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Suzuki Intruder VZ1500 Service Manual

Other manuals for Intruder VZ1500: Owner's Manual

Summary of Intruder VZ1500

  • Page 1

    Foreword this manual contains an introductory description on the suzuki vz1500 and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with the motor...

  • Page 3: Table Of Contents

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

  • Page 5: Section 00

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

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions warning / caution / note b940h20000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the message...

  • Page 7

    Precautions: 00-2 • use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. • after reassembling, check parts for tightness and proper operation. • to protect the environment, do not unlawfully dispose of used motor oil, engine cool...

  • Page 8

    00-3 precautions: • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female termina...

  • Page 9

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

  • Page 10

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

  • Page 11

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

  • Page 12

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

  • Page 13

    Precautions: 00-8 special tools and equipment special tool b940h20008001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 00-7) / )(page 00- 7) ) (page 00-7).

  • Page 14

    00-9 precautions:.

  • Page 15: Section 0

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

  • Page 16: General Information

    0a-1 general information: general information general information general description symbols b940h20101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b940h20...

  • Page 17

    General information: 0a-2 fp relay: fuel pump relay g: gen: generator gnd: ground gp switch: gear position switch h: hc: hydrocarbons ho2 sensor: heated oxgen sensor (ho2s) i: iap sensor: intake air pressure sensor (iaps) iat sensor: intake air temperature sensor (iats) ig: ignition isc valve: idle ...

  • Page 18

    0a-3 general information: r: random access memory (ram): — read only memory (rom): rom s: secondary air injection (air): — secondary throttle control system (stcs): stc system (stcs) secondary throttle valve (stv): st valve (stv) secondary throttle valve actuator (stva): stv actuator (stva) t: throt...

  • Page 19

    General information: 0a-4 engine oil (for other countries) oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of sf/sg or sh/sj in api with ma in jaso. Suzuki recommends the use of sae 10w-40 engine oil. If sae 10w-40 engine oil is no...

  • Page 20

    0a-5 general information: country and area codes b940h20101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b940h20101010 code country or area effective frame no. Vz1500 k9 (e-02) u.K. Js1cu111200100001 – vz1500 k9 (e-19) e.U. Js1cu111100100001 – vz1500...

  • Page 21

    General information: 0a-6 warning, caution and information labels location b940h20101011 14 5 8, 9, 10 4 [a] 12, 13 [b] [c] 2, 3 1, 11 6, 7 i940h1010008-05 1. Noise label (for e-03, 33) 10. General warning label (french/german/italian/swedish) (for e-19) 2. Noise label (for e-24) 11. Ices canada lab...

  • Page 22

    0a-7 general information: component location electrical components location b940h20103001 1 2 4 17 20 21 19 13 12 18 3 23 11 22 5 6 7 16 10 14 15 8 9 i940h1010006-03 1. Iap sensor (#2) 9. Ho2 sensor (for e-02, 19, 24, 33) 17. Isc valve 2. Iap sensor (#1) 10. Horn 18. Ecm (engine control module) 3. I...

  • Page 23

    General information: 0a-8 28 26 27 37 36 39 31 32 33 35 29 34 38 30 24 25 i940h1010007-02 24. Fuel injector #1 32. Generator 25. Fuel injector #2 33. Ckp sensor 26. Fuel level gauge 34. Speedometer sensor 27. Fuel pump 35. Side-stand switch 28. Ignition coil (#2) 36. To sensor 29. Ignition switch 37...

  • Page 24

    0a-9 general information: specifications specifications b940h20107001 note these specifications are subject to change without notice. Dimensions and curb mass engine drive train chassis item specification remark overall length 2 390 mm (94.1 in) e-03, 28, 33 2 410 mm (94.9 in) e-02, 19, 24 overall w...

  • Page 25

    General information: 0a-10 electrical capacities item specification remark ignition type electronic ignition (transistorized) ignition timing 4 ° b.T.D.C. At 1 000 r/min spark plug ngk cr6e or denso u20esr-n battery 12 v 64.8 kc (18 ah)/10 hr generator three-phase a.C. Generator main fuse 30 a fuse ...

  • Page 26

    0a-11 general information: special tools and equipment special tool b940h20108001 09900–06104 snap ring pliers 09900–06107 snap ring pliers 09900–06108 snap ring pliers 09900–18720 hexagon socket (14 mm) 09900–18740 hexagon socket (24 mm) 09900–20101 vernier calipers (1/15 mm, 150 mm) 09900–20102 ve...

  • Page 27

    General information: 0a-12 09900–26006 engine tachometer (solar cell type) 09900–28630 tps test wire harness 09904–41010 sds set 09910–60611 universal clamp wrench 09913–10130 carburetor adjust driver 09913–10750 compression gauge adapter 09913–50121 oil seal remover 09913–60250 journal bearing remo...

  • Page 28

    0a-13 general information: 09916–44920 valve guide installer attachment 09916–84511 tweezers 09917–10410 valve adjuster driver 09917–47011 vacuum pump gauge 09920–13120 crankcase separating tool 09920–31020 extension handle 09920–53740 clutch sleeve hub holder 09921–20210 bearing remover 09921–20240...

  • Page 29

    General information: 0a-14 09930–73140 starter torque limiter socket 09930–73170 starter torque limiter holder 09930–82720 mode select switch 09940–14911 steering stem nut wrench 09940–30221 front fork assembling tool 09940–34520 t handle 09940–34531 attachment a 09940–40211 fuel pressure gauge adap...

  • Page 30: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b940h20200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at p...

  • Page 31

    Maintenance and lubrication: 0b-2 lubrication points b940h20205002 proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off...

  • Page 32

    0b-3 maintenance and lubrication: 2) inspect the air cleaner element for clogging. If it is clogged with dirt, replace it with a new one. Caution ! Do not blow the air cleaner element with compressed air. Note if driving under dusty conditions, replace the air cleaner element more frequently. Make s...

  • Page 33

    Maintenance and lubrication: 0b-4 3) remove the cylinder head cover caps. 4) remove the air cleaner chamber. Refer to “air cleaner chamber removal and installation in section 1d (page 1d-7)”. 5) remove the spark plugs (1). Refer to “spark plug cap and spark plug removal and installation in section 1...

  • Page 35

    Maintenance and lubrication: 0b-6 12) inspect the #2 (front) cylinder tappet clearance as the same manner of #1 (rear) cylinder and adjust the clearance if necessary. Special tool (a): 09900–20803 (thickness gauge) (b): 09917–10410 (valve adjuster driver) tightening torque valve clearance adjuster l...

  • Page 36

    0b-7 maintenance and lubrication: spark plug inspection and cleaning b940h20206006 inspect spark plug every 6 000 km (4 000 miles, 12 months) heat range 1) remove the spark plugs. Refer to “spark plug cap and spark plug removal and installation in section 1h (page 1h-4)”. 2) check spark plug heat ra...

  • Page 37

    Maintenance and lubrication: 0b-8 4) inspect the fuel feed hose for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced. 5) after finishing the fuel feed hose inspection, reinstall the removed parts. Evaporative emission control system inspection (e-33 only) b940h2...

  • Page 38

    0b-9 maintenance and lubrication: oil level inspection • start up the engine and allow it to run about 15 minutes at idling speed. • keep the motorcycle upright. • turn off the engine and wait about three minutes, then check the oil level by removing the filler cap (1). If the level is below level l...

  • Page 39

    Maintenance and lubrication: 0b-10 final gear oil replacement b940h20206010 inspect final gear oil every 12 000 km (7 500 miles, 24 months) replace final gear oil initially at 1 000 km (600 miles, 2 months) replace initially at 1 000 km (600 miles, 2 months) and inspect every 12 000 km (7 500 miles,...

  • Page 40

    0b-11 maintenance and lubrication: throttle valve synchronization b940h20206013 inspect throttle valve synchronization initially 1 000 km (600 miles, 2 months) (e-33 only) and every 12 000 km (7 500 miles, 24 months) inspect the throttle valve synchronization periodically. Refer to “throttle valve s...

  • Page 41

    Maintenance and lubrication: 0b-12 4) pour engine coolant up to the radiator inlet. 5) slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. 6) add engine coolant up to the radiator inlet. 7) start up the engine and bleed air from the radiator inlet completely...

  • Page 42

    0b-13 maintenance and lubrication: 4) if the clutch release arm play “a” less than the service limit, adjust the clutch release screw as follows. A) drain engine oil. Refer to “engine oil and filter replacement (page 0b-8)”. B) remove the exhaust pipes and mufflers. Refer to “exhaust pipe / muffler ...

  • Page 43

    Maintenance and lubrication: 0b-14 11) install the secondary gear case cover and frame side lower cover. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. Brake system inspection b940h20206016 inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 00...

  • Page 44

    0b-15 maintenance and lubrication: front and rear brake hose inspection 1) remove the seat, right frame head cover and fuel tank. Refer to “exterior parts construction in section 9d (page 9d-2)” and “fuel tank removal and installation in section 1g (page 1g-9)”. 2) inspect the brake hoses and hose j...

  • Page 45

    Maintenance and lubrication: 0b-16 5) tighten the lock-nut (2) to the specified torque. Tightening torque rear master cylinder rod lock-nut (a): 18 n·m ( 1.8 kgf-m, 13.0 lbf-ft) 6) apply thread lock to the right footrest bracket bolts (1) and tighten them to the specified torque. : thread lock cemen...

  • Page 46

    0b-17 maintenance and lubrication: tire pressure if the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows. ...

  • Page 47

    Maintenance and lubrication: 0b-18 rear suspension inspection b940h20206020 inspect rear suspension every 12 000 km (7 500 miles, 24 months) inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective parts, if necessary. Refer to “rear sho...

  • Page 48

    0b-19 maintenance and lubrication: 9 rear shock absorber mounting nut 65 n ⋅m (6.5 kgf-m, 47.0 lbf-ft) 10 cushion lever nut 132 n ⋅m (13.2 kgf-m, 95.5 lbf-ft) 11 cushion rod nut 132 n ⋅m (13.2 kgf-m, 95.5 lbf-ft) 12 swingarm pivot shaft 100 n ⋅m (10.0 kgf-m, 72.5 lbf-ft) 8 brake hose union bolt 23 n...

  • Page 49

    Maintenance and lubrication: 0b-20 compression pressure check b940h20206022 refer to “compression pressure check in section 1d (page 1d-3)”. Oil pressure check b940h20206023 refer to “oil pressure check in section 1e (page 1e- 2)”. Sds check b940h20206024 refer to “sds check in section 1a (page 1a-1...

  • Page 50

    0b-21 maintenance and lubrication: special tools and equipment recommended service material b940h20208001 note required service material is also described in the following. “lubrication points (page 0b-2)” special tool b940h20208002 material suzuki recommended product or specification note brake flu...

  • Page 51: Service Data

    Service data: 0c-1 general information service data specifications service data b940h20307001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 33 (1.30) — ex. 30 (1.18) — tappet clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0...

  • Page 52

    0c-2 service data: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) oil pump item standard limit compression pressure (automatic decomp. Actuated) #1 cylinder 850 – 1 450 kpa (8.5 – 14.5 kgf/cm 2 , 121 – 206 psi) 750 kpa (7.5 kgf/cm 2 , 106.7 psi) #2 cylinder 650 – 1 2...

  • Page 53

    Service data: 0c-3 clutch unit: mm (in) thermostat + radiator + fan + coolant drive train unit: mm (in) except ratio item standard limit clutch cable play 10 – 15 (0.4 – 0.6) — clutch release arm play 6.0 (0.24) 2.0 (0.08) clutch release screw 1/2 turn back — clutch drive plate thickness no. 1 3.72 ...

  • Page 54

    0c-4 service data: driveline / axle unit: mm (in) injector + fuel pump + fuel pressure regulator fi sensors item standard/specification limit secondary bevel gear backlash 0.03 – 0.15 (0.001 – 0.006) — final bevel gear backlash 0.08 – 0.16 (0.003 – 0.006) — damper spring free length — 20.5 (0.81) fi...

  • Page 55

    Service data: 0c-5 throttle body electrical unit: mm (in) item specification bore size 42 mm (2.0 in) i.D. No. 40h1 (for e-33), 40h0 (for the others) idle r/min 1 000 ± 100 r/min/warmed engine throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firing order 1 ⋅ 2 spark plug typ...

  • Page 56

    0c-6 service data: wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-02, 19, 24 headlight hi 60 ← lo 55 ← position light — 5 brake light/taillight led ← front turn signal light/position light 21/5 — front turn signal light — 21 rear turn signal light 21 ← speedometer ligh...

  • Page 57

    Service data: 0c-7 suspension unit: mm (in) tire fuel + oil item standard limit front fork stroke 130 (5.1) — front fork spring free length 338 (13.3) 331 (13.0) front fork inner tube o.D. 43 (1.7) — front fork oil level (without spring, inner tube fully compressed) 121 (4.8) — front fork oil type s...

  • Page 58

    0c-8 service data: tightening torque list b940h20307002 engine item n ⋅m kgf-m lbf-ft cylinder head cover bolt 14 1.4 10.0 cylinder head cover bracket bolt 10 1.0 7.0 cylinder head bolt [l160] 26 2.6 19.0 [l180] 26 2.6 19.0 [l190] initial 25 2.5 18.0 final 42 4.2 30.5 cylinder head inspection cap bo...

  • Page 59

    Service data: 0c-9 driveline / axle fi system and intake air system cooling system muffler support bolt 26 2.6 19.0 muffler joint bolt 26 2.6 19.0 muffler mounting nut 26 2.6 19.0 rear muffler upper cover mounting bolt 10 1.0 7.0 air cleaner box mounting bolt 5.5 0.55 4.0 item n ⋅m kgf-m lbf-ft seco...

  • Page 60

    0c-10 service data: chassis item n ⋅m kgf-m lbf-ft handlebar clamp bolt 23 2.3 16.5 handlebar holder bolt 45 4.5 32.5 front fork clamp bolt (upper & lower) 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork cylinder bolt 30 3.0 21.5 steering stem nut 45 n ⋅m (4.5 kgf-m, 32.5 lbf-ft) then turn ba...

  • Page 61

    Service data: 0c-11 tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf-m lbf-ft n ⋅m kgf-m lbf-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 1...

  • Page 62

    0c-12 service data:.

  • Page 63: Section 1

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

  • Page 64

    1-ii table of contents pair reed valve removal and installation........1b-8 pair control solenoid valve removal and installation.........................................................1b-9 pair system inspection .....................................1b-9 crankcase breather (pcv) hose inspection........

  • Page 65

    Table of contents 1-iii special tool ......................................................1d-86 engine lubrication system .................... 1e-1 precautions........................................................... 1e-1 precautions for engine oil .................................. 1e-1 schemati...

  • Page 66

    1-iv table of contents spark plug cap and spark plug removal and installation.........................................................1h-4 ignition coil construction ....................................1h-5 ignition coil removal and installation .................1h-6 spark plug inspection and cleani...

  • Page 67: Precautions

    Precautions: 1-1 engine precautions precautions precautions for engine b940h21000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”..

  • Page 68

    1a-1 engine general information and diagnosis: engine engine general information and diagnosis general description injection timing description b940h21101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 69

    Engine general information and diagnosis: 1a-2 injection stop control self-diagnosis function b940h21101002 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 indicato...

  • Page 70

    1a-3 engine general information and diagnosis: for example: the ignition switch is turned on, and the engine stop switch is turned off. In this case, the speedometer does not receive any signal from the ecm, and the panel indicates “chec”. If chec is indicated, the lcd does not indicate the trouble ...

  • Page 71

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b940h21102001 ckps tps ig switch signal stps iaps #1 iaps #2 ects iats tos ho2s combination meter pilot lamp m cooling fan motor cooling fan relay fuel injector fp fp relay evap system purge control...

  • Page 72

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler b940h21102002 i940h1110005-03 terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) 28 — 2 iat sensor signal (iats) 29 — 3 iap sensor signal #2 (iaps.2) 30 — 4 stp sensor (stps) 31 serial data for speedomete...

  • Page 73

    Engine general information and diagnosis: 1a-6 component location fi system parts location b940h21103001 c d f e g h i o b k l j a m n i940h1110007-04 “a”: ecm “f”: fuel injector #1 “k”: engine coolant temperature sensor (ects) “b”: speedometer “g”: fuel injector #2 “l”: crank shaft position sensor ...

  • Page 74

    1a-7 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b940h21104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 75

    Engine general information and diagnosis: 1a-8 engine stalls often (incorrect fuel/air mixture) defective iap sensors or circuit. Repair or replace. Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace. Defective ect sensor. Replace. Defecti...

  • Page 76

    1a-9 engine general information and diagnosis: noisy engine (noise seems to come from water pump) too much play on pump shaft bearing. Replace. Worn or damaged impeller shaft. Replace. Worn or damaged mechanical seal. Replace. Contact between pump case and impeller. Replace. Engine runs poorly in hi...

  • Page 77

    Engine general information and diagnosis: 1a-10 engine lacks power (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective gp sensor. Replace. Defective iap sensors. Replace. Tp ...

  • Page 78

    1a-11 engine general information and diagnosis: self-diagnostic procedures b940h21104002 use of mode select switch note • do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Suc...

  • Page 79

    Engine general information and diagnosis: 1a-12 use of sds note • do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from the engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information...

  • Page 80

    1a-13 engine general information and diagnosis: 4) start the engine or crank the engine for more than 4 seconds. 5) check the dtc to determine the malfunction part. Refer to “dtc table (page 1a-20)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 81

    Engine general information and diagnosis: 1a-14 show data when trouble (displaying data at the time of dtc) b940h21104004 use of sds 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 c...

  • Page 82

    1a-15 engine general information and diagnosis: 1) click “show data when trouble” (1) to display the data. 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. 1 i718h1110269-02 2 i718h1110270-01.

  • Page 83

    Engine general information and diagnosis: 1a-16 sds check b940h21104005 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 troubleshoot...

  • Page 84

    1a-17 engine general information and diagnosis: data at 3 000 r/min under no load data at the time of racing check the water temperature. Xx °c approx. 3 000 r/min check the manifold absolute pressure. Xxx kpa i940h1110096-01 throttle: slowly open throttle: quick wide open secondary throttle valve o...

  • Page 85

    Engine general information and diagnosis: 1a-18 data of intake negative pressure during idling (100 °c) data of manifold absolute pressure operation at the time of starting check the engine coolant temperature. Xx °c check the manifold absolute pressure. Xxx kpa check the manifold absolute pressure....

  • Page 86

    1a-19 engine general information and diagnosis: example of trouble three data; value 1 (past data 1), value 2 (past data 2) and value 3 (current data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been sav...

  • Page 87

    Engine general information and diagnosis: 1a-20 dtc table b940h21104006 in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The m...

  • Page 88

    1a-21 engine general information and diagnosis: fail-safe function table b940h21104007 fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. The engine can start and can run even if th...

  • Page 89

    Engine general information and diagnosis: 1a-22 fi system troubleshooting b940h21104008 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 ...

  • Page 90

    1a-23 engine general information and diagnosis: visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mod...

  • Page 91

    Engine general information and diagnosis: 1a-24 c23 to sensor the sensor voltage should be the following for 2 sec. And more, after ignition switch is turned on. 0.2 v in other than the above value, c23 (p1651) is indicated. To sensor, lead wire/coupler connection p1651 h sensor voltage is higher th...

  • Page 92

    1a-25 engine general information and diagnosis: c42 ignition switch ignition switch signal is not input to the ecm. Ignition switch, lead wire/ coupler p1650 c44/p0130 ho2 sensor (for e-02, 19, 24, 33) ho2 sensor output voltage is not input to ecm during engine operation and running condition. (sens...

  • Page 93

    Engine general information and diagnosis: 1a-26 dtc “c12” (p0335): ckp sensor circuit malfunction b940h21104010 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm...

  • Page 94

    1a-27 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the left frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 5)”. 3) remove the left frame lower cover. Refer to “exterior parts removal and install...

  • Page 95

    Engine general information and diagnosis: 1a-28 2 6) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) ckp sensor continuity ∞Ω (infinity) (bl – ground, g – ground) are the resistance and continuity ok? Go to step 2. Replace t...

  • Page 96

    1a-29 engine general information and diagnosis: dtc “c13” (p1750) or “c17” (p0105): iap sensor circuit malfunction b940h21104011 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the te...

  • Page 97

    Engine general information and diagnosis: 1a-30 step action yes no 1 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) turn the ignition switch off. 3) check the iap sensor coupler (#2 (1) or #1 (2)) for loose or poor contacts. If ok, then measure t...

  • Page 98

    1a-31 engine general information and diagnosis: 2 1) connect the iap sensor coupler and ecm coupler. 2) connect the fuel feed hose and fuel pump read wire coupler, and lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g- 9)”. 3) insert the needle point...

  • Page 99

    Engine general information and diagnosis: 1a-32 3 1) turn the ignition switch off. 2) remove the iap sensor. Refer to “iap sensor removal and installation in section 1c (page 1c-2)”. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. 4) arrange 3 new 1.5 v batteries in series (1)...

  • Page 100

    1a-33 engine general information and diagnosis: dtc “c14” (p0120-h/l): tp sensor circuit malfunction b940h21104012 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 101

    Engine general information and diagnosis: 1a-34 c14 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the tp sensor coupler (1) for loose or poor conta...

  • Page 102

    1a-35 engine general information and diagnosis: p0120-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the tp sensor coupler (1) for loose or poor contacts. If ok,...

  • Page 103

    Engine general information and diagnosis: 1a-36 2 7) check the continuity between the p/b wire “a” and terminal “21”. Also, check the continuity between the b/br wire “b” and terminal “12”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester kn...

  • Page 104

    1a-37 engine general information and diagnosis: p0120-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the tp sensor coupler (1) for loose or poor contacts. If ok,...

  • Page 105

    Engine general information and diagnosis: 1a-38 2 7) check the continuity between the p/b wire “a” and terminal “21”. Also, check the continuity between the r wire “b” and terminal “5”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob i...

  • Page 106

    1a-39 engine general information and diagnosis: 4 1) turn the ignition switch off. 2) disconnect the tp sensor coupler. 3) connect the test harness to the tp sensor. 4) check the continuity between terminal “a” and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (c): 09900–28630 (tp...

  • Page 107

    Engine general information and diagnosis: 1a-40 5 7) if ok, then measure the tp sensor resistance at the test harness terminals (between terminal “a” and terminal “b”). Special tool (a): 09900–25008 (multi-circuit tester set) (c): 09900–28630 (tps test wire harness) tester knob indication resistance...

  • Page 108

    1a-41 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b940h21104013 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 109

    Engine general information and diagnosis: 1a-42 c15 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the right air cleaner box. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 3) check the ect sensor coupler (1) for loose ...

  • Page 110

    1a-43 engine general information and diagnosis: p0115-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the right air cleaner box. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 3) check the ect sensor coupler (1) for loose or poor con...

  • Page 111

    Engine general information and diagnosis: 1a-44 p0115-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the right air cleaner box. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 3) check the ect sensor coupler (1) for loose or poor con...

  • Page 112

    1a-45 engine general information and diagnosis: 2 9) measure the output voltage between the b/bl wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) ect sensor output voltage 0.1 – 4.85 v ((+) termin...

  • Page 113

    Engine general information and diagnosis: 1a-46 dtc “c21” (p0110-h/l): iat sensor circuit malfunction b940h21104014 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 114

    1a-47 engine general information and diagnosis: c21 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the iat sensor coupler (1) for loose or poor contacts. If o...

  • Page 115

    Engine general information and diagnosis: 1a-48 p0110-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the iat sensor coupler (1) for loose or poor contacts. If ok, then che...

  • Page 116

    1a-49 engine general information and diagnosis: p0110-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the iat sensor coupler (1) for loose or poor contacts. If ok, then che...

  • Page 117

    Engine general information and diagnosis: 1a-50 2 9) measure the output voltage between the dg wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) iat sensor output voltage 0.1 – 4.6 v ((+) terminal:...

  • Page 118

    1a-51 engine general information and diagnosis: dtc “c23” (p1651-h/l): to sensor circuit malfunction b940h21104015 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 119

    Engine general information and diagnosis: 1a-52 c23 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the to sensor. Refer to “to sensor removal and installation in section 1c (page 1c-5)”. 3) check the to sensor coupler (1) for loose or poor contacts. If ok...

  • Page 120

    1a-53 engine general information and diagnosis: p1651-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the to sensor. Refer to “to sensor removal and installation in section 1c (page 1c-5)”. 3) check the to sensor coupler (1) for loose or poor contacts. If ok, then chec...

  • Page 121

    Engine general information and diagnosis: 1a-54 2 8) check the continuity between the br wire “b” and terminal “20”. Also, check the continuity between b/br wire “c” and terminal “12”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob in...

  • Page 122

    1a-55 engine general information and diagnosis: p1651-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the to sensor. Refer to “to sensor removal and installation in section 1c (page 1c-5)”. 3) check the to sensor coupler (1) for loose or poor contacts. If ok, then chec...

  • Page 123

    Engine general information and diagnosis: 1a-56 2 8) check the continuity between the r wire “c” and terminal “5”. Also, then check the continuity between br wire “a” and terminal “20”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob i...

  • Page 124

    1a-57 engine general information and diagnosis: 3 1) connect the ecm coupler and to sensor coupler. 2) remove the to sensor. Refer to “to sensor removal and installation in section 1c (page 1c-5)”. 3) insert the needle pointed probes to the lead wire coupler. 4) turn the ignition switch on. 5) measu...

  • Page 125

    Engine general information and diagnosis: 1a-58 dtc “c24” (p0351), “c25” (p0352): ignition system malfunction b940h21104016 note • refer to “no spark or poor spark in section 1h (page 1h-3)” for details. • when indicating “c24” (p0351) for #1 • when indicating “c25” (p0352) for #2 dtc “c28” (p1655):...

  • Page 126

    1a-59 engine general information and diagnosis: step action yes no 1 1) remove the air cleaner chamber. Refer to “air cleaner chamber removal and installation in section 1d (page 1d-7)”. 2) check the stva lead wire coupler (1) for loose or poor contacts. 3) turn the ignition switch on to check the s...

  • Page 127

    Engine general information and diagnosis: 1a-60 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) stva continuity ∞Ω (i...

  • Page 128

    1a-61 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” (1). 4) click each button (2). At this time, if an operation soun...

  • Page 129

    Engine general information and diagnosis: 1a-62 dtc “c29” (p1654-h/l): secondary throttle position sensor (stps) circuit malfunction b940h21104018 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not str...

  • Page 130

    1a-63 engine general information and diagnosis: c29 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) remove the right air cleaner box. Refer to “air cleaner element r...

  • Page 131

    Engine general information and diagnosis: 1a-64 p1654-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the stp sensor coupler (1) for loose or poor contacts. If ok...

  • Page 132

    1a-65 engine general information and diagnosis: 2 7) check the continuity between the y/w wire “a” and terminal “4”. Also, check the continuity between the b/br wire “c” and terminal “12”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester kno...

  • Page 133

    Engine general information and diagnosis: 1a-66 p1654-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the stp sensor coupler (1) for loose or poor contacts. If ok...

  • Page 134

    1a-67 engine general information and diagnosis: 2 7) check the continuity between the y/w wire “a” and terminal “4”. Also, check the continuity between the r wire “c” and terminal “5”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob in...

  • Page 135

    Engine general information and diagnosis: 1a-68 4 1) turn the ignition switch off. 2) connect the ecm coupler. 3) remove the right air cleaner box. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 4) connect the special tool between the stp sensor and its coupler. S...

  • Page 136

    1a-69 engine general information and diagnosis: dtc “c31” (p0705): gp switch circuit malfunction b940h21104019 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm ...

  • Page 137

    Engine general information and diagnosis: 1a-70 step action yes no 1 1) turn the ignition switch off. 2) remove the left frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 5)”. 3) check the gp switch coupler (1) for loose or poor contacts. If ok, then measure...

  • Page 138

    1a-71 engine general information and diagnosis: dtc “c32” (p0201), “c33” (p0202): fuel injector circuit malfunction b940h21104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the t...

  • Page 139

    Engine general information and diagnosis: 1a-72 step action yes no 1 1) turn the ignition switch off. 2) remove the air cleaner chamber. Refer to “air cleaner chamber removal and installation in section 1d (page 1d-7)”. 3) check the primary fuel injector coupler for loose or poor contacts. If ok, th...

  • Page 140

    1a-73 engine general information and diagnosis: 2 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) injector continuity ∞Ω (infinity) are the resistance and continuity ok? Go to step 2. Replace the injector with a new one. ...

  • Page 141

    Engine general information and diagnosis: 1a-74 dtc “c40” (p0505 / p0506 / p0507): isc valve circuit malfunction b940h21104021 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! • be careful not to disconnect the isc valve coupler at least 5 sec...

  • Page 142

    1a-75 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) check the isc valve coupler (1) for loose or poor contacts. If ok, then check the isc valve lead wire continuity. 3) disconnect the isc valve coupler and ecm coupler. Refer to “ecm removal and in...

  • Page 143

    Engine general information and diagnosis: 1a-76 2 1) disconnect the isc valve coupler. 2) check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) isc valve continuity ∞Ω (infinity) (terminal – ground) 3) i...

  • Page 144

    1a-77 engine general information and diagnosis: active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” (1). 5) check that t...

  • Page 145

    Engine general information and diagnosis: 1a-78 dtc “c41” (p0230): fp relay circuit malfunction b940h21104022 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm c...

  • Page 146

    1a-79 engine general information and diagnosis: dtc “c42” (p1650): ig switch circuit malfunction b940h21104023 detected condition and possible cause troubleshooting note • refer to “ignition switch inspection in section 1h (page 1h-9)” for details. • after repairing the trouble, clear the dtc using ...

  • Page 147

    Engine general information and diagnosis: 1a-80 dtc “c44” (p0130/p0135): ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24, 33) b940h21104024 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting (when indicating c44/p0130:) caution ! When using the mu...

  • Page 148

    1a-81 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the right frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 5)”. 3) check the ho2 sensor for loose or poor contacts. If ok, then check the ho2 sen...

  • Page 149

    Engine general information and diagnosis: 1a-82 2 7) check the continuity between the br wire “b” and terminal “6”. Also check the continuity between the b/br wire “a” and terminal “12”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob ...

  • Page 150

    1a-83 engine general information and diagnosis: 3 1) connect the ecm coupler and ho2 sensor coupler. 2) warm up the engine enough. 3) insert the needle pointed probes to the lead wire coupler. 4) measure the ho2 sensor output voltage between br wire and b/br wire, when idling condition. Special tool...

  • Page 151

    Engine general information and diagnosis: 1a-84 troubleshooting (when indicating c44/p0135:) note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-13)”. Step action yes no 1 1) turn the ignition switch off. 2) remove the left frame s...

  • Page 152

    1a-85 engine general information and diagnosis: 2 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on and measure the heater voltage between the w/b wire and ground. If the tester voltage indicates the battery voltage, it is...

  • Page 153

    Engine general information and diagnosis: 1a-86 dtc “c49” (p1656): pair solenoid valve circuit malfunction b940h21104025 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal o...

  • Page 154

    1a-87 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the right frame head cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 5)”. 3) move the rear brake reservoir tank (1) by removing the mounting bolt. 4) check...

  • Page 155

    Engine general information and diagnosis: 1a-88 2 6) measure the resistance between terminals. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) pair control solenoid valve resistance 18 – 22 Ω at 20 – 30 °c (68 – 86 °f) (terminal – terminal) is the resi...

  • Page 156

    1a-89 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “pair sol operating control” (1). 4) click each button (2). At this time, if an operating sound is heard...

  • Page 157

    Engine general information and diagnosis: 1a-90 dtc “c60” (p0480): cooling fan relay circuit malfunction b940h21104026 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of ...

  • Page 158

    1a-91 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) start the engine and run it in idling condition. 3) click “cooling fan relay control” (1). Step action yes no 1 1) turn the ignition switch off. 2...

  • Page 159

    Engine general information and diagnosis: 1a-92 4) click the “operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. Note cooling fan relay and cooling fan motor operation can be checked until the engine cool...

  • Page 160

    1a-93 engine general information and diagnosis: dtc “c62” (p0443): evap system purge control solenoid valve circuit malfunction (for e-33) b940h21104027 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do n...

  • Page 161

    Engine general information and diagnosis: 1a-94 step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 3) check the evap system purge control valve coupler (1) for loose or poor contacts. If ok, then mea...

  • Page 162

    1a-95 engine general information and diagnosis: active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) turn the ignition switch on. 3) click “evap purge valve operating control” (1). 2 1) turn the ignition switch on. 2) measure the voltage between t...

  • Page 163

    Engine general information and diagnosis: 1a-96 4) click each button (2). At this time, if an operating sound is heard from the evap system purge control valve, the function is normal. Specifications service data b940h21107001 injector fi sensors 2 i940h1110116-01 item specification note injector re...

  • Page 164

    1a-97 engine general information and diagnosis: special tools and equipment special tool b940h21108001 09900–25008 ) (page 1a-60) / ) (page 1a-60) / ) (page 1a-63) / ) (page 1a-64) / ) (page 1a-65) / ) (page 1a-66) / ) (page 1a-67) / ) (page 1a-67) / ) (page 1a-68) / ) (page 1a-70) / ) (page 1a-72) ...

  • Page 165: Emission Control Devices

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b940h21200001 refer to “general precautions in section 00 (page 00-1)”. General description fuel injection system description b940h21201001 vz1500 motorcycles are equipped with a fuel ...

  • Page 166

    1b-2 emission control devices: crankcase emission control system description b940h21201002 the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion ch...

  • Page 167

    Emission control devices: 1b-3 exhaust emission control system description b940h21201003 the exhaust emission control system is composed of the pair system, three way catalyst system and isc system. The fresh air is drawn into the exhaust port through the pair control solenoid valve and pair reed va...

  • Page 168

    1b-4 emission control devices: noise emission control system description b940h21201004 tampering with the noise control system prohibited: local law or federal law prohibits the following acts or the causing thereof: • the removal or rendering inoperative by any person, other than for purposes of ma...

  • Page 169

    Emission control devices: 1b-5 evaporative emission control system diagram (only for e-33) b940h21201005 1 2 3 4 5 6 7 8 9 12 10 11 “c” “d” “a” “b” i940h1120018-01 1. Fuel-vapor separator 7. Evap canister “a”: fuel 2. Fuel tank 8. Purge hose “b”: hc vapor 3. Fuel pump 9. Evap purge control valve “c”...

  • Page 170

    1b-6 emission control devices: schematic and routing diagram pair system hose routing diagram b940h21202001 “ a ” “ a ” “ a ” “ a ” “ a ” 1 2 3 4 “b” “a” 2 5 “a” “a” fwd fwd fwd 1 3 2 i940h1120001-03 1. Pair control solenoid valve 5. Pair reed valve 2. Pair hose (rear) : pass the pair hose (rear) un...

  • Page 171

    Emission control devices: 1b-7 evap canister hose routing diagram (only for e-33) b940h21202002 1 2 1 1 3 4 6 5 “d” “e” “b” “c” “a” “b” 5 “f” i940h1120021-01 1. Evap canister “a”: face the white mark on the hose to backward. 2. Fuel shut-off valve “b”: face the tip of the clip to backward. 3. Purge ...

  • Page 172

    1b-8 emission control devices: repair instructions heated oxygen sensor (ho2s) removal and installation b940h21206001 removal refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-2)”. Warning ! Do not remove the ho2 sensor while it is hot. Caution ! • be careful not to ex...

  • Page 173

    Emission control devices: 1b-9 pair control solenoid valve removal and installation b940h21206004 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) remove the air cleaner chamber. Refer to “air cleaner chamber removal and installation in sec...

  • Page 174

    1b-10 emission control devices: 3) reinstall the pair reed valves. Refer to “pair reed valve removal and installation (page 1b-8)”. Pair control solenoid valve 1) remove the pair control solenoid valve. Refer to “pair control solenoid valve removal and installation (page 1b-9)”. 2) check that air fl...

  • Page 175

    Emission control devices: 1b-11 crankcase breather (pcv) hose removal and installation b940h21206007 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) disconnect the air cleaner chamber side of pcv hose (1). 3) disconnect the crankcase side ...

  • Page 176

    1b-12 emission control devices: installation 1) install the evap system purge control solenoid valve as shown in the evap canister hose routing diagram. Refer to “evap canister hose routing diagram (only for e-33) (page 1b-7)”. 2) tighten the mounting nut to the specified torque. Tightening torque e...

  • Page 177

    Emission control devices: 1b-13 evap system purge control solenoid valve note evap system purge control solenoid valve can be checked without removing it from the motorcycle. Refer to “dtc “c62” (p0443): evap system purge control solenoid valve circuit malfunction (for e-33) in section 1a (page 1a-9...

  • Page 178

    1b-14 emission control devices: 2) when air is blown into the fuel shut-off valve with its side “a” positioned sideways, the air cannot pass through to the canister side. If the fuel shut-off valve operates otherwise, it must be replaced. Warning ! Gasoline and gasoline vapor is toxic. A small amoun...

  • Page 179: Engine Electrical Devices

    Engine electrical devices: 1c-1 engine engine electrical devices precautions precautions for engine electrical device b940h21300001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location engine electrica...

  • Page 180

    1c-2 engine electrical devices: iap sensor removal and installation b940h21306005 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) disconnect the iap sensor (front and rear) couplers (1) and iap sensors (2) (front and rear) from the air cle...

  • Page 181

    Engine electrical devices: 1c-3 tp sensor adjustment b940h21306008 inspect the tp sensor setting position and adjust it if necessary in the following procedures: 1) connect the special tool (mode select switch) to the dealer mode coupler. Refer to “self-diagnostic procedures in section 1a (page 1a-1...

  • Page 182

    1c-4 engine electrical devices: ect sensor removal and installation b940h21306010 removal 1) drain engine coolant. Refer to “cooling system inspection in section 0b (page 0b-11)”. 2) remove the throttle body. Refer to “throttle body removal and installation in section 1d (page 1d- 12)”. 3) remove th...

  • Page 183

    Engine electrical devices: 1c-5 • apply engine coolant to the o-ring (3) and install the thermostat case (4). Caution ! Use a new o-ring (3) to prevent engine coolant leakage. • tighten the thermostat case mounting bolt (5). • tighten the water hose clamp screw (6) to the specified torque. Tightenin...

  • Page 184

    1c-6 engine electrical devices: 3) remove the battery holder mounting bolts and move the battery holder as shown. 4) disconnect the coupler (1) and remove the to sensor (2). Installation install the to sensor in the reverse order of removal. Pay attention to the following point: • when installing th...

  • Page 185

    Engine electrical devices: 1c-7 6) close the secondary throttle valve by finger and measure the stp sensor output voltage. Special tool (a): 09900–28630 (tps test wire harness) (b): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) stp sensor output voltage st valve is fully ...

  • Page 186

    1c-8 engine electrical devices: installation 1) close the secondary throttle valve by finger. 2) with the stv fully closed, install the stp sensor (1) and tighten the stp sensor mounting screw to the specified torque. Caution ! Replace the o-ring with a new one. Note • apply a thin coat of engine oi...

  • Page 187

    Engine electrical devices: 1c-9 5) click the “reset” button (2) to clear the isc leaned valve. Note the leaned value of the isc valve is set at preset position. 6) close the sds tool and turn the ignition switch off. Note the isc valve opening initialization is automatically started after the igniti...

  • Page 188

    1c-10 engine electrical devices: specifications service data b940h21307001 fi sensors tightening torque specifications b940h21307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-8)”. Item specification note ck...

  • Page 189

    Engine electrical devices: 1c-11 special tools and equipment recommended service material b940h21308001 special tool b940h21308002 material suzuki recommended product or specification note grease suzuki super grease a or equivalent p/no.: 99000–25010 ) (page 1c-2) / )(page 1c- 8) 09900–25008 09900–2...

  • Page 190: Engine Mechanical

    1d-1 engine mechanical: engine engine mechanical schematic and routing diagram.

  • Page 191

    Engine mechanical: 1d-2 throttle cable routing diagram b940h21402001 “ a ” in fwd out “ a ” “a” “b” “c” 4 4 “d” “e” “f” 6 4 “ b ” 5 1 3 2 4 1 2 (a) i940h1140323-06 1. Throttle cable no. 1 “a”: pass the throttle cables behind the cable guide. Pass the brake hose in front of the cable guide. 2. Thrott...

  • Page 192

    1d-3 engine mechanical: diagnostic information and procedures engine mechanical symptom diagnosis b940h21404001 refer to “engine symptom diagnosis in section 1a (page 1a-7)”. Compression pressure check b940h21404002 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 193

    Engine mechanical: 1d-4 8) repeat this procedure from 4) to 7) with the other cylinder. Compression pressure specification low compression pressure can indicate any of the following conditions: • excessively worn cylinder walls • worn piston or piston rings • piston rings stuck in grooves • poor val...

  • Page 194

    1d-5 engine mechanical: engine right side engine left side pair reed valve refer to “pair reed valve removal and installation in section 1b (page 1b-8)”. Refer to “pair system inspection in section 1b (page 1b-9)”. Refer to “pair reed valve removal and installation in section 1b (page 1b-8)”. Oil pr...

  • Page 195

    Engine mechanical: 1d-6 air cleaner element removal and installation b940h21406002 removal 1) remove the air cleaner box mounting bolts (1). 2) loosen the air cleaner box clamp screw, and disconnect the isc hoses (2) (right side) and coupler (3). 3) remove the isc valve (4) (right side). 4) remove t...

  • Page 196

    1d-7 engine mechanical: • connect the isc hoses (1) and isc coupler (2). • tighten the air cleaner box mounting bolts to the specified torque. Tightening torque air cleaner box mounting bolt (a): 5.5 n·m (0.55 kgf-m, 4.0 lbf-ft) air cleaner element inspection and cleaning b940h21406003 refer to “air...

  • Page 197

    Engine mechanical: 1d-8 installation install the air cleaner chamber in the reverse order of removal. Pay attention to the following points: • fit the throttle body clamps properly. Refer to “throttle body construction (page 1d-10)”. • route the hoses properly. Refer to “throttle body construction (...

  • Page 198

    1d-9 engine mechanical: throttle body components b940h21406005 1 2 3 4 5 5 6 7 8 6 8 7 4 9 10 10 11 12 (a) 13 (a) 13 (b) 15 (b) 15 (c) 16 17 17 fwd fwd i940h1140378-01 1. Tp sensor 7. Fuel injector 13. Fuel delivery pipe mounting screw : 3.5 n ⋅m (0.35 kgf-m, 2.5 lbf-ft) 2. Stp sensor 8. Cushion sea...

  • Page 199

    Engine mechanical: 1d-10 throttle body construction b940h21406006 lh fwd rh #2 cylinder #1 cylinder “ a ” “c” “c” “e” “b” 1 “b” 4 3 up fwd fwd 2 2 “a” “a” 2 “a” “d” fwd “ b ” i940h1140337-04 1. Pcv hose “a”: white mark “e”: face the lip right side of motorcycle. 2. Isc hose “b”: yellow mark “a”: 20 ...

  • Page 200

    1d-11 engine mechanical: 1 4 2 3 2 “c” 5 “a” fwd “b” i940h1140338-04 1. Canister (e-33 only) 4. Pcv hose “c”: face the tip of the clip to outside. 2. Canister purge valve (e-33 only) “a”: white mark 3. Purge hose (e-33 only) “b”: match mark.

  • Page 201

    Engine mechanical: 1d-12 isc valve removal and installation b940h21406007 removal caution ! Be careful not to disconnect the isc valve coupler at least 5 seconds after ignition switch is turned to off. If the ecm coupler or isc valve coupler is disconnected within 5 seconds after ignition switch is ...

  • Page 202

    1d-13 engine mechanical: 5) remove the clamp and disconnect the fuel injector couplers (4). 6) loosen the throttle body clamp screws. 7) disconnect the throttle cables from the throttle body and remove the throttle body assembly. Caution ! After disconnecting the throttle cables, do not snap the thr...

  • Page 203

    Engine mechanical: 1d-14 • turn in each throttle cable adjuster fully and locate each outer cable so that the clearance “a” is 0 – 1.0 mm (0 – 0.04 in). • tighten each lock-nut. • adjust the throttle cable play. Refer to “throttle cable play inspection and adjustment in section 0b (page 0b-10)”. • c...

  • Page 204

    1d-15 engine mechanical: 3) remove the each fuel injector (5) from the fuel delivery pipes (4). 4) remove the tp sensor (6) and stp sensor (7). Caution ! Never remove the stva (8) from the throttle body. Note prior to disassembly, mark sensor’s original position with a paint or scribe for accurate r...

  • Page 205

    Engine mechanical: 1d-16 note make sure the stp valve open or close smoothly. If the stp sensor adjustment is necessary, refer to “stp sensor adjustment in section 1c (page 1c-6)”. • apply thin coat of the engine oil to the o-ring. Caution ! Replace the o-ring with a new one. • with the throttle val...

  • Page 206

    1d-17 engine mechanical: • install the fuel injector (6) by pushing it straight to the delivery pipe (7). Caution ! Never turn the injector while pushing it. Note align the coupler “e” of the injector with boss “f” of the delivery pipe. • install the fuel delivery pipe assembly (7) to the throttle b...

  • Page 207

    Engine mechanical: 1d-18 2) inspect the isc valve for any carbon deposition defects. Clean or replace the isc valve, if necessary. Caution ! Normally, the removed o-ring must be replaced with a new one. However, this o- ring is not available for the spare parts. If it is found to be damaged, replace...

  • Page 208

    1d-19 engine mechanical: 13) click “on” button (3) to fix the isc air volume among 2 cylinders. Note when making this synchronization, be sure that the water temperature is within 70 – 100 °c (158 – 212 °f). 14) check for the synchronization of vacuum from #1 and #2 cylinder. 15) equalize the vacuum...

  • Page 209

    Engine mechanical: 1d-20 isc valve reset b940h21406012 when removing or replacing the throttle body assembly, reset the isc valve learned value in the following procedures: 1) turn the ignition switch on position. 2) set up the sds tools. (refer to the sds operation manual for further details.) 3) c...

  • Page 210

    1d-21 engine mechanical: 6) remove the air cleaner chamber (1). Refer to “air cleaner chamber removal and installation (page 1d-7)”. 7) disconnect the thermostat outlet hose (2). 8) disconnect the ect sensor coupler (3). 9) remove the throttle body (4). Refer to “throttle body removal and installati...

  • Page 211

    Engine mechanical: 1d-22 13) remove the heat shield (6). 14) disconnect the starter motor lead wire (7). 15) remove the oil pressure switch lead wire (8). 16) remove the rear master cylinder assembly (9) and right foot pedal. Refer to “rear brake master cylinder removal and installation in section 4...

  • Page 212

    1d-23 engine mechanical: 22) disconnect the clutch cable (17). 23) remove the left footrest (18) along with gearshift link arm (19). 24) remove the cylinder head cover no. 4 (20). 25) remove the swing arm pivot cover (21). 26) remove the right frame lower cover (22). 27) remove the rear brake pipe (...

  • Page 213

    Engine mechanical: 1d-24 30) release the lead wires. 31) remove the engine mounting bolt and nut (25). 32) remove the frame down tube (26) by removing their bolts and nuts. 33) remove the caps (27) left and right. 34) remove the engine mounting bolts, nuts and engine mounting plates (28). 35) remove...

  • Page 214

    1d-25 engine mechanical: • install the engine mounting plates (1). • insert the two mounting bolts from left side, and tighten their nuts. Note the engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. • install the frame down tube (2). • tighten the ...

  • Page 215

    Engine mechanical: 1d-26 • after remounting the engine, route the wiring harness properly. Refer to “wiring harness routing diagram in section 9a (page 9a-5)”. • connect the clutch cable. Refer to “clutch cable removal and installation in section 5c (page 5c-2)”. • apply thread lock to the bolts and...

  • Page 216

    1d-27 engine mechanical: engine top side disassembly b940h21406015 it is unnecessary to remove the engine assembly from the frame when servicing the cylinder head cover and camshafts. Note “engine top side components” can not be serviced with the engine installed in the frame. Caution ! Identify the...

  • Page 217

    Engine mechanical: 1d-28 3) remove the cam chain sprocket bolts (3) and lock washer (4). 4) remove the cam chain tension adjuster cap bolt (5) and spring. 5) remove the rear cam chain tension adjuster (6) and gasket. 6) remove the cam chain sprocket (7). 7) remove the camshaft journal holder (8). 8)...

  • Page 218

    1d-29 engine mechanical: cylinder head (#1 cylinder) 1) remove the rear cylinder head. Note loosen the cylinder head bolts little by little diagonally with the smaller sizes first. 2) remove the rear cylinder gasket (1) and dowel pins. Cylinder (#1 cylinder) 1) remove the cam chain guide (1) and rea...

  • Page 219

    Engine mechanical: 1d-30 camshaft (#2 cylinder) 1) turn the crankshaft 486 degrees (1 – 1/3 turns) to bring the “f i t” line mark on generator rotor to the index mark of the valve inspection hole. 2) remove the cam chain sprocket bolts (1) and sprocket washer (2). 3) remove the cam chain tension adj...

  • Page 220

    1d-31 engine mechanical: rocker arm (#2 cylinder) caution ! Be sure to identify each removed part as to its location, and lay the parts out in groups designated as “exhaust”, “intake”, so that each will be restored to the original location during assembly. 1) remove the rocker arm shaft (1). 2) remo...

  • Page 221

    Engine mechanical: 1d-32 front piston (#2 cylinder) 1) place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase. 2) remove the piston pin circlip (1). 3) draw out the piston pin (2) and remove the piston (3). Note scribe the cylinder number on the piston ...

  • Page 222

    1d-33 engine mechanical: • apply molybdenum oil solution to the position rings. M/o: molybdenum oil (molybdenum oil solution) • position the piston ring gaps as shown in the figure. Before inserting each piston into the cylinder, check that the gaps are properly positioned. • apply bond lightly to t...

  • Page 223

    Engine mechanical: 1d-34 cylinder head • pull the cam chains out of the cylinders and install the cam chain guides (1). • fit the dowel pins and a new cylinder head gaskets (2) to the cylinders. Caution ! • there is the guide holder for the bottom end of each cam chain guides (1) cast in the crankca...

  • Page 224

    1d-35 engine mechanical: front rear camshaft / cam chain • turn the crankshaft clockwise and align the “r i t” line “a” on the generator with the index marks “b” of the timing inspection hole. Caution ! • pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket...

  • Page 225

    Engine mechanical: 1d-36 • temporally install the cam chain sprockets and align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. Note each arrow mark points to forward, when the rear piston is at tdc. • engage the cam chain with the camshaft s...

  • Page 226

    1d-37 engine mechanical: rocker arm / camshaft journal holder / cam chain tension adjuster • install the dowel pins. • apply grease to the new o-rings. Caution ! Replace the o-rings with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) • apply engine oil to the rocker arm shafts ...

  • Page 227

    Engine mechanical: 1d-38 • the rear cam chain tension adjuster are identified by the embossed letters (r-up). • retract the push rod by pushing the stopper (2). • install a new gasket (3). Caution ! Use a new gasket to prevent oil leakage. • install the rear cam chain tension adjuster (4) and tighte...

  • Page 228

    1d-39 engine mechanical: • the front cam chain tension adjuster are identified by the embossed letters (f-up). • retract the push rod by pushing the stopper (8). • install a new gasket (9). Caution ! Use a new gasket to prevent oil leakage. • install the front cam chain tension adjuster (10) and tig...

  • Page 229

    Engine mechanical: 1d-40 • apply bond to the cam end caps of the gaskets as shown in the figure. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) • place the cylinder head covers on the cylinder heads. • fit new gaskets (1) to each head cover bolts. Caution ! Use the new gaskets to prevent...

  • Page 230

    1d-41 engine mechanical: • apply grease to the o-ring. Caution ! Use a new o-ring to prevent mixture air from soaking through the joint. : grease 99000–25010 (suzuki super grease a or equivalent) note face the “up” mark on the intake pipe to upper. Valve clearance inspection and adjustment b940h2140...

  • Page 231

    Engine mechanical: 1d-42 camshaft journal wear inspect the camshaft journal wear in the following procedures: 1) determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. 2) use the plastigauge to read the clearance at the wi...

  • Page 232

    1d-43 engine mechanical: camshaft runout measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit. Special tool : 09900–20607 (dial gauge (1/100 mm, 10 mm)) : 09900–20701 (magnetic stand) : 09900–21304 (v-block (100 mm)) camshaft runout (in. & ex.) service limit:...

  • Page 233

    Engine mechanical: 1d-44 cylinder head cover disassembly and assembly b940h21406022 disassembly 1) remove the head cover brackets (1) and (2), left and right. 2) remove the pair read valve cover (3) and pair read valve (4). 3) remove the valve timing inspection caps (5). Assembly 1) apply grease to ...

  • Page 234

    1d-45 engine mechanical: 5) install the cylinder head cover brackets, left and right. 6) tighten the cylinder head cover bracket bolts (3). Tightening torque cylinder head cover bracket bolt (b): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) pair reed valve / pair reed valve cover inspection b940h21406023 refer to...

  • Page 235

    Engine mechanical: 1d-46 4) remove the oil seal (6) and spring seat (7). Assembly assembly is in the reverse order of disassembly. Pay attention to the following points: valve / valve spring • install the valve spring seat (1). • apply molybdenum oil solution to the oil seal (2), and press-fit it in...

  • Page 236

    1d-47 engine mechanical: • be sure that the rounded lip “e” of the cotter fits snugly into the groove “f” in the stem end. Water jacket plug (cylinder head) apply thread lock to the water jacket plugs (1) and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement ...

  • Page 237

    Engine mechanical: 1d-48 3) install each rocker arm inside diameter using the dial caliper. Special tool (a): 09900–20605 (dial calipers (1/100 mm, 10 – 34 mm)) rocker arm i.D. (in. & ex.) standard: 12.000 – 12.018 mm (0.4724 – 0.4731 in) 4) visually inspect the camshaft contacting surface. If the d...

  • Page 238

    1d-49 engine mechanical: valve stem / valve face wear condition visually inspect each valve stem and valve face for wear and pitting. If it is worn of damaged, replace the valve with a new one. Valve stem deflection lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem def...

  • Page 239

    Engine mechanical: 1d-50 3) rotate the valve with light pressure. Special tool (a): 09916–10911 (valve lapper set) 4) check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face. If the seat width “a” measured exceeds the standard value, or seat...

  • Page 240

    1d-51 engine mechanical: 4) refinish the valve guide holes in the cylinder head using the reamer and handle. Caution ! When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. Special tool (b): 09916–34580 (valve guide reamer (10.8 mm)) (c): 09916–34542 (reamer ha...

  • Page 241

    Engine mechanical: 1d-52 9) install the valves and springs. Refer to “cylinder head disassembly and assembly (page 1d-45)”. 10) install the cylinder head. Refer to “engine top side assembly (page 1d-32)”. Valve seat repair b940h21406027 the valve seats (1) for both the intake and exhaust valves are ...

  • Page 242

    1d-53 engine mechanical: cam chain guide inspection b940h21406028 inspect the cam chain guide in the following procedures: 1) remove the cam chain guides. Refer to “engine top side disassembly (page 1d-27)”. 2) check the contacting surface and the part “a” of the cam chain guide. If it is worn or da...

  • Page 243

    Engine mechanical: 1d-54 installation note • when installing the piston ring, be careful not to damage the piston. • do not expand the piston ring excessively since it is apt to be broken down. 1) install the piston rings in the order of the oil ring, 2nd ring and 1st ring. A) the first member to go...

  • Page 244

    1d-55 engine mechanical: piston and piston ring inspection b940h21406031 refer to “piston ring removal and installation (page 1d-53)”. Piston diameter measure the piston diameter using the micrometer at 15mm (0.6 in) “a” from the skirt end. If the piston diameter is less than the service limit, repl...

  • Page 245

    Engine mechanical: 1d-56 piston ring free end gap and piston ring end gap measure the piston ring free end gap using vernier calipers. 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 exceed the service lim...

  • Page 246

    1d-57 engine mechanical: clutch release assembly / push rod remove the clutch release assembly and push rod. Refer to “clutch release assembly / push rod removal and installation in section 5c (page 5c-2)”. Water pump 1) disconnect the radiator outlet hose (1). 2) remove the water pump assembly (2) ...

  • Page 247

    Engine mechanical: 1d-58 clutch / secondary drive gear 1) remove the clutch drive plates (1) and driven plates (2). Refer to “clutch removal in section 5c (page 5c- 6)”. 2) remove the secondary gear case and driven gear assembly (3). Refer to “secondary driven gear assembly removal and installation ...

  • Page 248

    1d-59 engine mechanical: 9) remove the needle roller bearing (12), spacer (13) and washer (14). Primary drive gear remove the primary drive gear (1). Refer to “primary drive gear removal and installation in section 5c (page 5c-13)”. Caution ! The primary drive gear bolt (2) has left-hand threads. Re...

  • Page 249

    Engine mechanical: 1d-60 2) draw out the gearshift shaft assembly (3) and washer (4). 3) remove the gearshift cam plate bolt (5) and gearshift cam plate (6). 4) remove the gearshift cam stopper (7) and gearshift arm stopper (8). Gear position switch remove the gear position switch (1). Oil filter re...

  • Page 250

    1d-61 engine mechanical: crankcase 1) remove the crankcase bolts. Note loosen the crankcase bolts diagonally with the smaller sizes first. 2) make sure that all of the bolts are removed. Then, tap the sides of the right crankcase using a plastic hammer to separate the left and right crankcase halves...

  • Page 251

    Engine mechanical: 1d-62 oil pump / oil sump filter remove the oil pump assembly (1) and oil sump filter (2). Refer to “oil pump removal and installation in section 1e (page 1e-9)” and “oil sump filter removal and installation in section 1e (page 1e-4)”. Engine mount bushing remove the upper and low...

  • Page 252

    1d-63 engine mechanical: oil gallery plug 1) remove the oil gallery plugs (1) from the right crankcase. 2) remove the oil gallery plugs (2) from the left crankcase. Crankshaft journal bearing remove the crankshaft journal bearings (1). Refer to “crankshaft bearing inspection and adjustment (page 1d-...

  • Page 253

    Engine mechanical: 1d-64 engine bottom side assembly b940h21406033 assembly the engine bottom side in the reverse of disassembly. Pay attention to the following points: note apply engine oil to each running and sliding part before reassembling. Oil gallery plug caution ! Use each new gasket. • apply...

  • Page 254

    1d-65 engine mechanical: • fit the new o-ring (3) to each piston cooling oil jets and apply engine oil to them. • install the oil jet plates (4) and tighten the bolts (5). Crankshaft • apply molybdenum oil solution to each crankshaft journal and bearing lightly. M/o: molybdenum oil (molybdenum oil s...

  • Page 255

    Engine mechanical: 1d-66 crankcase • apply grease to the o-ring. Caution ! Use the new o-ring to prevent oil pressure leak. : grease 99000–25010 (suzuki super grease a or equivalent) • install the dowel pins and o-ring in the left crankcase. • apply bond to the mating surface of the lower crankcase....

  • Page 256

    1d-67 engine mechanical: • tighten the crankcase bolts a little at a time to equalize the pressure. Caution ! Use the new copper washers and new gasket washers to prevent oil leakage. Note fit the new copper washers “a” and lead wire “b” to the crankcase bolts. Tightening torque crankcase bolt (m6):...

  • Page 257

    Engine mechanical: 1d-68 gear position switch • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. Note align the gear position switch pin “a” with the gearshift cam hole “b”. : grease 99000–25010 (suzuki super grease a or equivalent) • install the gear position switch. Oil pum...

  • Page 258

    1d-69 engine mechanical: gearshift system • apply thread lock to the gearshift arm stopper (1) and tighten it to the specified torque. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) tightening torque gearshift arm stopper (a): 19 n·m (1.9 kgf-m, 13.5 lbf-ft) • install...

  • Page 259

    Engine mechanical: 1d-70 • install the gearshift cam shaft assembly (8). Note pinch the gearshift arm stopper (1) with return spring ends “d”. Rear cam chain / rear cam chain drive sprocket / cam chain tensioner • install the rear cam chain drive sprocket (1). Note when installing the cam chain driv...

  • Page 260

    1d-71 engine mechanical: clutch / secondary drive gear • install the clutch sleeve hub. Refer to “clutch installation in section 5c (page 5c-8)”. Note it is difficult to install the primary driven gear, rotate the crankshaft. • shift the transmission into 1st gear. • hold the clutch sleeve hub with ...

  • Page 261

    Engine mechanical: 1d-72 starter torque limiter / starter idle gear install the starter idle gear (1) and starter torque limiter (2). Refer to “starter torque limiter / starter clutch removal and installation in section 1i (page 1i-10)”. Starter driven gear • apply engine oil to the bushing of the s...

  • Page 262

    1d-73 engine mechanical: • apply engine coolant to the o-ring. Note use a new o-ring to prevent engine coolant leakage. • tighten the water inlet pipe mounting bolts. Clutch release assembly / push rod install the push rod and clutch release assembly. Refer to “clutch release assembly / push rod rem...

  • Page 263

    Engine mechanical: 1d-74 conrod removal and installation b940h21406035 removal 1) remove the crankshaft assembly from the crankcase. Refer to “engine bottom side disassembly (page 1d-56)”. 2) loosen the conrod cap bolts, and tap the conrod cap bolts lightly with plastic hammer to remove the conrod c...

  • Page 264

    1d-75 engine mechanical: 4) apply engine oil to the conrod cap bolts. 5) tighten the conrod cap bolts as following two steps. Tightening torque conrod cap bolt: 35 n ⋅m (3.5 kgf-m, 25.5 ib-ft) then turn in 1/4 (90 °) turn 6) check that the conrod moves smoothly. 7) install the crankshaft assembly to...

  • Page 265

    Engine mechanical: 1d-76 conrod crank pin bearing inspection and selection b940h21406037 refer to “conrod removal and installation (page 1d- 74)”. Inspection 1) inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. 2) pla...

  • Page 266

    1d-77 engine mechanical: 2) check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) “b”. 3) measure the conrod crank pin o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crank pin o.D. Specification special tool (a): 09900–20203 (...

  • Page 267

    Engine mechanical: 1d-78 2) measure the crankshaft journal o.D. With the special tool. Special tool (a): 09900–20203 (micrometer (1/100 mm, 50 – 75 mm)) crankshaft journal o.D. Standard: 54.985 – 55.000 mm (2.1648 – 2.1654 in) 3) if each crankshaft journal o.D. Is not within the standard range, repl...

  • Page 268

    1d-79 engine mechanical: • gradually press out the bearing (1) with the special tool by using the hydraulic press. Caution ! The removed bearings must be replaced with new ones. • set the specified crankshaft journal bearings to the special tool. Caution ! • before setting the bearing, apply enough ...

  • Page 269

    Engine mechanical: 1d-80 • apply enough engine oil to the special tool and the bearings and then set the special tool carefully. • gradually press in the bearing (1) into the main journal bore by using the hydraulic press until the special tool (2) stops the special tool (3). Special tool (a): 09913...

  • Page 270

    1d-81 engine mechanical: 2) place the thrust washer, camshaft drive sprocket and primary drive gear on the right end of the crankshaft and tighten primary drive gear bolt (2) to the specified torque. Refer to “primary drive gear removal and installation in section 5c (page 5c- 13)”. Tightening torqu...

  • Page 271

    Engine mechanical: 1d-82 2) select a thrust bearing from the selection table. Thrust bearing selection table 3) after selecting a thrust bearing, install it and then measure the thrust clearance again. Specifications service data b940h21407001 valve + guide unit: mm (in) part no. Thrust bearing thic...

  • Page 272

    1d-83 engine mechanical: camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit cam height in. 33.060 – 33.110 (1.3016 – 1.3035) 32.760 (1.2898) ex. 33.110 – 33.160 (1.304 – 1.306) 32.810 (1.2917) camshaft journal oi...

  • Page 273

    Engine mechanical: 1d-84 tightening torque specifications b940h21407002 note the specified tightening torque is described in the following. “throttle cable routing diagram (page 1d-2)” “throttle body components (page 1d-9)” “engine assembly installation (page 1d-24)” reference: for the tightening to...

  • Page 274

    1d-85 engine mechanical: special tools and equipment recommended service material b940h21408001 note required service material is also described in the following. “throttle body components (page 1d-9)” “engine bottom side assembly (page 1d-64)” material suzuki recommended product or specification no...

  • Page 275

    Engine mechanical: 1d-86 special tool b940h21408002 09900–06107 09900–20101 snap ring pliers vernier calipers (1/15 mm, 150 mm) ) (page 1d-59) / ) (page 1d-68) ) (page 1d-56) 09900–20102 09900–20202 vernier calipers (1/20 mm, 200 mm) micrometer (1/100 mm, 25 – 50 mm) ) (page 1d-52) ) (page 1d-41) 09...

  • Page 276

    1d-87 engine mechanical: 09900–21304 09900–22301 v-block (100 mm) plastigauge (0.025 – 0.076 mm) ) (page 1d-43) / ) (page 1d-48) / ) (page 1d-48) ) (page 1d-42) / ) (page 1d-76) 09900–22302 09900–22403 plastigauge (0.051 – 0.152 mm) small bore gauge (18 – 35 mm) ) (page 1d-42) ) (page 1d-42) / ) (pa...

  • Page 277

    Engine mechanical: 1d-88 09916–44920 09916–84511 valve guide installer attachment tweezers ) (page 1d-51) ) (page 1d-45) / ) (page 1d-46) 09920–31020 09920–53740 extension handle clutch sleeve hub holder ) (page 1d-58) / ) (page 1d-71) ) (page 1d-58) / ) (page 1d-71) 09930–11950 torx wrench ) (page ...

  • Page 278: Engine Lubrication System

    1e-1 engine lubrication system: engine engine lubrication system precautions precautions for engine oil b940h21500001 refer to “fuel and oil recommendation in section 0a (page 0a-3)”. Schematic and routing diagram engine lubrication system chart diagram b940h21502001 oil filter oil pump oil strainer...

  • Page 279

    Engine lubrication system: 1e-2 diagnostic information and procedures engine lubrication symptom diagnosis b940h21504001 oil pressure check b940h21504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 280

    1e-3 engine lubrication system: 6) after warm up, increase the engine speed to 3 000 r/ min (observe the tachometer), and read the oil pressure gauge. If the oil pressure is lower or higher than the specification, the following causes may be considered. Oil pressure specification 400 – 800 kpa (4.0 ...

  • Page 281

    Engine lubrication system: 1e-4 oil sump filter removal and installation b940h21506004 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-20)”. 2) disassemble the engine top side. Refer to “engine top side disassembly in section 1d (page 1d...

  • Page 282

    1e-5 engine lubrication system: oil pressure switch removal and installation b940h21506006 refer to “electrical components location in section 0a (page 0a-7)”. Removal 1) turn the ignition switch off. 2) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-8)”. 3) dis...

  • Page 283

    Engine lubrication system: 1e-6 installation installation is in the reverse order of removal. Pay attention to the following point: • apply engine oil to the o-ring. Caution ! Use a new o-ring to prevent oil leakage. Oil jet (for cylinder head) removal 1) remove the engine assembly. Refer to “engine...

  • Page 284

    1e-7 engine lubrication system: • tighten the oil jet plate bolts securely. Oil jet (for transmission) removal 1) remove the engine assembly. Refer to “engine bottom side disassembly in section 1d (page 1d- 56)”. 2) separate the crankcases, upper and lower. Refer to “engine bottom side disassembly i...

  • Page 285

    Engine lubrication system: 1e-8 • tighten the oil gallery plug (2) to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque oil gallery plug (m8) (b): 18 n·m (1.8 kgf-m, 13.0 lbf-ft) oil jet (for secondary gear) removal 1) remove the secondary driven gear assembl...

  • Page 286

    1e-9 engine lubrication system: oil pump removal and installation b940h21506010 removal 1) separate the crankcase. Refer to “engine bottom side disassembly in section 1d (page 1d-56)”. 2) remove the oil pump (1). 3) remove the cover (2), return pump outer rotor (3) and inner rotor (4). Installation ...

  • Page 287

    Engine lubrication system: 1e-10 • tighten the oil pump mounting bolts. • assemble the engine. Refer to “engine bottom side assembly in section 1d (page 1d-64)” and “engine top side assembly in section 1d (page 1d-32)”. Oil pump inspection b940h21506011 oil pump inspect the oil pump in the following...

  • Page 288

    1e-11 engine lubrication system: tightening torque specifications b940h21507002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-8)”. Special tools and equipment recommended service material b940h21508001 special ...

  • Page 289: Engine Cooling System

    Engine cooling system: 1f-1 engine engine cooling system precautions precautions for engine cooling system b940h21600001 warning ! • you can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully r...

  • Page 290

    1f-2 engine cooling system: schematic and routing diagram cooling circuit diagram b940h21602001 water pump radiator engine coolant temperature sensor cylinder head cylinder thermostat reservoir tank i822h1160053-01.

  • Page 291

    Engine cooling system: 1f-3 water hose routing diagram b940h21602002 2 1 “a” “l” “b” “c” “c” “c” “d” “e” “ a ” “d” “f” “n” “d” “f” “d” “g” “h” “d” “h” “i” “f” “h” 4 3 “j” a view a 5 except for e-33 inside “k” inside 2 2 6 “h” “m” i940h1160048-12 1. Jiggle valve : jiggle valve on the thermostat must ...

  • Page 292

    1f-4 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis b940h21604001 repair instructions cooling circuit inspection b940h21606001 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 293

    Engine cooling system: 1f-5 radiator cap inspection b940h21606002 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection (page 1f-4)”. 2) attach the radiator cap (1) to the radiator tester (2) as shown in the figure. 3) slowly apply pre...

  • Page 294

    1f-6 engine cooling system: 4) remove the radiator cover (1). 5) disconnect the radiator inlet hose (2). 6) remove the radiator assembly (3) by removing the bolts. 7) remove the cooling fan motor (4) from the radiator. Installation install the radiator in the reverse order of removal. Pay attention ...

  • Page 295

    Engine cooling system: 1f-7 4) any leakage from the connecting section should be corrected by proper tightening. Refer to “water hose routing diagram (page 1f-3)”. 5) after finishing the water hose inspection, reinstall the removed parts. Water hose removal and installation b940h21606006 removal 1) ...

  • Page 296

    1f-8 engine cooling system: installation install radiator reservoir tank in the reverse order of removal. Pay attention to the following point: • fill the reservoir tank to the upper level “a”. Refer to “cooling system inspection in section 0b (page 0b- 11)”. Cooling fan inspection b940h21606009 coo...

  • Page 297

    Engine cooling system: 1f-9 4) first check the insulation between “a” and “b” terminals with tester. Then apply 12 v to “c” and “d” terminals, (+) to “c” and (–) to “d”, and check the continuity between “a” and “b”. If there is no continuity, replace it with a new one. Special tool : 09900–25008 (mu...

  • Page 298

    1f-10 engine cooling system: thermostat inspection b940h21606014 inspect the thermostat in the following procedures: 1) remove the thermostat. Refer to “thermostat removal and installation (page 1f-9)”. 2) inspect the thermostat pellet for signs of cracking. 3) test the thermostat at the bench for c...

  • Page 299

    Engine cooling system: 1f-11 water pump components b940h21606015 water pump removal and installation b940h21606016 removal 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 o...

  • Page 300

    1f-12 engine cooling system: 5) remove the air cleaner box. Refer to “air cleaner chamber removal and installation in section 1d (page 1d-7)”. 6) remove the water pump outlet pipe (2). 7) remove the water pump (3). Installation install the water pump in the reverse order of removal. Pay attention to...

  • Page 301

    Engine cooling system: 1f-13 water pump disassembly and assembly b940h21606017 refer to “water pump removal and installation (page 1f-11)”. Disassembly 1) disconnect the water hoses. 2) remove the connector (1) and water pump case (2). 3) remove the o-ring (2). 4) remove the e-ring (3), cap (4), pin...

  • Page 302

    1f-14 engine cooling system: assembly 1) install the oil seal with the special tool. Caution ! Replace the oil seal with a new one. Note the stamped mark on the oil seal should face mechanical seal side. Special tool (a): 09913–70210 (bearing installer set) 2) apply a small quantity of grease to the...

  • Page 303

    Engine cooling system: 1f-15 6) apply molybdenum solution to the impeller shaft (3). M/o: molybdenum oil (molybdenum oil solution) 7) install the impeller (4). 8) install a new o-ring (5) and (6) apply engine coolant to it. Caution ! Use a new o-rings to prevent engine coolant leakage. 9) fit the wa...

  • Page 304

    1f-16 engine cooling system: impeller / shaft visually inspect the impeller and its shaft for damage. Replace the impeller or shaft if necessary. Impeller shaft journal visually inspect the journal for damage or scratch. Replace the water pump body if necessary. Specifications service data b940h2160...

  • Page 305

    Engine cooling system: 1f-17 tightening torque specifications b940h21607002 note the specified tightening torque is described in the following. “water pump components (page 1f-11)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in sec...

  • Page 306: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions for fuel system b940h21700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Caution ! • to...

  • Page 307

    Fuel system: 1g-2 general description fuel system description b940h21701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel feed hose (3), fuel delivery pipe (4) (including fuel injectors), fuel pressure regulator (5) and fuel filter (6). There is no fuel retu...

  • Page 308

    1g-3 fuel system: schematic and routing diagram fuel tank breather hose routing diagram b940h21702001 1 2 1 2 1 3 1 “b” “b” “a” “c” inside outside 1 “d” 5 4 i940h1170036-01 1. Fuel tank breather hose “a”: white mark 2. Fuel tank breather valve “b”: face the tip of the clip lower. 3. 3 way joint “c”:...

  • Page 309

    Fuel system: 1g-4 diagnostic information and procedures fuel system diagnosis b940h21704001 condition possible cause correction / reference item engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. R...

  • Page 310

    1g-5 fuel system: repair instructions fuel pressure inspection b940h21706001 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) lift and support the fuel tank. Refer...

  • Page 311

    Fuel system: 1g-6 fuel discharge amount inspection b940h21706003 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: 1) lift and support the fuel tank. Refer to ...

  • Page 312

    1g-7 fuel system: 3) first, check for insulation with the tester between terminals “a” and “b”. Next, check for continuity between “a” and “b” with 12 v voltage applied, positive (+) to terminal “c” and negative (–) to terminal “d”. If continuity does not exist, replace the relay with a new one. Spe...

  • Page 313

    Fuel system: 1g-8 fuel tank construction b940h21706009 “ a ” 1 2 3 4 6 5 7 outside i940h1170032-06 1. Clamp 4. Wiring harness 7. Cushion 2. Fuel tank 5. Fuel tank bracket “a”: 45 ° ± 5° 3. Fuel tank cap 6. Fuel tank cushion.

  • Page 314

    1g-9 fuel system: fuel tank removal and installation b940h21706010 removal warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”....

  • Page 315

    Fuel system: 1g-10 8) remove the fuel tank. Caution ! Be careful not to scratch the radiator cap. Installation install the fuel tank in the reverse order of removal. Pay attention to the following points: caution ! • be careful not to bend the hoses. • when installing the fuel tank, be careful not t...

  • Page 316

    1g-11 fuel system: fuel pump components b940h21706011 fwd fwd 7 (a) 5 4 3 2 1 6 i940h1170035-02 1. Filter cover 5. Fuel pressure regulator assembly : apply engine oil. 2. Fuel mesh filter 6. Fuel level gauge : apply grease. 3. Fuel pump 7. O-ring : do not reuse. 4. Thermistor : 10 n ⋅m (1.0 kgf-m, 7...

  • Page 317

    Fuel system: 1g-12 fuel pump assembly / fuel level gauge removal and installation b940h21706012 removal warning ! • spilled gasoline should be wiped off immediately. • keep away from fire or spark. • work in a well-ventilated area. 1) remove the fuel tank. Refer to “fuel tank removal and installatio...

  • Page 318

    1g-13 fuel system: • apply grease to the o-ring (2). Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque as shown in t...

  • Page 319

    Fuel system: 1g-14 assembly refer to “fuel mesh filter inspection (page 1g-14)”. Assemble the fuel tank pump in the reverse order of the disassembly. Pay attention to the following points: caution ! • to prevent fuel leakage, insulator and o- ring must be replaced with a new one. • apply engine oil ...

  • Page 320

    1g-15 fuel system: fuel injector inspection and cleaning b940h21706016 inspect the fuel injector in the following procedures: 1) remove the fuel injector. Refer to “throttle body disassembly and assembly in section 1d (page 1d- 14)”. 2) check the fuel injector filter for evidence of dirt and contami...

  • Page 321

    Fuel system: 1g-16 specifications service data b940h21707001 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b940h21707002 note the specified tightening torque is described in the following. “fuel pump components (page 1g-11)” reference: for the tightening torque...

  • Page 322

    1g-17 fuel system: special tools and equipment recommended service material b940h21708001 note required service material is also described in the following. “fuel pump components (page 1g-11)” special tool b940h21708002 material suzuki recommended product or specification note grease suzuki super gr...

  • Page 323: Ignition System

    Ignition system: 1h-1 engine ignition system schematic and routing diagram ignition system diagram b940h21802001 refer to “wire color symbols in section 0a (page 0a-5)”. Ignition system components location b940h21802002 refer to “electrical components location in section 0a (page 0a-7)”. Ecm tp sens...

  • Page 324

    1h-2 ignition system: diagnostic information and procedures ignition system symptom diagnosis b940h21804001 condition possible cause correction / reference item spark plug not sparking damaged spark plugs. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defe...

  • Page 325

    Ignition system: 1h-3 no spark or poor spark b940h21804002 troubleshooting 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 action yes ...

  • Page 326

    1h-4 ignition system: repair instructions spark plug cap and spark plug removal and installation b940h21806001 removal warning ! The hot engine can burn you. Wait until the engine is cool enough to touch. 1) turn the ignition switch off. 2) remove the cylinder head covers (1). 3) disconnect the spar...

  • Page 327

    Ignition system: 1h-5 ignition coil construction b940h21806002 1 3 4 “ a ” 3 2 2 fwd i940h1180017-01 1. Clamp : clamp the high tension code so it does not contact to the cylinder head cover cap. 4. Cushion : align both edges of cushion when adhering it. 2. #2 ignition coil “a”: 50 mm (1.97 in) 3. #1...

  • Page 328

    1h-6 ignition system: ignition coil removal and installation b940h21806003 removal #1 cylinder 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) remove the battery holder. Refer to “battery / battery holder removal a...

  • Page 329

    Ignition system: 1h-7 ignition coil and plug cap inspection b940h21806005 refer to “electrical components location in section 0a (page 0a-7)”. Ignition coil primary peak voltage inspect the multi-circuit tester with peak voltage adaptor as procedures: 1) connect new spark plug to each spark plug cap...

  • Page 330

    1h-8 ignition system: ignition coil resistance • disconnect the spark plug caps. Refer to “spark plug cap and spark plug removal and installation (page 1h-4)”. • measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard range, repla...

  • Page 331

    Ignition system: 1h-9 7) if the peak voltage is within the specification, check the continuity between the ckp sensor coupler and ecm coupler. Caution ! Normally, use the needle pointed probe to the backside of the lead wire coupler to prevent the terminal bend and terminal alignment. 8) after measu...

  • Page 332

    1h-10 ignition system: ignition switch removal and installation b940h21806010 removal 1) remove the left frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 2) remove the ignition switch (1). 3) disconnect the ignition switch lead wire coupler (2). Install...

  • Page 333

    Ignition system: 1h-11 special tools and equipment special tool b940h21808001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 1h-7) / )(page 1h- 8) / )(page 1h-8) / ) (page 1h-9) ) (page 1h-7) 09930–10121 spark plug wrench set ) (page 1h-4) / )(page 1h- 4).

  • Page 334: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b940h21902001 refer to “wire color symbols in section 0a (page 0a-5)”. Component location starting system components location b940h21903001 refer to “electrical components location in section 0a (page ...

  • Page 335

    Starting system: 1i-2 starter motor will not run b940h21904002 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b940h21904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 336

    1i-3 starting system: repair instructions starter motor components b940h21906001 starter motor removal and installation b940h21906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery / battery holder removal and installation in section 1j (page 1j-1...

  • Page 337

    Starting system: 1i-4 3) disconnect the starter motor read wire (2). 4) remove the starter motor (3) from the left side of the motorcycle. Installation install the starter motor in the reverse order of removal. Pay attention to the following points: • apply grease to the starter motor o-ring. : grea...

  • Page 338

    1i-5 starting system: • tighten the radiator heat shield mounting bolts (2) to the specified torque. Tightening torque radiator heat shield mounting bolt (left side) (c): 5.5 n·m (0.55 kgf-m, 4.0 lbf-ft) radiator heat shield mounting bolt (right side) (d): 10 n·m (1.0 kgf-m, 7.0 lbf-ft) starter moto...

  • Page 339

    Starting system: 1i-6 • align the match mark on the starter motor case with the match mark on the housing end. • tighten the starter motor housing bolts (2). Tightening torque starter motor housing bolt (b): 5 n·m (0.5 kgf-m, 3.5 lbf-ft) starter motor inspection b940h21906004 refer to “starter motor...

  • Page 340

    1i-7 starting system: oil seal check the seal lip for damage. If any damage is found, replace the housing end (inside). Starter relay removal and installation b940h21906005 removal 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (p...

  • Page 341

    Starting system: 1i-8 3) measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Special tool (a): 09900–25008 (multi-circuit tester set) starter relay resistance 3 – 6 Ω 4)...

  • Page 342

    1i-9 starting system: turn signal / side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Side-stand relay 1) remove the turn signal/side-stand relay. Refer to “turn signal / side-stand relay removal and installation (page 1i-8)”. 2) chec...

  • Page 343

    Starting system: 1i-10 gear position switch 1) remove the right frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 2) disconnect the gear position switch coupler. Caution ! When disconnecting and connecting the gear position switch coupler, make sure to t...

  • Page 344

    1i-11 starting system: 5) hold the generator rotor and remove the starter clutch bolts. 6) remove the one way clutch (6) from the guide (7). Installation install the starter clutch in the reverse order of removal. Pay attention to the following points: • when inserting the one way clutch (1) into th...

  • Page 345

    Starting system: 1i-12 • apply molybdenum oil solution to the idle gear shaft holes. M/o: molybdenum oil (molybdenum oil solution) • install the starter torque limiter (3), idle gear shaft (4) and starter idle gear (5). • apply engine oil to the bushing of the starter driven gear. • install the gene...

  • Page 346

    1i-13 starting system: starter driven gear bearing inspect the starter driven gear bushing for wear or damage. Starter button inspection b940h21906012 inspect the starter button in the following procedures: 1) remove the headlight assembly. Refer to “headlight removal and installation in section 9b ...

  • Page 347

    Starting system: 1i-14 specifications service data b940h21907001 unit: mm (in) tightening torque specifications b940h21907002 note the specified tightening torque is described in the following. “starter motor components (page 1i-3)” reference: for the tightening torque of fastener not specified in t...

  • Page 348

    1i-15 starting system: special tool b940h21908002 09900–20102 09900–25008 vernier calipers (1/20 mm, 200 mm) multi-circuit tester set ) (page 1i-6) ) (page 1i-6) / )(page 1i-7) / )(page 1i-8) / )(page 1i- 8) / )(page 1i-9) / ) (page 1i-9) / )(page 1i- 10) / )(page 1i-10) / ) (page 1i-13) 09900–25009...

  • Page 349: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b940h21a02001 component location charging system components location b940h21a03001 refer to “electrical components location in section 0a (page 0a-7)”. Generator regulator/rectifier ic scr battery load...

  • Page 350

    1j-2 charging system: diagnostic information and procedures charging system symptom diagnosis b940h21a04001 condition possible cause correction / reference item generator does not charge open- or short-circuited lead wires, or loose lead connections. Repair, replace or connect properly. Short-circui...

  • Page 351

    Charging system: 1j-3 battery runs down quickly b940h21a04002 troubleshooting repair instructions battery current leakage inspection b940h21a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal an...

  • Page 352

    1j-4 charging system: 5) connect the battery (–) terminal and install the seat. Refer to “battery / battery holder removal and installation (page 1j-11)” and “exterior parts removal and installation in section 9d (page 9d- 5)”. Regulated voltage inspection b940h21a06002 inspect the regulated voltage...

  • Page 353

    Charging system: 1j-5 4) connect the special tool to the high-tension cord. Special tool : 09900–26006 (engine tachometer (solar cell type)) 5) start the engine and keep it running at 5 000 r/min. 6) using the multi-circuit tester, measure the voltage between three lead wires. If the tester reads un...

  • Page 354

    1j-6 charging system: 9) loosen the generator rotor bolt. Note when loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. 10) remove the generator rotor assembly with the special tool. Note remove the starter clutch if necessar...

  • Page 355

    Charging system: 1j-7 • 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 these surfaces completely dry. • fit the key (4) in the key slot on the crankshaft. • install the generator rotor onto...

  • Page 356

    1j-8 charging system: regulator / rectifier inspection b940h21a06005 inspect the regulator/rectifier in the following procedures: 1) turn the ignition switch to off position. 2) remove the left frame lower cover. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 3) remove...

  • Page 357

    Charging system: 1j-9 battery components b940h21a06006 battery charging b940h21a06007 initial charging filling electrolyte note when filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. 1) remove the aluminum tape (1) which seals the battery filler h...

  • Page 358

    1j-10 charging system: note if no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. 6) after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from ...

  • Page 359

    Charging system: 1j-11 2) measure the battery voltage using the multi-circuit tester. If the voltage reading is less than the 12 v (dc), recharge the battery with a battery charger. Recharging time 1.8 a for 5 to 10 hours or 9 a for 1 hour caution ! Be careful not to permit the charging current to e...

  • Page 360

    1j-12 charging system: 8) remove the side stand relay. Refer to “turn signal / side-stand relay removal and installation in section 1i (page 1i-8)”. 9) lift the battery holder (9) by removing the bolts. 10) remove the shut-off valve (10). 11) remove the to sensor (11) and cooling fan relay (12). Ins...

  • Page 361

    Charging system: 1j-13 specifications service data b940h21a07001 electrical caution ! Never use anything except the specified battery. Unit: mm (in) tightening torque specifications b940h21a07002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening tor...

  • Page 362: Exhaust System

    1k-1 exhaust system: engine exhaust system precautions precautions for exhaust system b940h21b00001 warning ! To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure ...

  • Page 363

    Exhaust system: 1k-2 exhaust pipe / muffler removal and installation b940h21b06002 removal 1) remove the right frame side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 2) disconnect the ho2 sensor lead wire coupler (1) and remove the clamp (2). 3) remove the re...

  • Page 364

    1k-3 exhaust system: 9) remove the front muffler (9) along with the exhaust pipe. 10) remove the front exhaust pipe (10). 11) remove the ho2 sensor (11) from the exhaust pipe. Caution ! • be careful not to expose it to an excessive shock. • be careful not to twist or damage the sensor lead wire. Ins...

  • Page 365

    Exhaust system: 1k-4 • tighten the front muffler connecting bolt to the specified torque. Tightening torque muffler connecting bolt (front) (b): 26 n·m (2.6 kgf-m, 19.0 lbf-ft) • tighten the exhaust pipe bolts and exhaust pipe mounting bolt to the specified torque. Tightening torque exhaust pipe bol...

  • Page 366

    1k-5 exhaust system: specifications tightening torque specifications b940h21b07001 note the specified tightening torque is described in the following. “exhaust system construction (page 1k-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque...

  • Page 367: Section 2

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

  • Page 368: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b940h22000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the...

  • Page 369: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b940h22104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Repla...

  • Page 370: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front fork components b940h22206001 (b) 15 1 2 8 7 3 4 5 6 10 11 12 (b) 14 (c) 13 fwd fwd (a) 9 i940h1220031-01 1. O-ring 8. Spring 15. Front fork cap bolt 2. Spacer 9. Inner rod lock-nut : 15 n ⋅m (1.5 kgf-m, 11.0 lbf-ft) 3. Out...

  • Page 371

    Front suspension: 2b-2 front fork removal and installation b940h22206002 caution ! Do not operate the front brake lever and brake pedal with the front wheel removed. Note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that f...

  • Page 372

    2b-3 front suspension: 6) tighten the front fork upper clamp bolt (3). Tightening torque front fork upper clamp bolt (c): 23 n·m (2.3 kgf- m, 16.5 lbf-ft) 7) install the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-3)”. Note before tightening t...

  • Page 373

    Front suspension: 2b-4 4) remove the spacer (3) and spring (4). 5) invent the fork and stroke it several times to drain out fork oil. 6) hold the fork inverted for a few minutes to drain oil. 7) remove the front axle pinch bolts (5). 8) remove the damper rod bolt using the special tools. Special too...

  • Page 374

    2b-5 front suspension: 12) remove the oil seal (9) with the special tool. 13) remove the oil seal retainer (10). Special tool (d): 09913–50121 (oil seal remover) caution ! The removed oil seal must be replaced with a new one. Assembly assemble the front fork in the reverse order of disassembly. Pay ...

  • Page 375

    Front suspension: 2b-6 damper rod bolt apply thread lock to the damper rod bolt (1) and tighten it to the specified torque with a hexagon wrench and special tools. Caution ! Use a new cylinder bolt gasket to prevent oil leakage. Note check the front fork for smoothness by stroking it after installin...

  • Page 376

    2b-7 front suspension: • refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until bubbles do not come out from the oil. • keep the front fork vertically and wait 5 – 6 minutes. Note • always keep oil level over the cartridge t...

  • Page 377

    Front suspension: 2b-8 • slowly turn the cap bolt completely by hand until the end of the cap bolt seats on the lock-nut. • hold the cap bolt (1) and tighten the lock-nut (2) to the specified torque. Tightening torque front fork inner rod lock-nut (a): 15 n·m (1.5 kgf- m, 11.0 lbf-ft) • remove the s...

  • Page 378

    2b-9 front suspension: specifications service data b940h22207001 suspension unit: mm (in) tightening torque specifications b940h22207002 note the specified tightening torque is described in the following. “front fork components (page 2b-1)” reference: for the tightening torque of fastener not specif...

  • Page 379

    Front suspension: 2b-10 special tool b940h22208002 09913–50121 09940–30221 oil seal remover front fork assembling tool ) (page 2b-5) ) (page 2b-4) 09940–34520 09940–34531 t handle attachment a ) (page 2b-6) ) (page 2b-6) 09940–52841 09940–52861 front fork inner rod holder front fork oil seal install...

  • Page 380: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components b940h22306001 1 (b) 2 5 (b) 4 3 (a) 4 4 6 4 5 2 3 (c) 8 11 12 14 7 13 3 9 9 3 3 10 11 (b) fwd fwd (a) 12 i940h1230044-05 1. Rear shock absorber 8. Swingarm pivot shaft nut : 65 n ⋅m (6.5 kgf-m, 47.0 lbf-f...

  • Page 381

    Rear suspension: 2c-2 rear suspension assembly construction b940h22306002 (a) 1 (a) 2 (b) 4 (b) 5 “ c ” “ c ” (a) 1 (c) 8 (b) 5 (b) 4 (a) 2 (b) 3 “ d ” “ d ” 6 (c) 8 (b) 3 lh rh “ a ” “ b ” “ b ” 7 i940h1230042-04 1. Rear shock absorber mounting nut (upper) “a”: 0.25 mm (0.01 in) 2. Rear shock absor...

  • Page 382

    2c-3 rear suspension: swingarm assembly removal and installation b940h22306003 removal caution ! Make sure that the motorcycle is supported securely. 1) remove the exhaust pipe and muffler. Refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-2)”. 2) remove the rear wheel...

  • Page 383

    Rear suspension: 2c-4 10) hold the swingarm pivot shaft (6) with the special tool and remove the swingarm pivot shaft nut (7). Special tool (a): 09900–18720 (hexagon socket (14 mm)) 11) remove the swingarm assembly. 12) remove the rear shock absorber (8). 13) remove the cushion lever (9) and cushion...

  • Page 384

    2c-5 rear suspension: • install the oil seal with the special tool. Caution ! Replace the oil seal with a new one. Special tool (c): 09913–70210 (bearing installer set) • install the cushion rod (2) and cushion lever (3) and tighten the cushion rod nut to the specified torque. Note • the stamped mar...

  • Page 385

    Rear suspension: 2c-6 • tighten the cushion lever mounting nut to the specified torque. Tightening torque cushion lever mounting nut (e): 132 n·m (13.2 kgf-m, 95.5 lbf-ft) • install the rear brake pipe as shown in the rear brake hose routing diagram. Refer to “rear brake hose routing diagram in sect...

  • Page 386

    2c-7 rear suspension: rear shock absorber disposal b940h22306008 refer to “swingarm assembly removal and installation (page 2c-3)”. The rear shock absorber unit contains high-pressure nitrogen gas. Warning ! • the rear shock absorber unit contains high-pressure nitrogen gas. • mishandling can cause ...

  • Page 387

    Rear suspension: 2c-8 cushion lever bearing 1) insert the spacers into bearings. 2) check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a new one. Refer to “cushion lever bearing removal and installation (page 2c-8)”. Cushion lever inspect the cushi...

  • Page 388

    2c-9 rear suspension: installation caution ! The removed bearings and cushion seals must be replaced with new ones. 1) press the bearings into the cushion lever with the special tool as shown in the rear suspension assembly construction. Refer to “rear suspension assembly construction (page 2c-2)”. ...

  • Page 389

    Rear suspension: 2c-10 swingarm bearing 1) insert the spacers into bearings. 2) check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a new one. Refer to “swingarm bearing removal and installation (page 2c-11)”. Swingarm inspect the swingarm for damag...

  • Page 390

    2c-11 rear suspension: swingarm bearing removal and installation b940h22306013 removal 1) remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-10)”. 2) remove the swingarm. Refer to “cushion lever removal and installation (page 2c-7)”. 3) draw...

  • Page 391

    Rear suspension: 2c-12 specifications service data b940h22307001 suspension unit: mm (in) tightening torque specifications b940h22307002 note the specified tightening torque is described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2)” re...

  • Page 392

    2c-13 rear suspension: special tool b940h22308002 09900–18720 09900–20607 hexagon socket (14 mm) dial gauge (1/100 mm, 10 mm) ) (page 2c-4) ) (page 2c-10) 09900–20701 09900–21304 magnetic stand v-block (100 mm) ) (page 2c-10) ) (page 2c-10) 09910–60611 09913–70210 universal clamp wrench bearing inst...

  • Page 393: Wheels and Tires

    Wheels and tires: 2d-1 suspension wheels and tires precautions precautions for wheel and tire b940h22400001 warning ! • proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. • under-inflatio...

  • Page 394

    2d-2 wheels and tires: repair instructions front wheel components b940h22406001 (b) 1 2 3 4 (a) 5 11 7 8 10 6 3 2 9 (a) 5 6 fwd fwd i940h1240047-02 1. Front axle 7. Front wheel : 100 n ⋅m (10.0 kgf-m, 72.5 lbf-ft) 2. Dust seal 8. Front tire : apply grease. 3. Bearing 9. Collar : apply thread lock to...

  • Page 395

    Wheels and tires: 2d-3 front wheel assembly construction b940h22406002 front wheel assembly removal and installation b940h22406003 removal 1) raise the front wheel off the ground and support the motorcycle with a jack or a wooden block. Caution ! Do not carry out the work with the motorcycle resting...

  • Page 396

    2d-4 wheels and tires: 3) loosen the axle pinch bolts (1) on the left front fork leg. 4) remove the front axle (2) with the special tool and then remove the front wheel. Note after removing the front wheel, install the calipers temporarily to the original positions. Special tool (a): 09900–18740 (he...

  • Page 397

    Wheels and tires: 2d-5 4) tighten the front axle (3) to the specified torque with the special tool. Special tool (a): 09900–18740 (hexagon socket (24 mm)) tightening torque front axle (b): 100 n·m (10.0 kgf-m, 72.5 lbf-ft) 5) move the front fork up and down 4 or 5 times. 6) tighten the axle pinch bo...

  • Page 398

    2d-6 wheels and tires: wheel 1) remove the brake pads. Refer to “front brake pad replacement in section 4b (page 4b-2)”. 2) make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by ...

  • Page 399

    Wheels and tires: 2d-7 installation caution ! The removed dust seals and bearings must be replaced with new ones. 1) apply grease to the wheel bearings. : grease 99000–25010 (suzuki super grease a or equivalent) 2) first install the right wheel bearing, then install the spacer (1) and left wheel bea...

  • Page 400

    2d-8 wheels and tires: 4) apply grease to the lip of the dust seals. : grease 99000–25010 (suzuki super grease a or equivalent) 5) install the front wheel assembly. Refer to “front wheel assembly removal and installation (page 2d-3)”. I940h1240021-01.

  • Page 401

    Wheels and tires: 2d-9 rear wheel components b940h22406006 2 3 4 5 7 8 6 1 18 9 17 11 14 3 13 (b) 16 (a) 15 10 fwd fwd 12 i940h1240046-02 1. Rear axle 9. Spacer 17. Wheel balancer 2. Spacer 10. Rear wheel 18. Air valve 3. Bearing 11. Rear tire : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 4. Lock washer 12. Du...

  • Page 402

    2d-10 wheels and tires: rear wheel assembly construction b940h22406007 rear wheel assembly removal and installation b940h22406008 removal 1) support the motorcycle with the jack or wooden block. 2) remove the rear brake caliper. Refer to “rear brake caliper removal and installation in section 4c (pa...

  • Page 403

    Wheels and tires: 2d-11 4) remove the cap (2). 5) hold the rear axle with the special tool and remove the axle nut (3) and washer (4). Special tool (a): 09944–28320 (hexagon socket (19 mm)) 6) draw out the rear axle (5). 7) remove the brake caliper bracket (6). 8) remove the rear wheel assembly (7) ...

  • Page 404

    2d-12 wheels and tires: 3) apply grease to the dust seal lip. : grease 99000–25010 (suzuki super grease a or equivalent) 4) install the collar (1). 5) install the rear wheel, rear axle and brake caliper bracket. 6) apply thread lock to the brake caliper bracket mounting bolt (2) and tighten it to th...

  • Page 405

    Wheels and tires: 2d-13 dust seal inspect the dust seal lip for wear or damage. If any defects are found, replace the dust seal with a new one. Refer to “rear wheel dust seal / bearing removal and installation (page 2d-13)”. Wheel axle using a dial gauge, check the wheel axle for runout, if the runo...

  • Page 406

    2d-14 wheels and tires: 3) remove the bearings (2) on both sides using the special tool. Special tool (b): 09921–20240 (bearing remover set) 4) remove the spacer (3). Installation caution ! The removed dust seals and bearings must be replaced with new ones. 1) apply grease to the wheel bearings. : g...

  • Page 407

    Wheels and tires: 2d-15 3) install a new dust seal with the special tool. Special tool (c): 09913–70210 (bearing installer set) 4) apply grease to the dust seal lip. : grease 99000–25010 (suzuki super grease a or equivalent) 5) install the rear wheel assembly. Refer to “rear wheel assembly removal a...

  • Page 408

    2d-16 wheels and tires: 2) install the tire onto the wheel. Caution ! For installation procedure of tire onto the wheel, follow the instructions given by the tire changer manufacturer. Note • when installing the tire, the arrow “a” on the side wall should point to the direction of wheel rotation. • ...

  • Page 409

    Wheels and tires: 2d-17 tire tire must be checked for the following points: • nick and rupture on side wall • tire tread depth (refer to “tire inspection in section 0b (page 0b-16)”.) • tread separation • abnormal, uneven wear on tread • surface damage on bead • localized tread wear due to skidding ...

  • Page 410

    2d-18 wheels and tires: • install the air valve (2) in the wheel (3). Caution ! • be careful not to damage the lip (4) of the valve. • replace the air valve with a new one. Note to properly install the valve into the valve hole, apply a special tire lubricant or neutral soapy liquid to the valve. Wh...

  • Page 411

    Wheels and tires: 2d-19 tire tightening torque specifications b940h22407002 note the specified tightening torque is described in the following. “front wheel components (page 2d-2)” “front wheel assembly construction (page 2d-3)” “rear wheel components (page 2d-9)” “rear wheel assembly construction (...

  • Page 412

    2d-20 wheels and tires: special tool b940h22408002 09900–18740 09900–20607 hexagon socket (24 mm) dial gauge (1/100 mm, 10 mm) ) (page 2d-4) / )(page 2d- 5) ) (page 2d-5) / )(page 2d- 13) 09900–20701 09900–21304 magnetic stand v-block (100 mm) ) (page 2d-5) / )(page 2d- 13) ) (page 2d-5) / )(page 2d...

  • Page 413: Section 3

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

  • Page 414: Precautions

    3-1 precautions: driveline / axle precautions precautions precautions for driveline / axle b940h23000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! Support the motorcycle with a jack or wooden block when servicing the driveshafts and drive train..

  • Page 415

    Drive chain / drive train / drive shaft: 3a-1 driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b940h23104001 condition possible cause correction / reference item noisy shaft drive (noise seems to come from secon...

  • Page 416

    3a-2 drive chain / drive train / drive shaft: repair instructions secondary gear components b940h23106001 (a) 1 2 3 4 5 6 (b) 7 8 9 10 11 12 13 14 15 16 17 (c) fwd fwd i940h1310057-02 1. Driven bevel gear coupling nut 9. Oil seal 17. Shim(-s) 2. Washer 10. Bearing : 95 n ⋅m (9.5 kgf-m, 68.5 lbf-ft) ...

  • Page 417

    Drive chain / drive train / drive shaft: 3a-3 secondary gear construction b940h23106002 secondary driven gear assembly removal and installation b940h23106003 removal 1) remove the engine assembly. Refer to “engine assembly removal in section 1d (page 1d-20)”. 2) remove the speed sensor. Refer to “sp...

  • Page 418

    3a-4 drive chain / drive train / drive shaft: installation install the secondary driven gear assembly in the reverse order of removal. Pay attention to the following points: • when installing the secondary driven gear assembly, align the pin “a” and hole “b” of the bearing. • apply bond to the each ...

  • Page 419

    Drive chain / drive train / drive shaft: 3a-5 secondary driven gear disassembly and assembly b940h23106004 refer to “secondary driven gear assembly removal and installation (page 3a-3)”. Disassembly 1) remove the shims (1). 2) unlock the nut with a chisel. 3) remove the driven bevel gear coupling nu...

  • Page 420

    3a-6 drive chain / drive train / drive shaft: 9) remove the oil seal with the special tool. Special tool (c): 09913–50121 (oil seal remover) 10) remove the bearing (11). Special tool (d): 09913–70210 (bearing installer set) assembly note bearing installing the gears, apply engine oil to the rotating...

  • Page 421

    Drive chain / drive train / drive shaft: 3a-7 3) install the oil seal with the special tool. Caution ! The removed oil seal must be replaced with a new one. Special tool (a): 09913–70210 (bearing installer set) 4) install the bearing housing (1) and tighten the bearing stopper (2) to the specified t...

  • Page 422

    3a-8 drive chain / drive train / drive shaft: 8) install the coupling (8) and washer (9). 9) tighten the coupling nut (10) to the specified torque with the special tool. Caution ! Replace the coupling nut (10) with a new one. Special tool (d): 09924–64510 (final driving gear coupling holder) tighten...

  • Page 423

    Drive chain / drive train / drive shaft: 3a-9 oil seal inspect the oil seal for wear or damage. If any defects are found, replace the oil seal with a new one. Secondary gear shim inspection and adjustment b940h23106006 backlash refer to “secondary driven gear assembly removal and installation (page ...

  • Page 424

    3a-10 drive chain / drive train / drive shaft: tooth contact after bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. 1) remove the secondary gear case. 2) clean and degrease the secondary drive bevel gear teeth,...

  • Page 425

    Drive chain / drive train / drive shaft: 3a-11 final bevel gear components b940h23106007 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 18 17 23 22 20 19 21 fwd fwd (a) 24 (b) 25 (a) 26 (e) 28 (d) 27 (c) 29 30 i940h1310058-02 1. Oil seal 15. Oil seal 29. Drive bearing stopper 2. Final gear bearing case 16. ...

  • Page 426

    3a-12 drive chain / drive train / drive shaft: final gear construction b940h23106008 final gear assembly removal and installation b940h23106009 removal 1) drain final gear oil. Refer to “final gear oil replacement in section 0b (page 0b-10)”. 2) remove the rear wheel. Refer to “rear wheel assembly r...

  • Page 427

    Drive chain / drive train / drive shaft: 3a-13 installation 1) apply bond to the mating surface of the final gear case and swingarm. : sealant 99000–31110 (suzuki bond no.1215 or equivalent) caution ! When installing the stopper plate, fit the protrusion “a” of the plate to the one of the bearing st...

  • Page 428

    3a-14 drive chain / drive train / drive shaft: 6) install the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-10)”. 7) pour final gear oil. Refer to “final gear oil replacement in section 0b (page 0b-10)”. Final gear disassembly and assembly b940h23...

  • Page 429

    Drive chain / drive train / drive shaft: 3a-15 8) remove the bearing stopper with the special tool. Special tool (c): 09924–62410 (final drive gear bearing holder wrench) 9) remove the final drive bevel gear (8) and shims (9). 10) remove the bearing with the inner race from the final drive bevel gea...

  • Page 430

    3a-16 drive chain / drive train / drive shaft: 15) remove the shim (12) and final driven bevel gear (13). 16) remove the shims (14). 17) remove the final driven bevel gear bearing (15) from the bevel gear with two bolts or suitable bars. Note if no abnormal noise, the bearing removal is not necessar...

  • Page 431

    Drive chain / drive train / drive shaft: 3a-17 21) remove the oil seal (19) and o-ring (20) from the bearing stopper. Assembly reassemble the final gear case in the reverse order of disassembly. Pay attention to the following points: • install a oil seal (1) and o-ring (2) to the bearing stopper. No...

  • Page 432

    3a-18 drive chain / drive train / drive shaft: • install a new oil seal to the final gear bearing case with the special tool. Special tool (d): 09951–16310 (bearing installer) • apply grease to the lip of the oil seal. : grease 99000–25010 (suzuki super grease a or equivalent) • install the final dr...

  • Page 433

    Drive chain / drive train / drive shaft: 3a-19 • install the inner race (7), washer (8), bearing (9) and inner race (10) with the special tool. Special tool (f): 09913–84510 (bearing installer) note when installing the bearing, stamped mark on the bearing must face outside. • install the correct shi...

  • Page 434

    3a-20 drive chain / drive train / drive shaft: • tighten the nut to the specified torque with the special tool. Caution ! Use a new nut. Tightening torque final drive gear coupling nut (d): 100 n·m (10.0 kgf-m, 72.5 lbf-ft) special tool (h): 09924–62430 (long socket (22 mm)) (i): 09924–64510 (final ...

  • Page 435

    Drive chain / drive train / drive shaft: 3a-21 final gear parts inspection b940h23106011 drive / driven bevel gear inspect the drive and/or driven bevel gear wear or damage. If any defects are found, replace the drive and/ or driven bevel gear with a new one. Bearing inspect bearings, left and right...

  • Page 436

    3a-22 drive chain / drive train / drive shaft: installation install the universal joint in the reverse order of removal. Pay attention to the following point: • before installing the swingarm, install the boot and the universal joint. Note make sure that the “up” mark “a” on the boot faces to up. Un...

  • Page 437

    Drive chain / drive train / drive shaft: 3a-23 6) remove the dumpers with a screw driver. Installation install the wheel damper in the reverse order of removal. Pay attention to the following points: • install the wheel dumpers. Note if soap water is applied around the dumper, it makes the job easie...

  • Page 438

    3a-24 drive chain / drive train / drive shaft: final gear shim inspection and adjustment b940h23106016 refer to “final gear disassembly and assembly (page 3a-14)”. Right side shim adjustment 1) install the shims and final gear bearing case and tighten the bolts to the specified torque. Tightening to...

  • Page 439

    Drive chain / drive train / drive shaft: 3a-25 • adjust the dial gauge so that it touches the backlash measuring tool arm at the mark; hold the final driven bevel gear securely, and turn the final drive bevel gear coupling slightly in each direction, reading the total backlash on the dial gauge. Fin...

  • Page 440

    3a-26 drive chain / drive train / drive shaft: example: final gear to case shims (1); 1.45 mm + 1.40 mm = 2.85 mm final gear bearing to bearing case shims (2), 0.35 mm + 0.60 mm = 0.95 mm original total measurement (1) + (2) = 3.80 mm backlash too large: final gear to case shims (1); 1.35 mm + 1.45 ...

  • Page 441

    Drive chain / drive train / drive shaft: 3a-27 • if the tooth contact pattern is incorrect for either reason, the appropriate shim must be installed, and the tooth contact pattern rechecked by repeating the tooth coating procedure above. Note if it is necessary to adjust the shim (4) thickness betwe...

  • Page 442

    3a-28 drive chain / drive train / drive shaft: specifications service data b940h23107001 drive train unit: mm (in) except ratio tightening torque specifications b940h23107002 note the specified tightening torque is described in the following. “secondary gear components (page 3a-2)” “secondary gear c...

  • Page 443

    Drive chain / drive train / drive shaft: 3a-29 special tools and equipment recommended service material b940h23108001 note required service material is also described in the following. “secondary gear components (page 3a-2)” “secondary gear construction (page 3a-3)” “final bevel gear components (pag...

  • Page 444

    3a-30 drive chain / drive train / drive shaft: 09913–84510 09923–74511 bearing installer bearing remover ) (page 3a-19) ) (page 3a-16) 09924–34510 09924–41830 backlash measuring tool ( φ27 – 50) bearing retainer wrench ) (page 3a-9) / )(page 3a- 24) ) (page 3a-5) / )(page 3a- 7) 09924–62410 09924–62...

  • Page 445: Section 4

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

  • Page 446: Precautions

    4-1 precautions: brake precautions precautions precautions for brake system b940h24000001 refer to “general precautions in section 00 (page 00-1)”. Brake fluid information b940h24000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 447

    Brake control system and diagnosis: 4a-1 brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b940h24102001 “ b ” “ a ” “ b ” 1 (a) “a” “b” “b” “b” “c” “d” “c” (a) 1 “b” 1 (a) 1 “c” “d” i940h1410081-05 1. Stopper : position the brake hose union with...

  • Page 448

    4a-2 brake control system and diagnosis: rear brake hose routing diagram b940h24102002 “ b ” “ a ” “a” “a” “b” “c” “d” “e” “f” “g” “g” “h” (a) (a) (b) (b) i940h1410082-10 “a”: white marking “g”: position the brake hose union with the stopper before tightening the bolt. “b”: yellow marking “h”: posit...

  • Page 449

    Brake control system and diagnosis: 4a-3 diagnostic information and procedures brake symptom diagnosis b940h24104001 repair instructions brake pedal height inspection and adjustment b940h24106001 refer to “brake system inspection in section 0b (page 0b-14)”. Front brake light switch inspection b940h...

  • Page 450

    4a-4 brake control system and diagnosis: rear brake light switch inspection b940h24106003 inspect the rear brake light switch in the following procedures: 1) disconnect the rear brake light switch lead coupler (1). 2) inspect the switch for continuity with a tester. If any abnormality is found, repl...

  • Page 451

    Brake control system and diagnosis: 4a-5 2) attach a clear hose to the air bleeder valve, and insert the free end of the hose into a receptacle. 3) squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. 4) loosen the air bleeder valve ...

  • Page 452

    4a-6 brake control system and diagnosis: • fill the reservoir with brake fluid to the upper mark of the reservoir. Brake fluid replacement b940h24106008 caution ! Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. Front brake 1) place the motorcycle...

  • Page 453

    Brake control system and diagnosis: 4a-7 8) fill the reservoir with brake fluid to the upper mark of the reservoir. 9) install the reservoir cap. Rear brake 1) place the motorcycle on a level surface. 2) remove the right frame head cover. Refer to “exterior parts removal and installation in section ...

  • Page 454

    4a-8 brake control system and diagnosis: 9) fill the reservoir with brake fluid to the upper mark of the reservoir. Front brake hose removal and installation b940h24106009 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) remove the front brake hoses as shown in the fr...

  • Page 455

    Brake control system and diagnosis: 4a-9 front brake master cylinder components b940h24106011 fwd fwd (a) 6 (b) 8 fwd fwd (c) 9 7 5 1 2 3 (d) 10 4 i940h1410088-02 1. Reservoir cap 7. Brake lever : 10 n ⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Plate 8. Brake lever pivot bolt : apply brake fluid. 3. Diaphragm 9....

  • Page 456

    4a-10 brake control system and diagnosis: front brake master cylinder assembly removal and installation b940h24106012 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) disconnect the front brake light switch lead coupler (1). 3) place a rag underneath the brake hose un...

  • Page 457

    Brake control system and diagnosis: 4a-11 front brake master cylinder / brake lever disassembly and assembly b940h24106013 refer to “front brake master cylinder assembly removal and installation (page 4a-10)”. Disassembly 1) remove the brake lever (1) and brake light switch (2). 2) remove the reserv...

  • Page 458

    4a-12 brake control system and diagnosis: • apply grease to the brake lever pivot bolt. • apply grease to the contact point between piston and brake lever. : grease 99000–25100 (suzuki silicone grease or equivalent) • tighten the pivot bolt and lock-nut to the specified torque. Tightening torque bra...

  • Page 459

    Brake control system and diagnosis: 4a-13 rear brake master cylinder components b940h24106015 rear brake master cylinder removal and installation b940h24106016 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) disconnect the rear brake light switch coupler (1). 1 (b) 2...

  • Page 460

    4a-14 brake control system and diagnosis: 3) remove the union bolt (2). 4) disconnect the rear reservoir tank hose (3). 5) remove the footrest bracket bolts (4). 6) loosen the lock-nut (5) and remove the push rod (6). 7) remove the rear master cylinder (7) by removing the mounting bolts (8). 8) remo...

  • Page 461

    Brake control system and diagnosis: 4a-15 • turn the push rod (5) until the brake pedal becomes 60 – 70 mm (2.4 – 2.8 in.) “a” above the top of the footrest. • tighten the lock-nut (6) to the specified torque. Tightening torque rear brake master cylinder rod lock-nut (b): 18 n·m (1.8 kgf-m, 13.0 lbf...

  • Page 462

    4a-16 brake control system and diagnosis: rear brake master cylinder disassembly and assembly b940h24106017 refer to “rear brake master cylinder removal and installation (page 4a-13)”. Disassembly 1) remove the snap ring (1), brake hose connector (2) and o-ring (3). Special tool : 09900–06108 (snap ...

  • Page 463

    Brake control system and diagnosis: 4a-17 • install the o-ring (1) and brake hose connector (2). Caution ! Replace the o-ring (1) with a new one. • install the snap ring (3). Caution ! Do not reuse the snap ring (3). Rear brake master cylinder parts inspection b940h24106018 refer to “rear brake mast...

  • Page 464

    4a-18 brake control system and diagnosis: installation install the rear brake pedal in the reverse order of removal. Pay attention to the following points: • when installing the rear brake pedal, position the punched mark “a” of the brake rod and slit “b” of the brake pedal. • tighten the rear brake...

  • Page 465

    Brake control system and diagnosis: 4a-19 tightening torque specifications b940h24107002 note the specified tightening torque is described in the following. “front brake hose routing diagram (page 4a-1)” “rear brake hose routing diagram (page 4a-2)” “front brake master cylinder components (page 4a-9...

  • Page 466: Front Brakes

    4b-1 front brakes: brake front brakes repair instructions front brake components b940h24206001 front brake pad inspection b940h24206002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads wit...

  • Page 467

    Front brakes: 4b-2 front brake pad replacement b940h24206003 1) remove the brake caliper by removing the caliper mounting bolts (1). 2) remove the pads (2) by removing the pad set pin clip (3) and pad set pin (4). Caution ! Do not operate the brake lever and brake pedal while dismounting the pads. 3...

  • Page 468

    4b-3 front brakes: front brake caliper removal and installation b940h24206004 note the right and left calipers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) drain brake fluid. Refer to “brake fluid replacement in secti...

  • Page 469

    Front brakes: 4b-4 3) remove the caliper holder (2) and boots (3). 4) place a rag over the pistons to prevent it from popping out and then force out the pistons (4) using compressed air. Caution ! Do not use high pressure air to prevent piston damage. 5) remove the dust seals (5) and piston seals (6...

  • Page 470

    4b-5 front brakes: brake caliper • wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves. Bf: brake fluid (dot 4) caution ! • wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or g...

  • Page 471

    Front brakes: 4b-6 brake caliper piston inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, replace the piston with a new one. Brake pad set pin / clip inspect the brake pad set pin for wear and other damage. If any damage is found, replace defective p...

  • Page 472

    4b-7 front brakes: front brake disc removal and installation b940h24206007 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-3)”. 2) remove the front brake disc. Installation install the front brake disc in the reverse order of...

  • Page 473

    Front brakes: 4b-8 specifications service data b940h24207001 brake unit: mm (in) tightening torque specifications b940h24207002 note the specified tightening torque is described in the following. “front brake components (page 4b-1)” reference: for the tightening torque of fastener not specified in t...

  • Page 474

    4b-9 front brakes: special tool b940h24208002 09900–20205 09900–20607 micrometer (0 – 25 mm) dial gauge (1/100 mm, 10 mm) ) (page 4b-7) ) (page 4b-7) 09900–20701 magnetic stand ) (page 4b-7).

  • Page 475: Rear Brakes

    Rear brakes: 4c-1 brake rear brakes repair instructions rear brake components b940h24306001 (a) 1 5 2 3 4 (b) 6 7 8 (d) fwd fwd (c) i940h1430023-02 1. Rear brake caliper 7. Brake caliper bracket : apply thread lock to the thread part. 2. Piston seal/dust seal 8. Brake disc : apply thread lock to the...

  • Page 476

    4c-2 rear brakes: rear brake pad inspection b940h24306002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “rear brake pad replacement (page 4c-2)”. Caution ! Repla...

  • Page 477

    Rear brakes: 4c-3 6) insert the pad mounting pin (2) and install the clip (3) as shown in the figure. 7) apply thread lock to the caliper mounting bolts (1) and tighten them to the specified torque. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) tightening torque rear...

  • Page 478

    4c-4 rear brakes: • bleed air from the brake system after installing the caliper. Refer to “air bleeding from brake fluid circuit in section 4a (page 4a-4)”. • check the brake fluid leakage and brake operation. Warning ! Brake fluid, if it leaks, will interfere with safe running and discolor painted...

  • Page 479

    Rear brakes: 4c-5 brake caliper carrier remove the pad guide (1). Assembly assemble 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 grooves and piston seal grooves. ...

  • Page 480

    4c-6 rear brakes: rear brake caliper parts inspection b940h24306006 refer to “rear brake caliper disassembly and assembly (page 4c-4)”. Brake caliper cylinder inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. Bra...

  • Page 481

    Rear brakes: 4c-7 brake caliper carrier inspect the brake caliper carrier for damage. If any damages are found, replace the brake caliper carrier with new one. Rear brake disc removal and installation b940h24306007 removal 1) remove the rear wheel assembly. Refer to “rear wheel assembly removal and ...

  • Page 482

    4c-8 rear brakes: brake disc runout 1) dismount the rear brake caliper. Refer to “rear brake caliper removal and installation (page 4c- 3)”. 2) measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (a): 09900–20607 (dial gauge (1/100 mm, 10 m...

  • Page 483

    Rear brakes: 4c-9 special tools and equipment recommended service material b940h24308001 note required service material is also described in the following. “rear brake components (page 4c-1)” special tool b940h24308002 material suzuki recommended product or specification note brake fluid dot 4 — ) (...

  • Page 484

    4c-10 rear brakes:.

  • Page 485: Section 5

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

  • Page 486: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b940h25000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 487: Manual Transmission

    Manual transmission: 5b-1 transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis b940h25204001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission) worn or rubbing gear. Repl...

  • Page 488

    5b-2 manual transmission: repair instructions transmission components b940h25206001 14 14 15 12 13 (a) 11 10 9 8 7 6 1 2 3 4 5 fwd fwd i940h1520072-03 1. Countershaft/1st drive gear 6. Driveshaft 11. 1st driven gear : 6.5 n ⋅m (0.65 kgf-m, 4.5 lbf-ft) 2. 5th drive gear 7. 2nd driven gear 12. Gearshi...

  • Page 489

    Manual transmission: 5b-3 transmission removal and installation b940h25206002 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-20)”. 2) disassemble the engine top side. Refer to “engine top side disassembly in section 1d (page 1d-27)”. 3)...

  • Page 490

    5b-4 manual transmission: • install the gearshift forks (3). • install the gearshift cam (4). • with engaging each fork (3) and to the cam groove, insert the fork shaft (5) and gear shift fork (6). • assemble the engine. Refer to “engine bottom side assembly in section 1d (page 1d-64)”. • remount en...

  • Page 491

    Manual transmission: 5b-5 countershaft gear / driveshaft gear disassembly and assembly b940h25206004 refer to “transmission removal and installation (page 5b-3)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., drive or driven) s...

  • Page 492

    5b-6 manual transmission: • remove the 5th driven gear (5). • remove the snap ring (6), washer (7) and 4th driven gear (8). • remove the 4th driven gear bushing (9), washer (10), snap ring (11) and 3rd driven gear (12). • remove the snap ring (13), washer (14), 2nd driven gear (15) and its bushing. ...

  • Page 493

    Manual transmission: 5b-7 when installing a new snap ring (1), pay attention to its direction. Fit it to the side where the thrust is as shown in the figure. Driveshaft when installing the gear bushing onto the driveshaft, align the shaft oil hole “a” with the bushing oil hole “b”. Countershaft when...

  • Page 494

    5b-8 manual transmission: 5) remove the left driveshaft bearing (4) with the special tool. Special tool (d): 09913–70210 (bearing installer set) 6) remove the bearing retainers (5). 7) remove the right gearshift cam bearing (6) by hand. 8) remove the right countershaft bearing (7) and right drivesha...

  • Page 495

    Manual transmission: 5b-9 • install the left driveshaft bearing (5) using the hydraulic press and special tool. Special tool (a): 09913–70210 (bearing installer set) note the stamped mark side of bearing faces secondary drive gear side. • apply thread lock to the screws, and install the retainers (6...

  • Page 496

    5b-10 manual transmission: gearshift fork groove width measure the gearshift fork groove width using the vernier calipers. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) gearshift fork groove width standard: 5.0 – 5.1 mm (0.197 – 0.201 in) gearshift fork thickness measure the gea...

  • Page 497

    Manual transmission: 5b-11 installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. Note align the gear position switch pin “a” with the gearshift cam hole “b”. : g...

  • Page 498

    5b-12 manual transmission: 3) remove the left footrest along with the gearshift lever. 4) remove the gearshift lever as shown in the gearshift lever construction. Refer to “gearshift lever construction (page 5b-11)”. Installation 1) install the gearshift lever as shown in the gearshift lever constru...

  • Page 499

    Manual transmission: 5b-13 gearshift shaft / gearshift cam plate components b940h25206012 gearshift shaft / gearshift cam plate removal and installation b940h25206013 removal 1) remove the exhaust pipes and muffler. Refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-2)”...

  • Page 500

    5b-14 manual transmission: 6) remove the gearshift cam plate bolt (12) and gearshift cam plate (13). 7) remove the gearshift cam stopper (14). 8) remove the gearshift arm stopper (15). Installation install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to ...

  • Page 501

    Manual transmission: 5b-15 • check the gearshift cam stopper moves smoothly. • locate the gearshift cam in the neutral position. • install the gearshift cam stopper plate (6). Note align the gearshift cam pin “b” with the gearshift cam stopper plate hole “c”. • apply a small quantity of thread lock ...

  • Page 502

    5b-16 manual transmission: • install the clutch component parts (10). Refer to “clutch installation in section 5c (page 5c-8)”. • install the exhaust pipes and muffler. Refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-2)”. Gearshift linkage inspection b940h25206014 re...

  • Page 503

    Manual transmission: 5b-17 installation install the oil seal and bearing in the reverse order of removal. Pay attention to the following points: caution ! The removed oil seal and bearings must be replaced with new ones. • install the bearing with the special tool. Note the stamped mark side of the ...

  • Page 504

    5b-18 manual transmission: tightening torque specifications b940h25207002 note the specified tightening torque is described in the following. “transmission components (page 5b-2)” “gearshift lever construction (page 5b-11)” “gearshift shaft / gearshift cam plate components (page 5b-13)” reference: f...

  • Page 505

    Manual transmission: 5b-19 special tool b940h25208002 09900–06104 09900–06107 snap ring pliers snap ring pliers ) (page 5b-5) ) (page 5b-5) / )(page 5b- 13) 09900–20102 09900–20803 vernier calipers (1/20 mm, 200 mm) thickness gauge ) (page 5b-10) / ) (page 5b-10) ) (page 5b-9) 09913–70210 09920–1312...

  • Page 506: Clutch

    5c-1 clutch: transmission / transaxle clutch precautions precautions for clutch system b940h25300001 refer to “general precautions in section 00 (page 00-1)”. Schematic and routing diagram clutch cable routing diagram b940h25302001 refer to “throttle cable routing diagram in section 1d (page 1d-2)”....

  • Page 507

    Clutch: 5c-2 repair instructions clutch lever position switch inspection b940h25306001 inspect the clutch lever position switch in the following procedures: 1) disconnect the clutch lever position switch lead wires. 2) inspect the switch for continuity with a tester. If any abnormality is found, rep...

  • Page 508

    5c-3 clutch: 5) disconnect the clutch cable (3). 6) remove the push rod (4). 7) remove the clutch release arm (5), return spring (6) and washer (7) if necessary. 8) remove the push rod cap (8) if necessary. 9) remove the oil seals (9) if necessary. Installation install the clutch release cylinder in...

  • Page 509

    Clutch: 5c-4 • apply a small quantity of grease to the o-ring (1) and push rod. Caution ! The o-ring (1) should be replaced with a new one to prevent engine oil leakage. : grease 99000–25010 (suzuki super grease a or equivalent) • inspect the engine oil level and fill the engine oil. Refer to “engin...

  • Page 510

    5c-5 clutch: clutch components b940h25306006 5 4 7 2 (c) 1 (d) 13 (a) 6 (b) 9 10 11 8 12 3 i940h1530075-01 1. Clutch pressure plate 8. Driven plate no. 2 : 95 n ⋅m (9.5 kgf-m, 68.5 lbf-ft) 2. Clutch push piece 9. Clutch sleeve hub : 150 n ⋅m (15.0 kgf-m, 108.5 lbf-ft) 3. Drive plate no. 3 10. Primar...

  • Page 511

    Clutch: 5c-6 clutch removal b940h25306007 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-8)”. 2) remove the exhaust pipes and mufflers. Refer to “exhaust pipe / muffler removal and installation in section 1k (page 1k-2)”. 3) remove the clutch cover (1). 4) re...

  • Page 512

    5c-7 clutch: 10) unlock the clutch sleeve hub nut. 11) hold the clutch sleeve hub with the special tools. Special tool (a): 09920–53740 (clutch sleeve hub holder) : 09920–31020 (extension handle) 12) remove the clutch sleeve hub nut. 13) remove the clutch drive cam (12) and clutch driven cam (13). 1...

  • Page 513

    Clutch: 5c-8 17) remove the oil pump driven gear (18). Clutch installation b940h25306008 1) install the oil pump driven gear (1). Note use a new snap ring. 2) install the washer (2) onto the countershaft. Note the chamfer side “a” of washer should face the crankcase side. 3) install the spacer (3) a...

  • Page 514

    5c-9 clutch: 5) install the clutch lifter drive cam (7), driven cam (8) to the clutch sleeve hub (9). Note • align the punch mark “b” on the clutch lifter drive cam (7) with the punch mark “c” on its driven cam (8). • the clutch lifter drive (7) and driven cams (8) should be replaced as a set. • whe...

  • Page 515

    Clutch: 5c-10 8) tighten the new clutch sleeve hub nut (12) to the specified torque. Caution ! Do not use the removed clutch sleeve hub nut. Tightening torque clutch sleeve hub nut (b): 95 n·m (9.5 kgf-m, 68.5 lbf-ft) 9) lock the clutch sleeve hub nut with a center punch. 10) install the spring wash...

  • Page 516

    5c-11 clutch: note three kinds of the drive plate (no. 1, no. 2 and no. 3) are equipped in the clutch system, they can be distinguished by the inside diameter and clutch facing “g”. Note two kinds of the driven plate (no. 1 and no. 2) are equipped in the clutch system, they can be distinguished by t...

  • Page 517

    Clutch: 5c-12 16) after installed pressure plate, adjust the clutch push piece. Refer to “clutch cable play inspection and adjustment in section 0b (page 0b-12)”. 17) install the dowel pins and gasket (24). Caution ! Use a new gasket to prevent oil leakage. 18) fit the clamp to the bolts (25). 19) i...

  • Page 518

    5c-13 clutch: clutch spring measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit. Replace all the springs if any spring is not within the limit. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) clutch spring free lengt...

  • Page 519

    Clutch: 5c-14 2) hold the primary drive gear (2) with the special tool and remove the primary drive gear bolt. Caution ! The primary drive gear bolt has left-hand threads. Special tool (a): 09930–40113 (rotor holder) 3) remove the primary drive gear. Installation install the primary driven gear in t...

  • Page 520

    5c-15 clutch: drive train unit: mm (in) tightening torque specifications b940h25307002 note the specified tightening torque is described in the following. “clutch components (page 5c-5)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list ...

  • Page 521

    Clutch: 5c-16 09920–53740 09930–40113 clutch sleeve hub holder rotor holder ) (page 5c-7) / )(page 5c- 9) ) (page 5c-14) / ) (page 5c-14).

  • Page 522

    5c-17 clutch:.

  • Page 523: Section 6

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

  • Page 524: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b940h26000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 525: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b940h26104001 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. ...

  • Page 526: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions handlebars components b940h26206001 handlebars removal and installation b940h26206002 removal 1) remove the following parts from the left handlebar. A) clutch lever (1) b) left handlebar switch box (2) c) grip end cap (3) d...

  • Page 527

    Steering / handlebar: 6b-2 2) remove the following parts from the right handlebar. A) front brake master cylinder/front brake lever (5) caution ! Do not turn the front brake master cylinder upside down. B) right handlebar switch box (6) c) grip end cap (7) d) throttle grip (8) 3) remove the caps and...

  • Page 528

    6b-3 steering / handlebar: • apply grease to the end of the throttle cables and cable pulley. : grease 99000–25010 (suzuki super grease a or equivalent) • insert the projection “e” of the right handlebar switch box into the hole of the handlebars. • set the throttle cables as shown in the figure. No...

  • Page 529

    Steering / handlebar: 6b-4 steering components b940h26206004 steering removal and installation b940h26206005 removal 1) support the motorcycle with a jack or a wooden block. 2) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-3)”. 3) rem...

  • Page 530

    6b-5 steering / handlebar: 6) remove the wire harness, brake hose and each cables. Refer to “wiring harness routing diagram in section 9a (page 9a-5)”, “front brake hose routing diagram in section 4a (page 4a-1)” and “throttle cable routing diagram in section 1d (page 1d-2)”. 7) remove the handlebar...

  • Page 531

    Steering / handlebar: 6b-6 installation install the steering in the reverse order of removal. Pay attention to the following points: • temporarily tighten the handlebar holder bolts. Caution ! Use new precoated bolts. Bearing • apply grease to the bearings, races and dust seals before remounting the...

  • Page 532

    6b-7 steering / handlebar: 4) temporary install the handlebars and tighten the handlebar bolts (2) to the specified torque. Tightening torque handlebar holder bolt (b): 45 n·m (4.5 kgf-m, 32.5 lbf-ft) handlebars • install the handlebars. Refer to “handlebars removal and installation (page 6b-1)”. In...

  • Page 533

    Steering / handlebar: 6b-8 4) remove the steering stem upper and lower bearing races using the special tools. Special tool (a): 09941–54911 (bearing outer race remover) (b): 09941–74911 (steering bearing installer) installation install the steering stem bearings in the reverse order of removal. Pay ...

  • Page 534

    6b-9 steering / handlebar: 4) do the same on the other grip end. 5) if the initial force read on the scale when the handlebars start turning is either too heavy or too light, adjust it till it satisfies the specification. A) first, loosen the front fork upper clamp bolts and steering stem head nut, ...

  • Page 535

    Steering / handlebar: 6b-10 special tool b940h26208002 09940–14911 09940–92720 steering stem nut wrench spring scale ) (page 6b-5) / )(page 6b- 6) ) (page 6b-8) 09941–34513 09941–54911 steering race installer bearing outer race remover ) (page 6b-8) ) (page 6b-8) 09941–74911 steering bearing install...

  • Page 536

    6b-11 steering / handlebar:.

  • Page 537: Section 9

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

  • Page 538

    9-ii table of contents specifications.......................................................9d-7 tightening torque specifications........................9d-7 special tools and equipment .............................9d-7 recommended service material .........................9d-7 body structure .........

  • Page 539: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b940h29000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location electrical components location b940h29...

  • Page 540: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram b940h29102001 refer to “wire color symbols in section 0a (page 0a-5)”..

  • Page 541

    Wiring systems: 9a-2 for e-02, 19, 24 g b/w headligh t f r on t turn signa l light (r) f r on t turn signa l light (l) off ru n off on push engine s speedometer speed sensor pilot lamp handlebar switch (r) to p switch s ta r ter bu tt o n fr on t brake switch on off lock p ignition switch solenoid 1...

  • Page 542

    9a-3 wiring systems: for e-03, 28 g b/w headligh t f r on t turn signa l light (r) f r on t turn signa l light (l) off ru n off on push engine s speedometer speed sensor pilot lamp handlebar switch (r) to p switch s ta r ter bu tt o n fr on t brake switch on off lock p ignition switch solenoid 1 ign...

  • Page 543

    Wiring systems: 9a-4 for e-33 g b/w headligh t f r on t turn signa l light (r) f r on t turn signa l light (l) off ru n off on push engine s speedometer speed sensor pilot lamp handlebar switch (r) to p switch s ta r ter bu tt o n fr on t brake switch on off lock p ignition switch solenoid 1 ignitio...

  • Page 544

    9a-5 wiring systems: wiring harness routing diagram b940h29102002 2 6 7 8 8 6 “d” 9 10 “c” 8 1 “a” “b” 4 5 11 3 6 6 “ b ” “ d ” “ b ” “ c ” “ e ” “ a ” 8 i940h1910907-08 1. Clamp : bind the handlebar switch (l) lead wire and clutch cable with the clamp. Cut the tip of clamp after clamping. 11. Clamp...

  • Page 545

    Wiring systems: 9a-6 1 1 2 3 4 5 “f” “e” 1 1 5 7 “d” “a” “b” “ a ” “ a ” “ a ” “ a ” 1 6 1 “ b ” “c” i940h1910909-04 1. Clamp “b”: pass the wiring harness under the high tension cord. 2. Clamp : cut the tip of clamp after clamping. “c”: pass the wiring harness backward of the clutch cable. 3. Reserv...

  • Page 546

    9a-7 wiring systems: specifications service data b940h2910s001 electrical unit: mm (in) item specification note fuse size headlight hi 10 a lo 10 a fuel 10 a ignition 15 a signal 10 a fan motor 15 a main 30 a.

  • Page 547: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions front lighting system construction b940h29206001 1 2 3 4 (a) (a) i940h1920033-04 1. Headlight housing brace 3. Headlight cover plate : 8.5 n ⋅m (0.85 kgf-m, 6.0 lbf-ft) 2. Front turn signal cover 4. Headlight front cove...

  • Page 548

    9b-2 lighting systems: headlight components b940h29206002 headlight removal and installation b940h29206003 removal 1) disconnect the headlight coupler (1). 2) disconnect the position light coupler (2) (for e-02, 19, 24). 3) protect the speedometer assembly and headlight cover with a tape to prevent ...

  • Page 549

    Lighting systems: 9b-3 5) remove the headlight unit (4). Installation install the headlight in the reverse order of removal. Pay attention to the following points: caution ! Protect the part “a” of the speedometer assembly and headlight cover with a tape to prevent damage. • install the headlight as...

  • Page 550

    9b-4 lighting systems: 3) replace the headlight bulb (3) by unhooking the bulb holder spring (4). 4) install the headlight assembly and headlight cover. Refer to “headlight removal and installation (page 9b-2)”. Headlight beam adjustment b940h29206005 1) insert hexagon wrench as shown in the figure ...

  • Page 551

    Lighting systems: 9b-5 rear lighting system construction b940h29206007 rear combination light removal and installation b940h29206008 removal 1) remove the rear fender assembly. Refer to “exterior parts removal and installation in section 9d (page 9d-5)”. 2) disconnect the rear combination light coup...

  • Page 552

    9b-6 lighting systems: 3) remove the rear fender from the rear fender brace. Refer to “rear fender construction in section 9d (page 9d-4)”. 4) remove the rear combination light (2). Installation install the rear combination light in the reverse order of removal. License plate light components b940h2...

  • Page 553

    Lighting systems: 9b-7 3) remove the license plate light by removing the nuts. Installation install the license plate light in the reverse order of removal. License plate light bulb replacement b940h29206011 1) remove the license plate light by removing the nuts. 2) remove the lens by removing the s...

  • Page 554

    9b-8 lighting systems: turn signal light components b940h29206012 front turn signal light removal and installation b940h29206013 removal 1) remove the headlight assembly. Refer to “headlight removal and installation (page 9b-2)”. 2) disconnect the turn signal light couplers (1). 3) remove the turn s...

  • Page 555

    Lighting systems: 9b-9 rear turn signal light removal and installation b940h29206014 removal 1) remove the rear fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 5)”. 2) remove the rear fender from the rear fender brace. Refer to “rear fender construction in section 9...

  • Page 556

    9b-10 lighting systems: turn signal / side-stand relay inspection b940h29206016 refer to “electrical components location in section 0a (page 0a-7)”. Note make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If th...

  • Page 557

    Lighting systems: 9b-11 passing light switch inspection b940h29206020 inspect the passing light switch in the following procedures: 1) disconnect the left handlebar switch coupler (1). 2) inspect the passing light switch for continuity with a tester. If any abnormality is found, replace the left han...

  • Page 558

    9b-12 lighting systems: tightening torque specifications b940h29207002 note the specified tightening torque is described in the following. “front lighting system construction (page 9b-1)” “rear lighting system construction (page 9b-5)” reference: for the tightening torque of fastener not specified i...

  • Page 559

    Combination meter / fuel meter / horn: 9c-1 body and accessories combination meter / fuel meter / horn general description combination meter system description b940h29301001 this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting diode). The...

  • Page 560

    9c-2 combination meter / fuel meter / horn: repair instructions combination meter components b940h29306001 combination meter removal and installation b940h29306002 removal 1) remove the headlight assembly. Refer to “headlight removal and installation in section 9b (page 9b-2)”. 2) disconnect the com...

  • Page 561

    Combination meter / fuel meter / horn: 9c-3 4) remove the front brake hose joint (3). 5) remove the combination meter by removing the bolts (4). Installation install the combination meter in the reverse order of removal. Pay attention to the following points: • before install the combination meter, ...

  • Page 562

    9c-4 combination meter / fuel meter / horn: combination meter inspection b940h29306004 led inspection check that the leds (fi indicator light, oil pressure/ engine coolant temperature indicator light and meter panel illumination) immediately light up when the ignition switch is turned to on. Check t...

  • Page 563

    Combination meter / fuel meter / horn: 9c-5 3) disconnect the pilot lamp lead wire coupler (2). 4) remove the pilot lamp (3) from the fuel tank cover (1). Installation install the pilot lamp in the reverse order of removal. Engine coolant temperature indicator light inspection b940h29306006 inspect ...

  • Page 564

    9c-6 combination meter / fuel meter / horn: fuel level indicator inspection b940h29306008 inspect the fuel level indicator in the following procedures: 1) support the motorcycle with a jack or wooden block. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g...

  • Page 565

    Combination meter / fuel meter / horn: 9c-7 4) when the switch is immersed in kerosene, the bulb should go out. If the bulb remains lit, replace the unit with a new one. Note • when the bulb turns off, immediately pick up the switch from kerosene. • after the check has been completed, wash the switc...

  • Page 566

    9c-8 combination meter / fuel meter / horn: installation install the speed sensor in the reverse order of removal. Pay attention to the following points: • apply grease to the o-ring. Caution ! Use a new o-ring to prevent oil leakage. : grease 99000–25010 (suzuki super grease a or equivalent) • tigh...

  • Page 567

    Combination meter / fuel meter / horn: 9c-9 1) disconnect the oil pressure switch lead wire (1) from the oil pressure switch. 2) turn the ignition switch on. 3) check if the oil pressure indicator (led) and lcd will light up when grounding the lead wire (1). If the oil pressure indicator does not li...

  • Page 568

    9c-10 combination meter / fuel meter / horn: 3) inspect the horn button for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebars removal and installation in section 6b (page 6b-1)”. Special tool : 09900–25008 (multi-ci...

  • Page 569

    Combination meter / fuel meter / horn: 9c-11 specifications service data b940h29307001 wattage unit: w tightening torque specifications b940h29307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-8)”. Special t...

  • Page 570: Exterior Parts

    9d-1 exterior parts: body and accessories exterior parts schematic and routing diagram seat lock cable routing diagram b940h29402001 1 2 3 1 2 “a” 6 2 4 3 2 3 [a] [a] 1 2 5 i940h1940018-03 1. Frame 3. Seat lock 5. Clamp : clamp the seat lock cable only. “a”: white tape 2. Seat lock cable 4. Ecm 6. C...

  • Page 571

    Exterior parts: 9d-2 repair instructions exterior parts construction b940h29406001 1 2 3 3 4 4 7 8 6 5 i940h1940014-03 1. Frame head cover 5. Frame head cover 2. Frame lower cover (rh) 6. Regulator/rectifier 3. Frame side cover (rh) 7. Frame lower cover (lh) 4. Frame side lower cover (rh) 8. Frame s...

  • Page 572

    9d-3 exterior parts: frame head cover cushion construction b940h29406002 1 1 2 1 1 3 i940h1940015-02 1. Cushion : when sticking the cushion on the frame head cover, align the cushion edge with the extension of stopping line. 3. Frame head cover (rh) 2. Frame head cover (lh).

  • Page 573

    Exterior parts: 9d-4 rear fender construction b940h29406003 1 5 2 “c” “a” “b” (a) (a) (a) 6 2 2 4 4 (b) i940h1940016-07 1. Rear frame 6. Rear fender 2. Rear fender brace “abc”: after temporary tightening, tighten the bolts to the specified torque in order of “a” → “b” → “c”. 3. Rear frame plate : 50...

  • Page 574

    9d-5 exterior parts: exterior parts removal and installation b940h29406004 front seat removal 1) remove the right frame side cover. Refer to “exterior parts removal and installation (page 9d-5)”. 2) remove the seat with the ignition key. Installation slide the seat hooks into the seat hook retainers...

  • Page 575

    Exterior parts: 9d-6 installation install the frame covers in the reverse order of removal. Pay attention following point: • when installing the frame cover, insert the convex part “a” of the frame cover to the hole “b” of the frame lower cover. Rear fender removal 1) remove the front and rear seat....

  • Page 576

    9d-7 exterior parts: secondary gear case cover / left frame lower cover removal 1) remove the left frame side cover. Refer to “exterior parts removal and installation (page 9d-5)”. 2) remove the secondary gear case cover (1). 3) remove the left frame lower cover (2). Installation install the covers ...

  • Page 577: Body Structure

    Body structure: 9e-1 body and accessories body structure repair instructions body frame construction b940h29506001 1 2 (a) 4 3 (a) “b” 3 (a) “c” (a) “a” (a) 4 fwd fwd i940h1950003-02 1. Frame “abc”: after temporary tightening, tighten the bolts to the specified torque in order of “a” → “b” → “c”. 2....

  • Page 578

    9e-2 body structure: steering lock bracket construction b940h29506002 side-stand construction b940h29506003 1. Frame 3. Steering lock bracket bolt : do not reuse. 2. Steering lock bracket : 26 n ⋅m (2.6 kgf-m, 19.0 lbf-ft) 1 (a) 3 2 i940h1950001-02 1 2 (a) 3 (b) 4 i940h1950002-01 1. Side-stand 3. Si...

  • Page 579

    Body structure: 9e-3 side-stand removal and installation b940h29506004 removal 1) support the motorcycle with the jack or wooden block. 2) remove the side-stand as shown in the side-stand construction. Refer to “side-stand construction (page 9e-2)”. Installation install the side-stand as shown in th...

  • Page 580

    Prepared by september, 2008 part no. 99500-39370-03e printed in u.S.A. 580