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Suzuki Intruder VZR1800 Service Manual

Other manuals for Intruder VZR1800: Service Manual

Summary of Intruder VZR1800

  • Page 1

    9 9 5 0 0 - 3 9 2 9 0 - 0 1 e vzr1800

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 driveline/axle 4 fi system diagnosis 5 fuel system and throttle body 6 exhaust system 7 cooling and lubrication system 8 chassis 9 electrical system 10 servicing information 11 emission control information 12 wiring diagram 13 forewor...

  • Page 3: How To Use This Manual

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

  • Page 4

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

  • Page 5: Manual

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

  • Page 6

    O ohc : over head camshaft ops : oil pressure switch p pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae : society of automotive engineers sds : suzuki diagnosis system stc system : secondary throttle control system (stcs) stp sensor : secondary...

  • Page 7

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

  • Page 8: General Information

    General information 1-1 1 general information contents warning/caution/note......................................................................... 1- 2 general precautions .......................................................................... 1- 2 suzuki vzr1800k6 (’06-model) ....................

  • Page 9: Warning/caution/note

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

  • Page 10

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

  • Page 11: Serial Number Location

    1-4 general information suzuki vzr1800k6 (’06-model) • difference between illustration and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The engi...

  • Page 12

    General information 1-5 fuel, oil and engine coolant recommendation fuel (for usa and canada) use only unleaded gasoline of at least 90 pump octane (r/2 + m/2). Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and cor...

  • Page 13

    1-6 general information front fork oil use fork oil l01 or an equivalent fork oil. Engine coolant use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. Water for mixing use distilled water only. Water other than distilled water can corrode and clog ...

  • Page 14: Break-In Procedures

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

  • Page 15: Information Labels

    1-8 general information information labels a: attached vzr1800 vzr1800uf 1 noise label a (for e-03, 24, 33) 2 information label a (for e-03, 28, 33) 3 vacuum hose routing label a (for e-33) 4 fuel caution label a (for e-02, 24) 5 fuel information label a a 6 manual notice label a (for e-03, 33) 7 ti...

  • Page 16: Specifications

    General information 1-9 specifications dimensions and dry mass overall length ...................................................... 2 450 mm (96.5 in) .......... For e-03, 33 2 480 mm (97.6 in) .......... For others overall width ....................................................... 875 mm (34.4 ...

  • Page 17

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

  • Page 18: Periodic Maintenance

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

  • Page 19

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

  • Page 20

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

  • Page 21

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • remove the right and left air cleaner box bolts. Note: “ !” indicates hook location. • loosen the air cleaner box clamp sc...

  • Page 22

    Periodic maintenance 2-5 • carefully use air hose to blow the dust from the cleaner ele- ment. " note: if driving under dusty conditions, clean the air cleaner element more frequently. Make sure that the air cleaner is in good condi- tion at all times. The life of the engine depends largely on this ...

  • Page 23

    2-6 periodic maintenance exhaust pipe bolts and muffler bolts • tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. " tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. 1 gasket 2 exhaust pipe connector # it...

  • Page 24

    Periodic maintenance 2-7 exhaust control valve • remove the rubber cover 1. Check the exhaust control valve actuator 2 for its movement when the ignition switch is turned on. If the exhaust valve actua- tor does not move, check exhaust valve actuator electrical circuit and exhaust valve carbon stick...

  • Page 25

    2-8 periodic maintenance valve clearance • remove the frame side covers. ( $9-5) • remove the fuel tank. ( $6-3) • remove the frame head covers and radiator covers. ( $9-6) • remove the air cleaner chamber. ( $6-13) • remove the all spark plugs. ( $2-13) • remove the right and left cylinder head cov...

  • Page 27: 290

    2-10 periodic maintenance valve clearance adjustment the clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • remove the intake or exhaust camshafts. ( $3-14 to -15 and 3-17 to -18) • remove the tappet and shim by fingers or magnetic hand. • check the figures p...

  • Page 28

    Periodic maintenance 2-11 (intake side) measured t appet clearance (mm) suffix no . Present shim size (mm) t appet shim set (12800-41810) option t appet shim selection t able [int ake] t appet shim no . (12892-41c00-xxx) 230 2.30 235 2.35 240 2.40 245 2.45 250 2.50 255 2.55 260 2.60 265 2.65 270 2.7...

  • Page 29

    2-12 periodic maintenance (exhaust side) measured t appet clearance (mm) suffix no . Present shim size (mm) t appet shim set (12800-41810) option t appet shim selection t able [exha ust] t appet shim no . (12892-41c00-xxx) 230 2.30 235 2.35 240 2.40 245 2.45 250 2.50 255 2.55 260 2.60 265 2.65 270 2...

  • Page 30

    Periodic maintenance 2-13 spark plug #2 (front) spark plug removal • remove the frame side covers. ( $9-5) • remove the fuel tank. ( $6-3) • remove the right frame head cover and right radiator cover. ( $9-6) • disconnect lead wire coupler 1 from ignition coil/plug cap. " • remove the ignition coil/...

  • Page 31

    2-14 periodic maintenance #1 (rear) spark plug removal • remove the frame side covers. ( $9-5) • remove the fuel tank. ( $6-3) • disconnect lead wire coupler 1 from ignition coil/plug cap. " • remove the ignition coil/plug cap 2. " • remove the spark plug with a spark plug wrench. • remove the left ...

  • Page 32

    Periodic maintenance 2-15 heat range • check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one. Note: “r” ...

  • Page 33

    2-16 periodic maintenance spark plug installation • screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque. # spark plug: 11 n·m (1.1 kgf-m, 8.0 ib-ft) " ignition coil/plug cap installation • install the ignition coils/plug caps and connect their lea...

  • Page 34

    Periodic maintenance 2-17 engine oil and oil filter oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change. Engine oil replacement • keep the motorcycle upright. • place an oil pan below the engine, and drain ...

  • Page 35

    2-18 periodic maintenance oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the oil filter 1 with the special tool. & 09915-40610: oil filter wrench • apply engine oil lightly to the gasket of the new oil filter before installation. • inst...

  • Page 36

    Periodic maintenance 2-19 final gear oil • keep the motorcycle upright. • place an oil pan under the final gear case. • remove the filler cap 1 and drain plug 2 to drain oil. • tighten the drain plug 2 to the specified torque. Pour the specified oil (sae 90 hypoid gear oil with gl-5 under api classi...

  • Page 37

    2-20 periodic maintenance throttle valve synchronization inspect the throttle valve synchronization periodically. ( $6-23) cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. ...

  • Page 38

    Periodic maintenance 2-21 • drain engine coolant by disconnecting the radiator hose 2 from the radiator. ' • flush the radiator with fresh water if necessary. • connect the radiator hose 2 securely. • pour the specified engine coolant up to the radiator inlet. ( engine coolant capacity (excluding re...

  • Page 39

    2-22 periodic maintenance radiator hoses • remove the fuel tank. ( $6-3) • remove the frame head covers, radiator covers and radiator bottom cover. ( $9-6) • check to see the radiator hoses for crack, damage or engine coolant leakage. • if any defects are found, replace the radiator hoses with new o...

  • Page 40

    Periodic maintenance 2-23 brake brake fluid level check • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • when the level is below the lower limit line, replenish with brake ...

  • Page 41

    2-24 periodic maintenance brake pads front brake the extent of brake pad wear can be checked by observing the grooved limit line a on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ( $9-52) " rear brake the extent of brake pad wear can be checked by observ...

  • Page 42

    Periodic maintenance 2-25 brake pedal height • loosen the lock nut 1. • turn the push rod 2 until the brake pedal height becomes 25 – 35 mm (1.0 – 1.4 in) a below the top of the footrest. • tighten the lock nut 1 securely. # rear brake master cylinder rod lock nut: 18 n·m (1.8 kgf-m, 13.0 ib-ft) % b...

  • Page 43

    2-26 periodic maintenance air bleeding from brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper. The presence of air i...

  • Page 44

    Periodic maintenance 2-27 rear brake • bleed air from the rear brake system in the same manner as front brake. # air bleeder valve: 7.5 n·m (0.75 kgf-m, 5.5 ib-ft) note: the only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal. Tires tire tr...

  • Page 45

    2-28 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. % cold inflat...

  • Page 46

    Periodic maintenance 2-29 rear suspension • remove the under cover. ( $9-41) inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary. ( $9-41) chassis bolts and nuts check that all chassis bolts and nuts are tightened ...

  • Page 47

    2-30 periodic maintenance.

  • Page 48: Compression Pressure Check

    Periodic maintenance 2-31 compression pressure check the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should ...

  • Page 49: Oil Pressure Check

    2-32 periodic maintenance oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pr...

  • Page 50: Sds Check

    Periodic maintenance 2-33 sds check using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be co...

  • Page 51

    2-34 periodic maintenance data at 3 000 r/min under no load data at the time of racing ˚ approx. 3 000 r/min check the manifold absolute pressure #1. Xx mmhg check the water temperature. Xx ˚c ˚ check the manifold absolute pressure #1 in according with the throttle valve opening..

  • Page 52

    Periodic maintenance 2-35 data of intake negative pressure during idling (100 °c) data of manifold absolute pressure operation at the time of starting ˚ check the manifold absolute pressure #1. Xx mmhg check the water temperature. Approx. 100 ˚c check the manifold absolute pressure #1. Xx mmhg check...

  • Page 53: Engine

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

  • Page 54

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

  • Page 55

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • drain engine oil. ( !2-17) • drain e...

  • Page 56

    3-4 engine • disconnect the ect sensor lead wire coupler 4. • disconnect the ignition coil/plug cap lead wire couplers and remove the ignition coils/plug caps. ( !2-13 and -14) " • disconnect the spark plug caps. ( !2-13 and -14) • disconnect the radiator inlet hose 5. • remove the rear brake fluid ...

  • Page 57

    Engine 3-5 • remove the right footrest 8. • disconnect the starter motor lead wire 9. • disconnect the oil cooler hose 0. • remove the oil pressure switch lead wire a..

  • Page 58

    3-6 engine • disconnect the cooling fan coupler b and horn lead wire cou- plers c. • remove the left frame lower side cover d. • remove the secondary gear case cover e. • disconnect the generator lead wire coupler f. • disconnect the ckp sensor lead wire coupler g. • disconnect the regulator/rectifi...

  • Page 59

    Engine 3-7 • remove the clutch cable k. • support the engine with an engine jack. • remove the left footrest l and gearshift lever m. • remove the ground lead wire n. • disconnect the gp switch lead wire coupler o. • remove the engine mounting bolt and nut..

  • Page 60

    3-8 engine • slightly move the frame down tube by removing its bolts p, bolts and nuts q. • remove the caps. • remove the engine mounting bracket bolts r. • remove the engine mounting bolts and nuts s. • remove the the engine assembly..

  • Page 61

    Engine 3-9 engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: • install the boot and universal joint. Note: make sure that the “up” mark a faces up. • gradually raise the engine, and then engage the secondary driven gear shaft to the...

  • Page 62

    3-10 engine • install the frame down tube and tighten the bolts 2, bolts and nuts 3 to the specified torque. Note: the frame down tube nuts are self-locking. Once the nuts have been removed, they are no longer of any use. # frame down tube bolt: 50 n·m (5.0 kgf-m, 36.0 lb-ft) • install the engine mo...

  • Page 63

    Engine 3-11 note: the engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. • install the gearshift lever and tighten the mounting bolts to the specified torque. # left front footrest bolt: 50 n·m (5.0 kgf-m, 36.0 lb-ft) • footrest in the correct positi...

  • Page 64

    3-12 engine • tighten the right front footrest mounting bolts to the specified torque. # right front footrest bolt: 60 n·m (6.0 kgf-m, 43.5 lb-ft) • install the rear brake master cylinder cover 4. ( !9-72) • install the throttle body. ( !6-21) • install the exhaust pipe and muffler. ( !7-10) • perfo...

  • Page 65: Engine Disassembly

    Engine 3-13 engine disassembly " • remove the front and rear spark plugs. Starter motor • remove the starter motor 1. Intake pipe • remove the front and rear intake pipes 1. Thermostat • remove the thermostat assembly 1 and disconnect the water hoses ( 2, 3). Identify the position of each removed pa...

  • Page 66

    3-14 engine rear cylinder head cover • remove the right and left head cover brackets 1. • remove the rear cylinder head cover 2 and its gasket. Rear camshaft • remove the generator cover cap 1. • remove the valve timing inspection plug 2 and generator cover plug 3..

  • Page 67

    Engine 3-15 • turn the crankshaft to bring the “r i t” line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown. Note: at the above condition, the rear cylinder is at tdc of compres- sion stroke and also the engraved lines a on the ca...

  • Page 68

    3-16 engine rear cylinder head • remove the cylinder head bolts and washers. Note: loosen the cylinder head bolts little by little diagonally with the smaller sizes first. • remove the cylinder head 1. Rear cylinder • remove the cylinder head gasket 1, dowel pins 2 and cam chain guide no. 2 3. • rem...

  • Page 69

    Engine 3-17 front cylinder head cover • remove the right and left head cover brackets 1. • remove the front cylinder head cover 2 and its gasket. Front camshaft • turn the crankshaft to bring the “f i t” line mark on generator rotor to the index mark of the valve inspection hole and also to bring th...

  • Page 70

    3-18 engine • remove the cam chain guide no. 3 5. • remove the camshaft journal holder 6. • remove the dowel pins. " • remove the intake camshaft 7. • remove the exhaust camshaft 8. Front cylinder head • remove the cylinder head bolts and washers. Note: loosen the cylinder head bolts little by littl...

  • Page 71

    Engine 3-19 • remove the cylinder nuts. • remove the cylinder 5. Note: firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose. • remove the cylinder ...

  • Page 72

    3-20 engine • remove the clutch push rod 5 and clutch push rod release ball 6. Note: if it is difficult to pull out the push rod 5 and ball 6, use a long- bar. • unlock the clutch sleeve hub nut. • hold the generator rotor with a 41 mm offset wrench. • remove the clutch sleeve hub nut. • remove the ...

  • Page 73

    Engine 3-21 • remove the thrust washer a. • remove the primary driven gear assembly b. • remove the needle roller bearing c and spacer d. Rear cam chain tension adjuster • unlock the ratchet 1 and insert the special tool. % 09917-62430: chain tensioner lock tool • remove the rear cam chain tensioner...

  • Page 74

    3-22 engine • remove the cam chain no. 2 4, rear cam chain idler sprocket 5 and cam chain no. 1. Rear cam chain drive sprocket • hold the generator rotor and remove the rear cam chain drive sprocket bolt. " • remove the rear cam chain drive sprocket 1. Starter torque limiter/starter idle gear • remo...

  • Page 75

    Engine 3-23 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. • remove the generator rotor assembly with the special tool. % 09930-30721: rotor remover • remove the key 1. Front cam chain idler sprocket • loosen ...

  • Page 76

    3-24 engine • remove the cam chain tensioner no. 1 6. • remove the cam chain no. 2 7, front cam chain idler sprocket 8 and cam chain no. 1 9. • remove the front cam chain tension adjuster no. 1 0. Secondary driven gear • remove the secondary driven gear assembly 1 and shims. Secondary driven gear in...

  • Page 77

    Engine 3-25 • remove the gearshift cam plate 3. • remove the gearshift cam stopper 4. Secondary drive gear • shift the gear position to 1st or 2nd. • hold the primary driven gear with the special tool. % 09930-44541: rotor holder • remove the secondary drive gear bolt. • secondary drive gear 1 remov...

  • Page 78

    3-26 engine • remove the oil pump drive gear 5 and pin 6. Gear position switch • remove the gear position switch 1. Oil filter • remove the oil filter with the special tool. % 09915-40610: oil filter wrench oil cooler/oil pressure switch • disconnect the water hose 1. • remove the oil cooler 2 by re...

  • Page 79

    Engine 3-27 oil pan • remove the oil pan 1 and stay 2. Oil pressure regulator • remove the oil pressure regulator 1. Oil strainer • remove the oil strainers 2 and o-rings 3. Upper crankcase • remove the breather cover 1. • remove the upper crankcase bolts. Lower crankcase • remove the lower crankcas...

  • Page 80

    3-28 engine note: * the crankshaft and transmission components should remain in the upper crankcase half. * if it is difficult to separate the crankcase halves, set the proper bolts and nuts to the crankcase by separating the upper and lower crankcase halves, as shown in the illustration. Transmissi...

  • Page 81: And Service

    Engine 3-29 engine components inspection and service " cylinder head cover disassembly • remove the pair reed valve cover 1 and pair reed valve 2. Inspection • inspect the pair reed valve for the carbon deposit. • if the carbon deposit is found in the reed valve, replace the pair reed valve with a n...

  • Page 82

    3-30 engine cam wear • check the camshaft for wear or damage. • measure the cam height h with a micrometer. $ cam height h : service limit: (in. & ex.): 40.580 mm (1.5976 in) % 09900-20202: micrometer (25 – 50 mm) camshaft journal wear • determine whether or not each journal is worn down to the limi...

  • Page 83

    Engine 3-31 • if the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • replace the camshaft or the cylinder head depending upon which one exceeds the specification. $ camshaft journal ...

  • Page 84

    3-32 engine cam chain tension adjuster inspection • the cam chain tension adjusters are maintained at the proper cam chain tension automatically. • unlock the ratchet a, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mech- anism is faulty, replace ...

  • Page 85

    Engine 3-33 cylinder head distortion • decarbonize the combustion chambers. • check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • if the largest reading at any position of the straightedge e...

  • Page 86

    3-34 engine • remove the valve spring retainer 4 and valve spring 5. • pull out the valve 6 from the combustion chamber side. • remove the oil seal 7 and spring seat 8. " • remove the other valves in the same manner as described previously. Valve stem runout • support the valve using v-blocks and ch...

  • Page 87

    Engine 3-35 valve stem and valve face wear condition • visually inspect each valve stem and valve face for wear and pitting. If it is worn or 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 deflecti...

  • Page 88

    3-36 engine valve guide servicing • using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. % 09916-46020: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement part...

  • Page 89

    Engine 3-37 valve seat width inspection • visually check for valve seat width on each valve face. • if the valve face has worn abnormally, replace the valve. • coat the valve seat with a red lead (prussian blue) and set the valve in place. Rotate the valve with light pressure. • check that the trans...

  • Page 90

    3-38 engine • clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • if any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. ' valve spring the force of the coil spring k...

  • Page 91

    Engine 3-39 • install the valve spring with the small-pitch portion a facing cylinder head. B large-pitch portion c upward d paint • put on the valve spring retainer 3, and using the valve lifter and protector 4, press down the spring, fit the cotter halves to the stem end, and release the lifter to...

  • Page 92

    3-40 engine cam chain tensioner • inspect the cam chain tensioner for damage. If any damage are found, replace the cam chain tensioner with a new one. • install the cam chain tensioner 1, washers 2 and nuts 3. • tighten the cam chain tensioner nuts to the specified torque. # cam chain tensioner nut:...

  • Page 93

    Engine 3-41 cylinder cylinder distortion • check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • if the largest reading at any position of the straightedge exceeds the limit, replace the cylin...

  • Page 94

    3-42 engine piston and piston ring piston diameter • using a micrometer, measure the piston diameter at 10 mm (0.4 in) a from the piston skirt end. • if the measurement is less than the limit, replace the piston. $ piston diameter: service limit: 111.880 mm (4.4047 in) at 10 mm (0.4 in) from the ski...

  • Page 95

    Engine 3-43 piston ring-to-groove clearance • measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • if any of the clearances exceeds the limit, replace both the piston and piston rings. % 09900-20803: thickness gauge 09900-20205: micrometer (0 – 25 mm) $ piston rin...

  • Page 96

    3-44 engine clutch clutch plate thickness note: wipe off engine oil from the clutch plates with a clean rag. • measure the thickness of drive and driven plates with a ver- nier calipers. If each plate is not within the service limit or standard range, replace it with a new one. $ drive plate thickne...

  • Page 97

    Engine 3-45 clutch release bearing • inspect the clutch release bearing for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced. • smooth engagement and disengagement of the clutch depends on the condition of this bearing. Clutch push rod • inspect the cl...

  • Page 98

    3-46 engine primary drive gear bearing • inspect the needle bearing for abnormal noise, wear and damage. If necessary, replace it with a new one. Gearshift cover disassembly • remove the gearshift shaft oil seal 1. • remove the bearing with the special tools. % 09921-20210: bearing remover 09930-301...

  • Page 99

    Engine 3-47 starter clutch starter driven gear inspection • turn the starter driven gear by hand. • inspect the starter clutch for a smooth movement. • check that the gear turns only in one direction. • inspect the starter driven gear bushing for any damage. If necessary, replace it with a new one. ...

  • Page 100

    3-48 engine • apply thread lock super to the bolts, and then tighten them to the specified torque. # starter clutch bolt: 25 n·m (2.5 kgf-m, 18.0 lb-ft) * 99000-32030: thread lock super “1303” or equivalent oil pump removal • remove the oil pump assembly 1 with oil return pump. Disassembly • remove ...

  • Page 101

    Engine 3-49 reassembly • apply engine oil to the sliding surfaces of the oil pump inner rotor, outer rotor and shaft. • when installing the inner rotor 1, align the pin 2 with the groove 3. • when installing the inner rotor and outer rotor, face the punched marks a on the rotors to the outside. Inst...

  • Page 102

    3-50 engine starter torque limiter starter torque limiter inspection " • check the slip torque with the special tools. $ slip torque standard: 31 – 51 n·m (3.1 – 5.1 kgf-m, 22.5 – 37.0 lb-ft) % 09930-73170: starter torque limiter holder 09930-73180: starter torque limiter socket • set the starter to...

  • Page 103

    Engine 3-51 clutch release camshaft disassembly • remove the clutch release arm 1, return spring 2 and washer 3. • pull out the oil seal 4, bearing 5 with the clutch release cam- shaft 6. " • remove the clutch push rod cap 7 and oil seal 8. " reassembly • apply suzuki super grease “a” the release ca...

  • Page 104

    3-52 engine water pump !8-15 gearshift gearshift shaft/gearshift arm disassembly • remove the following parts from the gearshift shaft/gearshift arm. 1 washer 4 gearshift cam drive plate 2 snap ring 5 plate return spring 3 gearshift shaft return spring gearshift shaft/gearshift arm inspection • insp...

  • Page 105

    Engine 3-53 oil pressure regulator • inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • if the piston does not operate, replace the oil pressure regula- tor with a new one. Oil strainer • clean the oil strainer if necessary. • inspect the oil strainer b...

  • Page 106

    3-54 engine transmission construction 1 countershaft/1st drive gear 7 2nd driven gear 2 5th drive gear 8 3rd driven gear 3 4th drive gear 9 4th driven gear 4 3rd drive gear 0 5th driven gear 5 2nd drive gear a 1st driven gear 6 driveshaft.

  • Page 107

    Engine 3-55 disassembly " countershaft • remove the bearing 1 and oil seal 2. • open the 3rd drive gear snap ring 3 from its groove and slide it towards the 4th drive gear 4 side. • slide the 3rd 5 and 2nd 6 drive gears toward the 4th drive gear 4 side then remove the 2nd drive gear circlip 7. • rem...

  • Page 108

    3-56 engine • remove the snap ring d, washer e, 5th drive gear f and 5th drive gear bushing g. Driveshaft • remove the bearing 1, washer 2 and 1st driven gear 3. • remove the 1st driven gear bushing 4, washer 5 and 5th driven gear 6. • remove the snap ring 7, washer 8 and 4th driven gear 9. • remove...

  • Page 109

    Engine 3-57 • remove the snap ring d, washer e, 2nd driven gear f and its bushing. • remove the secondary drive gear with the bearing g. " reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: note: * rotate the bearings by ha...

  • Page 110

    3-58 engine • when installing a new snap ring, pay attention to its direction. Fit it to the side where the thrust is as shown in the illustration. A thrust b sharp edge " when installing the gear bushing onto the counter- shaft 1 and driveshaft 2 , align the shaft oil hole 3 with the 3rd drive gear...

  • Page 111

    Engine 3-59 transmission parts location 1 countershaft 2 driveshaft.

  • Page 112

    3-60 engine crankcase gearshift fork and gearshift cam removal • remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer plug 2 from the lower crankcase. • remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase. • remove the gearshift cam 5 and...

  • Page 113

    Engine 3-61 gearshift fork groove width • measure the gearshift fork groove width using the vernier cali- pers. $ shift fork groove width: standard: 5.0 – 5.1 mm (0.197 – 0.201 in) % 09900-20102: vernier calipers gearshift fork thickness • measure the gearshift fork thickness using the vernier cali-...

  • Page 114

    3-62 engine • remove the gearshift cam bearing with the special tools. % 09923-74511: bearing remover 09930-30104: sliding shaft installation • install the bearings with the special tool. % 09913-70210: bearing installer set ( 1 + 20) ( 2 + 32) note: the stamped mark side of the gearshift shaft bear...

  • Page 115

    Engine 3-63 • apply a small quantity of thread lock to the bearing retainer screws 8 and gearshift arm stopper bolt 9. • tighten the bearing retainer screws 8, gearshift arm stopper bolt 9 and gearshift fork shaft retainer plug 0 to the specified torque. & 99000-32050: thread lock “1342” or equivale...

  • Page 116

    3-64 engine inspection and cleaning • check the oil jets for clogging. • inspect the operation of the oil jet by pushing on the piston with a proper bar • if they are clogged or piston does not opreat, clean their oil passage with a proper wire and compressed air or replace the oil jet with a new on...

  • Page 117

    Engine 3-65 • remove the oil gallery plugs 2 (for upper crankcase side). • remove the oil gallery plugs 3 (for lower crankcase side). • remove the oil gallery plugs 4 (for oil pan)..

  • Page 118

    3-66 engine installation • apply thread lock to the water jaket plugoil gallery plugs 1 and oil gallery plugs ( 2, 3). & 99000-32050: thread lock “1342” or equivalent note: it is not require to apply thread lock when installing the other removed oil gallery plugs. • tighten each plug to the specifie...

  • Page 119

    Engine 3-67 balancer driven gear balancer driven gear inspection visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. Balancer driven gear disassembly • remove the balancer shaft with the special tool. % 09913-70210: bearing installer set • hold the...

  • Page 120

    3-68 engine • hold the balancer driven gear no. 2 3 with the special tool. % 09920-53740: clutch sleeve hub holder • turn the balancer driven gear no. 1 4 and align the holes. • apply thread lock super to the bolts ( 5, 6). * 99000-32030: thread lock super “1303” or equivalent • tighten the bolts ( ...

  • Page 121

    Engine 3-69 crankshaft and conrod conrod small end i.D. • using a small bore gauge, measure the inside diameter of the conrod small end. $ conrod small end i.D.: service limit: 23.040 mm (0.9071 in) % 09900-20602: dial gauge (1/1 000 mm, 1 mm) 09900-22403: small bore gauge (18 – 35 mm) • if the insi...

  • Page 122

    3-70 engine • remove the conrods, and mark them to identify the cylinder position. • inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. Conrod-big end bearing selection • place the plastigauge axially along the crank p...

  • Page 123

    Engine 3-71 • check the corresponding conrod i.D. Code number (“1” or “2”) a. • check the corresponding crank pin o.D. Code number (“1”, “2” or “3”) b. $ bearing selection table $ conrod i.D. Crank pin o.D. B code 1 2 3 conrod i.D. A 1 green black brown 2 black brown yellow code i.D. Specification 1...

  • Page 124

    3-72 engine $ crank pin o.D. % 09900-20202: micrometer (25 – 50 mm) $ bearing thickness " installation • when fitting the bearings to the bearing cap and conrod, be sure to fix the stopper part a first, and press in the other end. • apply a molybdenum oil solution to the crank pin and bearing surfac...

  • Page 125

    Engine 3-73 • apply engine oil to the bearing cap bolts. • tighten the bearing cap bolts as following two steps. # conrod bearing cap bolt (initial) : 35 n·m (3.5 kgf-m, 25.5 lb-ft) (final) : after tightening the bolts to the above torque, tighten them 1/4 of a turn (90°). • check the conrod movemen...

  • Page 126

    3-74 engine • remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. $ crankshaft journal oil clearance: standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in) service li...

  • Page 127

    Engine 3-75 $ crankshaft journal o.D. Specification % 09900-20203: micrometer (50 – 75 mm) $ bearing thickness specification note: upper and lower crankshaft journal bearings are the same. Installation • when fitting the crankshaft journal bearings to the upper and lower crankcases, be sure to fix t...

  • Page 128

    3-76 engine crankshaft thrust bearing • with the crankshaft and thrust bearing 1 inserted in the upper crankcase, measure the thrust clearance by using the thickness gauge. $ thrust clearance: standard: 0.100 – 0.200 mm (0.0039 – 0.0078 in) % 09900-20803: thickness gauge • if the thrust clearance ex...

  • Page 129

    Engine 3-77 $ thrust bearing selection table a color code clearance before inserting left-side thrust bearing color (part no.) thrust bearing thickness thrust clearance 2.400 – 2.450 mm (0.0944 – 0.0965 in) red (12228-48g00-0a0) 2.250 – 2.300 mm (0.0886 – 0.0906 in) 0.100 – 0.200 mm (0.0039 – 0.0079...

  • Page 130: Engine Reassembly

    3-78 engine engine reassembly • reassemble the engine in the reverse order of disassembly. • the following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Crankshaft • install the crankshaft ass...

  • Page 131

    Engine 3-79 • turn the bearing to install the bearing dowel pin c in the posi- tion. • install the oil seal 1. Transmission • install the countershaft assembly on the upper crankcase. Note: align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing. • install the ...

  • Page 132

    3-80 engine • install the o-rings 1. • apply suzuki super grease “a” to the o-rings. ) 99000-25010: suzuki super grease “a” or equivalent " • install the dowel pins 2. Use a new o-ring to prevent oil leakage..

  • Page 133

    Engine 3-81 • apply suzuki bond to the mating surface of the lower crankcase. , 99000-31110: suzuki bond “1215” or equivalent note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces thinly to form an even layer, and asse...

  • Page 134

    3-82 engine • tighten the crankcase bolts a little at a time to equalize the pressure. Note: * fit the new copper washers to the crankcase bolts b. * fit the new gasket washers to the crankcase bolts c. # crankcase bolt: (m6): 11 n·m (1.1 kgf-m, 8.0 lb-ft) (m8): 26 n·m (2.6 kgf-m, 19.0 lb-ft) (m10) ...

  • Page 135

    Engine 3-83 • apply suzuki bond to the mating surface of the breather cover. - 99000-31140: suzuki bond “1207b” or equivalent note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * spread on surfaces thinly to form an even layer, and asse...

  • Page 136

    3-84 engine oil strainer • clean the oil strainer using compressed air. • install the oil strainers 1. Note: align the boss a with the groove b of crankcase. • apply suzuki super grease “a” to the o-rings. ) 99000-25010: suzuki super grease “a” or equivalent " note: align the oil strainer c with the...

  • Page 137

    Engine 3-85 oil pan • apply suzuki bond to the mating surface of the oil pan. , 99000-31110: suzuki bond “1215” or equivalent note: use of suzuki bond is as follows: * make surfaces free from moisture, oil, dust and other foreign materials. * apply to distorted surfaces as it forms a comparatively t...

  • Page 138

    3-86 engine • apply engine coolant to the o-ring. " • install the water inlet pipe 1. • tighten the water inlet pipe mounting bolts. Oil pressure switch • apply suzuki bond to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. , 99000-31110: suzuki bond “...

  • Page 139

    Engine 3-87 oil filter • install the oil filter with the special tool. ( !2-18) % 09915-40610: oil filter wrench oil pump drive gear and driven gear • install the washer 1 and pin 2. Note: be careful not to drop the washer 1 and pin 2 into the crank- case. • install the oil pump driven gear 3. • ins...

  • Page 140

    3-88 engine gearshift • install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. Note: apply a small quantity of thread lock to the gearshift cam stopper bolt 2 and tighten its to the specified torque. & 99000-32050: thread lock “1342” or equivalent # gearshift cam stopper bolt...

  • Page 141

    Engine 3-89 secondary drive gear • change the gear position to the 1st or 2nd. • hold the primary driven gear with the special tool. % 09930-44541: rotor holder • apply a small quantity of thread lock super to the sec- ondary drive gear bolt and tighten its to the specified torque. * 99000-32030: th...

  • Page 142

    3-90 engine secondary driven gear • install the shims 1 onto the secondary driven gear case. ( !4-11) • fit the o-ring 2 and apply engine oil. " • install the secondary driven gear case 3 with the bolts and then tighten them to the specified torque. # secondary driven gear case bolt: 26 n·m (2.6 kgf...

  • Page 143

    Engine 3-91 front cam drive idle gear/sprocket • turn the crankshaft counterclockwise with the box wrench and align “r i t” line a on the crankshaft with the index marks b of the upper crankcase hole. " • install the front cam chain tensioner no. 1 assy 1. • apply a small quantity of thread lock sup...

  • Page 144

    3-92 engine • install the cam chain guide no. 1 3. • apply a small quantity of thread lock super to the bolts and tighten its to the specified torque. * 99000-32030: thread lock super “1303” or equivalent # cam chain guide no. 1 bolt: 18 n·m (1.8 kgf-m, 13.0 lb-ft) • remove the tensioner lock tool. ...

  • Page 145

    Engine 3-93 starter torque limiter/starter idle gear • install the starter idle gear 1 and shaft 2. • install the bushings 3 into the crankcase and generator cover. Note: apply molybdenum oil solution to the inside of the bushings. ( molybdenum oil solution • fit the washers 4 onto the starter torqu...

  • Page 146

    3-94 engine • after unlocking the ratchet, push the cam chain tension adjuster rod. • insert the special tool between the ratchet and the adjuster body. % 09917-62430: chain tensioner lock tool • install the rear cam chain tension adjuster no. 1 with the bolts and tighten its bolts to the specified ...

  • Page 147

    Engine 3-95 clutch • install the needle bearing 1 and spacer 2 onto the counter- shaft. • apply engine oil to them. • install the primary driven gear assembly 3 onto the counter- shaft. • install the thrust washer 4. • install the clutch sleeve hub assembly 5 onto the counter- shaft. • install the s...

  • Page 148

    3-96 engine outside drive plate: a drive plate no. 1 ...........5 pcs. B drive plate no. 2 ...........1 pc. C wave washer d wave washer seat driven plate: a driven plate no. 1 ...........4 pcs. B driven plate no. 2 ...........2 pcs. 2.9 mm (0.11 in) 2.9 mm (0.11 in) 3.4 mm (0.13 in) 3.6 mm (0.14 in)...

  • Page 149

    Engine 3-97 • install the drive plate no. 2 7, spring washer 8 and spring washer seat 9 onto the clutch sleeve hub correctly. Note: the conical curve side of spring washer 8 faces outside. • insert the clutch drive plates and driven plates one by one to the clutch sleeve hub after applying engine oi...

  • Page 150

    3-98 engine • tighten the clutch spring set bolts securely while holding the generator rotor. Note: tighten the clutch spring bolts diagonally. Piston ring • install the piston rings in the order of oil ring, 2nd ring and 1st ring. • the first member to go into the oil ring groove is a spacer 1. Aft...

  • Page 151

    Engine 3-99 • position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located. C 2nd ring and lower side rail d upper side rail e 1st ring and spacer • apply a small quantity of molybdenum oil solution onto each piston pins, front and ...

  • Page 152

    3-100 engine cylinder • fit the dowel pins and new gaskets 1 to the crankcase front and rear. " • apply a small quantity of molybdenum oil solution to the sliding surface of the pistons and cylinder walls. ( molybdenum oil solution note: the cylinders can be distinguished by the embossed-letters, “f...

  • Page 153

    Engine 3-101 • fit the dowel pins and new cylinder head gaskets 2 to the cylinders, front and rear. " note: the cylinder heads can be distinguished by the embossed-let- ters, “f” and “r”. “f”: front (#2) cylinder “r”: rear (#1) cylinder • place the front and rear cylinder head on the cylinder. Note:...

  • Page 154

    3-102 engine • tighten the front and rear cylinder nuts to the specified torque. # cylinder nut: 13 n·m (1.3 kgf-m, 9.5 lb-ft) front camshafts • turn the crankshaft counterclockwise approx. 1-1/3 turns (486°) with the box wrench and align “f i t” line a on the crankshaft with the index marks b of th...

  • Page 155

    Engine 3-103 • pull the cam chain lightly. • the exhaust camshaft sprocket has an arrow marked “1” c. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • engage the cam chain with the exhaust camshaft sprocket. • starting from the roller pin that is...

  • Page 156

    3-104 engine • install the dowel pins. • install the camshaft journal holders, intake and exhaust 1, and cam chain guide no. 3 2. • have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers. Note: * damage to head or ...

  • Page 157

    Engine 3-105 rear camshafts • from the position where the front camshafts have now been installed, rotate the generator rotor approx. 2/3 turn (234°) and align the “r i t” line a on the crankshaft with the index marks b of the upper crankcase hole. " • the camshafts are identified by the embossed le...

  • Page 158

    3-106 engine • pull the cam chain lightly. • the intake camshaft sprocket has an arrow marked “1” c. Turn the intake camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • engage the cam chain with the intake camshaft sprocket. • the other arrow marked “2” d should now...

  • Page 159

    Engine 3-107 • install the dowel pins. • install the camshaft journal holders, intake and exhaust 1, and cam chain guide no. 3 2. • have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers. Note: * damage to head or ...

  • Page 160

    3-108 engine • install the gasket 5 and cam chain tension adjuster cap bolt 6. Note: click sound is heard when the cam chain tension adjuster cap bolt is installed. • tighten the cam chain tension adjuster cap bolt to the speci- fied torque. # cam chain tension adjuster cap bolt: 23 n·m (2.3 kgf-m, ...

  • Page 161

    Engine 3-109 • install the gasket 5 and cam chain tension adjuster cap bolt 6. Note: click sound is heard when the cam chain tension adjuster cap bolt is installed. • tighten the cam chain tension adjuster cap bolt to the speci- fied torque. # cam chain tension adjuster cap bolt: 23 n·m (2.3 kgf-m, ...

  • Page 162

    3-110 engine • tighten the head cover bolts in ascending order of numbers to the specified torque. # head cover bolt (front and rear): 11 n·m (1.1 kgf-m, 8.0 lb-ft) generator cover • install the dowel pins and gasket 1. " • install the generator cover and tighten its bolts. Note: fit the new gasket ...

  • Page 163

    Engine 3-111 • apply engine oil to the new o-ring and install the generator cover plug. " • tighten the generator cover plug 2 and valve timing inspec- tion plug 3 to the specified torque. # generator cover plug: 16 n·m (1.6 kgf-m, 11.5 lb-ft) valve timing inspection plug: 23 n·m (2.3 kgf-m, 16.5 lb...

  • Page 164

    3-112 engine • install the clutch cover and tighten its bolts. Note: fit the new gasket washers to the bolts a. " thermostat • apply engine coolant to the o-ring. " • install the thermostat assembly 1 and connect the water hoses 2. • tighten the thermostat assembly bolt. Intake pipe • apply suzuki s...

  • Page 165

    Engine 3-113 starter motor • apply suzuki super grease “a” to the o-ring. ) 99000-25010: suzuki super grease “a” or equivalent • tighten the starter motor 1 bolts to the specified torque. # starter motor bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) • install the spark plugs. ( !2-16).

  • Page 166: Driveline/axle

    4 6 6 driveline/axle 4-1 contents driveline/axle secondary bevel gears ...................................................................... 4- 2 construction .................................................................................. 4- 2 removal ...............................................

  • Page 167: Secondary Bevel Gears

    4-2 driveline/axle secondary bevel gears construction ! 1 driven bevel gear coupling 8 shims e driven bevel gear bearing 2 oil seal 9 o-ring a driven bevel gear coupling nut 3 oil seal housing 0 secondary gear case b secondary driven bearing stopper 4 bearing housing set a output cam dog c secondary...

  • Page 168

    Driveline/axle 4-3 adjust backlash by selecting shims. (use two pieces of shims.) shim 1 size table the shims 1 are available as a set (24945-26810). Shim 2 size table the shims 2 are available as a set (24935-48810). Part number thickness 24945-26d00-030 0.30 mm (0.012 in) 24945-26d00-035 0.35 mm (...

  • Page 169

    4-4 driveline/axle removal the secondary bevel gear service requires engine removal and disassembly. Refer to the engine removal and the engine disas- sembly sections for secondary bevel gear assembly removal. Engine removal "3-3 disassembly secondary drive bevel gear ( " 3-28) secondary driven beve...

  • Page 170

    Driveline/axle 4-5 • remove the shims 5. • using a chisel, unlock the nut. • remove the driven bevel gear coupling nut with the special tool. # 09924-64510: final drive gear coupling holder • remove the washer 6 and the driven bevel gear coupling 7. • using a chisel, unlock the nut. • remove the bea...

  • Page 171

    4-6 driveline/axle • remove the bearing housing 8, secondary driven gear 9, output cam dog 0, damper spring a, spring cam stopper b and shaft c. Inspection * driven bevel gear damage or wear * improper tooth contact * output cam dog wear or damage * shaft damage or wear. * universal joint spline dam...

  • Page 172

    Driveline/axle 4-7 • remove the oil seal with the special tool. # 09913-50121: oil seal remover $ • remove the driven gear stopper with the special tool. # 09913-70210: bearing installer set (30 mm) • remove the bearings ( 1, 2) and oil seal housing 3 with the special tools. # 09921-20240: bearing r...

  • Page 173

    4-8 driveline/axle reassembly • reassemble the secondary driven gear in the reverse order of disassembly. • the following steps require special attention or precautionary measures should be taken. Bearing and oil seal housing • install the bearing with the special tool. # 09913-70210: bearing instal...

  • Page 174

    Driveline/axle 4-9 • install the oil seal with the special tool. # 09913-70210: bearing installer set (62 mm) • apply suzuki super grease “a” to the oil seal lip. ' 99000-25010: suzuki super grease “a” or equivalent secondary driven bevel gear • install the secondary driven gear 1. Note: when instal...

  • Page 175

    4-10 driveline/axle • install the secondary driven gear assembly 3. • apply a small quantity of the thread lock super to the bearing housing bolts and tighten it to the specified torque. ( 99000-32030: thread lock super “1303” or equivalnet ! Secondary driven bering housing bolt: 28 n·m (2.8 kgf-m, ...

  • Page 176

    Driveline/axle 4-11 • if the backlash is not within specification, the shims (driven bevel gear side) must be changed and the backlash should be re-checked until correct. Refer to the chart for appropriate changes. Note: when changing the shims (driven bevel gear side), measure the thickness of old ...

  • Page 177

    4-12 driveline/axle • if tooth contact is found to be incorrect, the shims of the sec- ondary drive bevel gear and secondary driven bevel gear must be changed, tooth contact should be re-checked until correct. $ shim specifications drive bevel gear side note: the shims (drive bevel gear side) are av...

  • Page 178: Final Bevel Gears

    Driveline/axle 4-13 final bevel gears construction ! 1 oil seal a final drive bavel gear k oil seal 2 final gear bearing case b shims l propeller shaft 3 shims c washer m universal joint 4 final driven gear bearing d final drive bevel gear bearing a final gear case bolt (m8) 5 final driven bevel gea...

  • Page 179

    4-14 driveline/axle standard clearance b : 2.8 mm (0.110 in) shim 2 size table the shims 2 are available as a set (27326-48810). Standard clearance a : 1.00 mm (0.039 in) shim 1 size table shim 3 – gear case cover clearance: 0.1 mm (0.004 in) shim 3 size table part number thickness part number thick...

  • Page 180

    Driveline/axle 4-15 final gear case removal after draining final gear oil, the following components must be removed in the described order before removing the final gear case. • drain final gear oil. ( "2-19) • remove the rear wheel. ( "9-34) • remove the final gear case nut, spring washer and final...

  • Page 181

    4-16 driveline/axle • remove the propeller shaft 4 and spring 5. • using a chisel, unlock the nut. • remove the final drive gear coupling nut with the special tool. # 09924-62430: 22 mm long socket 09924-64510: final drive gear coupling holder • remove the washer 6 and the final drive gear coupling ...

  • Page 182

    Driveline/axle 4-17 • remove the bearing with the inner race from the final drive bevel gear with the special tool. # 09913-60910: bearing puller $ note: if no abnormal noise, the bearing removal is not necessary. • remove the washer 0. • remove the inner race with the special tool. # 09913-60910: b...

  • Page 183

    4-18 driveline/axle • remove the shim a and final driven bevel gear b. • remove the shims c. • using two bolts or suitable bars, remove the final driven bevel gear bearing from the bevel gear. Note: if no abnormal noise the bearing removal is not necessary. $ • remove the oil seal with the special t...

  • Page 184

    Driveline/axle 4-19 • remove the final driven gear bearing d and oil seal e with the special tools. # 09941-64511: bearing remover 09930-30104: sliding shaft $ • remove the final drive gear bearing with the special tools. # 09923-74511: bearing remover 09930-30104: sliding shaft $ note: if no abnorm...

  • Page 185

    4-20 driveline/axle final gear shims adjustment final gear bearing case shim clearance • install the final driven gear, shims ( 1 and 2) and final gear bearing case to the final gear case. • tighten the final gear case bolts to the specified torque. ! Final gear case bolt (m8): 23 n·m (2.3 kgf-m, 16...

  • Page 186

    Driveline/axle 4-21 backlash after assembling the final gear case ( "4-24), measure the final bevel gear backlash as follows. • install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in photo. # 09924-34510: backlash measuring tool (27 – 50 mm) 09900-2...

  • Page 187

    4-22 driveline/axle shims 2 specifications the shims 2 are available as a set (27327-38810). 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 = 3.80 mm backlash too large: final gear to...

  • Page 188

    Driveline/axle 4-23 • remove the final gear bearing case and final driven bevel gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right: • if the tooth contact pattern is incorrect, as shown in 1, a thin- ner shim 4 is needed between the final drive...

  • Page 189

    4-24 driveline/axle final gear case reassembly reassemble the final gear case in the reverse order of disas- sembly. Pay attention to the following points. • install a new oil seal 1 and o-ring 2 to the bearing stopper. • install the final drive gear bearing into the final gear case with the special...

  • Page 190

    Driveline/axle 4-25 • install a new oil seal to the final gear bearing case with the special tool. # 09951-16310: final gear case oil seal installer • apply suzuki super grease “a” to the lip of the oil seal. ' 99000-25010: suzuki super grease “a” or equivalent • install the final driven bevel gear ...

  • Page 191

    4-26 driveline/axle • install the inner race 5, washer 6, bearing 7 and inner race 8, with the special tool. # 09913-84510: bearing installer note: when installing the bearing, stamped mark on the bearing must face outside. • install the correct shims 9 to the final drive bevel gear and install the ...

  • Page 192

    Driveline/axle 4-27 • tighten the nut to the specified torque with the special tool. ! Final drive gear coupling nut: 100 n·m (10.0 kgf-m, 72.5 lb-ft) # 09924-62430: 22 mm long socket 09924-64510: final drive gear coupling holder • lock the final drive bevel gear coupling nut with a center punch. • ...

  • Page 193

    4-28 driveline/axle • apply suzuki bond to the mating surface of final gear case. & 99000-31140: suzuki bond “1207b” or equivalent • install the stopper plate f to the final gear case. $ note: two kinds of plates are available to lock the stopper at the proper position. • apply suzuki bond to the ma...

  • Page 194

    Driveline/axle 4-29 • install the final gear case. • tighten the final gear case bolts to the specified torque. ! Final gear case nut: 40 n·m (4.0 kgf-m, 29.0 lb-ft) • install the rear wheel. ( "9-39) • pour final gear oil. ( "2-19).

  • Page 195: Fi System Diagnosis

    Fi system diagnosis 5-1 5 contents fi system diagnosis precautions in servicing .................................................................. 5- 3 electrical parts ........................................................................... 5- 3 fuse.................................................

  • Page 196: Fi System Diagnosis

    5-2 fi system diagnosis contents fi system diagnosis “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction..................................................................................... 5-68 “c40” (p0505-h/l or p0506 and p0507) isc valve circuit malfunction.............................

  • Page 197: Precautions In Servicing

    Fi system diagnosis 5-3 precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock type ...

  • Page 198

    5-4 fi system diagnosis • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), 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...

  • Page 199

    Fi system diagnosis 5-5 • when disconnecting and connecting the ecm, make sure to turn off the ignition switch 1, or electronic parts may get damaged. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly when r...

  • Page 200

    5-6 fi system diagnosis electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are as...

  • Page 201

    Fi system diagnosis 5-7 continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. 1 ecm • disconnect the coupler b and measure resistance between couplers a and b. If ...

  • Page 202

    5-8 fi system diagnosis short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/couple...

  • Page 203

    Fi system diagnosis 5-9 using the multi-circuit tester • use the suzuki multi-circuit tester set (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of t...

  • Page 204

    5-10 fi system diagnosis fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. Thes...

  • Page 205

    Fi system diagnosis 5-11 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant tempe...

  • Page 206

    5-12 fi system diagnosis fi system parts location a tachometer b isc valve (iscv) c intake air pressure sensor #2 (iaps) d ignition coil #1 (ig coil) e secondary throttle position sensor (stps) f throttle position sensor (tps) g secondary throttle valve actuator (stva) h pair control solenoid valve ...

  • Page 207

    Fi system diagnosis 5-13 a speedometer b intake air temperature sensor (iats) c pair control solenoid valve d fuel injector #1 e fuel injector #2 f intake air pressure sensor #1 (iaps) g fuel pump h ignition coil/plug cap #1 i tip-over sensor (tos) j fuel pump relay (fp relay) k cooling fan relay l ...

  • Page 208

    5-14 fi system diagnosis fi system wiring diagram b/w b/g b/g g/w g/bl r p/b y/w g/b p/b b/bl dg b b/br y b/r r/b b/w lg w/y lb l w/bl w/b w/g b/y y/g p bl r/y g b y w/bl o/g y/b y/r gr/b gr/w r/bl g/r m ch g w/b b/lg p/w b/w excv a tip-o v er sensor (t os) intak e air temper ature sensor (ia ts) en...

  • Page 209: Ecm Terminal

    Fi system diagnosis 5-15 ecm terminal terminal no. Circuit terminal no. Circuit 1 stva signal (stva. 2a) h stva signal (stva. 2b) 2 stva signal (stva. 1a) i stva signal (stva. 1b) 3 excva power (mo–) j stp sensor signal (stp) 4 excva power (mo+) k ignition switch signal 5 excva position sensor (mps)...

  • Page 210

    5-16 fi system diagnosis terminal no. Circuit terminal no. Circuit y isc signal (isc, 2a) l isc signal (isc, 2b) z isc signal (isc, 1a) m isc signal (isc, 1b) [ — n — \ — o — ] fuel pump relay (fp relay) p — ^ — q — a ho2 sensor heater (ho2, h) r mode select switch b starter relay s neutral switch c...

  • Page 211: Self-Diagnosis Function

    Fi system diagnosis 5-17 self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi indicator light). To check the function of the individual fi system...

  • Page 212

    5-18 fi system diagnosis dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from the devices....

  • Page 213

    Fi system diagnosis 5-19 in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The malfunction code is indicated in three digits. I...

  • Page 214

    5-20 fi system diagnosis tps adjustment 1. Warm up the engine and check the engine idle r/min. Adjust the engine rpm to 900 r/min if necessary. ( #6-22) 2. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. 3. Remove the fuel tank. ( #6-3) 4. Remove the r...

  • Page 215: Fail-Safe Function

    Fi system diagnosis 5-21 fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from each ...

  • Page 216: Fi System Troubleshooting

    5-22 fi system diagnosis fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for prope...

  • Page 217

    Fi system diagnosis 5-23 note: the above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual ...

  • Page 218

    5-24 fi system diagnosis self-diagnostic procedures note: * don’t disconnect couplers from the ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection wi...

  • Page 219

    Fi system diagnosis 5-25 use of sds diagnostic procedures * don’t disconnect couplers from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will era...

  • Page 220

    5-26 fi system diagnosis use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase th...

  • Page 221

    Fi system diagnosis 5-27 show data when trouble (displaing data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it is ...

  • Page 222

    5-28 fi system diagnosis malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical pa...

  • Page 223

    Fi system diagnosis 5-29 dtc no. Detected item detected failure condition check for c23 to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v sensor voltage in other than the above value, c23 (p1651) is indicated. To sensor, lead wire...

  • Page 224

    5-30 fi system diagnosis dtc no. Detected item detected failure condition check for c40 p0505 h isc valve isc valve motor current is higher than specified value. Isc valve circuit shorted to batt or ground circuit open l isc valve motor circuit is open. Isc valve circuit open or batt circuit open p0...

  • Page 225

    Fi system diagnosis 5-31 dtc no. Detected item detected failure condition check for c46 exhaust con- trol valve actuator excva position sensor produces fol- lowing voltage. 0.1 v sensor voltage in other than the above range, c46 (p1657) is indicated. When no actuator control signal is supplied from ...

  • Page 226

    5-32 fi system diagnosis “c12” (p0335) ckp sensor circuit malfunction inspection step 1 1) remove the right frame side cover. ( #9-5) 2) remove the left frame lower side cover. ( #3-6) 3) turn the ignition switch off. 4) check the ckp sensor coupler for loose or poor contacts. If ok, then measure th...

  • Page 227

    Fi system diagnosis 5-33 6) if ok, then check the continuity between each terminal and ground. $ ckp sensor continuity: ∞ Ω (infinity) (blue – ground) (green – ground) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance ( Ω ) are the resistance and continuity ok? 7) after re...

  • Page 228

    5-34 fi system diagnosis “c13” (p1750-h/l) or “c17” (p0105-h/l) iap sensor circuit malfunction inspection step 1 (when indicating c13 for iap sensor #2) (when indicating c17 for iap sensor #1) 1) remove the fuel tank. ( #6-3) 2) turn the ignition switch off. 3) check the iap sensor coupler (#2 1 or ...

  • Page 229

    Fi system diagnosis 5-35 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the red wire 3 and ground. 7) if ok, then measure the voltage at the red wire 3 and b/br wire 4. $ iap sensor input voltage: 4.5 – 5.5 v ( + red – - ground) ( + red – - b/br) ! 09...

  • Page 230

    5-36 fi system diagnosis step 3 1) turn the ignition switch off. 2) remove the iap sensor. ( #6-13) 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. 4) arrange 3 new 1.5 v batteries in series 1 (check that total - voltage is 4.5 – 5.0 v) and connect - terminal to the ground - t...

  • Page 231

    Fi system diagnosis 5-37 step 1 (when indicating p1750-h for iap sensor #2) (when indicating p0105-h for iap sensor #1) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the iap sensor coupler for loose or poor contacts. If ok, then check the iap sensor lead wire continuity....

  • Page 232

    5-38 fi system diagnosis 8) check the continuity between p/b wire b and terminal 9 (#2), and g/b wire b and terminal p (#1). 9) if ok, then check the continuity between b/br wire c (#1 and #2) and terminal s. " $ iaps lead wire continuity: continuity ( ( ) ! 09900-25008: multi-circuit tester set 099...

  • Page 233

    Fi system diagnosis 5-39 7) disconnect the ecm coupler. ( #5-37) 8) check the continuity between red wires a (#1 and #2) and terminal a. 9) also, check the continuity between p/b wire b and terminal 9, and g/b wire b and terminal p. " $ iaps lead wire continuity: continuity ( ( ) ! 09900-25008: mult...

  • Page 234

    5-40 fi system diagnosis step 2 1) connect the iap sensor coupler and ecm coupler. 2) reinstall the fuel tank and lift up the fuel tank. 3) insert the needle pointed probes to the lead wire coupler. 4) start the engine at idle speed and measure the iap sensor output voltage at the wire side coupler....

  • Page 235

    Fi system diagnosis 5-41 “c14” (p0120-h/l) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage. 4) disconnec...

  • Page 236

    5-42 fi system diagnosis step 1 (when indicating p0120-h:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the tp sensor coupler for loose or poor contacts. If ok, then check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuity b...

  • Page 237

    Fi system diagnosis 5-43 step 1 (when indicating p0120-l:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the tp sensor coupler for loose or poor contacts. If ok, then check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuity b...

  • Page 238

    5-44 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the tp sensor coupler and ecm coupler. 3) install the test harness to the tp sensor. 4) check the continuity between terminal a and ground. $ tp sensor continuity: ∞ Ω (infinity) (terminal a – ground) 5) if ok, then measu...

  • Page 239

    Fi system diagnosis 5-45 step 3 1) connect the tp sensor coupler 1 to the test harness. 2) turn the ignition switch on. 3) measure the tp sensor output voltage at the coupler (between + p/b and - b/br) by turning the throttle grip. $ tp sensor output voltage throttle valve is closed: approx. 1.1 v t...

  • Page 240

    5-46 fi system diagnosis “c15” (p0115-h/l) ect sensor circuit malfunction inspection step 1 (when indicating c15:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at ...

  • Page 241

    Fi system diagnosis 5-47 step 1 (when indicating p0115-h:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler and ecm co...

  • Page 242

    5-48 fi system diagnosis step 1 (when indicating p0115-l:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the output voltage. 4) disconnect the ect sensor coupler. 5) check the continuity ...

  • Page 243

    Fi system diagnosis 5-49 step 2 1) turn the ignition switch off. 2) disconnect the ect sensor coupler. 3) measure the ect sensor resistance. $ ect sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance (...

  • Page 244

    5-50 fi system diagnosis “c21” (p0110-h/l) iat sensor circuit malfunction inspection step 1 (when indicating c21:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor voltage at the wire side...

  • Page 245

    Fi system diagnosis 5-51 step 1 (when indicating p0110-h:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler and ecm coupler. ( #5-3...

  • Page 246

    5-52 fi system diagnosis step 1 (when indicating p0110-l:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler. 5) check the continuit...

  • Page 247

    Fi system diagnosis 5-53 step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. $ iat sensor resistance: approx. 2.45 k Ω at 20 °c (68 °f) (terminal – terminal) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance ( Ω ) is the resistance ok? $ iat senso...

  • Page 248

    5-54 fi system diagnosis “c23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) disconnect t...

  • Page 249

    Fi system diagnosis 5-55 step 1 (when indicating p1651-h:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity b...

  • Page 250

    5-56 fi system diagnosis step 1 (when indicating p1651-l:) 1) turn the ignition switch off. 2) remove the fuel tank. ( #6-3) 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity b...

  • Page 251

    Fi system diagnosis 5-57 step 2 1) connect the to sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between black and b/br wires. $ to sensor voltage (normal): 0.4 – 1.4 v ( + ...

  • Page 252

    5-58 fi system diagnosis “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) remove the air cleaner chamber. ( #6-13) 2) check the stva lead wire coupler for loose or poor contacts. 3) turn the ignition switch on to check the stv operation. (stv operating order: full open → 95% open)...

  • Page 253

    Fi system diagnosis 5-59 step 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each terminal and ground. $ stva continuity: ∞ Ω (infinity) (terminal – ground) 4) if ok, then measure the stva resistance (between black wire a and pink wire b)...

  • Page 254

    5-60 fi system 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 sound is heard from the stva, t...

  • Page 255

    Fi system diagnosis 5-61 “c29” (p1654-h/l) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input volta...

  • Page 256

    5-62 fi system diagnosis step 1 (when indicating p1654-h:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. Stp sensor lead wire coupler: black 4) disconne...

  • Page 257

    Fi system diagnosis 5-63 step 1 (when indicating p1654-l:) 1) turn the ignition switch off. 2) remove the right air cleaner box. ( #6-13) 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. Stp sensor lead wire coupler: black 4) disconne...

  • Page 258

    5-64 fi system diagnosis step 2 1) turn the ignition switch off. 2) remove the air cleaner chamber. ( #6-13) 3) disconnect the stp sensor coupler. 4) check the continuity between each terminal and ground. $ stp sensor continuity: ∞ Ω (infinity) (terminal – ground) 5) if ok, then measure the stp sens...

  • Page 259

    Fi system diagnosis 5-65 step 3 1) turn the ignition switch off. 2) disconnect the stp sensor coupler and install the test har- ness. 3) disconnect the stva lead wire coupler. 4) turn the ignition switch on. 5) measure the stp sensor output voltage at the terminals (between + terminal a y/w wire and...

  • Page 260

    5-66 fi system diagnosis “c31” (p0705) gp switch circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right frame side cover. ( #9-5) 3) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp switch voltage. 4) support the motorcycle with a...

  • Page 261

    Fi system diagnosis 5-67 is the voltage ok? 10)after repairing the trouble, clear the dtc using sds tool. ( #5-26) yes • pink wire open or shorted to ground • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and wire harness for open circuit and poor conne...

  • Page 262

    5-68 fi system diagnosis “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection (when indicating c32/p0201 for fuel injector #1) (when indicating c33/p0202 for fuel injector #2) step 1 1) remove the air cleaner chamber. ( #6-13) 2) turn the ignition switch off. 3) check the inje...

  • Page 263

    Fi system diagnosis 5-69 5) if ok, then check the continuity between each terminal and ground. $ stp sensor continuity: ∞ Ω (infinity) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance ( Ω ) are the resistance and continuity ok? 6) after repairing the trouble, clear the dt...

  • Page 264

    5-70 fi system diagnosis “c40” (p0505-h/l or p0506 and p0507) isc valve circuit malfunction " detected condition possible cause c40 p0505 h isc valve motor current is higher than the specified value. • isc valve circuit shorted to batt or ground circuit open • isc valve circuit open or shorted to gr...

  • Page 265

    Fi system diagnosis 5-71 inspection step 1 1) remove the fuel tank. ( #6-3) 2) turn the ignition switch off. 3) check the isc valve coupler for loose or poor contacts. 4) if ok, then check the isc valve lead wire continuity. 5) disconnect the isc valve coupler and ecm coupler. ( #5-37) 6) check the ...

  • Page 266

    5-72 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the isc valve coupler. 3) check the continuity between terminals 1 and 3, terminals 2 and 4. $ isc valve continuity: approx. ∞ Ω (infinity) (terminal 1 – terminal 3 ) (terminal 2 – terminal 4 ) 4) if ok, then measure the ...

  • Page 267

    Fi system diagnosis 5-73 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” 1. 5) check that the “spec” 2 is 900 rpm. 6...

  • Page 268

    5-74 fi system diagnosis check 2 1) click the button 1 and decrease the “spec” 2 to 800 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2. At the same time, check that the number of steps in the isc valve position decreases . 3) click the button 4 and increase the ...

  • Page 269

    Fi system diagnosis 5-75 check 3 1) click the button 1 and increase the “spec” 2 to 1 200 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2. Also, check that the number of steps 4 in the isc valve position increases . " check 4 1) increase the “spec” 1 to 1 400 rpm...

  • Page 270

    5-76 fi system diagnosis “c41” (p0230-h/l) fp relay circuit malfunction inspection step 1 (when indicating c41:) 1) turn the ignition switch off. 2) remove the right frame side cover. ( #9-5) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( #6-6) is the fp ...

  • Page 271

    Fi system diagnosis 5-77 step 1 (when indicating p0230-h:) 1) turn the ignition switch off. 2) remove the right frame side cover. ( #9-5) 3) check the fp relay coupler for loose or poor contacts. If ok, then check the fp relay. ( #6-6) is the fp relay ok? 4) after repairing the trouble, clear the dt...

  • Page 272

    5-78 fi system diagnosis “c42” (p01650) ig switch circuit malfunction inspection * refer to the ignition switch inspection for details. ( # 10-42) detected condition possible cause ignition switch signal is not input to the ecm. • ignition system circuit open or short • ecm malfunction.

  • Page 273

    Fi system diagnosis 5-79 “c44” (p0156/p0161) or “c64” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24) inspection step 1 (when indicating c44/p0156 for ho2 sensor #2) (when indicating c64/p0130 for ho2 sensor #1) 1) turn the ignition switch off. 2) check the ho2 sensor for loos...

  • Page 274

    5-80 fi system diagnosis 6) disconnect the ecm coupler. ( #5-37) 7) check the continuity between w/g or w/bl wire a and termi- nal b, e. 8) also, check the continuity between b/br wire b and terminal s. " $ ho2s lead wire continuity: continuity ( ( ) ! 09900-25008: multi-circuit tester set 09900-250...

  • Page 275

    Fi system diagnosis 5-81 is the voltage ok? 7) after repairing the trouble, clear the dtc using sds tool. ( #5-26) step 1 (when indicating c44/p0161 for ho2 sensor #2) (when indicating c64/p0135 for ho2 sensor #1) 1) turn the ignition switch off. 2) check the ho2 sensor for loose or poor contacts. I...

  • Page 276

    5-82 fi system diagnosis step 2 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w/b wire and ground. 4) if the tester voltage indicates the battery voltage, it is good condition. $...

  • Page 277

    Fi system diagnosis 5-83 “c46” (p1657-h/l or p1658) excv actuator circuit malfunction inspection step 1 (when indicating c46:) 1) turn the ignition switch off. 2) remove the lower frame cover. ( #7-8) 3) check the excva lead wire coupler for loose or poor con- tacts. 4) turn the ignition switch on. ...

  • Page 278

    5-84 fi system diagnosis step 1 (when indicating p1657-h:) 1) turn the ignition switch off. 2) remove the lower frame cover. ( #7-8) 3) check the excva position sensor coupler for loose or poor contacts. If ok, then check the excva position sensor lead wire conti- nuity. 4) disconnect the excva posi...

  • Page 279

    Fi system diagnosis 5-85 step 1 (when indicating p1657-l:) 1) turn the ignition switch off. 2) remove the lower frame cover. ( #7-8) 3) check the excva position sensor coupler for loose or poor contacts. If ok, then check the excva position sensor lead wire conti- nuity. 4) disconnect the excva posi...

  • Page 280

    5-86 fi system diagnosis step 1 (when indicating p1658:) 1) turn the ignition switch off. 2) remove the lower frame cover. ( #7-8) 3) check the excva motor coupler for loose or poor contacts. Is the contacting ok? 4) after repairing the trouble, clear the dtc using sds tool. ( #5-26) step 2 1) turn ...

  • Page 281

    Fi system diagnosis 5-87 step 3 1) turn the ignition switch off. 2) check the continuity between yellow wire and ground. $ position sensor continuity: ∞ Ω (infinity) 3) if ok, then measure the position sensor resistance. 4) connect the position sensor coupler. 5) set the excva to adjustment position...

  • Page 282

    5-88 fi system diagnosis step 4 1) turn the ignition switch off. 2) connect the position sensor coupler. 3) measure the position sensor output voltage at fully close posi- tion and fully open position. 4) insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler. (...

  • Page 283

    Fi system diagnosis 5-89 step 5 1) if the position sensor output voltage is 0.5 v and less at fully close position, adjust the output voltage to specified by turn- ing out the no. 1 cable adjuster 1. 2) repeat the above procedure (step 4) until the out put voltage becomes specified value. (if c46/p1...

  • Page 284

    5-90 fi system diagnosis step 6 1) turn the ignition switch off. 2) disconnect the motor lead wire coupler of the excva. 3) apply 12 volts to the terminal and check the operation of excva. 4) then, swap the wires supplied 12 volts and check the opera- tion of excva. (check the operation of excva bot...

  • Page 285

    Fi system diagnosis 5-91 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 “exhaust valve operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the excva, the f...

  • Page 286

    5-92 fi system diagnosis “c49” (p1768) or “c61” (p1656) pair control solenoid valve circuit malfunction inspection step 1 (when indicating c49/p1768 for #2) (when indicating c61/p1656 for #1) 1) turn the ignition switch off. 2) lift up the fuel tank. ( #6-3) 3) check the pair control solenoid valve ...

  • Page 287

    Fi system diagnosis 5-93 step 2 1) turn the ignition switch on. 2) measure the voltage between o/b wire and ground. $ pair valve voltage: battery voltage ( + o/b – - ground) ! 09900-25008: multi-circuit tester set & tester knob indication: voltage ( ' ) is the voltage ok? 3) after repairing the trou...

  • Page 288

    5-94 fi system diagnosis “c60” (p0480) cooling fan relay circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right frame side cover. ( #9-5) 3) check the cooling fan relay coupler for loose or poor contacts. If ok, then inspection the cooling fan relay. ( #8-8) is th...

  • Page 289

    Fi system diagnosis 5-95 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) start the engine and run it idling condition. 3) click “cooling fan relay control” 1. 4) click the operate button 2. At this time, if an operation sound is heard fro...

  • Page 290

    5-96 fi system diagnosis 6) click the off button 4 to check the cooling fan relay and cooling fan motor operation. Note: this inspection should be begun from when the engine coolant temperature is below 50 °c (122 °f). Check that the cooling fan relay operates for a few seconds as the engine coolant...

  • Page 291: Sensors

    Fi system diagnosis 5-97 sensors iap sensor inspection the intake air pressure sensor is located at the right and left side of the air cleaner box. ( #6-13) iap sensor removal and installation • remove the fuel tank. ( #6-3) • remove the iap sensors from the air cleaner chamber. • install the iap se...

  • Page 292

    5-98 fi system diagnosis stp sensor inspection the secondary throttle position sensor is installed on the no. 2 throttle body. ( #5-61) stp sensor removal and installation • remove the fuel tank. ( #6-3) • remove the right air cleaner box. ( #6-13) • remove the stp sensor and disconnect the coupler ...

  • Page 293

    Fi system diagnosis 5-99 iat sensor inspection the intake air temperature sensor is installed at the front left side of the air cleaner box. ( #5-50) iat sensor removal and installation • remove the fuel tank. ( #6-3) • remove the iat sensor from the air cleaner chamber. • install the iat sensor in ...

  • Page 294

    5-100 fi system diagnosis ho2 sensor inspection (for e-02, 19, 24) the heated oxygen sensor is installed on the pre-muffler. ( #5-79) ho2 sensor removal and installation (for e-02, 19, 24) • remove the ho2 sensor unit. + " • install the ho2 sensor in the reverse order of removal. " • tighten the sen...

  • Page 295

    Fuel system and throttle body 6-1 6 fuel system and throttle body contents fuel delivery system.......................................................................... 6- 2 fuel system............................................................................................. 6- 3 fuel tank remov...

  • Page 296: Fuel Delivery System

    6-2 fuel system and throttle body fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the f...

  • Page 297: Fuel System

    Fuel system and throttle body 6-3 fuel system fuel tank removal • remove the left and right frame side covers. ( "9-5) • remove the fuel tank mounting bolt. • lift and support the fuel tank about 10 cm (3.94 in) with the proper stay. Note: be careful not to lift the fuel more than about 10 cm (3.94 ...

  • Page 298

    6-4 fuel system and throttle body fuel pressure inspection • lift and support the fuel tank. ( "6-3) • place a rag under the fuel feed hose. • disconnect the fuel feed hose 1. • install the special tools between the fuel tank and fuel delivery pipe. $ 09940-40211: fuel pressure gauge adaptor 09940-4...

  • Page 299

    Fuel system and throttle body 6-5 fuel pump inspection turn the ignition switch on and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. If the fuel pu...

  • Page 300

    6-6 fuel system and throttle body fuel pump relay inspection cooling fan relay is located in front of the battery. • remove the right side frame cover. ( "9-5) • remove the fuel pump relay 1. First check the insulation between a and b terminals with tester. Then apply 12 v to c and d terminals, + to...

  • Page 301

    Fuel system and throttle body 6-7 fuel pump and fuel level gauge removal construction 1 thermistor 5 o-ring ( 2 fuel pump 6 fuel level gauge item n·m kgf-m lb-ft 3 fuel mesh filter a fuel pump mounting bolt a 10 1.0 7.0 4 filter cover.

  • Page 302

    6-8 fuel system and throttle body removal • remove the fuel tank. ( "6-3) • remove the fuel tank shield 1. A: clamp • remove the fuel pump assembly 2 mounting bolts diago- nally. ! • remove the fuel pump assembly and disconnect the fuel gauge lead wire coupler 3. • remove the fuel level gauge 4 whil...

  • Page 303

    Fuel system and throttle body 6-9 fuel pump disassembly • disconnect the fuel pump coupler 1. • remove the band 2 and clamp 3. • remove the hose 4 and filter cover 5. • remove the clamp 6 and thermistor 7. • remove the fuel mesh filter 8. • remove the fuel pump 9. • remove the clip 0 and pressure re...

  • Page 304

    6-10 fuel system and throttle body fuel mesh filter inspection • disconnect the clamp 1 and rubber boot 2. If the fuel mesh filter is clogged with sediment or rust, replace the fuel filter with a new one. Fuel pump and fuel level gauge reassembly and installation install the fuel pump and fuel level...

  • Page 305

    Fuel system and throttle body 6-11 • apply thin coat of the engine oil to the bushing. • install the fuel pump 1. • install a new o-ring and apply suzuki super grease “a” to it. ) 99000-25010: suzuki super grease “a” or equivalent ! • when installing the fuel pump assembly, first tighten all the fue...

  • Page 306: Throttle Body

    6-12 fuel system and throttle body throttle body construction only for e-33 1 tp sensor 8 cushion seal 2 stp sensor 9 air screw 3 stva 0 isc valve ( 4 fuel delivery pipe a vacuum hose item n·m kgf-m lb-ft 5 iap sensor a fuel delivery pipe mounting screw a 5 0.5 3.5 6 o-ring b stp sensor mounting scr...

  • Page 307

    Fuel system and throttle body 6-13 air cleaner box removal • remove the fuel tank. ( "6-3) • remove the bolts. *: hooked part • disconnect the drain hose 1. • loosen the clamp screw 2. • remove the right air cleaner box. • remove the bolts. *: hooked part • disconnect the drain hose 3. • loosen the ...

  • Page 308

    6-14 fuel system and throttle body • disconnect the pcv hose 8. • loosen the throttle body clamp screws at the air cleaner chamber side. • disconnect the pair lead wire couplers 9 and hoses 0. • remove the air cleaner chamber. For e-03, 28, 33 for the others • disconnect the stva lead wire coupler a...

  • Page 309

    Fuel system and throttle body 6-15 • disconnect the clamp and fuel injector lead wire couplers d. • loosen the throttle body clamp screws at the intake pipe side. • disconnect the throttle cables from their drum. • remove the throttle body assembly. # throttle body disassembly • disconnect the iap s...

  • Page 310

    6-16 fuel system and throttle body • remove the fuel injectors 5. • remove the tp sensor 6 and stp sensor 7 with the special tool. $ 09930-11950: torx wrench note: prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. # # # never remove the st...

  • Page 311

    Fuel system and throttle body 6-17 throttle body cleaning ! • clean passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air. # inspection • check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum...

  • Page 312

    6-18 fuel system and throttle body isc valve removal disconnect the hoses and remove the isc valve 1. Inspection check the isc valve for wear or damage, replace it with a new one if necessary. Isc valve installation install the isc valve in the reverse order of removal..

  • Page 313

    Fuel system and throttle body 6-19 throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • with the stv fully closed, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Note: * appl...

  • Page 314

    6-20 fuel system and throttle body • apply thin coat of the engine oil to the new cushion seal 3, and the o-ring 4. # • install the fuel injector 5 by pushing it straight to the delivery pipe 6. Note: align the coupler e of injector with boss f of the delivery pipe. # • install the fuel delivery pip...

  • Page 315

    Fuel system and throttle body 6-21 air cleaner chamber and throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. ...

  • Page 316

    6-22 fuel system and throttle body stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor out put voltage and adjust the stp sensor position as follows: • remove the air cleaner chamber. ( "6-13) • disconnect the stva coupler. ( "6-14) • insert the needle pointed probes ...

  • Page 317

    Fuel system and throttle body 6-23 fuel injector installation • apply thin coat of the engine oil to new injector cushion seals and o-rings. ( "6-20) • install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. ( "6-20) throttle valve synchronization ...

  • Page 318

    6-24 fuel system and throttle body step 2 • warm up the engine as follows: summer: approx. 5 min at idle r/min winter: approx. 8 min at idle r/min • water temperature should be more than 80 °c (176 °f) and then wait 30 second. • then isc valve automatically is set at throttle body synchroni- zation ...

  • Page 319: Exhaust System

    Exhaust system 7-1 4 7 exhaust system contents excva (exhaust control valve actuator) and excv (exhaust control valve)................................................ 7- 2 excva and excv removal ............................................................. 7- 2 excva inspection.........................

  • Page 320: (Exhaust Control Valve)

    7-2 exhaust system excva (exhaust control valve actuator) and excv (exhaust control valve) excva and excv removal • turn the ignition switch off. • remove the left frame side cover. ( !9-5) • connect the special tool (mode select switch) to the dealer mode coupler. ( !5-18) • after turning the speci...

  • Page 321

    Exhaust system 7-3 • disconnect the no. 2 cable 3 and then no. 1 cable 4 from the pulley. • remove the excva 5. • remove the excv cover 6 from the excv pulley. • disconnect the no. 1 7 and no. 2 8 cables. Excva inspection !5-83 excv inspection • turn the excv by hand and check that it moves smoothly...

  • Page 322

    7-4 exhaust system excva and excv installation install the excva and excv in the reverse order of removal. Pay attention to the following points: • connect the excv cables temporarily to the excv pulley. • adjust the clearance a between the adjuster end and excv pulley to provide 4 mm (0.16 in) and ...

  • Page 323

    Exhaust system 7-5 • check the excva to adjustment position. ( !7-2) # • install the pulley 8 to the shaft 9. Note: make sure that the shaft’s line d and cable slots e facing upward as shown. • hold the excva pulley with an adjustable wrench, and then tighten the pulley mounting bolt to the specifie...

  • Page 324

    7-6 exhaust system excva adjustment 1st step: • set the excva to adjustment position. ( !7-2) • make sure that the no. 2 cable and no. 1 cable are fixed into the clamp. 2nd step: • turn the mode select switch off. • turn the ignition switch on to check the excva operation. • turn the mode select swi...

  • Page 325

    Exhaust system 7-7 • to set the excv to fully close position, apply 12 volts to a and b terminals. Positive wire –– a (pink wire) terminal negative wire –– b (gray wire) terminal # • turn the ignition switch on. • measure the position sensor output voltage at fully close posi- tion. % position senso...

  • Page 326: Exhaust Pipe And Muffler

    7-8 exhaust system measure the position sensor output voltage at fully open posi- tion. % position sensor output voltage excv is fully open: 3.5 output voltage 4.5 v ( + yellow – - b/br) if the measured voltage is more than specification, adjust the no.2 cable adjuster as follows: • set the excva to...

  • Page 327

    Exhaust system 7-9 • disconnect the front and rear ho2 sensor lead wire couplers. (for e-02, 19, 24) • remove the muffler cover 3. • remove the no. 1 muffler 4. • remove the right frame lower cover 5. Note: “ ( ” indicates hook location..

  • Page 328

    7-10 exhaust system • remove the exhaust pipes 6 and the no. 2 muffler 7. Installation install the exhaust pipe and muffler in the reverse order of removal. Play attention to the following points: • install the exhaust pipes 1 with the no. 2 muffler 2. # • tighten the exhaust pipe bolts and no. 2 mu...

  • Page 329

    Exhaust system 7-11 • install the no. 1 muffler 3. • tighten the no. 1 muffler bolts and muffler connecting bolts. $ muffler mounting bolt : 23 n·m (2.3 kgf-m, 16.5 lb-ft).

  • Page 330

    7-12 exhaust system 23 n·m (2.3 kgf-m, 16.5 lb-ft) 4.0 mm (0.16 in) and more no. 1 no. 2 58 – 59 mm (2.28 – 2.32 in) 42 – 43 mm (1.65 – 1.69 in) 4.0 mm (0.16 in) and more 8.5 – 9.5 mm (0.33 – 0.73 in) no. 1 no. 2 23 n·m (2.3 kgf-m, 16.5 lb-ft) 23 n·m (2.3 kgf-m, 16.5 lb-ft) ho2 sensor (for e-02, 19,...

  • Page 331

    Cooling and lubrication system 8-1 8 cooling and lubrication system contents engine coolant ..................................................................................... 8- 2 cooling circuit ..................................................................................... 8- 3 cooling ci...

  • Page 332: Engine Coolant

    8-2 cooling and lubrication system engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the c...

  • Page 333: Cooling Circuit

    Cooling and lubrication system 8-3 cooling circuit cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • remove the fuel tank. ( #6-3) • remove the left frame head cover. ( #9-6) • remove the radiator cap 1 and connect t...

  • Page 334: Radiator And Water Hose

    8-4 cooling and lubrication system radiator and water hose radiator removal and disassembly • remove the fuel tank. ( #6-3) • remove the frame head covers and radiator covers. ( #9-6) • drain the engine coolant. ( #2-20) • disconnect the reservoir hose 1 and cooling fan lead wire coupler 2. • discon...

  • Page 335

    Cooling and lubrication system 8-5 radiator disassembly • remove the reservoir tank 1. • remove the coolong fan 2 and shield 3. • remove the radiator guard 4. Radiator cap inspection • fit the cap 1 to the radiator cap tester 2. • build up pressure slowly by operating the tester. Make sure that the ...

  • Page 336

    8-6 cooling and lubrication system radiator inspection and cleaning • road dirt or trash stuck on the fins must be removed. • use of compressed air is recommended for this cleaning. • fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Radiator reass...

  • Page 337

    Cooling and lubrication system 8-7 water hose inspection • remove the fuel tank. ( #6-3) • remove the frame head covers and radiator covers. ( #9-6) • remove the left and right air cleaner boxs. ( #6-13) • remove the secondary gear case cover. ( #3-6) • any water hose found in a cracked condition or...

  • Page 338: Cooling Fan

    8-8 cooling and lubrication system cooling fan inspection • remove the right frame head cover and right radiator cover. ( #9-6) • disconnect the cooling fan coupler 1. • test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • the voltmeter is for making ...

  • Page 339: Ect Sensor

    Cooling and lubrication system 8-9 ect sensor removal • drain the engine coolant. ( #2-20) • remove the air cleaner chamber and throttle body. ( #6-13) • disconnect the ect sensor coupler 1. • remove the rear intake pipe and thermostat assembly. ( #3-13) • remove the ect sensor 2. Inspection • check...

  • Page 340

    8-10 cooling and lubrication system if the resistance is noted to show infinity or too much different resistance value, replace the ect sensor with a new one. ! Installation • install the new sealing washer 1. • tighten the ect sensor 2 to the specified torque. ( ect sensor: 18 n·m (1.8 kgf-m, 13.0 ...

  • Page 341: Thermostat

    Cooling and lubrication system 8-11 thermostat removal • remove the left air cleaner box. ( #6-13) • place a rag under the thermostat cover. • remove the thermostat cover 1. • remove the thermostat 2. Inspection inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench fo...

  • Page 342

    8-12 cooling and lubrication system • keep on heating the water to raise its temperature. • just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). $ thermostat valve lift a standard: 8.0 mm and over at 100 °c (0.31 in and over at ...

  • Page 343: Water Pump

    Cooling and lubrication system 8-13 water pump removal and disassembly note: before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, v...

  • Page 344

    8-14 cooling and lubrication system • remove the water pump cover 3. • remove the impeller securing bolt by holding the impeller with a water pump pliers. • remove the mechanical seal ring 4 and rubber seal 5 from the impeller. • remove the impeller shaft 6, washer 7 and o-ring 8. • remove the mecha...

  • Page 345

    Cooling and lubrication system 8-15 • remove the oil seal 9. Note: if there is no abnormal condition, the oil seal removal is not nec- essary. ! Inspection mechanical seal • visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • replace the mechanic...

  • Page 346

    8-16 cooling and lubrication system case • visually inspect the case for damage or scratch. • replace the case if necessary. Reassembly and installation • install the oil seal with the special tool. % 09913-70210: bearing installer set ( ) 22) note: the stamped mark on the oil seal faces mechanical ...

  • Page 347

    Cooling and lubrication system 8-17 • apply suzuki super grease “ a ” to the impeller shaft and o-ring. ! * 99000-25010: suzuki super grease “a” or equivalent • install the impeller shaft 1, washer 2 and o-ring 3 to the water pump body. • install the rubber seal 4 into the impeller. • after wiping o...

  • Page 348

    8-18 cooling and lubrication system • install the new o-ring 9. ! Note: apply engine coolant to the o-ring. • tighten the water pump cover screws. • install the water pump. Note: set the water pump shaft end e to the oil pump shaft f as shown. • connect the water hose 0. • tighten the water pump mou...

  • Page 349

    Cooling and lubrication system 8-19 engine lubrication system chart second ar y bevel gears and bearing primar y driven gear bearing second ar y driven bevel shaft second ar y driven gear bearing #1 pist on pin bearing ider shaft and bearing cam chain tension adjuster #1 camshaft journals, cam f a c...

  • Page 350: Chassis

    Chassis 9-1 9 chassis contents exterior parts ...................................................................................... 9- 3 fastener removal and installation..................................... 9- 3 front and rear seat .....................................................................

  • Page 351: Chassis

    Chassis contents 9-2 chassis reassembly ...................................................................................... 9-46 installation..................................................................................... 9-49 suspension setting .................................................

  • Page 352: Exterior Parts

    Chassis 9-3 exterior parts fastener removal and installation fastener (type a) removal • depress the head of fastener center piece 1. • pull out the fastener a. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. ...

  • Page 353

    9-4 chassis installation • insert the fastener into the installation hole. Note: to prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • push in the head of center piece. Front and rear seat removal • remove the front seat with the ignition key. • remove the ...

  • Page 354

    Chassis 9-5 frame side cover removal • remove the front seat. ( !9-4) • remove the left frame side cover 1. Note: “ " ” indicates hook location. • disconnect the seat lock cable 2. • remove the right frame side cover 3. Note: “ " ” indicates hook location. Rear frame cover removal • remove the left ...

  • Page 355

    9-6 chassis frame head cover and radiator cover removal • remove the fuel tank. ( !6-3) • remove the right frame head cover 1 and left frame head cover 2. • remove the right radiator cover 3 by removing the bolt 4 and fastener 5. Note: “ " ” indicates hook location. • remove the left radiator cover ...

  • Page 356

    Chassis 9-7 installation install the frame head covers and radiator covers in the reverse order of removal. Pay attention to the following points: • install the radiator bottom cover 1. Note: pass the breather hose a in the hole b of a radiator bottom cover. • frame head cover and radiator cover ins...

  • Page 357: Front Wheel

    9-8 chassis front wheel construction 1 brake disc 5 collar # 2 dust seal 6 front wheel item n·m kgf-m lb-ft 3 bearing a front axle a 100 10.0 72.5 4 spacer b brake disc bolt b 23 23.0 16.5.

  • Page 358

    Chassis 9-9 removal • remove the brake calipers 1, left and right. $ • loosen the two axle pinch bolts 2 on the right front fork leg. • loosen the front axle with the special tool. % 09900-18740: hexagon socket (24 mm) • raise the front wheel off the ground and support the motorcy- cle with a jack o...

  • Page 359

    9-10 chassis wheel • 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 replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel. & wheel r...

  • Page 360

    Chassis 9-11 reassembly and installation reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease “a” to the wheel bearings. ' 99000-25010: suzuki super grease “a” or equivalent 23 n·m (2....

  • Page 361

    9-12 chassis • install the wheel bearings with the special tools as follows. % 09941-34513: bearing/steering race installer set 09924-84510: bearing installer set $ • install the dust seal with the special tool. % 09913-70210: bearing installer set (52 mm) • apply suzuki super grease “a” to the dust...

  • Page 362

    Chassis 9-13 wheel • install the collar 1 in the left side. • install the front wheel with the front axle and tighten the front axle with hand temporarily. ) front axle • tighten the front axle to the specified torque. % 09900-18740: hexagon socket (24 mm) # front axle bolt: 100 n·m (10.0 kgf-m, 72....

  • Page 363: Front Fork

    9-14 chassis front fork construction # 1 o-ring 6 oil seal stopper ring a front fork cap bolt 2 spacer 7 dust seal b inner rod lock nut 3 outer tube 8 spring c damper rod bolt 4 oil seal retainer 9 inner rod/damper rod (cartridge) d front axle pinch bolt 5 oil seal 0 inner tube item n·m kgf-m lb-ft ...

  • Page 364

    Chassis 9-15 removal and disassembly • remove the front wheel. ( !9-9) • remove the bolts, left and right and front fender. • remove the fasteners 1 and bolts 2. • remove the head light assembly and disconnect the cou- plers. • loosen the front fork upper clamp bolt 3. Note: slightly loosen the fron...

  • Page 365

    9-16 chassis • remove the front fork cap bolt 5 from the inner rod by loos- ening the lock nut. • remove the special tools. $ • remove the spacer 6 and spring 7. • remove the front axle pinch bolts. • invert the front fork and stroke the inner rod several times to let out fork oil. • under the inver...

  • Page 366

    Chassis 9-17 • remove the inner rod/damper rod (cartridge) 8. $ • extract the outer tube from the inner tube. Note: be careful not to damage the “anti-friction” metals. • remove the dust seal 9 and oil seal stopper ring 0. • remove the oil seal with the special tool. % 09913-50121: oil seal remover ...

  • Page 367

    9-18 chassis inspection inner and outer tubes • inspect the inner tube outer surface and outer tube inner sur- face for scratches. • inspect the “anti-friction” metal surfaces for scratches. • if any defects are found, replace them with a new one. $ fork spring • measure the fork spring free length....

  • Page 368

    Chassis 9-19 reassembly reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: oil seal and dust seal • install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1 dust seal 2 oil seal stopper ring 3 oil seal 4 oi...

  • Page 369

    9-20 chassis • tighten the damper rod bolt to the specified torque with the special tool. % 09940-30221: front fork assembling tool # damper rod bolt: 40 n·m (4.0 kgf-m, 29.0 lb-ft) fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front fork oil up to ...

  • Page 370

    Chassis 9-21 front fork inner rod lock nut • loosen the lock nut 1 to the bottom of inner rod threads. Fork spring • install the fork spring as shown in the illustration. • install the spring 1 and spacer 2. Front fork cap bolt • pull up the inner rod with the special tool a. • compress the spring w...

  • Page 371

    9-22 chassis installation install the front fork in the reverse order of removal. Pay atten- tion to the following points: • install the front fork to the steering stem and steering stem upper bracket. • install the top of outer tube 5 mm (0.2 in) higher than the upper surface of the steering stem u...

  • Page 372: Steering

    Chassis 9-23 steering construction # 1 handlebar clamp 6 dust seal b handlebar holder bracket bolt 2 handlebar clamp holder 7 steering stem upper bearing c steering stem head nut 3 handlebar holder bracket 8 steering stem lower bearing d front fork upper clamp bolt 4 steering stem upper bracket 9 st...

  • Page 373

    9-24 chassis removal • remove the front forks. ( !9-15) • remove the handlebar. ( !9-30) • remove the tachometer. ( !10-32) • remove the turn signal mounting bolts 1, brake hose guide bolts 2 and brake hose mounting bolt 3. • remove the steering stem head nut 4 and washer. • remove the steering stem...

  • Page 374

    Chassis 9-25 • remove the handlebar holder 9 from the steering stem upper bracket. • remove the following parts. 0 bolt a rubber cushion b rubber washer c washer inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distortion * distortion of the steering...

  • Page 375

    9-26 chassis • inspect handlebar bushings for damage. • if any damage is found, replace the handlebar bushing with a new one. Reassembly reassemble the steering stem in the reverse order of disassem- bly. Pay attention to the following points: outer race • press in the upper and lower bearing outer ...

  • Page 376

    Chassis 9-27 • tighten the steering stem nut to the specified torque with the special tool. % 09940-14911: steering stem nut wrench # steering stem nut: 45 n·m (4.5 kgf-m, 32.5 lb-ft) • turn the steering stem lower bracket about five or six times to the left and right so that the bearing will be sea...

  • Page 377

    9-28 chassis tighten the following points: • tighten the handlebar bracket bolts to the specified torque. # handlebar holder bracket bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • install the tachometer. ( !10-32) • install the handlebar. ( !9-31) # handlebar clamp bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) • tig...

  • Page 378: Handlebars

    Chassis 9-29 handlebars construction 1 handlebars 3 left handlebar grip 5 right handlebar grip 2 grip end cap 4 left handlebar switch 6 right handlebar switch.

  • Page 379

    9-30 chassis removal • remove the right rear view mirror 1. • remove the brake master cylinder 2. • remove the throttle grip end cap 3. • disconnect the front brake switch lead wire coupler 4 and remove the right handlebar switch 5. • disconnect the throttle cable by removing the throttle grip 6. • ...

  • Page 380

    Chassis 9-31 installation install the handlebar in the reverse order of removal. Pay atten- tion to the following points: • when setting the handlebar clamp to the handlebar holder, face the punched mark a to the forward. • align the punched mark b on handlebars with the handlebar clamp mating surfa...

  • Page 381

    9-32 chassis • install the front brake master cylinder. ( !9-61) • apply the suzuki super grease “a” to the throttle cables and their holder. ' 99000-25010: suzuki super grease “a” or equivalent • when remounting the right and left handlebar switches, engage the stopper with the handlebar hole. Afte...

  • Page 382: Rear Wheel

    Chassis 9-33 rear wheel construction # 1 rear axle 7 damper c collar 2 spacer 8 o-ring d brake disc 3 bearing 9 spacer e cotter pin (for e-03, 28, 33) 4 lock washer 0 bearing a rear brake disc bolt 5 driven joint stopper a rear wheel b rear axle nut 6 driven joint b dust seal item n·m kgf-m lb-ft a ...

  • Page 383

    9-34 chassis removal • remove the brake caliper bracket mounting bolt 1. • remove the cotter pin 2. (for e-03, 28, 33) • hold the rear axle with the special tool and remove the axle nut 3. % 09944-28320: hexagon socket • raise the rear wheel off the ground and support the motorcy- cle with a jack or...

  • Page 384

    Chassis 9-35 • remove the o-ring 2. Inspection and disassembly wheel damper • inspect the damper for wear or damage. • replace the damper if there is anything unusual. • remove the dampers with a screw driver. Wheel ( ! 9-73) wheel axle ( ! 9-9) tire ( ! 2-27 and 9-73) brake disc ( ! 9-69) • remove ...

  • Page 385

    9-36 chassis • remove the wheel bearings on both sides with the special tool. % 09921-20240: bearing remover set (25 mm) $ reassembly and installation reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: the removed bearings sh...

  • Page 386

    Chassis 9-37 wheel bearing • apply suzuki super grease “a” to the wheel bearings. ' 99000-25010: suzuki super grease “a” or equivalent • install the wheel bearings with the special tools as follows. % 09941-34513: bearing/steering race installer set 09924-84510: bearing installer set $ • install the...

  • Page 387

    9-38 chassis brake disc • make sure that the brake disc is clean and free of any greasy matter. • apply thread lock super to the disc mounting bolts and tighten them to the specified torque. # brake disc bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) ( 99000-32130: thread lock super “1360” or equivalent wheel...

  • Page 388

    Chassis 9-39 rear wheel • install the spacer 1. • apply suzuki super grease “a” to the final gear spline before installing the rear wheel. ' 99000-25010: suzuki super grease “a” or equivalent • remount the rear wheel, rear axle and coller. • install the washer and rear axle nut. • install the brake ...

  • Page 389: Rear Suspension

    9-40 chassis rear suspension construction # 1 rear shock absorber 6 dust seal b rear cushion rod mounting nut 2 rear cushion rod 7 swingarm pivot bearing c rear cushion lever mounting nut 3 spacer 8 swingarm d swingarm pivot shaft 4 rear cushion lever bearing 9 boot 5 rear cushion lever a rear shock...

  • Page 390

    Chassis 9-41 removal • remove the exhaust pipe and muffler. ( !7-8) • remove the rear wheel. ( !9-34) • remove the final gear case. ( !4-15) • remove the under plate 1. • remove the regulator/rectifier 2. • remove the rear shock absorber front mounting bolt and nut. • remove the rear shock absorber ...

  • Page 391

    9-42 chassis • loosen the swingarm pivot pinch bolt 5. • loosen the swingarm pivot shaft with the special tool. % 09944-28320: hexagon socket • draw out the swingarm pivot shaft. • remove the rear suspension assembly. • remove the cushion rods 6 and cushion lever 7. • remove the rear fender 8. Inspe...

  • Page 392

    Chassis 9-43 • remove the swingarm pivot bearings 1 with the special tools. % 09923-74511: bearing remover set 09930-30104: sliding shaft $ cushion lever bearing • insert the spacer into bearings and check the play when mov- ing the spacer up and down. • if excessive play is noted, replace the beari...

  • Page 393

    9-44 chassis cushion rod bearing • insert the spacer into bearings and check the play when mov- ing the spacer up and down. • if excessive play is noted, replace the bearings with a new one. • remove the cushion lever bearings 1 with the special tool. % 09913-70210: bearing installer set (25 mm) $ c...

  • Page 394

    Chassis 9-45 swingarm pivot shaft • using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. & swingarm pivot shaft runout: service limit: 0.3 mm (0.01 in) % 09900-20607: dial gauge (1/100 mm, 10 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm...

  • Page 395

    9-46 chassis reassembly reassemble the rear suspension in the reverse order of disassembly and removal. Pay attention to the following points: note: tightening order are e to f . Lh rh 1 1.0 mm (0.04 in) c rear cushion lever lower nut # 2 4.5 mm (0.17 in) d rear cushion rod nut item n·m kgf-m lb-ft ...

  • Page 396

    Chassis 9-47 cushion rod bearing • install the bearings into the cushion rod with the special tool. % 09913-70210: bearing installer set (35 mm) • press the bearing at 1.0 mm (0.04 in) depth from the cushion rod edge. ( !9-46) cushion lever bearing • press the cushion lever upper bearings into the c...

  • Page 397

    9-48 chassis • apply suzuki super grease “a” to the spacers. ' 99000-25010: suzuki super grease “a” or equivalent.

  • Page 398

    Chassis 9-49 installation remount the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the following points. Cushion rod and cushion lever • install the cushion rods 1 and cushion lever 2 onto the swin- garm temporarily. Swingarm • before installing t...

  • Page 399

    9-50 chassis • tighten the swingarm pivot pinch bolt. Cushion rod, cushion lever and rear shock absorber • assemble the cushion rod, cushion lever and rear shock absorber onto the swingarm. ( !9-46) • tighten the rear shock absorber front mounting nut to the specified torque. # rear shock absorber m...

  • Page 400: Front Brake

    Chassis 9-51 front brake construction 1 dust boot 9 brake pad # 2 piston set 0 brake pad spring item n·m kgf-m lb-ft 3 cap a master cylinder mounting bolt a 10 1.0 7.0 4 diaphrapm b brake caliper mounting bolt b 39 3.9 28.0 5 master cylinder c brake caliper air bleeder valve c 7.5 0.75 5.5 6 piston ...

  • Page 401

    9-52 chassis ) $ brake pad replacement • loosen the pad mounting pins 1. • remove the brake caliper by removing the caliper mounting bolts 2. • remove the pad mounting pins 1, brake pads. $ note: * when the brake caliper is removed, care must be used so as not to cause stress to the brake hose. (han...

  • Page 402

    Chassis 9-53 note: * install the brake pad shims 3 onto the new brake pad, as shown. * the arrow mark on the brake shim must face to the direction of brake disc rotation. • install the new brake pads. • install the brake caliper. • tighten the pad mounting pin 1 and front brake caliper mounting bolt...

  • Page 403

    9-54 chassis • connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system. • close the caliper air bleeder valve and disconnect a clear hose. F...

  • Page 404

    Chassis 9-55 caliper disassembly • remove the pad spring 1. • remove the caliper air bleeder valve 2. • separate the caliper halves by removing the caliper housing bolts 3 with the special tools. % 09930-11920: torx bit jt40h 09930-11940: bit holder • remove the o-ring 4. $ • place a rag over the pi...

  • Page 405

    9-56 chassis caliper inspection brake caliper • inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace it with a new one. Brake caliper piston • inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, ...

  • Page 406

    Chassis 9-57 piston seal • install the piston seals as shown in the illustration. O-ring • install the new o-ring 1 and reassemble caliper halves. $ • temporarily tighten the air bleeder valve 2. • tighten each bolt to the specified torque. # front brake caliper housing bolt 3 : 22 n·m (2.2 kgf-m, 1...

  • Page 407

    9-58 chassis caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • install the brake pads and brake caliper. ( !9-53) • to the specified torque. # brake hose union bolt: 23 n·m (2.3 kgf-m, 16.5 lb-ft) $ brake disc inspection • visually che...

  • Page 408

    Chassis 9-59 master cylinder removal and disassembly • drain the brake fluid. ( !9-53) • disconnect the front brake light switch lead wire coupler 1. • place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose...

  • Page 409

    9-60 chassis • remove the following parts. 0 piston a secondary cup b primary cup c return spring master cylinder inspection master cylinder • inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one. Piston and rubber parts •...

  • Page 410

    Chassis 9-61 • apply suzuki super grease “a” to the bolt and brake lever end. ' 99000-25010: suzuki super grease “a” or equivalent • tighten the pivot bolt and nut. • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. Master cylinder inst...

  • Page 411: Rear Brake

    9-62 chassis rear brake construction 1 piston/cup set 7 dust seal # 2 reservoir hose 8 brake pad spring item n·m kgf-m lb-ft 3 brake hose a caliper air bleeder valve a 7.5 0.75 5.5 4 brake pad b brake hose union bolt b 23 2.3 16.5 5 piston c brake master cylinder rod lock nut c 18 1.8 13.0 6 piston ...

  • Page 412

    Chassis 9-63 ) $ brake pad replacement • remove the brake caliper by removing the brake caliper mounting bolts. • remove the cotter pin 1. • remove the pad mounting pin 2. • remove the brake pads 3. $ note: * when the brake caliper is removed, care must be used so as not to cause stress to the brake...

  • Page 413

    9-64 chassis • inspect the pad mounting pin for bent or damage. If any defects are found, replace the pad mounting pins with the new ones. • install the new brake pads. • install the brake caliper. • tighten the rear brake caliper mounting bolt to the specified torque. # rear brake caliper mounting ...

  • Page 414

    Chassis 9-65 • connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • loosen the air bleeder valve and pump the brake pedal until old brake fluid flows out of the bleeder system. • close the caliper air bleeder valve and disconnect a clear hose. F...

  • Page 415

    9-66 chassis • remove the caliper air bleeder valves 3. • remove the rubber boots 4. • place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. $ • remove the dust seals 5 and piston seals 6. $ caliper inspection brake calipe...

  • Page 416

    Chassis 9-67 brake caliper holder • inspect the brake caliper holder for wear and other damage. If any defects are found, replace the holder with a new one. Rubber boot • inspect the rubber boot for damage and wear. If any defects are found, replace the boots with new ones. Brake pad spring • inspec...

  • Page 417

    9-68 chassis caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to the following points: • clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves. - specification and classification: dot 4 $ p...

  • Page 418

    Chassis 9-69 rubber boot • set the rubber boot onto the brake caliper. Caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • install the brake pads and brake caliper. ( !9-64) • tighten brake hose union bolt to the specified torque. (rear ...

  • Page 419

    9-70 chassis • temporarily tighten the master cylinder mounting bolts 2. • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 3 and disconnect the brake hose. • loosen the lock nut 4. • disconnect the reservoir hose 5. • remove t...

  • Page 420

    Chassis 9-71 • remove the push rod 8, piston/primary cup 9 and spring 0. Master cylinder inspection cylinder, piston • inspect the cylinder bore wall for any scratches or other dam- age. Cup set • inspect the cup set. Master cylinder reassembly reassemble the master cylinder in the reverse order of ...

  • Page 421

    9-72 chassis • apply suzuki silicone grease to the push rod end. . 99000-25100: suzuki silicone grease or equivalent • install the o-ring 1 and connector 2 to the master cylinder. Master cylinder installation install the master cylinder in the reverse order of removal. Pay attention to the following...

  • Page 422: Tire And Wheel

    Chassis 9-73 tire and wheel tire removal the most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For o...

  • Page 423

    9-74 chassis valve inspection • inspect the valve after the tire is removed from the rim. • replace the valve with a new one if the seal a rubber is peel- ing or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the se...

  • Page 424

    Chassis 9-75 tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. $ • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the t...

  • Page 425

    9-76 chassis • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 426: Electrical System

    Electrical system 10-1 electrical system contents 10 cautions in servicing ....................................................................... 10- 3 connector ...................................................................................... 10- 3 coupler........................................

  • Page 427: Electrical System

    Electrical system contents 10-2 electrical system lamps ...................................................................................................... 10-39 headlight, brake light/taillight, license plate light and turn signal light .................................................... 10-39 ...

  • Page 428: Cautions In Servicing

    Electrical system 10-3 cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock when dis- connecting, a...

  • Page 429

    10-4 electrical system semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as a ecm. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • the mf battery used in this mo...

  • Page 430

    Electrical system 10-5 using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make s...

  • Page 431

    10-6 electrical system location of electrical components 1 iap sensor (#2) ( !5-34) 2 iap sensor (#1) ( !5-34) 3 fuel injector (#1) ( !5-68) 4 fuel injector (#2) ( !5-68) 5 ignition coil (#1) 6 iat sensor ( !5-50) 7 ignition coil/plug cap (#2) 8 stp sensor ( !5-61) 9 stv actuator ( !5-58) 0 tp senso...

  • Page 432

    Electrical system 10-7 1 fuel level gauge 2 fuel pump ( !6-8) 3 battery 4 ecm (engine control module) 5 fuse box 6 ignition coil (#2) 7 mode selection switch coupler ( !5-24) 8 ignition switch 9 starter relay/main fuse 0 pair control solenoid valve ( !12-6) a regulator/rectifier b oil pressure switc...

  • Page 433: Charging System

    10-8 electrical system charging system troubleshooting battery runs down quickly step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leaks. ( !10-9) is the battery for current leaks ok? Step 3 1) measure the...

  • Page 434

    Electrical system 10-9 step 5 1) measure the generator no-load performance. ( !10-11) is the generator no-load performance ok? Step 6 1) inspect the regulator/rectifier. ( !10-11) is the regulator/rectifier ok? Step 7 1) inspect wirings. Is the wirings ok? Battery overcharges • faulty regulator/rect...

  • Page 435

    10-10 electrical system regulated voltage • remove the front seat. ( !9-4) • start the engine and keep it running at 5 000 r/min with the dimmer switch turned hi position. • measure the dc voltage between the + and - battery termi- nals using the multi-circuit tester. If the voltage is not within th...

  • Page 436

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

  • Page 437

    10-12 electrical system starter system and side-stand/ignition interlock system troubleshooting make sure that the fuses are not blown and the battery is fully-charged before diagnosing. Starter motor will not run step 1 1) shift the transmission to neutral. 2) pull the clutch lever, turn on the ign...

  • Page 438

    Electrical system 10-13 step 3 1) measure the starter relay voltage at the starter relay connectors (between y/g + and b/y -) when the starter button is pushed. Is a voltage ok? Step 4 1) check the starter relay. ( !10-18) is the starter relay ok? Starter motor runs but does not crank the engine ste...

  • Page 439

    10-14 electrical system starter motor removal • remove the right frame side cover. ( !9-5) • remove the exhaust pipe and muffler. ( !7-8) • remove the master cylinder cover 1. • disconnect the battery - lead wire. • disconnect the starter motor lead wire 2. • remove the starter motor 3..

  • Page 440

    Electrical system 10-15 starter motor disassembly • disassemble the starter motor as shown in the illustration. 1 o-ring 5 brush holder , 2 housing end (inside) 6 housing end (outside) item n·m kgf-m lb-ft 3 armature a starter motor lead wire nut a 6 0.6 4.5 4 starter motor case b starter motor moun...

  • Page 441

    10-16 electrical system starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Make sure that the length a is not less than 6.0 mm (0.24 in). If this length becomes l...

  • Page 442

    Electrical system 10-17 housing end inspection • inspect the bearing for abnormal noise and smooth rotation. • check the oil seal lip for damage or leakage. If any damage is found, replace the housing end. Starter motor reassembly reassemble the starter motor in the reverse order of disassem- bly. P...

  • Page 443

    10-18 electrical system • tighten the starter motor mounting lead wire bolts 5 and nut 6 to the specified torque. , starter motor mounting bolt: 6 n·m (0.6 kgf-m, 4.5 lb-ft) starter motor lead wire nut: 6 n·m (0.6 kgf-m, 4.5 lb-ft) starter relay inspection • remove the front seat. ( !9-4) • remove t...

  • Page 444

    Electrical system 10-19 side stand/ignition interlock system parts inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-...

  • Page 445

    10-20 electrical system gear position switch • remove the right frame side cover. ( !9-5) • disconnect the gear position switch coupler and check the continuity between blue and black/white with the transmis- sion in “neutral”. " 09900-25008: multi-circuit tester set - tester knob indication: contin...

  • Page 446

    Electrical system 10-21 turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • remove the left frame side cover. ( !9-5) • remove the turn signal/side-stand relay. Side-stand relay inspection first check the insulation betwee...

  • Page 447: Ignition System

    10-22 electrical system ignition system note: the fuel cut-off circuit is incorporated in this ecm in order to prevent over-running of engine. When engine speed reaches 7 200 r/min, this circuit cuts off fuel at the fuel injector. But under no load, the clutch lever is pulled or the gear position is...

  • Page 448

    Electrical system 10-23 troubleshooting no spark or poor spark note: check that the transmission is in neutral and the engine stop switch is in the “run” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) check the ignitio...

  • Page 449

    10-24 electrical system step 5 1) inspect the ignition coil/plug caps and ignition coils. ( !10-27 and -28) is the ignition coil/plug cap and ignition coils ok? Step 6 1) measure the crankshaft position sensor peak voltage and its resistance. ( !10-28 to -29) note: the crankshaft position sensor pea...

  • Page 450

    Electrical system 10-25 inspection ignition coil primary peak voltage • remove the left frame side covers. ( !9-5) • remove the fuel tank. ( !6-3) • remove the frame head covers and right radiator covers. ( !9-6) • remove the front cylinder right head cover cap and rear cylin- der left head cover ca...

  • Page 451

    10-26 electrical system ignition coil/plug cap primary peak voltage inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil/plug cap: w/bl wire terminal ( + probe) – ground ( - pr...

  • Page 452

    Electrical system 10-27 ignition coil primary peak voltage inspect each ignition coil primary peak voltage in the following procedure. • connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil: + probe: yellow lead wire terminal - probe: ground #2 ignition coil: + pro...

  • Page 453

    10-28 electrical system ignition coil resistance • disconnect the spark plug caps. ( !10-25) • measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the stan- dard range, replace the ignition coil with a new one. " 09900-25008: multi-circuit...

  • Page 454

    Electrical system 10-29 ckp sensor resistance • measure the resistance between the lead wires and ground. If the resistance is not within the standard range, replace the ckp sensor with a new one. " 09900-25008: multi-circuit tester set ( tester knob indication: resistance ( Ω ) $ ckp sensor resista...

  • Page 455: Speedometer And Tachometer

    10-30 electrical system speedometer and tachometer description this speedometer and tachometer mainly consists of the stepping motor (except for tachometer), lcd (liq- uid crystal display) and led (light emitting diode). The speedometer pointer is driven by the stepping motor. The lcds indicate tach...

  • Page 456

    Electrical system 10-31 speedometer removal and disassembly • disconnect the speedometer lead wire coupler. ( !6-3) • remove the screw. • remove the speedometer 1. Note: “ 2” indicates hook location. # • disassemble the speedometer as follows. # when disconnecting and reconnecting the speedome- ter ...

  • Page 457

    10-32 electrical system tachometer removal and disassembly • remove the handleber. ( !9-30) • remove the head light. ( !9-15) • remove the screws 1. • disconnect the tachometer lead wire coupler and remove the tachometer 2. • disassemble the tachometer as follows. # do not attempt to disassemble the...

  • Page 458

    Electrical system 10-33 inspection led (light emitting diode) check that the led lights (fi indicator light, fuel level indicator light) immediately after turning the ignition switch on. Also, other led lights (neutral indicator light, high-beam indicator light and turn signal indicator light) can b...

  • Page 459

    10-34 electrical system engine coolant temperature meter and indicator ect sensor inspection ( ! 8-9) • remove the right frame side cover. ( !9-5) • remove the right air cleaner box. ( !6-13) • disconnect the ect sensor coupler 1. # • connect the variable resistor a between the terminals. • disconne...

  • Page 460

    Electrical system 10-35 fuel level indicator switch inspection • remove and disassemble the fuel pump assembly. ( !6-8) • connect 12 v battery and test bulb (12 v, 3.4 w) to the fuel level indicator switch as shown in the right illustration. The bulb should come on after one minutes if the switch is...

  • Page 461

    10-36 electrical system fuel level meter inspection • lift and support the fuel tank. ( !6-3) • disconnect the fuel pump lead wire coupler 1. • connect variable resistor between the light green and black lead wires at the wire harness. • turn the ignition switch “on” position and wait for approx. 40...

  • Page 462

    Electrical system 10-37 speedometer if the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speed sensor and connection are functioning properly, replace the meter with a new one. Speedometer sensor • remove the left fr...

  • Page 463

    10-38 electrical system oil pressure indicator note: before inspecting the oil pressure switch, check if the engine oil level is correct. ( !2-17) • disconnect the oil pressure switch lead wire from the oil pres- sure switch. • turn the ignition switch on. • check if the oil pressure indicator a and...

  • Page 464: Lamps

    Electrical system 10-39 lamps headlight, brake light/taillight, license plate light and turn signal light headlight 12 v 60/55 w 1 position light ............. (e-02, 19, 24) 12 v 5 w brake light/taillight led licence plate light 12 v 5 w 2 turn signal/position light (e-03, 28, 33) 12 v 21 w/5 w × 2...

  • Page 465

    10-40 electrical system headlight relay inspection headlight relay is located in front of the battery. • remove the right frame side cover. ( !9-5) • remove the headlight relay 1. First check the insulation between a and b terminals with tester. Then apply 12 volts to c and d terminals, + to c and -...

  • Page 466: Relays

    Electrical system 10-41 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not ...

  • Page 467

    10-42 electrical system switches inspection color position hazard switch inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Note: before inspecting the oil pressure switch, check if the engine oil level is correct. (...

  • Page 468: Battery

    Electrical system 10-43 battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a. Note: wh...

  • Page 469

    10-44 electrical system note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers...

  • Page 470

    Electrical system 10-45 servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powde...

  • Page 471: Servicing Information

    Servicing information 11-1 11 servicing information contents troubleshooting ............................................................................... 11- 3 fi system malfunction code and defective condition.................................................................... 11- 3 engine ........

  • Page 472: Servicing Information

    Servicing information contents 11-2 servicing information ignition coil installation ........................................................ 11-51 side-stand installation ............................................................ 11-51 rear turn signal light, license light wire routing .... 11-52...

  • Page 473: Troubleshooting

    Servicing information 11-3 troubleshooting fi system malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp senso...

  • Page 474

    11-4 servicing information dtc no. Detected item detected failure condition check for c23 to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v sensor voltage in other than the above value, c23 (p1651) is indicated. To sensor, lead wi...

  • Page 475

    Servicing information 11-5 dtc no. Detected item detected failure condition check for c40 p0505 h isc valve isc valve motor current is higher than specified value. Isc valve circuit shorted to batt or ground circuit open l isc valve motor circuit is open. Isc valve circuit open or batt circuit open ...

  • Page 476

    11-6 servicing information dtc no. Detected item detected failure condition check for c46 exhaust con- trol valve actuator excva position sensor produces fol- lowing voltage. 0.1 v sensor voltage in other than the above range, c46 (p1675) is indicated. When no actuator control signal is supplied fro...

  • Page 477

    Servicing information 11-7 engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Tappet clearance out of adjustment 2. Worn valve guides or poor seating of valves 3. Mistiming valves 4. Excessively worn piston rings 5. Worn-down cylinde...

  • Page 478

    11-8 servicing information complaint symptom and possible causes remedy engine idles poorly. 1. Tappet clearance out of adjustment 2. Poor seating of valves 3. Defective valve guides 4. Worn down camshafts 5. Too wide spark plug gaps 6. Defective ignition coils 7. Defective ignition coil/plug caps 8...

  • Page 479

    Servicing information 11-9 complaint symptom and possible causes remedy noisy engine excessive valve chatter 1. Too large tappet clearance 2. Weakened or broken valve springs 3. Worn tappet or cam surface 4. Worn and burnt camshaft journal noise seems to come from piston 1. Worn down pistons or cyli...

  • Page 480

    11-10 servicing information complaint symptom and possible causes remedy engine runs poorly in high speed range. Defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshafts 3. Valve timing out of adjustment 4. Too narrow spark plug gaps 5. Ignition not advanced sufficientl...

  • Page 481

    Servicing information 11-11 complaint symptom and possible causes remedy engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinders 5. Poor seating of valves 6. Fouled spark ...

  • Page 482

    11-12 servicing information complaint symptom and possible causes remedy engine overheats defective engine internal parts 1. Heavy carbon deposit on piston crowns 2. Not enough oil in the engine 3. Defective oil pump or clogged oil circuit 4. Sucking air from intake pipes 5. Use incorrect engine oil...

  • Page 483

    Servicing information 11-13 radiator (cooling system) complaint symptom and possible causes remedy engine overheats 1. Not enough engine coolant 2. Radiator core clogged with dirt or scale 3. Faulty cooling fan 4. Defective cooling fan relay, or open- or short- circuited 5. Defective ecm 6. Defectiv...

  • Page 484

    11-14 servicing information chassis complaint symptom and possible causes remedy heavy steering 1. Overtightened steering stem nut 2. Broken bearing in steering stem 3. Distorted steering stem 4. Not enough pressure in tires adjust. Replace. Replace. Adjust. Wobbly handlebars 1. Loss of balance betw...

  • Page 485

    Servicing information 11-15 shaft drive brakes complaint symptom and possible causes remedy noisy shaft drive noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. Oil level too low 2. Drive and driven bevel gears damaged or worn 3. Excessive backlash 4. Improper tooth co...

  • Page 486

    11-16 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coils 2. Defective ignition coil/plug caps 3. Defective spark plugs 4. Defective ckp sensor 5. Defective ecm 6. Defective to sensor 7. Open-circuited wiring connecti...

  • Page 487

    Servicing information 11-17 battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates 1. Cracked battery case 2. Battery has been left in a run-down condition for a long time. Replace the battery. Replace the battery. Batter...

  • Page 488

    11-18 servicing information special tools 09900-06108 snap ring pliers 09900-18740 hexagon socket (24 mm) 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20210 micrometer (100 – 125 mm) 09900-20602 dial gauge (1/1 000 mm, 1 mm) 09...

  • Page 489

    Servicing information 11-19 09913-60910 bearing puller 09913-70210 bearing installer set 09913-75821 bearing installer 09913-76010 bearing installer 09913-84510 bearing installer 09915-17410 oil pressure gauge attachment 09915-40610 oil filter wrench 09915-64512 compression gauge set 09915-74511 099...

  • Page 490

    11-20 servicing information 09918-53810 chain tensioner lock tool 09919-28610 sleeve protector 09920-53740 clutch sleeve hub holder 09921-20210 bearing remover 09921-20240 bearing remover set 09923-74511 bearing remover 09924-34510 backlash measur- ing tool ( ! 27 – 50) 09924-41830 bearing retainer ...

  • Page 491

    Servicing information 11-21 note: when order the special tool, please confirm whether it is available or not. 09930-73170 starter torque limiter holder 09930-73180 starter torque limiter socket 09930-82720 mode selection switch 09940-14911 steering stem nut wrench 09940-30221 front fork assem- bling...

  • Page 492: Tightening Torque

    11-22 servicing information tightening torque engine item n·m kgf-m lb-ft cylinder head cover bolt 11 1.1 8.0 cylinder head cover cap bracket bolt 11 1.1 8.0 cylinder head bolt m: 6 11 1.1 8.0 m: 8 26 2.6 19.0 m: 10 initial 25 2.5 18.0 final 42 4.2 30.5 cylinder nut 13 1.3 9.5 cylinder head plug (wa...

  • Page 493

    Servicing information 11-23 driveline/axle fi system and intake air system cooling system item n·m kgf-m lb-ft gearshift cam stopper plate bolt 13 1.3 9.5 gearshift arm stopper bolt 19 1.9 13.5 gearshift cam stopper bolt 10 1.0 7.0 gearshift lever shaft 50 5.0 36.0 gearshift fork shaft retainer plug...

  • Page 494

    11-24 servicing information chassis item n·m kgf-m lb-ft handlebar clamp bolt 23 2.3 16.5 handlebar holder bolt 85 8.5 61.5 handlebar bracket bolt 23 2.3 16.5 front fork upper and lower clamp bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork damper rod bolt 40 4.0 29.0 front fork inner rod...

  • Page 495

    Servicing information 11-25 tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m lb-ft n·m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0...

  • Page 496: Service Data

    11-26 servicing information service data valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 42 (1.65) — ex. 38 (1.50) — tappet clearance (when cold) in. 0.09 – 0.16 (0.004 – 0.006) — ex. 0.20 – 0.30 (0.008 – 0.012) — valve guide to valve stem clear...

  • Page 497

    Servicing information 11-27 cylinder + piston + piston ring unit: mm (in) item standard limit camshaft runout in. & ex. — 0.10 (0.004) cam chain pin (at arrow “3”) 18th pin — cylinder head distortion — 0.05 (0.002) item standard limit compression pressure (automatic de-comp. Actuated) 1 100 – 1 500 ...

  • Page 498

    11-28 servicing information conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 23.010 – 23.018 (0.9059 – 0.9062) 23.040 (0.9071) conrod big end side clearance 0.100 – 0.200 (0.0039 – 0.0078) 0.30 (0.012) conrod big end width 23.95 – 24.00 (0.943...

  • Page 499

    Servicing information 11-29 thermostat + radiator + fan + coolant drive train unit: mm (in) expect ratio item standard limit thermostat valve opening temperature approx. 88 °c (190 °f) — thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) — engine coolant temperature sensor resistance 20 ...

  • Page 500

    11-30 servicing information driveline/axle unit: mm (in) injector + fuel pump + fuel pressure regulator fi-sensors item standard/specification limit secondary bevel gear backlush 0.03 – 0.15 (0.001 – 0.006) — final bevel gear backlush 0.08 – 0.16 (0.003 – 0.006) — damper spring free length — 64.6 (2...

  • Page 501

    Servicing information 11-31 throttle body electrical unit: mm (in) item specification note stp sensor output voltage closed approx. 0.6 v opened approx. 4.2 v stv actuator resistance approx. 7 Ω excva position sensor input voltage 4.5 – 5.5 v excva position sensor resistance approx. 3.1 k Ω at adjus...

  • Page 502

    11-32 servicing information wattage unit: w item specification note generator no-load voltage (when engine is cold) 70 v (ac) and more at 5 000 r/min regulated voltage 14.0 – 15.5 v at 5 000 r/min starter relay resistance 3 – 6 Ω battery type designation ftz16-bs capacity 12 v 64.8 kc (18 ah)/10 hr ...

  • Page 503

    Servicing information 11-33 brake + wheel unit: mm (in) item standard limit rear brake pedal height 25 – 35 (1.0 – 1.4) — brake disc thickness front 5.0 ± 0.2 (0.197 ± 0.008) 4.5 (0.18) rear 7 (0.276 ) 6.3 (0.25) brake disc runout (front & rear) — 0.30 (0.012) master cylinder bore front 15.870 – 15....

  • Page 504

    11-34 servicing information suspension unit: mm (in) tire pressure fuel + oil item standard limit front fork stroke 130 (5.1) — front fork spring free length 399 (15.7) 391 (15.4) front fork inner tube o.D. 46 (1.8) — front fork oil level (without spring, inner tube fully compressed) 133 (5.2) — fro...

  • Page 505

    Servicing information 11-35 wiring harness, cable and hose routing wiring harness routing clamp clamp wiring harness clamp isc valve wiring harness face the lead wire to the lower. Set the speedometer harness to the right side. Keep the clearance between wiring harness and fuel tank and frame. Clamp...

  • Page 506

    11-36 servicing information handlebar switch lead wire (l) clamp to the tachometer handlebar switch lead wire (r) clamp pass the handlebar switch lead wire upper the brake switch coupler. Clamp ignition coil high tension cord wiring harness pass the wiring harness upper the breather hose. Pass the l...

  • Page 507

    Servicing information 11-37 engine electrical parts lead wire routing clamp battery ground wire grommet gear position switch starter motor starter motor lead wire generator lead wire speedometer sensor ckp sensor clamp oil pressure switch oil pressure switch lead wire clamp.

  • Page 508

    11-38 servicing information cable routing throttle cable no.2 (returning cable) front brake hose throttle cable no.1 (pulling cable) throttle cable no.2 ( returning cable ) cable guide clutch cable clutch cable throttle cable no.1 (pulling cable) throttle cable no.2 ( returning cable) 0 mm 0 mm pass...

  • Page 509

    Servicing information 11-39 front brake hose routing 21˚ *1 *2 *3 *3 14˚ 14˚ 1 stopper 8 bolt 2 brake master cylinder 9 brake caliper (r) 3 throttle cable 0 brake caliper (l) 4 cable guide *1 tighten the brake hose union bolt to the specified torque after touching the brake hose union to the stopper...

  • Page 510

    11-40 servicing information rear brake hose routing 1 stopper a face the white paint on reservoir hose to forward. 2 reservoir b tighten the hose guide bolt after positioning the stopper of hose guide to the swingarm. 3 brake cylinder c fix the grommet of brake hose to the hose guide. 4 brake hose d...

  • Page 511

    Servicing information 11-41 throttle body hose routing *1 *2 *1 *4 *5 *7 *4 *6 *2 *3 intake pipe clamp air cleaner outlet clamp rear cylinder front cylinder rear cylinder front cylinder 25˚ – 35˚ 15˚ – 25˚ 15˚ rh lh rh lh 1 isc valve hose (r) 0 bolt 2 isc valve hose (l) *1 yellow mark 3 throttle bod...

  • Page 512

    11-42 servicing information cooling system hose routing rediator cap rediator mark face the tip of clip to the inside. White mark red mark thermostat face the tip of clip to the inside. Clamp face the tip of clip to the backward. Yellow mark red mark face the tip of clip to the lower. Oil cooler red...

  • Page 513

    Servicing information 11-43 pair (air supply) system hose routing (for e-03, 28, 33) set the pair hose to the concave of air cleaner tube. View a blue mark yellow mark a white mark white mark 1 pair control solenoid valve 2 pair reed valve.

  • Page 514

    11-44 servicing information pair (air supply) system hose routing (for the others) set the pair hose to the concave of air cleaner tube. Yellow mark white mark white mark 1 pair control solenoid valve 2 pair reed valve.

  • Page 515

    Servicing information 11-45 fuel tank installation 1 heat shield 6 fuel tank cushion 2 fuel pump 7 rear fender cover cushion 3 clamp 8 apply instant adhesive to the shaded portion. 4 face the tip of clamp to the backward. 9 fuel tank rear bracket 5 face the arrow mark to the forward, when install- i...

  • Page 516

    11-46 servicing information frame head cover and radiator cover installation 1 frame head cover (r) 6 radiator lower cover (l) 2 radiator cover (r) 7 radiator bottom cover 3 radiator lower cover (r) 8 throttle cable no.1 (pulling cable) 4 frame head cover (l) 9 throttle cable no.2 (returning cable) ...

  • Page 517

    Servicing information 11-47 frame head cover cushion installation radiator upper cover cushion installation 1 cushion 3 frame head cover (l) 2 frame head cover (r) 3 mm (0.1 in) 18 mm (0.7 in) 16 mm (0.6 in) 2 mm (0.08 in) 1 radiator upper cover 3 cushion 2 frame.

  • Page 518

    11-48 servicing information left frame covers installation 1 rear fender 4 side cover 2 rear fender cover 5 lower side cover 3 rear side cover.

  • Page 519

    Servicing information 11-49 right frame covers installation 1 rear fender 4 side cover 2 rear fender cover 5 lower cover 3 rear side cover.

  • Page 520

    11-50 servicing information headlight cover installation 1 headlight lower cover 4 headlight cover brace 2 headlight cover 5 steering stem upper bracket 3 headlight back cover 6 steering stem lower bracket.

  • Page 521

    Servicing information 11-51 ignition coil installation side-stand installation forward 1 ignition coil #1 3 ignition coil bracket 2 ignition coil #2 4 spacer.

  • Page 522

    11-52 servicing information rear turn signal light, license light wire routing seat lock cable routing license light and right and left rear turn signal lead wirres installtion order. 1 connect the license light and left rear turn signal light to the wiring harrness. 4 fix the right and left rear tu...

  • Page 523

    Servicing information 11-53 license light and license plate installation brake light/taillight installation 1 license light 4 washer " 2 license plate 5 spacer item n·m kgf-m lb-ft 3 nut a license light nut a 5 0.5 3.5 1 rear frame cover 2 brake light/taillight.

  • Page 524

    Emission control information 12-1 12 emission control information contents emission control systems .............................................................. 12- 2 fuel injection system................................................................. 12- 2 crankcase emission control system .......

  • Page 525: Emission Control Systems

    12-2 emission control information emission control systems fuel injection system vzr1800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With a...

  • Page 526

    Emission control information 12-3 crankcase emission control system the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the ...

  • Page 527

    12-4 emission control information exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the pair control solenoid valve and pair reed...

  • Page 528

    Emission control information 12-5 noise emission control system tampering with the noise control system prohibited: local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of ...

  • Page 529: Inspection

    12-6 emission control information pair (air supply) system and emission control system inspection pair hoses • remove the frame head covers. ( ! 9-6) • inspect the pair hoses for wear or damage. • inspect the pair hoses for secure connection. Pair reed valve • remove the fuel tank. ( ! 6-3) • remove...

  • Page 530

    Emission control information 12-7 • check the resistance between the terminals of the pair con- trol solenoid valve. " resistance: 18 – 22 Ω at 20 – 30 °c (68 – 86 °f) # 09900-25008: multi-circuit tester set $ tester knob indication: resistance ( Ω ) installation if the resistance is not within the ...

  • Page 531

    12-8 emission control information pair (air supply) system hose routing (for e-03, 28, 33) set the pair hose to the concave of air cleaner tube. View a blue mark yellow mark a white mark white mark 1 pair control solenoid valve 2 pair reed valve.

  • Page 532

    Emission control information 12-9 pair (air supply) system hose routing (for the others) 1 pair control solenoid valve 2 pair reed valve set the pair hose to the concave of air cleaner tube. Yellow mark white mark white mark.

  • Page 533

    12-10 emission control information heated oxgen sensor (ho2s) inspection (for e-02, 19, 24) • disconnect the ho2 sensor lead wire coupler. ( ! 5-79) • inspect the ho2 sensor and its circuit referring to flow table of the malfunction code c44 or 64 (p0156/p0161 or p0130/p0135). • check the resistance...

  • Page 534: Wiring Diagram

    13 wiring diagram e-02, 19, 24 wiring diagrams wire color, refer to section “wire color”. Lg b/w lg b/w b b/w b b/w y b/w w br b/w br b/w bl bl/b lg br y o/g o/b o/w o/g w/b y/g b/r b b/br b/g b/w br r/bl o/g b/w b/br o/r w b/r b/g g/y r/b b/lg g/bl bl o/w w/bl o/w b o/w y o/w g lg b/w gr b/w w/b gr...

  • Page 535

    E-03, 28, 33 b b/w gr lg b/w o/g b b/w gr b b/w o/g y b/w w br b/w br b/w bl bl/b lg br y o/g o/b o/w o/g w/b y/g b/r b b/br b/g b/w br r/bl o/g b/w b/br o/r w b/r b/g g/y r/b b/lg g/bl bl o/w w/bl o/w b o/w y o/w g lg b/w gr b/w w/b gr b/w b/w b b/w b/w b/y y/g r r b b b b/r b/w r b/w b b b y/r b/w...

  • Page 536

    Prepared by january, 2006 part no. 99500-39290-01e printed in japan 540

  • Page 537

    Printed in japan k6.

  • Page 538

    Motorcycle division 4-stroke bulletin vs-vx-vz-vl no. 49 date: 11/8/2006 subject: service manual correction - part identification model: vzr1800k7 reference: vzr1800 service manual (p/n 99500-39290-03e, pages 6-7 & 10-35) notice: this bulletin contains service manual correction information for the v...

  • Page 539

    Fuel system and throttle body 6-7 fuel pump and fuel level gauge removal construction 1 regulator 5 o-ring ( 2 fuel pump 6 fuel level gauge item n·m kgf-m lb-ft 3 fuel mesh filter thermistor a 10 1.0 7.0 4 filter cover fuel pump mounting bolt.

  • Page 540

    Electrical system 10-35 fuel level indicator switch (thermistor) inspection • remove and disassemble the fuel pump assembly. ( !6-8) • connect 12 v battery and test bulb (12 v, 3.4 w) to the fuel level indicator switch as shown in the right illustration. The bulb should come on after one minutes if ...

  • Page 541

    Motorcycle division 4-stroke bulletin vs-vx-vz-vl no. 60 date: 1/4/2008 subject: service manual corrections - valve spring specifications and clutch washer model: vzr1800k6-k8 reference: vzr1800 service manual (p/n 99500-39292-03e) pages 3-38 and 11-26 vzr1800 service manual (p/n 99500-39292-03e, pr...

  • Page 542

    Engine 3-21 • remove the thrust washer a. • remove the primary driven gear assembly b. Rear cam chain tension adjuster • unlock the ratchet 1 and insert the special tool. % 09917-62430: chain tensioner lock tool • remove the rear cam chain tensioner no. 1 assy 2. • remove the cam chain guide no. 1 3...

  • Page 543

    Engine 3-95 • install the primary driven gear assembly 3 onto the counter- shaft. • install the thrust washer 4. • install the clutch sleeve hub assembly 5 onto the counter- shaft. • install the spring washer 6. Note: the conical curve side of spring washer 6 faces outside. • hold the generator roto...

  • Page 544

    - 1/1 - motorcycle division 4-stroke bulletin vs/vx/vz/vl no. 50 date: 3/8/2007 subject: additional service manual information - clutch cable play adjustment procedure modification model: vzr1800 reference: vzr1800 service manual (p/n 99500-39291-03e) subject: this bulletin is to inform you of a mod...

  • Page 545

    2-22 periodic maintenance radiator hoses • remove the fuel tank. ( ! 6-3) • remove the frame head covers, radiator covers and radiator bottom cover. ( ! 9-6) • check to see the radiator hoses for crack, damage or engine coolant leakage. • if any defects are found, replace the radiator hoses with new...

  • Page 546

    Periodic maintenance 2-23 * loosen the lock nut 3 and turn in the release screw 4 to feel resistance. * from that position, turn out the release screw 4 1 turn and tighten the lock nut 3 securely by holding the release screw 4 . " clutch release screw: 1 turn back * install the clutch cover and muff...

  • Page 547

    2-24 periodic maintenance brake fluid level check • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • when the level is below the lower limit line, replenish with brake fluid ...

  • Page 548

    Periodic maintenance 2-25 rear brake the extent of brake pad wear can be checked by observing the grooved limit line a on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ( ! 9-63) % brake pedal height • loosen the lock nut 1 . • turn the push rod 2 until th...

  • Page 549

    - 1/24 - motorcycle division 4-stroke bulletin vs/vx/vz/vl no. 56 date: 7/9/2007 subject: supplemental service manual information model: vzr1800k8 reference: vzr1800 service manual (p/n 99500-39291-03e) notice: this bulletin contains additional technical information for the vzr1800k8. Please place a...

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  • Page 580: Safety Recall Campaign

    - 1/7 - motorcycle/atv division 4-stroke bulletin no. Vs/vx/vz/vl no. 51 date: 4/3/2007 safety recall campaign vzr1800k6 & vzr1800/zk7 (m109r) fuel delivery pipe replacement campaign #2096 subject: recall campaign - fuel delivery pipe replacement affected units: all 2006 and certain 2007 model year ...

  • Page 581

    - 2/7 - verify the unit requires modification: before performing the recall repair to a unit, first verify that the repair needs to be performed using one of the following methods; 1) check the repair status by checking the vehicle history in the suzuki connect service menu. If the repair needs to b...

  • Page 582

    - 3/7 - warranty claim processing: submit a warranty claim for each recall campaign service immediately upon completion of the repair. This campaign requires you to file a warranty claim using the method described below. Short form claim: labor time is 1.0 hours claim type for unit with additional t...

  • Page 583

    - 4/7 - note: the fuel delivery pipe assembly can be removed from the throttle body without removing the throttle body assembly from the motorcycle. 1) refer to section 6 of the service manual to remove the fuel tank and the air cleaner box. Place shop rags over the bore of each throttle body to pre...

  • Page 584

    - 5/7 - affected departments: the following departments in your dealership should be notified of this information: ⌧ ⌧ ⌧ ⌧ ⌧ management ⌧ ⌧ ⌧ ⌧ ⌧ service ⌧ ⌧ ⌧ ⌧ ⌧ warranty ⌧ ⌧ ⌧ ⌧ ⌧ sales ⌧ ⌧ ⌧ ⌧ ⌧ parts ⌧ ⌧ ⌧ ⌧ ⌧ accessories american suzuki motor corporation technical service department motorcycle...

  • Page 585

    - 6/7 - dear suzuki owner, this notice is sent to you in accordance with the requirements of the national traffic and motor vehicle safety act. What is the reason for this notice? Suzuki motor corporation has decided that a defect that relates to motor vehicle safety exists in all 2006 and certain 2...

  • Page 586

    - 7/7 - customer notification letter - page two of two questions & answers your suzuki dealer has been provided specific and complete instructions regarding this recall service. Please call your dealer if you have any questions. Your local suzuki dealer can provide the fastest responses to your ques...