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Suzuki shogun sports 125 Service Manual

Other manuals for shogun sports 125: Owner's Service Manual, Service Manual, Owner's Manual

Summary of shogun sports 125

  • Page 1

    Uh125 9 9 5 0 0 - 3 1 3 5 0 - 0 1 e.

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 fi system diagnosis 4 fuel system and throttle body 5 exhaust system 6 cooling and lubrication system 7 chassis 8 electrical system 9 servicing information 10 foreword this manual contains an introductory description on the suzuki uh1...

  • Page 3: How To Use This Manual

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

  • Page 4

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

  • Page 5: Manual

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

  • Page 6

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

  • Page 7: General Information

    General information 1-1 1 general information contents warning/caution/note........................................................................ 1- 2 general precautions ......................................................................... 1- 2 suzuki uh125k7 (’07-model) ........................

  • Page 8: Warning/caution/note

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

  • Page 9

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

  • Page 10: Serial Number Location

    1-4 general information suzuki uh125k7 (’07-model) • difference between illustrations and actual motorcycle may exist depending on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the frame. The engine serial numb...

  • Page 11

    General information 1-5 fuel, oil and engine coolant recommendation fuel gasoline used should be graded 91 octane (research method) or higher. Unleaded gasoline is recom- mended. Engine oil and final gear oil oil quality is a major contributor to your engine’s performance and life. Always select goo...

  • Page 12

    1-6 general information engine coolant use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. Water for mixing use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. Anti-freeze/engine coolant the engin...

  • Page 13: Break-In Procedures

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

  • Page 14: Specifications

    1-8 general information specifications dimensions and dry mass overall length.......................................................................... 2 055 mm overall width ........................................................................... 740 mm overall height...............................

  • Page 15

    General information 1-9 electrical ignition type ............................................................................. Electronic ignition (transistorized) ignition timing .......................................................................... 10° b.T.D.C. At 1 800 r/min spark plug .........

  • Page 16: Periodic Maintenance

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

  • Page 17

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer and time for your convenience. No...

  • Page 18

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

  • Page 19

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner removal • remove the air cleaner cover 1. • remove the polyurethane foam element 2. • remove the non-woven fabric element 3....

  • Page 20

    Periodic maintenance 2-5 inspection non-woven fabric element • inspect the element for clogging. If the element is clogged with dust, replace the element with a new one. ! Note: if driving under dusty conditions, replace the air cleaner ele- ments more frequently. Make sure that the air cleaner elem...

  • Page 21

    2-6 periodic maintenance exhaust pipe nuts and muffler bolts • remove the right side leg shield. ( "8-8) • remove the rear lower leg shield. ( "8-8) • tighten the exhaust pipe nuts 1, muffler mounting bolts 2 and muffler connecting bolt 3 to the specified torque. # exhaust pipe nut: 23 n·m (2.3 kgf-...

  • Page 22

    Periodic maintenance 2-7 note: * the piston must be at “tdc” on the compression stroke in order to check the valve clearance or to adjust valve clear- ance. * the clearance specification is for cold state. * to turn the crankshaft for clearance checking, and rotate in the normal running direction. •...

  • Page 23

    2-8 periodic maintenance spark plug gap measure the plug gap with the thickness gauge if it is correct. If not, adjust it to the following gap. $ spark plug gap a: standard: 0.7 – 0.8 mm % 09900-20803: thickness gauge electrode’s condition inspect the worn or burnt condition of the electrodes. If it...

  • Page 24

    Periodic maintenance 2-9 engine oil and oil filter oil charge should be performed while the engine is warm. Oil fil- ter replacement at the above intervals should be done together with the engine oil change. Engine oil replacement • place the motorcycle on the center stand. • place an oil pan below ...

  • Page 25

    2-10 periodic maintenance • replace the o-ring 3 with a new one. • install new oil filter. • install the spring 4 to the oil filter cap. • replace the o-ring 5 with a new one. Note: apply engine oil to the new o-ring 5. • install the oil filter cap. • pour fresh oil. • check the oil level. $ engine ...

  • Page 26

    Periodic maintenance 2-11 note: if oil is dirty with sludge or used for a long period, drain the oil by removing the drain plug 3 and pour fresh oil through the oil level hole. # oil drain plug: 12 n·m (1.2 kgf-m) $ final gear box oil capacity oil change : 150 ml overhaul : 160 ml throttle cable pla...

  • Page 27

    2-12 periodic maintenance cooling system radiator hose • remove the rear lower leg shield. ( "8-8) • inspect the radiator hoses for crack, damage or engine cool- ant leakage. If any defects are found, replace the radiator hose with a new one. Engine coolant level check • keep the motorcycle upright....

  • Page 28

    Periodic maintenance 2-13 engine coolant change • remove the rear lower leg shield. ( "8-8) • remove the radiator cap 1. • drain engine coolant by disconnecting the radiator outlet hose 2. & • flush the radiator with fresh water if necessary. • pour the specified engine coolant up to the radiator in...

  • Page 29

    2-14 periodic maintenance air bleeding for the cooling circuit • add engine coolant up to the radiator inlet. • slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • add engine coolant up to the radiator inlet. • start up the engine and bleed air from the ra...

  • Page 30

    Periodic maintenance 2-15 brake system brake fluid level check • keep the motorcycle upright and handlebars straight. • check the brake fluid level by observing the lower limit line on the front and combination brake fluid reservoirs. • when the level is below the lower limit line, replenish with br...

  • Page 31

    2-16 periodic maintenance front brake pad replacement • loosen the brake pad pin 1. • remove the brake hose clamp bolt 2. • remove the front brake caliper 3. • remove the brake pads 4 by removing the brake pad bolt. • install new pads and the caliper in the reverse order of removal. # brake pad bolt...

  • Page 32

    Periodic maintenance 2-17 front brake fluid replacement • place the motorcycle on a level ground and keep the handle- bars straight. • remove the front master cylinder reservoir cap and dia- phragm. • suck up old brake fluid as much as possible. • fill the reservoir with new brake fluid. ( specifica...

  • Page 33

    2-18 periodic maintenance air bleeding for the front brake fluid circuit air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of ai...

  • Page 34

    Periodic maintenance 2-19 air bleeding for the combination brake • bleed the air from the rear caliper first and then front caliper. • the combination brake system air bleeding is the same man- ner as that of the front one. Tire tire tread condition operating the motorcycle with excessively worn tir...

  • Page 35

    2-20 periodic maintenance steering steering should be adjusted properly for smooth turning of han- dlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping ...

  • Page 36

    Periodic maintenance 2-21 chassis bolt and nut check that all chassis bolts and nuts are tightened to their specified torque. (refer to pages 2-20 and 21 for the locations of the following nuts and bolts on the motorcycle.) tighten initially at 1 000 km (600 miles, 3 months) and every 4 000 km (2 50...

  • Page 37

    2-22 periodic maintenance.

  • Page 38: Compression Pressure Check

    Periodic maintenance 2-23 compression pressure check the compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression...

  • Page 39: Oil Pressure Check

    2-24 periodic maintenance oil pressure check check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than the specification, the following causes may be considered. Low oil pressure ...

  • Page 40: Automatic Clutch Inspection

    Periodic maintenance 2-25 automatic clutch inspection this motorcycle is equipped with an automatic clutch and vari- able ratio belt drive transmission. The engagement of the clutch is governed by engine rpms and centrifugal mechanism located in the clutch. To insure proper performance and longer li...

  • Page 41: Sds Check

    2-26 periodic maintenance sds check 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 troubleshooting since they can indicate the cond...

  • Page 42

    Periodic maintenance 2-27 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. Xx kpa check the engine coolant temperature. Xx ˚c ˚ check the manifold absolute pressure in according with the throttle valve opening..

  • Page 43

    2-28 periodic maintenance data of intake negative pressure during idling (100 °c) data of manifold absolute pressure operation at the time of starting ˚ check the manifold absolute pressure. Xx kpa check the engine coolant temperature. Approx. 100 ˚c check the manifold absolute pressure. Xx kpa.

  • Page 44

    Periodic maintenance 2-29 example of trouble three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same co...

  • Page 45: Engine

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

  • Page 46

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

  • Page 47

    Engine 3-3 engine removal and remounting removal • remove the trunk box. ( !8-11) • remove the rear lower leg shield. ( !8-8) • drain engine oil. ( !2-9) • drain engine coolant. ( !2-12) • drain final gear box oil. ( !2-10) • disconnect the battery - lead wire. • disconnect the crankcase breather ho...

  • Page 48

    3-4 engine • disconnect the radiator inlet hose 5. • disconnect the engine coolant temperature meter lead wire 6, ignition coil lead wires 7 and ect sensor coupler 8. • disconnect the tp sensor coupler 9, iap sensor coupler 0, isc valve coupler a and injector coupler b. • disconnect the throttle cab...

  • Page 49

    Engine 3-5 • loosen the muffler connecting bolt i. • remove the muffler. • remove the exhaust pipe j. • disconnect the radiator outlet hose k. • remove the exhaust pipe gasket l. • remove the rear brake caliper m. • remove the rear axle nut n and collar. • remove the rear swingarm o. • remove the sp...

  • Page 50

    3-6 engine • support the engine using a jack. • remove the rear shock absorber mounting bolt (lh). • remove the engine mounting bolt/nut. • remove the engine from the frame. • remove the crankcase bracket q..

  • Page 51

    Engine 3-7 remounting remount the engine in the reverse order of removal. Pay atten- tion to the following points: • install the crankcase bracket a to the engine, and insert the crankcase bracket bolt b from the left side. • position the crankcase bracket correctly by inserting a steel plate c of 2...

  • Page 52

    3-8 engine • tighten the engine mounting nut e and rear shock absorber mounting bolt d to the specified torque. " engine mounting nut: 100 n·m (10.0 kgf-m) lower rear shock absorber mounting bolt: 29 n·m (2.9 kgf-m) • install the rear wheel and rear swingarm 1. " rear axle nut: 120 n·m (12.0 kgf-m) ...

  • Page 53

    Engine 3-9 • install the insulator and throttle body assembly. $ 09930-11910: torx wrench note: * face the o-ring side of insulator to the engine. * face the tab f of insulator to forward. * use new twist-off bolts. Cautions after reinstallaton • after the engine has been mounted, rout the lead wire...

  • Page 54: Engine Disassembly

    3-10 engine engine disassembly # ignition coil and spark plug • remove the ignition coil 1. • remove the spark plug. $ 09930-10121: spark plug wrench set starter motor • remove the starter motor 1. Cylinder head cover • remove the cylinder head cover 1. Cooling fan filter • remove the cooling fan co...

  • Page 55

    Engine 3-11 camshaft • remove the generator cover plug 1. • bring the piston to tdc on the compression stroke by turning the crankshaft until the line a on the generator rotor aligns with the mark b on the generator cover. • remove the spring holder bolt 2 and spring. • remove the o-ring, cam chain ...

  • Page 56

    3-12 engine • slide and drop the camshaft sprocket to the camshaft groove c. • disengage the cam chain from the camshaft sprocket. • remove the camshaft journal holder no.1 5. • remove the camshaft 6 and camshaft sprocket. • remove the dowel pins and c-ring 7. Cylinder head • remove the cylinder hea...

  • Page 57

    Engine 3-13 • remove the cylinder head gasket 1 and dowel pins. Cylinder • remove the cam chain guide 1. • remove the cylinder nuts. • remove the cylinder. • remove the cylinder gasket 2 and dowel pins. Piston • remove the piston pin circlip 1. • remove the piston pin 2. # • remove the piston 3. Tak...

  • Page 58

    3-14 engine oil filter • remove the oil filter cap 1. • remove the oil filter 2. • remove the o-ring 3. Water pump • remove the water pump assembly 1. Generator cover • remove the generator cover 1. • remove the gasket 2 and dowel pins..

  • Page 59

    Engine 3-15 generator rotor and starter driven gear • remove the starter idle gear shaft 1 and starter idle gear 2. • with the generator rotor held immovable with the special tool, remove the generator rotor nut. $ 09930-44520: rotor holder • remove the generator rotor 3 and starter driven gear 4 us...

  • Page 60

    3-16 engine • remove the oil pump driven sprocket and oil pump 2 along with the oil pump drive chain 3. • remove the cam chain 4. Crankshaft right bearing nut • insert a proper steel rod into the crankcase hole a and pass it through the crankshaft web holes in order to prevent the crankshaft from tu...

  • Page 61

    Engine 3-17 • with the fixed drive face 2 held immovable using the special tool, loosen the nut. • remove the washer. • remove the fixed drive face. $ 09930-40113: rotor holder • with the clutch housing 3 held immovable using the special tool, remove the nut. • remove the clutch housing. $ 09930-401...

  • Page 62

    3-18 engine • remove the dowel pins. • remove the idle gear 2. • remove the shim 3. • remove the final driven gear/rear axle shaft 4. • remove the driveshaft 5 by tapping it with a plastic mallet. Oil sump filter • remove the oil sump filter cap 1. • remove the gasket 2. • pull out the oil sump filt...

  • Page 63

    Engine 3-19 crankcase • remove the 6 mm crankcase bolts first, then 8 mm ones evenly and diagonally. Crankshaft • separate the crankcase into left and right halves using the special tool. $ 09920-13120: crankcase/crankshaft separator note: * set the special tool so that the tool arms are in parallel...

  • Page 64

    3-20 engine engine component inspection and service rocker arm and shaft disassembly • pull out the rocker arm shafts 1. • remove the intake 2 and exhaust 3 valve rocker arms and wave washers 4. Rocker arm shaft outside diameter inspection • on the sliding surface, take two measurements, at right an...

  • Page 65

    Engine 3-21 cylinder head disassembly • remove the cam chain tensioner 1. • remove the thermostat cover 2. • remove the thermostat 3. • compress the valve spring using the special tools. • remove the cotter halves 4. $ 09916-14510: valve lifter 09916-14910: attachment 09916-84511: tweezers • remove ...

  • Page 66

    3-22 engine • remove the oil seal 8 and spring seat 9. # • remove the other valves in the same manner as described previously. Cylinder head distortion • decarbonize the combustion chambers. • check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge, takin...

  • Page 67

    Engine 3-23 valve head radial runout • place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. • if it measures more than the service limit, replace the valve. % valve head radial runout: service limit: 0.03 mm $ 09900-20607: dial gauge (1/100 mm) 09900...

  • Page 68

    3-24 engine valve guide servicing • using the valve guide remover 1, drive the valve guide out toward the camshaft side. $ 09916-44310: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement parts. (part no. 111...

  • Page 69

    Engine 3-25 • after installing the valve guide, re-finish the guiding bore using the reamer 7. • clean and oil the guides after reaming. $ 09916-34570: valve guide reamer 09916-34542: reamer handle note: * be sure to cool down the cylinder head to ambient air temper- ature. * insert the reamer from ...

  • Page 70

    3-26 engine valve seat servicing • the valve seats 1 for both the intake valves and exhaust valves are machined to four different angles. The seat contact surface is cut at 45°. # note: after servicing the valve seats, be sure to check the valve clear- ance after the cylinder head has been reinstall...

  • Page 71

    Engine 3-27 valve spring the force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. • check the valve spring for proper strength by measuring its free length and also ...

  • Page 72

    3-28 engine • compress the valve spring using the special tools. $ 09916-14510: valve lifter 09916-14910: attachment 09916-84511: tweezers # • install the valve cotter halves 2. # note: to facilitate assembly, apply a little grease to the valve cotter when fitting into the valve stem groove. Camshaf...

  • Page 73

    Engine 3-29 • tighten the camshaft journal holder bolts evenly and diago- nally to the specified torque. " camshaft journal holder bolt: 10 n·m (1.0 kgf-m) note: do not rotate the camshaft with the plastigauge in place. • remove the camshaft holder, and read the width of the com- pressed plastigauge...

  • Page 74

    3-30 engine cam chain tension adjuster cam chain tension adjuster inspection • check that the push rod 1 can slide smoothly with the lock 2 of the ratchet mechanism released. If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new ...

  • Page 75

    Engine 3-31 cylinder cylinder distortion • check the gasket surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. • if the largest reading at any position of the straightedge exceeds the limit, replace the cylinder ...

  • Page 76

    3-32 engine piston pin and pin bore • measure the piston pin bore diameter using the small bore gauge. • if the measurement is out of specification, replace the piston. % piston pin bore i.D.: service limit: 16.030 mm $ 09900-20602: dial gauge (1/1 000 mm) 09900-22401: small bore gauge (10 – 18 mm) ...

  • Page 77

    Engine 3-33 piston ring free end gap and piston ring end gap • measure the piston ring free end gap using the vernier cali- pers. • 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 exceeds the service lim...

  • Page 78

    3-34 engine conrod deflection inspection • move the small end sideways while holding the big end immovable in thrust direction. • measure the amount of deflection. • turn the conrod and see if it moves smoothly without play and noise. • this method can check the extent of wear on the parts of the co...

  • Page 79

    Engine 3-35 oil pump inspection • rotate the oil pump by hand and check that it moves smoothly. • if it does not move smoothly, replace the oil pump assembly with a new one. Disassembly • remove the circlip 1. • remove the oil pump driven gear 2. • remove the pin 3 and washer 4. # reassembly reassem...

  • Page 80

    3-36 engine movable drive face assembly disassembly • remove the spacer 1. • remove the movable drive face cover 2. • remove the movable drive plate 3. • remove the dampers 4. • remove the rollers 5. Inspection movable face • inspect each movable drive face for any stepped wear. If any defects are f...

  • Page 81

    Engine 3-37 spacer • inspect the spacer for any wear or damage. If any defects are found, replace the spacer with a new one. Roller • inspect the rollers for abnormal wear or other damage. If any defects are found, replace the rollers as a set. Reassembly assemble the movable drive face in the rever...

  • Page 82

    3-38 engine clutch shoe/movable driven face disassembly • attach the special tool to the clutch shoe/movable driven face assembly and compress the assembly by turning in the spe- cial tool handle. • remove the clutch shoe nut 1. $ 09922-31420: clutch spring compressor # • loosen the special tool han...

  • Page 83

    Engine 3-39 • remove the rollers 5 from the pins. • remove the movable driven face 6 from the fixed driven face 7. • remove the o-rings 8 and oil seal 9. • remove the oil seal 0. • remove the needle bearing using the special tool. $ 09921-20240: bearing remover set (20 mm) note: if abnormal noise do...

  • Page 84

    3-40 engine • remove the snap ring a. • remove the bearing using the special tool. $ 09913-70210: bearing installer set (22 mm) note: if abnormal noise does not occur, it is not necessary to remove the bearing. Inspection clutch shoe • check the boss and centrifugal weight fulcrum sections for loose...

  • Page 85

    Engine 3-41 movable driven face spring • measure the spring free length a using the vernier calipers. • if the length is shorter than the service limit, replace the spring with a new one. % movable driven face spring free length: service limit: 123.5 mm $ 09900-20102: vernier calipers drive v-belt •...

  • Page 86

    3-42 engine reassembly • install the bearing 1 to the fixed driven face 2 using an appropriate spacer. # • install the snap ring. # • install needle bearing 3 using an appropriate specer. # • apply grease to both bearings. # ) 99000-25010: suzuki super grease “a” or equivalent use a new bearing. Use...

  • Page 87

    Engine 3-43 • install the oil seals 4 and o-rings 5 to the movable driven face. $ 09913-70210: bearing installer set # • apply grease both to the lip of oil seals and o-rings. ) 99000-25010: suzuki super grease “a” or equivalent • apply grease to the grease groove and sliding surface of mov- able dr...

  • Page 88

    3-44 engine • install the movable driven face seat 8. # • set the spring and clutch shoe to the movable driven face. # • engage the pawls of special tool to the holes of clutch shoe plate. $ 09922-31420: clutch spring compressor • while the special tool handle is being turned in slowly, engage two f...

  • Page 89

    Engine 3-45 • inspect the starter driven gear bushing for any damages. Disassembly • remove the starter clutch 1 and shim 2. $ 09930-44520: rotor holder • remove the rollers 3, push pieces 4 and springs 5. Reassembly reassemble the starter clutch in the reverse order of removal. Pay attention to the...

  • Page 90

    3-46 engine generator cover disassembly • remove the generator stator 1 and ckp sensor 2. • remove the snap ring 3. • remove the bearing using the special tool. $ 09921-20240: bearing remover set (12 mm) • remove the oil seal 4..

  • Page 91

    Engine 3-47 reassembly reassemble the generator cover in the reverse order of disas- sembly. Pay attention to the following points: • install oil seal using the special tool. $ 09913-70210: bearing installer set (22 mm) # • install new bearing using the special tool. • install new snap ring. $ 09913...

  • Page 92

    3-48 engine final gear box cover disassembly • remove the o-ring 1. • remove the bearing retainer 2. • remove the bearing 3 using the special tool. $ 09921-20240: bearing remover set note: if abnormal noise does not occur, it is not necessary to remove the bearing. # • remove the oil seal. $ 09913-5...

  • Page 93

    Engine 3-49 • remove the bearing 5 using the special tools. $ 09921-20210: bearing remover 09930-30104: sliding shaft reassembly • install the bearings 1 and 2 using the special tool. $ 09913-70210: bearing installer set (40 mm, 35 mm) • install the oil seal. $ 09913-70210: bearing installer set • a...

  • Page 94

    3-50 engine final gear inspection inspect the removed gears and shafts for the following abnor- malities. * drive gear, idle gear and driven gear damage or wear * improper tooth contact * shaft spline damage crankcase bearing inspection rotate the bearing inner race by finger to inspect for abnormal...

  • Page 95

    Engine 3-51 • remove the oil seal 3. $ 09913-50121: oil seal remover # • remove the bearings ( 4, 5, 6) using the special tools. $ 09913-70210: bearing installer set (35 mm) 09921-20240: bearing remover set (15 mm) 09921-20240: bearing remover set (17 mm) note: if abnormal noise does not occur, it i...

  • Page 96

    3-52 engine bearing/oil seal installation (left crankcase) • install the bearing 1 using the special tool. $ 09913-70210: bearing installer set (72 × 75 mm) • install new oil seal 2 using the special tool. $ 09913-70210: bearing installer set (72 × 75 mm) • apply grease to the lip of oil seal. ) 990...

  • Page 97

    Engine 3-53 • apply thread lock super to the bolts. • install the plate 7. * 99000-32110: thread lock super “1322” or equivalent bearing removal (right crankcase) • remove the bearing using the special tool. $ 09913-70210: bearing installer set (42 × 47 mm) note: if abnormal noise does not occur, it...

  • Page 98

    3-54 engine oil nozzle installation • fit new o-ring to the oil nozzle. • apply thread lock to the bolt, tighten it securely. + 99000-32050: thread lock “1342” or equivalent note: before installing the oil nozzle, clean its oil passage. Bushing inspection inspect the engine mounting bushings 1, 2 an...

  • Page 99

    Engine 3-55 engine mounting bushing installation • using an appropriate side steel tube and vise, press in the bushing 1 into the crankcase 2. # rear shock absorber bushing remove and install the rear shock absorber bushing in the same manner of engine mounting bushing removal and installation. Pay ...

  • Page 100: Engine Reassembly

    3-56 engine engine reassembly reassembly is in the reverse order of removal. Pay attention to the following points: # crankshaft • using the special tools, install the crankshaft into the left crankcase. Note: when installing in the crankshaft into the crankcase, insert the attachments a ( (35 mm) a...

  • Page 101

    Engine 3-57 crankcase • clean and degrease the crankcase mating surfaces (both sur- faces). • fit the dowel pins 1 into the left crankcase. • apply suzuki bond to the both crankcases. , 99000-31110: suzuki bond “1215” or equivalent # • assemble the crankcases with in few minutes. * coat the sealant ...

  • Page 102

    3-58 engine • fit the radiator hose guide 2. • tighten the 8 mm crankcase bolts first, then 6 mm ones evenly and diagonally. " crankcase bolt 8 mm: 22 n·m (2.2 kgf-m) crankcase bolt 6 mm: 11 n·m (1.1 kgf-m) note: after crankcase bolts have been tightened, make sure that the crankshaft rotates smooth...

  • Page 103

    Engine 3-59 idle shaft shim selection in order to obtain proper clearance for the idle shaft, 7 kinds of shims in different thickness are available. Inspect the clearance as follows and replace the shim if neces- sary. • degreace the idle shaft and shim 1. • fit the idle shaft shim 1 on the bearing....

  • Page 104

    3-60 engine • if the measured clearance is not within the specification, mea- sure the thickness of the shim 1 with the micrometer and select the specified shim from the table below. $ 09900-20205: micrometer (0 – 25 mm) % idle shaft shim selection table after installing the correct shim, assemble t...

  • Page 105

    Engine 3-61 • check that no roller inside the movable drive face is out of the slot. • install the movable drive face 3. # • install the movable driven face assembly. • hook the drive v-belt onto the spacer 4. # • install the clutch housing 5. # • with the clutch housing held immovable using the spe...

  • Page 106

    3-62 engine • to obtain proper contact of the drive v-belt, turn the fixed drive face until the fixed drive face and the movable driven face can rotate synchronously. • fit a new clutch cover gasket. • install the clutch cover 8. # • tighten the clutch cover bolts to the specified torque. " clutch c...

  • Page 107

    Engine 3-63 oil pump • engage the oil pump drive chain 1 with the oil pump gear. • install the oil pump and cover. Generator rotor and starter driven gear • install the key 1. • install the generator rotor 2 together with the starter driven gear 3. Note: make sure that the starter clutch is engaged ...

  • Page 108

    3-64 engine starter idle gear • install the starter idle gear 1 and starter idle gear shaft 2. Generator cover • install the dowel pins and gasket 1. # • install the generator cover 2. Water pump • install the o-rings 1, 2 to the water pump. # • apply engine coolant to the o-ring 1. • apply grease t...

  • Page 109

    Engine 3-65 • fit the clamp c in position. • tighten the water pump bolts. Oil filter • install the o-ring 1. • install the oil filter 2. • install the o-ring 3 and spring 4. # • install the oil filter cap 5. Piston ring • install the piston rings in the order of oil ring, 2nd ring and 1st ring. • t...

  • Page 110

    3-66 engine • install the 2nd ring 3 and 1st ring 4. Note: 2nd ring 3 and 1st ring 4 differ in shape. • face the stamped mark a upward when assembling. • after installing all the piston rings, check that each ring rotates smoothly. • to prevent poor compression or oil leaking up to the cylinder insi...

  • Page 111

    Engine 3-67 cylinder • install the dowel pins and a new gasket 1 to the crankcase. # • coat the cylinder wall and piston surface with engine oil. • install the cylinder. # • temporary tighten the cylinder nuts 2. Cam chain guide • install the cam chain guide 1. # cylinder head • place the dowel pins...

  • Page 112

    3-68 engine note: * the rounded side of the washer 2 should be positioned upside. * apply engine oil to the washers 2 and thread of the bolts before installing them. • tighten the cylinder base nuts and cylinder head nuts to the specified torque. " cylinder base nut: 10 n·m (1.0 kgf-m) cylinder head...

  • Page 113

    Engine 3-69 • install the camshaft 2 and camshaft sprocket 3. # • align the engraved lines c on the camshaft end with the cyl- inder head top surface. • position the camshaft sprocket so that the locating pin hole d aligns with the locating pin on the camshaft. • engage the cam chain with the camsha...

  • Page 114

    3-70 engine • install the dowel pins. • install the camshaft holder no.2 5 and tighten the bolts to the specified torque. " camshaft holder bolt: 10 n·m (1.0 kgf-m) # cam chain tension adjuster • with the spring holder bolt and spring removed, release lock- ing of the ratchet mechanism 1 and push th...

  • Page 115

    Engine 3-71 cylinder head cover • install the gasket to the cylinder head cover. # • apply suzuki bond to the points shown in the photo. . 99000-31160: suzuki bond “1207b” or equivalent • install the cylinder head cover. • apply engine oil to both sides of the washer 1. • tighten the cylinder head c...

  • Page 116: Fi System Diagnosis

    Fi system diagnosis 4-1 4 contents fi system diagnosis precautions in servicing .................................................................. 4- 3 electrical parts ........................................................................... 4- 3 fuse.................................................

  • Page 117: Fi System Diagnosis

    4-2 fi system diagnosis contents fi system diagnosis “23” (p1651-h/l) to sensor circuit malfunction.................. 4-47 “24” (p0351) ignition system malfunction.............................. 4-50 “32” (p0201) fuel injector circuit malfunction ................. 4-51 “40” (p0505 or p0506 and p0507)...

  • Page 118: Precautions In Servicing

    Fi system diagnosis 4-3 precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock type ...

  • Page 119

    4-4 fi system diagnosis • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female...

  • Page 120

    Fi system diagnosis 4-5 • when disconnecting and connecting the ecm, make sure to turn off the ignition switch 1, or electronic parts may get damaged. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly when r...

  • Page 121

    4-6 fi system diagnosis electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are as...

  • Page 122

    Fi system diagnosis 4-7 continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. 1 ecm • disconnect the coupler b and measure resistance between couplers a and b. If ...

  • Page 123

    4-8 fi system diagnosis short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/couple...

  • Page 124

    Fi system diagnosis 4-9 using the multi-circuit tester • use the suzuki multi-circuit tester set (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of t...

  • Page 125

    4-10 fi system diagnosis fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. Thes...

  • Page 126

    Fi system diagnosis 4-11 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant tempe...

  • Page 127

    4-12 fi system diagnosis fi system parts location a ecm d crankshaft position sensor (ckps) b fuel injector e heated oxygen sensor (ho2s) c intake air pressure sensor (iaps) f fuel pump (fp).

  • Page 128

    Fi system diagnosis 4-13 a ecm j throttle position sensor (tps) g speedometer k engine coolant temperature sensor (ects) h tip-over sensor (tos) l ignition coil (ig coil) i idle speed control valve (isc valve).

  • Page 129

    4-14 fi system diagnosis fi system wiring diagram cr ankshaft position sensor (ckps) throttle position sensor (tps) intak e air pressure sensor (iaps) engine coolant temper ature sensor (ects) tip-o v er sensor (t os) heated o xygen sensor (ho2s) w o/bl br p bl/w lg b bl mode select s witch speedome...

  • Page 130: Ecm Terminal

    Fi system diagnosis 4-15 ecm terminal terminal no. Circuit terminal no. Circuit 1 starter motor d mode select switch 2 mode select switch e ho2 sensor (ox) 3 to sensor (to) f ect sensor (ect) 4 — g ignition switch 5 — h iap sensor (iap) 6 ckp sensor (ckp+) i tp sensor (tp) 7 ecm ground (e1) j sensor...

  • Page 131: Self-Diagnosis Function

    4-16 fi system diagnosis self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the fi indicator light. To check the function of the individual fi system devices, the dealer mode is p...

  • Page 132

    Fi system diagnosis 4-17 dealer mode the defective function is memorized in the ecm. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed by the flashing pattern of fi indicator light. Malfunction means that the ecm does not receive signal...

  • Page 133: Fail-Safe Function

    4-18 fi system diagnosis the malfunction code is indicated from small code to large code. Fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can star...

  • Page 134: Fi System Troubleshooting

    Fi system diagnosis 4-19 fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for prope...

  • Page 135

    4-20 fi system diagnosis note: the above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual ...

  • Page 136

    Fi system diagnosis 4-21 self-diagnostic procedures note: * do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in ...

  • Page 137

    4-22 fi system diagnosis understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the fi indicator light. The dtcs are displayed from a smaller number to a larger number in that order. When all the applicable dtcs have been displayed, the displaying of...

  • Page 138

    Fi system diagnosis 4-23 dtc indication chart flashing pattern dtc no. Malfunction part 00 none 12 ckp sensor ( #4-30) 13 iap sensor ( #4-33) 14 tp sensor ( #4-38) 15 ect sensor ( #4-43) 23 to sensor ( #4-47) 24 ignition coil ( #4-50) 32 fuel injector ( #4-51) *40 isc valve ( #4-53) 41 fuel pump ( #...

  • Page 139

    4-24 fi system diagnosis *40 40 code has no first digit display. For this reason, the interval a between the displays as shown below is longer than the others. Self-diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • if the fi indicator light tu...

  • Page 140

    Fi system diagnosis 4-25 use of sds diagnostic procedures * do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in ...

  • Page 141

    4-26 fi system diagnosis use of sds diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase the ...

  • Page 142

    Fi system diagnosis 4-27 show data when trouble (displaing data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it is ...

  • Page 143

    4-28 fi system diagnosis malfunction code and defective condition dtc no. Detected item detected failure condition check for 00 no fault ––––––––––– ––––––––––– 12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical part...

  • Page 144

    Fi system diagnosis 4-29 dtc no. Detected item detected failure condition check for 24 ignition signal ckp sensor (pick-up coil) signal is pro- duced, but signal from ignition coil is interrupted 8 times or more continu- ously. In this case, the code 24 (p0351) is indicated. Ignition coil, wiring/co...

  • Page 145

    4-30 fi system diagnosis “12” (p0335) ckp sensor circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right side leg shield. ( #8-8) 3) check the ckp sensor coupler 1 for loose or poor contacts. If ok, then measure the ckp sensor resistance. 4) disconnect the ckp sens...

  • Page 146

    Fi system diagnosis 4-31 5) if ok, then check the continuity between each terminal and ground. $ ckp sensor continuity: ∞Ω (infinity) (w – ground) (g – ground) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing th...

  • Page 147

    4-32 fi system diagnosis . Is the voltage ok? " 3) after repairing the trouble, clear the dtc using sds tool. ( #4-26) yes • w or b wire open or shorted to ground. • loose or poor contacts on the ckp sensor cou- pler or ecm coupler (terminal 6 or j). • if wire and connection are ok, intermittent tro...

  • Page 148

    Fi system diagnosis 4-33 “13” (p0105-h/l) iap sensor circuit malfunction inspection step 1 (when indicating 13:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #8-8) 3) check the iap sensor coupler 1 for loose or poor contacts. If ok, then measure the iap sensor input voltage. D...

  • Page 149

    4-34 fi system diagnosis 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the o/bl wire and ground. 7) if ok, then measure the voltage at the o/bl wire a and b wire b. $ iap sensor input voltage: 4.5 – 5.5 v ( + o/bl – - ground) ( + o/bl – - b) ! 09900-...

  • Page 150

    Fi system diagnosis 4-35 6) disconnect the ecm coupler. 7) check the continuity between p wire c and terminal h. 8) if ok, then check the continuity between b wire b and termi- nal j. $ iaps lead wire continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009: needle pointed prob...

  • Page 151

    4-36 fi system diagnosis 7) disconnect the ecm coupler. 8) check the continuity between o/bl wire a and terminal 9. 9) also, check the continuity between p wire c and terminal h. $ iaps lead wire continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set...

  • Page 152

    Fi system diagnosis 4-37 step 3 1) turn the ignition switch off. 2) remove the iap sensor. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. Arrange 3 new 1.5 v batteries in series 1 (check that total voltage is 4.5 – 5.0 v) and connect - terminal to the ground terminal 2 and + ...

  • Page 153

    4-38 fi system diagnosis “14” (p0120-h/l) tp sensor circuit malfunction inspection step 1 (when indicating 14:) 1) turn the ignition switch to off. 2) remove the front frame cover. ( #8-8) 3) check the tp sensor coupler 1 for loose or poor contacts. If ok, then measure the tp sensor input voltage. D...

  • Page 154

    Fi system diagnosis 4-39 4) disconnect the tp sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the o/bl wire b and ground. 7) if ok, then measure the voltage at the o/bl wire b and b wire c. $ tp sensor input voltage: 4.5 – 5.5 v ( + o/bl – - ground) ( + o/bl – - b) ! 09900-...

  • Page 155

    4-40 fi system diagnosis 6) disconnect the ecm coupler. 7) check the continuity between br wire a and terminal i. 8) also, check the continuity between b wire c and terminal j. $ tps lead wire continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set ) ...

  • Page 156

    Fi system diagnosis 4-41 7) disconnect the ecm coupler. 8) check the continuity between br wire a and terminal i. 9) also, check the continuity between o/bl wire b and terminal 9. $ tps lead wire continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set...

  • Page 157

    4-42 fi system diagnosis is the voltage ok? " 4) after repairing the trouble, clear the dtc using sds tool. ( #4-26) yes • br, o/bl or b wire open or shorted to ground, or poor i, 9 or j connection • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and wir...

  • Page 158

    Fi system diagnosis 4-43 “15” (p0115-h/l) ect sensor circuit malfunction inspection step 1 (when indicating 15:) 1) turn the ignition switch off. 2) remove the frame covers. ( #8-9) 3) check the ect sensor coupler 1 for loose or poor contacts. If ok, then measure the ect sensor voltage at the couple...

  • Page 159

    4-44 fi system diagnosis step 1 (when indicating p0115-h:) 1) turn the ignition switch off. 2) remove the frame covers. ( #8-9) 3) check the ect sensor coupler 1 for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler and ecm coupler. 5...

  • Page 160

    Fi system diagnosis 4-45 step 1 (when indicating p0115-l:) 1) turn the ignition switch off. 2) remove the frame covers. ( #8-9) 3) check the ect sensor coupler 1 for loose or poor contacts. If ok, then measure the output voltage. 4) disconnect the ect sensor coupler. 5) check the continuity between ...

  • Page 161

    4-46 fi system diagnosis step 2 1) turn the ignition switch off. 2) disconnect the ect sensor coupler. 3) measure the ect sensor resistance. $ ect sensor resistance: approx. 2.45 kΩ at 20 °c (terminal – terminal) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance (Ω) refer ...

  • Page 162

    Fi system diagnosis 4-47 “23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating 23:) 1) turn the ignition switch off. 2) remove the front leg shield. ( #8-6) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then measure the to sensor resistance. 4) disco...

  • Page 163

    4-48 fi system diagnosis step 1 (when indicating p1651-h:) 1) turn the ignition switch off. 2) remove the front leg shield. ( #8-6) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the con...

  • Page 164

    Fi system diagnosis 4-49 step 1 (when indicating p1651-l:) 1) turn the ignition switch off. 2) remove the front leg shield. ( #8-6) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the con...

  • Page 165

    4-50 fi system diagnosis step 2 1) connect the to sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage between lg and b wires. $ to sensor voltage (normal): 0.4 – 1.4 v ( + lg – - b) also, measure the vol...

  • Page 166

    Fi system diagnosis 4-51 “32” (p0201) fuel injector circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the trunk box. ( #8-11) 3) check the injector coupler 1 for loose or poor contacts. If ok, then measure the injector resistance. 4) disconnect the injector coupler and...

  • Page 167

    4-52 fi system diagnosis 5) if ok, then check the continuity between each terminal and ground. $ injector continuity: ∞Ω (infinity) ! 09900-25008: multi-circuit tester set % tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trouble, clear the dtc usi...

  • Page 168

    Fi system diagnosis 4-53 “40” (p0505 or p0506 and p0507) isc valve circuit malfunction " inspection step 1 1) turn the ignition switch off. 2) remove the trunk box. ( #8-11) 3) check the isc valve coupler 1 for loose or poor contacts. If ok, then check the isc valve lead wire continuity. Detected co...

  • Page 169

    4-54 fi system diagnosis 4) disconnect the isc valve coupler and ecm coupler. 5) check the continuity between terminals a and 0, terminals b and m, terminals c and k, terminals d and 8. " $ isc valve continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe...

  • Page 170

    Fi system diagnosis 4-55 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) make sure that the engine coolant temperature on data moni- tor is indicated 70°c or more. 4) click th...

  • Page 171

    4-56 fi system diagnosis check 3 1) click the button 1 and increase the “spec” 2 to 1 650 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2. Also, check that the number of steps 4 in the isc valve position increases . Check 4 1) increase the “spec” 1 to 1 900 rpm. ...

  • Page 172

    Fi system diagnosis 4-57 “41” (p0230-h/l) fp circuit malfunction inspection step 1 (when indicating 41:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #8-8) 3) check the fuel pump coupler 1 for loose or poor contacts. If ok, then check the main relay. ( #9-21) detected conditio...

  • Page 173

    4-58 fi system diagnosis is the main relay ok? " 4) after repairing the trouble, clear the dtc using sds tool. ( #4-26) step 1 (when indicating p0230-h:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #8-8) 3) check the fuel pump coupler for loose or poor contacts. If ok, then c...

  • Page 174

    Fi system diagnosis 4-59 step 1 (when indicating p0230-l:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #8-8) 3) check the fuel pump coupler for loose or poor contacts. If ok, then check the main relay. ( #9-21) is the main relay ok? 4) after repairing the trouble, clear the d...

  • Page 175

    4-60 fi system diagnosis “44” (p0130) ho2 sensor (ho2s) circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right side leg shield. ( #8-8) 3) check the ho2 sensor coupler 1 for loose or poor contacts. If ok, then check the ho2 sensor lead wire continuity. 4) disconne...

  • Page 176

    Fi system diagnosis 4-61 7) disconnect the ecm coupler. 8) check the continuity between bl wire (harness side) and ter- minal e. 9) also, check the continuity between b wire (harness side) and terminal j. $ ho2s lead wire continuity: continuity (() ! 09900-25008: multi-circuit tester set 09900-25009...

  • Page 177

    4-62 fi system diagnosis is the voltage ok? " 5) after repairing the trouble, clear the dtc using sds tool. ( #4-26) yes • bl wire or b wire open or shorted to ground, or poor e or j connection. • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and wire h...

  • Page 178: Sensors

    Fi system diagnosis 4-63 sensors ckp sensor inspection the crankshaft position sensor is installed behind the generator cover. ( #4-30) ckp sensor removal and installation • remove the generator cover. ( #3-14) • install the generator cover in the reverse order of removal. Iap sensor inspection the ...

  • Page 179

    4-64 fi system diagnosis to sensor inspection to sensor removal and installation the tip-over sensor is located inside the front leg shield. ( #4-47) • remove the to sensor. • install the to sensor in the reverse order of removal. Note: when installing the to sensor, the arrow mark must be pointed u...

  • Page 180

    Fuel system and throttle body 5-1 5 fuel system and throttle body contents fuel system............................................................................................. 5- 2 construction .................................................................................. 5- 2 removal and di...

  • Page 181: Fuel System

    5-2 fuel system and throttle body fuel system construction 1 fuel tank 3 cushion " 2 o-ring a fuel pump retainer item n·m kgf-m a 35 3.5.

  • Page 182

    Fuel system and throttle body 5-3 removal and disassembly • remove the engine. ( #3-3) • remove the footboard. ( #8-12) • disconnect the fuel pump/fuel level gauge coupler 1. ! • remove the fuel feed hose bracket 2. • remove the fuel tank bolt 3. • remove the fuel tank bolts 4 and 5. • remove the fu...

  • Page 183

    5-4 fuel system and throttle body • remove the fuel feed hose 6. • loosen the fuel pump retainer using the special tool. % 09941-51012: ring lock-nut wrench • remove the fuel pump assembly. • fuel pump inspection ( #5-7 and 9-29).

  • Page 184

    Fuel system and throttle body 5-5 fuel tank reassembly and installation reassemble and install the fuel tank in the reverse order of removal and disassembly. Pay attention to the following points: • apply thin coat of the engine oil to the o-ring 1. $ • install the fuel pump assembly. • align the al...

  • Page 185

    5-6 fuel system and throttle body fuel pressure inspection • remove the front frame cover. ( !8-11) • place a rag under the fuel feed hose 1 and disconnect the fuel feed hose 1 from the fuel tank. • install the special tools to the fuel tank. " 09915-77331: oil pressure gauge 09915-74521: oil pressu...

  • Page 186

    Fuel system and throttle body 5-7 fuel pump inspection 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 main relay and tip-over sensor. If the fuel pump ...

  • Page 187

    5-8 fuel system and throttle body fuel mesh filter inspection and cleaning • remove the fuel pump assembly. ( #5-3) • remove the fuel mesh filter 1. • if the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. • blow the fuel mesh filte...

  • Page 188: Throttle Body

    Fuel system and throttle body 5-9 throttle body construction 1 o-ring 6 vacuum hose " 2 fuel injector 7 throttle body item n·m kgf-m 3 cushion seal 8 tp sensor a 1.8 0.18 4 intake pipe 9 insulator 5 iap sensor.

  • Page 189

    5-10 fuel system and throttle body removal and disassembly $ • remove the trunk box. ( #8-11) • remove the air cleaner box outlet tube 1. • disconnect the engine coolant temperature meter lead wire 2, ignition coil lead wires 3 and ect sensor coupler 4. • disconnect the tp sensor coupler 5, iap sens...

  • Page 190

    Fuel system and throttle body 5-11 • remove the o-ring b. • remove the tp sensor c. • remove the iap sensor d. • disconnect the vacuum hose e. • remove the fuel injector f. • remove the intake pipe g..

  • Page 191

    5-12 fuel system and throttle body $ $ $ $ inspection • check following items any damage or clogging. * throttle valve * o-ring * vacuum hose * throttle body * cushion seal * intake pipe fuel injector inspection • check fuel injector filter for evidence of dirt and contamina- tion. If present, clean...

  • Page 192

    Fuel system and throttle body 5-13 i reassembly and installation reassembly and installation is in the reverse order of removal and disassembly. Pay attention to the following points: • install the cushion seal 1 and o-ring 2 to fuel injector. • apply thin coat of engine oil to the cushion seal and ...

  • Page 193: Exhaust System

    Exhaust system 6-1 4 6 exhaust system contents exhaust system ..................................................................................... 6- 2 removal .............................................................................................. 6- 2 inspection ...............................

  • Page 194: Exhaust System

    6-2 exhaust system exhaust system removal ! " • remove the right side leg shield. ( #8-8) • disconnect the ho2 sensor coupler 1. • loosen the muffler connecting bolt 2. • remove the muffler assembly. • remove the exhaust pipe 3. • remove the exhaust pipe gasket 4. To avoid the danger of being burned...

  • Page 195

    Exhaust system 6-3 inspection ho2 sensor ( #4-60) installation install the exhaust pipe and muffler in the reverse order of removal. Pay attention to the following points: • apply gas sealer to the muffler connector 1. Exhaust gas sealer: permatex 1372 (commercially available) " • install the exhaus...

  • Page 196

    Cooling and lubrication system 7-1 7 cooling and lubrication system contents engine coolant ..................................................................................... 7- 2 radiator and radiator hose ........................................................... 7- 3 inspection .................

  • Page 197: Engine Coolant

    7-2 cooling and lubrication system engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the c...

  • Page 198: Radiator and Radiator Hose

    Cooling and lubrication system 7-3 radiator and radiator hose inspection before removing the radiator and draining the engine coolant, inspect cooling system for tightness. • remove the lid. • remove the radiator cap and connect the tester 1 to the filler. • give a pressure of about 120 kpa (1.2 kgf...

  • Page 199

    7-4 cooling and lubrication system removal • remove the lower leg shield. ( $8-7) • remove the rear lower leg shield. ( $8-8) • place a container under the radiator hose. • remove the radiator cap. " • disconnect the radiator hose 1 to let coolant drain off. • remove the radiator mounting bolt. • di...

  • Page 200

    Cooling and lubrication system 7-5 disassembly • remove the cooling fan 1. • remove the cooling fan thermo-switch 2. Radiator inspection and cleaning • check the radiator for dirt or small bug stuck between the fins. • use compressed air for cleaning. If dirt is excessive, wash with water. • fins be...

  • Page 201

    7-6 cooling and lubrication system radiator • connect the cooling fan thermo-switch coupler 1 and the cooling fan lead wire coupler 2. • clamp the cooling fan thermo-switch lead wire and cooling fan lead wire with the frame. • with the hooked part a connected to the radiator end, install the radiato...

  • Page 202: Cooling Fan

    Cooling and lubrication system 7-7 cooling fan inspection • remove the lower leg shield. ( $8-7) • remove the clamp. • disconnect the cooling fan lead wire coupler 1. • test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • the voltmeter is for making s...

  • Page 203: Cooling Fan Thermo-Switch

    7-8 cooling and lubrication system cooling fan thermo-switch removal • remove the lower leg shield. ( $8-7) • drain engine coolant. ( $2-12) • remove the clamp. • disconnect the cooling fan thermo-switch coupler 1. • remove the cooling fan thermo-switch 2. Inspection • place the cooling fan thermo-s...

  • Page 204

    Cooling and lubrication system 7-9 engine coolant temperature gauge removal • remove the frame covers. ( $8-10) • disconnect the lead wire 1. • remove the engine coolant temperature gauge 2. Inspection • connect the engine coolant temperature gauge to the ohm- meter and dip it in water contained in ...

  • Page 205: Ect Sensor

    7-10 cooling and lubrication system ect sensor removal • remove the frame covers. ( $8-10) • remove the thermostat case. ( $7-11) • disconnect the ect sensor coupler 1. • remove the ect sensor 2. Inspection • check the ect sensor by testing it at the bench as shown in the figure. Connect the ect sen...

  • Page 206: Thermostat

    Cooling and lubrication system 7-11 installation • tighten the ect sensor to the specified torque. % ect sensor: 18 n·m (1.8 kgf-m) ! • after the thermostat case has been installed, fill engine cool- ant and perform air bleeding. ( $2-13) thermostat removal • remove the frame covers. ( $8-10) • drai...

  • Page 207

    7-12 cooling and lubrication system • immerse the thermostat in water contained in a pan as shown and measure the valve start-to-open temperature when water is heated gradually. If the thermostat valve opening temperature is not within the specified range, replace the thermostat with a new one. # th...

  • Page 208: Water Pump

    Cooling and lubrication system 7-13 water pump removal and disassembly note: before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolant is leaking, v...

  • Page 209

    7-14 cooling and lubrication system • remove the mechanical seal ring 0 and rubber seal a from the impeller. • remove the mechanical seal b with the special tool. & 09921-20240: bearing remover set (10 mm) note: if there is no abnormal condition, the mechanical seal removal is not necessary. ! • rem...

  • Page 210

    Cooling and lubrication system 7-15 inspection mechanical seal • visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. • replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. Oil seal • visually ins...

  • Page 211

    7-16 cooling and lubrication system • install the new mechanical seal using a suitable size socket wrench. Note: on the new mechanical seal, the sealer a has been applied. • install the rubber seal 1 into the impeller. • after wiping off the oily or greasy matter from the mechanical seal ring, insta...

  • Page 212

    Cooling and lubrication system 7-17 • install the new o-rings 3, 4 and 5. ! Note: * apply engine coolant to the o-ring 3, 5. * apply grease to the o-ring 4. ( 99000-25010: suzuki super grease “a” or equivalent • install the water pump assembly. ! • tighten the water pump mounting bolts securely. • i...

  • Page 213: Lubrication System

    7-18 cooling and lubrication system lubrication system oil pressure $2-23 oil filter $2-9 oil sump filter $3-35 oil pump $3-35.

  • Page 214

    Cooling and lubrication system 7-19 engine lubrication system chart oil pan oil sump filter oil pump oil filter main gallery generator cover crankshaft starter clutch crank pin bearing intake rocker arm intake rocker arm shaft camshaft journal cylinder head cylinder piston oil nozzle cam chain camsh...

  • Page 215: Chassis

    Chassis 8-1 chassis contents 8 exterior parts ...................................................................................... 8- 3 fastener ............................................................................................ 8- 3 handlebar covers .........................................

  • Page 216: Chassis

    8-2 chassis chassis contents rear wheel.............................................................................................. 8-35 construction .................................................................................. 8-35 removal .......................................................

  • Page 217: Exterior Parts

    Chassis 8-3 exterior parts fastener removal • depress the head of fastener center piece 1. • pull out the fastener. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. Note: to prevent the pawl 2 from damage, inse...

  • Page 218

    8-4 chassis handlebar covers removal • remove the rear view mirrors 1 and fasteners. • remove the rear handlebar cover 2 by pulling it upward. • remove the front handlebar cover 3. Installation installation is in the reverse order of removal. Front cover removal remove the screws. • remove the front...

  • Page 219

    Chassis 8-5 lower meter panel removal • remove the windscreen. ( "8-4) • remove the screw 1. • remove the lower meter panel 2 by removing the speedom- eter mounting screws. Installation installation is in the reverse order of removal..

  • Page 220

    8-6 chassis front leg shield removal • remove the front cover. ( "8-4) • remove the floor mats 1. • remove the screws (8 pcs) and fasteners (4 pcs). • disconnect the coupler 2 and remove the front leg shield along with the headlight assembly. Installation installation is in the reverse order of remo...

  • Page 221

    Chassis 8-7 lower leg shield removal • remove the front leg shield. ( "8-6) • remove the screws (6 pcs) and fasteners (4 pcs). • remove the horn mounting bolt 1. • remove the lower leg shield 2. # installation installation is in the reverse order of removal. Side leg shield (lh) removal • remove the...

  • Page 222

    8-8 chassis side leg shield (rh) removal • remove the floor mat (rh). • remove the battery cover 1. • remove the side leg shield (rh) 2. Installation installation is in the reverse order of removal. Rear lower leg shield removal • remove the side leg shields. ( "8-7 and -8) • remove the rear lower l...

  • Page 223

    Chassis 8-9 seat removal • open the seat. • remove the seat by removing the three nuts. Installation installation is in the reverse order of removal. Pillion rider handles removal • open the seat. • remove the pillion rider handles 1 (lh and rh). Installation installation is in the reverse order of ...

  • Page 224

    8-10 chassis • remove the rear combination light 2, upper frame cover 3 and rear footboards 4 (lh and rh) from the frame covers 5 (lh and rh). Installation installation is in the reverse order of removal..

  • Page 225

    Chassis 8-11 trunk box removal • remove the frame covers. ( "8-10) • remove the main fuse 1, ecm 2, brake switch relay 3 and main relay 4 from the upper trunk box. Note: do not disconnect the ecm and relay couplers. • remove the screw under the ecm. • disconnect the trunk box light coupler 5. • remo...

  • Page 226

    8-12 chassis footboard removal • remove the front frame cover. ( "8-8) • remove the floor mats. • remove the side leg shields. ( "8-7 and -8) • remove the frame covers. ( "8-10) • remove the battery and stater relay 1. • remove the screws (6 pcs) and bolts (4 pcs). • remove the fuel tank cap 2. • di...

  • Page 227

    Chassis 8-13 front box removal • remove the windscreen. ( "8-4) • remove the handlebars. ( "8-20) • remove the front leg shield. ( "8-6) • remove the side leg shields. ( "8-7 and -8) • remove the frame covers. ( "8-10) • remove the footboard. ( "8-12) • remove the screws and disconnect the output te...

  • Page 228: Front Wheel

    8-14 chassis front wheel construction 1 brake disc 6 speedometer gear box $ 2 collar 7 front axle item n·m kgf-m 3 dust seal a front axle nut a 44 4.4 4 bearing b brake disk bolt b 23 2.3 5 spacer.

  • Page 229

    Chassis 8-15 removal • support the motorcycle with the center stand. • remove the axle nut 1. • lift the front wheel off the ground using a jack. # • draw out the axle shaft and remove the front wheel. • remove the collar 2. Inspection and disassembly tire ( "8-52) brake disk ( "8-42) wheel • make s...

  • Page 230

    8-16 chassis • remove the dust seal 3. & 09913-50121: oil seal remover # • remove the bearing. & 09921-20240: bearing remover set # • remove the brake disc. Axle shaft • using a dial gauge, check the axle shaft for runout. • if the runout measured exceeds the service limit, replace the axle shaft. %...

  • Page 231

    Chassis 8-17 reassembly and installation to reassemble the front wheel, reverse the sequence of disas- sembly procedures while observing the following instructions. Wheel bearing • apply grease to the wheel bearings. ' 99000-25010: suzuki super grease “a” or equivalent • install the wheel bearing wi...

  • Page 232

    8-18 chassis dust seal • install the new dust seal using the special tool. & 09913-70210: bearing installer set (30mm) • apply grease to the dust seal lip. • apply grease to the collar and install the collar straight to pre- vent the dust seal lip from damage. ' 99000-25010: suzuki super grease “a” ...

  • Page 233: Handlebars

    Chassis 8-19 handlebars construction 1 handlebars 5 right handlebar switch box $ 2 handlebar balancer 6 throttle grip item n·m kgf-m 3 left grip rubber a handlebar set bolt a 25 2.5 4 left handlebar switch box b handlebar clamp nut b 50 5.0

  • Page 234

    8-20 chassis removal • remove the handlebar covers. ( "8-4) • remove the following items from the handlebars. 1 handlebar balancer 2 left handlebar switch box 3 rear brake light switch lead wires 4 rear brake master cylinder 5 grip rubber 6 handlebar balancer 7 right handlebar switch box 8 throttle ...

  • Page 235

    Chassis 8-21 • apply grease to the hatched area a before installing the throttle grip 1. A: 135 mm ' 99000-25010: suzuki super grease “a” or equivalent • insert the projection a of the right handlebar switch into the hole of the handlebar. • apply grease to the throttle cables and cable pulley. ' 99...

  • Page 236: Front Fork

    8-22 chassis front fork construction 1 o-ring 8 oil seal stopper ring $ 2 front fork spring 9 oil lock piece item n·m kgf-m 3 damper rod ring 0 oil seal a 45 4.5 4 damper rod a outer tube b 30 3.0 5 damper rod spring a front fork cap bolt 6 inner tube b damper rod bolt 7 dust seal.

  • Page 237

    Chassis 8-23 removal and disassembly • remove the front leg shield. ( "8-6) • dismount the front wheel. ( "8-15) • remove the brake caliper and brake hose guide. • remove the speed meter cable guide 1. # • remove the front fender. • remove the front fork cap bolt 2 using the special tool. & 09940-30...

  • Page 238

    8-24 chassis • remove the front fork spring 4 and drain front fork oil. • remove the damper rod bolt using the special tools. & 09940-34520: t-handle 09940-34531: attachment (a) • remove the inner tube 5 and oil lock piece 6 from the outer tube. • remove the damper rod 7 and spring 8 from the inner ...

  • Page 239

    Chassis 8-25 • remove the oil seal stopper ring 0. • remove the oil seal a. & 09913-50121: oil seal remover # inspection front fork spring measure the free length a of the front fork spring. If the length is found shorter than the service limit, replace the spring with a new one. % front fork spring...

  • Page 240

    8-26 chassis reassembly reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: # oil lock piece • with the oil lock piece 1 fitted to the damper rod, assemble the inner tube to the outer tube. Damper rod bolt • apply thread lock ...

  • Page 241

    Chassis 8-27 stopper ring/dust seal • install the oil seal stopper ring 1 and dust seal 2. # 1 oil seal stopper ring 2 dust seal 3 oil seal 4 slide metal front fork oil • pour the specified amount of fork oil and stroke the tube sev- eral times to expel air. % capacity (each leg): 141 ml , 99000-990...

  • Page 242

    8-28 chassis • insert the front fork inner tube top end into the steering stem all the way until the step of mounting hole has been con- tacted. • tighten the clamp bolts temporarily. Front fork cap bolt • install new o-ring to the front fork cap bolt and apply fork oil. • install the front fork cap...

  • Page 243: Steering

    Chassis 8-29 steering construction 1 washer 6 lower bearing $ 2 steering stem nut 7 steering stem item n·m kgf-m 3 upper bearing inner race 8 lower bearing inner race a 30 3.0 4 dust cover a steering stem lock nut b 23 2.3 5 upper bearing b front fork clamp bolt.

  • Page 244

    8-30 chassis removal and disassembly • remove the front leg shield. ( "8-6) • remove the front forks. ( "8-23) • remove the front brake hose guide 1 and speedometer guide 2. • remove the clamp 3. • remove the handlebar set bolt 4 and clamp bolt 5. • dismount the handlebars. # • remove the steering s...

  • Page 245

    Chassis 8-31 inspection and disassembly check the steering stem and steering stem head for any dam- age. Check the bearings and races for corrosion, nick or other dam- age. If any abnormal condition is noted, replace the damaged part with a new one. • to remove the lower inner race, use a chisel lik...

  • Page 246

    8-32 chassis reassembly reassembly and reinstallation can be performed in the reverse order of removal and disassembly procedures. Pay attention to the following points: • press in the upper and lower outer race using the special tool. & 09941-34513: steering race installer • install new dust seal. ...

  • Page 247

    Chassis 8-33 • tighten the steering stem nut. $ steering stem nut: 45 n·m (4.5 kgf-m) & 09940-14911: steering socket wrench 09940-11420: steering stem nut socket 09940-11430: steering stem nut socket • turn the steering stem right and left 5 – 6 times to break-in the bearing. • return the steering s...

  • Page 248

    8-34 chassis • tighten the handlebar set bolt 3 and handlebar clamp nut 4 to the specified torque. $ handlebar set bolt: 25 n·m (2.5 kgf-m) handlebar clamp nut: 50 n·m (5.0 kgf-m) # * 99000-32110: thread lock super “1322” or equivalent apply thread lock super to the handlebar set bolt..

  • Page 249: Rear Wheel

    Chassis 8-35 rear wheel construction 1 collar 4 rear wheel $ 2 spacer a rear axle nut item n·m kgf-m 3 brake disc b brake disk bolt a 120 12.0 b 23 2.3.

  • Page 250

    8-36 chassis removal • support the motorcycle with the center stand. • remove the muffler. ( "6-2) • remove the rear brake caliper 1. • remove the rear axle nut 2 and collar. • remove the rear swingarm 3. • remove the spacer 4. • remove the rear wheel. # • remove the brake disc. ( "8-16) inspection ...

  • Page 251: Front Brake

    Chassis 8-37 front brake construction 1 diaphragm 0 brake pad $ 2 master cylinder a pad spring item n·m kgf-m 3 piston/cup set a master cylinder bolt (upper) a 12 1.2 4 delay valve b master cylinder bolt (lower) b 10 1.0 5 brake caliper c brake hose union bolt c 23 2.3 6 caliper bracket d brake cali...

  • Page 252

    8-38 chassis ) # brake fluid replacement ( "2-16) brake pad replacement ( "2-15) front brake caliper removal and disassembly • remove the brake hose union bolts 1 and catch the brake fluid in a suitable receptacle. • remove the brake caliper 2. # • remove the brake pad bolt 3. • remove the brake pad...

  • Page 253

    Chassis 8-39 • remove the brake pad springs 4 and 5. • using an air blow gun, pressurize the caliper fluid chamber to push out the pistons. • blow the hole a to push out the center piston. • blow the hole b to push out the upper and lower pistons. ) • remove the dust seals 6 and piston seals 7. # * ...

  • Page 254

    8-40 chassis front brake caliper inspection inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace it with a new one. Inspect the caliper bracket 1 for any damage. Inspect the rubber boots 2 for any damage. If any abn...

  • Page 255

    Chassis 8-41 • apply suzuki silicone grease to the caliper bracket pin 1 and boots 2. . 99000-25100: suzuki silicone grease or equivalent • install the caliper bracket. • install the brake pad springs 3 and 4 properly. • install the brake pads. • install the brake pad bolt 5. $ brake pad bolt: 18 n·...

  • Page 256

    8-42 chassis brake disc inspection check the brake disc surface for scratch, crack or abnormal wear. Measure the disc thickness at several positions using a micrometer. If the measurement is less than the service limit or any abnormal condition is noted, replace the disc with a new one. (for replace...

  • Page 257

    Chassis 8-43 • remove the brake light switch 3 and brake lever 4. • remove the dust boot 5. • remove the snap ring 6. • remove the washer 7 and piston/cup set 8. Front brake master cylinder inspection check the cylinder inside wall, piston/cup set and spring for scratch, corrosion or other abnormal ...

  • Page 258

    8-44 chassis front brake master cylinder reassembly and installation reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: # - specification and classification: dot 4 • when installing the brake light switch, align the proj...

  • Page 259

    Chassis 8-45 • when installing the master cylinder onto the handlebars, align the master cylinder holder’s mating surface a with the punch mark b on the handlebars and tighten the upper holder bolt first. A mating surface b punch mark c master cylinder d handlebars e upper holder bolt f clearance $ ...

  • Page 260: Rear Brake

    8-46 chassis rear brake construction *2 *1 1 diaphragm a caliper bracket $ 2 master cylinder b rear brake pipe item n·m kgf-m 3 piston/cup set *1 to the delay valve a 12 1.2 4 brake pad shim *2 to the rear brake caliper b 10 1.0 5 brake pads a master cylinder bolt (upper) c 23 2.3 6 brake caliper b ...

  • Page 261

    Chassis 8-47 ) # rear brake caliper removal and disassembly • remove the muffler. ( "6-2) • remove the brake hose union bolt 1. • remove the brake caliper 2. • remove the brake pad bolt 3. • remove the caliper bracket 4 and brake pads. • remove the pad spring 5. * this brake system is filled with an...

  • Page 262

    8-48 chassis • using an air blow gun, pressurize the caliper fluid chamber to push out the piston. # • remove the dust seal 6 and piston seal 7. # rear brake caliper inspection caliper ( "8-40) rear brake caliper reassembly reassemble the caliper in the reverse order of disassembly. Pay attention to...

  • Page 263

    Chassis 8-49 • apply suzuki silicone grease to the caliper bracket pins. . 99000-25100: suzuki silicone grease or equivalent • install the brake pads and brake pad bolts. $ brake pad bolt: 18 n·m (1.8 kgf-m) • tighten the brake caliper mounting bolts 1. $ brake caliper mounting bolt: 26 n·m (2.6 kgf...

  • Page 264

    8-50 chassis rear brake master cylinder reassembly and installation reassemble and install the rear brake master cylinder in the same manner as the front one. ( "8-44) delay valve removal • drain brake fluid from the combination brake system. ( "2-16) • remove the front leg shield. ( "8-6) • remove ...

  • Page 265: Rear Suspension

    Chassis 8-51 rear suspension construction 1 rear swingarm a rear shock absorber mounting bolt (upper and lower) $ 2 dust seal item n·m kgf-m 3 bearing a 29 2.9 4 rear shock absorber.

  • Page 266

    8-52 chassis rear swingarm bearing inspection • inspect the play of the bearing by finger while it is in the swin- garm. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Note: if abnormal noise does not occur, it is not necessary to remove the bearing. Rear swingarm...

  • Page 267

    Chassis 8-53 rear shock absorber removal • remove the frame covers. ( "8-9) • remove the muffler for right rear shock absorber removal. ( "6-2) • move the air cleaner box upward for left rear shock absorber removal. ( "2-10) • remove the rear shock absorber. Rear shock absorber inspection • inspect ...

  • Page 268: Tire And Wheel

    8-54 chassis tire and wheel tire removal the most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For o...

  • Page 269

    Chassis 8-55 valve inspection • inspect the valve after the tire is removed from the rim. • replace the valve with a new one if the seal rubber a is peel- ing or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the se...

  • Page 270

    8-56 chassis tire installation • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. # • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the t...

  • Page 271

    Chassis 8-57 • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 272: Electrical System

    Electrical system 9-1 electrical system contents 9 cautions in servicing ......................................................................... 9- 3 connector ........................................................................................ 9- 3 coupler........................................

  • Page 273: Electrical System

    Electrical system contents 9-2 electrical system lamps ........................................................................................................ 9-30 headlight, position light, brake light/taillight, license plate light and turn signal light ......................... 9-30 bulb replace...

  • Page 274: Cautions In Servicing

    Electrical system 9-3 cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock when dis- connecting, an...

  • Page 275

    9-4 electrical system semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as a ecm. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • the mf battery used in this mot...

  • Page 276

    Electrical system 9-5 using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 277

    9-6 electrical system location of electrical components 1 iap sensor 2 fuel injector 3 isc valve 4 trunk light switch 5 regulator/rectifier 6 front brake switch 7 handlebar switch (rh) 8 ignition switch 9 ckp sensor 0 generator a ho2 sensor b starter relay c battery d cooling fan e cooling fan therm...

  • Page 278

    Electrical system 9-7 f to sensor g side-stand relay h turn signal relay i handlebar switch (lh) j combination brake switch k main fuse l ecm m brake start relay n main relay o tp sensor p horn q fuse box r side-stand switch s fuel pump t fuel level gauge u engine coolant temperature gauge v ect sen...

  • Page 279: Charging System

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

  • Page 280

    Electrical system 9-9 step 4 1) measure the resistance of the generator coil. ( !9-11) is the resistance of generator coil ok? Step 5 1) measure the generator no-load performance. ( !9-11) is the generator no-load performance ok? Step 6 1) inspect the regulator/rectifier. ( !9-12) is the regulator/r...

  • Page 281

    9-10 electrical system inspection battery current leakage • turn the ignition switch to the off position. • remove the battery cover. ( !8-8) • disconnect the battery - lead wire. • measure the current between battery - terminal and - lead wire using the multi-circuit tester. If the reading exceeds ...

  • Page 282

    Electrical system 9-11 generator coil resistance • remove the right side leg shield. ( !8-8) • disconnect the generator coupler 1. • 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 cor...

  • Page 283

    9-12 electrical system measure the voltage between the terminals using the multi-cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regu- lator/rectifier with a new one. " 09900-25008: multi-circuit tester set ) tester knob indication: di...

  • Page 284: Starter System

    Electrical system 9-13 starter system trouble shooting note: make sure the fuses are not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) grasp the front or rear brake lever, turn on the ignition switch with the engine stop switch in the “run” position ...

  • Page 285

    9-14 electrical system step 3 1) measure the starter relay voltage at the starter relay connectors (between bl/w + and r/w -) when the starter button is pushed. Is a voltage ok? Step 4 1) inspect the starter relay. ( !9-16) is the starter relay ok? Engine does not turn though the starter motor runs....

  • Page 286

    Electrical system 9-15 starter motor disassembly • disassemble the starter motor as shown in the illustration. 1 o-ring 6 starter motor case + 2 housing end (inside) 7 armature item n·m kgf-m 3 oil seal 8 housing end (outside) a 3 0.3 4 washer a starter motor lead wire bolt b 6 0.6 5 shim b starter ...

  • Page 287

    9-16 electrical system starter motor inspection carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Make sure that the length a is not less than 3.5 mm. If this length becomes less than 3....

  • Page 288

    Electrical system 9-17 starter motor reassembly reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • apply grease to the bearing and lip of oil seal. . 99000-25010: suzuki super grease “a” or equivalent • apply a little suzuki moly paste to the...

  • Page 289

    9-18 electrical system starter motor installation • apply grease to the o-ring 1. . 99000-25010: suzuki super grease “a” or equivalent • install the starter motor. • tighten the starter motor mounting bolts 1 and lead wire screw 2 to the specified torque. + starter motor mounting bolt: 6 n·m (0.6 kg...

  • Page 290

    Electrical system 9-19 starter relay inspection • remove the battery cover and right side leg shield. ( !8-8) • disconnect the battery - lead wire from the battery. • disconnect the starter motor read wire, battery + lead wire and starter relay coupler 1. • remove the starter relay 2. • apply 12 v t...

  • Page 291

    9-20 electrical system side-stand/ignition interlock system parts inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-s...

  • Page 292

    Electrical system 9-21 check there is continuity between the terminals 2 and 3 when 12 v battery voltage is applied; positive to the terminal 4 and negative to the terminal 5. If no continuity is noted, the relay must be replaced. Turn signal relay inspection • remove the front leg shield. ( !8-6) i...

  • Page 293: Ignition System

    9-22 electrical system ignition system note: the fuel cut-off circuit is incorporated in this ecm in order to prevent over-running of engine. When engine speed reaches 10 000 r/min, this circuit cuts off fuel at the fuel injector. # troubleshooting no spark or poor spark note: make sure the engine s...

  • Page 294

    Electrical system 9-23 step 2 1) measure the battery voltage between input lead wires (r/w and b/w) at the ecm with the ignition switch in the “on” position. Is the voltage ok? Step 3 measure the ignition coil primary peak voltage. ( !9-24) note: the ignition coil peak voltage inspection method is a...

  • Page 295

    9-24 electrical system inspection ignition coil primary peak voltage • remove the front frame cover. ( !8-8) • disconnect spark plug cap. • with the spark plug cap connected, place a new spark plug on the engine to ground it. Note: * check that all the couplers are connected. * check that the batter...

  • Page 296

    Electrical system 9-25 ignition coil resistance • remove the front frame cover. ( !8-8) • disconnect the ignition coil read wires. Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a n...

  • Page 297

    9-26 electrical system ckp sensor resistance • measure the resistance between the lead wires and ground. If the resistance is not as specified, the ckp sensor must be replaced. $ ckp sensor resistance: 158 – 238 Ω (w – g) ∞Ω (w – ground) " 09900-25008: multi-circuit tester set ( tester knob indicati...

  • Page 298: Combination Meter

    Electrical system 9-27 combination meter removal and disassembly • remove the speedometer. ( !8-5) • disassemble the speedometer, as shown. # when disconnecting and reconnecting the speedome- ter coupler, make sure to turn off the ignition switch, or electronic parts may get damaged..

  • Page 299

    9-28 electrical system inspection water temperature meter • remove the frame covers. ( !8-9) • disconnect the water temperature switch lead wire 1. • with the ignition switch turned on and a variable resister con- nected between the b/g lead wire and ground check for the water temperature meter need...

  • Page 300

    Electrical system 9-29 fuel level gauge inspection measure resistance between the terminals when the float is at the position instead below. " 09900-25008: multi-circuit tester set • if the resistance measured is out of the specification, replace the fuel pump a new one. Fuel float position resistan...

  • Page 301: Lamps

    9-30 electrical system lamps headlight, position light, brake light/taillight, license plate light and turn signal light headlight 12 v 55 w 1 × 2 position light 12 v 5 w 2 × 2 turn signal front: 12 v 21 w 3 × 2 brake light/taillight 12 v 21/5 w 4 × 2 turn signal rear: 12 v 16 w 5 × 2 licence plate ...

  • Page 302

    Electrical system 9-31 bulb replacement headlight • remove the front leg shield. ( !8-6) • remove the headlight bulb terminals 1 and rubber boot 2. • remove the headlight bulb by unhooking the bulb holder spring 3. • install new bulb and reassemble the headlight in the reverse order of the above pro...

  • Page 303

    9-32 electrical system front turn signal light • remove the front leg shield. ( !8-6) • turn the socket counterclockwise and remove it. • replace the bulb with a new one. • reinstall the socket and front leg shield in the reverse order of removal. Rear turn signal light • remove the lower frame cove...

  • Page 304

    Electrical system 9-33 brake light/taillight • remove the lower frame cover. ( !8-9) • move the rear fender downward. • turn the socket counterclockwise and remove it. • replace the bulb with a new one. • reinstall the socket and lower frame cover in the reverse order of removal. Trunk light • remov...

  • Page 305

    9-34 electrical system • replace the bulb with a new one. • reinstall the lens. Headlight beam adjustment the headlight beam can be adjusted vertically if necessary. • turn the adjuster 1 clockwise or counterclockwise with a screwdriver..

  • Page 306: Switches

    Electrical system 9-35 switches ignition switch removal and installation removal • remove the front leg shield. ( !8-6) • remove the right inner front box 1. • remove the torx bolt and nut. " 09930-11930: torx bit (jt30h) 09930-11940: bit holder • disconnect the seat lock cable. • remove the ignitio...

  • Page 307

    9-36 electrical system inspection check for continuity between each terminal. If any abnormal condition is noted, replace the switch. " 09900-25008: multi-circuit tester ignition switch r o g/w o/y on off lock dimmer switch color position w y y/w hi ( !) lo ( ") color position engine stop switch o/b...

  • Page 308: Battery

    Electrical system 9-37 battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a. Note: whe...

  • Page 309

    9-38 electrical system note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 310

    Electrical system 9-39 servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 311: Servicing Information

    Servicing information 10-1 10 servicing information contents troubleshooting ............................................................................... 10- 2 fi system malfunction code and defective condition.................................................................... 10- 2 engine ........

  • Page 312: Troubleshooting

    10-2 servicing information troubleshooting fi system malfunction code and defective condition dtc no. Detected item detected failure condition check for 00 no fault ––––––––––– ––––––––––– 12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor ...

  • Page 313

    Servicing information 10-3 dtc no. Detected item detected failure condition check for 23 to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v sensor voltage in other than the above value, 23 (p1651) is indicated. To sensor, lead wire...

  • Page 314

    10-4 servicing information engine dtc no. Detected item detected failure condition check for 42 ignition switch ignition switch signal is not input to the ecm. Ignition switch, lead wire/coupler, etc. P1650 44 ho2 sensor ho2 sensor output voltage is not input to ecm during engine operation and runni...

  • Page 315

    Servicing information 10-5 complaint symptom and possible causes remedy engine idles poorly. 1. Valve clearance out of adjustment 2. Poor seating of valves 3. Defective valve guides 4. Worn rocker arms or cam surfaces 5. Too wide spark plug gap 6. Defective ignition coil 7. Defective ckp sensor 8. D...

  • Page 316

    10-6 servicing information complaint symptom and possible causes remedy noisy engine excessive valve chatter 1. Too large valve clearance 2. Weakened or broken valve springs 3. Worn rocker arm or cam surface 4. Worn and burnt camshaft journal noise seems to come from piston 1. Worn down piston or cy...

  • Page 317

    Servicing information 10-7 complaint symptom and possible causes remedy engine runs poorly in high speed range. Defective engine internal/electrical parts 1. Weakened valve springs 2. Worn camshaft 3. Valve timing out of adjustment 4. Too narrow spark plug gap 5. Ignition not advanced sufficiently d...

  • Page 318

    10-8 servicing information complaint symptom and possible causes remedy engine lacks power. Defective engine internal/electrical parts 1. Loss of valve clearance 2. Weakened valve springs 3. Valve timing out of adjustment 4. Worn piston rings or cylinder 5. Poor seating of valves 6. Fouled spark plu...

  • Page 319

    Servicing information 10-9 radiator (cooling system) complaint symptom and possible causes remedy engine overheats defective engine internal parts 1. Heavy carbon deposit on piston crown 2. Not enough oil in the engine 3. Defective oil pump or clogged oil circuit 4. Sucking air from throttle body jo...

  • Page 320

    10-10 servicing information chassis complaint symptom and possible causes remedy heavy steering 1. Overtightened steering stem nut 2. Broken bearing in steering stem 3. Distorted steering stem 4. Not enough pressure in tires adjust. Replace. Replace. Adjust. Wobbly handlebars 1. Loss of balance betw...

  • Page 321

    Servicing information 10-11 brakes complaint symptom and possible causes remedy insufficient brake power 1. Leakage of brake fluid from hydraulic system 2. Worn pads or disc 3. Oil adhesion on friction surface of pads 4. Worn shoes or drum 5. Air in hydraulic system 6. Friction surfaces of pads are ...

  • Page 322

    10-12 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking 1. Defective ignition coil 2. Defective spark plug 3. Defective ckp sensor 4. Defective ecm 5. Defective to sensor 6. Open-circuited wiring connections replace. Replace. Replace. Replace....

  • Page 323

    Servicing information 10-13 battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates 1. Cracked battery case 2. Battery has been left in a run-down condition for a long time replace the battery. Replace the battery. Battery...

  • Page 324: Wiring Diagram

    10-14 servicing information wiring diagram b bl br g gr lbl lg o r w y b/g b/bl b/r b/w b/y g/bl o/b o/bl o/r o/w o/y w/b y/b y/g y/w : black : blue : brown : green : gray : light blue : light green : orange : red : white : yellow : black with green tracer : black with blue tracer : black with red t...

  • Page 325

    Servicing information 10-15 wiring harness, cable and hose routing wiring harness routing handlebar switch (rh & lh) front brake hose rear brake hose throttle cables clamp clamp clamp ignition switch lead wire to sensor side-stand relay turn signal relay wiring harness engine ground wire white tape ...

  • Page 326

    10-16 servicing information fuel pump clamp side-stand switch clamp clamp wiring harness clamp wiring harness generator ho2 sensor starter motor engine ground wire clamp wiring harness generator wiring harness engine ground wire starter motor battery + cap battery + terminal battery - terminal batte...

  • Page 327

    Servicing information 10-17 cable routing front brake hose handlebar switch (r) clamp clamp cable guide bolt cable guide clamp rear brake pipe rear brake hose handlebar switch (l) throttle cable no.1 (pulling cable) throttle cable no.1 (pulling cable) throttle cable no.2 (returning cable) throttle c...

  • Page 328

    10-18 servicing information cooling system hose routing overflow hose reservoir radiator cap radiator inlet hose radiator outlet hose white mark overflow hose radiator cooling fan switch radiator inlet hose radiator outlet hose radiator outlet hose radiator inlet hose clamp white mark thermostat cov...

  • Page 329

    Servicing information 10-19 brake hose routing rear brake pipe front brake hose clamp rear brake hose pass through the rear brake hose into the hose guide. Engage the brake hose clamps front brake hose delay valve hose brake hose joint clamp front brake caliper tighten the brake hose union bolt to t...

  • Page 330

    10-20 servicing information engine electrical parts harness routing *1 *2 high tension code ignition coil starter motor starter motor lead wire starter motor lead wire bolt ground wire grommet ckp sensor generator stator starter motor *1 bring the tip of spark plug cap to downward. *2 pass the high ...

  • Page 331

    Servicing information 10-21 ho2 sensor harness routing clamp ho2 sensor clamp ho2 sensor 48 n.M (4.8 kgf-m) *1 *1 pass the ho2 sensor lead wire between the frame and engine. Do not protrude the ho2 sensor lead wire from the frame..

  • Page 332

    10-22 servicing information speedometer cable routing *2 *1 1 speedometer *1 pass through the speedometer cable into the cable guide. 2 cable guide *2 tighten the front axle nut to the specified torque after touching the stopper of speedometer gear box to the stopper of front fork outer tube. 3 spee...

  • Page 333

    Servicing information 10-23 throttle body hose routing upper upper lower lower lh rh lh rh clamp a clamp b 18 n.M (1.8 kgf-m) *2 *1 fuel hose fuel hose ect sensor clamp iap sensor fuel tank throttle body *1 face the tab of intake pipe insulator to forward, when installing it. *2 align the arrow mark...

  • Page 334

    10-24 servicing information drain hose routing 1 footboard 3 drain hose 2 radiator duct 4 rear lower leg shield.

  • Page 335

    Servicing information 10-25 seat molding installation fwd 120 mm outside 1 end of seat molding 3 trunk box 2 seat molding.

  • Page 336

    10-26 servicing information exterior parts set-up windscreen lower meter panel inner front box front cover front leg shield front box lower leg shield *1 *2 *3 *4 *1 *1 *4 *1 *1 to frame *3 to side leg shield *2 from footboard *4 to rear lower leg shield.

  • Page 337

    Servicing information 10-27 rear footboard rear footboard side leg shield rear lower leg shield footboard side leg shield *1 *3 *1 *2 *3 *1 *3 *1 to front box *3 from lower leg shield *2 to frame.

  • Page 338

    10-28 servicing information center frame cover lower frame cover rear combination light rear fender frame cover (rh) footboard upper trunk box frame cover (lh) lower trunk box front frame cover *1 *2 *1 *1 *2 *2 *2 *1 *1 to frame *2 to footboard.

  • Page 339

    Servicing information 10-29 drive belt cooling filter and clutch cover gasket installation clutch cover gasket clutch cover drive v-belt cooling duct cover drive v-belt cooling filter.

  • Page 340

    10-30 servicing information front box cushion installation 1 front box 3 cushion 2 adhint of cushion.

  • Page 341

    Servicing information 10-31 side-stand installation center stand installation ! Item n·m kgf-m a 10 1.0 b 40 4.0

  • Page 342

    10-32 servicing information special tools 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-20102 vernier calipers (1/20 mm, 200 mm) 09900-20202 micrometer (1/100 mm, 25 – 50 mm) 09900-20203 micrometer (1/100 mm, 50 – 75 mm) 09900-20205 micrometer (1/1 000 mm, 0 – 25 mm) 09900-20530 cy...

  • Page 343

    Servicing information 10-33 09910-32812 crankshaft installer 09910-32840 crankshaft installer attachment 09913-50121 oil seal remover 09913-70210 bearing installer set 09915-64512 compression gauge 09915-63311 (adaptor) 09915-70610 oil pressure gauge adaptor 09915-74511 oil pressure gauge 09915-7452...

  • Page 344

    10-34 servicing information 09920-13120 crankcase/ crankshaft separator 09921-20210 bearing remover (12 mm) 09921-20240 bearing remover set 09922-21410 long socket wrench (46 mm) 09922-31420 clutch spring compressor 09923-73210 bearing remover 09924-84521 bearing installer set 09925-18011 steering b...

  • Page 345

    Servicing information 10-35 note: before placing order for the special tool, please check for availability. 09940-30230 hexagon socket (17 mm) 09940-34520 t-handle 09940-34531 attachment (a) 09940-40211 fuel pressure gauge adapter 09940-40220 fuel pressure gauge hose attachment 09940-51410 steering ...

  • Page 346: Tightening Torque

    10-36 servicing information tightening torque engine item n·m kgf-m cylinder head cover bolt initial 10 1.0 final 14 1.4 camshaft journal holder bolt 10 1.0 cylinder head bolt initial 25 2.5 final 42 4.2 cylinder head nut 6 mm 10 1.0 cylinder nut 6 mm 10 1.0 rocker arm adjuster lock-nut 10 1.0 exhau...

  • Page 347

    Servicing information 10-37 fi system and intake air system cooling system chassis item n·m kgf-m ckp sensor bolt 5 0.5 ho2 sensor 48 4.8 fuel pump retainer 35 3.5 tp sensor mounting screw 1.8 0.18 item n·m kgf-m cooling fan thermo-switch 12 1.2 engine coolant temperature gauge 13 1.3 water pump mou...

  • Page 348

    10-38 servicing information tightening torque chart for other bolts and nuts listed previously, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m n·m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9 50 5.0 12 45 ...

  • Page 349: Service Data

    Servicing information 10-39 service data valve + valve guide unit: mm camshaft + cylinder head unit: mm item standard limit valve diam. In. 22.0 — ex. 19.0 — valve clearance (when cold) in. 0.05 – 0.10 — ex. 0.17 – 0.22 — valve guide to valve stem clearance in. 0.010 – 0.037 — ex. 0.030 – 0.057 — va...

  • Page 350

    10-40 servicing information cylinder + piston + piston ring unit: mm conrod + crankshaft unit: mm oil pump clutch unit: mm item standard limit compression pressure 1 650 kpa (16.5 kgf/cm²) 1 500 kpa (15.0 kgf/cm 2 ) piston to cylinder clearance 0.020 – 0.030 0.120 cylinder bore 57.000 – 57.015 no ni...

  • Page 351

    Servicing information 10-41 transmission unit: mm except ratio injector + fuel pump + fuel pressure regulator fi sensors throttle body item specification note reduction ratio variable change (2.829 – 0.744) — final reduction ratio 9.166 (44/16 × 50/15) — drive v-belt width 22.4 21.4 movable driven f...

  • Page 352

    10-42 servicing information thermostat + radiator + fan + coolant item standard/specification limit thermostat valve opening temper- ature approx. 82 °c — thermostat valve lift over 3 mm at 95 °c — engine coolant temperature sensor resistance 20 °c approx. 2.45 k Ω — 50 °c approx. 0.81 k Ω — 80 °c a...

  • Page 353

    Servicing information 10-43 electrical unit: mm wattage unit: w item standard/specification note spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 spark performance over 8.0 at 1 atm. Ckp sensor resistance 158 – 238 Ω w – g ckp sensor peak voltage 2.0 v and more + probe: w, - probe: g ignition...

  • Page 354

    10-44 servicing information brake + wheel unit: mm suspension unit: mm tire unit: mm item standard limit brake disc thickness front 4.5 ± 0.2 4.0 rear 4.5 ± 0.2 4.0 brake disc runout — 0.30 master cylinder bore front 11.000 – 11.043 — rear 14.000 – 14.043 — master cylinder piston diameter front 10.9...

  • Page 355

    Servicing information 10-45 fuel + oil item specification note fuel type gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recom- mended. Fuel tank capacity 11.0 l engine oil and final gear box oil type sae 10w-40, api sf/sg or sh/sj with jaso ma engine oil capacity oi...

  • Page 356

    Prepared by october, 2006 part no. 99500-31350-01e printed in japan 364.

  • Page 357

    Printed in japan k7.