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Suzuki kq750 2008 Manual

Summary of kq750 2008

  • Page 1

    Foreword this manual contains an introductory description on the suzuki lt-a750x and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with the veh...

  • Page 3: Table of Contents

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

  • Page 5: Section 00

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

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions warning / caution / note b831g20000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the message...

  • Page 7

    Precautions: 00-2 • never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • use a torque wrench to ti...

  • Page 8

    00-3 precautions: • check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc. Clamp • clamp the wire harness at such positions as indicated in “wiring harness routing diagram in section 9a (page 9a-4)”. • bend ...

  • Page 9

    Precautions: 00-4 battery • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi systems instantly when reverse power is applied. • removing any battery terminal of a running engine is strictly prohibited. The moment such removal...

  • Page 10

    00-5 precautions: 3) using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each termin...

  • Page 11

    Precautions: 00-6 3) also, if measured values are as listed following, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “a” and “b”. Voltage between “a” and body ground: approx. 5 v “b” and body ground: approx. 5 v – 2 v voltage drop “c” and body groun...

  • Page 12

    00-7 precautions: using the multi-circuit testers • use the suzuki multi-circuit tester set. • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Special tool (a): 09900–25008 (multi-circuit tester set) using the testers • incorrectly connecting the (...

  • Page 13: Section 0

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

  • Page 14: General Information

    0a-1 general information: general information general information general description symbols b831g20101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b831g20...

  • Page 15

    General information: 0a-2 g: gen: generator gnd: ground gp switch: gear position switch h: hc: hydrocarbons i: iap sensor: intake air pressure sensor (iaps) iat sensor: intake air temperature sensor (iats) ig: ignition isc valve: idle speed control valve (iscv) j: jaso: japanese automobile standards...

  • Page 16

    0a-3 general information: vehicle side view b831g20101004 note difference between illustration and actual vehicle may exist depending on the markets. Suzuki lt-a750x (2008-model) right side left side vehicle identification number b831g20101005 the frame serial number or v.I.N. (vehicle identificatio...

  • Page 17

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

  • Page 18

    0a-5 general information: country and area codes b831g20101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b831g20101010 code country or area effective frame no. Lt-a750xk8 (p-17) sweden 5saar41a87100001 – lt-a750xk8 (p-24) australia lt-a750xk8 (p-28) ...

  • Page 19

    General information: 0a-6 warning, caution and information labels location b831g20101011 [a] 5 14 17, 18 11 9 6 3 7 8 10 12, 13 15, 16 4 2 1, 21 23, 24 20 19 i831g1010005-06 1. Certification plate for p-24, 33 13. Max amp caution label for p-17, 28 2. Information label for p-33 14. Fuel caution labe...

  • Page 20

    0a-7 general information: component location electrical components location b831g20103001 15 1 2 3 4 5 6 8 7 13 14 12 11 17 9 10 16 i831g1010006-02 1. Battery 7. 4wd/diff-lock relay 13. Ignition switch 2. Starter relay/main fuse 8. Mode selection switch coupler 14. Power source 3. Fuse box 9. Starte...

  • Page 21

    General information: 0a-8 18 19 20 21 22 25 23 24 26 30 28 27 31 29 33 34 32 i831g1010007-03 18. Cooling fan thermo-switch 24. Parking brake switch 30. High position diode 19. Resister 25. Brake lever switch 31. Low position diode 20. 4wd/diff-lock actuator diode 26. Regulator/rectifier 32. Speed se...

  • Page 22

    0a-9 general information: specifications specifications b831g20107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 115 mm (83.3 in) p-28, 33 2 135 mm (84.1 in) p-17, 24 overall width 1 210 mm (47...

  • Page 23

    General information: 0a-10 chassis electrical capacities item specification remark front suspension independent, double wishbone, coil spring, oil damped rear suspension independent, double wishbone, coil spring, oil damped front wheel travel 180 mm (7.1 in) rear wheel travel 200 mm (7.9 in) caster ...

  • Page 24

    0a-11 general information: special tools and equipment special tool b831g20108001 09900–06107 snap ring pliers 09900–06108 snap ring pliers 09900–20101 vernier calipers (1/15 mm, 150 mm) 09900–20102 vernier calipers (1/20 mm, 200 mm) 09900–20202 micrometer (1/100 mm, 25 – 50 mm) 09900–20205 micromet...

  • Page 25

    General information: 0a-12 09913–50121 oil seal remover 09913–60910 bearing remover 09913–61510 bearing puller 09913–70210 bearing installer set 09913–75520 bearing installer 09913–84510 bearing installer 09915–40610 oil filter wrench 09915–63311 compression gauge attachment 09915–64512 compression ...

  • Page 26

    0a-13 general information: 09919–28610 sleeve protector 09920–13120 crankcase separating tool 09920–31020 extension handle 09920–33540 clutch shoe remover 09920–53740 clutch sleeve hub holder 09921–20240 bearing remover set 09921–21910 bearing holder 09922–21410 long socket (46 mm) 09922–31430 clutc...

  • Page 27

    General information: 0a-14 09930–40131 balancer drive sprocket holder 09930–73140 starter torque limiter socket 09930–73170 starter torque limiter holder 09930–82720 mode select switch 09940–40211 fuel pressure gauge adapter 09940–40220 fuel pressure gauge hose attachment 09940–92430 rear axel wrenc...

  • Page 28: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b831g20200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak...

  • Page 29

    Maintenance and lubrication: 0b-2 lubrication points b831g20205002 proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off an...

  • Page 30

    0b-3 maintenance and lubrication: repair instructions air cleaner element inspection and cleaning b831g20206001 inspect and clean element every 1 000 km (600 miles, 3 months) inspection 1) remove the air cleaner element. Refer to “air cleaner element removal and installation in section 1d (page 1d-5...

  • Page 31

    Maintenance and lubrication: 0b-4 exhaust pipe bolt and muffler bolt inspection b831g20206002 tighten exhaust pipe bolts, muffler bolt and nut initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter check the exhaust pipe bolts, muffler bolts and nut to the speci...

  • Page 32

    0b-5 maintenance and lubrication: 5) drain a small amount of engine coolant and disconnect the radiator upper hose of thermostat side. Refer to “cooling system inspection (page 0b- 15)”. 6) remove the spark plug cap (4) and spark plug (5). Refer to “spark plug cap and spark plug removal and installa...

  • Page 33

    Maintenance and lubrication: 0b-6 10) insert the thickness gauge between the tappet and the cam. If the clearance is out of specification, adjust it to the specified range. Note the valve clearance specification is different for both intake and exhaust valves. Special tool (a): 09900–20803 (thicknes...

  • Page 34

    0b-7 maintenance and lubrication: (intake side) 0.00 – 0.04 0.05 – 0.09 0.10 – 0.20 0.21 – 0.25 0.26 – 0.30 0.31 – 0.35 0.36 – 0.40 0.41 – 0.45 0.46 – 0.50 0.51 – 0.55 0.56 – 0.60 0.61 – 0.65 0.66 – 0.70 0.71 – 0.75 0.76 – 0.80 0.81 – 0.85 0.86 – 0.90 0.91 – 0.95 0.96 – 1.00 1.01 – 1.05 1.06 – 1.10 ...

  • Page 35

    Maintenance and lubrication: 0b-8 (exhaust side) how t o use this char t: i. Measure valve clearance. “engine is cold” ii. Measure present shim size. Iii. Match clearance in vertical column with present shim size in horizontal column. Example v alve clearance is 0.38 mm present shim size 2.90 mm shi...

  • Page 36

    0b-9 maintenance and lubrication: 6) install the camshafts. Refer to “engine top side assembly in section 1d (page 1d-21)”. 7) rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then ch...

  • Page 37

    Maintenance and lubrication: 0b-10 spark arrester cleaning b831g20206006 spark arrester cleaning every 2 000 km (1 200 miles, 6 months) 1) remove the muffler end cover (1). 2) remove the spark arrester (2) from the muffler. 3) clean the spark arrester (2) with a brush. 4) after finishing the spark a...

  • Page 38

    0b-11 maintenance and lubrication: engine oil replacement 1) place the vehicle on a level ground and set the brake lock. 2) remove the engine side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 3) place an oil pan below the engine, and drain engine oi...

  • Page 39

    Maintenance and lubrication: 0b-12 oil filter replacement 1) drain engine oil as described in the engine oil replacement procedure. 2) remove left inner cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 3) remove the oil filter (1) using the special tool...

  • Page 40

    0b-13 maintenance and lubrication: 3) tighten the oil level plug (1) and oil filler plug (2) to the specified torque. Caution ! Replace the gasket washers with new ones. Tightening torque front differential gear oil level plug (a): 8.5 n·m ( 0.85 kgf-m, 6.0 lb-ft) tightening torque front differentia...

  • Page 41

    Maintenance and lubrication: 0b-14 final gear oil inspection b831g20206011 inspect final gear oil every 2 000 km (1 200 miles, 6 months) 1) place the vehicle on a level ground. 2) remove the filler plug (1), and inspect the oil level. If the oil level is below, add fresh oil until the oil level reac...

  • Page 42

    0b-15 maintenance and lubrication: throttle cable play inspection and adjustment b831g20206013 inspect throttle cable play initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter inspect and adjust the throttle cable play “a” as follows. Throttle cable play “a” 3...

  • Page 43

    Maintenance and lubrication: 0b-16 3) remove the left inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 4) remove the front under cover. Refer to “under cover removal and installation in section 9d (page 9d-12)”. 5) place a pan below the water pum...

  • Page 44

    0b-17 maintenance and lubrication: radiator hoses inspection inspect radiator hoses every 2 000 km (1 200 miles, 6 months) inspect the radiator hoses for damage and engine coolant leakage. If any defects are found, replace them with new ones. Drive v-belt inspection and replacement b831g20206016 ins...

  • Page 45

    Maintenance and lubrication: 0b-18 brake fluid level check inspect brake fluid level every 1 000 km (600 miles, 3 months) 1) place the vehicle on a level ground. 2) check the brake fluid level by observing the lower limit lines on the brake fluid reservoir. When the brake fluid level is below the lo...

  • Page 46

    0b-19 maintenance and lubrication: front brake hose replacement replace brake hose every 4 years refer to “front brake hose removal and installation in section 4a (page 4a-7)”. Rear brake pedal / rear brake (parking brake) lever inspection and adjustment b831g20206019 note adjust the rear brake by a...

  • Page 47

    Maintenance and lubrication: 0b-20 rear brake (parking brake) lever play adjustment 1) after adjusting the brake pedal, check the rear brake lever play “a” the brake lever play “a” as measured at the lever holder should be between 6 – 8 mm (0.2 – 0.3 in) when the lever is lightly pulled in towards t...

  • Page 48

    0b-21 maintenance and lubrication: tire inspection b831g20206021 inspect tire every 1 000 km (600 miles, 3 months) tire tread condition operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace ...

  • Page 49

    Maintenance and lubrication: 0b-22 if the toe-out is out of specification, bring it into the specified range. Refer to “toe adjustment (page 0b- 22)”. Toe adjustment b831g20206023 adjust the toe-out as follows: 1) loosen the lock-nuts (1), (2) on each tie-rod. Caution ! • the lock-nuts (2) have left...

  • Page 50

    0b-23 maintenance and lubrication: chassis bolt and nut inspection b831g20206025 tighten chassis bolt and nut initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter check that all chassis bolts and nuts are tightened to their specified torque. 1 handlebar upper ...

  • Page 51

    Maintenance and lubrication: 0b-24 10 rear wheel set nut 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 11 rear hub nut 121 n ⋅m (12.1 kgf-m, 87.5 lb-ft) 12 tie-rod end nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 13 steering knuckle end nut (upper and lower) 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 14 front shock absorber mounting...

  • Page 52

    0b-25 maintenance and lubrication: 22 rear brake pedal pivot bolt 11 n ⋅m (1.1 kgf-m, 8.0 lb-ft) 23 rear brake case bolt 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 24 rear brake cam lever nut 11 n ⋅m (1.1 kgf-m, 8.0 lb-ft) 25 rear shock absorber mounting nut (lower) 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 26 rear shoc...

  • Page 53

    Maintenance and lubrication: 0b-26 compression pressure check b831g20206026 refer to “compression pressure check in section 1d (page 1d-2)”. Oil pressure check b831g20206027 refer to “oil pressure check in section 1e (page 1e- 2)”. Sds check b831g20206028 refer to “sds check in section 1a (page 1a-1...

  • Page 54

    0b-27 maintenance and lubrication: specifications tightening torque specifications b831g20207001 note the specified tightening torque is also described in the following. “chassis bolt and nut inspection (page 0b-23)” reference: for the tightening torque of fastener not specified in this section, ref...

  • Page 55

    Maintenance and lubrication: 0b-28 09915–40610 oil filter wrench ) (page 0b-12) / ) (page 0b-12).

  • Page 56: Service Data

    0c-1 service data: general information service data specifications service data b831g20307001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 36.0 (1.42) — ex. 33.0 (1.30) — tappet clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) — ex...

  • Page 57

    Service data: 0c-2 cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit compression pressure (automatic- decomp. Actuated) approx. 1 000 kpa (10.0 kgf/cm 2 , 142 psi) — piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0...

  • Page 58

    0c-3 service data: drive train unit: mm (in) except ratio thermostat + radiator + fan + coolant item standard limit primary reduction ratio (automatic drive) variable change (2.763 – 0.780) — secondary reduction ratio 2.158 (40/21 x 17/15) — final reduction ratio front 3.600 (36/10) — rear 3.600 (36...

  • Page 59

    Service data: 0c-4 injector + fuel pump + fuel pressure regulator fi sensors + secondary throttle valve actuator throttle body item specification note injector resistance 11 – 13 Ω at 20 °c (68 °f) fuel pump discharge amount 55.5 ml (1.88/1.95 us/lmp qt) and more/10 sec. Fuel pressure regulator oper...

  • Page 60

    0c-5 service data: electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: cr6e denso: u20esr-n gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 150 – 250 Ω ckp sensor peak voltage 5.0 v and more ignition coil resistance prima...

  • Page 61

    Service data: 0c-6 brake + wheel unit: mm (in) tire unit: mm (in) suspension unit: mm (in) fuel + oil item standard limit front brake disc thickness — 3.0 (0.12) front brake disc runout — 0.30 (0.012) front master cylinder bore 14.000 – 14.043 (0.5512 – 0.5529) — front master cylinder piston diam. 1...

  • Page 62

    0c-7 service data: tightening torque list b831g20307002 engine item n ⋅m kgf-m lb-ft spark plug 11 1.1 8.0 cylinder head cover bolt initial 10 1.0 7.0 final 14 1.4 10.5 cam drive idle gear/sprocket shaft 41 4.1 29.5 intake pipe bolt 9 0.9 6.5 cylinder head bolt (m6) 10 1.0 7.0 cylinder head bolt (l2...

  • Page 63

    Service data: 0c-8 drive train fi system, intake air system and fuel system cooling system item n ⋅m kgf-m lb-ft 4wd/diff-lock actuator mounting bolt 22 2.2 16.0 front drive (differential) gear case bolt 22 2.2 16.0 front drive (differential) gear case mounting nut 50 5.0 36.0 front drive (different...

  • Page 64

    0c-9 service data: chassis item n ⋅m kgf-m lb-ft handlebar clamp bolt 26 2.6 19.0 handlebar holder nut 60 6.0 43.5 rear brake lever holder clamp bolt 11 1.1 8.0 throttle lever case bolt 5 0.5 3.5 steering shaft holder bolt 23 2.3 16.5 steering shaft lower nut 162 16.2 117.0 front suspension arm pivo...

  • Page 65

    Service data: 0c-10 tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf-m 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 10 ...

  • Page 66

    0c-11 service data:.

  • Page 67: Section 1

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

  • Page 68

    1-ii table of contents service data........................................................1c-6 tightening torque specifications........................1c-6 special tools and equipment .............................1c-7 recommended service material .........................1c-7 special tool ............

  • Page 69

    Table of contents 1-iii water pump disassembly and assembly ......... 1f-14 water pump related parts inspection.............. 1f-18 specifications..................................................... 1f-19 service data ..................................................... 1f-19 tightening torque spe...

  • Page 70

    1-iv table of contents charging system...................................... 1j-1 schematic and routing diagram........................ 1j-1 charging system diagram .................................. 1j-1 component location ........................................... 1j-1 charging system components ...

  • Page 71: Precautions

    Precautions: 1-1 engine precautions precautions precautions for engine b831g21000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”..

  • Page 72

    1a-1 engine general information and diagnosis: engine engine general information and diagnosis general description injection timing description b831g21101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 73

    Engine general information and diagnosis: 1a-2 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 self-diagnosis function the self-diagnosis function is incorporat...

  • Page 74

    1a-3 engine general information and diagnosis: if “chec” is indicated, the lcd does not indicate the trouble code. It is necessary to check the wiring harness between ecm and speedometer couplers. The possible cause of this indication is as follows; engine stop switch is in off position. Ignition fu...

  • Page 75

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b831g21102001 crankshaft position sensor (ckp sensor) throttle position sensor (tp sensor) intake air pressure sensor (iap sensor) engine coolant temperature sensor (ect sensor) intake air temperatu...

  • Page 76

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler b831g21102002 i831g1110003-03 terminal no. Circuit terminal no. Circuit 1 ignition coil (ig1) 18 ckp sensor signal (ckp-) 2 fuel injector (#1) 19 fuel pump relay (fp relay) 3 power source (+b) 20 injector power voltage ...

  • Page 77

    Engine general information and diagnosis: 1a-6 component location fi system parts location b831g21103001 “i” “e” “b” “c” “d” “g” “h” “a” “f” i831g1110004-02 “a”: ecm “c”: tp sensor “e”: iat sensor “g”: speed sensor “i”: diff-lock relay “b”: isc valve “d”: iap sensor “f”: ckp sensor “h”: combination ...

  • Page 78

    1a-7 engine general information and diagnosis: “j” “k” “n” “l” “a” “m” “i” i831g1110005-03 “a”: ecm “j”: to sensor “l”: ignition coil “n”: fuel pump “i”: ect sensor “k”: fuel injector “m”: fp relay.

  • Page 79

    Engine general information and diagnosis: 1a-8 diagnostic information and procedures engine symptom diagnosis b831g21104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 80

    1a-9 engine general information and diagnosis: engine stalls often (control circuit or sensor improperly operating) defective ecm. Replace. Defective fuel pressure regulator. Replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective ect sensor. Re...

  • Page 81

    Engine general information and diagnosis: 1a-10 engine runs poorly in high speed range (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensors. Replace. Defective iap sensor. Replace. Defective ap sensor. Replace. Defective ecm....

  • Page 82

    1a-11 engine general information and diagnosis: self-diagnostic procedures b831g21104002 use of mode select switch note • do not disconnect coupler from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming dtc (diagnostic trouble code) store...

  • Page 83

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

  • Page 84

    1a-13 engine general information and diagnosis: 4) start the engine or crank the engine for more than 4 seconds. 5) check the dtc to determine the malfunction part. Refer to “dtc table (page 1a-19)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 85

    Engine general information and diagnosis: 1a-14 show data when trouble (displaying data at the time of dtc) b831g21104004 use of sds ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is c...

  • Page 86

    1a-15 engine general information and diagnosis: 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. Sds check b831g21104005 using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by ...

  • Page 87

    Engine general information and diagnosis: 1a-16 sample data sampled from cold starting through warm-up data at 3 000 r/min under no load check the engine r/min. 1 300 r/min check the manifold absolute pressure. Xxx kpa check the engine coolant temperature. Xx° c i831g1110009-03 check the manifold ab...

  • Page 88

    1a-17 engine general information and diagnosis: data at the time of racing throttle: quick wide open throttle: slowly open i831g1110011-01.

  • Page 89

    Engine general information and diagnosis: 1a-18 example of trouble three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been sav...

  • Page 90

    1a-19 engine general information and diagnosis: dtc table b831g21104006 in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The m...

  • Page 91

    Engine general information and diagnosis: 1a-20 fi system troubleshooting b831g21104008 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collectin...

  • Page 92

    1a-21 engine general information and diagnosis: note the above form is a standard sample. The form should be modified according to condition and characteristics of each market. Visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea...

  • Page 93

    Engine general information and diagnosis: 1a-22 malfunction code and defective condition table b831g21104009 malfunction code 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 s...

  • Page 94

    1a-23 engine general information and diagnosis: c24 ignition signal ckp sensor (pick-up coil) signal is produced, but signal from ignition coil is interrupted 8 times or more continuously. In this case, the code c24 (p0351) is indicated. Ignition coil, wiring/coupler connection, power supply from th...

  • Page 95

    Engine general information and diagnosis: 1a-24 dtc “c12” (p0335): ckp sensor circuit malfunction b831g21104010 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm...

  • Page 96

    1a-25 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) check the ckp sensor coupler for loose or poor contacts. If ok, then measure the ckp sensor resistance. 3) disconnect the ckp sensor coupler and measure the resistance. Special tool (a): 09900–25...

  • Page 97

    Engine general information and diagnosis: 1a-26 1 4) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) ckp sensor continuity ∞Ω (infinity) (bl – ground, w – ground) are the resistance and continuity ok? Go to step 2. Replace t...

  • Page 98

    1a-27 engine general information and diagnosis: dtc “c13” (p0105-h/l): iap sensor circuit malfunction b831g21104011 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 99

    Engine general information and diagnosis: 1a-28 c13 (use of mode select switch) step action yes no 1 1) remove the front fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the iap sensor coupler for loose or poo...

  • Page 100

    1a-29 engine general information and diagnosis: p0105-h for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 3) check the iap sensor coupler for loose or...

  • Page 101

    Engine general information and diagnosis: 1a-30 step action yes no 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the g/b wire “b” and terminal “13”. If ...

  • Page 102

    1a-31 engine general information and diagnosis: p0105-l for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the front fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 3) check the iap sensor coupler for loose or...

  • Page 103

    Engine general information and diagnosis: 1a-32 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the r wire “a” and terminal “6”. Also, check the continuit...

  • Page 104

    1a-33 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) remove the iap sensor. Refer to “iap sensor removal and installation in section 1c (page 1c-2)”. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. Arrange 3 new 1.5 v batteries in series (1) (c...

  • Page 105

    Engine general information and diagnosis: 1a-34 dtc “c14” (p0120-h/l): tp sensor circuit malfunction b831g21104012 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 106

    1a-35 engine general information and diagnosis: c14 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or p...

  • Page 107

    Engine general information and diagnosis: 1a-36 p0120-h (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contact...

  • Page 108

    1a-37 engine general information and diagnosis: step action yes no 1 7) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 8) check the continuity between r wire “a” and terminal “6”. Also, check the continuity between b/br wire “c” and terminal “24”. Spec...

  • Page 109

    Engine general information and diagnosis: 1a-38 p0120-l (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contact...

  • Page 110

    1a-39 engine general information and diagnosis: step action yes no 1 7) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 8) check the continuity between y wire “b” and terminal “14”. Also, check the continuity between r wire “a” and terminal “6”. Special...

  • Page 111

    Engine general information and diagnosis: 1a-40 3 1) connect the tp sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage at the coupler (between (+) y wire and (–) b/br wire) by opening the throttle leve...

  • Page 112

    1a-41 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b831g21104013 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 113

    Engine general information and diagnosis: 1a-42 c15 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or ...

  • Page 114

    1a-43 engine general information and diagnosis: p0115-h (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contac...

  • Page 115

    Engine general information and diagnosis: 1a-44 p0115-l (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contac...

  • Page 116

    1a-45 engine general information and diagnosis: step action yes no 1 8) turn the ignition switch on. 9) measure the output voltage between b/bl wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) out...

  • Page 117

    Engine general information and diagnosis: 1a-46 2 1) turn the ignition switch off. 2) connect the ecm coupler. 3) disconnect the ect sensor coupler. 4) measure the ect sensor resistance. Refer to “ect sensor inspection in section 1c (page 1c-4)” for details. Special tool : 09900–25008 (multi-circuit...

  • Page 118

    1a-47 engine general information and diagnosis: dtc “c20” (p1752): diff-lock relay circuit malfunction b831g21104014 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of th...

  • Page 119

    Engine general information and diagnosis: 1a-48 step action yes no 1 1) remove the rear fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) connect the disconnected couplers and battery. 3) turn the ignition switch off. 4) check the diff-lock relay co...

  • Page 120

    1a-49 engine general information and diagnosis: dtc “c21” (p0110-h/l): iat sensor circuit malfunction b831g21104015 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 121

    Engine general information and diagnosis: 1a-50 c21 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or ...

  • Page 122

    1a-51 engine general information and diagnosis: p0110-h (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contac...

  • Page 123

    Engine general information and diagnosis: 1a-52 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) iat sensor resistance approx. 1.6 k Ω at 20 °c (68 °f) (terminal — terminal) note i...

  • Page 124

    1a-53 engine general information and diagnosis: dtc “c23” (p1651-h/l): to sensor circuit malfunction b831g21104016 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 125

    Engine general information and diagnosis: 1a-54 c23 (use of mode select switch) step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation in section 1d (page 1d-5)”. 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contact...

  • Page 126

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

  • Page 127

    Engine general information and diagnosis: 1a-56 p1651-l (use of sds) step action yes no 1 7) disconnect the ecm coupler. 8) check the continuity between br/w wire “b” and terminal “10”. Also, check the continuity between b/br wire “c” and terminal “24”. Special tool (a): 09900–25008 (multi-circuit t...

  • Page 128

    1a-57 engine general information and diagnosis: step action yes no 1 4) remove the to sensor. 5) disconnect the to sensor coupler. 6) insert the needle pointed probes to the lead wire coupler. 7) check the continuity between br/w wire “b” and ground. Also, check the continuity between br/w wire “b” ...

  • Page 129

    Engine general information and diagnosis: 1a-58 2 1) connect the to sensor 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 br/w and b/br wires. Also, measure the voltage when learning the v...

  • Page 130

    1a-59 engine general information and diagnosis: dtc “c24” (p0351): ignition coil circuit malfunction b831g21104017 note refer to “no spark or poor spark in section 1h (page 1h-2)” for details. Dtc “c32” (p0201): fuel injector circuit malfunction b831g21104018 detected condition and possible cause wi...

  • Page 131

    Engine general information and diagnosis: 1a-60 step action yes no 1 1) remove the side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the injector coupler for loose or poor contacts. If ok, then measure the ...

  • Page 132

    1a-61 engine general information and diagnosis: 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) injector continuity ∞Ω (infinity) (terminal – ground) are the resistance and continuity ok? Go to step 2. Replace the injec...

  • Page 133

    Engine general information and diagnosis: 1a-62 dtc “c40” (p05057): isc valve circuit malfunction b831g21104019 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! • be careful not to disconnect at lease 3 seconds after ignition switch is turned ...

  • Page 134

    1a-63 engine general information and diagnosis: step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d- 6)”. 2) turn the ignition switch off. 3) check the isc valve coupler for loose or poor contacts. If ok, then check ...

  • Page 135

    Engine general information and diagnosis: 1a-64 2 1) measure the resistance between terminals “a” and “c”, terminals “b” and “d”. Special tool (a): 09900–25008 (multi-circuit tester set) isc valve resistance approx. ∞ (terminal “a” – terminal “c”) (terminal “b” – terminal “d”) 2) if ok, then measure...

  • Page 136

    1a-65 engine general information and diagnosis: active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” (1). 5) check that t...

  • Page 137

    Engine general information and diagnosis: 1a-66 check 3 1) click the button (6) and increase the “spec” (2) to 1 400 rpm slowly. 2) check that the “desired idle speed” (3) is nearly equal to the “spec” (2). Also, check that the number of steps (5) in the isc valve position increases. Check 4 1) clic...

  • Page 138

    1a-67 engine general information and diagnosis: dtc “c41” (p230-h/l): fp relay circuit malfunction b831g21104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ec...

  • Page 139

    Engine general information and diagnosis: 1a-68 c41 (use of mode select switch) p0230-h (use of sds) step action yes no 1 1) remove the seat. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) turn the ignition switch to off. 3) check the fp relay coupler for...

  • Page 140

    1a-69 engine general information and diagnosis: p0230-l (use of sds) specifications service data b831g21107001 injector fi sensors + secondary throttle valve actuator step action yes no 1 1) turn the ignition switch to off. 2) remove the seat. Refer to “front side exterior parts removal and installa...

  • Page 141

    Engine general information and diagnosis: 1a-70 special tools and equipment special tool b831g21108001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 1a-25) / ) (page 1a-26) / ) (page 1a-26) / ) (page 1a-28) / ) (page 1a-29) / ) (page 1a-30) / ) (page 1a-31) / ) (p...

  • Page 142: Emission Control Devices

    1b-1 emission control devices: engine emission control devices precautions precautions for emission control devices b831g21200001 refer to “general precautions in section 00 (page 00-1)”. Repair instructions crankcase breather (pcv) hose inspection b831g21206001 inspect the pcv hose in the following...

  • Page 143: Engine Electrical Devices

    Engine electrical devices: 1c-1 engine engine electrical devices precautions precautions for engine electrical device b831g21300001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location engine electrica...

  • Page 144

    1c-2 engine electrical devices: iap sensor removal and installation b831g21306005 removal 1) remove the left inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) disconnect the iap sensor coupler (1) and vacuum hose (2). 3) remove the iap sensor (...

  • Page 145

    Engine electrical devices: 1c-3 tp sensor adjustment b831g21306008 adjust the tp sensor in the following procedures: 1) connect the special tool to the mode select switch. Refer to “self-diagnostic procedures in section 1a (page 1a-11)”. Special tool : 09930–82720 (mode select switch) 2) warm up the...

  • Page 146

    1c-4 engine electrical devices: ect sensor removal and installation b831g21306011 removal 1) drain engine coolant. Refer to “cooling system inspection in section 0b (page 0b-15)”. 2) disconnect the coupler (1) and remove the ect sensor (2). Caution ! Take special care when handling the ect sensor. I...

  • Page 147

    Engine electrical devices: 1c-5 to sensor inspection b831g21306013 refer to “dtc “c23” (p1651-h/l): to sensor circuit malfunction in section 1a (page 1a-53)”. To sensor removal and installation b831g21306014 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation in...

  • Page 148

    1c-6 engine electrical devices: installation note when replacing the isc valve, turn the ignition switch on and off. Install the isc valve in the reverse order of removal. Pay attention to the following points: • install the new o-ring (1). • install the isc valve (2) and tighten the isc valve mount...

  • Page 149

    Engine electrical devices: 1c-7 tightening torque specifications b831g21307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-7)”. Special tools and equipment recommended service material b831g21308001 special t...

  • Page 150: Engine Mechanical

    1d-1 engine mechanical: engine engine mechanical schematic and routing diagram throttle cable routing diagram b831g21402001 1 1 2 3 5 4 “a” “b” i831g1140002-02 1. Throttle cable 5. Throttle cable guide 2. Brake hose “a”: pass through the throttle cable inside of pin. 3. Handlebar “b”: pass through t...

  • Page 151

    Engine mechanical: 1d-2 diagnostic information and procedures engine mechanical symptom diagnosis b831g21404001 refer to “engine symptom diagnosis in section 1a (page 1a-8)”. Compression pressure check b831g21404002 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 152

    1d-3 engine mechanical: repair instructions engine components removable with the engine in place b831g21406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 153

    Engine mechanical: 1d-4 engine right side engine left side item removal inspection installation fixed drive face refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page 5a-5)”. Refer to “movable / fixed drive face parts inspection in section 5a...

  • Page 154

    1d-5 engine mechanical: air cleaner element removal and installation b831g21406002 removal 1) remove the seat. Refer to “seat removal and installation in section 9d (page 9d-11)”. 2) remove the air cleaner box cover (1). 3) remove the air cleaner element bolt (2). 4) remove the air cleaner element (...

  • Page 155

    Engine mechanical: 1d-6 5) remove the iat sensor coupler (5) and pcv hose (6). Installation install the air cleaner box in the reverse order of removal. Pay attention to the following points: • install the air cleaner box (1) and tighten the throttle body clamp screw. Refer to “throttle body constru...

  • Page 156

    1d-7 engine mechanical: throttle body components b831g21406008 fwd fwd 1 2 3 6 7 4 (a) (b) 8 9 13 11 12 10 (a) 5 i831g1140016-05 1. Tp sensor 6. Fuel injector 11. Tp sensor mounting screw : apply grease. 2. Isc valve 7. Cushion seal 12. Isc valve mounting screw : apply engine oil. 3. Iap sensor 8. V...

  • Page 157

    Engine mechanical: 1d-8 throttle body construction b831g21406009 throttle body removal and installation b831g21406010 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation (page 1d-5)”. 2) place a rug under the fuel feed hose (1) and disconnect the fuel feed hose ...

  • Page 158

    1d-9 engine mechanical: 3) disconnect the fuel injector coupler (2) and tp/iap/ iat sensor coupler (3). 4) disconnect the isc valve coupler (4). 5) remove the throttle cable cover (5). 6) disconnect the throttle cable. Caution ! After disconnecting the throttle cables, do not snap the throttle valve...

  • Page 159

    Engine mechanical: 1d-10 • connect the throttle cable. • tighten the throttle body clamp screws. Refer to “throttle body construction (page 1d-8)”. • after installed throttle cable, adjust the throttle cable play. Refer to “throttle cable play inspection and adjustment in section 0b (page 0b-15)”. T...

  • Page 160

    1d-11 engine mechanical: 5) remove the tp sensor (5). Note prior to disassembly, mark the tp sensors original position with a paint or scribe for accurate reinstallation. Caution ! Never remove the throttle valve (6). Caution ! • do not loosen the lock-nut (7). • the fast idle screw (8) is factory-a...

  • Page 161

    Engine mechanical: 1d-12 • apply a thin coat of engine oil to the o-ring and install the isc valve assembly. Caution ! Replace the o-ring with a new one. Special tool : 09930–11950 (torx wrench) tightening torque isc valve mounting screw (a): 2 n·m (0.2 kgf-m, 1.5 lb-ft) • apply a thin coat of engin...

  • Page 162

    1d-13 engine mechanical: throttle body inspection and cleaning b831g21406012 refer to “throttle body disassembly and assembly (page 1d-10)”. Cleaning warning ! Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow t...

  • Page 163

    Engine mechanical: 1d-14 5) remove the following parts from the vehicle. • front fender (1). Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. • rear fender (2). Refer to “rear side exterior parts removal and installation in section 9d (page 9d- 9)”. • mud guar...

  • Page 164

    1d-15 engine mechanical: 13) disconnect the generator coupler (10), ckp sensor coupler (11) and gear position sensor coupler (12). 14) remove the v-belt cooling ducts. Refer to “v-belt cooling duct removal and installation in section 5a (page 5a-5)”. 15) remove the muffler and exhaust pipes. Refer t...

  • Page 165

    Engine mechanical: 1d-16 23) support engine with a jack and remove the engine mounting bolts and nuts. 24) remove the engine from the right side. Warning ! Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed. Engine assembly installation b831g...

  • Page 166

    1d-17 engine mechanical: • install the rear brake cable clamp (5). • install the rear brake pedal. Refer to “rear brake pedal removal and installation in section 4a (page 4a-14)”. • install the exhaust pipe assembly and muffler. Refer to “exhaust pipe / muffler removal and installation in section 1k...

  • Page 167

    Engine mechanical: 1d-18 8) disconnect the ect sensor coupler (1). 9) remove the engine mounting dumper stopper (2). Water hose 1) disconnect the radiator inlet hose (1) of the thermostat. 2) disconnect the water bypass hose (2) of the cylinder head side. 3) remove the water pump outlet hose (3). Ex...

  • Page 168

    1d-19 engine mechanical: cylinder head cover remove the cylinder head cover (1) and its gasket. Cam shaft 1) remove the valve timing inspection plug. 2) turn the crankshaft and align the match mark “a” on the crankshaft with the mark “b” of the crankcase. Also position each of the camshaft as shown....

  • Page 169

    Engine mechanical: 1d-20 cylinder head 1) remove the cam drive idle gear/sprocket (1) by removing its shaft (2) with the idle shaft gasket (3) and cam chain idle shim (4). Note be careful not to drop the cam chain idle shim (4) into the crankcase. 2) remove the cylinder head bolts (m6) (5). Note sig...

  • Page 170

    1d-21 engine mechanical: 4) remove the dowel pins (6) and gasket (7). Note be careful not to drop the dowel pins (6) into the crankcase. Piston 1) place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase. 2) remove the piston pin circlip (1). 3) draw out ...

  • Page 171

    Engine mechanical: 1d-22 • place a clean rag over the cylinder base so as not to drop the piston pin circlip (1) into the crankcase. • install the piston pin circlip (1). Caution ! Use new piston pin circlip (1) to prevent circlip failure which will occur when it is bent. Note end gap of the circlip...

  • Page 172

    1d-23 engine mechanical: cam chain guide • install the cam chain guide (1). Caution ! Be sure that the cam chain guide (1) is installed properly. Cylinder head • fit the dowel pins (1) and new cylinder head gasket (2). Caution ! Replace the cylinder head gasket (2) with a new one. • place the cylind...

  • Page 173

    Engine mechanical: 1d-24 • tighten the cylinder base nuts (5) to the specified torque. Tightening torque cylinder base nut (c): 10 n·m (1.0 kgf-m, 7.0 lb-ft) cam drive idle gear / sprocket • align the match mark “a” on the generator rotor with the mark “b” on the crankcase. • install the cam drive i...

  • Page 174

    1d-25 engine mechanical: correct incorrect incorrect • tighten the cam drive idle gear/sprocket shaft (2) to the specified torque. Tightening torque cam drive idle gear/sprocket shaft (a): 41 n·m ( 4.1 kgf-m, 29.5 lb-ft) cam chain tension adjuster • install the cam chain tension adjuster (1) and tig...

  • Page 175

    Engine mechanical: 1d-26 • install the new o-ring (2), spring (3) and bar (4). Caution ! Use a new o-ring to prevent oil leakage. • install the cam chain tension adjuster cap bolt (5). Note click sound is heard when the cam chain tension adjuster cap bolt is installed. • tighten the cam chain tensio...

  • Page 176

    1d-27 engine mechanical: • be sure to check and adjust the valve clearance. Refer to “valve clearance inspection and adjustment in section 0b (page 0b-4)”. • before assemble the cylinder head cover, pour a small amount of engine oil in oil pocket in the cylinder head. Cylinder head cover • install a...

  • Page 177

    Engine mechanical: 1d-28 camshaft inspection b831g21406018 refer to “engine top side disassembly (page 1d-17)”. Refer to “engine top side assembly (page 1d-21)”. Camshaft identification the exhaust camshaft has the automatic decompression (1). Automatic decompression move the automatic decompression...

  • Page 178

    1d-29 engine mechanical: 2) use the plastigauge to read the clearance at the widest portion, which is specified as follows. Special tool (a): 09900–22301 (plastigauge (0.025 – 0.076 mm)) (b): 09900–22302 (plastigauge (0.051 – 0.152 mm)) 3) install each camshaft journal holder to its original positio...

  • Page 179

    Engine mechanical: 1d-30 camshaft sprocket inspection b831g21406019 inspect the camshaft sprocket in the following procedures: 1) remove the intake and exhaust camshafts. Refer to “engine top side disassembly (page 1d-17)”. 2) inspect the teeth of each camshaft sprocket for wear or damage. If they a...

  • Page 180

    1d-31 engine mechanical: cam chain tensioner inspection b831g21406023 inspect the cam chain tensioner in the following procedures: 1) remove the cylinder head. Refer to “engine top side disassembly (page 1d-17)”. 2) remove the starter driven gear. Refer to “engine bottom side disassembly (page 1d-45...

  • Page 181

    Engine mechanical: 1d-32 4) pull out the valve (6) from the combustion chamber side. 5) remove the oil seal (7) and spring seat (8). 6) remove the other valves in the same manner as described previously. 7) remove the bypass union (9). 8) remove the intake pipe. 9) remove the oil gallery plug (cylin...

  • Page 182

    1d-33 engine mechanical: • apply grease to the o-ring of the intake pipe. Caution ! Replace the o-ring with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) • apply a small quantity of thread lock to the intake pipe mounting bolts and tighten them to the specified torque. Note ma...

  • Page 183

    Engine mechanical: 1d-34 • insert the valve, with its stem coated with molybdenum oil all around and along the full stem length without any break. Caution ! When inserting the valve, take care not to damage the lip of the oil seal. M/o: molybdenum oil (molybdenum oil solution) • install the valve sp...

  • Page 184

    1d-35 engine mechanical: • install the other valves and springs in the same manner as described previously. • install the tappet shims and the tappets to their original positions. Note • apply engine oil to the stem end, shim and tappet before fitting them. • when seating the tappet shim, be sure th...

  • Page 185

    Engine mechanical: 1d-36 valve face wear visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve head “a”. If it is out of specification replace the valve with a new one. Special tool : ...

  • Page 186

    1d-37 engine mechanical: valve spring the force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free len...

  • Page 187

    Engine mechanical: 1d-38 valve seat sealing condition 1) clean and assemble the cylinder head and valve components. 2) 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 s...

  • Page 188

    1d-39 engine mechanical: 5) cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot plate. Caution ! Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. 6) apply engine oil to each valve gui...

  • Page 189

    Engine mechanical: 1d-40 valve seat repair b831g21406027 the valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45 °. Caution ! • the valve seat contact area must be inspected after each cut. • do not use lapping compound...

  • Page 190

    1d-41 engine mechanical: adjustment if the thrust clearance is exceed the standard, adjust the thrust clearance by the following procedures: • remove the shim, and measure its thickness with a micrometer. Special tool (a): 09900–20205 (micrometer (0 – 25 mm)) • replace the sim with a other size. • r...

  • Page 191

    Engine mechanical: 1d-42 cylinder bore inspect the cylinder wall for any scratches, nicks or other damage. If any defects are found, replace the cylinder with a new one. Measure the cylinder bore diameter at six places. Special tool (a): 09900–20530 (cylinder gauge set) cylinder bore standard: 104.0...

  • Page 192

    1d-43 engine mechanical: b) install the 2nd ring (3) and 1st ring (4) to piston. Note 1st ring (4) and 2nd ring (3) differ in shape. Note face the side with the edge “c” and stamped mark “d” upward when assembling. 2) position the gaps of the three rings and side rails as shown. Before inserting pis...

  • Page 193

    Engine mechanical: 1d-44 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 exceed the limit, replace both the piston and piston rings. Special tool (a): 09900–20803 (thickness gauge) (b): 09900–20205 (micro...

  • Page 194

    1d-45 engine mechanical: piston pin and pin bore measure the piston pin bore inside diameter using the small bore gauge. If measurement is out of specification, replace the piston. Special tool (a): 09900–20602 (dial gauge (1/1000 mm, 1 mm)) (b): 09900–22403 (small bore gauge (18 – 35 mm)) piston pi...

  • Page 195

    Engine mechanical: 1d-46 water pump remove the water pump (1). Starter cup 1) remove the starter cup nut (1) with a suitable bar. 2) remove the starter cup (2). Generator remove the generator component parts (1). Refer to “generator removal and installation in section 1j (page 1j-4)”. Starter torque...

  • Page 196

    1d-47 engine mechanical: gear shift system 1) remove the washers (1) and gearshift shaft (2). 2) remove the cam driven gear (3) by removing its bolt (4). 3) remove the gear shift cam stopper bolt (5) and gear shift cam stopper (6), washer (7) and return spring (8). Transfer output drive gear 1) remo...

  • Page 197

    Engine mechanical: 1d-48 3) remove the pin (4) and washer (5). 4) remove the oil pump (6). Note do not drop the pin (4) and washer (5) into the crankcase. Balancer shaft drive / driven gear 1) remove the balancer shaft driven gear bolts (1) by holding the crankshaft with the special tool. Special to...

  • Page 198

    1d-49 engine mechanical: 7) remove the washer (6) and crank balancer drive gear (7). 8) remove the pin (8). Automatic transmission remove the automatic component parts (1). Refer to “v- belt type continuously variable automatic transmission removal and installation in section 5a (page 5a-5)” and “cl...

  • Page 199

    Engine mechanical: 1d-50 crankcase 1) remove the crankcase bolts “a” and clamp (1). 2) remove the crankcase bolts “b”. Note loosen the crankcase bolts diagonally with the smaller sizes first. 3) separate the crankcase with the special tool. Note • the crankcase separator plate is parallel with the e...

  • Page 200

    1d-51 engine mechanical: crankshaft 1) install the removed generator cover (1) and tighten the bolts at three places. 2) remove the crankshaft (2) with the special tool. Special tool (a): 09920–13120 (crankcase separating tool) engine mount bushing remove the engine mount bushings if necessary. Engi...

  • Page 201

    Engine mechanical: 1d-52 oil strainer • install the oil strainer (1). Note fit the convex part “a” of the oil strainer in the concave part “b” of the crankcase. Transfer / rear output shaft / rear output shaft bevel gear • install the rear output shaft bevel gear (1) and rear output shaft (2). Refer...

  • Page 202

    1d-53 engine mechanical: • tighten the crankcase bolts a little at a time to equalize the pressure. • tighten the crankcase bolts to the specified torque. Note • tighten the larger diameter crankcase bolts first and then smaller ones diagonally and evenly. • fit the cramp to the bolt “a”. Tightening...

  • Page 203

    Engine mechanical: 1d-54 • tighten the gear position switch mounting bolts. Caution ! • be careful not to tighten the bolts too much. • clamp the read wire firmly. Oil gallery plug install the oil gallery plug to the specified torque. Caution ! Use a new gasket (1) to prevent oil pressure leak. Tigh...

  • Page 204

    1d-55 engine mechanical: • install the crank balancer drive gear (2) and washer (3). • hold the crank balancer drive gear with the special tools and tighten the drive gear nut to the specified torque with the special tool. Caution ! Do not reuse the balancer drive gear nut. Special tool (a): 09920–5...

  • Page 205

    Engine mechanical: 1d-56 • apply thread lock to the balancer driven gear bolts. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • hold the crank balancer drive gear nut with the special tool and tighten bolts to the specified torque. Special tool (a): 09924–52460 (sock...

  • Page 206

    1d-57 engine mechanical: • install the snap ring (3). Caution ! The removed snap ring must be replaced with a new one. Special tool : 09900–06107 (snap ring pliers) gearshift system • install the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4). Note hook the return spring end “...

  • Page 207

    Engine mechanical: 1d-58 starter torque limiter / starter idle gear • apply molybdenum oil solution to the starter idle gear pin. M/o: molybdenum oil (molybdenum oil solution) • install the starter idle gear (1). • install the bushings (2) into the crankcase and generator cover. Note apply molybdenu...

  • Page 208

    1d-59 engine mechanical: • tighten the starter cup nut to the specified torque by holding starter cup with the suitable bar (2). Tightening torque starter cup nut (a): 38 n·m (3.8 kgf-m, 27.5 lb-ft) water pump • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. : grease 99000–...

  • Page 209

    Engine mechanical: 1d-60 conrod deflection wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of ware on the parts of the conrod’s big end. Special tool (a): 09900–20701 (magnetic stand) (b): 09900–20607 (dia...

  • Page 210

    1d-61 engine mechanical: crankshaft oil seal inspection b831g21406037 check the oil seal for damage. If any damage is found, replace the oil seal with a new one. Refer to “engine bottom side disassembly (page 1d-45)” and “bearing removal and installation (page 1d-61)”. Bearing inspection b831g214060...

  • Page 211

    Engine mechanical: 1d-62 3) remove the other bearings (2) with the special tool. Special tool (b): 09913–70210 (bearing installer set) right crankcase 1) remove the bearing retainers. 2) remove the oil seal (1) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 3) remove the eac...

  • Page 212

    1d-63 engine mechanical: 6) remove the oil seal (5) with the special tool. Special tool (f): 09913–70210 (bearing installer set) generator cover 1) remove the magnet stator. Refer to “generator removal and installation in section 1j (page 1j-4)”. 2) remove the snap rings (1) with the special tool. S...

  • Page 213

    Engine mechanical: 1d-64 installation caution ! The removed bearings and oil seals must be replaced with new ones. Generator cover 1) install the oil seals (1) with suitable tool. 2) install the each bearing (2) with a special tool. Caution ! Use the special tool suitable size for each bearing to pr...

  • Page 214

    1d-65 engine mechanical: right crankcase 1) install the oil seals (1) with the special tool. Special tool : 09913–70210 (bearing installer set) 2) install the bearings (2) with the special tool. Caution ! Use the special tool suitable size for each bearing to prevent damage. Note the stamped mark si...

  • Page 215

    Engine mechanical: 1d-66 specifications service data b831g21407001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 36.0 (1.42) — ex. 33.0 (1.30) — tappet clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) — ex. 0.20 – 0.30 (0.008 – 0.01...

  • Page 216

    1d-67 engine mechanical: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure (automatic- decomp. Actuated) approx. 1 000 kpa (10.0 kgf/cm 2 , 142 psi) — piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047) cy...

  • Page 217

    Engine mechanical: 1d-68 tightening torque specifications b831g21407002 note the specified tightening torque is also described in the following. “throttle body components (page 1d-7)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in ...

  • Page 218

    1d-69 engine mechanical: special tools and equipment recommended service material b831g21408001 note required service material is also described in the following. “throttle body components (page 1d-7)” special tool b831g21408002 material suzuki recommended product or specification note grease suzuki...

  • Page 219

    Engine mechanical: 1d-70 09900–20530 09900–20602 cylinder gauge set dial gauge (1/1000 mm, 1 mm) ) (page 1d-42) ) (page 1d-29) / ) (page 1d-45) 09900–20605 09900–20607 dial calipers (1/100 mm, 10 – 34 mm) dial gauge (1/100 mm, 10 mm) ) (page 1d-59) ) (page 1d-28) / ) (page 1d-35) / ) (page 1d-35) / ...

  • Page 220

    1d-71 engine mechanical: 09915–40610 09915–63311 oil filter wrench compression gauge attachment ) (page 1d-45) ) (page 1d-2) 09915–64512 09916–10911 compression gauge valve lapper set ) (page 1d-2) ) (page 1d-37) 09916–14510 09916–14521 valve spring compressor valve spring compressor attachment ) (p...

  • Page 221

    Engine mechanical: 1d-72 09920–53740 09921–20240 clutch sleeve hub holder bearing remover set ) (page 1d-48) / ) (page 1d-55) ) (page 1d-61) / ) (page 1d-62) / ) (page 1d-63) 09923–74511 09924–52460 bearing remover socket (52 mm) ) (page 1d-62) ) (page 1d-48) / ) (page 1d-48) / ) (page 1d-55) / ) (p...

  • Page 222: Engine Lubrication System

    1e-1 engine lubrication system: engine engine lubrication system precautions precautions for engine oil b831g21500001 refer to “fuel and oil recommendation in section 0a (page 0a-3)”. Schematic and routing diagram engine lubrication system chart diagram b831g21502001 oil sump filter oil pump relief ...

  • Page 223

    Engine lubrication system: 1e-2 diagnostic information and procedures engine lubrication symptom diagnosis b831g21504001 oil pressure check b831g21504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 224

    1e-3 engine lubrication system: 7) after warm up, increase the engine speed to 3 000 r/ min (observe the tachometer), and read the oil pressure gauge. If the oil pressure is lower or higher than the specification, the following causes may be considered. Oil pressure specification 140 – 180 kpa (1.4 ...

  • Page 225

    Engine lubrication system: 1e-4 installation install the oil sump filter in the reverse order of removal. Pay attention to the following points: • install the oil sump filter (1). Caution ! • the lip “a” of the oil sump filter should be positioned downward. • the shorter side “b” of the oil sump fil...

  • Page 226

    1e-5 engine lubrication system: installation install the oil jet in the reverse order of removal. Pay attention to the following point: • apply engine oil to the o-ring. Caution ! Use a new o-ring to prevent oil leakage. Oil jet inspection b831g21506006 refer to “oil jet removal and installation (pa...

  • Page 227

    Engine lubrication system: 1e-6 7) remove the snap ring (7) and oil pump driven gear (8). Special tool : 09900–06107 (snap ring pliers) 8) remove the pin (9), washer (10) and oil pump (11). Installation install the oil pump in the reverse order of removal. Pay attention to the following points: • ap...

  • Page 228

    1e-7 engine lubrication system: • hold the crank balancer driven gear with the special tool and tighten the oil pump drive gear bolt (3) to the specified torque. Special tool (a): 09920–53740 (clutch sleeve hub holder) tightening torque oil pump drive gear/crank balancer driven gear bolt (a): 50 n·m...

  • Page 229

    Engine lubrication system: 1e-8 special tools and equipment recommended service material b831g21508001 special tool b831g21508002 material suzuki recommended product or specification note thread lock cement thread lock cement super 1303 or equivalent p/no.: 99000–32030 ) (page 1e-6) thread lock ceme...

  • Page 230: Engine Cooling System

    1f-1 engine cooling system: engine engine cooling system precautions precautions for engine cooling system b831g21600001 warning ! • you can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully r...

  • Page 231

    Engine cooling system: 1f-2 schematic and routing diagram cooling circuit diagram b831g21602001 water pump radiator cooling fan thermo switch engine coolant temperature switch thermostat cylinder head cylinder reservoir tank bypass i831g1160001-02.

  • Page 232

    1f-3 engine cooling system: water hose routing diagram b831g21602002 1 2 3 4 5 “ d ” 5 6 7 “c” “a” “b” “b” “a” “a” (a) (b) “a” i831g1160002-05 1. Thermostat 6. Radiator outlet hose “d”: face the tip of the clip to upper. 2. Radiator 7. Water pump : 17 n ⋅m (1.7 kgf-m, 12.5 lb-ft) 3. Reservoir tank “...

  • Page 233

    Engine cooling system: 1f-4 diagnostic information and procedures engine cooling symptom diagnosis b831g21604001 repair instructions cooling circuit inspection b831g21606001 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 234

    1f-5 engine cooling system: radiator cap inspection b831g21606002 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection (page 1f-4)”. 2) attach the radiator cap (1) to the radiator tester (2) as shown in the figure. 3) slowly apply pre...

  • Page 235

    Engine cooling system: 1f-6 4) disconnect the cooling fan motor coupler (3). 5) remove the cooling fan assembly (4) by removing the bolts. 6) disconnect the cooling fan thermo-switch (5). 7) disconnect the inlet hose (6) and outlet hose (7). 8) remove the radiator (8) by removing the bolts. 9) remov...

  • Page 236

    1f-7 engine cooling system: installation install the cooling fan assembly and radiator in the reverse order of removal. Pay attention to the following points: • connect the radiator hoses securely. Refer to “water hose routing diagram (page 1f-3)”. • tighten the cooling fan assembly mounting bolts (...

  • Page 237

    Engine cooling system: 1f-8 radiator reservoir tank removal and installation b831g21606007 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the reservoir tank mounting bolts. 3) disconnect the hoses (1) and d...

  • Page 238

    1f-9 engine cooling system: 3) any leakage from the connecting section should be corrected by proper tightening. Refer to “water hose routing diagram (page 1f-3)”. 4) after finishing the water hose inspection, reinstall the removed parts. Ect sensor removal and installation b831g21606010 refer to “e...

  • Page 239

    Engine cooling system: 1f-10 installation install the cooling fan thermo-switch in the reverse order of removal. Pay attention to the following points: • apply engine coolant to the o-ring. Caution ! Replace the removed o-ring with a new one. • tighten the cooling fan thermo-switch to the specified ...

  • Page 240

    1f-11 engine cooling system: thermostat removal and installation b831g21606014 removal 1) drain a small amount of engine coolant. Refer to “cooling system inspection in section 0b (page 0b- 15)”. 2) place a rag under the thermostat cover (1). 3) remove the thermostat case (1). 4) remove the thermost...

  • Page 241

    Engine cooling system: 1f-12 • pour engine coolant. Refer to “cooling system inspection in section 0b (page 0b-15)”. • bleed air from the cooling circuit. Refer to “cooling system inspection in section 0b (page 0b-15)”. Thermostat inspection b831g21606015 inspect the thermostat in the following proc...

  • Page 242

    1f-13 engine cooling system: water pump components b831g21606016 water pump removal and installation b831g21606017 removal note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the o...

  • Page 243

    Engine cooling system: 1f-14 installation install the water pump in the reverse order of removal. Pay attention to the following points: • apply grease to the o-rings. Caution ! Replace the o-rings with the new ones. : grease 99000–25010 (suzuki super grease a or equivalent) • set the water pump dri...

  • Page 244

    1f-15 engine cooling system: 4) remove the pin (7) and washer (8). 5) remove the impeller (9). 6) remove the mechanical seal ring (10) and rubber seal (11) from the impeller. 7) remove the mechanical seal with the special tool. Note if there is no abnormal condition, the mechanical seal removal is n...

  • Page 245

    Engine cooling system: 1f-16 assembly 1) install the oil seal with the special tool. Caution ! Replace the oil seal with a new one. Note the stamped mark on the oil seal should face mechanical seal side. Special tool (a): 09913–70210 (bearing installer set) 2) apply a small quantity of the grease to...

  • Page 246

    1f-17 engine cooling system: 6) apply grease to the impeller shaft. : grease 99000–25010 (suzuki super grease a or equivalent) 7) install the impeller shaft to the water pump body. 8) install the washer (3) and pin (4) to the impeller shaft. 9) install the water pump driven gear (5), washer (6) and ...

  • Page 247

    Engine cooling system: 1f-18 11) fit the water pump cover and tighten the water pump cover screws (9) to the specified torque. Tightening torque water pump cover screw (a): 6 n·m (0.6 kgf-m, 4.5 lb-ft) water pump related parts inspection b831g21606019 refer to “water pump disassembly and assembly (p...

  • Page 248

    1f-19 engine cooling system: specifications service data b831g21607001 thermostat + radiator + fan + coolant tightening torque specifications b831g21607002 note the specified tightening torque is also described in the following. “water hose routing diagram (page 1f-3)” “water pump components (page 1...

  • Page 249

    Engine cooling system: 1f-20 special tools and equipment recommended service material b831g21608001 note required service material is also described in the following. “water pump components (page 1f-13)” special tool b831g21608002 material suzuki recommended product or specification note grease suzu...

  • Page 250: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions for fuel system b831g21700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Caution ! • to...

  • Page 251

    Fuel system: 1g-2 general description fuel system description b831g21701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel mesh filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injector) and fuel pressure regulator (6). There is no fuel ...

  • Page 252

    1g-3 fuel system: schematic and routing diagram fuel hose routing diagram b831g21702001 a fr rr rr rh rh lh lh fr intake pipe outlet tube 1 5 2 2 1 3 4 3 1 view a i831g1170002-04 1. Fuel hose 4. Iap sensor hose 2. Air cleaner box 5. Pass the fuel hose between the air cleaner guide. 3. Pcv hose.

  • Page 253

    Fuel system: 1g-4 fuel tank breather hose routing diagram b831g21702002 1 3 2 7 2 3 5 6 4 1 2 6 8 (a) “a” i831g1170003-04 1. Frame 5. Valve (black) “a”: align the fuel pump nipple with the mark. 2. Fuel tank breather hose 6. Valve (orange) : 35 n ⋅m (3.5 kgf-m, 25.5 lb-ft) 3. Check valve hose 7. Mar...

  • Page 254

    1g-5 fuel system: diagnostic information and procedures fuel system diagnosis b831g21704001 condition possible cause correction / reference item engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. R...

  • Page 255

    Fuel system: 1g-6 repair instructions fuel pressure inspection b831g21706001 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) remove the seat. Refer to “seat remov...

  • Page 256

    1g-7 fuel system: fuel discharge amount inspection b831g21706003 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: 1) remove the rear fender. Refer to “rear si...

  • Page 257

    Fuel system: 1g-8 3) first, check for insulation with the tester between terminals “a” and “b”. Next, check for continuity between “a” and “b” with 12 v voltage applied, positive (+) to terminal “c” and negative (–) to terminal “d”. If continuity does not exist, replace the relay with a new one. Spe...

  • Page 258

    1g-9 fuel system: 7) remove the fuel tank lower cover (4). Installation install the fuel tank in the reverse order of removal. Fuel pump components b831g21706010 fuel pump assembly removal and installation b831g21706011 removal warning ! • spilled gasoline should be wiped off immediately. • keep awa...

  • Page 259

    Fuel system: 1g-10 fuel pump disassembly and assembly b831g21706012 refer to “fuel pump assembly removal and installation (page 1g-9)”. Disassembly remove the fuel cup holder (1) with a (–) screw driver. Assembly assemble the fuel tank pump in the reverse order of the disassembly. Fuel mesh filter i...

  • Page 260

    1g-11 fuel system: 4) disconnect the injector coupler (2). 5) remove the fuel delivery pipe (3) with the injector (4). 6) remove the fuel injector (4) from the fuel delivery pipe. Installation install the fuel injector / fuel delivery pipe in the reverse order of removal. Pay attention to the follow...

  • Page 261

    Fuel system: 1g-12 • install the fuel delivery pipe assembly (5) to the throttle body assembly. Caution ! Never turn the fuel injector while installing it. • tighten the fuel delivery pipe mounting screws to the specified torque. Tightening torque fuel delivery pipe mounting screw (a): 5 n·m (0.5 kg...

  • Page 262

    1g-13 fuel system: 7) move the rear fender upside. 8) disconnect the breather hoses (4) and remove the ftpc valve (5). Installation install the ftpc valve in the reverse order of removal, pay attention to the following points. • install the ftpc valve as shown in the fuel tank breather hose routing ...

  • Page 263

    Fuel system: 1g-14 tightening torque specifications b831g21707002 note the specified tightening torque is also described in the following. “fuel tank breather hose routing diagram (page 1g-4)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque...

  • Page 264: Ignition System

    1h-1 ignition system: engine ignition system general description override switch description b831g21801001 the override switch allows the rider to increase the power available by overriding the normal speed limiter in forward differential lock or reverse. For example, the rider may need to use extra...

  • Page 265

    Ignition system: 1h-2 diagnostic information and procedures ignition system symptom diagnosis b831g21804001 no spark or poor spark b831g21804002 troubleshooting note check that the transfer is in neutral and the engine stop switch is in the “run” position. Check that the fuse is not blown and the ba...

  • Page 266

    1h-3 ignition system: repair instructions spark plug cap and spark plug removal and installation b831g21806001 removal warning ! The hot engine can burn you. Wait until the engine is cool enough to touch. 1) turn the ignition switch off. 2) remove the right side cover and right inner fender. Refer t...

  • Page 267

    Ignition system: 1h-4 3) connect the new spark plug to spark plug cap and ground it to the cylinder head. Note be sure that the spark plug is connected properly and the battery used is in fully- charged condition. 4) connect the multi-circuit tester with the peak voltage adaptor as follows: caution ...

  • Page 268

    1h-5 ignition system: 3) measure the ignition coil resistance in both the primary and secondary coils. If the resistance is not within the standard range, replace the ignition coil with a new one. Special tool : 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) ignition c...

  • Page 269

    Ignition system: 1h-6 ckp sensor resistance 1) remove the left side cover and engine side cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) disconnect the ckp sensor coupler (1). 3) measure the resistance between the lead wires and ground. If the resi...

  • Page 270

    1h-7 ignition system: ignition switch removal and installation b831g21806008 removal 1) remove the left inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the combination meter cover. Refer to “combination meter removal and installation i...

  • Page 271

    Ignition system: 1h-8 specifications service data b831g21807001 electrical unit: mm (in) tightening torque specifications b831g21807002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-7)”. Special tools and equip...

  • Page 272: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b831g21902001 refer to “wire color symbols in section 0a (page 0a-5)”. Component location starting system components location b831g21903001 refer to “electrical components location in section 0a (page ...

  • Page 273

    Starting system: 1i-2 starter motor will not run b831g21904002 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b831g21904003 the starter motor runs when the transfer is in neutral, but does no...

  • Page 274

    1i-3 starting system: repair instructions starter motor components b831g21906001 4 1 2 3 5 6 4 (a) fwd fwd (b) i831g1190002-04 1. O-ring 5. Starter motor case : apply grease to sliding surface. 2. Housing end (inside) 6. Housing end (outside) : apply moly paste to sliding surface. 3. Armature : 6 n ...

  • Page 275

    Starting system: 1i-4 starter motor removal and installation b831g21906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j-12)”. 2) remove the right side cover. Refer to“front side exterior parts remo...

  • Page 276

    1i-5 starting system: • apply grease to the lip of the oil seal and bearing. : grease 99000–25010 (suzuki super grease a or equivalent) • fit the washer to the housing end correctly as shown in the figure. • apply a small quantity of moly paste to the armature shaft. : moly paste 99000–25140 (suzuki...

  • Page 277

    Starting system: 1i-6 commutator inspect the commutator for discoloration, abnormal wear or undercut “a”. If the commutator is abnormally worn, replace the armature. If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth. If there is no undercut, ...

  • Page 278

    1i-7 starting system: installation install the starter relay in the reverse order of removal. Starter relay inspection b831g21906006 inspect the starter relay in the following procedures: 1) remove the starter relay. Refer to “starter relay removal and installation (page 1i-6)”. 2) apply 12 v to “a”...

  • Page 279

    Starting system: 1i-8 neutral relay inspection b831g21906008 inspect the neutral relay in the following procedures: 1) remove the neutral relay. Refer to “neutral relay removal and installation (page 1i-7)”. 2) check the insulation between “a” and “b” terminals using the multi-circuit tester. 3) app...

  • Page 280

    1i-9 starting system: parking brake relay inspection b831g21906011 inspect the parking brake relay in the following procedures: 1) remove the parking brake relay. Refer to “parking brake relay removal and installation (page 1i-8)”. 2) check the insulation between “a” and “b” terminals using the mult...

  • Page 281

    Starting system: 1i-10 4) after finishing the gear position switch inspection, reinstall the removed parts. Starter torque limiter / starter clutch removal and installation b831g21906014 removal 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-10)”. 2) remove t...

  • Page 282

    1i-11 starting system: installation install the starter clutch in the reverse order of removal. Pay attention to the following points: • when inserting the one way clutch (1) into the guide (2), fit the flange “a” in the step of the guide (2). Note be sure to seat the flange “a” of the one way clutc...

  • Page 283

    Starting system: 1i-12 • fit the washers (3) onto the starter torque limiter (4). • install the starter torque limiter (4) to the crankcase. Starter driven gear bearing removal and installation b831g21906015 removal 1) remove the starter driven gear. Refer to “starter torque limiter / starter clutch...

  • Page 284

    1i-13 starting system: starter torque limiter caution ! Do not attempt to disassemble the starter torque limiter. The starter torque limiter is available only as an assembly. 1) set the starter torque limiter to the special tools and vise. 2) turn the starter torque limiter and check the slip torque...

  • Page 285

    Starting system: 1i-14 recoil starter components b831g21906018 recoil starter assembly removal and installation b831g21906019 removal • remove the recoil starter (1). Installation install the recoil starter assembly in the reverse order of removal. Pay attention to the following point: • apply a sma...

  • Page 286

    1i-15 starting system: recoil starter disassembly and assembly b831g21906020 refer to “recoil starter assembly removal and installation (page 1i-14)”. Disassembly warning ! Wear hand and eye protection when removing the reel, since the spring may quickly unwind and cause an injury. 1) remove the nut...

  • Page 287

    Starting system: 1i-16 assembly assemble the recoil starter in the reverse order of disassembly. Pay attention to the following points: warning ! Wear hand and eye protection when installing the reel, since the spring may quickly unwind and cause an injury. • when installing the spiral spring, hook ...

  • Page 288

    1i-17 starting system: recoil starter inspection b831g21906021 ratchet set inspect the ratchet set for wear or damage. If any defects are found, replace the ratchet set with a new one. Reel inspect the reel for wear or damage. If any defects are found, replace the reel with a new one. Rope inspect t...

  • Page 289

    Starting system: 1i-18 specifications service data b831g21907001 unit: mm (in) tightening torque specifications b831g21907002 note the specified tightening torque is also described in the following. “starter motor components (page 1i-3)” reference: for the tightening torque of fastener not specified...

  • Page 290

    1i-19 starting system: special tool b831g21908002 09900–20102 09900–25008 vernier calipers (1/20 mm, 200 mm) multi-circuit tester set ) (page 1i-5) ) (page 1i-6) / )(page 1i-7) / )(page 1i-7) / )(page 1i- 8) / )(page 1i-8) / ) (page 1i-9) / )(page 1i-9) / )(page 1i-9) / )(page 1i- 13) 09913–70210 09...

  • Page 291: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b831g21a02001 component location charging system components location b831g21a03001 refer to “electrical components location in section 0a (page 0a-7)”. Diagnostic information and procedures charging sy...

  • Page 292

    1j-2 charging system: battery runs down quickly b831g21a04002 troubleshooting battery overcharges faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire coupler. Repair. Battery runs down quickly trouble in charging system. Check the generator, regulator/re...

  • Page 293

    Charging system: 1j-3 repair instructions battery current leakage inspection b831g21a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “seat removal and installation in section 9d (page 9d-11)”. 3) disconnect the (–) ...

  • Page 294

    1j-4 charging system: 3) measure the resistance between the three lead wires. If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly. Note when making this test, it is not necessary to remove the generator. Special to...

  • Page 295

    Charging system: 1j-5 8) disconnect the gearshift lever arm (3) and speed sensor coupler (4). 9) disconnect the ckp sensor coupler (5) and generator coupler (6). 10) remove the starter cup nut with a suitable bar. 11) remove the starter cup (7). 12) remove the generator cover (8). 13) remove the gas...

  • Page 296

    1j-6 charging system: 17) remove the generator rotor assembly (10) with the special tool. Note remove the starter clutch if necessary. Refer to “starter torque limiter / starter clutch removal and installation in section 1i (page 1i-10)”. Special tool (b): 09930–30721 (rotor remover) 18) remove the ...

  • Page 297

    Charging system: 1j-7 • hold the generator rotor and tighten the generator rotor nut to the specified torque. Tightening torque generator rotor nut (d): 160 n·m (16.0 kgf-m, 115.5 lb-ft) • apply molybdenum oil solution to the inside of the bush. M/o: molybdenum oil (molybdenum oil solution) • instal...

  • Page 298

    1j-8 charging system: • tighten the starter cup nut (5) to the specified torque. Tightening torque starter cup nut (e): 38 n·m (3.8 kgf-m, 27.5 lb-ft) • when installing the gearshift lever arm, align the wide spline teeth “d” with “e”. Refer to “shift lever disassembly and assembly in section 5a (pa...

  • Page 299

    Charging system: 1j-9 4) measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. Note if the tester reads 1.4 v and below when the tester probes are...

  • Page 300

    1j-10 charging system: 2) remove the caps (2) from the electrolyte container. Note • do not remove or pierce the sealed areas “b” of the electrolyte container. • after filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes. 3) insert the nozzles of the el...

  • Page 301

    Charging system: 1j-11 charging for initial charging, use the charger specially designed for mf battery. Caution ! • for charging the battery, make sure to use the charger specially designed for mf battery. Otherwise, the battery may be overcharged resulting in shortened service life. • do not remov...

  • Page 302

    1j-12 charging system: battery removal and installation b831g21a06008 removal 1) remove the seat. Refer to “seat removal and installation in section 9d (page 9d-11)”. 2) remove the battery stay (1). 3) disconnect the battery (–) lead wire (2). 4) disconnect the battery (+) lead wire (3). Note be sur...

  • Page 303

    Charging system: 1j-13 tightening torque specifications b831g21a07002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c (page 0c-7)”. Special tools and equipment recommended service material b831g21a08001 special tool b831g...

  • Page 304: Exhaust System

    1k-1 exhaust system: engine exhaust system precautions precautions for exhaust system b831g21b00001 warning ! To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure ...

  • Page 305

    Exhaust system: 1k-2 exhaust pipe / muffler removal and installation b831g21b06002 removal 1) remove the inner fenders and side covers, left and right. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the rear carrier. Refer to “rear carrier removal ...

  • Page 306

    1k-3 exhaust system: • install the exhaust pipe gasket (2) and connector (3). Caution ! Replace the gasket and connector with new ones. • tighten the exhaust pipe nuts (4) and muffler connecting mounting bolt (5) to the specified torque. Tightening torque exhaust pipe nut (b): 23 n·m (2.3 kgf-m, 16....

  • Page 307

    Exhaust system: 1k-4 specifications tightening torque specifications b831g21b07001 note the specified tightening torque is also described in the following. “exhaust system construction (page 1k-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening t...

  • Page 308

    1k-5 exhaust system:.

  • Page 309: Section 2

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

  • Page 310: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b831g22000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the...

  • Page 311: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b831g22104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn hub bearings. Replace. Defe...

  • Page 312: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front suspension components b831g22206001 (a) 1 2 (b) 9 16 13 15 14 18 (d) 13 17 fwd fwd 19 19 19 (b) 3 (d) (d) 4 7 6 6 7 8 (c) 11 (c) 11 10 12 5 i831g1220002-08 1. Front shock absorber mounting bolt 10. Suspension arm bolt (lowe...

  • Page 313

    Front suspension: 2b-2 front suspension assembly construction b831g22206002 “ a ” “ a ” 10 11 (e) 7 8 (d) 6 (d) 6 (c) 4 (b) 3 (b) 2 (a) 1 12 12 11 9 (d) 5 i831g1220001-06 1. Front shock absorber mounting bolt 11. Inner dust seal : align the surface of dust seal with the edge of suspension arm. 2. Fr...

  • Page 314

    2b-3 front suspension: front shock absorber removal and installation b831g22206003 caution ! Make sure that the vehicle is supported securely. Removal 1) remove the front wheel. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 2) remove the front shock absorber upper...

  • Page 315

    Front suspension: 2b-4 spring pre-load adjustment b831g22206006 warning ! Be sure to adjust the spring pre-load on the both suspensions equally. • turn the spring tension ring (1) to the desired position. Note position 1 provides the softest spring tension and position 5 provides the stiffest. Std p...

  • Page 316

    2b-5 front suspension: 8) disengage the tie-rod end (8) with the special tool. Warning ! When using the tie-rod end remover, keep clear of the tie-rod end because it may come loose with some force and could strike you. Special tool (a): 09942–72410 (tie rod end remover) 9) remove the cotter pins, kn...

  • Page 317

    Front suspension: 2b-6 • install the cotter pins (4). Caution ! The removed cotter pins (4) must be replaced with new ones. • connect the tie-rod end (5) to the steering knuckle (6) and tighten the tie-rod end nut (7) to the specified torque. Tightening torque tie-rod end nut (b): 29 n·m (2.9 kgf-m,...

  • Page 318

    2b-7 front suspension: • install the brake caliper. Refer to “front brake caliper removal and installation in section 4b (page 4b-3)”. • install the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. • tighten the front hub nut (13) to the specifi...

  • Page 319

    Front suspension: 2b-8 4) remove the wheel hub bearing (4), using the hydraulic press and special tool. Special tool (b): 09913–70210 (bearing installer set) installation install the wheel hub bearing in the reverse order of removal. Pay attention to the following points: • install the wheel hub bea...

  • Page 320

    2b-9 front suspension: • install a new outer dust seal (4) using a suitable size socket wrench. Caution ! Replace the outer dust seal (4) with a new one. • apply grease to the lip of outer dust seal (4). : grease 99000–25160 (water resistance grease) front suspension upper / lower arm removal and in...

  • Page 321

    Front suspension: 2b-10 3) set the steering knuckle (3) and install the suspension upper arm (4). 4) temporarily tighten the suspension arm pivot nut (upper) (5) and shock absorber mounting nut (6). 5) tighten the steering knuckle end nut and tie-rod end nut, and then install the wheel hub. Refer to...

  • Page 322

    2b-11 front suspension: steering knuckle end removal and installation b831g22206012 refer to “front wheel hub / steering knuckle removal and installation (page 2b-4)” and “front suspension upper / lower arm removal and installation (page 2b- 9)”. Removal upper • remove the snap ring (1) with the spe...

  • Page 323

    Front suspension: 2b-12 • install the snap ring (2) with the special tool. Caution ! Replace the snap ring (2) with a new one. Special tool : 09900–06107 (snap ring pliers) lower • install the knuckle end (1) with the special tool. Special tool (a): 09913–70210 (bearing installer set) • install the ...

  • Page 324

    2b-13 front suspension: lower arm inspect the front lower arm (1) and bushings (2) for bend or damage. If any defects are found, replace the defective parts with new ones. Refer to “front suspension lower arm bushing removal and installation (page 2b-14)”. Front suspension upper arm bushing and inne...

  • Page 325

    Front suspension: 2b-14 2) apply grease to the lip of inner dust seals, spacer (1) and inside of dust seals (2). : grease 99000–25160 (water resistance grease) 3) install the washers (3) to the dust seals (2) and install the spacer (1) and dust seals (2) to the front suspension upper arm. Front susp...

  • Page 326

    2b-15 front suspension: specifications service data b831g22207001 suspension tightening torque specifications b831g22207002 note the specified tightening torque is also described in the following. “front suspension components (page 2b-1)” “front suspension assembly construction (page 2b-2)” referenc...

  • Page 327

    Front suspension: 2b-16 special tool b831g22208002 09900–06107 09900–06108 snap ring pliers snap ring pliers ) (page 2b-11) / ) (page 2b-11) / ) (page 2b-12) / ) (page 2b-12) ) (page 2b-7) / )(page 2b- 8) 09913–50121 09913–70210 oil seal remover bearing installer set ) (page 2b-7) / )(page 2b- 7) ) ...

  • Page 328: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components b831g22306001 7 6 8 (a) 16 14 (a) 18 2 4 3 7 (a) 15 1 (a) 16 9 7 (a) 18 (b) 17 (a) 15 12 10 13 11 5 fwd fwd 7 7 8 9 14 7 8 8 8 9 8 9 8 8 8 i831g1230061-10 1. Rear shock absorber 9. Spacer 17. Rear stabili...

  • Page 329

    Rear suspension: 2c-2 rear suspension assembly construction b831g22306002 9 9 7 (a) 1 “ a ” “ a ” 8 7 (b) 3 4 3 “ a ” “ a ” 7 8 8 7 7 (c) 12 “ a ” “ a ” 9 9 7 7 7 (a) 6 “ a ” “ a ” (a) 5 7 9 9 8 (a) 10 (a) 11 (a) 2 9 9 9 9 (c) 12 (a) 2 7 i831g1230003-10

  • Page 330

    2c-3 rear suspension: rear shock absorber removal and installation b831g22306003 removal 1) place the vehicle on level ground and support the vehicle with a jack. 2) remove the rear wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 3) remove the rear d...

  • Page 331

    Rear suspension: 2c-4 rear suspension inspection b831g22306004 refer to “suspensions inspection in section 0b (page 0b-22)”. Rear shock absorber inspection b831g22306005 inspect the rear shock absorber in the following procedures: 1) remove the rear shock absorber. Refer to “rear shock absorber remo...

  • Page 332

    2c-5 rear suspension: 2) remove the rear wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. Caution ! Make sure that the vehicle is supported securely. 3) remove the hub nut (3), washer (4) and rear wheel hub (5). 4) remove the suspension knuckle upper ...

  • Page 333

    Rear suspension: 2c-6 • install the rear wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. • tighten the hub nut (5) to the specified torque. Tightening torque rear wheel hub nut (b): 121 n·m (12.1 kgf-m, 87.5 lb-ft) • install the cotter pin (6). Cauti...

  • Page 334

    2c-7 rear suspension: 4) remove the hub bearing (4) using the hydraulic press and special tool. Special tool (b): 09913–70210 (bearing installer set) installation install the hub bearing in the reverse order of removal. Pay attention to the following points: • install the hub bearing (1) using the h...

  • Page 335

    Rear suspension: 2c-8 • apply grease to the lip of outer dust seal (4). : grease 99000–25160 (water resistance grease) rear suspension arm upper / lower removal and installation b831g22306010 removal 1) remove the rear wheel assembly. Refer to “front / rear wheel removal and installation in section ...

  • Page 336

    2c-9 rear suspension: • tighten the shock absorber mounting lower bolt and nut to the specified torque. Tightening torque rear shock absorber mounting nut (b): 60 n·m ( 6.0 kgf-m, 43.5 lb-ft) • connect the stabilizer joint by tightening the joint nut to the specified torque. Tightening torque rear s...

  • Page 337

    Rear suspension: 2c-10 lower arm 1) inspect the following parts for wear or damage. If any defects are found, replace defective parts with new ones. • suspension lower arm (1) • dust seal (2) • washer (3) • spacer (4) 2) insert the spacer into bushings. 3) check the play by moving the spacer up and ...

  • Page 338

    2c-11 rear suspension: rear suspension upper arm bushing removal and installation b831g22306012 refer to “rear suspension arm upper / lower removal and installation (page 2c-8)”. Removal 1) remove the following parts from the rear suspension upper arm. • dust seal (1) • washer (2) • spacer (3) 2) re...

  • Page 339

    Rear suspension: 2c-12 rear suspension lower arm bushing removal and installation b831g22306013 refer to “rear suspension arm upper / lower removal and installation (page 2c-8)”. Removal 1) remove the following parts from the rear suspension lower arm. • dust seal (1) • washer (2) • spacer (3) 2) re...

  • Page 340

    2c-13 rear suspension: 2) apply grease to the lip of inner dust seals, spacer (3) and inside of dust seals (4). : grease 99000–25160 (water resistance grease) 3) install the spacer (3), dust seals (4) and washers (5) to the rear suspension lower arm. Rear suspension knuckle bushing removal and insta...

  • Page 341

    Rear suspension: 2c-14 2) apply grease to the lip of the inner dust seals, spacer (1) and inside of dust seals (2). : grease 99000–25160 (water resistance grease) 3) install the spacers (1), dust seals (2) and washers (3) to the rear suspension knuckle. Rear stabilizer removal and installation b831g...

  • Page 342

    2c-15 rear suspension: • tighten the stabilizer joint nuts (2) to the specified torque. Tightening torque rear stabilizer joint nut (a): 34 n·m (3.4 kgf-m, 24.5 lb-ft) stabilizer parts inspection b831g22306016 refer to “rear stabilizer removal and installation (page 2c-14)”. Stabilizer bar inspect f...

  • Page 343

    Rear suspension: 2c-16 specifications service data b831g22307001 suspension unit: mm (in) tightening torque specifications b831g22307002 note the specified tightening torque is also described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2...

  • Page 344

    2c-17 rear suspension: special tool b831g22308002 09900–06108 09913–50121 snap ring pliers oil seal remover ) (page 2c-6) / )(page 2c- 7) ) (page 2c-6) / )(page 2c- 6) 09913–70210 09913–75520 bearing installer set bearing installer ) (page 2c-7) ) (page 2c-7) 09923–73210 09930–30104 bearing remover ...

  • Page 345: Wheels and Tires

    Wheels and tires: 2d-1 suspension wheels and tires precautions precautions for wheel and tire b831g22400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of vehicle control. • under-inflated tires make smooth corne...

  • Page 346

    2d-2 wheels and tires: front / rear wheel removal and installation b831g22406002 note the front and rear wheels are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) place the vehicle on level ground. 2) support the vehicle wi...

  • Page 347

    Wheels and tires: 2d-3 5) after removing the tire, inspect the wheel if necessary. Installation 1) clean up the sealing portion of the rim. 2) apply tire lubricant to the tire bead and the flange of the rim. Caution ! Never apply grease, oil or gasoline to the tire bead because they will deteriorate...

  • Page 348

    2d-4 wheels and tires: note check the “rim line” “b” cast on the tire sidewalls. It must be equidistant from the wheel rim all the way around. If the distance between the rim line and the wheel rim varies, this indicates that the bead is not properly seated. If this is so, deflate the tire completel...

  • Page 349: Section 3

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

  • Page 350

    3-ii table of contents recommended service material .......................3c-18 special tool ......................................................3c-18 propeller shafts....................................... 3d-1 repair instructions ..............................................3d-1 front output s...

  • Page 351: Precautions

    Precautions: 3-1 driveline / axle precautions precautions precautions for driveline / axle b831g23000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train..

  • Page 352

    3a-1 drive chain / drive train / drive shaft: driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive shaft symptom diagnosis b831g23104001 repair instructions front drive shaft components b831g23106001 condition possible cause correction / reference item...

  • Page 353

    Drive chain / drive train / drive shaft: 3a-2 front drive shaft assembly removal and installation b831g23106002 removal 1) drain the front differential gear oil. Refer to “front differential gear oil inspection in section 0b (page 0b-12)”. 2) remove the front wheel. Refer to “front / rear wheel remo...

  • Page 354

    3a-3 drive chain / drive train / drive shaft: 2) slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race. 3) remove the outer race from the front drive shaft. 4) wipe off any grease and remove the snap ring. Special tool (a): 09900–06107 (snap ring p...

  • Page 355

    Drive chain / drive train / drive shaft: 3a-4 3) install the new snap ring to the cage. Caution ! Replace the snap ring with a new one. Special tool (a): 09900–06107 (snap ring pliers) 4) apply grease to the entire surface of the cage and the inside of the outer race. Note the tube of joint grease i...

  • Page 356

    3a-5 drive chain / drive train / drive shaft: 8) install the circlip (2) into the groove of front drive shaft spline. Caution ! The removed circlip must be replaced with a new one. 9) inspect the axle play by using a push-and-pull motion given to the axle shaft and wheel spindle. Front drive shaft i...

  • Page 357

    Drive chain / drive train / drive shaft: 3a-6 rear drive shaft components b831g23106005 rear drive shaft assembly removal and installation b831g23106006 removal 1) drain the rear final gear oil. Refer to “final gear oil inspection in section 0b (page 0b-14)”. 2) remove the rear wheel. Refer to “fron...

  • Page 358

    3a-7 drive chain / drive train / drive shaft: installation install the rear drive shaft in the reverse order of removal. Pay attention to the following points: • install a new circlip (1) into the groove of drive shaft spline. Caution ! The removed circlip must be replaced with a new one. • apply gr...

  • Page 359: Differential

    Differential: 3b-1 driveline / axle differential diagnostic information and procedures drive train symptom diagnosis b831g23204001 dtc “c20” (p1752) diff-lock relay circuit malfunction b831g23204002 refer to “dtc “c20” (p1752): diff-lock relay circuit malfunction in section 1a (page 1a-47)”. Conditi...

  • Page 360

    3b-2 differential: repair instructions front drive (differential) components b831g23206001 1 11 (a) 25 24 3 5 4 6 7 2 (b) 26 11 (b) 27 13 12 8 9 10 20 21 22 23 14 15 16 17 18 19 fwd fwd i831g1320001-06 1. Front drive (differential) gear case 12. O-ring 23. Input shaft 2. Front drive (differential) g...

  • Page 361

    Differential: 3b-3 front drive (differential) construction b831g23206002 (a) 2 1 1 “a” i831g1320002-07 1. Shim : 1.3 n ⋅m (0.13 kgf-m, 0.94 lb-ft) : apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : apply grease. : apply bond to matching surface. “a”: matching sur...

  • Page 362

    3b-4 differential: front drive (differential) gear oil level inspection b831g23206003 refer to “front differential gear oil inspection in section 0b (page 0b-12)”. Front drive (differential) gear oil replacement b831g23206004 refer to “front differential gear oil inspection in section 0b (page 0b-12...

  • Page 363

    Differential: 3b-5 installation install the front drive (differential) assembly in the reverse order of removal. Pay attention to the following points: • apply 4.5 gram of grease to spline of the front propeller shaft. : grease 99000–25160 (water resistance grease) • apply thread lock to the bolts a...

  • Page 364

    3b-6 differential: 4) align the concave part of 2wd/4wd shifting cam and convex part of diff-lock shift fork. 5) remove the front drive (differential) gear assembly (2), diff-lock shifting fork (3) and shifting fork shaft (4). 6) remove the shims from the housing and cover. 7) remove the snap ring (...

  • Page 365

    Differential: 3b-7 13) remove the oil seal cap (10) and oil seal (11). • remove the snap ring (12) and input shaft (13). Special tool : 09900–06108 (snap ring pliers) 14) remove 2wd/4wd shifting sleeve (14). 15) remove the input shaft bearing (15) with the special tool. Note if there is no abnormal ...

  • Page 366

    3b-8 differential: 18) remove the pinion gear pilot bearing with the special tools. Note if there is no abnormal noise, the bearing removal is not necessary. Special tool (e): 09921–20240 (bearing remover set) (f): 09944–66010 (bearing installer) (g): 09924–84521 (bearing installer set) 19) remove t...

  • Page 367

    Differential: 3b-9 4) install the pinion gear into the front drive train (differential) gear case and fix the snap ring (4). Special tool : 09900–06108 (snap ring pliers) 5) install the input shaft bearing (5) onto the input shaft with the special tool. Special tool (a): 09913–70210 (bearing install...

  • Page 368

    3b-10 differential: 12) apply front differential gear oil to the 2wd/4wd sifting fork shaft (9). 13) install the left and right side shims into the case cover and case. 14) install the 2wd/4wd sifting cam bearing (10) with special tool. Special tool (a): 09913–70210 (bearing installer set) 15) insta...

  • Page 369

    Differential: 3b-11 19) install the diff-lock shifting fork (15) to the shifting sleeve. 20) install the front drive (differential) gear assembly, diff- lock shifting fork (15) and shifting fork shaft (16). 21) align the shifting fork pin with the groove of the 2wd/ 4wd shifting cam (13). 22) apply ...

  • Page 370

    3b-12 differential: 26) apply grease to the o-rings. Caution ! Replace the o-rings with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) 27) apply a small quantity of thread lock to the 4wd/diff- lock actuator mounting bolts (18). 28) install the 2wd/4wd/diff-lock actuator assemb...

  • Page 371

    Differential: 3b-13 diff-lock shifting shaft and 2wd/4wd shifting shaft inspect the 2wd/4wd shifting fork shafts for wear or damage. If any defects are found, replace the shifting fork shafts with new ones. Diff-lock shifting fork and 2wd/4wd shifting fork inspect the shifting forks for wear or dama...

  • Page 372

    3b-14 differential: pinion gear inspect the pinion gear for wear or damage. Inspect the pinion gear bearing for abnormal noise and smooth rotation. If any defects are found, replace defective parts. Front drive (differential) gear inspect the front drive (differential) gear for stick or damage. Insp...

  • Page 373

    Differential: 3b-15 • remove the oil filler cap and measure the backlash of the differential ring gear using the horizontal type dial gauge and drive shaft (3) as shown in the figure. • take backlash readings at three places while turning the front drive (differential) gear slightly in each directio...

  • Page 374

    3b-16 differential: • install the front drive (differential) case (2) and tighten the bolts to the special torque diagonally. Tightening torque front drive (differential) case bolt (a): 22 n·m (2.2 kgf-m, 16.0 lb-ft) • remove the front drive (differential) case. • measure the thickness of compressed...

  • Page 375

    Differential: 3b-17 • rotate the final drive (differential) gear several turns in each direction. This will provide a contact pattern on the coated teeth of final drive (differential) gear. • remove the final drive (differential) gear and compare the coated teeth to the examples shown in [a], [b] an...

  • Page 376

    3b-18 differential: 3) inspect the 2wd/4wd/diff-lock switch for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebars removal and installation in section 6b (page 6b-3)”. Special tool : 09900–25008 (multi-circuit tester...

  • Page 377

    Differential: 3b-19 4) check that both “differential lock position switch signal” and “differential lock switch signal” are “open”. 5) turn the transfer selecting switch (diff-lock position switch and diff-lock switch) on position. 6) check that both “differential lock position switch signal” and “d...

  • Page 378

    3b-20 differential: 4) apply 12 v to the terminal “b” and “e” ((+) to “e” and (–) to “b”), check the insulation between “a” and “d”. If any abnormality is found, replace the 4wd/diff-lock relay with a new one. Special tool : 09900–25008 (multi-circuit tester set) diff-lock relay check the insulation...

  • Page 379

    Differential: 3b-21 final gear components b831g23206012 1 2 3 4 5 6 7 8 9 10 11 12 13 (a) 14 (a) 15 (b) 16 (c) 17 (d) 17 (d) 18 (d) 19 fwd fwd 20 (e) i831g1320080-08 1. Final gear case 11. Shim : 100 n ⋅m (10.0 kgf-m, 72.0 lb-ft) 2. Final gear case cover 12. Pinion gear : 26 n ⋅m (2.6 kgf-m, 19.0 lb...

  • Page 380

    3b-22 differential: final gear construction b831g23206013 1 2 2 3 (b) 4 (b) 5 (b) 6 (a) “a” “a” i831g1320081-04 1. Shim (left side) 6. Lock-nut : apply water resistance grease. 2. Shim (right side) “a”: matching surface : apply thread lock to thread part. 3. Pinion gear shim(s) : 26 n ⋅m (2.6 kgf-m,...

  • Page 381

    Differential: 3b-23 final gear oil level inspection b831g23206014 refer to “final gear oil inspection in section 0b (page 0b-14)”. Final gear oil replacement. B831g23206015 refer to “final gear oil inspection in section 0b (page 0b-14)”. Final gear assembly removal and installation b831g23206016 rem...

  • Page 382

    3b-24 differential: installation installation the final gear assembly in the reverse order of removal. Pay attention to the following points: • apply 4.5 gram water resistance grease to the spline of the rear propeller shaft. : grease 99000–25160 (water resistance grease) • install the final gear ca...

  • Page 383

    Differential: 3b-25 4) remove the o-ring (3) and final driven gear (4). 5) remove the shim(s) (5). 6) remove the oil seal (6) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 7) remove the final driven gear bearing (7) with the special tool. Note if there is no abnormal condit...

  • Page 384

    3b-26 differential: 10) remove the final driven gear bearing (9) with the suitable tool. Note if there is no abnormal condition, the bearing removal is not necessary. 11) unlock the final drive stopper (10) with a chisel. 12) remove the final drive stopper (11) with the special tool. Special tool (d...

  • Page 385

    Differential: 3b-27 17) remove the bearing (16) and the upper inner race from the pinion gear with the special tool and suitable tool. Note if there is no abnormal condition, the bearing removal is not necessary. Special tool (g): 09913–61510 (bearing puller) 18) remove the lower inner race (17) wit...

  • Page 386

    3b-28 differential: • install the final drive gear bearing (1) to the final gear case with the special tool. Special tool (a): 09913–70210 (bearing installer set) • install the final drive bearing (2) with the special tool. Special tool (c): 09913–84510 (bearing installer) • install the washer (3) a...

  • Page 387

    Differential: 3b-29 • tighten the final drive gear bearing stopper (7) to the specified torque with the special tool. Caution ! The removed final drive gear bearing stopper must be replaced with a new one. Tightening torque final drive gear bearing stopper (b): 100 n·m ( 10.0 kgf-m, 72.5 lb-ft) spec...

  • Page 388

    3b-30 differential: • install the final driven gear (8) and shim(s) (9) into the final gear case. • install the shim(s) (10). • install the o-ring to the final gear cover (11). • apply a small quantity of grease to the o-ring. : grease 99000–25010 (suzuki super grease a or equivalent) • apply a smal...

  • Page 389

    Differential: 3b-31 final drive gear inspect the final drive gear for wear or damage. Inspect the final drive gear bearing for abnormal noise and smooth rotation. If any defects are found, replace defective parts. Final driven gear inspect the final driven gear for wear or damage. If any defects are...

  • Page 390

    3b-32 differential: left side shim selection put a few pieces of solder (o.D.: 1.2 – 1.5 mm x l: 6 mm) on the back side of final driven gear, as shown in the figure. Note do not install the left side shim(s) at this time. • install the final gear cover and tighten its bolts to the specified torque d...

  • Page 391

    Differential: 3b-33 • install the left and right side shim(s) (2) and final driven gear assembly (1). • install the final gear cover, and then tighten the bolts to the specified torque diagonally. Refer to “final gear assembly disassembly and assembly (page 3b-24)”. Note at this time, it is not nece...

  • Page 392

    3b-34 differential: specifications service data b831g23207001 drive train unit: mm (in) tightening torque specifications b831g23207002 note the specified tightening torque is also described in the following. “front drive (differential) components (page 3b-2)” “front drive (differential) construction...

  • Page 393

    Differential: 3b-35 special tools and equipment recommended service material b831g23208001 note required service material is also described in the following. “front drive (differential) components (page 3b-2)” “front drive (differential) construction (page 3b-3)” “final gear components (page 3b-21)”...

  • Page 394

    3b-36 differential: 09913–61510 09913–70210 bearing puller bearing installer set ) (page 3b-27) ) (page 3b-6) / )(page 3b- 8) / )(page 3b-8) / ) (page 3b-8) / )(page 3b- 9) / )(page 3b-9) / ) (page 3b-10) / ) (page 3b-10) / ) (page 3b-25) / ) (page 3b-27) / ) (page 3b-28) 09913–84510 09921–20240 bea...

  • Page 395: Transfer

    Transfer: 3c-1 driveline / axle transfer diagnostic information and procedures transfer symptom diagnosis b831g23304001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transfer) worn or rubbing gear. Replace. Worn transfer input/output shaft. Replac...

  • Page 396

    3c-2 transfer: repair instructions transfer components b831g23306001 1 1 2 3 5 6 9 10 20 20 12 13 14 15 16 17 14 18 4 21 19 22 23 24 25 26 28 29 30 33 27 fwd fwd 8 7 11 35 32 31 34 i831g1330001-09 1. Washer 14. Driven gear bushing 27. Counter shaft bearing (left side) 2. Reverse idle gear 15. Select...

  • Page 397

    Transfer: 3c-3 transfer removal and installation b831g23306002 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-13)”. 2) disassemble the engine top side. Refer to “engine top side disassembly in section 1d (page 1d-17)”. 3) separate the c...

  • Page 398

    3c-4 transfer: 9) remove the drive shaft (9) with a plastic mallet by installing a suitable washer with the drive face bolt. 10) remove the drive bevel gear (10). Refer to “rear output shaft removal and installation in section 3d (page 3d-6)”. 11) remove the output shaft (11) with a plastic mallet. ...

  • Page 399

    Transfer: 3c-5 • install the transfer output shaft assembly and reverse idle gear. Refer to “transfer components (page 3c- 2)”. • install the gearshift fork (2) and reverse gearshift fork (3). Note identify the shape of the shift forks and install them properly. • install the gearshift cam (4). • wi...

  • Page 400

    3c-6 transfer: transfer construction b831g23306003 counter shaft / reverse idle gear disassembly and assembly b831g23306004 caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original position. Disassembly refe...

  • Page 401

    Transfer: 3c-7 3) remove the low driven gear bushing (3) and select sliding dog (4). 4) remove the reverse select spacer (5), reverse gear (6) and reverse driven gear bushing (7). 5) remove the lock washer (8). 6) remove the lock washer (9) by aligning the teeth “a” of the lock washer with the splin...

  • Page 402

    3c-8 transfer: reverse idle gear 1) remove the washers (1). 2) remove the reverse idle gear shaft (2) and bering (3). Assembly note • when reassembling the driven gears, attention must be given to the locations and positions of washers. The cross sectional view shows the correct position of the snap...

  • Page 403

    Transfer: 3c-9 • when installing the gear bushing onto the counter shaft, align the shaft oil hole “c” with the bushing oil hole “d” as shown in the figure. Gearshift cam components b831g23306005 “c” “d” i831g1330033-05 “d” “c” i831g1330034-03 fwd fwd 5 1 7 8 9 10 13 16 17 20 22 21 2 3 11 12 15 4 14...

  • Page 404

    3c-10 transfer: gearshift system construction b831g23306006 6. Snap ring 15. Gearshift fork shaft : apply engine oil. 7. Washer 16. Gearshift cam stopper : do not reuse. 8. Spring 17. Gearshift arm 9. Gearshift cam 18. Washer 4 4 4 4 1 2 3 i831g1330004-04 1. Gearshift shaft 3. Gearshift cam 2. Rever...

  • Page 405

    Transfer: 3c-11 gearshift cam disassembly and assembly b831g23306007 disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. • remove the gearshift cam assembly. Refer to “transfer re...

  • Page 406

    3c-12 transfer: • install the snap ring (1) and gearshift cam (2). Caution ! • align the punch mark “a” of the gearshift cam with the punch mark “b” of the shaft. • install the washer (3), spring (4) and reverse shift cam (5). Caution ! • align the punch mark “c” of the reverse shift cam with the pu...

  • Page 407

    Transfer: 3c-13 gearshift fork groove width measure the gearshift fork groove width using the vernier calipers. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) gearshift fork groove width standard (reverse/low & high): 5.5 – 5.6 mm (0.217 – 0.220 in) gearshift fork thickness measu...

  • Page 408

    3c-14 transfer: installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten the gear position swit...

  • Page 409

    Transfer: 3c-15 6) remove the following parts from the gearshift shaft (4). • gearshift return spring (5) • shift gear (6) • snap ring (7) special tool : 09900–06107 (snap ring pliers) 7) remove the gearshift cam stopper plate (8). 8) remove the gearshift cam stopper (9). Installation install the ge...

  • Page 410

    3c-16 transfer: • install the gearshift cam stopper plate (5). Note • align the gearshift cam pin “b” with the gearshift cam stopper plate hole “c”. • tighten the gearshift cam stopper plate bolt securely. • when installing the shift arm return spring, position the stopper “d” of gearshift shaft no....

  • Page 411

    Transfer: 3c-17 gearshift linkage inspection b831g23306015 refer to “gearshift shaft no. 2 / gearshift cam plate removal and installation (page 3c-14)”. Gearshift shaft check the gearshift for bend or wear. Check the return spring for damage or fatigue. If any defects are found, replace the defectiv...

  • Page 412

    3c-18 transfer: specifications service data b831g23307001 drive train unit: mm (in) except ratio special tools and equipment recommended service material b831g23308001 note required service material is also described in the following. “transfer components (page 3c-2)” “gearshift cam components (page...

  • Page 413: Propeller Shafts

    Propeller shafts: 3d-1 driveline / axle propeller shafts repair instructions front output shaft components b831g23406001 front output shaft removal and installation b831g23406002 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-13)”. 2) d...

  • Page 414

    3d-2 propeller shafts: 4) remove the front output shaft (1) from the right crankcase. Installation install the front output shaft in the reverse order of removal. Pay attention to the following point: • apply engine oil to the front output bearing (rear). • apply a small quantity of grease to the o-...

  • Page 415

    Propeller shafts: 3d-3 3) remove the o-ring (6). 4) remove the oil seal (7) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 5) remove the snap ring (8) and washer (9). Special tool : 09900–06108 (snap ring pliers) 6) remove the front output shaft bearing (front) with the spec...

  • Page 416

    3d-4 propeller shafts: assembly caution ! The removed bearing, snap rings, oil seal, c- ring and o-rings must be replaced with new ones. 1) install the front output shaft bearing (rear) (1) to the right crankcase with the special tool. Special tool (a): 09913–70210 (bearing installer set) 2) install...

  • Page 417

    Propeller shafts: 3d-5 11) install the front output shaft to the right crankcase. 12) tighten the front output shaft bolts (10). 13) assemble the engine. Refer to “engine bottom side disassembly in section 1d (page 1d-45)” and “engine top side assembly in section 1d (page 1d- 21)”. 14) remount the e...

  • Page 418

    3d-6 propeller shafts: rear output shaft components b831g23406005 rear output shaft removal and installation b831g23406006 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-13)”. 2) disassemble the engine top side. Refer to “engine top sid...

  • Page 419

    Propeller shafts: 3d-7 4) remove the rear output shaft (1). 5) remove the c-ring (2). 6) remove the drive shaft, counter shaft assembly and reverse idle gear. Refer to “transfer removal and installation in section 3c (page 3c-3)”. 7) unlock the drive bevel gear nut with a chisel. 8) hold the transfe...

  • Page 420

    3d-8 propeller shafts: • install the rear output shaft (1). Note be sure to fit the c-ring (2) and bearing knock-pin “a” on the bearing to the groove of the crankcase. • after installed rear output shaft, inspect the backlash and tooth contact. Refer to “rear output shaft drive bevel gear shim inspe...

  • Page 421

    Propeller shafts: 3d-9 assembly assemble the rear output shaft in the reverse order of disassembly. Pay attention to the following points: note apply engine oil to each running part before reassembling. • install the shim(s) (1) and bearing (2). Note the bearing knock-pin “a” should be positioned in...

  • Page 422

    3d-10 propeller shafts: • lock the rear output shaft driven gear nut (9) with a center punch. Rear output shaft related parts inspection b831g23406008 refer to “rear output shaft disassembly and assembly (page 3d-8)”. Rear output shaft inspect the rear output shaft (1) for wear or damage. If any def...

  • Page 423

    Propeller shafts: 3d-11 rear output shaft drive bevel gear shim inspection and adjustment b831g23406009 refer to “rear output shaft removal and installation (page 3d-6)”. Backlash • install the shim, drive bevel gear, washer and new drive bevel gear nut. • hold the transfer output driven gear with t...

  • Page 424

    3d-12 propeller shafts: list of shims (for driven bevel gear) • check the tooth contact. Tooth contact caution ! Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed. Adjust the tooth contact and backlash until they are both within specification. If th...

  • Page 425

    Propeller shafts: 3d-13 list of shims (for drive bevel gear) part no. Shim thickness 24935-19b00-025: 0.25 mm (0.0098 in) co mbi ned shi m 0.25+0.25=0.50 mm (0.0197 in) 0.25+0.30=0.55 mm (0.0217 in) 0.30+0.30=0.60 mm (0.0236 in) 0.30+0.35=0.65 mm (0.0256 in) 24935-19b00-030: 0.30 mm (0.0118 in) 0.35...

  • Page 426

    3d-14 propeller shafts: front propeller shaft components b831g23406010 front propeller shaft removal and installation b831g23406011 refer to “front propeller shaft components (page 3d- 14)” and “front drive (differential) construction in section 3b (page 3b-3)”. Removal remove the front drive (diffe...

  • Page 427

    Propeller shafts: 3d-15 installation caution ! The removed circlips must be replaced with new ones. 1) fit the front propeller shaft boot (1) and universal joint boot (2) to the front propeller shaft groove. 2) apply grease (approx. 4 grams) to the spline of universal joint and spline of the front p...

  • Page 428

    3d-16 propeller shafts: front propeller shaft related parts inspection b831g23406012 refer to “front propeller shaft removal and installation (page 3d-14)”. Front propeller shaft inspect the front propeller shaft for wear or damage. If any defects are found, replace the front propeller shaft with a ...

  • Page 429

    Propeller shafts: 3d-17 rear propeller shaft components b831g23406013 rear propeller shaft removal and installation b831g23406014 refer to “rear propeller shaft components (page 3d- 17)”. Refer to “final gear construction in section 3b (page 3b-22)”. Removal 1) remove the final gear assembly. Refer ...

  • Page 430

    3d-18 propeller shafts: 4) remove the rear propeller shaft spring (3). 5) draw out the rear propeller shaft (4) horizontally. 6) loosen the boot clamp screw and remove the rear propeller shaft boot (5). 7) remove the rear propeller shaft joint boot (6). 8) remove the o-ring (7). 9) remove the circli...

  • Page 431

    Propeller shafts: 3d-19 12) unlock the nut with a chisel. 13) shift into the reverse gear. 14) remove the rear output shaft yoke (10). 15) remove the oil seal. Installation caution ! The removed oil seal, nut, circlips and o-ring must be replaced with a new ones. 1) install the oil seal into the fin...

  • Page 432

    3d-20 propeller shafts: 8) install the universal joint (4) to the yoke (5) and bearings (6) with the special tool. Special tool (a): 09913–70210 (bearing installer set) 9) install the circlips. 10) install the yoke (5). 11) install the bearings (6) by tapping with the special tool. Special tool (a):...

  • Page 433

    Propeller shafts: 3d-21 15) fit the rear propeller shaft joint boot (9) to the rear propeller shaft groove. 16) apply resistance grease (approx. 4 grams) to the splines of the rear propeller shaft. : grease 99000–25160 (water resistance grease) 17) install the rear propeller shaft. 18) apply grease ...

  • Page 434

    3d-22 propeller shafts: rear propeller shaft related parts inspection b831g23406015 refer to “rear propeller shaft removal and installation (page 3d-17)”. Rear propeller shaft / rear propeller shaft joint inspect the rear propeller shaft and rear propeller shaft joint for wear or damage. If any defe...

  • Page 435

    Propeller shafts: 3d-23 specifications service data b831g23407001 drive train unit: mm (in) tightening torque specifications b831g23407002 note the specified tightening torque is also described in the following. “rear output shaft components (page 3d-6)” “rear propeller shaft components (page 3d-17)...

  • Page 436

    3d-24 propeller shafts: special tool b831g23408002 09900–06107 09900–06108 snap ring pliers snap ring pliers ) (page 3d-2) ) (page 3d-3) / )(page 3d- 4) 09900–20607 09900–20701 dial gauge (1/100 mm, 10 mm) magnetic stand ) (page 3d-11) ) (page 3d-11) 09913–50121 09913–70210 oil seal remover bearing ...

  • Page 437: Section 4

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

  • Page 438

    4-ii table of contents parking / rear brake lever removal and installation.........................................................4d-4 parking / rear brake light switch inspection .....4d-4 parking / rear brake relay inspection ...............4d-4 specifications .......................................

  • Page 439: Precautions

    Precautions: 4-1 brake precautions precautions precautions for brake system b831g24000001 refer to “general precautions in section 00 (page 00-1)”. Brake fluid information b831g24000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 440

    4a-1 brake control system and diagnosis: brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b831g24102001 1 1 2 3 5 5 4 6 6 “d” “a” “d” “e” “f” “c” “g” “d” “j” “i” 6 fwd view a 7 9 9 “h” “b” 4 a 8 (a) 8 (a) 8 (a) i831g1410001-09 1. Master cylinder...

  • Page 441

    Brake control system and diagnosis: 4a-2 rear blake cable routing diagram b831g24102002 1 2 “a” 1 3 5 6 4 front side i831g1410035-05 1. Rear brake cable 3. Rear brake pedal 5. Washer “a”: fix the rear brake cable to the footrest bar with clamp. 2. Adjust nut 4. Pin 6. Cotter pin.

  • Page 442

    4a-3 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b831g24104001 condition possible cause correction / reference item insufficient brake power leakage of brake fluid from hydraulic system. Repair or replace. Worn pads or friction plate. Replace. Oi...

  • Page 443

    Brake control system and diagnosis: 4a-4 repair instructions brake pedal height inspection and adjustment b831g24106001 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment in section 0b (page 0b-19)”. Front brake light switch inspection b831g24106002 inspect the f...

  • Page 444

    4a-5 brake control system and diagnosis: parking / rear brake light switch inspection b831g24106005 inspect the parking/rear brake light switch in the following procedures: 1) remove the left inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) di...

  • Page 445

    Brake control system and diagnosis: 4a-6 4) loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. 5) close the air bleeder valve, pump and squeeze the le...

  • Page 446

    4a-7 brake control system and diagnosis: 7) loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system. 8) close the air bleeder valve (1) and disconnect the clear hose. Tightening torque front brake air bleeder valve (a): 6 n·m (0.6 kgf- m, 4.5 lb-...

  • Page 447

    Brake control system and diagnosis: 4a-8 rear brake cable removal and installation b831g24106012 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the right mud guard. Refer to “rear side exterior parts remova...

  • Page 448

    4a-9 brake control system and diagnosis: front brake master cylinder components b831g24106013 front brake master cylinder assembly removal and installation b831g24106014 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) remove the throttle case assembly. Refer to “hand...

  • Page 449

    Brake control system and diagnosis: 4a-10 4) place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. 5) remove the brake hose union bolt (2) and disconnect the brake hose. 6) remove the master cylinder assembly (3). Installation install the front b...

  • Page 450

    4a-11 brake control system and diagnosis: front brake master cylinder / brake lever disassembly and assembly b831g24106015 refer to “front brake master cylinder assembly removal and installation (page 4a-9)”. Disassembly 1) remove the brake lever (1) and brake light switch (2). 2) remove the reservo...

  • Page 451

    Brake control system and diagnosis: 4a-12 • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • apply grease to the brake lever pivot bolt. • apply grease to the contact point between piston and brake lever. : grease 99000–25100 (suzuki ...

  • Page 452

    4a-13 brake control system and diagnosis: rear brake pedal construction b831g24106017 “ a ” 1 2 3 (a) 4 i831g1410038-04 1. Brake pedal 4. Brake pedal pivot bolt : apply water resistance grease. 2. Brake light switch “a”: 17.5 mm (0.69 in) : apply thread lock to the thread part. 3. O-ring : 11 n ⋅m (...

  • Page 453

    Brake control system and diagnosis: 4a-14 rear brake pedal removal and installation b831g24106018 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the right mud guard. Refer to “rear side exterior parts remov...

  • Page 454

    4a-15 brake control system and diagnosis: specifications service data b831g24107001 brake unit: mm (in) oil tightening torque specifications b831g24107002 note the specified tightening torque is also described in the following. “front brake hose routing diagram (page 4a-1)” “front brake master cylin...

  • Page 455

    Brake control system and diagnosis: 4a-16 special tools and equipment recommended service material b831g24108001 note required service material is also described in the following. “front brake master cylinder components (page 4a-9)” “rear brake pedal construction (page 4a-13)” special tool b831g2410...

  • Page 456: Front Brakes

    4b-1 front brakes: brake front brakes precautions precautions for front brakes b831g24200001 warning ! When servicing the front brake system, place the vehicle on a level ground and support the vehicle with a jack. Note the right and left calipers, brake pads and discs are installed symmetrically an...

  • Page 457

    Front brakes: 4b-2 front brake pad inspection b831g24206002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement (page 4b-2)”. Caution ! Re...

  • Page 458

    4b-3 front brakes: 7) apply a small quantity of thread lock to the brake pad mounting pins (2). : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) 8) tighten the front brake pad mounting pins (2) to the specified torque. Tightening torque front brake pad mounting pin (a): 18 n·...

  • Page 459

    Front brakes: 4b-4 • after setting the brake hose union to the stopper, tighten the union bolt (3) to the specified torque. Caution ! The seal washers (4) should be replaced with the new ones to prevent fluid leakage. Tightening torque front brake hose union bolt (b): 23 n·m (2.3 kgf- m, 16.5 lb-ft)...

  • Page 460

    4b-5 front brakes: brake caliper holder • remove the caliper holder pin (1) and caliper holder slide pin (2) from caliper holder (3). Assembly assemble the caliper in the reverse order of disassembly. Pay attention to the following points: brake caliper holder • apply thread lock to the caliper hold...

  • Page 461

    Front brakes: 4b-6 • apply silicon grease to the two pins. : grease 99000–25100 (suzuki silicone grease or equivalent) • install the brake caliper holder (3) to the brake caliper (4). • install the brake pads. Refer to “front brake pad replacement (page 4b-2)”. • install the brake caliper and brake ...

  • Page 462

    4b-7 front brakes: brake pad mounting pin inspect the brake pad mounting pin for wear or other damage. If any damage is found, replace the mounting pin with a new one. Brake pad spring inspect the brake pad springs for damage or excessive bend. If any defects are found, replace them with new ones. B...

  • Page 463

    Front brakes: 4b-8 front brake disc inspection b831g24206008 brake disc thickness 1) dismount the front brake caliper. Refer to “front brake caliper removal and installation (page 4b- 3)”. 2) check the brake disc for damage or cracks and measure the thickness using the micrometer. 3) replace the bra...

  • Page 464

    4b-9 front brakes: tightening torque specifications b831g24207002 note the specified tightening torque is also described in the following. “front brake components (page 4b-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section ...

  • Page 465: Rear Brakes

    Rear brakes: 4c-1 brake rear brakes precautions precautions for rear brake b831g24300001 warning ! When servicing the rear brake system, place the vehicle on a level ground and support the vehicle with a jack. Repair instructions rear brake components b831g24306001 1 2 3 5 4 7 8 9 10 11 12 13 16 (a)...

  • Page 466

    4c-2 rear brakes: rear brake friction plate inspection b831g24306002 refer to “rear brake friction plate wear limit inspection in section 0b (page 0b-20)”. Rear brake friction plate replacement b831g24306003 refer to “rear brake disassembly and assembly (page 4c-3)”. Rear brake assembly removal and ...

  • Page 467

    Rear brakes: 4c-3 • install the return spring (3) and lining indicator (4). Note align the boss of lining indicator (4) with wide spline on the brake cam shaft. • install the rear brake cam lever (5) to the rear brake cam shaft. Note when installing the brake cam lever, align the punched mark “d” wi...

  • Page 468

    4c-4 rear brakes: 4) remove the rear bake cam shaft (6). 5) unlock the nut with a chisel. 6) remove the rear drive gear shaft nut (7) with the special tool and remove the washer (8). Special tool (a): 09924–52420 (secondary bevel gear holder) 7) remove the rear drive gear shaft (9), with plastic mal...

  • Page 469

    Rear brakes: 4c-5 11) remove the bearing with the special tool. Special tool (c): 09921–20240 (bearing remover set) 12) remove the side plate stopper (13). 13) remove the side plate (14), pins (15) and springs (16). 14) separate the friction plates (17) and separator plates (18). Assembly caution ! ...

  • Page 470

    4c-6 rear brakes: • install the oil seals (7) and (8) with the special tool. Special tool (a): 09913–70210 (bearing installer set) • apply grease to the lip of cam shaft oil seal. : grease 99000–25160 (water resistance grease) • install the rear final drive gear shaft (9). Note if the rear final dri...

  • Page 471

    Rear brakes: 4c-7 • bend the collar of the nut to the notch on the shaft of the rear propeller shaft coupling. • install the balls and rear brake pressure plate (14). Note when installing the rear brake pressure plate (14), align its groove “a” with the cam “b” of rear brake cam shaft (10). • instal...

  • Page 472

    4c-8 rear brakes: bearing inspect the inner race play of the bearing by hand while it is in the rear brake case. Turn the inner race by hand to inspect for abnormal noise or smooth rotation. • if there is anything unusual, replace it with a new one. Rear brake cam shaft inspect the rear brake cam sh...

  • Page 473

    Rear brakes: 4c-9 brake side plate spring • measure the free length “a”. • if the free length “a” is shorter than the limit, replace the spring with a new one. Brake side plate spring free length “a” service limit: 20.2 mm (0.80 in) rear brake pressure plate inspect the rear brake pressure plate for...

  • Page 474

    4c-10 rear brakes: special tools and equipment recommended service material b831g24308001 note required service material is also described in the following. “rear brake components (page 4c-1)” special tool b831g24308002 material suzuki recommended product or specification note grease water resistanc...

  • Page 475: Parking Brake

    Parking brake: 4d-1 brake parking brake schematic and routing diagram parking / rear brake cable routing diagram b831g24402001 1 2 4 3 1 “b” 4 3 “a” 1 1 i831g1440001-02 1. Parking brake cable 4. Wiring harness 2. Parking brake cable guide “a”: pass the parking brake cable under the wiring harness. 3...

  • Page 476

    4d-2 parking brake: 3 1 5 2 1 4 1 3 7 8 6 “c” 6 1 i831g1440002-03 1. Parking brake cable 6. Clamp 2. Parking brake cable guide 7. Parking brake cable adjust nut 3. Frame 8. Rear brake assembly 4. Wiring harness “c”: fix the rubber of parking brake cable with clamp. 5. Rear fender.

  • Page 477

    Parking brake: 4d-3 repair instructions parking / rear brake inspection and adjustment b831g24406001 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment in section 0b (page 0b-19)”. Parking / rear brake cable removal and installation b831g24406002 removal 1) remov...

  • Page 478

    4d-4 parking brake: parking / rear brake lever components b831g24406003 parking / rear brake lever removal and installation b831g24406004 removal refer to “handlebars removal and installation in section 6b (page 6b-3)”. Installation refer to “handlebars removal and installation in section 6b (page 6...

  • Page 479

    Parking brake: 4d-5 specifications tightening torque specifications b831g24407001 note the specified tightening torque is also described in the following. “parking / rear brake lever components (page 4d-4)” reference: for the tightening torque of fastener not specified in this section, refer to “tig...

  • Page 480

    4d-6 parking brake:.

  • Page 481: Section 5

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

  • Page 482: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b831g25000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 483: Automatic Transmission

    Automatic transmission: 5a-1 transmission / transaxle automatic transmission schematic and routing diagram drive train system b831g25102001 1 3 2 8 9 6 7 12 13 11 10 4 “a” 5 i831g1510001-04 1. Crankshaft 6. Fixed driven face 11. High driven gear 2. Movable drive face 7. Transfer input shaft 12. Tran...

  • Page 484

    5a-2 automatic transmission: diagnostic information and procedures automatic transmission symptom diagnosis b831g25104001 condition possible cause correction / reference item excessive engine noise gear worn or abnormal contact. Replace. Spline worn. Replace. Bearing worn or burned. Replace. V-belt ...

  • Page 485

    Automatic transmission: 5a-3 repair instructions automatic transmission components b831g25106001 16 17 15 18 19 15 20 22 21 (a) 23 (b) 24 (a) 11 10 (a) 1 2 3 5 8 4 9 6 7 fwd fwd 12 14 13 i831g1510002-03 1. Movable drive face bolt 11. Movable driven face bolt 21. Spring 2. Movable drive plate 12. Clu...

  • Page 486

    5a-4 automatic transmission: v-belt cooling duct construction b831g25106002 2 5 3 2 2 9 4 2 6 7 8 8 1 i831g1510003-06 1. Heat shield 3. Belt cooling inlet duct no. 1 5. Belt cooling inlet duct connector 7. Belt cooling outlet duct no. 2 2. Clamp 4. Belt cooling inlet duct no. 2 6. Belt cooling outle...

  • Page 487

    Automatic transmission: 5a-5 v-belt cooling duct removal and installation b831g25106003 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) loosen the clamp screw and remove the inlet cooling duct assembly (1). 3) remo...

  • Page 488

    5a-6 automatic transmission: 6) remove the v-belt outer cover (1). Movable drive face 1) remove the cap (1). 2) remove the movable drive face bolt with the special tool. Special tool (a): 09930–40113 (rotor holder) 3) remove the movable drive face cover (1) and collar (2). 4) remove the dowel pins (...

  • Page 489

    Automatic transmission: 5a-7 fixed drive face remove the fixed drive face (1). Installation install the automatic transmission component parts in the reverse order of removal. Pay attention to the following points: fixed drive face install the fixed drive face (1). Caution ! Degrease the fixed drive...

  • Page 490

    5a-8 automatic transmission: • tighten the movable driven face bolt (3) to the specified torque with the special tool. Tightening torque movable driven face bolt (a): 110 n·m (11.0 kgf- m, 79.5 lb-ft) special tool (a): 09930–40113 (rotor holder) movable drive face • install the movable drive face as...

  • Page 491

    Automatic transmission: 5a-9 v-belt outer cover • install the v-belt outer cover (1). Caution ! If there are wear or damage, replace the gasket (2) with a new one. • tighten the v-belt outer cover bolts to the specified torque. Tightening torque v-belt outer cover bolt (a): 8 n·m (0.8 kgf-m, 6.0 lb-...

  • Page 492

    5a-10 automatic transmission: assembly 1) install the oil seals with the special tool. Special tool (a): 09913–70210 (bearing installer set) note the removed oil seals must be replaced with new ones. 2) apply grease to the lip of oil seals and inside grease groove “a” of the movable drive face. : gr...

  • Page 493

    Automatic transmission: 5a-11 7) install the spacer (6). Note when installing the spacer, press down the movable drive face plate so as not to cause the rollers to come out of position. Movable driven face disassembly and assembly b831g25106007 1) hold the movable driven face assembly (1) with the s...

  • Page 494

    5a-12 automatic transmission: 4) loosen the special tool handle slowly and remove the special tool. 5) remove the spring plate (3) and spring (4). 6) remove the spring seat (5) and o-rings (6). 7) remove the pins (7) and rollers (8). 8) remove the movable driven face (9). 9) remove the oil seals (10...

  • Page 495

    Automatic transmission: 5a-13 • install the o-rings (1) to the movable driven face. • apply grease to the oil seal lips, o-rings and inside groove of movable driven face. Caution ! Replace the o-rings (1) with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) caution ! • wipe off ...

  • Page 496

    5a-14 automatic transmission: • compress the spring (7) with the special tool. Special tool (b): 09922–31430 (clutch spring compressor) note make sure to insert the spring end “a” into the slot “b” of the special tool as shown in the figure. • tighten the movable driven face ring nut (10) temporaril...

  • Page 497

    Automatic transmission: 5a-15 movable / fixed drive face parts inspection b831g25106009 movable / fixed drive face inspect the drive faces for any abnormal conditions such as stepped wear or discoloration caused by burning. If any damages are found, replace the drive faces with new ones. Roller insp...

  • Page 498

    5a-16 automatic transmission: movable driven spring measure the spring free length with the vernier calipers. • if the length is shorter than the service limit, replace the spring with a new one. Movable driven face spring free length service limit: 145.4 mm (5.72 in) o-ring and oil seal inspect the...

  • Page 499

    Automatic transmission: 5a-17 9) remove the washer (10). 10) remove the clutch shoe (11) with the special tools. Special tool (c): 09930–30104 (rotor remover slide shaft) (d): 09920–33540 (clutch shoe remover) installation install the clutch shoe in the reverse order of removal. Pay attention to the...

  • Page 500

    5a-18 automatic transmission: • apply molybdenum oil solution to the inside of the one way clutch (4). M/o: molybdenum oil (molybdenum oil solution) • install the one way clutch (4) with facing the “outside” mark “a” outside. • install the dowel pins (5) and gasket (6). Caution ! Use a new gasket (6...

  • Page 501

    Automatic transmission: 5a-19 clutch housing case disassembly and assembly b831g25106012 refer to “clutch shoe removal and installation (page 5a-16)”. Disassembly • remove the clutch housing (1) from clutch housing case. • remove the collar (2). • remove the oil seal (3) with the special tool. Speci...

  • Page 502

    5a-20 automatic transmission: • apply a small quantity of thread lock to the bearing retainer screws (2), and tighten them securely. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) note • when installing the bearing retainer (3), align the convex part “a” of clutch hou...

  • Page 503

    Automatic transmission: 5a-21 clutch shoe inspect the boss and centrifugal weight fulcrum sections for looseness, damage and operation. Inspect the clutch shoe for damage and fouling with oil on the surface. If any defects are found, replace the clutch shoe assembly with a new one. Measure the thick...

  • Page 504

    5a-22 automatic transmission: movable drive face cover disassembly and assembly b831g25106014 disassembly • remove the oil seal (1) with the special tool. Special tool (a): 09913–50121 (oil seal remover) • remove the snap ring (2). • remove the bearing (3) with the special tool. Note if there is no ...

  • Page 505

    Automatic transmission: 5a-23 • install the oil seal (3) with the special tool. Special tool (a): 09913–70210 (bearing installer set) caution ! The removed oil seal must be replaced with a new one. • apply grease to the lip of oil seal. : grease 99000–25010 (suzuki super grease a or equivalent) clut...

  • Page 506

    5a-24 automatic transmission: gear shift knob removal and installation b831g25106017 removal 1) loosen the lock-nut (1). 2) remove the gear shift knob (2). Installation install the gear shift knob in the reverse order of removal. Note tighten the lock-nut securely. Shift lever assembly removal and i...

  • Page 507

    Automatic transmission: 5a-25 installation install the gear shift lever in the reverse order of removal. Pay attention to the following points: • apply grease to pivot. : grease 99000–25010 (suzuki super grease a or equivalent) • apply thread lock to the shift lever assembly mounting bolts. : thread...

  • Page 508

    5a-26 automatic transmission: note be careful not to separate the rod from the joint by turning the rod too much. Shift lever side shift arm side specifications service data b831g25107001 clutch unit: mm (in) drive train unit: mm (in) except ratio transmission unit: mm (in) 1 2 i831g1510117-01 2 1 i...

  • Page 509

    Automatic transmission: 5a-27 tightening torque specifications b831g25107002 note the specified tightening torque is also described in the following. “automatic transmission components (page 5a-3)” “shift lever assembly components (page 5a-23)” reference: for the tightening torque of fastener not sp...

  • Page 510

    5a-28 automatic transmission: special tool b831g25108002 09900–20101 09913–50121 vernier calipers (1/15 mm, 150 mm) oil seal remover ) (page 5a-14) ) (page 5a-19) / ) (page 5a-22) 09913–70210 09917–23711 bearing installer set ring nut wrench ) (page 5a-10) / ) (page 5a-12) / ) (page 5a-19) / ) (page...

  • Page 511: Section 6

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

  • Page 512: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b831g26000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 513: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b831g26104001 condition possible cause correction / reference item heavy steering distorted steering shaft. Replace. Improper front wheel alignment. Adjust. Insuffici...

  • Page 514: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions steering / handlebars components b831g26206001 21 21 1 15 16 2 (a) 3 4 (b) 8 12 10 9 fwd fwd 7 (c) 13 11 6 6 19 fwd fwd “a” “a” “a” “a” 14 (e) 17 17 18 (d) 5 20 14 i831g1620001-17.

  • Page 515

    Steering / handlebar: 6b-2 steering / handlebars assembly construction b831g26206002 1. Handlebars 11. O-ring 21. Handle grip 2. Handlebar upper clamp 12. Washer “a”: apply grip bond. 3. Handlebar clamp bolt 13. Steering shaft lower nut : 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 4. Steering shaft 14. Cotter ...

  • Page 516

    6b-3 steering / handlebar: handlebars removal and installation b831g26206003 removal 1) remove the combination meter. Refer to “combination meter removal and installation in section 9c (page 9c-3)”. 2) remove the following parts from left handlebar. A) left grip (1) b) left switch box (2) 3) disconn...

  • Page 517

    Steering / handlebar: 6b-4 8) remove the following parts from the right handlebar. A) right grip (4) b) front brake master cylinder/front brake lever (5) caution ! Do not turn the front brake master cylinder upside down. C) throttle lever case (6) 9) remove the handlebar upper clamps (7) and handleb...

  • Page 518

    6b-5 steering / handlebar: • apply adhesive agent to the handlebar right and left end and right and left grip inner wall. : handle grip bond (handle grip bond (commercially available)) • insert the projection “d” of the left switch assembly into the hole of the handlebars. • tighten the left handleb...

  • Page 519

    Steering / handlebar: 6b-6 steering shaft removal and installation b831g26206005 removal 1) remove the front wheels. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 2) remove the front fender. Refer to “front side exterior parts removal and installation in section 9...

  • Page 520

    6b-7 steering / handlebar: 15) remove the steering shaft bushing (10) and dust seal (11) with the special tools and suitable socket wrench. Special tool (a): 09924–84521 (bearing installer set) (b): 09930–30721 (rotor remover) installation install the steering shaft in the reverse order of removal. ...

  • Page 521

    Steering / handlebar: 6b-8 • apply grease to the steering shaft holders before installing the shaft holders. : grease 99000–25160 (water resistance grease) caution ! To prevent the entry of dirt, the dust seal end “a” must face rearward when installing the dust seal to steering shaft. • install the ...

  • Page 522

    6b-9 steering / handlebar: • connect the tie-rod ends. Refer to “front wheel hub / steering knuckle removal and installation in section 2b (page 2b-4)”. • tighten the handlebar holder nut (10) to the specified torque. Tightening torque handlebar holder nut (c): 60 n·m (6.0 kgf-m, 43.5 lb-ft) • insta...

  • Page 523

    Steering / handlebar: 6b-10 installation install the tie-rod in the reverse order of removal. Pay attention to the following points: • when installing the tie-rods, make sure the short side “a” of tie-rod come outside. • push the tie-rod to tie-rod lock-nut tightening direction. • tighten the lock-n...

  • Page 524

    6b-11 steering / handlebar: tie-rod end inspect the tie-rod ends for smooth movement. If there are any abnormalities, replace the tie-rod ends with new ones. Inspect the tie-rod end boots for wear or damage. If any defects are found, replace the tie-rod ends with new ones. Steering shaft inspect the...

  • Page 525

    Steering / handlebar: 6b-12 tightening torque specifications b831g26207002 note the specified tightening torque is also described in the following. “steering / handlebars components (page 6b-1)” “steering / handlebars assembly construction (page 6b-2)” reference: for the tightening torque of fastene...

  • Page 526

    6b-13 steering / handlebar:.

  • Page 527: Section 9

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

  • Page 528

    9-ii table of contents trailer towing construction ................................9e-7 trailer towing removal and instruction..............9e-7 specifications.......................................................9e-8 tightening torque specifications........................9e-8 special tools and eq...

  • Page 529: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b831g29000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location electrical components location b831g29...

  • Page 530: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram b831g29102001 refer to “wire color symbols in section 0a (page 0a-5)”..

  • Page 531

    Wiring systems: 9a-2 for p-17 r o/y o/y y/b y/b b/w b/w bl/w bl/w o/y o/y w/b w/b b/w b/w o bl/r bl/r bl bl r/g r/g r o/y o/y r/b r/b bl/b bl/b w w/r w/r b/y b/y o/y o/y b/w b/w w/g w/g b/g b/g y/b y/b y/bl y/bl w/bl w/bl o/bl o/bl o o/w o/w y/g y/g b/w b/w br br br bl/b bl/b bl/b gr gr w/r w/r w/y ...

  • Page 532

    9a-3 wiring systems: for p-24, 28, 33 on off on off on3 on2 on1 off 2wd 4wd lock l r n w on off hi lo run off on off on off push push push 123 45 6 1 m diff-lock rela y cooling fa n thermo- switch cooling fa n mot or brake lever switch horn (p-24) (p-24) horn butt on ignition switch p arking brake s...

  • Page 533

    Wiring systems: 9a-4 wiring harness routing diagram b831g29102002 clamp wiring harness wiring harness wiring harness 60 – 80 mm (2.36 – 3.15 in) clamp wiring harness clamp clamp clamp wiring harness clamp clamp brake light/taillight back up relay (p-17) clamp wiring harness generator gear position s...

  • Page 534

    9a-5 wiring systems: horn button (p-17, 24) fix front brake hose starter motor engine earth 4wd/diff-lock relay set the dealer mode coupler to the rear fender hole. Starter motor terminal battery ecm fuse box master cylinder reservoir tank to combination meter set the writing harness as shown. Pass ...

  • Page 535

    Wiring systems: 9a-6 specifications service data b831g29107001 electrical unit: mm “ a ” 1 5 4 7 7 2 3 6 i831g1910905-05 1. Starter motor 3. Generator stator 5. Starter motor lead wire 7. Clamp 2. Gear position switch 4. Ground wire 6. Grommet “a”: 30 ° item specification note fuse size headlight hi...

  • Page 536: Lighting Systems

    9b-1 lighting systems: body and accessories lighting systems repair instructions headlight components b831g29206001 headlight removal and installation b831g29206002 removal 1) remove the front grill upper cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”....

  • Page 537

    Lighting systems: 9b-2 installation install the headlight in the reverse order of removal. Pay attention to the following point: • after installing, be sure to inspect the headlight beam. Refer to “headlight beam adjustment (page 9b-2)”. Headlight bulb replacement b831g29206003 caution ! • if you to...

  • Page 538

    9b-3 lighting systems: auxiliary headlight components b831g29206005 auxiliary headlight removal and installation b831g29206006 removal 1) remove the screws (1). 2) remove the auxiliary headlight cover (2) by removing the fasteners (3). Fwd fwd 1 i831g1920009-05 1. Auxiliary headlight bulb (12 v 35/3...

  • Page 539

    Lighting systems: 9b-4 3) remove the auxiliary headlight mounting bolt (4). 4) disconnect the auxiliary headlight coupler (5) by removing the auxiliary headlight assembly (6). Installation install the auxiliary headlight in the reverse order of removal. Auxiliary headlight bulb replacement b831g2920...

  • Page 540

    9b-5 lighting systems: 4) properly fit the bulb socket cap (1). Note make sure that the “top” mark “a” face to upper side. 5) reinstall the removed parts. Auxiliary headlight beam adjustment b831g29206008 • loosen the auxiliary headlight mounting bolt (1). • adjust the auxiliary headlight beam. • ti...

  • Page 541

    Lighting systems: 9b-6 rear combination light removal and installation b831g29206010 removal 1) remove the rear combination light mounting bolts. 2) remove the rear combination light assembly by disconnecting the clamp (1) and coupler (2). Installation install the rear combination light in the rever...

  • Page 542

    9b-7 lighting systems: reversing light bulb replacement (for p-17) b831g29206012 remove the reversing light bulb (1) as shown in the figure. Reversing light relay inspection (for p-17) b831g29206013 first, check the insulation between “a” and “b” terminals with the multi-circuit tester. Then apply 1...

  • Page 543

    Lighting systems: 9b-8 specifications service data b831g29207001 wattage unit: w special tools and equipment special tool b831g29208001 item specification p-24, 28, 33 p-17 headlight hi 35 x 2 ← lo 35 x 2 ← auxiliary headlight 35/35 ← brake light/taillight 21/5 ← revercing light — 21 09900–25008 mul...

  • Page 544

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn general description combination meter system description b831g29301001 this combination meter mainly consists of lcd (liquid crystal display) and led (light emitting diode). The lcds indicate speed...

  • Page 545

    Combination meter / fuel meter / horn: 9c-2 repair instructions combination meter components b831g29306001 1 2 3 fwd fwd i831g1930002-04 1. Upper case 2. Combination meter 3. Lower case.

  • Page 546

    9c-3 combination meter / fuel meter / horn: combination meter removal and installation b831g29306002 caution ! When disconnecting and reconnecting the combination meter coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. Removal 1) remove the combination meter co...

  • Page 547

    Combination meter / fuel meter / horn: 9c-4 combination meter inspection b831g29306004 led inspection check that the leds (diff-lock indicator light, reverse indicator light and fi indicator light / engine coolant temperature indicator light) immediately light up for two seconds when the ignition sw...

  • Page 548

    9c-5 combination meter / fuel meter / horn: fuel level indicator inspection b831g29306007 inspect the fuel level indicator in the following procedures: 1) move the rear fender upside. Refer to “fuel tank pressure control (ftpc) valve removal and installation in section 1g (page 1g-12)”. 2) disconnec...

  • Page 549

    Combination meter / fuel meter / horn: 9c-6 fuel level gauge inspection b831g29306008 inspect the fuel level gauge in the following procedures: 1) remove the fuel pump. Refer to “fuel pump assembly removal and installation in section 1g (page 1g-9)”. 2) measure the resistance at each fuel level gaug...

  • Page 550

    9c-7 combination meter / fuel meter / horn: speed sensor inspection b831g29306011 inspect the speed sensor in the following procedures: 1) remove the speed sensor. Refer to “speed sensor removal and installation (page 9c-6)”. 2) connect a 12 v battery, 10 k Ω resistor and multi- circuit tester as sh...

  • Page 551

    Combination meter / fuel meter / horn: 9c-8 horn inspection (for p-17, 24) b831g29306014 note if the horn sound condition is normal, it is not necessary to inspect the horn button continuity. Horn button inspection 1) disconnect the horn couplers as shown in the wiring harness routing diagram. Refer...

  • Page 552

    9c-9 combination meter / fuel meter / horn: special tools and equipment recommended service material b831g29308001 special tool b831g29308002 material suzuki recommended product or specification note grease water resistance grease p/no.: 99000–25160 ) (page 9c-6) 09900–25008 multi-circuit tester set...

  • Page 553: Exterior Parts

    Exterior parts: 9d-1 body and accessories exterior parts repair instructions exterior parts construction b831g29406001.

  • Page 554

    9d-2 exterior parts: front side 1 2 3 4 7 5 6 i831g1940001-08 1. Front fender 3. Air cleaner box cover 5. Front grill cover 7. Right inner fender 2. Front box 4. Side cover 6. Left inner fender.

  • Page 555

    Exterior parts: 9d-3 rear side 1 2 4 5 3 i831g1940002-02 1. Rear fender 2. Right mud guard 3. Left mud guard 4. Engine side cover 5. Rear box.

  • Page 556

    9d-4 exterior parts: rear fender heat shield construction b831g29406002 2 “ a ” “ b ” “ a ” 1 2 2 “ c ” “ d ” i831g1940003-07 1. Rear fender “a”: 1 – 3 mm (0.04 – 0.12 in) “c”: 67 mm (2.64 in) 2. Heat shield “b”: 5 mm (0.2 in) “d”: 8 mm (0.3 in).

  • Page 557

    Exterior parts: 9d-5 fuel tank lower cover heat shield installation b831g29406003 1 2 4 “ a ” 3 2 4 1 i831g1940045-02 1. Heat shield 2. Cushion 3. Fuel tank lower cover “a”: max. 5 mm (0.2 in).

  • Page 558

    9d-6 exterior parts: fastener removal and installation b831g29406004 removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls “a” closes. 2) insert the fastener into the installation hole....

  • Page 559

    Exterior parts: 9d-7 air cleaner box cover removal 1) remove the seat. Refer to “seat removal and installation (page 9d-11)”. 2) remove the air cleaner box cover (1) by removing the fasteners (2). Installation install the air cleaner box cover in the reverse order of removal. Front box removal 1) re...

  • Page 560

    9d-8 exterior parts: inner fender removal remove the inner fenders (1) by removing the screw (2), bolt (3) and fastener (4), left and right. Installation install the inner fenders in the reverse order of removal. Side cover removal 1) remove the seat. Refer to “seat removal and installation (page 9d...

  • Page 561

    Exterior parts: 9d-9 5) remove the front fender (2) by removing the screws (3) and fasteners (4). Installation install the front fender in the reverse order of removal. Rear side exterior parts removal and installation b831g29406006 engine side cover removal remove the engine side cover (1). Install...

  • Page 562

    9d-10 exterior parts: mud guard removal remove the mud guards (1) by removing the bolts (2), screws (3) and fastener (4), left and right. Installation install the mud guard in the reverse order of removal. Fuel tank outer cover removal 1) remove the fasteners (1) and screw (2). 2) remove the fastene...

  • Page 563

    Exterior parts: 9d-11 5) remove the fasteners (1) and screws (2). 6) remove the battery. Refer to “battery removal and installation in section 1j (page 1j-12)”. 7) remove the starter relay. Refer to “starter relay removal and installation in section 1i (page 1i-6)”. 8) disconnect the couplers and re...

  • Page 564

    9d-12 exterior parts: under cover components b831g29406008 under cover removal and installation b831g29406009 front under cover removal remove the front under cover (1) by removing the bolts (2) and fasteners (3). Installation 1) fix the front under cover “b” to the groove “a” of engine under cover....

  • Page 565

    Exterior parts: 9d-13 engine under cover removal remove the engine under cover (1). Installation 1) fix the engine under cover (1) with the front under cover (2) and rear under cover (3). 2) install the engine under cover. Rear under cover removal remove the rear under cover (1). Installation instal...

  • Page 566: Body Structure

    9e-1 body structure: body and accessories body structure repair instructions body frame construction b831g29506001 footrest construction b831g29506002 2 1 fwd fwd i831g1950005-06 1. Frame 2. Battery plate 3 1 2 (b) 3 fwd fwd (a) i831g1950001-04 1. Footrest (r) 3. Footrest plate : 55 n ⋅m (5.5 kgf-m,...

  • Page 567

    Body structure: 9e-2 footrest removal and installation b831g29506003 removal 1) remove the mud guard. Refer to “rear side exterior parts removal and installation in section 9d (page 9d-9)”. 2) remove the rear brake cable clamp (1) (rh). 3) remove the footrest (2) (rh & lh). Installation install the ...

  • Page 568

    9e-3 body structure: carrier construction b831g29506004 fwd fwd 1 2 i831g1950006-06 1. Front carrier 2. Rear carrier : apply thread lock to the thread part..

  • Page 569

    Body structure: 9e-4 front carrier removal and installation b831g29506005 removal 1) remove the front grill upper cover. Refer to “front side exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the front carrier (1) by removing the bolts (2). Installation install the front ...

  • Page 570

    9e-5 body structure: rear carrier removal and installation b831g29506006 removal 1) remove the rear carrier (1) by removing the bolts (2) and screw (3). Installation install the rear carrier in the reverse order of removal. Pay attention to the following point: • apply thread lock to the rear carrie...

  • Page 571

    Body structure: 9e-6 front grip bar construction b831g29506007 front grip bar removal and installation b831g29506008 removal 1) remove the front carrier. Refer to “front carrier removal and installation (page 9e-4)”. 2) remove the front cover. Refer to “front side exterior parts removal and installa...

  • Page 572

    9e-7 body structure: trailer towing construction b831g29506009 trailer towing removal and instruction b831g29506010 removal remove the trailer towing (1). Installation install the trailer towing with the trailer towing mounting bolts and then tighten them to the specified torque. Tightening torque t...

  • Page 573

    Body structure: 9e-8 specifications tightening torque specifications b831g29507001 note the specified tightening torque is also described in the following. “footrest construction (page 9e-1)” “trailer towing construction (page 9e-7)” reference: for the tightening torque of fastener not specified in ...

  • Page 576

    Prepared by october, 2007 part no. 99500-47020-03e printed in u.S.A. 576.