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Suzuki LT-Z400 Service Manual

Other manuals for LT-Z400: Service Manual

Summary of LT-Z400

  • Page 1

    Foreword this manual contains an introductory description on the suzuki lt-z400 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 vehi...

  • Page 2: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 7 8 9 10 11 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ....................

  • Page 4: Partshark.Com

    Partshark.Com 877-999-5686.

  • 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 b933h20000001 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: Partshark.Com

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

  • Page 8: Partshark.Com

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

  • Page 9: Partshark.Com

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

  • Page 10: Partshark.Com

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

  • Page 11: Partshark.Com

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

  • Page 12: Partshark.Com

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

  • Page 13: 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 b933h20101001 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. Symbol definition tor...

  • Page 15: Partshark.Com

    General information: 0a-2 abbreviations b933h20101002 a: abdc: after bottom dead center ac: alternating current acl: air cleaner, air cleaner box api: american petroleum institute atdc: after top dead center a/f: air fuel mixture b: bbdc: before bottom dead center btdc: before top dead center b+: ba...

  • Page 16: Partshark.Com

    0a-3 general information: manifold absolute pressure (map): intake air pressure (iap), intake vacuum o: on-board diagnostic (obd): self-diagnosis function, diagnostic p: programmable read only memory (prom): — r: random access memory (ram): — read only memory (rom): rom t: throttle body (tb): thrott...

  • Page 17: Partshark.Com

    General information: 0a-4 engine oil (for usa) oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of suzuki performance 4 motor oil or an equivalent engine oil. Use of sf/sg or sh/sj in api with ma in jaso. Suzuk...

  • Page 18: Partshark.Com

    0a-5 general information: country and area codes b933h20101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b933h20101010 code country or area effective frame no. Lt-z400k9 (e-19) e.U. Jsaak4aa92 100001– lt-z400k9 (e-28) canada lt-z400k9 (e-33) u.S.A. S...

  • Page 19: Partshark.Com

    General information: 0a-6 warning, caution and information labels location b933h20101011 10 [e] 5 [e] 3 [e] 17 [e] [f] 11 [f] 6 [f] 8 [f] 4 [f] 9 [e] 7 [e] [d] [g] [a] 1 [e],13 [e] fwd 19 [b] [e], 20 [c] [f] 2 [e] 12 [e] [f], 16 18 fwd 15 [f] 14 [e] i933h1010007-06 1. Certification plate for e-19, 3...

  • Page 20: Partshark.Com

    0a-7 general information: component location electrical components location b933h20103001 1 2 3 4 5 6 7 8 9 10 11 i933h1010005-02 1. Battery 5. Ignition coil 9. Cooling fan fuse 2. Ignition fuse 6. Cooling fan relay 10. Cooling fan 3. Starter relay/main fuse 7. To sensor 11. Iat sensor 4. Fuel injec...

  • Page 21: Partshark.Com

    General information: 0a-8 13 14 15 16 17 19 18 20 21 22 12 i933h1010006-02 12. Mode select switch coupler 16. Regulator/rectifier 20. Gp switch 13. Fuel level gauge (thermistor) 17. Fuel pump 21. Ckp sensor 14. Iap sensor 18. Ect sensor 22. Generator 15. Tp sensor 19. Starter motor partshark.Com 877...

  • Page 22: Partshark.Com

    0a-9 general information: specifications specifications b933h20107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification overall length 1 830 mm (72.0 in) overall width 1 190mm (46.9 in) overall height 1 145 mm (45.1 in) whee...

  • Page 23: Partshark.Com

    General information: 0a-10 chassis electrical capacities item specification front suspension independent, double wishbone, coil spring, oil damped rear suspension swingarm type, coil spring, oil damped front wheel travel 215 mm (8.5 in) rear wheel travel 230 mm (9.1 in) caster 6.3 ° trail 28.6 mm (1...

  • Page 24: Partshark.Com

    0a-11 general information: special tools and equipment special tool b933h20108001 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) 09900–20204 micromet...

  • Page 25: Partshark.Com

    General information: 0a-12 09910–60611 universal clamp wrench 09911–11310 crankshaft installer attachment 09913–50121 oil seal remover 09913–70210 bearing installer set 09915–63311 compression gauge attachment 09915–64512 compression gauge 09915–74511 oil pressure gauge set 09915–74521 oil pressure ...

  • Page 26: Partshark.Com

    0a-13 general information: 09922–22711 drive chain cutting and joining tool 09923–73210 bearing remover 09923–74511 bearing remover 09924–84510 bearing installer set 09924–84521 bearing installer set 09930–10121 spark plug wrench set 09930–11950 torx wrench 09930–30104 rotor remover slide shaft 0993...

  • Page 27: Maintenance and Lubrication

    Maintenance and lubrication: 0b-1 general information maintenance and lubrication precautions precautions for maintenance b933h20200001 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 28: Partshark.Com

    0b-2 maintenance and lubrication: scheduled maintenance periodic maintenance schedule chart b933h20205001 note i = inspect and clean, adjust, replace or lubricate as necessary. R = replace. T = tighten. C = clean. L = lubricate. Item interval initial 1 month every 3 months every 6 months air cleaner...

  • Page 29: Partshark.Com

    Maintenance and lubrication: 0b-3 lubrication points b933h20205002 lubricate exposed parts initially at 1 month and every 3 months thereafter proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated as follows. Not...

  • Page 30: Partshark.Com

    0b-4 maintenance and lubrication: repair instructions air cleaner element cleaning b933h20206001 air cleaner element cleaning every 3 months inspect and clean the air cleaner element in the following procedures: 1) remove the air cleaner element. Refer to “air cleaner element removal and installatio...

  • Page 31: Partshark.Com

    Maintenance and lubrication: 0b-5 valve clearance inspection and adjustment b933h20206003 inspect valve clearance initially at 1 month and every 6 months thereafter inspection tappet clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism...

  • Page 32: Partshark.Com

    0b-6 maintenance and lubrication: 8) 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 (thickness...

  • Page 33: Partshark.Com

    Maintenance and lubrication: 0b-7 (intake side) t appet shim selection t able (int ake) t appet shim no . (12892-41c00-xxx) t appet shim set no .(12800-41810) i. Measure tappet clearance when the engine is cold. Ii. Measure present shim siz e . Iii. Match clearance in v er tical column with present ...

  • Page 34: Partshark.Com

    0b-8 maintenance and lubrication: (exhaust side) i. Measure tappet clearance when the engine is cold. Ii. Measure present shim siz e . Iii. Match clearance in v er tical column with present shim siz e in hor iz ontal column. Example: t appet clearance is 0.38 mm present shim siz e 2.90 mm shim siz e...

  • Page 35: Partshark.Com

    Maintenance and lubrication: 0b-9 6) install the intake or exhaust camshafts. Refer to “engine top side assembly in section 1d (page 1d- 20)”. 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 m...

  • Page 36: Partshark.Com

    0b-10 maintenance and lubrication: spark arrester cleaning b933h20206006 spark arrester cleaning every 6 months clean the spark arrester in the following procedures: 1) remove the spark arrester (1). 2) clean the spark arrester (2) with a brush. 3) install the spark arrester and tighten its bolts to...

  • Page 37: Partshark.Com

    Maintenance and lubrication: 0b-11 3) tighten the lock-nut (1) while holding the adjuster (2). 4) install the boot correctly. Warning ! After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle lever returns smoothly and automatically...

  • Page 38: Partshark.Com

    0b-12 maintenance and lubrication: 4) pour new oil through the oil filler hole. When performing an oil change (without oil filter replacement), the engine will hold about 2.0 l (2.1/ 1.8 us/lmp qt) of oil. Use of sf/sg or sh/sj in api with ma in jaso. 5) start up the engine and allow it to run for f...

  • Page 39: Partshark.Com

    Maintenance and lubrication: 0b-13 6) install the oil filter cap (1) and tighten the bolts securely. Note face the triangle mark “a” on the cap upward. 7) add new engine oil and check the oil level is as described in the engine oil replacement procedure. Necessary amount of engine oil oil change: 2 ...

  • Page 40: Partshark.Com

    0b-14 maintenance and lubrication: engine coolant change refer to “engine coolant description in section 1f (page 1f-2)”. Warning ! Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. Engine coolant may be harmful if swallowed or if it comes in...

  • Page 41: Partshark.Com

    Maintenance and lubrication: 0b-15 9) after warming up and cooling down the engine several times, add the engine coolant up to the full level of the reservoir tank. Caution ! Make sure that the radiator is filled with engine coolant up to the reservoir tank full level. 10) reinstall the removed part...

  • Page 42: Partshark.Com

    0b-16 maintenance and lubrication: drive chain length inspection 1) place the vehicle on level ground. 2) loosen the rear axle housing bolts (1). 3) tense the drive chain fully by turning chain adjuster nut (2). 4) count out 21 pins (20 pitches) on the chain and measure the distance between the two ...

  • Page 43: Partshark.Com

    Maintenance and lubrication: 0b-17 1) clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. Caution ! Do not use trichloroethylene, gasoline or any similar solvent. These fluids have too great a dissolving power for this chain and they can da...

  • Page 44: Partshark.Com

    0b-18 maintenance and lubrication: brake pedal height inspection and adjustment 1) inspect the brake pedal height “a” between the pedal top face and footrest. Adjust the brake pedal height if necessary. Brake pedal height “a” standard: 0 – 10 mm (0 – 0.4 in) 2) loosen the lock-nut (1). 3) turn the p...

  • Page 45: Partshark.Com

    Maintenance and lubrication: 0b-19 brake fluid level check inspect brake fluid level every 3 months 1) place the vehicle on a level ground and place the handlebars straight. 2) check the brake fluid level by observing the lower limit lines on the brake fluid reservoir. When the brake fluid level is ...

  • Page 46: Partshark.Com

    0b-20 maintenance and lubrication: special tool : 09900–20805 (tire depth gauge) tire tread depth “a” (service limit) front: 4.0 mm (0.16 in) rear: 4.0 mm (0.16 in) tire pressure if the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, main...

  • Page 47: Partshark.Com

    Maintenance and lubrication: 0b-21 check that the rear axle nut is tightened to it specified torque. If the specified torque is lower than specification, tighten the rear axle nut and lock-nut as follows. Special tool (a): 09940–92460 (rear axle nut wrench set) tightening torque rear axle nut (a): 2...

  • Page 48: Partshark.Com

    0b-22 maintenance and lubrication: suspensions inspection b933h20206021 inspect suspensions every 6 months inspect the suspensions in the following procedures: 1) inspect the front suspension arm bearing for scratches, wear or damage. If any damages are found, replace the suspension arm, bearing or ...

  • Page 49: Partshark.Com

    Maintenance and lubrication: 0b-23 chassis bolts and nuts inspection b933h20206023 tighten chassis bolts and nuts initially at 1 month and 3 months thereafter check that all chassis bolts and nuts are tightened to their specified torque. 1 handlebar clamp bolt 26n ⋅m (2.6 kgf-m, 19.0 lb-ft) 2 steeri...

  • Page 50: Partshark.Com

    0b-24 maintenance and lubrication: 9 tie-rod end nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 10 tie-rod end lock-nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 11 knuckle end nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 12 front brake caliper mounting bolt 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 13 front brake hose union bolt 23 n ⋅m ...

  • Page 51: Partshark.Com

    Maintenance and lubrication: 0b-25 compression pressure check b933h20206024 refer to “compression pressure check in section 1d (page 1d-1)”. Oil pressure check b933h20206025 refer to “oil pressure check in section 1e (page 1e- 3)”. Sds check b933h20206026 refer to “sds check in section 1a (page 1a-1...

  • Page 52: Partshark.Com

    0b-26 maintenance and lubrication: specifications tightening torque specifications b933h20207001 note the specified tightening torque is also described in the following. “chassis bolts and nuts inspection (page 0b-23)” reference: for the tightening torque of fastener not specified in this section, r...

  • Page 53: Partshark.Com

    Maintenance and lubrication: 0b-27 special tools and equipment recommended service material b933h20208001 note required service material is also described in the following. “lubrication points (page 0b-3)” special tool b933h20208002 material suzuki recommended product or specification note brake flu...

  • Page 54: Service Data

    0c-1 service data: general information service data specifications service data b933h20307001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit valve diam. In. 36.0 (1.42) — ex. 29.0 (1.14) — tappet clearance (w...

  • Page 55: Partshark.Com

    Service data: 0c-2 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) drive train + drive chain unit: mm (in) except ratio piston ring groove width 1st 0.78 – 0.80 (0.0307 – 0.0315) — 1.30 – 1.32 (0.0512 – 0.0520) — 2nd 0.81 – 0.83 (0.0319 – 0.0327) — oil 2.01 – 2.03 (0.0791 – 0.0799) —...

  • Page 56: Partshark.Com

    0c-3 service data: thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator fi sensors item standard note thermostat valve opening temperature approx. 76.5 °c (170 °f) — thermostat valve lift over 4.5 mm (0.18 in) and at 90 °c (194 °f) — ect sensor resistance 20 °c (68 °f...

  • Page 57: Partshark.Com

    Service data: 0c-4 throttle body electrical unit: mm (in) wattage unit: w brake + wheel unit: mm (in) item specification bore size 36 mm (1.42 in) i.D. No. 33h0 idle r/min 1 600 ± 100 r/min idle air screw 1-5/8 turns back throttle cable play 3 – 5 mm (0.12 – 0.20 in) item specification note spark pl...

  • Page 58: Partshark.Com

    0c-5 service data: tire unit: mm (in) suspension unit: mm (in) fuel + oil brake disc thickness front 2.8 – 3.2 (0.11 – 0.13) 2.5 (0.10) rear 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14) brake disc runout — 0.30 (0.012) master cylinder bore front 12.700 – 12.743 (0.5000 – 0.5017) — rear 14.000 – 14.043 (0.5512...

  • Page 59: Partshark.Com

    Service data: 0c-6 tightening torque specifications b933h20307002 engine fi system and intake air system item n ⋅m kgf-m lb-ft cylinder head cover bolt 14 1.4 10.0 spark plug 11 1.1 8.0 cylinder head bolt (m10) initial 25 2.5 18.0 final 46 4.6 33.5 (m6) 10 1.0 7.0 cylinder base nut 10 1.0 7.0 camsha...

  • Page 60: Partshark.Com

    0c-7 service data: cooling system chassis tightening torque item n ⋅m kgf-m lb-ft water pump cover bolt 10 1.0 7.0 engine coolant drain plug 6 0.6 4.5 ect sensor 12 1.2 8.5 item n ⋅m kgf-m lb-ft handlebar clamp bolt 26 2.6 19.0 handlebar holder nut 60 6.0 43.5 steering shaft holder bolt 23 2.3 16.5 ...

  • Page 61: Partshark.Com

    Service data: 0c-8 tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf-m lb-ft n ⋅m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1...

  • Page 62: Partshark.Com

    0c-9 service data: partshark.Com 877-999-5686.

  • Page 63: Section 1

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

  • Page 64: Partshark.Com

    1-ii table of contents service data........................................................1c-7 tightening torque specifications........................1c-7 special tools and equipment .............................1c-8 recommended service material .........................1c-8 special tool ............

  • Page 65: Partshark.Com

    Table of contents 1-iii radiator reservoir tank removal and installation......................................................... 1f-9 cooling fan inspection ....................................... 1f-9 cooling fan relay inspection ........................... 1f-10 ect sensor removal and installatio...

  • Page 66: Partshark.Com

    1-iv table of contents repair instructions .............................................. 1j-3 battery current leakage inspection.................... 1j-3 regulated voltage inspection ............................. 1j-3 generator inspection........................................... 1j-4 generator re...

  • Page 67: Precautions

    Precautions: 1-1 engine precautions precautions precautions for engine b933h21000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Partshark.Com 877-999-5686.

  • Page 68: Partshark.Com

    1a-1 engine general information and diagnosis: engine engine general information and diagnosis general description injection timing description b933h21101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 69: Partshark.Com

    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 70: Partshark.Com

    1a-3 engine general information and diagnosis: *1 when one of the signals is not received by ecm, the fail-safe circuit works and injection is not stopped. In this case, “fi” light is lighted in the indicator panel and vehicle can run. *2 the injection signal is stopped, when the crankshaft position...

  • Page 71: Partshark.Com

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b933h21102001 crankshaft position sensor (ckps) bi y/b gr/w o/g o/w o/w w/bl g/r y/b b r y g/b b/br b/bl br/w dg g/w throttle position sensor fuel pump relay (tps) intak e air pressure sensor (iaps)...

  • Page 72: Partshark.Com

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler b933h21102002 i933h1110005-01 terminal no. Circuit terminal no. Circuit 1 power source 19 — 2 to sensor signal (tos) 20 — 3 ckp sensor signal (ckp+) 21 fi/ect indicator 4 gp switch signal (gp) 22 ect sensor signal (ect)...

  • Page 73: Partshark.Com

    Engine general information and diagnosis: 1a-6 component location fi system parts location b933h21103001 “a” “c” “e” “d” “b” ecm i933h1110006-01 “a”: intake air temperature sensor (iats) “c”: engine coolant temperature sensor (ects) “e”: cooling fan “b”: ignition coil (ig coil) “d”: cooling fan rela...

  • Page 74: Partshark.Com

    1a-7 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b933h21104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 75: Partshark.Com

    Engine general information and diagnosis: 1a-8 engine stalls often (control circuit or sensor improperly operating) defective ecm. Replace. Defective fuel pump. Replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective ect sensor. Replace. Engine ...

  • Page 76: Partshark.Com

    1a-9 engine general information and diagnosis: engine lacks power (defective engine internal/ electrical parts) loss of tappet clearance. Adjust. Weakened valve springs. Replace. Valve timing out of adjustment. Adjust. Worn piston rings or cylinder. Replace. Poor seating of valves. Repair. Fouled sp...

  • Page 77: Partshark.Com

    Engine general information and diagnosis: 1a-10 self-diagnostic procedures b933h21104002 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 78: Partshark.Com

    1a-11 engine general information and diagnosis: 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 79: Partshark.Com

    Engine general information and diagnosis: 1a-12 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-18)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 80: Partshark.Com

    1a-13 engine general information and diagnosis: 6) follow the displayed instructions. 7) check that both “current dtc” (3) and “past dtc” (4) are deleted (nil). 8) close the sds tool and turn the ignition switch off. 9) disconnect the sds tool and install the left side cover. Show data when trouble ...

  • Page 81: Partshark.Com

    Engine general information and diagnosis: 1a-14 1) click “show data when trouble” (1) to display the data. 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. 1 i718h1110269-02 2 i831g1110017-01 partshark.Com 877-999-5686.

  • Page 82: Partshark.Com

    1a-15 engine general information and diagnosis: sds check b933h21104005 using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshoot...

  • Page 83: Partshark.Com

    Engine general information and diagnosis: 1a-16 data at 3 000 r/min under no load data at the time of racing approx. 3 000 r/min check the manifold absolute pressure. Xxx kpa check the engine coolant temperature. Xx °c i933h1110075-01 throttle: quick wide open throttle: slowly open i933h1110076-01 p...

  • Page 84: Partshark.Com

    1a-17 engine general information and diagnosis: data of intake negative pressure during idling (80 °c) example of trouble three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in comparison by showing them in the graph. Read the change of value by compari...

  • Page 85: Partshark.Com

    Engine general information and diagnosis: 1a-18 dtc table b933h21104006 code fi light flashing pattern malfunction part remarks c00 none c12 ) (page 1a-23) crankshaft position sensor (ckps) pick-up coil signal, signal generator c14 ) (page 1a-26) throttle position sensor (tps) c15 ) (page 1a-34) eng...

  • Page 86: Partshark.Com

    1a-19 engine general information and diagnosis: in the fi light, the dtc is indicated from small code to large code. Fail-safe function table b933h21104007 fi system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum performance necessary even under ...

  • Page 87: Partshark.Com

    Engine general information and diagnosis: 1a-20 fi system troubleshooting b933h21104008 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 88: Partshark.Com

    1a-21 engine general information and diagnosis: visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mod...

  • Page 89: Partshark.Com

    Engine general information and diagnosis: 1a-22 c21 iat sensor the sensor voltage should be the following. 0.2 v ≤ sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection. P0110 h sensor voltage is higher than specified value. Iat sensor circu...

  • Page 90: Partshark.Com

    1a-23 engine general information and diagnosis: dtc “c12” (p0335): ckp sensor circuit malfunction b933h21104010 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnos...

  • Page 91: Partshark.Com

    Engine general information and diagnosis: 1a-24 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 92: Partshark.Com

    1a-25 engine general information and diagnosis: 2 1) press the starter button and allow the engine to crank for a few seconds, and measure the ckp sensor peak voltage at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) ckp sensor peak voltage 1...

  • Page 93: Partshark.Com

    Engine general information and diagnosis: 1a-26 dtc “c14” (p0120-h/l): tp sensor circuit malfunction b933h21104011 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 94: Partshark.Com

    1a-27 engine general information and diagnosis: c14 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel pump mounting bolts and move the fuel pump. Refer to “tp sensor removal and installation in section 1c (page 1c-3)”. 3) check the tp sensor coupler...

  • Page 95: Partshark.Com

    Engine general information and diagnosis: 1a-28 p0120-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the fuel pump mounting bolts and move the fuel pump. Refer to “tp sensor removal and installation in section 1c (page 1c-3)”. 3) check the tp sensor coupler for loose ...

  • Page 96: Partshark.Com

    1a-29 engine general information and diagnosis: p0120-l (use of sds) 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-2)”. 7) check the continuity between y wire and terminal “5”. Also, check the continuity between b/br wire and terminal “24”. Tester kno...

  • Page 97: Partshark.Com

    Engine general information and diagnosis: 1a-30 1 4) disconnect the tp sensor coupler. 5) check the continuity between y wire and ground. Also, check the continuity between y wire and b/br wire. If sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-...

  • Page 98: Partshark.Com

    1a-31 engine general information and diagnosis: 2 1) correct the ecm coupler. 2) turn the ignition switch on. 3) measure the input voltage between the r wire and ground. If ok, the measure the input voltage between the r wire and b/br wire. Special tool (a): 09900–25008 (multi-circuit tester set) (b...

  • Page 99: Partshark.Com

    Engine general information and diagnosis: 1a-32 3 4) if ok, then measure the tp sensor resistance at the test harness terminals (between terminal “a” (y wire) and “c” (b/br wire)). 5) push the throttle lever and measure the resistance. Tp sensor resistance throttle valve is closed: approx. 0.6 k Ω t...

  • Page 100: Partshark.Com

    1a-33 engine general information and diagnosis: 4 1) connect the test harness to tp sensor coupler. 2) turn the ignition switch on. 3) measure the tp sensor output voltage at the coupler (between terminal “a” (y wire) (+) and terminal “c” (b/br wire) (–)) by opening the throttle lever. Special tool ...

  • Page 101: Partshark.Com

    Engine general information and diagnosis: 1a-34 dtc “c15” (p0115-h/l): ect sensor circuit malfunction b933h21104012 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 102: Partshark.Com

    1a-35 engine general information and diagnosis: c15 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at the wire side coupler. 3) disconnect the coupler and turn th...

  • Page 103: Partshark.Com

    Engine general information and diagnosis: 1a-36 p0115-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 3) disconnect the ect sensor coupler. 4) disconnect the ecm co...

  • Page 104: Partshark.Com

    1a-37 engine general information and diagnosis: p0115-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 3) disconnect the ect sensor coupler. 4) check the continuity ...

  • Page 105: Partshark.Com

    Engine general information and diagnosis: 1a-38 1 8) 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 ( ) ect sensor output voltage 0.2 – 4.9 v ((+) terminal: b...

  • Page 106: Partshark.Com

    1a-39 engine general information and diagnosis: 2 1) turn the ignition switch off. 2) connect the ecm coupler and disconnect the ect sensor coupler. 3) remove the fuel pump mounting bolts and move the fuel pump. Refer to “tp sensor removal and installation in section 1c (page 1c-3)”. 4) measure the ...

  • Page 107: Partshark.Com

    Engine general information and diagnosis: 1a-40 dtc “c17” (p1750-h/l): iap sensor circuit malfunction b933h21104013 detected condition and possible cause wiring diagram ecm coupler (harness side) detected condition possible cause c17 iap sensor voltage is not within the following range. 0.2 v ≤ sens...

  • Page 108: Partshark.Com

    1a-41 engine general information and diagnosis: troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc usi...

  • Page 109: Partshark.Com

    Engine general information and diagnosis: 1a-42 step action yes no 1 1) turn the ignition switch off. 2) check the iap sensor coupler for loose or poor contacts. If ok, then check the iap sensor lead wire continuity. 3) disconnect the iap sensor coupler. 4) check the continuity between the r wire an...

  • Page 110: Partshark.Com

    1a-43 engine general information and diagnosis: p 0105-l for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the iap sensor coupler for loose or poor contacts. If ok, then check the iap sensor lead wire continuity. 3) disconnect the iap sensor coupler. 4) check...

  • Page 111: Partshark.Com

    Engine general information and diagnosis: 1a-44 1 6) check the continuity between the r wire and terminal “13”. Also, check the continuity between the g/b wire and terminal “6”. Tester knob indication continuity ( ) ecm coupler (harness side) is the continuity ok? Go to step 2. R and g/b wire open, ...

  • Page 112: Partshark.Com

    1a-45 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) connect the ecm coupler and iap sensor coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) run the engine at idle speed and measure the iap sensor output voltage at the wire side coupler betwe...

  • Page 113: Partshark.Com

    Engine general information and diagnosis: 1a-46 4 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 114: Partshark.Com

    1a-47 engine general information and diagnosis: dtc “c21” (p0110-h/l): iat sensor circuit malfunction b933h21104014 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 115: Partshark.Com

    Engine general information and diagnosis: 1a-48 c21 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor voltage at the wire side coupler. 3) disconnect the iat sensor coupler ...

  • Page 116: Partshark.Com

    1a-49 engine general information and diagnosis: p0110-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 3) disconnect the iat sensor coupler. 4) disconnect the ecm co...

  • Page 117: Partshark.Com

    Engine general information and diagnosis: 1a-50 p0110-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 3) disconnect the iat sensor coupler. 4) heck the continuity b...

  • Page 118: Partshark.Com

    1a-51 engine general information and diagnosis: 1 8) measure the output voltage between the dg wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) iat sensor output voltage 0.2 – 4.9 v ((+) terminal:...

  • Page 119: Partshark.Com

    Engine general information and diagnosis: 1a-52 dtc “c23” (p1651-h/l): to sensor circuit malfunction b933h21104015 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 120: Partshark.Com

    1a-53 engine general information and diagnosis: c23 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 3) check the to sensor coupler for loose or poor contacts...

  • Page 121: Partshark.Com

    Engine general information and diagnosis: 1a-54 p1651-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 3) check the to sensor coupler for loose or poor contacts. If ok, th...

  • Page 122: Partshark.Com

    1a-55 engine general information and diagnosis: p1651-l (use of sds) 1 7) check the continuity between br/w wire and terminal “2”. Also, check the continuity between b/br wire “c” and terminal “24”. Special tool (b): 09900–25009 (needle pointed probe set) tester knob indication continuity test ( ) e...

  • Page 123: Partshark.Com

    Engine general information and diagnosis: 1a-56 1 5) check the continuity between br/w wire and ground. Also, check the continuity between br/w wire and b/br wire. If sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob...

  • Page 124: Partshark.Com

    1a-57 engine general information and diagnosis: 2 1) connect the ecm coupler and 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. Special tool (a): 09900–25008...

  • Page 125: Partshark.Com

    Engine general information and diagnosis: 1a-58 dtc “c24” (p0351): ignition coil circuit malfunction b933h21104016 note refer to “no spark or poor spark in section 1h (page 1h-3)” for details. Dtc “c31” (p0705): gp switch circuit malfunction b933h21104017 detected condition and possible cause wiring...

  • Page 126: Partshark.Com

    1a-59 engine general information and diagnosis: troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-12)”. Step action yes no 1 1) turn the ignition switch off. 2) check the gp switch coupler for loose or poor contac...

  • Page 127: Partshark.Com

    Engine general information and diagnosis: 1a-60 dtc “c32” (p0201): fuel injector circuit malfunction b933h21104018 detected condition and possible cause wiring diagram ecm coupler (harness side) detected condition possible cause ckp signal is produced but fuel injector signal is interrupted by 8 tim...

  • Page 128: Partshark.Com

    1a-61 engine general information and diagnosis: troubleshooting note • after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-12)”. • injector voltage can be detected only for 2 seconds after ignition switch is turned on. Step action yes n...

  • Page 129: Partshark.Com

    Engine general information and diagnosis: 1a-62 1 5) if ok, then check the continuity between each terminal and ground. Tester knob indication resistance ( Ω) injector continuity ∞Ω (infinity) are the resistance and continuity ok? Go to step 2. Replace the injector with a new one. Refer to “fuel inj...

  • Page 130: Partshark.Com

    1a-63 engine general information and diagnosis: dtc “c41” (p0230): fp relay circuit malfunction b933h21104019 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm c...

  • Page 131: Partshark.Com

    Engine general information and diagnosis: 1a-64 c41 (use of mode select switch) step action yes no 1 1) turn the ignition switch to off. 2) remove the headlight. Refer to “headlight removal and installation in section 9b (page 9b-2)”. 3) check the ecm coupler for loose or poor contacts. If ok, then ...

  • Page 132: Partshark.Com

    1a-65 engine general information and diagnosis: dtc “c60” (p0480): cooling fan relay circuit malfunction b933h21104020 detected condition and possible cause wiring diagram ecm coupler (harness side) detected condition possible cause cooling fan relay signal is not input to ecm. • cooling fan relay c...

  • Page 133: Partshark.Com

    Engine general information and diagnosis: 1a-66 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-12)”. Active control inspection note cooling fan relay and cooling fan motor operation can be checked until the eng...

  • Page 134: Partshark.Com

    1a-67 engine general information and diagnosis: 4) click the “operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. 5) click the “stop” (3) to check the operation properly. Specifications service data b933h2...

  • Page 135: Partshark.Com

    Engine general information and diagnosis: 1a-68 special tools and equipment special tool b933h21108001 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 1a-24) / ) (page 1a-25) / ) (page 1a-27) / ) (page 1a-28) / ) (page 1a-30) / ) (page 1a-31) / ) (page 1a-31) / ) (p...

  • Page 136: Emission Control Devices

    1b-1 emission control devices: engine emission control devices precautions precautions for emission control devices b933h21200001 refer to “general precautions in section 00 (page 00-1)”. Schematic and routing diagram oil return tank hose routing diagram b933h21202001 repair instructions crankcase b...

  • Page 137: Partshark.Com

    Emission control devices: 1b-2 3) inspect the pcv hoses (1) for wear or damage. If it is worn or damaged, replace the pcv hoses with a new ones. Check that the pcv hoses (1) is securely connected. 4) reinstall the removed parts. Crankcase breather (pcv) hose removal and installation b933h21206002 re...

  • Page 138: Engine Electrical Devices

    1c-1 engine electrical devices: engine engine electrical devices precautions precautions for engine electrical device b933h21300001 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 139: Partshark.Com

    Engine electrical devices: 1c-2 repair instructions ecm removal and installation b933h21306001 removal 1) remove the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j- 12)”. 2) remove the headlight assembly. Refer to “headlight removal and installation in secti...

  • Page 140: Partshark.Com

    1c-3 engine electrical devices: tp sensor removal and installation b933h21306007 removal 1) remove the fuel pump mounting bolts (1) and move the fuel pump (2). 2) disconnect the tp sensor coupler (3) and remove the tp sensor (4) with the special tool. Note prior to disassembly, mark the tp sensor or...

  • Page 141: Partshark.Com

    Engine electrical devices: 1c-4 tp sensor adjustment b933h21306008 adjust the tp sensor in the following procedures: 1) warm up the engine and check the idling speed. Refer to “engine idle speed inspection and adjustment in section 0b (page 0b-10)”. 2) turn the ignition switch off. 3) disconnect the...

  • Page 142: Partshark.Com

    1c-5 engine electrical devices: iat sensor removal and installation b933h21306010 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) remove the air cleaner box cover. Refer to “air cleaner element removal and installation in section 1d (page ...

  • Page 143: Partshark.Com

    Engine electrical devices: 1c-6 ect sensor inspection b933h21306012 refer to “dtc “c15” (p0115-h/l): ect sensor circuit malfunction in section 1a (page 1a-34)”. Inspect the ect sensor in the following procedures: 1) remove the ect sensor. Refer to “ect sensor removal and installation (page 1c-5)”. 2...

  • Page 144: Partshark.Com

    1c-7 engine electrical devices: specifications service data b933h21307001 fi sensors tightening torque specifications b933h21307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-6)”. Item specificatio...

  • Page 145: Partshark.Com

    Engine electrical devices: 1c-8 special tools and equipment recommended service material b933h21308001 special tool b933h21308002 material suzuki recommended product or specification note grease water resistance grease or equivalent p/no.: 99000–25160 ) (page 1c-3) 09900–25008 09900–28630 multi-circ...

  • Page 146: Engine Mechanical

    1d-1 engine mechanical: engine engine mechanical diagnostic information and procedures engine mechanical symptom diagnosis b933h21404001 refer to “engine symptom diagnosis in section 1a (page 1a-7)”. Compression pressure check b933h21404002 the compression pressure reading of a cylinder is a good in...

  • Page 147: Partshark.Com

    Engine mechanical: 1d-2 9) press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression. Compression pressure specification low compression pressure can indicate any of the following conditions: • excessively worn cylinder wall • worn ...

  • Page 148: Partshark.Com

    1d-3 engine mechanical: engine right side engine left side item removal inspection installation clutch cover refer to “clutch removal in section 5c (page 5c-7)”. — refer to “clutch installation in section 5c (page 5c-9)”. Clutch plates refer to “clutch removal in section 5c (page 5c-7)”. Refer to “c...

  • Page 149: Partshark.Com

    Engine mechanical: 1d-4 air cleaner element removal and installation b933h21406002 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) remove the air cleaner box cover (1). 3) remove the holder (2) and air cleaner element (3). 4) separate the ...

  • Page 150: Partshark.Com

    1d-5 engine mechanical: 4) disconnect the iat sensor coupler (4). 5) remove the air cleaner box (5) by removing the air cleaner box mounting bolts. Installation install the air cleaner box in the reverse order of removal. Pay attention to the following points: tighten the air cleaner box mounting bo...

  • Page 151: Partshark.Com

    Engine mechanical: 1d-6 starter cable removal and installation b933h21406008 removal 1) remove the front fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) disconnect the clamp. 3) remove the left handlebar switch box (1) and disconnect the starter cable. 4) di...

  • Page 152: Partshark.Com

    1d-7 engine mechanical: throttle body components b933h21406009 3 8 7 1 6 5 4 2 fwd fwd i933h1140018-07 1. Tp sensor 4. L-joint 7. Idle air screw : apply engine oil. 2. Iap sensor 5. Fuel delivery pipe 8. Starter valve : do not reuse. 3. Throttle body 6. Fuel injector : apply water resistance grease....

  • Page 153: Partshark.Com

    Engine mechanical: 1d-8 throttle body construction b933h21406010 “ a ” intake pipe clamp outlet tube clamp rh lh rh lh upper upper 1 (a) 4 5 (a) 7 “a” 6 (a) 2 3 “a” 5 “a” i933h1140241-07 1. Throttle body 5. Fuel vapor return hose “a”: white mark 2. Fuel valve 6. Air cleaner box “a”: 10 – 30 ° 3. Fue...

  • Page 154: Partshark.Com

    1d-9 engine mechanical: throttle body inspection b933h21406011 refer to “throttle body inspection in section 0b (page 0b-10)”. Throttle body removal and installation b933h21406012 removal 1) remove the front fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) re...

  • Page 155: Partshark.Com

    Engine mechanical: 1d-10 installation install the throttle body in the reverse order of removal. Pay attention to the following points: note when installing the throttle body, fit the concave part of the intake pipe onto the convex part of the throttle body. • tighten the throttle body clamp screws....

  • Page 156: Partshark.Com

    1d-11 engine mechanical: caution ! Avoid removing the idle air screw (8). Caution ! Never remove the throttle valve (9). Caution ! Avoid removing the throttle lever stopper screw (10). Assembly assembly is the throttle body in the reverse order of removal. Pay attention to the following points: • in...

  • Page 157: Partshark.Com

    Engine mechanical: 1d-12 note • make sure the throttle valve smoothly open and close. • for tp sensor setting procedure, refer to “tp sensor adjustment in section 1c (page 1c-4)”. • apply thin coat of engine oil to the new cushion seal (2) and the o-ring (3). Caution ! Replace the cushion seal and o...

  • Page 158: Partshark.Com

    1d-13 engine mechanical: • install the l-joint (6) by pushing it straight to the delivery pipe (5). Caution ! Never turn the l-joint (6) while pushing it. Throttle body inspection and cleaning b933h21406014 refer to “throttle body disassembly and assembly (page 1d-10)”. Cleaning warning ! Some carbu...

  • Page 159: Partshark.Com

    Engine mechanical: 1d-14 5) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 6) disconnect the battery (–) lead wire. 7) remove the fuel tank and fuel tank lower cover. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 8) disconnec...

  • Page 160: Partshark.Com

    1d-15 engine mechanical: 17) disconnect the reverse lock release cable (15). Refer to “gear position (gp) switch removal and installation in section 5b (page 5b-12)”. 18) disconnect the engine ground wire coupler (16), starter motor lead wire (17) and breather hose (18). 19) disconnect the generator...

  • Page 161: Partshark.Com

    Engine mechanical: 1d-16 25) remove the engine mounting bolts and nuts. 26) remove the engine from the left side. Engine assembly installation b933h21406016 reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • tighten the engine mounting bracket bolts...

  • Page 162: Partshark.Com

    1d-17 engine mechanical: • after finishing the engine installation, check the following items: – throttle cable play refer to “throttle cable play inspection and adjustment in section 0b (page 0b-10)”. – clutch cable play refer to “clutch inspection and adjustment in section 0b (page 0b-13)”. – reve...

  • Page 163: Partshark.Com

    Engine mechanical: 1d-18 3) remove the oil return tank. Refer to “oil return tank removal and installation in section 1b (page 1b-2)”. 4) remove the cam chain tension adjuster cap bolt (3), washer and spring. 5) remove the cam chain tension adjuster (4) and its gasket. 6) remove the cam chain guide ...

  • Page 164: Partshark.Com

    1d-19 engine mechanical: 7) remove the cylinder head. Note • when loosening the cylinder head bolts, loosen each bolt little by little diagonally. • if the cylinder head does not come off easily, lightly tap using a plastic hammer. 8) remove the cylinder head gasket (7) and dowel pins. Cylinder 1) d...

  • Page 165: Partshark.Com

    Engine mechanical: 1d-20 engine top side assembly b933h21406018 assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: piston • apply molybdenum oil solution onto piston pin and small end of conrod. M/o: molybdenum oil (molybdenum oil solution) • ins...

  • Page 166: Partshark.Com

    1d-21 engine mechanical: • hold each piston ring and put it into the cylinder. Make sure that the piston rings are caught by the cylinder skirt. Note when mounting the cylinder, keep the camshaft drive chain taut. The camshaft drive chain must not be caught between the cam drive chain sprocket and c...

  • Page 167: Partshark.Com

    Engine mechanical: 1d-22 • after tightening the cylinder head bolts to specification, tighten the cylinder head bolts (4) and cylinder base nuts (5) to the specified torque. Tightening torque cylinder head bolt (m6) (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) cylinder base nut (b): 10 n·m (1.0 kgf-m, 7.0 lb-...

  • Page 168: Partshark.Com

    1d-23 engine mechanical: • just before installing the camshaft into the cylinder head, apply engine oil to the camshaft journals, cam faces and camshaft journal holders. • apply molybdenum oil solution to the camshaft journals. Caution ! Do not apply molybdenum oil into the screw hole. M/o: molybden...

  • Page 169: Partshark.Com

    Engine mechanical: 1d-24 • place each camshaft journal holders (1) and cam chain guide no. 2 (2) into the correct position. Note camshaft journal holders marked “ex” “d” are for the exhaust side and those marked “in” “e” are for the intake side. • tighten the camshaft journal holder bolts (“f” (l45)...

  • Page 170: Partshark.Com

    1d-25 engine mechanical: • after installing the cam chain tension adjuster, rotate the crankshaft (some turns), and recheck the positions of the camshafts. • be sure to check and adjust the valve clearance. Refer to “valve clearance inspection and adjustment in section 0b (page 0b-5)”. • apply engin...

  • Page 171: Partshark.Com

    Engine mechanical: 1d-26 • tighten the cylinder head cover bolts in diagonal stages to the specified torque. Tightening torque cylinder head cover bolt: 14 n·m (1.4 kgf-m, 10.0 lb-ft) valve clearance inspection and adjustment b933h21406019 refer to “valve clearance inspection and adjustment in secti...

  • Page 172: Partshark.Com

    1d-27 engine mechanical: camshaft journal wear inspect the camshaft journal wear in the following procedures: 1) determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. 2) use the plastigauge to read the clearance at the wi...

  • Page 173: Partshark.Com

    Engine mechanical: 1d-28 cam chain tension adjuster inspection b933h21406021 the cam chain tension adjuster is maintained at the proper tension by an automatically adjusted. 1) remove the cam chain tension adjuster. Refer to “engine top side disassembly (page 1d-17)”. 2) check that the push rod slid...

  • Page 174: Partshark.Com

    1d-29 engine mechanical: cam chain tensioner inspection b933h21406024 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 clutch components. Refer to “clutch removal in section 5c (page 5c-7)”. 3...

  • Page 175: Partshark.Com

    Engine mechanical: 1d-30 4) using the special tools, compress the valve spring and remove the two cotter halves (4) from the valve stem. Caution ! To prevent damage of the tappet sliding surface with the special tool, use the sleeve protector. Special tool (b): 09916–14510 (valve spring compressor) ...

  • Page 176: Partshark.Com

    1d-31 engine mechanical: assembly assembly is in the reverse order of disassembly. Pay attention to the following points: • tighten the oil gallery plug (1) (cylinder head) to the specified torque. Tightening torque oil gallery plug (cylinder head) (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) caution ! Replac...

  • Page 177: Partshark.Com

    Engine mechanical: 1d-32 • install the valve spring seat. • apply engine oil to the oil seal (5), and press-fit it into position. Caution ! Do not reuse the removed oil seal. • insert the valve, with its stem coated with molybdenum oil all around and along the full stem length without any break. Cau...

  • Page 178: Partshark.Com

    1d-33 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 179: Partshark.Com

    Engine mechanical: 1d-34 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 180: Partshark.Com

    1d-35 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 181: Partshark.Com

    Engine mechanical: 1d-36 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 182: Partshark.Com

    1d-37 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 183: Partshark.Com

    Engine mechanical: 1d-38 caution ! • the valve seat contact area must be inspected after each cut. • do not use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for th...

  • Page 184: Partshark.Com

    1d-39 engine mechanical: piston ring removal and installation b933h21406030 removal 1) draw out the piston pin and remove the piston. Refer to “engine top side disassembly (page 1d-17)”. 2) carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remov...

  • Page 185: Partshark.Com

    Engine mechanical: 1d-40 3) install the piston and piston pin. Refer to “engine top side assembly (page 1d-20)”. Piston and piston ring inspection b933h21406031 refer to “piston ring removal and installation (page 1d-39)”. Piston diameter measure the piston diameter using the micrometer at 15 mm (0....

  • Page 186: Partshark.Com

    1d-41 engine mechanical: piston ring free end gap and piston ring end gap measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service lim...

  • Page 187: Partshark.Com

    Engine mechanical: 1d-42 starter torque limiter remove the starter torque limiter (1). Refer to “starter torque limiter / starter clutch removal and installation in section 1i (page 1i-8)”. Generator cover / starter idle gear remove the generator cover (1) and starter idle gear (2). Refer to “genera...

  • Page 188: Partshark.Com

    1d-43 engine mechanical: oil pump 1) remove the snap rings (1). Note do not drop the snap ring (1) into the crankcase. Special tool : 09900–06107 (snap ring pliers) 2) remove the oil pump idle gear (2) and oil pump driven gear (3). 3) remove the pin (4) and washer (5). Note do not drop the pin (4) a...

  • Page 189: Partshark.Com

    Engine mechanical: 1d-44 4) remove the gearshift pawls (7), pins (8), springs (9) and roller (10). 5) remove the gearshift cam stopper plate bolt (11) and gearshift cam stopper plate (12). 6) remove the gearshift cam stopper (13), washer and spring. 7) remove the gearshift arm stopper (14). Balancer...

  • Page 190: Partshark.Com

    1d-45 engine mechanical: 4) remove the pin (6). Generator / starter driven gear 1) remove the generator rotor (1). Refer to “generator removal and installation in section 1j (page 1j-5)”. 2) remove the generator rotor key (2) and starter driven gear (3). Gear position switch 1) remove the gear posit...

  • Page 191: Partshark.Com

    Engine mechanical: 1d-46 3) separate the crankcase using the special tool. Special tool (a): 09920–13120 (crankcase separating tool) note fit the crankcase separating tool to the right crankcase, so that the tool plate is paralleled with the end face of the crankcase. 4) remove the dowel pins. Oil s...

  • Page 192: Partshark.Com

    1d-47 engine mechanical: oil gallery plug 1) remove the oil gallery plugs (1) from the right crankcase. 2) remove the oil gallery plug (2) from the generator cover. 3) remove the oil gallery plug (3) and main oil gallery plug (4) from the clutch cover. Transmission oil seal / bearing remove the tran...

  • Page 193: Partshark.Com

    Engine mechanical: 1d-48 engine bottom side assembly b933h21406033 assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: note apply engine oil to each running and sliding part before reassembling. Oil pump idle gear shaft install the oil pump idl...

  • Page 194: Partshark.Com

    1d-49 engine mechanical: balancer shaft install the balancer shaft (1). Transmission / gear shift install the transmission component. Refer to “transmission removal and installation in section 5b (page 5b-5)”. Oil sump filter align the oil passage holes when installing the oil sump filter (1). Crank...

  • Page 195: Partshark.Com

    Engine mechanical: 1d-50 • tighten the crankcase bolts to the specified torque. Tightening torque crankcase bolt: 11 n·m (1.1 kgf-m, 8.0 lb-ft) • after the crankcase bolts have been tightened, check if the crankshaft, countershaft, and driveshaft rotate smoothly. If a large resistance is felt to rot...

  • Page 196: Partshark.Com

    1d-51 engine mechanical: primary drive gear / balancer drive gear • install the pin (1) and balancer drive gear (2). • install the cam chain drive sprocket (3) and key (4). • install the primary drive gear (5) and washer (6). Note the conical curve side of washer (6) face outside. • apply engine oil...

  • Page 197: Partshark.Com

    Engine mechanical: 1d-52 gearshift / gearshift cam plate • apply a small quantity of thread lock to the gearshift arm stopper and tighten it to the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque gearshift arm stopper (a): 19 n·m (1....

  • Page 198: Partshark.Com

    1d-53 engine mechanical: • apply a small quantity of thread lock to the gearshift pawl lifter screws, and then tighten the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque gearshift pawl lifter screw (c): 9 n·m (0.9 kgf-m, 6.5 lb-ft) ...

  • Page 199: Partshark.Com

    Engine mechanical: 1d-54 • apply a small quantity of thread lock to the oil pump mounting screws. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tighten the oil pump mounting screws to the specified torque. Tightening torque oil pump mounting screw (a): 8.5 n·m (0.85 ...

  • Page 200: Partshark.Com

    1d-55 engine mechanical: oil filter • apply engine oil to the new o-rings (1). Caution ! Replace the new o-rings with new ones. • install the oil filter (2) and spring (3) correctly. • install the oil filter cap (4) and tighten the bolts securely. Note face the triangle mark “a” on the oil filter ca...

  • Page 201: Partshark.Com

    Engine mechanical: 1d-56 oil sump filter inspection b933h21406034 refer to “oil sump filter inspection and cleaning in section 1e (page 1e-4)”. Oil pump inspection b933h21406035 refer to “oil pump inspection in section 1e (page 1e- 6)”. Gearshift shaft inspection b933h21406036 refer to “gearshift li...

  • Page 202: Partshark.Com

    1d-57 engine mechanical: crankshaft runout support the crankshaft using v-blocks and measure the crankshaft runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the crankshaft with a new one. Note • place the crankshaft onto the v-blocks so that it becomes horizont...

  • Page 203: Partshark.Com

    Engine mechanical: 1d-58 crankshaft bearing / balancer shaft bearing removal and installation b933h21406040 removal 1) disassemble the engine bottom side. Refer to “engine bottom side disassembly (page 1d-41)”. 2) remove the right crankcase bearings (1) using the special tool. Special tool (a): 0992...

  • Page 204: Partshark.Com

    1d-59 engine mechanical: crankshaft oil seal inspection b933h21406041 inspect the crankshaft oil seal in the following procedures: 1) remove the clutch cover. Refer to “clutch removal in section 5c (page 5c-7)”. 2) inspect the crankshaft oil seal lip for damage or wear. If any defect is found, repla...

  • Page 205: Partshark.Com

    Engine mechanical: 1d-60 specifications service data b933h21407001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit valve diam. In. 36.0 (1.42) — ex. 29.0 (1.14) — tappet clearance (when cold) in. 0.10 – 0.20 (...

  • Page 206: Partshark.Com

    1d-61 engine mechanical: conrod + crankshaft unit: mm (in) tightening torque specifications b933h21407002 note the specified tightening torque is also described in the following. “throttle body construction (page 1d-8)” “engine assembly installation (page 1d-16)” reference: for the tightening torque...

  • Page 207: Partshark.Com

    Engine mechanical: 1d-62 special tools and equipment recommended service material b933h21408001 note required service material is also described in the following. “throttle body components (page 1d-7)” special tool b933h21408002 material suzuki recommended product or specification note grease suzuki...

  • Page 208: Partshark.Com

    1d-63 engine mechanical: 09900–20605 09900–20607 dial calipers (1/100 mm, 10 – 34 mm) dial gauge (1/100 mm, 10 mm) ) (page 1d-56) ) (page 1d-33) / ) (page 1d-33) / ) (page 1d-34) / ) (page 1d-56) / ) (page 1d-57) 09900–20701 09900–20803 magnetic stand thickness gauge ) (page 1d-33) / ) (page 1d-33) ...

  • Page 209: Partshark.Com

    Engine mechanical: 1d-64 09915–64512 09916–10911 compression gauge valve lapper set ) (page 1d-1) ) (page 1d-35) 09916–14510 09916–14910 valve spring compressor valve spring compressor attachment ) (page 1d-30) / ) (page 1d-32) ) (page 1d-30) / ) (page 1d-32) 09916–34542 09916–34570 reamer handle va...

  • Page 210: Partshark.Com

    1d-65 engine mechanical: 09930–44520 rotor holder ) (page 1d-44) / ) (page 1d-44) / ) (page 1d-51) / ) (page 1d-51) partshark.Com 877-999-5686.

  • Page 211: Engine Lubrication System

    Engine lubrication system: 1e-1 engine engine lubrication system precautions precautions for engine oil b933h21500001 refer to “fuel and oil recommendation in section 0a (page 0a-3)”. Schematic and routing diagram engine oil hose and pipe routing diagram b933h21502001 4 3 1 2 3 5 7 6 “a” i933h115003...

  • Page 212: Partshark.Com

    1e-2 engine lubrication system: engine lubrication system chart diagram b933h21502002 primary gears piston orifice oil tank oil pump oil pump (for return) oil sump filter oil hose oil hose idle gear drive gear left crankcase countershaft oil pipe by-pass oil filter clutch cover orifice crank pin rig...

  • Page 213: Partshark.Com

    Engine lubrication system: 1e-3 diagnostic information and procedures engine lubrication symptom diagnosis b933h21504001 oil pressure check b933h21504002 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 214: Partshark.Com

    1e-4 engine lubrication system: 6) stop the engine and remove the oil pressure gauge and attachment. 7) reinstall the main oil gallery plug (1) and tighten it to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque main oil gallery plug (a): 18 n·m (1.8 kgf-m, 1...

  • Page 215: Partshark.Com

    Engine lubrication system: 1e-5 3) install the oil sump filter. Refer to “oil sump filter removal and installation (page 1e-4)”. Oil pump components b933h21506005 oil pump removal and installation b933h21506006 removal note do not drop the each parts into the crankcase. 1) drain engine oil and coola...

  • Page 216: Partshark.Com

    1e-6 engine lubrication system: • apply engine oil to the sliding surfaces of the oil pump inner rotor, outer rotor and shaft. • when installing the inner rotor (1), align the pin (2) with the groove (3). • when installing the inner rotor and outer rotor, face the punched marks “a” on the inner roto...

  • Page 217: Partshark.Com

    Engine lubrication system: 1e-7 engine oil hose and pipe construction b933h21506008 (a) 2 3 2 4 1 i933h1150036-03 1. Oil tank overflow hose : 12 n ⋅m (1.2 kgf-m, 8.5 lb-ft) 2. Engine oil pipe : apply engine oil. 3. Oil tank : do not reuse. 4. Engine oil level gauge partshark.Com 877-999-5686.

  • Page 218: Partshark.Com

    1e-8 engine lubrication system: oil tank inspection b933h21506009 inspect the oil tank oil leaks. If any defects are found, replace the oil tank with a new one. Refer to “oil tank removal and installation (page 1e-9)”. Engine oil pipe removal and installation b933h21506010 removal 1) drain engine oi...

  • Page 219: Partshark.Com

    Engine lubrication system: 1e-9 installation install the engine oil pipes in the reverse order of removal. Pay attention to the following points: apply engine oil to the o-rings. Caution ! Replace the o-rings with new ones to prevent oil leakage. • install the engine oil pipes as shown in the oil ta...

  • Page 220: Partshark.Com

    1e-10 engine lubrication system: installation install the oil tank in the reverse order of removal. Pay attention to the following points. • apply engine oil to the o-rings. Caution ! Use the new o-rings to prevent oil leakage. • after install the removed parts. Pour engine oil and engine coolant. R...

  • Page 221: Partshark.Com

    Engine lubrication system: 1e-11 oil pipe inspection b933h21506013 refer to “oil pipe removal and installation (page 1e- 10)”. Make sure that the oil pipes are not clogged. If it is clogged, clean the oil passage using a wire of the proper size and compressed air. Specifications service data b933h21...

  • Page 222: Partshark.Com

    1e-12 engine lubrication system: special tools and equipment recommended service material b933h21508001 note required service material is also described in the following. “oil pump components (page 1e-5)” “engine oil hose and pipe construction (page 1e-7)” special tool b933h21508002 material suzuki ...

  • Page 223: Engine Cooling System

    Engine cooling system: 1f-1 engine engine cooling system precautions precautions for engine cooling system b933h21600001 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 224: Partshark.Com

    1f-2 engine cooling system: general description engine coolant description b933h21601001 caution ! • use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. • do not put in more than 60% anti-freeze ...

  • Page 225: Partshark.Com

    Engine cooling system: 1f-3 water hose routing diagram b933h21602002 2 4 3 1 5 6 5 6 i933h1160054-10 1. Radiator 4. Cooling fan 2. Reservoir 5. Yellow mark 3. Reservoir overflow hose 6. White mark partshark.Com 877-999-5686.

  • Page 226: Partshark.Com

    1f-4 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis b933h21604001 repair instructions cooling circuit inspection b933h21606001 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 227: Partshark.Com

    Engine cooling system: 1f-5 radiator cap inspection b933h21606002 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 228: Partshark.Com

    1f-6 engine cooling system: 4) disconnect the cooling fan motor lead wire coupler (3). 5) remove the radiator guard (4) and radiator assembly (5) by removing the bolts. 6) disconnect the overflow hose (6) and reservoir tank (7). 7) remove the cooling fan motor fuse box (8) and cooling fan assembly (...

  • Page 229: Partshark.Com

    Engine cooling system: 1f-7 cooling fan motor removal and installation b933h21606005 removal 1) remove the side covers, left and right. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) disconnect the cooling fan motor lead wire coupler (1) and cooling fan motor fuse b...

  • Page 230: Partshark.Com

    1f-8 engine cooling system: water hose inspection b933h21606006 inspect the water hose in the following procedures: 1) remove the side covers, left and right. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) check the water hoses for crack, damage or engine coolant le...

  • Page 231: Partshark.Com

    Engine cooling system: 1f-9 radiator reservoir tank inspection b933h21606009 inspect the radiator reservoir tank in the following procedures: 1) remove the left side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) inspect the radiator reservoir tank coolant l...

  • Page 232: Partshark.Com

    1f-10 engine cooling system: note • when making this test, it is not necessary to remove the cooling fan. • make sure that the battery has a capacity enough to supply the motor with 12 v. With the motor running at full speed, the ammeter should indicate not higher than 5 a. 4) connect the cooling fa...

  • Page 233: Partshark.Com

    Engine cooling system: 1f-11 installation 1) apply engine coolant to the rubber seal on the thermostat (1). 2) install the thermostat (1). 3) install the thermostat case. 4) pour engine coolant and bleed air from the cooling circuit. Refer to “cooling system inspection in section 0b (page 0b-13)”. T...

  • Page 234: Partshark.Com

    1f-12 engine cooling system: water pump components b933h21606018 6 (a) 2 3 2 4 5 2 1 i933h1160031-02 1. Water pump cover 4. Mechanical seal : 6 n ⋅m (0.6 kgf-m, 4.5 lb-ft) : do not reuse. 2. O-ring 5. Oil seal : apply water resistance grease. 3. Impeller 6. Water pump driven gear : apply engine cool...

  • Page 235: Partshark.Com

    Engine cooling system: 1f-13 water pump removal and installation b933h21606019 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 oil seal and o-ring. If engine coolan...

  • Page 236: Partshark.Com

    1f-14 engine cooling system: water pump disassembly and assembly b933h21606020 refer to “water pump removal and installation (page 1f-13)”. Disassembly 1) remove the water pump cover (1). 2) remove the o-ring (2) and impeller (3). 3) remove the mechanical seal ring (4) and rubber seal (5) from the i...

  • Page 237: Partshark.Com

    Engine cooling system: 1f-15 2) apply a small quantity of the grease to the oil seal lip. : grease 99000–25160 (water resistance grease or equivalent) 3) install a new mechanical seal using a suitable size socket wrench. Caution ! Replace the mechanical seal with a new one. Note on the new mechanica...

  • Page 238: Partshark.Com

    1f-16 engine cooling system: 9) fit the water pump cover and tighten the water pump cover screws. Water pump related parts inspection b933h21606021 refer to “water pump disassembly and assembly (page 1f-14)”. Mechanical seal visually inspect the mechanical seal for damage, with particular attention ...

  • Page 239: Partshark.Com

    Engine cooling system: 1f-17 specifications service data b933h21607001 thermostat + radiator + fan + coolant tightening torque specifications b933h21607002 note the specified tightening torque is also described in the following. “water pump components (page 1f-12)” reference: for the tightening torq...

  • Page 240: Partshark.Com

    1f-18 engine cooling system: special tools and equipment recommended service material b933h21608001 note required service material is also described in the following. “water pump components (page 1f-12)” special tool b933h21608002 material suzuki recommended product or specification note grease wate...

  • Page 241: Fuel System

    Fuel system: 1g-1 engine fuel system precautions precautions for fuel system b933h21700001 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 242: Partshark.Com

    1g-2 fuel system: general description fuel system description b933h21701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel valve (2), fuel pump (3), fuel filter (4), fuel feed hoses (6) and (7), fuel delivery pipe (8), fuel injector (9), fuel pressure regulator (11). The fu...

  • Page 243: Partshark.Com

    Fuel system: 1g-3 schematic and routing diagram fuel hose routing diagram b933h21702001 “ a ” 4 5 3 7 2 1 6 “a” “b” “c” “d” “d” i933h1170037-03 1. Reverse gear cable 5. Fuel pump “b”: face the tip of clip to left. 2. Fuel hose 6. Starter cable “c”: face the tip of clip to right. 3. Fuel feed hose 7....

  • Page 244: Partshark.Com

    1g-4 fuel system: diagnostic information and procedures fuel system diagnosis b933h21704001 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 245: Partshark.Com

    Fuel system: 1g-5 repair instructions fuel pressure inspection b933h21706001 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 fuel tank mounting bolts. ...

  • Page 246: Partshark.Com

    1g-6 fuel system: fuel pump inspection b933h21706002 turn the ignition switch on and check that the fuel pump operates for a few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and to sensor. Refer to “fuel pump ...

  • Page 247: Partshark.Com

    Fuel system: 1g-7 fuel pump relay inspection b933h21706004 refer to “dtc “c41” (p0230): fp relay circuit malfunction in section 1a (page 1a-63)”. Fuel hose inspection b933h21706005 refer to “fuel line inspection in section 0b (page 0b- 11)”. Fuel level indicator inspection b933h21706006 refer to “in...

  • Page 248: Partshark.Com

    1g-8 fuel system: fuel tank construction b933h21706009 2 1 3 4 (a) 5 i933h1170038-01 1. Fuel tank 5. Fuel hose 2. Fuel level indicator switch (thermistor) : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 3. O-ring : do not reuse. 4. Fuel valve partshark.Com 877-999-5686.

  • Page 249: Partshark.Com

    Fuel system: 1g-9 fuel tank removal and installation b933h21706010 removal warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. 1) remove the fuel tank cover and front fender. Refer to “exterior parts removal and installation...

  • Page 250: Partshark.Com

    1g-10 fuel system: • full open the fuel valve screw (1) by turning the fuel valve screw counter clockwise. • connect the breather hose and fuel vapor return hose as shown in the oil return tank hose routing diagram and throttle body construction. Refer to “oil return tank hose routing diagram in sec...

  • Page 251: Partshark.Com

    Fuel system: 1g-11 • tighten the fuel valve mounting bolts to specified torque. Tightening torque fuel valve mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) • connect the fuel feed hoses (3) and fuel hose (4). Refer to “fuel hose routing diagram (page 1g-3)”. Note connect the fuel feed hoses to the...

  • Page 252: Partshark.Com

    1g-12 fuel system: 1) remove the fuel tank. Refer to “fuel tank removal and installation (page 1g-9)”. 2) disconnect the injector coupler (1). 3) remove the fuel delivery pipe (2) with the injector (3). Note slightly loosen the l-joint mounting screw (4) to facilitate later disassembly, if necessary...

  • Page 253: Partshark.Com

    Fuel system: 1g-13 caution ! Never turn the fuel injector while installing it. • tighten the fuel delivery pipe mounting screws and l- joint mounting screw. Fuel pump removal and installation b933h21706015 removal 1) remove the fuel tank cover. Refer to “exterior parts removal and installation in se...

  • Page 254: Partshark.Com

    1g-14 fuel system: specifications service data b933h21707001 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b933h21707002 note the specified tightening torque is also described in the following. “fuel tank construction (page 1g-8)” reference: for the tightening ...

  • Page 255: Ignition System

    Ignition system: 1h-1 engine ignition system schematic and routing diagram ignition system diagram b933h21802001 refer to “wire color symbols in section 0a (page 0a-5)”. Ignition system components location b933h21802002 refer to “electrical components location in section 0a (page 0a-7)”. Ckp sensor ...

  • Page 256: Partshark.Com

    1h-2 ignition system: diagnostic information and procedures ignition system symptom diagnosis b933h21804001 condition possible cause correction / reference item spark plug not sparking damaged spark plug cap. Replace. Damaged spark plug. Replace. Fouled spark plug. Clean or replace. Wet spark plug. ...

  • Page 257: Partshark.Com

    Ignition system: 1h-3 no spark or poor spark b933h21804002 troubleshooting note check that the transmission is in neutral and the engine stop switch is in the “run” position. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step action yes no 1 check the ignition ...

  • Page 258: Partshark.Com

    1h-4 ignition system: repair instructions spark plug cap and spark plug removal and installation b933h21806001 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 front fender. Refer to “exterior parts removal a...

  • Page 259: Partshark.Com

    Ignition system: 1h-5 7) connect the multi-circuit tester with the peak voltage adaptor as follows: caution ! Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual. Note do not disconnect the ignition coil lead wires. Special tool : 09900–25008 (...

  • Page 260: Partshark.Com

    1h-6 ignition system: ckp sensor inspection b933h21806004 refer to “electrical components location in section 0a (page 0a-7)”. Ckp sensor peak voltage 1) remove the ignition switch and connect the ignition switch coupler. Refer to “ignition switch removal and installation (page 1h-7)”. 2) disconnect...

  • Page 261: Partshark.Com

    Ignition system: 1h-7 ckp sensor removal and installation b933h21806005 refer to “generator removal and installation in section 1j (page 1j-5)”. Engine stop switch inspection b933h21806006 inspect the engine stop switch in the following procedures: 1) turn the ignition switch off. 2) remove the left...

  • Page 262: Partshark.Com

    1h-8 ignition system: specifications service data b933h21807001 electrical unit: mm (in) tightening torque specifications b933h21807002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-6)”. Special tools...

  • Page 263: Starting System

    Starting system: 1i-1 engine starting system schematic and routing diagram starting system diagram b933h21902001 refer to “wire color symbols in section 0a (page 0a-5)”. Component location starting system components location b933h21903001 refer to “electrical components location in section 0a (page ...

  • Page 264: Partshark.Com

    1i-2 starting system: starter motor will not run b933h21904002 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 b933h21904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 265: Partshark.Com

    Starting system: 1i-3 repair instructions starter motor components b933h21906001 fw d fwd 3 2 1 (d) (a) (b) (c) 6 7 8 4 5 4 i933h1190003-03 1. O-ring 7. Brush holder : apply grease. 2. Housing end (inside) 8. Housing end (outside) : apply water resistance grease. 3. O-ring : 6 n ⋅m (0.6 kgf-m, 4.5 l...

  • Page 266: Partshark.Com

    1i-4 starting system: starter motor removal and installation b933h21906002 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) drain engine coolant. Refer to “cooling system inspection in section...

  • Page 267: Partshark.Com

    Starting system: 1i-5 • apply grease to the lip of the dust 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 (suzuk...

  • Page 268: Partshark.Com

    1i-6 starting system: 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 269: Partshark.Com

    Starting system: 1i-7 starter relay inspection b933h21906006 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” and “b” terminals and check for continuity between the positive and neg...

  • Page 270: Partshark.Com

    1i-8 starting system: starter torque limiter / starter clutch removal and installation b933h21906008 removal starter torque limiter 1) remove the starter torque limiter cover (1). 2) remove the starter torque limiter (2) with the washers (3). 3) remove the bushings (4) from the starter torque limite...

  • Page 271: Partshark.Com

    Starting system: 1i-9 5) remove the key (6) and starter driven gear (7). 6) hold the generator rotor with the special tool and remove the starter clutch bolts. Special tool (a): 09930–44520 (rotor holder) 7) remove the one way clutch (8) from the guide (9). Installation install the starter clutch in...

  • Page 272: Partshark.Com

    1i-10 starting system: • apply thread lock to the bolts, and then tighten them to the specified torque with the special tool. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) special tool (a): 09930–44520 (rotor holder) tightening torque starter clutch bolt (a): 10 n·m ...

  • Page 273: Partshark.Com

    Starting system: 1i-11 starter torque limiter inspection b933h21906009 inspect the starter torque limiter in the following procedures: caution ! • do not attempt to disassemble the starter torque limiter. • the starter torque limiter is available only as an assembly part. 1) hold the starter torque ...

  • Page 274: Partshark.Com

    1i-12 starting system: starter driven gear bearing removal and installation b933h21906011 removal 1) remove the starter driven gear. Refer to “starter torque limiter / starter clutch removal and installation (page 1i-8)”. 2) remove the bearing with the special tool. Special tool (a): 09913–70210 (be...

  • Page 275: Partshark.Com

    Starting system: 1i-13 specifications service data b933h21907001 unit: mm (in) tightening torque specifications b933h21907002 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 276: Partshark.Com

    1i-14 starting system: special tools and equipment recommended service material b933h21908001 note required service material is also described in the following. “starter motor components (page 1i-3)” special tool b933h21908002 material suzuki recommended product or specification note grease suzuki s...

  • Page 277: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b933h21a02001 component location charging system components location b933h21a03001 refer to “electrical components location in section 0a (page 0a-7)”. Diagnostic information and procedures charging sy...

  • Page 278: Partshark.Com

    1j-2 charging system: battery runs down quickly b933h21a04002 troubleshooting battery overcharges faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire coupler. Repair. “sulfation”, acidic white powdery substance or spots on surfaces of cell plates cracked...

  • Page 279: Partshark.Com

    Charging system: 1j-3 repair instructions battery current leakage inspection b933h21a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 3) disconnect...

  • Page 280: Partshark.Com

    1j-4 charging system: generator inspection b933h21a06003 generator coil resistance 1) disconnect the generator coupler (1). 2) 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 i...

  • Page 281: Partshark.Com

    Charging system: 1j-5 generator removal and installation b933h21a06004 removal 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-11)”. 2) disconnect the reverse lock release cable. (for transmission side) refer to “gear position (gp) switch removal and installat...

  • Page 282: Partshark.Com

    1j-6 charging system: 12) remove the generator rotor assembly (8) with the special tool. Special tool (b): 09930–31921 (rotor remover) caution ! Do not hit the generator rotor with a hammer, otherwise the rotor may be damaged. Note remove the starter clutch if necessary. Refer to “starter torque lim...

  • Page 283: Partshark.Com

    Charging system: 1j-7 • degrease the tapered portion “a” of generator rotor assembly and also the crankshaft “b”. Use nonflammable cleaning solvent to wipe off oily or greasy matter to make these surfaces completely dry. • install the generator rotor assembly onto crankshaft. • hold the generator ro...

  • Page 284: Partshark.Com

    1j-8 charging system: • install the generator cover (3) and tighten the generator cover bolts. Warning ! Be careful not to pinch the finger between the generator cover and the crankcase. • route the ckp sensor and generator lead wire. Refer to “wiring harness routing diagram in section 9a (page 9a-3...

  • Page 285: Partshark.Com

    Charging system: 1j-9 3) 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 286: Partshark.Com

    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 287: Partshark.Com

    Charging system: 1j-11 8) insert the caps (2) into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover. Caution ! • once the caps are installed to the battery, do not remove the caps. • do not tap the caps with a hammer ...

  • Page 288: Partshark.Com

    1j-12 charging system: 4) install the battery to the vehicle. Refer to “battery removal and installation (page 1j-12)”. Battery removal and installation b933h21a06008 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) disconnect the clamp and...

  • Page 289: Partshark.Com

    Charging system: 1j-13 specifications service data b933h21a07001 electrical unit: mm caution ! Never use anything except the specified battery. Tightening torque specifications b933h21a07002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque s...

  • Page 290: Partshark.Com

    1j-14 charging system: special tools and equipment recommended service material b933h21a08001 special tool b933h21a08002 material suzuki recommended product or specification note grease water resistance grease or equivalent p/no.: 99000–25160 ) (page 1j-7) molybdenum oil molybdenum oil solution — ) ...

  • Page 291: Exhaust System

    Exhaust system: 1k-1 engine exhaust system precautions precautions for exhaust system b933h21b00001 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 292: Partshark.Com

    1k-2 exhaust system: repair instructions exhaust system construction b933h21b06001 (a) 4 1 3 fwd fwd (a) 6 (a) 5 2 7 (b) 8 i933h11b0012-03 1. Exhaust pipe 5. Muffler mounting bolt : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Muffler 6. Muffler connecting bolt : 13 n ⋅m (1.3 kgf-m, 9.5 lb-ft) 3. Connector 7....

  • Page 293: Partshark.Com

    Exhaust system: 1k-3 muffler / exhaust pipe removal and installation b933h21b06002 removal 1) loosen the muffler connecting bolt (1). 2) remove the muffler (2) by removing the mounting bolts. Note support the muffler to prevent it from falling. 3) remove the side covers, left and right. Refer to “ex...

  • Page 294: Partshark.Com

    1k-4 exhaust system: • install the new muffler connector (2). Note when installing new connector, remove the old sealer from the exhaust pipe and muffler. Apply the exhaust gas sealer to both the inside and outside of the new connector. : muffler seal (muffler seal loctite 5920 (commercially availab...

  • Page 295: Partshark.Com

    Exhaust system: 1k-5 specifications tightening torque specifications b933h21b07001 note the specified tightening torque is also described in the following. “exhaust system construction (page 1k-2)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening t...

  • Page 296: Partshark.Com

    1k-6 exhaust system: partshark.Com 877-999-5686.

  • Page 297: 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 298: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b933h22000001 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 299: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b933h22104001 condition possible cause correction / reference item tires rapidly or unevenly wear worn or loose front wheel hub bearings. Replace. I...

  • Page 300: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front suspension components b933h22206001 1 3 5 5 5 6 6 7 7 8 8 9 11 14 14 15 4 4 (a) (b) (b) (d) (c) 10 10 (c) 10 5 (c) 16 15 18 19 20 21 18 22 23 (b) 10 fwd fwd 19 2 12 13 (a) 17 i933h1220001-14 partshark.Com 877-999-5686.

  • Page 301: Partshark.Com

    Front suspension: 2b-2 front suspension / steering assembly construction b933h22206002 1. Front shock absorber 12. Snap ring 23. Front hub plate 2. Upper wishbone arm 13. Knuckle end : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Lower wishbone arm 14. Tie-rod end : 65 n ⋅m (6.5 kgf-m, 47.0 lb-ft) 4. Collar 1...

  • Page 302: Partshark.Com

    2b-3 front suspension: front shock absorber removal and installation b933h22206003 caution ! Make sure that the vehicle is supported securely. Removal 1) remove the front shock absorber (1). 2) remove the spacer (2). Installation 1) apply grease to the busing and dust seals. : grease 99000–25160 (wa...

  • Page 303: Partshark.Com

    Front suspension: 2b-4 bush / dust seal inspect the bushing and dust seal for wear or damage. If any damages are found, replace the front shock absorber with a new one. Rubber bush inspect the rubber bushing for wear or damage. If any damages are found, replace the front shock absorber with a new on...

  • Page 304: Partshark.Com

    2b-5 front suspension: compression damping force adjustment after installing the front suspension, adjust the spring pre-load and damping force as follows. Note • turn the adjuster clockwise to stiffen the damping force and turn it counterclockwise to soften the damping force. • fine-tune the adjust...

  • Page 305: Partshark.Com

    Front suspension: 2b-6 front wheel hub / steering knuckle removal and installation b933h22206008 removal 1) remove the cotter pin (1) and loosen the hub nut (2). 2) remove the front wheel assembly (3). Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 3) remove the fr...

  • Page 306: Partshark.Com

    2b-7 front suspension: installation install the front wheel hub and steering knuckle in the reverse order of removal. Pay attention to the following points: • degrease the tapered position of knuckle and also knuckle end and tie-rod end with nonflammable cleaning solvent. • install the washers (1) a...

  • Page 307: Partshark.Com

    Front suspension: 2b-8 • install the front wheel hub (6), washer (7) and front wheel hub nut (8). • install the brake caliper (9). Refer to “front brake caliper removal and installation in section 4b (page 4b-3)”. • install the front wheel assembly (10). Refer to “front / rear wheel removal and inst...

  • Page 308: Partshark.Com

    2b-9 front suspension: steering knuckle inspection b933h22206010 refer to “front wheel hub / steering knuckle removal and installation (page 2b-6)”. Inspect the steering knuckle for damage. If any defects are found, replace the steering knuckle with a new one. Front wheel hub dust seal / bearing rem...

  • Page 309: Partshark.Com

    Front suspension: 2b-10 2) first install the right hub bearing, then install the spacer (1) and left hub bearing with the special tool. Special tool (a): 09913–70210 (bearing installer set) (b): 09924–84510 (bearing installer set) caution ! The sealed cover of the bearing must face outside. Insert t...

  • Page 310: Partshark.Com

    2b-11 front suspension: 5) disconnect the front brake hose (3) and remove the upper wishbone arm (1) by removing the upper wishbone arm bolts and pivot nut (4). 6) remove the front shock absorber lower mounting bolt and nut (5) and remove the lower wishbone arm (2) by removing the lower wishbone arm...

  • Page 311: Partshark.Com

    Front suspension: 2b-12 • install the front wheel hub. Refer to “front wheel hub / steering knuckle removal and installation (page 2b-6)”. • install the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. Knuckle end boot inspection b933h22206013 r...

  • Page 312: Partshark.Com

    2b-13 front suspension: front suspension wishbone arm dust seal / bearing removal and installation b933h22206015 removal 1) remove the front suspension upper/lower wishbone arm. Refer to “front suspension upper / lower wishbone arm removal and installation (page 2b- 10)”. 2) remove the dust covers (...

  • Page 313: Partshark.Com

    Front suspension: 2b-14 • apply grease to the bearings. : grease 99000–25160 (water resistance grease or equivalent) • install the dust seals with the special tool. Special tool (b): 09913–70210 (bearing installer set) • apply grease to the oil seal lip. : grease 99000–25160 (water resistance grease...

  • Page 314: Partshark.Com

    2b-15 front suspension: lower wishbone arm inspect the knuckle end boot and lower wishbone arm for wear or damage. If any defects are found, replace the lower wishbone arm with a new one. Inspect the knuckle end smooth movement. If there are any abnormalities, replace the knuckle end with a new one....

  • Page 315: Partshark.Com

    Front suspension: 2b-16 specifications service data b933h22207001 suspension unit: mm (in) tightening torque specifications b933h22207002 note the specified tightening torque is also described in the following. “front suspension components (page 2b-1)” “front suspension / steering assembly construct...

  • Page 316: Partshark.Com

    2b-17 front suspension: special tool b933h22208002 09900–06107 09910–60611 snap ring pliers universal clamp wrench ) (page 2b-12) / ) (page 2b-12) ) (page 2b-4) 09913–50121 09913–70210 oil seal remover bearing installer set ) (page 2b-9) ) (page 2b-10) / ) (page 2b-10) / ) (page 2b-12) / ) (page 2b-...

  • Page 317: Rear Suspension

    Rear suspension: 2c-1 suspension rear suspension repair instructions rear suspension components b933h22306001 12 11 10 (e) 11 9 (d) 7 (a) 1 (a) (b) (b) 2 5 5 5 3 (b) 4 6 (c) 4 fwd fwd 8 (f) 13 i933h1230001-07 1. Rear shock absorber 9. Swingarm : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Cushion rod 10. C...

  • Page 318: Partshark.Com

    2c-2 rear suspension: rear suspension assembly construction b933h22306002 (c) “ a ” 4 3 rh lh rh lh 2 5 1 (a) 1 “ b ” “ b ” “c” “c” (b) (a) 2 (b) rh lh 4 3 5 “c” “c” i933h1230067-05 1. Rear shock absorber mounting nut (upper) 5. Cushion rod nut (upper) : apply water resistance grease. 2. Rear shock ...

  • Page 319: Partshark.Com

    Rear suspension: 2c-3 rear shock absorber removal and installation b933h22306003 removal 1) remove the cushion rod and cushion lever. Refer to “cushion rod / cushion lever removal and installation (page 2c-7)”. 2) remove the rear shock absorber lower mounting bold and nut (1). 3) remove the rear sho...

  • Page 320: Partshark.Com

    2c-4 rear suspension: rear suspension inspection b933h22306004 refer to “suspensions inspection in section 0b (page 0b-22)”. Rear shock absorber inspection b933h22306005 inspect the rear shock absorber in the following procedures: 1) remove the rear shock absorber. Refer to “rear shock absorber remo...

  • Page 321: Partshark.Com

    Rear suspension: 2c-5 rebound side turn the damping force adjuster (1) to the desired position. Std position 1 and 1/4 turns out from stiffest position compression side turn the damping force adjuster (1) to the desired position. Std position 2 turns out from stiffest position rear shock absorber di...

  • Page 322: Partshark.Com

    2c-6 rear suspension: rear wheel hub removal and installation b933h22306008 removal 1) remove the cotter pin (1) and loosen the hub nut (2). 2) remove the rear wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 3) remove the hub nut (3), washer (4) and ...

  • Page 323: Partshark.Com

    Rear suspension: 2c-7 cushion rod / cushion lever removal and installation b933h22306010 removal 1) remove the cushion lever cover (1). 2) remove the swingarm under cover (2). 3) place the vehicle on the level ground and support the vehicle with a jack. 4) remove the cushion rod (1). 5) remove the c...

  • Page 324: Partshark.Com

    2c-8 rear suspension: 3) tighten the cushion rod nuts (3) to the specified torque. Tightening torque cushion rod nut (c): 78 n·m (7.8 kgf-m, 56.5 lb- ft) 4) install the swingarm under cover (4). Note fit the washers to the bolts “a”. 5) tighten the cushion lever cover bolts (5) to the specified torq...

  • Page 325: Partshark.Com

    Rear suspension: 2c-9 4) remove the bearings (4) with the special tools. Special tool (a): 09923–73210 (bearing remover) (b): 09930–30104 (rotor remover slide shaft) installation caution ! The removed dust seals and bearings must be replaced with new ones. Note stamped marks on the dust seals and be...

  • Page 326: Partshark.Com

    2c-10 rear suspension: cushion rod dust seal / bearing removal and installation b933h22306012 removal 1) remove the cushion rod. Refer to “cushion rod / cushion lever removal and installation (page 2c- 7)”. 2) remove the spacer (1). 3) remove the dust seals (2). 4) remove the bearings (3) with the s...

  • Page 327: Partshark.Com

    Rear suspension: 2c-11 3) install the dust seals with the special tool. Special tool (b): 09913–70210 (bearing installer set) 4) apply grease to the oil seal lip. : grease 99000–25160 (water resistance grease or equivalent) 5) install the spacer. 6) install the cushion rod. Refer to “cushion rod / c...

  • Page 328: Partshark.Com

    2c-12 rear suspension: bearing 1) remove the dust seals. Refer to “cushion lever dust seal / bearing removal and installation (page 2c-8)” and “cushion rod dust seal / bearing removal and installation (page 2c-10)”. 2) insert the spacers into bearings. 3) check the play by moving the spacers up and ...

  • Page 329: Partshark.Com

    Rear suspension: 2c-13 4) remove the swingarm by removing the pivot shaft and nut (3) and washer (4). 5) remove the chain buffer (5). 6) remove the dust covers (6) and washers (7). Installation install the swingarm in the reverse order removal. Pay attention to the following points. • apply grease t...

  • Page 330: Partshark.Com

    2c-14 rear suspension: swingarm dust seal / bearing removal and installation b933h22306015 refer to “rear axle assembly construction in section 3a (page 3a-3)”. Removal 1) remove the swingarm. Refer to “swingarm removal and installation (page 2c-12)”. 2) remove the spacers (1). 3) remove the dust se...

  • Page 331: Partshark.Com

    Rear suspension: 2c-15 4) apply grease to the dust seal lips. : grease 99000–25160 (water resistance grease or equivalent) 5) install the spacers (1). 6) install the swingarm. Refer to “swingarm removal and installation (page 2c-12)”. Swingarm related parts inspection b933h22306016 refer to “swingar...

  • Page 332: Partshark.Com

    2c-16 rear suspension: cushion lever / rod bolt inspect the cushion lever/rod bolts for damage and bend. If any defects are noted, replace them with new ones. Swingarm pivot shaft measure the swingarm pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot...

  • Page 333: Partshark.Com

    Rear suspension: 2c-17 special tools and equipment recommended service material b933h22308001 note required service material is also described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2)” special tool b933h22308002 material suzuki rec...

  • Page 334: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires precautions precautions for wheel and tire b933h22400001 warning ! • proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. • under-inflatio...

  • Page 335: Partshark.Com

    Wheels and tires: 2d-2 front / rear wheel removal and installation b933h22406002 caution ! Make sure that the vehicle is supported securely. Removal 1) place the vehicle on level ground. 2) support the vehicle with a jack or wooden block. 3) remove the wheel (1). Front rear installation install the ...

  • Page 336: Partshark.Com

    2d-3 wheels and tires: tire removal and installation b933h22406003 1) remove the wheel from vehicle. Refer to “front / rear wheel removal and installation (page 2d-2)”. 2) after removing the air valve cap, release the tire pressure by depressing the valve. Note to properly remove the tire, if a pneu...

  • Page 337: Partshark.Com

    Wheels and tires: 2d-4 3) mount the tire on the rim by hand or tire levers and rim protectors. Caution ! The standard tire fitted on this vehicle is at22 x 7r10 œœ for the front and at20 x 10r9 œœ for the rear. The use of tires other than the standard may cause instability. It is highly recommended ...

  • Page 338: Partshark.Com

    2d-5 wheels and tires: 5) adjust the tire pressure to the specified pressure. Caution ! Before inflating the tire, check the maximum operating pressure rating of the tire. This is indicated by a “œ” following the tire size shown on the sidewall. The number of “œ” on the tire indications the maximum ...

  • Page 339: 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 340: Precautions

    3-1 precautions: driveline / axle precautions precautions precautions for driveline / axle b933h23000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! Never inspect or adjust the drive chain while the engine is running. Caution ! • do not use trichloroethylene, gasoline or such...

  • Page 341: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-1 driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b933h23104001 condition possible cause correction / reference item noisy drive chain worn sprocket. Replace. Worn dr...

  • Page 342: Partshark.Com

    3a-2 drive chain / drive train / drive shaft: repair instructions drive chain / rear axle related components b933h23106001 12 10 9 11 10 9 7 6 5 (a) 4 (a) 2 13 14 fwd fwd 1 3 (b) 8 i933h1310044-03 1. Stopper ring 8. Dust seal : 240 n.M (24.0 kgf-m, 173.5 lb-ft) 2. Rear axle lock-nut 9. Bearing : 60 ...

  • Page 343: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-3 rear axle assembly construction b933h23106002 “ a ” “ b ” “ a ” “ c ” “ b ” “ a ” “ c ” (b) 2 (e) 6 “ b ” (c) 3 (d) 4 (d) 5 (f) 7 (g) 8 (a) 1 9 9 i933h1310045-04 1. Swingarm pivot nut 9. O-ring : apply thread lock to the thread part. 2. Brake disc bolt :...

  • Page 344: Partshark.Com

    3a-4 drive chain / drive train / drive shaft: engine sprocket removal and installation b933h23106003 removal 1) remove the engine sprocket cover (1). 2) remove the bracket (2). 3) remove the engine sprocket washer (3). 4) loosen the chain adjuster nut (4) and rear axle housing bolts (5) to provide a...

  • Page 345: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-5 2) apply thread lock to the sprocket bolts and tighten them. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 3) install the bracket and engine sprocket cover (2). Note fit the clamp to the bolt “b”. Refer to “hose and cable...

  • Page 346: Partshark.Com

    3a-6 drive chain / drive train / drive shaft: 9) loosen the rear axle housing bolts (6) and chain adjuster nut (7). 10) disengage the drive chain (8) from the rear sprocket. 11) draw out the rear sprocket assembly (9). 12) remove the o-ring (10). 13) remove the rear sprocket (11) from the sprocket f...

  • Page 347: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-7 • install the rear sprocket assembly (1) to the axle shaft. • engage the drive chain (2) to the rear sprocket. • install the concave washers (3) as shown in the figure. • apply thread lock to the rear axle nut bolt. : thread lock cement 99000–32110 (thre...

  • Page 348: Partshark.Com

    3a-8 drive chain / drive train / drive shaft: drive chain related parts inspection b933h23106006 refer to “engine sprocket removal and installation (page 3a-4)” and “rear sprocket removal and installation (page 3a-5)”. Rear sprocket flange inspect the rear sprocket flange for damage and wear of spli...

  • Page 349: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-9 2) place the drive chain link being disjointed on the holder part (8) of the tool. 3) turn in both the adjuster bolt (6) and pressure bolt [a] (3) so that each of their end hole fits over the chain joint pin properly. 4) tighten the pressure bolt [a] (3)...

  • Page 350: Partshark.Com

    3a-10 drive chain / drive train / drive shaft: 4) apply grease on the recessed portion of the joint plate holder (3) and set the joint plate (10). Note when positioning the joint plate (10) on the tool, its stamp mark must face the joint plate holder (3) side. 5) set the drive chain on the tool as i...

  • Page 351: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-11 3) adjust the drive chain slack, after connecting it. Refer to “drive chain inspection and adjustment in section 0b (page 0b-15)”. Drive chain roller construction b933h23106008 “a” i649g1310036-03 (a) 1 2 3 i933h1310048-02 1. Drive chain roller 3. Washe...

  • Page 352: Partshark.Com

    3a-12 drive chain / drive train / drive shaft: drive chain roller inspection b933h23106009 inspect the drive chain roller bearings for abnormal noise and smooth rotation. Replace the drive chain control roller bearings if there is anything unusual. Refer to “drive chain roller removal and installati...

  • Page 353: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-13 6) remove the boot (5). 7) remove the snap ring (6), washer (7) and nut (8). Special tool : 09900–06107 (snap ring pliers) installation install the rear axle housing in the reverse order of removal. Pay attention to the following points: • when installi...

  • Page 354: Partshark.Com

    3a-14 drive chain / drive train / drive shaft: boot inspect the boot for wear or damage. If any defects are found, replace the boot with a new one. Rear axle 1) remove the rear brake disc plate housing from the rear axle. Refer to “rear brake disc removal and installation in section 4c (page 4c-8)”....

  • Page 355: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-15 install the rear axle dust seal / bearing in the reverse order of removal. Pay attention to the following points. • first install the right bearing, then install the spacer (1) and left bearings with the special tools. Special tool (a): 09913–70210 (bea...

  • Page 356: Partshark.Com

    3a-16 drive chain / drive train / drive shaft: specifications service data b933h23107001 drive train unit: mm (in) wheel unit: mm (in) tightening torque specifications b933h23107002 note the specified tightening torque is also described in the following. “drive chain / rear axle related components (...

  • Page 357: Partshark.Com

    Drive chain / drive train / drive shaft: 3a-17 special tools and equipment recommended service material b933h23108001 note required service material is also described in the following. “drive chain / rear axle related components (page 3a-2)” “rear axle assembly construction (page 3a-3)” special tool...

  • Page 358: Partshark.Com

    3a-18 drive chain / drive train / drive shaft: partshark.Com 877-999-5686.

  • Page 359: 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 360: Partshark.Com

    4-ii table of contents parking brake removal and installation .............4d-2 parking brake inspection ....................................4d-3 specifications.......................................................4d-4 tightening torque specifications........................4d-4 special tools and e...

  • Page 361: Precautions

    Precautions: 4-1 brake precautions precautions precautions for brake system b933h24000001 refer to “general precautions in section 00 (page 00-1)”. Brake fluid information b933h24000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 362: Partshark.Com

    4a-1 brake control system and diagnosis: brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b933h24102001 “e” “f” “b” forward right side left side “c” “d” (e) 3 2 (e) “a” 1 (a) (d) “ a ” “ a ” “ b ” “ b ” (a) (a) (c) (b) (b) (c) i933h1410055-06 1....

  • Page 363: Partshark.Com

    Brake control system and diagnosis: 4a-2 rear brake hose routing diagram b933h24102002 (b) “ b ” 1 2 3 “b” “d” 1 2 outside forward under backward “e” 2 (a) “c” “f” “b” (d) (c) (a) (c) “c” 4 “a” “ a ” (a) “ c ” i933h1410056-05 1. Parking brake cable “b”: after the brake hose union has contacted the s...

  • Page 364: Partshark.Com

    4a-3 brake control system and diagnosis: hose and cable routing diagram b933h24102003 1 2 3 4 1 “a” 1 5 4 3 “b” 6 5 “c” 7 5 8 2 3 i933h1410057-05 1. Throttle cable 5. Reverse gear cable “a”: pass the throttle cable inside the steering cover. 2. Starter cable 6. Reverse cable adjuster “b”: pass the s...

  • Page 365: Partshark.Com

    Brake control system and diagnosis: 4a-4 3 “a” 1 2 4 5 1 2 5 6 “b” 7 “c” 2 3 5 4 i933h1410058-01 1. Throttle cable 5. Parking brake cable “b”: pass the starter cable between fuel hose and reverse gear cable. 2. Reverse gear cable 6. Starter cable “c”: set the reverse gear cable between the oil filte...

  • Page 366: Partshark.Com

    4a-5 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b933h24104001 repair instructions brake pedal height inspection and adjustment b933h24106001 refer to “brake system inspection in section 0b (page 0b-17)”. Front brake light switch inspection b933h...

  • Page 367: Partshark.Com

    Brake control system and diagnosis: 4a-6 rear brake light switch inspection b933h24106003 inspect the rear brake light switch in the following procedures: 1) remove the fuel tank cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) disconnect the rear brake light ...

  • Page 368: Partshark.Com

    4a-7 brake control system and diagnosis: 2) attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle. 3) squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. 4) loosen the air bleeder valve (1) by...

  • Page 369: Partshark.Com

    Brake control system and diagnosis: 4a-8 • fill the reservoir with brake fluid to the upper mark of the reservoir. • install the fuel tank cover. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. Brake fluid replacement b933h24106008 caution ! • make sure that the vehicle...

  • Page 370: Partshark.Com

    4a-9 brake control system and diagnosis: rear brake 1) remove the fuel tank cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) remove the master cylinder reservoir cap and diaphragm. 3) suck up the old brake fluid as much as possible. 4) fill the reservoir with ...

  • Page 371: Partshark.Com

    Brake control system and diagnosis: 4a-10 front brake master cylinder components b933h24106010 1 2 3 (a) 5 4 (b) 5 (c) (c) (b) 5 (b) 5 7 6 (d) fwd fwd fwd fwd i933h1410060-04 1. Reservoir cap 6. Brake lever : apply silicone grease. 2. Diaphragm 7. Brake lever pivot bolt : apply brake fluid. 3. Maste...

  • Page 372: Partshark.Com

    4a-11 brake control system and diagnosis: front brake master cylinder assembly removal and installation b933h24106011 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-8)”. 2) place a rag underneath the brake hose union bolt (1) on the master cylinder to catch any spilt brake ...

  • Page 373: Partshark.Com

    Brake control system and diagnosis: 4a-12 front brake master cylinder / brake lever disassembly and assembly b933h24106012 refer to “front brake master cylinder assembly removal and installation (page 4a-11)”. Disassembly 1) remove the reservoir cap (1) and diaphragm (2). 2) remove the brake lever (...

  • Page 374: Partshark.Com

    4a-13 brake control system and diagnosis: • when installing the brake light switch, align the projection on the switch with the hole on 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 375: Partshark.Com

    Brake control system and diagnosis: 4a-14 rear brake pedal construction b933h24106014 4 (a) (b) 2 “ a ” 3 5 1 i933h1410061-01 1. Brake pedal 5. White mark : do not reuse. 2. Brake light switch : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) “a”: 5 mm (0.2 in) 3. O-ring : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) 4. Brake ma...

  • Page 376: Partshark.Com

    4a-15 brake control system and diagnosis: rear brake pedal removal and installation b933h24106015 removal 1) remove the right footrest mud guard. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) remove the right footrest. Refer to “footrest removal and installation in...

  • Page 377: Partshark.Com

    Brake control system and diagnosis: 4a-16 rear brake master cylinder components b933h24106016 1 (a) 2 (a) 2 (b) 8 7 6 3 4 5 (c) 9 i933h1410062-06 1. Reservoir tank 6. Piston/cup set : 18 n ⋅m (1.8 kgf-m, 13.0 lb-ft) 2. Brake hose union bolt 7. Push rod : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 3. Master cyli...

  • Page 378: Partshark.Com

    4a-17 brake control system and diagnosis: rear brake master cylinder assembly removal and installation b933h24106017 removal 1) remove the fuel tank cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) remove the fastener (1). 3) remove the rear fender mounting sc...

  • Page 379: Partshark.Com

    Brake control system and diagnosis: 4a-18 • bleed air from the brake system after reassembling the master cylinder. Refer to “air bleeding from brake fluid circuit (page 4a-6)”. • adjust the brake pedal height. Refer to “brake system inspection in section 0b (page 0b-17)”. Rear brake master cylinder...

  • Page 380: Partshark.Com

    4a-19 brake control system and diagnosis: assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the brake fluid off after washing the comp...

  • Page 381: Partshark.Com

    Brake control system and diagnosis: 4a-20 specifications service data b933h24107001 brake unit: mm (in) oil tightening torque specifications b933h24107002 note the specified tightening torque is also described in the following. “front brake hose routing diagram (page 4a-1)” “rear brake hose routing ...

  • Page 382: Partshark.Com

    4a-21 brake control system and diagnosis: special tools and equipment recommended service material b933h24108001 note required service material is also described in the following. “rear brake hose routing diagram (page 4a-2)” “front brake master cylinder components (page 4a-10)” “rear brake pedal co...

  • Page 383: Front Brakes

    Front brakes: 4b-1 brake front brakes repair instructions front brake components b933h24206001 fw d fwd 10 8 6 (b) (c) 5 (d) 9 (a) 2 3 (e) 7 4 1 (c) i933h1420001-07 1. Front brake caliper 8. Front brake disc : 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 2. Piston seal 9. Brake pad spring : apply thread lock to ...

  • Page 384: Partshark.Com

    4b-2 front brakes: front brake pad inspection b933h24206002 refer to “brake system inspection in section 0b (page 0b-17)”. Front brake pad replacement b933h24206003 1) remove the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 2) loosen the bra...

  • Page 385: Partshark.Com

    Front brakes: 4b-3 9) tighten the brake caliper mounting bolts (2) to the specified torque. Tightening torque brake caliper mounting bolt (a): 26 n·m (2.6 kgf- m, 19.0 lb-ft) 10) tighten the front brake pad mounting pins (1) to the specified torque. Tightening torque front brake pad mounting pin (b)...

  • Page 386: Partshark.Com

    4b-4 front brakes: • bleed air from the brake system after installing the caliper. Refer to “air bleeding from brake fluid circuit in section 4a (page 4a-6)”. • install the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. • check the brake fluid...

  • Page 387: Partshark.Com

    Front brakes: 4b-5 8) remove the caliper holder pin (8). Note if there is no abnormal condition, the caliper holder pin removal is not necessary. 9) remove the rubber boots (9). Note if there is no abnormal condition, the rubber boots removal is not necessary. Assembly assemble the caliper in the re...

  • Page 388: Partshark.Com

    4b-6 front brakes: • tighten the brake caliper holder slide pin (1) to the specified torque. Tightening torque front brake caliper holder slide pin (b): 23 n·m ( 2.3 kgf-m, 16.5 lb-ft) • wash the caliper bore and piston with specified brake fluid. Particularly wash the dust seal groove and piston se...

  • Page 389: Partshark.Com

    Front brakes: 4b-7 brake caliper piston inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, replace the piston with a new one. Boots inspect the boots for damage or wear. If any defects are found, replace them with new ones. Brake pad mounting pin insp...

  • Page 390: Partshark.Com

    4b-8 front brakes: front brake disc removal and installation b933h24206007 removal 1) remove the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-2)”. 2) remove the front wheel hub and front brake disc cover. Refer to “front wheel hub / steering knuc...

  • Page 391: Partshark.Com

    Front brakes: 4b-9 front brake disc cover inspection b933h24206009 inspect the front brake disc cover in the following procedures: 1) remove the front brake disc cover. Refer to “front wheel hub / steering knuckle removal and installation in section 2b (page 2b-6)”. 2) inspect the brake disc cover f...

  • Page 392: Partshark.Com

    4b-10 front brakes: special tools and equipment recommended service material b933h24208001 note required service material is also described in the following. “front brake components (page 4b-1)” special tool b933h24208002 material suzuki recommended product or specification note brake fluid dot 4 — ...

  • Page 393: Rear Brakes

    Rear brakes: 4c-1 brake rear brakes repair instructions rear brake components b933h24306001 8 (d) (c) (b) 1 5 7 (b) (a) 4 6 fwd fwd 2 3 9 10 (c) i933h1430001-09 1. Rear brake caliper 8. Front brake disc : apply thread lock to the thread part. 2. Piston seal 9. Stopper ring : apply thread lock to the...

  • Page 394: Partshark.Com

    4c-2 rear brakes: rear brake pad inspection b933h24306002 refer to “brake system inspection in section 0b (page 0b-17)”. Rear brake pad replacement b933h24306003 1) flatten the lock washer, and slightly loosen the pad mounting pins (1). 2) loosen the lock-nut (2) and parking brake adjuster (3) sever...

  • Page 395: Partshark.Com

    Rear brakes: 4c-3 7) install the new lock washer (6) and temporarily tighten the pad mounting pins (1). 8) apply a small quantity of thread lock to the brake caliper mounting bolts (4). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 9) tighten the brake caliper mounti...

  • Page 396: Partshark.Com

    4c-4 rear brakes: installation 1) apply a small quantity of thread lock to the brake caliper mounting bolts (1). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 2) tighten the brake caliper mounting bolts (1) and slide pin (2). Tightening torque brake caliper mounting ...

  • Page 397: Partshark.Com

    Rear brakes: 4c-5 4) remove the caliper holder pin (5). Note if there is no abnormal condition, the caliper holder pin removal is not necessary. 5) remove the rubber boots (6). Note if there is no abnormal condition, the rubber boots removal is not necessary. 6) place a rag over the brake caliper pi...

  • Page 398: Partshark.Com

    4c-6 rear brakes: assembly assemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bore and piston with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves. Bf: brake fluid (dot 4) note • wash the caliper ...

  • Page 399: Partshark.Com

    Rear brakes: 4c-7 • apply thread lock to the brake caliper holder slide pin (5). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • install the caliper holder slide pin (5), washer (6) and caliper holder (7) to the caliper. Note when installing the caliper holder slide ...

  • Page 400: Partshark.Com

    4c-8 rear brakes: brake pad mounting pin inspect the brake pad mounting pins for wear or damage. If any defects are found, replace the mounting pin with new ones. Brake caliper slide pin inspect the brake caliper slide pin for wear or damage. If any damage is found, replace it with a new one. Brake ...

  • Page 401: Partshark.Com

    Rear brakes: 4c-9 5) push the rear brake disc plate housing (3) and remove the stopper ring (4). 6) remove the rear brake disc plate housing (3) from the rear axle. 7) remove the o-ring (5). Installation install the rear brake disc in the reverse order of removal. Pay attention to the following poin...

  • Page 402: Partshark.Com

    4c-10 rear brakes: rear brake disc inspection b933h24306008 brake disc thickness inspect the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (a): 09900–20205 (mi...

  • Page 403: Partshark.Com

    Rear brakes: 4c-11 tightening torque specifications b933h24307002 note the specified tightening torque is also described in the following. “rear brake components (page 4c-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in...

  • Page 404: Parking Brake

    4d-1 parking brake: brake parking brake repair instructions parking brake inspection and adjustment b933h24406001 refer to “brake system inspection in section 0b (page 0b-17)”. Parking brake cable removal and installation b933h24406002 removal 1) loosen the parking brake cable adjuster lock-nut (1) ...

  • Page 405: Partshark.Com

    Parking brake: 4d-2 parking brake lock / knob removal and installation b933h24406004 refer to “clutch lever removal and installation in section 5c (page 5c-3)”. Parking brake removal and installation b933h24406005 removal 1) loosen the lock-nut (1) and remove the parking brake adjuster (2). 2) remov...

  • Page 406: Partshark.Com

    4d-3 parking brake: 4) loosen the lock-nut (4) and turn the adjuster (5) in completely, so that the cable play is maximum. 5) set the parking brake shaft (6) in neutral position by rotating the shaft. 6) install the parking lever (7) onto the parking brake shaft (6) with the punch mark “a” aligned w...

  • Page 407: Partshark.Com

    Parking brake: 4d-4 specifications tightening torque specifications b933h24407001 note the specified tightening torque is also described in the following. “parking brake components (page 4d-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torqu...

  • Page 408: Partshark.Com

    4d-5 parking brake: partshark.Com 877-999-5686.

  • Page 409: Section 5

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

  • Page 410: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b933h25000001 refer to “general precautions in section 00 (page 00-1)”. Partshark.Com 877-999-5686.

  • Page 411: Manual Transmission

    Manual transmission: 5b-1 transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis b933h25204001 repair instructions reverse lock cable play inspection and adjustment b933h25206001 the cable adjuster is located at inside of the fuel tan...

  • Page 412: Partshark.Com

    5b-2 manual transmission: reverse lock cable removal and installation b933h25206002 removal 1) remove the reverse lock release knob (1) from the front fender. 2) remove the bracket (2) by removing the screws and nuts. 3) remove the cap (3). 4) remove the screw (4) and washer (5). 5) draw out the rev...

  • Page 413: Partshark.Com

    Manual transmission: 5b-3 installation install the reverse lock cable in the reverse order of removal. Pay attention to the following points: • install the reverse lock cable as shown in the rear brake cable routing diagram. Refer to “hose and cable routing diagram in section 4a (page 4a-3)”. • inst...

  • Page 414: Partshark.Com

    5b-4 manual transmission: transmission components b933h25206003 fwd fwd 23 24 (a) 18 19 17 16 20 22 21 5 4 2 1 6 7 13 10 11 12 15 14 9 8 3 i933h1520014-05 partshark.Com 877-999-5686.

  • Page 415: Partshark.Com

    Manual transmission: 5b-5 transmission removal and installation b933h25206004 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-13)”. 2) remove the engine top side. Refer to “engine top side disassembly in section 1d (page 1d-17)”. 3) sepa...

  • Page 416: Partshark.Com

    5b-6 manual transmission: installation reverse idle gear assembly / driveshaft assembly / countershaft assembly 1) install the countershaft assembly (1) and driveshaft assembly (2). 2) install the reverse idle gear (3) and shaft (4). 3) install the wave washer (5) and washer (6). Reverse lock shaft ...

  • Page 417: Partshark.Com

    Manual transmission: 5b-7 transmission construction b933h25206005 countershaft gear / driveshaft gear / reverse idle gear disassembly and assembly b933h25206006 refer to “transmission removal and installation (page 5b-5)”. Disassembly caution ! Identify the position of each removed part. Organize th...

  • Page 418: Partshark.Com

    5b-8 manual transmission: caution ! • never reuse a snap ring. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed. • when installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft. • af...

  • Page 419: Partshark.Com

    Manual transmission: 5b-9 gearshift fork groove width measure the gearshift fork groove width using the vernier calipers. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) gearshift fork groove width standard: 5.0 – 5.1 mm (0.197 – 0.201 in) gearshift fork thickness measure the gear...

  • Page 420: Partshark.Com

    5b-10 manual transmission: transmission oil seal / bearing inspection b933h25206008 refer to “transmission removal and installation (page 5b-5)”. Oil seal inspect the oil seal lips for wear or damage. If any defects are found, replace the oil seal with new ones. Refer to “transmission oil seal / bea...

  • Page 421: Partshark.Com

    Manual transmission: 5b-11 5) remove the gearshift cam right bearing (5). 6) remove the bearings using the special tool. Special tool (b): 09921–20240 (bearing remover set) installation caution ! The removed oil seals and bearings must be replaced with new ones. 1) install the bearings using the spe...

  • Page 422: Partshark.Com

    5b-12 manual transmission: 2) install the gearshift cam right bearing (1). Caution ! The stamped mark side of bearing face inside. 3) install the bearing retainers (2). 4) apply a small quantity of thread lock to the bearing retainers screws, and tighten them securely. : thread lock cement 99000–320...

  • Page 423: Partshark.Com

    Manual transmission: 5b-13 3) loosen the reverse lock release cable lock-nut (1) and adjuster (2). 4) disconnect the reverse lock release cable (3) by removing the mounting bolt. 5) disconnect the gear position switch coupler (4) and clamp. 6) remove the gear position switch (5). 7) remove the switc...

  • Page 424: Partshark.Com

    5b-14 manual transmission: gearshift shaft / gearshift cam plate components b933h25206012 gearshift construction b933h25206013 gearshift shaft / gearshift cam plate removal and installation b933h25206014 removal 1) remove the engine sprocket cover. Refer to “engine sprocket removal and installation ...

  • Page 425: Partshark.Com

    Manual transmission: 5b-15 5) remove the gearshift return spring (7). 6) remove the gearshift pawl lifter (8) and gearshift cam driven gear (9). Note be careful not to drop the pins and springs when removing the gearshift cam driven gear. 7) remove the gearshift pawls (10), pins (11), springs (12) a...

  • Page 426: Partshark.Com

    5b-16 manual transmission: • install the gearshift cam stopper (1), bolt (2), washer (3) and return spring (4). • tighten the gearshift cam stopper bolt (2). Note hook the return spring end to the gearshift cam stopper (1) and crankcase. • check the gearshift cam stopper moves smoothly. • locate the...

  • Page 427: Partshark.Com

    Manual transmission: 5b-17 • apply a small quantity of thread lock to the gearshift pawl lifter screws, and then tighten the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque gearshift pawl lifter screw (c): 9 n·m (0.9 kgf-m, 6.5 lb-ft...

  • Page 428: Partshark.Com

    5b-18 manual transmission: gearshift shaft oil seal inspect the gearshift shaft oil seal lip for damage or wear. If any defect is found, replace the oil seal with a new one. Gearshift shaft bearing inspect the gearshift shaft bearings for abnormal noise and smooth rotation. Replace the bearing if th...

  • Page 429: Partshark.Com

    Manual transmission: 5b-19 specifications service data b933h25207001 transmission + drive chain unit: mm (in) except ratio tightening torque specifications b933h25207002 note the specified tightening torque is also described in the following. “transmission components (page 5b-4)” “gearshift shaft / ...

  • Page 430: Partshark.Com

    5b-20 manual transmission: special tools and equipment recommended service material b933h25208001 note required service material is also described in the following. “transmission components (page 5b-4)” “gearshift shaft / gearshift cam plate components (page 5b-14)” “gearshift construction (page 5b-...

  • Page 431: Clutch

    Clutch: 5c-1 transmission / transaxle clutch precautions precautions for clutch system b933h25300001 refer to “general precautions in section 00 (page 00-1)”. Diagnostic information and procedures clutch system symptom diagnosis b933h25304001 repair instructions clutch lever position switch inspecti...

  • Page 432: Partshark.Com

    5c-2 clutch: clutch cable inspection and adjustment b933h25306002 refer to “clutch inspection and adjustment in section 0b (page 0b-13)”. Clutch cable removal and installation b933h25306003 removal 1) loosen the cable adjuster lock-nut (1) and adjuster (2). 2) loosen the cable lock-nut (3) and remov...

  • Page 433: Partshark.Com

    Clutch: 5c-3 clutch lever components b933h25306004 clutch lever removal and installation b933h25306005 removal 1) disconnect the clutch cable (1) and parking brake cable (2). Refer to “clutch cable removal and installation (page 5c-2)” and “parking brake cable removal and installation in section 4d ...

  • Page 434: Partshark.Com

    5c-4 clutch: 4) remove the screw (5), washer (6), parking knob (7) and spring (8). 5) remove the parking lock set (9) and spacer (10). 6) disconnect clutch lever position switch (11). 7) remove the clutch lever (12). Installation install the clutch lever in the reverse order of removal. Pay attentio...

  • Page 435: Partshark.Com

    Clutch: 5c-5 clutch release camshaft removal and installation b933h25306006 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) s...

  • Page 436: Partshark.Com

    5c-6 clutch: clutch components b933h25306007 12 11 10 (a) 9 8 2 1 7 6 3 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 fwd fwd i933h1530021-02 1. Clutch pressure plate 6. Spring washer 11. Primary driven gear assembly 2. No. 3 drive plate 7. Spring washer seat 12. Push rod 3. No. 2 drive plate 8. Release bearing : 7...

  • Page 437: Partshark.Com

    Clutch: 5c-7 clutch removal b933h25306008 1) drain engine oil and coolant. Refer to “engine oil and filter replacement in section 0b (page 0b-11)” and “cooling system inspection in section 0b (page 0b-13)”. 2) remove the rear brake pedal. Refer to “rear brake pedal removal and installation in sectio...

  • Page 438: Partshark.Com

    5c-8 clutch: 8) remove the clutch drive plates (5) and driven plates (6). 9) remove the spring washer (7) and its seat (8). 10) remove the clutch push piece (9) and push rod (10). 11) flatten the clutch sleeve hub washer (11). 12) hold the clutch sleeve hub with the special tool. Special tool (b): 0...

  • Page 439: Partshark.Com

    Clutch: 5c-9 clutch installation b933h25306009 1) install the spacer (1). 2) apply engine oil to the spacer (1) and bushing of the primary driven gear assembly (2). 3) install the primary driven gear assembly (2). 4) install the thrust washer (3). 5) install the clutch sleeve hub (4) and new washer ...

  • Page 440: Partshark.Com

    5c-10 clutch: 11) install the spring washer seat (9) and spring washer (10) onto the clutch sleeve hub correctly. 12) apply engine oil to the clutch drive plates and driven plates. 13) insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. Not...

  • Page 441: Partshark.Com

    Clutch: 5c-11 17) install the clutch springs. 18) tighten the clutch spring set bolts securely in diagonal stages. 19) install the gasket (17) and the dowel pins. Caution ! Use the new gasket to prevent oil leakage. 20) install the clutch cover (18) and tighten its bolts. Note fit the gasket to the ...

  • Page 442: Partshark.Com

    5c-12 clutch: special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) clutch drive plate claw width service limit (no. 1, no. 2 and no. 3 drive plate): 13.2 mm (0.520 in) measure each driven plate for distortion with a thickness gauge and surface plate. Replace driven plates which exceed ...

  • Page 443: Partshark.Com

    Clutch: 5c-13 specifications service data b933h25307001 clutch unit: mm (in) tightening torque specifications b933h25307002 note the specified tightening torque is also described in the following. “clutch components (page 5c-6)” reference: for the tightening torque of fastener not specified in this ...

  • Page 444: Partshark.Com

    5c-14 clutch: special tools and equipment recommended service material b933h25308001 note required service material is also described in the following. “clutch lever components (page 5c-3)” “clutch components (page 5c-6)” special tool b933h25308002 material suzuki recommended product or specificatio...

  • Page 445: 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 446: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b933h26000001 refer to “general precautions in section 00 (page 00-1)”. Partshark.Com 877-999-5686.

  • Page 447: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b933h26104001 condition possible cause correction / reference item handling is too heavy or stiff improper front wheel alignment. Adjust. Insufficiently lubricated. L...

  • Page 448: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions steering / handlebars components b933h26206001 1 (a) 2 “a” “a” 8 10 9 10 (c) 9 7 15 (d) (b) (e) 16 16 17 (e) (e) 18 (e) 3 5 6 3 fwd fwd fwd fwd 11 12 14 13 4 i933h1620001-09 1. Handlebar upper holder 10. Dust seal “a”: appl...

  • Page 449: Partshark.Com

    Steering / handlebar: 6b-2 handlebar construction b933h26206002 forward 1 2 3 (a) “a” “b” “c” i933h1620048-02 1. Punch mark “a”: align the edge of throttle case upper with punch mark on handlebars. 2. Handlebars “b”: align the edge of clutch lever holder with punch mark on handlebars. 3. Handlebar c...

  • Page 450: Partshark.Com

    6b-3 steering / handlebar: handlebars removal and installation b933h26206003 refer to “front suspension / steering assembly construction in section 2b (page 2b-2)”. Removal 1) remove the throttle lever case (1). 2) disconnect the clamp. 3) remove front brake master cylinder (2) and right grip (3). C...

  • Page 451: Partshark.Com

    Steering / handlebar: 6b-4 10) remove the handlebar lower holder nuts and washer (12). 11) remove the handlebar lower holder (13). Installation install the handlebars in the reverse order of removal. Pay attention to the following points: • set the handlebar holder with facing the projection “a” for...

  • Page 452: Partshark.Com

    6b-5 steering / handlebar: • connect the starter cable (3) to the starter lever. • apply grease to the end of starter cable (3). : grease 99000–25160 (water resistance grease or equivalent) • insert the projection “d” of the handlebar switch box into the hole of the handlebars. • install the clutch ...

  • Page 453: Partshark.Com

    Steering / handlebar: 6b-6 6) disconnect wheel side tie-rod ends using the special tool. Special tool (a): 09942–72410 (tie-rod end remover) 7) remove the cotter pin (1) and steering shaft nut (2), washer (3), dust seal (4) and o-ring (5). 8) remove the guide (6). 9) remove the steering shaft holder...

  • Page 454: Partshark.Com

    6b-7 steering / handlebar: 14) remove the steering shaft (14). 15) remove the dust seal (15) from the steering shaft. 16) remove the steering shaft bushing (16) using the special tools and suitable socket wrench “a”. Note if there are wear or damage, remove the steering shaft bushing (16). Refer to ...

  • Page 455: Partshark.Com

    Steering / handlebar: 6b-8 • temporarily install the lock-nuts (4), (5) and tie-rod end (6) to the tie-rod (7). Note the lock-nuts (4) have left-hand threads. • when installing the tie-rods, make sure the narrow end “a” of tie-rod comes outside. • temporarily tighten the tie-rod end nuts. • apply gr...

  • Page 456: Partshark.Com

    6b-9 steering / handlebar: • apply grease to the o-rings (8), and dust seal (9). Caution ! Replace the o-rings (8) with new ones. : grease 99000–25160 (water resistance grease or equivalent) • tighten the steering shaft nut to the specified torque. Tightening torque steering shaft nut (b): 49 n·m (4...

  • Page 457: Partshark.Com

    Steering / handlebar: 6b-10 • install the handlebars. Refer to “handlebars removal and installation (page 6b-3)”. • check the steering moves smoothly. • check the wiring harness routing, cable routing and brake hose routing. Refer to “wiring harness routing diagram in section 9a (page 9a-3)”, “hose ...

  • Page 458: Partshark.Com

    6b-11 steering / handlebar: steering shaft bushing inspect the steering shaft bushing for wear or damage. If any defects are found, replace the steering shaft bushing with a new one. Toe-out adjustment b933h26206007 adjust the toe-out as follows: 1) inspect the toe-out. Refer to “steering system ins...

  • Page 459: Partshark.Com

    Steering / handlebar: 6b-12 tightening torque specifications b933h26207002 note the specified tightening torque is also described in the following. “steering / handlebars components (page 6b-1)” “handlebar construction (page 6b-2)” reference: for the tightening torque of fastener not specified in th...

  • Page 460: Partshark.Com

    6b-13 steering / handlebar: partshark.Com 877-999-5686.

  • Page 461: 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 462: Precautions

    9-1 precautions: body and accessories precautions precautions precautions for electrical system b933h29000001 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 b933h29...

  • Page 463: Wiring Systems

    Wiring systems: 9a-1 body and accessories wiring systems schematic and routing diagram wiring diagram b933h29102001 refer to “wire color symbols in section 0a (page 0a-5)”. Partshark.Com 877-999-5686.

  • Page 464: Partshark.Com

    9a-2 wiring systems: ecm brake light/t aillight indica t or light dimmer switch engine st op switch hanlebar switch front brake light switch rear brake light switch ignition coil to sensor fuel pump fuel gauge st arter butt on nu re fu fi/wt off off on off on run push hi lo nu: neutral indica t or l...

  • Page 465: Partshark.Com

    Wiring systems: 9a-3 wiring harness routing diagram b933h29102002 3 4 2 1 7 7 1 1 1 6 1 1 5 1 11 12 8 10 “a” 9 i933h1910903-08 1. Clamp : bind the wiring harness with the clamp. 6. Clamp : bind the brake light / taillight with the clamp. 11. Engine sprocket cover 2. Clamp : bind the handlebar switch...

  • Page 466: Partshark.Com

    9a-4 wiring systems: 1 2 3 4 6 5 7 3 8 i933h1910904-01 1. Clamp : bind the brake switch with the clamp. 5. Starter motor 2. Clamp : bind the handlebar switch (l), starter cable and clutch lever position switch. With the clamp. 6. Wiring harness 3. Clamp 7. Clamp : bind the wiring harness with the cl...

  • Page 467: Partshark.Com

    Wiring systems: 9a-5 (a) 2 (b) (c) (d) 3 4 5 (e) 6 (f) (e) “ b ” “ c ” 1 “ a ” i933h1910905-02 1. Starter motor lead wire 6. Ckp sensor : 5.5 n ⋅m (0.55 kgf-m, 4.0 lb-ft) 2. Battery ground wire : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) : 11 n ⋅m (1.1 kgf-m, 8.0 lb-ft) 3. Starter motor : 6 n ⋅m (0.6 kgf-m, 4....

  • Page 468: Partshark.Com

    9a-6 wiring systems: specifications service data b933h29107001 electrical unit: mm tightening torque specifications b933h29107002 note the specified tightening torque is also described in the following. “wiring harness routing diagram (page 9a-3)” reference: for the tightening torque of fastener not...

  • Page 469: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components b933h29206001 1 fwd fwd i933h1920014-02 1. Headlight bulb (12 v 35/35 w) partshark.Com 877-999-5686.

  • Page 470: Partshark.Com

    9b-2 lighting systems: headlight removal and installation b933h29206002 removal 1) remove the headlight bulb. Refer to “headlight bulb replacement (page 9b-2)”. 2) remove the headlight assembly (1). 3) remove the headlight cover (2). Installation install the headlight in the reverse order of removal...

  • Page 471: Partshark.Com

    Lighting systems: 9b-3 headlight beam adjustment b933h29206004 adjust the headlight beam in the following procedures: 1) loosen the headlight adjusting bolt (1). 2) move the headlight up or downwards and adjust the headlight beam vertically. 3) tighten the headlight adjusting bolt (1). Rear combinat...

  • Page 472: Partshark.Com

    9b-4 lighting systems: rear combination light removal and installation b933h29206006 removal 1) disconnect the rear combination coupler (1) and clamp. 2) remove the rear combination light assembly (2). 3) remove the rear combination light assembly bracket (3). Installation install the rear combinati...

  • Page 473: Partshark.Com

    Lighting systems: 9b-5 dimmer switch inspection b933h29206008 inspect the dimmer switch in the following procedures: 1) disconnect the headlight coupler (1). Refer to “headlight bulb replacement (page 9b-2)”. 2) disconnect the handlebar switch coupler (2). 3) inspect the dimmer switch for continuity...

  • Page 474: Partshark.Com

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn repair instructions indicator light components b933h29306001 indicator light removal and installation b933h29306002 caution ! When disconnecting and reconnecting the indicator light coupler, make s...

  • Page 475: Partshark.Com

    Combination meter / fuel meter / horn: 9c-2 2) remove the steering head cover (2). 3) remove the indicator light assembly (3). Installation install the indicator light in the reverse order of removal. Indicator light replacement b933h29306003 replace the indicator lights in the following procedures:...

  • Page 476: Partshark.Com

    9c-3 combination meter / fuel meter / horn: 3) when the switch is immersed in kerosene, the bulb should go out. If the bulb remains lit, replace the unit with a new one. Note • when the bulb turns off, immediately pick up the switch from kerosene. • after the check has been completed, wash the switc...

  • Page 477: Partshark.Com

    Combination meter / fuel meter / horn: 9c-4 ignition switch inspection b933h29306010 inspect the ignition switch in the following procedures: 1) remove the left side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 4)”. 2) disconnect the ignition switch coupler (1). 3...

  • Page 478: Exterior Parts

    9d-1 exterior parts: body and accessories exterior parts repair instructions exterior parts construction b933h29406001 1 2 4 3 (a) fwd fwd i933h1940023-08 1. Fuel tank cover 4. Side cover (lh) 2. Side cover (rh) : 12 n ⋅m (1.2 kgf-m, 8.5 lb-ft) 3. Front fender : apply thread lock to thread part. Par...

  • Page 479: Partshark.Com

    Exterior parts: 9d-2 1 2 3 fwd fwd i933h1940024-03 1. Rear fender 3. Mudguard (lh) 2. Mudguard (rh) : apply thread lock to thread parts. Partshark.Com 877-999-5686.

  • Page 480: Partshark.Com

    9d-3 exterior parts: fuel tank cover cushion installation b933h29406002 i933h1940025-09 partshark.Com 877-999-5686.

  • Page 481: Partshark.Com

    Exterior parts: 9d-4 fastener removal and installation b933h29406003 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 482: Partshark.Com

    9d-5 exterior parts: 2) disconnect the ignition switch coupler (4). 3) remove the screw (5). 4) remove the reverse selection knob (6) and screw (7). 5) remove the screws (8). 6) remove the front fender (9) by removing the fasteners (10). 7) remove the front fender bracket (11), left and right. Insta...

  • Page 483: Partshark.Com

    Exterior parts: 9d-6 fuel tank cover removal caution ! To prevent the fuel tank from contamination with foreign particles, install the fuel tank cap, after removing the fuel tank cover. 1) remove the seat. 2) remove the side covers, left and right. 3) remove the fasteners (1) and fuel tank cap (2). ...

  • Page 484: Partshark.Com

    9d-7 exterior parts: rear fender removal 1) remove the seat. 2) remove the fasteners (1) and screws (2). 3) remove the battery (3). Refer to “battery removal and installation in section 1j (page 1j-12)”. 4) remove the starter relay (4). Refer to “starter relay removal and installation in section 1i ...

  • Page 485: Partshark.Com

    Exterior parts: 9d-8 specifications tightening torque specifications b933h29407001 note the specified tightening torque is also described in the following. “exterior parts construction (page 9d-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening t...

  • Page 486: Body Structure

    9e-1 body structure: body and accessories body structure repair instructions body frame construction b933h29506001 3 fwd fwd (b) 6 (b) 6 1 2 6 (b) (b) 6 (a) 5 7 4 (a) 5 i933h1950014-01 1. Frame 4. Rear grip 7. Battery plate 2. Seat rail 5. Seat rail mounting bolt : 66 n ⋅m (6.6 kgf-m, 47.5 lb-ft) 3....

  • Page 487: Partshark.Com

    Body structure: 9e-2 footrest removal and installation b933h29506002 removal remove the footrests (1), left and right. Installation 1) install the footrest (1). 2) apply thread lock to the footrest mounting bolts (2) and footrest mud guard mounting screw (3). : thread lock cement 99000–32110 (thread...

  • Page 488: Partshark.Com

    9e-3 body structure: seat rail removal and installation b933h29506005 removal 1) remove the seat and rear fender. Refer to “exterior parts removal and installation in section 9d (page 9d-4)”. 2) remove the muffler. Refer to “muffler / exhaust pipe removal and installation in section 1k (page 1k-3)”....

  • Page 489: Partshark.Com

    Body structure: 9e-4 • rout the rear brake hose. Refer to “rear brake hose routing diagram in section 4a (page 4a-2)” and “wiring harness routing diagram in section 9a (page 9a-3)”. • tighten the air cleaner box mounting bolts (3) to the specified torque. Tightening torque air cleaner box mounting b...

  • Page 490: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 491: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 492

    Prepared by march, 2008 part no. 99500-43080-03e printed in japan 492 partshark.Com 877-999-5686.