7...

  • Page 639: Partshark.Com

    Fuel tank drain hose routing 1 fuel tank water drain hose 6 brake pipe (for abs model) 2 reservoir tank overflow hose *1 pass through the hoses under the brake pipe. (for abs model) 3 reservoir tank inlet hose *2 pass through the hoses outside of brake pipe and reservoir tank hose. 4 ho2 sensor (for...

  • Page 640: Partshark.Com

    Throttle body installation 1 isc valve *4 matching mark (yellow) *1 clamp ends should face back side. *5 matching mark (white) *2 clamp ends should face lower side. *6 align the marking with the rib of pipe. *3 clamp ends should face left side. 10 n.M (1.0 kgf-m, 7.0 lb-ft) *5, *6 *1 *1 *5 to canist...

  • Page 641: Partshark.Com

    Cooling system hose routing 1 clamp *4 clamp the water drain hose and oil pressure switch lead wire. 2 wiring harness *5 fill the bearing with engine oil until engine oil comes out from the hole of the be bearing housing. 3 oil pressure switch *6 clamp bolt head upward. 4 oil filter *7 clamp bolt he...

  • Page 642: Partshark.Com

    1 clamp *3 marking (yellow) 2 jiggle valve *4 clamp bolt head downward. 3 union *5 clamp bolt head left side. 4 radiator hose *6 make clearance between bulge of union and clamp. *1 marking *7 clamp face left side. *2 matching mark (white) 0 – 90˚ 90˚ 90˚ 90˚ *1 *2 *5 *7 *4 *5 *3 marking position *6 ...

  • Page 643: Partshark.Com

    Pair (air supply) system hose routing *1 approx. 20˚ 1 matching mark (white) 4 pair control solenoid valve 2 matching mark (yellow) *1 pass through the pair hose between the cylin- der head cover and intake pipe. 3 hose dl650k7/ak7 (’07-model) 13-139 partshark.Com 877-999-5686.

  • Page 644: Partshark.Com

    Battery protector installation *1 align the top of protector with the upper surface of the battery holder. Fwd 45 mm (1.77 in) 3.12 mm (0.12 in) 6.2 mm (0.24 in) 20 mm (0.79 in) *1 *1 13-140 dl650k7/ak7 (’07-model) partshark.Com 877-999-5686.

  • Page 645: Special Tools

    Special tools note: when order the special tool, please confirm whether it is available or not. Tightening torque 09900-20803 09900-20806 thickness gauge 09900-25008 multi-circuit tester set 09900-25009 needle pointed probe set 09900-28630 tps test wire har- ness 09904-41010 sds set tool 09913-10130...

  • Page 646: Service Data (Dl650K7)

    Service data (dl650k7) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0.0019) ---- ...

  • Page 647: Partshark.Com

    Camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. & ex. 2...

  • Page 648: Partshark.Com

    Cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm 2 , 185 – 242 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 – 0.0026...

  • Page 649: Partshark.Com

    Conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pin width...

  • Page 650: Partshark.Com

    Transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.851 (23/2...

  • Page 651: Partshark.Com

    Thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ---- 40 °c...

  • Page 652: Partshark.Com

    Fi sensors + stva + isc valve throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage (f & r) 4.5 – 5.5 v iap sensor output voltage (f & r) * approx. 1.6 v at idle speed tp sensor input voltage 4.5 ...

  • Page 653: Partshark.Com

    Electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary * 1 – 5 Ω terminal – terminal second...

  • Page 654: Partshark.Com

    Wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam indicato...

  • Page 655: Partshark.Com

    Brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front * 14.000 – 14.043 (0.5512 – 0.5529) ---- rear 14.000 – 14.043 (0.55...

  • Page 656: Partshark.Com

    Tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 psi) --...

  • Page 657: Partshark.Com

    Fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and co...

  • Page 658: Service Data (Dl650Ak7)

    Service data (dl650ak7) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0.0019) ----...

  • Page 659: Partshark.Com

    Camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. & ex. 2...

  • Page 660: Partshark.Com

    Cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm 2 , 185 – 242 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 – 0.0026...

  • Page 661: Partshark.Com

    Conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pin width...

  • Page 662: Partshark.Com

    Transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.851 (23/2...

  • Page 663: Partshark.Com

    Thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ---- 40 °c...

  • Page 664: Partshark.Com

    Fi sensors + stva + isc valve throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage (f & r) 4.5 – 5.5 v iap sensor output voltage (f & r) approx. 1.6 v at idle speed tp sensor input voltage 4.5 – ...

  • Page 665: Partshark.Com

    Electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 1 – 5 Ω terminal – terminal secondar...

  • Page 666: Partshark.Com

    Wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam indicato...

  • Page 667: Partshark.Com

    Brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 14.000 – 14.043 (0.5512 – 0.5529) ---- rear 14.000 – 14.043 (0.5512...

  • Page 668: Partshark.Com

    Tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 psi) --...

  • Page 669: Partshark.Com

    Fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and co...

  • Page 670: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 671: Dl650/ak  (’0 -Model)

    Contents page service data (dl650k8) ..................................................................... 14- 2 service data (dl650a/auek8) ........................................................... 14-14 note: specifications are the same as the k7-model. Dl650/ak (’0 -model) dl650/ak8 (’08-model)...

  • Page 672: Service Data (Dl650K8)

    – 2 – service data (dl650k8) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0.0019)...

  • Page 673: Partshark.Com

    – 3 – camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. &...

  • Page 674: Partshark.Com

    – 4 – cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm 2 , 185 – 242 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 – ...

  • Page 675: Partshark.Com

    – 5 – conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pin...

  • Page 676: Partshark.Com

    – 6 – transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.851...

  • Page 677: Partshark.Com

    – 7 – thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ----...

  • Page 678: Partshark.Com

    – 8 – fi sensors + stva + isc valve throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage (f & r) 4.5 – 5.5 v iap sensor output voltage (f & r) approx. 1.6 v at idle speed tp sensor input voltage ...

  • Page 679: Partshark.Com

    – 9 – electrical item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 1 – 5 Ω terminal – terminal secondary 25 – 4...

  • Page 680: Partshark.Com

    – 10 – wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam i...

  • Page 681: Partshark.Com

    – 11 – brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 14.000 – 14.043 (0.5512 – 0.5529) ---- rear 14.000 – 14.043 ...

  • Page 682: Partshark.Com

    – 12 – tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 ...

  • Page 683: Partshark.Com

    – 13 – fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents...

  • Page 684: Service Data (Dl650A/auek8)

    – 14 – service data (dl650a/auek8) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) ---- ex. 0.20 – 0.30 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.020 – 0.047 (0.0008 – 0...

  • Page 685: Partshark.Com

    – 15 – camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.48 – 35.53 (1.3968 – 1.3988) 35.18 (1.3850) ex. 33.48 – 33.53 (1.3181 – 1.3201) 33.18 (1.3063) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D. In. ...

  • Page 686: Partshark.Com

    – 16 – cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm 2 , 185 – 242 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.065 (0.0022 –...

  • Page 687: Partshark.Com

    – 17 – conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00 (0.825 – 0.827) ---- crank pi...

  • Page 688: Partshark.Com

    – 18 – transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio 3.133 (47/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29/21) ---- 4th 1.125 (27/24) ---- 5th 0.961 (25/26) ---- top 0.85...

  • Page 689: Partshark.Com

    – 19 – thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 88 °c (190 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) ---- ect sensor resistance 20 °c (68 °f) approx. 2.45 k Ω ---...

  • Page 690: Partshark.Com

    – 20 – fi sensors + stva + isc valve throttle body item specification note ckp sensor resistance 130 – 240 Ω w – g ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage (f & r) 4.5 – 5.5 v iap sensor output voltage (f & r) approx. 1.6 v at idle speed tp sensor input voltage...

  • Page 691: Partshark.Com

    – 21 – electrical item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Ckp sensor resistance 130 – 240 Ω w – g ignition coil resistance primary 1 – 5 Ω terminal – terminal secondary 25 – ...

  • Page 692: Partshark.Com

    – 22 – wattage unit: w item specification e-03, 24, 28, 33 others headlight 12 v 60/55 w × 2 (h4) ← position/parking light 12 v 5 w × 2 brake light/taillight 12 v 21/5 w × 2 ← turn signal light 12 v 21 w ← license light 12 v 5 w ← speedometer light led ← turn signal indicator light led ← high beam i...

  • Page 693: Partshark.Com

    – 23 – brake + wheel unit: mm (in) item standard limit rear brake pedal height 15 – 25 (0.59 – 0.98) ---- brake disc thickness front 5 (0.20) 4.5 (0.18) rear 5 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bore front 14.000 – 14.043 (0.5512 – 0.5529) ---- rear 14.000 – 14.043 ...

  • Page 694: Partshark.Com

    – 24 – tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 280 kpa (2.80 kgf/cm², 41 ...

  • Page 695: Partshark.Com

    – 25 – fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents...

  • Page 696: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 697: L650/ak9   (’09-Model)

    Contents page 52'%+(+%#6+105 6jkuejcrvgtfguetkdguugtxkegurgekhkecvkqpuugtxkegfcvccpfugtxkekpirtqegfwtgtuyjkej fkhhgthtqovjqugqhvjg&.- ŏ/1&'.Cpf&.#- ŏ/1&'. 016' #p[fkhhgtgpegudgvyggpvjg&.- ŏ/1&'.Qt&.#- ŏ/1&'. Cpf&.- ŏ/1&'.Cpf&.#- ŏ/1&'.Kpurgekhkecvkqpuctgengct[kpfkecvgf ykvjcpcuvgtkum octm 2ngcugtghg...

  • Page 698: Specifications

    Specifications dimensions and curb mass overall length ...................................................................................... 2 290 mm (90.2 in) overall width........................................................................................ 840 mm (33.1 in) overall height ........

  • Page 699: Partshark.Com

    13 3 3 , 8 2 , 4 2 , 3 0 e r o o/y o/g br b/r o o/r o/g br b/o b o/w w/bl o/g w/b y/b o/w r/w y/r r br/w b/br w/bl b b/w br/b gr/w gr/b br o/w r bl/g b/w dg r/w g/b b/y p/w b/r r/b b/br b/br b/w bl/b gr/r w p y/b o/r b/br b/bl b/g bl/w w/r br/w bl/y bl/r y b/br bl/w bl/b bl/g bl/r bl/y r o/w w/r gr/...

  • Page 700: Partshark.Com

    Dl650k7 (for e-03, 28, 33) b/bl r o o/y gr br b/r o o/r o/g br o/b o/w b/r b/bl y/g y/w o/r o/b o/w o/g w/b y/g y/w o b/w o/g b/o b o/w w/bl o/g w/b y/b o/w r/w y/r r br/w b/br w/bl gr/w b/w w/y lbl w/b br g b gr/b b/w dbr lg p/w br/b b/lg y/b bl/y gr/r b/g w/r w bl y/g b/w g/y p/w br/w b/bl o/r bl/...

  • Page 701

    Dl650ak7 (for e-03, 28, 33) b/bl r o o/y gr br b/r o o/r o/g br o/b o/w b/r b/bl y/g y/w o/r o/b o/w o/g w/b y/g y/w o b/w o/g b/o b o/w w/bl o/g w/b y/b o/w r/w y/r r br/w b/br w/bl gr/w b/w w/y lbl w/b br g b gr/b b/w dbr lg p/w br/b b/lg y/b bl/y gr/r b/g w/r w bl y/g b/w g/y p/w br/w b/bl o/r bl...