TOP
VZ800
99500-38050-01E
K5
Printed in Japan
K5
VZ800
BOTTOM
No.5230 99500-38050-01E VZ800K5 Service Manual 2004. 11. 29 Cover_14 for PS printing (16 mm)
DIC75
FOREWORD
This manual contains an introductory description on
the SUZUKI VZ800 and procedures for its inspection/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast
and reliable service.
* This manual has been prepared on the basis
of the latest specifications at the time of publication. If modifications have been made since
then, differences may exist between the content of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
SHAFT DRIVE
4
FI SYSTEM
5
FUEL SYSTEM AND THROTTLE
BODY
6
COOLING AND LUBRICATION
SYSTEM
7
CHASSIS
8
ELECTRICAL SYSTEM
9

Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
SERVICING INFORMATION
10
EMISSION CONTROL
INFORMATION
11
WIRING DIAGRAM
12
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 the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1
2
3
4
5
Front axle
Bearing (R)
Front wheel
Spacer
Bearing (L)
6 Brake disc
7 Spacer
A Front axle
B Brake disc mounting bolt

ITEM
A
B
N·m
65
23
kgf-m
6.5
2.3
lb-ft
47.0
16.5
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.
SYMBOL
1216
DEFINITION
SYMBOL
DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply oil. Use engine oil unless otherwise specified.
Use engine coolant.
99000-99032-11X
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Use fork oil.
99000-99044-L01
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in resistance range.
Apply SUZUKI BOND “1207B”.
99000-31140
Measure in current range.
Apply SUZUKI BOND “1216B”.
99000-31230
Measure in diode test range.
Apply THREAD LOCK SUPER “1303”.
99000-32030
Measure in continuity test range.
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
Use special tool.
Apply THREAD LOCK “1342”.
99000-32050
Indication of service data.
ABBREVIATIONS USED IN THIS
MANUAL
E
A
ECM
: Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
EOT Sensor : Engine Oil Temperature
Sensor (EOTS), Oil Temp.
Sensor
EVAP
: Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Canister)
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)
A/F
: Air Fuel Mixture
F
B
BBDC
BTDC
B+
FI
FP
FPR
FP Relay
: Before Bottom Dead Center
: Before Top Dead Center
: Battery Positive Voltage
: Fuel Injection, Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT
: Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO
: Carbon Monoxide
CPU
: Central Processing Unit
G
GEN
GND
GP Switch
: Generator
: Ground
: Gear Position Switch
H
HC
: Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
D
DC
DMC
DOHC
DRL
: Direct Current
: Dealer Mode Coupler
: Double Over Head Camshaft
: Daytime Running Light
I
IAP Sensor
IAT Sensor
IG
: Intake Air Pressure Sensor (IAPS)
: Intake Air Temperature Sensor
(IATS)
: Ignition
L
LCD
LED
LH
: Liquid Crystal Display
: Light Emitting Diode
(Malfunction Indicator Lamp)
: Left Hand
M
MAL-Code
Max
MIL
Min
: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
(LED)
: Minimum
N
NOx
: Nitrogen Oxides
O
OHC
OPS
: Over Head Camshaft
: Oil Pressure Switch
P
PCV
: Positive Crankcase
Ventilation (Crankcase Breather)
R
RH
ROM
: Right Hand
: Read Only Memory
S
SAE
: Society of Automotive Engineers
SDS
: Suzuki Diagnosis System
STC System : Secondary Throttle Control
System (STCS)
STP Sensor : Secondary Throttle Position
Sensor (STPS)
ST Valve
: Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor
TP Sensor
: Tip Over Sensor (TOS)
: Throttle Position Sensor (TPS)
WIRE COLOR
B
Bl
Br
Dg
G
B/Bl
B/G
B/R
B/Y
Bl/G
Bl/W
Br/B
G/B
G/Y
Gr/R
Lg/G
O/BI
O/R
O/Y
R/B
W/B
W/R
Y/Bl
Y/R
: Black
: Blue
: Brown
: Dark green
: Green
Gr
Lbl
Lg
O
P
: Black with Blue tracer
: Black with Green tracer
: Black with Red tracer
: Black with Yellow tracer
: Blue with Green tracer
: Blue with White tracer
: Brown with Black tracer
: Green with Black tracer
: Green with Yellow tracer
: Gray with Red tracer
: Light green with Green tracer
: Orange with Blue tracer
: Orange with Red tracer
: Orange with Yellow tracer
: Red with Black tracer
: White with Black tracer
: White with Red tracer
: Yellow with Blue tracer
: Yellow with Red tracer
: Gray
: Light blue
: Light green
: Orange
: Pink
R
W
Y
B/Br
B/Lg
B/W
Bl/B
Bl/R
Bl/Y
Br/W
G/W
Gr/B
Gr/W
O/B
O/G
O/W
P/W
R/Bl
W/Bl
Y/B
Y/G
Y/W
: Red
: White
: Yellow
: Black with Brown tracer
: Black with Light green tracer
: Black with White tracer
: Blue with Black tracer
: Blue with Red tracer
: Blue with Yellow tracer
: Brown with White tracer
: Green with White tracer
: Gray with Black tracer
: Gray with White tracer
: Orange with Black tracer
: Orange with Green tracer
: Orange with White tracer
: Pink with White tracer
: Red with Blue tracer
: White with Blue tracer
: Yellow with Black tracer
: Yellow with Green tracer
: Yellow with White tracer
GENERAL INFORMATION
1-1
GENERAL INFORMATION
1
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1GENERAL PRECAUTIONS ...........................................................................1SUZUKI VZ800K5 (’05-MODEL) ...................................................................1SERIAL NUMBER LOCATION ......................................................................1FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .......................1FUEL (FOR USA AND CANADA) ..........................................................1FUEL (FOR OTHER COUNTRIES) ........................................................1ENGINE OIL ...........................................................................................1BRAKE FLUID ........................................................................................1FRONT FORK OIL .................................................................................1ENGINE COOLANT ...............................................................................1WATER FOR MIXING ............................................................................1ANTI-FREEZE/ENGINE COOLANT .......................................................1LIQUID AMOUNT OF WATER/ENGINE COOLANT .............................1BREAK-lN PROCEDURES ...........................................................................1CYLINDER IDENTIFICATION .......................................................................1INFORMATION LABELS ...............................................................................1SPECIFICATIONS .........................................................................................1-
2
2
4
4
4
4
4
5
5
5
5
5
5
5
6
6
7
8
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE
E-02
E-03
E-19 (VZ800)
E-19 (VZ800U)
E-24
E-28
E-33
COUNTRY or AREA
U.K.
U.S.A. (Except for California)
E.U.
E.U.
Australia
Canada
California (U.S.A.)
EFFECTIVE FRAME NO.
JS1B4111200100001 –
JS1VS56A 52100001 –
JS1B4111100100001 –
JS1B4211100100001 –
JS1B4111300100001 –
JS1VS56A 52100001 –
JS1VS56A 52100001 –
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 messages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
* When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
GENERAL INFORMATION

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
* 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 sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head and case bolts or nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-3
1-4
GENERAL INFORMATION
SUZUKI VZ800K5 (’05-MODEL)
RIGHT SIDE
LEFT SIDE
* Difference between illustration and actual motorcycle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the
steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the
research method.
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 COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.
GENERAL INFORMATION
1-5
ENGINE OIL
Oil quality is a major contributor to your engine’s performance
and life. Always select good quality engine oil. Use of API SF/
SG or SH/SJ with JASO MA.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available, select an alternative according to the right chart.
BRAKE FLUID
Specification and classification: DOT 4

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.
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
The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use
an equivalent which is compatible with an aluminum radiator.
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total): 1 750 ml (1.85/1.54 US/Imp qt)
For engine coolant mixture information, refer to cooling system section in page 5-3.

Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce
its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point.
1-6
GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very
high standard. 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 depends on the care and restraint
exercised during its early life. Refer to the following break-in engine speed recommendations.
• Keep to these break-in throttle positions during the break-in period.
Break-in throttle operation
Initial
800 km ( 500 miles): Less than 1/2 throttle
Up to 1 600 km (1 000 miles): Less than 3/4 throttle
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation.
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No. 1 and No. 2 cylinder, as counted from front to rear (as
viewed by the rider on the seat).
#2
#1
GENERAL INFORMATION
INFORMATION LABELS
VZ800
1 Noise label
2 Information label
3 Vacuum hose routing label
4 Manual notice label
5 Fuel caution label
6 Tire information label
7 General warning label
8 ICES Canada label
9 I.D. plate
0 Safety plate
A For E-03, 24, 33
A For E-03, 28, 33
A For E-33
A For E-03, 33
A For E-02, 24
A
A
A For E-28
A Except for E-03, 28, 33
A For E-03, 28, 33
A: Attached
Except for E-03, 33
For E-03, 33
For E-24
For E-03, 33
1-7
1-8
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.......................................................2 370 mm (93.3 in)
Overall width ........................................................ 920 mm (36.2 in)
Overall height.......................................................1 125 mm (44.3 in)
Wheelbase ...........................................................1 655 mm (65.2 in)
Ground clearance ................................................ 140 mm (5.5 in)
Seat height........................................................... 700 mm (27.6 in)
Dry mass.............................................................. 247 kg (545 lbs)
ENGINE
Type .....................................................................4-stroke, liquid-cooled, OHC, 45° degree V-twin
Number of cylinders .............................................2
Bore .....................................................................83.0 mm (3.268 in)
Stroke...................................................................74.4 mm (2.929 in)
Displacement .......................................................805 cm³ (49.1 cu. in)
Compression ratio................................................9.4 : 1
Fuel system..........................................................Fuel injection
Air cleaner............................................................Non-woven fabric element
Starter system......................................................Electric
Lubrication system ...............................................Wet sump
Idle speed ............................................................1 100 ± 100 r/min
DRIVE TRAIN
Clutch...................................................................Wet multi-plate type
Transmission........................................................5-speed constant mesh
Gearshift pattern ..................................................1-down, 4-up
Primary reduction ratio.........................................1.690 (71/42)
Gear ratios, Low ..................................................2.461 (32/13)
2nd...................................................1.631 (31/19)
3rd ...................................................1.227 (27/22)
4th....................................................1.000 (25/25)
Top ..................................................0.814 (22/27)
Final reduction ratio .............................................3.503 (17/15 × 34/11)
Drive system ........................................................Shaft drive
GENERAL INFORMATION
CHASSIS
Front suspension................................................. Inverted telescopic, coil spring, oil damped
Rear suspension ................................................. Swingarm type, coil spring, oil damped
Front suspension stroke...................................... 140 mm (5.5 in)
Rear wheel travel ................................................ 105 mm (4.1 in)
Caster.................................................................. 33° 15’
Trail ..................................................................... 141 mm (5.6 in)
Steering angle ..................................................... 38° (right & left)
Turning radius ..................................................... 3.0 m (9.8 ft)
Front brake.......................................................... Disc brake, twin
Rear brake .......................................................... Drum brake
Front tire size ...................................................... 130/90-16M/C (67H), tubeless
Rear tire size ....................................................... 170/80-15M/C (77H), tubeless
ELECTRICAL
lgnition type ......................................................... Electronic ignition (Transistorized)
lgnition timing ...................................................... 5° B.T.D.C at 1 100 r/min
Spark plug ........................................................... NGK: DPR7EA-9 or DENSO: X22EPR-U9
Battery................................................................. 12 V 36.0 kC (10 Ah)/10 HR
Generator ............................................................ Three-phase A.C. Generator
Main fuse............................................................. 30 A
Fuse .................................................................... 10/10/10/10/10/15 A
Headlight ............................................................. 12 V 60/55 W (H4)
Parking or city light.............................................. 12 V 5 W...................................... For E-02, 19
Front turn signal light........................................... 12 V 21/5 W................................. For E-03, 28, 33
12 V 21 W.................................... For the others
Rear turn signal light ........................................... 12 V 21 W
Brake light/Taillight.............................................. LED
Speedometer light ............................................... LED
Fuel level indicator light....................................... LED
Turn signal indicator light .................................... LED
Neutral indicator light .......................................... LED
High beam indicator light..................................... LED
Oil pressure/Coolant temperature/Fuel injection
warning light ........................................................ LED
CAPACITIES
Fuel tank, including reserve................................ 15.0 L (4.0/3.3 US/Imp gal) ....... For E-33
15.5 L (4.1/3.4 US/Imp gal) ....... For the others
reserve............................................... 3.0 L (0.8/0.7 US/Imp gal)
Engine oil, oil change ........................................ 3 000 ml (3.2/2.6 US/Imp qt)
with filter change.............................. 3 400 ml (3.6/3.0 US/Imp qt)
overhaul ........................................... 3 700 ml (3.9/3.3 US/Imp qt)
Front fork oil (each leg) ....................................... 493 ml (16.7/17.4 US/Imp oz)
Coolant................................................................ 1.5 L (1.59/1.32 US/Imp qt)
These specifications are subject to change without notice.
1-9
PERIODIC MAINTENANCE
2-1
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
LUBRICATION POINTS .........................................................................2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 4
AIR CLEANER .......................................................................................2- 4
SPARK PLUG ........................................................................................2- 5
VALVE CLEARANCE ............................................................................2- 7
FUEL HOSE ...........................................................................................2-10
ENGINE OIL AND OIL FILTER ..............................................................2-11
ENGINE IDLE SPEED ............................................................................2-13
THROTTLE CABLE PLAY .....................................................................2-14
THROTTLE VALVE SYNCHRONIZATION ............................................2-15
EVAPORATIVE EMISSON CONTROL SYSTEM (FOR E-33 ONLY) ...2-15
PAIR (AIR SUPPLY) SYSTEM ...............................................................2-15
CLUTCH .................................................................................................2-16
COOLING SYSTEM ...............................................................................2-17
FINAL GEAR OIL ...................................................................................2-19
BRAKE ...................................................................................................2-19
TIRE ........................................................................................................2-23
STEERING ..............................................................................................2-23
FRONT FORK ........................................................................................2-24
REAR SUSPENSION .............................................................................2-24
EXHAUST PIPE BOLT ...........................................................................2-24
CHASSIS BOLT AND NUT ....................................................................2-25
COMPRESSION PRESSURE CHECK ............................................................2-27
COMPRESSION TEST PROCEDURE ...................................................2-27
OIL PRESSURE CHECK .................................................................................2-28
OIL PRESSURE TEST PROCEDURE ...................................................2-28
SDS CHECK ....................................................................................................2-29
SAMPLE: ................................................................................................2-29
Data sampled from cold starting through warm-up ..........................2-29
Data at 3 000 r/min under no load .......................................................2-30
Data at the time of racing .....................................................................2-30
2
6
6
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 kilometers, miles and time for your convenience.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
km
miles
Item
Air cleaner element
Exhaust pipe bolts and muffler bolts
Valve clearance
Spark plugs
Fuel hose
Engine oil
Engine oil filter
Idle speed
Throttle cable play
Throttle valve synchronization
Evaporative emission control system
(California model only)
months
1 000
6 000
12 000
18 000
24 000
600
2
—
T
I
—
—
R
R
I
I
I
(CA. only)
—
4 000
12
I
—
—
I
I
R
—
I
I
7 500
24
I
T
I
R
I
R
—
I
I
11 000
36
R
—
—
I
I
R
R
I
I
14 500
48
I
T
I
R
I
R
—
I
I
—
I
—
I
PAIR (air supply) system
Engine coolant
Radiator hose
Clutch
Final gear oil
Brakes
Brake hose
—
Brake fluid
—
Tires
Steering
Front fork
Rear suspension
Chassis bolts and nuts
—
I
—
—
T
—
—
R
I
—
—
I
—
Replace vapor hose every 4 years.
—
I
—
Replace every 2 years.
I
I
I
I
I
I
—
I
—
I
I
I
I
I
I
Replace every 4 years.
I
I
I
Replace every 2 years.
I
I
I
—
I
—
—
I
—
—
I
—
T
T
T
NOTE:
I = Inspect and clean, adjust, replace or lubricate as necessary
R = Replace
T = Tighten
I
I
I
I
I
I
I
I
I
I
I
I
T
PERIODIC MAINTENANCE
2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Clutch lever holder
Side-stand pivot and
spring hook
Gearshift link pivot
Brake lever holder
Throttle cable
Brake pedal pivot
and brake rod link
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
2-4
PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
AIR CLEANER
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 18 000 km (11 000 miles, 36 months).
• Remove the air cleaner cover 1.
• Remove the air cleaner element 2.
• Carefully use air hose to blow the dust from the cleaner element.

Always use air pressure on the engine side of the air
cleaner element. If air pressure is used on the other
side, dirt will be forced into the pores of the air cleaner
element thus restricting air flow through the air
cleaner element.
• Reinstall the cleaned or new air cleaner element in the
reverse order of removal.

If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component!
PERIODIC MAINTENANCE
NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug.
SPARK PLUG
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 12 000 km (7 500 miles, 24 months).
No. 1 (FRONT) SPARK PLUG REMOVAL
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Remove the right frame cover 1.
: Hooked part
• Remove the spark plug cap.

The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.
• Remove the spark plug with a spark plug wrench.
 09930-14530: Universal joint
2-5
2-6
PERIODIC MAINTENANCE
No. 2 (REAR) SPARK PLUG REMOVAL
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Remove the spark plug cap.
• Remove the spark plug with a spark plug wrench.
HEAT RANGE
• Check to see the heat range of the plug.
NGK
DENSO
Standard
DPR7EA-9
X22EPR-U9
Cold type
DPR8EA-9
X24EPR-U9
CARBON DEPOSIT
• Check to see if there are carbon deposits on the plugs. If carbon is deposited, remove it with a spark plug cleaner machine
or carefully using a tool with a pointed end.
SPARK PLUG GAP
• Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.
 09900-20803: Thickness gauge
 Spark plug gap A
Standard: 0.8 – 0.9 mm (0.031 – 0.035 in)
ELECTRODES CONDITION
• Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.

Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine damage may result.
PERIODIC MAINTENANCE
SPARK PLUG AND PLUG CAP INSTALLATION
• Install the spark plugs to the cylinder heads by finger tight,
and then tighten them to the specified torque.
 Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

When installing a spark plug, carefully turn the spark
plug wrench by finger into the threads of the cylinder
head to prevent damage the aluminum threads.
• Install the spark plug caps.
VALVE CLEARANCE
Inspect initially at 1 000 km (600 miles, 2 months) and
every 12 000 km (7 500 miles, 24 months) thereafter.
Valve clearance must be checked and adjusted when:
(1) the valve mechanism is service, and
(2) the camshafts are serviced.
Check and adjust the clearance to the specification.
 Valve clearance (when cold):
IN. 0.08 – 0.13 mm (0.003 – 0.005 in)
EX. 0.17 – 0.22 mm (0.007 – 0.009 in)
NOTE:
* The clearance specification is for COLD state.
* Both intake and exhaust valves must be checked and adjusted
when the piston is at Top Dead Center (TDC) of the compression stroke.
•
•
•
•
•
Remove the rear and front seats. (8-3)
Remove the fuel tank. (6-3)
Remove the right frame cover. (8-4)
Remove the spark plug caps.
Loosen the inlet pipe screws.
2-7
2-8
PERIODIC MAINTENANCE
• Remove the cylinder head cover caps (1, 2).
• Remove the PAIR pipe.
• Remove the gasket 3.

Do not reuse the removed gasket.
PERIODIC MAINTENANCE
• Remove all the inspection caps.
• Remove all the spark plugs.
• Remove the generator cover plug 4.
• Remove the cap 5 and the timing inspection plug 6.
• Rotate the generator rotor to set the No. 1 engine’s piston at
TDC of the compression stroke. (Rotate the rotor until the “R I
T” line on the rotor is aligned with the center of hole on the
generator cover.)
R T
• To inspect the No. 1 engine’s valve clearance, insert the thickness gauge to the clearance between the valve stem end and
the adjusting screw on the rocker arms.
 09900-20806: Thickness gauge
• If the clearance is out of the specification, bring it into the
specified range by using the special tool.
 09917-10410: Valve adjust driver
2-9
2-10
PERIODIC MAINTENANCE

Both right and left valve clearances should be as
closely set as possible.
• Rotate the generator rotor 450 degrees (1 and 1/4 turns) and
align the “F I T” line on the rotor with the center of hole on the
generator cover.
F T
Inspect the No. 2 engine’s valve clearance as the same manner
above.
NOTE:
Use the thickness gauge from the arrow marks as shown in the
illustration.
FRONT
No. 2 Engine
FUEL HOSE
Inspect every 6 000 km (4 000 miles, 12 months).
Inspect the fuel feed hose for damage and fuel leakage. If any
defects are found, the fuel hoses must be replaced.
No. 1 Engine
PERIODIC MAINTENANCE
ENGINE OIL AND OIL FILTER
(ENGINE OIL)
Replace initially at 1 000 km (600 miles, 2 months) and
every 6 000 km (4 000 miles, 12 months) thereafter.
(OIL FILTER)
Replace initially at 1 000 km (600 miles, 2 months) and
every 18 000 km (11 000 miles, 36 months) thereafter.
Oil should be changed while the engine is warm. Oil filter
replacement at the above intervals, should be done together
with the engine oil change.
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright.
• Place an oil pan below the engine, and drain oil by removing
the drain plug 1 and filler cap 2.
• Tighten the drain plug 1 to the specified torque, and pour
fresh oil through the oil filler. The engine will hold about 3.0 L
(3.2/2.6 US/Imp qt) of oil. Use of API SF/SG or SH/SJ with
JASO MA.
 Oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
• Start up the engine and allow it to run for several minutes at
idling speed.
• Turn off the engine and wait about three minutes, then check
the oil level through the inspection window A. If the level is
below mark “L”, add oil to “F” level. If the level is above mark
“F”, drain oil to “F” level.
2-11
2-12
PERIODIC MAINTENANCE
OIL FILTER REPLACEMENT
• Drain engine oil in the same manner of engine oil replacement
procedure.
• Remove the oil filter 1 by using the oil filter wrench. (Special
tool)
• Apply engine oil lightly to the O-ring of the new filter before
installation.
• Install the new filter turning it by hand until you feel that the filter O-ring contacts the mounting surface. Then tighten it 2
turns using the oil filter wrench. ( 20 N·m, 2.0 kgf-m, 14.5
lb-ft)
 09915-40610: Oil filter wrench
NOTE:
To properly tighten the filter, use the special tool. Never tighten
the filter by hand.
• Pour fresh engine oil and check the oil level in the same manner of engine oil replacement procedure.
 Engine oil capacity
Oil change:
3.0 L (3.2/2.6 US/Imp qt)
Filter change:
3.4 L (3.6/3.0 US/Imp qt)
Overhaul engine: 3.7 L (3.9/3.3 US/Imp qt)

ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL
FILTER. Other manufacturer’s oil filters may differ in
thread specifications (thread diameter and pitch), filtering performance and durability which may lead to
engine damage or oil leaks. Also, do not use a genuine
Suzuki automobile oil filter on this motorcycle.
After contacting the O-ring,
tighten 2 turns.
PERIODIC MAINTENANCE
ENGINE IDLE SPEED
Inspect initially at 1 000 km (600 miles, 2 months) and
every 6 000 km (4 000 miles, 12 months) thereafter.
NOTE:
Warm up the engine before adjusting the engine idle speed.
• Connect the multi-circuit tester to the high-tension cord.
• Start up the engine and set its idle speed to the specified
range by turning the throttle stop screw 1.
 Engine idle speed: 1 100 ± 100 r/min
 09900-25008: Multi-circuit tester set
2-13
2-14
PERIODIC MAINTENANCE
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (600 miles, 2 months) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Adjust the throttle cable play A with the following three steps.
MINOR ADJUSTMENT
First step:
• Loosen the lock nut 1 of the throttle returning cable 2 and
turn in the adjuster 3 fully into the threads.
Second step:
• Loosen the lock nut 4 of the throttle pulling cable 5.
• Turn the adjuster 6 in or out until the throttle cable play A
should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.
• Tighten the lock nut 4 while holding the adjuster 6.
Third step:
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster 3 of the throttle returning cable 2
to feel resistance.
• Tighten the lock nut 1 while holding the adjuster 3.
 Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
NOTE:
Major adjustment can be made by the throttle body side
adjuster.
PERIODIC MAINTENANCE
MAJOR ADJUSTMENT
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Loosen the lock nut 1 of the throttle returning cable.
• Turn the returning cable adjuster 2 to obtain proper cable
play.
• Loosen the lock nut 3 of the throttle pulling cable.
• Turn the pulling cable adjuster 4 in or out until the throttle
cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the
throttle grip.
• Tighten the lock nut 3 securely while holding the adjuster 4.
Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
• While holding the throttle grip at the fully closed position,
slowly turn the returning cable adjuster 2 to obtain a slack of
1.0 mm (0.04 in).
• Tighten the lock nut 1 securely.

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
THROTTLE VALVE SYNCHRONIZATION
Inspect initially at 1 000 km (600 miles, 2 months) (For
E-33 only) and every 12 000 km (7 500 miles, 24
months).
Inspect the throttle valve synchronization periodically.
(6-24)
EVAPORATIVE EMISSON CONTROL SYSTEM (FOR E-33 ONLY)
Inspect every 12 000 km (7 500 miles, 24 months).
Replace vapor hose every 4 years.
(11-9)
PAIR (AIR SUPPLY) SYSTEM
Inspect every 12 000 km (7 500 miles, 24 months).
Inspect the PAIR (air supply) system periodically.
(11-5)
1 mm
(0.04 in)
2-15
2-16
PERIODIC MAINTENANCE
CLUTCH
Inspect every 6 000 km (4 000 miles, 12 months).
• Loosen the lock nut 1.
• Turn in the adjuster 2 all the way into the clutch lever assembly.
• Remove the left frame cover. (8-3)
• Remove the secondary gear case cover 3.
• Remove the clutch release cover 4.
• Loosen the lock nut 3 and turn out the adjusting screw 4 two
or three rotations.
• From that position, slowly turn in the adjusting screw 4 to feel
resistance.
• From this position, turn out the adjusting screw 4 1/4 rotations, and tighten the lock nut 3.
• Loosen the lock nut 5, and turn the cable adjuster 6 to
obtain 10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch
lever end.
• Tighten the lock nut 5.
• Tighten the lock nut 1.
 Clutch lever play A: 10 – 15 mm (0.4 – 0.6 in)
Clutch release screw: 1/4 turn out
PERIODIC MAINTENANCE
COOLING SYSTEM
RADIATOR HOSE
Inspect every 6 000 km (4 000 miles, 12 months).
ENGINE COOLANT
Replace engine coolant every 2 years.
ENGINE COOLANT LEVEL CHECK
• Keep the motorcycle upright.
• Check the engine coolant level by observing the full and lower
lines on the engine coolant reserve tank.
A Full line
B Lower line
• If the level is below the lower line, add engine coolant to the
full line from the engine coolant reserve tank filler.
NOTE:
To remove the filler cap, remove the tool box cover and secondary gear case cover. (2-16)
ENGINE COOLANT CHANGE
• Remove the rear and front seat. (8-3)
• Remove the fuel tank. (6-3)
• Remove the radiator cap 1.
• Drain engine coolant by disconnecting the radiator hose 2
from the pump.

* Do not open the radiator cap when the engine is hot,
as you may be injured by escaping hot liquid or
vapor.
* Engine coolant may be harmful if swallowed or if it
comes in contact with skin or eyes. If engine coolant
gets into the eyes or in contact with the skin, flush
thoroughly with plenty of water. If swallowed, induce
vomiting and call physician immediately!
•
•
•
•
Flush the radiator with fresh water if necessary.
Connect the radiator hose 2 securely.
Pour the specified engine coolant up to the radiator inlet.
Bleed the air from the engine coolant circuit as following procedure.
NOTE:
For engine coolant information, refer to page 7-2.
2-17
2-18
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 inlet completely.
• Add engine coolant up to the radiator inlet.
• Repeat the above procedure until bleed no air from the radiator inlet.
• Close the radiator cap securely.
• After warming up and cooling down the engine several times,
add the engine coolant up to the full level of the reservoir.

Repeat the above procedure several times and make
sure that the radiator is filled with engine coolant up to
the reserve tank full level.
 Engine coolant capacity
Reverse tank side: 250 ml (0.26/0.22 US/Imp qt)
Engine side:
1 500 ml (1.59/1.32 US/Imp qt)
RADIATOR HOSES
• Check to see the radiator hoses for crack, damage or engine
coolant leakage.
• If any defects are found, replace the radiator hoses with new
ones.
PERIODIC MAINTENANCE
FINAL GEAR OIL
Replace initially at 1 000 km (600 miles, 2 months) and
inspect every 12 000 km (7 500 miles, 24 months)
thereafter.
•
•
•
•
Keep the motorcycle upright.
Place an oil pan under the final gear case.
Remove the filler cap 1 and drain plug 2 to drain oil.
Refit the drain plug 2. Pour the specified oil (SAE 90 hypoid
gear oil with GL-5 under API classification) through the filler
hole until the oil level reaches the filler hole.
• Refit the filler cap 1.
 Final gear oil: 200 – 220 ml
(6.8/7.0 – 7.4/7.7 US/Imp oz)
BRAKE
(BRAKE)
Inspect initially at 1 000 km (600 miles, 2 months) and
every 6 000 km (4 000 miles, 12 months) thereafter.
(BRAKE HOSE AND BRAKE FLUID)
Inspect every 6 000 km (4 000 miles, 12 months).
Replace hoses every 4 years. Replace fluid every 2
years.
FRONT BRAKE FLUID LEVEL CHECK
• Keep the motorcycle upright and place the handlebars
straight.
• Check the brake fluid level by observing the lower limit line on
the front brake fluid reservoir.
• When the level is below the lower limit line, replenish with
brake fluid that meets the following specification.
 Specification and classification: DOT 4

* The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from
old, used or unsealed containers. Never re-use brake
fluid left over from the last servicing or stored for a
long period.
* Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check
the brake hoses and hose joints for cracks and oil
leakage before riding.
2-19
2-20
PERIODIC MAINTENANCE
FRONT BRAKE PADS
The extent of brake pad wear can be checked by observing the
grooved limit A on the pad. When the wear exceeds the
grooved limit, replace the pads with new ones.
(8-52)

Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
REAR BRAKE PEDAL HEIGHT
• Loosen the lock nut 1.
• Adjust the brake pedal height A by turning the adjuster 2.
 Rear brake pedal height : 75 – 85 mm (3.0 – 3.3 in)
PERIODIC MAINTENANCE
REAR BRAKE ADJUSTING
• Adjust the free travel A to 20 – 30 mm by turning the adjusting nut 1.
 Rear brake pedal free travel A:
20 – 30 mm (0.8 – 1.2 in)
REAR BRAKE SHOE WEAR
This motorcycle is equipped with brake lining wear limit indicator
on the rear brake.
To check brake lining wear, perform the following steps.
• Make sure that the rear brake is properly adjusted.
• Depress the rear brake pedal. Make sure that the index mark
1 is within the range 2 embossed on the brake panel.
• If the index mark goes beyond the range, the brake shoe
assembly should be replaced with a new set of shoes.
(8-62)
BRAKE LIGHT SWITCH
Adjust the rear brake light switch so that the brake light will
come on just before pressure is felt when the brake pedal is
depressed.
2-21
2-22
PERIODIC MAINTENANCE
AIR BLEEDING FROM THE BRAKE FLUID CIRCUIT
Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master cylinder 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 braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
• Fill up the master cylinder reservoir to the top of the inspection window. Place the reservoir cap to prevent entry of dirt.
• Attach a pipe to the air bleeder valve, and insert the free end
of the pipe into a receptacle.
• Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this will remove
the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever,
and open the valve. Repeat this process until the fluid flowing
into the receptacle no longer contains air bubbles.
NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is always some
fluid visible in the reservoir.
• Close the bleeder valve, and disconnect the pipe. Fill the reservoir with brake fluid to the top of the inspection window.
 Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials and so on.
PERIODIC MAINTENANCE
TIRE
Inspect every 6 000 km (4 000 miles, 12 months).
TIRE TREAD CONDITION
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
situation. It is highly recommended to replace a tire when the
remaining depth of tire tread reaches the following specification.
 09900-20805: Tire depth gauge
 Tire tread depth
Service Limit (FRONT) : 1.6 mm (0.06 in)
(REAR) : 2.0 mm (0.08 in)
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased. Therefore, maintain
the correct tire pressure for good roadability or shorter tire life
will result. Cold inflation tire pressure is as follows.
SOLO RIDING
COLD INFLATION
TIRE PRESSURE kPa kgf/cm² psi
FRONT
200
2.0
29
REAR
250
2.5
36
DUAL RIDING
kPa kgf/cm² psi
200
2.0
29
250
2.5
36

The standard tire fitted on this motorcycle is
130/90-16M/C (67H) for front and 170/80-15M/C (77H)
for rear. The use of tires other than those specified
may cause instability. It is highly recommended to use
a SUZUKI Genuine Tire.
TIRE TYPE
IRC (FRONT) : GS-23F A
IRC (REAR) : GS-23R A
STEERING
Inspect initially at 1 000 km (600 miles, 2 months) and
every 12 000 km (7 500 miles, 24 months) thereafter.
Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtighten steering prevents smooth
turning of the handlebars and too loose steering will cause poor
stability. Check that there is no play in the steering stem while
grasping the lower fork tubes by supporting the machine so that
the front wheel is off the ground, with the wheel straight ahead,
and pull forward. If play is found, perform steering bearing
adjustment as described in page 8-24 of this manual.
2-23
2-24
PERIODIC MAINTENANCE
FRONT FORK
Inspect every 12 000 km (7 500 miles, 24 months).
Inspect the front forks for oil leakage, scoring or scratches on
the outer surface of the inner tubes. Replace any defective
parts, if necessary. (8-13)
REAR SUSPENSION
Inspect every 12 000 km (7 500 miles, 24 months).
Inspect the damper for oil leakage and the spring unit for damage. Check that there is no play in the swingarm assembly.
Replace any defective parts, if necessary. (8-40)
EXHAUST PIPE BOLT
Tighten initially at 1 000 km (600 miles, 2 months) and
every 12 000 km (7 500 miles, 24 months) thereafter.
• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.
 Muffler mounting bolt and exhaust pipe bolt A: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Muffler mounting nut B: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
 99000-32050: THREAD LOCK ‘‘1342’’
EXHAUST GAS SEALER: PERMATEX 1372

ITEM
A
B
5 mm
(0.2 in)
5 mm Apply PERMATEX 1372.
(0.2 in)
N·m
23
23
kgf-m
2.3
2.3
lb-ft
16.5
16.5
PERIODIC MAINTENANCE
2-25
CHASSIS BOLT AND NUT
Tighten initially at 1 000 km (600 miles, 2 months) and
every 6 000 km (4 000 miles, 12 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-26 for the locations of the following nuts and bolts on the motorcycle.)
ITEM
1 Steering stem head nut
2 Steering stem nut
3 Front fork lower clamp bolt
4 Front fork upper clamp bolt
5 Front fork cap bolt
6 Front axle
7 Front axle pinch bolt
8 Handlebar holder set nut
9 Handlebar clamp bolt
0 Front brake master cylinder mounting bolt
A Front brake caliper mounting bolt
B Brake hose union bolt
C Caliper air bleeder valve
D Brake disc bolt
E Swingarm pivot bolt lock nut
F Torque link bolt and nut (Front)
G Torque link bolt and nut (Rear)
H Rear shock absorber mounting bolt/nut
(Upper & Lower)
I Rear cushion lever/rod mounting nut
J Rear axle nut
K Brake cam lever bolt
L Front footrest bracket mounting bolt
N·m
90
45
30
23
23
65
23
45
23
10
39
23
7.5
23
100
35
25
kgf-m
9.0
4.5
3.0
2.3
2.3
6.5
2.3
4.5
2.3
1.0
3.9
2.3
0.75
2.3
10.0
3.5
2.5
lb-ft
65.0
32.5
21.5
16.5
16.5
47.0
16.5
32.5
16.5
7.0
28.0
16.5
5.5
16.5
72.5
25.5
18.0
50
5.0
36.0
78
65
10
55
7.8
6.5
1.0
5.5
57.5
47.0
7.0
40.0
2-26
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
2-27
COMPRESSION PRESSURE CHECK
The compression of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
COMPRESSION PRESSURE SPECIFICATION (Automatic de-comp. actuated)
Standard
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
Limit
1 100 kPa
(11 kgf/cm2, 156 psi)
Difference
200 kPa
(2 kgf/cm2, 28 psi)
Low compression pressure can indicate any of the following conditions:
* Worn-down piston or piston rings
* Piston rings stuck in grooves
* Poor seating of valves
* Ruptured or otherwise defective cylinder head gasket
Overhaul the engine in the following cases:
* Compression pressure in one of the cylinders is less than 1 100 kPa (11 kgf/cm2, 156 psi).
* Difference in compression pressure between two cylinders is more than 200 kPa (2 kgf/cm2, 28 psi).
* All compression pressure are below 1 100 kPa (11 kgf/cm2, 156 psi) even when they measure more than
1 300 kPa (13 kgf/cm2, 185 psi).
COMPRESSION TEST PROCEDURE
NOTE:
* Before testing the engine for compression pressure, make
sure that the cylinder head bolts are tightened to the specified
torque values and valves are properly adjusted.
* Have the engine warmed up by idling before testing.
* Be sure that the battery used is in fully-charged condition.
Remove the parts concerned and test the compression pressure
in the following manner.
• Remove all the spark plugs. (2-5 and -6)
• Fit the compression gauge in one of the plug holes, while taking care of the tight connection.
• Keep the throttle grip in full-open position.
• While cranking the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of
that cylinder.
• Repeat this procedure with an other cylinder.
 09915-64512: Compression gauge
09915-63210: Compression gauge adaptor
2-28
PERIODIC MAINTENANCE
OIL PRESSURE CHECK
Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.
OIL PRESSURE SPECIFICATION
Above 350 kPa (3.5 kgf/cm², 50 psi)
Below 650 kPa (6.5 kgf/cm², 92 psi)
at 3 000 r/min, Oil temp. at 60°C (140°F)
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage way
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Used of high viscosity engine oil
* Clogged oil passage way
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
Start the engine and check if the oil pressure indicator light is
turned on. If it keeps on lighting, check the oil pressure indicator
light circuit. If it is in good condition, check the oil pressure in the
following manner.
• Remove the main oil gallery plug 1.
• Install the oil pressure gauge with attachment in the position
shown in the photo.
• Warm up the engine as follows:
Summer 10 min at 2 000 r/min
Winter 20 min at 2 000 r/min
• After warming up, increase the engine speed to 3 000 r/min
(with the multi circuit tester 2-13), and read the oil pressure gauge.
 09915-74511: Oil pressure gauge hose
09915-74532: Oil pressure gauge attachment
09915-77331: Meter (for high pressure)
 Oil gallery plug: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
PERIODIC MAINTENANCE
2-29
SDS CHECK
Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at
your dealership.
Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for
troubleshooting as they can be compared periodically with changes over time or failure conditions of the
motorcycle.
For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with
the normal data that have been saved or filed can allow the specific engine failure to be determined.
• Remove the right frame cover. (8-3)
• Set up the SDS tool. (5-24)
 09904-41010: SDS set tool
99565-01010: CD-ROM Ver. 5
A number of different data under a fixed condition as shown below should be saved or filed as sample.
SAMPLE:
Data sampled from cold starting through warm-up
Check the fast idle time.
Approx. XX sec.
Check the engine r/min.
XXXX r/min
Fast idle section
Check the engine r/min.
XXXX r/min
Check the manifold absolute pressure #1.
XXX mmHg
Check the water temperature.
XX ˚C
Check the secondary throttle valve operation
in according with the engine r/min.
2-30
PERIODIC MAINTENANCE
Data at 3 000 r/min under no load
XXXX r/min
Check the manifold absolute pressure.
XXX mmHg
Secondary valve moves approx. XX degree.
Data at the time of racing
Throttle : Quick
Quick wide open
Throttle : Slo
Slowly
wly open
Check
Chec
k the manifold
manifold absolute pressure
valve
valv
e opening.
in according with the throttle valve
Secondary
Secondar
y throttle valv
vvalve
alve
e operation
operation
valve
valv
e opening.
in according with the throttle valve
ENGINE
3-1
ENGINE
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..............3- 2
ENGINE REMOVAL AND INSTALLATION ....................................................3- 3
ENGINE REMOVAL ...............................................................................3- 3
ENGINE INSTALLATION .......................................................................3- 8
ENGINE DISASSEMBLY .......................................................................3-11
ENGINE COMPONENTS INSPECTION AND SERVICING ............................3-27
CYLINDER HEAD COVER .....................................................................3-27
CAMSHAFT ............................................................................................3-28
CAM CHAIN TENSIONER AND GUIDE ................................................3-30
CYLINDER HEAD ..................................................................................3-30
CYLINDER ..............................................................................................3-40
PISTON ...................................................................................................3-41
CONROD/CRANKSHAFT ......................................................................3-44
CLUTCH .................................................................................................3-53
GENERATOR/SIGNAL GENERATOR/ STARTER CLUTCH ................3-54
OIL PUMP ...............................................................................................3-56
TRANSMISSION ....................................................................................3-57
GEARSHIFT FORK ................................................................................3-60
OIL JET ..................................................................................................3-60
CRANKCASE .........................................................................................3-61
ENGINE REASSEMBLY .................................................................................3-65
3
6
6
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
the page listed in this section for removal and reinstallation instructions.
ENGINE CENTER
PARTS
REMOVAL
3-12
3-11
9-14
3-21
INSTALLATION
3-85
3-86
9-14
3-72
PARTS
REMOVAL
3-22
3-23
3-24
3-24
INSTALLATION
3-72
3-71
3-69
3-68
REMOVAL
3-18
3-20
3-20
3-21
3-21
INSTALLATION
3-76
3-74
3-74
3-73
3-69
Inspection cap
PAIR pipe
Starter motor
Oil filter
ENGINE LEFT SIDE
Neutral switch
Generator
Water pump
Secondary driven bevel gear
ENGINE RIGHT SIDE
PARTS
Clutch
Oil pump
Gearshift
Primary drive gear
Driveshaft bolt/Secondary driven gearshaft nut
ENGINE
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.
•
•
•
•
•
Drain engine oil. (2-11)
Drain engine coolant. (2-17)
Remove the seats. (8-3)
Remove the fuel tank. ( 6-3)
Disconnect the battery - lead wire and starter motor lead
wire.
• Remove the frame head covers 1.
• Remove the radiator. (7-4)
• Remove the left frame cover. (8-3)
• Remove the tool box and secondary gear case cover.
(2-16)
• Remove the secondary drive unit cover 2.
3-3
3-4
ENGINE
• Remove the engine coolant reservoir tank.
• Disconnect the water hoses 3.
• Disconnect the side-stand switch lead wire coupler 4.
• Disconnect the neutral switch lead wire coupler 5.
• Disconnect the generator lead wire coupler 6 and the signal
generator lead wire coupler 7.
• Remove the clutch release mechanism 8.
• Remove the push rod 9.
• Remove the left footrest 0 and the gearshift lever A.
ENGINE
• Remove the PAIR (AIR SUPPLY) cover.
• Remove the PAIR mounting bolts.
• Disconnect the PAIR hoses B and lead wire coupler C.
• Remove the air cleaner box D and air intake pipe E.
(5-47)
• Remove the air cleaner box bracket.
• Remove the throttle body F. (6-14)
3-5
3-6
ENGINE
• Disconnect the ECT sensor lead wire coupler G.
• Disconnect the spark plug caps.
• Remove the right frame cover. (8-4)
• Disconnect the HO2 sensor lead wire coupler H.
(For E-02, 19, 24)
• Remove the No. 1 muffler I.
• Remove the exhaust pipes and the No. 2 muffler.
ENGINE
• Remove the rear clutch cover J.
• Remove the rear brake link K.
• Disconnect the horn lead wire coupler L and rear brake
switch lead wire coupler M.
• Remove the cooling fan N. (7-8)
• Remove the engine frame mounting bolt O.
•
•
•
•
Remove the ground lead wire P.
Support the engine with an engine jack.
Remove the engine mounting bolts and nuts.
Gradually lower the engine.
3-7
3-8
ENGINE
ENGINE INSTALLATION
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
• Install the universal joint.
NOTE:
Be sure to face the short portion A backward when installing it.
• Install the boot.
NOTE:
Make sure that the “UP” mark B faces up.
• Gradually raise the engine, and then engage the secondary
driven gear shaft to the universal joint.
• Properly fit the boot onto the engine and the swingarm.
• Install the engine mounting bolts and nuts and tighten them.
ENGINE
3-9
NOTE:
* The engine mounting nuts are self-locking. Once the nut has
been removed, they are no longer of any use.
* Be sure to use new nuts and tighten them to the specified
torque.
50 N.m
(5.0 kgf-m, 36.0 lb-ft)
79 N.m
(7.9 kgf-m, 57.0 lb-ft)
23 N.m
(2.3 kgf-m, 16.5 lb-ft)
50 N.m
(5.0 kgf-m, 36.0 lb-ft)
79 N.m
(7.9 kgf-m, 57.0 lb-ft)
• Install the gearshift lever and the footrest in the correct position.
 Gearshift lever height A
Standard: 85 – 95 mm (3.3 – 3.7 in)
25 N.m
(2.5 kgf-m, 18.0 lb-ft)
3-10
ENGINE
• Apply grease to the push rod and install it.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply grease to the clutch release mechanism and install it.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 Clutch release screw
Standard: 1/4 turn back
CLUTCH CABLE ADJUSTMENT2-16
• Install the new gaskets.
• Install the exhaust pipes and mufflers.
• Apply gas sealer to the exhaust pipe connectors.
EXHAUST GAS SEALER: PERMATEX 1372
• Adjust the following items.
* Engine oil 2-11
* Engine coolant 2-17 and -18
* Idling adjustment 2-13
* Throttle cable play 2-14 and -15
* Rear brake adjusting 2-21
ENGINE
ENGINE DISASSEMBLY
• Remove the PAIR pipes.
• Remove the spark plugs.
 09930-10121: Spark plug wrench set
• Remove the gaskets.
• Remove the cylinder head cover caps (1, 2).
• Remove the water outlet union 3.
• Remove the breather cover 4 and gasket 5.
3-11
3-12
ENGINE
• Remove the valve inspection caps. (F & R)
• Remove the intake pipes 6. (F & R)
CYLINDER HEAD COVER
• Remove the valve timing inspection plug 1 and the generator
cover cap 2.
• Position “R I T” line on the generator with the center of the
valve timing inspection hole.
R
• Remove the cylinder head cover. (Rear)
T
ENGINE
• Remove the dowel pins and camshaft end cap 3.
• Rotate the generator rotor 450 degrees (1 and 1/4 turns) and
align the “F I T” line on the generator with the center of the
valve timing inspection hole.
F
• Remove the cylinder head cover. (Front)
• Remove the dowel pins and camshaft end cap 4.
CAMSHAFT
• Flatten the lock washer.
• Remove the cam sprocket and camshaft. (Front and rear cylinders)
T
3-13
3-14
ENGINE
CYLINDER HEAD/CYLINDER
• Loosen the water hose clamp screws.
• Remove the cylinder head bolts. (Front cylinder)
• After unlocking the ratchet, push the cam chain tension
adjuster rod fully.
• Insert the special tool between the ratchet and the adjuster
body.
 09918-53810: Chain tensioner lock tool
• Remove the cylinder head 1 and cylinder 2. (Front cylinder)
• Remove the dowel pins and gasket 3.
ENGINE
• Separate the cylinder head/cylinder assembly. (Front cylinder)
• Remove the cam chain guide 4.
• Remove the dowel pins and gasket 5.
• Remove the cylinder head bolts. (Rear cylinder)
• Push the cam chain tension adjuster rod and insert the special tool.
 09918-53810: Chain tensioner lock tool
• Remove the cylinder head 6. (Rear cylinder)
3-15
3-16
ENGINE
• Remove the dowel pins and gasket 7.
• Remove the cam chain guide 8.
• Remove the water hose and pipe.
• Remove the cylinder 9. (Rear cylinder)
• Remove the dowel pins and gasket 0.
PISTON
• Place a clean rag under the piston to prevent any parts from
falling into the crankcase.
• Remove the piston pin circlip 1 using long-nose pliers.
ENGINE
• Draw out each piston pin 2 and remove the pistons 3. (F & R)
NOTE:
Scribe the cylinder position on the head.
STARTER MOTOR
• Remove the starter motor cover 1.
• Remove the starter motor 2.
CLUTCH
• Remove the clutch cover.
• Remove the dowel pins and gasket 1.
3-17
3-18
ENGINE
• Remove the clutch spring mounting bolts and springs diagonally.
• Remove the pressure plate 2.
• Remove the thrust washer 3, bearing 4, push piece 5 and
push rod 6.
• Remove the clutch drive and driven plates 7.
• Remove the spring washer 8 and spring washer seat 9.
ENGINE
• Remove the clutch sleeve hub nut with the special tool.
 09920-53740: Clutch sleeve hub holder
• Remove the washer 0 and the clutch sleeve hub A.
• Remove the thrust washer B, spacer C, and needle roller
bearing D.
• Remove the primary driven gear assembly E and the oil
pump drive chain F.
• Remove the thrust washer G and spacer H.
3-19
3-20
ENGINE
OIL PUMP
• Remove the oil pump by removing the snap ring.
 09900-06107: Snap ring pliers
• Remove the pin 1 and washer 2.
• Remove the oil pump 3.
GEARSHIFT
• Draw out the gearshift shaft 1.
• Remove the cam guide and the pawl lifter.
• Remove the cam driven gear assembly 2 by removing the
gearshift cam stopper bolt.
• Remove the gearshift cam plate 1.
• Remove the gearshift cam stopper 2, washer 3, spring 4.
• Remove the washer 5.
ENGINE
PRIMARY DRIVE GEAR
• Remove the primary drive gear by removing the primary drive
gear bolt with the special tool.
 09930-40113: Rotor holder

This bolt has left-hand thread.
Turning it counter-clockwise may cause damage.
• Remove the cam chain tensioner 1, washers, spacer 2 and
the chain 3.
• Remove the cam chain drive sprocket 4 and the thrust
washer 5.
OIL FILTER
• Remove the oil filter with the special tool.
 09915-40610: Oil filter wrench
DRIVESHAFT BOLT/SECONDARY DRIVEN GEAR SHAFT
NUT
• Install the universal joint on the secondary driven gear shaft.
• While holding the universal joint with an adjustable wrench,
remove the driveshaft bolt 1, thrust washer 2, secondary
drive gear shaft nut 3 and the thrust washer 4.

The driveshaft bolt 1 has left-hand thread.
Turning it counter-clockwise may cause damage.
3-21
3-22
ENGINE
NEUTRAL SWITCH
• Remove the oil pressure switch lead wire.
• Remove the neutral switch assembly.
• Remove the neutral switch contacts 1 and spring 2.
GENERATOR
• Remove the generator cover.
• Remove the dowel pins and gasket 1.
• Remove the starter motor driven gear and the idle gear.
ENGINE
• Loosen the generator rotor bolt.
NOTE:
When loosen the rotor bolt, do not remove it. The rotor bolt is
used in conjunction with the rotor remover when removing the
rotor.
• Remove the generator rotor assembly with the special tool.
 09930-33730: Rotor remover
• Remove the starter gear 3 and key 4.
• Remove the cam chain tensioner 5, washers, spacer 6 and
the chain.
WATER PUMP
• Remove the water pump cover.
3-23
3-24
ENGINE
• Remove the water pump assembly and gasket 1.
SECONDARY DRIVEN GEAR
• Remove the secondary driven gear housing bolts.
• Remove the secondary driven gear case.
• Remove the secondary driven gear assembly 1 and shims
2.
• Remove the bearing 3, pin 4, oil jet 5, and dowel pins.
ENGINE
OIL JET
• Remove the oil jets.
CRANKCASE
• Remove the crankcase bolts.
• Separate the crankcase into two parts with the special tool.
 09920-13120: Crankcase separator
• Remove the dowel pins and O-ring.
3-25
3-26
ENGINE
• Remove the thrust shim 1 and crankshaft 2.
• Remove the gearshift fork shafts 3 gearshift forks 4 and
gearshift cam 5.
• Remove the transmission.
• Remove the washer.
SECONDARY DRIVE BEVEL GEAR
• Remove the over driving gear 1 and bush 2.
• Remove the secondary drive bevel gear assembly.
• Remove the shims 3.
ENGINE
ENGINE COMPONENTS INSPECTION
AND SERVICING
CYLINDER HEAD COVER
DISASSEMBLY

Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
“No. 1 cylinder”, “No. 2 cylinder”, “Exhaust”, “Intake”,
so that each will be restored to the original location
during assembly.
• Loosen the rocker arm shafts and pull out the rocker arm
shafts.
CYLINDER HEAD COVER DISTORTION
After removing sealant from the fitting surface of the cylinder
head cover, place the cylinder head cover on a surface plate
and check for distortion with a thickness gauge.
 Cylinder head cover distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
If the distortion exceeds the limit, replace the cylinder head
cover.
ROCKER ARM SHAFT O.D.
Measure diameter of rocker arm shaft.
 Rocker arm shaft O.D. (IN. & EX.)
Standard: 11.977 – 11.995 mm (0.4715 – 0.4722 in)
 09900-20205: Micrometer (0 – 25 mm)
ROCKER ARM I.D.
When checking the valve rocker arm, the inside diameter of the
valve rocker arm and wear of the camshaft contacting surface
should be checked.
 Rocker arm I.D.
Standard: 12.000 – 12.018 mm (0.4724 – 0.4731 in)
 09900-20605: Dial calipers
3-27
3-28
ENGINE
REASSEMBLY
• Apply SUZUKI MOLY PASTE to the rocker arms and their
shafts.
 99000-25140: SUZUKI MOLY PASTE
 Rocker arm shaft: 27 N·m (2.7 kgf-m, 19.5 lb-ft)
CAMSHAFT
The camshafts should be checked for wear and also for runout
of cams and journals if the engine has been noted to produce
abnormal noise or vibration or to lack output power. Any of these
malconditions could be caused by a worn camshafts.
The camshaft can be distinguished by the embossed-letters, “F”
and “R”, on the camshaft.
“F” : Front (No. 2) camshaft
“R” : Rear (No. 1) camshaft
CAMSHAFT CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is
specified for both intake and exhaust cams in terms of cam
height H, which is to be measured with a micrometer. Replace
camshafts if found worn down to the limit.
 Cam height H
Service Limit: (IN.) : 35.20 mm (1.386 in)
(EX.): 36.28 mm (1.428 in)
 09900-20202: Micrometer (25 – 50 mm)
“R”
“F”
ENGINE
CAMSHAFT JOURNAL WEAR
Determine whether each journal is worn down to the limit or not
by measuring camshaft journal oil clearance with the camshaft
installed. Use plastigauge to read the clearance, which is specified as follows:
 Camshaft journal oil clearance
Service Limit: 0.150 mm (0.0059 in)
 09900-22302: Plastigauge
NOTE:
To properly measure the oil clearance with plastigauge, all gasket material must be removed from fitting surfaces of cylinder
head and cover. Do not apply SUZUKI BOND “1216B” until after
the oil clearance has been determined.
• Tighten the cylinder head cover bolts evenly and diagonally to
the specified torque.
 Cylinder head cover bolts
(M6): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
(M8): 24.5 N·m (2.45 kgf-m, 18.0 lb-ft)
NOTE:
Do not rotate the camshafts with the plastigauge in place.
Remove the cylinder head cover, and read the width of the compressed plastigauge with envelop scale. This measurement
should be taken at the widest part.
If the camshaft journal oil clearance measured exceeds the limit,
measure the outside diameter of camshaft.
Replace either the cylinder head set or the camshaft if the clearance is incorrect.
 Camshaft journal O.D.
(Sprocket side): 24.959 – 24.980 mm
(0.9826 – 0.9835 in)
(Other side) :
19.959 – 19.980 mm
(0.7858 – 0.7866 in)
 09900-20205: Micrometer (0 – 25 mm)
CAMSHAFT RUNOUT
Measure the runout with a dial gauge. Replace the camshaft if
the runout exceeds the limit.
 Camshaft runout (IN. & EX.)
Service Limit: 0.10 mm (0.004 in)
 09900-20607: Dial gauge (1/100, 10 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 mm)
3-29
3-30
ENGINE
CAM CHAIN TENSIONER AND GUIDE
CAM CHAIN TENSIONER
For driving the camshafts, two cam chain tensioners are used
on the respective cam drive chains. Unlock the ratchet mechanism, and move the push rod in place to see if it slides smoothly.
If any stickiness is noted or ratchet mechanism is faulty, replace
the cam chain tensioner assembly with a new one.
The cam chain tensioner can be distinguished by the embossed
letters, “F” and “R”, on the cam chain tensioners.
“F”: Front (No. 2) cam chain tensioner
“R”: Rear (No. 1) cam chain tensioner
CAM CHAIN GUIDE
Check the contacting surface of the cam chain guide for wear
and damage. If it is found to be damaged, replace it with a new
one.
Two kinds of cam chain guide are used on the respective cam
drive chains.
1: For front cylinder
2: For rear cylinder
CYLINDER HEAD
VALVE AND VALVE SPRING DISASSEMBLY
• Using special tools, compress the valve springs and remove
the two cotter halves 1 from valve stem.
 09916-14510: Valve spring compressor
09916-14910: Valve spring compressor attachment
09916-84511: Tweezers
• Remove the valve spring retainer 2, inner spring 3 and outer
spring 4.
“R”
“F”
ENGINE
• Pull out the valve 5 from the other side.
• Remove the valve stem seal 6 and valve spring seat 7.
NOTE:
Removal of valves completes ordinary disassembling work. If
valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. (3-32)
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.
 Cylinder head distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
VALVE FACE WEAR
Visually inspect each valve for wear of its seating face. Replace
any valve with an abnormally worn face.
The thickness T decreases as the wear of the face advances.
Measure the thickness and, if the thickness is found to have
been reduced to the limit, replace it.
 Valve head thickness
Service Limit T: 0.5 mm (0.02 in)
 09900-20102: Vernier calipers
VALVE STEM RUNOUT
Support the valve with “V” blocks, as shown, and check its
runout with a dial gauge.
The valve must be replaced if the runout exceeds the limit.
 Valve stem runout
Service Limit: 0.05 mm (0.002 in)
 09900-20701: Magnetic stand
09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block
3-31
3-32
ENGINE
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at right angles to the valve head face, and
measure the valve head radial runout.
If it measures more than limit, replace the valve.
 Valve head radial runout
Service Limit: 0.03 mm (0.001 in)
 09900-20701: Magnetic stand
09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other, by positioning the dial gauge as
shown. If the deflection measured exceeds the limit, (see below)
then determine whether the valve or the guide should be
replaced with a new one.
 Valve stem deflection (IN. & EX.)
Service Limit: 0.35 mm (0.14 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
VALVE STEM WEAR
If the valve stem is worn down to the limit, as measured with a
micrometer, where the clearance is found to be in excess of the
limit indicated replace the valve, if the stem is within the limit,
then replace the guide. After replacing valve or guide, be sure to
re-check the clearance.
 Valve stem O.D.
Standard (IN.) : 5.475 – 5.490 mm (0.2156 – 0.2161 in)
(EX.) : 5.455 – 5.470 mm (0.2148 – 0.2154 in)
 09900-20205: Micrometer (0 – 25 mm)
VALVE GUIDE SERVICING
• Using the valve guide remover, drive the valve guide out
toward the intake or exhaust rocker arm side.
 09916-44910: Valve guide remover/installer
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement
parts. (Part No. 11115-38A71)
ENGINE
• Re-finish the valve guide holes in cylinder head with a 10.8
mm reamer and handle.
 09916-34580: Valve guide hole reamer
09916-34542: Reamer handle
• Cool down the new valve guides in a freezer for about one
hour and heat the cylinder head to 100 – 150 °C (212 – 302
°F) with a hot plate.

Do not use a burner to heat the valve guide hole to
prevent cylinder head distortion.
• Oil the stem hole, too, of each valve guide and drive the guide
into the guide hole with the valve guide installer and attachment.
 09916-44910: Valve guide remover/installer
09916-44920: Valve guide installer attachment

Failure to oil the valve guide hole before driving the
new guide into place may result in a damage guide or
head.
• After fitting all valve guides, re-finish their guiding bores with a
5.5 mm reamer. Be sure to clean and oil the guide after reaming.
 09916-34550: Valve guide reamer
09916-34542: Reamer handle
NOTE:
* Be sure to cool down the cylinder head to ambient air temperature.
* Insert the reamer from the combustion chamber and always
turn the reamer handle clockwise.
VALVE SEAT WIDTH
• Coat the valve seat with prussian blue uniformly. Fit the valve
and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
In this operation, use the valve lapper to hold the valve head.
Valve
guide
Cylinder
head
3-33
3-34
ENGINE
• The ring-like dye impression left on the valve face must be
continuous – without any break. In addition, the width of the
dye ring, which is the visualized seat “width”, must be within
the following specification:
 Valve seat width W
Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)
 09916-10911: Valve lapper set
If either requirement is not met, correct the seat by servicing it
as follows:
VALVE SEAT SERVICING
The valve seats for intake and exhaust valves are machined to
four different angles. The seat contact surface is cut at 45°.
INTAKE
15°
30°
45°
60°
N-128
N-128
N-111
45˚
EXHAUST
N-121
15˚
Valve seat
N-122
EXHAUST
NOTE:
The valve seat contact area must be inspected after each cut.
 09916-21111: Valve seat cutter set
09916-22430: Valve seat cutter (N-128)
60˚
30˚
45˚
Valve seat
INTAKE
ENGINE
3-35
• Insert the solid pilot 1 (09916-24450: N-100-5.52) with a
slight rotation. Seat the pilot snugly. Install the 45° cutter,
attachment and T-handle.
INITIAL SEAT CUT
• Using the 45° cutter, descale and clean up the seat. Rotate
the cutter one or two turns.
• Measure the valve seat width W after every cut.
• If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more.
NOTE:
Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the
camshaft.
TOP NARROWING CUT
• If the contact area W is too high on the valve, or if it is too
wide, use the 15° (for the exhaust side) and the 30° (for the
intake side) to lower and narrow the contact area.
Contact area too high and
too wide on face of valve
15˚ (Exhaust)
30˚ (Intake)
3-36
ENGINE
BOTTOM NARROWING CUT
• If the contact area W is too wide or too low, use the 60°
(intake side only) to narrow and raise the contact area.
60˚
(Intake only)
FINAL SEAT CUT
• If the contact area W is too low or too narrow, use the 45° cutter to raise and widen the contact area.
NOTE:
After cutting the 15°, 30° and 60° angles, it is possible that the
valve seat (45°) is too narrow. If so, re-cut the valve seat to the
correct width.
• After the desired seat position and width is achieved, use the
45° cutter very lightly to clean up any burrs caused by the previous cutting operations.

Do not use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few
seconds of engine operation.
NOTE:
After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (2-7)
Contact area too low and
too narrow on face of valve
ENGINE
3-37
• 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.

Always use extreme caution when handling gasoline.
VALVE STEM END CONDITION
Inspect the valve stem end face for pitting and wear. If pitting or
wear of the stem end face are present, the valve stem end may
be resurfaced, providing that the length 1 will not be reduced to
less than the service limit. If this length becomes less than the
service limit, the valve must be replaced.
 Valve stem end length
Service Limit: 3.1 mm (0.12 in)
VALVE SPRING
The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often
account for the chattering noise coming from the valve mechanism.
Check the valve springs for proper strength by measuring their
free length and also by the force required to compress them. If
the spring length is less than the service limit, or if the force
required to compress the spring does not fall within the range
specified, replace both the inner and outer springs as a set.
 09900-20102: Vernier calipers
.
 Valve spring free length (IN. & EX.)
Service Limit INNER : 38.3 mm (1.51 in)
OUTER: 40.1 mm (1.58 in)
 Valve spring tension (IN. & EX.)
Standard
INNER:
64 – 73 N/32.5 mm
(6.51 – 7.49 kgf/32.5 mm, 14.35 – 16.51 lbs/1.28 in)
OUTER:
119 – 136 N/36.0 mm
(12.09 – 13.91 kgf/36.0 mm, 26.65 – 30.67 lbs/1.42 in)
64 – 73 N
(6.51 – 7.49 kgf, 14.35 – 16.51 lbs)
32.5 mm (1.28 in)
3-38
ENGINE
VALVE AND VALVE SPRING REASSEMBLY
• Fit the valve spring lower seats 1.
• Oil each oil seal, and press-fit the oil seal 2 into position with
the valve guide installer.
 09916-44910: Valve guide remover/installer

Do not reuse the oil seal.
• Insert the valves, with their stems coated with high quality
molybdenum disfluid lubricant (SUZUKI MOLY PASTE) all
around and along the full stem length without any break.
 99000-25140: SUZUKI MOLY PASTE

When inserting each valve, take care not to damage
the lip of the stem seal.
• Install the valve springs with the small-pitch portion A facing
cylinder head.
B: Large-pitch portion
• Put on the valve spring retainer using the valve spring compressor, press down the springs, fit the two cotter halves to
the stem end, and release the compressor to allow the cotter
1 to wedge in between seat and stem. Be sure that the
rounded lip 2 of the cotter fits snugly into the groove 3 in the
stem end.
 09916-14510: Valve spring compressor
09916-14910: Valve spring compressor attachment
09916-84511: Tweezers

Be sure to restore each spring, valve and spring
retainer to their original positions.
Yellow paint
ENGINE
NOTE:
When installing the water union to the cylinder head, apply
grease to the new O-rings.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
3-39
3-40
ENGINE
CYLINDER
CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places as indicated. If the largest reading at any position
of the straightedge exceeds the limit, replace the cylinder.
 Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
CYLINDER BORE
Measure the cylinder bore diameter at six places. If any one of
the measurements exceeds the limit, overhaul the cylinder and
replace the piston with an oversize, or replace the cylinder.
Once the reboring is done on any one cylinder which measurements is beyond the limit, the remaining cylinders must be also
rebored accordingly. Otherwise the imbalance might cause
excess vibration.
 Cylinder bore
Service Limit: 83.085 mm (3.2711 in)
 09900-20508: Cylinder gauge set
NOTE:
When installing the water union to the cylinder, apply grease to
the new O-rings.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
ENGINE
3-41
PISTON
PISTON DIAMETER
Using a micrometer, measure the piston outside diameter at the
place shown in Fig. If the measurement is less than the limit,
replace the piston.
 Piston diameter
Service Limit: 82.880 mm (3.2630 in)
 09900-20204: Micrometer (75 – 100 mm)
PISTON-TO-CYLINDER CLEARANCE
As a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder
and use an oversize piston, or replace both cylinder and piston.
 Piston to cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
Piston oversize: 0.5, 1.0 mm
PISTON RING TO GROOVE CLEARANCE
Using a thickness gauge, measure the side clearances of the
1st and 2nd rings. If any of the clearances exceeds the limit,
replace both piston and piston rings.
 Piston ring-groove clearance
Service Limit (1st) : 0.180 mm (0.007 in)
(2nd): 0.150 mm (0.006 in)
 Piston ring groove width
Standard (1st) : 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(2nd): 1.21 – 1.23 mm (0.0476 – 0.0484 in)
(Oil) : 2.51 – 2.53 mm (0.0988 – 0.0996 in)
 Piston ring thickness
Standard (1st) : 0.970 – 0.990 mm (0.0382 – 0.0390 in)
(2nd): 1.170 – 1.190 mm (0.0461 – 0.0469 in)
 09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)
15 mm (0.6 in)
3-42
ENGINE
PISTON RING FREE END GAP AND END GAP
Before installing piston rings, measure the free end gap of each
ring using vernier calipers. Next, fit the ring in the cylinder, and
measure each ring end gap using a thickness gauge.
If any ring has an excess end gap, replace the ring.
 Piston ring free end gap
Service Limit (1st) : 7.7 mm (0.30 in)
(2nd): 9.4 mm (0.37 in)
 Piston ring end gap
Service Limit (1st) : 0.70 mm (0.028 in)
(2nd): 0.70 mm (0.028 in)
 09900-20102: Vernier calipers
09900-20803: Thickness gauge
Oversize piston ring
The following two types of oversize piston rings are used. They
bear the following identification numbers.
SIZE
0.5 mm O.S.
1.0 mm O.S.
1st
50
100
2nd
50
100
0.5 mm O.S.
Oversize oil ring
The following two types of oversize oil rings are available as
optional parts. They bear the following identification marks.
SIZE
STD
0.5 mm O.S.
1.0 mm O.S.
1.0 mm O.S.
COLOR
NIL
Painted Red
Painted Yellow
Oversize side rail
Just measure outside diameter to identify the side rail as there is
no mark or numbers on it.
Oil ring spacer
Paint
ENGINE
PISTON PIN AND PIN BORE
Using a small bore gauge, measure the piston pin bore inside
diameter, and using a micrometer, measure the piston pin outside diameter. If the reading exceeds following limit, replace
both piston and piston pin.
 Piston pin bore I.D.
Service Limit: 20.030 mm (0.7886 in)
 09900-20602: Dial gauge (1/1 000 mm, 1 mm)
09900-22403: Small bore gauge (18 – 35 mm)
Using a micrometer, measure the piston pin outside diameter at
three positions.
 Piston pin O.D.
Service Limit: 19.980 mm (0.7866 in)
 09900-20205: Micrometer (0 – 25 mm)
PISTON RING REASSEMBLY
• Install the piston rings in the order of oil ring, 2nd ring and 1st
ring.
• The first member to go into the oil ring groove is a spacer 1.
After placing the spacer, fit the two side rails 2.
NOTE:
Side designations, top and bottom, are not applied to the spacer
and side rails: you can position each either way.

When installing the spacer, be careful not to allow its
two ends to overlap in the groove.
• Install the 2nd ring 3 and the 1st ring 4.
NOTE:
1st ring and 2nd ring differ in shape.
3-43
3-44
ENGINE
• 1st ring and 2nd ring have letter “R” marked on the side. Be
sure to bring the marked side to the top when fitting them to
the piston.
1st ring
2nd ring
• Position the gaps of the three rings as shown. Before inserting
each piston into the cylinder, check that the gaps are so
located.
EX
2nd ring
Lower side
rail
120˚
120˚
Upper side
rail
120˚
1st ring
Spacer
IN
CONROD/CRANKSHAFT
CONROD SMALL END I.D.
Using a small bore gauge, measure the conrod small end inside
diameter.
 Conrod small end I.D.
Service Limit: 20.040 mm (0.7890 in)
 09900-20602: Dial gauge (1/1 000 mm, 1 mm)
09900-22403: Small bore gauge (18 – 35 mm)
If the conrod small end inside diameter exceeds the above mentioned limit, replace the conrod.
CONROD BIG END SIDE CLEARANCE
Check the conrod thrust clearance by using a thickness gauge.
If the clearance exceeds the limit, replace conrod or crankshaft.
 Conrod big end side clearance
Service Limit: 0.30 mm (0.012 in)
 09900-20803: Thickness gauge
ENGINE
 Conrod big end width
Standard: 21.95 – 22.00 mm (0.864 – 0.866 in)
Crank pin width
Standard: 22.10 – 22.15 mm (0.870 – 0.872 in)
 09900-20205: Micrometer (0 – 25 mm)
09900-20605: Dial calipers (10 – 34 mm)
CONROD-CRANK PIN BEARING SELECTION
• Loosen the bearing cap nuts and tap the bolt end lightly with
plastic hammer to remove the bearing cap.
• Remove the rods and mark them to identify the cylinder position.
• Inspect the bearing surfaces for any sign of fusion, pitting,
burn, or flaws. If any, replace them with a specified set of
bearings.
NOTE:
Never try to remove or loosen the conrod cap bolts due to their
possible loosening in the rod. Once displaced, the bearing cap
will not be fitted properly.
• Place plastigauge axially on the crank pin avoiding the oil
hole, at TDC or BDC side as shown.
• Tighten the bearing cap with two-step torque values.
NOTE:
When fitting the bearing cap to crank pin, be sure to discriminate
between its two ends, I.D. code side and the other.
I.D. code always faces intake valve side.
 Conrod nut
Initial tightening torque: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final tightening torque: 51 N·m (5.1 kgf-m, 37.0 lb-ft)
 09900-22301: Plastigauge
NOTE:
Never rotate the crankshaft or conrod when a piece of plastigauge is in the clearance.
3-45
3-46
ENGINE
• Remove the caps and measure the width of compressed plastigauge with envelope scale. This measurement should be
taken at the widest part.
 Conrod big end oil clearance
Standard: 0.024 – 0.042 mm (0.0009 – 0.0017 in)
Service Limit: 0.080 mm (0.0031 in)
• If oil clearance exceeds the service limit, select the specified
bearings from the following table.
• Check the corresponding conrod I.D. code number 1, “1”, “2”
or “3”.
• Check the corresponding crank pin O.D. code number 2, “1”,
“2” or “3”.
• The crank pin O.D. code number 2, “1”, “2” or “3” which are
stamped on the left crank web.
Bearing selection table
Conrod
I.D. code
2
Code
1
2
3
1
Green
Black
Brown
Crank pin O.D. 2
2
3
Black
Brown
Brown
Yellow
Yellow
Blue
Conrod I.D. specification
Code 1
1
2
3
I.D. specification
44.000 – 44.006 mm
(1.7323 – 1.7325 in)
44.006 – 44.012 mm
(1.7325 – 1.7328 in)
44.012 – 44.018 mm
(1.7328 – 1.7330 in)
Crank pin O.D. specification
Code 2
1
2
3
O.D. specification
40.994 – 41.000 mm
(1.6139 – 1.6142 in)
40.988 – 40.994 mm
(1.6137 – 1.6139 in)
40.982 – 40.988 mm
(1.6135 – 1.6137 in)
 09900-20202: Micrometer (25 – 50 mm)
ENGINE
Bearing thickness specification
Color (Part No.)
Green
(12164-38E00-0A0)
Black
(12164-38E00-0B0)
Brown
(12164-38E00-0C0)
Yellow
(12164-38E00-0D0)
Blue
(12164-38E00-0E0)
Thickness
1.485 – 1.488 mm
(0.0585 – 0.0586 in)
1.488 – 1.491 mm
(0.0586 – 0.0587 in)
1.491 – 1.494 mm
(0.0587 – 0.0588 in)
1.494 – 1.497 mm
(0.0588 – 0.0589 in)
1.497 – 1.500 mm
(0.0589 – 0.0591 in)

The bearings should be replaced as a set.
CONROD/CRANK PIN BEARING ASSEMBLY
• When fitting the bearing to the bearing cap and conrod, be
sure to fix the stopper part 1 first and press in the other end.
• Apply molybdenum oil solution to the crank pin and bearing
surface.
 MOLYBDENUM OIL SOLUTION
• When mounting the conrod on the crankshaft, make sure that
I.D. code 2 of the conrod faces rearward.
• Tighten the conrod fitting nuts with specified torque after
applying engine oil to the nut thread.
 Conrod nut
Initial tightening torque: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final tightening torque: 51 N·m (5.1 kgf-m, 37.0 lb-ft)
• Check the conrod movement for smooth turning.
Color code
3-47
3-48
ENGINE
CRANKCASE/CRANKSHAFT BEARING INSPECTION
• Inspect the crankshaft and crankshaft journal bearings for any
damage. If any, replace them with a specified set of bearings.
• Measure the crankshaft journal O.D. 1 by using the special
tool.
 Crankshaft journal O.D. 1
Standard: 47.965 – 47.980 mm (1.8884 – 1.8890 in)
 09900-20202: Micrometer (25 – 50 mm)
• Measure the crankshaft journal bearing I.D. 2 by using the
special tool.
 Crankshaft journal bearing I.D. 2
Standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in)
 09900-20508: Cylinder gauge set
• If each crankshaft journal bearing I.D. is not within the standard range, replace them with new ones.
CRANKCASE-CRANKSHAFT BEARING SELECTION
Select the specified bearings from the crankcase bore I.D. code.
The crankcase bore I.D. code A “A”, “B” or “C”, is stamped on
the inside of each crankcase half.
Bearing selection table
I.D. code A
A
B
C
I.D. specification
52.000 – 52.006 mm
(2.0472 – 2.0475 in)
52.006 – 52.012 mm
(2.0475 – 2.0477 in)
52.012 – 52.018 mm
(2.0477 – 2.0479 in)
Bearing
Green
Black
Brown
ENGINE
Bearing thickness
Color (Part No.)
Green
(12229-39G00-0A0)
Black
(12229-39G00-0B0)
Brown
(12229-39G00-0C0)
3-49
Color code
Thickness
2.006 – 2.009 mm
(0.0789 – 0.0790 in)
2.009 – 2.012 mm
(0.0790 – 0.0792 in)
2.012 – 2.015 mm
(0.0792 – 0.0793 in)

Bearing must be replaced as a set.
CRANKSHAFT JOURNAL BEARING REPLACEMENT
Use the special tool to replace the crankshaft journal bearings.
The replacement procedure is as follows:
 09913-60230: Journal bearing remover/installer
• Set the special tool as shown to remove the crankshaft journal
bearings.
NOTE:
Remove the crankshaft journal bearings in only one direction,
from inside to outside of each crankcase half.
• Gradually press out the bearing with the special tool by using
the hand-press.
Hand-press

The removed bearings must be replaced with new
ones.
Crankcase
Bearing
3-50
ENGINE
NOTE:
Using the hand-press is recommended to remove the crankshaft
journal bearings. However, the crankshaft journal bearings can
be removed by using with the following special tools.
Bearing
 09924-84510: Bearing installer set
09924-74570: Final drive gear bearing remover/installer
• Set the specified crankshaft journal bearings to the special
tool.

* Before setting the bearing, apply enough engine oil
to the special tool and bearings.
* When setting the bearing, align the bearing side with
the engraved line A and also the bearing edge with
the mating surface of the special tool.
 09913-60241: Journal bearing remover/installer
• Tighten the special tool bolt to the specified torque.
 Special tool bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Before installing the bearings, lightly shave off the
sharp edge part of the crankcase chamfer by using an
oilstone and wash the crankcase bore with enough
engine oil.
Sharp edge
ENGINE
3-51
• Set the bearings installed in the special tool to the crankcase
half as shown.

* Be sure the bearing protruded side B faces the
crankcase bore.
* Align the special tool mating surface with the line
mark C on the crankcase.
NOTE:
The upper and lower bearings are same.
• Insert the thickness gauge 1 between the crankcase and
special tool 3 for 1 mm (0.04 in) clearance.
• Apply enough engine oil to the special tool and the bearings
and then set the special tool carefully.
• Gradually press in the bearing into the main journal bore by
using the hand-press until the special tool 2 stops the special
tool 3.
 09913-60230: Journal bearing remover/installer
09900-20803: Thickness gauge
Hand-press
Bearing
Clearance
1 mm (0.04 in)
Bearing
Clearance
1 mm (0.04 in)
• Measure the clearance from case surface to bearing.
Clearance
1 mm (0.04 in)
3-52
ENGINE
NOTE:
Using the hand-press is recommended to install the crankshaft
journal bearings. However, the crankshaft journal bearings can
be installed by using the following special tools.
 09924-84510: Bearing installer set
09924-74570: Final drive gear bearing remover/installer
Clearance
1 mm (0.04 in)
• After installing the bearings, check the bearing surface for any
scratch or damage.
CRANKSHAFT THRUST CLEARANCE
Install the crankshaft in the right crankcase half after installing
the thrust shim on the crankshaft.
NOTE:
The oil grooved face A of thrust shim 1 is faced to crankshaft
web side.
• Place the thrust washer, camshaft drive sprocket and primary
drive gear on the right end of the crankshaft and tighten primary drive gear bolt to the specified torque. (3-73)
 09930-40113: Rotor holder
 Primary drive gear bolt: 95 N·m (9.5 kgf-m, 68.5 lb-ft)
• Use a thickness gauge to measure the thrust clearance
between right crankcase and thrust washer.
 Crankshaft thrust clearance
Standard: 0.05 – 0.10 mm (0.002 – 0.004 in)
 09900-20803: Thickness gauge
ENGINE
• If the thrust clearance exceeds the standard range, adjust the
thrust clearance by the following procedures:
• Remove the thrust shim, and measure its thickness with a
micrometer.
• Change the thrust shim with the other shim if the thrust clearance is incorrect.
• Perform the thrust clearance measurement described above
once again.
 09900-20205: Micrometer (0 – 25 mm)
Checking to make sure it is within standard
Part number
09160-48001
09160-48002
09160-48003
09160-48004
09160-48005
09160-48006
09160-48007
09160-48008
09160-48009
09160-48010
Unit: mm (in)
Thrust shim thickness
1.925 – 1.950 (0.0758 – 0.0768)
1.950 – 1.975 (0.0768 – 0.0778)
1.975 – 2.000 (0.0778 – 0.0787)
2.000 – 2.025 (0.0787 – 0.0797)
2.025 – 2.050 (0.0797 – 0.0807)
2.050 – 2.075 (0.0807 – 0.0817)
2.075 – 2.100 (0.0817 – 0.0827)
2.100 – 2.125 (0.0827 – 0.0837)
2.125 – 2.150 (0.0837 – 0.0846)
2.150 – 2.175 (0.0846 – 0.0856)
CLUTCH
CLUTCH DRIVE AND DRIVEN PLATES
NOTE:
Wipe off the engine oil from the drive and driven plates with a
clean rag.
Measure the thickness of drive plates with a vernier calipers. If
each drive plate is not within the standard range, replace it with
a new one.
 Clutch drive plate thickness
Standard (No. 1): 2.92 – 3.08 mm (0.115 – 0.121 in)
(No. 2): 3.42 – 3.58 mm (0.135 – 0.141 in)
 09900-20102: Vernier calipers
Measure the claw width of drive plates with a vernier calipers.
Replace the drive plates found to have worn down to the limit.
 Clutch drive plate claw width (No. 1 & No. 2)
Service Limit: 15.1 mm (0.594 in)
 09900-20102: Vernier calipers
3-53
3-54
ENGINE
Measure each driven plate for distortion with a thickness gauge
and surface plate.
Replace driven plates which exceed the limit.
 Clutch driven plate distortion
Service Limit: 0.10 mm (0.004 in)
 09900-20803: Thickness gauge
CLUTCH SPRING FREE LENGTH
Measure the free length of each coil spring with a vernier calipers, and compare the elastic strength of each with the specified
limit. Replace all the springs if any spring is not within the limit.
 Clutch spring free length
Service Limit: 46.8 mm (1.84 in)
 09900-20102: Vernier calipers
CLUTCH BEARING
Inspect the clutch release bearing for any abnormality, particularly cracks, upon removal from the clutch, to decide whether it
can be reused or should be replaced.
Smooth engagement and disengagement of the clutch depends
much on the condition of this bearing.
NOTE:
Thrust washer is located between the pressure plate and thrust
bearing.
GENERATOR/SIGNAL GENERATOR/
STARTER CLUTCH
GENERATOR STATOR AND SIGNAL GENERATOR STATOR
INSPECTION 9-10, -23 and -24
GENERATOR STATOR AND SIGNAL
GENERATOR STATOR SERVICING
When replacing the generator stator or signal generator stator,
route the wire properly.
ENGINE
STARTER CLUTCH INSPECTION
Install the starter driven gear onto the starter clutch and turn the
starter driven gear by hand to inspect the starter clutch for a
smooth movement. The gear turns one direction only. If a large
resistance is felt to rotation, inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter
driven gear for wear or damage.
If they are found to be damaged, replace them with new ones.
STARTER DRIVEN GEAR BEARING INSPECTION
Inspect the starter driven gear bearing for any damages.
STARTER CLUTCH SERVICING
• Hold the rotor with off-set wrench and remove the starter
clutch securing bolts.
• Remove the one way clutch 1 and guide 2 from the rotor 3.
• When fitting the one way clutch 1 to the guide 2, position
flange side A of one way clutch to the rotor side.
3-55
3-56
ENGINE
• When installing the starter clutch guide 2, make sure that the
flange B side faces out.
• Apply THREAD LOCK SUPER “1303” to the securing bolts
and tighten them to the specified torque while holding the
rotor with off-set wrench.
 99000-32030: THREAD LOCK SUPER “1303”
 Starter clutch securing bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)
OIL PUMP
• Rotate the oil pump by hand and check that it moves
smoothly.
• If it does not move smoothly, replace the oil pump assembly.

Do not attempt to disassemble the oil pump assembly.
The oil pump is available only as an assembly.
ENGINE
TRANSMISSION
DISASSEMBLY
• Disassemble the transmission gears as shown in the illustration.
(USA)
(Others)
(USA)
(Others)
D
FW
1
2
3
4
5
6
7
Driveshaft bolt
Over driving gear
1st driven gear
4th driven gear
3rd driven gear
Driveshaft
5th driven gear
8
9
0
A
B
C
2nd driven gear
Countershaft/1st drive gear
4th drive gear
3rd drive gear
5th drive gear
2nd drive gear

ITEM
1
N·m
65
kgf-m
6.5
lb-ft
47.0
3-57
3-58
ENGINE
REASSEMBLY
Assemble the countershaft and driveshaft in the reverse order of
disassembly. Pay attention to following points:
NOTE:
Always use new circlips.
NOTE:
Before installing the gears, coat lightly moly paste or engine oil
to the driveshaft and countershaft.
 99000-25140: SUZUKI MOLY PASTE

* Never reuse a circlip. After a circlip has been
removed from a shaft, it should be discarded and a
new snap ring must be installed.
* When installing a new snap ring, care must be taken
not to expand the end gap larger than required to slip
the snap ring over the shaft.
* After installing a snap ring, always ensure that it is
completely seated in its groove and securely fitted.
• When installing a new snap ring, pay attention to the direction
of the snap ring. Fit it to the side where the thrust is as shown
in figure.
Thrust
Sharp edge

When installing the top drive gear bushing, align the
bushing oil hole A with the countershaft hole B.
When installing the 3rd driven gear onto the driveshaft, install
the lock washer No. 2 1 onto the driveshaft, and turn and fit it
into the groove.
Then, fit the lock washer No. 1 2 in the lock washer No. 2 1.
ENGINE

When installing the 1st and 3rd driven gear bushings,
align the bushing oil hole C with the driveshaft oil
hole D.
TRANSMISSION GEARS AND RELATED PARTS
3-59
3-60
ENGINE
GEARSHIFT FORK
GEARSHIFT FORK TO GROOVE CLEARANCE
Using a thickness gauge, check the shifting fork clearance in the
groove of its gear.
The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.
If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.
 Gearshift fork to groove clearance
Standard: 0.10 – 0.30 mm (0.004 – 0.012 in)
Service Limit: 0.50 mm (0.020 in)
 09900-20803: Thickness gauge
09900-20102: Vernier calipers
 Shift fork groove width
Standard (No. 1): 5.50 – 5.60 mm (0.217 – 0.220 in)
(No. 2): 4.50 – 4.60 mm (0.177 – 0.181 in)
 Shift fork thickness
Standard (No. 1): 5.30 – 5.40 mm (0.209 – 0.213 in)
(No. 2): 4.30 – 4.40 mm (0.169 – 0.173 in)
OIL JET
Check the all oil jets for clogging. If it is clogged, clean its oil
passage with a compressed air.

Use new O-rings to prevent the oil pressure down.
NOTE:
When installing the oil jets apply oil to the O-rings.
ENGINE
CRANKCASE
OIL SUMP FILTER
• Remove the oil sump filter cover.
• Remove the oil sump filter.
• Clean the oil sump filter using compressed air.
• When installing the new O-ring, apply grease to it.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
OIL PIPE
• Remove the oil pipe.
3-61
3-62
ENGINE
• When installing the oil pipe, use the new O-rings.
• Apply grease to the O-rings.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply a small quantity of the THREAD LOCK “1342” to the oil
pipe retainer bolts and tighten them securely.
 99000-32050: THREAD LOCK “1342”
OIL PRESSURE REGULATOR
• Remove the oil pressure regulator.
Check the operation of the oil pressure regulator by pushing on
the piston with an appropriately shaped tool. If the piston does
not operate, replace the oil pressure regulator with a new one.
• When installing the oil pressure regulator, install the new
washer 1.
BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for abnormal
play, noise and smooth rotation while the bearings are in the
crankcase.
Replace the bearing in the following procedure if there is anything unusual.
ENGINE
3-63
BEARING DISASSEMBLY
• Remove the bearing retainers.
• Remove the bearing with the special tools.
 09913-70210: Bearing installer set
09921-20240: Bearing remover set
NOTE:
If abnormal noise does not occur, it is not necessary to remove
the bearing.
BEARING REASSEMBLY
• Install the bearing into the crankcase with the special tool.
NOTE:
* The stamped mark side of the bearing faces (1, 2, 4) outside.
* The stamped mark side of the bearing faces (3, 5, 6) inside.
 09913-70210: Bearing installer set
• Apply a small quantity of the THREAD LOCK “1342” to the
bearing retainer screws. (USA)
• Apply a small quantity of the THREAD LOCK SUPER “1322”
to the bearing retainer screws. (Others)
(USA)
(USA)
(Others)
(Others)
 99000-32050: THREAD LOCK “1342” (USA)
 99000-32110: THREAD LOCK SUPER “1322” (Others)
(USA)
(Others)
OIL PRESSURE SWITCH
• Remove the oil pressure switch.
3-64
ENGINE
• When installing the switch, apply SUZUKI BOND “1207B”.
 Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
 99000-31140: SUZUKI BOND ‘‘1207B”
OIL SEAL
• Remove the oil seal with the special tool.
 09913-70210: Bearing installer set
• Install the oil seal with the special tool.
• Apply grease to the oil seal lip.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 09913-70210: Bearing installer set
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 reassembling.
SECONDARY DRIVE BEVEL GEAR
• Install the secondary drive bevel gear shim(s).
SHIM SELECTION 4-7
• Install the secondary drive bevel gear assembly and tighten
the retainer bolts to the specified torque.
NOTE:
Apply THREAD LOCK SUPER “1303” to the thread of the bolts.
 99000-32030: THREAD LOCK SUPER “1303”
 Secondary drive gear bearing retainer bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
COUNTERSHAFT/DRIVESHAFT
• Install the countershaft assembly and driveshaft assembly.
• Install the over driving gear 1 and bush 2.
3-65
3-66
ENGINE
• Install the gearshift forks 3 4, gearshift fork shafts and gearshift cam.
3 No. 1 shift forks (For 4th and 5th driven gears)
4 No. 2 shift fork (For 3rd drive gear)
CRANKSHAFT
• Install the thrust shim 1 on the crankshaft.
NOTE:
* The grooved face A of thrust shim 1 faces to crankshaft web
side.
* The thrust shim is selected by the crankshaft thrust clearance.
(3-52)
• Install the crankshaft into the left crankcase half.
NOTE:
Coat lightly moly paste to the crankshaft journal bearings and
the thrust shim.
 99000-25140: SUZUKI MOLY PASTE

Never strike the crankshaft with a plastic hammer
when inserting it into the crankcase. It will be easy to
install the crankshaft to left crankcase.
ENGINE
• Install the dowel pins and O-ring on the left crankcase half.
NOTE:
Apply grease to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

Use the new O-ring to prevent oil leakage.
• Clean the mating surfaces of the left and right crankcase
halves.
• Apply SUZUKI BOND “1207B” to the mating surface of the
right crankcase.
 99000-31140: SUZUKI BOND ‘‘1207B”
NOTE:
Use of SUZUKI BOND “1207B” is as follows:
* Make surfaces free from moisture, oil, dust and other foreign
materials.
* Spread on surfaces thinly to form an even layer, and assemble
the crankcases within few minutes.
* Take extreme care not to apply any BOND “1207B” to the oil
hole, oil groove and bearing.
* Apply to distorted surfaces as it forms a comparatively thick
film.
• Fit the gaskets to the bolts A.
• Fit the lead wire to the bolt B.
• When securing the right and left crankcase halves, tighten
each bolt a little at a time to equalize the pressure. Tighten all
the securing bolts to the specified torque values.
 Crankcase 8 mm bolt:
Initial: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
Final : 22 N·m (2.2 kgf-m, 16.0 lb-ft)
Crankcase 6 mm bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

Do not drop the O-ring into the crankcase when
assembling the right and left crankcase halves.
NOTE:
After the crankcase bolts have been tightened, check if the
crankshaft, secondary drive bevel gear shaft, countershaft and
the driveshaft rotate smoothly.
3-67
3-68
ENGINE
SECONDARY DRIVEN BEVEL GEAR
• Install the secondary driven bevel gear bearing and the pin 1.
NOTE:
* Align the hole A of the secondary driven bevel gear bearing
with the pin 1.
* The stamped mark side of the bearing face rearward.
• Install the secondary driven bevel gear assembly, shim(s) 2
and O-ring 3.
• Install the dowel pins and the oil jet 4.

Use the new O-ring to prevent oil leakage.
NOTE:
* Refer to the section 4 for shim selection.
* Apply grease to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Clean the mating surfaces of the crankcase and the secondary gear case.
• Apply SUZUKI BOND “1207B” to the mating surface of the
secondary gear case.
 99000-31140: SUZUKI BOND ‘‘1207B”
NOTE:
* Make surfaces free from moisture, oil, dust and other foreign
materials.
* Spread on surfaces thinly to form an even layer, and assemble
the crankcases within few minutes.
* Take extreme care not to apply any BOND “1207B” to the oil
hole, oil groove and bearing.
* Apply to distorted surfaces as it forms a comparatively thick
film.
• Tighten the secondary gear case bolts to the specified torque.
 Secondary gear case bolt
Initial: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
Final : 22 N·m (2.2 kgf-m, 16.0 lb-ft)
NOTE:
* Fit the washer to the bolt C.
* Fit the clamp to the bolt D.
ENGINE
• Tighten the secondary driven bevel gear bolt to the specified
torque.
NOTE:
* Hollow portion E of the secondary driven gear assembly faces
inside.
* Apply a small quantity of THREAD LOCK SUPER “1303” to the
bolt.
 99000-32030: THREAD LOCK SUPER “1303”
 Secondary driven bevel gear bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
DRIVESHAFT BOLT/SECONDARY DRIVEN GEAR SHAFT
NUT
• Install the universal joint on the secondary driven gear shaft.
• While holding the universal joint with a adjustable wrench,
tighten the secondary drive gear shaft nut 1 and driveshaft
bolt 2 to the specified torque.

Driveshaft bolt 2 has left-hand thread.
 Secondary drive gear shaft nut:
105 N·m (10.5 kgf-m, 76.0 lb-ft)
Driveshaft bolt: 65 N·m (6.5 kgf-m, 47.0 lb-ft)
WATER PUMP
• Install the new O-ring and new gasket.
• Tighten the water pump mounting screws.

Use the new O-ring to prevent oil leakage.
NOTE:
Apply grease to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
3-69
3-70
ENGINE
• Install the new O-ring.
• Install the water pump cover.

Use the new O-ring to prevent oil leakage.
NOTE:
* Fit the clamp to the bolt A.
* Apply grease to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
CAM CHAIN/CAM CHAIN TENSIONER
• Install the cam chain tensioner 1, washers 2, spacer 3 and
cam chain.
 Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
1 For front cylinder
2 For rear cylinder
NOTE:
The No. 2 cam chain (For front cylinder) is a little longer than the
No. 1 cam chain.
GENERATOR
• Degrease the tapered portion of the generator rotor assembly
and also the crankshaft. Use nonflammable cleaning solvent
to wipe off the oily or greasy matter to make these surfaces
completely dry.
• Install the key.
ENGINE
• Install the starter driven gear to the rotor.
• Install the generator rotor assembly and tighten its bolt to the
specified torque.
 Generator rotor bolt: 160 N·m (16.0 kgf-m, 115.5 lb-ft)
• Install the starter driven gear and the idle gear.
• Install the new gasket 3 and dowel pins.
• Install the generator cover.
NOTE:
Fit the new gaskets to the bolts A.
NEUTRAL SWITCH
• Install the springs 1 and switch contacts 2.
NOTE:
Apply grease to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
3-71
3-72
ENGINE
• Install the neutral switch.
• Install the oil pressure switch lead wire.
OIL FILTER
• Apply engine oil lightly to the gasket of the oil filter before
installation.
• Install the oil filter turning it by hand until feeling that the filter
gasket contacts the mounting surface. Then tighten it 2 turns
using the oil filter wrench. ( 20 N·m, 2.0 kgf-m, 14.5 lb-ft)
 09915-40610: Oil filter wrench
PRIMARY DRIVE GEAR
• Install the thrust washer 1 onto the crankshaft.
NOTE:
The chamfer side A of thrust washer 1 face crankcase side.
• Align the punch mark B on the crankshaft with the punch
mark C on the camshaft drive sprocket.
• Install the cam chain, cam chain tensioner 2, washers 3 and
spacer 4.
• Tighten the cam chain tensioner bolt to the specified torque.
 Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
ENGINE
• Install the primary drive gear and tighten the primary drive
gear bolt to the specified torque with the special tool.
 Primary drive gear bolt: 95 N·m (9.5 kgf-m, 68.5 lb-ft)
 09930-40113: Rotor holder
NOTE:
This bolt has left-hand thread.
GEARSHIFT
• Install the washer 1.
• Install the gearshift cam stopper plate after aligning the gearshift cam pins A with the gearshift cam stopper plate holes
B.
• Install the washer 2.
• Apply a small quantity of THREAD LOCK “1342” to the gearshift cam stopper bolt 3 and tighten it.
 99000-32050: THREAD LOCK “1342”
• Install the cam driven gear 4 after installing the springs, pins
and gearshift pawls.
• Install the cam guide and the pawl lifter.
• Apply a small quantity of THREAD LOCK “1342” to the nuts.
 99000-32050: THREAD LOCK “1342”
3-73
3-74
ENGINE
• Install the gearshift return spring properly.
• Install the gearshift shaft with the center of shift gear on the
shaft aligned the center of gearshift cam driven gear.
OIL PUMP
• Install the oil pump.
 Oil pump mounting bolt: 11 N·m (1.1 kgf-m, 8 lb-ft)
NOTE:
Set the oil pump shaft end A to the water pump shaft B.
• Install the washer 1 and pin 2.
• Install the oil pump driven gear and the snap ring.
 09900-06107: Snap ring pliers
CLUTCH
• Install the spacer 1 and the thrust washer 2.
• Engage the chain with the oil pump drive gear.
ENGINE
• Install the primary driven gear assembly and engage the
chain with the oil pump driven gear.
• Apply engine oil to the primary driven gear bearing 3 and
install it.
• Install the spacer 4 and thrust washer 5.
• Install the clutch sleeve hub 6 and washer 7.
NOTE:
The convex side of the washer 7 faces outside.
• Tighten the clutch sleeve hub nut to the specified torque with
the special tool.
 Clutch sleeve hub nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft)
 09920-53740: Clutch sleeve hub holder
3-75
3-76
ENGINE
95 N.m
(9.5 kgf-m, 68.5 lb-ft)
Clutch drive plate No. 2
Clutch drive plate No. 1
60 N.m
(6.0 kgf-m, 43.5 lb-ft)
Wave washer
seat
Wave
washer
Clutch driven plate
A No. 2 Drive plate
Thickness: 3.5 mm (0.14 in) ..........1 pc.
B No. 1 Drive plate
Thickness: 3.0 mm (0.12 in) ..........6 pcs.
a Driven plate ......................................6 pcs.
• Install the wave washer seat 8 and the wave washer 9.
ENGINE
• Install the clutch drive plate No. 2 A first.
• Install the drive and driven plate one by one into the clutch
sleeve hub.
• Install the push rod.
• Install the clutch push piece 0, bearing A and thrust washer
B.
• Apply engine oil to the bearing.
• Install the springs and tighten the clutch spring set bolts diagonally to the specified torque.
 Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Install the new gasket C and dowel pins.
• Install the clutch cover and tighten the bolts.
NOTE:
Fit the new gaskets to the bolts B.
3-77
3-78
ENGINE
STARTER MOTOR
• Install the starter motor.
NOTE:
Apply grease to the new O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the starter motor cover.
OIL JET
• Apply engine oil to the new O-ring and install the oil jets.
PISTON
• Apply a light coat of SUZUKI MOLY PASTE to the piston pins.
 99000-25140: SUZUKI MOLY PASTE
• When installing the piston, the arrow mark on the piston head
is located to the exhaust side.
• Place a cloth beneath the piston, and install the circlip 1.

When turning the crankshaft, pull the cam chains
upward, or the chains will be caught between the
crankcase and the cam drive sprocket.
ENGINE
CYLINDER
• Install the cam chain tension adjuster to the cylinder.
• After unlocking the ratchet, push the cam chain tension
adjuster rod.
• Insert the special tool between the ratchet and the adjuster
body.
 09918-53810: Chain tensioner lock tool
 Cam chain tension adjuster mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Coat SUZUKI BOND “1207B” lightly to the mating surfaces
among the crankcase mating surfaces.
 99000-31140: SUZUKI BOND ‘‘1207B”
• Fit the dowel pins and the new gasket 1.

Use a new gasket to prevent gas leakage.
• Install the cylinder. (Rear cylinder)
• Install the water hose and pipe.
NOTE:
Apply grease to the new O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
3-79
3-80
ENGINE
CYLINDER HEAD
• Install the cam chain guide.
1 For front cylinder
2 For rear cylinder
• Fit the dowel pins and the new gasket 3.

Use a new gasket to prevent gas leakage.
• Install the cylinder head and tighten the cylinder head bolts
diagonally to the specified torque. (Rear cylinder)
 Cylinder head bolt (M10):
Initial: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final : 38 N·m (3.8 kgf-m, 27.5 lb-ft)
NOTE:
Bolt A: 165 mm (6.5 in)
Bolt B: 155 mm (6.1 in)
• Install the water hoses to the rear cylinder.
FRONT CYLINDER
• Fit the dowel pins and new gasket 1.

Use a new gasket to prevent gas leakage.
ENGINE
• Fit the dowel pins and the new gasket 2.

Use a new gasket to prevent gas leakage.
• Install the front cylinder assembly to the crankcase.
• Connect the water hoses.
• Tighten the cylinder head bolts diagonally to the specified
torque.
 Cylinder head bolt (M10):
Initial: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final : 38 N·m (3.8 kgf-m, 27.5 lb-ft)
NOTE:
Bolt A: 165 mm (6.5 in)
Bolt B: 155 mm (6.1 in)
CAMSHAFT
• Position “R I T” mark on the generator rotor with the center of
the valve timing inspection hole.

Pull the cam chains upward, or the chain will be
caught between crankcase and cam drive sprocket.
• Before installing the camshafts onto each cylinder head, apply
SUZUKI MOLY PASTE onto the camshaft journals. Also,
apply engine oil onto the camshaft journal holders.
 99000-25140: SUZUKI MOLY PASTE
NOTE:
The camshaft is identified by the embossed letters “F” and “R”.
1 Front cam shaft
2 Rear cam shaft
R
R
T
F
3-81
3-82
ENGINE
• Align the arrow marks on the front and rear camshafts so it is
parallel with the surface of the cylinder heads.
NOTE:
Arrow marks are located to forward.
Front
• Engage the chains on the cam sprockets with the locating pin
holes A as shown in the photograph.
NOTE:
Do not rotate the generator rotor while doing this. When the
sprocket is not positioned correctly, turn the sprocket.
• Recheck the position of the “R I T” mark on the generator
rotor, arrow mark on the No. 1 (Rear) camshaft and arrow
mark on the No. 2 (Front) camshaft.
Front
• Install the lock washer so that it is covering the locating pin.
• Apply THREAD LOCK SUPER “1303” to the bolts and tighten
them to the specified torque.
 Cam chain sprocket bolt: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
 99000-32030: THREAD LOCK SUPER “1303”
• Bend up the washer tongue positively to lock the bolts.
Camshaft
Bend up
Bolt
Pin
Washer
Sprocket
CYLINDER HEAD COVER
• Clean the mating surfaces of the cylinder head and head
cover before matching.
• Install the dowel pins to the cylinder head.
ENGINE
• Apply SUZUKI BOND “1216B” to the mating surface of the
cylinder head cover.
• Fit the camshaft end caps 1.
• Apply grease to the new O-ring 2 and install it. (Front cylinder only)
1216
99000-31230: SUZUKI BOND “1216B”
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
FWD
1216
1216
FRONT
• Lightly tighten the cylinder head cover bolts diagonally, and
then if everything is satisfactory, tighten securely with a
torque wrench to the specified torque.
 Cylinder head cover bolt
(M6): 10 N·m (1.0 kgf-m, 7.0 lb-ft)
(M8): 25 N·m (2.5 kgf-m, 18.0 lb-ft)
NOTE:
When tightening the cylinder head cover bolts, the piston must
be at top dead center on the compression stroke.
(3-12 and -13)
REAR
3-83
3-84
ENGINE
LOCATION OF CYLINDER HEAD COVER BOLT
L: Length
L: 30
L: 20
L: 55
L: 50
L: 250
Unit: mm
L: 250
L: 20
L: 30
L: 20
L: 30
L: 30
L: 40
L: 55
L: 55
L: 55
FWD
L: 25
L: 30
L: 30
L: 20
L: 25
L: 30
L: 25
L: 25
L: 20
L: 55
L: 30
L: 30
L: 20
L: 40
L: 30
L: 30
L: 20
L: 80
L: 20
L: 250
L: 250
FRONT
L: 50
L: 30
REAR
NOTE:
* Before installing the bolt 1, apply SUZUKI BOND “1207B” to the thread of the bolt.
* Allen bolt: 2
* Fit the gasket to the bolt 3.
• Remove the tensioner lock tools.
NOTE:
Click sound is heard when the cam chain tension adjuster is
released.
L: 55
ENGINE
• Install the intake pipe.
3-85
“R”
“F”
• Apply grease to the new O-ring and install the water outlet
union.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the gasket and the breather cover.
• Apply grease to the new O-rings and install the valve inspection caps.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the valve timing inspection plug 1 and the generator
cover cap 2.
• Install the head cover caps 3.
3-86
ENGINE
• Install the new gaskets.
• Install the PAIR pipes.
• Install the spark plugs.
 09930-10121: Spark plug wrench set
SHAFT DRIVE
4-1
SHAFT DRIVE
CONTENTS
SECONDARY BEVEL GEARS .......................................................................4- 2
CONSTRUCTION ...................................................................................4- 2
REMOVAL ..............................................................................................4- 4
DISASSEMBLY ......................................................................................4- 4
INSPECTION ..........................................................................................4- 5
SECONDARY GEAR SHIMS ADJUSTMENT ........................................4- 6
REASSEMBLY .......................................................................................4-10
INSTALLATION ......................................................................................4-10
FINAL BEVEL GEARS ....................................................................................4-11
CONSTRUCTION ...................................................................................4-11
FINAL GEAR CASE REMOVAL ............................................................4-13
FINAL GEAR CASE DISASSEMBLY ....................................................4-13
FINAL GEAR SHIMS ADJUSTMENT ....................................................4-17
FINAL GEAR CASE REASSEMBLY .....................................................4-21
FINAL GEAR CASE INSTALLATION ....................................................4-25
4
6
6
4-2
SHAFT DRIVE
SECONDARY BEVEL GEARS
CONSTRUCTION
*A
1
Bush
7
Shims (5 kinds)
C
Oil seal
2
Overdriving driven gear
8
Driven bevel gear bearing
D
Bearing stopper
3
Circlip
9
O-ring
E
Universal joint
4
Output cam dog
0
Shims (5 kinds)
A
Secondary drive gear shaft nut
5
Damper spring
A
O-ring
B
Secondary drive bevel gear bearing retainer bolt
6
Secondary bevel gear set
B
Oil seal housing
C
Secondary driven bevel gear bolt
* A: Do not disassemble the secondary driven gear.

ITEM
A
B, C
N·m
105
23
kgf-m
10.5
2.3
lb-ft
76.0
16.5
SHAFT DRIVE
Backlash
Standard clearance A: 1.00 mm (0.039 in)
B: 1.00 mm (0.039 in)
Adjust backlash by selecting shims. (Use two pieces of shims.)
Shim 1 size table
Part number
24945-05A-0A0
24945-05A-0B0
24945-05A-0C0
24945-05A-0D0
24945-05A-0E0
Thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
The shims 1 are available as a set (24945-05810).
Shim 2 size table
Part number
24935-38A01-030
24935-38A01-035
24935-38A01-040
24935-38A01-050
24935-38A01-060
Thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
The shims 2 are available as a set (24935-38810).
0.05 – 0.32 mm
(0.002 – 0.013 in)
4-3
4-4
SHAFT DRIVE
REMOVAL
SECONDARY DRIVE BEVEL GEAR
The crankcase must be separated to service the secondary
drive bevel gear. The secondary drive bevel gear service
requires engine removal and disassembly. Refer to the engine
removal and the engine disassembly sections for secondary
drive bevel gear assembly removal.
Engine removal 3-3
Engine disassembly 3-11
SECONDARY DRIVEN BEVEL GEAR
The following components must be removed in the described
order before removing the secondary driven bevel gear.
NOTE:
Refer to the following pages for the details of each step.
•
•
•
•
Remove the rear wheel. (8-33)
Remove the swingarm. (8-40)
Remove the universal joint.
Remove the secondary driven bevel gear.
DISASSEMBLY
SECONDARY DRIVE BEVEL GEAR
• Compress the damper spring with a vice, and remove the snap
ring with the special tool.
 09900-06107: Snap ring pliers
• Remove the cam dog 1 and damper spring 2.

Do not attempt to remove the secondary drive bevel
gear bearing. The secondary drive bevel gear and its
bearing are available only as an assembly.
SHAFT DRIVE
SECONDARY DRIVEN BEVEL GEAR
• Remove the bearing stopper with the special tool.
 09921-21820: Bearing retainer wrench
• Remove the oil seal 1 and O-ring 2.
INSPECTION
Inspect the removed parts for the following abnormalities.
* Drive and driven bevel gears damage or wear
* Improper tooth contact
* Abnormal noise of bearings
* Bearing damage or wear
* Oil seal damage or wear
* Output cam dog wear or damage
* Universal joint spline damage or wear
DAMPER SPRING
Measure the free length of the damper spring. If the length is
shorter than the service limit, replace the spring with a new one.
 Damper spring free length
Service limit: 58.5 mm (2.30 in)
4-5
4-6
SHAFT DRIVE
SECONDARY GEAR SHIMS ADJUSTMENT
BACKLASH
• Install the secondary drive bevel gear assembly with the
removed shims and tighten the bolts to the specified torque.
 Secondary drive bevel gear bearing retainer bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
When replacing the secondary drive and driven bevel gears,
install the removed shims to the secondary drive bevel gear
assembly and tighten the bolts to the specified torque.
• Install the secondary driven bevel gear assembly with
removed shims, the driven bevel gear bearing and secondary
gear case.
NOTE:
Do not install the O-ring on the driven gear housing at this stage.
O-ring is installed after backlash and tooth contact are correct.
• Tighten the secondary bevel gear case bolts and secondary
driven bevel gear bolts to the specified torque.
 Secondary bevel gear case bolt:
22 N·m (2.2 kgf-m, 16.0 lb-ft)
Secondary driven bevel gear bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
* Hollow portion A of the secondary driven bevel gear assembly
faces inside.
* It is not necessary to apply SUZUKI BOND “1207B” to the
matching surface at this stage.
SHAFT DRIVE
• Measure the backlash as follows.
• Set-up a dial gauge as shown in photo.
 09900-20606: Dial gauge (1/100 mm, 10 mm)
09900-20701: Magnetic stand
• Adjust the dial gauge so that it touches the secondary drive
bevel gear cam dog; hold the driven bevel gear securely, and
turn the drive bevel gear in each direction, reading the total
backlash on the dial gauge.
 Secondary bevel gear backlash
Standard: 0.05 – 0.32 mm (0.002 – 0.013 in)
NOTE:
When measuring backlash, hold the left crankcase horizontally
pull the secondary drive gear to take the bearing play out.
• If the backlash is not within specification, the shims (Driven
bevel gear side) must be changed and the backlash should be
re-checked until correct.
Refer to the chart for appropriate changes.
NOTE:
When changing the shims (Driven bevel gear side), measure the
thickness of old shims. Using the thickness of the old shims as a
guide, adjust the backlash by referring to the chart.
Backlash
Under 0.05 mm (0.002 in)
0.05 – 0.32 mm
(0.002 – 0.013 in)
Over 0.32 mm (0.013 in)
Shim adjustment
Increase shim thickness
Correct
Decrease shim thickness
SHIM SPECIFICATIONS
Drive bevel gear side
Part No.
24935-38A01-030
24935-38A01-035
24935-38A01-040
24935-38A01-050
24935-38A01-060
Shim thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
NOTE:
The shims (drive bevel gear side) are available as a set
(24935-38810).
4-7
4-8
SHAFT DRIVE
Driven bevel gear side
Part No.
24945-05A00-0A0
24945-05A00-0B0
24945-05A00-0C0
24945-05A00-0D0
24945-05A00-0E0
Shim thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
NOTE:
The shims (driven bevel gear side) are available as a set
(24945-05810).
TOOTH CONTACT
After bringing the backlash within specification by changing the
secondary driven bevel gear shims, it will be necessary to check
tooth contact.
• Remove the drive bevel gear assembly from the crankcase.
• Clean and degrease the secondary drive bevel gear teeth,
and apply a coating of machinist’s layout dye or paste to several teeth.
1 INCORRECT (Contact at tooth top)
• Reinstall the secondary drive bevel gear assembly, with correct shim, onto the secondary gear housing.
• Rotate the secondary driven bevel gear several turns in bothdirections.
• Remove the secondary drive bevel gear from the crankcase,
and observe the tooth contact pattern made in the dye or
paste.
• Compare the tooth contact pattern to the examples as shown
in 1, 2 and 3.
2 CORRECT
• If tooth contact is found to be incorrect, the shims of the secondary drive bevel gear and secondary driven bevel gear
must be changed, tooth contact should be re-checked until
correct.
3 INCORRECT (Contact at tooth root)

After the tooth contact adjustment is made, the backlash must be re-checked, as it may change. Refer to
the backlash checking sub-section, and readjust until
both backlash and tooth contact are correct.
Tooth contact
Contact at tooth top 1
Contact at tooth root 3
Shim adjustment
Decrease thickness of shims
4 or 5
Increase thickness of shims
4 or 5
SHAFT DRIVE
SHIM SPECIFICATIONS
Drive bevel gear side
Part No.
24935-38A01-030
24935-38A01-035
24935-38A01-040
24935-38A01-050
24935-38A01-060
Shim thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
NOTE:
The shims (drive bevel gear side) are available as a set
(24935-38810).
Driven bevel gear side
Part No.
24945-05A00-0A0
24945-05A00-0B0
24945-05A00-0C0
24945-05A00-0D0
24945-05A00-0E0
Shim thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
NOTE:
The shims (driven bevel gear side) are available as a set
(24945-35810).
4-9
4-10
SHAFT DRIVE
REASSEMBLY
SECONDARY DRIVEN BEVEL GEAR
• Apply grease to the lip of oil seal.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Tighten the bearing stopper to the specified torque with the
special tool.
 Bearing stopper: 105 N·m (10.5 kgf-m, 76.0 lb-ft)
 09921-21820: Bearing retainer wrench
SECONDARY DRIVE BEVEL GEAR
Reassemble the secondary drive bevel gear in the reverse order
of disassembly. Pay attention to the following points.
• When installing a new circlip, pay attention to the direction of
the snap ring. Fit the snap ring to the side where the thrust is,
as shown in the illustration. The rounded side should be
against the output cam dog surface.
Thrust
Sharp edge

* Never reuse a snap ring. After a snap ring has been
removed from a shaft, it should be discarded and a
new circlip must be installed.
* When installing a new snap ring, do not expand the
end gap larger than required to slip the circlip over
the shaft.
* After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.
INSTALLATION
SECONDARY DRIVEN BEVEL GEAR/SECONDARY DRIVE
BEVEL GEAR
• Refer to the engine reassembly sections.
Engine reassembly 3-65
SHAFT DRIVE
4-11
FINAL BEVEL GEARS
CONSTRUCTION
1
2
3
4
5
6
7
8
9
0
Oil seal
Final gear bearing case
O-ring
Plate
Final driven gear bearing
Shims (4 kinds)
Final driven bevel gear
Shims (8 kinds)
Bearing retainer
Final driven gear bearing
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Final drive bevel gear bearing A
Oil seal
B
Bearing stopper
C
O-ring
D
Oil seal
Final gear case
Shims (5 kinds)
Stopper plate (2 kinds)
Final drive gear bearing
Final drive bevel gear
Final drive coupling
Snap ring
Oil seal
Spring
Propeller shaft
Universal joint
Final gear case bolt
Final driven bevel gear bearing retainer screw
Final gear case nut
Final driven bevel gear coupling nut

ITEM
A
B
N·m
23
9
kgf-m
2.3
0.9
lb-ft
16.5
6.5
ITEM
C
D
N·m
40
100
kgf-m
4.0
10.0
lb-ft
29.0
72.5
4-12
SHAFT DRIVE
Backlash
0.03 – 0.064 mm
(0.001 – 0.025 in)
Standard clearance A: 1.00 mm (0.039 in)
Shim 1 size table
Part number
Thickness
27445-38A00-030
0.30 mm (0.012 in)
27445-38A00-035
0.35 mm (0.014 in)
27445-38A00-040
0.40 mm (0.016 in)
27445-38A00-050
0.50 mm (0.020 in)
27445-38A00-060
0.60 mm (0.024 in)
The shims 1 are available as a set
(27445-38810).
Standard clearance C: 1.00 mm (0.039 in)
Shim 3 size table
Part number
Thickness
27327-34200
0.35 mm (0.014 in)
27327-34210
0.40 mm (0.016 in)
27327-34220
0.50 mm (0.020 in)
27327-34230
0.60 mm (0.024 in)
The shims 3 are available as a set
(27327-34810).
Standard clearance B: 2.3 mm (0.091 in)
Shim 2 size table
Part number
27326-34201
27326-34211
27326-34221
27326-34231
27326-34241
27326-34201-140
27326-34201-145
27326-34201-150
Thickness
1.05 mm (0.041 in)
1.10 mm (0.043 in)
1.20 mm (0.047 in)
1.25 mm (0.049 in)
1.35 mm (0.053 in)
1.40 mm (0.055 in)
1.45 mm (0.057 in)
1.50 mm (0.059 in)
The shims 2 are available as a set {27326-34810 (1.40 –
1.50), 27326-34820 (1.05 – 1.35)}.
SHAFT DRIVE
FINAL GEAR CASE REMOVAL
After draining final gear oil, the following components must be
removed in the described order before removing the final gear
case.
NOTE:
Refer to the following pages for the details of each step.
• Drain final gear oil. (2-19)
• Remove the rear wheel. (8-33)
• Remove the final gear case.
FINAL GEAR CASE DISASSEMBLY
• Remove the plate 1.
• Remove the oil seal 2.

The removed oil seal must be replaced with a new one.
• Remove the snap ring 3 with the special tool and take off the
propeller shaft and spring.
 09900-06108: Snap ring pliers
4-13
4-14
SHAFT DRIVE
4 Spring
5 Propeller shaft
6 Snap ring
• Using a chisel, unlock the nut.
• Remove the final drive bevel gear coupling nut with the special tool.
 09924-62430: 22 mm Long socket
09924-64510: Final drive gear coupling holder
• Remove the washer 7 and the final drive coupling 8.
• Remove the bearing stopper by with the special tool.
 09924-62410: Final drive gear bearing holder wrench
• Remove the final drive bevel gear 9 and shims 0.
SHAFT DRIVE
• Remove the bearing from the final drive bevel gear with the
special tool.
 09913-50121: Bearing puller

The removed bearing must be replaced with a new one.
NOTE:
If no abnormal noise, the bearing removal is not necessary.
• Remove the final gear bearing case bolts.
• Remove the final gear bearing case from the final gear case,
by using two 5 mm screws.
• Remove the final driven bevel gear A and shims B.
• Remove the oil seal with the special tool.
 09913-50121: Oil seal remover
NOTE:
If no oil leakage, the oil seal removal is not necessary.
4-15
4-16
SHAFT DRIVE
• Remove the bearing retainer screws, using an impact driver
set.
 09900-09004: Impact driver set
• Remove the final driven gear bearing C and oil seal D with
the special tools.
 09941-64511: Bearing remover
09930-30104: Sliding shaft

The removed bearing and oil seal must be replaced
with new ones.
NOTE:
If no abnormal noise, the bearing removal is not necessary.
• Remove the final drive gear bearing with the special tools.
 09923-73210: Bearing remover
09930-30104: Sliding shaft

The removed bearing must be replaced with a new one.
NOTE:
If no abnormal noise, the bearing removal is not necessary.
• Remove the oil seal E and O-ring F from the bearing stopper.

The removed oil seal and O-ring must be replaced with
new ones.
NOTE:
If no oil leakage, the oil seal removal is not necessary.
INSPECTION
Inspect the removed parts for the following abnormalities.
* Drive and driven bevel gear damage or wear
* Improper tooth contact
* Abnormal noise of bearings
* Bearing damage or wear
* Oil seal damage or wear
* Propeller shaft spline damage or wear
SHAFT DRIVE
FINAL GEAR SHIMS ADJUSTMENT
FINAL GEAR BEARING CASE SHIM CLEARANCE
• Install the final driven gear, shims (1 and 2) and final gear
bearing case to the final gear case.
• Tighten the final gear case bolts to the specified torque.
 Final gear case bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
It is not necessary to apply SUZUKI BOND “1207B” to the
matching surface at this stage.
• Measure the clearance between the shims and bearing. If it is
not within the specification, the shims must be changed.
Standard
 Final gear case shim clearance
Standard: 1.00 mm (0.039 in)
Shims 2 specifications
Part No.
27327-34200
27327-34210
27327-34220
27327-34230
Shim thickness
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
NOTE:
The shims 2 are available as a set (27327-34810).
4-17
4-18
SHAFT DRIVE
BACKLASH
After assembling the final gear case, measure the final bevel
gear backlash as follows.
• Install the backlash measuring tool on the drive bevel gear
coupling, and set-up a dial gauge as shown in photo.
 09924-34510: Backlash measuring tool (27 – 50 mm)
09900-20607: Dial gauge (1/100 mm, 10 mm)
09900-20701: Magnetic stand
• Adjust the dial gauge so that it touches the backlash measuring tool arm at the mark; hold the final driven bevel gear
securely, and turn the final drive bevel gear coupling slightly in
each direction, reading the total backlash on the dial gauge.
 Final bevel gear backlash
Standard: 0.03 – 0.64 mm (0.001 – 0.025 in)
If the backlash is not within the specification, adjust the shim
thickness as follows:
• Remove shims from final gear bearing case and final gear
case, and measure total thickness.
• In order not to change the clearance between final driven
bevel gear and bearing, the total thickness of the shims
installed after a change is made must equal the original total
thickness of shims.
• If backlash is too large:
a) Install a thinner shim pack 1 between final driven bevel
gear and final gear case.
b) Increase thickness of shims 2 between final driven bevel
gear bearing and bearing case by an amount equal to
decrease above.
• If backlash is too small:
a) Install a thicker shim pack 1 between final driven bevel
gear and final gear case.
b) Decrease thickness of shims 2 between final driven gear
bearing and bearing case by an amount equal to increase
above.
Shims 1 specifications
Part No.
27326-34201
27326-34211
27326-34221
27326-34231
27326-34241
27326-34201-140
27326-34201-145
27326-34201-150
Shim thickness
1.05 mm (0.041 in)
1.10 mm (0.043 in)
1.20 mm (0.047 in)
1.25 mm (0.049 in)
1.35 mm (0.053 in)
1.40 mm (0.055 in)
1.45 mm (0.057 in)
1.50 mm (0.059 in)
The shims 1 are available as a set {27326-34810 (1.40 –
1.50), 27326-34820 (1.05 – 1.35)}.
SHAFT DRIVE
Shims 2 specifications
Part No.
27327-34200
27327-34210
27327-34220
27327-34230
Shim thickness
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
The shims 1 are available as a set (27327-34810).
EXAMPLE:
Final gear to case shims 1; 1.45 mm + 1.40 mm = 2.85 mm
Final gear bearing to bearing case shims 2,
0.35 mm + 0.60 mm = 0.95 mm
Original total measurement = 3.80 mm
Backlash too large:
Final gear to case shims 1; 1.35 mm + 1.45 mm = 2.80 mm
Final gear bearing to bearing case shims 2,
0.60 mm + 0.40 mm = 1.00 mm
Total thickness = 3.80 mm
Backlash too small:
Final gear to case shims 1; 1.50 mm + 1.40 mm = 2.90 mm
Final gear bearing to bearing case shims 2;
0.50 mm + 0.40 mm = 0.90 mm
Total thickness = 3.80 mm
TOOTH CONTACT
After backlash adjustment is carried out, the tooth contact must
be checked.
• Remove the bolts from the final gear bearing case, and
remove the case with the two 5 mm screws. (4-15) Do not
misplace the shims. Remove the final driven bevel gear.
• Clean and de-grease several teeth on the final driven bevel
gear. Coat these teeth with machinist’s dye or paste, preferably of a light color.
• Re-install the final driven bevel gear with shims in place, positioning the coated teeth so that they are centered on the final
drive bevel gear.
• Re-install the final gear bearing case and bolts, and tighten to
specification.
 Final gear case bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Using a socket and handle on the final drive bevel gear coupling nut, rotate the final drive bevel gear several turns in
each direction, while loading the final driven bevel gear. This
will provide a contact pattern on the coated teeth of the driven
bevel gear.
1 INCORRECT (Contact at tooth top)
2 CORRECT
4-19
4-20
SHAFT DRIVE
• Remove the final gear bearing case and final driven bevel
gear, and inspect the coated teeth of the driven bevel gear.
The contact patch should be as shown at right:
• If the tooth contact pattern is incorrect, as shown in 1, a thinner shim 4 is needed between the final drive bevel gear
bearing and final gear case.
• If the tooth contact pattern is incorrect, as shown in 3, a
thicker shim 4 is needed between the final drive bevel gear
bearing and final gear case.
• If the tooth contact pattern is incorrect for either reason, the
appropriate shim must be installed, and the tooth contact pattern rechecked by repeating the tooth coating procedure
above.
NOTE:
If it is necessary to adjust the shim 4 thickness between final
drive bevel gear bearing and final gear case, the final gear backlash may change, and should be re-checked according to the
procedure outlined under the Backlash Measurement sub-section. Both adjustments may be needed until both backlash and
tooth contact are correct.
Shims 4 specification
Part No.
27445-38A00-030
27445-38A00-035
27445-38A00-040
27445-38A00-050
27445-38A00-060
Shim thickness
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.50 mm (0.020 in)
0.60 mm (0.024 in)
The shims 4 are available as a set (27445-38810).
3 INCORRECT (Contact at tooth root)
SHAFT DRIVE
FINAL GEAR CASE REASSEMBLY
Reassemble the final gear case in the reverse order of disassembly. Pay attention to the following points.
• Install a new oil seal 1 and O-ring 2 to the bearing stopper.

Use new O-ring and oil seat to prevent oil leakage.
• Install the bearing to the final drive bevel gear with the special
tool.
 09913-84510: Bearing installer

When replacing the drive bevel gear, replace the
driven bevel gear also, as they must be replaced
together.
• Install the needle roller bearing for the final drive bevel gear
into the final gear case with the special tool.
 09913-75821 : Bearing installer
• Install the oil seal into the final gear case with the special tool.
 09913-70210: Bearing installer set (40 mm)

* Use a new oil seal to prevent oil leakage.
* Apply final gear oil to the lip of the oil seal.
* The lip and spring of the oil seal should face A to the
driven bevel gear side.
4-21
4-22
SHAFT DRIVE
• Install the needle roller bearing for the final driven bevel gear
into the final gear case with the special tool.
 09913-76010: Bearing installer
NOTE:
The boss on the bearing end should face to the driven bevel
gear side.
• Install the bearing retainer. Apply a small quantity of the
THREAD LOCK on the screws, and tighten them to the specified torque.
 99000-32050: THREAD LOCK “1342”
 Bearing retainer screw: 9 N·m (0.9 kgf-m, 6.5 lb-ft)
• Install a new oil seal to the final gear bearing case.
• Apply grease to the lip of the oil seal.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply SUZUKI BOND to the mating surface of the final gear
case and final gear bearing case.

Do not block the breather passage when applying
SUZUKI BOND.
 99000-31140: SUZUKI BOND “1207B”
• Apply THREAD LOCK to the final gear case bolts and tighten
them to the specified torque.
 Final gear case bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
 99000-32050: THREAD LOCK “1342”
SHAFT DRIVE
• Install the correct shims 2 to the final drive bevel gear and
install the bevel gear to the final gear case.
Shim adjustment (4-18)
• Apply grease to the O-ring and the oil seal.
• Install the bearing stopper 3.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Tighten the bearing stopper to the specified torque with the
special tool.
 09924-62410: Final drive gear bearing holder wrench
 Final drive bevel gear bearing stopper:
110 N·m (11.0 kgf-m, 79.5 lb-ft)
• Install the final drive coupling 4 and washer 5.
• Apply a small quantity of the THREAD LOCK to the final drive
bevel gear coupling nut.
 99000-32030: THREAD LOCK “1303”
• Tighten the nut to the specified torque with the special tool.
 Final drive bevel gear coupling nut:
100 N·m (10.0 kgf-m, 72.5 lb-ft)
 09924-62430: 22 mm Long socket
09924-64510: Final drive gear coupling holder
• Lock the final drive bevel gear coupling nut with a center
punch.
4-23
4-24
SHAFT DRIVE
• Apply Lithium Base Molybdenum grease (NLGI #2) to the propeller shaft splines and final drive bevel gear coupling.
• Install the spring 6 and propeller shaft 7.
 99000-25140: SUZUKI MOLY PASTE
• Install the snap ring 8.
• After installing the propeller shaft with a new snap ring, make
sure that the propeller shaft turns smoothly without any hitch
or bearing noise.
 09900-06108: Snap ring pliers
• Install the oil seal with the special tool.
 09940-51410: Steering bearing installer
09925-18011: Bearing installer
• Apply grease to the lip of the oil seal.

Use a new oil seal to prevent oil leakage.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the stopper plate 9.

When installing the plate, fit the protrusion B of plate
to the one of the bearing stopper grooves.
NOTE:
Two kinds of plates are available to lock the stopper at the
proper position.
SHAFT DRIVE
FINAL GEAR CASE INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Refer to the following pages for the details of each step.
• Install the final gear case.
• Tighten the final gear case bolts to the specified torque.
 Final gear case nut: 40 N·m (4.0 kgf-m, 29.0 lb-ft)
• Install the rear wheel. (8-37)
• Pour final gear oil. (2-19)
4-25
FI SYSTEM
5-1
FI SYSTEM
CONTENTS
PRECAUTIONS IN SERVICING ....................................................................5- 3
CONNECTOR/COUPLER .......................................................................5- 3
FUSE .......................................................................................................5- 4
ECM/VARIOUS SENSORS .....................................................................5- 4
ELECTRICAL CIRCUIT INSPECTION PROCEDURE............................5- 6
USING THE MULTI-CIRCUIT TESTER ..................................................5- 9
FI SYSTEM TECHNICAL FEATURES ..........................................................5-10
INJECTION TIME (INJECTION VOLUME) .............................................5-10
COMPENSATION OF INJECTION TIME (VOLUME) .............................5-11
INJECTION STOP CONTROL ................................................................5-11
FI SYSTEM PARTS LOCATION ...................................................................5-12
FI SYSTEM WIRING DIAGRAM .............................................................5-14
ECM TERMINAL ............................................................................................5-15
SELF-DIAGNOSIS FUNCTION .....................................................................5-16
USER MODE ...........................................................................................5-16
DEALER MODE ......................................................................................5-17
TPS ADJUSTMENT ................................................................................5-19
FAIL-SAFE FUNCTION .................................................................................5-20
FI SYSTEM TROUBLESHOOTING ...............................................................5-21
CUSTOMER COMPLAINT ANALYSIS...................................................5-21
VISUAL INSPECTION.............................................................................5-22
SELF-DIAGNOSTIC PROCEDURES......................................................5-23
SELF-DIAGNOSIS RESET PROCEDURE .............................................5-23
USE OF SDS DIAGNOSTIC PROCEDURES .........................................5-24
USE OF SDS DIAGNOSIS RESET PROCEDURE .................................5-25
SHOW DATA WHEN TROUBLE
(DISPLAING DATA AT THE TIME OF DTC) ..........................................5-26
MALFUNCTION CODE AND DEFECTIVE CONDITION ........................5-27
“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION .....................5-30
“C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT
MALFUNCTION.......................................................................................5-33
“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION .................5-37
“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION...............5-42
ECT SENSOR INSPECTION...................................................................5-46
“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION ................5-47
“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION.................5-52
“C24” (P0351) or “C25” (P0352) IGNITION SYSTEM
MALFUNCTION.......................................................................................5-55
“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION.................5-56
“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION...............5-59
“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION.........................5-64
5
5-2
FI SYSTEM
FI SYSTEM
CONTENTS
“C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT
MALFUNCTION ...................................................................................... 5-66
“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION........................... 5-68
“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION........................ 5-68
“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT
MALFUNCTION (FOR E-02, 19, 24)....................................................... 5-69
“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT
MALFUNCTION ...................................................................................... 5-73
SENSORS ..................................................................................................... 5-75
IAP SENSOR INSPECTION ................................................................... 5-75
IAP SENSOR REMOVAL/INSTALLATION ............................................ 5-75
TP SENSOR INSPECTION..................................................................... 5-75
TP SENSOR REMOVAL/INSTALLATION ............................................. 5-75
STP SENSOR INSPECTION .................................................................. 5-76
STP SENSOR REMOVAL/INSTALLATION ........................................... 5-76
CKP SENSOR INSPECTION.................................................................. 5-76
CKP SENSOR REMOVAL/INSTALLATION .......................................... 5-76
IAT SENSOR INSPECTION.................................................................... 5-77
IAT SENSOR REMOVAL/INSTALLATION ............................................ 5-77
ECT SENSOR INSPECTION .................................................................. 5-77
ECT SENSOR REMOVAL/INSTALLATION........................................... 5-77
TO SENSOR INSPECTION .................................................................... 5-77
TO SENSOR REMOVAL/INSTALLATION ............................................. 5-77
HO2 SENSOR INSPECTION (FOR E-02, 19, 24) .................................. 5-78
HO2 SENSOR REMOVAL/INSTALLATION........................................... 5-78
FI SYSTEM 5-3
PRECAUTIONS IN SERVICING
When handling the FI component parts or servicing the FI system, observe the following points for the safety of the system.
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 disconnecting, and push in fully to engage the lock when connecting.
• When disconnecting the coupler, be sure to hold the coupler
body and do not pull the lead wires.
• Inspect each terminal on the connector/coupler for looseness
or bending.
• Inspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
• Inspect each lead wire circuit for poor connection by shaking it
by hand lightly. If any abnormal condition is found, repair or
replace.
• When taking measurements at electrical connectors using a
tester probe, be sure to insert the probe from the wire harness
side (backside) of the connector/coupler.
1 Coupler
2 Probe
Click
Click
5-4
FI SYSTEM
• When connecting meter probe from the terminal side of the
coupler where (connection from harness side not being possible), use extra care not to force and cause the male terminal
to bend or the female terminal to open.
Connect the probe as shown to avoid opening of female terminal.
Never push in the probe where male terminal is supposed to
fit.
• Check the male connector for bend and female connector for
excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.
1 Coupler
2 Probe
3 Where male terminal fits
FUSE
• When a fuse blows, always investigate the cause to correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
ECM/VARIOUS SENSORS
• Since each component is a high-precision part, great care
should be taken not to apply any sharp impacts during
removal and installation.
• Be careful not to touch the electrical terminals of the ECM.
The static electricity from your body may damage this part.
INCORRECT
FI SYSTEM 5-5
• When disconnecting and connecting the ECM couplers, make
sure to turn OFF the ignition switch, or electronic parts may
get damaged.
Ignition S/W
• Battery connection in reverse polarity is strictly prohibited.
Such a wrong connection will damage the components of the
FI system instantly when reverse power is applied.
INCORRECT
• Removing any battery terminal of a running engine is strictly
prohibited.
The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in
serious damage.
• Before measuring voltage at each terminal, check to make
sure that battery voltage is 11 V or higher. Terminal voltage
check with a low voltage battery will lead to erroneous diagnosis.
• Never connect any tester (voltmeter, ohmmeter, or whatever)
to the ECM when its coupler is disconnected. Otherwise,
damage to the ECM may result.
• Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to the ECM or sensors may
result.
• Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained and personal
injury may result.
V
5-6
FI SYSTEM
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 circuit are as follows. As the cause
can exist in the connector/coupler or terminal, they need to be
checked carefully.
• Loose connection of connector/coupler
• Poor contact of terminal (due to dirt, corrosion or rust, poor
contact tension, entry of foreign object etc.)
• Wire harness being open
• Poor terminal-to-wire connection
• Disconnect the negative cable from the battery.
• Check each connector/coupler at both ends of the circuit
being checked for loose connection. Also check for condition
of the coupler lock if equipped.
1 Check for loose connection
Sensor
ECM
• Using a test male terminal, check the female terminals of the
circuit being checked for contact tension.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust, entry of foreign object, etc.). At
the same time, check to make sure that each terminal is fully
inserted in the coupler and locked.
If contact tension is not enough, rectify the contact to increase
tension or replace.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
• Using continuity inspect or voltage check procedure as
described below, inspect the wire harness terminals for open
circuit and poor connection. Locate abnormality, if any.
1 Looseness of crimping
2 Open
3 Thin wire (a few strands left)
Check contact
tension by inserting
and removing.
Check each terminal
for bend and proper
alignment.
FI SYSTEM 5-7
Continuity check
• Measure resistance across coupler B (between A and C in
the figure).
If no continuity is indicated (infinity or over limit), the circuit is
open between terminals A and C.
ECM
• Disconnect the coupler B and measure resistance between
couplers A and B.
If no continuity is indicated, the circuit is open between couplers A and B. If continuity is indicated, there is an open circuit between couplers B’ and C or an abnormality in coupler
B’ or coupler C.
ECM
VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
• With all connectors/couplers connected and voltage applied
to the circuit being checked, measure voltage between each
terminal and body ground.
If measurements were taken as shown in the figure at the right
and results are as listed below, it means that the circuit is open
between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground:
0V
5V
Also, if measured values are as listed below, a resistance
(abnormality) exists which causes the voltage drop in the circuit
between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground:
3V
2 V voltage drop
5V
0V
5V
5-8
FI SYSTEM
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.
To other
parts
NOTE:
If the circuit to be checked branches to other parts as shown,
disconnect all connectors/couplers of those parts. Otherwise,
diagnosis will be misled.
• Measure resistance between terminal at one end of circuit (A
terminal in figure) and body ground. If continuity is indicated,
there is a short circuit to ground between terminals A and C.
Other parts
5V
• Disconnect the connector/coupler included in circuit (coupler
B) and measure resistance between terminal A and body
ground.
If continuity is indicated, the circuit is shorted to the ground
between terminals A and B.
To other
parts
ECM
FI SYSTEM 5-9
USING THE MULTI-CIRCUIT TESTER
• Use the Suzuki multi-circuit tester (09900-25008).
• Use well-charged batteries in the tester.
• Be sure to set the tester to the correct testing range.
USING THE TESTER
• Incorrectly connecting the + and - probes may cause the
inside of the tester to burnout.
• If the voltage and current are not known, make measurements using the highest range.
• When measuring the resistance with the multi-circuit tester, ∞
will be shown as 10.00 MΩ and “1” flashes in the display.
• Check that no voltage is applied before making the measurement. If voltage is applied, the tester may be damaged.
• After using the tester, turn the power off.
MULTI-CIRCUIT TESTER
 09900-25008: Multi-circuit tester set
NOTE:
* When connecting the multi-circuit tester, use a needle pointed
probe set to the back side of the lead wire coupler and connect
the probes of tester to them.
* Use a needle pointed probe set to prevent the rubber of the
water proof coupler from damage.
 09900-25009: Needle pointed probe set
NEEDLE POINTED PROBE SET
5-10
FI SYSTEM
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 the intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine
and driving conditions.
ECM
Intake Air Pressure
Sensor (IAP Sensor)
Intake air pressure
signal
Crankshaft Position
Sensor (CKP Sensor)
Engine speed
signal
Throttle Position
Sensor (TP Sensor)
Throttle opening
signal
Various
Sensors
Various signals
Injectors
Injection signal
Basic
fuel
injection
time
Compensation
Ultimate
fuel
injection
time
FI SYSTEM 5-11
COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensation of the fuel injection
time (volume).
SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
HEATED OXYGEN SENSOR SIGNAL
(FOR E-02, 19, 24)
BATTERY VOLTAGE SIGNAL
ENGINE RPM SIGNAL
STARTING SIGNAL
ACCELERATION SIGNAL/
DECELERATION SIGNAL
DESCRIPTION
When engine coolant temperature is low, injection time (volume) is increased.
When intake air temperature is low, injection time (volume)
is increased.
Air/fuel ratio is compensated to the theoretical ratio from
density of oxygen in exhaust gasses. The compensation
occurs in such a way that more fuel is supplied if detected
air/fuel ratio is lean and less fuel is supplied if it is rich.
ECM operates on the battery voltage and at the same time,
it monitors the voltage signal for compensation of the fuel
injection time (volume). A longer injection time is needed to
adjust injection volume in the case of low voltage.
At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during
cranking engine.
During acceleration, the fuel injection time (volume) is
increased, in accordance with the throttle opening speed
and engine rpm. During deceleration, the fuel injection time
(volume) is decreased.
INJECTION STOP CONTROL
SIGNAL
TIP-OVER SENSOR SIGNAL
(FUEL SHUT-OFF)
OVER-REV. LIMITER SIGNAL
DESCRIPTION
When the motorcycle tips over, the tip-over sensor sends a
signal to the ECM. Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors and ignition coils.
The fuel injectors stop operation when engine rpm reaches
rev. limit rpm.
5-12
FI SYSTEM
FI SYSTEM PARTS LOCATION
#2
#1
ECM
A
B
C
D
E
F
G
Speedometer
Starter relay
Starter motor
Intake air pressure sensor #1 (IAPS)
Fuel pump relay (FP RELAY)
Fuel pump
Tip-over sensor (TOS)
H
I
J
K
L
M
Gear position switch
Crankshaft position sensor (CKPS)
Fuel injector #2 (FI)
Fuel injector #1 (FI)
Ignition coil #1 (IG COIL)
PAIR solenoid valve
FI SYSTEM 5-13
ECM
N
O
P
Q
Intake air pressure sensor #2 (IAPS)
Secondary throttle position sensor (STPS)
Throttle position sensor (TPS)
Secondary throttle valve actuator (STVA)
R
S
T
U
Intake air temperature sensor (IATS)
Ignition coil #2 (IG COIL)
Engine coolant temperature sensor (ECTS)
HO2 sensor (HO2S) [For E-02, 19, 24]
B/Bl
Engine coolant temperature
sensor (ECTS)
Secondary throttle position
sensor (STPS)
B/Br
P/W
B/Lg
B
G
B/W
B/W
Y/B
P
Y/G
Bl
Br/B
B/Y
W
O/G (E-02, 19, 24)
O/W (E-03, 28, 33)
Heated oxygen sensor
W/B
(HO2S)
W/Bl
B/Br
Y/W
R
Fuel injector (FI)
#1
Fuel pump
4
5
Starter switch
2
1
Secondary throttle
valve actuator (STVA)
Clutch lever position
switch
N
PAIR control solenoid valve
Ignition coil (IG COIL)
Gear position switch 3
#2
#1
#2
Fuel pump relay
Y/B
Y
O/Y
O/G (E-02, 19, 24) O/W (E-03, 28, 33)
Gr/W
Gr/B
R/Bl
B/W
B/Br
ECM
B/G
Br/W
Tip-over sensor
(TOS)
Dg
G/W
Intake air pressure sensor
(IAPS) Rear
Intake air temperature sensor
(IATS)
G/B
Bl/B
R
G/Y
Br
Intake air pressure sensor
(IAPS) Front
Throttle position sensor
(TPS)
Crankshaft position sensor
(CKPS)
Speedometer
15 A
Starter motor
Starter relay
Side-stand switch
Neutral indicator
light
Side-stand
relay
10 A
10 A
Engine stop switch
30 A
Ignition switch
5-14
FI SYSTEM
FI SYSTEM WIRING DIAGRAM
FI SYSTEM 5-15
ECM TERMINAL
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
TERMINAL
NO.
Y
Z
[
\
]
^
a
b
c
TERMINAL
NO.
GP switch signal (GP)
H
IAT sensor signal (IAT)
I
Rear cylinder IAP sensor signal (IAP. R)
J
STP sensor signal (STP)
K
Blank
L
Power source for sensors (VCC)
M
CIRCUIT
HO2 sensor signal (HO2S)
[For E-02, 19, 24]
Clutch lever position switch (CLP)
CKP sensor signal (CKP-)
Power source for fuel injector (VM)
Power source (B+1)
Power source for back-up (B+2)
ECM ground (E1)
Sensors ground (E2)
–
–
–
CIRCUIT
STVA signal (STVA. 1B)
HO2 sensor heater (HO2. H)
[For E-02, 19, 24]
STVA signal (STVA. 1A)
Blank
Ground (E01)
Rear cylinder Fuel injector (#1)
Rear cylinder Fuel injector (#2)
Blank
Front cylinder Ignition coil (IG2)
N
O
P
Q
R
S
T
U
V
W
X
TERMINAL
NO.
d
e
f
g
h
i
j
k
l
CIRCUIT
Ignition switch signal (AT)
ECT sensor signal (ECT)
TO sensor signal (TOS)
TP sensor signal (TP)
Front cylinder IAP sensor signal (IAP. F)
HO2 control selector (EXS)
[For E-02, 19, 24]
Mode select switch (MS)
Starter switch (STA)
Neutral switch (NT)
CKP sensor signal (CKP+)
–
Blank
Blank
Serial data for speedometer (TECH)
Serial data for self-diagnosis (SDL)
–
–
CIRCUIT
STVA signal (STVA. 2B)
Fuel pump relay (FP Relay)
STVA signal (STVA. 2A)
PAIR control solenoid valve (PAIR)
Ground (E02)
Blank
Blank
Blank
Rear cylinder Ignition coil (IG1)
5-16
FI SYSTEM
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 (FI light). To check the
function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is
necessary to read the code of the malfunction items.
USER MODE
LCD (DISPLAY)
INDICATION A
“NO”
Odometer
*1
“YES”
Odometer (*1) and
“FI” letters
*2
Engine can start
Engine can not start “FI” letter
*3
MALFUNCTION
FI LIGHT
INDICATION B
INDICATION MODE
----
----
FI light turns ON.
FI light turns ON
and blinks.
Each 2 sec. Odometer
(*1) and “FI” are indicated alternately.
“FI” is indicated
continuously.
*1
Current letter displayed any one of the Odometer, Tripmeter or
Clock.
*2
When one of the signals is not received by ECM, the fail-safe
circuit works and injection is not stopped. In this case, “FI” and
Odometer (*1) are indicated in the LCD panel and motorcycle
can run.
*3
The injection signal is stopped, when the crankshaft position
sensor signal, tip-over sensor signal, both #1/#2 ignition signals,
both #1/#2 injector signals, fuel pump relay signal or ignition
switch signal is not sent to ECM. In this case, “FI” is indicated in
the LCD panel. Motorcycle does not run.
“CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 3
seconds.
For Example
: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from ECM, and the panel indicates “CHEC”.
If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers.
The possible cause of this indication is as follows;
Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working. Ignition
fuse is burnt.
NOTE:
Until starting the engine, the FI light turns ON.
The FI light is also turned ON when engine temperature is high or oil pressure is low.
FI SYSTEM 5-17
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 the LCD (DISPLAY) panel. Malfunction
means that the ECM does not receive signal from the devices. These affected devices are indicated in the
code form.
 09930-82720: Mode select switch

Before checking the malfunction code, do not disconnect the ECM lead wire couplers.
If the couplers from the ECM are disconnected, the malfunction code memory is erased and the
malfunction code can not be checked.
MALFUNCTION
“NO”
“YES”
LCD (DISPLAY)
INDICATION
C00
C** code is indicated
from small numeral to
large one.
FI LIGHT
INDICATION
INDICATION MODE
—
FI light turns OFF.
For each 2 sec.,
code is indicated.
5-18
FI SYSTEM
CODE
C00
C12
C13
C14
C15
C17
C21
C23
C24
C25
C28
C29
C31
C32
C33
C41
C42
C44
C49
MALFUNCTION PART
None
Crankshaft position sensor (CKPS)
Intake air pressure sensor #2 (IAPS #2)
Throttle position sensor (TPS)
Engine coolant temp. sensor (ECTS)
Intake air pressure sensor #1 (IAPS #1)
Intake air temp. sensor (IATS)
Tip-over sensor (TOS)
Ignition signal #1 (IG coil #1)
Ignition signal #2 (IG coil #2)
Secondary throttle valve actuator (STVA)
Secondary throttle valve position sensor
(STPS)
Gear position signal (GP switch)
Injector signal #1 (FI #1)
Injector signal #2 (FI #2)
Fuel pump control system (FP control system)
Ignition switch signal (IG switch signal)
Heated oxygen sensor (HO2S)
PAIR control solenoid valve (PAIR valve)
REMARKS
No defective part
Pick-up coil signal, signal generator
For Front cylinder
*1
For Rear cylinder
For Rear cylinder
For Front cylinder
*2
For Rear cylinder
For Front cylinder
Fuel pump, fuel pump relay
Anti-theft
For E-02, 19, 24
In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.
*1
To get the proper signal from the throttle position sensor, the sensor basic position is indicated in the LCD
(DISPLAY) panel. The malfunction code is indicated in three digits. In front of the three digits, a line appears
in any of the three positions, upper, middle or lower line. If the indication is upper or lower line when engine
rpm is 1 100 r/min, slightly turn the throttle position sensor and bring the line to the middle.
In the normal condition, the throttle valve stop screw pushes throttle valves slightly, and middle line will be
indicated.
*2
When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to
ECM. In this case, C28 and C29 are indicated alternately.
FI SYSTEM 5-19
TPS ADJUSTMENT
1. Warm up the engine and adjust the engine idle speed to 1 100
± 100 r/min. (2-13)
2. Connect the special tool (Mode select switch) and select the
dealer mode.
3. Remove the fuel tank. (6-3)
4. Loosen the inlet pipe screws. (5-47)
5. Move the inlet pipe 1.
6. Loosen the screw with a torx wrench (T25) and turn the throttle position sensor 2 and bring the line to the middle.
7. Then, tighten the screw to fix the throttle position sensor.
 09930-82720: Mode select switch
The LCD displays the line for 0.4 sec. at a time, and when such
a display repeats two times, it indicates the current position
where the sensor is fixed.
A Incorrect
B Correct position
5-20
FI SYSTEM
FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
ITEM
IAP sensor
TP sensor
ECT sensor
IAT sensor
Ignition signal
FAIL-SAFE MODE
Intake air pressure is fixed to 760
mmHg.
The throttle opening is fixed to full
open position.
Ignition timing is also fixed.
Engine coolant temperature value is
fixed to 80 °C (176 °F).
Intake air temperature value is fixed
to 40 °C (104 °F).
#1 Ignition-off and #1 Fuel-cut
#2 Ignition-off and #2 Fuel-cut
Injection signal
#1 Fuel-cut
#2 Fuel-cut
Secondary throttle valve
actuator
STP sensor
Gear position signal
Heated oxygen sensor
(E-02, 19, 24)
PAIR control solenoid valve
Secondary throttle valve is fixed to
full close position. When motor disconnection or lock occurs, power
from ECM is shut off.
Secondary throttle valve is fixed to
full close position.
Gear position signal is fixed to 5th
gear.
Fuel-air compensation ratio is fixed
to normal condition.
ECM stops controlling PAIR control
solenoid valve.
STARTING
ABILITY
RUNNING
ABILITY
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
#2 cylinder can run.
“YES”
“YES”
#1 cylinder can run.
“YES”
“YES”
#2 cylinder can run.
“YES”
“YES”
#1 cylinder can run.
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.
When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work
and ignition or injection is stopped.
FI SYSTEM 5-21
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 an inspection form such as below will facilitate collecting information required for proper
analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM
User name:
Date of issue:
Model:
Date Reg.
VIN:
Date of problem:
Mileage:
Malfunction indicator
Always ON
Sometimes ON
Always OFF
lamp condition (LED)
Malfunction display/code User mode:
No display
Malfunction display (
(LCD)
Dealer mode:
No code
Malfunction code (
PROBLEM SYMPTOMS
Difficult Starting
No cranking
No initial combustion
No combustion
Poor starting at
( cold
warm
always)
Other
Poor Idling
Poor fast idle
Abnormal idling speed
( High
Low) (
r/min)
Unstable
Hunting (
Other
OTHERS:
r/min to
r/min)
Poor Driveability
Hesitation on acceleration
Back fire/ After fire
Lack of power
Surging
Abnormal knocking
Engine rpm jumps briefly
Other
Engine Stall when
Immediately after start
Throttle valve is opened
Throttle valve is closed
Load is applied
Other
Good condition
)
)
5-22
FI SYSTEM
MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental condition
Weather
Fair
Cloudy
Rain
Snow
Always
Other
Temperature
Hot
Warm
Cool
Cold (
°C/
°F)
Always
Frequency
Always
Sometimes (
times/
day, month)
Only once
Under certain condition
Road
Urban
Suburb
Highway
Mountainous ( Uphill
Downhill)
Tarmacadam
Gravel
Other
Motorcycle condition
Engine condition
Cold
Warming up phase
Warmed up
Always
Other at starting
Immediately after start
Racing without load
Engine speed ( r/min)
Motorcycle con- During driving:
Constant speed
Accelerating
Decelerating
dition
Right hand corner
Left hand corner
At stop
Motorcycle speed when problem occurs (
km/h,
mile/h)
Other
NOTE:
The above form is a standard sample. The form should be modified according to conditions and characteristics of each market.
VISUAL INSPECTION
• Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the
screen with the use of mode select switch or SDS.
* Engine oil level and leakage (2-11)
* Fuel level and leakage (2-10)
* Clogged air cleaner element (2-4)
* Battery condition (9-37)
* Throttle cable play (2-14)
* Vacuum hoses looseness, bend and disconnection
* Broken fuse
* FI light operation (5-16 and 9-29)
* Each warning light operation (9-29)
* Speedometer operation (9-31)
* Exhaust gas leakage and noise (2-24)
* Each coupler disconnection
* Clogged radiator core (7-5)
* Engine coolant level and leakage. (7-6)
FI SYSTEM 5-23
SELF-DIAGNOSTIC PROCEDURES
NOTE:
* Don’t disconnect couplers from the ECM, the battery cable
from the battery, ECM ground wire harness from the engine or
main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will
erase the memorized information in ECM memory.
* Malfunction code stored in ECM memory can be checked by
the special tool.
* Before checking malfunction code, read SELF-DIAGNOSIS
FUNCTION “USER MODE and DEALER MODE” (5-16 and
-17) carefully to have good understanding as to what functions
are available and how to use it.
* Be sure to read “PRECAUTIONS IN SERVICING” (5-3)
before inspection and observe what is written there.
• Remove the right frame cover. (8-4)
• Connect the special tool to the dealer mode coupler A at the
wiring harness, and start the engine or crank the engine for
more than 4 seconds.
• Turn the special tool’s switch ON and check the malfunction
code to determine the malfunction part.
 09930-82720: Mode select switch
SELF-DIAGNOSIS RESET PROCEDURE
• After repairing the trouble, turn OFF the ignition switch and
turn ON again.
• If the malfunction code indicates (C00), the malfunction is
cleared.
• Disconnect the special tool from the dealer mode coupler.
NOTE:
* Even though the malfunction code (C00) is indicated, the previous malfunction history code still remains stored in the ECM.
Therefore, erase the history code memorized in the ECM using
SDS.
* The malfunction code is memorized in the ECM also when the
wire coupler of any sensor is disconnected. Therefore, when a
wire coupler has been disconnected at the time of diagnosis,
erase the stored malfunction history code using SDS.
5-24
FI SYSTEM
USE OF SDS DIAGNOSTIC PROCEDURES
* Don’t disconnect couplers from ECM, the battery cable from
the battery, ECM ground wire harness from the engine or main
fuse before confirming the malfunction code (self-diagnostic
trouble code) stored in memory. Such disconnection will erase
the memorized information in ECM memory.
* Malfunction code stored in ECM memory can be checked by
the SDS.
* Be sure to read “PRECAUTIONS IN SERVICING” (5-3)
before inspection and observe what is written there.
• Remove the right frame cover. (8-4)
• Set up the SDS tool. (Refer to the SDS operation manual for
further details)
• Read the DTC (Diagnostic Trouble Code) and show data
when trouble (displaying data at the time of DTC) according to
instructions displayed on SDS.
• Not only is SDS used for detecting Diagnostic Trouble Codes
but also for reproducing and checking on screen the failure
condition as described by customers using the trigger.
• How to use trigger. (Refer to the SDS operation manual for
further details.)
 09904-41010: SDS set tool
99565-01010-005: CD-ROM Ver. 5
FI SYSTEM 5-25
USE OF SDS DIAGNOSIS RESET PROCEDURE
• After repairing the trouble, turn OFF the ignition switch and
turn ON again.
• Click the DTC inspection button 1.
• Check the DTC.
• The previous malfunction history code (Past DTC) still
remains stored in the ECM. Therefore, erase the history code
memorized in the ECM using SDS tool.
NOTE:
The malfunction code is memorized in the ECM also when the
wire coupler of any sensor is disconnected. Therefore, when a
wire coupler has been disconnected at the time of diagnosis,
erase the stored malfunction history code using SDS.
• Click “Clear” 2 to delete history code (Past DTC).
• Follow the displayed instructions.
• Check that both “Current DTC” 3 and “Past DTC” 4 are
deleted (NIL).
5-26
FI SYSTEM
SHOW DATA WHEN TROUBLE
(DISPLAING DATA AT THE TIME OF DTC)
ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of
the detection of a malfunction in its memory. This data is called “Show data when trouble”.
Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not,
where the motorcycle was running or stopped) when a malfunction was detected by checking the show data
when trouble. This show data when trouble function can record the maximum of two Diagnostic Trouble
Codes in the ECM.
Also, ECM has a function to store each show data when trouble for two different malfunctions in the order as
the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have
been detected. lts use is helpful when rechecking or diagnosing a trouble.
• Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure
#1” or “Failure #2” can be selected.
FI SYSTEM 5-27
MALFUNCTION CODE AND DEFECTIVE CONDITION
DTC No.
C00
C12
P0335
C13/C17
P1750/P0105
C14
H
P0120
L
C15
H
P0115
L
DETECTED
DETECTED FAILURE CONDITION
CHECK FOR
ITEM
–––––––––––
–––––––––––
NO FAULT
CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechansec. or more, after receiving the starter ical parts
CKP sensor, lead wire/coupler
signal.
connection
IAP sensor
The sensor should produce following IAP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C13
(P1750) or C17 (P0105) is indicated.
TP sensor
The sensor should produce following TP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C14
(P0120) is indicated.
Sensor voltage is higher than specified TP sensor circuit shorted to
value.
VCC or ground circuit open
Sensor voltage is lower than specified TP sensor circuit open or
value.
shorted to ground or VCC circuit
open
ECT sensor The sensor voltage should be the fol- ECT sensor, lead wire/coupler
connection
lowing.
0.1 V
sensor voltage < 4.6 V
In other than the above range, C15
(P0115) is indicated.
Sensor voltage is higher than specified ECT sensor circuit open or
value.
ground circuit open
Sensor voltage is lower than specified ECT sensor circuit shorted to
value.
ground
5-28
FI SYSTEM
DTC No.
C21
H
P0110
L
C23
H
P1651
L
C24/C25
P0351/P0352
C28
P1655
C29
H
P1654
L
DETECTED
DETECTED FAILURE CONDITION
ITEM
IAT sensor
The sensor voltage should be the following.
0.1 V
sensor voltage < 4.6 V
In other than the above range, C21
(P0110) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
TO sensor
The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.
0.2 V
sensor voltage
4.6 V
In other than the above value, C23
(P1651) is indicated.
Sensor voltage is higher than specified
value.
CHECK FOR
IAT sensor, lead wire/coupler
connection
IAT sensor circuit open or
ground circuit open
IAT sensor circuit shorted to
ground
TO sensor, lead wire/coupler
connection
TO sensor circuit open or
shorted to VCC or ground circuit
open
Sensor voltage is lower than specified TO sensor circuit shorted to
value.
ground or VCC circuit open
Ignition sigCKP sensor (pick-up coil) signal is pro- Ignition coil, lead wire/coupler
connection, power supply from
nal
duced, but signal from ignition coil is
the battery
interrupted 8 times or more continuously. In this case, the code C24
(P0351) or C25 (P0352) is indicated.
STVA motor, STVA lead wire/
When no actuator control signal is
Secondary
coupler
throttle valve supplied from the ECM, communication signal does not reach ECM or
actuator
operation voltage does not reach
STVA motor, C28 (P1655) is indicated.
STVA can not operate.
STP sensor The sensor should produce following STP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C29 is
indicated.
Sensor voltage is higher than specified STP sensor circuit shorted to
value.
VCC or ground circuit open
Sensor voltage is lower than specified STP sensor circuit open or
value.
shorted to ground or VCC circuit
open
FI SYSTEM 5-29
DTC No.
C31
P0705
C32/C33
P0201/P0202
C41
P0230
C42
P1650
C44
P0130
C44
P0135
C49
P1656
DETECTED
DETECTED FAILURE CONDITION
ITEM
Gear posiGear position signal voltage should be
tion signal
higher than the following for 3 seconds
and more.
Gear position sensor voltage > 0.6 V
If lower than the above value, C31
(P0705) is indicated.
Fuel injector CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 4 times or more continuously. In
this case, the code C32 (P0201) or
C33 (P0202) is indicated.
Fuel pump
No voltage is applied to the fuel pump,
relay
although fuel pump relay is turned ON,
or voltage is applied to fuel pump,
although fuel pump relay is turned
OFF.
Ignition
Ignition switch signal is not input to
switch
ECM.
HO2 sensor HO2 sensor output voltage is not input
(E-02, 19, 24) to ECM during engine operation and
running condition.
(Sensor voltage
0.1 V)
In other than the above value, C44
(P0130) is indicated.
The Heater can not operate so that
heater operation voltage is not supply
to the oxygen heater circuit, C44
(P0135) is indicated.
PAIR control PAIR control solenoid valve voltage is
not input to ECM.
solenoid
valve
CHECK FOR
GP switch, lead wire/coupler
connection, Gearshift cam, etc.
Fuel injector, wiring/coupler connection, power supply to the
injector
Fuel pump relay, lead wire/coupler connection. power source to
the fuel pump relay and fuel
injectors
Ignition switch, lead wire/coupler
HO2 sensor circuit open or
shorted to ground
HO2 sensor lead wire/coupler
connection
Battery voltage supply to the
HO2 sensor
PAIR control solenoid valve, lead
wire/coupler
NOTE:
HO2 SENSOR VOLTAGE MEASURING CONDITION
1. 10 minutes after the engine start (Idling) or 100 sec. after the engine start (Engine revolution is over 2 000
r/min).
2. Coolant temperature is upper 45 ºC (113 ºF).
5-30
FI SYSTEM
“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
POSSIBLE CAUSE
The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on
after receiving the starter signal.
the CKP sensor and rotor tip
• CKP sensor circuit open or short
• CKP sensor malfunction
• ECM malfunction
ECM
CKP sensor
G
G/Y
CKP
BI
Br
CKP
To regulator/rectifier
GEN.
INSPECTION
Step 1
1) Remove the left frame cover (8-3)
2) Remove the left frame lower cover 1.
1
: Hooked part
3) Remove the tool box cover 2.
1
FI SYSTEM 5-31
4) Remove the tool box 3.
1
5) Turn the ignition switch OFF.
6) Check the CKP sensor coupler for loose or poor contacts.
If OK, then measure the CKP sensor resistance.
1
7) Disconnect the CKP sensor coupler and measure the resistance.
1
 CKP sensor resistance: 184 – 276 Ω
(Green – Blue)
8) If OK, then check the continuity between each terminal and
ground.
 CKP sensor continuity: ∞ Ω (Infinity)
(Blue – Ground)
(Green – Ground)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Are the resistance and continuity OK?
YES
NO
Go to Step 2.
Replace the CKP sensor with a new one.
9) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
5-32
FI SYSTEM
Step 2
1) Crank the engine a few seconds with the starter motor, and
measure the CKP sensor peak voltage at the coupler.
2) Repeat the above test procedure a few times and measure
the highest peak voltage.
2
Bl
G
 CKP sensor peak voltage: 4.0 V and more
(+ Green – - Blue)
1 Peak volt adaptor
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
.
Is the voltage OK?
YES
NO
• G/Y or Brown wire open or shorted to ground
• Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal 9 or Q)
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
• Inspect that metal particles or foreign material
stuck on the CKP sensor and rotor tip.
• If there are no metal particles and foreign material, then replace the CKP sensor with a new
one.
3) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
ECM coupler (Harness side)
FI SYSTEM 5-33
“C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
IAP sensor voltage low or high
(0.1 V
Sensor voltage < 4.8 V)
NOTE:
Note that atmospheric pressure varies depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
•
•
•
•
•
POSSIBLE CAUSE
Clogged vacuum passage between throttle body
and IAP sensor
Air being drawn from vacuum passage between
throttle body and IAP sensor
IAP sensor circuit open or shorted to ground
IAP sensor malfunction
ECM malfunction
ECM
IAP sensor #2 (Front cylinder)
R
VCC
G/B
IAP. F
B/Br
E2
R
G/W
IAP. R
B/Br
IAP sensor #1 (Rear cylinder)
INSPECTION
Step 1
(When indicating C13/P1750 for IAP sensor #2)
1) For the other inspection procedures are the same as C17/
P0105.
(When indicating C17/P0105 for IAP sensor #1)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the IAP sensor coupler (Front cylinder side 1 or Rear
cylinder side 2) for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
1
4) Disconnect the IAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire 3 and ground.
7) Also, measure the voltage at the Red wire 3 and B/Br wire 4.
1
 IAP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
V
5-34
FI SYSTEM
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal 6 or D)
• Open or short circuit in the Red wire or B/Br
wire
8) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
Step 2
1) Connect the IAP sensor coupler.
2) Reinstall the fuel tank and lift up the fuel tank.
2
3) Insert the needle pointed probes to the lead wire coupler.
4) Start the engine at idle speed and measure the IAP sensor
output voltage at the wire side coupler.
(Front cylinder side: between G/B and B/Br wires)
(Rear cylinder side: between G/W and B/Br wires)
2
 IAP sensor output voltage: Approx. 2.6 V at idle speed
(Front cylinder side: + G/B – - B/Br)
(Rear cylinder side: + G/W – - B/Br)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 3.
• Check the vacuum hose for crack or damage.
• Open or short circuit in the G/B wire
(Front cylinder side)
• Open or short circuit in the G/W wire
(Rear cylinder side)
• If vacuum hose and wire are OK, replace the
IAP sensor with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
V
B/Br
G/B
FI SYSTEM 5-35
Step 3
1) Turn the ignition switch OFF.
2) Remove the IAP sensor. (5-75)
3) Connect the vacuum pump gauge to the vacuum port of the
IAP sensor.
4) Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground terminal 2 and + terminal to the VCC terminal 3.
5) Check the voltage between Vout 4 and ground. Also, check if
voltage reduces when vacuum is applied up to 400 mmHg by
using vacuum pump gauge. (5-36)
3
 09917-47011: Vacuum pump gauge
09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• Red, B/Br or G/B wire open or shorted to
ground, or poor 6, D or L connection
(Front cylinder side)
• G/W, Red or B/Br wire open or shorted to
ground, or poor 3, 6 or D connection
(Rear cylinder side)
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
If check result is not satisfactory, replace the IAP
sensor with a new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
3
ECM coupler (Harness side)
5-36
FI SYSTEM
Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp.
20 – 30 °C, 68 – 86 °F)
ALTITUDE
(Reference)
(ft)
(m)
0
0


2 000
610
2 001
611


5 000
1 524
1 525
5 001


8 000
2 438
8 001
2 439


10 000
3 048
ATMOSPHERIC
PRESSURE
(mmHg)
kPa
760
100


707
94
707
94


634
85
634
85


567
76
567
76


526
70
OUTPUT
VOLTAGE
(V)
3.4 – 4.0
2.8 – 3.7
2.6 – 3.4
2.4 – 3.1
FI SYSTEM 5-37
“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
C14
Output voltage is not within the following
range.
Difference between actual throttle opening and opening calculated by ECM is
larger than specified value.
0.1 V
Sensor voltage < 4.8 V
P0120
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
•
•
•
•
POSSIBLE CAUSE
TP sensor maladjusted
TP sensor circuit open or short
TP sensor malfunction
ECM malfunction
• TP sensor circuit shorted to VCC or ground circuit
open
• TP sensor circuit open or shorted to ground or
VCC circuit open
TP sensor
ECM
Bl
R
Y
Bl/B
TP
B
B/Br
E2
VCC
INSPECTION
Step 1 (When indicating C14:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
4) Disconnect the TP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire B and ground.
7) Also, measure the voltage at the Red wire B and B/Br wire C.
1
 TP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
1
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal 6 or D)
• Open or short circuit in the Red wire or B/Br
wire
V
5-38
FI SYSTEM
Step 1 (When indicating P0120-H:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.
1
4) Disconnect the TP sensor coupler.
5) Check the continuity between BI/B wire A and Red wire B.
If the sound is not heard from the tester, the circuit condition is
OK.
1
6) Remove the right frame cover (8-4), ECM bracket 1 and
disconnect the ECM coupler.
7) Check the continuity between BI/B wire A and terminal K.
8) Also, check the continuity between B/Br wire C and terminal
D.
 TPS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
BI/B wire shorted to VCC, or B/Br wire open
9) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
]
FI SYSTEM 5-39
Step 1 (When indicating P0120-L:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor lead wire continuity.
1
4) Disconnect the TP sensor coupler.
5) Check the continuity between BI/B wire A and ground.
6) Also, check the continuity between BI/B wire A and B/Br wire
C. If the sound is not heard from the tester, the circuit condition is OK.
1
7) Remove the right frame cover. (8-4), ECM bracket
(5-38) and disconnect the ECM coupler.
8) Check the continuity between BI/B wire A and terminal K.
9) Also, check the continuity between Red wire B and terminal 6.
1
]
 TPS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 1 (5-38) and go to Step 2.
Red wire or BI/B wire open, or BI/B wire shorted to
ground
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-40
FI SYSTEM
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the TP sensor coupler.
3) Check the continuity between Yellow wire and ground.
2
 TP sensor continuity: ∞ Ω (Infinity)
(Yellow – Ground)
4) If OK, then measure the TP sensor resistance at the terminals (between Yellow wire and Black wire).
5) Turn the throttle grip and measure the resistance.
2
 TP sensor resistance
Throttle valve is closed : Approx. 1.1 kΩ
Throttle valve is opened: Approx. 4.4 kΩ
6) If OK, then measure the TP sensor resistance at the terminals (between Blue wire and Black wire).
 TP sensor resistance: Approx. 4.66 kΩ
(Blue wire – Black wire)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Are the continuity and resistance OK?
YES
NO
Go to Step 3.
• Reset the TP sensor position correctly.
• Replace the TP sensor with a new one.
7) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
FI SYSTEM 5-41
Step 3
1) Connect the TP sensor coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Turn the ignition switch ON.
4) Measure the TP sensor output voltage at the coupler
(between Bl/B wire A and B/Br wire B) by turning the throttle
grip.
3
V
 TP sensor output voltage
Throttle valve is closed: Approx. 1.1 V
Throttle valve is opened: Approx. 4.4 V
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• R, B/Br or BI/B wire open or shorted to ground,
or poor 6, D or K connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
If check result is not satisfactory, replace TP sensor with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
3
ECM coupler (Harness side)
5-42
FI SYSTEM
“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
C15
Output voltage is not within the following
range.
0.1
Sensor voltage < 4.6 V
P0115
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
•
•
•
•
POSSIBLE CAUSE
ECT sensor circuit open or short
ECT sensor malfunction
ECM malfunction
ECT sensor circuit open or ground circuit open
• ECT sensor circuit shorted to ground
ECM
ECT sensor
B/BI
ECT
B/Br
E2
INSPECTION
Step 1 (When indicating C15:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the ECT sensor coupler for loose or poor contacts.
If OK, then measure the ECT sensor voltage at the wire side
coupler.
4) Disconnect the ECT sensor coupler and turn the ignition
switch ON.
5) Measure the voltage between B/Bl wire terminal 1 and
ground.
1
6) Also, measure the voltage between B/Bl wire terminal 1 and
B/Br wire terminal 2.
1
 ECT sensor input voltage: 4.5 – 5.5 V
(+ B/Bl – - Ground)
(+ B/Bl – - B/Br)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal D or I)
• Open or short circuit in the B/Bl wire or B/Br
wire
FI SYSTEM 5-43
Step 1 (When indicating P0115-H:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the ECT sensor coupler for loose or poor contacts.
If OK, then check the ECT sensor lead wire continuity.
1
4) Remove the right frame cover. (8-4)
5) Disconnect the ECT sensor coupler.
6) Remove the ECM bracket (5-38) and ECM coupler.
7) Check the continuity between B/Bl wire A and terminal I.
8) Also, check the continuity between B/Br wire B and terminal D.
1
]
 ECTS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
B/BI or B/Br wire open
9) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-44
FI SYSTEM
Step 1 (When indicating P0115-L:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the ECT sensor coupler for loose or poor contacts.
If OK, then check the ECT sensor lead wire continuity.
1
4) Disconnect the ECT sensor coupler.
5) Check the continuity between B/Bl wire 1 and ground.
6) If the sound is not heard from the tester, the circuit condition is
OK.
1
 Tester knob indication: Continuity test ()
7) Connect the ECT sensor coupler.
8) Turn the ignition switch ON.
9) Measure the voltage between B/Bl wire 1 and ground.
 Output voltage: 0.1 – 4.6 V (+ B/Bl – - Ground)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Are the continuity and voltage OK?
YES
NO
Go to Step 2.
B/Bl wire shorted to ground.
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
V
FI SYSTEM 5-45
Step 2
1) Turn the ignition switch OFF.
2) Loosen the inlet pipe screw.
3) Lift up the inlet pipe 1.
2
4) Disconnect the ECT sensor coupler.
5) Measure the ECT sensor resistance.
2
2
 ECT sensor resistance:
Approx. 2.3 – 2.6 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Refer to next page for details.
Is the resistance OK?
YES
NO
• B/Bl or B/Br wire open or shorted to ground, or
poor D or I connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Replace the ECT sensor with a new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
 ECT sensor specification
Engine Coolant Temp.
20 °C (68 °F)
40 °C (104 °F)
60 °C (140 °F)
80 °C (176 °F)
Resistance
Approx. 2.45 kΩ
Approx. 1.148 kΩ
Approx. 0.587 kΩ
Approx. 0.322 kΩ
2
ECM coupler (Harness side)
5-46
FI SYSTEM
ECT SENSOR INSPECTION
• Remove the ECT sensor. (5-77)
• Check the ECT sensor by testing it at the bench as shown in
the figure. Connect the ECT sensor 1 to a circuit tester and
place it in the oil 2 contained in a pan, which is placed on a
stove.
• Heat the oil to raise its temperature slowly and read the column thermometer 3 and the ohmmeter.
• If the ECT sensor ohmic value does not change in the proportion indicated, replace it with a new one.
 ECT sensor specification
Engine Coolant Temp
20 °C (68 °F)
40 °C (104 °F)
60 °C (140 °F)
80 °C (176 °F)
Resistance
Approx. 2.45 kΩ
Approx. 1.148 kΩ
Approx. 0.587 kΩ
Approx. 0.322 kΩ
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
If the resistance is noted to show infinity or too much different
resistance value, replace the ECT sensor with a new one.

* Take special care when handling the ECT sensor. It
may cause damage if it gets a sharp impact.
* Do not contact the ECT sensor and the column thermometer with a pan.
FI SYSTEM 5-47
“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
C21
Output voltage is not within the following
range.
0.1
Sensor voltage < 4.6 V
P0110
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
•
•
•
•
POSSIBLE CAUSE
IAT sensor circuit open or short
IAT sensor malfunction
ECM malfunction
IAT sensor circuit open or ground circuit open
• IAT sensor circuit shorted to ground
ECM
IAT sensor
Dg
IAT
B/Br
E2
INSPECTION
Step 1 (When indicating C21:)
1) Loosen the inlet pipe screw 1.
2) Remove the air cleaner box 2.
1
3) Turn the ignition switch OFF.
4) Check the IAT sensor coupler for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire side
coupler.
5) Disconnect the IAT sensor coupler and turn the ignition switch
ON.
1
5-48
FI SYSTEM
6) Measure the voltage between Dg wire terminal 3 and
ground.
7) Also, measure the voltage between Dg wire terminal 3 and
B/Br wire terminal 4.
 IAT sensor input voltage: 4.5 – 5.5 V
(+ Dg – - Ground)
(+ Dg – - B/Br)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal 2 or D)
• Open or short circuit in the Dg wire or B/Br wire
1
V
FI SYSTEM 5-49
Step 1 (When indicating P0110-H:)
1) Loosen the inlet pipe screw. (5-47)
2) Remove the air cleaner box. (6-13)
3) Turn the ignition switch OFF.
4) Check the IAT sensor coupler for loose or poor contacts.
If OK, then check the IAT sensor lead wire continuity.
1
5) Remove the right frame cover. (8-4)
6) Disconnect the IAT sensor coupler.
7) Remove the ECM bracket (5-38) and ECM coupler.
8) Check the continuity between Dg wire A and terminal 2.
9) Also, check the continuity between B/Br wire B and terminal D.
1
]
 IATS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
Dg wire or B/Br wire open
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-50
FI SYSTEM
Step 1 (When indicating P0110-L:)
1) Loosen the inlet pipe screw. (5-47)
2) Remove the air cleaner box. (6-13)
3) Turn the ignition switch OFF.
4) Check the IAT sensor coupler for loose or poor contacts.
If OK, then check the IAT sensor lead wire continuity.
1
5) Disconnect the IAT sensor coupler.
6) Check the continuity between Dg wire 1 and ground. If the
sound is not heard from the tester, the circuit condition is OK.
1
 Tester knob indication: Continuity test ()
7) Connect the IAT sensor coupler and turn the ignition switch
ON.
8) Measure the voltage between Dg wire 1 and ground.
 IAT sensor output voltage: 0.1 – 4.6 V
(+ Dg – - Ground)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Are the continuity and voltage OK?
YES
NO
Go to Step 2.
• Dg wire shorted to ground
• If wire is OK, go to Step 2.
9) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
V
FI SYSTEM 5-51
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the IAT sensor coupler.
3) Measure the IAT sensor resistance.
2
 IAT sensor resistance: Approx. 2.6 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
2
• Dg or B/Br wire open or shorted to ground, or
poor 2 or D connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Replace the IAT sensor with a new one.
 IAT sensor specification
Intake Air Temp.
20 °C (68 °F)
50 °C (122 °F)
80 °C (176 °F)
110 °C (230 °F)
Resistance
Approx. 2.6 kΩ
Approx. 0.8 kΩ
Approx. 0.3 kΩ
Approx. 0.2 kΩ
NOTE:
IAT sensor resistance measurement method is the same way as
that of the ECT sensor. Refer to 5-46 for details.
4) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-52
FI SYSTEM
“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
C23
The sensor voltage should be the following for 2 sec. and more, after ignition
switch is turned ON.
0.2
Sensor voltage < 4.6 V
P1651
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
POSSIBLE CAUSE
• TO sensor circuit open or short
• TO sensor malfunction
• ECM malfunction
• TO sensor circuit open or shorted to VCC or
ground circuit open
• TO sensor circuit shorted to ground or VCC circuit
open
ECM
TO SENSOR
R
VCC
Br/W
TOS
B/Br
E2
INSPECTION
Step 1 (When indicating C23:)
1) Remove the right frame cover. (8-4)
2) Turn the ignition switch OFF.
3) Check the TO sensor coupler for loose or poor contacts.
If OK, then measure the TO sensor resistance.
4) Disconnect the TO sensor coupler.
1
5) Measure the resistance between terminal A and terminal C.
1
 TO sensor resistance: 19.1 – 19.7 kΩ
(Terminal A – Terminal C)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
Go to Step 2.
Replace the TO sensor with a new one.
FI SYSTEM 5-53
Step 1 (When indicating P1651-H:)
1) Remove the right frame cover. (8-4)
2) Turn the ignition switch OFF.
3) Check the TO sensor coupler for loose or poor contacts.
If OK, then check the TO sensor lead wire continuity.
1
4) Disconnect the TO sensor coupler.
5) Check the continuity between Red wire A and Br/W wire B.
If the sound is not heard from the tester, the circuit condition is
OK.
1
6) Remove the ECM bracket (5-38) and disconnect the
ECM coupler.
7) Check the continuity between Br/W wire B and terminal J.
8) Also, check the continuity between B/Br wire C and terminal D.
1
!
]
 TOS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
Br/W wire shorted to VCC, or B/Br wire open
9) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-54
FI SYSTEM
Step 1 (When indicating P1651-L:)
1) Remove the right frame cover. (8-4)
2) Turn the ignition switch OFF.
3) Check the TO sensor coupler for loose or poor contacts.
If OK, then check the TO sensor lead wire continuity.
1
4) Disconnect the TO sensor coupler.
5) Check the continuity between Br/W wire B and ground.
6) Also, check the continuity between Br/W wire B and B/Br wire
C. If the sound is not heard from the tester, the circuit condition is OK.
1
7) Remove the ECM bracket (5-38) and disconnect the
ECM coupler.
8) Check the continuity between Red wire A and terminal 6.
9) Also, then check the continuity between Br/W wire B and terminal J.
1
!
]
 TOS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
Red or Br/W wire open, or Br/W wire shorted to
ground
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
FI SYSTEM 5-55
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 Br/W 1
and B/Br 2 wires.
Also, measure the voltage when leaning the motorcycle.
2
V
 TO sensor voltage (Normal): 0.4 – 1.4 V
(+ Br/W – - B/Br)
5) Dismount the TO sensor from its bracket and measure the
voltage when it is leaned 65° and more, left and right, from the
horizontal level.
2
V
 TO sensor voltage (Leaning): 3.7 – 4.4 V
(+ Br/W – - B/Br)
65˚
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• Red, Br/W or B/Br wire open or shorted to
ground, or poor 6, D or J connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
• Loose or poor contacts on the ECM coupler
• Open or short circuit
• Replace the TO sensor with a new one.
2
ECM coupler (Harness side)
6) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
“C24” (P0351) or “C25” (P0352) IGNITION SYSTEM MALFUNCTION
(When indicating C24/P0351 for IG coil #1)
(When indicating C25/P0352 for IG coil #2)
* Refer to the IGNITION SYSTEM for details. (9-20)
5-56
FI SYSTEM
“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION
DETECTED CONDITION
The operation voltage does not reach the STVA.
ECM does not receive communication signal from
the STVA.
POSSIBLE CAUSE
• STVA malfunction
• STVA circuit open or short
• STVA motor malfunction
ECM
STVA
B
B/Lg
STVA. 1B
P
P/W
STVA. 1A
G
G
STVA. 2B
W/Bl
B
STVA. 2A
INSPECTION
Step 1
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the STVA lead wire coupler for loose or poor contacts.
1
4) Loosen the inlet pipe screw. (2-7)
Lift up the inlet pipe. (5-45)
5) Turn the ignition switch ON to check the STV operation.
(STV operating order: 95% open → Full open → 95% open)
1
Is the operating OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the STVA coupler
• Open or short circuit in the B/Lg, P/W, Black or
Green wires
• If wire and connection are OK, go to Step 2.
6) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
FI SYSTEM 5-57
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the STVA lead wire coupler.
3) Check the continuity between each terminal and ground.
2
 STVA continuity: ∞ Ω (Infinity)
(Terminal – Ground)
4) If OK, then measure the STVA resistance (between Black
wire A and Pink wire B) and (between Green wire C and W/
Bl wire D).
2
 STVA resistance: Approx. 6.5 Ω
(Black A – Pink B)
(Green C – W/Bl D)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
• B/Lg, P/W, Green and Black wire open or
shorted to ground, or poor Y, [, d and f connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
• Loose or poor contacts on the ECM coupler
• Replace the STVA with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
ECM coupler (Harness side)
5-58
FI SYSTEM
ACTIVE CONTROL INSPECTION
1) Set up the SDS tool. (Refer to the SDS operation manual for
further details)
2) Turn the ignition switch ON.
3) Click “Secondary throttle operating control” 1.
4) Click each button 2.
At this time, if an operation sound is heard from the STVA,
the function is normal.
FI SYSTEM 5-59
“C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
C29
Signal voltage is not within the following
range.
Difference between actual throttle opening and opening calculated by ECM is
larger than specified value.
0.1 V
Sensor voltage < 4.8 V
P1654
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
•
•
•
•
POSSIBLE CAUSE
STP sensor maladjusted
STP sensor circuit open or short
STP sensor malfunction
ECM malfunction
• STP sensor circuit shorted to VCC or ground circuit open
• STP sensor circuit open or shorted to ground or
VCC circuit open
ECM
BI
VCC
R
Y
Y/W
STP
B
B/Br
E2
STP sensor
INSPECTION
Step 1 (When indicating C29:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then measure the STP sensor input voltage.
4) Disconnect the STP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire A and ground.
7) Also, measure the voltage at the Red wire A and B/Br wire B.
1
 STP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
1
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal 6 or D)
• Open or short circuit in the Red wire or B/Br
wire
V
5-60
FI SYSTEM
Step 1 (When indicating P1654-H:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then check the STP sensor lead wire continuity.
1
4) Disconnect the STP sensor coupler.
5) Check the continuity between Y/W wire C and Red wire A.
If the sound is not heard from the tester, the circuit condition is
OK.
1
6) Remove the right frame cover. (8-4)
7) Remove the ECM bracket (5-38) and disconnect the
ECM coupler.
8) Check the continuity between Y/W wire C and terminal 4.
9) Also, check the continuity between B/Br wire B and terminal D.
1
!
]
 STPS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2.
Y/W wire shorted to VCC, or B/Br wire open
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
FI SYSTEM 5-61
Step 1 (When indicating P1654-L:)
1) Remove the fuel tank. (6-3)
2) Turn the ignition switch OFF.
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then check the STP sensor lead wire continuity.
1
4) Disconnect the TO sensor coupler.
5) Check the continuity between Y/W wire C and ground.
6) Also, check the continuity between Y/W wire C and B/Br wire
B. If the sound is not heard from the tester, the circuit condition is OK.
1
7) Remove the right frame cover. (8-4)
8) Remove the ECM bracket (5-38) and disconnect the
ECM coupler.
9) Check the continuity between Y/W wire C and terminal 4.
10)Also, check the continuity between Red wire A and terminal
6.
1
]
]
 STPS lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 1 (5-60) and go to Step 2.
Red or Y/W wire open, or Y/W wire shorted to
ground
11)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ECM coupler (Harness side)
5-62
FI SYSTEM
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the STP sensor coupler.
3) Check the continuity between each terminal and ground.
2
 STP sensor continuity: ∞ Ω (Infinity)
(Terminal – Ground)
4) If OK, then measure the STP sensor resistance at the wire
terminals (between Yellow wire A and Black wire B).
5) Loosen the inlet pipe screw. (2-7)
Lift up the inlet pipe. (5-45)
6) Close and open the secondary throttle valve by finger, and
measure the valve closing and opening resistance.
2
 STP sensor resistance
Secondary throttle valve is closed : Approx. 0.5 kΩ
Secondary throttle valve is opened: Approx. 3.9 kΩ
(Yellow A – Black B)
2
7) If OK, then measure the STP sensor resistance at the wire
terminals (between Blue wire C and Black wire B).
2
 STP sensor resistance: Approx. 4.69 kΩ
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Are the continuity and resistance OK?
YES
NO
Go to Step 3.
• Reset the STP sensor position correctly.
• Replace the STP sensor with a new one.
8) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
FI SYSTEM 5-63
Step 3
1) Turn the ignition switch OFF.
2) Connect the STP sensor coupler.
3) Insert the needle pointed probes to the STP sensor coupler.
4) Disconnect the STVA lead wire coupler.
5) Loosen the inlet pipe screw. (2-7)
Lift the inlet pipe. (5-45)
6) Turn the ignition switch ON.
7) Measure the STP sensor output voltage at the coupler
(between + Y/W C wire and - B/Br B wire) by turning the
secondary throttle valve (close and open) with a finger.
3
 STP sensor output voltage
Secondary throttle valve is closed: Approx. 0.5 V
Secondary throttle valve is opened: Approx. 3.9 V
3
V
3
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• Red, Y/W or B/Br wire open or shorted to
ground, or poor 4, 6 or D connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
If check result is not satisfactory, replace STP
sensor with a new one.
8) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
3
ECM coupler (Harness side)
5-64
FI SYSTEM
“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION
DETECTED CONDITION
No Gear Position switch voltage.
Switch voltage is not within the following range.
Switch voltage > 0.6 V
POSSIBLE CAUSE
• Gear Position switch circuit open or short
• Gear Position switch malfunction
• ECM malfunction
ECM
Side-stand relay
To engine stop switch
BI
BI
GP
P
B/W
P
B/W
Ignition
switch
GP switch
N
5
1
Neutral indicator
light
4
3
2
Side-stand switch
INSPECTION
Step 1
1) Remove the secondary gear case cover.
(2-16)
2) Turn the ignition switch OFF.
3) Check the GP switch coupler for loose or poor contacts.
If OK, then measure the GP switch voltage.
1
4) Support the motorcycle with a jack.
5) Fold the side-stand to up position.
6) Make sure the engine stop switch is in the “RUN” position.
7) Insert the needle pointed probe to the lead wire coupler.
8) Turn the ignition switch ON.
9) Measure the voltage at the wire side coupler between Pink
wire A and B/W wire B, when shifting the gearshift lever from
1st to Top.
1
 GP switch voltage: 0.6 V and more
(+ P A – - B/W B)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
V
FI SYSTEM 5-65
Is the voltage OK?
YES
NO
• Pink wire open or shorted to ground
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
• P or B/W wire open, or Pink wire shorted to
ground
• Loose or poor contacts on the ECM coupler
(terminal 1)
• If wire and connection are OK, replace the GP
switch with a new one.
10)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
ECM coupler (Harness side)
5-66
FI SYSTEM
“C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
DETECTED CONDITION
CKP signals produced but fuel injector signal is
interrupted continuous by 4 times or more.
POSSIBLE CAUSE
• Injector circuit open or short
• Injector malfunction
• ECM malfunction
ECM
Fuel pump relay
Y/R
#1
Gr/B
#2
Gr/W
To engine
stop switch
(Front cylinder)
(Rear cylinder)
Fuel injector
INSPECTION
(When indicating C32/P0201 for fuel injector #1)
(When indicating C33/P0202 for fuel injector #2)
1
Step 1
1) Remove the fuel tank. (6-3)
2) Loosen the inlet pipe screw. (2-7)
Lift up the inlet pipe. (5-45)
3) Turn the ignition switch OFF.
4) Check the injector coupler (Front cylinder side 1 or Rear cylinder side 2) for loose or poor contacts.
If OK, then measure the injector resistance.
5) Disconnect the injector coupler and measure the resistance
between terminals.
 Injector resistance: Approx. 11.7 Ω at 20 °C (68 °F)
(Terminal – Terminal)
1
1
FI SYSTEM 5-67
6) If OK, then check the continuity between each terminal and
ground.
1
 STP sensor continuity: ∞ Ω (Infinity)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Are the resistance and continuity OK?
YES
NO
Go to Step 2.
Replace the injector with a new one.
(6-22)
7) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
Step 2
1) Turn the ignition switch ON.
2) Measure the injector voltage between Y/R wire A and
ground.
2
V
 Injector voltage: Battery voltage
(+ Y/R A – - Ground)
NOTE:
Injector voltage can be detected only 3 seconds after ignition
switch is turned ON.
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• Gr/W wire open or shorted to ground, or poor a
connection
(Front cylinder side)
• Gr/B wire open or shorted to ground, or poor ^
connection
(Rear cylinder side)
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Open circuit in the Y/R wire
3) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
ECM coupler (Harness side)
5-68
FI SYSTEM
“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION
DETECTED CONDITION
POSSIBLE CAUSE
• Fuel pump relay circuit open or short
No voltage is applied to fuel pump although fuel
pump relay is turned ON, or voltage is applied to fuel • Fuel pump relay malfunction
• ECM malfunction
pump, although fuel pump relay is turned OFF.
ECM
M
Fuel pump
Engine stop
switch
VM
FP Relay
Y/R
Y
To GP
switch
R/W
O/W
Side-stand
relay
Ignition
switch
Fuel pump
relay
INSPECTION
Step 1
1) Remove the secondary gear case cover. (2-16)
2) Turn the ignition switch OFF.
3) Check the FP relay coupler for loose or poor contacts.
If OK, then check the FP relay.
(Refer to page 6-6 for details.)
1
Is the FP relay OK?
YES
NO
• Yellow or O/W wire open or shorted to ground,
or poor e connection
• Y/R or R/W wire open or poor 0 connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Replace the FP relay with a new one.
1
ECM coupler (Harness side)
4)After repairing the trouble, clear the DTC using SDS tool. (5-25)
“C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION
DETECTED CONDITION
Ignition switch signal is not input in the ECM.
POSSIBLE CAUSE
• Ignition system circuit open or short
• ECM malfunction
INSPECTION
* Refer to the IGNITION SWITCH INSPECTION for details. (9-36)
FI SYSTEM 5-69
“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION
(FOR E-02, 19, 24)
C44
(P0130)
C44
(P0135)
DETECTED CONDITION
HO2 sensor output voltage is not input
to ECM during engine operation and
running condition.
(Sensor voltage
0.1 V)
The heater can not operate so that
heater operation voltage is not supply to
the oxygen heater circuit.
POSSIBLE CAUSE
• HO2 sensor circuit open or shorted to ground
• Fuel system malfunction
• ECM malfunction
• Battery voltage supply to the HO2 sensor
ECM
HO2S
W/Bl
HO2. H
W/B
Engine stop Side-stand
switch
relay
Ignition
switch
O/W
To GP
switch
W
B/Br
W
B
Gr
E2
HO2 sensor
INSPECTION
Step 1 (When indicating C44/P0130:)
1) Remove the right frame cover. (8-4)
2) Turn the ignition switch OFF.
3) Check the HO2 sensor for loose or poor contacts.
If OK, then check the HO2 sensor lead wire continuity.
1
4) Disconnect the HO2 sensor coupler
5) Check the continuity between W/Bl wire A and ground.
6) Also, check the continuity between W/Bl wire A and B/Br wire
B. If the sound is not heard from the tester, the circuit condition is OK.
1
 09900-25008: Multi-circuit tester set
 Tester knob indication: Continuity test ()
]
5-70
FI SYSTEM
7) Remove the right frame cover. (8-4)
8) Remove the ECM bracket (5-38) and disconnect the
ECM coupler.
9) Check the continuity between W/Bl wire A and terminal 7.
10)Also, check the continuity between B/Br wire B and terminal
D.
1
!
 HO2S lead wire continuity: Continuity ()
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
ECM coupler (Harness side)
 Tester knob indication: Continuity test ()
Is the continuity OK?
YES
NO
Go to Step 2. (When indicating C44/P0130:)
W/Bl wire shorted to ground, or W/Bl or B/Br wire
open
11)After repairing the trouble, clear the DTC using SDS tool.
(5-25)
Step 2 (When indicating C44/P0130:)
1) Connect the ECM coupler and HO2 sensor coupler.
2) Warm up the engine enough.
3) Insert the needle pointed probes to the HO2 sensor coupler.
4) Measure the HO2 sensor output voltage between W/Bl wire
A and B/Br wire B, when idling condition.
2
V
 HO2 sensor output voltage at idle speed:
0.2 V and less (+ W/Bl A – - B/Br B)
5) If OK, then pinch the PAIR hose1 with a proper hose clamp.
6) Measure the HO2 sensor output voltage while holding the
engine speed at 5 000 r/min.
2
 HO2 sensor output voltage at 5 000 r/min:
0.7 V and more (+ W/Bl – - B/Br)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
NOTE:
HO2 SENSOR VOLTAGE MEASURING CONDITION
1. 10 minutes after the engine start (Idling) or 100 sec. after the engine start (Engine revolution is over 2 000
r/min).
2. Coolant temperature is upper 45 ºC (113 ºF).
FI SYSTEM 5-71
Is the voltage OK?
YES
NO
2
ECM coupler (Harness side)
• W/Bl wire or B/Br wire open or shorted to
ground, or poor 7 or D connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Replace the HO2 sensor with a new one.
3) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
Step 1 (When indicating C44/P0135:)
1) Remove the right frame cover. (8-4)
2) Turn the ignition switch OFF.
3) Check the HO2 sensor for loose or poor contacts.
If OK, then measure the HO2 sensor resistance.
1
4) Disconnect the HO2 sensor coupler and measure the resistance between terminals.
1
 HO2 heater resistance: 6.5 – 8.9 Ω at 23 °C (73.4 °F)
(White – White)
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
Is the voltage OK?
YES
NO
Go to Step 2.
Replace the HO2 sensor with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
5-72
FI SYSTEM
Step 2 (When indicating C44/P0135:)
1) Connect the HO2 sensor coupler.
2) Insert the needle pointed probes to the HO2 sensor coupler.
3) Turn the ignition switch ON and measure the heater voltage
between W/B wire A and ground.
4) If the tester voltage indicates the battery voltage, it is good
condition.
2
V
 Heater voltage: Battery voltage
(+ W/B A – - Ground)
NOTE:
Battery voltage can be detected only before starting the engine.
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• O/W or W/B wire open or shorted to ground, or
poor Z connection
• Recheck each terminal and wire harness for
open circuit and poor connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Replace the ECM with a known good one, and
inspect it again.
• Open or short circuit in the W/B wire or O/W
wire
• Loose or poor contacts on the ECM coupler
(terminal Z) or HO2 sensor coupler
5) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
2
ECM coupler (Harness side)
FI SYSTEM 5-73
“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
DETECTED CONDITION
PAIR control solenoid valve voltage is not input to
ECM.
POSSIBLE CAUSE
• PAIR valve circuit open or short
• PAIR valve malfunction
• ECM malfunction
ECM
Engine stop Side-stand
switch
relay
O/W
To GP switch
B
Br/B
B
SOL
PAIR control
solenoid valve
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the PAIR control solenoid valve coupler for loose or
poor contacts.
If OK, then measure the PAIR control solenoid valve resistance.
1
3) Disconnect the PAIR control solenoid valve coupler.
4) Measure the resistance between Black and Black wire terminals.
1
 PAIR valve resistance:
20 – 24 Ω at 20 – 30 °C (68 – 86 °F)
(Black – Black)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
5) If OK, then check the continuity between each terminal and
ground.
 PAIR valve resistance: ∞ Ω (Infinity)
(Terminal – Ground)
 Tester knob indication: Resistance (Ω)
Is the resistance OK?
YES
NO
Go to Step 2.
Replace the PAIR valve with a new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
1
Ignition
switch
5-74
FI SYSTEM
Step 2
1) Turn the ignition switch ON.
2) Measure the voltage between O/W wire A and ground.
2
V
 PAIR valve voltage: Battery voltage
(+ O/W A – - Ground)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
• Br/B wire open or shorted to ground, or poor g
connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Open or short circuit in the O/W wire
3) After repairing the trouble, clear the DTC using SDS tool.
(5-25)
ACTIVE CONTROL INSPECTION
1) Set up the SDS tool. (Refer to the SDS operation manual for
further details)
2) Turn the ignition switch ON.
3) Click “PAIR Sol operating control” 1.
4) Click each button 2.
At this time, if an operation sound is heard from the PAIR
control solenoid valve, the function is normal.
2
ECM coupler (Harness side)
FI SYSTEM 5-75
SENSORS
IAP SENSOR INSPECTION
The intake air pressure sensor is located on the air inlet pipe.
(5-33)
IAP SENSOR REMOVAL/INSTALLATION
• Remove the fuel tank. (6-3)
• Remove the IAP sensors 1 and disconnect the couplers 2
and vacuum hoses 3.
• Installation is in the reverse order of removal.
TP SENSOR INSPECTION
The throttle position sensor is installed on the No. 2 throttle
body. (5-37)
TP SENSOR REMOVAL/INSTALLATION
•
•
•
•
•
Remove the fuel tank. (6-3)
Loosen the inlet pipe screws. (5-47)
Move the inlet pipe. (5-19)
Disconnect the coupler 1.
Remove the screw with a torx wrench (T25) and TP sensor
2.
• Install the TP sensor to the No. 2 throttle body.
(6-18)
• TP sensor setting procedure. (5-19)
5-76
FI SYSTEM
STP SENSOR INSPECTION
The secondary throttle position sensor is installed on the No. 2
throttle body. (5-59)
STP SENSOR REMOVAL/INSTALLATION
• Remove the fuel tank. (6-3)
• Disconnect the coupler 1.
• Remove the screw with a torx wrench (T25) and STP sensor
2.
• Install the STP sensor to the No. 2 throttle body.
(6-18)
• STP sensor setting procedure. (6-21)
CKP SENSOR INSPECTION
The signal rotor is mounted on the generator rotor and crankshaft position sensor is installed at the inside of the generator
cover. (5-30)
CKP SENSOR REMOVAL/INSTALLATION
• Remove the generator cover. (3-22)
• Remove the CKP sensor.
• Installation is in the reverse order of removal.
FI SYSTEM 5-77
IAT SENSOR INSPECTION
The intake air temperature sensor is installed at the back side of
the air cleaner box. (5-47)
IAT SENSOR REMOVAL/INSTALLATION
• Remove the air cleaner box. (5-47)
• Disconnect the IAT sensor coupler 1 and remove the IAT
sensor 2.
• Installation is in the reverse order of removal.
ECT SENSOR INSPECTION
The engine coolant temperature sensor is installed at the No. 2
cylinder head cover. (5-42)
ECT SENSOR REMOVAL/INSTALLATION
• Remove the fuel tank. (6-3)
• Disconnect the ECT sensor coupler 1 and remove the ECT
sensor 2.
• Installation is in the reverse order of removal.
 ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
TO SENSOR INSPECTION
The tip-over sensor is located under the front seat. (5-52)
TO SENSOR REMOVAL/INSTALLATION
• Remove the right frame cover. (8-4)
• Disconnect the coupler 1 and remove the TO sensor 2.
• Installation is in the reverse order of removal.
NOTE:
When installing the TO sensor, bring the “UPPER” letter A on it
to the top.
5-78
FI SYSTEM
HO2 SENSOR INSPECTION
(FOR E-02, 19, 24)
The heated oxygen sensor is installed on the pre-muffler.
(5-69)
HO2 SENSOR REMOVAL/INSTALLATION
• Remove the right frame cover. (8-4)
• Disconnect the coupler 1 and remove the HO2 sensor unit.

Do not remove the HO2 sensor while it is hot.

Be careful not to expose it to excessive shock.
Do not use an impact wrench while removing or
installing the HO2 sensor unit.
Be careful not to twist or damage the sensor lead wire.
• Installation is in the reverse order of removal.

Do not apply oil or other materials to the sensor air
hole.
• Tighten the sensor unit to the specified torque.
 HO2 SENSOR: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
• Route the HO2 sensor lead wire properly.
FUEL SYSTEM AND THROTTLE BODY 6-1
FUEL SYSTEM AND THROTLE BODY
CONTENTS
FUEL DELIVERY SYSTEM ...........................................................................6- 2
FUEL SYSTEM ..............................................................................................6- 3
FUEL TANK REMOVAL..........................................................................6- 3
FUEL TANK INSTALLATION .................................................................6- 3
FUEL PRESSURE INSPECTION............................................................6- 4
FUEL PUMP INSPECTION .....................................................................6- 5
FUEL DISCHARGE AMOUNT INSPECTION .........................................6- 5
FUEL PUMP RELAY INSPECTION ........................................................6- 6
FUEL PUMP REMOVAL AND DISASSEMBLY .....................................6- 7
FUEL MESH FILTER INSPECTION AND CLEANING ...........................6-11
FUEL PUMP REASSEMBLY AND INSTALLATION ..............................6-11
THROTTLE BODY .........................................................................................6-12
CONSTRUCTION ....................................................................................6-12
AIR CLEANER BOX REMOVAL.............................................................6-13
AIR CLEANER BOX INSTALLATION ....................................................6-13
THROTTLE BODY REMOVAL ...............................................................6-13
THROTTLE BODY DISASSEMBLY .......................................................6-14
THROTTLE BODY CLEANING...............................................................6-17
INSPECTION ...........................................................................................6-17
THROTTLE BODY REASSEMBLY ........................................................6-17
THROTTLE BODY INSTALLATION .......................................................6-20
STP SENSOR ADJUSTMENT ................................................................6-21
FUEL INJECTOR REMOVAL .................................................................6-21
FUEL INJECTOR INSPECTION .............................................................6-21
FUEL INJECTOR INSTALLATION .........................................................6-22
FAST IDLE ..............................................................................................6-22
FAST IDLE ADJUSTMENT.....................................................................6-22
THROTTLE VALVE SYNCHRONIZATION.............................................6-24
THROTTLE POSITION SENSOR (TPS) SETTING ................................6-25

Gasoline must be handled carefully in an area well ventilated and away from fire or
sparks.
6
6-2 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 injector installed in the fuel delivery pipe.
Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the
fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 3.0 kgf/cm² (300 kPa, 43
psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the
injection signal from the ECM.
The fuel relieved by the fuel pressure regulator flows back to the fuel tank.
1
2
3
4
5
6
Fuel tank
Fuel filter (For high pressure)
Fuel pressure regulator
Fuel delivery pipe
Fuel injector
Fuel feed hose
7
8
A
B
C
Fuel mesh filter (For low pressure)
Fuel pump
Before-pressurized fuel
Pressurized fuel
Relieved fuel
FUEL SYSTEM AND THROTTLE BODY
FUEL SYSTEM
FUEL TANK REMOVAL
• Remove the seats. (8-3)
• Remove the fuel tank mounting bolt.
• Lift and support the fuel tank about 10 cm (3.94 in) with the
proper stay.
NOTE:
Be careful not to lift the fuel more than about 10 cm (3.94 in), or
hoses will be twisted.
• Remove the pilot lamp coupler 1.
• Disconnect the fuel pump lead wire coupler 2.
• Place a rag under the fuel feed hose and remove the fuel feed
hose 3.

When removing the fuel tank, do not leave the fuel
feed hose 3 on the fuel tank side.

Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
• Remove the fuel tank.

Be careful not to damage the frame A by the fuel tank.
FUEL TANK INSTALLATION
• Installation is in the reverse order of removal.
6-3
6-4 FUEL SYSTEM AND THROTTLE BODY
FUEL PRESSURE INSPECTION
• Lift and support the fuel tank. (6-3)
• Place a rag under the fuel feed hose.
• Remove the fuel feed hose 1.
• Install the special tools between the fuel tank and fuel delivery
pipe.
 09940-40211: Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge hose attachment
09915-74511: Oil pressure gauge set
Turn the ignition switch ON and check the fuel pressure.
 Fuel pressure: Approx. 300 kPa (3.0 kgf/cm², 43 psi)
If the fuel pressure is lower than the specification, inspect the
following items:
* Clogged fuel filter
* Pressure regulator
* Fuel pump
If the fuel pressure is higher than the specification, inspect the
following items:
* Fuel pump check valve
* Pressure regulator

* Before removing the special tools, turn the ignition
switch to OFF position and release the fuel pressure
slowly.
* Gasoline is highly flammable and explosive. Keep
heat, sparks and flame away.
A To fuel tank
B To fuel delivery pipe
FUEL SYSTEM AND THROTTLE BODY
6-5
FUEL PUMP INSPECTION
Turn the ignition switch ON and check that the fuel pump operates for few seconds.
If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect
the fuel pump relay and tip-over sensor.
If the fuel pump relay, tip-over sensor and fuel pump circuit connections are OK, the fuel pump may be
faulty, replace the fuel pump with a new one.
FUEL DISCHARGE AMOUNT INSPECTION

Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
• Lift and support the fuel tank. (6-3)
• Disconnect the fuel feed hose 1 from the fuel delivery pipe.
• Disconnect the fuel pump lead wire coupler 2.
• Place the measuring cylinder and insert the fuel feed hose
end into the measuring cylinder.
• Connect a proper lead wire into the fuel pump lead wire coupler (fuel pump side) and apply 12 volts to the fuel pump
(between Y/R wire and B/W wire) for 10 seconds and measure the amount of fuel discharged.
Battery + terminal
(Yellow with red tracer)
Battery - terminal
(Black with white tracer)
If the pump does not discharge the amount specified, it means
that the fuel pump is defective or that the fuel filter is clogged.
 Fuel discharge amount: 168 ml and more/10 sec.
(5.7/5.9 US/Imp oz)/10 sec.
NOTE:
The battery must be in fully charged condition.
6-6 FUEL SYSTEM AND THROTTLE BODY
FUEL PUMP RELAY INSPECTION
Fuel pump relay is located inside the secondary gear case
cover.
• Remove the secondary gear case cover. (2-16)
• Remove the fuel pump relay.
First, check the insulation between A and B terminals with
pocket tester. Then apply 12 volts to C and D terminals, + to
C and - to D, and check the continuity between A and B.
If there is no continuity, replace it with a new one.
FUEL SYSTEM AND THROTTLE BODY
6-7
FUEL PUMP REMOVAL AND DISASSEMBLY
CONSTRUCTION
1
2
3
4
5
Thermistor
Fuel pump
Vessel
Rubber cushion
Fuel pump holder
6
7
8
A
O-ring
Cover
Fuel mesh filter
Fuel pump mounting bolt

ITEM
A
N·m
10
kgf-m
1.0
lb-ft
7.0
6-8 FUEL SYSTEM AND THROTTLE BODY
• Remove the fuel tank. (6-3)
• Remove the fuel pump assembly mounting bolts diagonally.

Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
• Lift the fuel pump assembly 1 as shown in the photograph.
• With the recessed section A of the delivery pipe positioned at
the edge of the tank opening as shown in the photograph, turn
the pump assembly 90° counterclockwise.
Front side
90˚
Front side
90˚
• Remove the high pressure filter 2 from the tank opening.
Front side
FUEL SYSTEM AND THROTTLE BODY
• With the fuel pump assembly 1 being turned approximately
30° counterclockwise as shown in the photograph, pull the
fuel pump wiring coupler 3 out of the tank opening while
taking care not to cause it to interfere with the tank opening.
Front side
Approx. 30˚
Front side
Approx. 30˚
• Remove the thermistor 4 from the tank opening.
• Remove the fuel pump assembly 1 along with the fuel mesh
filter cover 5.
• Remove the nuts 6.
6-9
6-10 FUEL SYSTEM AND THROTTLE BODY
• Remove the thermistor 7.
• Disconnect fuel pump coupler 8.
• Remove the fuel pump 9.
• Remove the rubber cushion 0 and vessel A.
• Remove the fuel pump holder B.
• Remove the cover C and fuel mesh filter D.
FUEL SYSTEM AND THROTTLE BODY
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 mesh filter is clogged with many sediment or rust,
replace the fuel filter cartridge with a new one.
FUEL PUMP REASSEMBLY AND INSTALLATION
Install the fuel pump in the reverse order of removal and disassembly. Pay attention to the following points:
• Install a new bushing 1 to the fuel pump.

Use the new bushing to prevent fuel leakage.
• Be sure to connect the wires to the proper terminals.
A ..... Thermistor (HIGH)
B ..... Thermistor (LOW)
C ..... Positive terminal for fuel pump
• Install a new O-ring and apply SUZUKI SUPER GREASE “A”
to it.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

The O-ring must be replaced with a new one to prevent
fuel leakage.
• When installing the fuel pump assembly, first tighten all the
fuel pump mounting bolts lightly and then to the specified
torque, in the ascending order of numbers.
 Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Apply a small quantity of the THREAD LOCK to the thread portion of fuel pump mounting bolt.
 99000-32050: THREAD LOCK “1342”
1
3
4
5
2
6-11
6-12 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY
CONSTRUCTION
1
2
3
4
5
6
7
8
STP sensor
TP sensor
IAP sensor
STVA
Fuel delivery pipe
O-ring
Fuel injector
Fuel feed hose
9
0
A
B
C
A
B
Three way joint (For E-33)
Hose (For E-33)
Vacuum hoses
Throttle stop screw
Idle adjusting screw
STP sensor mounting screw
TP sensor mounting screw

ITEM
A
B
N·m
3.5
3.5
kgf-m lb-ft
0.35 2.45
0.35 2.45
FUEL SYSTEM AND THROTTLE BODY
AIR CLEANER BOX REMOVAL
• Remove the fuel tank. (6-3)
• Remove the bolts.
: Hooked part
•
•
•
•
Loosen the clamp screw 1.
Disconnect the IAP sensor lead wire coupler 2.
Disconnect the PAIR hose 3.
Remove the air cleaner box.
AIR CLEANER BOX INSTALLATION
Installation is in the reverse order of removal.
THROTTLE BODY REMOVAL
• Remove the air cleaner box. (Above)
• Remove the IAP sensors (Front cylinder side 1 and Rear cylinder side 2) from the mount stay.
• Remove the PCV hose 3 and loosen the clamp screw 4.
• Remove the air intake pipe 5.
• Disconnect the TP sensor lead wire coupler 6, STVA lead
wire coupler 7 and STP sensor lead wire coupler 8.
6-13
6-14 FUEL SYSTEM AND THROTTLE BODY
• Disconnect the fuel injector lead wire couplers 9.
• Disconnect the vacuum hoses 0.
• Loosen the throttle body clamp screw at the intake pipe side.
• Disconnect the throttle cables from their drum.

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.
THROTTLE BODY DISASSEMBLY
• Remove the vacuum hose 1 and fuel feed hose 2.
• Remove the clamp 3.
FUEL SYSTEM AND THROTTLE BODY
• Remove the fuel delivery hose 4.
• Remove the fuel delivery pipes 5.
• Remove the fuel injectors 6.
• Remove the TP sensor 7 and STP sensor 8 with the special
tool.
 09930-11950: Torx wrench
NOTE:
Prior to disassembly, mark each sensor’s original position with a
paint or scribe for accurate reinstallation.

Never remove the STVA 9 from the throttle body.
6-15
6-16 FUEL SYSTEM AND THROTTLE BODY

* Do not loosen the nut 0.
* The fast idle screw A is factory-adjusted at the time
of delivery and therefore avoid removing or turning it
unless otherwise necessary.
* Do not turn the screw B.

Never remove the secondary throttle valve C and
throttle valve D.
• Remove the fuel delivery pipes E.
FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY CLEANING

Some carburetor cleaning chemicals, especially
dip-type soaking solutions, are very corrosive and
must be handled carefully. Always follow the chemical
manufacturer’s instructions for proper use, handling
and storage.
• Clean all passageways with a spray-type carburetor cleaner
and blow dry with compressed air.

Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be
cleaned with a spray cleaner it may be necessary to
use a dip-type cleaning solution and allow them to
soak. Always follow the chemical manufacturer’s
instructions for proper use and cleaning of the throttle
body components. Do not apply carburetor cleaning
chemicals to the rubber and plastic materials.
INSPECTION
•
*
*
*
*
*
*
Check following items for any damage or clogging.
O-ring
Throttle valve
Secondary throttle valve
Vacuum hose
Delivery hose
Injector dust seal
THROTTLE BODY REASSEMBLY
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:
• Apply thin coat of the engine oil to the new O-rings.

Replace the O-rings with the new ones.
6-17
6-18 FUEL SYSTEM AND THROTTLE BODY
• With the STV fully opened, install the STP sensor 1 and
tighten the STP sensor mounting screw to the specified
torque.

TPS and STPS resemble each other very closely in
external appearance.
Make sure to check the color of coupler before installing.
STP sensor: Green color coupler
NOTE:
* Apply thin coat of the engine oil to the new O-ring.
* Align the secondary throttle shaft end A with the groove B of
STP sensor.
* Apply SUZUKI SUPER GREASE “A” to the secondary throttle
shaft end A if necessary.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 09930-11950: Torx wrench
 STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.45 lb-ft)
NOTE:
* Make sure the STP valve open or close smoothly.
* If the STP sensor adjustment is necessary, refer to page 6-20
for STP sensor setting procedure.
• With the throttle valve fully closed, install the TP sensor 2
and tighten the TP sensor mounting screw to the specified
torque.
NOTE:
* Apply thin coat of the engine oil to the new O-ring.
* Align the throttle shaft end C with the groove D of TP sensor.
* Apply SUZUKI SUPER GREASE “A” to the throttle shaft end
C if necessary.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 09930-11950: Torx wrench
 TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.45 lb-ft)
NOTE:
* Make sure throttle valve open or close smoothly.
* TP sensor setting procedure. (5-19)
FUEL SYSTEM AND THROTTLE BODY
• Install the O-rings and dust seals to each fuel injector.
• Apply thin coat of the engine oil to the new O-rings and dust
seal.

Replace the O-rings and dust seals with the new ones.
• Install the fuel injector 3 by pushing it straight to the delivery
pipe 4.
NOTE:
Align the boss E of the injector with the groove F of the delivery
pipe.

Never turn the injector while pushing it.
• Install the fuel delivery pipes 5 to the throttle body assembly.

Never turn the fuel injectors while installing them.
• Tighten the fuel delivery pipe mounting screws to the specified torque.
 Fuel delivery pipe mounting screw:
3.5 N·m (0.35 kgf-m, 2.45 lb-ft)
• Apply thin coat of the engine oil to the new O-rings.

Replace the O-rings with the new ones.
6-19
6-20 FUEL SYSTEM AND THROTTLE BODY
• Install the fuel delivery pipe joint hose 6 to the delivery pipes.
• Tighten the fuel delivery pipe hose mounting screws to the
specified torque.
 Fuel delivery pipe joint hose mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
THROTTLE BODY INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following points:
• Connect the TP sensor lead wire coupler 1.

TP sensor lead wire coupler and STP sensor lead wire
coupler resemble each other very closely in external
appearance.
Make sure to check the color of coupler before installing.
TP sensor lead wire coupler: Black
• Connect the throttle pulling cable 2 and throttle returning
cable 3 to the throttle cable drum.
• Loosen each throttle cable lock-nut.
• Turn in each throttle cable adjuster fully and locate each outer
cable so that the clearance is 0 – 2 mm (0 – 0.08 in).
• Tighten each lock-nut.
• Adjust the throttle cable play.
Refer to page 2-14 and -15 for details.
• Install the air cleaner box and tighten the throttle body clamp
screws as shown in the illustration. (10-19)
0 – 2 mm
(0 – 0.08 in)
0 – 2 mm
(0 – 0.08 in)
FUEL SYSTEM AND THROTTLE BODY
STP SENSOR ADJUSTMENT
If the STP sensor adjustment is necessary, measure the sensor
out put voltage and adjust the STP sensor position as follows:
• Remove the air cleaner box. (6-13)
• Disconnect the STVA coupler. (6-13)
• Insert the needle pointed probes to the lead wire coupler.
• Turn the ignition switch ON.
• Close the secondary throttle valve by finger, and measure the
STP sensor out put voltage.
 STP sensor out put voltage
ST valve is fully closed: Approx. 0.5 V
(+ Y/W – - B/Br)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
• If the STP sensor voltage is out of specification, loosen the
STP sensor mounting screw and adjust the STP sensor voltage to specification.
• Tighten the STP sensor mounting screw.
 09930-11950: Torx wrench
 STP sensor mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
FUEL INJECTOR REMOVAL
• Remove the fuel tank. (6-3)
• Remove the air intake pipe. (2-7)
• With battery negative cable disconnected, disconnect the
injector couplers.
• Remove the fuel delivery pipes. (6-15)
• Remove the fuel injectors #1 and #2. (6-15)
FUEL INJECTOR INSPECTION
Check fuel injector filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in the fuel lines and
fuel tank.
The fuel injector can be checked without removing it from the
throttle body.
Refer to page 5-66 for details.
V
Y/W
B/Br
6-21
6-22 FUEL SYSTEM AND THROTTLE BODY
FUEL INJECTOR INSTALLATION
• Apply thin coat of the engine oil to new injector dust seals and
O-rings. (6-19)
• Install the injector by pushing it straight to the throttle body.
Never turn the injector while pushing it. (6-19)
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 temperature, ambient temperature and lapsed time, the fast idle is
cancelled allowing the engine to resume idle speed.
Ambient Temp.
Fast idle rpm
–5 °C (23 °F)
15 °C (59 °F)
25 °C (77 °F)
1 500 – 2 100 rpm
1 500 – 2 100 rpm
1 500 – 2 100 rpm
Fast idle cancelling time
Approx. 100 sec.
Approx. 60 sec.
Approx. 50 sec.
FAST IDLE ADJUSTMENT
• Lift and support the fuel tank. (6-3)
• Start up the engine and run it in idling condition for warming
up.
• Set the idle rpm to 1 100 rpm by the throttle stop screw 1.
• Check and adjust the TP sensor. (5-19)
• Measure the TP sensor output voltage at the coupler
(between + Bl/B wire and - B/Br wire).
 TP sensor output voltage at idle position: Approx. 1.12 V
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
V
FUEL SYSTEM AND THROTTLE BODY
•
•
•
•
Turn the ignition switch OFF.
Disconnect the STVA coupler.
Turn the ignition switch ON.
Open the secondary throttle valve fully by moving the fast idle
link with your finger.
• With the secondary throttle valve held at this position, measure the output voltage of the TP sensor as shown.
• Calculate the voltage difference between TP sensor output
voltage at idle and TP sensor output voltage with the STV full
opened.
Example: TP sensor output voltage with the STV fully open
Minus TP sensor output voltage at idle is 0.08 V
STV fully open 1.20 V
Idle
- 1.12 V
0.08 V
 TP sensor output voltage variation: 0.064 – 0.096 V
• If the voltage variation is out of specification, loosen the
lock-nut 2 and turn in or out the fast idle adjust screw 3 to
adjust the voltage to specification.

The fast idle screw is factory-adjusted at the time of
delivery and therefore avoid removing or turning it
unless otherwise necessary.
• Cool down the engine to ambient air temperature and start the
engine to check the fast idle rpm comes within the specified
rpm.
 Standard
Fast idle rpm: 1 500 – 2 100 rpm/Cold engine
Idle rpm
: 1 100 ± 100 rpm/Warmed engine
• If it is not at the specified rpm, the cause may possibly be
short-circuit in water temperature sensor or wiring harness or
STVA.
6-23
6-24 FUEL SYSTEM AND THROTTLE BODY
THROTTLE VALVE SYNCHRONIZATION
Check and adjust the throttle valve synchronization among two
cylinders.
USE OF VACUUM BALANCER GAUGE
Calibrating each vacuum gauge
• Start up the engine and run it in idling condition for warming
up.
• Stop the warmed-up engine.
• Disconnect the vacuum hose 1 from the No. 1 (Rear cylinder) throttle body.
• Connect one of the vacuum balancer gauge hose to the vacuum nipple on the No. 1 throttle body with the special tools.
*2
 13685-02FA0: Three way joint
13681-39F00-225: Hose
*1: To vacuum nipple
*2: To vacuum hose
*3: To vacuum balancer gauge hose
• Connect a tachometer.
• Start up the engine and keep it running at 1 100 rpm by turning throttle stop screw 2.

Avoid drawing dirt into the throttle body while running
the engine without intake pipe and air cleaner box. Dirt
drawn into the engine will damage the internal engine
parts.
• Turn the air screw 3 of the gauge so that the vacuum acting
on the tube of that hose will bring the steel ball 4 in the tube
to the center line 5.
NOTE:
* The vacuum gauge is positioned vertical level.
* During balancing the throttle valves, always set the engine
rpm at 1 100 rpm, using throttle stop screw.
*1
*3
FUEL SYSTEM AND THROTTLE BODY
• After making sure that the steel ball stays steady at the center
line, disconnect the hose from the No. 1 throttle body vacuum
nipple and connect the next hose to this vacuum nipple.
• Turn air screw to bring the other steel ball 6 to the center
line.
The balancer gauge is now ready for use in balancing the throttle valves.
Throttle valve synchronization
Using the vacuum balancer gauge, inspect the throttle valve
synchronization in the same manner of the digital vacuum tester.
Pay attention to the following points:
The vacuum gauge is positioned vertical level, and in this position the two balls should be within one ball dia. If the difference
is larger than one ball, turn the balance adjusting screw on the
throttle body and bring the ball to the same level.
A correctly adjusted throttle valve synchronization has the balls
in the No. 1 and No. 2 at the same level.
 09913-13121: Vacuum balancer gauge
NOTE:
* During balancing the throttle valves, always set the engine
rpm at 1 100 rpm, using throttle stop screw.
* After balancing the two valves, set the idle rpm to 1 100 rpm
by the throttle stop screw.
THROTTLE POSITION SENSOR (TPS) SETTING
After all adjustments are completed, check or adjust the TPS
setting condition. (5-19)
6-25
COOLING AND LUBRICATION SYSTEM
7-1
COOLING AND LUBRICATION SYSTEM
CONTENTS
ENGINE COOLANT .......................................................................................7- 2
COOLING CIRCUIT .......................................................................................7- 3
COOLING CIRCUIT INSPECTION..........................................................7- 3
RADIATOR AND WATER HOSES ................................................................7- 4
RADIATOR REMOVAL ...........................................................................7- 4
RADIATOR CAP INSPECTION ..............................................................7- 5
RADIATOR INSPECTION AND CLEANING ..........................................7- 5
RADIATOR REMOUNTING ....................................................................7- 5
WATER HOSE AND RESERVOIR TANK INSPECTION........................7- 6
COOLING FAN ..............................................................................................7- 7
INSPECTION ...........................................................................................7- 7
REMOVAL ...............................................................................................7- 7
INSTALLATION.......................................................................................7- 8
COOLING FAN THERMO-SWITCH ..............................................................7- 9
REMOVAL ...............................................................................................7- 9
INSPECTION ...........................................................................................7- 9
INSTALLATION.......................................................................................7- 9
ENGINE COOLANT TEMPERATURE SENSOR ..........................................7-10
REMOVAL ...............................................................................................7-10
INSPECTION ...........................................................................................7-10
INSTALLATION.......................................................................................7-11
THERMOSTAT ..............................................................................................7-12
REMOVAL ...............................................................................................7-12
INSPECTION ...........................................................................................7-12
INSTALLATION.......................................................................................7-13
WATER PUMP ...............................................................................................7-14
REMOVAL AND DISASSEMBLY ...........................................................7-14
INSPECTION ...........................................................................................7-15
REASSEMBLY AND INSTALLATION....................................................7-16
LUBRICATION SYSTEM ...............................................................................7-19
OIL PRESSURE ......................................................................................7-19
OIL FILTER .............................................................................................7-19
OIL PRESSURE REGULATOR ..............................................................7-19
OIL STRAINER........................................................................................7-19
OIL JET ...................................................................................................7-19
OIL PUMP................................................................................................7-19
OIL PRESSURE SWITCH .......................................................................7-19
ENGINE LUBRICATION SYSTEM CHART ............................................7-20
7
7-2
COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT
At the time of manufacture, the cooling system is filled with a
50:50 mixture of distilled water and ethylene glycol anti-freeze.
This 50:50 mixture will provide the optimum corrosion protection
and excellent heat protection, and will protect the cooling system
from freezing at temperatures above –31 °C (–24 °F).
If the motorcycle is to be exposed to temperatures below –31 °C
(–24 °F), this mixing ratio should be increased up to 55% or 60%
according to the figure.
Anti-freeze
density
50%
55%
60%

Freezing point
* Use a high quality ethylene glycol base anti-freeze,
mixed with distilled water. Do not mix an alcohol
base anti-freeze and different brands of anti-freeze.
* Do not put in more than 60% anti-freeze or less than
50%. (Refer to Right figure.)
* Do not use a radiator anti-leak additive.
(˚F)
(˚C)
32
0
14
–10
–4
–20
–22
–30
–40
–40
–58
–50
–76
–60
–94
–70
Freezing point
–30 ˚C (–24 ˚F)
–40 ˚C (–44 ˚F)
–55 ˚C (–67 ˚F)
50% Engine coolant including reserve tank capacity
Anti-freeze
Water
750 ml (1.6/1.3 US/lmp.pt)
750 ml (1.6/1.3 US/lmp.pt)
20 40 60 80 100
Density (%)
Fig.1 Engine coolant density-freezing
point curve.
(˚F) (˚C)
(kgf/cm²)
284 140
1.5
266 130
0.9
248 120
0.5
230 110
0
212 100
0
10
20 30 40
Density (%)
50
60
Fig.2 Engine coolant density-boiling
point curve.

* You can be injured by scalding fluid or steam if you open the radiator cap when the engine is
hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
* The engine must be cool before servicing the cooling system.
* Coolant is harmful;
• If it comes in contact with skin or eyes, flush with water.
• If swallowed accidentally, induce vomiting and call physician immediately.
• Keep it away from children.
Gauge pressure
Boiling point
302 150
COOLING AND LUBRICATION SYSTEM
7-3
COOLING CIRCUIT
RESERVOIR
TANK
THERMOSTAT
CYLINDER HEAD
CYLINDER
COOLING
FAN THERMO
SWITCH
RADIATOR
WATER
PUMP
COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant,
inspect the cooling circuit for tightness.
• Remove the fuel tank. (6-3)
• Remove the radiator cap 1 and connect the tester 2 to the
filler.

Do not remove the radiator cap when the engine is
hot.
• Give a pressure of about 120 kPa (1.2 kgf/cm², 17 psi) and
see if the system holds this pressure for 10 seconds.
• If the pressure should fall during this 10-second interval, it
means that there is a leaking point in the system. In such a
case, inspect the entire system and replace the leaking component or part.

When removing the radiator cap tester, put a rag on
the filler to prevent spouting of engine coolant.

Do not allow the pressure to exceed the radiator cap
release pressure, or the radiator can be damaged.
ENGINE COOLANT
TEMPERATURE
SENSOR
7-4
COOLING AND LUBRICATION SYSTEM
RADIATOR AND WATER HOSES
RADIATOR REMOVAL
• Remove the fuel tank. (6-3)
• Remove the frame head covers. (3-3)
• Drain the engine coolant. (2-17)
• Remove the radiator cover 1.
• Remove the radiator mounting bolts.
• Disconnect the ECT sensor coupler 2 and water hoses.
• Remove the radiator.
COOLING AND LUBRICATION SYSTEM
RADIATOR CAP INSPECTION
• Fit the cap 1 to the radiator cap tester 2.
• Build up pressure slowly by operating the tester. Make sure
that the pressure build-up stops at 95 – 125 kPa (0.95 – 12.5
kgf/cm², 13.5 – 17.8 psi) and that, with the tester held standstill, the cap is capable of holding that pressure for at least 10
seconds.
• Replace the cap if it is found not to satisfy either of these two
requirements.
 Radiator cap valve opening pressure
Standard: 95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
RADIATOR 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 blade of a small screwdriver.
RADIATOR REMOUNTING
• The radiator is to be installed in the reverse order of the
removal procedure.
• Install the radiator.
• Route the radiator hoses. (10-20)
• Bleed air from the cooling circuit. (2-18)
7-5
7-6
COOLING AND LUBRICATION SYSTEM
WATER HOSE AND RESERVOIR TANK
INSPECTION
•
•
•
•
Remove the fuel tank. (6-3)
Remove the secondary gear case cover. (8-40)
Remove the frame head covers. (3-3)
Any water hose and reservoir tank 1 found in a cracked condition or flattened must be replaced.
• Any leakage from the connecting section should be corrected
by proper tightening.
COOLING AND LUBRICATION SYSTEM
COOLING FAN
INSPECTION
• Disconnect the cooling fan lead wire coupler 1.
• Test the cooling fan motor for load current with an ammeter
connected as shown in the illustration.
• The voltmeter is for making sure that the battery applies 12
volts to the motor. With the motor with electric motor fan running at full speed, the ammeter should be indicating not 5
amperes and more.
• If the fan motor does not turn, replace the motor assembly
with a new one.
REMOVAL
• Remove the radiator. (7-4)
• Remove the cooling fan mounting bolts.
• Slightly move the down tube by removing its mounting bolts.
Fan motor
Battery
Ammeter
7-7
7-8
COOLING AND LUBRICATION SYSTEM
• Remove the cooling fan 1 by disconnecting the cooling fan
lead wire coupler.
INSTALLATION
Install the cooling fan in the reverse order of removal. Pay attention to the following points:
• Put the cooling fan 1 between the down tube and the engine.
• Temporary tighten the down tube mounting bolts. (3-9)
• Tighten the cooling fan mounting bolts.
• Tighten the down tube mounting bolts to the specified torque.
(3-9)
• Install the radiator. (7-5)
COOLING AND LUBRICATION SYSTEM
COOLING FAN THERMO-SWITCH
REMOVAL
• Drain the engine coolant. (2-17)
• Disconnect the cooling fan thermo-switch coupler 1.
• Remove the cooling fan thermo-switch 2.
INSPECTION
• Check the thermo-switch closing or opening temperatures by
testing it at the bench as shown in the figure. Connect the
thermo-switch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove.
• Heat the oil to raise its temperature slowly, and read the column thermometer when the switch closes or opens.
 09900-25008: Multi circuit tester set
 Tester knob indication: Continuity test ()
 Cooling fan thermo-switch operating temperature:
Standard (OFF→ON): Approx. 105 °C (221 °F)
(ON→OFF): Approx. 100 °C (212 °F)

* Take special care when handling the thermo-switch.
It may cause damage if it gets a sharp impact.
* Do not contact the cooling fan thermo-switch 1 and
the column thermometer 2 with a pan.
INSTALLATION
• Install the O-ring 1.
• Tighten the cooling fan thermo-switch to the specified torque.
 Cooling fan thermo-switch:
17 N·m (1.7 kgf-m, 12.5 lb-ft)
• Bleed air from the cooling circuit. (2-18)
Oil
7-9
7-10
COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR
REMOVAL
• Lift and support the fuel tank. (6-3)
• Remove the frame head covers. (3-3)
• Disconnect the engine coolant temperature sensor coupler
1.
• Keep the motorcycle upright.
• Place a rag under the sensor and remove the engine coolant
temperature sensor 2.
INSPECTION
• Check the engine coolant temperature sensor by testing it at
the bench as shown in the figure. Connect the temperature
sensor 1 to a circuit tester and place it in the oil contained in
a pan, which is placed on a stove.
• Heat the oil to raise its temperature slowly and read the column thermometer 2 and the ohmmeter.
Oil
• If the temperature sensor ohmic value does not change in the
proportion indicated, replace it with a new one.
 Temperature sensor specification
Temperature
20 °C (68 °F)
40 °C (104 °F)
60 °C (140 °F)
80 °C (176 °F)
Standard resistance
Approx. 2.45 kΩ
Approx. 1.148 kΩ
Approx. 0.587 kΩ
Approx. 0.322 kΩ
If the resistance is noted to show infinity or too much different
resistance value, replace the temperature sensor with a new
one.

* Take special care when handling the temperature
sensor. It may cause damage if it gets a sharp impact.
* Do not contact the engine coolant temperature sensor 1 and the column thermometer 2 with a pan.
COOLING AND LUBRICATION SYSTEM
INSTALLATION
Install the engine coolant temperature sensor order of removal.
Pay attention to the following points:
• Tighten the engine coolant temperature sensor to the specified torque.
 Engine coolant temperature sensor:
18 N·m (1.8 kgf-m, 13.0 lb-ft)

Take special care when handling the temperature sensor. It may cause damage if it gets a sharp impact.
7-11
7-12
COOLING AND LUBRICATION SYSTEM
THERMOSTAT
REMOVAL
• Drain engine coolant. (2-17)
• Remove the reservoir tank. (3-4)
• Remove the water hoses 1 and water pump case 2.
• Remove the thermostat case 3.
• Remove the thermostat 4.
INSPECTION
Inspect the thermostat pellet for signs of cracking.
Test the thermostat at the bench for control action, in the following manner.
• Pass a string 1 between flange of thermostat 2, as shown.
• Immerse the thermostat in the water contained in a beaker, as
shown in the illustration. Note that the immersed thermostat is
in suspension. Heat the water 3 by placing the beaker on a
stove 4 and observe the rising temperature on a thermometer 5.
• Read the thermometer just when opening the thermostat. This
reading, which is the temperature level at which the thermostat valve begins to open, should satisfy the standard value.
 Thermostat valve opening temperature
Standard: Approx. 75 °C (167 °F)
COOLING AND LUBRICATION SYSTEM
• Keep on heating the water to raise its temperature.
• Just when the water temperature reaches specified value, the
thermostat valve should have lifted by at least 6.0 mm (0.24
in).
 Thermostat valve lift A
Standard: 6.0 mm and over at 90 °C
(0.24 in and over at 194 °F)
• A thermostat failing to satisfy either of the two requirements
(start-to-open temperature and valve lift) must be replaced.
INSTALLATION
Install the thermostat in the revers order of removal. Pay attention to the following points:
• Apply engine coolant to the O-ring and install the water pump
cover.
• Tighten the water pump cover bolts.
NOTE:
Fit the clamp to the bolt A.
• Bleed air from the cooling circuit. (2-18)
7-13
7-14
COOLING AND LUBRICATION SYSTEM
WATER PUMP
REMOVAL AND DISASSEMBLY
• Drain the engine oil. (2-11)
• Drain engine coolant. (2-17)
• Remove the water pump case. (7-12)
NOTE:
Before draining engine oil and engine coolant, inspect engine oil
and coolant leakage between the water pump and crankcase. If
engine oil is leaking, visually inspect the oil seal and O-ring. If
engine coolant is leaking, visually inspect the mechanical seal
and seal washer. (7-16)
• Turn the crankshaft and align the water pump impeller holes
with the screws.
• Remove the water pump 1.
• Remove the E-ring 2.
• Remove the pin 3 and draw out the impeller shaft 4.
• Remove the mechanical seal ring 5 and the rubber seal 6
from the impeller.
COOLING AND LUBRICATION SYSTEM
• Remove the bearings with the special tool.
 09921-20240: Bearing remover set
NOTE:
If there is no abnormal noise condition, bearing removal is not
necessary.

The removed bearing must be replaced with a new
one.
• Remove the mechanical seal with the special tool.
 09921-20240: Bearing remover set
NOTE:
If there is no abnormal condition, the mechanical seal removal is
not necessary.

The removed mechanical seal must be replaced with a
new one.
• Remove the oil seal using a suitable bar.
NOTE:
If no abnormal, the oil seal removal is not necessary.

The removed oil seal must be replaced with a new one.
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 particular attention given to the sealing face.
• Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary.
7-15
7-16
COOLING AND LUBRICATION SYSTEM
OIL SEAL
• Visually inspect the oil seal for damage, with particular attention given to the lip.
• Replace the oil seal that shows indications of leakage.
BEARING CASE
• Visually inspect the bearing case for damage.
• Replace the water pump body if necessary.
REASSEMBLY AND INSTALLATION
• Install the oil seal with the special tool.
 09913-70210: Bearing installer set
NOTE:
The stamped mark on the oil seal faces outside.
• Apply a small quantity of the SUZUKI SUPER GREASE “A” to
the oil seal lip.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
COOLING AND LUBRICATION SYSTEM
• Install the new mechanical seal using a suitable size socket
wrench.
NOTE:
On the new mechanical seal, the sealer A has been applied.
• Install the new bearings with the special tool.
 09913-70210: Bearing installer set
NOTE:
The stamped mark on the bearing faces crankcase side.
• Apply SUZUKI SUPER GREASE “A” 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 1 into the impeller.
• After wiping off the oily or greasy matter from the mechanical
seal ring, install it into the impeller.
NOTE:
The marked side B of the mechanical seal ring faces the impeller.
7-17
7-18
COOLING AND LUBRICATION SYSTEM
• Apply grease to the new O-ring.
• Install the impeller 2 and impeller shaft 3 to the water pump
body.
• Install the pin 4 and E-ring 5.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the new gasket 6.
• Apply grease to the O-ring.
• Set the water pump shaft end C to the oil pump shaft D.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the water pump.
• Tighten the screws.
• Install the water pump cover. (7-13)
•
•
•
•
•
Connect the water hose.
Install the reserve tank.
Install the secondary gear case cover.
Pour engine oil. (2-11)
Bleed air from the cooling circuit. (2-18)
COOLING AND LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PRESSURE
2-28
OIL FILTER
2-12
OIL PRESSURE REGULATOR
3-62
OIL STRAINER
3-61
OIL JET
3-60
OIL PUMP
3-56
OIL PRESSURE SWITCH
3-63
7-19
7-20
COOLING AND LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM CHART
ROCKER ARM SHAFT (EX.)
CAMSHAFT R. JOURNAL
ROCKER ARM SHAFT (EX.)
CAMSHAFT L. JOURNAL
CAM FACES
(IN. & EX.)
VALVES AND
SPRINGS (IN. & EX.)
CAM FACES
(IN. & EX.)
VALVES AND
SPRINGS (IN. & EX.)
ROCKER ARM (IN.)
ROCKER ARM (IN.)
CAMSHAFT
CAMSHAFT
ROCKER ARM
SHAFT (IN.)
ROCKER ARM
SHAFT (IN.)
CAM CHAIN
CAM CHAIN
CAMSHAFT L. JOURNAL
CYLINDER HEAD
CAMSHAFT R. JOURNAL
CYLINDER WALL,
PISTON AND
PISTON PIN
CYLINDER HEAD
FRONT CYLINDER
OIL JET
CYLINDER WALL,
PISTON AND
PISTON PIN
REAR CYLINDER
NO.1 CONROD
BIG END
L. CRANK JOURNAL
STARTER
CLUTCH
BEARING
NO.2 CONROD
BIG END
OIL JET
R. CRANK JOURNAL
MAIN GALLERY
ORIFICE
OIL JET
SECONDARY
BEVEL GEAR
AND BEARINGS
DRIVESHAFT
LEFT BEARING
COUNTERSHAFT
LEFT BEARING
DRIVESHAFT
COUNTERSHAFT
OIL FILTER
PRESSURE
REGULATOR
DRIVESHAFT GEARS
COUNTERSHAFT GEARS
OIL PUMP
DRIVEN CHAIN
CLUTCH SLEEVE HUB
OIL PUMP
SECONDARY
BEVEL GEAR
OIL SUMP FILTER
CLUTCH PLATES
OIL PAN
CHASSIS
8-1
CHASSIS
CONTENTS
EXTERIOR PARTS........................................................................................8- 3
REMOVAL ...............................................................................................8- 3
REMOUNTING ........................................................................................8- 4
FRONT WHEEL .............................................................................................8- 5
CONSTRUCTION ....................................................................................8- 5
REMOVAL AND DISASSEMBLY ...........................................................8- 7
INSPECTION ...........................................................................................8- 8
REASSEMBLY AND REMOUNTING......................................................8- 9
FRONT FORK................................................................................................8-12
CONSTRUCTION ....................................................................................8-12
REMOVAL AND DISASSEMBLY ...........................................................8-13
INSPECTION ...........................................................................................8-16
REASSEMBLY AND REMOUNTING......................................................8-17
HANDLEBAR.................................................................................................8-21
CONSTRUCTION ....................................................................................8-21
REMOVAL AND DISASSEMBLY ...........................................................8-22
REASSEMBLY AND REMOUNTING......................................................8-22
STEERING .....................................................................................................8-24
CONSTRUCTION ....................................................................................8-24
REMOVAL AND DISASSEMBLY ...........................................................8-25
INSPECTION AND DISASSEMBLY .......................................................8-27
REASSEMBLY AND REMOUNTING......................................................8-27
STEERING TENSION ADJUSTMENT ....................................................8-30
REAR WHEEL ...............................................................................................8-31
CONSTRUCTION ....................................................................................8-31
REMOVAL ...............................................................................................8-33
DISASSEMBLY .......................................................................................8-34
INSPECTION AND DISASSEMBLY .......................................................8-35
REASSEMBLY AND REMOUNTING......................................................8-36
REAR SUSPENSION.....................................................................................8-38
CONSTRUCTION ....................................................................................8-38
REMOVAL ...............................................................................................8-40
INSPECTION AND DISASSEMBLY .......................................................8-43
REASSEMBLY ........................................................................................8-45
REMOUNTING ........................................................................................8-46
REAR SHOCK ABSORBER DISPOSAL................................................8-49
SUSPENSION SETTING.........................................................................8-49
FRONT BRAKE .............................................................................................8-50
CONSTRUCTION ....................................................................................8-50
8
8-2 CHASSIS
CHASSIS
CONTENTS
BRAKE PAD REPLACEMENT............................................................... 8-52
BRAKE FLUID REPLACEMENT............................................................ 8-53
BRAKE CALIPER REMOVAL AND
DISASSEMBLY....................................................................................... 8-53
BRAKE CALIPER INSPECTION ............................................................ 8-54
BRAKE CALIPER REASSEMBLY AND REMOUNTING....................... 8-55
BRAKE DISC INSPECTION ................................................................... 8-56
MASTER CYLINDER REMOVAL AND DISASSEMBLY ....................... 8-57
MASTER CYLINDER INSPECTION ....................................................... 8-58
MASTER CYLINDER REASSEMBLY AND REMOUNTING.................. 8-59
REAR BRAKE ............................................................................................... 8-61
CONSTRUCTION.................................................................................... 8-61
REMOVAL AND DISASSEMBLY........................................................... 8-62
INSPECTION........................................................................................... 8-62
REASSEMBLY AND REMOUNTING ..................................................... 8-63
REAR BRAKE ROD................................................................................ 8-64
REASSEMBLY REMOUNTING .............................................................. 8-65
TIRE AND WHEEL ........................................................................................ 8-66
TIRE REMOVAL ..................................................................................... 8-66
INSPECTION........................................................................................... 8-66
VALVE INSPECTION.............................................................................. 8-67
TIRE INSTALLATION ............................................................................. 8-68
BALANCER WEIGHT INSTALLATION.................................................. 8-69
CHASSIS
EXTERIOR PARTS
REMOVAL
SEAT
• Remove the rear seat by removing the bolt.

Be careful not to scratch the rear fender.
• Remove the rear seat grip band by removing the bolts.
• Remove the seat.

Be careful not to scratch the rear fender.
FRAME COVER
• Remove the left frame cover 1 with the ignition key.
: Hooked part
8-3
8-4
CHASSIS
• Remove the right frame covers 2 by removing the bolts.

* Wait until the engine and exhaust pipe are cool
enough to touch with bare hands before draining oil.
* Be careful not to scratch the frame covers.
: Hooked part
REAR FENDER
• Remove the seat. (8-3)
• Disconnect the coupler 1.
• Remove the left and right side frame handle grip.
• Remove the rear fender 2.

Be careful not to scratch the rear fenders.
NOTE:
When installing the frame handle grip bolts, apply a small quantity of THREAD LOCK to its mounting bolts and tighten them to
the specified torque.
: Hooked part
 99000-32030: THREAD LOCK SUPER “1303”
 Frame handle grip mounting bolt A (M10):
50 N·m (5.0 kgf-m, 36.0 lb-ft)
 : Hooked part
REMOUNTING
Remount the seats, covers and rear fender in the reverse order
of removal.
CHASSIS
FRONT WHEEL
CONSTRUCTION
1
2
3
4
Bearing (R)
Front wheel
Spacer
Bearing (L)
5
6
A
B
Brake disc
Spacer
Front axle
Brake disc mounting bolt

ITEM
A
B
N·m
65
23
kgf-m
6.5
2.3
lb-ft
47.0
16.5
8-5
8-6
CHASSIS
Right
Left
A Front axle
B Brake disc bolt

ITEM
A
B
N·m
65
23
kgf-m
6.5
2.3
lb-ft
47.0
16.5
CHASSIS
REMOVAL AND DISASSEMBLY
• Loosen the front axle pinch bolt 1.
• Loosen the front axle with the special tool.
 09900-18710: Hexagon socket (12 mm)
• Raise the front wheel off the ground with a jack or a wooden
block.
• Remove the front axle 2, spacer 3 and front wheel.

Do not operate the brake lever during or after front
wheel removal.
• Remove the brake disc by removing its bolts.
8-7
8-8
CHASSIS
INSPECTION
WHEEL BEARINGS
Inspect the play of the wheel bearings by finger while they are in
the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is anything unusual.
WHEEL BEARINGS REMOVAL
• Remove the wheel bearings by with the special tool A or B.
 09921-20240: A Bearing remover set (17 mm)
or 09941-50111: B Wheel bearing remover

The removed bearings should be replaced with new
ones.
FRONT WHEEL
Make sure that the wheel runout (axial and radial) does not
exceed the service limit when checked as shown. An excessive
amount of runout is usually due to worn or loose wheel bearings
and can be corrected by replacing the bearings. If bearing
replacement fails to reduce the runout, replace the wheel with a
new one.
 Wheel rim runout (axial and radial)
Service Limit: 2.0 mm (0.08 in)
CHASSIS
FRONT AXLE
Measure the front axle runout using the dial gauge. If the runout
exceeds the service limit, replace the front axle with a new one.
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
 Wheel axle runout
Service Limit: 0.25 mm (0.010 in)
TIRE 2-23
REASSEMBLY AND REMOUNTING
Reassemble and remount the front wheel in the reverse order of
removal and disassembly. Pay special attention to the following
points:
WHEEL BEARING
• Apply SUZUKI SUPER GREASE “A” to the bearings before
installing.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the wheel bearings with the used bearings and special
tool as described below.
 A 09941-34513: Bearing installer set
B 09913-70210: Bearing installer set (40 mm)

* First install the right wheel bearing, then install the
left wheel bearing.
* The sealed covers on the bearings must face to the
outside.
Left
Right
Right
Left
Clearance
Spacer
8-9
8-10
CHASSIS
BRAKE DISC
• Make sure that the brake disc is clean and free of any grease.
Apply THREAD LOCK SUPER to the brake disc bolts and
tighten them to the specified torque.
 99000-32130: THREAD LOCK SUPER “1360”
 Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
SPEED SENSOR
• Apply SUZUKI SUPER GREASE “A” to the speed sensor dust
seal.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Align the grooves 1 on the speed sensor with the lugs 2 on
the wheel hub.
FRONT WHEEL
• Make sure that the front fork stopper 1 and the speed sensor
stopper 2 are installed as shown.

When installing the front wheel, position the brake
disc between the brake pads. Be careful not to damage the brake pads.
CHASSIS
• Tighten the front axle to the specified torque.
• Tighten the front axle pinch bolt 3 on the specified torque.
 Front axle: 65 N·m (6.5 kgf-m, 47.0 lb-ft)
Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
 09900-18710: Hexagon socket (12 mm)
NOTE:
Before tightening the front axle pinch bolt 3, move the front fork
up and down four or five times.
NOTE:
After remounting the front wheel, pump the brake lever a few
times to check for proper brake operation.
8-11
8-12
CHASSIS
FRONT FORK
CONSTRUCTION
1
2
3
4
5
O-ring
Spacer
Spring
Outer tube
Oil seal retainer
6
7
8
9
0
Oil seal
Oil seal stopper ring
Dust seal
Inner rod/Damper rod (cartridge)
Inner tube
A
B
C
D

ITEM
A
B
N·m
23
15
kgf-m
2.3
1.5
lb-ft
16.5
11.0
ITEM
C
D
N·m
33
39
kgf-m
3.3
3.9
lb-ft
24.0
28.0
Front fork cap bolt
Inner rod lock-nut
Front axle pinch bolt
Caliper rod bolt
CHASSIS
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (8-7)
• Remove the front brake caliper. (8-52)
• Remove the front fender.
• Loosen the front fork upper clamp bolts 1.
NOTE:
Slightly loosen the front fork cap bolts 2 before loosening the
lower clamp bolts to facilitate later disassembly.
• Loosen the turn signal light clamp screws and front fork lower
clamp bolts.
• Remove the front forks.
• Separate the front fork cap bolt from the front fork.
• Compress the front fork spring with the special tool A and
insert the special tool B between the lock-nut and the spacer.
 09940-94930: Front fork spacer holder A
09940-94922: Stopper plate B
8-13
8-14
CHASSIS
• Remove the front fork cap bolt from the inner rod by loosening
the lock nut.
• Compress the fork spring with the special tool and remove the
special tool.
• Remove the spacer 3 and spring 4.
• Invert the front fork and stroke the inner rod several times to
let out fork oil.
• Under the inverted condition of front fork, drain oil completely
by holding the fork for a while.
• Remove the damper rod bolt with the special tool.
 09940-30221: Front fork assembling tool
• Remove the inner rod/damper rod (cartridge) 5.

Do not disassemble the inner rod/damper rod (cartridge).
CHASSIS
• Extract the outer tube from the inner tube.
NOTE:
Be careful not to damage the “ANTI-FRICTION” metals.
• Remove the dust seal 6.
• Remove the oil seal stopper ring 7.
• Remove the oil seal 8 with the special tool.
 09913-50121: Oil seal remover

The removed oil seal must be replaced with a new one.
• Remove the oil seal retainer 9.
8-15
8-16
CHASSIS
INSPECTION
INNER AND OUTER TUBES
• Inspect the inner tube outer surface and outer tube inner surface for scratches.
• Inspect the “ANTI-FRICTION” metal surfaces for scratches.
• If any defects are found, replace them with a new one.

Do not remove the “ANTI-FRICTION” metal A and B.
FORK SPRING
Measure the fork spring free length.
If it is shorter than the service limit, replace it with a new one.
Upper side
 Front fork spring free length:
Service Limit: 372 mm (14.6 in)
Lower side
DAMPER ROD
Move the inner rod by hand to examine it for smoothness.
If any defects are found, replace inner rod/damper rod (cartridge) with a new one.
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.
1 Dust seal
2 Oil seal stopper ring
3 Oil seal
4 Oil seal retainer

* When installing the oil seal to outer tube, be careful
not to damage the oil seal lip.
* Do not use solvents for washing to prevent oil seal
damage.
* Apply fork oil to the Anti-friction metals and lip of the
oil seal.
* Make sure that the oil seal stopper ring has been fitted securely.
• Insert the inner tube into the outer tube and fit the oil seal and
dust seal with the special tool.
 09940-52861: Front fork oil seal installer
NOTE:
Stamped mark on the oil seal should face outside.
DAMPER ROD BOLT
• Insert the inner rod/damper rod (cartridge) into the inner tube
with the gasket 1 fitted, apply the damper rod bolt 2.
• Apply THREAD LOCK to the damper rod bolt.
 99000-32050: THREAD LOCK “1342” (USA)
 99000-32110: THREAD LOCK SUPER “1322” (Others)

Replace the gasket with a new one.
(USA)
(Others)
8-17
8-18
CHASSIS
• Tighten the damper rod bolt to the specified torque, using the
special tool.
 09940-30221: Front fork assembling tool
 Caliper rod bolt: 39 N·m (3.9 kgf-m, 28.0 lb-ft)
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.
 Capacity (each leg): 490 ml (16.6/17.3 US/lmp oz)
 99000-99044-L01: SUZUKI FORK OIL L01
or an equivalent fork oil
• Move the inner rod slowly with the special tool ten times and
more until no more bubbles come out from the oil.
 09940-52841: Inner rod holder
NOTE:
Refill front fork oil up to the top of the outer tube so that bubbles
are visible while bleeding air.
• Refill specified front fork oil up to the top level of the outer
tube again. Move the outer tube up and down several strokes
until no more bubbles come out from the oil.
• Keep the front fork vertically and wait 5 – 6 minutes.
NOTE:
* Always keep oil level over the cartridge top end, or air may
enter the cartridge during this procedure.
* Take extreme care so as to pump out air completely.
• Hold the front fork vertically and adjust fork oil level with the
special tool.
NOTE:
When adjusting the fork oil level, compress the outer tube fully
without the fork spring.
 Fork oil level: 153 mm (6.02 in)
 09943-74111: Front fork oil level gauge
CHASSIS
FORK SPRING
• Install the fork spring as shown in the illustration.
Upper side
Lower side
• Install the spring 1 and spacer 2.
FRONT FORK CAP BOLT
• Pull up the inner rod with the special tool A.
• Compress the spring with the special tool B and then insert
the special tool C between the lock-nut and the spacer.
 09940-52841: Inner rod holder A
09940-94930: Front fork spacer holder B
09940-94922: Stopper plate C
• Slowly turn the cap bolt 1 until the inner rod is lightly seated.
• Hold the cap bolt 1 and tighten the lock-nut 2 to the specified torque.
 Inner rod lock-nut: 15 N·m (1.5 kgf-m, 11.0 lb-ft)
• Remove the special tools.
• Fit the O-ring to the front fork cap bolt and apply grease.
 99000-25010: SUZUKI SUPER GREASE “A”

Use a new O-ring to prevent oil leakage.
8-19
8-20
CHASSIS
• Install the front fork to the steering stem, turn signal clamps
(10-22 and -23) and steering stem upper bracket.
• Align the upper surface of the outer tube with the upper surface of the steering stem upper bracket.
• After loosening the front fork upper clamp bolts 4 slightly,
tighten the front fork cap bolt 3 to the specified torque.
 Front fork cap bolt 3: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the front fork upper clamp bolts 4 to the specified
torque.
 Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Tighten the turn signal light clamp bolts 5.
• Tighten the front lower clamp bolts 6 to the specified torque.
 Front fork lower clamp bolt: 33 N·m (3.3 kgf-m, 24.0 lb-ft)
• Remount the front wheel. (8-10 to -11)
CHASSIS
HANDLEBAR
CONSTRUCTION
D
FW
1 Handlebars
2 Handlebar balancer
3 Left handle grip
4 Left handle switch
5 Right handle grip
6 Right handle switch
8-21
8-22
CHASSIS
REMOVAL AND DISASSEMBLY
•
•
•
•
Remove the brake master cylinder 1. (8-57)
Remove the right handle switch 2.
Remove the handle balancer 3.
Remove the throttle grip 4.
•
•
•
•
Remove the left rear view mirror 5.
Disconnect the clutch lever position switch lead wires 6.
Loosen the clutch lever holder bolt 7.
Remove the left handlebar balancer 8 and the left handlebar
switch 9.
• Remove the handlebar clamp bolt caps, handlebar clamp
bolts and handlebar clamps.
• Remove the speedometer by removing the speedometer
mounting bolts.
• Remove the handlebar.
REASSEMBLY AND REMOUNTING
Reassemble and remount the handlebar in the reverse order of
removal and disassembly. Pay attention to the following points:
• Install the handlebar.
• Install the speedometer.
• Tighten the speedometer mounting bolts.
CHASSIS
• Install the handlebars with the punch mark A aligned with the
handlebar clamp as shown.
• First, tighten the handlebar clamp bolts 1 to the half of specified torque, and then tighten the handlebar clamp bolts 1 and
2 to the specified torque.
Forward
 Handlebar set bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Install the handlebar set bolt caps.
Clearance
• Apply the SUZUKI SUPER GREASE “A” to the throttle cables
and their holder.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• When remounting the right and left handle switches, engage
the stopper with the handlebar hole.
• Install the front brake master cylinder. (8-60)
• Install the clutch lever holder with the punch mark B aligned
with the clutch lever holder clamp as shown.
 Clutch lever holder clamp bolt:
10 N·m (1.0 kgf-m, 7.3 lb-ft)
• Adjust the throttle cable play. (2-14)
Punch mark
8-23
8-24
CHASSIS
STEERING
CONSTRUCTION
1
2
3
4
5
Handlebar set bolt cap
Handlebar clamp/holder
Steering stem upper bracket
Steering stem nut
Dust seal
6
7
8
A
B
Steering stem upper bearing
Steering stem lower bearing
Steering stem
Handlebar set bolt
Steering stem head nut
C Front fork upper clamp bolt
D Handlebar holder nut
E Front fork lower clamp bolt

ITEM
A
B
C
N·m
23
90
23
kgf-m
2.3
9.0
2.3
lb-ft
16.5
65.5
16.5
ITEM
D
E
N·m
54
33
kgf-m
5.4
3.3
lb-ft
39.0
24.0
CHASSIS
REMOVAL AND DISASSEMBLY
•
•
•
•
Remove the front forks. (8-13)
Remove the brake hose union bolt 1. (8-57)
Disconnect the clamps.
Remove the handlebar. (8-22)
• Remove the steering stem head nut 2 and washer.
• Remove the steering stem upper bracket 3.
• Remove the speed sensor lead wire coupler. (9-31)
• Remove the cable guide 4.
• Remove the headlight mounting bolts.
• Remove the brake hose guide.
• Remove the brake hose and speed sensor lead wire.
8-25
8-26
CHASSIS
• Remove the steering stem nut with the special tool.
 09940-14911: Steering stem nut wrench
• Remove the steering stem lower bracket.
NOTE:
Hold the steering stem lower bracket to prevent it from falling.
• Remove the dust seal 5, steering stem upper bearing inner
race 6 and bearing 7.
• Remove the steering stem lower bearing 8.
• Remove the handlebar holders 9 from the steering stem
upper bracket.
• Remove the handlebar bushes with the proper tool.
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.

The removed bearing outer race must be replaced with
a new one.
• Drive out the steering stem bearing outer races (upper and
lower) using the steel rod.

The removed bearing outer race must be replaced with
a new one.
REASSEMBLY AND REMOUNTING
Reassemble and remount the steering stem in the reverse order
of removal and disassembly. Pay attention to the following
points:
OUTER RACE
• Press in the upper and lower bearing outer races with the
special tools.
 09941-34513: Steering outer race installer set
INNER RACE
• Press in the lower bearing inner race with the special tool.
 09941-74911: Steering bearing installer
8-27
8-28
CHASSIS
BEARING
• Apply SUZUKI SUPER GREASE “A” 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.
STEERING STEM NUT
• Install the dust seal.
• Install the steering stem.
• Install the steering stem nut as shown.
NOTE:
The flange side A of the steering stem must face down.
• Tighten the steering stem nut to the specified torque with the
special tool.
 09940-14911: Steering stem nut wrench
 Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
• Turn the steering stem lower bracket about five or six times to
the left and right so that the angular ball bearings will be
seated properly.
• Loosen the stem nut by 1/4 – 1/2 turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
1/4 – 1/2 turn
CHASSIS
HANDLEBAR HOLDER
• Install the handlebar holders and related parts to the steering
stem head.
• Tighten the handlebar holder nuts to the specified torque.
 Handlebar holder nut: 54 N·m (5.4 kgf-m, 39.0 lb-ft)
FRONT FORK AND STEERING STEM UPPER BRACKET
• Install the steering stem upper bracket, washer and steering
stem head nut.
• Install the front forks. (8-20)
• Tighten the steering stem head nut 1 to the specified torque.
 Steering stem head nut 1: 90 N·m (9.0 kgf-m, 65.0 lb-ft)
NOTE:
Rout the brake hose, throttle cables and handlebar switch lead
wires, before installing the front forks. (10-15, -18 and -21)
• Speed sensor lead wire routing. (10-22)
• Install the handlebar. (8-22 to -23)
• Install the front wheel. (8-10 to -11)
8-29
8-30
CHASSIS
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 (0.8 – 1.2 in).
• Check to make sure that the cables and wire harnesses are
properly routed.
• With the front wheel in the straight ahead state, hitch the
spring scale (special tool) on one handlebar grip end as
shown in the figure and read the graduation when the handlebar starts moving. Do the same on the other grip end.
 Initial force: 200 – 500 grams
 09940-92720: Spring scale
• If the initial force read on the scale when the handlebar starts
turning is either too heavy or too light, adjust it till it satisfies
the specification.
1) First, loosen the front fork upper clamp bolts, handlebar clamp
bolts, steering stem head nut and steering stem lock-nut, and
then adjust the steering stem nut by loosening or tightening it.
2) Tighten the steering stem lock-nut, stem head nut, handlebar
clamp bolts and front fork upper clamp bolts to the specified
torque and re-check the initial force with the spring scale
according to the previously described procedure.
3) If the initial force is found within the specified range, adjustment has been completed.
NOTE:
Hold the front fork legs, move them back and forth and make
sure that the steering is not loose.
CHASSIS
REAR WHEEL
CONSTRUCTION
1
2
3
4
5
6
7
8
9
0
A
B
C
D
Rear axle
Spacer (LH)
Lock washer
Driven joint stopper
Driven joint
Damper
O-ring

ITEM
A
B
C
N·m
10
10
65
kgf-m
1.0
1.0
6.5
lb-ft
7.0
7.0
47.0
Bearing (LH)
Spacer (RH)
Bearing (RH)
Rear wheel
Brake shoe
Brake camshaft
Brake panel
E
F
A
B
C
Brake cam lever
Cotter pin (For E-03, 28, 33)
Driven joint stopper bolt
Rear brake cam lever bolt
Rear axle nut
8-31
8-32
CHASSIS
Left
Right
For E-03, 28, 33
A
B
C
D
Rear axle nut
Brake cam lever nut
Rear torque link nut (F)
Rear torque link nut (R)

ITEM
A
B
N·m
65
10
kgf-m
6.5
1.0
lb-ft
47.0
7.0
ITEM
C
D
N·m
35
25
kgf-m
3.5
2.5
lb-ft
25.5
18.0
CHASSIS
REMOVAL
• Raise the rear wheel off the ground and support the motorcycle with a jack or wooden block.
• Remove the rear brake rod 1.
• Remove the torque link rod 2.
• Remove the left frame cover. (8-3)
• Remove the left frame lower cover 3.
: Hooked part
• Remove the rear swingarm left cover mounting bolts.
• Remove the rear swingarm left cover.
8-33
8-34
CHASSIS
• Remove the cotter pin 4. (For E-03, 28, 33)
• Remove the axle nut 5 and draw out the rear axle.
NOTE:
The rear fender removal is not necessary when the rear part of
motorcycle can be lifted high enough to take the rear wheel out
smoothly.

Do not operate the brake pedal while removing the
rear wheel.
DISASSEMBLY
• Flatten the lock washers.
• Remove the fitting bolts, washers and plates.
• Pull off the driven joint 1.
• Remove the O-ring 2.
• Remove the dampers with a screw driver.

The removed O-ring must be replaced with a new one.
CHASSIS
INSPECTION AND DISASSEMBLY
WHEEL (8-66)
TIRE (2-23 and 8-66)
WHEEL BEARINGS
Inspect the play of the wheel bearings by finger while they are in
the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is anything
unusual.
• Remove the wheel bearings by with the special tool.
 09921-20240: Bearing remover set (17 mm)

The removed bearings should be replaced with new
ones.
REAR AXLE
Using a dial gauge, check the rear axle for runout.
If the runout exceeds the limit, replace the rear axle.
 Axle shaft runout
Service Limit: 0.25 mm (0.010 in)
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
WHEEL DAMPER
Inspect the dampers for wear and damage.
Replace the dampers if there is anything unusual.
8-35
8-36
CHASSIS
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel in the reverse order of
removal and disassembly. Pay attention to the following points:
WHEEL BEARING
• Apply grease to the bearings before installation.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the wheel bearings with the special tool.
 09941-34513: Bearing installer set

* First, install the right wheel bearing, then install the
left wheel bearings.
* The sealed cover on the bearing must face out.
Left
Right
Left
Right
Clearance
Spacer
WHEEL DAMPER
• Install the dampers.
NOTE:
If soap water is applied around the damper, it makes the job
easier.
CHASSIS
DRIVEN JOINT
• Install the driven joint 1.
NOTE:
Apply grease to the O-ring and the final gear spline before
installing the driven joint.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Apply THREAD LOCK SUPER to the thread of driven joint
stopper bolts.
 99000-32030: THREAD LOCK SUPER “1303”
• Tighten the driven joint stopper bolts to the specified torque.
 Driven joint stopper bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Bend up the washer to lock the bolts.
REAR WHEEL
• Install the spacer 1.
• Apply grease to the final gear spline before installing the rear
wheel.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Remount the rear wheel spacer and rear axle.
• Install the washer and rear axle nut.
NOTE:
Refer to the page 8-31 for the spacer positioning.
• Install the torque link rod 2.
• Tighten the rear axle nut and torque link bolts and nuts to the
specified torque.
 Rear axle nut: 65 N·m (6.5 kgf-m, 47 lb-ft)
Torque link nut (Front): 35 N·m (3.5 kgf-m, 25.5 lb-ft)
(Rear) : 25 N·m (2.5 kgf-m, 18.0 lb-ft)
NOTE:
After remounting the rear wheel, check for proper brake operation. (2-21)
8-37
8-38
CHASSIS
REAR SUSPENSION
CONSTRUCTION
1
2
3
4
5
Rear shock absorber
Rear cushion rod
Spacer
Rear cushion lever bearing
Rear cushion lever
6
7
8
9
A
Swingarm pivot bearing
Swingarm bearing
Swingarm
Boot
Rear shock absorber mounting nut
B
C
D
E
F
Rear cushion rod mounting nut
Rear cushion lever mounting nut
Rear swingarm pivot bolt lock nut
Rear swingarm pivot bolt (Right)
Rear swingarm pivot bolt (Left)

ITEM
A
B
N·m
50
78
kgf-m
5.0
7.8
lb-ft
36.0
56.5
ITEM
C
D
N·m
78
100
kgf-m
7.8
10.0
lb-ft
56.5
72.5
ITEM
E
F
N·m
9.5
100
kgf-m
0.95
10.0
lb-ft
7.0
72.5
CHASSIS
Left
Right
50 N.m
5.0 kgf-m
43.5 lb-ft
(
1 mm
)
1 mm
78 N.m
7.8 kgf-m
56.5 lb-ft
(
1 mm
1 mm
100 N.m
10.0 kgf-m
72.5 lb-ft
(
)
100 N.m
10.0 kgf-m
72.5 lb-ft
(
)
9.5 N.m
0.95 kgf-m
7.0 lb-ft
(
)
)
8-39
8-40
CHASSIS
REMOVAL
• Remove the rear wheel. (8-33)
• Remove the final gear case with propeller shaft.
• Remove the fuel tank. (6-3)
• Remove the battery 1 and disconnect the coupler 2.
• Remove the set mounting bracket 3.
• Disconnect the starter motor lead wire 4 and starter relay
coupler 5.
• Remove the battery case 6.
• Remove the frame covers (L & R). (8-3 to -4)
• Remove the exhaust pipesand mufflers. (3-6)
• Remove the secondary gear case cover 7.
CHASSIS
• Remove the right frame lower cover 8, clutch rear cover 9.
: Hooked part
• Remove the tool box cover 0.
• Remove the tool box.
• Remove the fuse box and relay stay.
• Remove the cushion lever mounting bolt and nut and cushion
rods A (L & R).
8-41
8-42
CHASSIS
• Remove the shock absorber B.
• Remove the right side swingarm pivot bolt lock nut C.
• Remove the left and right side swingarm pivot bolts D.
NOTE:
Slightly loosen the cushion rod mounting nuts and the shock
absorber lower mounting nut before removing the swingarm to
facilitate later disassembly.
• Remove the rear suspension assembly.
• Remove the tapered roller bearings.
• Remove the cushion lever.
CHASSIS
INSPECTION AND DISASSEMBLY
SPACER
• Remove spacer from swingarm.
• Remove the spacers from the cushion lever.
• Inspect the spacers for any flaws or other damage. If any
defects are found, replace the spacers with new ones.
SWINGARM BEARING
Insert the spacer into swingarm cushion rod upper side bearing
and check the play to move the spacer up and down.
If excessive play is noted, replace the bearing with a new one.
Inspect the swingarm pivot bearing, its race and dust seal for
wear or damage. If any defects are found, replace the bearing
with a new one.
• Remove the swingarm pivot right side bearing plate 1 and
bearing races 2 by using a suitable bar and so on.
NOTE:
The swingarm pivot right side bearing and its plate are available
as one component.
• Remove the swingarm pivot bearing races by with the special
tool.
 09921-20240: Bearing remover set (30 mm)

The removed bearings must be replaced with new
ones.
• Remove the swingarm cushion rod upper side bearings by
with the special tool.
 09921-20240: Bearing remover set (17 mm)

The removed bearings must be replaced with new
ones.
8-43
8-44
CHASSIS
CUSHION LEVER BEARING
Insert the spacer into bearing and check the play to move the
spacer up and down. If an excessive play is noted, replace the
bearing with a new ones.
• Remove the cushion rod lower side bearings by with the special tool.
 09921-20240: Bearing remover set (17 mm)

The removed bearings must be replaced with new
ones.
• Remove the cushion lever mounting bearing 2 and shock
absorber lower side bearing 3 by using the special tool.
 09913-70210: Bearing installer set

The removed bearings must be replaced with new
ones.
SHOCK ABSORBER
Inspect the shock absorber body and bush for damage and oil
leakage. If any defects are found, replace the shock absorber
with a new one.

Do not attempt to disassemble the rear shock
absorber unit. It is unserviceable.
CHASSIS
REASSEMBLY
Reassemble the swingarm and shock absorber in the reverse
order of disassembly and removal, and pay attention to the following points:
SWINGARM BEARING
• Install the swingarm pivot bearing races by with the special
tool.
 09913-70210: Bearing installer set (40 mm)
NOTE:
The swingarm pivot bearing race with plate is positioned right
side.
• Install the swingarm cushion rod upper side bearings with the
special tool. (8-39)
 09924-84510: Bearing installer set
NOTE:
When reinstalling the bearings, stamped mark of bearing must
face outside.
CUSHION LEVER BEARING
• Install the bearings into the cushion lever by with the special
tool. (8-39)
 09924-84521: Bearing installer
NOTE:
When installing the bearings, stamped mark of bearing must
face outside.
• Apply grease to the spacers and bearings.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
8-45
8-46
CHASSIS
• Tighten the cushion lever to the specified torque.
 Shock absorber mounting nut:
50 N·m (5.0 kgf-m, 36.0 lb-ft)
REMOUNTING
Remount the swingarm and shock absorber in the reverse order
of disassembly and removal, and pay attention to the following
points.
SWINGARM
• Before installing the swingarm, install the boot and the universal joint.
NOTE:
Make sure that the “UP” mark A on the boot faces up.
• Install the swingarm assembly, its pivot bearings and bolts
(1, 2).
NOTE:
Apply grease to the swingarm pivot bearings.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
1: For left side swingarm pivot bolt
2: For right side swingarm pivot bolt
• Tighten the left side swingarm pivot bolt 1 to the specified
torque.
 Swingarm pivot bolt (left side):
100 N·m (10.0 kgf-m, 72.5 lb-ft)
NOTE:
Before tightening the left side swingarm pivot bolt 1, loosen the
right side one 2.
CHASSIS
• Tighten the right side swingarm pivot bolt 2 to the specified
torque.
 Swingarm pivot bolt (right side):
9.5 N·m (0.95 kgf-m, 7.0 lb-ft)
• Tighten the swingarm pivot lock nut 3 to the specified torque.
 Swingarm pivot lock nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
NOTE:
After tightening the swingarm pivot lock nut, be sure to check the
swingarm operation.
SHOCK ABSORBER AND CUSHION LEVER
• Assemble the shock absorber and cushion rods onto the
swingarm. (8-39)
• Tighten the shock absorber upper mounting nut 1 to the
specified torque.
 Shock absorber mounting nut:
50 N·m (5.0 kgf-m, 36.0 lb-ft)
• Tighten the cushion rod nuts 2 to the specified torque.
 Cushion rod mounting nut: 78 N·m (7.8 kgf-m, 56.5 lb-ft)
NOTE:
The stamped marks A on the cushion rod should be face outside.
• Tighten the cushion lever mounting nut 3 to the specified
torque.
 Cushion lever mounting nut:
78 N·m (7.8 kgf-m, 56.5 lb-ft)
FINAL GEAR CASE
• Install the plate to the final gear case 1. Apply SUZUKI
BOND to the mating surface of swingarm and final gear case.
 99000-31140: SUZUKI BOND ‘‘1207B”

When installing the plate 1, align the lug A of the
plate 1 to the bearing retainer groove.
8-47
8-48
CHASSIS
• Apply Lithium Base Molybdenum grease (NLGI #2) to the propeller shaft spline.
NOTE:
To install the final gear case easily, move the dust boot front and
the universal joint back. Engage the universal joint to the propeller shaft first and then engage it to the secondary driven bevel
gear shaft.
• Tighten the final gear case mounting nuts to the specified
torque.
 Final gear case nut: 40 N·m (4.0 kgf-m, 29.0 lb-ft)
• Install the rear wheel. (8-37)
• Install the exhaust pipes and mufflers. (3-10)
CHASSIS
8-49
REAR SHOCK ABSORBER DISPOSAL

The rear shock 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
• Mark the drill hole with a center punch.
10 mm
• Cover the rear shock absorber with a transparent plastic bag
1.
• Hold the rear shock absorber 2 with a vice.
• Mark a hole with a 3 mm drill.

Wear eye protection to protect your eyes from
released gas and metal chips.
SUSPENSION SETTING
After installing the rear suspension, adjust the spring pre-load as
follows.
Spring pre-load adjuster
3rd
Mark the
drill hole.
8-50
CHASSIS
FRONT BRAKE
CONSTRUCTION
1
2
3
4
5
6
7
8
9
0
Cap
Diaphragm
Master cylinder
Piston set
Brake hose

ITEM
A
B
C
N·m
10
23
39
kgf-m
1.0
2.3
3.9
lb-ft
7.0
16.5
28
Caliper holder
Caliper
Pad set
Piston
Piston and dust seal
A
A
B
C
Insulator
Master cylinder mounting bolt
Brake hose union bolt
Brake caliper mounting bolt
CHASSIS
8-51

* The brake system is filled with an glycol-based brake fluid, which is classified DOT 4. Do not
use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
* Do not use any brake fluid taken from old, used, or unsealed containers.
* Do not reuse brake fluid left over from the last servicing or which has been stored for a long
period of time.
* When storing brake fluid, be sure to seal the container completely and keep it out of the reach
of children.
* When replenishing brake fluid, be sure not to get any dust or other foreign materials in the
fluid.
* When washing brake components, always use new brake fluid. Do not use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the brake disc with high-quality brake cleaner or a neutral detergent.

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber material,
etc.
8-52
CHASSIS
BRAKE PAD REPLACEMENT
• Remove the reflex reflector 1. (For E-03, 28, 33)
• Remove the brake caliper by removing the brake caliper
mounting bolts.
• Remove the pin 2.
• Remove the pad pin 3.
• Remove the brake pads 4.

* Do not operate the brake lever during or after brake
pad removal.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
• Install the new brake pads.
• Tighten the brake caliper mounting bolts to the specified
torque.
 Brake caliper mounting bolts: 39 N·m (3.9 kgf-m, 28 lb-ft)
• Install the reflex reflector 1. (For E-03, 28, 33)
NOTE:
After replacing the brake pads, pump the brake lever a few times
to check for proper brake operation and then check the brake
fluid level.
CHASSIS
BRAKE FLUID REPLACEMENT
• Place the motorcycle on a level surface and keep the handlebar straight.
• Remove the master cylinder reservoir cap and diaphragm.
• Remove as much old brake fluid as possible.
• Fill the reservoir with new brake fluid.
 Specification and classification: DOT 4
• Connect a clear hose to the air bleeder valve and insert the
other end of the hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until
the old brake fluid is completely out of the brake system.
• Close the air bleeder valve and disconnect the clear hose. Fill
the reservoir with new brake fluid to the upper end of the
inspection window.

Bleed air from the brake system. (2-22)
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
• Remove the reflex reflector 1. (For E-03, 28, 33)
• Disconnect the brake hose from the brake caliper by removing the brake hose union bolt 2 and allow the brake fluid to
drain into a suitable receptacle.
• Remove the brake caliper by removing the brake caliper
mounting bolts.

* Do not reuse the brake fluid left over from the last
servicing or which has been stored for a long period
of time, otherwise serious damage to the brake system will result.
* Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and oil leakage.
8-53
8-54
CHASSIS
• Remove the brake pads. (8-52)
• Remove the insulator 3.
• Remove the brake caliper holder 4.
• Remove the spring 5.
• Place a rag over the brake caliper pistons to prevent them
from popping out, and then force out the pistons using compressed air.

Do not use extremely high pressure to remove the
brake caliper pistons, otherwise damage to the pistons will result.
• Remove the dust seals 6 and piston seals 7.

Do not reuse the dust seals and piston seals to prevent fluid leakage.
BRAKE CALIPER INSPECTION
BRAKE CALIPER
Inspect each brake caliper cylinder wall for nicks, scratches or
other damage. If any damages are found, replace the brake caliper with a new one.
BRAKE CALIPER PISTONS
Inspect the brake caliper pistons for any scratches or other damage. If any damages are found, replace the piston with a new
one.
CHASSIS
RUBBER PARTS
Replace the removed rubber parts with new ones.
BRAKE CALIPER REASSEMBLY AND
REMOUNTING
Reassemble and remount the brake caliper in the reverse order
of removal and disassembly. Pay special attention to the following points:
• Wash the caliper bores and pistons with the specified brake
fluid. Thoroughly wash the dust seal grooves and piston seal
grooves.
 Specification and classification: DOT 4

* Wash the brake caliper components with new brake
fluid before reassembly.
* Do not wipe the brake fluid off after washing the
components.
* When washing the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine, etc.
* Replace the removed piston seals and dust seals
with new ones.
* Apply brake fluid to all of the seals, brake caliper
bores and pistons before reassembly.
PISTON SEALS
• Install the piston seals 1 and dust seals 2 as shown.
8-55
8-56
CHASSIS
INSULATORS
• Apply SUZUKI SILICONE GREASE to the insulators.
 99000-25100: SUZUKI SILICONE GREASE
BRAKE CALIPER HOLDER
• Apply SUZUKI SILICONE GREASE to the brake caliper holder.
 99000-25100: SUZUKI SILICONE GREASE
• Tighten the brake caliper mounting bolts 1, and brake hose
union bolt 2 to the specified torque.
 Brake caliper mounting bolt: 39 N·m (3.9 kgf-m, 28 lb-ft)
Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• For assembly procedure of brake hose: (10-21)
• Install the reflex reflector 3. (For E-03, 28, 33)
NOTE:
Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper.

Bleed air from the system after reassembling the
brake caliper. (2-22)
BRAKE DISC INSPECTION
Check the brake disc for cracks or damage and measure the
thickness using the micrometer. If any damages are found or if
the thickness is less than the service limit, replace the brake disc
with a new one.
 09900-20205: Micrometer (0 – 25 mm)
 Brake disc thickness
Service Limit: 4.5 mm (0.098 in)
CHASSIS
Measure the runout using the dial gauge. If the runout exceeds
the service limit, replace the brake disc with a new one.
 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
 Brake disc runout
Service Limit: 0.3 mm (0.012 in)
• If either measurement exceeds the service limit, replace the
brake disc with a new one. (8-7 and -10)
MASTER CYLINDER REMOVAL AND DISASSEMBLY
• Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake
hose union bolt and disconnect the brake hose.

Immediately wipe off any brake fluid contacting any
part of the motorcycle. The brake fluid reacts chemically with paint, plastics, rubber materials, etc., and
will damage them severely.
• Disconnect the front brake light switch lead wire 1.
• Remove the right rear view mirror 2 and master cylinder
assembly 3.
• Remove the brake lever 4 and front brake light switch 5.
8-57
8-58
CHASSIS
• Pull the dust boot 6 out and remove the snap ring 7.
• Remove the piston assembly.
MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or damage. If
any damages are found, replace the master cylinder with a new
one.
PISTON AND RUBBER PARTS
Inspect the piston surface, primary/secondary cup, and dust
boot for any scratches, wear or damage. If any damages are
found, replace the piston set with a new one.
CHASSIS
MASTER CYLINDER REASSEMBLY AND
REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay special attention to the
following points:

* Wash the master cylinder components with new
brake fluid before reassembly.
* Do not wipe the brake fluid off after washing the
components.
* When washing the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine, etc.
* Apply brake fluid to the master cylinder bore and all
of the master cylinder components before reassembly.
 Specification and classification: DOT 4
• When installing the brake light switch, align the projection on
the switch with the hole in the master cylinder.
• Apply SUZUKI SUPER GREASE “A” to the bolt.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
8-59
8-60
CHASSIS
• When remounting the master cylinder onto the handlebars,
align the master cylinder holder’s mating surface 1 with the
punch mark 2 on the handlebars and tighten the upper clamp
bolt first.
 Master cylinder mount bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Master cylinder
Handlebar
Upper
clamp
bolt
Punched
mark
Clearance
• Tighten the brake hose union bolt to the specified torque.
• For assembly procedure of brake hose. (10-21)
 Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Bleed air from the brake system after installing the
master cylinder. (2-22)
CHASSIS
REAR BRAKE
CONSTRUCTION
1
2
3
4
5
A
B
Brake shoe
Brake camshaft
Brake panel
Brake cam lever
Cotter pin (For E-03, 28, 33)
Rear axle nut
Rear brake cam lever bolt

ITEM
A
B
N·m
65
10
kgf-m
6.5
1.0
lb-ft
47.0
7.0
8-61
8-62
CHASSIS
REMOVAL AND DISASSEMBLY
• Remove the rear wheel. (8-33)
• Remove the rear brake panel 1.
• Remove the brake shoes 2.
• Remove the rear brake cam lever 3 by removing bolt.
• Remove the washer 4, spring 5 and O-ring 6.
• Remove the rear brake cam 7.
INSPECTION
BRAKE DRUM
Inspect the brake drum and measure the brake drum I.D. to
determine the extent of wear. Replace the brake drum if the
measurement exceeds the service limit. The value of this limit is
indicated inside the brake drum.
 09900-20102: Vernier calipers
 Brake drum I.D.
Service Limit: 180.7 mm
CHASSIS
BRAKE SHOES
Check the brake shoe wear (2-21) and decide whether it
should be replaced or not.

Replace the brake shoes as a set, otherwise braking
performance will be adversely affected.
REASSEMBLY AND REMOUNTING
BRAKE CAMSHAFT
• When installing the brake camshaft, apply SUZUKI SUPER
GREASE “A” to the camshaft and cam face.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the brake shoes with spring hooks faced inside.

Be careful not to apply too much grease to the cam
and pin. If grease gets on the lining, brake slippage
will result.
BRAKE CAM LEVER
• Install the new O-ring and washer.
• Install the brake cam lever to the brake camshaft as shown.
• Tighten the brake cam lever bolt to the specified torque.
 Brake cam lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
• Install the rear wheel. (8-37)
• Adjust the rear brake pedal free travel. (2-21)
31
8-63
8-64
CHASSIS
REAR BRAKE ROD
REMOVAL AND DISASSEMBLY
• Remove the exhaust pipes and mufflers assembly. (3-6)
• Remove the right frame lower cover 1, clutch rear cover 2.
: Hooked part
•
•
•
•
Remove the rear brake switch spring 3.
Remove the rear brake pedal 4.
Remove the cotter pin 5.
Remove the rear brake pedal shaft 6.
• Remove the return spring.
• Remove the rear brake adjust nut, spring and washer.
• Remove the rear brake link 7.
CHASSIS
• Remove the cotter pins.
REASSEMBLY REMOUNTING
Reassemble and remount the rear brake rod in the reverse
order of removal and disassembly. Pay attention to the following
points.
• Apply grease to the rear brake link pivot bolt and tighten it to
the specified torque.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 Rear brake link pivot bolt: 29 N·m (2.9 kgf-m, 21 lb-ft)
• Apply grease to the rear brake pedal shaft.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Tighten the rear brake pedal mount bolt to the specified
torque.
 Rear brake pedal mount bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
NOTE:
* When remounting the rear brake pedal onto the rear brake
pedal shaft, align the rear brake pedal mounting surface A
with the punch mark B.
* After remounting the rear wheel, check for proper brake operation. (2-21)
• Install the exhaust pipes and mufflers. (3-10)
8-65
8-66
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 supplied by
the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection, mark
the tire with a chalk to indicate the tire position relative to the
valve position.
Even though the tire is refitted to the original position after
repairing puncture, the tire may have to be balanced again since
such a repair can cause imbalance.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following:
• Distortion and crack
• Any flaws and scratches at the bead seating area.
• Wheel rim runout (8-8)
TIRE
Tire must be checked for the following points:
• Nick and rupture on side wall
• Tire tread depth (2-23)
• Tread separation
• Abnormal, uneven wear on tread
• Surface damage on bead
• Localized tread wear due to skidding (Flat spot)
• Abnormal condition of inner liner
CHASSIS
VALVE INSPECTION
Inspect the valve after the tire is removed from the rim. Replace
the valve with a new one if the seal A rubber is peeling or has
damage.
NOTE:
If the external appearance of the valve shows no abnormal condition, removing of the valve is not necessary.
If the seal has abnormal deformation, replace the valve with a
new one.
Any dust or rust around the valve hole B must be cleaned off.
Then install the valve C in the rim.
NOTE:
To properly install the valve into the valve hole, apply a special
tire lubricant or neutral soapy liquid to the valve.

Be careful not to damage the lip C of valve.
8-67
8-68
CHASSIS
TIRE INSTALLATION
• Apply tire lubricant to the tire bead.
• When installing the tire onto the wheel, observe the following
points.

* Do not reuse the valve which has been once removed.
* Never use oil, grease or gasoline on the tire bead in
place of tire lubricant.
• When installing the tire, the arrow A on the side wall should
point to the direction of wheel rotation.
• Align the chalk mark put on the tire at the time of removal with
the valve position.
• For installation procedure of tire onto the wheel, follow the
instructions given by the tire changer manufacturer.
• Bounce the tire several times while rotating. This makes the
tire bead expand outward to contact the wheel, thereby facilitating air inflation.
• Inflate the tire.

* Do not inflate the tire to more than 400 kPa (4.0
kgf/cm², 57 psi). If inflated beyond this limit, the tire
can burst and possibly cause injury. Do not stand
directly over the tire while inflating.
* In the case of preset pressure air inflator, pay special
care for the set pressure adjustment.
CHASSIS
• In this condition, check the “rim line” B cast on the tire side
walls. The line must be equidistant from the wheel rim all
around. If the distance between the rim line and wheel rim
varies, this indicates that the bead is not properly seated. If
this is the case, deflate the tire completely and unseat the
bead for both sides. Coat the bead with lubricant and fit the
tire again.
• When the bead has been fitted properly, adjust the pressure
to specification.
• As necessary, adjust the tire balance.

Do not run with a repaired tire at a high speed.
 Cold inflation tire pressure
Solo riding
Dual riding
Front
200 kPa
(2.00 kgf/cm², 29 psi)
200 kPa
(2.00 kgf/cm², 29psi)
Rear
250 kPa
(2.50 kgf/cm², 36 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
BALANCER WEIGHT INSTALLATION
• When installing the balancer weights to the wheel, set the two
balancer weights A on both sides of wheel rim.

Weight difference between the two balancer weights
must be less than 10 g (0.02 lb).
8-69
ELECTRICAL SYSTEM
9-1
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING ..........................................................................9- 3
CONNECTOR..........................................................................................9- 3
COUPLER ...............................................................................................9- 3
CLAMP ....................................................................................................9- 3
FUSE .......................................................................................................9- 3
SEMI-CONDUCTOR EQUIPPED PART .................................................9- 4
BATTERY ................................................................................................9- 4
CONNECTING THE BATTERY...............................................................9- 4
WIRING PROCEDURE............................................................................9- 4
USING THE MULTI-CIRCUIT TESTER ..................................................9- 5
LOCATION OF ELECTRICAL COMPONENTS ...........................................9- 6
CHARGING SYSTEM ...................................................................................9- 8
TROUBLESHOOTING ............................................................................9- 8
INSPECTION ...........................................................................................9- 9
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM ........................................................................................................9-12
TROUBLESHOOTING ............................................................................9-12
STARTER MOTOR REMOVAL AND DISASSEMBLY...........................9-14
STARTER MOTOR INSPECTION...........................................................9-15
STARTER MOTOR REASSEMBLY........................................................9-15
STARTER RELAY INSPECTION............................................................9-16
SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ...........................................................................................9-17
IGNITION SYSTEM .......................................................................................9-20
TROUBLESHOOTING ............................................................................9-20
INSPECTION ...........................................................................................9-22
SPEEDOMETER AND PILOT LAMP BOX ..................................................9-25
DESCRIPTION ........................................................................................9-25
SPEEDOMETER REMOVAL AND DISASSEMBLY...............................9-26
PILOT LAMP BOX REMOVAL AND DISASSEMBLY............................9-28
INSPECTION ...........................................................................................9-29
LAMPS ..........................................................................................................9-33
HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT
AND TURN SIGNAL LIGHT....................................................................9-33
RELAYS ........................................................................................................9-35
TURN SIGNAL/SIDE-STAND RELAY ....................................................9-35
STARTER RELAY...................................................................................9-35
FUEL PUMP RELAY ...............................................................................9-35
9
9-2 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONTENTS
SWITCHES ................................................................................................... 9-35
BATTERY ..................................................................................................... 9-37
SPECIFICATIONS .................................................................................. 9-37
INITIAL CHARGING ............................................................................... 9-37
SERVICING............................................................................................. 9-39
RECHARGING OPERATION.................................................................. 9-39
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 breakage in its cover.
Click
COUPLER
Click
• With a lock type coupler, be sure to release the lock before
disconnecting and push it in fully till the lock works when connecting.
• When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or bent.
• Inspect each terminal for corrosion and contamination.
CLAMP
• Clamp the wire harness at such positions as indicated in
“WIRE HARNESS ROUTING”. (10-15 to -16)
• Bend the clamp properly so that the wire harness is clamped
securely.
• In clamping the wire harness, use care not to allow it to hang
down.
• Do not use wire or any other substitute for the band type
clamp.
FUSE
• When a fuse blows, always investigate the cause, correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
CORRECT
INCORRECT
9-3
9-4
ELECTRICAL SYSTEM
SEMI-CONDUCTOR EQUIPPED PART
• Be careful not to drop the part with a semi-conductor built in
such as a ECM.
• When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
BATTERY
• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water
replenishment).
• During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open
area.
• Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.
CONNECTING THE BATTERY
• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the - battery lead
wire, first.
• When connecting the battery lead wires, be sure to connect
the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the
battery terminals.
• Install the cover over the + battery terminal.
WIRING PROCEDURE
• Properly route the wire harness according to the “WIRE
ROUTING” section. (10-15 to -16)
INCORRECT
ELECTRICAL SYSTEM
USING THE MULTI-CIRCUIT TESTER
• Properly use the multi-circuit tester + and - probes.
Improper use can cause damage to the motorcycle and
tester.
• If the voltage and current values are not known, begin measuring in the highest range.
• When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF
position.
 09900-25008: Multi-circuit tester set

Before using the multi-circuit tester, read its instruction manual.
NOTE:
* When connecting the multi-circuit tester, use the needle
pointed probe to the back side of the lead wire coupler and
connect the probes of tester to them.
* Use the needle pointed probe to prevent the rubber of the
water proof coupler from damage.
 09900-25009: Needle pointed probe set
9-5
9-6
ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
1 IAP sensor (#2) (5-33)
2 IAP sensor (#1) (5-33)
3 Fuel injector (#1) (5-66)
4 ECM (Engine Control Module)
5 Speed sensor
6 Ignition coil (#2)
7 IAT sensor (5-47)
8 STP sensor (5-59)
9 STV actuator (5-56)
0 TP sensor (5-37)
A TO sensor (5-52)
B Starter motor
C Ignition switch
D Horn
E Cooling fan thermo-switch (7-9)
F Cooling fan (7-7)
G Rear brake switch
H Mode selection switch coupler
ELECTRICAL SYSTEM
1 Fuel level switch
2 Fuel pump (6-5)
3 Battery
4 ECT sensor (5-42)
5 Fuse box
6 Ignition coil (#1)
7 Fuel pump relay (6-6)
8 Fuel injector (#2) (5-66)
9 Starter relay/Main fuse
0 Turn signal/Side-stand relay
A Regulator/Rectifier
B Oil pressure switch
C Generator
D CKP sensor (5-30)
E GP switch (5-64)
F Side-stand switch
9-7
9-8
ELECTRICAL SYSTEM
CHARGING SYSTEM
Regulator/rectifier
IG.switch
Generator
SCR
TROUBLESHOOTING
Battery runs down quickly
Step 1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed?
YES
NO
Remove accessories.
Go to Step 2.
Step 2
1) Check the battery for current leaks. (9-9)
Is the battery for current leaks OK?
YES
NO
Go to Step 3.
• Short circuit of wire harness
• Faulty electrical equipment
Step 3
1) Measure the regulated voltage between the battery terminals. (9-10)
Is the regulated voltage OK?
YES
NO
• Faulty battery
• Abnormal driving condition
Go to Step 4.
Step 4
1) Measure the resistance of the generator coil. (9-10)
Is the resistance of generator coil OK?
YES
NO
Go to Step 5.
• Faulty generator coil
• Disconnected lead wires
Load
Battery
IC
ELECTRICAL SYSTEM
Step 5
1) Measure the generator no-load voltage. (9-11)
Is the generator no-load voltage OK?
YES
NO
Go to Step 6.
Faulty generator
Step 6
1) Inspect the regulator/rectifier. (9-11)
Is the regulator/rectifier OK?
YES
NO
Go to Step 7.
Faulty regulator/rectifier
Step 7
1) Inspect wirings.
Is the wirings OK?
YES
NO
Faulty battery
• Short circuit of wire harness
• Poor contact of couplers
Battery overcharges
• Faulty regulator/rectifier
• Faulty battery
• Poor contact of generator lead wire coupler
INSPECTION
BATTERY CURRENT LEAKAGE
• Remove the seat. (8-3)
• Turn the ignition switch to the OFF position.
• Disconnect the battery - lead wire.
Measure the current between - battery terminal and the - battery lead wire using the multi circuit tester. If the reading
exceeds the specified value, leakage is evident.
 Battery current (leak): Under 1 mA
 09900-25008: Multi circuit tester set
 Tester knob indication: Current (, 20 mA)
DCmA

* Because the current leak might be large, turn the
tester to high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position
when measuring current.
When checking for excessive current leakage, remove the couplers and connectors, one by one, so as to locate the position of
trouble.
Battery
9-9
9-10
ELECTRICAL SYSTEM
REGULATED VOLTAGE
• Remove the seat. (8-3)
• Start the engine and keep it running at 5 000 r/min. with lighting switch turned ON and dimmer switch turned HI position.
Measure the DC voltage between the + and - battery terminals using the multi circuit tester. If the voltage is not within the
specified value, inspect the generator and regulator/rectifier.
(9-10 and -11)
NOTE:
When making this test, be sure that the battery is in
fully-charged condition.
 Regulated voltage (Charging output):
13.5 – 15.0 V at 5 000 r/min
Battery
DCV
 09900-25008: Multi circuit tester set
 Tester knob indication: Voltage ()
GENERATOR COIL RESISTANCE
• Remove the tool box. (8-41)
• Disconnect the generator coupler.
Measure the resistance between the three lead wires.
If the resistance is out of specified value, replace the stator with
a new one. Also, check that the generator core is insulated properly.
 Generator coil resistance: 0.2 – 1.5 Ω (Yellow – Yellow)
∞ Ω (Yellow – Ground)
 09900-25008: Multi circuit tester set
 Tester knob indication: Resistance (Ω)
NOTE:
When making above test, it is not necessary to remove the generator.
Y
Y
Y
ELECTRICAL SYSTEM
GENERATOR NO-LOAD PERFORMANCE
• Disconnect the generator coupler. (9-10)
• Start the engine and keep it running at 5 000 r/min.
Using the multi circuit tester, measure the voltage between three
lead wires.
If the tester reads under the specified value, replace the generator with a new one.
9-11
Y
Y
Y
 Generator no-load performance:
More than 70 V at 5 000 r/min (When engine is cold)
 09900-25008: Multi circuit tester set
 Tester knob indication: Voltage (~)
REGULATOR/RECTIFIER
• Remove the secondary gear case cover. (8-40)
• Disconnect the regulator/rectifier couplers.
Measure the voltage between the lead wires using the multi circuit tester as indicated in the table below. If the voltage is not
within the specified value, replace the regulator/rectifier with a
new one.
 09900-25008: Multi circuit tester set
 Tester knob indication: Diode test ()
- Probe of tester to:
Unit: V
B/R1
B/R1
B/R2
B1
B2
B3
B/W1
B/W2
1.4
+ Probe of tester to:
B/R2
B1
B2
B3
0
0
B/W1
B2
B1
B/W2
B3
B/W1
B/R1
B/R2
0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2
0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2







0.4 – 0.7 0.4 – 0.7

0.4 – 0.7 0.4 – 0.7














0.4 – 0.7 0.4 – 0.7
0
0
V and more (tester’s battery voltage)
NOTE:
If the tester reads 1.4 V and below when the tester probes are
not connected, replace its battery.
B/W2
WIRE COLOR
B: Black, B/R: Black with Red tracer,
B/W: Black with White tracer
9-12
ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
Engine stop
switch
To Ignition
coil
Starter
motor
Ignition
switch
Fuse (30 A)
O/W
R
O/B
Starter relay
Fuse
(15 A)
Gear position
switch (Neutral)
Battery
Y/G
Bl
Y/B
Clutch lever
position switch
B/W
Starter
button
Turn signal/
G
side-stand relay
side-stand
switch
TROUBLESHOOTING
Starter motor will not run
Step 1
1) Shift the transmission to neutral.
2) Pull the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and
listen for a click from the starter relay when the starter button is pushed.
Is a click sound heard?
YES
NO
Go to Step 2.
Go to Step 3.
Step 2
1) Check if the starter motor runs when its terminal is connected to the battery + terminal. (Do not use thin
“wire” because a large amount of current flows.)
Does the starter motor run?
YES
NO
• Faulty starter relay
• Loose or disconnected starter motor lead wire
• Loose or disconnected between starter relay and battery + terminal
Faulty starter motor
ELECTRICAL SYSTEM
9-13
Step 3
1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and Y/B -) when the
starter button is pushed.
Is a voltage OK?
YES
NO
Go to Step 4.
• Faulty engine stop switch
• Faulty clutch lever position switch
• Faulty gear position switch
• Faulty turn signal/side-stand relay
• Faulty starter button
• Faulty ignition switch
• Faulty side-stand switch
• Poor contact of connector
• Open circuit in wire harness
Step 4
1) Check the starter relay. (9-16 to -17)
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 than neutral, with the side-stand up.
2) Check the side-stand switch. (9-17)
Is the side-stand switch OK?
YES
NO
Go to Step 2.
Faulty side-stand switch
Step 2
1) Check the starter clutch.
Is the starter clutch OK?
YES
NO
Faulty starter clutch
• Open circuit in wire harness
• Poor contact of connector
9-14
ELECTRICAL SYSTEM
STARTER MOTOR REMOVAL AND DISASSEMBLY
•
•
•
•
•
Disconnect the battery - lead wire.
Drain engine coolant. (2-17)
Remove the mufflers and exhaust pipe. (3-6)
Remove the engine coolant pipe 1.
Remove the starter motor cover 2.
• Remove the water union 3.
• Remove the starter motor 4.
• Disassemble the starter motor as shown in the illustration.
1
2
3
4
5
6
O-ring
Housing end (inside)
Starter motor case
Armature
Brush holder
Housing end (outside)
ELECTRICAL SYSTEM
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness
in the brush holder.
If any damages are found, replace the brush assembly with a
new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or
undercut A.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand
paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw
blade.
ARMATURE COIL INSPECTION
Check for continuity between each segment and between each
segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature
with a new one.
 09900-25008: Multi circuit tester set
 Tester knob indication: Continuity test ()
OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
• Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
Segment
9-15
9-16
ELECTRICAL SYSTEM
• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
 99000-25140: SUZUKI MOLY PASTE
• Align the torque 1 on the brush holder with the groove 2 on
the housing end.
• Align the torque 3 on the brush holder with the mark 4 on
the starter motor case.
• Align the threaded parts 5 on the housing end.
• Apply a small quantity of THREAD LOCK to the starter motor
housing bolts.
 99000-32050: THREAD LOCK “1342”
• Apply SUZUKI SUPER GREASE “A” to the O-ring.
 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
STARTER RELAY INSPECTION
•
•
•
•
Remove the seats. (8-3)
Remove the battery.
Remove the starter relay cover.
Disconnect the starter motor lead wire 1, battery lead wire 2
and starter relay coupler 3.
• Remove the starter relay 4.
ELECTRICAL SYSTEM
Apply 12 V to A and B terminals and check for continuity
between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the
relay is ok.
 09900-25008: Multi circuit tester set
 Tester knob indication: Continuity test ()

Do not apply a battery voltage to the starter relay for
more than five seconds, since the relay coil may overheat and damaged.
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.
 09900-25008: Multi circuit tester set
 Starter relay resistance: 3 – 7 Ω
SIDE STAND/IGNITION INTERLOCK SYSTEM
PARTS INSPECTION
Check the interlock system for proper operation. If the interlock
system does not operate properly, check each component for
damage or abnormalities. If any abnormality is found, replace
the component with a new one.
SIDE-STAND SWITCH
• Remove the left frame lower cover. (8-3)
• Remove the secondary gear case cover. (8-40)
• Remove the secondary drive unit cover. (3-3)
• Disconnect the side-stand switch coupler and measure the
voltage between Green and Black/White lead wires.
 09900-25008: Multi circuit tester set
 Tester knob indication: Diode test ()
Green
(+ Probe)
ON
(Side-stand up)
OFF
(Side-stand down)
Black/White
(- Probe)
0.4 – 0.6 V
1.4 V and more
(Tester’s battery voltage)
NOTE:
If the tester reads 1.4 V and below when the tester probes are
not connected, replace its battery.
9-17
9-18
ELECTRICAL SYSTEM
GEAR POSITION SWITCH
• Remove the secondary gear case cover. (8-40)
• Disconnect the gear position switch coupler and check the
continuity between Blue and Black/White with the transmission in “NEUTRAL”.
 09900-25008: Multi circuit tester set
 Tester knob indication: Continuity test ()
Blue
Black/White
ON (Neutral)
OFF (Except neutral)

When disconnecting and connecting the gear position
switch coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
• Connect the gear position switch coupler to the wiring harness.
• Turn the ignition switch to “ON” position and side-stand to
upright position.
• Insert the needle pointed probes to the gear position switch
coupler.
Measure the voltage between Pink and Black/White lead wires
using the multi circuit tester when shifting the gearshift lever
from low to top.
 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
 Gear position switch voltage: 0.6 V and more
to top gear position
(** Low
Except neutral position )
(Pink + – B/W -)
V
ELECTRICAL SYSTEM
TURN SIGNAL/SIDE-STAND RELAY
The turn signal/side-stand relay is composed of the turn signal
relay, side-stand relay and diode.
• Remove the secondary gear case cover. (8-40)
• Remove the turn signal/side-stand relay.
SIDE-STAND RELAY INSPECTION
First check the insulation between D and E terminals with the
tester. Then apply 12 V to terminals D and C (+ to D and - to
C) and check the continuity between D and E. If there is no
continuity, replace the turn signal/side-stand relay with a new
one.
 09900-25008: Multi circuit tester set
 Tester knob indication: Continuity test ()
SIDE-STAND RELAY
DIODE
- Probe of
tester to:
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
C, B
A
+ Probe of tester to:
C, B
A
1.4 V and more
(Tester’s battery voltage)
0.4 – 0.6 V
 09900-25008: Multi circuit tester set
 Tester knob indication: Diode test ()
NOTE:
If the multi circuit tester reads 1.4 V and below when the tester
probes are not connected, replace its battery.
TURN
SIGNAL
RELAY
9-19
9-20
ELECTRICAL SYSTEM
IGNITION SYSTEM
Engine stop switch
Ignition
coil
Spark plug
Sidestand
relay
#1
CKP
sensor
Fuse
ECM
#2
Ignition
switch
Fuse
Throttle
position
sensor
Engine
oil temp.
sensor
Gear
position
switch
Battery
NOTE:
The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine
speed reaches 8 000 r/min during running, this circuit cuts off fuel at the fuel injector.
TROUBLESHOOTING
No spark or poor spark
NOTE:
Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the
clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.
Step 1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition switch couplers?
YES
NO
Go to Step 2.
Poor connection of couplers
ELECTRICAL SYSTEM
9-21
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, 24: O/G and B/W, E-03, 28, 33: O/W and B/W)
Is the voltage OK?
YES
NO
Go to Step 3.
• Faulty ignition switch
• Faulty turn signal/side-stand relay
• Faulty engine stop switch
• Broken wire harness or poor connection of related circuit couplers
Step 3
1) Measure the ignition coil primary peak voltage. (9-22)
NOTE:
This inspection method is applicable only with the multi circuit tester and the peak volt adaptor.
Is the peak voltage OK?
YES
NO
Go to Step 4.
Go to Step 5.
Step 4
1) Check the plug caps for poor contacts.
2) If OK, then inspect the spark plugs. (2-6)
Are the spark plugs OK?
YES
NO
Go to Step 5.
Faulty spark plug(-s)
Step 5
1) Inspect the ignition coils. (9-23)
Are the ignition coils OK?
YES
NO
Go to Step 6.
Faulty ignition coil(-s)
Step 6
1) Measure the CKP sensor peak voltage and its resistance. (9-23 to -24)
NOTE:
The CKP peak voltage inspection is applicable only with the multi-circuit tester and peak volt adaptor.
Are the peak voltage and its resistance OK?
YES
NO
•
•
•
•
•
Faulty ECM
Open or short circuit in wire harness
Poor connection of ignition couplers
Faulty CKP sensor
Metal particles or foreign material being stuck on the CKP sensor and rotor tip
9-22
ELECTRICAL SYSTEM
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Remove the fuel tank. (6-3)
• Remove the frame head covers. (3-3)
• Disconnect the spark plug caps.
• Connect new spark plugs to each spark plug cap and ground
them to the cylinder head.
NOTE:
Make sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition.
Measure the ignition coils primary peak voltage in the following
procedure.
• Connect the multi-circuit tester with peak voltage adaptor as
follows.
#1 ignition coil: + Probe: White terminal
- Probe: Ground
# 2 ignition coil: + Probe: Black/Yellow terminal
- Probe: Ground
NOTE:
Do not disconnect the ignition coil primary wire coupler.
 09900-25008: Multi-circuit tester set

Before using the multi-circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
• Shift the transmission into neutral and turn ignition switch
“ON”.
• Pull the clutch lever.
• 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 procedure a few times and measure the
highest ignition coil primary peak voltage. If the peak voltage
is lower than the specified values, inspect the ignition coil.
 Ignition coil primary peak voltage: 205 V and more
Tester knob indication: Voltage ()

Avoid touching the tester probes and spark plugs to
prevent an electric shock while testing.
Peak volt adaptor
W or B/Y
Ignition
coil
ECM
Battery
New
spark
plug
ELECTRICAL SYSTEM
IGNITION COIL RESISTANCE
• Remove the fuel tank. (6-3)
• Remove the frame head covers. (3-3)
• Disconnect the spark plug caps.
• Measure the ignition coil resistance in both the primary and
secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
Ω
kΩ
 Ignition coil resistance
Primary: 2 – 6 Ω (+ terminal – - terminal)
Secondary: 15 – 30 kΩ (Plug cap – + terminal)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
CKP SENSOR PEAK VOLTAGE
• Remove the right frame cover. (8-4)
NOTE:
Be sure that all couplers are connected properly and the battery
used is in fully-charged condition.
• Disconnect the ECM coupler 1.
• Connect the multi circuit tester with peak volt adaptor as follows.
• Insert the needle pointed probes to the ECM coupler.
• Measure the CKP sensor peak voltage between Green/Yellow and Yellow/Brown lead wires at the ECM coupler.
Br
Green/Yellow (+ Probe) – Brown (- Probe)
 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set

Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
G/Y
9-23
9-24
ELECTRICAL SYSTEM
• Shift the transmission into the neutral and turn ignition switch
“ON”.
• Crank the engine a few seconds with the starter motor by
depressing starter button and check the CKP sensor peak
voltage.
• Repeat the above test procedure a few times and measure
the highest peak voltage.
ECM
CKP sensor coupler
coupler
G/W
G/Y
Br
W
CKP sensor
Peak
volt
adaptor
 Tester knob indication: Voltage ()
 CKP sensor peak voltage: 4.0 V and more
(Green/Yellow – Brown)
If the peak voltage is lower than the standard range, check the
peak voltage at the CKP sensor lead wire coupler.
• Remove the secondary gear case cover. (8-40)
• Remove the tool box. (8-41)
• Disconnect the CKP sensor lead wire coupler 2 and connect
the multi circuit tester with the peak volt adaptor.
Blue (+ Probe) – Green (- Probe)
• Measure the CKP sensor peak voltage at the CKP sensor
lead wire coupler.
 Tester knob indication: Voltage ()
 CKP sensor peak voltage: 4.0 V and more (Green – Bl)
If the peak voltage is lower than the standard range, check each
coupler at both ends of the circuit or replace the CKP sensor
and inspect it again.
CKP sensor
coupler
G
Bl
CKP sensor
Peak
volt
adaptor
CKP SENSOR RESISTANCE
• Measure the resistance between the lead wires and ground. If
the resistance is not as specified, the CKP sensor must be
replaced.
CKP sensor
coupler
 09900-25008: Multi circuit tester set
 Tester knob indication: Resistance (Ω)
 CKP sensor resistance: 184 – 276 Ω (Green – Blue)
∞ Ω (Green – Ground)
CKP sensor
ELECTRICAL SYSTEM
9-25
SPEEDOMETER AND PILOT LAMP BOX
DESCRIPTION
This speedometer mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). This speedometer is light, thin and of high response compared to those currently in use
because of this composition.
The speedometer pointer is driven by the stepping motor.
The LCD indicates Odo/Trip 1/Trip 2/Clock/oil pressure and engine coolant temp respectively.
NOTE:
If the engine stop switch is turned OFF while the ignition switch is ON, the LCD displays “CHEC”. But it is not
a malfunction.
This condition implies that combination meter receives no signal from the ECM.
In that case, they are restored to normal indication by turning the engine stop switch to RUN position.
LED (Light Emitting Diode)
LED is used for the illumination light and each indicator light.
LED is maintenance free. LED is less electric-power consuming and stronger to vibration resistance compared to the bulb.
1 Select switch (Odo/Trip/Clock)
2 Adjust switch
3 Speedometer
4 LCD (Odo/Trip1/Trip2/Clock/FI)
LCD (Oil pressure/Engine coolant temperature
5
indicator light)
LED (FI/Oil pressure/Engine coolant temperature indicator light)
7 LED (Turn signal indicator light)
8 LED (High-beam indicator light)
9 LED (Neutral indicator light)
6
0 LED (Fuel level)
9-26
ELECTRICAL SYSTEM
SPEEDOMETER REMOVAL AND
DISASSEMBLY
• Remove the headlight.
• Disconnect the speedometer lead wire couplers.
• Remove the speedometer cover 1.
: Hooked part
• Remove the speedometer.

When disconnecting and reconnecting the speedometer coupler, make sure to turn OFF the ignition switch,
or electronic parts may get damaged.
ELECTRICAL SYSTEM
• Disassemble the speedometer as follows.

Do not attempt to disassemble the speedometer unit.
1 Speedometer cover
2 Speedometer unit
3 Speedometer case
9-27
9-28
ELECTRICAL SYSTEM
PILOT LAMP BOX REMOVAL AND
DISASSEMBLY
• Lift and support the fuel tank. (6-3)
• Remove the coupler 1.

When disconnecting and reconnecting the pilot lamp
box coupler, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
• Remove the fuel tank upper cover 2.
• Remove the pilot lamp box.
ELECTRICAL SYSTEM
9-29
INSPECTION
LED (LIGHT EMITTING DIODE)
Check that the LED lights (FI light, Oil pressure indicator light, Engine coolant indicator light and Fuel level
indicator light) immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light,
High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.
If the LED fails in operation, replace the speedometer unit with a new one after checking its wire harness/coupler.
STEPPING MOTOR
Check that the pointer calibrates itself immediately after turning the ignition switch on and stops at zero
point.
If abnormal condition is found, replace the speedometer unit with a new one after checking its wire harness/coupler.
NOTE:
The pointer may not return to the proper position even turning the ignition switch on under low temperature
condition. In that case, you can reset the pointer to the proper position by following the instruction below:
1)
2)
3)
*
With the function switch A pressed, turn the ignition switch on.
Release the function switch A, 3 to 5 seconds after turning the ignition switch on.
Press the function switch A twice (within 1 second). →Reset
Complete the operation within 10 seconds after the ignition switch has been turned on.
Time
Ignition switch
OFF
0
•
•
ON
3 sec.
•
5 sec.
•
•
•
•
10 sec.
Adjuster switch
PUSH
Release
Push
Push→Reset
Pointer will return to the starting point right after the completion of the operation. In the case of the pointer
not returning to the proper position after doing above, replace the speedometer unit.
9-30
ELECTRICAL SYSTEM
ENGINE COOLANT TEMPERATURE METER AND
INDICATOR
ECT sensor inspection. (!7-10)
• Remove the fuel tank. (!6-3)
• Remove the frame head covers. (!3-3)
• Disconnect the ECT sensor coupler 1.
"
When connecting and disconnecting the engine coolant temperature sensor lead wire coupler, make sure
to turn OFF the ignition switch, or electronic parts
may get damaged.
• Connect the variable resistor A between the terminals.
• Turn the ignition switch ON.
• Check the LCD and LED operation when the resistance is
adjusted to the specified values.
Resistance A
2.45 kΩ and over
Approx. 0.811 kΩ
Approx. 0.1 kΩ
0 Ω (Jumper wire)
LED B LCD c
OFF
—
OFF
—
ON
Flicker
ON
Flicker
Water temperature
19 °C and below
Approx. 50 °C
120 – 139 °C
140 °C and over
E
L
P
M
If either one or all indication are abnormal, replace the speedometer with a new one.
A
S
FUEL LEVEL INDICATOR SWITCH INSPECTION
• Remove and disassemble the fuel pump assembly. (!6-8)
• Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel
level indicator switch as shown in the right illustration. The
bulb should come on after one minutes if the switch is in good
condition.
ON
Test
bulb
Battery
ELECTRICAL SYSTEM
• When the switch is immersed in kerosene under the above
condition, the bulb should go out. If the bulb remains lit,
replace the unit with a new one.
OFF
Test
bulb
Kerosene
FUEL LEVEL INDICATOR LIGHT INSPECTION
If the fuel level indicator light does not function properly, check
the fuel level indicator switch and its lead wire/coupler.
If the fuel level indicator switch and its lead wire/coupler are
functioning properly, replace the combination meter with a new
one.
SPEED SENSOR INSPECTION
If the speedometer, odometer or tripmeter does not function
properly. Inspect the speed sensor and connection of couplers.
If the speed sensor and connection is all right, replace the unit
with a new one.
• Remove the front wheel. (8-7)
• Remove the head light. (9-26)
• Disconnect the speed sensor lead wire couplers.
• Remove the speed sensor 1. (8-7)
Battery
9-31
9-32
ELECTRICAL SYSTEM
• Connect 12 V battery (between O/R and B/W), 10 kΩ resistor
(between O/R and P) and the multi circuit tester (+ probe of
tester to O/R and - to P) as shown right illustration.
O/R : Orange with Red tracer
B/W : Black with White tracer
P : Pink
 09900-25008: Multi circuit tester set
 Tester knob indication: Voltage ()
V
B/W
P
Under above condition, by rotating the drive lugs of speed sensor slowly, the tester reading voltage relatively changes (0 V →
12 V or 12 V → 0 V). If the tester reading voltage does not
change, replace the speed sensor with a new one.
NOTE:
The highest tester reading voltage (12 V) while testing is same
as battery voltage.
OIL PRESSURE INDICATOR
NOTE:
Before inspecting the oil pressure switch, check if the engine oil
level is correct. (2-11)
• Disconnect the oil pressure switch lead wire from the oil pressure switch.
• Turn the ignition switch ON.
• Check if the oil pressure indicator A will light and LCD B will
flicker, when grounding the lead wire.
If any indications are abnormal, replace the speedometer with a
new one after checking connection of couplers.
12 V
10 kΩ
Speed sensor
O/R
ELECTRICAL SYSTEM
9-33
LAMPS
HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT
HEADLIGHT
12 V 60/55 W
POSITION LIGHT
12 V 5 W (E-02, 19)
BRAKE LIGHT/TAILLIGHT
LED
LICENCE PLATE LIGHT 4
12 V 5 W
TURN SIGNAL LIGHT 5
Front
12 V 21/5 W ...................... (E-03, 28, 33)
12 V 21 W ......................... (E-02, 19, 24)
Rear
12 V 21 W

If you have touched and the bulb with your bare hands, clean it with a cloth moistened with
alcohol or soapy water to maintain lens clarity.
9-34
ELECTRICAL SYSTEM
HEADLIGHT BEAM ADJUSTMENT
• Adjust the headlight beam.
A: Vertical adjuster
B: Horizontal adjuster
NOTE:
To adjust the headlight beam, adjust the beam horizontally first,
then adjust vertically.
ELECTRICAL SYSTEM
RELAYS
TURN SIGNAL/SIDE-STAND RELAY
The turn signal/side-stand relay is composed of the turn signal
relay, side-stand relay and diode.
INSPECTION
Before removing the turn signal/side-stand relay, check the
operation of the turn signal light.
If the turn signal light does not illuminate, inspect the bulb, turn
signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are OK, the
turn signal relay may be faulty. In this case, replace the turn signal/side-stand relay with a new one.
NOTE:
* Make sure that the battery is fully charged.
* Refer to the page 9-16 for the side-stand relay and diode
inspection.
STARTER RELAY
9-16 to -17
FUEL PUMP RELAY
6-6
SWITCHES
IGNITION SWITCH REMOVAL
• Remove the fuel tank. (6-3)
• Remove the frame head covers. (3-3)
• Disconnect the coupler 1.
• Remove the ignition switch mounting bolts with the special
tools.
 09930-11920: Torx bit JT40H
09930-11940: Bit holder

When reusing the ignition switch bolt, clean thread
and apply the THREAD LOCK.
 99000-32050: THREAD LOCK “1342” (USA)
 99000-32110: THREAD LOCK SUPER “1322” (Others)
SIDE-STAND RELAY
DIODE
TURN
SIGNAL
RELAY
9-35
9-36
ELECTRICAL SYSTEM
Inspect each switch for continuity with a tester. If any STARTER BUTTON
abnormality is found, replace the respective switch
Color
O/W
Position
assemblies with new ones.
B
Lbl
Lg
(OFF)
(ON)
R
O
O/Y
Br
ON
OFF
LOCK
P
µ¶
HI (
LO (
W
Y
Y/W
Lg
Lbl
B
B/R
B/Bl
O/G
W/B
OFF
ON
B/Y
B/Y
OFF
ON
OIL PRESSURE SWITCH
Color
Position
O/R
Y
PUSH
ENGINE STOP SWITCH
À¾
Color
Position
Color
Position
PASSING LIGHT SWITCH
)
OFF (
(
)
RUN
B/W
CLUTCH LEVER POSITION SWITCH
L
PUSH
R
Color
Position
B/Bl
FRONT BRAKE SWITCH
Color
Position
TURN SIGNAL SWITCH
Color
Position
Color
Position
REAR BRAKE SWITCH
)
)
Color
Position
HORN BUTTON
OFF
ON
DIMMER SWITCH
Color
Position
O/R
PUSH
IGNITION SWITCH
Color
Position
Y/W
PUSH
HAZARD SWITCH
Color
Position
Y/G
O/B
O/W
G/Y
Ground
ON (engine
is at stop)
OFF (engine
is running)
:
NOTE:
Before inspecting the oil pressure switch, check if the
2-11)
engine oil level is correct. (
WIRE COLOR
B
Br
Gr
G
B/BI
B/W
B/Y
B/R
G/Y
O/B
O/BI
O/G
O/R
O/W
O/Y
W/B
Y/G
Y/W
: Black
Lbl : Light blue
: Brown
Lg : Light green
: Gray
O : Orange
: Green
: Black with Blue tracer
: Black with White tracer
: Black with Yellow tracer
: Black with Red tracer
: Green with Yellow tracer
: Orange with Black tracer
: Orange with Blue tracer
: Orange with Green tracer
: Orange with Red tracer
: Orange with White tracer
: Orange with Yellow tracer
: White with Black tracer
: Yellow with Black tracer
: Yellow with White tracer
R : Red
Y : Yellow
W : White
ELECTRICAL SYSTEM
BATTERY
Upper
cover
breather
SPECIFICATIONS
Type designation
Capacity
FTX12-BS
12 V, 36 kC (10 Ah)/10 HR
Cathode
plates
Stopper
9-37
Filter
Terminal
Safety valve
Anode plates
Separator
(fiberglass plate)
INITIAL CHARGING
Filling electrolyte
• Remove the aluminum tape 1 sealing the battery electrolyte
filler holes.
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 3 of the electrolyte
container.
Insert the nozzles of the electrolyte container into the battery’s
electrolyte filler holes, holding the container firmly so that it does
not fall. Take precaution not to allow any of the fluid to spill.
Electrolyte
containers
Insert in
filler holes
• Make sure air bubbles 6 are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
9-38
ELECTRICAL SYSTEM
NOTE:
If no air bubbles are coming up from a filler port, tap the bottom
of the electrolyte container two or three times.
Never remove the container from the battery.
• After confirming that the electrolyte has entered the battery
completely, remove the electrolyte containers from the battery. Wait for about more than 20 minutes.
• Insert the caps 7 into the filler holes, pressing in firmly so that
the top of the caps do not protrude above the upper surface of
the battery’s top cover.

* Never use anything except the specified battery.
* Once the caps have been installed to the battery, do
not remove the caps.
* Do not tap the caps with a tool such as hammer
when installing them.
CORRECT
• For initial charging, use the charger specially designed for MF
battery.

* For charging the battery, make sure to use the
charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in
shortened service life.
* Do not remove the cap during charging.
* Position the battery with the cap facing upward during charging.
INCORRECT
ELECTRICAL SYSTEM
9-39
SERVICING
Visually inspect the surface of the battery container. If any signs
of cracking or electrolyte leakage from the sides of the battery
have occurred, replace the battery with a new one. If the battery
terminals are found to be coated with rust or an acidic white
powdery substance, clean the battery terminals with sandpaper.
RECHARGING OPERATION
• Using the multi circuit tester, check the battery voltage. If the
voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger.

* When recharging the battery, remove the battery
from the motorcycle.
* Do not remove the caps on the battery top while
recharging.
(V)
18
17
16
15
14
13
12
Charging period
Stop charging
0
Recharging time: 5 A for 1 hour or 1.2 A for 5 to 10 hours
(V)
14

13
Be careful not to permit the charging current to
exceed 5 A at any time.
10
20 30
Time
40
50
60
(Minutes)
(at 0 – 40 ˚C)
12
11
10
• After recharging, wait for more than 30 minutes and check the
battery voltage with a multi circuit tester.
• If the battery voltage is less than the 12.5 V, recharge the battery again.
• If battery voltage is still less than 12.5 V, after recharging,
replace the battery with a new one.
• When the motorcycle is not used for a long period, check the
battery every 1 month to prevent the battery discharge.
100 75
50 25
0 (%)
Battery charged condition
SERVICING INFORMATION
10-1
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING .................................................................................10- 2
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION ..10- 2
ENGINE .................................................................................................10- 5
RADIATOR (COOLING SYSTEM) ........................................................10-10
CHASSIS ...............................................................................................10-11
SHAFT DRIVE .......................................................................................10-12
BRAKES................................................................................................10-12
ELECTRICAL ........................................................................................10-13
BATTERY ..............................................................................................10-14
WIRING HARNESS, CABLE AND HOSE ROUTING..................................10-15
WIRING HARNESS ROUTING .............................................................10-15
CABLE ROUTING .................................................................................10-18
THROTTLE BODY INSTALLATION .....................................................10-19
COOLING SYSTEM HOSE ROUTING..................................................10-20
FRONT BRAKE ROUTING ...................................................................10-21
SPEED SENSOR HARNESS ROUTING ..............................................10-22
FRONT TURN SIGNAL INSTALLATION..............................................10-22
FRONT TURN SIGNAL LEAD WIRE ROUTING ..................................10-23
MUFFLER & EXHAUST PIPE INSTALLATION ...................................10-23
HANDLEBAR BALANCER ...................................................................10-24
BATTERY PROTECTOR ......................................................................10-24
LUBRICATION POINTS........................................................................10-25
FUEL TANK INSTALLATION ...............................................................10-26
REAR COMBINATION LAMP INSTALLATION ...................................10-27
FRAME HEAD COVER CUSHION INSTALLATION ............................10-28
LEFT SIDE COVER CUSHION INSTALLATION..................................10-28
REAR FENDER CUSHION INSTALLATION ........................................10-29
LEFT SIDE COVER INSTALLATION ...................................................10-30
LID CUSHION INSTSALLATION..........................................................10-31
TAIL LAMP INSTALLATION ................................................................10-32
PAIR (AIR SUPPLY) SYSTEM DIAGRAM ..................................................10-33
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .......................................10-34
SPECIAL TOOLS ........................................................................................10-35
TIGHTENING TORQUE ...............................................................................10-39
ENGINE .................................................................................................10-39
SECONDARY AND FINAL....................................................................10-40
FI SYSTEM AND INTAKE AIR SYSTEM..............................................10-40
COOLING SYSTEM ..............................................................................10-40
CHASSIS ...............................................................................................10-41
TIGHTENING TORQUE CHART...........................................................10-42
SERVICE DATA...........................................................................................10-43
10
10-2
SERVICING INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
DTC No.
C00
C12
P0335
C13/C17
P1750/P0105
C14
H
P0120
L
C15
H
P0115
L
DETECTED
DETECTED FAILURE CONDITION
CHECK FOR
ITEM
–––––––––––
–––––––––––
NO FAULT
CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechansec. or more, after receiving the starter ical parts
(CKP sensor, lead wire/coupler
signal.
connection)
IAP sensor
The sensor should produce following IAP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C13
(P1750) or C17 (P0105) is indicated.
TP sensor
The sensor should produce following TP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C14
(P0120) is indicated.
Sensor voltage is higher than specified TP sensor circuit shorted to
value.
VCC or ground circuit open
Sensor voltage is lower than specified TP sensor circuit open or
value.
shorted to ground or VCC circuit
open
ECT sensor The sensor voltage should be the fol- ECT sensor, lead wire/coupler
connection
lowing.
0.1 V
sensor voltage < 4.6 V
In other than the above range, C15
(P0115) is indicated.
Sensor voltage is higher than specified ECT sensor circuit open or
value.
ground circuit open
Sensor voltage is lower than specified ECT sensor circuit shorted to
value.
ground
SERVICING INFORMATION
DTC No.
C21
H
P0110
L
C23
H
P1651
L
C24/C25
P0351/P0352
C28
P1655
C29
H
P1654
L
DETECTED
DETECTED FAILURE CONDITION
ITEM
IAT sensor
The sensor voltage should be the following.
0.1 V
sensor voltage < 4.6 V
In other than the above range, C21
(P0110) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
TO sensor
The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.
0.2 V
sensor voltage
4.6 V
In other than the above value, C23
(P1651) is indicated.
Sensor voltage is higher than specified
value.
10-3
CHECK FOR
IAT sensor, lead wire/coupler
connection
IAT sensor circuit open or
ground circuit open
IAT sensor circuit shorted to
ground
TO sensor, lead wire/coupler
connection
TO sensor circuit open or
shorted to VCC or ground circuit
open
Sensor voltage is lower than specified TO sensor circuit shorted to
value.
ground or VCC circuit open
Ignition sigCKP sensor (pick-up coil) signal is pro- Ignition coil, lead wire/coupler
connection, power supply from
nal
duced, but signal from ignition coil is
the battery
interrupted 8 times or more continuously. In this case, the code C24
(P0351) or C25 (P0352) is indicated.
STVA motor, STVA lead
When no actuator control signal is
Secondary
wire/coupler
throttle valve supplied from the ECM, communication signal does not reach ECM or
actuator
operation voltage does not reach
STVA motor, C28 (P1655) is indicated.
STVA can not operate.
STP sensor The sensor should produce following STP sensor, lead wire/coupler
connection
voltage.
0.1 V
sensor voltage < 4.8 V
In other than the above range, C29 is
indicated.
Sensor voltage is higher than specified STP sensor circuit shorted to
value.
VCC or ground circuit open
Sensor voltage is lower than specified STP sensor circuit open or
value.
shorted to ground or VCC circuit
open
10-4
SERVICING INFORMATION
DTC No.
C31
P0705
C32/C33
P0201/P0202
C41
P0230
C42
P1650
C44
P0130
C44
P0135
C49
P1656
DETECTED
DETECTED FAILURE CONDITION
ITEM
Gear posiGear position signal voltage should be
tion signal
higher than the following for 3 seconds
and more.
Gear position sensor voltage > 0.6 V
If lower than the above value, C31
(P0705) is indicated.
Fuel injector CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 4 times or more continuously. In
this case, the code C32 (P0201) or
C33 (P0202) is indicated.
Fuel pump
No voltage is applied to the fuel pump,
relay
although fuel pump relay is turned ON,
or voltage is applied to fuel pump,
although fuel pump relay is turned
OFF.
Ignition
Ignition switch signal is not input to
switch
ECM.
HO2 sensor HO2 sensor output voltage is not input
(E-02, 19, 24) to ECM during engine operation and
running condition.
(Sensor voltage
0.1 V)
In other than the above value, C44
(P0130) is indicated.
The Heater can not operate so that
heater operation voltage is not supply
to the oxygen heater circuit, C44
(P0135) is indicated.
PAIR control PAIR control solenoid valve voltage is
not input to ECM.
solenoid
valve
CHECK FOR
GP switch, lead wire/coupler
connection. Gearshift cam, etc.
Fuel injector, wiring/coupler connection, power supply to the
injector
Fuel pump relay, lead wire/coupler connection. power source to
the fuel pump relay and fuel
injectors
Ignition switch, lead wire/coupler
HO2 sensor circuit open or
shorted to ground
HO2 sensor lead wire/coupler
connection
Battery voltage supply to the
HO2 sensor
PAIR control solenoid valve, lead
wire/coupler
SERVICING INFORMATION
ENGINE
Complaint
Symptom and possible causes
Engine will not start Compression too low
or is hard to start.
1. Out of adjustment valve clearance
2. Worn valve guides or poor seating of valves
3. Mistiming valves
4. Excessively worn piston rings
5. Worn-down cylinder bores
6. Too slowly starter motor cranks
7. Poor seating of spark plugs
Remedy
Adjust.
Repair or replace.
Adjust.
Replace.
Replace.
See electrical section.
Retighten.
Plug not sparking
1. Fouled spark plugs
2. Wet spark plugs
3. Defective ignition coil
4. Defective CKP sensor
5. Defective ECM
6. Open-circuited wiring connections
7. Open or short in high-tension cords
Clean.
Clean and dry.
Replace.
Replace.
Replace.
Repair or Replace.
Replace.
No fuel reaching the intake manifold
1. Clogged fuel filter or fuel hose
2. Defective fuel pump
3. Defective fuel pressure regulator
4. Defective fuel injector
5. Defective fuel pump relay
6. Defective ECM
7. Open-circuited wiring connections
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Incorrect fuel/air mixture
1. Out of adjustment TP sensor
2. Defective fuel pump
3. Defective fuel pressure regulator
4. Defective TP sensor
5. Defective CKP sensor
6. Defective IAP sensor
7. Defective ECM
8. Defective ECT sensor
9. Defective IAT sensor
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
10-5
10-6
SERVICING INFORMATION
Complaint
Engine idles poorly.
Symptom and possible causes
1. Out of adjustment valve clearance
2. Poor seating of valves
3. Defective valve guides
4. Worn down camshafts
5. Too wide spark plug gaps
6. Defective ignition coil
7. Defective CKP sensor
8. Defective ECM
9. Defective TP sensor
10. Defective fuel pump
11. Imbalanced throttle valve
12. Damaged or cracked vacuum hose
Engine stalls easily. Incorrect fuel/air mixture
1. Defective IAP sensor or circuit
2. Clogged fuel filter
3. Defective fuel pump
4. Defective fuel pressure regulator
5. Defective ECT sensor
6. Defective thermostat
7. Defective IAT sensor
8. Damaged or cracked vacuum hose
Remedy
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Improperly working fuel injector
1. Defective fuel injector
2. No injection signal from ECM
3. Open or short circuited wiring connection
4. Defective battery or low battery voltage
Replace.
Repair or replace.
Repair or replace.
Replace or recharge.
Improperly working control circuit or sensors
1. Defective ECM
2. Defective fuel pressure regulator
3. Defective TP sensor
4. Defective IAT sensor
5. Defective CKP sensor
6. Defective ECT sensor
7. Defective fuel pump relay
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Improperly working engine internal parts
1. Fouled spark plugs
2. Defective CKP sensor or ECM
3. Clogged fuel hose
4. Out of adjustment valve clearance
Clean.
Replace.
Clean.
Adjust.
SERVICING INFORMATION
Complaint
Noisy engine
Symptom and possible causes
Excessive valve chatter
1. Too large valve clearance
2. Weakened or broken valve springs
3. Worn tappet or cam surface
4. Worn and burnt camshaft journal
Adjust.
Replace.
Replace.
Replace.
Noise seems to come from piston
1. Worn down pistons or cylinders
2. Fouled with carbon combustion chambers
3. Worn piston pins or piston pin bore
4. Worn piston rings or ring grooves
Replace.
Clean.
Replace.
Replace.
Noise seems to come from timing chain
1. Stretched chain
2. Worn sprockets
3. Not working tension adjuster
Replace.
Replace.
Repair or replace.
Noise seems to come from clutch
1. Worn splines of countershaft or hub
2. Worn teeth of clutch plates
3. Distorted clutch plates, driven and drive
4. Worn clutch release bearing
5. Weakened clutch dampers
Remedy
Replace.
Replace.
Replace.
Replace.
Replace the primary
driven gear.
Noise seems to come from crankshaft
1. Due to wear rattling bearings
2. Worn and burnt crank pin bearings
3. Worn and burnt journal bearings
4. Too large thrust clearance
Replace.
Replace.
Replace.
Replace thrust bearing.
Noise seems to come from transmission
1. Worn or rubbing gears
2. Worn splines
3. Worn or rubbing primary gears
4. Worn bearings
Replace.
Replace.
Replace.
Replace.
Noise seems to come from water pump
1. Too much play on pump shaft bearing
2. Worn or damaged impeller shaft
3. Worn or damaged mechanical seal
4. Touches pump case and impeller
Replace.
Replace.
Replace.
Replace.
10-7
10-8
SERVICING INFORMATION
Complaint
Symptom and possible causes
Engine runs poorly Defective engine internal/electrical parts
in high speed range. 1. Weakened valve springs
2. Worn camshafts
3. Valve timing out of adjustment
4. Too narrow spark plug gaps
5. Ignition not advanced sufficiently due to poorly
working timing advance circuit
6. Defective ignition coils
7. Defective CKP sensor
8. Defective ECM
9. Clogged air cleaner element
10. Clogged fuel hose, resulting in inadequate fuel
supply to injector
11. Defective fuel pump
12. Defective TP sensor
13. Defective STP sensor or STV actuator
Remedy
Replace.
Replace.
Adjust.
Adjust.
Replace ECM.
Replace.
Replace.
Replace.
Clean.
Clean and prime.
Replace.
Replace.
Replace.
Defective air flow system
1. Clogged air cleaner element
2. Defective throttle valve
3. Defective secondary throttle valve
4. Sucking air from throttle body joint
5. Defective ECM
6. Imbalancing throttle valve synchronization
Clean or replace.
Adjust or replace.
Adjust or replace.
Repair or replace.
Replace.
Adjust.
Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective GP sensor
6. Defective IAP sensor
7. Defective ECM
8. Out of adjustment TP sensor
9. Defective STP sensor and/or STV actuator
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
SERVICING INFORMATION
Complaint
Symptom and possible causes
Engine lacks power. Defective engine internal/electrical parts
1. Loss of valve clearance
2. Weakened valve springs
3. Out of adjustment valve timing
4. Worn piston rings or cylinders
5. Poor seating of valves
6. Fouled spark plugs
7. Incorrect spark plugs
8. Clogged injectors
9. Out of adjustment TP sensor
10. Clogged air cleaner element
11. Imbalancing throttle valve synchronization
12. Sucking air from throttle valve or vacuum hose
13. Too much engine oil
14. Defective fuel pump or ECM
15. Defective CKP sensor and ignition coils
Engine overheats
Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective GP sensor
6. Defective IAP sensor
7. Defective ECM
8. Out of adjustment TP sensor
9. Defective STP sensor and/or STV actuator
10. Defective EXCV actuator
Defective engine internal parts
1. Heavy carbon deposit on piston crowns
2. Not enough oil in the engine
3. Defective oil pump or clogged oil circuit
4. Sucking air from intake pipes
5. Use incorrect engine oil
6. Defective cooling system
Lean fuel/air mixture
1. Short-circuited IAP sensor/lead wire
2. Short-circuited IAT sensor/lead wire
3. Sucking air from intake pipe joint
4. Defective fuel injectors
5. Defective ECT sensor
Remedy
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Adjust or replace.
Clean.
Adjust.
Clean.
Adjust.
Retighten or replace.
Drain out excess oil.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Add oil.
Replace or clean.
Retighten or replace.
Change.
See radiator section.
Repair or replace.
Repair or replace.
Clean or replace.
Repair or replace.
Replace.
The other factors
Replace.
1. Ignition timing is too advanced due to defective
timing advance system (ECT sensor, GP sensor,
CKP sensor and ECM).
Adjust.
2. Drive chain is too tight.
10-9
10-10
SERVICING INFORMATION
Complaint
Dirty or heavy
exhaust smoke
Slipping clutch
Dragging clutch
Transmission will
not shift.
Transmission will
not shift back.
Transmission jumps
out of gear.
Symptom and possible causes
1. Too much engine oil in the engine
2.
3.
4.
5.
6.
7.
1.
2.
3.
1.
2.
1.
2.
3.
1.
2.
3.
1.
2.
3.
4.
Worn piston rings or cylinders
Worn valve guides
Scored or scuffed cylinder walls
Worn valves stems
Defective stem seal
Worn oil ring side rails
Weakened clutch springs
Worn or distorted pressure plates
Distorted clutch plates or pressure plates
Some clutch spring weakened while others are
not.
Distorted pressure plates or clutch plates
Broken gearshift cam
Distorted gearshift forks
Worn gearshift pawl
Broken return spring on shift shaft
Rubbing or stickily shift shaft
Distorted or worn gearshift forks
Worn shifting gears on driveshaft or countershaft
Distorted or worn gearshift forks
Weakened stopper spring on gearshift stopper
Worn gearshift cam plate
Remedy
Check with inspection window drain out excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
RADIATOR (COOLING SYSTEM)
Complaint
Engine overheats
Engine overcools
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
Symptom and possible causes
Not enough engine coolant
Clogged with dirt or trashes radiator core
Faulty cooling fan
Defective cooling fan thermo-switch
Clogged water passage
Air trapped in the cooling circuit
Defective water pump
Use incorrect coolant
Defective thermostat
Defective cooling fan thermo-switch
Extremely cold weather
Defective thermostat
Remedy
Add coolant.
Clean.
Repair or replace.
Replace.
Clean.
Bleed out air.
Replace.
Replace.
Replace.
Replace.
Put on the radiator cover.
Replace.
SERVICING INFORMATION
CHASSIS
Complaint
Heavy steering
Wobbly handlebars
Wobbly front wheel
Front suspension
too soft
Front suspension
too stiff
Noisy front
suspension
Wobbly rear wheel
Rear suspension
too soft
Rear suspension
too stiff
Noisy rear
suspension
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
1.
2.
3.
4.
5.
1.
2.
3.
4.
1.
2.
3.
4.
5.
1.
2.
Symptom and possible causes
Overtightened steering stem nut
Broken bearing in steering stem
Distorted steering stem
Not enough pressure in tires
Loss of balance between right and left front forks
Distorted front fork
Distorted front axle or crooked tire
Loose steering stem nut
Worn or incorrect tire or wrong tire pressure
Worn bearing/race in steering stem
Distorted wheel rim
Worn front wheel bearings
Defective or incorrect tire
Loose axle or axle pinch bolt
Incorrect front fork oil level
Weakened springs
Not enough fork oil
Wrong weight fork oil
Improperly set front fork spring adjuster
Improperly set front fork damping force adjuster
Too viscous fork oil
Too much fork oil
Improperly set front fork spring adjuster
Improperly set front fork damping force adjuster
Bent front axle
Not enough fork oil
Loose bolts on suspension
Distorted wheel rim
Worn rear wheel bearing or swingarm bearings
Defective or incorrect tire
Worn swingarm and rear suspension bearings
Loose nuts or bolts on rear suspensions
Weakened spring of shock absorber
Leakage oil or gas of shock absorber
Improperly set rear spring pre-load adjuster
Improperly set damping force adjuster
Bent shock absorber shaft
Bent swingarm
Worn swingarm and rear suspension bearings
Improperly set rear spring pre-load adjuster
Improperly set damping force adjuster
Loose nuts or bolts on rear suspension
Worn swingarm and suspension bearings
Remedy
Adjust.
Replace.
Replace.
Adjust.
Adjust.
Repair or replace.
Replace.
Adjust.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Retighten.
Adjust.
Replace.
Replenish.
Replace.
Adjust.
Adjust.
Replace.
Drain excess oil.
Adjust.
Adjust.
Replace.
Replenish.
Retighten.
Replace.
Replace.
Replace.
Replace.
Retighten.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Retighten.
Replace.
10-11
10-12
SERVICING INFORMATION
SHAFT DRIVE
Complaint
Noisy shaft drive
Symptom and possible causes
Noise seems to come from secondary bevel gear
and final bevel gear assemblies.
1. Oil level too low
2. Drive and driven bevel gears damaged or worn
3. Excessive backlash
4. Improper tooth contact
5. Damage to bearings
Noise seems to come from propeller shaft area.
1. Propeller shaft universal joint damaged
2. Propeller shaft splines damaged or worn
3. Insufficient lubricant
4. Cam dog contacting surface damaged or worn
Remedy
Refill.
(Check oil jet./Replace oil
seal.)
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Refill. (Replace oil seal.)
Replace.
BRAKES
Complaint
Insufficient brake
power
Brake squeaking
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
7.
Excessive brake
lever stroke
Leakage of brake
fluid
Brake drags
1.
2.
3.
1.
2.
3.
1.
2.
Symptom and possible causes
Leakage of brake fluid from hydraulic system
Worn pads
Oil adhesion of engaging surface of pads/shoe
Worn disc
Air in hydraulic system
Not enough brake fluid in the reservoir
Carbon adhesion on pad surface
Remedy
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replenish.
Repair surface with
sandpaper.
Modify pad fitting or
Tilted pad
replace.
Replace.
Damaged wheel bearing
Tighten to specified
Loosen front-wheel axle or rear-wheel axle
torque.
Replace.
Worn pads
Replace brake fluid.
Foreign material in brake fluid
Disassemble and
Clogged return port of master cylinder
clean master cylinder.
Air in hydraulic system
Bleed air.
Replenish fluid to specified
Insufficient brake fluid
level; bleed air.
Replace with correct fluid.
Improper quality of brake fluid
Tighten to specified torque.
Insufficient tightening of connection joints
Replace.
Cracked hose
Replace piston and/or cup.
Worn piston and/or cup
Clean and lubricate.
Rusty part
Insufficient brake lever or brake pedal pivot lubri- Lubricate.
cation
SERVICING INFORMATION
10-13
ELECTRICAL
Complaint
No sparking or poor
sparking
Spark plug soon
become fouled with
carbon.
Spark plug become
fouled too soon.
Spark plug electrodes overheat or
burn.
Generator does not
charge.
Generator does
charge, but charging rate is below the
specification.
Generator
overcharges
Unstable charging
Starter button is not
effective.
1.
2.
3.
4.
5.
1.
2.
Symptom and possible causes
Defective ignition coils or CKP sensor
Defective spark plugs
Defective ECM
Defective tip over sensor
Open-circuited wiring connections
Mixture too rich
Idling speed set too high
3.
4.
5.
1.
2.
3.
Incorrect gasoline
Dirty element in air cleaner
Too cold spark plugs
Worn piston rings
Worn piston or cylinders
Excessive clearance of valve stems in valve
guides
4. Worn stem oil seal
1. Too hot spark plugs
2.
3.
4.
1.
2.
3.
1.
2.
3.
4.
1.
2.
3.
Overheated engine
Loose spark plugs
Too lean mixture
Open or short lead wires, or loose lead connections.
Shorted, grounded or open generator coils
Shorted or punctured regulator/rectifier
Lead wires tend to get shorted or open-circuited
or loosely connected at terminals
Grounded or open-circuited generator coils or
generator
Defective regulator/rectifier
Defective cell plates in the battery
Internal short-circuit in the battery
Damaged or defective regulator/rectifier
Poorly grounded regulator/rectifier
1. Lead wire insulation frayed due to vibration,
resulting in intermittent shorting
2. Internally shorted generator
3. Defective regulator/rectifier
1. Run down battery
2. Defective switch contacts
3. Not seating properly brushes on commutator in
starter motor
4. Defective starter relay/starter interlock switch
5. Defective main fuse
Remedy
Replace.
Replace.
Replace.
Replace.
Check and repair.
Inspect FI system.
Adjust fast idle or throttle
stop screw.
Change.
Clean or replace.
Replace with hot type plug.
Replace.
Replace.
Replace.
Replace.
Replace with cold type
plugs.
Tune-up.
Retighten.
Inspect FI system.
Repair or replace or
retighten.
Replace.
Replace.
Repair or retighten.
Replace.
Replace.
Replace the battery.
Replace the battery.
Replace.
Repair, replace, or
connect properly.
Repair or replace.
Replace.
Replace.
Repair or replace.
Replace.
Repair or replace.
Replace.
Replace.
10-14
SERVICING INFORMATION
BATTERY
Complaint
“Sulfation”, acidic
white powdery substance or spots on
surface of cell
plates.
Battery runs down
quickly.
Symptom and possible causes
1. Cracked battery case
2. Battery has been left in a run-down condition for
a long time.
Remedy
Replace the battery.
Replace the battery.
1. Not correct the charging system
Check the generator, regulator/rectifier and circuit
connections and make necessary adjustments to
obtain specified charging
operation.
Replace the battery, and
correct the charging system.
Replace the battery.
Recharge the battery fully.
Replace the battery.
Replace the battery.
2. Cell plates have lost much of their active
material as a result of overcharging.
Battery “sulfation”
3.
4.
5.
1.
Internal short-circuit in the battery
Too low battery voltage
Too old battery
Incorrect charging rate
(When not in use batteries should be checked at
least once a month to avoid sulfation.)
2. The battery was left un used in a cold climate for Replace the battery if badly
too long.
sulfated.
SERVICING INFORMATION
10-15
WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING
Clamp
Clamp
Handlebar switch (L)
Handlebar switch (R)
Clamp
Cushion
Speedometer
Clamp
Handlebar switch (L & R)
Wiring harness
Front turn signal light (L & R)
Speed sensor
Regulator/Rectifier
*1
Clamp
Clamp
Solenoid branch wire
High tension cord
Wiring harness
Clamp
Clamp
To generator
High tension cord
Rear ignition coil To wiring harness
5 mm
Electrical parts
holder
Fuse
*2
Clamp
Clamp
*3
High tension cord
To horn
Clamp
Wiring harness
Generator leadwire
Clamp
Clamp
Starter motor
leadwire
To
To generator
generator
*4
*1 Do not slacker.
*3 Cut after excess clamp.
Connect with the gear position switch inside
*2 Do not pass through the harness on the bracket. *4
cover.
10-16
SERVICING INFORMATION
Turn
down.
*1
Breaser hose
match mark
Indicator lamp
harness
Resorvoir
hose
Tapping
clamp
To brake
switch,
etc.
To ECT
sensor
To Horn
horn
Set inside of the frame.
Frame
No use.
TO sensor
Set under the starter relay.
Cleaner
Harness
Tapping
clamp
Set inside of
the cover.
Tapping
clamp
IAT sensor
Battery
To HO2 sensor
(For E-02, 19, 24)
harness
28 mm
(1.1 in)
Shuroud
Wiring
harness
Frame
FWD
Horn
*1
Pass through the ⊕ harness under the starter
relay.
Radiator
Oil pressure switch
20˚ – 45˚
Starter motor
30˚ – 60˚
80˚ – 110˚
90˚
Clamp
Crankcase (R)
Clamp
Generator lead wire
Starter motor lead wire
Clamp
SERVICING INFORMATION
10-17
10-18
SERVICING INFORMATION
CABLE ROUTING
Throttle cable No. 1
150
mm
Throttle cable No. 2
Clamp
Clip
UP
White
tape
Clutch cable
*1
Outside
Frame
*2
High-tension cord
Guide
Solenoid
harness
Clamp
UP
Cushion
Clutch
cable
*3
Outside
*4
*2
High-tension cord
*5
Frame
High-tension
cord
Clutch cable
UP
Clutch cable
Outside
Clutch cable
*2
0
–
2
m
m
*6
Fuel tank cushion bar
0–
2m
Throttle
cable No. 1
Harness
Throttle cable No. 2
Set the clutch cable dented part and clamp the clutch
cable at white tape of cable.
*2 Clamp with this direction.
*3 Clamp the clutch cable attach to the cushion.
*1
m
Guide
*4 Clamp the back side of cushion.
*5 Do not hang the clamp on the bar.
*6 Clamp inside the bar.
SERVICING INFORMATION
10-19
THROTTLE BODY INSTALLATION
FWD
FWD
*1
Intake pipe side
Air cleaner side
*2
67 mm
*3
1 IAP sensor (Front cylinder) 7 IAT sensor
2 IAP sensor (Rear cylinder) 8 Purge hose (E-33 only)
3 PCV (Breather) hose
*1 Match mark
Pass through the PCV (Breather)
4 Fuel feed hose
*2
hose upper the fuel hose.
Install intake pipe with top surface
5 ECT sensor
*3
being horizontal.
6 Cleaner case

ITEM
5
N·m kgf-m
18
1.8
lb-ft
13.0
*1
VIEW B
B
VIEW A
Set the white mark.
) right side.
45˚
) right side.
Clamp from back side.
Pass through the reservoir hose between frame and
throttle valve actuator.
*2 Clamp the hose with frame and harness.
*3 Be careful not to dent hose with frame cover.
) left side.
)
C
30˚
) left side.
Set the yellow
mark.
out side.
Set the white mark.
*4
17.5 N.m
(1.75kgf-m, 12.5 lb-ft)
) left side.
Match mark
Clearance
Set the yellow mark.
) left side.
)
VIEW C
Clamp from right side.
Clamp from
left side.
left side.
up side.
Set the cut-rib inside.
)
Set the yellow mark.
Set the white mark.
Clamp
(big side)
)
*3
A
) left side.
Set the
white mark.
) left side.
*2
Set the
white mark.
Clamp (small side)
left side.
Set the
white mark.
Set the white mark.
*1
10-20
SERVICING INFORMATION
COOLING SYSTEM HOSE ROUTING
*4 Set the hose with dent of engine case.
A The end of the clamp should face...
SERVICING INFORMATION
10-21
FRONT BRAKE ROUTING
*1
*2
28 ˚
*3
*4
*1
After the brake hose union touching to the stop*3 Clamp the sleeve firmly.
per, tighten the union bolt.
*2 Pass through the brake hose firmly.
*4 Set the clamp with stopper before tightening.
*1
10-22
SERVICING INFORMATION
SPEED SENSOR HARNESS ROUTING
FWD
FWD
Pass through the speed sensor harness in front of the brake hose
and guide.
2 Pass through the speed sensor harness in front of the brake hose.
3 Do not catch the speed sensor harness to the caliper boss.
4 Touch the stopper
1
FRONT TURN SIGNAL INSTALLATION
1 No slack
5 Clamp
6 Clip
7 Yellow mark
8 Guide
SERVICING INFORMATION
FRONT TURN SIGNAL LEAD WIRE ROUTING
Brake hose guide
Left handle switch harness
Clamp
*1
Wiring harness
Right front turn signal
Speed sensor
Clamp
Left front turn signal
Right front turn signal
*1 Cut after clamping.
MUFFLER & EXHAUST PIPE INSTALLATION
5 mm
(0.12 in)
5 mm
(0.12 in)
Apply PERMATEX 1372.
10-23
10-24
SERVICING INFORMATION
HANDLEBAR BALANCER
5.5 N·m
(0.5 kgf-m, 4.0 lb-ft)
Clearance : Right side
0 mm (0 in) : Left side
1 Handlebar
2 Nut
3 Throttle grip
4 Handle balancer expander
5 Handlebar balancer
6 Screw
BATTERY PROTECTOR
1 Stick protectors to upper end of this surface.
2 90 mm (3.54 in)
3 30 mm (1.18 in)
4 60 mm (2.36 in)
5 65 mm (2.56 in)
SERVICING INFORMATION
LUBRICATION POINTS
5.3 mm
(2.1 in)
10-25
10-26
SERVICING INFORMATION
FUEL TANK INSTALLATION
Inside
1 Cut after clamping.
2 Frame
SERVICING INFORMATION
REAR COMBINATION LAMP INSTALLATION
1.8 N.m
(0.18 kgf-m, 1.3 lb-ft)
1.8 N.m
(0.18 kgf-m, 1.3 lb-ft)
1 Pass through the left turn signal harness.
2 Reflex reflector
3 License plate bracket (For E-02, 19, 24)
4 Reflex reflector
5 Right reflex reflector (For E-03, 28, 33)
6 Left reflex reflector (For E-03, 28, 33)
10-27
10-28
SERVICING INFORMATION
FRAME HEAD COVER CUSHION INSTALLATION
1 Cushion
2 3 mm (0.12 in)
3 12 mm (0.47 in)
4
5
6
5 mm (0.20 in)
15 mm (0.59 in)
20 mm (0.79 in)
7 10 mm (0.39 in)
LEFT SIDE COVER CUSHION INSTALLATION
1 Cushion
2 27 mm (1.06 in)
3 35 mm (1.38 in)
SERVICING INFORMATION
13.5 mm
(0.53 in)
7 mm
(0.28 in)
REAR FENDER CUSHION INSTALLATION
10-29
10-30
SERVICING INFORMATION
LEFT SIDE COVER INSTALLATION
SERVICING INFORMATION
LID CUSHION INSTSALLATION
1 Cushion
2
10 mm (0.39 in)
3 45 mm (1.77 in)
10-31
10-32
SERVICING INFORMATION
TAIL LAMP INSTALLATION
*1
*2
*3
Clamp
*4
Grommet
Pass through the tail lamp harness and left turn
*1 signal harness over the right side mounting
boss.
*3
Pass through the wiring harness outside of
cushions.
*2 Assemble to the rear fender.
*4
Pass through the wiring harness between rear
fender and rear brace.
SERVICING INFORMATION
PAIR (AIR SUPPLY) SYSTEM DIAGRAM
*2
*1
*3
1 PAIR control solenoid valve
2 PAIR reed valve
A FRESH AIR
*1 From air cleaner
*2 To #1 cylinders
*3 To #2 cylinders
10-33
10-34
SERVICING INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
*3
*1
*2
*4
*2
*5
1 PAIR control solenoid valve
2 Throttle body
3 Bolt
*1 To air cleaner box
*2 Matching mark
*3 Do not contact the hose and throttle cable drum.
*4 The sealant side should face PAIR pipe side.
With the bolt lightly contacted with the PAIR pipe,
*5
tighten the bolt.
SERVICING INFORMATION
10-35
SPECIAL TOOLS
09900-06107
Snap ring pliers
09900-06108
Snap ring pliers
09900-09004
Impact driver set
09900-18710
Hexagon socket
(12 mm)
09900-20202
Micrometer
(25 – 50 mm)
09900-20203
Micrometer
(50 – 75 mm)
09900-20204
Micrometer
(75 – 100 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20605
09900-20607
09900-20602
Dial calipers
Dial gauge
Dial gauge
09900-20701
(1/1000 mm, 1 mm) (1/100 mm, 10 – 34 mm) (1/100 mm, 10 mm) Magnetic stand
09900-20101
09900-20102
Vernier calipers
09900-20508
Cylinder gauge set
09900-20803
09900-20806
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V-block set
(100 mm)
09900-22301
09900-22302
Plastigauge
09900-22401 (10 – 18 mm) 09900-25008
09900-22403 (18 – 35 mm) Multi circuit tester
Small bore gauge set
09900-25009
Needle pointed
probe set
09904-41010
SDS Set
99565-01010-005
CD-ROM Ver. 5
09913-13121
Vacuum balancer
gauge
09913-50121
Oil seal remover
10-36
SERVICING INFORMATION
09913-60230
Journal bearing
remover/installer
09913-60241
Journal bearing
remover/installer
09913-60910
Bearing puller
09913-70210
Bearing installer
set
09913-75821
Bearing installer
09913-76010
Bearing installer
09913-84510
Bearing installer
09915-40610
Oil filter wrench
09915-63210
Adaptor
09915-74511
Oil pressure
gauge hose
09915-74532
Oil pressure
gauge adaptor
09915-64512
Compression
gauge set
09915-77331
Meter (for high
pressure)
09916-10911
Valve lapper set
09916-14510
Valve lifter
09916-14910
Valve lifter
attachment
09916-21111
Valve seat cutter
set
09916-22430
Valve seat cutter
(N-128)
09916-34542
Reamer handle
09916-34550
Valve guide
reamer (5.5 mm)
09916-44910
Valve guide
remover/installer
09916-44920
Valve guide
installer
attachment
09916-84511
Tweezers
09917-10410
Valve adjust driver
09916-34580
Valve guide
reamer (10.8 mm)
SERVICING INFORMATION
09917-47011
Vacuum pump
gauge
09918-03810
Compression
gauge adaptor
10-37
09918-53810
Chain tensioner
lock tool
09920-53740
09920-13120
Crankcase & Shaft Clutch sleeve hub
holder
remover
09921-21820
Bearing retainer
wrench
09921-20240
Bearing remover
set
09923-73210
Bearing remover
09924-62410
Final drive gear
09924-34510
Backlash measur- bearing holder
ing tool (27 – 50) wrench
09924-62430
22 mm Long
socket
09924-64510
Final drive gear
coupring holder
09924-74570
Final drive gear
bearing
remover/installer
09924-84510
Bearing installer
set
09924-84521
Bearing installer
09925-18011
Steering bearing
installer
09930-10121
Spark plug wrench 09930-11920
set
Torx bit JT40H
09930-11940
Bit holder
09930-11950
Torx wrench
09930-40113
Rotor holder
09930-82720
Mode selection
switch
09930-14530
Universal joint
09930-30104
Sliding shaft
09930-33730
Rotor remover
10-38
SERVICING INFORMATION
09940-30221
Front fork assembling tool
09940-40211
Fuel pressure
gauge adaptor
09940-51410
Bearing installer
09940-52841
Inner rod holder
09940-52861
Front fork oil seal
installer
09940-94930
Front fork spacer
holder
09941-34513
Steering race
installer
09941-50111
Bearing remover
set
09940-14911
Steering stem nut
wrench
09940-40220
09940-50120
Fuel pressure gauge Front fork inner
rod holder
hose attachment
09940-92720
Spring scale
09940-94922
Front fork spring
stopper plate
09941-64511
Bearing remover
09941-74911
Steering bearing
installer
09943-74111
Fork oil level
gauge
NOTE:
When order the special tool, please confirm whether it is available or not.
SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
ITEM
Rocker arm shaft
Cylinder head cover bolt
Cylinder head bolt and nut
8 mm
10 mm
6 mm
8 mm
Initial
Final
Initial
Final
Cam sprocket bolt
Cam chain tension adjuster mounting bolt
Cam chain tensioner bolt
Primary drive gear bolt
Clutch spring set bolt
Clutch sleeve hub nut
Driveshaft bolt
Secondary drive gear shaft nut
Secondary gear case bolt
Initial
Final
Generator rotor bolt
Starter clutch allen bolt
Crankcase bolt
6 mm
Initial
8 mm
Final
Initial
Conrod cap nut
Final
Oil pressure regulator
Oil pump mounting bolt
Oil pressure switch
Oil drain plug
Rocker arm valve adjuster bolt
Oil plug
6 mm
8 mm
10 mm
14 mm
16 mm
Engine mounting bolt
Engine mounting bracket bolt
8 mm
Frame mounting bolt/nut
10 mm
Exhaust pipe clamp bolt
Muffler mounting bolt
Speed sensor rotor bolt
Spark plug
N·m
27
10
25
10
25
25
38
15
10
10
95
10
60
65
105
15
22
160
26
11
15
22
25
51
28
11
14
21
15
6.0
18
15
23
35
79
23
23
50
23
23
100
18
kgf-m
2.7
1.0
2.5
1.0
2.5
2.5
3.8
1.5
1.0
1.0
9.5
1.0
6.0
6.5
10.5
1.5
2.2
16.0
2.6
1.1
1.5
2.2
2.5
5.1
2.8
1.1
1.4
2.1
1.5
0.6
1.8
1.5
2.3
3.5
7.9
2.3
2.3
5.0
2.3
2.3
10.0
1.8
lb-ft
19.5
7.0
18.0
7.0
18.0
18.0
27.5
11.0
7.0
7.0
68.5
7.0
47.0
44.2
76.0
11.0
16.0
115.5
19.0
8.0
11.0
16.0
18.0
37.0
20.0
8.0
10.0
15.0
11.0
4.3
13.0
11.0
16.5
25.5
57.0
16.5
16.5
36.0
16.5
16.5
72.5
13.0
10-39
10-40
SERVICING INFORMATION
SECONDARY AND FINAL
ITEM
Secondary drive bevel gear bearing retainer bolt
Secondary driven bevel gear bolt
Secondary driven bevel gear bearing stopper
Secondary drive gear shaft nut
Final gear case nut
Final drive bevel gear coupling nut
Final drive bevel gear bearing stopper
Final gear case oil drain plug
Final gear case bolt
8 mm
10 mm
Final driven bevel gear bearing retainer screw
N·m
23
23
105
105
40
100
110
23
23
50
9
kgf-m
2.3
2.3
10.5
10.5
4.0
10.0
11.0
2.3
2.3
5.0
0.9
lb-ft
16.5
16.5
76.0
76.0
29.0
72.5
79.5
16.5
16.5
36.0
6.5
N·m
8
18
3.5
10
3.5
kgf-m
0.8
1.8
0.35
1.0
0.35
lb-ft
6.0
13.0
2.5
7.0
2.5
N·m
6
10
17
18
kgf-m
0.6
1.0
1.7
1.8
lb-ft
4.5
7.0
12.5
13.0
FI SYSTEM AND INTAKE AIR SYSTEM
ITEM
CKP sensor mounting bolt
IAT sensor
Fuel delivery pipe mounting screw
Fuel pump mounting bolt
TPS and STPS mounting screw
COOLING SYSTEM
ITEM
Water pump cover bolt
Water pump mounting screw
Cooling fan thermo-switch
ECT sensor
SERVICING INFORMATION
CHASSIS
ITEM
Front axle
Front axle pinch bolt
Brake disc bolt
Front fork cap bolt
Front fork spring stopper nut
Front fork damper rod bolt
Front fork upper clamp bolt
Front fork lower clamp bolt
Front fork inner rod lock-nut
Steering stem head nut
Steering stem nut
Front master cylinder mounting bolt
Front brake caliper mounting bolt
Brake hose union bolt
Air bleeder valve
Handlebar set bolt
Handlebar holder nut
Front footrest bracket mounting bolt
Frame down tube mounting bolt (M8)
Frame down tube mounting bolt (M10)
Rear brake pedal bolt
Rear swingarm pivot bolt (Left)
Rear swingarm pivot bolt (Right)
Rear swingarm pivot bolt lock nut
Rear shock absorber mounting nut
(Upper and Lower)
Rear cushion lever/rod mounting nut
Rear axle nut
Rear torque link nut (front)
Rear torque link nut (rear)
Rear brake link pivot bolt
Rear brake cam lever bolt
Driven joint stopper bolt
Frame handle grip mounting bolt (M10)
Fuel level gauge mounting bolt
N·m
65
23
23
23
35
40
23
30
15
90
45
10
39
23
7.5
23
45
55
23
50
11
100
9.5
100
kgf-m
6.5
2.3
2.3
2.3
3.5
4.0
2.3
3.0
1.5
9.0
4.5
1.0
3.9
2.3
0.75
2.3
4.5
5.5
2.3
5.0
1.1
10.0
0.95
10.0
lb-ft
47.0
16.5
16.5
16.5
25.5
29.0
16.5
21.5
11.0
65.0
32.5
7.0
28.0
16.5
5.5
16.5
32.5
40.0
16.5
36.0
8.0
72.5
7.0
72.5
50
5.0
36.0
78
65
35
25
29
10
10
50
10
7.8
6.5
3.5
2.5
2.9
1.0
1.0
5.0
1.0
57.5
47.0
25.5
18.0
21.0
7.3
7.0
36.0
7.0
10-41
10-42
SERVICING INFORMATION
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A (mm)
4
5
6
8
10
12
14
16
18
Conventional bolt
Conventional or “4” marked bolt
N·m
kgf-m
lb-ft
1.5
0.15
1.0
3
0.3
2.0
5.5
0.55
4.0
13
1.3
9.5
29
2.9
21.0
45
4.5
32.5
65
6.5
47.0
105
10.5
76.0
160
16.0
115.5
“4” marked bolt
N·m
2.3
4.5
10
23
50
85
135
210
240
“7” marked bolt
kgf-m
0.23
0.45
1.0
2.3
5.0
8.5
13.5
21.0
24.0
“7” marked bolt
lb-ft
1.5
3.0
7.0
16.5
36.0
61.5
97.5
152.0
173.5
SERVICING INFORMATION
10-43
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
STANDARD
30
(1.18)
26
(1.02)
0.08 – 0.13
(0.003 – 0.005)
0.17 – 0.22
(0.007 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
—
—
—
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
3.1
(0.12)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
INNER
—
OUTER
—
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
Valve spring tension
INNER
OUTER
64 – 73 N
(6.51 – 7.49 kgf, 14.35 – 16.51 lbs)
at length 32.5 mm (1.28 in)
119 – 136 N
(12.09 – 13.91 kgf, 26.65 – 30.67 lbs)
at length 36.0 mm (1.42 in)
—
—
10-44
SERVICING INFORMATION
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Rear left side
Front right side
Rear right side
Front left side
Rear left side
Front right side
Rear right side
Front left side
Camshaft runout
STANDARD
35.50 – 35.54
(1.398 – 1.399)
36.58 – 36.62
(1.440 – 1.442)
0.032 – 0.066
(0.0013 – 0.0026)
20.012 – 20.025
(0.7879 – 0.7884)
25.012 – 25.025
(0.9847 – 0.9852)
19.959 – 19.980
(0.7858 – 0.7866)
24.959 – 24.980
(0.9826 – 0.9835)
IN. & EX.
Rocker arm shaft O. D.
IN. & EX.
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
Cylinder head distortion
—
Cylinder head cover distortion
—
—
—
—
—
0.10
(0.004)
—
Rocker arm I. D.
Unit: mm (in)
LIMIT
35.20
(1.386)
36.28
(1.428)
0.150
(0.0059)
—
—
0.05
(0.002)
0.05
(0.002)
CYLINDER + PISTON + PISTON RING
Unit: mm (in)
ITEM
Compression pressure
LIMIT
1 100 kPa
Compression pressure
difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
(11 kgf/cm² 156 psi)
—
(2 kgf/cm² 28 psi)
0.045 – 0.055
(0.0018 – 0.0022)
83.000 – 83.015
(3.2677 – 3.2683)
82.950 – 82.965
(3.2657 – 3.2663)
Measure at 15 mm (0.6 in) from the skirt end.
0.120
(0.0047)
83.085
(3.2711)
—
0.05
(0.002)
7.7
(0.30)
9.4
(0.37)
0.70
(0.028)
0.70
(0.028)
0.180
(0.007)
0.150
(0.006)
Cylinder distortion
Piston ring free end gap
1st
2nd
Piston ring end gap
Piston ring to groove clearance
200 kPa
Approx. 9.6 (0.38)
R
Approx. 11.8 (0.46)
2nd
0.20 – 0.35
(0.008 – 0.014)
0.20 – 0.35
(0.008 – 0.014)
1st
—
2nd
—
1st
82.880
(3.2630)
SERVICING INFORMATION
ITEM
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
0.970 – 0.990
(0.0382 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7871 – 0.7874)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing
thickness
Crankshaft thrust clearance
Crankshaft runout
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866)
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
40.982 – 41.000
(1.6135 – 1.6142)
0.002 – 0.029
(0.00008 – 0.0011)
47.965 – 47.980
(1.8884 – 1.8890)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
LIMIT
—
—
—
—
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
0.05
(0.002)
STANDARD
350 – 650 kPa
(3.5 – 6.5 kgf/cm², 50 – 92 psi)
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
10-45
—
10-46
SERVICING INFORMATION
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
No. 1
No. 2
Drive plate claw width
Driven plate distortion
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
3.42 – 3.58
(0.135 – 0.141)
15.9 – 16.0
(0.626 – 0.630)
—
Clutch spring free length
49.2
(1.94)
TRANSMISSION
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
No. 1
No. 2
Shift fork groove width
No. 1
No. 2
Shift fork thickness
No. 1
No. 2
STANDARD
1.690 (71/42)
1.000 (30/30)
3.503 (17/15 × 34/11)
2.461 (32/13)
1.631 (31/19)
1.227 (27/22)
1.000 (25/25)
0.814 (22/27)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
4.50 – 4.60
(0.177 – 0.181)
5.30 – 5.40
(0.209 – 0.213)
4.30 – 4.40
(0.169 – 0.173)
SHAFT DRIVE
ITEM
Secondary bevel gear backlash
Final bevel gear backlash
Damper spring free length
Drive side
STANDARD
0.05 – 0.32
(0.002 – 0.013)
0.03 – 0.064
(0.001 – 0.025)
—
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
46.8
(1.84)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
—
—
—
—
Unit: mm (in)
LIMIT
—
—
58.5
(2.30)
SERVICING INFORMATION
THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT
ITEM
Thermostat valve opening
temperature
Thermostat valve lift
ECT sensor resistance
Radiator cap valve opening
pressure
Cooling fan thermo-switch
operating temperature
Engine coolant type
Engine coolant capacity
STANDARD/SPECIFICATION
NOTE
Approx. 75 °C (167 °F)
—
Over 6 mm (0.24 in) at 90 °C (194 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
40 °C
Approx. 1.148 kΩ
(104 °F)
60 °C
Approx. 0.587 kΩ
(140 °F)
80 °C
Approx. 0.322 kΩ
(176 °F)
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
OFF→ON
Approx. 105 °C (221 °F)
ON→OFF
Approx. 100 °C (212 °F)
Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 500 ml
(1.6/1.3 US/lmp qt)
—
—
—
—
—
—
—
—
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
Approx. 168 ml (5.7/5.9 US/lmp oz)
and more/10 sec.
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
NOTE
10-47
10-48
SERVICING INFORMATION
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
SPECIFICATION
184 – 276 Ω
4.0 V and more
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.4 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.4 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.6 kΩ at 20 °C (68 °F)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Leaning
GP switch voltage
Injector voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
Heated oxygen sensor output
voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
3.7 – 4.4 V
0.6 V and more
Battery voltage
4.5 – 5.5 V
Closed
Approx. 0.5 kΩ
Opened
Approx. 3.9 kΩ
Closed
Approx. 0.5 V
Opened
Approx. 3.9 V
Approx. 6.5 Ω
0.2 V and less at idle speed
0.7 V and more at 5 000 r/min
6.5 – 8.9 Ω at 23 °C (73.4 °F)
20 – 24 Ω at 20 – 30 °C (68 – 86 °F)
NOTE
When cranking
When leaning
65°
From 1st to Top
For E-02, 19, 24
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
SPECIFICATION
34 mm
41F1 (For E-33), 41F0 (For the others)
1 100 ± 100 r/min
1 800 r/min (When cold engine)
2.0 – 4.0 mm
(0.08 – 0.16 in)
SERVICING INFORMATION
ELECTRICAL
ITEM
Firing order
Spark plug
SPECIFICATION
1·2
NGK: DPR7EA-9
DENSO: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
184 – 276 Ω
4.0 V and more
Type
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Primary
2–6Ω
Secondary
15 – 30 kΩ
Ignition coil primary peak voltage
205 V and more
Generator coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator maximum output
Starter relay resistance
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Main
Power source
10-49
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Terminal
+W
#1
- Ground
+ B/Y
#2
- Ground
0.2 – 1.5 Ω
70 V (AC) and more at 5 000 r/min
Y–Y
14.0 – 15.5 V at 5 000 r/min
350 W at 5 000 r/min
3–7Ω
0.6 V and more (From 1st to top without neutral)
FTX12-BS
12 V 36 kC (10 Ah)/10 HR
10 A
10 A
10 A
15 A
10 A
30 A
10 A
Y–Y
10-50
SERVICING INFORMATION
WATTAGE
Unit: W
ITEM
Headlight
HI
LO
Position/Parking light
Brake light/Taillight
Turn signal light
Licence plate light
Speedometer light
Engine coolant temp. warning light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure indicator light
FI indicator light
E-03, 28, 33
60
55
SPECIFICATION
E-24
←
←
LED
21/5 (Front),
21 (Rear)
5
LED
LED
LED
LED
LED
LED
LED
←
Others
←
←
5
←
21
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
←
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
STANDARD
20 – 30
(0.8 – 1.2)
75 – 85
(3.0 – 3.3)
Rear brake pedal height
Brake drum I.D.
Rear
----
Brake disc thickness
Front
4.8 – 5.2
(0.19 – 0.21)
Brake disc runout
----
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Wheel rim runout
Wheel axle runout
Wheel rim size
Unit: mm (in)
LIMIT
------180.7
(7.11)
4.5
(0.18)
0.30
(0.012)
----
Front
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4993)
30.230 – 30.306
(1.1901 – 1.1931)
30.150 – 30.200
(1.1870 – 1.1889)
Axial
----
Radial
----
Front
----
Rear
----
Front
Rear
J16 M/C × MT 3.00
J15 M/C × MT 4.00
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
-------
----------
SERVICING INFORMATION
10-51
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Front
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
Tire type
Tire tread depth
Front
Rear
Front
Rear
STANDARD
200 kPa
(2.00 kgf/cm², 29 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
200 kPa
(2.00 kgf/cm², 29 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
130/90-16 M/C 67H
170/80-15 M/C 77H
IRC GS-23F A
IRC GS-23R A
Front
----
Rear
----
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring)
Front fork oil type
Front fork oil capacity (each leg)
Front fork inner tube outside diam.
Rear shock absorber spring
adjuster
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
140
(5.5)
380.4
(14.98)
153
(6.02)
SUZUKI FORK OIL L01
or an equivalent fork oil
490 ml
(16.6/17.3 US/Imp oz)
41
(1.61)
LIMIT
------------------------1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
LIMIT
---372
(14.6)
-------------
3rd
----
105
(4.13)
----
----
0.3
(0.01)
10-52
SERVICING INFORMATION
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
Final bevel gear oil type
Final bevel gear oil capacity
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
15.0 L
reserve
(4.0/3.3 US/lmp gal)
Including
15.5 L
reserve
(4.1/3.4 US/lmp gal)
Fuel level
1.5 L
indicator light
(0.4/0.3
US/lmp gal)
lighting
SAE 10 W-40, API, SF/SG or SH/SJ with JASO MA
3 000 ml
Change
(3.2/2.6 US/lmp qt)
3 400 ml
Filter change
(3.6/3.0 US/lmp qt)
3 700 ml
Overhaul
(3.9/3.3 US/lmp qt)
SAE 90 hypoid gear oil with
GL-5 under API classification
200 – 220 ml
(6.8/7.0 – 7.4/7.7 US/lmp oz)
DOT 4
NOTE
E-03, 28, 33
Others
E-33
Others
EMISSION CONTROL INFORMATION
11-1
EMISSION CONTROL INFORMATION
CONTENTS
EMISSION CONTROL SYSTEMS ...............................................................11- 2
FUEL INJECTION SYSTEM..................................................................11- 2
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM).............11- 3
NOISE EMISSION CONTROL SYSTEM...............................................11- 4
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) ......11- 4
PAIR (AIR SUPPLY) SYSTEM INSPECTION .............................................11- 5
HOSES ..................................................................................................11- 5
PAIR REED VALVE ..............................................................................11- 5
PAIR CONTROL SOLENOID VALVE...................................................11- 6
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .......................................11- 7
HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24).....11- 8
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33).............................................................................................11- 9
HOSES (EVAP hose)............................................................................11- 9
EVAP CANISTER..................................................................................11- 9
EVAP CANISTER HOSE ROUTING (Only for E-33)..................................11-10
11
11-2 EMISSION CONTROL INFORMATION
EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
VZ800 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.
1
2
3
4
5
6
Fuel tank
Fuel filter (For high pressure)
Fuel pressure regulator
Fuel delivery pipe
Fuel injector
Fuel feed hose
7
8
A
B
C
Fuel mesh filter (For low pressure)
Fuel pump
Before-pressurized fuel
Pressurized fuel
Relieved fuel
EMISSION CONTROL INFORMATION
11-3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)
The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system (For E-02, 19, 24, 33). The fresh air is drawn into the exhaust port with the PAIR control solenoid valve
and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS.
1
2
3
4
5
PAIR control solenoid valve
PAIR reed valve
Air cleaner box
Fuel injector
ECM
6
7
A
B
HO2 sensor (E-02, 19, 24)
Threeway catalyst (E-02, 19, 24, 33)
FRESH AIR
EXHAUST GAS
11-4 EMISSION CONTROL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local 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 into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2. The use of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any
other component which conducts exhaust gases.
• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which
conducts intake air.
• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label.
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
1
2
3
4
5
6
7
8
A
B
C
Fuel-vapor separator
IAP sensor
Throttle body
3-way connector
Purge hose
Fuel shut-off valve
Surge hose (red stripe)
EVAP canister
FRESH AIR
HC VAPOR
VACUUM
EMISSION CONTROL INFORMATION
PAIR (AIR SUPPLY) SYSTEM INSPECTION
HOSES
• Remove the PAIR cover. (3-5)
• Inspect the hoses for wear or damage.
• Inspect that the hoses for secure connection.
PAIR REED VALVE
• Remove the PAIR control solenoid valve. (3-5)
• Remove the reed valve case 1 and PAIR reed valve 2.
• Inspect the reed valve for the carbon deposit.
• If the carbon deposit is found in the reed valve, replace the
PAIR control solenoid valve with a new one.
• Install the reed valve A and its case B with outlet pipes C
the facing the inlet pipe D.
11-5
11-6 EMISSION CONTROL INFORMATION
PAIR CONTROL SOLENOID VALVE
• Remove the PAIR control solenoid valve. (3-5)
• Check that air flows through the air inlet port to the air outlet
port.
• If air does not flow out, replace the PAIR control solenoid
valve with a new one.
A Air flow
• Connect the 12 V battery to the PAIR control solenoid valve
terminals and check the air flow.
• If air does not flow out, the solenoid valve is in normal condition.
12V
• Check the resistance between the terminals of the PAIR control solenoid valve.
 Resistance: 20 – 24 Ω at 20 – 30 °C (68 – 86 °F)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
If the resistance is not within the standard range, replace the
PAIR control solenoid valve with a new one.
Installation is in the reverse order of removal.
• Connect the PAIR control solenoid valve lead wire coupler
and PAIR hoses securely.
• PAIR system hose routing. (11-7)
EMISSION CONTROL INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
*3
*1
*2
*4
*2
*5
1 PAIR control solenoid valve
2 Throttle body
3 Bolt
*1 To air cleaner box.
*2 Matching mark
*3 Do not contact the hose and throttle cable drum.
*4 The sealant side should face PAIR pipe side.
With the bolt lightly contacted with the PAIR pipe,
*5
tighten the bolt.
11-7
11-8 EMISSION CONTROL INFORMATION
HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24)
• Disconnect the HO2 sensor lead wire coupler. (5-69)
• Inspect the HO2 sensor and its circuit referring to flow table of
the malfunction code C44 (P0130/P0135).
• Check the resistance between the terminals of the HO2 sensor.
 Resistance: 6.5 – 8.9 Ω at 23 °C (73.4 °F)
(White – White)
 09900-25008: Multi-circuit tester set
 Tester knob indication: Resistance (Ω)
If the resistance is not within the standard range, replace the
HO2 sensor with a new one.
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.

Do not remove the HO2 sensor while it is hot.

Be careful not to expose it to excessive shock.
Do not use an impact wrench while removing or
installing the HO2 sensor unit.
Be careful not to twist or damage the sensor lead wire.
White
White
EMISSION CONTROL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33)
• Remove the seats 1. (8-3)
• Remove the fuel tank 2. (6-3)
• Remove the right frame cover 3. (8-4)
HOSES (EVAP hose)
Inspect the hoses for wear or damage.
Make sure that the hoses are securely connected.
EVAP CANISTER
Inspect the canister for damage to the body.
11-9
11-10 EMISSION CONTROL INFORMATION
EVAP CANISTER HOSE ROUTING (Only for E-33)
*1
*2
*4
*3
*5
*6
1
2
3
4
Three way joint
Wiring harness
Fuel shut-off valve
EVAP canister
Pass through the purge hose over the wiring
*1
harness.
*2
*3
*4
*5
White paint mark should face upside.
To three way joint.
Face the clamp end right side.
Face the clamp end right side.
*6 Face the clamp end forward.
WIRING DIAGRAM
E-02, 19, 24
Wiring diagrams wire color, refer to section “WIRE COLOR”.
: ENGINE COOLANT TEMP. WARNING LIGHT
: FI LIGHT
: FUEL WARNING LIGHT
: TURN SIGNAL INDICATOR LIGHT
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: OIL INDICATOR LIGHT
HANDLEBAR SWITCH (R)
PILOT LAMP
ECM
M
Lg
B/W
Lg
Br
B/W
W/B
B
Lg
B/W
HEADLIGHT
Gr
B/W
W/B
Y
B/W
W
B
B/W
Gr/R
B/W
O/G
FRONT TURN SIGNAL
LIGHT (R)
B
B/W
W/R
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
Y
O/W
R/Bl
Y/R
Y/R
B/W
B/Lg
Y/B
R
Br/W
B/Br
W
FUEL PUMP
RELAY
Y/W
G/W
Dg
P
TO
SENSOR
O/W
B/Br
W/Bl
W/B
B/W
O/G
B/Y
Y
Bl/B
Lg
B
R
Bl/B
B/Br
O/G
W/B
O/W
B/Y
O/W
W
B
Lbl
Lg
O/B
O/W
O/G
W/B
Y/G
Y/W
O
B/W
O/Bl
Y/B
B/Lg
B/Y
G/Y
B/W
B/G
O/G
R/Bl
OPTION
FUEL
PUMP
W/R
G/Y
Bl
Y/G
B/Br
B/Br
G/B
Bl/B
Br/W
B/Bl
O/Y
Bl/W
Bl/B
Bl/G
B/Br
B/W
R/Bl
O/G
Y/R
Br
Y/B
W/Bl
R
TP
SENSOR
IGNITION IGNITION
COIL (R) COIL (F)
HO2
SENSOR
P/W
W/B
B/Lg
Bl/R
Bl/Y
Gr/R
B/G
ON
OFF
Gr/W
Gr/B
B/W
PUSH
B/W
Br/B
B
Y
G
B/Y
FRONT BRAKE
SWITCH
OFF
REAR BRAKE
ON
SWITCH
Y/R
B/W
B/Lg
R/B
STARTER
BUTTON
W
Gr
B
W
O/R
P
B/W
Y/B
B/Lg
B
G/Y
B/W
B/G
O/G
R
OFF
RUN
Bl
Y
B
SPEED
SENSOR
SPEEDOMETER
OFF
RUN
B/W
O/G
Y
B/Y
Bl
Lg
B
ENGINE
HAZARD STOP
SWITCH SWITCH
B
Lbl
Lg
O/B
O/W
B/R
B/Bl
Y/G
Y/W
O/R
TEMP
FI
F
TU
HI
NU
OIL
B
B/W
REAR TURN
SIGNAL LIGHT (R)
BRAKE LIGHT/
TAILLIGHT
Gr
B/W
LICENSE LIGHT
B/W
B
REAR TURN
SIGNAL LIGHT (L)
FRONT TURN SIGNAL
LIGHT (L)
Br
B/W
Br
B/W
B
B
B
B
B
B/W
B
B
B
R
R
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
Y/B
Y/G
R
R
Br
G/Y
B
B
B
Bl
G
Y
Y
Y
Dg
B/Br
B/Lg
P/W
G
B
R
Y/W
B/Br
B/Bl
B/Br
B/Br
G/B
R
B/Br
G/W
R
O/W
Br/B
Gr/W
Y/R
Gr/B
Y/R
O/B
Br
Lbl
G
O/Y
O/Y
O/G
O
O/Bl
Bl/B
Bl
B/W
G
B/W
G
R
W
Y
Y/Bl
W/Bl
R/Bl
G/Y
Bl
P
G/Y
Bl
P
B/Bl
B/W
Lg
Lbl
B
Y/W
W/Bl
Y/Bl
Y/W
B/W
Y/B
B/Bl
B/W
Lg
Lbl
B
O/R
W
Y
Y/W
B/Y
B/Y
R
O
O/Y
Br
B/Bl
O/G
B/R
O/Y
HORN
B
Bl
B/R
B/W
POSITION LIGHT
(E-02,19 ONLY)
GP
SWITCH PUSH
FREE
OIL PRESSURE
SWITCH
SIDE STAND
SWITCH
1
FUSE BOX
5
2
6
3
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. POWER SOURCE
B Bl
INJECTOR (F)
INJECTOR (R)
10 A
10 A
10 A
15 A
10 A
10 A
IAP
SENSOR
(R)
PAIR
SOLENOID
IAP
SENSOR ECT
SENSOR
(F)
STV
STP
ACTUATOR SENSOR
B/W
R
O
O/Y
Br
HANDLEBAR SWITCH (L)
4
B
B
PUSH
B
B
P
P
G
G
W/Bl
W/B
Bl
Bl
Y
Y
B
B
FREE
PUSH
B/W
G
ON
OFF
PASSING
CLUTCH
HORN
COOLING
LIGHT
SWITCH
BUTTON
FAN
SWITCH
THERMOL
P
HI
SWITCH COOLING
PUSH
LOCK
LO
FAN
R
OFF
ON
MOTOR
DIMMER
ON
OFF
TURN SIGNAL
SWITCH
LIGHT SWITCH
IGNITION SWITCH
1
IAT
SENSOR
CKP
REGULATOR/
SENSOR
RECTIFIER
GENERATOR
STARTER 1: MAIN (30 A)
MOTOR
STARTER
RELAY
BATTERY
12
E-03, 28, 33
: ENGINE COOLANT TEMP. WARNING LIGHT
: FI LIGHT
: FUEL WARNING LIGHT
: TURN SIGNAL INDICATOR LIGHT
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: OIL INDICATOR LIGHT
HANDLEBAR SWITCH (R)
PILOT LAMP
FRONT BRAKE
SWITCH
OFF
REAR BRAKE
ON
SWITCH
FUEL
PUMP
ECM
FRONT TURN SIGNAL
LIGHT (R)
B
B/W
Gr
W/R
Gr/R
B/W
Lg
B/W
Lg
Br
B/W
W/B
B
Lg
B/W
O/G
HEADLIGHT
Y
B/W
W
B
B/W
Gr
O/W
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
R
Y/W
G/W
Dg
P
G/B
Bl/B
Br/W
B/Bl
O/Y
Bl/W
Bl/B
Bl/G
B/Br
B/W
R/Bl
O/W
Y/R
Br
Y/B
Y
O/W
R/Bl
Y/R
Y/R
B/W
B/Lg
Y/B
R
Bl/B
B/Br
O/G
W/B
O/W
B/Y
O/W
W
B
Lbl
Lg
O/B
O/W
O/G
W/B
Y/G
Y/W
O
W/R
G/Y
Bl
Y/G
B/Br
FUEL PUMP
RELAY
P/W
Y/R
B/W
B/Lg
R/B
M
W
Y/B
B/Lg
B/Y
G/Y
B/W
B/G
O/G
R/Bl
OPTION
B/W
O/Bl
TO
SENSOR
B/Lg
Bl/R
Bl/Y
Gr/R
B/G
TP
SENSOR
IGNITION IGNITION
COIL (R) COIL (F)
Gr/W
Gr/B
B/W
ON
OFF
B/W
Br/B
B
Y
G
B/Y
PUSH
R
Br/W
B/Br
STARTER
BUTTON
B/W
O/G
Y
B/Y
Bl
Lg
B
O/R
P
B/W
Y/B
B/Lg
B
G/Y
B/W
B/G
O/G
R
OFF
RUN
Bl
Y
B
SPEED
SENSOR
SPEEDOMETER
OFF
RUN
B/W
O/G
B/Y
Y
Bl/B
Lg
B
ENGINE
HAZARD STOP
SWITCH SWITCH
B
Lbl
Lg
O/B
O/W
B/R
B/Bl
Y/G
Y/W
O/R
TEMP
FI
F
TU
HI
NU
OIL
B
B/W
O/G
B/W
B
B
B
R
R
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
Y/B
Y/G
R
R
Br
G/Y
B
B
B
Bl
G
Y
Y
Y
Dg
B/Br
B/Lg
P/W
G
B
R
Y/W
B/Br
B/Bl
B/Br
B/Br
G/B
R
B/Br
G/W
R
O/W
Br/B
Gr/W
Y/R
Gr/B
Y/R
O/B
Br
Lbl
G
O/Y
O/Y
O/G
O
O/Bl
Bl/B
Bl
B/W
G
B/W
G
R
W
Y
Y/Bl
W/Bl
R/Bl
G/Y
Bl
P
G/Y
Bl
P
B/Bl
B/W
Lg
Lbl
B
Y/W
W/Bl
Y/Bl
Y/W
B/W
Y/B
B/Bl
B/W
Lg
Lbl
B
O/R
W
Y
Y/W
B/Y
B/Y
R
O
O/Y
Br
B/Bl
O/G
B/R
O/Y
HORN
B
Bl
B/R
B/W
FRONT TURN SIGNAL
LIGHT (L)
GP
SWITCH PUSH
FREE
OIL PRESSURE
SWITCH
SIDE STAND
SWITCH
1
5
2
FUSE BOX
6
B Bl
3
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. POWER SOURCE
INJECTOR (F)
INJECTOR (R)
10 A
10 A
10 A
15 A
10 A
10 A
IAP
SENSOR
(R)
PAIR
SOLENOID
IAP
SENSOR ECT
SENSOR
(F)
STV
STP
ACTUATOR SENSOR
B/W
R
O
O/Y
Br
HANDLEBAR SWITCH (L)
4
B
B
PUSH
B
P
G
W/B
W/Bl
Bl
Y
B
FREE
PUSH
B/W
G
ON
OFF
PASSING
CLUTCH
HORN
COOLING
LIGHT
SWITCH
BUTTON
FAN
SWITCH
THERMOL
P
HI
SWITCH COOLING
PUSH
LOCK
LO
FAN
R
OFF
ON
MOTOR
DIMMER
ON
OFF
TURN SIGNAL
SWITCH
LIGHT SWITCH
IGNITION SWITCH
1
IAT
SENSOR
CKP
SENSOR
GENERATOR
REGULATOR/
RECTIFIER
STARTER 1: MAIN (30 A)
MOTOR
STARTER
RELAY
BATTERY
Gr
B/W
W/B
REAR TURN
SIGNAL LIGHT (R)
BRAKE LIGHT/
TAILLIGHT
Gr
B/W
LICENSE LIGHT
B/W
B
REAR TURN
SIGNAL LIGHT (L)
Prepared by
December, 2004
Part No. 99500-38050-01E
Printed in Japan
456
TOP
VZ800
99500-38050-01E
K5
Printed in Japan
K5
VZ800
BOTTOM
No.5230 99500-38050-01E VZ800K5 Service Manual 2004. 11. 29 Cover_14 for PS printing (16 mm)
DIC75
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