L5 june ’14 (tk) 19 99505-01055-01e © copyright suzuki motor japan foreword this motorcycle has been designed and produced utilizing suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been prod...
1 preparation workshop a: packed vehicle b: working space self protection uncrating the motorcycle cut the strap by using scissors. A: strap remove the carton. A: crate caution assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it i...
2 remove the strap. Take out the front wheel assembly from the crate base. A: strap b: front wheel assembly remove the bolts of the bracket. Remove the bolts to take off the rear wheel holding bracket. A: bolt b: rear wheel holding bracket remove the bolts from the crate. A: bolt.
3 lift the steel frame to separate it from the base of the crate. A: steel frame b: crate base open the vinyl package. Take out the various component parts and spare parts packaged from the crate. A: component parts b: spare parts caution careless steel frame separation can injure a person. Lift t...
4 spare parts check all spare parts. Item part name q’ty 1 magneto cover gasket 1 2 clutch cover outer gasket 1 3 water pump case o-ring 1 4 sprocket spacer o-ring 1 5 engine oil filter comp 1 6 oil filter cap o-ring 1 7 exhaust pipe gasket 1 8 muffler joint connector 1 9 drive chain joint set 1 0 c...
5 location of parts check all the components which have been removed from the base of the crate. Parts listed above are installed respectively into the positions as follows. Item part name q’ty remarks a number plate 1 flange bolt (with small washer) 1 6 × 12 mm b handlebars assembly 1 handlebar cla...
6 the photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: front brake master cylinder b: throttle assembly engine stop switch clutch cable s-hac switch l l ii n n a a e e j j h h k k m m g g b b d d c c f f.
7 before assembling the motorcycle, thoroughly understand the “safety check out” described on page 39. After completion of assembly, carefully check the motorcycle referring to the “safety check out”, then deliver the motorcycle to the customer. Assembly removing the bracket remove the bolt to take ...
8 handlebars loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. A: throttle assembly b: handlebars c: spacer install the handlebar assembly with the clamp and the four bolts. A: clamp b: 8 × 35 mm flange bolt c: arrow mark d: matching mark tighten the han...
9 a: front brake hose b: throttle cables c: clutch cable d: engine stop switch wiring harness e: s-hac switch wiring harness f: cable guide note: • the line drawings on page 37 and 38 show the proper routing of the control cables, hose and wirings. • refer to them in addition to following the instru...
10 throttle align the matching mark on the handlebars with mat- ing surface of the throttle housing. Install the throttle assembly with two screws after the assembly is positioned so that there is approximately 0.5–1.0 mm of clearance between the grip end and the end of the handlebars. A: throttle a...
11 front brake master cylinder install the front brake master cylinder onto the handle- bars. A: holder b: front brake master cylinder c: 6 × 22 mm flange bolt d: matching mark e: spacer tighten the front brake master cylinder mounting bolts to the specified torque. front brake master cylinder mou...
12 clutch cable pass the clutch cable through the adjuster cover and lever cover. A: clutch cable b: adjuster cover c: lever cover check the clutch cable end. Align the clutch cable end with the recess of clutch release arm. A: cable end b: recess (clutch release arm) turn the clutch lever adjuster ...
13 engine stop switch hook the holders on the grooves of the engine stop switch. A: engine stop switch b: holder (upper) c: holder (lower) d: thread cutting install the engine stop switch to the left of handlebars. A: engine stop switch b: 3 × 14 mm screw (with lock washer) s-hac switch hook the hol...
14 clamp clamp the engine stop switch wiring harness and s-hac switch wiring harness to the handlebars with strap. A: strap l:100 mm b: strap l:130 mm c: engine stop switch wiring harness d: s-hac switch wiring harness e: handlebars front fender install the front fender with four sets of mounting pa...
15 taking out the motorcycle bind a hoist band around the handlebar clamps as shown in the photograph. A: hoist band remove the crate axle bracket from the crate base. A: crate axle bracket b: bolt 1 . Lift the front of motorcycle by using a hoist. 2 . Raise the rear of motorcycle. 3 . Pull the crat...
16 front wheel loosen the axle holder bolts. Remove the front axle from the fork legs. A: axle holder bolt b: front axle mount the front wheel assembly properly. A: right fork leg b: left fork leg c: front wheel spacer d: front axle e: axle nut (18 mm flange nut) right left attach the front wheel sp...
17 insert the front axle from the right side of fork leg and fix the front wheel assembly to the front fork. A: front axle tighten the front axle nut to the specified torque. front axle nut: 35 n·m (3.5 kgf-m) a: axle nut stand insert the boss of stand to the hole of rear axle shaft. A: stand plac...
18 extract the stand. Move the front fork up and down hard 4 or 5 times. Tighten the axle holder bolts to the specified torque. front axle holder bolt: 21 n·m (2.1 kgf-m) a: axle holder bolt place the motorcycle on the stand..
19 radiator louver insert the boss of radiator louver into the hole of radia- tor. Set the radiator louver as shown in the photograph. A: radiator louver b: boss c: hole radiator cover install the radiator cover with flange bolt and stepped washer. A: radiator cover b: 6 × 12 mm flange bolt (with la...
20 number plate insert the hole of the front number plate to the boss of front fender. A: number plate b: hole c: boss install the front number plate with flange bolt. A: number plate b: 6 × 12 mm flange bolt (with small washer) c: front brake hose d: throttle cable e: clutch cable f: s-hac switch w...
21 fuel tank vent hose install the fuel tank vent hose to the fuel tank cap. Insert the free end of fuel tank vent hose to the hole of steering shaft. A: fuel tank vent hose b: fuel tank cap c: hole (steering shaft) removing the wrap film remove the wrap film from the muffler. A: muffler b: wrap fil...
