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Suzuki GW250 Service Manual

Summary of GW250

  • Page 1

    K dic128 gw250 l3 99500-32170-01e cover14 (18 mm) 2012.06.12 printed in japan l3 l3 service manual se rv ic e m a n u a l gw250 g w 25 0 9 9 5 0 0 - 3 2 1 7 0 - 0 1 e changzhou haojue suzuki motorcycle co.,ltd..

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 fi system diagnosis 4 fuel system and throttle body 5 exhaust system 6 cooling and lubrication system 7 chassis 8 electrical system 9 servicing information 10 emission control information 11 wiring diagram 12 foreword this manual cont...

  • Page 3: How to Use This Manual

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

  • Page 4: Symbol Marks and Materials

    Symbol marks and materials listed in the table below are the symbols indicating instructions and other information. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Use suzuki super long ...

  • Page 5: Abbreviations Used In This

    Abbreviations used in this manual a abdc : after bottom dead center ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center a/f : air fuel mixture b bbdc : before bottom dead center btdc : before top dead center b+ : battery positiv...

  • Page 6

    P pair : pulsed secondary air injection pcm : power control module pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae : society of automotive engineers sds : suzuki diagnosis system t to sensor : tip-over sensor (tos) tp sensor : throttle positio...

  • Page 7: General Information

    General information 1-1 1 general information contents warning/caution/notice/note ......................................................... 1- 2 general precautions ......................................................................... 1- 2 suzuki gw250l3 (’13-model) ...............................

  • Page 8: Warning/caution/notice/note

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

  • Page 9

    General information 1-3 * never use gasoline as a cleaning solvent. * after servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related to the system for leaks. * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. ...

  • Page 10: Suzuki Gw250L3 (’13-Model)

    1-4 general information suzuki gw250l3 (’13-model) note: difference between illustration and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The en...

  • Page 11

    General information 1-5 fuel, oil and engine coolant recommendation fuel gasoline used should be graded 91 octane (research method) or higher. Unleaded gasoline is recom- mended. Engine oil oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oi...

  • Page 12

    1-6 general information brake fluid specification and classification: dot 4 front fork oil use suzuki fork oil g10 or equivalent. Engine coolant recommendation recommended engine coolant the factory filled engine coolant of this vehicle is suzuki super long life coolant (blue). It is recommended to ...

  • Page 13: Break-In Procedures

    General information 1-7 break-in procedures during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performa...

  • Page 14: Information Labels

    1-8 general information information labels no. Label or plate name 1 i.D. Plate (for-p21, 24, 71) 2 tire information label 3 general warning label 4 brake approval label (for-p21, 24) 5 fuel limitation label (for-p12) 6 noise label (for-p24) chain case frame (rh).

  • Page 15: Specifications

    General information 1-9 specifications dimensions and curb mass overall length .......................................................................... 2 145 mm (84.4 in) overall width ........................................................................... 760 mm (29.9 in) overall height ........

  • Page 16

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

  • Page 17: Periodic Maintenance

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

  • Page 18

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

  • Page 19

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

  • Page 20: Maintenance and Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • remove the fuel tank. ( 5-2) • remove the screws 1 and slide the air cleaner cover 2 upward. • remove the air cleaner ele...

  • Page 21

    Periodic maintenance 2-5 exhaust pipe bolts and muffler bolts • tighten the exhaust pipe bolts, muffler support bolts, muffler chamber support bolt and exhaust connecting bolts to the specified torque. Tighten initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) t...

  • Page 22

    2-6 periodic maintenance spark plugs removal • disconnect the spark plug caps. • remove the spark plugs.  09930-10121: spark plug wrench set heat range • check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark pl...

  • Page 23

    Periodic maintenance 2-7 electrode’s condition • check the condition of the electrode. • if it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. Installation • screw the spark plugs into the cylinder head with fingers, and t...

  • Page 24

    2-8 periodic maintenance valve clearance • remove the fuel tank covers. ( 8-5) • remove the spark plugs 1. ( 2-6) • remove the cylinder head caps 2 and reservoir tank mount- ing bolts 3. • disconnect the pair hose 4 and remove the cylinder head cover 5. ( 3-12) the valve clearance specification i...

  • Page 26

    2-10 periodic maintenance • turn the crankshaft counterclockwise 540 degrees (1-1/2 turns) to set the #1 (left) cylinder at tdc of compression stroke. Bring the notch c on the left end of camshaft to the position as shown. D intake side • inspect the #1 (left) cylinder valve clearance as the same ma...

  • Page 27

    Periodic maintenance 2-11 engine oil and oil filter engine oil replacement • keep the motorcycle upright. • place an oil pan below the engine, and drain oil by removing the filler cap 1 and oil drain plug 2. • tighten the drain plug 2 to the specified torque, and pour new oil through the oil filler....

  • Page 28

    2-12 periodic maintenance oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the clamp 1 and move the ho2 sensor lead wire 2 to left side of the oil filter. Note: be careful not to damage the ho2 sensor lead wire by the engine oil. • remove...

  • Page 29

    Periodic maintenance 2-13 pair (air supply) system • inspect the pair (air supply) system periodically. ( 11-3) throttle cable play • adjust the throttle cable play a as follows. • slide the boot 1. • loosen the lock-nut 2 of the throttle pulling cable. • turn the adjuster 3 clockwise or counterclo...

  • Page 30

    2-14 periodic maintenance clutch cable play • slide the boot 1. • loosen the lock-nut 2 and turn the adjuster 3 clockwise as far as it will go. • slide the boot 4. • loosen the lock-nut 5 and turn the cable adjuster 6 clock- wise as far as it will go. • drain engine oil and remove the clutch cover. ...

  • Page 31

    Periodic maintenance 2-15 cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the “f” and “l” lines on the engine coolant reservoir. • if the level is below the “l” line, and add engine coolant to the “f” line from the engine coolant...

  • Page 32

    2-16 periodic maintenance air bleeding the cooling circuit 1) add engine coolant up to the radiator inlet. 2) support the motorcycle upright. 3) slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. 4) add engine coolant up to the radiator inlet. 5) start up t...

  • Page 33

    Periodic maintenance 2-17 drive chain • support the motorcycle with a jack. (for p-21, 24, 71) • place the motorcycle on the center stand. (for p-12) • visually check the drive chain for the possible defects listed below. * loose pins * excessive wear * damaged rollers * improper chain adjustment * ...

  • Page 34

    2-18 periodic maintenance • loosen or tighten both chain adjuster nuts 2 until there is 20 – 30 mm (0.8 – 1.2 in) of slack a at the middle of the chain between the engine and rear sprockets as shown.  drive chain slack a: standard: 20 – 30 mm (0.8 – 1.2 in) • after adjusting the drive chain, tighte...

  • Page 35

    Periodic maintenance 2-19 brake brake fluid level check • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level by observing the lower lines a on the front and rear brake fluid reservoirs. • when the brake fluid level is below the lower line, replenish with bra...

  • Page 36

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

  • Page 37

    Periodic maintenance 2-21 brake pedal height • loosen the lock-nut 1. • turn the push rod 2 until the brake pedal height becomes 38 – 48 mm (1.5 – 1.9 in) a below the top of the footrest. • tighten the lock-nut 1 securely.  rear brake master cylinder rod lock-nut: 18 n·m (1.8 kgf-m, 13.0 ibf-ft)  ...

  • Page 38

    2-22 periodic maintenance front brake • fill the master cylinder reservoir to the upper level. Place the reservoir cap to prevent dirt from entering. • attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle. • squeeze and release the brake lever several times in...

  • Page 39

    Periodic maintenance 2-23 tires 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 specificatio...

  • Page 40

    2-24 periodic maintenance steering the steering should be adjusted properly for smooth turning of the handlebars and safe running. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support t...

  • Page 41

    Periodic maintenance 2-25 chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-26 for the loca- tions of the following nuts and bolts on the motorcycle.) tighten initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 mi...

  • Page 42

    2-26 periodic maintenance.

  • Page 43: Compression Pressure Check

    Periodic maintenance 2-27 compression pressure check the compression pressure reading 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 ...

  • Page 44: Oil Pressure Check

    2-28 periodic maintenance oil pressure check check the engine oil pressure periodically. This will give a good indication of 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 pr...

  • Page 45: Sds Check

    Periodic maintenance 2-29 sds check using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the cond...

  • Page 46

    2-30 periodic maintenance data at 3 000 r/min under no load data at the time of racing approx. 3 000 r/min check the manifold absolute pressure. Xx kpa check the engine coolant temperature. Xx ˚c pair control solenoid valve on off in accordance with the throttle valve opens closes throttle: slowly o...

  • Page 47

    Periodic maintenance 2-31 data of intake negative pressure during idling (100 °c) data of manifold absolute pressure operation at the time of starting check the manifold absolute pressure. Xx kpa check the engine coolant temperature. Approx. 100 ˚c check the manifold absolute pressure. Xx kpa.

  • Page 48

    2-32 periodic maintenance example of trouble three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same co...

  • Page 49: Engine

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

  • Page 50

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

  • Page 51

    Engine 3-3 engine removal and installation engine removal • drain engine oil. ( 2-11) • drain engine coolant. ( 2-15) • remove the seat. ( 8-5) • disconnect the battery - lead wire. • remove the fuel tank 1. ( 5-2) • remove the throttle body assembly 2. ( 5-12).

  • Page 52

    3-4 engine • remove the exhaust pipes and mufflers 3. ( 6-2) • disconnect the spark plug cap #2 4, pcv hose 5, starter motor lead wire 6 and battery - lead wire 7. • disconnect the clamps 8, gp switch coupler 9, generator coupler 0, ckp sensor coupler a and side-stand switch cou- pler b. • disconne...

  • Page 53

    Engine 3-5 • remove the oil pressure switch lead wire e. • remove the engine sprocket cover f. • loosen the clutch cable nuts g and clutch cable adjuster h. • remove the clutch release arm i along with the clutch cable j. • remove the clutch release camshaft retainer k. • disconnect the spark plug c...

  • Page 54

    3-6 engine • move the speed sensor bracket o and remove the dowel pins p. • remove the speed sensor rotor q by removing it bolt while depressing the rear brake pedal. • remove the engine sprocket nut r while depressing the rear brake pedal. • remove the washer s. • loosen the rear axle nut t and lef...

  • Page 55

    Engine 3-7 • disengage the gearshift link arm w by removing the bolt. Note: mark the position of the gearshift link arm on the gearshift shaft before removing. • remove the bolts x and washers y. • move the right footrest bracket assembly z. • remove the bolts [ and washers \. • remove the left foot...

  • Page 56

    3-8 engine • remove the engine mounting bolts and nuts. • gradually lower the engine. • remove the engine assembly. Engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: note: the engine mounting nuts and frame down tube nuts are self-l...

  • Page 57

    Engine 3-9 • tighten the gearshift link arm bolt 3 to the specified torque.  gearshift link arm bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • inspect the gearshift lever height d between the gearshift lever top and footrest.  gearshift lever height: standard: 28 – 38 mm (1.1 – 1.5 in) • install the engin...

  • Page 58

    3-10 engine • install the clutch release camshaft retainer 9. ( 10-16) • apply a small quantity of thread lock to the oil clutch release camshaft retainer bolt 0.  99000-32110: thread lock cement super “1322” or equivalent • when installing the clutch release arm a, align the groove e of clutch re...

  • Page 59

    Engine 3-11 • after finishing the engine installation, check the following items. * wiring harness, cables and hoses routing ( 10-14 to 10-22 and 10-25) * throttle cable play ( 2-13) * clutch cable play ( 2-14) * drive chain slack ( 2-18) * engine oil ( 2-11) * engine coolant ( 2-15) * throttl...

  • Page 60: Engine Disassembly

    3-12 engine engine disassembly • remove the spark plugs 1.  09930-10121: spark plug wrench set • remove the cylinder head cover caps 2. Cylinder head cover • remove the cylinder head cover 1 and its gasket. • remove the dowel pins 2. Camshaft • remove the valve timing inspection cap 1 and generator...

  • Page 61

    Engine 3-13 • turn the crankshaft counterclockwise to bring the “i r” line on generator rotor to the index mark a of the valve inspection hole and also to bring the camshaft to the position as shown. Note: at the above condition, the cylinder is at tdc of compression stroke and also the engraved lin...

  • Page 62

    3-14 engine • turn the crankshaft counterclockwise and remove the cam- shaft sprocket bolts 9. Note: do not drop the camshaft sprocket bolts 9 into the cylinder head. • slide and drop the camshaft sprocket 0 to the camshaft a. • disengage the cam chain b from the camshaft sprocket 0. • remove the ca...

  • Page 63

    Engine 3-15 • remove the cylinder head gasket 4, dowel pins 5 and cam chain guide 6. • remove the water inlet connector 7. • remove the cylinder bolts 1 and cylinder 8. Note: if the cylinder does not come off, lightly tap it with a plastic ham- mer. • remove the gasket 9 and dowel pins 0. Piston • p...

  • Page 64

    3-16 engine clutch cover • remove the clutch cover 1. • remove the dowel pins 2 and gasket 3. Clutch • remove the clutch spring bolts and clutch springs. Note: loosen the clutch spring set bolts little by little and diagonally. • remove the clutch pressure plate 1. • remove the clutch drive plates 2...

  • Page 65

    Engine 3-17 • remove the thrust washer 6, bearing 7 and clutch push piece 8. • remove the clutch push rod 9. Note: if it is difficult to pull out the push rod 9, use a magnetic hand or a wire. • flatten the lock washer 0 of the clutch sleeve hub nut. • remove the clutch sleeve hub nut a with the spe...

  • Page 66

    3-18 engine • remove the thrust washer c and primary driven gear assem- bly d. • remove the spacer e. Oil pump • remove the snap ring 1, washer 2 and oil pump driven sprocket 3.  0990-06107: snap ring pliers (open type) note: do not drop the snap ring 1 and washer 2 into the crankcase. • remove the...

  • Page 67

    Engine 3-19 gearshift system • remove the snap ring 1 and washer 2 from the gearshift shaft.  0990-06107: snap ring pliers (open type) • remove the gearshift shaft assembly 3 and washer 4. • remove the gearshift cam stopper plate bolt 5 and gearshift cam stopper plate 6. • remove the gearshift cam ...

  • Page 68

    3-20 engine primary drive gear • hold the primary drive gear nut and remove the crank bal- ancer bolt 1 and washer 2. • hold the generator rotor and remove the primary drive gear nut 3.  09930-44521: rotor holder note: the primary drive gear nut 3 has left-hand threads. • remove the spring washer 4...

  • Page 69

    Engine 3-21 generator rotor • hold the generator rotor with the special tool.  09930-44521: rotor holder • loosen the generator rotor bolt 1. Note: when loosen the generator rotor bolt 1, do not remove it. The generator rotor bolt is used in conjunction with the generator rotor remover when removin...

  • Page 70

    3-22 engine gear position switch • remove the gear position switch 1. • remove the switch contacts 2 and springs 3. Oil filter and oil pressure switch • remove the oil filter 1 with the special tool.  09915-40620: oil filter wrench • remove the oil pressure switch 2. Engine sprocket spacer • remove...

  • Page 71

    Engine 3-23 oil strainer and oil pressure regulator • remove the oil strainer 1. • remove the oil pressure regulator 2. Crankcase • remove the upper and lower crankcase bolts (m6). • remove the upper and lower crankcase bolts (m8). Note: loosen the crankcase bolts diagonally and the smaller sizes fi...

  • Page 72

    3-24 engine transmission • remove the oil seal 1. • remove the driveshaft assembly 2 and countershaft assem- bly 3. • remove the c-rings 4 and pins 5. Crank balancer and crankshaft • remove the crank balancer assembly 1. • remove the crankshaft assembly 2 and thrust bearings 3. • remove the cam chai...

  • Page 73

    Engine 3-25 engine components inspection and service cylinder head cover • clean and check the gasket grooves a and pair reed valve gasket mating surfaces b of cylinder head cover. If it is damaged, replace the cylinder head cover with a new one. Pair reed valve removal • remove the pair reed valve ...

  • Page 74

    3-26 engine camshaht housing disassembly • pull out the rocker arm shafts 1. • remove the valve rocker arms 2 and wave washers 3. Rocker arm shaft outside diameter inspection • measure each rocker arm shaft out side diameter using the micrometer. • if the diameter exceeds the limit, replace the rock...

  • Page 75

    Engine 3-27 cylinder head disassembly • remove the intake pipes 1 and cylinder head water outlet pipe 2. • remove the oil gallery plugs 3 if necessary. • compress the valve spring using the special tools.  09916-14510: valve lifter 09916-14910: valve lifter attachment • remove the two cotter halves...

  • Page 76

    3-28 engine • remove the oil seal 9 and spring seat 0. • remove the other valves in the same manner as described previously. Cylinder head distortion • decarbonize the combustion chambers. • check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take cl...

  • Page 77

    Engine 3-29 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 09900...

  • Page 78

    3-30 engine • if the seat width w measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter.  valve seat width w: standard (in. & ex.): 0.9 – 1.1 mm (0.035 – 0.043 in) valve seat servicing • the valve seats 1 for both the intake valves and exhaust valve...

  • Page 79

    Engine 3-31 valve stem end condition • inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. • make sure that the length a is not less than 2.2 mm (0.09 in). If this length becomes less than 2.2 mm (0.09 in), replace the valve.  valve ste...

  • Page 80

    3-32 engine • insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break.  molybdenum oil solution • install each valve spring with the small-pitch portion a facing cylinder head. A small-pitch portion b large-pitch portion c upwa...

  • Page 81

    Engine 3-33 • apply engine coolant to the new o-ring of the cylinder head water outlet pipe 6. • tighten the water outlet pipe bolt 7 to the specified torque.  cylinder head water outlet pipe bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • apply grease to the new o-rings of the intake pipes 8.  99000-25010...

  • Page 82

    3-34 engine camshaft cam wear • check the camshaft for wear or damage. • measure the cam height h with the micrometer. Replace a camshaft if the cams are worn to the service limit.  cam height h: service limit: (in.) : 33.04mm (1.301 in) (ex.) : 32.75 mm (1.289 in)  09900-20202: micrometer (25 – 5...

  • Page 83

    Engine 3-35 • if the camshaft journal oil clearance exceeds the limit, mea- sure 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.  camshaft journal holder ...

  • Page 84

    3-36 engine cam chain tension adjuster inspection • check that the push rod 1 can slide smoothly with the lock 2 of the ratchet mechanism released. • if it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one. Cam chain tensioner ...

  • Page 85

    Engine 3-37 cylinder bore • measure the cylinder bore diameter at six places. • if any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder.  cylinder bore: service limit: 53.590 mm (2.1098 in)  09900-20530: cylinde...

  • Page 86

    3-38 engine piston pin and pin bore • measure the piston pin bore diameter using the small bore gauge. • if the measurement is out of specification, replace the piston.  piston pin bore i.D.: service limit: 15.030 mm (0.5917 in)  09900-20602: dial gauge 09900-22401: small bore gauge (10 – 18 mm) •...

  • Page 87

    Engine 3-39 piston ring free end gap and piston ring end gap • measure the piston ring free end gap using the vernier cali- pers. • next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. • if any of the measurements exceeds the service lim...

  • Page 88

    3-40 engine clutch clutch drive plate inspection 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 the drive plate thickness is found to have reached the limit, replace it with a new one.  drive plate thickness...

  • Page 89

    Engine 3-41 clutch release bearing inspection inspect the clutch release bearing for any abnormality, particu- larly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearing. Clutch sleeve hub/primary...

  • Page 90

    3-42 engine starter clutch starter driven gear inspection • install the starter driven gear to the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns one direction only. If a large resistance is felt to rotation, inspect the st...

  • Page 91

    Engine 3-43 reassembly • apply engine oil to the one way clutch 1. • when inserting the one way clutch 1 into the guide 2, fit the flange a in the step of the guide 2. Note: be sure to seat the flange a of the one way clutch 1 to the guide 2. • when installing the guide 2 to the generator rotor 3, f...

  • Page 92

    3-44 engine primary drive gear rotate the primary drive scissors gear by finger to inspect for smooth rotation. If there are signs of any abnormalities, replace the springs. • when installing the primary drive scissors gear, align the punch mark a on the scissors gear with the rib b. Generator inspe...

  • Page 93

    Engine 3-45 gearshift system gearshift shaft disassembly • remove the following parts from the gearshift shaft. 1 snap ring 4 plate return spring 2 gearshift shaft return spring 5 washer 3 gearshift cam drive plate gearshift shaft inspection • inspect the gearshift shaft for wear or bend. • inspect ...

  • Page 94

    3-46 engine clutch release camshaft disassembly • pull out the clutch release camshaft 1. • remove the oil seal 2 and washer 3. • remove the bearing 4. Inspection inspect the clutch release camshaft of wear bend. Replace the camshaft if there is anything unusual. Reassembly reassemble the clutch rel...

  • Page 95

    Engine 3-47 oil pressure regulator inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. Oil strainer • clean the oil strainer if necessary. • inspect the oil strainer body fo...

  • Page 96

    3-48 engine transmission disassembly disassemble the countershaft and driveshaft as shown in the illustration. Note: identify the position of each removed part. Organize the parts in their respective groups (i.E., drive or driven) so that they can be reinstalled in their original positions. Fwd 1 co...

  • Page 97

    Engine 3-49 reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: note: * when reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view sho...

  • Page 98

    3-50 engine transmission parts location 1 countershaft 2 driveshaft.

  • Page 99

    Engine 3-51 crankcase gearshift fork and gearshift cam removal • remove the gearshift cam bearing retainer no.1 1 and no.2 2 by removing the bearing retainer screws 3 from the lower crankcase. • remove the gearshift fork shafts 4 and gearshift forks 5 from the lower crankcase. • remove the gearshift...

  • Page 100

    3-52 engine gearshift fork groove width measure the gearshift fork groove width using the vernier cali- pers.  shift fork groove width: standard: 5.0 – 5.1 mm (0.197 – 0.201 in)  09900-20101: vernier calipers (150 mm) gearshift fork thickness measure the gearshift fork thickness using the vernier ...

  • Page 101

    Engine 3-53 bearing removal • remove the gearshift shaft bearing with the special tools.  09921-20210: bearing remover (12 mm) 09930-30104: rotor remover sliding shaft • remove the oil seal 1. • remove the gearshift shaft bearing with the special tools.  09921-20210: bearing remover (12 mm) 09930-...

  • Page 102

    3-54 engine gearshift fork and gearshift cam installation • apply a small quantity of thread lock to the gearshift arm stop- per 1 and tighten it to the specified torque.  09900-32030: thread lock cement super “1303” or equivalent  gearshift arm stopper: 19 n·m (1.9 kgf-m, 13.5 lbf-ft) • install t...

  • Page 103

    Engine 3-55 oil jet removal • remove the oil jet 1 (for cylinder head) from the upper crank- case. • remove the crankshaft journal bearings 2. • remove the piston cooling oil jets 3 from the upper crank- case. • remove the oil jet 4 (for transmission) from the lower crank- case. Inspection and clean...

  • Page 104

    3-56 engine installation installation is in the reverse order of removal. Pay attention to the following points: • after tightening the oil jet 1 (for transmission), make sure that the oil jet end is flush with the crankcase mating surface. • apply engine oil to the new o-rings. • install the oil je...

  • Page 105

    Engine 3-57 installation installation is in the reverse order of removal. Pay attention to the following points: • fit the new gaskets 1 to the oil gallery plugs 2 as shown in the illustration. • tighten the oil gallery plugs 2 to the specified torque.  oil gallery plug (lower crankcase): 25 n·m (2...

  • Page 106

    3-58 engine crank balancer disassembly • remove the snap ring 1 and washer 2.  09900-06107: snap ring pliers (open type) • remove the following parts from the crank balancer 3. 4 balancer spring (6 pcs.) 5 pin (3 pcs.) 6 crank balancer driven gear 7 wave washer inspection • inspect the crank balanc...

  • Page 107

    Engine 3-59 crank balancer journal bearing inspection • inspect each bearing of upper and lower crankcases for any damage. Selection • place the plastigage axially along the crank balancer journal as shown.  09900-22301: plastigage (0.025 – 0.076 mm) • mate the lower crankcase with the upper crankc...

  • Page 108

    3-60 engine • check the corresponding crankcase journal i.D. Codes a, “a” or “b” which is stamped on the rear of upper crankcase. • check the corresponding crank balancer journal o.D. Codes b, “a”, “b” or “c” which is stamped on the crank balancer.  bearing selection table  crankcase i.D. Specific...

  • Page 109

    Engine 3-61 installation • when installing the bearings into the upper and lower crank- cases, be sure to install the tab a first, and then press in the other opposite side of the bearing. Note: do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell. Crankshaft and...

  • Page 110

    3-62 engine conrod big end side clearance • inspect the conrod side clearance using a thickness gauge. • if the clearance exceeds the limit, remove the conrod and inspect the conrod big end width and the crank pin width. • if the width exceed the limit, replace conrod or crankshaft.  conrod big end...

  • Page 111

    Engine 3-63 • tighten the conrod cap bolts to the specified torque, in two steps. ( 3-65) note: * when installing the conrod cap bolts to the crank pin, make sure that i.D. Code a on the conrod faces towards the intake side. * never rotate the crankshaft or conrod when a piece of plasti- gage is in...

  • Page 112

    3-64 engine  crank pin o.D.  09900-20202: micrometer (25 – 50 mm)  bearing thickness c color code note: the bearings must be replaced as a set. Conrod crank pin bearing and conrod installation • when installing the bearings into the conrod cap and conrod, be sure to install the tab a first, and t...

  • Page 113

    Engine 3-65 • apply engine oil to the thread portion and bearing surface of the bolts. • tighten the conrod cap bolts in the following two steps.  conrod cap bolt: 15 n·m (1.5 kgf-m, 11.0 lbf-ft) then turn 90° (1/4 turn) clockwise crankshaft journal bearing inspection • inspect each bearing of uppe...

  • Page 114

    3-66 engine • mate the lower crankcase with the upper crankcase. • tighten each crankshaft journal bolt (m:8) to the specified torque. ( 3-73) note: never rotate the crankshaft when a piece of plastigage is installed.  crankshaft journal bolt (m:8): initial : 15 n·m (1.5 kgf-m, 11.0 lbf-ft) final ...

  • Page 115

    Engine 3-67  crankshaft journal o.D. Specification  09900-20202: micrometer (25 – 50 mm)  bearing thickness specification c color code note: upper and lower crankshaft journal bearings are the same. Installation • when installing the bearings into the upper and lower crank- cases, be sure to inst...

  • Page 116

    3-68 engine crankshaft thrust bearing inspection • with the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase. • measure the thrust clearance a between the left side thrust bearing and crankshaft using the thickness gauge. L: left-side thrust bearing ...

  • Page 117

    Engine 3-69  thrust bearing selection table (right side) • after selecting a right-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it is within the standard range. A color code note: left-side thrust bearing has the same specification as the yel- low (...

  • Page 118: Engine Reassembly

    3-70 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. Crankshaft • before installing the cranksha...

  • Page 119

    Engine 3-71 transmission • install the bearing pins 1 and the c-rings 2 on the upper crankcase. • install the countershaft assembly to the upper crankcase. Note: align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing. • install the driveshaft assembly to the u...

  • Page 120

    3-72 engine crankcase • clean the mating surfaces of the crankcases. • install the dowel pins to the upper crankcase. • apply bond to the mating surface of the lower crankcase as follows.  99000-31140: suzuki bond no.1207b or equivalent note: • use of suzuki bond is as follows: * make surfaces free...

  • Page 121

    Engine 3-73 • match the upper and lower crankcases. Note: align the gearshift forks 1 with their grooves 2. • fit the new gasket washers to the bolts 5 to 8 numbers. • tighten the crankshaft journal bolts (m:8) in ascending order of numbers assigned to these bolts. Tighten each bolt a little at a ti...

  • Page 122

    3-74 engine • after the crankshaft journal bolts and crankcase bolts have been tightened, check if the crankshaft rotates smoothly. • also check that the driveshaft and countershaft rotate smoothly. Oil pressure regulator • fit a new gasket washer 1 to the oil pressure regulator 2. • apply thread lo...

  • Page 123

    Engine 3-75 oil pan • install a new gasket 1. • install the oil pan 2. Note: fit the clamp to the oil pan bolts a. • tighten the oil pan bolts diagonally to the specified torque.  oil pan bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) engine sprocket spacer • apply grease to the new o-ring and oil seal lip. ...

  • Page 124

    3-76 engine oil pressure switch • apply bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque.  99000-31140: suzuki bond no.1207b or equivalent  oil pressure switch: 13 n·m (1.3 kgf-m, 9.5 lbf-ft) note: be careful not to apply bond to the hole of th...

  • Page 125

    Engine 3-77 generator rotor • apply engine oil to the bushing of the starter driven gear. • fit the key 1 in the key slot on the crankshaft. • degrease the tapered portion a of generator rotor and also the crankshaft b. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make the...

  • Page 126

    3-78 engine • hold the generator rotor and tighten the primary drive gear nut 5 to the specified torque. Note: this primary drive gear nut 5 has left-hand threads.  09930-44521: rotor holder  primary drive gear nut: 70 n·m (7.0 kgf-m, 50.5 lbf-ft) • hold the primary drive gear nut 5 and tighten th...

  • Page 127

    Engine 3-79 • install the generator cover 3 and tighten the generator cover bolts to the specified torque.  generator cover bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) gearshift system • install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. • tighten the gearshift cam stopper bolt...

  • Page 128

    3-80 engine • install the gearshift shaft assembly 7 with the washer 8. Note: pinch the gearshift arm stopper 9 with return spring ends d. • install the washer 0 and new snap ring a.  09900-06107: snap ring pliers (open type) oil pump • when install the oil pump 1, fit the convex part a of the oil ...

  • Page 129

    Engine 3-81 • engage the oil pump drive chain 5 to the oil pump drive sprocket 6 and oil pump driven sprocket 7. • install the oil pump drive chain 5 with the oil pump drive sprocket 6 and oil pump driven sprocket 7. Note: teeth c on the oil pump drive sprocket 6 must face the clutch side. • install...

  • Page 130

    3-82 engine • apply engine oil to the inside and outside surface of the spacer 1. • install the spacer 1 onto the countershaft. Note: the chamfer side a of spacer 1 crankcase inside. • install the primary driven gear assembly 2 onto the countershaft. Note: * be sure to engage the oil pump drive spro...

  • Page 131

    Engine 3-83 • 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 lbf-ft) • bend the lock washer 5 securely. • install the clutch push rod 6 into the co...

  • Page 132

    3-84 engine • apply engine oil to the clutch drive plates and driven plates. • insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. • when install the clutch pressure plate b, fit the convex part a of the clutch pressure plate onto the conca...

  • Page 133

    Engine 3-85 • install dowel pins 1 and new gasket 2. • install the clutch cover 3 and tighten its bolts to the specified torque. F  clutch cover bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) starter motor • apply grease to the new o-ring.  99000-25010: suzuki super grease “a” or equivalent piston ring • in...

  • Page 134

    3-86 engine • install the 2nd ring 3 and the 1st ring 4 to the piston. Note: 1st ring and 2nd ring differ in shape. Note: face the side with the stamped mark upward when assembling. • position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps ar...

  • Page 135

    Engine 3-87 • place a clean rag over the cylinder base so as not to drop the piston pin circlip 2 into the crankcase. • install a piston pin circlip 2. Note: end gap of the circlip 2 should not be aligned with the cutaway in the piston pin bore. Cylinder • install the dowel pins and new gasket 1 to ...

  • Page 136

    3-88 engine • place the cylinder head 4 on the cylinder. Note: when installing the cylinder head, keep the cam chain taut. • apply engine oil to the washers a and thread portion of the bolts before installing the cylinder head bolts. • the conical curve side of washers a faces upside. • tighten the ...

  • Page 137

    Engine 3-89 camshaft • turn the crankshaft counterclockwise and align the “i r” line on the generator rotor with the index mark a of valve timing inspection hole while keeping the cam chain pulled upward. Note: * pull the cam chain upward, or the chain will be caught between crankcase and cam drive ...

  • Page 138

    3-90 engine • turn the crankshaft counterclockwise and tighten the cam- shaft sprocket bolts 5 to the specified torque.  camshaft sprocket bolt: 15 n·m (1.5 kgf-m, 11.0 lbf-ft) • turn the crankshaft counterclockwise to bring the “i r” line on generator rotor to the index mark e of the valve inspect...

  • Page 139

    Engine 3-91 • tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque.  camshaft journal holder bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) the camshaft journal holder bolts are made of a spe- cial material and much superior in strength, compared with other types of...

  • Page 140

    3-92 engine cam chain tension adjuster • retract the push rod by pushing the stopper 1. • fit a new gasket 2. • install the cam chain tension adjuster 3 and tighten its mounting bolts 4.  cam chain tension adjuster mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • install the spring 5, new o-ring 6 a...

  • Page 141

    Engine 3-93 • install new gasket 1 to the cylinder head cover. • apply bond to the cam end caps of the gaskets as shown.  99000-31140: suzuki bond no.1207b or equivalent • place the cylinder head cover on the cylinder head. • apply engine oil to both sides of the new gaskets 2. • fit a new gasket 2...

  • Page 142: Fi System Diagnosis

    Fi system diagnosis 4-1 4 contents fi system diagnosis precautions in servicing .................................................................. 4- 3 electrical parts ........................................................................... 4- 3 fuse.................................................

  • Page 143: Fi System Diagnosis

    4-2 fi system diagnosis contents fi system diagnosis dtc “c41” (p0230-h/l): fp relay circuit malfunction ......... 4-66 dtc “c41” (p2505): ecm power input signal malfunction..................................................................................... 4-69 dtc “c42” (p1650): ig switch circuit...

  • Page 144: Precautions In Servicing

    Fi system diagnosis 4-3 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 • faulty fi system is often related to poor electrical contact of connector/coupler. Before ser...

  • Page 145

    4-4 fi system diagnosis • when taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler. 1 coupler 2 probe • when connecting meter probe from the terminal side of the coupler (where connection from harne...

  • Page 146

    Fi system diagnosis 4-5 ecm/various sensors • since each component is a high-precision part, great care should be taken not to apply any severe impacts during removal and installation. • be careful not to touch the electrical terminals of the elec- tronic parts (ecm, etc.). The static electricity fr...

  • Page 147

    4-6 fi system diagnosis • before measuring voltage at each terminal, check to make sure that battery voltage is 11 v or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagno- sis. • never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit w...

  • Page 148

    Fi system diagnosis 4-7 • using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each t...

  • Page 149

    4-8 fi system diagnosis voltage check if voltage is supplied to the circuit being checked, voltage check can be used as circuit check. • with all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. If measurements wer...

  • Page 150

    Fi system diagnosis 4-9 • disconnect the connector/coupler included in circuit (coupler b) and measure resistance between terminal a and body ground. If continuity is indicated, the circuit is shorted to the ground between terminals a and b. 1 ecm *1 to other parts using the multi circuit tester • u...

  • Page 151: Fi System Technical Features

    4-10 fi system diagnosis 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. Thes...

  • Page 152

    Fi system diagnosis 4-11 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant tempe...

  • Page 153

    4-12 fi system diagnosis fi system parts location a ecm f heated oxygen sensor (ho2s) b ignition coil #2 (ig coil #2) g tip-over sensor (tos) c engine coolant temperature sensor (ects) h intake air pressure sensor #2 (iaps #2) d fuel injector #2 i pair control solenoid valve e idle speed control val...

  • Page 154

    Fi system diagnosis 4-13 a ecm p gear position switch (gp switch) j combination meter q speed sensor k ignition coil #1 (ig coil #1) r fuel pump relay (fp relay) l fuel injector #1 s cooling fan relay m throttle position sensor (tps) t fuel pump (fp) n intake air temperature sensor (iats) u cooling ...

  • Page 155

    4-14 fi system diagnosis fi system wiring diagram combination meter generator regulator/ rectifier tps ckps iaps #1 iaps #2 iats ects tos ho2s r g v bl/w w/r y/r b/bl br w b b/br bl/y y/w bl/g o/bl y o/r b gr br/y bl p y/g b/y w/r b/r w/b lbl b/g dg cooling fan motor cooling fan relay 10 a 10 a 10 a...

  • Page 156: Ecm Terminal

    Fi system diagnosis 4-15 ecm terminal terminal no. Circuit terminal no. Circuit 1 isc valve signal (isc 2a) m — 2 isc valve signal (isc 1a) n serial data for self-diagnosis 3 ho2 sensor (ho2s) o power source for fuel injectors (vm) 4 — p ecm ground (e1) 5 iap sensor signal #1 (iaps #1) q power sourc...

  • Page 157: Self-Diagnosis Function

    4-16 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 indicator light). To check the function of the individual fi system...

  • Page 158

    Fi system diagnosis 4-17 dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode selection switch. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from the device...

  • Page 159

    4-18 fi system diagnosis in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The malfunction code is indicated in three digits. I...

  • Page 160

    Fi system diagnosis 4-19 * tps adjustment 1. Connect the special tool (mode selection switch) to the mode select coupler. ( 4-23) 2. Warm up the engine and keep it running in idling speed. 3. Turn the mode selection switch on. 4. Check the position of the bar in the left of c code displayed on the ...

  • Page 161: Fail-Safe Function

    4-20 fi system diagnosis 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 162: Fi System Troubleshooting

    Fi system diagnosis 4-21 fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point r...

  • Page 163

    4-22 fi system diagnosis note: the form is a standard sample. The form should be modified according to conditions and characteristics of each market. Visual inspection prior to diagnosis using the mode selection switch or sds, perform the following visual inspections. The rea- son for visual inspect...

  • Page 164

    Fi system diagnosis 4-23 self-diagnostic procedures note: * do not disconnect the couplers from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in...

  • Page 165

    4-24 fi system diagnosis use of sds diagnostic procedures note: * do not disconnect the couplers from ecm, battery cable from battery, ecm ground wire from the engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized info...

  • Page 166

    Fi system diagnosis 4-25 use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase th...

  • Page 167

    4-26 fi system diagnosis show failure data (displaying data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show failure data”. Therefore, it is possible ...

  • Page 168

    Fi system diagnosis 4-27 malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical pa...

  • Page 169

    4-28 fi system diagnosis c23 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 sensor voltage in other than the above value, c23 (p1651) is indicated. To sensor, lead wire/coupler connection p1651 h sensor voltage is higher than s...

  • Page 170

    Fi system diagnosis 4-29 c44 ho2 sensor ho2 sensor output voltage is not input to ecm during engine operation and running condition. C44 (p0130) is indicated. Output state of ho2 sensor p0130 c44 the heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit, ...

  • Page 171

    4-30 fi system diagnosis dtc “c12” (p0335): ckp sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause the signal does not reach ecm for 3 sec. Or more...

  • Page 172

    Fi system diagnosis 4-31 step 1 ckp sensor signal circuit check 1) turn the ignition switch off. 2) remove the seat and right frame cover. ( 8-4 and 8-5) 3) disconnect the ckp sensor coupler 1 and ecm couplers 2. 4) check for proper terminal connection to the ckp sensor cou- pler and ecm couplers. ...

  • Page 173

    4-32 fi system diagnosis – between the g wire and b wire at ckp sensor coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between g wire or b wire and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 2 ckp sensor check...

  • Page 174

    Fi system diagnosis 4-33 step 3 ckp sensor and signal rotor check 1) remove the generator cover. ( 3-19) 2) check that end face of the ckp sensor 1 and generator teeth 2 are free from any metal particles and damage. Is check result ok? Step 4 ckp sensor signal check 1) connect the ecm couplers. 2) ...

  • Page 175

    4-34 fi system diagnosis dtc “c13” (p1750-h/l) or “c17” (p0105-h/l): iap sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c13/c17 iap sensor volt...

  • Page 176

    Fi system diagnosis 4-35 step 1 iap sensor power supply circuit check 1) turn the ignition switch off. 2) remove the fuel tank. ( 5-2) 3) disconnect the iap sensor coupler related dtc. (#1 cylinder 1 or #2 cylinder 2) 4) check for proper terminal connection to the iap sensor cou- pler. 5) if connec...

  • Page 177

    4-36 fi system diagnosis 3) check for proper terminal connection to the ecm couplers. 4) if connections are ok, check the following points. • resistance  09900-25008: multi circuit tester set 09900-25009: needle-point probe set  tester knob indication: resistance () – between bl/w wire (#1) or w/...

  • Page 178

    Fi system diagnosis 4-37 step 4 iap sensor check 1 1) turn the ignition switch off. 2) connect the ecm couplers and iap sensor coupler. 3) insert the needle-point probes to the lead wire coupler. 4) run the engine at idle speed and measure the iap sensor output voltage between the bl/w wire (#1) or ...

  • Page 179

    4-38 fi system diagnosis dtc “c14” (p0120-h/l): tp sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c14 output voltage is not within the followin...

  • Page 180

    Fi system diagnosis 4-39 step 1 tp sensor power supply circuit check 1) turn the ignition switch off. 2) remove the left frame front cover. ( 8-4) 3) disconnect the tp sensor coupler 1. 4) check for proper terminal connection to the tp sensor cou- pler. 5) if connections are ok, turn the ignition s...

  • Page 181

    4-40 fi system diagnosis step 3 tp sensor signal circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ecm couplers 1. 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, check the following points. • resistance  09900-25008:...

  • Page 182

    Fi system diagnosis 4-41 • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between v wire and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 4 tp sensor check 1) turn the ignition switch off. 2) connect the ecm couplers and tp sensor...

  • Page 183

    4-42 fi system diagnosis dtc “c15” (p0115-h/l): ect sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c15 output voltage is not within the followi...

  • Page 184

    Fi system diagnosis 4-43 step 1 ect sensor input voltage check 1) turn the ignition switch off. 2) remove the right fuel tank cover. ( 8-5) 3) disconnect the ect sensor coupler 1. 4) check for proper terminal connection to the ect sensor cou- pler. 5) if connections are ok, turn the ignition switch...

  • Page 185

    4-44 fi system diagnosis – between each of b/bl and b/br wire and ground: infinity – between b/bl wire terminal and b/br wire at ect sensor coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between b/bl wire or b/br wire and ground: approx. 0...

  • Page 186

    Fi system diagnosis 4-45 step 3 ect sensor check 1) turn the ignition switch off. 2) drain a small amount of engine coolant. ( 2-15) 3) disconnect the ect sensor coupler 1 and remove the ect sensor 2. 4) measure the ect sensor resistance. Note: refer to “ect sensor inspection” for details. ( 7-10)...

  • Page 187

    4-46 fi system diagnosis dtc “c21” (p0110-h/l): iat sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c21 output voltage is not within the followi...

  • Page 188

    Fi system diagnosis 4-47 step 1 iat sensor input voltage check 1) turn the ignition switch off. 2) disconnect the iat sensor coupler 1. 3) check for proper terminal connection to the iat sensor cou- pler. 4) if connections are ok, turn the ignition switch on. 5) measure the input voltage between the...

  • Page 189

    4-48 fi system diagnosis step 2 iat sensor circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ecm couplers 1. 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, check the following points. • resistance  09900-25008: multi...

  • Page 190

    Fi system diagnosis 4-49 • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between y/r wire or b/br wire and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 3 iat sensor check 1) turn the ignition switch off. 2) measure the iat sensor...

  • Page 191

    4-50 fi system diagnosis dtc “c23” (p1651-h/l): to sensor circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c23 the sensor voltage should be the follow- ...

  • Page 192

    Fi system diagnosis 4-51 step 1 to sensor power supply circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) remove the to sensor 1 and disconnect the to sensor coupler 2. ( 4-92) 4) check for proper terminal connection to the to sensor cou- pler. 5) if connections are ok, t...

  • Page 193

    4-52 fi system diagnosis step 3 to sensor signal circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ecm couplers 1. 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, check the following points. • resistance  09900-25008:...

  • Page 194

    Fi system diagnosis 4-53 step 4 to sensor check 1) turn the ignition switch off. 2) connect the ecm couplers and to sensor coupler. 3) insert the needle-point probes to the lead wire coupler. 4) turn the ignition switch on. 5) measure the to sensor voltage between the br wire and b/br wire.  09900-...

  • Page 195

    4-54 fi system diagnosis dtc “c31” (p0705): gp switch circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) step 1 gp switch input voltage check 1) turn the ignition switch off. 2) remove the...

  • Page 196

    Fi system diagnosis 4-55 4) check for proper terminal connection to the gp switch cou- pler. 5) if connections are ok, turn the ignition switch on. 6) measure the input voltage between the p wire and ground. 7) if ok, measure the input voltage between the p wire and b/w wire.  09900-25008: multi ci...

  • Page 197

    4-56 fi system diagnosis – between p wire terminal and other terminal at gp switch coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between p wire or b/w wire and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 3 gp...

  • Page 198

    Fi system diagnosis 4-57 dtc “c32” (p0201) or “c33” (p0202): fuel injector circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) step 1 injector power supply circuit check 1) turn the ignitio...

  • Page 199

    4-58 fi system diagnosis 4) check for proper terminal connection to the injector coupler. 5) if connections are ok, turn the ignition switch on. 6) measure the voltage between o/bl wire and ground. Note: voltage can be detected only for 3 seconds after ignition switch is turned on.  09900-25008: mu...

  • Page 200

    Fi system diagnosis 4-59 – between bl/y (#1) or bl/g (#2) wire terminal and other ter- minal at injector coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between bl/y (#1) or bl/g (#2) and ground wire: approx. 0 v (when ignition switch is on...

  • Page 201

    4-60 fi system diagnosis dtc “c40” (p0505): isc valve circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause the circuit voltage of motor drive is unusual. Is...

  • Page 202

    Fi system diagnosis 4-61 step 1 isc valve drive circuit check 1) turn the ignition switch off. 2) remove the fuel tank. ( 5-2) 3) disconnect the isc valve coupler 1 and ecm couplers 2. 4) check for proper terminal connection to the isc valve coupler and ecm couplers. 5) if connections are ok, check...

  • Page 203

    4-62 fi system diagnosis – between w/r wire terminal and other terminal at isc valve coupler: infinity – between b/r wire terminal and other terminal at isc valve coupler: infinity – between w/b wire terminal and other terminal at isc valve coupler: infinity – between lbl wire terminal and other ter...

  • Page 204

    Fi system diagnosis 4-63 • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between w/r, b/r, w/b or lbl wires and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 2 isc valve check 1) remove the isc valve. ( 5-18) 2) check the continu...

  • Page 205

    4-64 fi system diagnosis active control inspection (isc rpm control) check 1 1) set up the sds tools. ( 4-24 and refer to the sds opera- tion 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 “command...

  • Page 206

    Fi system diagnosis 4-65 check 3 1) click the button 6 and increase the “command value” 2 to 1 600 rpm slowly. 2) check that the “desired idle rpm” 3 is nearly equal to the “command value” 2. Also, check that the number of steps 5 in the isc valve position increases. Check 4 1) click the button 6 an...

  • Page 207

    4-66 fi system diagnosis dtc “c41” (p0230-h/l): fp relay circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c41 no voltage is applied to fuel pump. • fp r...

  • Page 208

    Fi system diagnosis 4-67 step 1 fp relay power supply circuit check 1) turn the ignition switch off. 2) remove the frame upper cover assembly. ( 8-6) 3) disconnect the fp relay coupler 1. 4) check for proper terminal connection to the fp relay coupler. 5) if connections are ok, turn the ignition sw...

  • Page 209

    4-68 fi system diagnosis step 3 fp relay drive circuit check 1) turn the ignition switch off. 2) disconnect the ecm couplers 1. 3) check for proper terminal connection to the ecm couplers. 4) if connections are ok, check the following points. • resistance  09900-25008: multi circuit tester set 0990...

  • Page 210

    Fi system diagnosis 4-69 dtc “c41” (p2505): ecm power input signal malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause no voltage is applied to the ecm. • lead wir...

  • Page 211

    4-70 fi system diagnosis step 1 ecm power supply circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ecm couplers 1. 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, measure the voltage between r/y and ground. 09900-2500...

  • Page 212

    Fi system diagnosis 4-71 dtc “c44” (p0130/p0135): ho2 sensor (ho2s) circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause c44 ho2 sensor output voltage is no...

  • Page 213

    4-72 fi system diagnosis step 1 ho2 sensor heater power supply circuit check 1) turn the ignition switch off. 2) disconnect the ho2 sensor coupler 1. ( 4-93) 3) check for proper terminal connection to the ho2 sensor cou- pler. 4) if connections are ok, turn the ignition switch on. 5) measure the vo...

  • Page 214

    Fi system diagnosis 4-73 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, check the following points. • resistance  09900-25008: multi circuit tester set 09900-25009: needle-point probe set  tester knob indication: resistance () – between w, b and b/br wires ...

  • Page 215

    4-74 fi system diagnosis • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between w, b or b/br wires and ground: approx. 0 v (when ignition switch is on) is check result ok? Step 3 ho2 sensor heater check 1) measure the resistance between terminals. Note: * t...

  • Page 216

    Fi system diagnosis 4-75 step 4 ho2 sensor output voltage check 1) connect the ecm coupler and ho2 sensor coupler. 2) warm up the engine enough. 3) insert the needle-point probes to the lead wire coupler. 4) measure the ho2 sensor output voltage between the b wire and b/br wire, in idling condition....

  • Page 217

    4-76 fi system diagnosis p0130 for ho2 sensor (use of sds) step 1 ho2 sensor circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ho2 sensor coupler 1 ( 4-93) and ecm couplers 2. 4) check for proper terminal connection to the ho2 sensor cou- pler and the ecm ...

  • Page 218

    Fi system diagnosis 4-77 – between b/br wire terminal and other terminal at ho2 sen- sor coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between b wire or b/br wire and ground: approx. 0 v (when ignition switch is on) is check result ok? St...

  • Page 219

    4-78 fi system diagnosis 6) measure the ho2 sensor output voltage while holding the engine speed at 5 000 r/min.  ho2 sensor output voltage at 5 000 r/min: 0.6 v or more (+ terminal: b – - terminal: b/br) is check result ok? P0135 for ho2 sensor (use of sds) step 1 ho2 sensor heater power supply ci...

  • Page 220

    Fi system diagnosis 4-79 step 2 ho2 sensor heater drive circuit check 1) turn the ignition switch off. 2) remove the seat. ( 8-5) 3) disconnect the ecm couplers 1. 4) check for proper terminal connection to the ecm couplers. 5) if connections are ok, check the following points. • resistance  09900...

  • Page 221

    4-80 fi system diagnosis step 3 ho2 sensor heater check 1) measure the resistance between terminals. Note: * temperature of the ho2 sensor affects resistance value largely. * make sure that the ho2 sensor heater is in atmospheric tem- perature.  09900-25008: multi circuit tester set  tester knob i...

  • Page 222

    Fi system diagnosis 4-81 dtc “c49” (p1656): pair control solenoid valve circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause pair control solenoid valve vol...

  • Page 223

    4-82 fi system diagnosis step 1 pair control solenoid valve power supply circuit check 1) turn the ignition switch off. 2) remove the fuel tank. ( 5-2) 3) disconnect the pair control solenoid valve coupler 1. 4) check for proper terminal the pair control solenoid valve coupler. 5) if connections ar...

  • Page 224

    Fi system diagnosis 4-83 – between br/y wire and ground: infinity – between br/y wire terminal and other terminal at pair con- trol solenoid valve coupler: infinity • voltage  09900-25008: multi circuit tester set  tester knob indication: voltage () – between br/y wire and ground: approx. 0 v (wh...

  • Page 225

    4-84 fi system diagnosis active control inspection 1) set up the sds tools. ( 4-24 and refer to the sds opera- tion manual for further details.) 2) turn the ignition switch on. 3) click “pair control solenoid drive control” 1. 4) click each button 2. At this time, if an operation sound is heard fro...

  • Page 226

    Fi system diagnosis 4-85 dtc “c60” (p0480): cooling fan relay circuit malfunction detected condition and possible cause wiring diagram troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) detected condition possible cause cooling fan relay signal is not input to ...

  • Page 227

    4-86 fi system diagnosis step 1 cooling fan relay power supply circuit check 1) turn the ignition switch off. 2) remove the frame upper cover assembly. ( 8-6) 3) disconnect the cooling fan relay coupler 1. 4) check for proper terminal connection to the cooling fan relay coupler. 5) if connections a...

  • Page 228

    Fi system diagnosis 4-87 step 3 cooling fan relay drive circuit check 1) turn the ignition switch off. 2) disconnect the ecm couplers 1. 3) check for proper terminal connection to the ecm couplers. 4) if connections are ok, check the following points. • resistance  09900-25008: multi circuit tester...

  • Page 229

    4-88 fi system diagnosis active control inspection 1) set up the sds tools. ( 4-24 and refer to the sds opera- tion manual for further details.) 2) start the engine and run it idling condition. 3) click “cooling fan relay control” 1. 4) click the “operate” 2. At this time, if an operation sound is ...

  • Page 230

    Fi system diagnosis 4-89 dtc “c65” (p0506/p0507): idle speed malfunction detected condition and possible cause troubleshooting note: after repairing the trouble, clear the dtc using sds tool. ( 4-25) step 1 engine combustion check 1) run the engine at idle speed. 2) by spraying water to exhaust pip...

  • Page 231

    4-90 fi system diagnosis step 3 air intake system check 1) check air intake system for clogging and leakage. Is check result ok? Step 4 engine mechanical systems check 1) check the following points related to engine mechanical sys- tem. • engine compression. ( 2-27) • fuel pressure. ( 5-3) is chec...

  • Page 232: Sensors

    Fi system diagnosis 4-91 sensors ckp sensor inspection the signal rotor is mounted on the generator rotor 1 and ckp sensor 2 is installed at the inside of the generator cover. ( 9-25) ckp sensor removal and installation • remove the generator cover. ( 3-19) • remove the ckp sensor 2. • install the...

  • Page 233

    4-92 fi system diagnosis ect sensor inspection the ect sensor 1 is installed at the thermostat connector. ( 7-10) ect sensor removal and installation • remove the ect sensor 1. ( 7-9) • install the ect sensor in the reverse order of removal.  ect sensor: 18 n·m (1.8 kgf-m, 13.0 lbf-ft) iat sensor...

  • Page 234

    Fi system diagnosis 4-93 ho2 sensor inspection the heated oxygen sensor is installed to the muffler chamber. ( 4-71) ho2 sensor removal and installation • remove the left and right fuel tank covers. ( 8-5) • remove the reservoir tank mounting bolt 1 and radiator mounting bolts 2. • remove the clam...

  • Page 235

    4-94 fi system diagnosis • install the ho2 sensor is in the reverse order of removal. Pay attention to the following points: • apply anti-seize compound to thread part a of ho2 sensor. • tighten the ho2 sensor 5 to the specified torque.  ho2 sensor: 25 n·m (2.5 kgf-m, 18.0 lbf-ft) • clamp the ho2 s...

  • Page 236

    Fuel system and throttle body 5-1 5 fuel system and throttle body contents fuel system............................................................................................. 5- 2 fuel tank removal ........................................................................ 5- 2 fuel tank installat...

  • Page 237: Fuel System

    5-2 fuel system and throttle body fuel system fuel tank removal • remove the seat. ( 8-5) • remove the fuel tank covers. ( 8-5) • remove the fuel tank bolts and brackets 1. • lift and support the fuel tank. Note: do not lift the fuel tank too much, or the fuel feed hose 3 will be bent or twisted. ...

  • Page 238

    Fuel system and throttle body 5-3 fuel tank installation • installation is in the reverse order of removal. Pay attention to the following point: note: connect the fuel feed hose to the fuel pump until it locks securely (a click is heard). • place the front end a of the right and left frame upper co...

  • Page 239

    5-4 fuel system and throttle body 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, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. If the fuel ...

  • Page 240

    Fuel system and throttle body 5-5 • connect proper lead wires to the fuel pump lead wire coupler (fuel pump side) and apply 12 v to the fuel pump (between y/r wire and b/w wire) for 10 seconds and measure the amount of fuel discharged. Battery + terminal y/r terminal battery - terminal b/w terminal ...

  • Page 241

    5-6 fuel system and throttle body fuel pump and fuel level gauge removal construction fwd 1 fuel pressure regulator assembly 5 fuel mesh filter 2 joint 6 dust cover item n·m kgf-m lbf-ft 3 fuel pump a fuel pump mounting bolt a 10 1.0 7.0 4 reservoir cup.

  • Page 242

    Fuel system and throttle body 5-7 removal • remove the fuel tank. ( 5-2) • remove the fuel pump assembly 1 by removing its mounting bolts diagonally. • disconnect the fuel level gauge lead wire coupler 2 and remove the fuel pump assembly 1. • remove the fuel level gauge 3 while pushing the pawl end...

  • Page 243

    5-8 fuel system and throttle body fuel pump disassembly • remove the fuel pump assembly. ( 5-7) • disconnect the lead wires 1 and lead wire coupler 2. • remove the dust cover 3. • remove the screw 4. • remove the fuel pump 5. • remove the cover 6 and fuel pressure regulator assembly 7. • remove the...

  • Page 244

    Fuel system and throttle body 5-9 • remove the fuel mesh filter 0. • remove the lead wires a. • remove the fuel pump b from the reservoir cup. Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engi...

  • Page 245

    5-10 fuel system and throttle body • replace the lead wire coupler 3 with a new one. • be sure to connect the wires to the proper terminals. A (b).......... + terminal for fuel pump b (w)......... + terminal for fuel level gauge • install the fuel level gauge 4 into the fuel tank. Note: push the loc...

  • Page 246: Throttle Body

    Fuel system and throttle body 5-11 throttle body construction fwd fw d 1 tp sensor 6 isc valve 2 fuel delivery pipe 7 isc valve hose 3 o-ring 8 air screw 4 fuel injector a fuel delivery pipe mounting screw item n·m kgf-m lbf-ft 5 cushion seal a 5 0.5 3.5.

  • Page 247

    5-12 fuel system and throttle body throttle body removal • remove the fuel tank. ( 5-2) • disconnect the fuel injector lead wire couplers 1. • disconnect the pair hose 2 from the air cleaner box and isc valve coupler 3. • disconnect the tp sensor coupler 4, isc valve hose 5, fuel feed hose 6, iap s...

  • Page 248

    Fuel system and throttle body 5-13 • loosen the throttle body clamp screws. • move the air cleaner box backward. • remove the throttle body assembly. Throttle body disassembly note: identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstal...

  • Page 249

    5-14 fuel system and throttle body • remove the fuel injectors 3 from the fuel delivery pipe. • remove the isc valve 4. • remove the tp sensor 5 with the special tool.  09930-11950: torx r wrench (t25h) note: prior to disassembly, mark the tp sensor original position with a paint or scribe for accu...

  • Page 250

    Fuel system and throttle body 5-15 throttle body cleaning • use a swab moistened with a carburetor cleaner (petroleum solvent) to clean the passageways, throttle valve, and main bore and then dry the cleaned surfaces with compressed air. Inspection check following items for any damage or clogging. R...

  • Page 251

    5-16 fuel system and throttle body throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • apply thin coat of engine oil to the new o-ring. • with the throttle valves fully closed, install the tp sensor 1 and tighten the t...

  • Page 252

    Fuel system and throttle body 5-17 throttle body installation install the throttle body assembly in the following points: 1) install the throttle body assembly 1 into the intake pipes 2. Note: never tighten the intake pipe clamp screws 3. 2) install the air cleaner box 4 to the throttle body assembl...

  • Page 253

    5-18 fuel system and throttle body fuel injector removal • remove the fuel delivery pipe assembly with the fuel injec- tors. ( 5-19) • remove the fuel injectors 1. Fuel injector inspection check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of...

  • Page 254

    Fuel system and throttle body 5-19 • loosen the outlet tube clamp screws 2. • move the air cleaner box 3 backward. • disconnect the fuel feed hose 4. • disconnect the fuel injector lead wire couplers 5. • remove the fuel delivery pipe mounting screws 6. • remove the fuel delivery pipe assembly 7 wit...

  • Page 255

    5-20 fuel system and throttle body isc valve inspection • inspect the isc valve for any carbon deposition defects. Clean or replace the isc valve if necessary. *refer to the isc valve inspection for details. ( 4-60) isc valve installation install the isc valve in the reverse order of removal. Pay a...

  • Page 256

    Fuel system and throttle body 5-21 isc valve reset when removing isc valve or replacing the throttle body assem- bly, reset the isc valve learned value in the following proce- dures: 1) set up the sds tool. ( 4-24) 2) turn the ignition switch on. 3) click “active control”. 4) click “isc aperture le...

  • Page 257

    5-22 fuel system and throttle body tp reset when replacing the throttle body assembly or tp sensor with a new one or reinstalling the tp sensor, reset the tp fully closed learned value in the following procedures: 1) set up the sds tool. ( 4-24) 2) turn the ignition switch on. 3) click “active cont...

  • Page 258

    Fuel system and throttle body 5-23 throttle valve synchronization check and adjust the throttle valve synchronization among two cylinders. Step 1 • lift up support the fuel tank. ( 5-2) • disconnect the respective vacuum hoses 1 from each vac- uum nipples on the throttle body. • connect the respect...

  • Page 259

    5-24 fuel system and throttle body • click “active control”. • click “isc air volume control” 1. • click “on” button 2 to fix the isc air volume of two cylinders. Note: when making this synchronization, be sure that the water tem- perature is within 80 – 100 °c (176 – 212 °f). B engine speed: approx...

  • Page 260

    Fuel system and throttle body 5-25 step 3 • repeat the procedures of step 2 when air screws were cleaned. • close the sds tool and turn the ignition switch off. • disconnect the vacuum tester and reinstall the removed parts. • after completing the throttle valve synchronization, clear the dtc and re...

  • Page 261: Exhaust System

    Exhaust system 6-1 exhaust system contents 6 exhaust system...................................................................................... 6- 2 removal .............................................................................................. 6- 2 inspection .................................

  • Page 262: Exhaust System

    6-2 exhaust system exhaust system removal • remove the left fuel tank cover. ( 8-5) • remove the left radiator mounting bolts (lower) 1. • remove the clamp 2 and disconnect the ho2 sensor coupler 3. To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any servi...

  • Page 263

    Exhaust system 6-3 • remove the clamps 4. • remove the exhaust pipe/muffler assembly 5 by removing the exhaust pipe bolts 6, muffler support bolts/nuts 7 and chamber support bolt 8. Note: support the exhaust pipe/muffler assembly to prevent it from falling. • remove the each part from the muffler as...

  • Page 264

    Cooling and lubrication system 7-1 cooling and lubrication system contents 7 engine coolant ..................................................................................... 7- 2 cooling circuit ..................................................................................... 7- 4 cooling ci...

  • Page 265: Engine Coolant

    7-2 cooling and lubrication system engine coolant for suzuki super long life coolant suzuki super long life coolant will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above –36 °c (–33 °f). Anti-freeze concen...

  • Page 266

    Cooling and lubrication system 7-3 50% engine coolant including reserve tank capacity * use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. * do not put in 60% and more anti-freeze or 50% and les...

  • Page 267: Cooling Circuit

    7-4 cooling and lubrication system cooling circuit cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • remove the right fuel tank cover. ( 8-5) • remove the radiator cap 1 and connect the radiator cap tester 2 to the ...

  • Page 268

    Cooling and lubrication system 7-5 radiator and cooling fan motor radiator and cooling fan motor removal • remove the left and right fuel tank covers. ( 8-5) • drain the engine coolant. ( 2-15) • disconnect the reservoir tank over flow hose 1 and reservoir tank inlet hose 2. • remove the reservoir...

  • Page 269

    7-6 cooling and lubrication system • remove the cooling fan motor assembly a. Radiator and cooling fan motor installation install the radiator and cooling fan motor in the reverse order of removal. Pay attention to the following points: • tighten the cooling fan motor assembly mounting bolts 1 to th...

  • Page 270

    Cooling and lubrication system 7-7 • apply thread lock to the reservoir tank mounting bolts 3 and tighten them to the specified torque as shown in the cooling system hose routing. ( 10-20)  reservoir tank mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lbf-ft)  99000-32110: thread lock cement super “1322” o...

  • Page 271: Cooling Fan

    7-8 cooling and lubrication system radiator inspection and cleaning • remove the left and right fuel tank covers. ( 8-5) • inspect the radiator for water leaks. If any defects are found, replace the radiator with a new one. If the fins are bent or dented, repair them by carefully straightening them...

  • Page 272: Ect Sensor

    Cooling and lubrication system 7-9 cooling fan relay inspection cooling fan relay is located inside of the left frame upper cover. • remove the frame upper cover assembly. ( 8-6) • disconnect the cooling fan relay coupler 1 and remove the cooling fan relay 2. First check the insulation between a an...

  • Page 273

    7-10 cooling and lubrication system inspection • check the ect sensor by testing it at the bench as shown in the figure. Connect the ect sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove. • heat the oil to raise its temperature slowly and read the ...

  • Page 274: Thermostat

    Cooling and lubrication system 7-11 thermostat removal • remove the right fuel tank cover. ( 8-5) • drain a small amount of engine coolant. ( 2-15) • place a rag under the connector cap 1. • move the connector cap 1 by removing the connector cap bolts. • remove the thermostat 2. Inspection inspect...

  • Page 275

    7-12 cooling and lubrication system • 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 4.5 mm (0.18 in).  thermostat valve lift a: standard: 4.5 mm and over at 100 °c (0.18 in and over ...

  • Page 276: Water Pump

    Cooling and lubrication system 7-13 water pump construction fwd 1 water pump cover 7 o-ring 2 o-ring 8 impeller shaft item n·m kgf-m lbf-ft 3 impeller a water pump air bleeder bolt a 6 0.6 4.5 4 mechanical seal b impeller securing bolt b 8 0.8 6.0 5 oil seal c water pump cover screw c 5.5 0.55 4.0 6...

  • Page 277

    7-14 cooling and lubrication system removal and disassembly note: before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, visually ins...

  • Page 278

    Cooling and lubrication system 7-15 • remove the impeller securing bolt 7 by holding the impeller 8 with a water pump pliers. • remove the mechanical seal ring 9 and rubber seal 0 from the impeller. • remove the impeller shaft a and washer b. • remove the mechanical seal with the special tool.  099...

  • Page 279

    7-16 cooling and lubrication system inspection mechanical seal • visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. Oil seal • visually inspe...

  • Page 280

    Cooling and lubrication system 7-17 reassembly and installation • install a new oil seal with the special tool.  09913-70210: bearing installing set (10 – 75 ) note: the stamped mark on the oil seal faces mechanical seal side. • apply a small quantity of the grease to the oil seal lip.  99000-250...

  • Page 281

    7-18 cooling and lubrication system • install the rubber seal 3 into the impeller 4. • after wiping off the oily or greasy matter from the mechanical seal ring 5, install it into the impeller. Note: the paint marked side b of mechanical seal ring faces the rub- ber seal. • install the washer 6 and s...

  • Page 282

    Cooling and lubrication system 7-19 • apply grease to the new o-ring c.  99000-25010: suzuki super grease “a” or equivalent • install the water pump with the slot on the pump shaft end e securely engaged with the flat f of the oil pump shaft. • tighten the water pump mounting bolts d to the specifi...

  • Page 283: Lubrication System

    7-20 cooling and lubrication system lubrication system oil pressure 2-28 oil filter 2-12 oil pressure regulator 3-23 and 3-47 oil strainer 3-23 and 3-47 oil jet 3-55 oil pump 3-18 and 3-41 oil pressure switch 9-34.

  • Page 284: Main Gallery

    Cooling and lubrication system 7-21 engine lubrication system chart orifice starter one way clutch camshaft right-side #1 piston and cylinder wall #1 piston cooling oil jet #1 crankshaft journal bearing #2 crankshaft journal bearing #3 crankshaft journal bearing #4 crankshaft journal bearing #1 cran...

  • Page 285: Chassis

    Chassis 8-1 chassis contents 8 exterior parts ...................................................................................... 8- 3 fastener............................................................................................ 8- 3 frame cover................................................

  • Page 286: Chassis

    Chassis contents 8-2 chassis insallation ....................................................................................... 8-44 suspension setting ....................................................................... 8-44 rear suspension .........................................................

  • Page 287: Exterior Parts

    Chassis 8-3 exterior parts fastener removal • depress the head of fastener center piece 1. • pull out the fastener a. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. Note: to prevent the pawl 2 from damage, in...

  • Page 288

    8-4 chassis frame cover removal note: the left and right side frame covers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. • remove the frame cover 1 by removing the screw 2. : hooked point installation • install the frame cover i...

  • Page 289

    Chassis 8-5 fuel tank cover removal note: the left and right side fuel tank covers are installed symmetri- cally and therefore the removal procedure for one side is the same as that for the other side. • remove the frame front cover. ( 8-4) • remove the fuel tank center cover. ( 8-4) • pull the fr...

  • Page 290

    8-6 chassis frame upper cover removal • remove the seat. ( 8-5) • remove the left and right frame front covers. ( 8-4) • remove the pillion rider handle. ( 8-6) • disconnect the clamp 1 and seat lock cable 2. • remove the screws 3 and fasteners 4. • remove the frame upper cover assembly 5. Instal...

  • Page 291: Front Wheel

    Chassis 8-7 front wheel construction fwd 1 front axle 5 front wheel 2 brake disc 6 spacer item n·m kgf-m lbf-ft 3 dust seal 7 collar 1 65 6.5 47.0 4 bearing a brake disc bolt a 18 1.8 13.0

  • Page 292

    8-8 chassis removal note: do not operate the brake lever with the caliper removed. • loosen the front axle pinch bolt 1. • loosen the front axle 2 using the special tool.  09900-18710: hexagon socket (12 mm) • raise the front wheel off the ground and support the motorcy- cle with a jack or a wooden...

  • Page 293

    Chassis 8-9 • remove the brake disc 1. • remove the dust seals 2 on both sides using the special tool.  09913-50121: oil seal remover axle shaft using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.  09900-20607: dial gauge 09900-20701: dial gauge chuc...

  • Page 294

    8-10 chassis wheel bearing inspect the play of wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual. • remove the wheel bearings 1 on both...

  • Page 295

    Chassis 8-11 reassembly and installation reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply grease to the new wheel bearings.  99000-25010: suzuki super grease “a” or equivalent a lh b rh a clearance 2...

  • Page 296

    8-12 chassis • first install the left wheel bearing 1, then install the spacer 2 and right wheel bearing 3 using the special tool and removed wheel bearings 4.  09924-84510: bearing installer set note: the sealed cover of the bearing must face outside. • remove the removed wheel bearings 4. Dust se...

  • Page 297

    Chassis 8-13 brake disc • make sure that the brake disc is clean and free of any greasy matter. • apply thread lock to the brake disc bolts and tighten them to the specified torque.  99000-32130: thread lock cement super “1360” or equivalent  brake disc bolt (front): 18 n·m (1.8 kgf-m, 13.0 lbf-ft...

  • Page 298

    8-14 chassis • tighten the front axle pinch bolt 3 to the specified torque.  front axle pinch bolt: 23 n·m (2.3 kgf-m, 16.5 lbf-ft) • then, tighten the front stabilizer bolts 2. After installing the front wheel, pump the brake lever until the pistons push the pads correctly..

  • Page 299: Front Fork

    Chassis 8-15 front fork construction fwd 1 o-ring a dust seal 2 spacer b oil seal stopper ring 3 washer c oil seal 4 spring d spacer 5 damper rod ring e outlet tube slide bushing 6 rebound spring f outer tube (rh) 7 damper rod g outer tube (lh) item n·m kgf-m lbf-ft 8 oil lock piece a front fork cap...

  • Page 300

    8-16 chassis removal and disassembly note: the left and right front forks are installed symmetrically and therefore the removal and disassembly procedure for one side is the same as that for the other side. • remove the front wheel. ( 8-8) • remove the front brake caliper 1 and brake hose clamp bol...

  • Page 301

    Chassis 8-17 • remove the front fork cap bolt 8. • remove the spacer a, washer b and fork spring c. • invert the front fork and stroke it several times to drain out fork oil. • hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain. • remove the damper ro...

  • Page 302

    8-18 chassis • remove the dust seal f and oil seal stopper ring g. • pull the inner tube out of the outer tube. • remove the oil lock piece h. • remove the following parts from the inner tube. I outer tube slide bushing j spacer k oil seal inspection inner and outer tubes inspect the inner tube slid...

  • Page 303

    Chassis 8-19 damper rod ring inspect the damper rod ring for wear or damage. If it is worn or damaged, replace it with a new one. Reassembly and installation reassemble and install the front fork in the reverse order of removal and disassembly. Pay attention to the following points: inner tube • ins...

  • Page 304

    8-20 chassis • insert the inner tube into the outer tube and install the oil seal 4 using the special tool.  09940-52861: front fork oil seal installer set • install the oil seal stopper ring 6 and new dust seal 7. Damper rod • install the rebound spring 1 and install them into the inner tube. • fi...

  • Page 305

    Chassis 8-21 • move the inner tube up and down several strokes until no more bubbles come out from the fork oil. • keep the front fork vertically and wait 5 – 6 minutes. Note: take extreme attention to pump out air completely. • hold the front fork vertically and adjust the fork oil level using the ...

  • Page 306

    8-22 chassis • tighten the front fork lower clamp bolt 1 to the specified torque.  front fork lower clamp bolt: 33 n·m (3.3 kgf-m, 24.0 lbf-ft) • tighten the front fork cap bolt 2 and front fork upper clamp bolt 3 to the specified torque.  front fork cap bolt: 23 n·m (2.3 kgf-m, 16.5 lbf-ft) front...

  • Page 307: Steering

    Chassis 8-23 steering construction fwd fw d for p-12 only 1 steering stem upper bracket 8 lower bearing inner race 2 dust seal 9 lower seal item n·m kgf-m lbf-ft 3 upper bearing inner race 0 steering stem lower bracket a 65 6.5 47.0 4 steering stem upper bearing a steering stem head nut b 23 n·m (2....

  • Page 308

    8-24 chassis removal • remove the combination meter and headlight assembly. ( 9-27 and 9-36) • remove the front wheel. ( 8-8) • remove the front forks. ( 8-16) • remove the clamps 1. • disconnect the ignition switch coupler 2. • remove the brake hose clamp bolt 3 and cable guide bolt 4. • remove ...

  • Page 309

    Chassis 8-25 • remove the ignition switch d if necessary. Inspection and disassembly inspect the removed parts for the following abnormalities. * distortion of the steering stem * bearing wear or damage * abnormal bearing noise * race wear or damage * dust seal wear or damage if any abnormal points ...

  • Page 310

    8-26 chassis reassembly reassemble the steering in the reverse order of disassembly. Pay attention to the following points: outer race • press in the new upper and lower bearing outer races using the special tool.  09941-34513: bearing installer inner race • apply grease to the new lower seal 1.  ...

  • Page 311: Steering Tension Adjustment

    Chassis 8-27 steering stem upper bracket • temporarily install the steeringstem upper bracket 1. • temporarily install the front forks 2. • tighten the steeringstem head nut 3 to the specified torque.  steering stem head nut: 65 n·m (6.5 kgf-m, 47.0 lbf-ft) • install the front licence plate (only f...

  • Page 312: Handlebars

    8-28 chassis handlebars construction 1 handlebars 5 throttle grip a handlebar holder bolt 2 rear view mirror 6 handlebar holders item n·m kgf-m lbf-ft 3 handlebar balancer 7 right handlebar switch box b handlebar clamp bolt a 23 2.3 16.5 4 left handlebar grip 8 left handlebar switch box b 16 1.6 11....

  • Page 313

    Chassis 8-29 removal handlebar left side parts • remove the rear view mirror 1. • remove the handlebar switch box 2. • disconnect the clutch lever position switch coupler 3. • remove the handlebar balancer 4. • remove the handlebar grip 5. • loosen the clutch lever holder bolt 6. Handlebar right sid...

  • Page 314

    8-30 chassis installation install the handlebars in the reverse order of removal. Pay atten- tion to the following points: • insert the boss a of the handlebar holder into the hole b of the upper bracket. • tighten the handlebar holder bolts 1 to the specified torque.  handlebar holder bolt: 23 n·m...

  • Page 315

    Chassis 8-31 • install the front brake master cylinder. ( 8-62) • insert the projection e of the right handlebar switch box into hole of the right handlebar. • apply grease to the throttle cables and cable pulley.  99000-25010: suzuki super grease “a” or equivalent • align the clutch lever holder’...

  • Page 316: Rear Wheel

    8-32 chassis rear wheel construction fwd 1 rear axle 0 rear sprocket 2 brake disc a retainer 3 collar b bearing 4 dust seal c dust seal 5 bearing d spacer 6 rear wheel a brake disc bolt item n·m kgf-m lbf-ft 7 wheel damper b rear sprocket nut a 23 2.3 16.5 8 spacer c rear axle nut b 49 4.9 35.5 9 sp...

  • Page 317

    Chassis 8-33 removal • loosen the axle nut 1. • raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • remove the axle nut 1 and draw out the rear axle 2. • with the rear wheel 3 moved forward, remove the drive chain 4 from the sprocket 5. • remove the rear b...

  • Page 318

    8-34 chassis • remove the rear sprocket mounting drum retainer b. Inspection and disassembly tire........................................................... ( 2-23, 8-73) wheel ...................................................... ( 8-9 and 8-73) axle shaft ..........................................

  • Page 319

    Chassis 8-35 sprocket inspect the sprocket teeth for wear. If they are worn as shown, replace the two sprockets and drive chain as a set. A normal wear b excessive wear bearing inspect the play wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. Rotate the inn...

  • Page 320

    8-36 chassis reassembly and installation reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: a lh b rh a clearance *1 insert the protrusion on the wheel damper firmly. 49 n.M 4.9 kgf-m 35.5 lbf-ft ( ) 2 – 5 mm (0.08 – 0.20 in)...

  • Page 321

    Chassis 8-37 bearing • apply grease to the new bearings.  99000-25010: suzuki super grease “a” or equivalent • install the bearing to the sprocket mounting drum using the special tool.  09913-70210: bearing installing set (10 – 75) • first install the right wheel bearing 1, then install the spac...

  • Page 322

    8-38 chassis dust seal • install the new dust seals using the special tool.  09913-70210: bearing installing set (10 – 75) • apply grease to the dust seal lips.  99000-25010: suzuki super grease “a” or equivalent wheel damper • insert the protrusion on the wheel damper firmly. ( 8-36) rear spro...

  • Page 323

    Chassis 8-39 • tighten the rear sprocket nuts to the specified torque.  rear sprocket nut: 49 n·m (4.9 kgf-m, 35.5 lbf-ft) note: stamped mark a on the sprocket must face outside. • install the spacer 2. Brake disc • make sure that the brake disc is clean and free of any greasy matter. • apply threa...

  • Page 324: Rear Shock Absorber

    8-40 chassis rear shock absorber construction fwd 1 rear shock absorber b rear shock absorber mounting nut (lower) item n·m kgf-m lbf-ft a rear shock absorber mounting nut (upper) a 50 5.0 36.0 b 84 8.4 61.0

  • Page 325

    Chassis 8-41 removal • remove the seat, frame covers, frame front covers, pillion rider handle and frame upper cover assembly. ( 8-4 to -6) • remove the left muffler. ( 6-2) • remove the rear wheel. ( 8-33) • unhook the return spring 1 and remove the right front foot- rest bracket 2. • open the b...

  • Page 326

    8-42 chassis bearing replacement • remove the spacer 1. • remove the rear shock absorber bearing 2 using the special tools.  09923-73210: bearing remover 09930-30104: rotor remover sliding shaft • press the new bearing using the special tool.  09924-84510: bearing installer set • apply grease to t...

  • Page 327

    Chassis 8-43 rear shock absorber disposal gas pressure release • remove the screw 1. • cover the rear shock absorber with a plastic bag 2. • hold the rear shock absorber 3 with a vice. • make a hole to the rubber part of the screw hole with a needle 4. The rear shock unit contains high-pressure nitr...

  • Page 328

    8-44 chassis insallation install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • install the rear shock absorber and tighten the rear shock absorber mounting nuts to the specified torque.  rear shock absorber mounting nut (upper): 50 n·m (5.0 kgf-m,...

  • Page 329: Rear Suspension

    Chassis 8-45 rear suspension construction fwd 1 swingarm pivot shaft 6 spacer 2 chain buffer 7 swingarm 3 dust cover 8 chain case 4 spacer 9 chain adjuster item n·m kgf-m lbf-ft 5 bearing a swingarm pivot nut a 65 6.5 47.0

  • Page 330

    8-46 chassis removal • remove the right frame cover. ( 8-4) • remove the right front footrest bracket. ( 8-41) • support the motorcycle with a jack to be no load for the swin- garm. • remove the rear wheel. ( 8-33) • open the brake hose guides 1. • remove the rear shock absorber lower mounting bo...

  • Page 331

    Chassis 8-47 • remove the chain adjusters 5 and brake hose guides 1. • remove the dust covers 6, washers 7 and chain buffer 8. Inspection and disassembly spacer • remove the spacers from swingarm. • inspect the spacers for wear and damage. If any defects are found, replace the spacer with a new one....

  • Page 332

    8-48 chassis • remove the swingarm pivot bearings 1 using the special tools.  09923-74511: bearing remover 09930-30104: rotor remover sliding shaft swingarm pivot shaft using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit.  swingarm pivot shaft runout: se...

  • Page 333

    Chassis 8-49 reassembly reassemble the rear suspension in the reverse order of disassembly. Pay attention to the following points: 1 washer b rh item n·m kgf-m lbf-ft 2 dust cover c rear shock absorber mounting nut (upper) c 50 5.0 36.0 3 spacer d rear shock absorber mounting nut (lower) d 84 8.4 61...

  • Page 334

    8-50 chassis swingarm bearing • press the new bearings into the swingarm pivot using the spe- cial tool. Note: when installing the bearing, stamped mark on bearing must face outside.  09941-34513: bearing installer • apply grease to the bearings and dust covers.  99000-25010: suzuki super grease “...

  • Page 335: Front Brake

    Chassis 8-51 front brake construction fwd fw d 1 brake lever b brake pad mounting pin plug  item n·m kgf-m lbf-ft 2 brake light switch c brake pad mounting pin a 10 1.0 7.0 3 piston cup set d brake caliper air bleeder valve b 2.5 0.25 2.0 4 piston seal e brake caliper sliding pin a c 18 1.8 13.0 5 ...

  • Page 336

    8-52 chassis brake pad replacement • remove the pad pin plug 1. • loosen the pad mounting pin 2. • remove the brake caliper mounting bolts 3. * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-...

  • Page 337

    Chassis 8-53 • remove the pad mounting pin 2 and brake pads 4. Note: when the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (hang the brake caliper on the frame with a string etc.) • clean up the caliper especially around the caliper piston. • push the pist...

  • Page 338

    8-54 chassis brake fluid replacement • place the motorcycle on a level surface and keep the handle- bars straight. • remove the brake fluid reservoir cap 1 and diaphragm. • suck up the old brake fluid as much as possible. • fill the reservoir with new brake fluid. • connect a clear hose to the calip...

  • Page 339

    Chassis 8-55 caliper disassembly • remove the brake pads. ( 8-52) • remove the brake caliper holder 1. • remove the pad spring 2. • remove the rubber boots 3. • place a clean rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. • remove the dust s...

  • Page 340

    8-56 chassis 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 any scratches and other damage. If any damage is ...

  • Page 341

    Chassis 8-57 caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves.  specification and classification: dot...

  • Page 342

    8-58 chassis caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • tighten the brake caliper mounting bolts 1 to the specified torque.  front brake caliper mounting bolt: 26 n·m (2.6 kgf-m, 19.0 lbf-ft) • install the brake hose with union...

  • Page 343

    Chassis 8-59 master cylinder removal and disas- sembly • remove the right rear view mirror 1. • drain brake fluid. ( 8-54) • place a clean rag underneath the brake hose union bolt 2 on the master cylinder to catch any split brake fluid. • remove the brake hose union bolt 2 and disconnect the brake ...

  • Page 344

    8-60 chassis • pull out the dust boot 0 and remove the snap ring a.  09900-06108: snap ring pliers (close type) • remove the stopper plate b, piston cup set c and spring d. Master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or other dam- age.If any damage ...

  • Page 345

    Chassis 8-61 master cylinder reassembly and installation reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: • wash the master cylinder components with new brake fluid before reassembly.  specification and classification...

  • Page 346

    8-62 chassis • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • when installing the master cylinder 3 onto the handlebar 4, align the master cylinder holder’s mating surface a with the punch mark b on the handlebar 4 and tighten the u...

  • Page 347: Rear Brake

    Chassis 8-63 rear brake construction fwd fwd 1 brake pedal a piston cup set 2 brake caliper bracket a brake caliper mounting bolt item n·m kgf-m lbf-ft 3 brake pad spring b brake pad mounting pin a 23 2.3 16.5 4 caliper piston c brake pad mounting pin plug b 18 1.8 13.0 5 dust seal d brake caliper s...

  • Page 348

    8-64 chassis brake pad replacement • remove the pad pin plug 1. • remove the pad mounting pin 2. • remove the brake caliper mounting bolt 3. • remove the brake pads 4 with the rear brake caliper pivoted up. • clean up the caliper especially around the caliper piston. * this brake system is filled wi...

  • Page 349

    Chassis 8-65 • push the piston all the way into brake caliper. • install the new brake pads 5. Note: * replace the brake pads as a set, otherwise braking perfor- mance will be adversely affected. * make sure that the detent a of the pad is seated onto the pad guide on the caliper bracket. • tighten ...

  • Page 350

    8-66 chassis caliper removal • drain the brake fluid. ( 8-54) • place a clean rag underneath the union bolt on the brake cali- per to catch any split brake fluid. • remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable recepta- cle. • remove the...

  • Page 351

    Chassis 8-67 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 any scratches and other damage. If any damage is ...

  • Page 352

    8-68 chassis caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bore and piston with specified brake fluid. Particularly wash the dust seal groove and piston seal groove.  specification and classification: dot 4 •...

  • Page 353

    Chassis 8-69 caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • install the brake pads and tighten the brake caliper mounting bolt 1 to the specified torque. ( 8-65)  rear brake caliper mounting bolt: 23 n·m (2.3 kgf-m, 16.5 lbf-ft) •...

  • Page 354

    8-70 chassis • place a clean rag underneath the union bolt 2 on the master cylinder to catch spilled drops of brake fluid. • remove the union bolt 2 and disconnect the brake hose. • loosen the lock-nut 3. • remove the master cylinder mounting bolts 4. • remove the master cylinder along with the rese...

  • Page 355

    Chassis 8-71 • remove the push rod 5, piston cup set c and spring d. Master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or other dam- age. If any damage is found, replace the master cylinder with a new one. Piston inspect the piston surface for any scratche...

  • Page 356

    8-72 chassis • apply grease to the push rod end.  99000-25100: suzuki silicone grease or equivalent • install a new o-ring 1. • tighten the master cylinder mounting bolts 2 and lock-nut 3 to the specified torque.  rear brake master cylinder mounting bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) rear brake ...

  • Page 357: Tire and Wheel

    Chassis 8-73 tire and wheel tire removal • the most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recom- mended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. N...

  • Page 358

    8-74 chassis valve • inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal a rubber is peel- ing or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the seal has abnorm...

  • Page 359

    Chassis 8-75 tire installation • apply tire lubricant to the tire bead. When installing the tire onto the wheel, observe the following points: • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the time ...

  • Page 360

    8-76 chassis • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 361: Drive Chain

    Chassis 8-77 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 362

    8-78 chassis • place the drive chain link being disjointed on the chain holder 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 363

    Chassis 8-79 • apply grease on the recessed portion of the joint plate holder 3. Then install 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 to secure the wedge holder & wedge pin...

  • Page 364

    8-80 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. • after joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.  pi...

  • Page 365: Electrical System

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

  • Page 366: Electrical System

    Electrical system contents 9-2 electrical system relays ...................................................................................................... 9-42 turn signal relay inspection .................................................. 9-42 starter relay inspection .............................

  • Page 367: Cautions In Servicing

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

  • Page 368

    9-4 electrical system switch • never apply grease material to switch contact points to pre- vent damage. 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...

  • Page 369

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

  • Page 370

    9-6 electrical system location of electrical components 1 fuel injector (#1) ( 4-57) 8 isc valve ( 4-60) e generator 2 tp sensor ( 4-38) 9 ecm f ckp sensor ( 4-30) 3 iat sensor ( 4-46) 0 to sensor ( 4-50) g speed sensor ( 9-33 to -34) 4 starter motor a fuel pump relay ( 5-5) h gp switch ( 4...

  • Page 371

    Electrical system 9-7 1 battery ( 9-9 to -10) 6 horn a ho2 sensor ( 4-71) 2 fuse box 7 oil pressure switch ( 9-34) b mode select coupler 3 fuel pump ( 5-4) 8 ignition coil (#2) ( 9-23 to -24) c side-stand diode (9-19) 4 fuel level gauge ( 9-32) 9 fuel injector (#2) ( 4-57) 5 ect sensor ( 7-...

  • Page 372: Charging System

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

  • Page 373

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

  • Page 374

    9-10 electrical system regulated voltage • remove the seat. ( 8-5) • start the engine and keep it running at 5 000 r/min with the dimmer switch turned hi position. • measure the dc voltage between the + and - battery termi- nals using the multi circuit tester. If the voltage is not within the speci...

  • Page 375

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

  • Page 376: Starter System

    9-12 electrical system starter system troubleshooting note: make sure that the fuses are not blown and the battery is fully-charged before diagnosing. Starter motor will not run step 1 1) shift the transmission to neutral. 2) grasp the clutch lever, turn on the ignition switch with the engine stop s...

  • Page 377

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

  • Page 378

    9-14 electrical system starter motor disassembly • disassemble the starter motor as shown in the illustration. Starter motor inspection carbon brush inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush with a n...

  • Page 379

    Electrical system 9-15 armature coil inspect for continuity between each segment and between each segment and the armature shaft using the multi circuit tester. If there is no continuity between the segments or there is conti- nuity between the segments and shaft, replace the armature with a new one...

  • Page 380

    9-16 electrical system • fit the washer 1 to the housing end correctly as shown in the figure. • fit the depression a of the starter motor case to the groove b of the housing end (outside). • align the match mark on the starter motor case with the match mark on the housing end (inside). • apply grea...

  • Page 381

    Electrical system 9-17 starter relay inspection • remove the seat. ( 8-5) • remove the left frame cover. ( 8-4) • disconnect the battery - lead wire from the battery. • disconnect the starter motor lead wire 1, battery + lead wire 2 and starter relay coupler 3. • remove the starter relay 4. • appl...

  • Page 382

    9-18 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

    Electrical system 9-19 diode inspection • remove the right frame front cover. ( 8-4) • remove the diode 1. Measure the voltage between the terminals using the multi cir- cuit tester.  09900-25008: multi circuit tester set tester knob indication: diode test ( ) note: if the multi circuit tester rea...

  • Page 384

    9-20 electrical system gear position switch inspection • remove the right frame cover. ( 8-4) • disconnect the gear position switch coupler 1 and check the continuity between bl and b/w lead wires with the transmis- sion in “neutral”.  09900-25008: multi circuit tester set  tester knob indication...

  • Page 385: Ignition System

    Electrical system 9-21 ignition system troubleshooting no spark or poor spark note: * check that the transmission is in neutral and the engine stop switch is in the run position. Grasp the clutch lever. * check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) ...

  • Page 386

    9-22 electrical system step 3 1) measure the ignition coil primary peak voltage. ( 9-23) note: this inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage ok? Step 4 1) inspect the spark plugs. ( 2-6 to -7) are the spark plugs ok? Step 5 1...

  • Page 387

    Electrical system 9-23 inspection ignition coil primary peak voltage • remove the fuel tank. ( 5-2) • disconnect the spark plug caps. ( 2-6) • connect new spark plugs to the spark plug caps and ground them to the cylinder head. Note: make sure that spark plug cap and spark plug are connected prope...

  • Page 388

    9-24 electrical system ignition coil resistance • remove the fuel tank. ( 5-2) • disconnect the ignition coil lead wires and plug cap. • measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil w...

  • Page 389

    Electrical system 9-25 ckp sensor peak voltage note: be sure that all couplers are connected properly and the battery used is in fully-charged condition. • remove the right frame cover. ( 8-4) • disconnect the ckp sensor coupler 1 and connect the multi circuit tester with the peak volt adaptor as f...

  • Page 390: Combination Meter

    9-26 electrical system combination meter description this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting diode). The rpm pointer is driven by the stepping motor. The lcds indicate speed, odo/trip 1/trip 2/clock/gear position, eco/norm an...

  • Page 391

    Electrical system 9-27 removal and disassembly • remove the headlight upper cover 1 upward. : hooked point • move the combination meter assembly 2 upward. : hooked point • disconnect the boot 3 and combination meter assembly cou- pler 4. • remove the combination meter assembly 2. • disassemble the...

  • Page 392

    9-28 electrical system inspection led (light emitting diode) check that the led lights [fi light, engine rpm indicator light, oil pressure indicator light and engine coolant temperature indicator light] immediately after turning the ignition switch on. Also, other led lights (neutral indicator light...

  • Page 393

    Electrical system 9-29 engine rpm indicator light while in eco mode a or norm mode b, when the tachometer shows engine rpm within the specified range the engine rpm indicator light 1 turns on or blinks. Eco mode a: norm mode b: eco/norm 1) press and hold the sel button 1 for more than 2 seconds to c...

  • Page 394

    9-30 electrical system maintenance the maintenance comes on to notify engine oil replacement timing. The display comes on at initial 1 000 km (600 miles) and the display comes on at every time 5 000 km (3 000 miles) thereafter. After the initial 1 000 km (600 miles) reset, interval can be varied in ...

  • Page 395

    Electrical system 9-31 fuel level indicator inspection • lift and support the fuel tank. ( 5-2) • disconnect the fuel pump lead wire coupler 1. • connect variable resistor between the r/bl and b/w lead wires at the wire harness. • turn the ignition switch to the “on” position when the motor- cycle ...

  • Page 396

    9-32 electrical system fuel level gauge inspection • remove the fuel level gauge. ( 5-7) • 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  tester knob indication: r...

  • Page 397

    Electrical system 9-33 engine coolant temperature indicator light ect sensor inspection ( 7-10) • remove the right fuel tank cover. ( 8-5) • disconnect the ect sensor coupler 1. • connect the variable resistor a between the terminals. • turn the ignition switch on. • check the engine coolant tempe...

  • Page 398

    9-34 electrical system • move a screwdriver back and forth across the pickup surface of the speed sensor. The voltage readings should cycle as fol- lows (0 v 12 v or 12 v 0 v). If the voltage reading does not change, replace the speed sensor with a new one. Note: the highest voltage reading in this ...

  • Page 399: Lamps

    Electrical system 9-35 lamps headlight and position light headlight bulb 1: 12 v 60/55 w position light bulb 2: 12 v 5 w note: do not use bulb other than those with predetermined wattage. Remove the bulb when it gets cool, since it may be heated to an extremely high temperature when the headlight is...

  • Page 400

    9-36 electrical system headlight bulb replacement • remove the combination meter assembly. ( 9-27) • remove the headlight mounting screws 1. • move the headlight assembly 2 forward. • disconnect the headlight coupler 3. Note: when removing the headlight assembly 4, disconnect the posi- tion light c...

  • Page 401

    Electrical system 9-37 headlight beam adjustment adjust the headlight beam in the following procedures: adjust the headlight beam vertically. Position light bulb replacement note: the right and left position light bulbs are installed symmetrically and therefore the replacement procedure for one side...

  • Page 402

    9-38 electrical system license plate light license plate light bulb 1: 12 v 5 w note: do not use bulb other than those with predetermined wattage. License plate light bulb replacement • disconnect the clamp 1. • remove the license plate light nuts 2. • remove the lens cover 3. • replace the license ...

  • Page 403

    Electrical system 9-39 brake/tail light brake/tail light 1: 12 v 21/5 w note: do not use bulb other than those with predetermined wattage. Brake/tail light bulb replacement • remove the lens 1. • push in on the brake/tail light bulb 2, turn it counterclockwise, and pull it out. • replace the brake/t...

  • Page 404

    9-40 electrical system turn signal light turn signal light 1: 12 v 10 w note: do not use bulb other than those with predetermined wattage. Front turn signal light bulb replacement note: the right and left front turn signal light bulbs are installed sym- metrically and therefore the replacement proce...

  • Page 405

    Electrical system 9-41 rear turn signal light bulb replacement note: the right and left rear turn signal light bulbs are installed sym- metrically and therefore the replacement procedure for one side is the same as that for the other side. • remove the lens assembly 1. • remove the socket 2. • push ...

  • Page 406: Relays

    9-42 electrical system relays turn signal relay inspection the turn signal relay 1 is located under the fuel tank. If the turn signal light does not light, inspect the bulb or repair the circuit connection. If the bulb and circuit connection are ok, the turn signal relay 1 may be faulty, replace it ...

  • Page 407

    Electrical system 9-43 switches inspection inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones.  09900-25008: multi circuit tester set  tester knob indication: continuity test () note: before inspecting the oil pres...

  • Page 408: Battery

    9-44 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: whe...

  • Page 409

    Electrical system 9-45 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 410

    9-46 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 411: Servicing Information

    Servicing information 10-1 10 servicing information contents troubleshooting ................................................................................ 10- 3 fi system malfunction code and defective condition..................................................................... 10- 3 engine ......

  • Page 412: Servicing Information

    Servicing information contents 10-2 servicing information regulator/rectifier installation ........................................ 10-40 special tools ................................................................................. 10-41 tightening torque .............................................

  • Page 413: Troubleshooting

    Servicing information 10-3 troubleshooting fi system malfunction code and defective condition ( 4-27 to -29) engine complaint symptom and possible causes remedy engine will not start or is hard to start compression too low 1. Valve clearance out of adjustment 2. Worn valve guides or poor seating of...

  • Page 414

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

  • Page 415

    Servicing information 10-5 complaint symptom and possible causes remedy noisy engine excessive valve chatter 1. Too large valve clearance 2. Weakened or broken valve springs 3. Worn rocker arm or cam surface 4. Worn and burnt camshaft journal noise seems to come from piston 1. Worn down pistons or c...

  • Page 416

    10-6 servicing information complaint symptom and possible causes remedy engine runs poorly in high speed range defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshaft 3. Valve timing out of adjustment 4. Too narrow spark plug gaps 5. Ignition not advanced sufficiently d...

  • Page 417

    Servicing information 10-7 complaint symptom and possible causes remedy engine lacks power defective engine internal/electrical parts 1. Loss of valve clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark plu...

  • Page 418

    10-8 servicing information complaint symptom and possible causes remedy dirty or heavy exhaust smoke 1. Too much engine oil in the engine 2. Worn piston rings or cylinders 3. Worn valve guides 4. Scored or scuffed cylinder walls 5. Worn valves stems 6. Defective stem oil seal 7. Worn oil ring side r...

  • Page 419

    Servicing information 10-9 radiator (cooling system) complaint symptom and possible causes remedy engine overheats 1. Not enough engine coolant 2. Radiator core clogged with dirt or scale 3. Faulty cooling fan 4. Defective cooling fan relay, or open- or short- circuited 5. Defective ecm 6. Defective...

  • Page 420

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

  • Page 421

    Servicing information 10-11 brakes complaint symptom and possible causes remedy insufficient brake power 1. Leakage of brake fluid from hydraulic system 2. Worn pads 3. Friction surfaces of pad are dirty oil or dust 4. Worn disc 5. Air in hydraulic system 6. Not enough brake fluid in the reservoir r...

  • Page 422

    10-12 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coils 2. Defective spark plugs 3. Defective ckp sensor 4. Defective ecm 5. Defective to sensor 6. Open-circuited wiring connections replace. Replace. Replace. Replac...

  • Page 423

    Servicing information 10-13 battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates 1. Cracked battery case 2. Battery has been left in a run-down condition for a long time replace the battery. Replace the battery. Battery...

  • Page 424

    10-14 servicing information wiring harness, cable and hose routing wiring harness routing iap sensor #1 injector #1 injector #2 iap sensor #2 isc valve clamp right handlebar switch brake hose clamp left handlebar switch clutch cable cooling fan motor coupler turn signal relay pair control solenoid v...

  • Page 425

    Servicing information 10-15 face the lock part of clamp left side. Oil pressure switch coupler view a clamp wiring harness (white tape point) regulator/rectifier speed sensor fixed clamp rear brake light switch coupler battery coupler clamp pass the lead wire outside of frame. Set the rear brake lig...

  • Page 426

    10-16 servicing information route the generator lead wire between the crankcase and starter motor and pass it over the crankcase. Do not pinch the lead wires ground lead wire 20˚ – 40˚ 10 n·m (1.0 kgf-m, 7.0 lbf-ft) generator lead wire gear position switch lead wire starter motor view b speed sensor...

  • Page 427

    Servicing information 10-17 cable routing *5 *5 *1 *6 *3 *4 *5 *7 *8 *2 view a a a 1 throttle cable no.1 9 left handlebar switch *7 3 mm (0.12 in) 2 throttle cable no.2 0 frame *8 pass the clutch cable into the clutch cable guide. 3 clutch cable *1 pass the throttle cables over the water bypass hose...

  • Page 428

    10-18 servicing information intake system hose routing 1 fuel feed hose 6 washer 2 isc valve hose *1 white mark item n·m kgf-m lbf-ft 3 intake pipe clamp *2 clamp end should face left side. A 10 1.0 7.0 4 outlet tube clamp *3 pass the iap sensor hose #1 between the fuel feed hose. 5 5.5 0.55 4.0 5 a...

  • Page 429

    Servicing information 10-19 fuel tank drain hose routing *6 *5 *2 *1 a *3 view a *4 *8 *7 95 mm (3.74 in) 70 mm (2.76 in) 1 fuel tank water drain hose *2 pass the hoses to the forward of frame. 2 fuel tank breather hose no.1 *3 connect the reservoir tank overflow hose 6 to the narrow side of 3 way j...

  • Page 430

    10-20 servicing information cooling system hose routing frame wiring harness reservoir tank overflow hose clamp pass the drain hose between the air cleaner, upper crankcase and frame bridge. Frame bridge fuel tank water drain hose the clamp end should face downward. Yellow mark the clamp end should ...

  • Page 431

    Servicing information 10-21 connect the 3 way joint under the air cleaner box. 10 n·m (1.0 kgf-m, 7.0 lbf-ft) yellow mark the clamp screw head should face left diagonal backward. White mark the clamp screw head should face backward. The clamp screw head should face backward. The clamp screw head sho...

  • Page 432

    10-22 servicing information ignition coil installation 1 ignition coil #1 *1 pass the high tension cord behind the throt- tle cable guide. 2 ignition coil #2 item n·m kgf-m lbf-ft 3 spark plug cap *2 pass the high tension cord under the fuel hose. A 6.5 0.65 4.5 4 high tension cord 5 clamp 0 – 30˚ f...

  • Page 433

    Servicing information 10-23 front brake hose routing 1 brake hose *3 after the brake hose union has contacted the stopper, tighten the union bolt. *1 pass the brake hose as shown. Item n·m kgf-m lbf-ft *2 clamp the brake hose firmly. A 23 2.3 16.5 *1 view b 21˚ 21˚ *3 view a *3 21˚ *2 a b b *2.

  • Page 434

    10-24 servicing information rear brake hose routing 1 rear brake master cylinder *1 clamp ends should face as shown. 2 rear brake hose *2 insert the reservoir tank hose to the union firmly. Item n·m kgf-m lbf-ft 3 rear brake reservoir tank hose a 23 2.3 16.5 *3 white paint faces outside before bindi...

  • Page 435

    Servicing information 10-25 pair (air supply) system hose routing 1 pair control solenoid valve *2 the clamp end should face downward. 2 pair reed valve *3 the clamp end should face left side. Item n·m kgf-m lbf-ft 3 air cleaner box *4 the clamp end should face upward. A 10 1.0 7.0 *1 white mark *3 ...

  • Page 436

    10-26 servicing information fuel tank installation 1 fuel tank *2 hung on projection part firmly. 2 fuel tank center cover *3 clean the surface before attaching the cushion. 3 fuel tank cover *4 keep clearance 2 – 4 mm (0.08 – 0.16 in) between the fuel tank and fuel tank covers 2, 3, 4. 4 fuel tank ...

  • Page 437

    Servicing information 10-27 muffler & exhaust pipe installation 1 ho2 sensor *2 the chamfer side of connector face the muffler side. 2 muffler item n·m kgf-m lbf-ft 3 rear muffler cover *3 contact the connector 4 to the stopper. A 23 2.3 16.5 4 connector *4 install the connector 4 to the exhaust pip...

  • Page 438

    10-28 servicing information seat lock cable routing 1 seat lock cable *2 the tip of the cable is cylindrical shaped. 2 clamp *3 the tip of the cable is spherical shaped. 3 flame *4 set the cable firmly. *1 the lock part of clamp over the frame. *5 align the lib of seat lock assembly and groove of ea...

  • Page 439

    Servicing information 10-29 front fender installation front license plate installation (only for p-12) 1 front fender 3 washer (rh only) 2 front stabilizer *1 the embossed lettering of the front stabilizer must face lower side 1 front license plate 2 clamp *1.

  • Page 440

    10-30 servicing information front side reflex reflector installation (only for p-24) 1 reflex reflector 3 washer  item n·m kgf-m lbf-ft 2 reflector bolt 4 front fork a 4.5 0.45 3.5 b 1.8 0.18 1.5.

  • Page 441

    Servicing information 10-31 frame cover installation 1 frame upper cover (lh) 9 frame head cover (rh) 2 frame upper cover (rh) 0 rear fender 3 frame upper cover (center) a pillion rider handle 4 frame front cover (lh) *1 to footrest bracket. 5 frame front cover (rh) *2 to air cleaner box. 6 frame co...

  • Page 442

    10-32 servicing information frame installation side-stand installation 1 frame down tube  item n·m kgf-m lbf-ft 2 frame a 60 6.0 43.5 3 engine mounting bracket b 50 5.0 36.0 *1 install the spring as shown.  item n·m kgf-m lbf-ft a 40 4.0 29.0 b 10 1.0 7.0 *1.

  • Page 443

    Servicing information 10-33 center stand installation (for p-12) 1 center stand 3 center stand cushion  item n·m kgf-m lbf-ft 2 center stand spring *1 do not apply grease to the flange and thread part. A 60 6.0 43.5 to muffler *1.

  • Page 444

    10-34 servicing information rear brake pedal installation 1 brake pedal 6 rear brake master cylinder 2 footrest bracket 7 circlip item n·m kgf-m lbf-ft 3 brake pedal spring 8 washer a 10 1.0 7.0 4 brake switch spring *1 measuring position. B 18 1.8 13.0 5 brake switch 38 – 48 mm (1.50 – 1.89 in) *1 ...

  • Page 445

    Servicing information 10-35 handlebars installation 1 front brake master cylinder *1 set the boss of handlebar holder into the hole of upper bracket. Item n·m kgf-m lbf-ft 2 clutch lever holder *2 punch mark. A 16 1.6 11.5 3 handlebar holder *3 align the matching surface of front brake master cylind...

  • Page 446

    10-36 servicing information headlight cover installation 1 headlight lower cover 4 headlight side cover (rh) 2 headlight upper cover 5 headlight housing brace 3 headlight side cover (lh) 6 cushion.

  • Page 447

    Servicing information 10-37 headlight installation 1 headlight unit 4 headlight side cover (lh) 2 combination meter assembly 5 headlight side cover (rh) item n·m kgf-m lbf-ft 3 headlight upper cover 6 headlight housing brace a 6 0.6 4.5 k l f i k l e h fwd fw d h c d j m m i j c d d b n f g a b a n ...

  • Page 448

    10-38 servicing information front turn signal light installation 1 front turn signal light (rh) 3 radiator reservoir tank *2 pass the front turn signal lead wire behind the front turn signal light. 2 front turn signal light (lh) *1 coupler position. *1 *1 *1 *1 *2 *2 view b b a view a rh lh.

  • Page 449

    Servicing information 10-39 rear combination light installation 1 brake/tail light *1 cut the tip of clamp after clamping the lead wires. After clamping the rear turn signal light lead wire and license plate light lead wire, pass the lead wires inside the hole of the rear fender. Do not slacken. 2 r...

  • Page 450

    10-40 servicing information regulator/rectifier installation 1 regulator/rectifier 4 clamp *2 pass the regulator/rectifier lead wire along the frame. Do not slacken. 2 bracket 5 ecm *3 clamp the regulator/rectifier lead wire at root of the connector. 3 clamp *1 install the clamp to the bracket. A fw...

  • Page 451

    Servicing information 10-41 special tools 09900-06107 snap ring pliers (open type) 09900-06108 snap ring pliers (close type) 09900-18710 hexagon socket (12 mm) 09900-20101 vernier calipers (150 mm) 09900-20102 vernier calipers (200 mm) 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (50 –...

  • Page 452

    10-42 servicing information 09913-70210 bearing installing set (10 – 75 ) 09915-40620 oil filter wrench 09915-64512 compression gauge 09915-72410 oil pressure gauge attachment 09915-74521 adapter hose 09915-77331 oil pressure gauge (1 000 kpa) 09916-10911 valve lapper set 09916-14510 valve lifter 0...

  • Page 453

    Servicing information 10-43 torx r is the registered trademark of camcar division of textron inc. U.S.A. Note: when order the special tool, please confirm whether it is available or not. 09930-82720 mode selection switch 09940-14911 steering stem nut socket wrench 09940-34520 t type handle 09940-345...

  • Page 454: Tightening Torque

    10-44 servicing information tightening torque engine item n·m kgf-m lbf-ft cylinder head cover bolt (initial) 10 1.0 7.0 (final) 14 1.4 10.0 cylinder head bolt 25 2.5 18.0 cylinder head cover cap bolt 10 1.0 7.0 cylinder side bolt 10 1.0 7.0 primary drive gear nut 70 7.0 50.5 exhaust pipe bolt 23 2....

  • Page 455

    Servicing information 10-45 item n·m kgf-m lbf-ft shift cam bearing retainer screw 10 1.0 7.0 oil pressure switch 13 1.3 9.5 oil filter 20 2.0 14.5 oil pressure switch lead wire bolt 1.5 0.15 1.0 gearshift arm stopper 19 1.9 13.5 gearshift fork shaft plug 25 2.5 18.0 oil pressure regulator 28 2.8 20...

  • Page 456

    10-46 servicing information fi system and intake air system cooling system chassis item n·m kgf-m lbf-ft gp switch mounting bolt 6.5 0.65 4.5 ckp sensor mounting bolt 5.5 0.55 4.0 fuel delivery pipe mounting screw 5 0.5 3.5 fuel pump mounting bolt 10 1.0 7.0 ho2 sensor 25 2.5 18.0 evap canister brac...

  • Page 457

    Servicing information 10-47 front brake master cylinder holder bolt 10 1.0 7.0 front brake caliper mounting bolt 26 2.6 19.0 front brake caliper sliding pin a 23 2.3 16.5 front brake caliper sliding pin b 13 1.3 9.5 front brake pad mounting pin 18 1.8 13.0 front brake pad pin plug 2.5 0.25 2.0 brake...

  • Page 458

    10-48 servicing information tightening torque chart each fastener should be tightened to the torque specified in “tightening list”. If no description or speci- fication is provided, refer to the following tightening torque chart for the applicable torque for each fastener. *1: small crown shape bolt...

  • Page 459: Service Data

    Servicing information 10-49 service data valve + guide unit: mm (in) item standard limit valve diam. In. 27.0 (1.06) — ex. 22.5 (0.89) — valve clearance (when cold) in. 0.05 – 0.10 (0.002 – 0.004) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0...

  • Page 460

    10-50 servicing information camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.34 – 33.38 (1.313 – 1.314) 33.04 (1.301) ex. 33.05 – 33.09 (1.301 – 1.303) 32.75 (1.289) camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) camshaft journal holder i.D....

  • Page 461

    Servicing information 10-51 cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm², 185 – 242 psi) 1 000 kpa (10 kgf/cm 2 , 142 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to-cylinder clearance 0.04 – ...

  • Page 462

    10-52 servicing information conrod + crankshaft unit: mm (in) crank balancer unit: mm (in) oil pump item standard limit conrod small end i.D. 15.006 – 15.014 (0.5908 – 0.5911) 15.040 (0.5921) conrod big end side clearance 0.10 – 0.20 (0.004 – 0.008) 0.30 (0.012) conrod big end width 19.95 – 20.00 (0...

  • Page 463

    Servicing information 10-53 clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio item standard / specification limit clutch cable play 10 – 15 (0.39 – 0.59) — clutch release screw 1 turn counterclockwise — drive plate thickness no. 1 and 2 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.10...

  • Page 464

    10-54 servicing information thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temper- ature approx. 88 °c (190 °f) — thermostat valve lift 4.5 mm (0.18 in) and over at 100 °c (212 °f) — ect sensor resistance...

  • Page 465

    Servicing information 10-55 fi sensors throttle body item standard note ckp sensor resistance 150 – 230 ckp sensor peak voltage 1.5 v or more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor output ...

  • Page 466

    10-56 servicing information electrical unit: mm (in) wattage unit: w item standard / specification note firing order 1.2 spark plug type ngk: cr7e denso: u22esr-n gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 150 – 230 ckp sensor peak voltage 1.5 v or m...

  • Page 467

    Servicing information 10-57 brake + wheel unit: mm (in) tire item standard / specification limit rear brake pedal height 38 – 48 (1.5 – 1.9) — brake disc thickness front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) rear 4.3 – 4.7 (0.169 – 0.185) 4.0 (0.16) brake disc runout — 0.30 (0.012) brake master cylin...

  • Page 468

    10-58 servicing information suspension unit: mm (in) fuel + oil item standard / specification limit front fork stroke 120 (4.72) — front fork spring free length 275.9 (10.86) 270 (10.6) front fork oil level (without spring, outer tube fully compressed) 136 (5.4) — front fork oil type suzuki fork oil...

  • Page 469: Emission Control Information

    Emission control information 11-1 11 emission control information contents emission control systems ............................................................... 11-2 noise emission control system............................................... 11-2 ho2 sensor inspection...............................

  • Page 470: Emission Control Systems

    11-2 emission control information emission control systems noise emission control system tampering with the noise control system prohibited: local law or federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of...

  • Page 471: Inspection

    Emission control information 11-3 pair (air supply) system and emission control system inspection pair hoses • remove the fuel tank. ( 5-2) • inspect the pair hoses 1 for wear or damage. If it is worn or damaged, replace the pair hoses 1 with a new one. Pair reed valve • remove the left fuel tank c...

  • Page 472

    11-4 emission control information pcv hose • inspect the pcv hose 1 for wear and damage. If it is worn or damaged, replace the pcv hose 1 with a new one. Pair control solenoid valve removal • remove the fuel tank. ( 5-2) • disconnect the pair hose 1 and pair control solenoid valve coupler 2. • disc...

  • Page 473

    Emission control information 11-5 • check the resistance between the terminals of the pair con- trol solenoid valve.  pair control solenoid valve resistance: 18 – 22  at 20 °c (68 °f)  09900-25008: multi circuit tester set  tester knob indication: resistance () installation installation is in t...

  • Page 474

    11-6 emission control information pair (air supply) system hose routing *3 *2 *2 *4 min. 10 mm (0.4 in) min. 10 mm (0.4 in) *1 1 pair control solenoid valve *2 the clamp end should face downward. 2 pair reed valve *3 the clamp end should face left side. Item n·m kgf-m lbf-ft 3 air cleaner box *4 the...

  • Page 475

    12 wiring diagram p-21 wiring diagrams wire color, refer to section “wire color”. Dimmer switch off on speed sensor fuse box oil pressure switch push engine stop switch front brake switch ignition switch regulator/ rectifier ignition coil #2 ignition coil #1 rear brake switch handlebar switch (r) ru...

  • Page 476

    P-12, 24, 71 dimmer switch off on speed sensor fuse box oil pressure switch push engine stop switch front brake switch ignition switch regulator/ rectifier ignition coil #2 ignition coil #1 rear brake switch handlebar switch (r) run off on off on off on off cooling fan cooling fan relay to sensor fu...

  • Page 477

    Prepared by supplied by april, 2012 part no. 99500-32170-01e printed in japan 480 changzhou haojue suzuki motorcycle co.,ltd..

  • Page 478: Service Manual

    K dic128 gw250 l3 99500-32170-01e cover14 (18 mm) 2012.06.12 printed in japan l3 l3 service manual se rv ic e m a n u a l gw250 g w 25 0 9 9 5 0 0 - 3 2 1 7 0 - 0 1 e changzhou haojue suzuki motorcycle co.,ltd..