Suzuki GSX-R1000 manual

FOREWORD GROUP INDEX COOLING AND LUBRICATION SYSTEM FUEL SYSTEM AND THROTTLE BODY EMISSION CONTROL INFORM A TION ~----. B =================== ___ B ~-_. I PERIODIC MAINTENANCE I GENERAL INFORMA TlON I FI SYSTEM DIAGNOSIS I ENGINE I EXHAUST SYSTEM I CHASSIS I ELECTRICAL SYSTEM I WIRING DIAGRAM I SERVICING INFORMA TlON * This manual has been prepared[...]

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 the first page of each section to help you find th[...]

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. • Apply THREAD LOCK SUPER "1360" . Data beside it indicates specified 99000-32130 torque. l!r A[...]

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 ATM Pressure: Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor) A/F : Air Fuel Mixture E ECM : Engine Control Module Engine Control Unit (EC[...]

M MAL-Code Max MIL Min N NOX o OHC OPS p PCV R RH ROM S SAE STC System STP Sensor ST Valve STV Actuator T TO Sensor TP Sensor TPC Valve : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshaft : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right[...]

SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION A Air Cleaner ACl Air Cleaner, Air Cleaner Box B Barometric Pressure BARO Bar[...]

SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION G Generator GEN Generator Ground GND Ground (GND, GRD) I Idle Speed Control ISC - Ignition Control IC Electronic Spark Advance (ESA) Ignition Control Module ICM - Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature M I Malfunction Indicator Lamp MIL LED Lamp Malfunction Indicat[...]

WIRE COLOR B : Black Gr : Gray R : Red BI : Blue Lbl : Light blue W : White Br : Brown Lg : Light green Y : Yellow Dg : Dark green 0 : Orange G : Green P : Pink BIBI BIG BIR BN BI/G BI/W GIB G/W GrlB Gr/W OIB OIR ON P/w RIBI WIB WIR YIBI YIR : Black with Blue tracer : Black with Green tracer : Black with Red tracer : Black with Yellow tracer : Blue[...]

GENERAL INFORMATION 1·1 I GENERALWFORMATION CONTENTS WARNING/CAUTION/NOTE 1- 2 GENERAL PRECAUTIONS ........................................... . . .. ..... .... .. ... ... ..... • . . .. . 1- 2 SUZUKI GSX-R1000K3 ('03-MODEL) .......................•.................................. 1- 4 SERIAL NUMBER LOCA TION ............•............[...]

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. A WARNING Indicates a potential hazard that could result in[...]

GENERAL INFORMATION 1·3 !CAUTIONI * 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 special tools when instructed. * Make su[...]

1-4 GENERAL INFORMATION SUZUKI GSX-R1000K3 ('03-MODEL) RIGHT SIDE LEFT SIDE • Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the right side of the steering head pipe. The engine serial number (2) is located[...]

GENERAL INFORMATION 1·5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) R M Use only unleaded gasoline of at least 90 pump octane ( ~ ). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER C[...]

1·6 GENERAL INFORMATION FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT[...]

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 performance and reliability of the engine depend[...]

1-8 GENERAL INFORMATION INFORMATION LABELS GSX-R1000 GSX-R1000UF G) Noise label o For E-03, 24, 33 Cllinformation label o For E-03, 28, 33 @ Vacuum hose routing label o For E-33 @ Fuel caution label o For E-02, 24 @ Fuel information label 0 0 @ Manual notice label o For E-03, 33 (f) Frame caution plate 0 0 @ Warning screen label 0 0 ® Warning stee[...]

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length . Overall width . Overall height .. Wheelbase . Ground clearance . Seat height . Dry mass . ENGINE Type . Number of cylinders .. Bore . Stroke . Displacement . Compression ratio . Fuel system . Air cleaner . Starter system . Lubrication system . Idle speed . DRIVE TRAIN Clutch .. Transmission . [...]

1·10 GENERAL INFORMATION CHASSIS Front suspension Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front fork stroke...................................................................... 120 mm (4.7 in) Rear wheel travel...... 130 mm (5.1 in) Steering angle.............................................[...]

COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). GENERAL INFORMATION 1·11 MODEL CODE COUNTRY or AREA E-02 U.K. E-03 U.S.A. (Except for california) GSX-R1000 E-19 EU E-24 Australia E-28 Canada E-33 California (U.S.A.) GSX-R1000UF E-19 EU[...]

PERIODIC MAINTENANCE 2-1 I PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ...•..•.•••.•...••....•....................... ...... .. 2- 2 PERIODIC MAINTENANCE CHART ....................•.•......•.....•.......•.••....... 2- 2 LUBRICATION POINTS ................................................ ... ....... ..[...]

2·2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. IMPORTANT: The periodic maintenance inter[...]

PERIODIC MAINTENANCE 2-3 ~I miles 600 4 000 7500 11 000 14500 km 1 000 6 000 12 000 18 000 24000 Item months 1 6 12 18 24 - I III Brake fluid Replace every 2 years. Tires - I I I I Steering I - I - I Front forks - - I - I Rear suspension - - I - I Exhaust pipe bolts and muffler bolt and nut T - T - T Chassis bolts and nuts T T T T T NOTE: t-tnsoect[...]

2-4 PERIODIC MAINTENANCE 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. o ~~ ~ Brake pedal pivot and footrest pivot A Clutch lever holder NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease[...]

MAINTENANCE AND TUNE-UP '-/ PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4000 miles, 6 months). Replace every 18 000 km (11 000 miles, 18 months). • Remove the front and rear seats. (c::::rS-6) • Lift and support the fuel tank. (c::::r[...]

2-6 PERIODIC MAINTENANCE SPARK PLUG Inspect at 6 000 km (4 000 miles, 6 months) and repla- ce every 12 000 km (7500 miles, 12 months) thereafter. SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL • Remove the front and rear seat. (c:::7'8-6) • Lift and support the fuel tank. (c:::7'5-5) • Remove the air cleaner box. (c:::7'5-15) ?[...]

SPARK PLUG GAP • Measure the spark plug gap with a thickness gauge. • Adjust the spark plug gap if necessary. _ Spark plug gap: Standard: 0.7 - 0.8 mm (0.028 - 0.031 in) I-fcXiti 09900-20803: Thickness gauge ELECTRODE'S CONDITION • Check the condition of the electrode. • If it is extremely worn or burnt, replace the spark plug. Replace[...]

2·8 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months). • Remove the right under cowling. (c::::Ta-3) • Remove the front and rear seats. (c::::Ta-6) • Lift and support the fuel tank. (c::::TS-S) • Remove the spark plugs. (c::::T2-6) • Remove the cylinder head covers. (c::::T3-1S) The valve clearance sp[...]

• Turn the crankshaft to bring the "Top" line on the starter clutch to the index mark and also to bring the notches ® on the left ends of both camshafts (Ex and In) to the positions as shown. • In this condition, read the valve clearance at the valves ® (In and Ex of No.4 cylinder, Ex of No.3 and In of No.2). • If the clearance is[...]

2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. (c::::r3-16) • Remove the tappet and shim by fingers or magnetic hand. • Check the figures printed on the shim. These figures indicate the thickness of the[...]

TAPPET SHIM SELECTION TABLE [INTAKE] TAPPET SHIM NO. (12892-05COO-XXX) I TAPPET SHIM SET (12800-05830) I -- ( -:::: Z -f » " m ~ c m - SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 NO. MEASURED VALVE PRESENT CLEARANCE SHIM SIZE (mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 ,7() 1.75 1[...]

I TAPPET SHIM SET (12800-05830) I TAPPET SHIM SELECTION TABLE [EXHAUST] TAPPET SHIM NO. (12892-05COO-XXX) SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 NO. MEASURED VALVE PRESENT CLEARANCE SHIM SIZE (mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 t."7P 1.75 1.80 1.85 1.90 1.95 2.00 2.05 [...]

I i ! ~ ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 months) and every 18 000 km (11 000 miles, 18 months) thereafter. ENGINE OIL REPLACEMENT • Remove the under cowling. (c:=ra-3) • Keep th[...]

2-14 PERIODIC MAINTENANCE OIL FILTER REPLACEMENT • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter G) with the special tool. l;!fotl 09915-40610: Oil filter wrench • Apply engine oil lightly to the gasket of the new oil filter before installation. • Install the new oil filter. Turn it by [...]

• Remove the two bolts and cover. • Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. FUEL LINE Inspect initially at 6 000 km (4000 miles, 6 months). Replace every 4 years. • Inspect the fuel hose G) for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.[...]

2·16 PERIODIC MAINTENANCE THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 1 months) (E-33 only) and every 12 000 km (7 500 miles, 12 moths). Inspect the throttle valve synchronization periodically. (c::::TS-2S) EVAPORATIVE EMISSION CONTROL SYS- TEM (E-33 ONLY) Inspect every 12 000 km (7500 miles, 12 months). Replace vapor [...]

THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Adjust the throttle cable play ® as follows. MINOR ADJUSTMENT 1st step: • Loosen the lock-nut CD of the throttle returning cable (2) and fully turn in the adjuster @. 2nd step: • Loosen the lock-nut @ of the throttle pu[...]

2·18 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Lift and support the fuel tank with its prop stay. (c::::::r5-5) • Loosen the lock-nuts CD of the throttle returning cable CZl. • Turn the returning cable adjuster @ to obtain proper cable play. • Loosen the lock-nuts @ of the throttle pulling cable @. • Turn the pulling cable adjuster @ in or[...]

~ I COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. Replace radiator hoses every 4 years. ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Remove the under cowling. (c::::ra-3) • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir.[...]

2·20 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • 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 radiator in[...]

RADIATOR HOSES • Remove the under cowling. (c::::T8-3) • Check the radiator hoses for crack, damage or engine coolant leakage. • If any defect is found, replace the radiator hose with new one. PERIODIC MAINTENANCE 2·21[...]

* Excessive wear * Improper chain adjustment * Missing O-ring seals 2-22 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects listed below. (Support the motorcy[...]

• Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. _ Drive chain 20-pitch length: Service limit: 319.4 mm (12.57 in) ADJUSTING • Loosen or tighten both chain adjuster bolts CD until there is 20 - 30 mm (0.8 - 1.2 in) of slack at th[...]

2-24 PERIODIC MAINTENANCE CLEANING AND LUBRICATING • Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. I CAUTION I Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to clean the drive chain. • After washing and dryi[...]

r l i I~ BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fluid every 2 years. BRAKE FLUID LEVEL CHECK • Keep the motorcycle upright and place the handlebars strai[...]

2-26 PERIODIC MAINTENANCE Rear brake • The extent of brake pad wear can be checked by observing the grooved limit line ® on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (c::::T"8-65) I CAUTION I Replace the brake pads as a set, otherwise braking performance will be adversely affected. BRAKE PEDAL HE[...]

AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by "sponginess" of the brake lever and also by lack of[...]

2-28 PERIODIC MAINTENANCE REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal. TIRES Inspect every 6 000 km (4 000 miles, 6 months). TIRE TREAD CONDITION Operating the motorcycle with excessive[...]

STEERING Inspect initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no p[...]

2·30 PERIODIC MAINTENANCE EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7500 miles, 12 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. t!J 25 Nrn ( 2. 5 kgt-m) 18.0 Ib-ft ~ ~ t!J 23 N·m ( 2 . 3 kgt-m) 16.5Ib-ft "<, ~ ./(@C@ [...]

PERIODIC MAINTENANCE 2·31 CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 1 month) and every 6000 km (4000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-32 for the loca- tions of the following nuts and bolts on the motorcycle.) Item N·m kgf-m Ib-ft CD [...]

2·32 PERIODIC MAINTENANCE[...]

PERIODIC MAINTENANCE 2-33 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance [...]

2-34 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 100 - 400 kPa (1.0 - 4.0 kgf/cm 2 , 14 - 57 psi) at 3 000 r/min., Oil temp. at 60°C (140 OF) If the oil pressure is lower or higher than the specification, the fo[...]

ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 3- 2 ENGINE REMOVAL AND INSTALLATION ....................•..................... ... ..... . 3- 3 ENGINE REMOVAL ..................................................•............................. 3- 3 ENGINE INSTALLA TION .................•............••...........••.......[...]

3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION REINSTALLATION PAIR valve L7'3-28 L7'3-28 L7'3-28 Starter[...]

ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Remove the under cowlings. (c:::::TS-3) • Remove the front and rear seats (seat tail cover). [...]

3·4 ENGINE • Remove the air cleaner box. (c::::T5-15) • Remove the throttle body. (c::::T5-16) OIL COOLER • Remove the oil cooler pipes. • Remove the oil cooler. RADIATOR • Disconnect the reservoir inlet hoses.[...]

• Disconnect the cooling fan coupler CD. • Disconnect the cooling fan thermo-switch coupler (2). • Remove the radiator mounting bolts. • Remove the radiator. I CAUTION I I Be careful not to bent the radiator fin. • Remove the front engine cover. EXHAUST PIPE AND MUFFLER • Remove the exhaust pipe bolts. • With the muffler connecting bo[...]

3·6 ENGINE • Remove the radiator mounting bracket G) and the oil cooler mounting bracket (2). G) ELECTRIC PARTS • Disconnect the oil pressure switch lead wire G) and remove it from the clamps. • Disconnect the starter motor lead wire (2). • Disconnect the ground lead wire @. • Disconnect the crankshaft position sensor coupler @. • Disc[...]

• Disconnect the couplers from each ignition coil/plug cap and camshaft position sensor. ! CAUTION I Do not remove the ignition coil/plug cap before dis- connecting its coupler. • Remove the ignition coils/plug caps. I CAUTION I * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage. * Be careful not to drop[...]

3-8 ENGINE • Remove the cotter pin. (For E-03, 28, 33) • Loosen the rear axle nut @. • Loosen the left and right chain adjusters @. • Push the rear wheel forward and make sure that the drive chain has enough slack. • Disengage the drive chain from the rear sprocket. • Remove the engine sprocket @. ENGINE MOUNTING • Support the engine [...]

• Loosen the engine mounting pinch bolts CD and (2). • Remove the engine mounting bolts @ and ©. • Remove the engine mounting nut @. • Remove the engine mounting thrust adjuster lock-nut (f) with the special tool. • Loosen the engine mounting thrust adjuster @ fully. Ir1iotl 09940-14990: Engine mounting thrust adjuster socket wrench • [...]

3·10 ENGINE • Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft. • Remove the engine assembly. ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Be careful not to damage the frame and eng[...]

• Tighten all engine mounting bolts and nuts to the specified torque. (c:::::r3-12) NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. • Tighten the engine mounting pinch bolt to the specified torque. (c:::::r3-12) ENGINE 3·11[...]

3-12 ENGINE @ r==r===r=;==r--- @ @ ~====="~/ n(® c::> Right Left¢::l © ~ ITEM N·m kgf-m Ib-ft LENGTH ®@©© 55 5.5 39.8 ITEM mm in ®© 45 1.77 @@ 75 7.5 54.0 Bolt @© 55 2.17 (1)(2) 23 2.3 16.5 ®® 215 8.46 ®® 23 2.3 16.5 Spacer @@ 30.5 1.20 CV@ 45 4.5 32.5 Adjuster ®® 40 1.57[...]

1,,-, • Install the engine sprocket and the washer. • Apply a small quantity of THREAD LOCK to the drive shaft thread portion. ~99000-32050: THREAD LOCK "1342" • Tighten the engine sprocket nut CD to the specified torque. ~ Engine sprocket nut: 115 N·m (11.5 kgf-m, 83.2 Ib-ft) • Install the speed sensor rotor. • Tighten the spe[...]

3-14 ENGINE • Install the radiator mounting bracket CD and oil cooler bracket ~. • Install the exhaust pipe. I CAUTION I I Replace the gaskets with new ones. ~ Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) ~ Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) • Fit the new a-ring @. • Apply THREAD LOCK to the bolts, install the oi[...]

ENGINE DISASSEMBLY I CAUTION I Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the spark plugs. ([72-6) STARTER MOTOR • Remove the starter motor. PAIR CONTROL VALVE • Remove the PAIR control valve CD. CYLIN[...]

3·16 ENGINE • Remove the dowel pins and O-rings. CAMSHAFTS • Remove the valve timing inspection cap CD. • Turn the crankshaft to bring the line ® on the starter clutch to the index mark ® of the valve timing inspection hole and also to bring the cams to the position as shown. • Remove the cam chain tension adjuster cap bolt ~. • Remove[...]

I~ • Remove the cam chain guide @, • Remove the intake camshaft journal holder @. • Remove the exhaust camshaft journal holder @. • Remove the dowel pins. I CAUTION ! Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally. • Remove the intake camshaft @. • Remove the exhaust camshaft (f). CYLINDER H[...]

3·18 ENGINE CLUTCH • Remove the clutch cover. • Hold the clutch housing with the special tool. I CAUTION I Do not damage the clutch plates by the special tool. i-Mot, 09920-53740: Clutch sleeve hub holder • Remove the clutch springs. NOTE: Loosen the clutch spring set bolts little by little and diagonally. • Remove the pressure plate and c[...]

• Unlock the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. ,Qt. 09920-53740: Clutch sleeve hub holder • Remove the clutch sleeve hub nut. • Remove the concaved washer @, washer @, clutch sleeve hub @ and washer 0. • Remove the spacer @ and bearing ®. • Remove the primary driven gear assembly @. NOTE: If it [...]

3·20 ENGINE OIL PUMP • Remove the snap ring CD. • Remove the oil pump driven gear (2). NOTE: Do not drop the circlip CD, the pin @ and the washer @ into the crankcase. • Remove the pin @ and the washer @. • Remove the oil pump @. GEAR SHIFT SYSTEM • With the snap ring CD and washer removed, remove the gear- shift shaft assembly (2). • [...]

STARTER IDLE GEAR • Remove the starter idle gear cover. • Remove the dowel pins and gasket. • Remove the shaft CD, washer r2), starter idle gear No.1 @, con caved washer, bearing and washer. • Remove the starter clutch cover and clamp. • Remove the dowel pins and gasket. • Remove the wave washer @, the starter idle gear No.2, @ and its [...]

3-22 ENGINE STARTER CLUTCH • Hold the starter clutch with the special tool. iKiOti 09920-34830: Starter clutch holder • Remove the starter clutch bolt and washer. • Remove the starter clutch assembly and washer. CAM CHAIN, CAM CHAIN TENSIONER, CAM CHAIN GUIDE • Remove the cam chain tensioner CD and cam chain guide ~. • Remove the cam chai[...]

GENERATOR COVER • Remove the generator cover. GENERATOR ROTOR • Hold the generator rotor with the special tool. Irut. 09930-44520: Rotor holder • Remove the generator rotor bolt. • Install a bolt ® of suitable size to the left end of crankshaft. SUITABLE BOLT ® [M12, length: 28 - 38 mm] • Remove the generator rotor with the special tool[...]

3-24 ENGINE GEAR POSITION SWITCH • Remove the gear position switch CD. • Remove the switch contacts ~ and springs @. BREATHER COVER • Remove the breather cover CD. OIL FILTER • Remove the oil filter with the special tool. (c:::::r2-14) ,;!Oot, 09915-40610: Oil filter wrench OIL PAN • Remove the oil pan CD.[...]

l~ Oil PRESSURE REGULATOR • Remove the oil pressure regulator CD. Oil PRESSURE SWITCH • Remove the oil pressure switch (2). Oil STRAINER • Remove the oil strainer @ and O-ring. lOWER CRANK CASE • Remove the lower crankcase bolts (6 mm). • Remove the lower crankcase bolts (8 mm). • Remove the lower crankcase assembly. TRANSMISSION • Re[...]

3·26 ENGINE MIDDLE CRANKCASE • Remove the crankcase bolts. NOTE: Loosen the crankcase bolts diagonally with the smaller sizes first. • Remove the crankcase bolts (8 mm). • Remove the crankshaft journal bolts (9 mm). BALANCER SHAFT • Remove the balancer shaft CD. CRANKSHAFT • Loosen the bearing cap bolts by using 12 mm, 12 point socket wr[...]

PISTON AND CONROD • Push the conrad upward and remove the piston and conrad from the upper crankcase. I CAUTION I Be careful not to damage the cylinder wall by the con- rod. ENGINE 3·27 • Remove the piston pin circlip. • Separate the piston and conrad by driving out the piston pin. NOTE: Scribe the cylinder number on the head of the piston.[...]

3·28 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE I CAUTION I Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER CAM POSITION SENSOR • Install the oil seal CD and cam position sensor (2). [...]

PAIR CONTROL VALVE • Inspect that air flows through the PAIR control valve air inlet port to the air outlet ports. • If air does not flow out, replace the PAIR valve with a new one. • Connect the vacuum pump gauge to the vacuum port of the control valve as shown in the photograph. • Apply negative pressure of the specification slowly to the[...]

3·30 ENGINE CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. • Use the plastigauge to read the clearance at the widest por- tion, which is specified as follows: _ Camshaft journal oil clearance: Service Limit: (IN & EX): 0.150 mm (0.[...]

• If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. LD Journal holder 1.0.: Standard: (IN & EX): 24.012 - 24.025 mm (0.9454 -[...]

3-32 ENGINE CAM CHAIN TENSIONER INSPECTION • Check the contacting surface of the cam chain tensioner. • If it is worn or damaged, replace it with a new one. CAM CHAIN GUIDE INSPECTION • Check the contacting surfaces of the cam chain guides. • If they are worn or damaged, replace them with the new ones. CYLINDER HEAD AND VALVE VALVE AND VALV[...]

• Using special tools, compress the valve springs and remove the two cotter halves @ from valve stem. ITUti 09916-14510: Valve lifter 09916-14910: Valve lifter attachment 09916-84511: Tweezers I CAUTION I Be careful not to damage the tappet sliding surface with the special tool. • Remove the valve spring retainer @ and valve springs ®. • Pul[...]

3-34 ENGINE CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.[...]

I f ,. , , VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. • Measure the valve stem deflection in two directions, perpen- dicular to each other, by positioning the dial gauge as shown. • If the deflection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new o[...]

3·36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. ,rootl 09916-53310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No. 11115-11070) • Re-finish th[...]

VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. • Check that the transferred blue on the valve face is uniform all around and in center o[...]

3-38 ENGINE • When installing the solid pilot CD, rotate it slightly. Seat the pilot snugly. Install the 45 0 cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45 0 cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width @ after every cut. • If the valve seat is pitted or burned,[...]

I r ~ I , , BOTTOM NARROWING CUT • If the contact area ® is too wide or too low, use the 60 0 cutter to narrow and raise the contact area. FINAL SEAT CUT • If the contact area ® is too low or too narrow, use the 45 0 cutter to raise and widen the contact area. NOTE: After cutting the 15 0, 30 0 and 60 0 angles, it is possible that the valve s[...]

3·40 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. A WARNING Always use extreme caution when handling gasoline. VALVE STEM END CONDITION • [...]

VALVE AND VALVE SPRING REASSEMBLY • Install the valve spring seats. • Apply MOLYBDENUM OIL SOLUTION to each oil seal CD, and press-fit them into position. lIr MOLYBDENUM OIL SOLUTION I CAUTION I I Do not reuse the removed oil seals. • Insert the valves, with their stems coated with MOLYBDE- NUM OIL SOLUTION all around and along the full stem [...]

3-42 ENGINE • Install the tappet shims and the tappets to their original posi- tion. NOTE: * Apply engine oil to the shim and tappet before fitting them. * When seating the tappet shim, be sure the figure printed sur- face faces the tappet. INTAKE PIPE • Remove the intake pipe. • Install the intake pipe in the following procedure. • Apply S[...]

CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: * Wipe off engine oil from the clutch drive plates with a clean rag. * Clutch drive plate NO.1: Green paint * Clutch drive plate NO.2: Brown paint • Measure the thickness of drive plates with a vernier calipers. • If each drive plate thickness is less than the limit, replace it with a new one. ~ Drive[...]

3-44 ENGINE CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY • Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one. OIL PUMP INSPECTION • Rotate the oil pump by hand and check that it moves smoothly. • If it does not move smoothly, rep[...]

@ Plate return spring @ Washer (J) Snap ring @ Plate return spring @ Washer (J) Circlip WATER PUMP (c::?7 -14) GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. CD Washer (2) Snap ring @ Gearshift shaft return spring @ Gearshift cam drive plate GEARSHIFT SHAFT/GEARSHIFT[...]

3·46 ENGINE OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER • Inspect the oil strainer body for damage. • Clean the oil strainer if necessary.[...]

TRANSMISSION • Disassemble the countershaft and drive shaft. Pay attention to the following point. • Remove the 6th drive gear circlip from its groove and slide it towards the 3rd/4th drive gear. • Slide the 6th CD and 2nd C2l drive gears toward the 3rd/4th drive gears, then remove the 2nd drive gear circlip @. ENGINE 3·47 CD Countershatt/t [...]

3-48 ENGINE REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE: * Rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When [...]

ENGINE 3·49 C9J 8 ~~ ~ (Q) ~ I'?-o'~ ~~ ~~~ (Q) ~ ~ ~~ ~ PARTS LOCATION 8 @_ ........ o ~ C~ ~ ~ g TRANSMISSION[...]

3·50 ENGINE CYLINDER CRANKCASE SERVICING (c::=r3-53) CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. _ Cylind[...]

ENGINE 3·51 PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston outside diameter at 15 mm (0.6 in) from the piston skirt end. • If the measurement is less than the limit, replace the piston. _ Piston diameter: Service Limit: 72.880 mm (2.8693 in) at 15 mm (0.6 in) from the skirt end iT'Oot, 09900-20203: Microme[...]

3·52 ENGINE PISTON RING TO GROOVE CLEARANCE • Measure the side clearances of the 1 st and 2nd piston rings using the thickness gauge. • If any of the clearances exceed the limit, replace both the pis- ton and piston rings. 1.:&1.09900-20803: Thickness gauge 09900-20205: Micrometer (0 - 25 mm) _ Piston ring to groove clearance: Service Limi[...]

CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer CD and gearshift fork retainer ~ from the lower crankcase. • Remove the gearshift fork shafts and gearshift forks from the lower crankcase. • Remove the gear shift cam and its bearing. GEARSHIFT FORK TO GROOVE CLEARANCE • Using a thickness gauge, [...]

3·54 ENGINE GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers. ~ Shift fork thickness: Standard: 4.8 - 4.9 mm (0.189 - 0.193 in) ,roEt, 09900-20102: Vernier calipers • Inspect the gearshift cam bearing for abnormal noise and smooth rotation. • Replace the bearings if there is anything unusual. • I[...]

• Remove the oil seal @. • Remove the gearshift shaft bearing with the special tool. jT'OOt, 09921-20240: Bearing remover set (15 mm) Installation • Install the bearings with the special tool. j.;!oot, 09913-70210: Bearing installer set (15 mm) NOTE: The stamped mark side of the gearshift shaft bearing faces out- side. • Install the oi[...]

3·56 ENGINE • Install the gearshift forks and their shafts as shown. CD For 3rd/4th drive gears (2) For 6th driven gear @ For 5th driven gear • Apply a small quantity of THREAD LOCK to the bearing retainer screws and the shift fork shaft retainer bolt. • Tighten them to the specified torque. ~ 99000-32050: THREAD LOCK "1342" ~ Bear[...]

OIL JET Removal • Remove the piston cooling oil jets eD from the upper crank- case. • Remove the oil jet (for transmission) from the lower crank- case. • Remove the oil jet (2) (for cam chain tension adjuster) from the cylinder head. Inspection and cleaning • Check the oil jets for clogging. • If they are clogged, clean their oil passage [...]

3-58 ENGINE Installation • Fit the new O-rings CD to each piston cooling oil jets as shown and apply engine oil to them. [CAUTION I Use the new O-rings to prevent oil pressure leak. NOTE: Be sure the oil holes ® on each piston cooling oil jet faces the top when installing them. • Install each piston cooling oil jet with the bolt. NOTE: Apply a[...]

I , I ~. PLUGS • Install each plug. ~ G) Water jacket plug: 9.5 N·m (0.95 kgf-m, 6.9 Ib-ft) ell Oil gallery plug (upper crankcase): 18 N·m (1.8 kgf-m, 13.0 Ib-ft) @ Oil gallery plug (lower crankcase): 35 N·m (3.5 kgf-m, 25.3Ib-ft) @ Oil gallery plug (cylinder head): 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Apply engine coolant to the a-ring. ENGIN[...]

3-60 ENGINE BALANCER SHAFT DISASSEMBLY • Draw out the balancer gear and damper from the balancer shaft. INSPECTION • Inspect the damper for wear and damage, replace it if any defects are found. REASSEMBLY • Apply MOLYBDENUM OIL SOLUTION to each part. 1r MOLYBDENUM OIL SOLUTION • Set the dampers and install the balancer shaft to balancer gea[...]

• Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. _ Balancer shaft journal oil clearance: Standard: 0.020 - 0.044 mm (0.00079 - 0.00173 in) Service Limit: 0.080 mm (0.031 in) • If the oil clearance exce[...]

3·62 ENGINE INSTALLATION • When fitting the balancer shaft journal bearings to the upper and middle crankcases, be sure to fix the stopper part ® first and press the other end. I CAUTION I Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell.[...]

CRANKSHAFT AND CONROD CRANKSHAFT RUNOUT • Support the crankshaft with "V" blocks as shown, with the two end journals resting on the blocks. • Set up the dial gauge, as shown. • Rotate the crankshaft slowly to read the runout. • Replace the crankshaft if the runout is greater than the limit. _ Crankshaft runout: Service Limit: 0.05[...]

3·64 ENGINE CON ROD BIG END SIDE CLEARANCE • Inspect the conrad side clearance by using a thickness gauge. • If the clearance exceeds the limit, remove the conrad and inspect the conrad big end width and the crank pin width. • If the width exceed the limit, replace conrad or crankshaft. _ Conrod big end side clearance: Service Limit: 0.30 mm[...]

• Remove the bearing caps and measure the width of the com- pressed plastigauge using the envelope scale. This measure- ment should be taken at the widest part of the compressed plastigauge. _ Conrod big end oil clearance: Standard: 0.032 - 0.056 mm (0.0013 - 0.0022 in) Service Limit: 0.080 mm (0.0031 in) • If the oil clearance exceeds the serv[...]

'L Color code 3-66 ENGINE B Crank pin 0.0. Code 0.0. specification 1 34.992 - 35.000 mm (1.3776 - 1.3780 in) 2 34.984 - 34.992 mm (1.3773 - 1.3776 in) 3 34.976 - 34.984 mm (1.3770 - 1.3773 in) IroOt! 09900-20202: Micrometer (25 - 50 mm) B Bearing thickness Color (Part No.) Thickness Green 1 .480 - 1.484 mm (12164-40FOO-OAO) (0.0583 - 0.0584 in[...]

t CRANKSHAFT JOURNAL BEARING INSPECTION • Inspect each bearing of upper and lower crankcases for any damage. SELECTION • Place the plastigauge axially along the crankshaft journal, avoiding the oil hole, as shown. 1m 09900-22301: Plastigauge [CAUTION I Never rotate the crankshaft when a piece of plasti- gauge is installed. • Mate the lower cr[...]

3·68 ENGINE • Check the corresponding crankcase journal I.D. code number @, "A" or "B" which is stamped on the rear of upper crank- case. • Check the corresponding crankshaft journal O.D. code num- ber @, "A", "B" or "C" which is stamped on the crankshaft. _ Bearing selection table Crankshaft j[...]

_ Crankshaft journal 0.0. specification Code 0.0. specification A 34.992 - 35.000 mm (1.3776 - 1.3780 in) B 34.984 - 34.992 mm (1.3773 - 1.3776 in) C 34.976 - 34.984 mm (1.3770 - 1.3773 in) !Tuh 09900-20202: Micrometer (25 - 50 mm) _ Bearing thickness specification Color (Part No.) Thickness Green 1.488 - 1.492 mm (12229-40FOO-OAO) (0.0586 - 0.0587[...]

3·70 ENGINE CRANKSHAFT THRUST BEARING • With the crankshaft, right-side thrust bearing and left-side thrust bearing inserted in the upper crankcase, measure the thrust clearance on the left side by using the thickness gauge. ®: Right-side thrust bearing CD: Left-side thrust bearing NOTE: Pull the crankshaft to the right-side, so that there is n[...]

_ Thrust bearing selection table ENGINE 3·71 Clearance before Color Thrust bearing inserting left-side Thrust clearance thrust bearing (Part No.) thickness 2.570 - 2.590 mm 8rown 2.480 - 2.500 mm 0.070 - 0.110 mm (0.1012 - 0.1020 in) ( 12228-48800-080) (0.0976 - 0.0984 in) (0.0028 - 0.0043 in) 2.550 - 2.570 mm Red 2.460 - 2.480 mm 0.070 - 0.110 mm[...]

3·72 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. • Be sure to install the following items to the crankcase. * Crankshaft journal be[...]

• 1st ring and 2nd ring have letters "R" and "RN" marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located. PISTON AND CONROD • Rub a small quantity of M[...]

3·74 ENGINE • Install the pistons and conrods into the cylinders from upside. NOTE: When installing the pistons, the indent ® of each piston head must be brought to the exhaust side. I CAUTION I Be careful not to damage the cylinder wall and piston jet by the conrod. • Check that ID code ® on the each conrod faces intake side. I CAUTION I I [...]

• Set the crankshaft to the conrods and upper crankcase. • Apply MOLYBDENUM OIL SOLUTION to the crank pin and bearing surface. 1r MOLYBDENUM OIL SOLUTION I CAUTION I I Be sure to clean the conrod big end. • When fitting the conrod cap, make sure that I.D. code ® on each conrod faces intake valve side. • Apply engine oil to the bearing cap [...]

3·76 ENGINE • Insert the right and left-thrust bearings with oil groove ® fac- ing the crank web. NOTE: Right-thrust bearing has green painting. BALANCERSHAFT • Install the thrust washers CD, CZl and oil seal @. • Apply MOLYBDENUM OIL SOLUTION to each balancershaft journal lightly. ""if MOLYBDENUM OIL SOLUTION • Set the balancer[...]

• Apply SUZUKI BOND to the mating surface of the middle crankcase. ~99104-31140: SUZUKI BOND "1207B" (USA) II(iffiJ 99000-31110: SUZUKI BOND "1215" (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and a[...]

3·78 ENGINE • Tighten the other crankcase bolts a little at a time to equalize the pressure. ~ Crankcase bolt: (M8) initial: 15 N·m (1.5 kgf-m, 10.8Ib-ft) Final : 26 N·m (2.6 kgf-m, 19.0 Ib-ft) ~ Crankcase bolt: (M6) initial: 6 N·m (0.6 kgf-m, 4.5 Ib-ft) Final : 11 N·m (1.1 kgf-m, 8.0 Ib-ft) NOTE: Fit the new gasket to the crankcase bolt ®.[...]

TRANSMISSION • Install the bearing pins CD and the C-ring (2) on the upper crankcase. • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the bearing pin with the indent on the bearing. • Install the driveshaft assembly on the upper crankcase. NOTE: Align the bearing ring with [...]

3·80 ENGINE • Apply SUZUKI BOND to the mating surface of the lower crankcase . • 12078]99104-31140: SUZUKI BOND "1207B" (USA) 1I(!ffiJ99000-31110: SUZUKI BOND "1215" (Others) NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form[...]

• Tighten the crankcase bolts a little at a time to equalize the pressure. ~ Crankcase bolt: (M6) initial: 6 N·m (0.6 kgf-m, 4.5 Ib-ft) Final : 11 N·m (1.1 kgf-m, 8.0 Ib-ft) (M8) initial: 15 N·m (1.5 kgf-m, 10.8 Ib-ft) Final: 26 N.m (2.6 kgf-m, 19.0 Ib-ft) NOTE: * Fit the new copper washer to the crankcase bolts ®. * Fit the new gasket washer[...]

• 3-82 ENGINE OIL STRAINER • Install the O-ring. • Apply SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) I-C-A-UT-I-O-N I Use the new O-ring to prevent oil leakage. • Install the oil strainer as shown. ~ Oil strainer bolt: 10 N·m (1.0 kgf-m, 7[...]

• Install the oil pan. -.-/ NOTE: Fit the gasket washer to the oil pan bolt ®. • Tighten the oil pan bolts diagonally to the specified torque. ~ Oil pan bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) OIL PRESSURE SWITCH • Apply SUZUKI BOND to the thread part of the oil pressure switch CD and tighten it to the specified torque . • 1207~ 99104-31140: [...]

3·84 ENGINE GEAR POSITION SWITCH • Install the gear position switch contacts G) and the springs 12). • Apply the SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the gear position switch @ as shown.[...]

WATER PUMP • Apply SUZUKI SUPER GREASE to the G-ring. ICAUTIONl Use the new O-ring to prevent oil leakage. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000·25010: SUZUKI SUPER GREASE "A" (Others) • Tighten the water pump mounting bolts to the specified torque. (!J Water pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) N[...]

3·86 ENGINE • Install the generator rotor onto the crankshaft. • Install the rotor bolt with the washer. • Hold the generator rotor with the special tool and tighten its bolt to the specified torque. ,rodt, 09930-44520: Rotor holder ~ Generator rotor bolt: 120 N·m (12.0 kgf-m, 88.5 Ib-ft) GENERATOR COVER • Apply SUZUKI BOND lightly to the[...]

• Apply SUZUKI BOND light to the groove of the signal genera- tor lead wire gromet. ~99104-31140: SUZUKI BOND "1207B" (USA) 99000-31140: SUZUKI BOND "1207B" (Others) CAM CHAIN DRIVE SPROCKET • Install the cam chain drive sprocket onto the crankshaft. CAM CHAIN TENSIONER AND CAM CHAIN GUIDE • Install the cam chain . • App[...]

3·88 ENGINE • Install the starter clutch assembly onto the crankshaft. NOTE: When install the starter clutch assembly, fit the concave part ® of the starter clutch onto the convex part @ of the crankshaft. • Install the starter clutch bolt with the washer. • Hold the starter clutch with special tool and tighten its bolt to the specified tor[...]

r • Install the starter clutch cover and tighten its bolt as shown. NOTE: * Fit the wire clamp to the starter clutch cover bolt ® as shown. * Fit the new gasket washer to the starter clutch cover bolt @ as shown. I CAUTION I Use the new gasket washer to prevent oil leakage. (!J Starter idle gear cover bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) • Ins[...]

3·90 ENGINE NOTE: Hook the return spring end to the stopper@. • Check the gearshift cam stopper moves smoothly. • Rocate the gearshift cam in the neutral position. • Install the gearshift cam stopper plate after aligning the gear- shift cam pin ® with the gearshift cam stopper plate hole ®. • Apply a small quantity of THREAD LOCK to the [...]

• Install the gearshift shaft/gearshift arm @ with the washers as shown. NOTE: Pinch the gearshift arm stopper(J) with return spring ends ©. • Install the washer @ and snap ring ®. OIL PUMP • Install the O-ring to the oil pump and apply grease to it. I CAUTION I Use the new O-ring to prevent oil leakage. ~ 99000-25030: SUZUKI SUPER GREASE &[...]

3·92 ENGINE CLUTCH • Install the thrust washer onto the countershaft. NOTE: The chamfer side ® of the thrust washer faces inner side. • Install the oil pump drive gear CD to the primary driven gear assembly. NOTE: Be careful not to contact the primary driven gear with the crank- web when installing the clutch housing. • Install the primary [...]

• Install the clutch sleeve hub @ onto the countershaft. • Install the washer @ and spring washer ([). NOTE: The convex side of the spring washer ([) faces outside. • Install the clutch sleeve hub nut. • Hold the clutch sleeve hub with the special tool. I.;oK, 09920-53740: Clutch sleeve hub holder • Tighten the clutch sleeve hub nut to th[...]

3·94 ENGINE • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. NOTE: Insert the outermost NO.1 drive plate claws ® to the other slits ® of clutch housing as shown. Direction of outside .. DRIVE PLATE: ® NO.1 Drive Plate 8 pcs [Green paint] @ NO.2 Drive plate 2 pes [Brown paint] DR[...]

• Install the clutch pressure plate. • Install the clutch springs. • Hold the clutch housing with the special tool. I CAUTION I Be careful not to damage the clutch housing or clutch plates. i-footl 09920-53740: Clutch sleeve hub holder • Tighten the clutch spring set bolts to the specified torque. ~ Clutch spring set bolt: 10 N·m (1.0 kgf-[...]

3·96 ENGINE CYLINDER HEAD • Fit the dowel pins CD and the new cylinder head gasket ~ to the cylinder. I CAUTION I Use the new gasket to prevent gas leakage. • Place the cylinder head on the cylinder. NOTE: When installing the cylinder head, keep the cam chain taut. • Tighten the cylinder head bolts (M 10) to the specified two-step torque wit[...]

• Fit the gasket ® and tighten the EeT sensor gauge. (!J Water temp. gauge: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) • Install the thermostat. (c:r7-10) • Install the thermostat cover @. (!J Thermostat cover bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) NOTE: Fit the clamp to the bolt ®. • Install the water hose @. (c:r10-19) ENGINE 3·97[...]

3-98 ENGINE Camshaft • Turn the crankshaft clockwise with the box wrench and align the line ® on the starter clutch with the index mark @ of the valve timing inspection hole while keeping the cam chain pulled upward. I CAUTION I Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. I CAUTION I To adjust[...]

[ f • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked "1" ®. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. • Bind the cam chain and the sprocket with a proper wire clamp CD to prevent t[...]

3·100 ENGINE • Install the dowel pins CD. • Install the camshaft journal holders, intake and exhaust, and cam chain guide. • Fasten the camshaft journal holders evenly by tightening the camshaft journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journ[...]

I Cam chain tension adjuster • Retract the push rod by pushing the stopper CD. • Install the ball C2l to the cam chain tension adjuster. • Install the new gasket. I CAUTION I Use the new gasket to prevent oil leakage. • Install the cam chain tension adjuster @ and tighten the mounting bolt. ~ Cam chain tension adjuster mounting bolt: 10 N·[...]

3·102 ENGINE / ~ 23N·m (2.3 kgf-m, 16.5Ib-ft) 10 N·m (1.0 kgf-m, 7.0 Ib-ft)[...]

• Tighten the valve timing inspection plug (f) to the specified torque. ~ Valve timing inspection plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) CYLINDER HEAD COVER • Pour engine oil in each oil pocket in the cylinder head. NOTE: Be sure to check the valve clearance. rc::=r2-8) • Install the dowel pins. • Install the a-rings. • Install the new gask[...]

3·104 ENGINE PAIR CONTROL VALVE • Install the PAIR control valve CD. STARTER MOTOR • Apply SUZUKI SUPER GREASE to the O-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the starter motor CD. ~ Starter motor mounting bolt: 10 N·m (1.0 kgf-m, 7 Ib-ft) • Install th[...]

FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERViCiNG 4- 2 ELETRICAL PARTS ..............................................•.....•.......................... 4- 2 FUSE ..•.....•...................•..................... ... ... .... ...• ... .... .....• ..... . .. ...• • .... . ...... . . 4- 3 ECMN ARIOUS SENSORS .....................[...]

FI SYSTEM DIAGNOSIS 4-1 "C41" FP RELA Y CIRCUIT MALFUNCTION .4-53 "C42" IG SWITCH CIRCUIT MALFUNCTlON .4-53 "C46" EXCV ACTUATOR CIRCUIT MALFUNCTION ..........••.••.....•.....• .4-54 SENSORS 4-60 CMP SENSOR INSPECTION •................................................................. 4-60 CMP SENSOR REMOVA[...]

4·2 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELETRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt. • With a lock type coupler, be sure to release the lock when dis-[...]

• When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal. Never push in the probe where male terminal is supposed to fit. •[...]

4-4 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch, or electronic parts may get dam- aged. • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the Fl system instantly when reverse power is applied. • Removing any batt[...]

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 follows. As the cause can exist in the connector/coupler or terminal, the[...]

4·6 FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler @ (between ® and © in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals ® and ©. • Disconnect the coupler @ and measure resistance between couplers ® and @. If no continuity is indicated, the circuit is ope[...]

FI SYSTEM DIAGNOSIS 4·7 Other parts D v 5V ® ,)~ To other ~' / parts /@ ~ ,/ r J ' r=1Lp(-~~~ o © Q 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 part[...]

4·8 FI SYSTEM DIAGNOSIS USING TESTERS • Use the Suzuki multi-circuit tester set (09990-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the CB and 8 probes may cause the inside of the tester to burnout. • If the voltage and current are [...]

FI SYSTEM DIAGNOSIS 4-9 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. These compensations are determined according to the sig[...]

4·10 FI SYSTEM DIAGNOSIS COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the SIGNAL signal to the ECM and reduce the injection time (v[...]

FI SYSTEM DIAGNOSIS 4-11 INJECTION TIMING The system employs a sequential, four-cylinder independent injection type, using the crankshaft position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the cam- shaft position sensor to identify the cylinder during operation, and these information are s[...]

" - en -< en -I m s: ""C » :x:J -I en r- o o » ::! o z i'" ...... N :::!! ~ ~ m s::: c » G) z o en en ® Speedometer @ Engine coolant temperature sensor (ECTS) © Ignition coil (IG COIL) © Speed sensor ® Atmospheric pressure sensor (APS) eEl Camshaft position sensor (CMPS) © Intake air pressur sensor (lAPS) <8l [...]

Q) Intake air temperature sensor (IATS) ® Throttle position sensor (TPS) CD Crankshaft position sensor (CKPS) CMl Secondary throttle valve actuator (STVA) eM! Fuel pump (FP) <Ql Fuel pump relay (FP RELAY) ® Secondary throttle position sensor (STPS) @ Exhaust control valve actuator (EXCVA) :!! en ~ m :: c :i> C> :z o en en f" ...... [...]

~ ...... ~ ::!! en -< ~ m 3: c ~ :z o en en "'T1 - en -< en -I m s: ~ - :c - z C> C - » C> :c » s: I 10A Engine stop switch ·-1 6 - i : : Side stand switch I I ~ I Clutch 'WItch 1 o co 5 Fuel pump Ignition coil (IG COIL) Fuel injector (FI) Gear position switch 111-+ 111-+ 111-+ ' 111-+ Speedometer ECM o~ I Throttl[...]

FI SYSTEM DIAGNOSIS 4-15 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, "User mode" and "Dealer mode". The user can only be notified by the LCD (DISPLAY) panel and LED (Fllight). To check the function of the individual FI system devices, the dealer mode is prepared. In[...]

4·16 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool's coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the[...]

FI SYSTEM DIAGNOSIS 4·17 CODE MALFUNCTION PART REMARKS COO None No defective part C11 Camshaft position sensor (CMPS) C12 Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator C13 Intake air pressure sensor (lAPS) C14 Throttle position sensor (TPS) *1 C15 Engine coolant temperature sensor (ECTS) C21 Intake air temperature sensor [...]

4·18 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1.Adjust the engine rpm to 1 150 rpm. (c::::::r2-15) 2.Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3.lf the throttle position sensor adjustment is necessary, loosen the screws and turn the throttle position sensor and bring the line to middle. 4.Then, tight[...]

FI SYSTEM DIAGNOSIS 4·19 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. ITEM FAIL-SAFE MODE STARTING RUNNING ABILITY ABILITY Camshaft position sensor When camshaft position signal has "NO" "[...]

4·20 FI SYSTEM DIAGNOSIS ITEM FAIL-SAFE MODE STARTING RUNNING ABILITY ABILITY Secondary throttle valve Secondary throttle valve is fixed to actuator full close position. When motor dis- "YES" "YES" connection or lock occurs, power from ECM is shut off. Secondary throttle position Secondary throttle valve is fixed to "YES&q[...]

FI SYSTEM DIAGNOSIS 4-21 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 will facilitate collecting information to the point required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM[...]

4-22 FI SYSTEM DIAGNOSIS MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather o Fair o Cloudy o Rain o Snow o Always o Other Temperature o Hot o Warm o Cool o Cold ( °F/ 0c) o Always Frequency o Always o Sometimes ( times/ day, month) o Only once o Under certain condition Road o Urban o Suburb o Highway o Mountain[...]

SELF-DIAGNOSTIC PROCEDURES • Don't disconnect couplers from ECM, battery cable from bat- tery, ECM ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase mem- orized information in ECM memory. • Malfunction code stored in ECM memory can [...]

4-24 FI SYSTEM DIAGNOSIS MALFUNCTION CODe AND DEFECTIVE CONDITION MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR coo NO FAULT Camshaft position The signal does not reach ECM for 4 sec, and more, after sensor receiving the starter signal. C11 The camshaft position sensor wiring and mechanical parts. (Camshaft position sensor, in[...]

FI SYSTEM DIAGNOSIS 4-25 MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage C28 does not reach STVA motor, C28 is indicated. STVA can not operate. STVA lead wire/coupler. Seconda[...]

4·26 FI SYSTEM DIAGNOSIS "C11" CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 4 sec. and more, • Metal particles or foreign material being after receiving the starter signal. attached on the CMP sensor and rotor tip. • CMP sensor circuit open or short. • CMP sensor malfunction. ?[...]

FI SYSTEM DIAGNOSIS 4-27 Step2 1) Disconnect the CMP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CMP sensor peak voltage at the sensor. _ CMP sensor peak voltage: 0.5 V and more (@ BN- Br 8) 3) Repeat the above test procedure a few times and measure the highest peak voltage. If OK, then measure the CMP [...]

4-28 FI SYSTEM DIAGNOSIS "C12" CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 4 sec. and more, • Metal particles or foreign materiel being attached after receiving the starter signal. on the CKP sensor and rotor tip. • CKP sensor circuit open or short. • CKP sensor malfunction. •[...]

Step2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. _ CKP sensor peak voltage: 0.5 V and more «(±) Black - 8 Green) 3) Repeat the above test procedure a few times and measure the highest peak voltage. If OK, then measure the CKP sensor peak v[...]

4·30 FI SYSTEM DIAGNOSIS "C13" lAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE lAP sensor voltage low or high. • Clogged vacuum passage between throttle body 0.5 V ~ Sensor voltage < 4.85 V and lAP sensor. (without the above range.) • Air being drawn from vacuum passage between NOTE: throttle body and lAP sensor. [...]

Step 2 1) Connect the lAP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed. 3) Measure the lAP sensor output voltage at the wire side cou- pler (between G/B and B/Br wires). _ lAP sensor output voltage: Approx. 2.6 V at idle speed (ffi GIB - 8 B/Br) 'T'OOti 09900·25008: Multi ci[...]

4·32 FI SYSTEM DIAGNOSIS Output voltage (Vee voltage 4.5 - 5.0 V, ambient temp. 20- 30°C, 68 - 86 OF) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (m) (mmHg) kPa (V) 0 0 760 100 II I I 3.1 - 3.6 2000 610 707 94 2001 611 707 94 I I I I 2.8 - 3.4 5000 1 524 634 85 5001 1 524 634 85 I II I 2.6 - 3.1 8000 2438 567 76 8001 2439 567 76[...]

"C14" TP SENSOR CIRCUIT MALFUNCTION FI SYSTEM DIAGNOSIS 4·33 DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high • TP sensor maladjusted. Difference between actual throttle opening and • TP sensor circuit open or short. opening calculated by ECM in larger than specified • TP sensor malfunction. value. • ECM malfunction. [...]

4·34 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between terminal ® and ground. _ TP sensor continuity: 00 0 (Infinity) (Terminal ® - Ground) 4) If OK, then measure the TP sensor resistance at the terminal (between ® and @). [EJ 5) Turn the throttle grip and measure th[...]

FI SYSTEM DIAGNOSIS 4·35 ,-------- ------------------------------------- Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the injectorlTP sensor lead wire coupler. 3) Turn the ignition switch ON. Measure the TP sensor output voltage at the coupler (between CB PIS and 8 S/Sr) by turning the throttle grip. _ TP sensor [...]

4-36 FI SYSTEM DIAGNOSIS "C15" ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high • ECT sensor circuit open or short. 0.15 ;;;;;; Sensor voltage < 4.85 V • ECT sensor malfunction. (without the above range.) • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its pro[...]

Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. _ ECT sensor resistance: Approx. 2.3 - 2.6 kO at 20°C (68 OF) (Terminal - Terminal) ,gb 09900-25008: Multi circuit tester set ~ Tester knob indication: Resistance (0) Refer to page 7-8 for details. Is the resistance OK? • BIBI or BIBr wire open or shorted to ground, or[...]

4·38 FI SYSTEM DIAGNOSIS "C21" IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage low or high • IAT sensor circuit open or short. 0.15 ~ Sensor voltage < 4.85 V • IAT sensor malfunction. (without the above range.) • ECM malfunction. INSPECTION Step 1 1) Lift and support the fuel tank with its prop st[...]

-- Step 2 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. _ IAT sensor resistance: Approx. 2.2 - 2.7 kO at 20°C (68 OF) (Terminal - Terminal) ,root, 09900-25008: Multi circuit tester set ~ Tester knob indication: Resistance (0) Is the resistance OK? • Dg or B/Br wire open or shorted to ground, or poor ® or ~ connection.[...]

4·40 FI SYSTEM DIAGNOSIS "C22" AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE AP sensor voltage low or high. • Clogged air passage with dust. 0.5 V ;;;;; Sensor voltage < 4.S5 V • Red wire circuit open or shorted to ground . (without the above range.) • B/Br or G/Y wire circuit shorted to ground. NOTE: • AP se[...]

Step 2 1) Connect the AP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. Turn the ignition switch ON. 3) Measure the AP sensor output voltage at the wire side cou- pler (between GIY and B/Br wires). _ AP sensor output voltage: Approx. 2.6 V at 760 mmHg (100 kPa) (@ GN - 8 BIBr) ,roOt, 09900-25008: Multi circuit tester [...]

4-42 FI SYSTEM DIAGNOSIS Output voltage (Vee voltage 4.5 - 5.0 V, ambient temp. 20- 30°C, 68 - 86 OF) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (m) (mmHg) kPa (V) 0 0 760 100 I I I I 3.1 - 3.6 2000 610 707 94 2001 611 707 94 I I I I 2.8 - 3.4 5000 1 524 634 85 5001 1 524 634 85 I I I I 2.6 - 3.1 8000 2438 567 76 8001 2439 567 7[...]

FI SYSTEM DIAGNOSIS 4·43 "C23" TO SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE • TO sensor circuit open or short. • TO sensor malfunction. • ECM malfunction. DETECTED CONDITION ---------+-------------------1 Output voltage low or high 0.2 ;;;;; Sensor voltage < 4.8 V (without the above range.) ________ ---J.- ---' INSPECTION S[...]

4-44 FI SYSTEM DIAGNOSIS Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Black and BIBr wires. _ TO sensor voltage: 0.4 - 1.4 V (CB Black - 8 B/Br) Also, measure the voltage when leaning of the motorcycle. 5[...]

"C28" STY ACTUATOR CIRCUIT MALFUNCTION FI SYSTEM DIAGNOSIS 4·45 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from • STVA circuit open or short. the STVA. • STVA motor malfunction. INSPECTION Step 1 1) Lift and support the fuel tank wit[...]

4·46 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each wire and ground. _ STVA continuity: 00 n (Infinity) If OK, then measure the STVA resistance. (between Pink and Black wires) and (between W/BI and Green wires) _ STVA resistance: Approx. 6.5 n (@ Pink - 8 B[...]

"C29" STP SENSOR CIRCUIT MALFUNCTION FI SYSTEM DIAGNOSIS 4-47 DETECTED CONDITION POSSIBLE CAUSE Signal voltage low or high. • STP sensor maladjusted. Difference between actual throttle opening and • STP sensor circuit open or short. opening calculated by ECM in larger than specified • STP sensor malfunction. value. • ECM malfuncti[...]

4-48 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner element. 3) Disconnect the STP sensor coupler (White color). 4) Check the continuity between Yellow wire and ground. _ STP sensor continuity: 00 0 (Infinity) (Yellow wire - Ground) 5) If OK, then measure the STP sensor resistance at the cou- pler (between Yel[...]

Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the lead wire coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between ffi Yellow and 8 Black wires) by turning the sec- ondary throttle valve (c[...]

4·50 FI SYSTEM DIAGNOSIS "C31" GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short. Switch voltage low. • Gear Position switch malfunction. Sensor voltage> 0.6 V • ECM malfunction. (without the above range.) INSPECTION Step 1[...]

FI SYSTEM DIAGNOSIS 4·51 "C32", "C33", "C34" or "C35" FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by 4 times or more. • Injector malfunction. • ECM malfunction. INSPECTION S[...]

4-52 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch ON. 2) Measure the injector voltage between Y/R wire and ground. _ Injector voltage: Battery voltage (cB VIR - 8 Ground) NOTE: Injector voltage can be detected only 3 seconds after ignition switch is turned ON. ,mob 09900-25008: Multi circuit tester set ~ Tester knob indication: Voltage (:[...]

"C41" FP RELAY CIRCUIT MALFUNCTION FI SYSTEM DIAGNOSIS 4·53 DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although fuel • Fuel pump relay circuit open or short. pump relay is turned ON, or voltage is applied to fuel • Fuel pump relay malfunction. pump although fuel pump relay is turned OFF. • ECM malfunction.[...]

4-54 FI SYSTEM DIAGNOSIS "C46" EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the EXCV • EXCVA maladjusted. actuator. • EXCVA circuit open or short. EXCVA position sensor voltage low or high. • EXCVA motor malfunction. 0.1 ;;;;; Sensor voltage ;;;;; 4.9 V • EXCVA position se[...]

Step 2 1) Check the installation of EXCV cables. (CTS-14) If it is necessary, adjust the EXCV cables. (CTS-B) 2) Turn the ignition switch OFF. 3) Disconnect the EXCVA position sensor lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the voltage between the Red wire terminal and ground. S) If OK, then measure the voltage between the Red [...]

4·56 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Yellow wire and ground. _ Position sensor continuity: 00 0 (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position. (CT'6-4) 6) Disconnect the position senso[...]

Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close position and fully open position. 4) Insert the needle pointed probes to the back side of the position sensor lead wire coupler. (0 Yellow - 8 White) 5) Disconnect the EXCVA motor lead wire coupler~. 6) To set[...]

4·58 FI SYSTEM DIAGNOSIS Step 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turning out the NO.1 cable adjuster CD. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value. (If C46 code is indicated after adjusting the voltage, increa[...]

Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCV A. 3) Apply 12 volts to the terminal and check the operation of EXCVA. 4) Then, swap the wires supplied 12 volts and check the operation of EXCV A. (Check the operation of EXCVA both way) Is the operation OK? FI SYSTEM DIAGNOSIS 4·59 YES NO Loose or poor [...]

4-60 FI SYSTEM DIAGNOSIS SENSORS CMP SENSOR INSPECTION The camshaft position sensor is installed on the cylinder head cover. (c:::::r 4-26) CMP SENSOR REMOVAL AND INSTALLATION • Remove the CMP sensor. (c:::::r3-28) • Install the CMP sensor in the reverse order of removal. CKP SENSOR INSPECTION The crankshaft position sensor is installed on the [...]

ECT SENSOR INSPECTION The engine coolant temperature sensor is installed at the cylin- der head. (c:::::r 4-36) ECT SENSOR REMOVAL AND INSTALLATION • Remove the ECT sensor. (c:::::r7-8) • Install the ECT sensor in the reverse order of removal. Pay attention to the following points: ~ EeT sensor: 18 N·m (1.8 kgf-m, 13 Ib-ft) IAT SENSOR INSPECTI[...]

4·62 FI SYSTEM DIAGNOSIS STP SENSOR INSPECTION STP SENSOR REMOVAL AND INSTALLATION The secondary throttle position sensor is installed at the right side of the No.4 throttle body. • Remove the STP sensor. (c:::::rS-17) • Install the STP sensor in the reverse order of removal. STP SENSOR ADJUSTMENT • Adjust the STP sensor. (c:::::rS-22)[...]

FUEL SYSTEM AND THROTTLE BODY 5-1 FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM 5- 2 INTAKE AIR SYSTEM ....•........•.•................................................................... 5- 3 SECONDARY THROTTLE CONTROL SYSTEM ..........................••....... 5- 3 OPERA TION 5- 4 FUEL SYSTEM 5- 5 FUEL TANK LIFT-UP .••.[...]

5·2 FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the inje[...]

FUEL SYSTEM AND THROTTLE BODY 5-3 INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM The secondary throttle control system (STCS) consists of the secondary throttle valve (STV), secondary throttle valve actuator (STVA) and secondary throttle position sensor (STPS). STV is installed in each throttle body. STVA and STPS are installed on the right si[...]

5·4 FUEL SYSTEM AND THROTILE BODY OPERATION The secondary throttle control system (STCS) is operated by the signal supplied from the ECM. The open/close operation of the secondary throttle valve (STV) is performed by the secondary throttle valve actuator (STVA) which is controlled by the ECM. The STPS detects the STVA movement by measuring the vol[...]

FUEL SYSTEM FUEL TANK LIFT-UP • Remove the front seat. • Remove the frame cover. (CTa-G) • Remove the fuel tank mounting bolts. • Lift and support the fuel tank with the fuel tank prop stay CD. FUEL TANK REMOVAL • Lift and support the fuel tank with the fuel tank prop stay. • Disconnect the fuel pump coupler CD. • Place a rag under th[...]

5-6 FUEL SYSTEM AND THROTILE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank with its prop stay. (c:::.:rS-S) • Place a rag under the fuel feed hose. (c:::.:rS-S) • Remove the fuel feed hose and install the special tools between the fuel tank and fuel delivery pipe. lrUt! 09940-40211: Fuel pressure gauge adaptor 09940-40220: Fu[...]

FUEL PUMP INSPECTION ~ Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor. FUEL DISCHARGE AMOUNT INSPECTION A WARNING Gasoline is highly flammable and explosive. Keep heat, spark a[...]

5-8 FUEL SYSTEM AND THROTTLE BODY • Place the measuring cylinder and insert the fuel hose end into the measuring cylinder. • Apply 12 volts to the fuel pump for 30 seconds and measure the amount of fuel discharged. Battery (±) terminal -- Power source lead wire CD (Yellow with red tracer) If the pump does not discharge the amount specified, it[...]

FUEL PUMP RELAY INSPECTION Fuel pump relay is located in front of the battery. • Remove the front and rear seats. • Lift and support the fuel tank with its prop stay. (c::::FS-S) • Remove the fuel pump relay. First, check the insulation between CD and (2) terminals with pocket tester. Then apply 12 volts to @ and @ terminals, CB to @ and 8 to[...]

5·10 FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. (c:::::rS-S) • Remove the fuel pump assembly by removing its mounting bolts diagonally. A WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the nuts. • Remove the screws. • Remove the fuel pump assy from the fuel pump plate. •[...]

• Remove the fuel mesh filter. • Remove the fuel pressure regulator holder G) and the fuel pressure regulator CZl. FUEL MESH FILTER INSPECTION AND CLEANING 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 filter with compressed air. NOTE: If the fuel me[...]

5·12 FUEL SYSTEM AND THROTTLE BODY • Pass through the wires behind the thermistor CD. • Be sure to connect the wires to the proper terminals. ® CB terminal for fuel pump @ Thermistor Pass through the wires behind the thermistors.[...]

• Install the O-ring and apply SUZUKI SUPER GREASE to it. JifJl99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) A WARNING The O-ring must be replaced with a new one to prevent fuel leakage. • When installing the fuel pump assembly, lightly tighten all the fuel pump assembly mounting bo[...]

FU E L SYSTEM AND THROTTLE BODY 5·14 THROTTLE BODY CONSTRUCTION Except E-33[...]

AIR CLEANER BOX AND THROTTLE BODY REMOVAL AIR CLEANER BOX • Lift and support the fuel tank with its prop stay. (c::::T5-5) • Disconnect the IAT sensor coupler CD and PAIR hose (2). • Disconnect the lAP sensor coupler @ and vacuum hose @. • Disconnect the crankcase breather hose @. • Loosen the throttle body clamp screws. • Remove the ai[...]

5-16 FUEL SYSTEM AND THROTILE BODY THROTTLE BODY • Disconnect the throttle cables from their drum. I CAUTION I After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. • Place a rag under the fuel feed hose and disconnect the fuel feed hose[...]

THROTTLE BODY DISASSEMBLY • Disconnect the respective vacuum hoses from each throttle body. (Except E-33) • Disconnect the respective vacuum hoses CD and EVAP purge hoses (2) from each throttle body. (For E-33) • Remove the lead wire clamps. • Disconnect the TP sensor coupler @, STP sensor coupler @, STVA motor lead wire coupler @ and fuel [...]

5·18 FUEL SYSTEM AND THROTTLE BODY • Remove the STP sensor ® with the special tool. ,roob 09930-11950: Torx wrench NOTE: Prior to disassembly, mark the STP sensor's original position with a paint or scribe for accurate reinstallation. I CAUTION I Never remove the STVA from the throttle body. I CAUTION I Never remove the secondary throttle [...]

THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • With the STV fully opened, install the STP sensor CD. NOTE: * Align the secondary throttle shaft end ® with the groove @ of the STP sensor. * Apply SUZUKI SUPER GREASE to the secondary throttle shaft end ® if nec[...]

5·20 FUEL SYSTEM AND THROTTLE BODY • Apply thin coat of the engine oil to the new O-rings ell. I CAUTION I I Replace the O-ring with a new one. • Assemble the fuel delivery pipes. • Install the fuel delivery pipe assembly to the throttle body assembly. ! CAUTION I Never turn the fuel injectors while installing them. • Tighten the fuel deli[...]

FUEL SYSTEM AND THROTILE BODY 5·21 THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the throttle pulling cable CD and throttle returning cable (2) to the throttle cable drum. • Adjust the throttle cable play with the cable adjusters @ and @. Refer to page 5-29 for deta[...]

5·22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows: • Disconnect the STVA coupler. • Turn the ignition switch ON. • Close the secondary throttle valve by finger, and measure the STP sensor output voltage. _ STP sensor [...]

FUEL INJECTOR INSPECTION The fuel injector can be checked without removing it from the throttle body. Refer to page 4-S1 for details. FUEL INJECTOR REMOVAL • Lift and support the fuel tank with its prop stay. (c::::T'S-S) • Remove the air cleaner box. (c::::T'S-1S) • With battery negative cable disconnected, disconnect the injector [...]

5-24 FUEL SYSTEM AND THROTTLE BODY FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambie[...]

THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH VACUUM GAUGE • Lift and support the fuel tank. (c::::rS-S) • Start up the engine and run it in idling condition for warming up. • Stop the warmed-up engine. • Disconnect the IAT sensor coupler CD and remove the IA T sens[...]

5·26 FUEL SYSTEM AND THROTTLE BODY • Connect a tachometer. • Start up the engine and keep it running at 1 150 rpm by turn- ing throttle stop screw @. ! CAUTION I Avoid drawing dirt into the throttle body while running the engine without air cleaner box. Dirt drawn into the engine will damage the internal engine parts. • Turn the air screw @ [...]

~~ ~ * During balancing the throttle valves, always set the engine rpm at 1 150 rpm, using throttle stop screw. * After balancing the four valves, set the idle rpm to 1 150 rpm by the throttle stop screw after installing the air cleaner box. * If the above procedures cannot still synchronize the valves, proceed to the next step. THROTTLE VALVE SYNC[...]

5-28 FUEL SYSTEM AND THROTTLE BODY Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between No.1 and NO.2. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower. Similarly perform the same procedures between NO.3 [...]

THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS setting condition. (Refer to page 4-18 for TPS setting procedure.) THROTTLE CABLE ADJUSTMENT NOTE: Minor adjustment can be made by the throttle grip side adjuster. (c:::::r 2- 17) MAJOR ADJUSTMENT • Loosen the lock-nuts CD of the throttle returning[...]

EXHAUST SYSTEM 6·1 EXHAUST SYSTEM CONTENTS EXHAUST SYSTEM ••..•••...............•..•..•.••.••...............•..•..•...........••................ 6- 2 EXHAUST CONTROL SYSTEM ................................•..•.•..................•.... 6- 2 OPERA TION •..................••..•..••................[...]

6-2 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST CONTROL SYSTEM The exhaust control system (EXeS) consists of the exhaust control valve (EXeV), exhaust control valve actuator (EXeVA) and exhaust control valve cables (EXeV cables). EXeV is installed between the exhaust pipes and joint pipe. EXeVA is mounted on the right side of the seat rail. The EXeV is o[...]

EXHAUST SYSTEM 6·3 OPERATION The EXCS is operated by the signal supplied from the ECM. The open/close operation of the EXCV is performed by the EXCVA which is controlled by the ECM by changing the current direction of the actuator motor. The position sensor (incorporated in the EXCVA) detects the EXCVA movement by measuring the voltage and then th[...]

6-4 EXHAUST SYSTEM Before removing the EXCVA, be sure to set the EXCVA pulley to the adjustment position. EXCVA(EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA REMOVAL • Turn the ignition switch OFF. • Remove the front and rear seats. • Remove the fuel tank. (c::::rS-S) • Connect the special tool (Mode select switch) [...]

• Remove the clamp CD. • Disconnect the NO.2 cable (2) and then NO.1 cable @ from the pulley. • Disconnect the EXCVA lead wire couplers @. • Remove the EXCVA. EXCVA can also be removed in the following procedures. • Remove the front footrest @. • Disconnect the EXCV cable. (L7"6-12) • Remove the EXCVA mounting bolt. (L7"6-4)[...]

6·6 EXHAUST SYSTEM • Check the EXCVA to adjustment position. (c:::?6-4) I CAUTION I Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. • Install the pulley @ to the shaft @. NOTE: Make sure that the shaft's line @ and cable slots © facing upward as shown. • Hold the pulley w[...]

EXHAUST SYSTEM 6-7 NOTE: The EXCV cables are identified by the plated chrome color and shape. Black chrome plated adjuster: NO.1 cable G) Silver chrome plated adjuster: NO.2 cable ~ • Connect the EXCV cables (No.1 and No.2) temporarily to the EXCVA pulley, • Check or adjust the clearance ® becomes the adjuster end and EXCVA pulley to provide 3[...]

6·8 EXHAUST SYSTEM • Connect the NO.1 cable and NO.2 cable to the EXCVA pulley. (t:76-5) • After connecting the NO.2 cable @, loosen the lock-nut ® and turn the adjuster @ in or out until 11 - 12 mm (0.43 - 0.47 in) of the thread length CQl on the cable adjuster cam be provided and tighten the lock-nut ®. • Check the EXCVA to adjustment po[...]

EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (c:::::r6-4) • Make sure that the NO.2 cable and NO.1 cable are fixed into the clamp. 2nd step: • Turn the mode select switch OFF. • Turn the ignition switch ON to check the EXCVA operation. • Turn the mode select switch ON. • If C46 is not indicated on the LCD (DISPLAY)[...]

6·10 EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 volts to ® and @ terminals. Positive wire - ® (Pink wire) terminal Negative wire - @ (Gray wire) terminal I CAUTION I To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position. • Turn the ignition switch ON. • Measure the position[...]

4th step: To set the EXCV to fully open position, apply 12 volts to ® and @ terminals. Positive wire - @ (Gray wire) terminal Negative wire - ® (Pink wire) terminal !CAUTION! To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully open position. Measure the position sensor output voltage at fully open posi- tion. _ Posit[...]

6·12 EXHAUST SYSTEM EXCV REMOVAL • Disconnect the two cables from the EXCVA pulley. (Refer to the EXCVA REMOVAL procedures.) ( CT"6-4) • Remove the muffler joint pipe CD together with the muffler body ~ by removing the mounting bolts and loosen the con- nector bolt. • Remove the EXCV cover @ and disconnect the two cables from the EXCV p[...]

EXCV INSTALLATION • Connect the EXCV cables temporarily to the EXCV pulley. • Adjust the clearance ® between the adjuster end and EXCV pulley to provide 3 mm (0.12 in) and more. • Adjust the inner cable length of the NO.2 cable. (c::::T6-7) • Install the EXCV cover. • Install the muffler joint pipe CD together with the muffler body ~. ~ [...]

6-14 EXHAUST SYSTEM ICAUTION! * When adjusting the No.1 and No.2 cables, the cable slots of EXCVA pUlley must be located to adjustment position. * Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. 3 mm (0.12 in) NO.2 58-59 mm (2.28 - 2.32 in) -No.1 .. ~ Cable guide /~--ft1J-ql- ~23N.m [...]

COOLING AND LUBRICATION SYSTEM 7·1 COOLING AND LUBRICA TION SYSTEM CONTENTS ENGINE COOLANT .........................................••..•. ..... ... ....... ... ...... ....... .. ....... 7- 2 COOLING CIRCUIT 7- 3 COOLING CIRCUIT INSPECTION 7- 3 RADIATOR AND WATER HOSES ........................................•........ .... . ........ .. 7-[...]

7-2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT Anti-freeze Freezing point density 50% -30°C (-24 OF) 55% -40 °C (-44 OF) 60% -55°C (-67 OF) 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 excel[...]

COOLING AND LUBRICATION SYSTEM 7·3 COOLING CIRCUIT COOLING FAN THERMO SWITCH RADIATOR THERMOSTAT CYLINDER HEAD CYLINDER WATER PUMP ENGINE COOLANT TEMPERATURE SENSOR COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the under cowling. (L7S-3) • Remove the[...]

7-4 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES RADIATOR REMOVAL • Remove the under cowling. (CT8-3) • Drain the engine coolant. (CT2-19) • Remove the radiator. (CT3-4) RADIATOR CAP INSPECTION • Fit the cap CD to the radiator cap tester ~. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up[...]

RADIATOR REMOUNTING • Install the radiator. • Route the radiator hoses. (L::r10-19) • Pour engine coolant. (L::r2-19) • Bleed air from the cooling circuit. (L::r2-20) • Install the under cowling. WATER HOSE INSPECTION • Remove the under cowling. (L::r8-3) • Any water hose found in a cracked condition or flattened must be replaced. •[...]

7·6 COOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL • Remove the under cowling. ([78-3) • Drain the engine coolant. ([72-19) • Remove the radiator. ([73-4) • Remove the cooling fan. INSPECTION • Remove the under cowling. ([78-3) • Disconnect the cooling fan coupler CD. • Test the cooling fan motor for load current with an ammeter [...]

COOLING FAN THERMO-SWITCH REMOVAL • Remove the under cowling. (L7a-3) • Drain the engine coolant. (L72-19) • Disconnect the cooling fan thermo-switch coupler CD. • Remove the cooling fan thermo-switch (2). COOLING AND LUBRICATION SYSTEM 7·7 INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as[...]

7·8 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SEN- SOR REMOVAL • Remove the front seat. (0=8-6) • Lift and support the fuel tank. (0=5-5) • Disconnect the engine coolant temperature sensor coupler. • Keep the motorcycle upright. • Place a rag under the sensor and remove the engine coolant temperature sensor CD. INSPECTION[...]

INSTALLATION • Tighten the engine coolant temperature sensor to the speci- fied torque. (!J Engine coolant temperature sensor: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) I CAUTION I Take special care when handling the temperature sen- sor. It may cause damage if it gets a sharp impact. • Install the fuel tank. (L7'5-5) • Install the front seat. THE[...]

7·10 COOLING AND LUBRICATION SYSTEM INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • Pass a string CD between flange of thermostat (2), as shown. • Immerse the thermostat in the water contained in a beaker, as shown in the illustration. Note that t[...]

• Install the thermostat case. NOTE: Fit the clamp to the thermostat case bolt@. • Tighten the thermostat cover bolt to the specified torque. ~ Thermostat cover bolt: 10 N·m (1.0 kgf-m 7.0 Ib-ft) • Install the fuel tank. (c::::TS-S) • Install the front seat. WATER PUMP REMOVAL AND DISASSEMBLY • Remove the under cowling. (c::::TS-3) • D[...]

7·12 COOLING AND LUBRICATION SYSTEM • Remove the gearshift lever. • Remove the engine sprocket cover (1). • Disconnect the water hoses. • Remove the water pump. • Remove the water pump cover. • Remove the impeller securing bolt (2) by holding the impeller shaft with a water pump pliers.[...]

• Remove the mechanical seal ring @ and the rubber seal @ from the impeller. • Remove the impeller shaft @. • Remove the bearings with the special tool. ,-root. 09921·20240: Bearing remover set NOTE: If there is no abnormal noise condition, bearing removal is not necessary. I CAUTION I The removed bearing must be replaced with a new one. •[...]

7-14 COOLING AND LUBRICATION SYSTEM INSPECTION BEARING • Inspect the play of the bearing by hand while it is in the water pump case. • Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • Replace the bearing if there is anything unusual. MECHANICAL SEAL • Visually inspect the mechanical seal for damage, with pa[...]

r I REASSEMBLY AND INSTALLATION • Install the oil seal with the special tool. ,gOt, 09913·70210: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE to the oil seal lip . .JifJf 99000·25030: SUZUKI SUPER GREASE "A" (USA) 99000·25010: SUZUKI SUPER GREASE &qu[...]

7·16 COOLING AND LUBRICATION SYSTEM • Apply SUZUKI SUPER GREASE to the impeller shaft. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the impeller shaft to the water pump body. • Install the rubber seal CD into the impeller. • After wiping off the oily or greasy matt[...]

• Install the new O-rings, @ and @. I CAUTION I Use the new O-rings to prevent engine coolant leak- age. NOTE: * Apply engine coolant to the O-ring@. * Apply SUZUKI SUPER GREASE to the a-ring @. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Tighten the water pump cover screws to[...]

7·18 COOLING AND LUBRICATION SYSTEM • Connect the water hoses. (c::?10-19) • Install the engine sprocket cover. • Install the gearshift lever. • Pour engine coolant. (c::?2-19) • Pour engine oil. (c::?2-14) • Install the under cowling. LUBRICATION SYSTEM OIL PRESSURE c::?2-34 OIL FILTER c::?2-14 OIL PRESSURE REGULATOR c::?3-46 OIL STRA[...]

OIL COOLER REMOVAL • Remove the under cowling. (c::Ta-3) • Drain the engine oil. (c::T2-13) • Remove the oil cooler. (c::T3-4) INSPECTION AND CLEANING • Road dirt or trash stuck to the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the[...]

7·20 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART INTAKE CAMSHAFT _---,---1 INTAKE CAMSHAFT 1------------------, _________ JOURNAL HOLDER 1..-------, CAM CHAIN TENSION ADJUSTER • " ~ ... EXHAUST CAMSHAFT CAMSHAFT JOURNALS, CAM FACES AND TAPPETS ~ ~EXHAUSTCAMSHAFTI..--------~ '-- ...J JOURNAL HOLDER '-------, • [...]

ENGINE LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM 7-21[...]

7-22 COOLING AND LUBRICATION SYSTEM To transmission I[...]

CHASSIS CONTENTS EXTERIOR PARTS .........................................................................•............. 8- 2 FASTENER REMOVAL AND REINSTALLATION 8- 2 SCREEN 8- 3 BODY COWLING COVER AND LOWER BRACKET COVER 8- 3 RIGHT AND LEFT UNDER COWLINGS .............•.................................. 8- 3 BODY COWLING 8- 4 RIGHT AND LEFT AIR[...]

CHASSIS 8-1 REMOVAL 8-42 INSPECTION .................................•..............................•.......................... 8-42 REAR SHOCK ABSORBER DISPOSAL .............................................•.. 8-43 REMOUNTING 8-44 SUSPENSION SETTING .....................................................................•... 8-44 REAR SUSPENS[...]

8-2 CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND REINSTALLATION FASTENER Removal • Depress the head of fastener center piece CD. • 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, ins[...]

[ SCREEN • Remove the bolts and nuts. • Remove the screen. BODY COWLING COVER AND LOWER BRACKET COVER • Remove the body cowling cover CD by removing the fasten- ers. • Remove the lower bracket cover ~ by removing the bolts. RIGHT AND LEFT UNDER COWLINGS • Remove the fastener. • Remove the fastener. • Remove the right under cowling. ?[...]

8·4 CHASSIS • Remove the left under cowling. • Disconnect the turn signal light lead wire coupler. BODY COWLING REMOVAL • Remove the rear view mirrors and bolts. • Remove the fasteners. • Remove the bolts.[...]

• Remove the screws. • Disconnect the coupler and clamp. • Remove the body cowling. REMOUNTING NOTE: When remounting the body cowling, install the hooks ® to the cowling brace holes. RIGHT AND LEFT AIR INTAKE PIPES • Remove the body cowling. (c::::7'8-4) • Remove the fastener. • Remove the air intake pipes CD. COWLING BRACE REMOVA[...]

8-6 CHASSIS FRONT SEAT • Remove the front seat by removing the bolts. REAR SEAT AND SEAT TAIL COVER • Remove the rear seat (seat tail cover) with the ignition key. FRAME COVER • Remove the seats. • Remove the bolts. • Disconnect the seat lock cable CD. • Disconnect the rear combination light lead wire coupler ~. • Remove the fasteners[...]

FRONT WHEEL CONSTRUCTION ® .: CHASSIS 8·7 CD Brake disc ~ Dust seal @ Bearing @ Spacer @ Spacer nut @ Front wheel ® Front axle @ Brake disc bolt (Front) ITEM N·m kgf-m Ib-ft ® 100 10.0 72.5 @ 23 2.3 16.5[...]

8-8 CHASSIS REMOVAL • Remove the brake calipers. I CAUTION I Do not operate the brake lever while removing the cal- ipers. • Loosen two axle pinch bolts CD on the right front fork leg. • Slightly loosen the front axle C2l with the special tool. ,-Pooh 09900-1S740: Hexagon socket (24 mm) • Raise the front wheel off the ground and support the[...]

• Remove both side dust seals with the special tool. mm 09913-50121: Oil seal remover I CAUTION I The removed dust seals must be replaced with new ones. AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. jgot, 09900-20607: Dial gauge (11100) 09900-20701: Magnetic stand 09900-21304: V-blo[...]

8·10 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: Left <::=J c:::> Right ~ 23N·m (2.3 kgf-m, 16.5 Ib-ft) ~ 23N·m (2.3 kgf-m, 16.5 Ib-ft) ~ 100N·m ~~~d~~~~~~~~~~~~IV (10.0 kgf-m, 72.5Ib-ft) WHEEL BEARING • Apply SUZUKI SUPE[...]

• Install the wheel bearings as follows with the special tools. ,foOt, 09941-34513: Bearing/Steering race installer set 09924-84510: Bearing installer set I CAUTION I First install the left wheel bearing, then install the right wheel bearing. The sealed cover of the bearing must face outside. • Install the dust seal with the special tool. ,@, 0[...]

8·12 CHASSIS SPACER NUT With the flange of spacer nut CD contacting the left front fork leg, tighten the two axle pinch bolts (2) on the left front fork leg to the specified torque. ~ Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) WHEEL Install the front wheel with the front axle and hand-tighten the front axle temporarily. A WARNING The d[...]

FRONT FORK CONSTRUCTION CD O-ring C2J Spring retainer @ Spacer @ Spring @ Adjuster rod @ Inner rod/damper rod (cartridge) (J) Outer tube @ Oil seal retainer @ Oil seal ®J Oil seal stopper ring ® Dust seal @ Inner tube ® Front fork cap bolt @ Lock-nut © Front axle pinch bolt (Ql Damper rod bolt ITEM N·m kgf-m Ib-ft ® 23 2.3 16.5 @ 29 2.9 21.0 [...]

8·14 CHASSIS REMOVAL AND DISASSEMBLY • Remove the front wheel. (c:::rS-S) • Disconnect the brake hose from the brake hose guides on the front fender. • Remove the front fender. • Loosen the front fork upper clamp bolts CD, left and right. • Loosen the handlebar clamp bolts (2), left and right. NOTE: * Slightly loosen the front fork cap b[...]

• Separate the front fork cap bolt from the front fork. • Compress the front fork spring with the special tool ® and insert the special tool @ between the lock-nut and the spacer. jrUh 09940-94930: Front fork spacer holder ® 09940-94922: Stopper plate @ • Remove the front fork cap bolt from the inner rod by loosening the lock nut. • Compr[...]

8·16 CHASSIS • Remove the inner rod/damper rod (cartridge) @. I CAUTION I Do not disassemble the inner rod/damper rod (car- tridge). • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the "ANTI-FRICTION" metals. • Remove the following parts. OJ) Dust seal @ Oil seal stopper ring ® Oil seal ® Oil seal ret[...]

FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. _ Front fork spring free length: Service Limit: 225 mm (8.86 in) -~~ i I i i -~~ CHASSIS 8·17 Upper side Lower side DAMPER ROD Move the inner rod by hand to examine it for smoothness. If any defects are found, replace inner rod/damp[...]

8·18 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. CD Dust seal 11) Oil seal stopper ring @ Oil seal @ Oil sea[...]

,root. 09940-30221: Front fork assembling tool ~ Damper rod bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) I CAUTION I Use a new damper rod bolt gasket to prevent oil leak- age. I 'Mb CHASSIS 8·19 FORK OIL • Place the front fork vertically without spring. • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube.[...]

8·20 CHASSIS FRONT FORK INNER ROD LOCKNUT • Adjust the height (8) of the inner rod threads by turning the lock-nut CD as shown in illustration. (8): 11 mm (0.43 in) FORK SPRING • Install the fork spring as shown in the illustration. ~ Upper side I I I ~ Lower side • Install the adjuster rod CD, spring (2), spring retainer @ and spacer@. FRON[...]

• Hold the cap bolt (2) and tighten the lock-nut @ to the speci- fied torque. ~ Inner rod lock-nut: 29 N·m (2.9 kgf-m, 21.0 Ib-ft) • Remove the special tools. • Install the front fork cap bolt to the outer tube temporarily. • Set the upper surface of the outer tube height ® at 4.5 mm (0.18 in) from the upper surface of the steering stem u[...]

8·22 CHASSIS SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are five grooved lines on the side of the spring adjuster. Position 1 provides the maximum spring pre-load and position 5 provides the minimum spring pre-load. STD POSITION: 4.5 I I I T .- r -1-[...]

STEERING DAMPER CONSTRUCTION CHASSIS 8·23 G) Steering damper ~ Dust seal ® Damper rod bolt @ Damper rod nut ~ ITEM N·m kgf-m Ib-ft ® 23 2.3 16.5 @ 23 2.3 16.5 REMOVAL • Remove the body cowling cover and lower bracket cover. (CT'8-3) • Remove the nut G) by holding the nut (2). • Remove the bolt @ and remove the steering damper. INSPEC[...]

8·24 CHASSIS STEERING CONSTRUCTION REMOVAL AND DISASSEMBLY • Remove the front wheel. (eTa-a) • Remove the front fork. (eTa-14) G) Steering stem upper bracket (1) Handlebar @ Handlebar balancer @ Steering stem nut @ Dust seal @ Bearing (f) Steering stem lower bracket ® Steering stem head nut @ Steering stem lock-nut © Front fork upper clamp b[...]

• Remove the right handlebar switch lead wires from the guide. • Remove the steering stem upper bracket by removing its head nut. NOTE: It is not necessary to remove the ignition switch, only when replacing the steering stem lower bracket and bearings. (Ignition switch removal: c=T9-31) • Remove the brake hose clamp bolt. • Remove the steer[...]

8·26 CHASSIS INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal noise of bearing If any abnormal points are found, replace defective parts with the new ones. • Remove the steering stem lower bearing inner race with a chisel. [...]

BEARING • Apply SUZUKI SUPER GREASE to the bearings and bearing races. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the lower bearing to the steering stem lower bracket. • Install the upper bearing and bearing inner race. STEM NUT • Install the dust seal. • Tighte[...]

8·28 CHASSIS FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket in the fol- lowing steps: 1) Install the upper bracket, washer CD and steering stem head nut (2) temporarily. NOTE: Pay attention to the direction of the washer. 2) Position the handlebars on the front forks and tighten the ste- ering ste[...]

STEERING TENSION ADJUSTMENT Check the steering movement in the following procedure. • By supporting the motorcycle with a jack, lift the front wheel until it is off the floor by 20 - 30 mm (O.S - 1.2 in). • Remove the steering damper. (c:::::rS-23) • Check to make sure that the cables and wire harnesses are properly routed. • With the front[...]

8·30 CHASSIS HANDLEBAR CONSTRUCTION CD Left handle grip ~ Right handle grip @ Right handle switch @ Left handle switch @ handlebar @ Handle balancer ® Handlebar clamp bolt REMOVAL AND DISASSEMBLY RIGHT HANDLEBAR • Remove the brake master cylinder G). (c::78-61) • Remove the right handle switch CZl. • Remove the handle balancer @. • Remove[...]

• Loosen the handlebar clamp bolts. • Loosen the front fork upper clamp bolt. • Remove the steering stem upper bracket by removing the steering stem head nut. NOTE: Place the rags under the steering stem upper bracket to prevent scratching the body cowling and the air intake pipes. • Draw out the handlebars to upward. REASSEMBLY AND REMOUNT[...]

8·32 CHASSIS • Tighten the handlebar clamp bolts. ~ Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 Ib-ft) • When remounting the clutch lever holder, align the holder's mating surface ® with punch mark @ on the handlebar. • Install the front brake master cylinder. (L7'8-62) • When remounting the brake master cylinder, align the h[...]

CHASSIS 8-33 CD Rear axle ~ Caliper bracket @ Brake disc @Collar @ Bearing @ Rear wheel (J) Spacer @ Bearing ® Cushion ® Spacer ® Sprocket drum @ Sprocket © Bearing @ Dust seal @Collar . ® Cotter pin ® Brake disc bolt t @ Rear sprocket nu © Rear axle nut @ CD .: REAR WHEEL CONSTRUCTIIOO~N~ ~ __[...]

8·34 CHASSIS REMOVAL • Remove the cotter pin. (For E-03, 28, 33) • Loosen the axle nut. • Raise the rear wheel off the ground and support the motorcy- cle with a jack or wooden block. • Remove the axle nut and draw out the rear axle. • Remove the rear wheel by disengaging the drive chain. I CAUTION I Do not operate the brake pedal while [...]

• Remove the dust seal with the special tool. S 09913-50121: Oil seal remover I CAUTION I The removed dust seal must be replaced with a new one. INSPECTION AND DISASSEMBLY TIRE INSPECTION (c::::r2-2S, S-70) WHEEL INSPECTION (c::::rS-70) REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear[...]

8·36 CHASSIS BEARINGS Inspect the play of the wheel bearing and sprocket mounting drum bearing by hand while they are installed in place. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. • Remove the sprocket mounting drum bearing and wheel bear- ings with the spec[...]

CHASSIS 8·37 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points: ~100N.m (10.0 kgf-m, 72.5 Ib-ft) ~60N.m (6.0 kgf-m, 43.5 Ib-ft) ~100N.m (10.0 kgf-m, 72.5 Ib-ft) Left¢J c::::> Right ~35N.m (3.5 kgf-m, 25.5 Ib-ft) ~25N.m i.===b".------i~~ (2[...]

8-38 CHASSIS BEARINGS • Apply SUZUKI SUPER GREASE to the bearings before installing. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) • Install the new bearing to the sprocket mounting drum with the special tool. jgot. 09924-84510: Bearing installer set • First install the right wh[...]

DUST SEALS • Install the new dust seal with the special tool. nut. 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE to the dust seal lip before assembling rear wheel. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE "A" (Others) CHASSIS 8·39 REAR SPROCKET AND SPROCKET MOUNTING DRUM[...]

8·40 CHASSIS REAR AXLE • Remount the rear wheel and rear axle shaft and, install the washer CD and rear axle nut (2). • Adjust the chain slack after rear wheel installation. (c::::7'2-22) • Tighten both chain adjuster lock-nuts ® securely. • Tighten the rear axle nut (2) to the specified torque. ~ Rear axle nut: 100 N·m (10.0 kgf-m,[...]

REAR SHOCK ABSORBER CONSTRUCTION ITEM N·m kgf-m Ib-ft ® 50 5.0 36.0 @ 115 11.5 83.0 CHASSIS 8·41 CD Rear shock absorber ~ Rear shock absorber bracket ® Rear shock absorber mounting bolt/nut @ Rear shock absorber bracket nut Left ¢::J c:::> Right[...]

8-42 CHASSIS REMOVAL • Support the motorcycle with a jack relieve no load on the rear shock absorber. • Remove the rear shock absorber upper and lower mounting bolts and nuts. • Take out the rear shock absorber. INSPECTION Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absor[...]

REAR SHOCK ABSORBER DISPOSAL A. WARNING * The rear shock absorber unit contains high-pressure nitrogen gas. * Mishandling can cause explosion. * Keep away from fire and heat. High gas pressure caused by heat can cause an explosion. * Release gas pressure before disposing. GAS PRESSURE RELEASE The rear cushion damper unit contains high-pressure nitr[...]

8-44 CHASSIS REMOUNTING Remount the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Install the rear shock absorber and tighten the rear shock absorber upper/lower mounting bolts and nuts. ~ Rear shock absorber mounting nut: 50 N·m (5.0 kgf-m, 36.0 Ib-ft) • Damping force adjuster REAR Rebound Compr[...]

REAR SUSPENSION CONSTRUCTION ITEM N·m kgf-m Ib-ft ® 50 5.0 36.0 @ 78 7.8 56.5 © 78 7.8 56.5 © 15 1.5 11.0 ® 90 9.0 65.0 ® 100 10.0 72.5 © 65 6.5 47.0 CHASSIS 8-45 G) Rear shock absorber (2) Rear cushion rod @ Rear cushion lever @ Spacer @ Bearing @ Dust seal (j) Chain cover @ Chain buffer ® Chain adjuster (j]) Chain adjuster lock-nut ® Swi[...]

8-46 CHASSIS REMOVAL • Cut the drive chain. (c::::::;=a-74) NOTE: It is necessary to cut the drive chain, only when replacing drive chain or swingarm. • Raise the rear wheel off the ground and support the motorcy- cle with a jack or a wooden block. • Remove the rear wheel. (c::::::;=a-34) • Remove the side stand. NOTE: It is necessary to re[...]

• Remove the swingarm pivot shaft lock-nut with the special tool. IT'foti 09940-14940: Swingarm pivot thrust adjuster socket wrench • Hold the swingarm pivot shaft CD and remove the swingarm pivot nut (2). IKiOh 09900-18740: Hexagon socket (24 mm) • Draw out the swingarm pivot shaft. • Remove the rear suspension assembly. • Remove th[...]

8-48 CHASSIS • Remove the swingarm pivot boss by removing its set screws. • Set the swingarm pivot boss by its set screws. • Tighten the swingarm boss nut to the specified torque. ~ Swingarm pivot boss nut: 65 N·m (6.5 kgf-m, 47.0 Ib-ft) INSPECTION AND DISASSEMBLY SPACER • Remove the spacers from swingarm. • Remove the spacers from the c[...]

SWINGARM BEARING Insert the spacer into bearing and check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Draw out the swingarm pivot bearings CD and the swingarm cushion rod upper bearings ~ with the special tool. 1m 09921-20240: Bearing remover set I CAUTION I The removed bearings m[...]

8·50 CHASSIS CUSHION LEVER AND CUSHION LEVER RODS Inspect the cushion lever and cushion lever rods for damage. SWINGARM PIVOT SHAFT Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. _ Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) n13KI 09900-20607: Dial gauge (11100 mm, 10 mm) 09900-207[...]

CHASSIS 8·51 REASSEMBLY Reassemble the swingarm in the reverse order of disassembly and removal. Pay attention to the following points: c:::> Right ..-:-----~ 115 Nrn ( 11.5 kgt-m) 83.0Ib-ft Left ¢:::l I LL V I VVasher @--+-flI-------..1H-++--f1+- ©+-f---+=:::m-----+J+.-='f#H-------, ~ 78 N·m ( 7.8 kgt-m) .0 56.5 Ib-ft 1 ~ 90N·m ( 9.[...]

8-52 CHASSIS SWINGARM BEARING • Press the bearing into the swingarm pivot with the special tool. jr'OOt! 09941-34513: Steering race installer • Press the swingarm cushion rod upper side bearing with the special tool. j-FoR, 09941-34513: Steering race installer NOTE: When reinstalling the bearing, stamped mark on bearing must face outside. [...]

• Assemble the cushion rod onto the swingarm temporarily. • Remount the chain case CD and chain buffer~. REMOUNTING Remount the swingarm in the reverse order of disassembly and removal, and pay attention to the following points. SWINGARM PIVOT THRUST CLEARANCE ADJUSTMENT Adjust swingarm pivot thrust clearance in the following procedure. • Ins[...]

8·54 CHASSIS SHOCK ABSORBER AND CUSHION LEVER MOUNTING NUT • Install the washers ® and cushion lever. (c:::::rS-51) • Tighten the cushion lever mounting nut CD to the specified torque. ~ Cushion lever mounting nut: 78 N·m (7.8 kgf-m, 56.5 Ib-ft) • Assemble the cushion lever, cushion rod and rear shock absorber. (c:::::rS-44) ~ Rear shock a[...]

CHASSIS 8·55 FRONT BRAKE CONSTRUCTION ITEM N·m kgf-m Ib-ft ® 10 1.0 7.0 @ 23 2.3 16.5 © 25 2.5 18.0 (Ql 8 0.8 6.0 ~ 22 2.2 16.0 ® 16 1.6 11.5 CD Front brake lever ~ Dust boot Q) Piston set @ Piston seal @ Dust seal @ Brake caliper piston (l) Brake pad @ Brake pad spring @ Brake hose ®J Brake hose ®Tape ® Front master cylinder mounting bolt [...]

8·56 CHASSIS BRAKE PAD REPLACEMENT • Remove the pad mounting pins CD and springs. • Remove the brake pads. I CAUTION I * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. ~® »® • Install the new brake pads. ~ Pad mounting pin: 16 N·m (1.[...]

CALIPER REMOVAL AND DISASSEMBLY • Remove the brake pads. (c:::::ra-S6) • Remove the brake hose from the caliper by removing the union bolt CD and catch the brake fluid in a suitable recepta- cle. NOTE: * Place a rag underneath the union bolt on the brake caliper to catch any split brake fluid. * When reusing the pad, put a reference mark on the[...]

8·58 CHASSIS • Remove the dust seals and piston seals. I CAUTION I Do not reuse the dust seals and piston seals to pre- vent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage.[...]

PISTON SEAL • Install the piston seals as shown in the illustration. Piston seal ~~ CHASSIS 8·59 O-RING • Install the new O-ring and reassemble caliper halves. I CAUTION I I Replace the O-ring with a new one. • Tighten each bolt to the specified torque. ~ Front brake caliper housing bolt: 22 N·m (2.2 kgf-m, 16.0 Ib-ft) Front brake caliper m[...]

8·60 CHASSIS BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. _ Front disc thickness: Service Limit: 5.0 mm (0.197 in) j@t. 09900-20205: Micrometer (0 - 25 mm) • Remove the brake calipers. (c::[...]

MASTER CYLINDER REMOVAL AND DISAS- SEMBLY • Disconnect the front brake light switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch any split brake fluid. Remove the union bolt and dis- connect the brake hose. I CAUTION I Immediately and completely wipe off any brake fluid contacting any part of the motorcycl[...]

8·62 CHASSIS • Pull out the dust boot CD and remove the snap ring (2), • Remove the piston/secondary cup, primary cup and return spring. @ Secondary cup @ Piston @ Primary cup @ Return spring • Remove the snap ring (f), connector @ and O-ring @. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other dam- age. [...]

• When remounting the brake master cylinder onto the handle- bar, align the master cylinder holders mating surface with punched mark ® on the handlebar and tighten the upper clamp bolt first as shown. ~ Front brake master cylinder mounting bolt: 10 N·m (1.0 kgf-m, 7.0 Ib-ft) • Tighten the union bolt. (Brake hose routing: CT1 0-20) ~ Brake hos[...]

8·64 CHASSIS REAR BRAKE CONSTRUCTION ITEM N·m kgf-m Ib-ft ® 8 0.8 6.0 @ 23 2.3 16.5 © 25 2.5 18.0 © 10 1.0 7.0 eEl 18 1.8 13.0 ® 37 3.7 27.0 © 17 1.7 12.5 A WARNING CD Brake pedal ~ Piston/cup set ® Reservoir tank hose @ Brake hose @ Pad @ Inner shim (j) Outer shim ® Piston ® Spring ® Caliper air bleeder valve @ Brake hose union bolt © [...]

BRAKE PAD REPLACEMENT • Remove the brake pad mounting pin CD and spring ~. • Remove the brake pads. ICAUTION! * Do not operate the brake pedal while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. • Install the new brake pads and shims. ~ Pad mounting pin: 17 N·m (1.7 kgf-m, [...]

8·66 CHASSIS CALIPER REMOVAL AND DISASSEMBLY • Remove the brake pads. (c:::::Ta-65) • Remove the union bolt G) and catch the brake fluid in a suit- able receptacle. NOTE: Slightly loosen the caliper housing bolts CZ) to facilitate later dis- assembly before removing the caliper mounting bolts. I CAUTION I Never reuse the brake fluid left over [...]

CALIPER INSPECTION CALIPER INSPECTION (L78-58) BRAKE DISC INSPECTION (L78-60) _ Service Limit Rear disc thickness: 4.5 mm (0.177 in) Rear disc runout: 0.30 mm (0.012 in) CALIPER REASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of removal and dis- assembly. Pay attention to the following points: • Clean the caliper bores and p[...]

8·68 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBL Y • Remove the frame cover. (CT8-6) • Remove the brake fluid reservoir tank mounting bolt W. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt (Z) and disconnect the brake hose. • Loosen the lock-nut @. • Remove t[...]

MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET Inspect the cylinder bore wall for any scratches or other dam- age. Inspect the cup set and each rubber part for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: [...]

8·70 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 operating procedures, refer to the instructions su[...]

VALVE INSPECTION Inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal ® rubber is peeling 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 seal has abnormal deformation, replace the valve with a new one. Any d[...]

8·72 CHASSIS TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. I CAUTION I * Do not reuse the valve which has been once remo- ved. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant. • When installing the tire, the arrow ® on the s[...]

• In this condition, check the "rim line" @ 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 completely and unseat the bead for both sides. Coat the[...]

8·74 CHASSIS DRIVE CHAIN Use the special tool in the following procedures, to cut and rejoin the drive chain. ,ggt! 09922-22711: Drive chain cutting and joining tool set NOTE: When using the special tool, apply a small quantity of grease to the threaded parts of the special tool. DRIVE CHAIN CUTTING • Set up the special tool as shown in the illu[...]

• Place the drive chain link being disjointed on the holder part @ of the tool. • Turn in both the adjuster bolt @ and pressure bolt "A" @ so that each of their end hole fits over the chain joint pin properly. • Tighten the pressure bolt "A" @ with the bar. • Turn in the pressure bolt "B" @ with the bar @ and f[...]

8·76 CHASSIS • Apply grease on the recessed portion of the joint plate holder @ and set the joint plate @. NOTE: When positioning the joint plate @ on the tool, its stamp mark must face the joint plate holder@ side. • Set the drive chain on the tool as illustrated and turn in the adjuster bolt @ to secure the wedge holder & wedge pin @. ?[...]

CHASSIS 8-77 • Adjust the drive chain, after connecting it. (c:::::r2-22) • Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt "A" @ with the bar until the pin end diameter becomes the specified dimension. _ Pin end diameter specification © * After joining of the chain has been completed, check to make sure tha[...]

ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING .•......................••......................•......................... 9- 2 CONNECTOR ...............................................•.................................•....... 9- 2 COUPLER •..••...........•.....•.•....................•.......................••....•[...]

ELECTRICAL SYSTEM 9·1 FUEL PUMP RELAy 9-31 SWITCHES 9-31 BATTERY 9-33 SPECIFICA TIONS .••........................•..••...................•....................•..•..•.... 9-33 INITIAL CHARGING 9-33 SERVICING 9-34 RECHARGING OPERA TION 9-35 •[...]

9·2 ELECTRICAL SYSTEM 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 before disconnecting and push it in fully till the lock works when [...]

SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with semi-conductor built in such as 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 vehicle does not require mainte- nance (e.g., electrolyte level inspectio[...]

9·4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester c±l and 8 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 sure that no voltage is applied. If voltag[...]

ELECTRICAL SYSTEM 9-5 LOCATION OF ELECTRICAL COMPONENTS CD Ignition coil (No.1, 2, 3, 4) (2) Camshaft position sensor (c::::T 4-60) @ Fuel injector (c::::T4-51) @ Intake air pressure sensor (c::::T4-60) @ Engine coolant temperature sensor (c::::T4-61) @ Intake air temperature sensor (c::::T4-61) ({) Secondary throttle position sensor (c::::T4-62) @[...]

9-6 ELECTRICAL SYSTEM CD Fuel pump (CT5-7) 12) Fuel level switch @ Battery @ ECM (Engine Control Module) @ Starter relay/Main fuse @ Fuel pump relay (CT5-9) ([) Tip over sensor (CT4-61) @ Regulator/Rectifier @ Mode selection switch coupler (CT 4-23) @ Cooling fan (CT7-6) ® Speedometer sensor @ Gear position switch ® Side-stand switch ® Generator[...]

ELECTRICAL SYSTEM 9-7 CHARGING SYSTEM Generator Regulator/rectifier r------------, Ie IG.switch L ~ TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Go to Step 2. I i: I Remove accessories. Step 2 1) Check the battery for current leaks. (erg-8) Is the [...]

9-8 ELECTRICAL SYSTEM StepS 1) Measure the generator no-load voltage. (c:::79-9) Is the generator no-load voltage OK? I YES I_G_o_to_S_te...:- p_6_. ----------------------- NO _F_a_ul....:ty;,-.g:::,.e_n_e_ra_t_o_r. _ Step 6 1) Inspect the regulator/rectifier. (c:::79-10) Is the regulator/rectifier OK? YES Go to Step 7. NO Faulty regulator/rectifie[...]

ELECTRICAL SYSTEM 9·9 ( Battery 8 ) ••• ) j I Dev I 0=0 o~o ( REGULATED VOLTAGE • Remove the front seat. (c::::ra-6) • Start the engine and keep it running at 5 000 r/rnin. with light- ing switch turned ON and dimmer switch turned HI position. Measure the DC voltage between the @ and 8 battery termi- nals using the multi circuit tester. [...]

9·10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the frame cover. (c:::::ra-6) • Disconnect the regulator/rectifier coupler. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulatorlrectifier with a new one. ,gob 09900[...]

ELECTRICAL SYSTEM 9·11 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Fuse (30 A) Gear position i 2:- : (]) switch (Neutral) : 'iii ~ Ignition switch £7R Engine stop switch Starter button To Ignition coil A-It---t--- Y/G Starter relay BIY ~ Clutch lever ~ position switch B/W I ~ , TROUBLESHOOTING Starter motor will not run Step 1 1)[...]

9·12 ELECTRICAL SYSTEM Step 4 1) Check the starter relay. (c:::7'9-14) Is the starter relay OK? YES NO Poor contact of the starter relay. Faulty starter relay. Starter motor runs but does not crank the engine Step 1 1) The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other t[...]

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. COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut ®. If abnormal wear is found, replace the armature with a new one. If the commuta[...]

9·14 ELECTRICAL SYSTEM • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. ~ 99000-25140: SUZUKI MOLY PASTE • Fit the projection of the starter motor case to the depression of the housing end. • Apply SUZUKI SUPER GREASE to the a-ring. ~ 99000-25030: SUZUKI SUPER GREASE "A" (USA) 99000-25010: SUZUKI SUPER GREASE [...]

Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. ITUt! 09900-25008: Multi circuit tester set _ Starter relay resistance: 3 - 5 n SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for pr[...]

9·16 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Lift the fuel tank. (c::::TS-S) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in "NEUTRAL". ,gb 09900-25008: Multi circuit tester set ~ Tester knob indication: Continuity test (elll) ---- Blue Black/White ON (Ne[...]

TURN SIGNAL RELAY 8EB TURN SIGNAUSIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between © and ® terminals with the tester. Then apply 12 V to terminals © and © (CB to © and 8 t[...]

9·18 ELECTRICAL SYSTEM IGNITION SYSTEM ECM I P.owersource I circuit : Battery Fuse 1 Ignition switch .,. , #3 Engine stop switch bS;de- #1 -;;l stand relay I r-----,-Ern..~ r: v";»..-----t------t---------J -= CPU Cam position sensor 6 Waveform ~ b arrangement '--+--+-1-+-...-------. '-P--4---1 circuit - L::.::.:.~---l----' CKP[...]

ELECTRICAL SYSTEM 9·19 Step 2 1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the "ON" position. (E-02, 19: O/G and BIW, E-03, 24, 28, 33: OIW and BIW) Is the voltage OK? YES Go to Step 3. • Faulty ignition switch. • Faulty turn signal/side-stand relay. NO • Faulty engine stop switch. [...]

9·20 ELECTRICAL SYSTEM "- Contact to the cylinder head Avoid grounding the spark plugs and suppling the electrical shock to the cylinder head cover (magne- sium parts) to prevent the magnesium material from damage. INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the air cleaner box. (c::::75-15) • Disconnect all the ignition coil/p[...]

NOTE: Use the special tool, to prevent the rubber of the water proof coupler from damage. • Shift the transmission into neutral and turn ignition switch "ON". • Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage. • Repeat the above inspection a few time[...]

9·22 ELECTRICAL SYSTEM CKP SENSOR PEAK VOLTAGE • Remove the front seat. (eTa-6) NOTE: Be sure that all couplers are connected properly and the battery used is in fully-charged condition. • Disconnect the both couplers CD. • Connect the multi circuit tester with peak volt adaptor as fol- lows. • Measure the CKP sensor peak voltage between G[...]

ELECTRICAL SYSTEM 9·23 Peak volt adaptor CKP sensor coupler Q ~ G CKP sensor B--'----f"'"~ If the peak voltage is lower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. • Lift up the fuel tank. (c::::.rS-S) • Disconnect the CKP sensor lead wire coupler and connect the multi circuit tester[...]

9·24 ELECTRICAL SYSTEM COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This combination meter is light, thin and of high response compared to those currently in use because of this composition. The rpm pointer is driven by the stepping motor. T[...]

REMOVAL AND DISASSEMBLY • Remove the screws W, • Draw out the hook ~ from the head lamp housing. • Disconnect the lead wire coupler. • Remove the combination meter. I CAUTION I When disconnecting and reconnecting the combina- tion meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Disassemble [...]

9-26 ELECTRICAL SYSTEM INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights immediately after turning the ignition switch on. If the LED fails in operation, replace the combination meter unit with a new one after checking its wire har- ness/coupler. STEPPING MOTOR Check that the pointer calibrates itself immediately after turning the ign[...]

ENGINE COOLANT TEMPERATURE METER AND INDICATOR Engine coolant temperature sensor inspection. (c::::77-8) • Lift up the fuel tank. (c::::75-5) • Disconnect the engine coolant temperature sensor coupler CD. I CAUTION I When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition s[...]

9·28 ELECTRICAL SYSTEM FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (c::::rS-10, 11) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel level indicator switch as shown in the right illustrations. The bulb should come on after one minutes if the switch is in good condition. • When the swi[...]

ELECTRICAL SYSTEM 9-29 SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of couplers. If the speedometer sensor and connection are func- tioning properly, replace the meter with a new one. SPEEDOMETER SENSOR • Lift and support the fuel tank with its prop stay. (c::::rS[...]

9·30 ELECTRICAL SYSTEM LAMPS HEADLIGHT, BRAKE LlGHTrrAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT BRAKE L1GHTrrAILLIGHT: LED HEADLIGHT 12V55WH7(1) 12 V 60/55 W H4 ~ I I I I I I I l LICENCE PLATE LIGHT @ ~ 12 V 5 W ~ ~=~- 'fJ> (fJJ ~ ~ / ":---( / ~~f%, " ~ @ '~ / / ~ ~ ~ ~------------ ,/1 / .~~ ~~~® ~~ POSIT[...]

RELAYS TURN SIGNAUSIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. ELECTRICAL SYSTEM 9·31 SIDE-STAND RELAY "-------------, DIODE r TURN "- - - - - -, LollI : SIGNAL ..... , , RELAY : .. ~ 8 ffi ,-- ---, --- -- --" INSPECTION Before removing the turn signal/side-stan[...]

9·32 ELECTRICAL SYSTEM ~ O/w Y/G Position • PUSH 0 -0 Inspect each switch for continuity with a tester. If any STARTER BUnON abnormality is found, replace the respective switch assemblies with new ones. HAZARD SWITCH ~r B Lbl Lg Position • (OFF) ItA (ON) C r-.. -0 '-./ IGNITION SWITCH HORN BUnON ~ OIG G Position • PUSH 0 -0 ~r R 0 OIY B[...]

ELECTRICAL SYSTEM 9-33 INITIAL CHARGING Filling electrolyte • Remove the aluminum tape G) sealing the battery electrolyte filler holes. • Remove the caps (2). NOTE: * After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes. * Do not remove or pierce the sealed areas @ of the electrolyte containe[...]

9·34 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 from the bat- tery. Wait for about more than 20[...]

ELECTRICAL SYSTEM 9-35 o 10 20 30 40 50 60 Time (Minutes) Charging period ..L __ Stop charging ~ 1 """'" (V) 18 17 16 15 14 13 12 * When recharging the battery, remove the battery from the motorcycle. * Do not remove the caps on the battery top while recharging. RECHARGING OPERATION • Using the multi circuit tester, chec[...]

SERVICING INFORMATION 10-1 SERVICING INFORMA TION CONTENTS TROUBLESHOOTING .........................................••..•................................... 10- 2 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ...............................•..................•..••....•...........................•... 10- 2 ENGINE .............[...]

10-2 SERVICING INFORMATION TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR COO NO FAULT Camshaft position The signal does not reach ECM for 4 sec. and more, after sensor receiving the starter signal. C11 The camshaft position sensor wiring and mechanical parts. ([...]

SERVICING INFORMATION 10·3 MALFUNCTION DETECTED ITEM DETECTED FAILURE CONDITION CODE CHECK FOR Secondary throttle When no actuator control signal is supplied from the ECM or valve actuator communication signal does not reach ECM or operation voltage C28 does not reach STVA motor, C28 is indicated. STVA can not operate. STVA lead wire/coupler. Seco[...]

10-4 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Out of adjustment tappet clearance. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3. Mistiming valves. Adjust. 4. Excessively worn piston rings. Replace. 5. Worn-down cylinder [...]

SERVICING INFORMATION 10-5 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Out of adjustment tappet clearance. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshafts. Replace. 5. Too wide spark plug gaps. Adjust or repalace. 6. Defective ignition coil/plug caps. Replace.[...]

10-6 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large tappet clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace. Noise seems to come from piston 1. Worn down pistons or cylinders. Rep[...]

SERVICING INFORMATION 10·7 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs. Replace. 2. Worn camshafts. Replace. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Adjust. 5. Ignition not advanced sufficiently due to poo[...]

10·8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance. Adjust. 2. Weakened valve springs. Replace. 3. Out of adjustment valve timing. Adjust. 4. Worn piston rings or cylinders. Replace. 5. Poor seating of valves. Repair. 6. Fouled spark plu[...]

SERVICING INFORMATION 10·9 Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine. Check with inspection exhaust smoke. window drain out excess oil. 2. Worn piston rings or cylinders. Replace. 3. Worn valve guides. Replace. 4. Scored or scuffed cylinder walls. Replace. 5. Worn valves stems. Replace. 6. Def[...]

10·10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Adjust. 2. [...]

BRAKES SERVICING INFORMATION 10-11 Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion of engaging surface of pads/shoe. Clean disc and pads. 4. Worn disc. Replace. 5. Air in hydraulic system. Bleed air. 6. Not enough brake [...]

10·12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils or CKP sensor. Replace. sparking. 2. Defective spark plugs. Replace. 3. Defective sensor. Replace. 4. Defective ECM. Replace. 5. Defective tip over sensor. Replace. 6. Open-circuited wiring connections. Check and repa[...]

BATTERY SERVICING INFORMATION 10·13 I Complaint Symptom and possible causes Remedy "Sulfation", acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates. Battery runs down 1. Not correct the char[...]

10-14 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Position light Wiring harness Clamp Clamp IBa".", 8 r--~~ Brake light switch Headlight lead wire is made to slacken. Clamp Handlebar switch (R) Ignition switch[...]

SERVICING INFORMATION 10·15 License light Clamp Wiring harness Clamp Wiring harn~';.._~._.". 't h Oil pressure SWI c Side-stand switch Battery 8 CKP sensor Speed sensor EXCV actuator Clamp Wiring harness Clamp Clamp the wiring ~~~~=~;:;I harness to the frame, Clamp Handlebar switch (L) Clutch cable Rear turn signal light (L)[...]

....... er ....... en en m :::a < o z C) Z "T1 o :::a s:: ~ o z Clamp CKP sensor CMP sensor ' . , Let direction of a clamp be a clutch cover f mating surface at parallel. Oil pressure switch ~ 14N·m (1.4 kgf-m, 10.0 Ib-ft) J ~ 1.5 N·m (0.15 kgf-m, 1.0 Ib-ft) Front Q Clamp Generator Water bypass hose Water hose (Cylinder inlet) ~6N.m[...]

.",. .... CABLE ROUTING Throttle cable NO.1 ~ Throttle cable No.2 ~ Throttle cable NO.2 ~ Clutch cable Guide Pass through the throttle cable NO.1 over the throttle cable No.2. Throttle cable NO.2 ---.;'----"~'" Pass through the clutch cable under the engine mounting bracket. SERVICING INFORMATION 10-17 Clutch cable[...]

." I~ c: m r- en -I m :JJ » < ('; Z z " G> Z C "T1 0 ::D :JJ » :s:: » - -I Z 0 :z ::I: 0 /----'~-------~_/ ~ ~ en m ::D 0 c: :::! z G) .: /:--/ " r /~-_-=- -3- - ~ , , -' , , , , , , , , , , , , , , , , , , , r- : L ':. 1,- , ' , I : ) : -, ... ~-- , , , ---~';Tf;Oc~--,~l7'-,::) , -[...]

en m ::J:I < <'5 Z C> Z "T1 o ::J:I ii: :I> -I o :z ...... C? ...... CD o o o r- - Z C) (J) -< (J) -t m s: :J: o (J) m ::D o c: ::j z C) ® Left side Do not toutch the hose to the push rod. ®: The ends of the clamp face . ®: The clamp bolt head face . ® Left side t!J Clamp bolt 2 N·m (0.2 kgf-m, 1.5 lb-ft) ~ ® ~PR::; s[...]

en m :D < (") z C> z ~ :::D s:: ~ (5 z .... :G o "T1 :D o Z -I OJ :D ~ " m ::J: o en m :D o c: :::! z C) Insert the clamp to the hole of the front fender fully. '~-lln~ ·~OOUll Pass through the brake hose r ~ behind the throttle cables. I ~' ~~=J ~ . L _ ~ ~ . After positioning the clamp with I 1/ the stopper, tigh[...]

Pass thorough the brake hose inside of the guide. en m ;:Q < ('; z C> Z "T1 o ;:Q s:: ~ <5 :z: ...... ~ :D m » :D D:J :D » " m :::I: o CJ) m :D o c: -t - Z C) Face the clamp ends backward. ~~ X Frame --tm ~: ~(WJx~ ~ After touchinq the brake / Face the clamp ends forward hose union fa the 'toppe~ ~/ . tighten the un[...]

10·22 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Air cleaner box ' ! To throttle body (NO.~ cylinder) , PAIR valve vacuum hose ----f (530 mm) PAIR reed valve PAIR valve hose R (50 mm) PAIR valve ~ II It . ~ PAIR cleaner hose! mil ~"""' .. ~) I ~ 10 Nrn (1.0 kgf-m, 7.5Ib-ft) ~~~~~~--Matching mark : ~ ![...]

Adh~ r-: ~ "T1 C m r- -t » Z " en m -t I C "0 en m :XJ < (") z C) Z "'TI o :XJ 3: » --I zs :z .- CI ~ Co)[...]

U) m :::D < ('; z C> z on o :D 3: ~ (5 z ...... CI ~ o o =E .... - Z G') en m -I • c: "'tJ ~/ Left air intake pipe ~ ~~eftUnder ~ mner cowl I,g ~ Right al~ intake pipe /'41 Lower bracket cover ~[...]

FRAME COVER SET-UP SERVICING INFORMATION 10·25 HEAT SHIELD SET-UP >< Right under cowling Right under cowling heat shield Under cowling molding[...]

10·26 SERVICING INFORMATION SIDE-STAND SET-UP • (USA) I : : : t ~ e : ) <, 1 (5.0 kgf-m, 36.0 Ib-ft) / ~ 40N·m (4.0 kgf-m, 29.0 Ib-ft) GEARSHIFT PEDAL SET-UP /'" / / 60-70 mm (2.4 - 2.8 in)[...]

SEAT LOCK CABLE ROUTING SERVICING INFORMATION 10·27 Seat lock cable Seat lock[...]

10·28 SERVICING INFORMATION HANDLEBAR BALANCER Handle balancer expander Throttle grip Har"' ~.- Screw ~ 5.5N·m (0.5 kgf-m, 4.0 Ib-ft) Handlebar balancer[...]

SERVICING INFORMATION 10-29 SPECIAL TOOLS r 09900-06108 Snap ring pliers 09900-18740 Hexagon socket (24 mm) 09900-20101 09900-20102 Vernier calipers 09900-20202 Micrometer (25 - 50 mm) 09900-20203 Micrometer (50 -75 mm) 09900-20205 Micrometer (0-25 mm) 09900-20602 09900-20605 09900-20607 09900-20508 Dial gauge Dial calipers Dial gauge Cylinder gaug[...]

10·30 SERVICING INFORMATION 09913-13121 Vacuum balancer gauge 09913-50121 Oil seal remover 09913-70210 09915-40610 Bearing installer set Oil filter wrench 09915-64510 Compression gauge set 09915-74521 09915-74540 09915-77331 Oil pressure gauge Oil pressure gauge Meter 09916-10911 hose attachment (for high pressure) Valve lapper set 09916-14510 Val[...]

SERVICING INFORMATION 10·31 09921-20240 Bearing remover set 09920-53740 Clutch sleeve hub 09921-20210 holder Bearing remover 09920-34830 Starter clutch holder 09917-47010 Vacuum pump gauge 09922-22711 09925-18011 Drive chain cutting 09924-84510 Steering bearing and joining tool Bearing installer set installer 09930-11920 Torx bit JT40H 09930-11940[...]

10-32 SERVICING INFORMATION 09943-74111 Fork oil level gauge 09940-52861 Front fork oil seal 09940-92720 installer Spring scale ~ ~:: ;:::: ~ e 09940-40211 09940-40220 09940-50120 Fuel pressure gauge Fuel pressure gauge Front fork inner adaptor hose attachment rod holder £fJ 09940-94922 09940-94930 09941-34513 Front fork spring Front fork spacer S[...]

TIGHTENING TORQUE ENGINE SERVICING INFORMATION 10·33 ITEM N·m kgf-m Ib-ft Exhaust pipe bolt 23 2.3 16.5 Muffler connecting nut 25 2.5 18.0 Muffler mounting nut 23 2.3 16.5 Speed sensor rotor bolt 20 2.0 14.4 Engine sprocket nut 115 11.5 83.2 Engine mounting bolt and nut (M:12) 75 7.5 54.0 (M:10) 55 5.5 39.8 Engine mounting thrust adjuster 23 2.3 [...]

10·34 SERVICING INFORMATION ITEM N·m kgf-m Ib-ft Oil gallery plug (M: 6) 10 1.0 7.0 (M: 8) 18 1.8 13.0 (M: 10) 18 1.8 13.0 (M: 16) 35 3.5 26.5 Oil drain plug 23 2.3 16.5 Piston cooling oil jet bolt 10 1.0 7.0 Oil pump mounting bolt 10 1.0 7.0 Conrad bearing cap bolt (Initial) 21 2.1 15.1 (Final) 90 0 (1/4 turn) Bearing retainer screw 10 1.0 7.0 B[...]

CHASSIS SERVICING INFORMATION 10-35 ITEM N·m kgf-m Ib-ft Steering stem head nut 90 9.0 65.0 Steering stem lock-nut 80 8.0 58.0 Steering damper bolt and nut 23 2.3 16.5 Front fork upper clamp bolt 23 2.3 16.5 Front fork lower clamp bolt 23 2.3 16.5 Front fork cap bolt 23 2.3 16.5 Front fork inner rod lock-nut 29 2.9 21.0 Front fork damper rod bolt [...]

10·36 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or "4" marked bolt "7" marked bolt ®(mm) N·m kgf-m Ib-ft N·m kgf-m Ib-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1.0 7.0 8 13 1.3 9.5 23[...]

SERVICE DATA VALVE + VALVE GUIDE SERVICING INFORMATION 10·37 Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. 29 - (1.14) EX. 24 - (0.94) Tappet clearance (when cold) IN. 0.10 - 0.20 - (0.004 - 0.008) EX. 0.20 - 0.30 - (0.008 - 0.012) Valve guide to valve stem IN. 0.010- 0.037 - clearance (0.0004 - 0.0015) EX. 0.030 - 0.057 - (0.0012 - 0.0022) Va[...]

10-38 SERVICING INFORMATION ITEM STANDARD LIMIT Camshaft journal holder I.D. IN. & EX. 24.012 - 24.025 - (0.9454 - 0.9459) Camshaft journal O.D. IN. & EX. 23.959 - 23.980 - (0.9433 - 0.9441) Camshaft runout 0.10 - (0.004) Cam chain pin (at arrow "3") 14th pin - Cylinder head distortion 0.20 - (0.008) CYLINDER + PISTON + PISTON RIN[...]

SERVICING INFORMATION 10·39 ITEM STANDARD LIMIT Piston ring thickness 1st 0.97 - 0.99 - (0.0382 - 0.0390) 2nd 0.77 - 0.79 - (0.0303 - 0.0311) Piston pin bore 1.0. 16.002 - 16.008 16.030 (0.6300 - 0.6302) (0.6311 ) Piston pin 0.0. 15.995 - 16.000 15.980 (0.6297 - 0.6299) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small en[...]

10·40 SERVICING INFORMATION OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C, 140 OF) 100 - 400 kPa (1.0 - 4.0 kgf/cm 2 , 14 - 57 psi) - at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 -15 - (0.4 - 0.6) Clutch release screw 1/4 turn back - Drive plate thickness No.1, 2 and 3 2.45 - 2.95 2.15 (0.096 - 0.116) (0.085)[...]

SERVICING INFORMATION 10·41 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening Approx. 82°C (180 OF) - temperature Thermostat valve lift 8 mm (0.31 in) and over at 95°C (203 OF) - ECT sensor resistance 20°C Approx. 2.45 kQ - (68 OF) 50°C Approx. 0.811 kQ - (122 OF) 80°C Approx. 0.318 kQ - (176 OF) [...]

10-42 SERVICING INFORMATION FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE CMP sensor resistance 0.9 -1.7 k Q CMP sensor peak voltage 0.5 V and more When cranking CKP sensor resistance 70 -220 Q CKP sensor peak voltage 0.5 V and more When cranking lAP sensor input voltage 4.5 - 5.5 V lAP sensor output voltage Approx. 2.6 V at[...]

THROTTLE BODY SERVICING INFORMATION 10·43 ITEM SPECIFICATION Bore size 42mm 1.0. No. 40F5 (For E-33), 40F4 (For the others) Idle r/min. 1150±100r/min. Fast idle r/min. 2200 r/min. (After warming up) Throttle cable play 2.0-4.0 mm (0.08 - 0.16 in) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1.2.4.3 Spark plug Type NGK: CR9E DENSO[...]

10-44 SERVICING INFORMATION WATTAGE Unit: W ITEM STANDARD/SPECIFICATION E-03, -24, -28, -33 Others Headlight HI 60/55 W f- LO 55/55 W 55W Position/Parking light 5W Brake lightlTaillight LED f- Turn signal light 18 W x 4 f- License plate light 5W f- Combination meter light LED f- Turn signal indicator light LED f- High beam indicator light LED f- Ne[...]

SERVICING INFORMATION 10·45 ITEM STANDARD LIMIT Brake caliper piston diam 30.150 - 30.200 - Front (1.1870-1.1890) - Rear 38.110 - 38.130 - (1.5004 - 1.5012) Brake fluid type DOT 4 - Wheel rim runout Axial 2.0 - (0.08) Radial 2.0 - (0.08) Wheel rim size Front 17 MIG x MT 3.50 - Rear 17 MIG x MT 6.00 - Wheel axle runout Front 0.25 - (0.010) Rear 0.2[...]

10·46 SERVICING INFORMATION SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke 120 - (4.92) Front fork spring free length 230.0 225 (9.06) (8.86) Front fork oil level (without spring, 101 - outer tube fully compressed) (3.98) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil - Front fork oil capacity (each leg) 509 ml -[...]

FUEL + OIL SERVICING INFORMATION 10·47 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane ( R:2 M ). Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be [...]

EMISSION CONTROL INFORMATION 11-1 EMISSION CONTROL INFORMA TION CONTENTS EMISSION CONTROL SySTEMS 11- 2 FUEL INJECTION SySTEM 11- 2 CRANKCASE EMISSION CONTROL SYSTEM .................................•. 11- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) 11- 4 NOISE EMISSION CONTROL SYSTEM 1 1- 5 EVAPORA TIVE EMISSION CONTROL SYSTEM (Only for E-33[...]

11-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM G8X-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. Fuel tank Fuel mesh filter "". (Forlow pres[...]

EMISSION CONTROL INFORMATION 11·3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body. <::::=:J FRESH AIR ~ VACUUM ¢:s FUEUAIR MIXTURE ... BLOW-BY[...]

11-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and exhaust control system. The fresh air is drawn into the exhaust port with the PAIR valve and PAIR reed valve. The PAIR valve is oper- ated by the engine vacuum, and the exhaust gas flow is controlled[...]

EMISSION CONTROL INFORMATION 11-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated int[...]

11·6 EMISSION CONTROL INFORMATION PAIR (AIRSUPPL Y) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VALVE • Remove the PAIR reed valve cover. • Inspect the reed valve for the carbon deposit. • If the carbon deposit is found in the reed valve, replace the[...]

PAIR (AIR SUPPLY) SYSTEM DIAGRAM To #4 throttle body (Vacuum inlet) SECTION A-A E FRESH AIR ~-------- EXHAUST GAS EMISSION CONTROL INFORMATION 11-7 From air cleaner[...]

11-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Air cleaner box , PAIR valve hose L (30 mm) I r ) ~ To throttle body (No.4 cylinder) PAIR valve hose R (50 mm) r PAIR de""e' hosJ ~=====:;:;::;;7---- Matching mark ! I PAIR valve vacuum hose -----f (530 mm) PAIR reed valve PAIRvalve~ • ~ .. -'" ~ [...]

EMISSION CONTROL INFORMATION 11·9 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION ~ (Only for E-33) • Remove the seat and frame cover. (c:::J"a-6) • Lift and support the fuel tank with its prop stay. (c:::J"S-S) HOSES Inspect the hoses for wear or damage. Make sure that the hoses are securely connected. EVAP CANISTER Inspect the canis[...]

11·10 EMISSION CONTROL INFORMATION EV AP CANISTER HOSE ROUTING (Only for E-33) Surge hose (Red tracer) -- -- - -[...]

WIRING DIAGRAM E-03, 24, 28, 33 Wiring diagrams wire color, refer to section "WIRE COLOR". HANDLEBAR SWITCH (R) HAZARD ENGINESTOP STARTER FRONT BRAKE SWITCH SWITCH BUTTON SWITCH ~ {.:..=iT ~ ~tz~~~AND I -------l I IGNITIDNSWITCH ~~ij~ rr ...... RO Br FREE SPEED ON PUSH • 1"""1::: I':; I r~ "!'TI P I J BRAKE[...]

[...]

E-02,19 TURN SIGNAL INDICATOR LIGHT HI BEAM INDICATOR LIGHT NEUTRAL INDICATOR LIGHT FUEL WARNNING LIGHT OIL INDICATOR LIGHT 1 I HANDLEBAR SWITCH (Rl HAZARD ENGINESTDP STARTER FRONT BRAKE SWITCH SWITCH BUTTON SWITCH ~~ OFF IGNITION IGNITION IGNITION IGNIT10l ~ il il m= ,:"~~~:~~.," 1~1I',;i1l~ lit. ",:E "@~f!;,,,r SENSOR OFF[...]

( !I!~R CIlIB~B/l9 <! p P/W )lO G G- 3: W/B W/B BI R- ~~ Y YIW z-a B BlBr CIl o " 3:~~GrlW ~~Y/R ::!i ~ rnilOOrl1- G,/B ~~Y/R ~ ~ rnilOOrl1- G,ty ~~V/R ~- ~~~Gr/R ~ = VIR ~<n-<lGE. R ~-a P P/B o • BlBr '" ~U~~og ~ BlBr o '" ( ( lUI WIB -G- GIS B/lg P/W V/W Og VIR -R- P/B G,ty G,IB III __ ~: ---B/Br ~f;!VIR!lE:V/R[...]