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FOREWORD
This manual contains an introductory description on the SUZUKI TU250X 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.
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.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM DIAGNOSIS
FUEL SYSTEM AND THROTTLE
BODY
EXHAUST SYSTEM
COOLING AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
1
2
3
4
5
6
7
8
9
10
11
WIRING DIAGRAM
12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2009
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 Collar
2 Bearing
3 Front wheel
4 Spacer
5 Brake disc
6 Speedometer gearbox
7 Balancer weight
A Front axle
B Spoke nipple
C Brake disc bolt
ITEM N·m kgf-m lbf-ft
A 65 6.5
47.0
B 3 0.3
2.0
C 23 2.3
16.5
FW
D
FWD
SYMBOL MARKS AND MATERIALS
Listed in the table below are the symbols indicating instructions and other information. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified torque.
SYMBOL DEFINITION
Apply THREAD LOCK SUPER “1360” or equivalent.
99000-32130
Apply oil. Use engine oil or transmission oil unless otherwise specified.
Use SUZUKI FORK OIL SS-08 or equivalent.
99000-99001-SS8
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Apply SUZUKI SUPER GREASE “A” or equivalent.
99000-25010
Apply SUZUKI SILICONE GREASE or equivalent.
99000-25100
Apply SUZUKI WATER RESISTANCE
GREASE or equivalent.
99000-25160
Apply SUZUKI MOLY PASTE or equivalent.
99000-25140
Apply SUZUKI BOND “1215” or equivalent.
99000-31110
Apply THREAD LOCK SUPER “1303” or equivalent.
99000-32030
Apply THREAD LOCK SUPER “1322” or equivalent.
99000-32110
Apply THREAD SUPER “1342” or equivalent.
99000-32050
Apply or use brake fluid. (DOT 4)
Measure in voltage range.
Measure in current range.
Measure in resistance range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Indication of service data.
ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC
AC
ACL
API
ATDC
A/F
: After Bottom Dead Center
: Alternating Current
: Air Cleaner, Air Cleaner Box
: American Petroleum Institute
: After Top Dead Center
: Air Fuel Mixture
B
BBDC
BTDC
B+
: Before Bottom Dead Center
: Before Top Dead Center
: Battery Positive Voltage
H
HC : Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
L
LED
LH
: Light Emitting Diode
(Malfunction Indicator Lamp)
: Left Hand
F
FI
FP
FPR
G
GEN
GND
D
DC
DMC
DRL
DTC
E
ECM
C
CKP Sensor : Crankshaft Position Sensor
CKT
(CKPS)
: Circuit
CLP Switch : Clutch Lever Position Switch
CO
(Clutch Switch)
: Carbon Monoxide
CPU : Central Processing Unit
: Direct Current
: Dealer Mode Coupler
: Daytime Running Light
: Diagnostic Trouble Code
ET Sensor
: Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
: Engine Temperature Sensor
(ETS)
: Fuel Injection, Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Generator
: Ground
M
MAL-Code
Max
MIL
Min
N
NOX
O
OHC
P
PAIR
PCV
R
RH
ROM
: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
(LED)
: Minimum
: Nitrogen Oxides
: Over Head Camshaft
: Pulsed Secondary Air Injection
: Positive Crankcase
Ventilation (Crankcase Breather)
: Right Hand
: Read Only Memory
S
SAE
SDS
: Society of Automotive Engineers
: Suzuki Diagnosis System
STC System : Secondary Throttle Control System
(STCS)
STP Sensor : Secondary Throttle Position Sensor
ST Valve
(STPS)
: Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor
TP Sensor
: Tip-Over Sensor (TOS)
: Throttle Position Sensor (TPS)
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
A
Air Cleaner
SAE TERM
FULL TERM
B
Barometric Pressure
ABBREVIATION
ACL
BARO
FORMER SUZUKI TERM
Air Cleaner, Air Cleaner Box
B+
Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Voltage, +B Battery Positive Voltage
C
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector
Diagnostic Test Mode
Diagnostic Trouble Code
E
Electronic Ignition
Engine Control Module
DLC
DTM
DTC
El
ECM
ET
RPM
Dealer Mode Coupler
––––
Diagnostic Code, Malfunction Code
––––
Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Temperature
Engine Speed (RPM)
Engine Temperature
Engine Speed
F
Fuel Level Sensor
Fuel Pump
G
––––
FP
Fuel Level Sensor, Fuel Level Gauge
Fuel Pump (FP)
I
Ground
Ignition Control
Ignition Control Module
Intake Air Temperature
GND
IC
ICM
IAT
Ground (GND, GRD)
Electronic Spark Advance (ESA)
––––
Intake Air Temperature (IAT), Air Temperature
SAE TERM
FULL TERM
M
Malfunction Indicator Lamp
ABBREVIATION
MIL
Manifold Absolute Pressure
Mass Air Flow
O
On-Board Diagnostic
MAP
MAF
OBD
FORMER SUZUKI TERM
LED Lamp
Malfunction Indicator Lamp (MIL)
Intake Air Pressure (IAP), Intake Vacuum
Air Flow
Self-Diagnosis Function
Diagnostic
–––– Open Loop
P
OL
Programmable Read Only Memory PROM
Pulsed Secondary Air Injection PAIR
R
Random Access Memory
Read Only Memory
S
RAM
ROM
Secondary Air Injection AIR
Secondary Throttle Control System STCS
Secondary Throttle Valve STV
Secondary Throttle Valve Actuator STVA
T
Throttle Body
Throttle Body Fuel Injection
Throttle Position Sensor
TB
TBI
TP Sensor
TPC Valve Tank Pressure Control Valve
V
Voltage Regulator
Volume Air Flow
VR
VAF
––––
Pulse Air Control (PAIR)
––––
ROM
––––
STC System (STCS)
ST Valve (STV)
STV Actuator (STVA)
Throttle Body (TB)
Throttle Body Fuel Injection (TBI)
TP Sensor (TPS)
TPC Valve (TPCV)
Voltage Regulator
Air Flow
WIRE COLOR
B : Black
Bl : Blue
Br : Brown
Dg : Dark green
G : Green
B/Bl : Black with Blue tracer
B/Br : Black with Brown tracer
B/G : Black with Green tracer
B/R : Black with Red tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
Bl/B : Blue with Black tracer
Bl/R : Blue with Red tracer
Bl/W : Blue with White tracer
Bl/Y : Blue with Yellow tracer
Lg/W : Light green with White tracer
O/B : Orange with Black tracer
O/BI : Orange with Blue tracer
O/G : Orange with Green tracer
Gr : Gray
Lbl : Light blue
Lg : Light green
O : Orange
P : Pink
R
V
: Red
: Violet
W : White
Y : Yellow
O/R : Orange with Red tracer
O/W : Orange with White tracer
O/Y : Orange with Yellow tracer
R/W : Red with White tracer
R/Y : Red with Yellow tracer
W/B : White with Black tracer
W/Bl : White with Blue tracer
W/R : White with Red tracer
Y/B : Yellow with Black tracer
Y/Bl : Yellow with Blue tracer
Y/G : Yellow with Green tracer
Y/R : Yellow with Red tracer
Y/W : Yellow with White tracer
GENERAL INFORMATION
GENERAL INFORMATION 1-1
1
CONTENTS
WARNING/CAUTION/NOTE........................................................................ 1- 2
GENERAL PRECAUTIONS ......................................................................... 1- 2
SUZUKI TU250X (’09-MODEL).................................................................... 1- 4
SERIAL NUMBER LOCATION .................................................................... 1- 4
FUEL AND OIL RECOMMENDATION ........................................................ 1- 5
FRONT FORK OIL................................................................................. 1- 5
BREAK-IN PROCEDURES.......................................................................... 1- 5
DIMENSIONS AND CURB MASS......................................................... 1- 7
COUNTRY AND AREA CODE
The following code stand for the applicable country and area.
CODE
E-03
COUNTRY or AREA
U.S.A. (Except for California)
EFFECTIVE FRAME NO.
JS1NJ4CA 92100001 –
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 WARN-
INGS 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, exhaust or brake systems, check all lines and fittings related to the system for leaks.
GENERAL INFORMATION 1-3
* 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 or case bolts and 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 and other fluids: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION
SUZUKI TU250X (’09-MODEL)
RIGHT SIDE
LEFT SIDE
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 left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
GENERAL INFORMATION 1-5
FUEL AND OIL RECOMMENDATION
FUEL
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
ENGINE OIL
Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in
JASO.
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 following 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 reuse brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL
Use SUZUKI FORK OIL SS-08 or an equivalent fork oil.
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Initial 800 km ( 500 miles): Below than 1/2 throttle
Up to 1 600 km (1 000 miles): Below 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 for short periods of time.
1-6 GENERAL INFORMATION
INFORMATION LABELS
1 Noise label
2 Information label
3 Manual notice label
4 General warning label
5 Tire information label
6 Safety plate
A: Attached
Right frame cover (Inside)
TU250X
A
A
A
A
A
A
Frame (Left side)
GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND CURB MASS
Overall length ..........................................................................
2 070 mm (81.5 in)
Overall width ...........................................................................
750 mm (29.5 in)
Overall height ..........................................................................
1 075 mm (42.3 in)
Wheelbase ..............................................................................
1 375 mm (54.1 in)
Ground clearance....................................................................
165 mm (6.5 in)
Seat height ..............................................................................
770 mm (30.3 in)
Curb mass...............................................................................
148 kg (326 lbs)
ENGINE
Type ........................................................................................
4-stroke, air-cooled, OHC
Number of cylinders ................................................................
1
Bore.........................................................................................
72.0 mm (2.835 in)
Stroke......................................................................................
61.2 mm (2.409 in)
Displacement ..........................................................................
249 cm³ (15.2 cu. in)
Compression ratio ...................................................................
9.2 : 1
Fuel system.............................................................................
Fuel injection
Air cleaner ...............................................................................
Polyurethane foam element
Starter system .........................................................................
Electric
Lubrication system ..................................................................
Wet sump
Idle speed................................................................................
1 300 ± 100 r/min
DRIVE TRAIN
Clutch ......................................................................................
Wet multi-plate type
Transmission ...........................................................................
5-speed constant mesh
Gearshift pattern .....................................................................
1-down, 4-up
Primary reduction ratio ............................................................
3.238 (68/21)
Gear ratios, Low ....................................................................
2.636 (29/11)
2nd .....................................................................
1.687 (27/16)
3rd......................................................................
1.200 (24/20)
4th ......................................................................
0.952 (20/21)
Top.....................................................................
0.818 (18/22)
Final reduction ratio.................................................................
2.866 (43/15)
Drive chain ..............................................................................
DID520V, 108 links
1-8 GENERAL INFORMATION
CHASSIS
Front suspension ....................................................................
Telescopic, coil spring, oil damped
Rear suspension .....................................................................
Swingarm type, coil spring, oil damped
Front suspension stroke..........................................................
120 mm (4.7 in)
Rear wheel travel ....................................................................
95 mm (3.7 in)
Steering angle.........................................................................
40° (right & left)
Caster .....................................................................................
25° 55’
Trail .........................................................................................
92 mm (3.62 in)
Turning radius .........................................................................
2.4 m (7.9 ft)
Front brake..............................................................................
Disc brake
Rear brake ..............................................................................
Drum brake
Front tire..................................................................................
90/90-18 M/C 51S, tube type
Rear tire ..................................................................................
110/90-18 M/C 61S, tube type
ELECTRICAL
Ignition type.............................................................................
Electronic ignition (Transistorized)
Ignition timing..........................................................................
5° B.T.D.C. at 1 300 r/min
Spark plug...............................................................................
NGK DR8EA or DENSO X24ESR-U
Battery.....................................................................................
12 V 21.6 kC (6 Ah)/10 HR
Generator................................................................................
Three-phase A.C. generator
Main fuse ................................................................................
30 A
Fuse ........................................................................................
10/10/10/10/10 A
Headlight.................................................................................
12 V 60/55 W (H4)
Brake light/Taillight..................................................................
12 V 21/5 W
Turn signal light.......................................................................
12 V 21 W
Speedometer light...................................................................
12 V 1.7 W
Neutral indicator light ..............................................................
12 V 3.4 W
High beam indicator light ........................................................
12 V 1.7 W
Turn signal indicator light ........................................................
12 V 1.7 W
Fuel level indicator light ..........................................................
12 V 3.4 W
Fuel injection indicator light.....................................................
12 V 3 W
CAPACITIES
Fuel tank, including reserve ....................................................
12.0 L (3.2 US gal)
Engine oil, oil change .............................................................
1 400 ml (1.5 US gal) with filter change ..................................................
1 500 ml (1.6 US gal) overhaul................................................................
1 900 ml (2.0 US gal)
These specifications are subject to change without notice.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE SCHEDULE .................................................... 2- 2
PERIODIC MAINTENANCE CHART .................................................... 2- 2
LUBRICATION POINTS ........................................................................ 2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ....................................... 2- 4
VALVE CLEARANCE ........................................................................... 2- 5
THROTTLE CABLE PLAY .................................................................... 2- 8
ENGINE IDLE SPEED ........................................................................... 2- 8
CLUTCH CABLE PLAY ........................................................................ 2- 9
PAIR (AIR SUPPLY) SYSTEM .............................................................. 2- 9
ENGINE OIL AND OIL FILTER ............................................................. 2-10
REAR SUSPENSION ............................................................................ 2-20
EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS ........... 2-21
CHASSIS BOLTS AND NUTS .............................................................. 2-22
COMPRESSION PRESSURE CHECK ........................................................ 2-24
COMPRESSION TEST PROCEDURE .................................................. 2-24
OIL PRESSURE TEST PROCEDURE .................................................. 2-25
2
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.
IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be required on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval km miles
Item months
Air cleaner element (polyurethane foam type)
Exhaust pipe bolts and muffler mounting bolts
Valve clearance (rocker arm type)
Spark plug
Fuel line
Engine oil
Engine oil filter
Throttle cable play
Engine idle speed
PAIR (air supply) system
Clutch cable play
Drive chain
Brakes
Brake fluid
Brake hose
Tires
Steering
Front fork
Rear suspension
Chassis bolts and nuts
I
----
----
I
R
R
I
1 000
600
3
5 000
3 000
10 000
6 000
15 30
Clean every 3 000 km (2 000 miles)
15 000
9 500
45
T
I
----
----
----
I
I
I
T
R
I
I
----
I
I
I
R
----
I
I
I
I
I
R
R
I
I
I
I
----
I
I
I
I
R
----
I
----
I
----
----
T
Clean and lubricate every 1 000 km (600 miles)
I I I I
---I I
Replace every 2 years
I
---I I I
Replace every 4 years
I
----
I
I
----
----
T
I
I
T
I
----
----
----
T
NOTE:
I = Inspect and clean, adjust, replace or lubricate as necessary, R = Replace, T = Tighten
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.
Brake lever holder
Side-stand pivot and spring hook
Throttle cables
Drive chain
Brake lever holder
Brake pedal pivot
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 in the Periodic Maintenance chart.
AIR CLEANER
Inspect every 3 000 km (2 000 miles).
If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption. Clean the air cleaner element in the following manner:
• Remove the left frame cover. (
8-3)
• Remove the air cleaner element holder 1 .
• Separate the polyurethane foam element 2 from the air cleaner element holder 1 .
• Fill a container with a non-flammable cleaning solvent.
• Immerse the air cleaner element in the cleaning solvent and wash it.
• Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears.
• Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil.
Inspect the air cleaner element for tears. A torn element must be replaced.
A Non-flammable cleaning solvent
B Motor oil SAE #30 or SAE 10W-40
• Remove the drain plug 3 to allow any water to drain out.
Reinstall the cleaned air cleaner element and drain plug in the reverse order of removal.
• Install the element holder with “UP” mark A faced upward.
If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.
VALVE CLEARANCE
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
REMOVAL
• Remove the front seat. (
8-3)
• Remove the fuel tank. (
5-3)
• Remove the spark plug. (
2-7)
• Disconnect the throttle cables from their drum. (
5-11)
• Remove the valve inspection caps 1 .
• Remove the TDC plug 2 and generator cover plug 3 .
PERIODIC MAINTENANCE 2-5
2-6 PERIODIC MAINTENANCE
INSPECTION
The valve clearance specification is same for both valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing.
NOTE:
* The piston must be at (TDC) on the compression stroke in order to check the valve clearance or to adjust valve clearance.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, rotate in the normal running direction. The spark plug should be removed.
• Rotate the crankshaft and align the line A on the generator rotor with the mark B on the generator cover.
• Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm.
If the clearance is out of specification, bring it into the specified range.
Valve clearance (when cold):
IN.: 0.03 – 0.08 mm (0.001 – 0.003 in)
EX.: 0.08 – 0.13 mm (0.003 – 0.005 in)
Valve clearance adjusting screw lock-nut:
15 N·m (1.5 kgf-m, 11.0 lbf-ft)
09900-20803: Thickness gauge
09917-14910: Tappet adjust driver
• After finishing the valve clearance adjustment, reinstall the following items.
* Throttle cables (
5-17)
* TDC plug and generator cover plug (
3-73)
* Valve inspection caps (
3-74)
* Spark plug and plug cap (
2-7)
* Fuel tank (
5-3)
* Front seat
Lock-nut
Rocker arm
Valve stem
Adjusting screw
SPARK PLUG
Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 10 000 km (6 000 miles, 30 months).
NGK
DENSO
STD
DR8EA
X24ESR-U
Cold type
DR9EA
X27ESR-U
Hot type
DR7EA
X22ESR-U
• Disconnect the spark plug cap and remove the spark plug.
09930-10121: Spark plug wrench set
Confirm the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.
• Carbon deposits on the spark plug will prevent good sparking and may cause the engine to misfire. Be sure to clean the carbon deposits off periodically.
• If the center electrode is fairly worn down, the spark plug should be replaced and the spark plug gap set to the specification using a thickness gauge.
Spark plug gap A : 0.6 – 0.7 mm (0.024 – 0.028 in)
09900-20803: Thickness gauge
• Check the spark plug for burns. If any abnormalities are found, replace the spark plug.
Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage.
• Tighten the spark plug to the specified torque using the special tool.
Spark plug: 18 N·m (1.8 kgf-m, 13.0 lbf-ft)
09930-10121: Spark plug wrench set
PERIODIC MAINTENANCE 2-7
2-8 PERIODIC MAINTENANCE
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Throttle cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) as measured at throttle grip when turning the throttle grip lightly. If the play A is incorrect, adjust it as follows:
• Loosen the lock-nut 1 and turn the adjuster 2 in or out until the specified play is obtained.
• Tighten the lock-nut 1 while holding the adjuster 2 .
Throttle cable play A : 2.0 – 4.0 mm (0.08 – 0.16 in)
After the adjustment is completed, check that handlebars movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.
ENGINE IDLE SPEED
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Warm up the engine.
NOTE:
Make this adjustment when the engine is hot.
• Connect the multi circuit tester or engine tachometer 1 to the high-tension cord.
• Start the engine and set the engine idle speed between 1 200 and 1 400 r/min by turning the air screw 2 .
Engine idle speed: 1 300 ± 100 r/min
09900-25008: Multi circuit tester set
09900-26006: Engine tachometer
FUEL LINE
Inspect every 5 000 km (3 000 miles, 15 months) thereafter.
Inspect the fuel feed hose for damage and fuel leakage. If any defects are found, replace the fuel feed hose with a new one.
CLUTCH CABLE PLAY
Inspect every 5 000 km (3 000 miles, 15 months) thereafter.
• Loosen the lock-nut 1 .
• Turn in the adjuster 2 all the way into the clutch lever assembly.
• Loosen the lock-nut 3 , and turn the cable adjuster 4 to obtain 10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch lever end.
• Tighten the lock-nut 3 .
Clutch lever play A : 10 – 15 mm (0.4 – 0.6 in)
PAIR (AIR SUPPLY) SYSTEM
Inspect initially at 5 000 km (3 000 miles, 15 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
• Inspect the PAIR (air supply) system periodically. (
11-6)
PERIODIC MAINTENANCE 2-9
2-10 PERIODIC MAINTENANCE
ENGINE OIL AND OIL FILTER
ENGINE OIL REPLACEMENT
Replace initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1 .
• Remove the oil filler cap 2 .
• Tighten the engine oil drain plug 1 to the specified torque.
Pour new oil through the oil filler hole. When performing an oil change (without oil filter replacement), the engine will hold about 1 400 ml (1.5 US qt) of oil. Use of SF/SG or SH/SJ in
API with MA in JASO.
Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Make sure that the engine is cooled.
• Place the motorcycle on level ground and hold it vertically.
• Install the oil filler cap 2 .
• Start the engine and allow it to run for a few minutes at idling speed.
• Turn off the engine and wait about three minutes, and then check the oil level through the inspection window. If the oil level is below “L”, add oil to “F”. If the level is above “F”, drain oil to “F”.
F
L
OIL FILTER REPLACEMENT
Replace initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
• Drain engine oil as described in the engine oil replacement procedure.
• Remove the oil filter cap 1 , spring 2 and oil filter 3 .
PERIODIC MAINTENANCE 2-11
• Apply engine oil to new O-rings ( 4 , 5 ).
• Install a new oil filter.
• Install the spring 2 correctly.
• Install the oil filter cap and tighten the nuts securely.
• Add new engine oil and check the oil level as described in the engine oil replacement procedure.
Engine oil capacity
Oil change: 1 400 ml (1.5 US qt)
Oil and filter change: 1 500 ml L (1.6 US qt)
Engine overhaul: 1 900 ml (2.0 US qt)
Make sure that the oil filter is installed properly. If the filter is installed improperly, serious engine damage may result.
OIL STRAINER CLEANING
(
3-43)
DRIVE CHAIN
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Clean and lubricate every 1 000 km (600 miles).
Visually inspect the drive chain for the possible defects listed below.
* Loose pins
* Damaged rollers
* Improper chain adjustment
* Excessive wear
* Dry or rusted links
* Missing O-ring seals
* Kinked or binding links
If any defects are found, the drive chain must be replaced.
(
8-54)
NOTE:
When replacing the drive chain, replace the drive chain and sprockets as a set.
O-ring seal
Pin
Roller
2-12 PERIODIC MAINTENANCE
CHECKING AND ADJUSTING
• Place the motorcycle on the side-stand.
• Loosen the rear axle nut 1 .
• Loosen the rear brake adjuster nut 2 and torque link nut
(rear) 3 .
• Loosen the both chain adjuster lock-nuts 4 .
• Tense the drive chain fully by turning both chain adjuster bolts
5 .
• Count out 21 pins (20-pitch) on the chain measure the distance between the two points. If the distance exceeds the service limit, the drive chain must be replaced. (
8-54)
Drive chain 20-pitch length:
Service Limit: 323.8 mm (12.75 in)
NOTE:
When replacing the drive chain, replace the drive chain and sprockets as a set.
PERIODIC MAINTENANCE 2-13
• Loosen or tighten both chain adjuster bolts 5 until the chain has 10 – 20 mm (0.4 – 0.8 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks A must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.
Drive chain slack: 10 – 20 mm (0.4 – 0.8 in)
• After adjusting the drive chain, tighten the rear axle nut 1 to the specified torque.
Rear axle nut: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
• Recheck the chain slack after tightening the rear axle nut and readjust if necessary.
• Tighten both chain adjuster lock-nut securely.
• Tighten the torque link nut (rear) to the specified torque.
Torque link nut (rear): 16 N·m (1.6 kgf-m, 11.5 lbf-ft)
• Readjust the rear brake pedal free travel. (
2-17)
CLEANING AND LUBRICATING
• Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.
Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings. Use only kerosine to clean the drive chain.
• After cleaning and drying the chain, oil it with a heavy-weight engine oil.
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.
* The standard drive chain is DID520V. Suzuki recommends to use this standard drive chain as a replacement.
10 – 20 mm (0.4 – 0.8 in)
2-14 PERIODIC MAINTENANCE
BRAKES
(BRAKE)
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
(BRAKE HOSE AND BRAKE FLUID)
Inspect every 5 000 km (3 000 miles, 15 months).
Replace brake hose every 4 years.
Replace brake fluid every 2 years.
FRONT BRAKE PADS
The extent of brake pad wear can be checked by observing the grooved limit line A on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones.
(
8-12)
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
BRAKE HOSE
Check the brake hose for leakage, cracks, wear and damage. If any defects are found, replace the brake hose with new a one.
BRAKE FLUID LEVEL
Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 2 years.
• 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 brake fluid 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 and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for a long period of time.
* 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 fluid leakage before riding.
BRAKE FLUID REPLACEMENT
8-13
PERIODIC MAINTENANCE 2-15
2-16 PERIODIC MAINTENANCE
AIR BLEEDING FROM BRAKE FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master 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 the master cylinder reservoir to the “UPPER” line. Place the reservoir cap to prevent dirt from entering.
• Attach a hose to the air bleeder valve 1 and insert the free end of the hose into a receptacle.
• Bleed air from the brake system.
• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.
Loosen the air 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 air bleeder valve, pump and squeeze the brake lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.
NOTE:
While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.
• Close the air bleeder valve and disconnect the hose. Fill the reservoir with brake fluid to the “UPPER” line.
Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lbf-ft)
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
REAR BRAKE PEDAL HEIGHT
• Loosen the lock-nut 1 and rotate the adjusting bolt 2 to locate brake pedal 25 mm (1.0 in) A below the top face of the footrest.
• Retighten the lock-nut 1 to secure the adjusting bolt 2 in the proper position.
Brake pedal height A : 20 – 30 mm (0.8 – 1.2 in)
PERIODIC MAINTENANCE 2-17
REAR BRAKE ADJUSTING
• By repositioning the adjusting nut 1 on the brake rod, set the pedal play to between 20 – 30 mm (0.8 – 1.2 in) A as measured at pedal tip.
Brake pedal free travel A : 20 – 30 mm (0.8 – 1.2 in)
2-18 PERIODIC MAINTENANCE
REAR BRAKE SHOE WEAR
This motorcycle is equipped with the brake lining wear limit indicator on the rear brake.
To check wear of the brake lining, perform the following steps:
• First, check if the brake system is properly adjusted.
(
2-17)
• While operating the brake, check to see that the tip of indicator A is within the range B on the brake panel.
• If the tip of indicator A is beyond the range B , the brake shoe assembly should be replaced with a new set of shoe.
(
8-39)
BRAKE LIGHT SWITCH
Adjust the rear brake light switch so that the brake light will come on just before pressure is fell when the brake pedal is depressed.
STEERING
Inspect initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
The steering should be adjusted properly for smooth turning of handlebars and safe operation. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork.
Support the motorcycle so that the front wheel is off the ground.
With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. (
8-37)
TIRES
TIRE TREAD CONDITION
Inspect every 5 000 km (3 000 miles, 15 months).
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.
Tire tread depth (Recommended depth):
Service Limit: Front : 1.6 mm (0.06 in)
Rear : 2.0 mm (0.08 in)
09900-20805: Tire depth gauge
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
Cold inflation tire pressure:
Solo riding: Front: 175 kPa (1.75 kgf/cm 2 , 25 psi)
Rear: 200 kPa (2.00 kgf/cm 2 , 29 psi)
Dual riding: Front: 175 kPa (1.75 kgf/cm 2 , 25 psi)
Rear: 225 kPa (2.25 kgf/cm 2 , 33 psi)
The standard tire fitted on this motorcycle is 90/90-18
M/C 51S for the front and 110/90-18 M/C 61S for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.
TIRE TYPE
CHENG SHIN (Front: C-6009, Rear: C-822)
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.
(Wheel inspection:
8-59)
Wheel runout:
Service Limit (axial and radial): 2.0 mm (0.08 in)
PERIODIC MAINTENANCE 2-19
2-20 PERIODIC MAINTENANCE
SPOKE NIPPLES
Make sure that the nipples are tight. If necessary, tighten them with a spoke nipple wrench.
Spoke nipple: 3 N·m (0.3 kgf-m, 2.0 lbf-ft)
09940-60113: Spoke nipple wrench
FRONT FORK
Inspect every 10 000 km (6 000 miles, 30 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. (
8-26)
REAR SUSPENSION
Inspect every 10 000 km (6 000 miles, 30 months).
Inspect the rear shock absorbers for oil leakage and damage. If any defects are found, replace the rear shock absorber with a new one.
EXHAUST PIPE BOLTS AND MUFFLER
MOUNTING BOLTS
Tighten initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
Tighten the exhaust pipe bolts, muffler connecting bolt and muffler mounting bolts to the specified torque.
Exhaust pipe bolt 1 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler connecting bolt 2 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler mounting bolt (Front) 3 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler mounting bolt (Rear) 4 : 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
PERIODIC MAINTENANCE 2-21
2-22 PERIODIC MAINTENANCE
CHASSIS BOLTS AND NUTS
Tighten initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-23 for the locations of the following bolts and nuts on the motorcycle.)
Item
1 Handlebar clamp bolt
2 Steering stem head bolt
3 Front fork upper clamp bolt
4 Front fork lower clamp bolt
5 Front axle
6 Front axle pinch bolt
7 Front brake caliper mounting bolt
8 Front brake hose union bolt
9 Front brake caliper air bleeder valve
0 Front brake disc bolt
A Front brake master cylinder holder bolt
B Swingarm pivot nut
C Front footrest bolt
D Torque link nut (Front and Rear)
E Rear axle nut
F Rear brake cam lever nut
G Rear shock absorber nut (Upper and Lower)
H Seat rail bolt (M8)
I Seat rail bolt (M12)
N·m
16
65
23
33
65
23
39
23
7.5
23
10
65
39
16
65
10
29
26
85 kgf-m
1.6
6.5
2.3
3.3
6.5
2.3
3.9
2.3
0.75
2.3
1.0
6.5
3.9
1.6
6.5
1.0
2.9
2.6
8.5
28.0
16.5
5.5
16.5
7.0
47.0
28.0
11.5
lbf-ft
11.5
47.0
16.5
24.0
47.0
16.5
47.0
7.0
21.0
19.0
61.5
PERIODIC MAINTENANCE 2-23
2-24 PERIODIC MAINTENANCE
COMPRESSION PRESSURE CHECK
The compression pressure reading of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
COMPRESSION PRESSURE SPECIFICATION
Standard
1 200 – 1 400 kPa
(12 – 14 kgf/cm 2 , 171 – 199 psi)
Limit
850 kPa
(8.5 kgf/cm 2 , 121 psi)
Low compression pressure can indicate any of the following conditions:
* Excessively worn cylinder walls
* Worn piston or piston rings
* Piston rings stuck in grooves
* Poor valve seating
* Ruptured or otherwise defective cylinder head gasket
NOTE:
When the compression pressure goes below specification, check the engine for conditions listed above.
COMPRESSION TEST PROCEDURE
NOTE:
* Before testing the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted.
* Warm up the engine before testing.
* Make sure that the battery is fully-charged.
Remove the related parts and test the compression pressure in the following manner:
• Remove the front seat. (
8-3)
• Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
• Remove the spark plug. (
2-7)
• Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.
• Keep the throttle grip in the fully opened position.
• Press the starter button and crank the engine for a few seconds.
• Record the maximum gauge reading as the cylinder compression.
09915-63210: Compression gauge adaptor
09915-64512: Compression gauge
PERIODIC MAINTENANCE 2-25
OIL PRESSURE CHECK
Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.
Oil pressure:
Above 30 kPa (0.3 kgf/cm², 4.3 psi)
Below 70 kPa (0.7 kgf/cm², 10.0 psi) at 3 000 r/min, oil temp. at 60 °C (140 °F)
Low or high oil pressure can indicate any of the following conditions:
LOW OIL PRESSURE
* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE
* Engine oil viscosity is too high
* Clogged oil passage
* Combination of the above items
OIL PRESSURE TEST PROCEDURE
• Connect the multi circuit tester or engine tachometer to the high-tension cord. (
2-8)
• Remove the oil gallery plug 1 .
• Install the oil pressure gauge and adaptor into the main oil gallery.
• Warm up the engine as follows:
Summer: 10 minutes at 2 000 r/min
Winter: 20 minutes at 2 000 r/min
• After warming up the engine, increase the engine speed to
3 000 r/min (observe the tachometer), and read the oil pressure gauge.
Oil gallery plug: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
09900-25008: Multi circuit tester set
09900-26006: Engine tachometer
09915-74511: Oil pressure gauge (600 kPa)
2-26 PERIODIC MAINTENANCE
SDS CHECK
Using SDS, sample the data at the time of new and periodic motorcycle inspections.
After saving the sampled data in the computer, file them by model and by user.
The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of motorcycle functions that has changed with time.
For example, when a motorcycle is brought in for service but the troubleshooting of a failure is not easy, comparing the current data value to the past filed data value at time of normal condition can allow the specific engine failure to be determined.
Also, in the case of a customer motorcycle which is not periodically brought in for service with no past data value having been saved, if the data value of a good motorcycle condition have been already saved as a master (STD), comparison between the same models helps facilitate the troubleshooting.
• Remove the right frame cover. (
8-3)
• Set up the SDS tool. (
4-23)
09904-41010: SUZUKI Diagnostic system set
99565-01010-020: CD-ROM Ver.20
NOTE:
* Before taking the sample of data, check and clear the Past DTC.
* 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
Check the engine temperature.
XX ˚C
Check the manifold absolute pressure.
XX kPa
PERIODIC MAINTENANCE 2-27
Data at 3 000 r/min under no load
Approx. 3 000 r/min
Check the engine temperature.
XX ˚C
Check the manifold absolute pressure.
XX kPa
Data at the time of racing
Throttle: Slowly open
Throttle: Quick wide open
Secondary throttle valve opens closes in according with the throttle valve opening
PAIR control solenoid valve
ON OFF in according with the throttle valve opens closes
2-28 PERIODIC MAINTENANCE
Data of intake negative pressure during idling (90 °C)
Check the manifold absolute pressure.
XX kPa
Check the engine temperature.
Approx. 90 ˚C
Data of manifold absolute pressure operation at the time of starting
Check the manifold absolute pressure.
XX kPa
PERIODIC MAINTENANCE 2-29
Example of trouble
Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.
NOTE:
With DTC not output, if the value of engine temperature is found to be lower than the data saved previously, the possible cause may probably lie in a sensor circuit opened, ground circuit opened or influence of internal resistance value changes, etc.
Unstable idling speed
Abnormal value of secondary throttle valve position
Abnormal value of engine temperature
No DTC output
ENGINE
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE .......... 3- 2
ENGINE REMOVAL AND INSTALLATION................................................. 3- 3
ENGINE COMPONENTS INSPECTION AND SERVICE............................. 3-25
CYLINDER HEAD COVER.................................................................... 3-25
CYLINDER HEAD.................................................................................. 3-26
CONROD AND CRANKSHAFT ............................................................ 3-38
STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING ........ 3-40
BALANCER DRIVEN GEAR ................................................................. 3-41
GEARSHIFT SHAFT ............................................................................. 3-42
CRANKCASE BEARING AND OIL SEAL ............................................ 3-49
CLUTCH RELEASE CAMSHAFT ......................................................... 3-54
CLUTCH COVER................................................................................... 3-55
ENGINE 3-1
3
3-2 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions.
ENGINE CENTER
ITEM
PAIR control solenoid valve
Starter motor
Cylinder head cover
Camshaft
Camshaft sprocket
Cylinder head
Cam chain tension adjuster
Cam chain tensioner
Cam chain guide
Spark plug
Cylinder
Piston
Cam chain
Oil strainer
Clutch release camshaft
REMOVAL
11-7
9-13
3-12
3-13
3-13
3-14
3-12
3-26
3-14
2-7
3-14
3-14
3-20
3-43
3-54
INSPECTION
11-8
9-15
3-25
3-35
3-35
3-27
3-36
3-32
3-36
2-7
3-35
3-36
—
3-43
—
INSTALLATION
11-8
9-17
3-72
3-70
3-71
3-70
3-73
3-34
3-70
2-7
3-69
3-68
3-62
3-44
3-54
ENGINE RIGHT SIDE
ITEM
Exhaust pipe and muffler
Clutch cover
Clutch (plates)
Oil filter
Oil pump driven gear
Oil pump
Gearshift shaft
Gearshift cam driven gear
Primary drive gear
Cam chain drive sprocket
ENGINE LEFT SIDE
ITEM
Gearshift lever
Engine sprocket
Generator (cover)
Generator rotor
Starter idle gear
Starter driven gear
Starter clutch
CKP sensor
REMOVAL
6-2
3-16
3-16
2-10
3-18
3-18
3-19
3-19
3-20
3-20
REMOVAL
3-6
3-5
3-15
3-20
3-16
3-21
3-41
3-42
INSPECTION
6-4
—
3-48
—
—
3-44
3-42
—
—
—
INSPECTION
—
—
—
—
—
—
3-40
9-25
INSTALLATION
6-4
3-66
3-64
2-11
3-63
3-63
3-63
3-62
3-61
3-61
INSTALLATION
—
3-9
3-66
3-60
3-66
3-60
3-41
3-42
ENGINE REMOVAL AND INSTALLATION
REMOVAL
Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure.
• Remove the front seat. (
8-3)
• Remove the fuel tank. (
5-3)
• Drain engine oil. (
2-10)
• Remove the frame covers. (
8-3)
• Disconnect the battery lead wire.
• Remove the exhaust pipe/muffler 1 . (
6-2)
• Remove the spark plug cap 2 .
• Remove the PAIR pipe bolt and nut.
• Remove the gasket 3 .
ENGINE 3-3
3-4 ENGINE
• Remove the PAIR control solenoid valve bracket bolts.
• Loosen the clutch cable adjuster and lock-nut.
• Remove the clutch cable 4 along with clutch release arm 5 .
• Remove the throttle body assembly 6 . (
5-11)
• Disconnect the ET sensor coupler 7 .
• Disconnect the starter motor lead wire 8 .
• Remove the generator coupler 9 , CKP sensor coupler 0 , neutral switch coupler A and clamp.
• Remove the engine sprocket cover B .
• Remove the PCV hose C .
• Flatten the tab of lock washer D .
• Remove the engine sprocket nut E and lock washer D .
NOTE:
When loosening the engine sprocket nut E , depress the rear brake pedal.
• Loosen the rear axle nut F .
• Loosen the both chain adjuster lock-nuts G .
• Loosen the both chain adjuster bolts H .
• Push the rear wheel forward and make sure that the drive chain has enough slack.
• Remove the engine sprocket I .
ENGINE 3-5
3-6 ENGINE
• Remove the gearshift lever J .
NOTE:
Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation.
• Disconnect the engine ground wire K .
• Support the engine using an engine jack.
• Remove the engine mounting bolts, nuts and brackets.
• Remove the swingarm pivot shaft nut and washer.
• Partially remove the swingarm pivot shaft so that the engine can be removed.
NOTE:
Be careful not to draw out the swingarm pivot shaft.
• Gradually lower the engine.
ENGINE 3-7
3-8 ENGINE
INSTALLATION
Install the engine in the reverse order of engine removal. Pay attention to the following points:
• Fit the swingarm in its position and hold it with the swingarm pivot shaft.
• Mount the engine on the frame.
• Tighten the engine mounting nuts and swingarm pivot nut to the specified torque.
NOTE:
* The engine mounting nuts and swingarm pivot nut are self-locking. Once the nuts have been removed, they are no longer of any use.
* The engine mounting nuts and swingarm pivot nut are located at the right side of motorcycle.
40 N.m
(4.0 kgf-m, 29.0 lbf-ft)
41 N.m
(4.1 kgf-m, 29.5 lbf-ft)
65 N.m
(6.5 kgf-m, 47.0 lbf-ft)
BOLT LENGTH a 67 mm (2.6 in) b 105 mm (4.1 in) c 50 mm (2.0 in) d 246 mm (9.7 in)
41 N.m
(4.1 kgf-m, 29.5 lbf-ft)
28 N.m
(2.8 kgf-m, 20.0 lbf-ft)
NOTE:
* Pass the PAIR pipe 1 between the engine mounting upper plats.
* Fit the clamp 2 to the bolt.
* Fit the guide 3 to the bolt.
ENGINE 3-9
• Connect the engine ground wire 4 .
NOTE:
Fit the engine ground wire 4 and clamp 5 to the crankcase bolt.
Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
• Install the engine sprocket.
NOTE:
The convex part side A of engine sprocket faces outside.
• Tighten the engine sprocket nut to the specified torque.
NOTE:
When tightening the engine sprocket nut, depress the rear brake pedal.
Engine sprocket nut: 90 N·m (9.0 kgf-m, 65.0 lbf-ft)
• Bend a new lock washer securely.
3-10 ENGINE
• Install the throttle body assembly. (
5-17)
• Position the throttle body clamps correctly. (
10-20)
• Install the clutch release arm as shown in the illustration.
NOTE:
Align the release arm slit surface B with the notch mark C on the release camshaft.
• Install sealing surface D of the gasket upward.
Replace the gasket with a new one.
• Tighten the PAIR pipe bolt and nut to the specified torque.
PAIR pipe bolt/nut: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Install the exhaust pipe/muffler 6 . (
6-5)
• After remounting the engine, route the wiring harness, cables and hoses properly. (
10-12 to -15, 10-18, 10-20)
• Pour engine oil. (
2-10)
• After finishing the engine installation, check the following items.
* Throttle cable play (
2-8)
* Drive chain slack (
2-13)
* Rear brake pedal free travel (
2-17)
* Engine idle speed (
2-8)
* Clutch lever play (
2-9)
* Engine oil leakage
ENGINE DISASSEMBLY
Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.
STARTER MOTOR
• Remove the starter motor 1 .
SPARK PLUG
• Remove the spark plug 1 .
09930-10121: Spark plug wrench set
CAP/PLUG
• Remove the valve inspection caps 1 .
• Remove the generator cover plug 2 and TDC plug 3 .
ENGINE 3-11
3-12 ENGINE
• Rotate the crankshaft and align the line A on the generator rotor with the mark B on the generator cover.
NOTE:
The piston must be at TDC on the compression stroke.
CAM CHAIN TENSION ADJUSTER
• Remove the cam chain tension adjuster cap 1 .
• Turn the adjusting screw clockwise until the push rod locked.
• Remove the cam chain tension adjuster 2 and gasket 3 .
CYLINDER HEAD COVER
• Remove the cylinder head cover 1 .
CAMSHAFT
• Remove the cylinder head plug 1 .
• Remove the dowel pins.
• Remove the camshaft sprocket bolts.
• Remove the camshaft sprocket 2 and camshaft 3 .
Do not drop the cam chain 4 , locating pin 5 and dowel pin 6 into the crankcase.
• Remove the locating pin 5 and dowel pin 6 from the camshaft 3 .
• Remove the C-ring 7 .
Do not drop the C- ring 7 into the crankcase.
ENGINE 3-13
3-14 ENGINE
CYLINDER HEAD/CAM CHAIN GUIDE
• Remove the cylinder head nuts diagonally.
• Remove the cylinder head 1 .
NOTE:
If the cylinder head does not come off easily, lightly tap it using a plastic hammer.
• Remove the dowel pins and gasket 2 .
• Remove the cam chain guide 3 .
CYLINDER
• Remove the cylinder 1 .
NOTE:
If the cylinder does not come off easily, lightly tap it using a plastic hammer.
• Remove the dowel pins and gasket 2 .
PISTON
• Place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. Then, remove the piston pin circlip 1 .
• Remove the piston pin 2 using the special tool if necessary.
09910-34510: Piston pin puller
• Remove the piston 3 .
ENGINE 3-15
NEUTRAL SWITCH
• Remove the neutral switch 1 and O-ring 2 .
• Remove the switch contacts 3 and springs 4 .
GENERATOR COVER
• Remove the generator cover 1 .
• Remove the dowel pins and gasket 2 .
3-16 ENGINE
STARTER IDLE GEAR
• Remove the starter idle gear shaft 1 and starter idle gear 2 .
CLUTCH COVER
• Remove the clutch cover 1 .
• Remove the dowel pins and gasket 2 .
CLUTCH
• Remove the clutch spring set bolts, clutch springs and clutch pressure plate 1 .
NOTE:
Loosen the clutch spring set bolts little by little and diagonally.
• Remove the washer 2 , release bearing 3 , push piece 4 .
• Remove the push rod 5 .
NOTE:
If it is difficult to pull out the push rod 5 , use a magnetic hand or a wire.
• Remove the clutch drive No.1 plates 6 and driven plates 7 .
• Remove the clutch drive No.2 plate 8 .
• Remove the spring washer 9 and spring washer seat 0 .
• Flatten the lock washer A .
• Hold the clutch sleeve hub with the special tools and remove the clutch sleeve hub nut B .
09920-31020: Extension handle
09920-53740: Clutch sleeve hub holder
• Remove the lock washer A .
ENGINE 3-17
3-18 ENGINE
• Remove the clutch sleeve hub C .
• Remove the thrust washer D .
• Remove the primary driven gear assembly E .
• Remove the spacer F and thrust washer G .
OIL PUMP
• Remove the circlip 2 and oil pump drive gear 3 from the primary driven gear assembly 1 .
• Remove the snap ring 4 and oil pump driven gear 5 .
09900-06107: Snap ring remover (Open type)
• Remove the pin 6 and washer 7 .
• Remove the oil pump 8 .
Do not attempt to disassemble the oil pump assembly.
GEARSHIFT
• Remove the gearshift shaft 1 .
• Remove the cam guide 2 and pawl lifter 3 .
• Remove the gearshift cam driven gear 4 .
NOTE:
When removing the gearshift cam driven gear 4 , do not lose the pawls 5 , pins 6 and springs 7 .
• Remove the gearshift arm stopper 8 .
PRIMARY DRIVE GEAR
• Hold the generator rotor with the special tool and remove the crank balancer bolt 1 .
09930-44521: Rotor holder
• Remove the washer 2 .
ENGINE 3-19
3-20 ENGINE
• Remove the cam chain 3 .
• Hold the generator rotor with the special tool and remove the primary drive gear nut 4 .
The primary drive nut has left-hand threads.
09930-44521: Rotor holder
• Remove the washer 5 , key 6 , primary drive gear 7 , sprocket key (L-shape) 8 and cam chain drive sprocket 9 .
GENERATOR
• Hold the generator rotor with the special tool and remove the generator rotor nut 1 .
09930-44521: Rotor holder
• Remove the generator rotor 2 with the special tool.
09930-34960: Rotor remover
• Remove the key 3 .
• Remove the starter driven gear 4 and bearing 5 .
• Remove the washer 6 .
CRANKCASE
• Remove the gearshift cam stopper plug 1 .
• Remove the spring 2 and gearshift cam stopper No.2 3 .
• Remove the oil seal retainer 4 and engine sprocket spacer
5 .
• Remove the O-ring 6 from the spacer 5 .
ENGINE 3-21
3-22 ENGINE
• Remove the crankcase bolts, left and right.
• Separate the left and right crankcases with the special tool.
09920-13120: Crankcase remover
NOTE:
* Fit the crankcase separator, so that the tool arms are in parallel with the side of crankcase.
* The crankshaft and transmission components should remain in the left crankcase half.
* When separating the crankcase, tap the end of the countershaft with a plastic mallet.
• Remove the O-rings ( 1 , 2 ) and dowel pins.
CRANK BALANCER
• Remove the shim 1 , washers 2 and crank balancer driven gear 3 .
• Remove the key 4 and crank balancer shaft 5 .
TRANSMISSION
• Remove the gearshift cam stopper spring 1 .
• Remove the gearshift fork shafts ( 2 , 3 ).
• Remove the gearshift forks ( 4 , 5 , 6 ).
• Remove the gearshift cam stopper 7 .
• Remove the gearshift cam 8 .
• Remove the gearshift cam stopper plate 9 and pin 0 from the gearshift cam 8 .
• Remove the countershaft assembly A and driveshaft assembly B .
ENGINE 3-23
3-24 ENGINE
CRANKSHAFT
• Remove the crank balancer drive gear 1 .
• Remove the crankshaft with the special tool.
09920-13120: Crankcase remover
ENGINE COMPONENTS INSPECTION
AND SERVICE
Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations.
CYLINDER HEAD COVER
DISASSEMBLY
• Remove the rocker arm shafts 1 .
• Remove the rocker arms 2 and wave washers 3 .
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 the thickness gauge.
If the distortion exceeds the limit, replace the cylinder head cover.
Cylinder head cover distortion
Service Limit: 0.05 mm (0.002 in)
09900-20803: Thickness gauge
ROCKER ARM SHAFT O.D.
Measure the diameter of the rocker arm shafts.
Rocker arm shaft O.D.
Standard (IN. & EX.):
11.983 – 11.994 mm (0.4718 – 0.4722 in)
09900-20205: Micrometer (0 – 25 mm)
ROCKER ARM I.D.
Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface.
Rocker arm I.D.
Standard (IN. & EX.):
12.000 – 12.018 mm (0.4724 – 0.4731 in)
09900-20605: Dial calipers (10 – 34 mm)
ENGINE 3-25
3-26 ENGINE
REASSEMBLY
Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points:
• Apply engine oil to the rocker arms, rocker arm shafts and
O-rings.
Use the new O-rings to prevent oil leakage.
• When inserting the rocker arm shaft, align the shaft hole A with the bolt hole B .
CYLINDER HEAD
DISASSEMBLY
• Remove the cam chain tensioner 1 .
• Remove the intake pipe 2 .
• Compress the valve spring with the special tools.
Compressing of the valve spring must be limited to the extent only necessary to prevent the spring from fatigue.
09916-14510: Valve lifter
09916-14910: Valve lifter attachment
• Remove the valve cotters 3 from the valve stem.
09916-84511: Tweezer
• Remove the valve spring retainer 4 and valve spring 5 .
• Remove the valve 6 from the combustion chamber side.
• Remove the valve stem seal 7 .
• Remove the valve spring seat 8 .
NOTE:
Remove the intake valve in the same manner.
CYLINDER HEAD DISTORTION
Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head.
Cylinder head distortion
Service Limit: 0.05 mm (0.002 in)
09900-20803: Thickness gauge
ENGINE 3-27
3-28 ENGINE
VALVE FACE WEAR
The thickness of the valve face decreases as the face wears.
Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness
T , if it is out of specification, replace the valve with a new one.
Valve head thickness T
Service Limit (IN. & EX.): 0.5 mm (0.02 in)
09900-20101: Venier calipers (150 mm)
VALVE STEM RUNOUT
Support the valve using V blocks, as shown, and measure its runout with the dial gauge. If the runout exceeds the limit, replace the valve.
Valve stem runout
Service Limit (IN. & EX.): 0.05 mm (0.002 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout.
If it measures more than the service limit, replace the valve.
Valve head radial runout
Service Limit (IN. & EX.): 0.03 mm (0.001 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
VALVE STEM DEFLECTION
Lift the valve about 10 mm (0.4 in) from the valve seat. Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one.
Valve stem deflection
Service Limit (IN. & EX.): 0.35 mm (0.014 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
X
Y
VALVE STEM WEAR
Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem
O.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, re-check the deflection.
Valve stem O.D.
Standard: (IN.): 5.460 – 5.475 mm (0.2150 – 0.2156 in)
(EX.): 5.445 – 5.460 mm (0.2144 – 0.2150 in)
09900-20205: Micrometer (0 – 25 mm)
NOTE:
If valve guides have to be replaced, refer to the valve guide servicing steps below.
VALVE GUIDE SERVICING
• Using the valve guide remover, drive the valve guide out toward the camshaft side.
09916-44910: Valve guide installer & remover
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement parts.
• Re-finish the valve guide holes in cylinder head with the reamer and handle.
When refinishing or removing the reamer from the valve guide hole, always turn it clockwise.
09916-34542: Reamer handle
09916-34561: Valve guide reamer (11.3 mm)
ENGINE 3-29
3-30 ENGINE
• 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.
• Apply engine oil to the valve guide hole.
• Drive the valve guide into the hole using the valve guide installer.
Replace the valve guide and ring with new ones.
NOTE:
Install the valve guide until the ring A contacts with the cylinder head.
09916-44910: Valve guide installer & remover
• After installing the valve guides, re-finish their guiding bores using the valve guide reamer.
• Clean and oil the valve guides after reaming.
09916-34542: Reamer handle
09916-34550: Valve guide reamer (5.5 mm)
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.
ENGINE 3-31
VALVE SEAT WIDTH INSPECTION
Visually check for valve seat width on each valve face.
If the valve face has worn abnormally, replace the valve.
Coat the valve seat with a red lead (Prussian Blue) and set the valve in place. Rotate the valve with light pressure. Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face.
If the seat width W measured exceeds the standard value, or seat width is not uniform, reface the seat using the seat cutter.
Valve seat width W
Standard (IN. & EX.): 0.9 – 1.1 mm (0.035 – 0.043 in)
09916-10911: Valve lapper set
VALVE SEAT SERVICING
• The valve seats 1 for both the intake valve and exhaust valve are machined to two different angles. The seat contact surface is cut at 45°.
Valve seat angles
Valve seat width
Valve diameter
Valve guide I.D.
INTAKE
30°, 45°
0.9 – 1.1 mm
(0.035 – 0.043 in)
34 mm (1.3 in)
5.500 – 5.512 mm
(0.2165 – 0.2170 in)
EXHAUST
15°, 45°
←
29 mm (1.1 in)
←
* The valve seat contact area must be inspected after each cut.
* Do not use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for 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. (
2-5)
45˚
30˚
45˚
15˚
IN.
EX.
3-32 ENGINE
• Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks.
• If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
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 is present, resurface the valve stem end. Make sure that the length A is not less than 2.1 mm (0.08 in). If this length becomes less than 2.1 mm (0.08 in), replace the valve.
Valve stem end length A
Service Limit (IN. & EX.): 2.1 mm (0.08 in)
09900-20101: Venier calipers (150 mm)
VALVE SPRING
Check the valve spring for proper strength by measuring its free length and also the force required to compress it. If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the specified range, replace the spring.
Valve spring free length
Service Limit (IN. & EX.): 39.3 mm (1.55 in)
09900-20101: Venier calipers (150 mm)
Valve spring tension
Standard: 185 – 219 N
(18.9 – 22.3 kgf, 41.7 – 49.2 lbs)/
36.0 mm (1.42 in)
CAM CHAIN TENSIONER
Inspect the cam chain tensioner for damage. If any damage is found, replace the cam chain tensioner with a new one.
REASSEMBLY
Reassemble the cylinder head in the reverse order of disassembly. Pay attention to the following points:
• Install each valve spring seat 1 .
• Apply molybdenum oil solution to the valve stem seal 2 , and press-fit it into position.
Do not reuse the removed valve stem seal.
MOLYBDENUM OIL SOLUTION
• Insert the valve, with its stem coated with molybdenum oil solution all around and along the full stem length without any break.
When inserting the valve, take care not to damage the lip of valve stem seal.
MOLYBDENUM OIL SOLUTION
• Install the valve spring with the small-pitch portion A facing cylinder head.
B Large-pitch portion
C UPWARD
ENGINE 3-33
3-34 ENGINE
• Compress the valve spring with the special tools.
09916-14510: Valve lifter
09916-14910: Valve lifter attachment
09916-84511: Tweezer
Compressing of the valve spring must be limited to the extent only necessary to prevent the spring from fatigue.
• Install the valve cotter halves 3 .
Check that the rounded lip D of the cotter is securely fitted in the groove E in the valve stem end.
NOTE:
To facilitate assembly, apply a little grease to the valve cotter when fitting into the valve stem groove.
INTAKE PIPE
• Apply grease to the O-ring.
Use the new O-ring to prevent sucking air from the joint.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the intake pipe with “UP” mark A faced upward.
CAM CHAIN TENSIONER
• Install the cam chain tensioner 1 and gasket.
• Tighten the cam chain tensioner bolt 2 to the specified torque.
Cam chain tensioner bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
CAMSHAFT
CAM WEAR
Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output.
Measure the cam height H using the micrometer. Replace a camshaft if the cams are worn to the service limit.
Cam height H
Service Limit: (IN.): 33.54 mm (1.320 in)
(EX.): 33.00 mm (1.299 in)
09900-20202: Micrometer (25 – 50 mm)
CAMSHAFT BEARING
Rotate the camshaft bearing outer races by finger to inspect for abnormal play, noise and smooth rotation.
Replace the camshaft assembly, if there is anything unusual.
CAMSHAFT SPROCKET
Check the camshaft sprocket teeth for wear or damage. If any defects are found, replace the camshaft sprocket and cam chain as a set.
CYLINDER
DISTORTION
Check the gasket surface of the cylinder for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder.
Cylinder distortion
Service Limit: 0.05 mm (0.002 in)
09900-20803: Thickness gauge
ENGINE 3-35
3-36 ENGINE
CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other damage.
Measure the cylinder bore diameter at six places.
Cylinder bore
Standard: 72.000 – 72.015 mm (2.8346 – 2.8352 in)
09900-20530: Cylinder gauge set
CAM CHAIN TENSION ADJUSTER
Make sure the push rod movement. If the push rod is stuck or spring mechanism failed, replace the cam chain tension adjuster with a new one.
CAM CHAIN GUIDE
Inspect the cam chain guide for damage. If any damage is found, replace the cam chain guide with a new one.
PISTON
DIAMETER
Measure the piston diameter using the micrometer at 10 mm
(0.4 in) A from the skirt end.
If the piston diameter is less than the service limit, replace the piston.
Piston diameter
Service Limit: 71.880 mm (2.8299 in)
09900-20203: Micrometer (50 – 75 mm)
PISTON TO CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace the cylinder or the piston, or both.
Piston to cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
PISTON PIN AND PIN BORE
Measure the piston pin bore diameter using the small bore gauge.
If the measurement is out of specification, replace the piston.
Piston pin bore I.D.
Service Limit: 18.030 mm (0.7098 in)
09900-20602: Dial gauge
09900-22403: Small bore gauge (18 – 35 mm)
Measure the piston pin outside diameter at three positions using the micrometer.
If any of the measurements is out of specification, replace the piston pin.
Piston pin O.D.
Service Limit: 17.980 mm (0.7079 in)
09900-20205: Micrometer (0 – 25 mm)
PISTON RING GROOVE CLEARANCE
Measure the side clearance of the 1st and 2nd rings using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings.
Piston ring to groove clearance
Service Limit (1st): 0.180 mm (0.0071 in)
(2nd): 0.150 mm (0.0059 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): 0.975 – 0.990 mm (0.0384 – 0.0390 in)
(2nd): 1.170 – 1.190 mm (0.0461 – 0.0469 in)
09900-20205: Micrometer (0 – 25 mm)
09900-20803: Thickness gauge
NOTE:
Remove any carbon from the piston crown and ring grooves using a soft-metal scraper.
ENGINE 3-37
3-38 ENGINE
PISTON RING FREE END GAP AND PISTON RING END GAP
Measure the piston ring free end gap using a vernier calipers.
Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge.
If the piston ring’s end gap is out of specification, replace the piston ring.
Piston ring free end gap
Service Limit (1st): 8.0 mm (0.31 in)
(2nd): 8.8 mm (0.35 in)
09900-20101: Venier calipers (150 mm)
Piston ring end gap
Service Limit (1st): 0.5 mm (0.020 in)
(2nd): 0.7 mm (0.028 in)
09900-20803: Thickness gauge
CONROD AND CRANKSHAFT
CONROD SMALL END I.D.
Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter exceeds the service limit, replace the conrod.
Conrod small end I.D.
Service Limit: 18.040 mm (0.7102 in)
09900-20605: Dial calipers (10 – 34 mm)
CONROD DEFLECTION
Move the small end sideways while holding the big end immovable in thrust direction. Measure the amount of deflection.
Turn the conrod and see if it moves smoothly without play and noise. This method can check the extent of wear on the parts of the conrod’s big end.
Conrod deflection
Service Limit: 3.0 mm (0.12 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
CONROD BIG END SIDE CLEARANCE
Push the big end of the conrod to one side and measure the side clearance using a thickness gauge.
If the clearance exceeds the service limit, replace crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts. (e.g., conrod, big end bearing and crank pin)
Conrod big end side clearance
Service Limit: 1.0 mm (0.04 in)
09900-20803: Thickness gauge
CRANKSHAFT RUNOUT
With the right and left crank journals supported with V blocks, turn the crankshaft slowly. At this time, measure the crankshaft end runout using a dial gauge. If the runout exceeds the service limit, replace the crankshaft.
NOTE:
Place the crankshaft onto the V blocks so that it becomes horizontally.
Crankshaft runout
Service Limit: 0.080 mm (0.031 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
CRANKSHAFT WEB TO WEB WIDTH
When rebuilding the crankshaft, the width between the webs A should be within the standard range.
Crank web to web width A
Standard: 59.9 – 60.1 mm (2.36 – 2.37 in)
ENGINE 3-39
3-40 ENGINE
STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING
1 Starter driven gear
2 Bearing
3 Roller
4 Push piece
5 Spring
A Starter clutch bolt
STARTER CLUTCH
Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction).
The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any defects are found, replace the defective part(-s).
STARTER DRIVEN GEAR BEARING
Install the starter driven gear bearing 1 and gear 2 onto the crankshaft and turn the starter driven gear by hand. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it.
ITEM N·m kgf-m lbf-ft
A 26 2.6
19.0
DISASSEMBLY
• Remove the starter driven gear.
• Remove the rollers 1 , push pieces 2 and springs 3 .
• Hold the generator rotor with the special tool and remove the starter clutch bolts.
09930-44521: Rotor holder
• Remove the starter clutch body 4 .
REASSEMBLY
• Apply a small quantity of thread lock to the starter clutch bolts and tighten them to the specified torque while holding the special tool.
99000-32030: THREAD LOCK SUPER “1303” or equivalent
Starter clutch bolt: 26 N·m (2.6 kgf-m, 19.0 lbf-ft)
09930-44521: Rotor holder
BALANCER DRIVEN GEAR
DISASSEMBLY
• Remove the inner race 1 , springs 2 and pins 3 .
* Do not drop the springs 2 , when removing the inner race.
* Note the location of the pins 3 .
REASSEMBLY
• Install the springs 2 and pins 3 onto the inner race 1 .
ENGINE 3-41
3-42 ENGINE
• Align the punch mark A on inner race with the punch mark B on balancer driven gear.
GENERATOR
REMOVAL
• Remove the stator coil 1 and CKP sensor 2 .
INSTALLATION
Install the stator coil and CKP sensor in the reverse order of removal. Pay attention to the following point:
• Route the lead wire properly. (
10-14)
GEARSHIFT SHAFT
DISASSEMBLY
• Remove the return spring 2 and spacer 3 from the gearshift shaft 1 .
INSPECTION
Inspect the gearshift shaft for wear or bend.
Inspect the return springs for damage or fatigue.
Replace the gearshift shaft or spring if there is anything unusual.
REASSEMBLY
• Install the spacer 3 and return spring 2 .
NOTE:
When installing the gearshift shaft return spring, position the stopper A of gearshift arm between the shaft return spring ends
B .
OIL FILTER
REMOVAL
• Remove the oil filter cap 1 .
• Remove the oil filter 2 .
INSTALLATION
• Apply engine oil to the O-rings ( 1 , 2 ) and install them.
• Install a new oil filter 3 .
• Install the spring 4 and oil filter cap 5 .
NOTE:
Before installing the new oil filter and oil filter cap, make sure that the spring 4 and new O-rings ( 1 , 2 ) are installed correctly.
OIL STRAINER
REMOVAL
• Remove the oil strainer cap 1 .
• Remove the oil strainer 2 .
CLEANING AND INSPECTION
Check the oil strainer for any damage or clogs.
Clean the oil strainer with a compressed air.
ENGINE 3-43
3-44 ENGINE
INSTALLATION
• Install the oil strainer 1 as shown.
• Apply grease to the O-ring 2 and install it.
Replace the O-ring with a new one.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the oil strainer cap and tighten the oil strainer bolts securely.
OIL PUMP
INSPECTION
Rotate the oil pump by hand and check that it moves smoothly.
If it does not move smoothly, replace the oil pump assembly.
* Do not attempt to disassemble the oil pump assembly.
* The oil pump is available only as an assembly.
Crankcase
TRANSMISSION
DISASSEMBLY
• Disassemble the transmission gears as shown in the illustration.
ENGINE 3-45
1 1st driven gear
2 5th driven gear
3 3rd driven gear
4 4th driven gear
5 2nd driven gear
6 Driveshaft
7 Countershaft
8 5th drive gear
9 3rd drive gear
0 4th drive gear
A 2nd drive gear
A Engine sprocket nut
ITEM N·m kgf-m lbf-ft
A 90 9.0
65.0
3-46 ENGINE
REASSEMBLY
Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points:
NOTE:
* Rotate the bearings by hand to inspect for smooth rotation. Replace the bearings if there is anything unusual.
* Before installing the gears, apply engine oil to the driveshaft and countershaft.
* Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
* When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
* After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.
NOTE:
When reassembling the transmission, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, washers and snap rings.
(
3-47)
• When installing a new snap ring, pay attention to its direction.
Fit it to the side where the thrust is as shown in the illustration.
A Thrust
B Sharp edge
TRANSMISSION PARTS LOCATION
ENGINE 3-47
A 2 mm (0.08 in) B 1 mm (0.03 in)
GEARSHIFT FORK TO GROOVE CLEARANCE
Using a thickness gauge, check the gearshift fork clearance in the groove of its gear.
The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.
Shift fork to groove clearance
Service Limit (No.1, 2, 3): 0.60 mm (0.024 in)
09900-20803: Thickness gauge
If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
3-48 ENGINE
GEARSHIFT FORK GROOVE WIDTH
Measure the gearshift fork groove width using the vernier calipers.
Shift fork groove width
Standard (No.1, 2, 3):
4.25 – 4.35 mm (0.167 – 0.171 in)
09900-20101: Vernier calipers (150 mm)
GEARSHIFT FORK THICKNESS
Measure the gearshift fork thickness using the vernier calipers.
Shift fork thickness
Standard (No.1, 2, 3):
3.95 – 4.05 mm (0.156 – 0.159 in)
09900-20101: Vernier calipers (150 mm)
CLUTCH
CLUTCH DRIVE PLATE
Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
Clutch drive plate thickness
Service Limit (No.1): 2.62 mm (0.103 in)
(No.2): 3.12 mm (0.123 in)
09900-20101: Venier calipers (150 mm)
Clutch drive plate claw width
Service Limit (No.1, 2): 15.1 mm (0.59 in)
CLUTCH DRIVEN PLATE
Measure each clutch driven plates for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
Clutch driven plate distortion
Service Limit: 0.10 mm (0.004 in)
09900-20803: Thickness gauge
ENGINE 3-49
CLUTCH SPRING FREE LENGTH
Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring.
Clutch spring free length
Service Limit: 40.9 mm (1.61 in)
09900-20101: Venier calipers (150 mm)
CLUTCH RELEASE BEARING
Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.
Smooth engagement and disengagement of the clutch depends on the condition of this bearing.
CRANKCASE BEARING AND OIL SEAL
BEARING INSPECTION
While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced as follows:
OIL SEAL INSPECTION
Inspect each oil seal lip for wear and damage. If any defects are found, replace the oil seal with a new one.
Play
Play
3-50 ENGINE
BEARING AND OIL SEAL REMOVAL
The removed bearings and oil seals must be replaced with new ones.
Right crankcase
• Remove the bearing retainer 1 .
• Remove the bearings ( 2 , 3 , 4 , 5 ) with the special tool.
Bearing 2 :
47 Attachment
Bearing 3 :
40 Attachment
Bearing 4 :
35 Attachment
Bearing 5 :
30 Attachment
09913-70210: Bearing installer set (10 – 75
)
Left crankcase
• Remove the oil seals ( 1 , 2 , 3 ) with the special tool.
09913-50121: Oil seal remover
• Remove the bearings ( 4 , 5 , 6 ) with the special tool.
Bearing 4 : 35 mm Remover
Bearing 5 : 17 mm Remover
Bearing 6 : 25 mm Remover
09921-20240: Bearing remover set
• Remove the washer 7 .
• Remove the oil seal 8 with the special tool.
Oil seal 8 :
62 Attachment
09913-70210: Bearing installer set (10 – 75
)
• Remove the bearing 9 with the special tool.
Bearing 9 :
35 Attachment
09913-70210: Bearing installer set (10 – 75
)
• Remove the washer 0 .
BEARING AND OIL SEAL INSTALLATION
Right crankcase
• Install new bearings ( 1 , 2 , 3 , 4 ) with the special tool.
Bearing 1 :
72 Attachment
Bearing 2 :
62 Attachment
Bearing 3 :
55 Attachment
Bearing 4 :
40 Attachment
09913-70210: Bearing installer set (10 – 75
)
• Install the bearing retainer 5 .
• Apply a small quantity of thread lock to the bearing retainer screws and tighten them.
99000-32110: THREAD LOCK SUPER “1322” or equivalent
Left crankcase
• Install the washer 1 .
• Install a new bearing 2 with the special tool.
Bearing 2 :
55 Attachment
09913-70210: Bearing installer set (10 – 75
)
ENGINE 3-51
3-52 ENGINE
• Install a new oil seal 3 with the special tool.
Oil seal 3 :
68 Attachment
Align the oil hole of crankcase with the concave part of oil seal 3 .
09913-70210: Bearing installer set (10 – 75
)
• Install the washer 4 .
NOTE:
The convex curve side of washer 4 faces outside.
• Install a new bearing 5 with the special tool.
Bearing 5 :
75 Attachment
09913-70210: Bearing installer set (10 – 75
)
• Install new bearings ( 6 , 7 ) with the special tool.
Bearing 6 :
40 Attachment
Bearing 7 :
62 Attachment
09913-70210: Bearing installer set (10 – 75
)
NOTE:
The sealed side of bearing 6 faces outside.
• Install new oil seals ( 8 , 9 ) with the special tool.
Oil seal 8 :
42 Attachment
Oil seal 9 :
47 Attachment
* The stamped mark on the oil seal 8 must face inside.
* The stamped mark on the oil seal 9 must face outside.
* Align the oil hole A of crankcase with the concave part of oil seal 9 .
09913-70210: Bearing installer set (10 – 75
)
ENGINE 3-53
• Install a new oil seal 0 with the special tool.
Oil seal 0 :
22 Attachment
09913-70210: Bearing installer set (10 – 75
)
• Apply a small quantity of grease to each oil seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
3-54 ENGINE
CLUTCH RELEASE CAMSHAFT
REMOVAL
• Remove the oil seal plate 1 and clutch cable stopper 2 .
• Remove the clutch release camshaft 3 , oil seal 4 and washer 5 .
INSTALLATION
• Apply a small quantity of grease to the oil seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the clutch release camshaft 1 , washer 2 and new oil seal 3 .
• Install the oil seal plate 4 and clutch cable stopper 5 .
CLUTCH COVER
OIL SEAL INSPECTION
Inspect the oil seal lip for wear and damage. If any defects are found, replace the oil seal with a new one.
OIL SEAL REMOVAL
• Remove the oil seal retainer 1 .
• Remove the oil seal 2 with the special tool.
09913-50121: Oil seal remover
OIL SEAL INSTALLATION
• Install a new oil seal 1 with the special tool.
09913-70210: Bearing installer set (10 – 75
)
• Install the oil seal retainer.
• Apply a small quantity of grease to the oil seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
ENGINE 3-55
3-56 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.
CRANKSHAFT
• When installing the crankshaft into the crankcase, it is necessary to pull its left end into the left crankcase with the special tools.
Never install the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft may be misaligned.
09910-20116: Connecting rod stopper
09910-32812: Crankshaft installer
09910-32840: Crankshaft installer adapter
• Apply engine oil to the crankshaft bearings.
• Install the crank balancer drive gear 1 .
NOTE:
* Align the pin A on crankshaft with the crank balancer drive gear hole.
* The punch mark side B of crank balancer drive gear faces outside.
TRANSMISSION
• Install the countershaft and the driveshaft assemblies.
• Align the pin groove A of gearshift cam stopper plate 1 with the pin B on gearshift cam.
• Install the gearshift cam stopper 2 .
• Install the gearshift forks and gearshift cam 6 .
3 : Gearshift fork No.1
4 : Gearshift fork No.2
5 : Gearshift fork No.3
• Install the gearshift fork shafts ( 7 , 8 ).
NOTE:
Three kinds of gearshift forks ( 3 , 4 , 5 ) are used. They resemble each other very closely in external appearance and configuration. Carefully examine the photograph for correct installing positions and directions.
• Install the gearshift cam stopper spring 9 as shown.
CRANK BALANCER
• Install the crank balancer shaft 1 and key 2 .
ENGINE 3-57
3-58 ENGINE
• Install the washers 3 , crank balancer driven gear 4 and shim 5 as shown.
NOTE:
Align the punch mark A on crank balancer driven gear with the punch mark B on crank balancer drive gear.
CRANKCASE
• Clean and degrease the crankcase mating surfaces (both surfaces).
• Apply engine oil to the O-rings 1 and install them.
Replace the O-rings with new ones.
• Apply engine oil to the gears and bearings.
• Install the dowel pins into the left crankcase.
• Apply bond to the both crankcases.
99000-31110: SUZUKI BOND “1215” or equivalent
* Coat the sealant evenly without break.
* Application of sealant must be performed within a short period of time.
* Take extreme care not to let sealant enter into the oil hole or bearing.
• Assemble the crankcases with in few minutes.
Right crankcase
Left crankcase
• Install the clamp to the bolt A .
• Tighten the crankcase bolts to the specified torque.
Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
ENGINE 3-59
NOTE:
After the crankcase bolts have been tightened, check if the crankshaft, countershaft and driveshaft rotates smoothly.
• Apply grease to the O-ring and install it to the engine sprocket spacer 2 .
Replace the O-ring with a new one.
• Apply grease to each oil seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the engine sprocket spacer 2 .
NOTE:
The oil hole side B of engine sprocket spacer faces inside.
3-60 ENGINE
• Install the gearshift cam stopper No.2 3 , spring 4 and gearshift cam stopper plug 5 .
Gearshift cam stopper plug:
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
GENERATOR
• Install the washer 1 .
NOTE:
The chamber side A of washer faces inside.
• Apply engine oil to the bearing 2 and install it.
• Install the starter driven gear 4 onto the starter clutch 3 .
• Degrease the tapered portion B of generator rotor and also the crankshaft C . Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry.
• Install the key 5 .
• Apply thread lock to the generator rotor nut 6 .
99000-32030: THREAD LOCK SUPER “1303” or equivalent
• Hold the generator rotor with the special tool.
• Tighten the generator rotor nut 6 to the specified torque.
Generator rotor nut: 160 N·m (16.0 kgf-m, 115.5 lbf-ft)
09930-44521: Rotor holder
PRIMARY DRIVE GEAR
• Install the cam chain drive sprocket 1 and sprocket key
(L-shape) 2 .
• Install the primary drive gear 3 and key 4 .
• Install the washer 5 and primary drive gear nut 6 .
The primary drive gear nut has left-hand threads.
NOTE:
* The conical curve side of washer faces outside.
* The “L” mark side A of primary drive gear nut faces outside.
• Hold the generator rotor with the special tool.
• Tighten the primary drive gear nut 6 (left-hand threads) to the specified torque.
Primary drive gear nut: 100 N·m (10.0 kgf-m, 72.5 lbf-ft)
09930-44521: Rotor holder
ENGINE 3-61
3-62 ENGINE
• Install the cam chain 7 .
• Install the washer 8 .
• Apply thread lock to the crank balancer bolt 9 .
99000-32110: THREAD LOCK SUPER “1322” or equivalent
• Hold the generator rotor with special tool.
• Tighten the crank balancer bolt to the specified torque.
Crank balancer bolt: 40 N·m (4.0 kgf-m, 29.0 lbf-ft)
09930-44521: Rotor holder
GEARSHIFT
• Apply a small quantity of thread lock to the gearshift arm stopper 1 and tighten it to the specified torque.
99000-32030: THREAD LOCK SUPER “1303” or equivalent
Gearshift arm stopper: 19 N·m (1.9 kgf-m, 13.5 lbf-ft)
• Install the springs 2 , pins 3 and pawls 4 to the gearshift cam driven gear 5 .
NOTE:
The large shoulder A must face to the outside.
• Install the gearshift driven gear assembly 6 .
• Apply a small quantity of thread lock to the screws.
99000-32110: THREAD LOCK SUPER “1322” or equivalent
• Install the pawl lifter 7 and cam guide 8 .
• Install the gearshift shaft 9 .
NOTE:
Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear.
OIL PUMP
• Install the oil pump 1 with the oil pump mounting bolts and then tighten them to the specified torque.
Oil pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Install the washer 2 and pin 3 .
• Install the oil pump driven gear 4 and snap ring 5 .
Never reuse a snap ring.
NOTE:
Align the groove A of oil pump driven gear 4 with the pin 3 .
09900-06107: Snap ring remover (Open type)
• Install the oil pump drive gear 6 and circlip 7 to the primary driven gear assembly 8 .
Never reuse a circlip.
ENGINE 3-63
3-64 ENGINE
CLUTCH
• Install the thrust washer 1 and spacer 2 .
• Apply engine oil to the inside and outside surfaces of the spacer 2 .
• Install the primary driven gear assembly 3 and thrust washer
4 .
NOTE:
Be sure to engage the oil pump driven gear with the drive gear and the primary driven gear with the drive gear.
• Install the clutch sleeve hub 5 and lock washer 6 .
Replace the lock washer with a new one.
• Hold the clutch sleeve hub with the special tools and tighten the clutch sleeve hub nut 7 to the specified torque.
Clutch sleeve hub nut: 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
09920-31020: Extension handle
09920-53740: Clutch sleeve hub holder
• Bent the lock washer to secure the clutch sleeve hub nut.
• Install the spring washer seat 8 and spring washer 9 onto the clutch sleeve hub correctly.
ENGINE 3-65
• Apply engine oil to the clutch drive plates and driven plates.
• Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order.
0 Clutch drive No.2 plate ....... 1 pc.
A Clutch driven plate .............. 4 pcs.
B Clutch drive No.1 plate ....... 4 pcs.
Direction of outside
Clutch drive No.2 plate
Clutch drive No.1 plate
*
Friction piece
=
36 pcs.
36 pcs.
I.D.
>
120 mm (4.72 in)
116 mm (4.57 in)
• Install the push rod C , push piece D , release bearing E and washer F .
• Apply engine oil to the release bearing E .
• Install the clutch pressure plate G , clutch spring and clutch spring set bolt.
• Tighten the clutch spring set bolts to the specified torque.
NOTE:
Tighten the clutch spring set bolt diagonally.
Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
3-66 ENGINE
CLUTCH RELEASE SCREW ADJUSTMENT
• Loosen the lock-nut 1 , and turn in the release screw 2 to feel resistance.
• From that position, turn out the release screw 2 1/4 turn, and tighten the lock-nut 1 by holding the release screw 2 .
CLUTCH COVER
• Install the dowel pins and gasket 1 .
Replace the gasket with a new one.
Dowel pin length: 18 mm (0.71 in) .... 2 pcs.
• Install the clutch cover 2 and tighten the clutch cover bolts to the specified torque.
Clutch cover bolt: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
STARTER IDLE GEAR
• Install the starter idle gear 1 and starter idle gear shaft 2 .
GENERATOR COVER
• Install the dowel pins and gasket 1 .
Replace the gasket with a new one.
• Install the generator cover 2 and tighten the generator cover bolts to the specified torque.
Generator cover bolt (M6): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
Generator cover bolt (M5): 6 N·m (0.6 kgf-m, 4.5 lbf-ft)
NEUTRAL SWITCH
• Install the springs 1 and switch contacts 2 .
• Apply grease to the O-ring 3 and install it.
Replace the O-ring with a new one.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the neutral switch 4 .
PISTON RING
• Install the piston rings in the order of oil ring, 2nd ring and 1st ring.
• To install the oil ring, fit the spacer 1 first and then the side rails 2 .
* Do not remove the wire 3 from the spacer 1 .
* When installing the piston rings, be careful not to damage the piston.
* Do not expand the piston ring excessively since it is apt to be broken down.
ENGINE 3-67
3-68 ENGINE
• Install the 2nd ring 4 and 1st ring 5 .
NOTE:
1st ring and 2nd ring differ in shape.
• Face the stamped mark A upward when assembling.
• Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so located.
B 2nd ring and lower side rail
C Upper side rail
D 1st ring and spacer
PISTON
• Apply molybdenum oil solution to the piston pin and the small end of conrod.
MOLYBDENUM OIL SOLUTION
• Install the piston with the dent mark A facing towards the exhaust side.
EX
120˚
120˚ 120˚
IN
1st ring
2nd ring
• Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
• Install the piston pin circlip 1 .
Use new piston pin circlips to prevent circlip failure which will occur with a bend one.
NOTE:
End gap of the circlip should not be aligned with the cutaway in the piston pin bore.
CYLINDER
• Apply bond to the mating surfaces at the parting line between the left and right crankcases as shown.
99000-31110: SUZUKI BOND “1215” or equivalent
• Apply engine oil to the big end of conrod.
• Install the dowel pins ( 1 , 2 ) and cylinder gasket 3 .
Use the new O-rings to prevent oil leakage.
1 Dowel pin length .... 18 mm (0.71 in)
2 Dowel pin length .... 14 mm (0.55 in)
• Apply molybdenum oil solution to the cylinder wall.
MOLYBDENUM OIL SOLUTION
• Apply engine oil to the piston rings.
• Hold each piston ring with properly position, and insert the piston into the cylinder 4 .
When inserting the piston into the cylinder, take care not to bend the piston rings.
NOTE:
When installing the cylinder, keep the cam chain taut.
ENGINE 3-69
3-70 ENGINE
CYLINDER HEAD/CAM CHAIN GUIDE
• Install the cam chain guide 1 .
When installing the cam chain guide, check that the chain is properly engaged with the crankshaft sprocket.
• Install the dowel pin and cylinder head gasket 2 .
Use new gasket to prevent gas leakage.
• Install the cylinder head 3 .
• Tighten the cylinder head nuts to the specified torque diagonally.
Cylinder head nut: 37 N·m (3.7 kgf-m, 27.0 lbf-ft)
CAMSHAFT
• Turn the crankshaft counterclockwise, and align the line A on the generator rotor with the mark B on the generator cover while keeping the cam chain pulled upward.
• Install the locating pin 1 and dowel pin 2 into the camshaft.
• Install the C-ring 3 .
Do not drop the C-ring into the crankcase.
• Apply engine oil to the camshaft bearings.
• Apply molybdenum oil solution to the cam faces.
MOLYBDENUM OIL SOLUTION
• Set the notch C on camshaft toward the intake side of cylinder head.
• Align the engraved lines D on the camshaft sprocket with the cylinder head top surface.
• Engage the cam chain on the camshaft sprocket. Make sure that the locating pin E on the camshaft aligns with the locating pin hole on the camshaft sprocket.
• Apply a small quantity of thread lock to the camshaft sprocket bolts.
99000-32030: THREAD LOCK SUPER “1303” or equivalent
• Tighten the camshaft sprocket bolts to the specified torque.
Camshaft sprocket bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Rotate the crankshaft (two turns), and recheck the positions of the camshaft.
ENGINE 3-71
3-72 ENGINE
CYLINDER HEAD COVER
• Clean and degrease the mating surfaces of the cylinder head and cylinder head cover.
• Install the dowel pins and cylinder head plug 1 .
• Apply bond to the cylinder head cover and part A of the cylinder head.
99000-31110: SUZUKI BOND “1215” or equivalent
* Coat the sealant evenly without break.
* Application of sealant must be performed within a short period of time.
* Take extreme care not to let sealant enter into the oil hole or bearing.
• Install the cylinder head cover.
• Lightly tighten the cylinder head cover bolts and nuts diagonally, and then tighten them to the specified torque.
Fit new gasket to the bolt 2 .
Cylinder head cover bolt/nut:
11 N·m (1.1 kgf-m, 8.0 lbf-ft)
CAM CHAIN TENSION ADJUSTER
• Apply engine oil to the push rod.
• Turn the adjusting screw clockwise until the push rod locked.
• Install the gasket 1 .
Replace the gasket with a new one.
• Install the cam chain tension adjuster with “UP” mark A faced upward.
Cam chain tension adjuster bolt:
10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Unlock the push rod by turning the adjusting screw counterclockwise.
• Install the cam chain tension adjuster cap 2 .
NOTE:
Be sure to check the valve clearance. (
2-5)
CAP/PLUG
• Apply grease to the O-ring 1 .
Replace the O-ring 1 and gasket 2 with new ones.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Tighten the TDC plug and the generator cover plug to the specified torque.
TDC plug: 21 N·m (2.1 kgf-m, 15.0 lbf-ft)
Generator cover plug: 15 N·m (1.5 kgf-m, 11.0 lbf-ft)
ENGINE 3-73
3-74 ENGINE
• Apply grease to the O-rings and install the valve inspection caps.
Replace the O-rings with new ones.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
SPARK PLUG
• Tighten the spark plug 1 to the specified torque.
Spark plug: 18 N·m (1.8 kgf-m, 13.0 lbf-ft)
09930-10121: Spark plug wrench set
STARTER MOTOR
• Apply grease to the O-ring and install the starter motor.
Replace the O-ring with a new one.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
FI SYSTEM DIAGNOSIS
FI SYSTEM DIAGNOSIS 4-1
CONTENTS
PRECAUTIONS IN SERVICING .................................................................. 4- 3
ELECTRICAL PARTS ........................................................................... 4- 3
ECM/VARIOUS SENSORS ................................................................... 4- 4
ELECTRICAL CIRCUIT INSPECTION PROCEDURE .......................... 4- 6
USING THE MULTI CIRCUIT TESTER................................................. 4- 9
FI SYSTEM TECHNICAL FEATURES......................................................... 4-10
INJECTION TIME (INJECTION VOLUME) ........................................... 4-10
COMPENSATION OF INJECTION TIME (VOLUME) ........................... 4-11
INJECTION STOP CONTROL .............................................................. 4-11
FI SYSTEM PARTS LOCATION ........................................................... 4-12
FI SYSTEM WIRING DIAGRAM............................................................ 4-13
SELF-DIAGNOSIS FUNCTION.................................................................... 4-15
FAIL-SAFE FUNCTION......................................................................... 4-17
FI SYSTEM TROUBLESHOOTING....................................................... 4-18
SELF-DIAGNOSTIC PROCEDURES.................................................... 4-20
USE OF SDS DIAGNOSTIC PROCEDURES ....................................... 4-23
USE OF SDS DIAGNOSIS RESET PROCEDURE ............................... 4-24
(DISPLAING DATA AT THE TIME OF DTC) ........................................ 4-25
MALFUNCTION CODE AND DEFECTIVE CONDITION ...................... 4-26
“12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION ...................... 4-29
“13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION................. 4-31
“14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION .................. 4-36
“15” (P0115-H/L) ET SENSOR CIRCUIT MALFUNCTION .................. 4-41
“21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION ................. 4-45
“23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION.................. 4-49
“24” (P0351) IGNITION SYSTEM MALFUNCTION.............................. 4-52
“28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION.................. 4-53
“29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION................ 4-56
“32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION ................. 4-60
“41” (P0230-H/L) FP CIRCUIT MALFUNCTION .................................. 4-62
“42” (P01650) IG SWITCH CIRCUIT MALFUNCTION ......................... 4-63
“44” (P0130) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION ......... 4-64
“49” (P1656) PAIR CONTROL SOLENOID VALVE
CIRCUIT MALFUNCTION ..................................................................... 4-66
4
4-2 FI SYSTEM DIAGNOSIS
FI SYSTEM DIAGNOSIS
CONTENTS
CKP SENSOR INSPECTION ................................................................ 4-68
CKP SENSOR REMOVAL AND INSTALLATION ................................ 4-68
IAP SENSOR INSPECTION .................................................................. 4-68
IAP SENSOR REMOVAL AND INSTALLATION.................................. 4-68
TP SENSOR INSPECTION ................................................................... 4-68
TP SENSOR REMOVAL AND INSTALLATION ................................... 4-68
TPS ADJUSTMENT............................................................................... 4-69
ET SENSOR INSPECTION ................................................................... 4-70
ET SENSOR REMOVAL AND INSTALLATION ................................... 4-70
IAT SENSOR INSPECTION .................................................................. 4-70
IAT SENSOR REMOVAL AND INSTALLATION .................................. 4-70
TO SENSOR INSPECTION ................................................................... 4-71
TO SENSOR REMOVAL AND INSTALLATION ................................... 4-71
STP SENSOR INSPECTION ................................................................. 4-71
STP SENSOR REMOVAL AND INSTALLATION................................. 4-71
STP SENSOR ADJUSTMENT .............................................................. 4-71
HO2 SENSOR INSPECTION................................................................. 4-71
HO2 SENSOR REMOVAL AND INSTALLATION ................................ 4-72
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the FI system, observe the following points for the safety of the system.
ELECTRICAL PARTS
CONNECTOR/COUPLER
• Faulty FI system is often related to poor electrical contact of connector/coupler. Before servicing individual electronic part, check electrical contact of 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.
• Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact.
• Inspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material which could impede proper terminal contact.
• Before refitting the sealed coupler, make sure its seal rubber is positioned properly. The seal rubber may possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber improperly positioned, it may result in poor water sealing.
• Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.
FI SYSTEM DIAGNOSIS 4-3
Click
4-4 FI SYSTEM DIAGNOSIS
• 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
• 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.
SWITCH
• Never apply grease material to switch contact points to prevent damage.
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.
INCORRECT
• Be careful not to touch the electrical terminals of the ECM.
The static electricity from your body may damage this part.
• When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1 , or electronic parts may get damaged.
• Battery connection in reverse polarity is strictly prohibited.
Such a wrong connection will damage the components of the
FI system instantly when reverse power is applied.
• 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.
FI SYSTEM DIAGNOSIS 4-5
INCORRECT
4-6 FI SYSTEM DIAGNOSIS
• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected.
Otherwise, damage to ECM may result.
• Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to 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.
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, 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 Sensor
2 ECM
*1 Check for loose connection.
• 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.
*1 Check contact tension by inserting and removing.
*2 Check each terminal for bend and proper alignment.
*1
*2
*1
*1
• 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.
A Looseness of crimping
B Open
C Thin wire (a few strands left)
Continuity check
• Measure resistance across coupler B (between A and C in the figure).
If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C .
1 ECM
• Disconnect the coupler B and measure resistance between couplers A and B .
If 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 .
1 ECM
FI SYSTEM DIAGNOSIS 4-7
4-8 FI SYSTEM DIAGNOSIS
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: 0 V
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: 3 V
2 V voltage drop
SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)
• Disconnect the negative cable from the battery.
• Disconnect the connectors/couplers at both ends of the circuit to be checked.
NOTE:
If the circuit to be checked branches to other parts as shown, disconnect all connectors/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 .
0 V
5 V
5 V
5 V
*1
5 V
1 Other parts
*1 To other parts
• 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 .
1 ECM
*1 To other parts
USING THE MULTI CIRCUIT TESTER
• Use the Suzuki multi circuit tester set (09900-25008).
• Use well-charged batteries in the tester.
• Be sure to set the tester to the correct testing range.
USING THE TESTER
• Incorrectly connecting the + and probes may cause the inside of 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 1 ,
∞ will be shown as 10.00 M Ω 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.
09900-25008: Multi circuit tester set
NOTE:
* When connecting the multi circuit tester, use the needle-point probe to the back side of the lead wire coupler and connect the probes of tester to them.
* Use the needle-point probe to prevent the rubber of the water proof coupler from damage.
09900-25009: Needle-point probe set
• When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
FI SYSTEM DIAGNOSIS 4-9
*1
4-10 FI SYSTEM DIAGNOSIS
FI SYSTEM TECHNICAL FEATURES
INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations.
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)
Crankshaft Position
Sensor (CKP Sensor)
Throttle Position
Sensor (TP Sensor)
Various
Sensors
Intake air pressure signal
Engine speed signal
Throttle opening signal
Various signals
Basic fuel injection time
Compensation
Injectors
Injection signal
Ultimate fuel injection time
FI SYSTEM DIAGNOSIS 4-11
COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensation of the fuel injection time (volume).
SIGNAL
ENGINE TEMPERATURE SENSOR SIG-
NAL
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
HEATED OXYGEN SENSOR SIGNAL
BATTERY VOLTAGE SIGNAL
ENGINE RPM SIGNAL
STARTING SIGNAL
ACCELERATION SIGNAL/
DECELERATION SIGNAL
DESCRIPTION
When engine 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.
THROTTLE POSITION SENSOR SIGNAL When trying to start the engine with the throttle opened approx. 2/3 and more, both the fuel injector and ignition stop their operation.
4-12 FI SYSTEM DIAGNOSIS
FI SYSTEM PARTS LOCATION
A ECM
B Tip-over sensor (TOS)
C Heated oxygen sensor (HO2S)
D PAIR control solenoid valve
E Engine temperature sensor (ET)
F Fuel pump (FP)
G Ignition coil (IG coil)
H Intake air temperature sensor (IATS)
A ECM
I Speedometer
J Intake air pressure sensor (IAPS)
K Fuel injector
L Secondary throttle position sensor (STPS)
M Secondary throttle valve actuator (STVA)
N Crank position sensor (CKPS)
O Throttle position sensor (TPS)
FI SYSTEM DIAGNOSIS 4-13
FI SYSTEM WIRING DIAGRAM
Speedometer
B/G
Crankshaft positon sensor (CKPS)
Bl/R
R
V
Throttle position sensor (TPS)
Bl/Y
Secondary throttle position sensor (STPS)
W/Bl
Intake air pressure sensor (IAPS)
Y/R
Intake air temperatue sensor (IATS)
B/Bl
Engine temperatue sensor (ETS)
Bl/W
B/Br
Heated oxygen sensor (HO2S)
Br
Tip-over sensor
(TOS)
Secondary throttle valve actuator
(STVA)
O/R
Lg/W
O/Y
R/Y
B
Fuel injector
Ignition coil
Fuel pump
Main relay
10A
W/R
B
W/B
B/R
ECM
Y/W solenoid valve
B/G
PAIR control
P
B/Y
B
Bl
Newtral switch
Side-stand switch
Engine stop switch
Side-stand relay
10A
Starter button
10A
Ignition switch
30A
Head light
Battery
B/W
B/W
Clutch lever position switch
Starter relay
Starter motor
4-14 FI SYSTEM DIAGNOSIS
ECM TERMINAL
TERMINAL
NO.
1
2
3
4
5
0
A
B
C
6
7
8
9
D
E
F
G
CIRCUIT
STVA signal (STVA. 2A)
STVA signal (STVA. 1A)
TP sensor signal (TPS)
TO sensor signal (TOS)
IAT sensor signal (IAT)
—
IAP sensor signal (IAP)
Gear position switch signal (GP)
Starter relay
Neutral signal
Power source for sensors (VCC)
CKP sensor signal (CKP)
ECM ground (E1)
Power source (+B)
PAIR control solenoid valve (PAIR)
Fuel injector
Ignition coil
TERMINAL
NO.
H
I
J
K
L
Q
R
S
T
M
N
O
P
U
V
W
X
STVA signal (STVA. 2B)
STVA signal (STVA. 1B)
STP sensor (STPS)
HO2 sensor (HO2S)
ET sensor (ET)
—
—
—
Mode selection switch
Clutch lever switch
Serial data for speedometer
Sensor ground (E2)
Power source for back-up
Fuel pump (FP)
FI indicator light
CIRCUIT
—
Ignition system ground (E3)
FI SYSTEM DIAGNOSIS 4-15
SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and
“Dealer mode”. The user can only be notified by the FI indicator light. To check the function of the individual
FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items.
USER MODE
MALFUNCTION
“NO”
“YES”
FI INDICATOR LIGHT
INDICATION
----
Engine can start
FI indicator light turns ON.
*1
Engine can not start FI indicator light turns ON and blinks.
*2
*1
When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, FI indicator light is lighted and the motorcycle can run.
*2
The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, ignition signal, injector signal, fuel pump signal or ignition switch signal is not sent to ECM.
In this case, FI indicator light is ON and blinks and the motorcycle can not run.
NOTE:
When the ignition switch is turned ON, FI indicator light is lit for approx. 3 seconds and thereafter remains unlit.
4-16 FI SYSTEM DIAGNOSIS
DEALER MODE
The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed by the flashing pattern of FI indicator light.
Malfunction means that the ECM does not receive normal signal from the devices. These affected devices are indicated in the code form.
09930-82720: Mode selection switch
Before checking DTC (Diagnostic Trouble Code), do not disconnect the ECM lead wire coupler.
If the coupler from the ECM is disconnected, the DTC memory may be erased and can not be checked.
MALFUNCTION
“NO”
“YES”
FI INDICATOR LIGHT
INDICATION
OFF
ON and blinks
The DTC is indicated from small code to large code.
FI SYSTEM DIAGNOSIS 4-17
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 FAIL-SAFE MODE
STARTING
ABILITY
RUNNING
ABILITY
IAP sensor
TP sensor
IAT sensor
ET sensor
HO2 sensor
STV actuator
Intake air pressure is fixed to 101.3 kPa (760 mmHg).
The throttle opening is fixed to full open position.
Ignition timing is also fixed.
Intake air temperature value is fixed to 40 °C (104 °F).
Engine temperature value is fixed to
90 °C (194 °F).
Feedback compensation is inhibited.
(Air/fuel ratio is fixed to normal.)
When motor disconnection or lock occurs, power from ECM is shut off.
STP sensor Secondary throttle valve is fixed to full open position.
PAIR control solenoid valve ECM stops controlling PAIR control solenoid valve.
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“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.
4-18 FI SYSTEM DIAGNOSIS
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM
User name:
Date of issue:
Model:
Date Reg.
VIN:
Date of problem: Mileage:
FI indicator light condition Always ON Sometimes ON Always OFF Good condition
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 ( r/min to r/min)
Other
OTHERS:
PROBLEM SYMPTOMS
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
FI SYSTEM DIAGNOSIS 4-19
Weather
Temperature
Frequency
MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental condition
Fair Cloudy Rain Snow Always Other
Hot Warm Cool Cold ( °C) Always
Always Sometimes ( times/ day, month) Only once
Road
Under certain condition
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 condition
During driving: Constant speed Accelerating Decelerating
Right hand corner Left hand corner
At stop Motorcycle speed when problem occurs ( km/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 selection 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 selection switch or SDS.
* Engine oil level and leakage (
2-10)
* Fuel level and leakage
* Clogged air cleaner element (
2-4)
* Battery condition (
9-39)
* Throttle cable play (
2-8)
* Broken fuse
* FI indicator light operation (
4-15, 9-27)
* Speedometer operation
* Exhaust gas leakage and noise (
6-4)
* Each coupler disconnection
4-20 FI SYSTEM DIAGNOSIS
SELF-DIAGNOSTIC PROCEDURES
NOTE:
* Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in memory. Such disconnection may erase the memorized information in ECM memory.
* DTC stored in ECM memory can be checked by the special tool.
* Before checking DTC, read SELF-DIAGNOSIS FUNCTION
“USER MODE and DEALER MODE” (
4-15 and -16) carefully to have good understanding as to what functions are available and how to use it.
* Be sure to read “PRECAUTIONS IN SERVICING” (
4-3) before inspection and observe what is written there.
• Remove the right frame cover. (
8-3)
• Connect the special tool to the dealer mode coupler 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. (
4-21)
09930-82720: Mode selection switch
• After repairing the trouble, start the engine or crank the engine for more than 4 seconds. If FI indicator is not indicated the DTC, the malfunction is cleared.
UNDERSTANDING THE DTC (Diagnostic Trouble Code)
A two-digit DTC is shown through the flashing pattern of the FI indicator light.
The DTCs are displayed from a smaller number to a larger number in that order. When all the applicable
DTCs have been displayed, the displaying of the DTCs repeat from the first one again.
If no DTC is recorded, the FI indicator light will not turned on.
Current DTC (example)
ON
FI indicator light
1
0.3
OFF
1.0
2
0.3
0.3
0.3
3.0
2
0.3 0.3
3
0.3
0.3 0.3
0.3
1.0
0.3
0.3
3.0
1
0.3
1.0
2
0.3
0.3
0.3
(Sec.)
FI SYSTEM DIAGNOSIS 4-21
DTC INDICATION CHART
FLASHING PATTERN DTC No.
00 None
MALFUNCTION PART
1
1
2
2
1
1 2
3
5
3
4
2 1
3
4
2
12
13
14
15
21
23
24
28
29
32
41
42
CKP sensor (
4-29)
IAP sensor (
4-31)
TP sensor (
4-36)
ET sensor (
4-41)
IAT sensor (
4-45)
TO sensor (
4-49)
Ignition coil (
4-52)
STV actuator (
4-53)
STP sensor (
4-56)
Fuel injector (
4-60)
Fuel pump (
4-62)
Ignition switch (
4-63)
4 2
REMARKS
Pick up coil signal
4-22 FI SYSTEM DIAGNOSIS
FLASHING PATTERN
4 4
DTC No.
44
MALFUNCTION PART
HO2 sensor (
4-64)
49
PAIR control solenoid valve
(
4-66)
SELF-DIAGNOSIS RESET PROCEDURE
• After repairing the trouble, turn OFF the ignition switch and turn ON again.
• If the FI indicator light turns OFF, the malfunction is cleared.
• Disconnect the special tool from the dealer mode coupler.
NOTE:
* Even though the Current DTC is cleared, Past DTC (previous malfunction history code) still remains stored in the ECM.
Therefore, erase the Past DTC memorized in the ECM using
SDS.
* DTC 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 DTC (Past DTC) using SDS.
REMARKS
USE OF SDS DIAGNOSTIC PROCEDURES
* Do not disconnect the couplers from ECM, battery cable from battery, ECM ground wire from the engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in memory. Such disconnection may erase the memorized information in ECM memory.
* DTC stored in ECM memory can be checked by SDS.
* Be sure to read “PRECAUTIONS IN SERVICING” (
4-3) before inspection and observe what is written there.
• Remove the front right frame cover. (
8-3)
• 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.
• SDS is not only used for detecting DTC 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: SUZUKI Diagnostic system set
99565-01010-020: CD-ROM Ver.20
FI SYSTEM DIAGNOSIS 4-23
4-24 FI SYSTEM DIAGNOSIS
USE OF SDS DIAGNOSIS RESET PROCE-
DURE
• 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).
FI SYSTEM DIAGNOSIS 4-25
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. Its 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.
4-26 FI SYSTEM DIAGNOSIS
MALFUNCTION CODE AND DEFECTIVE CONDITION
DTC No.
00
12
P0335
13
P0105
14
P0120
15
P0115
21
P0110
H
L
H
L
H
L
H
L
DETECTED
ITEM
NO FAULT
DETECTED FAILURE CONDITION
–––––––––––
CKP sensor The CKP sensor signal does not reach
ECM for 3 seconds or more, after receiving the starter signal.
CHECK FOR
–––––––––––
CKP sensor wiring and mechanical parts
CKP sensor, lead wire/coupler connection
IAP sensor, lead wire/coupler connection
IAP sensor The sensor should produce following voltage.
0.24 V sensor voltage < 4.1 V
In other than the above range, 13
(P0105) is indicated.
Sensor voltage is higher than specified value.
TP sensor
ET sensor
IAT sensor
Sensor voltage is lower than specified value.
The sensor should produce following voltage.
0.35 V sensor voltage < 4.9 V
In other than the above range, 14
(P0120) is indicated.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
IAP sensor circuit open or shorted to VCC or ground circuit open
IAP sensor circuit shorted to ground or VCC circuit open
TP sensor, lead wire/coupler connection
TP sensor circuit shorted to
VCC or ground circuit open
TP sensor circuit open or shorted to ground or VCC circuit open
ET sensor, lead wire/coupler connection
The sensor voltage should be the following.
0.1 V sensor voltage < 4.7 V
In other than the above range, 15
(P0115) is indicated.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
The sensor voltage should be the following.
ET sensor circuit open or ground circuit open
ET sensor circuit shorted to ground
IAT sensor, lead wire/coupler connection
0.15 V sensor voltage < 4.85 V
In other than the above range, 21
(P0110) is indicated.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
IAT sensor circuit open or ground circuit open
IAT sensor circuit shorted to ground
FI SYSTEM DIAGNOSIS 4-27
DTC No.
23
P1651
24
P0351
28
P1655
29
P1654
32
P0201
41
P0230
42
P1650
H
L
H
L
H
L
DETECTED
ITEM
TO sensor
DETECTED FAILURE CONDITION CHECK FOR
The sensor voltage should be the following.
0.2 V sensor voltage < 4.6 V
In other than the above value, 23
(P1651) is indicated.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
TO sensor, lead wire/coupler connection
TO sensor circuit shorted to
VCC or ground circuit open
TO sensor circuit open or shorted to ground or VCC circuit open
Ignition coil, wiring/coupler connection, power supply from the battery
Ignition signal
Signal from ignition coil is interrupted 8 times or more continuously although ignition signal is supplied from the
ECM. In this case, the code 24
(P0351) is indicated.
STV actuator When no actuator control signal is supplied from the ECM, communication signal does not reach ECM or operation voltage does not reach
STVA motor, C28 (P1655) is indicated.
STVA can not operate.
STP sensor The sensor should produce following voltage.
0.35 V sensor voltage < 4.9 V
In other than the above range, C29
(P1654) is indicated.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
STVA motor, STVA lead wire/coupler connection
STP sensor, lead wire/coupler connection
STP sensor circuit shorted to
VCC or ground circuit open
STP sensor circuit open or shorted to ground or VCC circuit open
Fuel injector, wiring/coupler connection, power supply to the injector
Fuel injector Fuel injector signal is interrupted 4 times or more continuously although ignition signal is supplied from the
ECM. In this case, the code 32
Fuel pump
(P0201) is indicated.
No voltage is applied to fuel pump.
Ignition switch
Voltage is applied to fuel pump although FP circuit is shut.
No voltage is applied to fuel pump although FP circuit is normal.
Ignition switch signal is not input to the
ECM.
FP, lead wire/coupler connection
FP circuit shorted to power source
FP circuit open
Ignition switch, lead wire/coupler, etc.
4-28 FI SYSTEM DIAGNOSIS
DTC No.
44
P0130
49
P1656
DETECTED
ITEM
DETECTED FAILURE CONDITION
HO2 sensor HO2 sensor output voltage is not input to ECM during engine operation and
PAIR control solenoid valve running condition.
(Sensor voltage < 0.60 V)
In other than the above value, 44
(P0130) is indicated.
PAIR control solenoid valve voltage is not input to ECM.
CHECK FOR
HO2 sensor circuit open or shorted to ground
PAIR control solenoid valve, lead wire/coupler
FI SYSTEM DIAGNOSIS 4-29
“12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
The signal does not reach ECM for 3 seconds or more, after receiving the starter signal.
POSSIBLE CAUSE
• Metal particles or foreign material being stuck on the CKP sensor and rotor tip
• CKP sensor circuit open or short
• CKP sensor malfunction
• ECM malfunction
CKP sensor
G
Bl
Bl/R
B/Br
ECM
CKP
E2
To regulator/rectifier
Generator
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1
1) Turn the ignition switch OFF.
2) Remove the front seat. (
8-3)
3) Check the CKP sensor coupler for loose or poor contacts.
If OK, then measure the CKP sensor resistance.
4) Disconnect the CKP sensor coupler and measure the resistance.
CKP sensor resistance: 420 – 620 Ω (Bl – G)
1
1
4-30 FI SYSTEM DIAGNOSIS
5) If OK, then check the continuity between each terminal and ground.
CKP sensor continuity: ∞ Ω (Infinity)
(Bl – Ground)
(G – 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.
1
Step 2
1) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the CKP sensor coupler.
2) Repeat the above test procedure a few times and measure the highest peak voltage.
CKP sensor peak voltage: 2.0 V and more ( + G – Bl)
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (
)
1 Peak volt adaptor
.
Is the voltage OK?
YES
NO
• Bl/R or B/Br wire open or shorted to ground.
• Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal B or T ).
• 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.
2
2
ECM coupler (Harness side)
FI SYSTEM DIAGNOSIS 4-31
“13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
13
P0105
H
L
DETECTED CONDITION
IAP sensor voltage is not within the following range.
0.24 V Sensor voltage < 4.1 V
NOTE:
Note that atmospheric pressure varies depending on weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
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.
• IAP sensor circuit shorted to VCC or ground circuit open.
• IAP sensor circuit shorted to ground or VCC circuit open.
ECM
IAP sensor
W/Bl
B/Br
R
IAP
E2
VCC
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 13:)
1) Turn the ignition switch OFF.
2) Check the IAP sensor coupler for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
1
4-32 FI SYSTEM DIAGNOSIS
3) Disconnect the IAP sensor coupler.
4) Turn the ignition switch ON.
5) Insert the needle-point probes to the lead wire coupler.
6) Measure the voltage at the R wire and ground.
7) If OK, then measure the voltage at the R wire and B/Br wire.
IAP sensor input voltage: 4.5 – 5.5 V
( + R – Ground)
( + R – B/Br)
09900-25008: Multi circuit tester set
09900-25009: Needle-point 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 A or T ).
• Open or short circuit in the R wire or B/Br wire.
Step 1 (When indicating P0105-H:)
1) Turn the ignition switch OFF.
2) Check the IAP sensor coupler for loose or poor contacts.
If OK, then check the IAP sensor lead wire continuity.
1
1
3) Disconnect the IAP sensor coupler.
4) Check the continuity between R wire and W/Bl wire.
If the sound is not heard from the tester, the circuit condition is OK.
1
V
FI SYSTEM DIAGNOSIS 4-33
5) Disconnect the ECM coupler.
6) Check the continuity between W/Bl wire A and terminal 7 .
7) If OK, then check the continuity between B/Br wire B and terminal T .
IAPS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
W/Bl wire shorted to VCC, or B/Br wire open.
1
Step 1 (When indicating P0105-L:)
1) Turn the ignition switch OFF.
2) Check the IAP sensor coupler for loose or poor contacts.
If OK, then check the IAP sensor lead wire continuity.
1
ECM coupler (Harness side)
!
3) Disconnect the IAP sensor coupler.
4) Check the continuity between W/Bl wire A and ground.
5) 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
4-34 FI SYSTEM DIAGNOSIS
6) Disconnect the ECM coupler.
7) Check the continuity between R wire C and terminal A .
8) Also, check the continuity between W/Bl wire A and terminal
7 .
IAPS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 1 (
4-31) and go to Step 2.
R wire or W/Bl wire open, or W/Bl wire shorted to ground
1
ECM coupler (Harness side)
!
Step 2
1) Connect the IAP sensor coupler and ECM coupler.
2) Insert the needle-point probes to the lead wire coupler.
3) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between W/Bl and
B/Br wires).
IAP sensor output voltage: 1.5 – 3.5 V at idle speed
( + W/Bl – B/Br)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
2
Is the voltage OK?
YES
NO
Go to Step 3.
• Open or short circuit in the W/Bl wire
• If wire are OK, replace the IAP sensor with a new one.
FI SYSTEM DIAGNOSIS 4-35
Step 3
1) Turn the ignition switch OFF.
2) Remove the IAP sensor. (
4-68)
3) Connect the vacuum pump gauge to the vacuum port of the
IAP sensor.
Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 – 5.0 V) and connect terminal to the ground terminal 2 and + terminal to the VCC terminal 3 .
4) Check the voltage between Vout 4 and ground. Also, check if voltage reduces when vacuum is applied by using vacuum pump gauge. (
Below)
09917-47011: Vacuum pump gauge set
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (
)
Is the voltage OK?
YES
NO
• W/Bl, R or B/Br wire open or shorted to ground, or poor 7 , A or T 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 the IAP sensor with a new one.
3
3
Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 –
30 °C, 68 – 86 °F)
Atmospheric pressure
(mmHg)
760 kPa
100
707
634
567
526
94
85
76
70
Output voltage
(V)
Approx. 2.86
Approx. 2.70
Approx. 2.45
Approx. 2.21
Approx. 2.05
V
ECM coupler (Harness side)
4-36 FI SYSTEM DIAGNOSIS
“14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION
14
P0120
H
L
DETECTED CONDITION
Output voltage is not within the following range.
0.35 V Sensor voltage < 4.9 V
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified 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
ECM
TP sensor
B/Br
V
R
E2
TP
VCC
* When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
* The TP sensor has been adjusted, removed or replaced, the TP learned valve reset must be performed using special tool. (
4-40)
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 14:)
1) Turn the ignition switch OFF.
2) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
1
3) Disconnect the TP sensor coupler.
4) Turn the ignition switch ON.
5) Measure the voltage at the R wire and ground.
6) If OK, then measure the voltage at the R wire and B/Br wire.
TP sensor input voltage: 4.5 – 5.5 V
( + R – Ground)
( + R – 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 A or T ).
• Open or short circuit in the R wire or B/Br wire.
Step 1 (When indicating P0120-H:)
1) Turn the ignition switch OFF.
2) Check the TP sensor coupler for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.
1
FI SYSTEM DIAGNOSIS 4-37
V
3) Disconnect the TP sensor coupler.
4) Check the continuity between V wire A and R wire B .
If the sound is not heard from the tester, the circuit condition is OK.
]
4-38 FI SYSTEM DIAGNOSIS
5) Disconnect the ECM coupler.
6) Check the continuity between V wire A and terminal 3 .
7) Also, check the continuity between B/Br wire C and terminal
T .
TP sensor lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
V wire shorted to VCC, or B/Br wire open
Step 1 (When indicating P0120-L:)
1) Turn the ignition switch OFF.
2) Check the TP sensor coupler for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.
1
1
ECM coupler (Harness side)
!
3) Disconnect the TP sensor coupler.
4) Check the continuity between V wire A and ground.
5) Also, check the continuity between V wire A and B/Br wire
C . If the sound is not heard from the tester, the circuit condition is OK.
]
FI SYSTEM DIAGNOSIS 4-39
6) Disconnect the ECM coupler.
7) Check the continuity between V wire A and terminal 3 .
8) Also, check the continuity between R wire B and terminal A .
TP sensor lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 1 (
4-36) and go to Step 2.
R wire or V wire open, or V wire shorted to ground
1
Step 2
1) Connect the special tool between TP sensor and its coupler.
2) Warm up the engine and keep it running at idling speed.
3) Measure the TP sensor output voltage at the terminals
(between + V and B/Br).
NOTE:
When measure the TP sensor output voltage, make sure that the fast idle cam is not contacted to the throttle lever.
4) Turn OFF the ignition switch and ON again.
5) Measure the TP sensor output voltage at the terminals
(between + V and B/Br) by turning the throttle grip.
TP sensor output voltage
Throttle valve is closed: Approx. 0.6 V
Throttle valve is opened: Approx. 3.8 V
09900-25008: Multi circuit tester set
09900-28630: TP Sensor test lead
Tester knob indication: Voltage (
)
2
2
TPS
ECM coupler (Harness side)
V
R
B/Br
!
ECM
Is the voltage OK?
YES
NO
• V, R or B/Br wire open or shorted to ground, or poor 3 , A or T 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.
• Short circuit in the V wire.
• If check result is not satisfactory, replace TP sensor with a new one.
2
ECM coupler (Harness side)
4-40 FI SYSTEM DIAGNOSIS
TP LEARNED VALUE RESET
When replacing the throttle body assembly or TP sensor with a new one or reinstalling the TP sensor, reset the TP learned value in the following procedures:
1) Turn the ignition switch ON.
2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)
3) Click the “Active control”.
4) Click the “TP learned value reset” 1 .
5) Click the “Reset” button 2 to clear the TP learned value.
NOTE:
The leaned value of the TP sensor is set at Preset position.
6) Close the SDS tool and turn the ignition switch OFF.
FI SYSTEM DIAGNOSIS 4-41
“15” (P0115-H/L) ET SENSOR CIRCUIT MALFUNCTION
15
P0115
H
L
DETECTED CONDITION
Output voltage is not within the following range.
0.1 V Sensor voltage < 4.7
V
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
POSSIBLE CAUSE
• ET sensor circuit open or short
• ET sensor malfunction
• ECM malfunction
• ET sensor circuit open or ground circuit open
• ET sensor circuit shorted to ground
ET sensor ECM
B/Br
B/Bl
E2
ET
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 15:)
1) Turn the ignition switch OFF.
2) Check the ET sensor coupler for loose or poor contacts.
If OK, then measure the ET sensor voltage at the wire side coupler.
1
4-42 FI SYSTEM DIAGNOSIS
3) Disconnect the coupler and turn the ignition switch ON.
4) Measure the voltage between B/Bl wire terminal and ground.
5) If OK, then measure the voltage between B/Bl wire terminal and B/Br wire terminal.
ET sensor 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 L or T ).
• Open or short circuit in the B/Bl wire or B/Br wire
Step 1 (When indicating P0115-H:)
1) Turn the ignition switch OFF.
2) Check the ET sensor coupler for loose or poor contacts.
If OK, then check the ET sensor lead wire continuity.
1
V
3) Disconnect the ET sensor coupler and ECM coupler.
4) Check the continuity between B/Bl wire A and terminal L .
5) Also, check the continuity between B/Br wire B and terminal
T .
ETS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
B/Bl or B/Br wire open
1
ECM coupler (Harness side)
!
Step 1 (When indicating P0115-L:)
1) Turn the ignition switch OFF.
2) Check the ET sensor coupler for loose or poor contacts.
If OK, then check the ET sensor lead wire continuity.
1
3) Disconnect the ET sensor coupler.
4) Check the continuity between B/Bl wire and ground.
If the sound is not heard from the tester, the circuit condition is OK.
Tester knob indication: Continuity test (
)
5) Connect the ET sensor coupler and turn the ignition switch
ON.
6) Measure the voltage between B/Bl wire and ground.
ET sensor output voltage: 0.1 – 4.6 V
( + B/BI – Ground)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
Are the continuity and voltage OK?
YES
NO
Go to Step 2.
• B/BI wire shorted to ground
• If wire is OK, go to Step 2.
1
V
FI SYSTEM DIAGNOSIS 4-43
4-44 FI SYSTEM DIAGNOSIS
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the ET sensor coupler.
3) Measure the ET sensor resistance.
ET sensor resistance:
1.95 – 4.18 k
Ω
at 20 – 40 °C (68 – 104 °F)
(Terminal – Terminal)
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Refer to page 4-70 for details.
Is the resistance OK?
YES
NO
• B/Bl or B/Br wire open or shorted to ground, or poor L or T 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 ET sensor with a new one.
2
2
ECM coupler (Harness side)
FI SYSTEM DIAGNOSIS 4-45
“21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION
21
P0110
H
L
DETECTED CONDITION
Output voltage is not within the following range.
0.15 V Sensor voltage < 4.85 V
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified 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
IAT sensor
Y/R IAT
ECM
B/Br E2
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 21:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (
5-3)
3) Check the IAT sensor coupler for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire side coupler.
1
4-46 FI SYSTEM DIAGNOSIS
4) Disconnect the coupler and turn the ignition switch ON.
5) Measure the voltage between Y/R wire terminal and ground.
6) If OK, then measure the voltage between Y/R wire terminal and B/Br wire terminal.
IAT sensor input voltage: 4.5 – 5.5 V
( + Y/R – Ground)
( + Y/R – 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 5 or T )
• Open or short circuit in the Y/R wire or B/Br wire
Step 1 (When indicating P0110-H:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (
5-3)
3) Check the IAT sensor coupler for loose or poor contacts.
If OK, then check the IAT sensor lead wire continuity.
1
1
V
4) Disconnect the IAT sensor coupler and ECM coupler.
5) Check the continuity between Y/R wire A and terminal 5 .
6) Also, check the continuity between B/Br wire B and terminal
T .
IATS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
Y/R wire or B/Br wire open
1
ECM coupler (Harness side)
!
Step 1 (When indicating P0110-L:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (
5-3)
3) Check the IAT sensor coupler for loose or poor contacts.
If OK, then check the IAT sensor lead wire continuity.
1
4) Disconnect the IAT sensor coupler.
5) Check the continuity between Y/R wire and ground. If the sound is not heard from the tester, the circuit condition is OK.
Tester knob indication: Continuity test (
)
1
6) Connect the IAT sensor coupler and turn the ignition switch
ON.
7) Measure the voltage between Y/R wire and ground.
IAT sensor output voltage: 0.15 – 4.84 V
( + Y/R – Ground)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
Are the continuity and voltage OK?
YES
NO
Go to Step 2.
• Y/R wire shorted to ground
• If wire is OK, go to Step 2.
1
FI SYSTEM DIAGNOSIS 4-47
V
4-48 FI SYSTEM DIAGNOSIS
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the IAT sensor coupler.
3) Measure the IAT sensor resistance.
IAT sensor resistance: Approx. 2.45 k
Ω
at 20 °C (68 °F)
(Terminal – Terminal)
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Is the resistance OK?
YES
NO
• Y/R or B/Br wire open or shorted to ground, or poor 5 or T 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)
80 °C (140 °F)
Resistance
Approx. 2.45 k
Ω
Approx. 0.32 k
Ω
NOTE:
IAT sensor resistance measurement method is the same way as that of the ET sensor. Refer to page 4-70 for details.
2
2
ECM coupler (Harness side)
FI SYSTEM DIAGNOSIS 4-49
“23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION
23
P1651
H
L
DETECTED CONDITION
The sensor voltage is not within the following range.
0.2 V Sensor voltage < 4.8 V
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified value.
POSSIBLE CAUSE
• TO sensor circuit open or short
• TO sensor malfunction
• ECM malfunction
• TO sensor circuit shorted to VCC or ground circuit open
• TO sensor circuit open or shorted to ground or
VCC circuit open
TO sensor
R
Br
B/Br
ECM
VCC
TO
E2
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 23:)
1) Turn the ignition switch OFF.
2) Check the TO sensor coupler for loose or poor contacts.
If OK, then measure the TO sensor resistance.
3) Remove the TO sensor. (
4-71)
1
4-50 FI SYSTEM DIAGNOSIS
4) Measure the resistance between terminal A and terminal C .
TO sensor resistance: 16.5 – 22.3 k Ω
(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.
Step 1 (When indicating P1651-H:)
1) Turn the ignition switch OFF.
2) Check the TO sensor coupler for loose or poor contacts.
If OK, then check the TO sensor lead wire continuity.
1
1
3) Disconnect the TO sensor coupler.
4) Check the continuity between R wire A and Br wire B .
If the sound is not heard from the tester, the circuit condition is OK.
1
]
5) Disconnect the ECM coupler.
6) Check the continuity between Br wire B and terminal 4 .
7) Also, check the continuity between B/Br wire C and terminal
T .
TOS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
Br wire shorted to VCC, or B/Br wire open.
1
ECM coupler (Harness side)
!
FI SYSTEM DIAGNOSIS 4-51
Step 1 (When indicating P1651-L:)
1) Turn the ignition switch OFF.
2) Check the TO sensor coupler for loose or poor contacts.
If OK, then check the TO sensor lead wire continuity.
1
3) Disconnect the TO sensor coupler.
4) Check the continuity between Br wire B and ground.
5) Also, check the continuity between Br wire B and B/Br wire
C . If the sound is not heard from the tester, the circuit condition is OK.
1
]
6) Disconnect the ECM coupler.
7) Check the continuity between R wire A and terminal A .
8) Also, then check the continuity between Br wire B and terminal 4 .
TOS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
R or Br wire open, or Br wire shorted to ground.
1
ECM coupler (Harness side)
!
4-52 FI SYSTEM DIAGNOSIS
Step 2
1) Remove the TO sensor. (
4-71)
2) Connect the TO sensor coupler and ECM coupler.
3) Insert the needle-point probes to the lead wire coupler.
4) Turn the ignition switch ON.
5) Measure the voltage at the wire side coupler between Br and
B/Br wires.
TO sensor voltage (Normal): 0.4 – 1.4 V
( + Br – B/Br)
6) Also, measure the voltage when leaning the motorcycle.
7) Measure the voltage when it is leaned 65° and more, left and right, from the horizontal level.
TO sensor voltage (Leaning): 3.7 – 4.4 V
( + Br – B/Br)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
Is the voltage OK?
YES
NO
• R, Br or B/Br wire open or shorted to ground, or poor 4 , A or T 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
2
2
V
V
ECM coupler (Harness side)
“24” (P0351) IGNITION SYSTEM MALFUNCTION
* Refer to the IGNITION SYSTEM for details. (
9-22)
NOTE:
After repairing the trouble, clear the DTC using SDS tool. (
4-24)
FI SYSTEM DIAGNOSIS 4-53
“28” (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
STVA
B
P
G
W/Bl
G
W/R
B/R
W/B
ECM
STVA. 1B
STVA. 1A
STVA. 2B
STVA. 2A
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1
1) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
2) Check the STVA lead wire coupler for loose or poor contacts.
1
3) Move the air cleaner box by removing the mounting bolts.
4) Turn the ignition switch ON to check the STV operation.
(STV operating order: Fully open
→
1
Is the operation OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the STVA coupler
• Open or short circuit in the G, W/R, W/B or B/R wires
• If wire and connection are OK, go to Step 2.
4-54 FI SYSTEM DIAGNOSIS
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the STVA lead wire coupler.
3) Check the continuity between each terminal and ground.
STVA continuity:
∞ Ω
(Infinity)
(Terminal – Ground)
2
4) If OK, then measure the STVA resistance (between B wire A and P wire B ) and (between G wire C and W/BI wire D ).
STVA resistance: Approx. 6.5 Ω
(B A – P B )
(G C – W/BI D )
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
2
Is the resistance OK?
YES
NO
• W/B, W/R, B/R and B wire open or shorted to ground, or poor 1 , 2 , H and 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 throttle body assembly with a new one.
2
ECM coupler (Harness side)
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 DIAGNOSIS 4-55
4-56 FI SYSTEM DIAGNOSIS
“29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION
29
P1654
H
L
DETECTED CONDITION
Signal voltage is not within the following range.
Difference between actual throttle opening and opening calculated by ECM is larger than specified value.
0.35 V Sensor voltage < 4.9 V
Sensor voltage is higher than specified value.
Sensor voltage is lower than specified 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
Bl
Y
B
R
Bl/Y
B/Br
VCC
STPS
E2
STP sensor
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 29:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then measure the STP sensor input voltage.
1
4) Disconnect the STP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the R wire A and ground.
7) Also, measure the voltage at the R wire A and B/Br wire C .
STP sensor input voltage: 4.5 – 5.5 V
( + R – Ground)
( + R – 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 A or T )
• Open or short circuit in the R wire or B/Br wire
Step 1 (When indicating P1654-H:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then check the STP sensor lead wire continuity.
1
1
4) Disconnect the STP sensor coupler.
5) Check the continuity between R wire A and Bl/Y wire B .
If the sound is not heard from the tester, the circuit condition is OK.
1
FI SYSTEM DIAGNOSIS 4-57
V
]
4-58 FI SYSTEM DIAGNOSIS
6) Disconnect the ECM coupler.
7) Check the continuity between Bl/Y wire B and terminal J .
8) Also, check the continuity between B/Br wire C and terminal
T .
STPS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
Bl/Y wire shorted to VCC, or B/Br wire open
1
Step 1 (When indicating P1654-L:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the STP sensor coupler for loose or poor contacts.
If OK, then check the STP sensor lead wire continuity.
1
ECM coupler (Harness side)
!
4) Disconnect the STP sensor coupler.
5) Check the continuity between Bl/Y wire B and ground.
6) Also, check the continuity between Bl/Y wire B and B/Br wire
C . If the sound is not heard from the tester, the circuit condition is OK.
1
]
7) Disconnect the ECM coupler.
8) Check the continuity between R wire A and terminal A .
9) Also, check the continuity between Bl/Y wire B and terminal
J .
STPS lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 1 (
4-56) and go to Step 2.
R or Bl/Y wire open, or Bl/Y wire shorted to ground
1
ECM coupler (Harness side)
!
FI SYSTEM DIAGNOSIS 4-59
Step 2
1) Turn the ignition switch OFF.
2) Connect the STP sensor coupler.
3) Insert the needle-point probes to the STP sensor coupler.
4) Disconnect the STVA lead wire coupler 1 .
5) Turn the ignition switch ON.
6) Measure the STP sensor output voltage at the coupler
(between + Y wire and B wire) by turning the fast idle cam
2 (secondary throttle valve close and open) with a finger.
STP sensor output voltage
Secondary throttle valve is closed : Approx. 0.5 V
Secondary throttle valve is opened: Approx. 3.9 V
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
2
2
Close
Open
Is the voltage OK?
YES
NO
• R, Bl/Y or B/Br wire open or shorted to ground, or poor A , J or T 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.
• Short circuit in the Bl/Y wire
• If check result is not satisfactory, replace STP sensor with a new one.
2
ECM coupler (Harness side)
4-60 FI SYSTEM DIAGNOSIS
“32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION
DETECTED CONDITION
Fuel injector signal is interrupted by 4 times or more continuously although ignition signal is supplied from the ECM.
POSSIBLE CAUSE
• Injector circuit open or short
• Injector malfunction
• ECM malfunction
ECM
Side-stand relay Ignition switch
Lg/W
O/W
To side-stand switch
Fuel injector
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the fuel injector coupler for loose or poor contacts.
If OK, then measure the fuel injector resistance.
4) Disconnect the fuel injector coupler and measure the resistance between terminals.
Fuel injector resistance: Approx. 10.5
Ω
at 20 °C (68 °F)
(Terminal – Terminal)
1
1
FI SYSTEM DIAGNOSIS 4-61
5) If OK, then check the continuity between each terminal and ground.
Fuel injector 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 fuel injector with a new one.
(
5-19)
1
Step 2
1) Turn the ignition switch ON.
2) Measure the fuel injector voltage between O/W wire and ground.
Fuel injector voltage: Battery voltage
( + O/W – Ground)
NOTE:
Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (
)
Is the voltage OK?
YES
NO
• Lg/W wire open or shorted to ground, or poor 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.
Open circuit in the O/W wire
2
2
ECM coupler (Harness side)
V
4-62 FI SYSTEM DIAGNOSIS
“41” (P0230-H/L) FP CIRCUIT MALFUNCTION
41
P0230
H
L
DETECTED CONDITION
No voltage is applied to fuel pump.
POSSIBLE CAUSE
• FP circuit open or short
• FP malfunction
• ECM malfunction
• FP circuit shorted to power source Voltage is applied to fuel pump although
FP circuit is shut.
No voltage is applied to fuel pump although FP circuit is normal.
• FP circuit open
ECM
B R
M Fuel pump
FP Y/W O/W
To side-stand switch
Side-stand relay
Ignition switch
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1 (When indicating 41:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the FP coupler for loose or poor contacts.
If OK, then check the fuel pump. (
5-5)
1
FI SYSTEM DIAGNOSIS 4-63
Is the fuel pump OK?
YES
NO
• O/W or Y/W wire open or shorted to ground or poor V 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 fuel pump with a new one.
Step 1 (When indicating P0230-H:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the Fuel pump coupler for loose or poor contacts.
If OK, then check the fuel pump. (
5-5)
1
1
Is the fuel pump OK?
YES
NO
O/W, Y/W wire shorted to power source
Replace the fuel pump with a new one.
Step 1 (When indicating P0230-L:)
1) Turn the ignition switch OFF.
2) Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
3) Check the Fuel pump coupler for loose or poor contacts.
If OK, then check the fuel pump. (
5-5)
Is the fuel pump OK?
YES
NO
• O/W, Y/W wire open or shorted to ground, or poor V 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 fuel pump with a new one.
1
1
ECM coupler (Harness side)
ECM coupler (Harness side)
“42” (P01650) IG SWITCH CIRCUIT MALFUNCTION
INSPECTION
* Refer to the IGNITION SWITCH INSPECTION for details. (
9-36)
NOTE:
After repairing the trouble, clear the DTC using SDS tool. (
4-24)
4-64 FI SYSTEM DIAGNOSIS
“44” (P0130) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION
DETECTED CONDITION
HO2 sensor output voltage is not input to ECM during engine operation and running condition.
POSSIBLE CAUSE
• HO2 sensor circuit open or short
• ECM malfunction
• HO2 sensor malfunction
ECM
E2
HO2
E1
B/Br
Bl/W
B/W
Engine stop switch
O/W
To side-stand switch
Side-stand relay
W B Gr W
HO2 sensor
Ignition switch
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
Step 1
1) Turn the ignition switch OFF.
2) Remove the right frame cover. (
8-3)
3) Check the HO2 sensor coupler for loose or poor contacts.
If OK, then check the HO2 sensor lead wire continuity.
4) Disconnect the HO2 sensor coupler.
5) Check the continuity between Bl/W wire A and ground.
6) Also, check the continuity between Bl/W wire A and B/Br wire B . If the sound is not heard from the tester, the circuit condition is OK.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (
)
1
1
!
FI SYSTEM DIAGNOSIS 4-65
7) Disconnect the ECM coupler.
8) Check the continuity between Bl/W wire A and terminal K .
9) Also, check the continuity between B/Br wire B and terminal
T .
HO2S lead wire continuity: Continuity (
)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Continuity test (
)
Is the continuity OK?
YES
NO
Go to Step 2.
Bl/W wire shorted to ground, or Bl/W or B/Br wire open.
1
Step 2
1) Connect the ECM couplers and HO2 sensor coupler.
2) Warm up the engine enough.
3) Measure the HO2 sensor output voltage between B wire and
Gr wire, when idling condition.
HO2 sensor output voltage at idle speed:
0.3 V and less ( + B – Gr)
2
!
ECM coupler (Harness side)
4) If OK, then pinch the PAIR hose with proper hose clamps.
5) Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r/min.
HO2 sensor output voltage at 5 000 r/min:
0.6 V and more ( + B – Gr)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
Is the voltage OK?
YES
NO
• Bl/W wire or B/Br wire open or shorted to ground, or poor K or T 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.
2
2
ECM coupler (Harness side)
4-66 FI SYSTEM DIAGNOSIS
“49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
DETECTED CONDITION
PAIR control solenoid valve voltage is not input to
ECM.
POSSIBLE CAUSE
• PAIR control solenoid valve circuit open or short
• PAIR control solenoid valve malfunction
ECM
PAIR
Ignition switch
B/G O/W
To side-stand switch
Side-stand relay
PAIR control solenoid valve
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
INSPECTION
NOTE:
After repairing the trouble, clear the DTC using SDS tool.
(
4-24)
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) Remove the PAIR control solenoid valve. (
11-7)
4) Measure the resistance between terminals.
PAIR control solenoid valve resistance:
Approx. 22
Ω
at 20 °C (68 °F)
(Terminal – Terminal)
09900-25008: Multi circuit tester set
Tester knob indication: Resistance (
Ω
)
Is the resistance OK?
YES
NO
Go to Step 2.
Replace the PAIR control solenoid valve with a new one.
1
FI SYSTEM DIAGNOSIS 4-67
Step 2
1) Turn the ignition switch ON.
2) Measure the voltage between O/W wire and ground.
PAIR valve voltage: Battery voltage
( + O/W – Ground)
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (
)
2
Is the voltage OK?
YES
NO
• B/G wire open or shorted to ground, or poor E connection failure.
• 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.
ACTIVE CONTROL INSPECTION
1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)
2) Turn the ignition switch to ON.
3) Click “PAIR Sol operating control” 1 .
2
ECM coupler (Harness side)
V
4) Click each button 2 .
At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
4-68 FI SYSTEM DIAGNOSIS
SENSORS
CKP SENSOR INSPECTION
The crankshaft position sensor is installed in the generator cover. (
9-25)
CKP SENSOR REMOVAL AND INSTALLATION
• Remove the generator cover. (
3-15)
• Remove the CKP sensor from the generator cover. (
3-42)
• Install the generator cover in the reverse order of removal.
IAP SENSOR INSPECTION
The intake air pressure sensor is installed on the top side of the throttle body. (
4-31)
IAP SENSOR REMOVAL AND INSTALLATION
• Remove the throttle body. (
5-11)
• Remove the IAP sensor from the throttle body. (
5-13)
• Install the IAP sensor in the reverse order of removal.
TP SENSOR INSPECTION
The throttle position sensor is installed at the left side of the throttle body. (
4-36)
TP SENSOR REMOVAL AND INSTALLATION
• Remove the TP sensor. (
5-13)
• Install the TP sensor in the reverse order of removal.
TPS ADJUSTMENT
Inspect the TP sensor setting position and adjust it if necessary in the following procedures:
1) Connect the special tool between TP sensor and its coupler.
09900-28630: TP Sensor test lead
2) Warm up the engine and keep it running at idling speed.
3) Measure the TP sensor output voltage at the terminals.
(between + V and B/Br)
NOTE:
When measure the TP sensor output voltage, make sure that the fast idle cam is not contacted to the throttle lever.
09900-25008: Malti circuit tester set
Tester knob indication: Voltage (
)
4) Loosen the TP sensor mounting screw 1 using the special tool and turn the TP sensor to turning the specified value
(0.6 V).
09930-11950: Torx wrench (5 mm)
5) Tighten the TP sensor mounting screw 1 to the specified torque.
TP sensor mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
09930-11950: Torx wrench (5 mm)
6) Turn off the engine and connect the TP sensor coupler.
After adjusted the TP sensor, perform the TP learned value reset with special tool. (
4-40)
FI SYSTEM DIAGNOSIS 4-69
V
4-70 FI SYSTEM DIAGNOSIS
ET SENSOR INSPECTION
The engine temperature sensor is installed at the cylinder.
(
4-41)
• Check the ET sensor by testing it at the bench as shown in the figure. Connect the ET sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.
09900-25008: Malti circuit tester set
Tester knob indication: Resistance (
Ω
)
• Heat the oil to raise its temperature slowly and read the column thermometer 3 and the ohmmeter.
• If the ET sensor ohmic value does not change in the proportion indicated, replace it with a new one.
ET sensor specification
Engine Temp.
20 °C (68 °F)
50 °C (122 °F)
80 °C (176 °F)
110 °C (230 °F)
Resistance
Approx. 4.2 k
Ω
Approx. 2.0 k
Ω
Approx. 0.5 k
Ω
Approx. 0.3 k
Ω
ET SENSOR REMOVAL AND INSTALLATION
• Disconnect the ET sensor coupler 1 .
• Remove the ET sensor 2 .
• Install the ET sensor in the reverse order of removal.
ET sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
IAT SENSOR INSPECTION
The intake air temperature sensor is installed on the top side of the outlet tube. (
4-45)
IAT SENSOR REMOVAL AND INSTALLATION
• Lift up the fuel tank by removing the fuel tank mounting bolt.(
5-3)
• Remove the IAT sensor.
• Install the IAT sensor in the reverse order of removal.
TO SENSOR INSPECTION
The tip-over sensor is located in front of the battery holder.
(
4-49)
TO SENSOR REMOVAL AND INSTALLATION
• Remove the PAIR solenoid valve bracket bolt.
• Remove the TO sensor from the battery holder.
• Install the TO sensor in the reverse order of removal.
NOTE:
When installing the TO sensor, the arrow mark A must be pointed upward.
STP SENSOR INSPECTION
The secondary throttle position sensor is installed at the left side of the throttle body. (
4-56)
STP SENSOR REMOVAL AND INSTALLATION
• Remove the STP sensor. (
5-13)
• Install the STP sensor in the reverse order of removal.
STP SENSOR ADJUSTMENT
• Adjust the STP sensor. (
5-18)
HO2 SENSOR INSPECTION
The heated oxygen sensor is installed to the exhaust pipe.
(
4-64)
HO2 SENSOR HEATER INSPECTION
1) Turn the ignition switch OFF.
2) Remove the right frame cover. (
8-3)
3) Check the HO2 sensor coupler for loose or poor contacts. If
OK, then measure the HO2 sensor resistance.
FI SYSTEM DIAGNOSIS 4-71
4-72 FI SYSTEM DIAGNOSIS
4) Disconnect the HO2 sensor coupler and measure the resistance between terminals. If the resistance is not specified value, replace the HO2 sensor with a new one.
HO2 heater resistance: Approx. 8 Ω at 23 °C (73 °F)
(W – W)
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at atmospheric temperature.
09900-25008: Multi circuit tester set
Tester knob indication: Resistance ( Ω )
HO2 SENSOR REMOVAL AND
INSTALLATION
• Remove the left frame cover. (
8-3)
• Remove the bracket bolt 1 .
• Disconnect the HO2 sensor coupler 2 .
• Pass the HO2 sensor lead wire 3 between the engine and frame tube.
• Remove the HO2 sensor 4 .
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.
* Be careful not to twist or damage the sensor lead wires.
• Installation is in the reverse order of removal.
Do not apply oil or other materials to the sensor air hole.
• Tighten the HO2 sensor to the specified torque.
HO2 sensor: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
FUEL SYSTEM AND THROTTLE BODY 5-1
FUEL SYSTEM AND THROTTLE BODY
CONTENTS
FUEL DELIVERY SYSTEM.......................................................................... 5- 2
FUEL TANK REMOVAL........................................................................ 5- 3
FUEL TANK INSTALLATION ............................................................... 5- 3
FUEL PRESSURE INSPECTION .......................................................... 5- 4
FUEL PUMP INSPECTION ................................................................... 5- 5
FUEL DISCHARGE AMOUNT INSPECTION ....................................... 5- 5
FUEL PUMP CONSTRUCTION ............................................................ 5- 6
FUEL PUMP REMOVAL AND DISASSEMBLY.................................... 5- 7
FUEL MESH FILTER INSPECTION...................................................... 5- 8
FUEL PUMP REASSEMBLY AND INSTALLATION ............................ 5- 9
CONSTRUCTION .................................................................................. 5-10
THROTTLE BODY REMOVAL.............................................................. 5-11
THROTTLE BODY DISASSEMBLY...................................................... 5-12
THROTTLE BODY CLEANING............................................................. 5-14
THROTTLE BODY INSPECTION.......................................................... 5-14
THROTTLE BODY REASSEMBLY....................................................... 5-15
THROTTLE BODY INSTALLATION ..................................................... 5-17
STP SENSOR ADJUSTMENT .............................................................. 5-18
FUEL INJECTOR REMOVAL................................................................ 5-19
FUEL INJECTOR INSPECTION............................................................ 5-19
FUEL INJECTOR INSTALLATION ....................................................... 5-19
5
Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
5-2 FUEL SYSTEM AND THROTTLE BODY
FUEL DELIVERY SYSTEM
The fuel delivery system consists of the fuel tank, fuel pump, fuel mesh filter, fuel feed hose, fuel delivery pipe (including fuel injector) and fuel pressure regulator. 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 294 kPa (2.94 kgf/cm 2 , 41.8 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 Fuel tank
2 Fuel pressure regulator
3 Fuel delivery pipe
4 Fuel injector
5 Fuel feed hose
6 Fuel mesh filter
7 Fuel pump
A Pressurized fuel
B Before-pressurized fuel
C Relieved fuel
FUEL SYSTEM
FUEL TANK REMOVAL
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
• Remove the front seat. (
8-3)
• Remove the fuel tank mounting bolt.
• Lift up the fuel tank.
• Disconnect the fuel pump lead wire coupler 1 .
• Place a clean rag under the fuel feed hose 2 and disconnect the fuel feed hose 2 from the fuel pump.
• Remove the fuel tank assembly.
FUEL TANK INSTALLATION
Install the fuel tank in the reverse order of removal. Pay attention to the following point:
• When installing the fuel tank, do not pinch the fuel pump lead wire coupler between the fuel pump and frame.
FUEL SYSTEM AND THROTTLE BODY 5-3
5-4 FUEL SYSTEM AND THROTTLE BODY
FUEL PRESSURE INSPECTION
• Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
• Place a clean rag under the fuel feed hose 1 .
• Remove the fuel feed hose 1 .
• Install the special tools between the fuel pump and fuel delivery pipe.
09915-74511: Oil pressure gauge (600 kPa)
09940-40211: Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge attachment
• Turn the ignition switch ON and check the fuel pressure.
Fuel pressure: Approx. 294 kPa (2.94 kgf/cm 2 , 41.8 psi)
If the fuel pressure is lower than the specification, inspect the following items:
* Clogged fuel mesh filter
* Pressure regulator
* Fuel pump
If the fuel pressure is higher than the specification, inspect the following items:
* Fuel pump
* Pressure regulator
* Before removing the special tools, turn the ignition switch OFF position and release the fuel pressure slowly.
* Gasoline is highly flammable and explosive. Keep heat, sparks and flame away.
A To fuel pump
B To fuel delivery pipe
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 and TO sensor.
If the TO 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 up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
• 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 it.
FUEL SYSTEM AND THROTTLE BODY 5-5
• Connect proper lead wires to the fuel pump lead wire coupler
(fuel pump side) and apply 12 V to the fuel pump (between R wire and B wire) for 10 seconds and measure the amount of fuel discharged.
Battery + terminal
Battery terminal
R terminal
B terminal
If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel mesh filter is clogged.
Fuel discharge amount:
33.3 ml (1.13 US oz) and more/10 sec.
NOTE:
The battery must be in fully charged condition.
5-6 FUEL SYSTEM AND THROTTLE BODY
FUEL PUMP CONSTRUCTION
FW
D
FWD
1 Fuel pressure regulator
2 O-ring
3 Fuel pump
4 O-ring
5 Fuel mesh filter
6 O-ring
A Fuel pump mounting bolt
ITEM N·m kgf-m lbf-ft
A 10 1.0
7.0
FUEL PUMP REMOVAL AND DISASSEMBLY
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
• Remove the fuel tank. (
5-3)
• Remove the fuel pump assembly 1 by removing its mounting bolts diagonally.
• Remove the O-ring 2 .
FUEL SYSTEM AND THROTTLE BODY 5-7
• Remove the clip and then fuel mesh filter 3 .
• Remove the band 4 .
• Disconnect the fuel hose 5 and fuel pump terminals 6 .
• Remove the fuel pump assembly 7 .
• Remove the holder 8 .
• Remove the fuel pump 9 .
5-8 FUEL SYSTEM AND THROTTLE BODY
• Remove the wire clamp 0 , fuel hose A and fuel return hose
B .
• Remove the adapter C along with the fuel pressure regulator
D .
• Remove the fuel pressure regulator E and joint F .
Because the O-ring is not available as spare part, the fuel pressure regulator E should not be removed unless necessary.
FUEL MESH FILTER INSPECTION
If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
NOTE:
If the fuel mesh filter is clogged with many sediment or rust, replace the fuel mesh filter cartridge with a new one.
FUEL PUMP REASSEMBLY AND
INSTALLATION
Reassembly and install the fuel pump in the reverse order of removal and disassembly. Pay attention to the following points:
• Install the fuel pressure regulator.
Normally, the removed O-ring must be replaced with a new one. However, this O-ring 1 is not available for the spare parts. If it is found to be damaged, replace the fuel pressure regulator with new one.
• Apply thin coat of engine oil to the O-rings.
Use new O-rings to prevent fuel leakage.
FUEL SYSTEM AND THROTTLE BODY 5-9
• Apply grease to the O-ring 1 and install it.
The O-ring must be replaced with a new one to prevent fuel leakage.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• 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 lbf-ft)
5-10 FUEL SYSTEM AND THROTTLE BODY
THROTTLE BODY
CONSTRUCTION
FW
D
FWD
1 Fuel delivery pipe
2 O-ring
3 Fuel injector
4 Cushion seal
5 STVA
6 STP sensor
7 TP sensor
8 O-ring
9 IAP sensor
0 O-ring
A TP sensor mounting screw
B STP sensor mounting screw
ITEM N·m kgf-m lbf-ft
A 3.5
0.35
2.5
B 3.5
0.35
2.5
THROTTLE BODY REMOVAL
Once the throttle body has been removed, disassembled or replaced, the TP learned value reset must be performed using SDS tool with the throttle body assembled. (
4-40)
• Turn the ignition switch OFF.
• Remove the fuel tank. (
5-3)
• Remove the frame covers. (
8-3)
• Disconnect the STVA lead wire coupler 1 , STP sensor lead wire coupler 2 and wire clamp.
FUEL SYSTEM AND THROTTLE BODY 5-11
• Disconnect the TP sensor lead wire coupler 3 , fuel injector lead wire coupler 4 and IAP sensor lead wire coupler 5 .
• Disconnect the throttle cables 6 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.
5-12 FUEL SYSTEM AND THROTTLE BODY
• Loosen the throttle body clamp screws and remove the throttle body assembly 7 .
THROTTLE BODY DISASSEMBLY
• Remove the fuel feed hose 1 .
• Remove the fuel delivery pipe 2 along with the fuel injector
3 .
• Remove the fuel injector 3 from the fuel delivery pipe 2 .
• Remove the IAP sensor 4 .
• Remove the TP sensor 5 and STP sensor 6 with the special tool.
NOTE:
Prior to disassembly, mark the each sensor’s original position with a paint or scribe for accurate reinstallation.
09930-11950: Torx wrench (5 mm)
FUEL SYSTEM AND THROTTLE BODY 5-13
Never remove the STVA 7 from the throttle body.
Never remove the secondary throttle valve 8 .
5-14 FUEL SYSTEM AND THROTTLE BODY
Never remove the throttle valve 9 .
* The air screw 0 should not be turned or removed unless necessary.
* The adjusting screw A is factory-adjusted at the time of delivery and do not turn or remove it.
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 on proper use, handling and storage.
• Clean 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.
THROTTLE BODY INSPECTION
• Check following items for any damage or clogging.
* O-rings
* Throttle valve
* Secondary throttle valve
* Fuel delivery pipe
* Cushion seal
THROTTLE BODY REASSEMBLY
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:
• With the secondary throttle valve fully opened, install the STP sensor 1 and tighten the STP sensor mounting screw to the specified torque.
NOTE:
* Apply thin coat of engine oil to the O-ring.
* Align the secondary throttle shaft end A with the groove B of
STP sensor.
* Apply grease to the secondary throttle shaft end A if necessary.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
STP sensor mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lbf-ft)
09930-11950: Torx wrench (5 mm)
NOTE:
* Make sure the secondary throttle valve smoothly open and close.
* If the STP sensor adjustment is necessary, refer to page 5-18 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 engine oil to the O-ring.
* Align the throttle shaft end C with the groove D of TP sensor.
* Apply grease to the throttle shaft end C if necessary.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
TP sensor mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lbf-ft)
09930-11950: Torx wrench (5 mm)
NOTE:
* Make sure the throttle valve smoothly open and close.
After installed TP sensor, adjust the TP sensor and perform the TP learned value reset with SDS tool.
(
4-40, -69)
FUEL SYSTEM AND THROTTLE BODY 5-15
5-16 FUEL SYSTEM AND THROTTLE BODY
• Install a new O-ring 3 and IAP sensor 4 .
Replace the O-ring with a new one.
• Apply thin coat of engine oil to the cushion seal 5 and O-ring
6 .
Replace the cushion seal and O-ring with new ones.
• Install the fuel injector 7 by pushing it straight to the fuel delivery pipe 8 .
Never turn the injector while pushing it.
NOTE:
Align the coupler E of injector with the groove F of delivery pipe.
• Fit the projection G on the fuel delivery pipe in the hole H of the throttle body.
Never turn the injector 7 while installing it.
• Install the fuel delivery pipe 9 .
I White paint
FUEL SYSTEM AND THROTTLE BODY 5-17
THROTTLE BODY INSTALLATION
Install the throttle body in the reverse order of removal.
Pay attention to the following points:
• Fit the projection on the throttle body in the depression of the intake pipe.
• Position the throttle body clamps correctly. (
10-20)
• Loosen each throttle cable lock-nut 1 .
• Turn in each throttle cable adjuster 2 fully and locate each outer cable 3 so that the clearance is 0 mm (0 in).
• Tighten each lock-nut 1 .
• Adjust the throttle cable play. (
2-8)
• Route the fuel feed hose and wiring harness properly.
(
10-12, -13, -20)
After installed throttle body, perform the TP learned value reset with SDS tool. (
4-40)
0 mm
(0 in)
0 mm
(0 in)
5-18 FUEL SYSTEM AND THROTTLE BODY
STP SENSOR ADJUSTMENT
If the STP sensor adjustment is necessary, measure the sensor output voltage and adjust the STP sensor position as follows:
• Lift up the fuel tank by removing the fuel tank mounting bolt.
(
5-3)
• Disconnect the STVA lead wire coupler 1 .
• Set the STV to fully closed position by turning the fast idle cam 2 .
• Insert the needle-point probes to the STP sensor coupler.
• Turn the ignition switch ON and measure the STP sensor output voltage.
STP sensor output voltage
ST valve is fully closed: Approx. 0.5 V ( + Y – B)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
• Loosen the STP sensor mounting screw.
• Adjust the STP sensor until the output voltage comes within the specified value and tighten the STP sensor mounting screw.
STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lbf-ft)
09930-11950: Torx wrench (5 mm)
V
FUEL SYSTEM AND THROTTLE BODY 5-19
FAST IDLE
The fast idle system is automatic type.
On the secondary throttle valve shaft 1 , the fast idle cam 2 is installed. When this fast idle cam 2 is operated, the throttle valve is opened to control the fast idle speed.
With the secondary throttle valve 1 turned, the fast idle cam 2 pushes the throttle lever 3 , causing the throttle valve to open slightly and increase the engine speed to the fast idle.
When the engine has warmed up, depending on the engine temperature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
Opened Closed
FUEL INJECTOR REMOVAL
• Remove the throttle body assembly. (
5-11)
• Remove the fuel delivery pipe along with the fuel injector.
(
5-12)
• Remove the fuel injector from the fuel delivery pipe.
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.
NOTE:
The fuel injector can be checked without removing it from the throttle body. (
4-60, -61)
FUEL INJECTOR INSTALLATION
• Install the fuel injector onto the throttle body assembly.
(
5-16)
• Install the throttle body assembly. (
5-17)
EXHAUST SYSTEM 6-1
EXHAUST SYSTEM
CONTENTS
6
6-2 EXHAUST SYSTEM
EXHAUST SYSTEM
REMOVAL
To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool.
Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
• Remove the right frame cover. (
8-3)
• Remove the bracket bolt 1 and disconnect the HO2 sensor coupler 2 .
• Remove the muffler cover 3 .
• Remove the exhaust pipe bolts 4 .
: Hooked part
• Remove the exhaust pipe/muffler 5 by removing the mounting bolt and nut.
NOTE:
Support the muffler to prevent it from falling.
• Remove the exhaust pipe gasket 6 .
• Remove the exhaust pipe cover 7 .
• Loosen the muffler connecting bolt 8 .
• Remove the exhaust pipe 0 from the muffler 9 .
• Remove the HO2 sensor A .
* Be careful not to expose the HO2 sensor to excessive shock.
* Do not use an impact wrench while removing or installing the HO2 sensor.
* Be careful not to twist or damage the HO2 sensor lead wire.
EXHAUST SYSTEM 6-3
6-4 EXHAUST SYSTEM
INSPECTION
Inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe or muffler with a new one.
Check the exhaust pipe bolts, muffler connecting bolt and muffler mounting bolts are tightened to their specified torque.
Exhaust pipe bolt 1 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler connecting bolt 2 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler mounting bolt (Front) 3 : 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler mounting bolt (Rear) 4 : 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
INSTALLATION
Installation is in the reverse order of removal.
Pay attention to the following points:
Do not apply oil or other materials to the HO2 sensor air holes.
• Tighten the HO2 sensor 1 to the specified torque.
HO2 sensor: 25 N·m (2.5 kgf-m, 18.0 lbf-ft)
• Install the muffler connector 2 .
Replace the muffler connector with a new one.
NOTE:
The chamfer side A faces backward.
• Tighten the muffler connecting bolt 3 to the specified torque.
Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Install the exhaust pipe cover 4 .
• Tighten the exhaust pipe cover screw 5 to the specified torque.
NOTE:
The tip B of clamp should face inside of the exhaust pipe cover.
Exhaust pipe cover screw: 4 N·m (0.4 kgf-m, 3.0 lbf-ft)
EXHAUST SYSTEM 6-5
20 – 30˚
• Install the exhaust pipe gasket 6 .
Replace the exhaust pipe gasket with a new one.
NOTE:
Be sure to face the tabs c on the exhaust pipe gasket to the engine side when installing it.
6-6 EXHAUST SYSTEM
• Tighten the exhaust pipe bolts 7 to the specified torque.
Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Apply thread lock to the muffler mounting bolt (Front) 8 .
99000-32110: THREAD LOCK SUPER “1322” or equivalent
• Tighten the muffler mounting bolts ( 8 , 9 ) to the specified torque.
Muffler mounting bolt (Front):
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Muffler mounting bolt (Rear):
50 N·m (5.0 kgf-m, 36.0 lbf-ft)
• Apply thread lock to the muffler cover bolts and tighten them.
99000-32050: THREAD LOCK “1342” or equivalent
• Route the HO2 sensor lead wire properly. (
10-13)
LUBRICATION SYSTEM
LUBRICATION SYSTEM 7-1
CONTENTS
ENGINE LUBRICATION SYSTEM CHART .......................................... 7- 2
7
7-2 LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PRESSURE
2-25
OIL FILTER
2-10, 3-43
OIL STRAINER
3-43
OIL PUMP
3-19, -44, -63
ENGINE LUBRICATION SYSTEM CHART
CAMSHAFT JOURNAL
BEARING
PISTON
CAM FACES
CYLINDER WALL CONROD SMALL END
CONROD BIG END BEARING
CAM CHAIN
CLUTCH RELEASE CAM
OIL FILTER
ENGINE SPROCKET
SPACER
CRANKSHAFT
BEARING
COUNTERSHAFT, GEARS
AND BEARING
OIL PUMP
BY-PASS
DRIVESHAFT, GEARS
AND BEARING
PRIMARY DRIVEN GEAR
SPACER
OIL STRAINER
CLUTCH PLATES
OIL PAN
CHASSIS
CONTENTS
CONSTRUCTION .................................................................................. 8- 4
INSPECTION AND DISASSEMBLY ..................................................... 8- 6
REASSEMBLY AND INSTALLATION .................................................. 8- 7
CONSTRUCTION .................................................................................. 8-11
BRAKE PAD REPLACEMENT ............................................................. 8-12
BRAKE FLUID REPLACEMENT .......................................................... 8-13
BRAKE CALIPER REMOVAL AND DISASSEMBLY ........................... 8-13
BRAKE CALIPER INSPECTION........................................................... 8-14
CALIPER REASSEMBLY AND INSTALLATION ................................. 8-15
BRAKE DISC INSPECTION.................................................................. 8-17
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...................... 8-17
MASTER CYLINDER INSPECTION...................................................... 8-18
MASTER CYLINDER REASSEMBLY AND INSTALLATION .............. 8-19
CONSTRUCTION .................................................................................. 8-21
CONSTRUCTION .................................................................................. 8-25
REMOVAL AND DISASSEMBLY ......................................................... 8-26
REASSEMBLY AND INSTALLATION .................................................. 8-29
CONSTRUCTION .................................................................................. 8-33
REMOVAL AND DISASSEMBLY ......................................................... 8-33
REASSEMBLY AND INSTALLATION .................................................. 8-37
CHASSIS 8-1
8
8-2 CHASSIS
CHASSIS
CONTENTS
CONSTRUCTION .................................................................................. 8-39
REMOVAL AND DISASSEMBLY ......................................................... 8-39
REASSEMBLY AND INSTALLATION .................................................. 8-41
REAR BRAKE PEDAL REMOVAL ....................................................... 8-42
REAR BRAKE PEDAL INSTALLATION............................................... 8-42
REAR SHOCK ABSORBER ........................................................................ 8-43
CONSTRUCTION .................................................................................. 8-43
REAR SUSPENSION SETTING............................................................ 8-44
CONSTRUCTION .................................................................................. 8-45
INSPECTION AND DISASSEMBLY ..................................................... 8-48
REASSEMBLY AND INSTALLATION .................................................. 8-50
CONSTRUCTION .................................................................................. 8-53
INSPECTION AND DISASSEMBLY ..................................................... 8-55
TIRE INSTALLATION............................................................................ 8-60
EXTERIOR PARTS
REMOVAL
FRONT SEAT
• Remove the front seat by removing the bolts (left & right).
REAR SEAT
• Remove the front seat. (
Above)
• Remove the rear seat by removing the bolts.
LEFT FRAME COVER
• Remove the screw.
• Remove the left frame cover.
: Hooked part
RIGHT FRAME COVER
• Remove the screw.
• Remove the right frame cover.
: Hooked part
INSTALLATION
• Install the seats and frame covers in the reverse order of removal.
CHASSIS 8-3
8-4 CHASSIS
FRONT WHEEL
CONSTRUCTION
1 Collar
2 Bearing
3 Front wheel
4 Spacer
5 Brake disc
6 Speedometer gearbox
7 Balancer weight
A Front axle
B Spoke nipple
C Brake disc bolt
REMOVAL
• Disconnect the speedometer cable 1 .
Do not bent the speedometer cable.
ITEM N·m kgf-m lbf-ft
A 65 6.5
47.0
B 3 0.3
2.0
C 23 2.3
16.5
• Loosen the front axle pinch bolt 2 .
• Loosen the front axle 3 with the special tool.
09900-18710: Hexagon socket (12 mm)
• Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block.
* Do not support the motorcycle with the exhaust pipes.
* Make sure that the motorcycle is supported securely.
• Remove the front wheel 4 by removing the front axle 3 .
Do not operate the brake lever while front wheel is removed.
• Remove the collar 5 and speedometer gearbox 6 .
• Remove the brake disc 7 by removing its bolts.
CHASSIS 8-5
8-6 CHASSIS
INSPECTION AND DISASSEMBLY
TIRE (
8-59)
BRAKE DISC (
8-17)
SPEEDOMETER GEARBOX
Turn the speedometer gear and check that the gear turns smoothly together with the speedometer pinion.
WHEEL (
2-19)
SPOKE NIPPLE (
2-20)
WHEEL BEARING
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 if there is anything unusual.
• Remove the wheel bearings 1 with the special tool.
The removed bearing must be replaced with a new one.
09941-50111: Wheel bearing remover set
• Remove the spacer 2 .
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.
Axle shaft runout
Service Limit: 0.25 mm (0.010 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
REASSEMBLY AND INSTALLATION
Reassembly and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:
WHEEL BEARING
• Apply grease to the wheel bearings.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
CHASSIS 8-7
8-8 CHASSIS
• Install new wheel bearings with removed wheel bearings and the special tool.
* First install the left wheel bearing, then install the spacer and right wheel bearing.
* The sealed cover of bearing must face outside.
09924-84510: Bearing installer set
NOTE:
The flange side A of spacer should face front brake disc side.
LH RH LH RH
1 New wheel bearing
2 Removed wheel bearing
3 Spacer
A Flange
B Clearance
BRAKE DISC
• Apply thread lock to the brake disc bolts and tighten them to the specified torque.
Keep the front brake disc clean, free from dirt and grease.
99000-32130: THREAD LOCK SUPER “1360” or equivalent
Front brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
SPEEDOMETER GEARBOX
• Apply grease to the speedometer gearbox.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Align the lugs A of speedometer gearbox with the recesses
B on front wheel.
FRONT WHEEL
• Install the collar 1 and front wheel.
When installing the front wheel, position the brake disc between the brake pads. Be careful not to damage the brake pads.
• Lightly tighten the front axle 2 .
CHASSIS 8-9
8-10 CHASSIS
• Connect the speedometer cable 3 .
Tighten the speedometer cable nut firmly.
• Set the speedometer gearbox 4 as shown.
• Tighten the front axle 2 to the specified torque.
09900-18710: Hexagon socket (12 mm)
Front axle: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
• Tighten the front axle pinch bolt 5 to the specified torque.
Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
NOTE:
* Before tightening the front axle pinch bolt, move the front fork up and down four or five times.
* After installing the front wheel, pump the brake lever a few times to check for proper brake operation.
90 ± 5˚
90 ± 5˚
FRONT BRAKE
CONSTRUCTION
CHASSIS 8-11
1 Reservoir cap
2 Diaphragm
3 Piston/cup set
4 Master cylinder
5 Brake hose
6 Caliper holder
7 Piston
8 Dust seal
9 Piston seal
0 Brake caliper
A Brake pad
B Brake lever
C Brake light switch
A Master cylinder holder bolt
B Brake hose union bolt
C Air bleeder valve
D Brake caliper mounting bolt
E Brake lever pivot bolt
F Brake lever pivot bolt lock-nut
ITEM N·m kgf-m lbf-ft
A 10 1.0
7.0
B
C
23
7.5
2.3
0.75
16.5
5.5
D
E
39
6
3.9
0.6
28.0
4.5
F 6 0.6
4.5
8-12 CHASSIS
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use 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 reuse brake fluid left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent.
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.
BRAKE PAD REPLACEMENT
• Remove the brake caliper 1 .
• Remove the clip 2 and pad pin 3 .
• Remove the brake pads 4 .
* Do not operate the brake lever after removing the brake pads.
* Replace the brake pad as a set, otherwise braking performance will be adversely affected.
• Install new brake pads.
• Tighten the brake caliper mounting bolts to the specified torque.
Front brake caliper mounting bolt:
39 N·m (3.9 kgf-m, 28.0 lbf-ft)
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.
BRAKE FLUID REPLACEMENT
• Place the motorcycle on a level surface and keep the handlebars straight.
• Remove the brake fluid reservoir cap 1 and diaphragm 2 .
• Suck up the old brake fluid as much as possible.
• Fill the reservoir tank with new brake fluid.
Specification and classification: DOT 4
• Connect a clear hose to the air bleeder valve 3 and insert the other end of the hose into a receptacle.
• Loosen the air bleeder valve 3 and pump the brake lever until old brake fluid flows out of the brake system.
• Close the air bleeder valve and disconnect a clear hose. Fill the reservoir with new brake fluid to the upper line of the reservoir.
Front brake caliper air bleeder valve:
7.5 N·m (0.75 kgf-m, 5.5 lbf-ft)
Bleed air from the brake system. (
2-16)
BRAKE CALIPER REMOVAL AND
DISASSEMBLY
• Remove the brake hose union bolt 1 .
NOTE:
Place a clean rag underneath the union bolt on the brake caliper to catch any split brake fluid.
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.
• Remove the brake caliper 2 by removing the caliper mounting bolts.
CHASSIS 8-13
8-14 CHASSIS
• Remove the brake pads. (
8-12)
• Remove the brake caliper holder 3 .
• Remove the pad spring 4 and pad guide 5 .
• Remove the rubber boots ( 6 , 7 ).
• Place a clean rag over the piston to prevent it from popping out and then force out the piston using compressed air.
Do not use high pressure air to prevent piston damage.
• Remove the dust seals 8 and piston seals 9 .
* Take care not to scratch the caliper bore.
* Do not reuse the removed dust seals and piston seals to prevent fluid leakage.
BRAKE CALIPER INSPECTION
CALIPER AND PISTON
Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages.
If any abnormal condition is noted, replace the it with a new one.
PAD SPRING
Inspect the brake pad spring for damage excessive bend. If any damage is found, replace it with a new one.
RUBBER PARTS
Inspect the boots for damage and cracks. If any defects are found, replace it with a new one.
CALIPER REASSEMBLY AND
INSTALLATION
Reassemble and install the caliper in the reverse order of removal and disassembly. Pay attention to the following points:
• Clean the caliper bores and pistons with specified brake fluid, especially the dust seal grooves and piston seal grooves.
Specification and classification: DOT 4
* Clean the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them.
* Do not wipe the brake fluid off after cleaning the components.
* When cleaning the components, use the specified brake fluid. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or others.
* Replace the piston seals 1 and dust seals 2 with the new ones when reassembly. Apply brake fluid to both seals when installing them.
CHASSIS 8-15
8-16 CHASSIS
PISTON SEAL
• Install new piston seals 1 and dust seals 2 as shown in the illustration.
CALIPER HOLDER
• Apply grease to the caliper holder pins.
99000-25100: SUZUKI SILICONE GREASE or equivalent
• Tighten the brake caliper mounting bolts to the specified torque.
Front brake caliper mounting bolt:
39 N·m (3.9 kgf-m, 28.0 lbf-ft)
• With the brake hose union contacted to the stopper A , tighten the brake hose union bolt 1 to the specified torque.
Front brake hose union bolt:
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
* The seal washers should be replaced with new ones to prevent brake fluid leakage.
* Bleed air from the brake system after installing the brake caliper. (
2-16)
BRAKE DISC INSPECTION
Check the brake disc for cracks or damage and measure the thickness using the micrometer.
Replace the disc if the thickness is less than the service limit, or if damage is found. (
8-5, -9)
Brake disc thickness
Service Limit: 4.5 mm (0.18 in)
09900-20205: Micrometer (0 – 25 mm)
Measure the runout with a dial gauge.
If either measurement exceeds the service limit, replace the brake disc with a new one. (
8-5, -9)
Brake disc runout
Service Limit: 0.30 mm (0.012 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
MASTER CYLINDER REMOVAL AND
DISASSEMBLY
• Drain brake fluid. (
8-13)
• Remove the brake hose union bolt 1 .
NOTE:
Place a clean rag underneath the union bolt on the master cylinder to catch any split brake fluid.
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.
• Remove the rear view mirror (RH) 2 .
• Disconnect the brake light switch lead wire coupler 3 .
• Remove the front brake master cylinder 4 .
CHASSIS 8-17
8-18 CHASSIS
• Remove the brake light switch 5 and brake lever 6 .
• Pull out the dust boot 7 .
• Remove the snap ring 8 .
• Remove the piston/cup set 9 .
MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or damage. If any damage is found, replace the master cylinder with a new one.
PISTON/CUP SET
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust boot for wear or damage. If any damage is found, replace them with new ones.
MASTER CYLINDER REASSEMBLY AND
INSTALLATION
Reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points:
* Clean the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to clean them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the component to be inserted into the bore.
Specification and classification: DOT 4
• Install the following parts into the master cylinder.
1 Spring
2 Primary cup
3 Piston
4 Secondary cup
5 Snap ring
6 Dust boot
• When installing the brake light switch, align the projection A on switch with the hole B of master cylinder.
• Apply grease to the brake lever pivot bolt.
• Apply grease to the contacting surfaces between piston and brake lever.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
CHASSIS 8-19
8-20 CHASSIS
• Tighten the brake lever pivot bolt 7 and lock-nut 8 to the specified torque.
Front brake lever pivot bolt: 6 N·m (0.6 kgf-m, 4.5 lbf-ft)
Front brake lever pivot bolt lock-nut:
6 N·m (0.6 kgf-m, 4.5 lbf-ft)
• When installing the master cylinder 0 onto the handlebar 9 , align the master cylinder holder’s mating surface with punch mark C on the handlebar and tighten the upper holder bolt A first as shown.
Front brake master cylinder holder bolt:
10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Install the brake hose union as shown and tighten the union bolt B to the specified torque.
Front brake hose union bolt:
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
* The seal washers should be replaced with new ones to prevent brake fluid leakage.
* Bleed air from the brake system after installing the master cylinder. (
2-16)
“ UP ” mark
Clearance
20 – 30˚
HANDLEBARS
CONSTRUCTION
1 Handlebars
2 Handlebar balancer
3 Throttle grip
4 Right handlebar switch box
5 Left handlebar grip
6 Left handlebar switch box
REMOVAL
HANDLEBAR LEFT SIDE PARTS
• Remove the rear view mirror (LH) 1 .
• Remove the left handlebar switch box 2 .
• Disconnect the clutch lever position switch coupler 3 .
• Remove the left handlebar balancer 4 .
• Remove the left handlebar grip 5 .
• Loosen the clutch lever holder bolt 6 .
• Remove the clamp 7 .
HANDLEBAR RIGHT SIDE PARTS
• Remove the rear view mirror (RH) 1 .
• Remove the right handlebar switch box screws 2 .
• Disconnect the brake light switch coupler 3 .
• Remove the front brake master cylinder 4 .
• Remove the right handle balancer 5 .
• Remove the clamp 6 .
CHASSIS 8-21
8-22 CHASSIS
• Remove the handlebar clamps 7 by removing the handlebar clamp bolts.
• Remove the right handlebar switch box 9 , throttle grip 0 and clutch lever holder A from the handlebars 8 .
INSPECTION
Inspect the handlebars for distortion or damage.
If any defects are found, replace the handlebars with a new one.
INSTALLATION
Install the handlebars in the reverse order of removal. Pay attention to the following points:
• Install the handlebars with the punch mark A aligned with the mating surface of the handlebar holder.
• Tighten the handlebar clamp bolts 1 to the specified torque.
Handlebar clamp bolt: 16 N·m (1.6 kgf-m, 11.5 lbf-ft)
NOTE:
The clearances B between the handlebar clamp and holder should be even.
• Insert the right handlebar switch box 2 , throttle grip 3 and clutch lever holder 4 onto the handlebars.
• Apply grease to the throttle cables.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Engage the projection C of right handlebar switch box with the hole of handlebars.
NOTE:
Check that the throttle grip turns smoothly.
• Install the front brake master cylinder. (
8-20)
CHASSIS 8-23
8-24 CHASSIS
• Align the mating surface of clutch lever holder with the punch mark D on handlebars.
• Tighten the clutch lever holder bolt to the specified torque.
Clutch lever holder bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Apply handle grip bond to the left handlebar end E before installing the left handlebar grip.
• Engage the projection F of left handlebar switch box with the hole of handlebars.
FRONT FORK
CONSTRUCTION
CHASSIS 8-25
1 O-ring
2 Spring collar
3 Spring joint
4 Front fork spring
5 Damper rod ring
6 Damper rod
7 Rebound spring
8 Inner tube
9 Slide bushing
0 Dust seal
A Oil seal stopper ring
B Oil seal
C Spacer
D Guide bushing
E Oil lock piece
F Outer tube
G Reflex refractor
A Front fork cap bolt
B Front axle pinch bolt
C Damper rod bolt
ITEM N·m kgf-m lbf-ft
A
B
23
23
2.3
2.3
16.5
16.5
C 20 2.0
14.5
8-26 CHASSIS
REMOVAL AND DISASSEMBLY
NOTE:
* The left and right front forks are installed symmetrically and therefore the disassembly procedure for one side is the same as that for the other side.
* When the brake caliper is removed, care must be used so as not to cause stress to the brake hose.
• Remove the front brake caliper. (
8-13)
• Remove the front wheel. (
8-4)
• Disconnect the speedometer cable guide 1 .
• Remove the front fender 2 .
• Remove the front fork cap 3 .
• Loosen the front fork upper clamp bolt 4 .
NOTE:
Slightly loosen the front fork cap bolt 5 to facilitate later disassembly.
09940-30230: Hexagon socket (17 mm)
• Loosen the front fork lower clamp bolt 6 and remove the front fork 7 .
NOTE:
Hold the front fork by the hand to prevent sliding out of the steering stem.
• Remove the front fork cap bolt 8 .
Take care so that the cap bolt does not spring out by the force of the spring.
09940-30230: Hexagon wrench (17 mm)
• Remove the spring collar 9 , spring joint 0 and front fork spring A .
• Invert the front fork and stroke it several times to drain out fork oil.
• Hold the front fork inverted for a few minutes to drain oil.
• Remove the damper rod bolt B using the wrench and special tools.
09940-34520: T type handle
09940-34561: Front fork assembling attachment (D)
• Remove the damper rod C and rebound spring D .
• Remove the dust seal E and oil seal stopper ring F .
Be careful not to damage the inner tube.
CHASSIS 8-27
8-28 CHASSIS
• Pull the inner tube out of the outer tube.
• Remove the oil lock piece G .
• Remove the oil seal H , spacer I , guide bushing J and slide bushing K .
INSPECTION
INNER AND OUTER TUBE
Inspect the inner tube sliding surface and outer tube sliding surface for any scuffing or damage.
FRONT FORK SPRING
Measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one.
Front fork spring free length
Service limit: 338 mm (13.3 in)
DAMPER ROD RING
Inspect the damper rod ring for wear or damage. If it is worn or damaged, replace it with a new one.
REASSEMBLY AND INSTALLATION
Reassemble and install the front fork in the reverse order of removal and disassembly. Pay attention to the following points:
* Thoroughly wash all the component parts being assembled.
* When reassembling the front fork, use new fork oil.
* Use the specified fork oil for the front fork.
* When reassembling, replace the oil seal, dust seal and damper rod bolt gasket with new ones.
INNER TUBE
• Hold the inner tube vertically, clean the metal groove and install the slide bushing 1 by hand.
• Install the following parts onto the inner tube.
2 Guide bushing
3 Spacer
4 Oil seal
NOTE:
The stamped mark on the oil seal outside.
• Apply fork oil to the slide bushing 1 , guide bushing 2 and oil seal lip 4 .
99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent
• Insert the oil lock piece 5 into the inner tube.
NOTE:
* When installing the oil lock piece, insert the tapered end A of oil lock piece into the inner tube.
* When inserting the inner tube into the outer tube, take care not to come off the oil lock piece from the inner tube.
CHASSIS 8-29
8-30 CHASSIS
• Insert the inner tube into the outer tube and install the oil seal using the special tool.
09940-52861: Front fork oil seal installer
• Install the oil seal stopper ring 6 and dust seal 7 .
Make sure that the oil seal stopper ring is fitted securely.
DAMPER ROD
• Install the rebound spring 2 onto the damper rod 1 and install them to the inner tube.
• Apply thread lock to the damper rod bolt 3 and tighten it to the specified torque using the hexagon wrench and special tools.
Use the new damper rod bolt gasket 4 to prevent oil leakage.
Damper rod bolt: 20 N·m (2.0 kgf-m, 14.5 lbf-ft)
99000-32110: THREAD LOCK SUPER “1322” or equivalent
09940-34520: T type handle
09940-34561: Front fork assembling attachment (D)
FRONT FORK OIL
• Pour specified front fork oil into the inner tube.
Front fork oil capacity (each leg):
411 ml (13.9 US oz)
99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent
• Move the inner tube up and down several strokes until no more bubbles come out from the fork oil.
• Keep the front fork vertically and wait 5 – 6 minutes.
• Hold the front fork vertically and adjust the fork oil level A by using the special tool.
NOTE:
When adjusting the fork oil level, compress the inner tube fully without the fork spring.
Front fork oil level (without spring): 72 mm (2.8 in)
09943-74111: Front fork oil level gauge
FRONT FORK SPRING
• Install the fork spring into the inner tube.
NOTE:
The smaller pitch end A of fork spring must face downward.
• Apply front fork oil to the O-ring and install it.
Use the new O-ring to prevent oil leakage.
99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent
• Temporarily tighten the front fork cap bolt.
09940-30230: Hexagon socket (17 mm)
CHASSIS 8-31
8-32 CHASSIS
• Install the front fork to the motorcycle.
• Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket.
• Tighten the front fork lower clamp bolt 1 and front fork cap bolt 2 to the specified torque.
• Tighten the front fork upper clamp bolt 3 to the specified torque.
Front fork lower clamp bolt:
33 N·m (3.3 kgf-m, 24.0 lbf-ft)
Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Front fork upper clamp bolt:
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Install the front fender and tighten the mounting bolts temporarily.
• Install the front wheel and front brake caliper. (
8-9, -16)
• Move the front fork up and down several times, and tighten the front fender mounting bolts securely.
* After assembling the front fork, check each tightening part for looseness, play and other conditions.
* Check for oil leakage.
STEERING
CONSTRUCTION
CHASSIS 8-33
1 Steering stem upper bracket A Steering stem head bolt
2 Dust seal B Handlebar clamp bolt
3 Steering stem upper bearing C Front fork upper clamp bolt
4 Steering stem lower bearing D Front fork lower clamp bolt
5 Lower seal E Steering stem nut
6 Steering stem lower bracket
ITEM N·m kgf-m lbf-ft
A 65 6.5
47.0
B
C
16
23
1.6
2.3
11.5
16.5
D 33 3.3
24.0
E
45 N·m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/4 – 1/2
REMOVAL AND DISASSEMBLY
• Remove the front wheel. (
8-4)
• Remove the front forks. (
8-26)
• Remove the throttle cable guide 1 .
8-34 CHASSIS
• Remove the headlight. (
9-30)
• Disconnect the ignition switch coupler, speedometer coupler and turn signal couplers.
• Remove the headlight housing bolts, nuts and clamps.
• Remove the headlight housing 2 by removing the clamp and housing plate bolt.
• Remove the headlight brackets 3 .
• Remove the speedometer 4 .
• Remove the handlebars 5 .
• Remove the steering stem upper bracket 6 by removing the steering stem head bolt and washer.
NOTE:
Place a clean rag on the fuel tank to prevent the fuel tank scratched.
• Remove the steering stem nut with the special tool.
09940-14911: Steering stem nut socket wrench
• Remove the steering stem lower bracket 7 .
When removing the steering stem nut, hold the steering stem lower bracket to prevent it from falling.
• Remove the dust seal 8 and upper bearing inner race 9 .
• Remove the steering stem upper bearing 0 and lower bearing A .
• Remove the ignition switch B with the special tools, if necessary.
09930-11920: Torx bit (JT40H)
09930-11940: Torx bit holder
CHASSIS 8-35
8-36 CHASSIS
INSPECTION
Inspect the removed parts for the following abnormalities. If any abnormal points are found, replace the respective parts with new ones.
* Bearing race wear or damage
* Bearing wear or damage
* Abnormal bearing noise
* Distortion of steering stem
• Remove the steering stem lower inner race 1 and lower seal
2 using a chisel.
* Unless corrosion, damage or other abnormal condition is found, the bearing race need not be replaced.
* Once the lower inner race has been removed, replace it with a new one.
• Remove the steering stem upper and lower bearing races using the special tools.
09941-54911: Bearing outer race remover
09941-74911: Steering race installer
REASSEMBLY AND INSTALLATION
Reassemble and install 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 outer races using the special tool.
09941-34513: Bearing installer
BEARING
• Press in the steering stem lower inner race using the special tool.
09941-74911: Steering race installer
• Apply grease to the steering stem upper and lower bearings.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
STEERING STEM
• Tighten the steering stem nut 1 to the specified torque (45
N·m (4.5 kgf-m, 32.5 lbf-ft)) using the special tool.
09940-14911: Steering stem nut socket wrench
• Turn the steering stem bracket about five or six times to the left and right so that the bearings seat properly.
• Loosen the steering stem nut 1/4 – 1/2 turn A .
Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/4 – 1/2
• In this condition, check that the steering stem can turn smoothly with no rattle and stiffness.
• If there is a rattle or heavy movement, adjust the tightness by the stem nut.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
CHASSIS 8-37
8-38 CHASSIS
• Before tightening the steering stem head bolt 2 , temporarily install the front forks 3 .
• Tighten the steering stem head bolt 2 to the specified torque.
Steering stem head bolt: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
NOTE:
Tightening the steering stem head bolt can affect the steering stem nut adjustment. Therefore after tightening the steering stem head bolt, check the steering movement again and adjust it if necessary.
• Install the handlebars. (
8-23)
• Install the speedometer.
• Remove the front forks.
• Install the headlight brackets and front forks. (
8-32)
• Tighten the front fork upper and lower clamp bolts to the specified torque. (
8-32)
Front fork upper clamp bolt:
23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Front fork lower clamp bolt:
33 N·m (3.3 kgf-m, 24.0 lbf-ft)
• Install the headlight.
• Install the front wheel. (
8-9)
• Check that the cables and wire harnesses are properly routed. (
10-12, 10-13, 10-15 to -17)
Check that the cable or wire harness does not prevent the handle operation.
NOTE:
Hold the front fork legs, move them back and forth and make sure that the steering is not loose.
After performing the adjustment and installing the handlebars, “rock” the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. Finally, check to make sure that the steering stem moves freely from left to right with its own weight. If play or stiffness is noticeable, readjust the steering stem nut.
CHASSIS 8-39
REAR BRAKE
CONSTRUCTION
1 Brake pedal
2 Brake pedal return spring
3 Brake rod
4 Brake panel
5 Brake cam lever
6 Spring
7 Brake cam
8 Brake shoe
A Brake cam lever nut
REMOVAL AND DISASSEMBLY
BRAKE SHOE
• Remove the rear wheel. (
8-46)
• Remove the brake panel 1 .
ITEM N·m kgf-m lbf-ft
A 10 1.0
7.0
• Remove the brake shoes 2 from the brake panel.
8-40 CHASSIS
• Remove the brake cam lever nut 3 .
• Remove the brake cam lever 4 .
• Remove the brake cam 5 .
• Remove the washer 6 and O-ring 7 .
INSPECTION
BRAKE DRUM
Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear.
If the measurement exceeds the service limit, replace the brake drum with a new one. The value of this limit is indicated inside the brake drum.
Brake drum I.D.
Service Limit: 130.7 mm (5.15 in)
09900-20101: Vernier calipers (150 mm)
BRAKE SHOE
Inspect the brake shoes for wear or damage. If any defects are found, replace the brake shoes as a set.
Replace the brake shoes as a set, otherwise braking performance will be adversely affected.
BRAKE CAM
Inspect the brake cam for abnormal wear.
Place the brake cam into the brake panel and check for smooth rotation.
Check that the rotating parts are coated with sufficient grease.
BRAKE PANEL
Inspect the brake panel for wear or damage. If any defects are found, replace the brake panel with a new one.
REASSEMBLY AND INSTALLATION
Reassemble and install the rear brake in the reverse order of removal and disassembly. Pay attention to the following points:
• Apply grease to the camshaft, cam face and pin.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the brake shoes with spring hooks 1 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.
• When installing the brake cam lever, align the line A of brake cam with slit B of brake cam lever.
• Tighten the brake cam lever nut to the specified torque.
Rear brake cam lever nut: 10 N·m (1.0 kgf-m, 7.0 lbf-ft)
• Install the rear wheel. (
8-52)
CHASSIS 8-41
8-42 CHASSIS
REAR BRAKE PEDAL REMOVAL
• Remove the brake adjuster nut 1 , pin 2 , spring 3 and washer 4 .
NOTE:
When removing the brake rod, depressing the brake pedal.
• Remove the rear brake light switch spring 5 .
• Remove the cotter pin 6 and washer 7 .
Never reuse a cotter pin.
• Remove the brake pedal return spring 8 .
• Remove the brake pedal 9 along with brake rod.
REAR BRAKE PEDAL INSTALLATION
Install the rear brake pedal in the reverse order of removal. Pay attention to the following points:
• Apply grease to the brake pedal shaft.
99000-25160: SUZUKI WATER RESISTANCE GREASE or equivalent
• After assembling, check the brake for operating condition, play and braking effect.
• Check the brake lamp lighting timing.
REAR SHOCK ABSORBER
CONSTRUCTION
CHASSIS 8-43
1 Rear shock absorber
2 Washer
3 Washer
A Rear shock absorber nut
REMOVAL
NOTE:
The left and right rear shock absorbers are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.
• Remove the rear shock absorber 1 .
ITEM N·m kgf-m lbf-ft
A 29 2.9
21.0
8-44 CHASSIS
INSPECTION
Inspect the shock absorber body and bushings 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. It is unserviceable.
INSTALLATION
• Install the rear shock absorber 1 .
• Tighten the rear shock absorber nuts to the specified torque.
Rear shock absorber nut: 29 N·m (2.9 kgf-m, 21.0 lbf-ft)
• Check the rear suspension for proper operation.
REAR SUSPENSION SETTING
The rear shock absorber spring preload is adjustable.
After installing the rear shock absorber, adjust the spring adjuster 1 .
Spring adjuster: 3/5 position
REAR WHEEL
CONSTRUCTION
CHASSIS 8-45
1 Rear axle
2 Spacer
3 Brake cam lever
4 Brake panel
5 Brake cam
6 Brake shoe
7 Spring
8 Bearing
9 Spacer
0 Rear wheel
A Bearing
B Wheel damper
C Sprocket mounting drum
D Collar
E Bearing
F Spacer
G Rear sprocket
A Rear axle nut
B Brake cam lever nut
C Rear sprocket nut
D Spoke nipple
ITEM N·m kgf-m lbf-ft
A 65 6.5
47.0
B 10 1.0
7.0
C 60 6.0
43.5
D 3 0.3
2.0
8-46 CHASSIS
REMOVAL
• Remove the drive chain case 1 .
• Remove the torque link nut (rear) 2 , brake adjuster nut 3 , pin 4 , spring 5 and washer 6 .
NOTE:
When removing the brake rod, depressing the brake pedal.
• Remove the rear axle nut 7 .
• Raise the rear wheel off the ground and support the motorcycle with a jack or a wooden block.
Make sure that the motorcycle is supported securely.
• Loosen the both chain adjuster lock-nuts 8 .
• Loosen the both chain adjuster bolts 9 .
• Remove the rear axle 0 and disengage the drive chain A from the rear sprocket.
• Remove the rear wheel B .
• Remove the left and right spacers ( C , D ).
• Remove the brake panel E .
• Remove the rear sprocket F along with sprocket mounting drum G .
• Remove the wheel damper H .
CHASSIS 8-47
8-48 CHASSIS
INSPECTION AND DISASSEMBLY
WHEEL (
2-19)
TIRE (
8-59)
SPOKE NIPPLE (
2-20)
REAR AXLE
Measure the rear axle runout using the dial gauge.
If the runout exceeds the service limit, replace the rear axle with a new one.
Axle shaft runout
Service Limit: 0.25 mm (0.010 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
WHEEL DAMPER
Inspect the dampers for wear or damage.
Replace the damper if there is anything unusual.
DUST SEAL
Insect the dust seal lip for wear or damage.
If any defects are found, replace it with a new one.
• Remove the dust seal with the special tool.
The removed dust seal must be replaced with a new one.
09913-50121: Oil seal remover
CHASSIS 8-49
BEARING
Inspect the play of the wheel and sprocket mounting drum bearings by finger while they are in the wheel and drum. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual.
• Remove the drum bearing 1 and collar 2 with the special tool.
The removed bearing must be replaced with a new one.
09913-70210: Bearing installer set (10 – 75
)
• Remove the wheel bearings 3 with the special tool.
The removed bearings must be replaced with new ones.
09941-50111: Wheel bearing remover set
• Remove the spacer 4 .
REAR SPROCKET
Inspect the rear sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set.
• Remove the rear sprocket 2 from the sprocket mounting drum 1 .
Normal wear Excessive wear
8-50 CHASSIS
REASSEMBLY AND INSTALLATION
Reassemble and install the rear wheel in the reverse order of removal and disassembly. Pay attention to the following points:
REAR SPROCKET
• Tighten the rear sprocket nut to the specified torque.
Rear sprocket nut: 60 N·m (6.0 kgf-m, 43.5 lbf-ft)
NOTE:
The stamped mark A on the sprocket should face outside.
BEARING
• Apply grease to the bearings before installing them.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the collar 1 into the sprocket mounting drum.
NOTE:
The flange side A of collar 1 should face sprocket side.
• Install a new sprocket mounting drum bearing with the special tool.
NOTE:
The stamped mark on bearing should face outside.
09913-70210: Bearing installer set (10 – 75
)
WHEEL BEARING
• Install new wheel bearings with removed wheel bearing and special tool.
* First install the right wheel bearing, then install the spacer and left wheel bearing.
* The sealed cover on the bearing must face outside.
09924-84510: Bearing installer set
LH RH LH RH
CHASSIS 8-51
1 New wheel bearing
2 Removed wheel bearing
3 Spacer
A Clearance
8-52 CHASSIS
DUST SEAL
• Install a new dust seal with the special tool.
09913-70210: Bearing installer set (10 – 75
)
• Apply grease to the dust seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
REAR SPROCKET MOUNTING DRUM
• Apply grease to the contacting surface between the sprocket mounting drum and rear wheel hub.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
REAR WHEEL
• Adjust the drive chain slack after installing the rear wheel.
(
2-13)
• Temporary tighten the rear axel nut 1 .
• Tighten the rear axle nut 1 and torque link nut (rear) 2 to the specified torque.
Rear axle nut: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
Torque link nut: 16 N·m (1.6 kgf-m, 11.5 lbf-ft)
• Tighten both chain adjuster lock-nuts 3 securely.
• Check the rear brake pedal free travel. (
2-17)
SWINGARM
CONSTRUCTION
CHASSIS 8-53
1 Torque link
2 Dust cover
3 Washer
4 Dust seal
5 Swingarm pivot bushing
6 Collar
7 Chain buffer
8 Swingarm pivot shaft
A Swingarm pivot nut
B Torque link nut
ITEM N·m kgf-m lbf-ft
A 65 6.5
47.0
B 16 1.6
11.5
8-54 CHASSIS
REMOVAL
• Remove the rear wheel.
(
8-46)
• Remove the rear shock absorber nuts (lower) 1 and washers.
• Remove the rear brake light switch spring 2 .
• Remove the swingarm pivot nut 3 and washer.
• Draw out the swingarm pivot shaft and remove the swingarm assembly 4 .
• Remove the engine sprocket cover 5 and drive chain 6 , if necessary.
• Remove the torque link 7 .
• Remove the dust covers 8 , washers 9 and collars 0 .
• Remove the dust seals A .
• Remove the chain buffer B .
INSPECTION AND DISASSEMBLY
SWINGARM
Inspect the swingarm for damage. If any damage is found, replace the swingarm with a new one.
CHAIN BUFFER
Inspect the chain buffer for wear or damage. If any defects are found, replace the chain buffer with a new one.
CHASSIS 8-55
8-56 CHASSIS
SWINGARM PIVOT SHAFT
Measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft with a new one.
Swingarm pivot shaft runout
Service limit: 0.6 mm (0.02 in)
09900-20607: Dial gauge
09900-20701: Dial gauge chuck
09900-21304: V blocks
SWINGARM PIVOT BUSHING
Insert the collars into the swingarm bushings, move the collar up and down and check for any play. If there is excessive play, replace the bushings with new ones.
• Remove the swingarm pivot bushings with the special tools.
The removed bushings must be replaced with new ones.
09923-74511: Bearing remover
09930-30104: Rotor remover sliding shaft
REASSEMBLY
Reassemble the swingarm in the reverse order of disassembly.
Pay attention to the following points:
• Press the swingarm pivot bushings into the swingarm at 8 mm
(0.31 in) depth A from the swingarm surface with the special tool and suitable size socket wrench. (
8-57)
09924-84521: Bearing installer set
• Press the dust seals (inside) into the swingarm at 3 mm (0.12
in) depth B from the swingarm surface with the special tool and suitable size socket wrench. (
8-57)
09924-84521: Bearing installer set
• Apply grease to the dust seals, swingarm pivot bushings and dust covers.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
LH RH
CHASSIS 8-57
1 Swingarm pivot bushing
2 Swingarm
3 Dust seal (Inner)
4 Dust seal (Outer)
5 Collar (LH)
6 Collar (RH)
A 8 mm (0.31 in)
B 3 mm (0.12 in)
C 0 mm (0 in)
D 64.8 mm (2.55 in)
E 59.8 mm (2.35 in)
8-58 CHASSIS
INSTALLATION
Install the swingarm in the reverse order of removal. Pay attention to the following points:
• Tighten the swingarm pivot nut to the specified torque.
Swingarm pivot nut: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
• Tighten the rear shock absorber nuts (lower) to the specified torque.
Rear shock absorber nut: 29 N·m (2.9 kgf-m, 21.0 lbf-ft)
• Install the rear wheel. (
8-52)
FINAL INSPECTION AND ADJUSTMENT
After installing the rear suspension and wheel, the following adjustments are required before driving.
* Drive chain (
2-13)
* Rear brake (
2-17)
* Chassis bolts and nuts (
2-22)
* Rear suspension (
2-20)
TIRE AND WHEEL
TIRE REMOVAL
Tube tires are used for this motorcycle. When removing or installing the tire, be careful not to damage the tube.
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 (
2-19)
CHASSIS 8-59
TIRE
Tire must be checked for the following points:
• Nick and rupture on side wall
• Tire tread depth (
2-19)
• Tread separation
• Abnormal, uneven wear on tread
• Surface damage on bead
• Localized tread wear due to skidding (Flat spot)
• Abnormal condition of inner liner
TUBE
• Inspect the tube after the tire is removed from the rim.
• If the tube has abnormality, replace the tube with a new one.
8-60 CHASSIS
TIRE INSTALLATION
• Apply tire lubricant to the tire bead.
Do not use oil, grease or gasoline on the tire bead in place of tire lubricant.
• Install the tube.
When installing the tire onto the wheel, observe the following points.
• When installing the tire, the arrow 1 on the side wall should point to the direction of wheel rotation.
• In case of a new tire, align the light point mark 2 on the tire side wall to the valve hole to balance the tire and wheel.
• 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/cm 2 , 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.
• In this condition, check the “rim line” cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides. Coat the 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.
* After mending a puncture of the tire, do not travel with that tire at a speed of more than 50 km/h (31.1
mile/h) at least for 24 hours after mending.
* Do not run with a repaired tire at a high speed.
Tire pressure
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
SOLO RIDING DUAL RIDING kPa kgf/cm 2 psi kPa kgf/cm 2 psi
175 1.75
25 175 1.75
25
200 2.00
29 225 2.25
33
Rim line
CHASSIS 8-61
ELECTRICAL SYSTEM 9-1
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING ......................................................................... 9- 3
SEMI-CONDUCTOR EQUIPPED PART ............................................... 9- 4
CONNECTING THE BATTERY............................................................. 9- 4
WIRING PROCEDURE.......................................................................... 9- 5
USING THE MULTI CIRCUIT TESTER ................................................. 9- 5
LOCATION OF ELECTRICAL COMPONENTS ......................................... 9- 6
TROUBLESHOOTING........................................................................... 9- 8
STARTER SYSTEM AND SIDE-STAND/IGNITION
TROUBLESHOOTING........................................................................... 9-12
STARTER MOTOR REMOVAL............................................................. 9-13
STARTER MOTOR DISASSEMBLY ..................................................... 9-14
STARTER MOTOR INSPECTION......................................................... 9-15
STARTER MOTOR REASSEMBLY ...................................................... 9-16
STARTER MOTOR INSTALLATION .................................................... 9-17
STARTER RELAY INSPECTION .......................................................... 9-18
SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS
TROUBLESHOOTING........................................................................... 9-22
REMOVAL AND DISASSEMBLY ......................................................... 9-26
9
9-2 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONTENTS
BRAKE LIGHT/TAILLIGHT ................................................................... 9-32
TURN SIGNAL LIGHT........................................................................... 9-33
TURN SIGNAL/SIDE-STAND RELAY .................................................. 9-34
IGNITION SWITCH REMOVAL ............................................................. 9-35
IGNITION SWITCH INSTALLATION..................................................... 9-35
SWITCH INSPECTION .......................................................................... 9-36
INITIAL CHARGING .............................................................................. 9-37
RECHARGING OPERATION ................................................................ 9-39
ELECTRICAL SYSTEM 9-3
CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in until a click is felt.
• Inspect the connector for corrosion, contamination and breakage in its cover.
• Avoid applying grease or other similar material to connector/coupler terminals to prevent electric trouble.
COUPLER
• 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 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.
• Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact.
• Before refitting the sealed coupler, make sure its seal rubber is positioned properly. The seal rubber may possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber improperly positioned, it may result in poor water sealing.
CLAMP
• Clamp the wire harness at such positions as indicated in
“WIRING HARNESS ROUTING”. (
10-12 to -14)
• 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 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.
Click
CORRECT INCORRECT
9-4 ELECTRICAL SYSTEM
SWITCH
• Never apply grease material to switch contact points to prevent damage.
SEMI-CONDUCTOR EQUIPPED PART
• Be careful not to drop the part with a semi-conductor built in such as a ECM.
• When inspecting these parts, follow the instructions carefully.
Failure to follow the proper procedure can cause damage to these parts.
INCORRECT
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 “WIRING
HARNESS ROUTING” section. (
10-12 to -14)
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 OFF.
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-point probe to the back side of the lead wire coupler and connect the probes of tester to them.
* Use the needle-point probe to prevent the rubber of the water proof coupler from damage.
09900-25009: Needle-point probe set
• When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a needle-point probe to prevent the terminal damage or terminal bend.
ELECTRICAL SYSTEM 9-5
9-6 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
1 ECM
2 Check relay or Main relay
3 Main relay or Check relay
4 IAT sensor
5 Ignition coil
6 Starter relay/Main fuse
7 Battery
8 Fuse box
9 Mode select coupler
0 TO sensor
A PAIR control solenoid valve
B ET sensor
C HO2 sensor
D Starter motor
E Horn
1 Fuel pump
2 TP sensor
3 STP sensor
4 STV actuator
5 IAP sensor
6 Fuel injector
7 Turn signal/Side-stand relay
8 Generator
9 CKP sensor
0 Neutral switch
A Side-stand switch
B Regulator/Rectifier
ELECTRICAL SYSTEM 9-7
9-8 ELECTRICAL SYSTEM
CHARGING SYSTEM
Generator
B
B
B
B
B
B
Regulator/Rectifier
Ignition switch
R
IC
SCR
B/W
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
ELECTRICAL SYSTEM 9-9
Step 5
1) Measure the generator no-load performance. (
9-11)
Is the generator no-load performance 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 right frame cover. (
8-3)
• Turn the ignition switch OFF.
• 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)
* In case of a large current leak, turn the tester to high range first to avoid tester damage.
* Do not turn the ignition switch ON when measuring current.
A
9-10 ELECTRICAL SYSTEM
REGULATED VOLTAGE
• Remove the right frame cover. (
8-3)
• Start the engine and keep it running at 5 000 r/min with the 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, -11)
NOTE:
When making this test, be sure that the battery is in fully-charged condition.
Regulated voltage (Charging output):
13.5 – 15.5 V at 5 000 r/min
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (
)
GENERATOR COIL RESISTANCE
• Remove the front seat. (
8-3)
• Disconnect the generator coupler 1 .
• Measure the resistance between the three lead wires.
If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly.
Generator coil resistance: 0.1 – 1.5
Ω
(B – B)
∞ Ω
(B – 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.
B
B
B
Battery
DCV
GENERATOR NO-LOAD PERFORMANCE
• Remove the front seat. (
8-3)
• Disconnect the generator coupler.
• 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.
Generator no-load performance:
60 V and more at 5 000 r/min (When engine is cold)
09900-25008: Multi circuit tester set
Tester knob indication: Voltage (~)
REGULATOR/RECTIFIER
• Disconnect the regulator/rectifier coupler 1 and remove the regulator/rectifier 2 .
• 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 (
)
Unit: V
R
+ Probe of tester to:
B
1
B
2
R
B
B
B
1
2
3
B/W
0.1 – 0.8
0.1 – 0.8
1.4 V and more (tester’s battery voltage)
B
3
0.1 – 0.8
B/W
0.4 – 1.1
0.1 – 0.8
0.1 – 0.8
0.1 – 0.8
NOTE:
If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.
ELECTRICAL SYSTEM 9-11
B
B
B
R B/W
B
1 B
2
B
3
9-12 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
Starter motor
To Ignition coil
Bl/B
Starter relay
B/Y
B/W
Clutch switch
O/W
Starter button
Engine stop switch
B/Bl
O/G
Ignition switch
R
Fuse (30 A)
Fuse
(10 A) Neutral switch
Battery
Bl
Turn signal/ side-stand relay
G side-stand switch
TROUBLESHOOTING
Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
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 Bl/B + and B/Y ) when the starter button is pushed.
Is a voltage OK?
YES
NO
Go to Step 4.
• Faulty engine stop switch
• Faulty clutch switch
• Faulty neutral 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. (
9-18)
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. (
9-19)
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
STARTER MOTOR REMOVAL
• Disconnect the battery lead wire.
• Disconnect the starter motor lead wire 1 .
• Remove the starter motor 2 .
9-14 ELECTRICAL SYSTEM
STARTER MOTOR DISASSEMBLY
• Disassemble the starter motor as shown in the illustration.
1 O-ring
2 O-ring
3 Housing end (inside)
4 O-ring
5 Oil seal
6 Bearing
7 Snap ring
8 Armature
9 Shim
0 Starter motor case
A Spring
B Brush holder
C Brush
D Housing end (outside)
E O-ring
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
If either carbon brush is defective, replace the brushes with new ones.
Measure the length A of the carbon brushes using a vernier calipers. If the measurement is less than the service limit, replace the brushes with new ones.
Starter motor brush length A
Service Limit: 8.5 mm (0.33 in)
09900-20101: Vernier calipers (150 mm)
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 with a saw blade.
1 Insulator
2 Segment
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 (
)
BEARING INSPECTION
Check the bearing for smooth rotation and any abnormal noise.
If any defects are found, replace the bearing with a new one.
ELECTRICAL SYSTEM 9-15
9-16 ELECTRICAL SYSTEM
OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage.
If any defects are found, replace the oil seal with a new one.
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
• Install a new oil seal with the special tool.
09913-70210: Bearing installer set (10 – 75
)
• Apply grease to the of the oil seal lip.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Install the bushing 1 and positive terminal (brush) 2 .
NOTE:
The convex part A of bush holder should face housing end side.
• Install a new bearing 3 using a suitable size socket wrench.
The removed bearing must be replaced with a new one.
NOTE:
The sealed side of bearing should face inside.
• Apply a small quantity of moly paste to the armature shaft.
99000-25140: SUZUKI MOLY PASTE or equivalent
• Apply grease to the bearing.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Align the groove B of housing end 4 with the groove C of brush holder 5 .
• Align the groove B of housing end with the match mark D on starter motor case.
• Align the match mark E on starter motor case with the bolt hole.
STARTER MOTOR INSTALLATION
• Apply grease to the O-ring.
99000-25010: SUZUKI SUPER GREASE “A” or equivalent
• Tighten the starter motor mounting bolt 1 and starter motor lead wire nut 2 .
ELECTRICAL SYSTEM 9-17
9-18 ELECTRICAL SYSTEM
STARTER RELAY INSPECTION
• Remove the right frame cover. (
8-3)
• Disconnect the battery lead wire from the battery.
• Disconnect the starter relay coupler 1 and remove the starter relay cover 2 .
• Disconnect the starter motor lead wire 3 and battery lead wire 4 .
• Remove the starter relay 5 .
• 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 battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and get 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.
Starter relay resistance: 2 – 6
Ω
Tester knob indication: Resistance (
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
• Disconnect the side-stand switch coupler 1 .
• Measure the voltage between G and B/W lead wires.
09900-25008: Multi circuit tester set
Tester knob indication: Diode test (
)
G
( + Probe)
B/W
( Probe)
ON
(Side-stand up)
OFF
(Side-stand down)
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.
NEUTRAL SWITCH
• Remove the front seat. (
8-3)
• Disconnect the neutral switch coupler 1 and check the continuity between Bl and B/W with the transmission in “NEU-
TRAL”.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (
)
Bl B/W
ON (Neutral)
OFF (Except neutral)
When disconnecting and connecting the neutral switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
ELECTRICAL SYSTEM 9-19
9-20 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.
• Disconnect the PCV hose 1 .
• Remove the turn signal/side-stand relay 2 .
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
TURN
SIGNAL
RELAY
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
C ,
A
B
+ 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.
ELECTRICAL SYSTEM 9-21
IGNITION SYSTEM
Main relay Engine stop switch Side-stand relay
R/Y
CKP sensor
ECM
B lgnition coil lgnition fuse lgnition switch
Main fuse
B/W
Battery
TP sensor
ET sensor
Neutral switch
NOTE:
The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 9 700 r/min, this circuit cuts off fuel at the fuel injector.
9-22 ELECTRICAL SYSTEM
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 system couplers?
YES
NO
Go to Step 2.
Poor connection of couplers
Step 2
1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in ON position. (R/Y and B/W)
Is the voltage OK?
YES
NO
Go to Step 3.
• Faulty ignition switch
• Faulty turn signal/side-stand relay
• Faulty main 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. (
9-23)
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) Inspect the spark plug. (
2-7)
Is the spark plug OK?
YES
NO
Go to Step 5.
Faulty spark plug
ELECTRICAL SYSTEM 9-23
Step 5
1) Inspect the ignition coil. (
9-24)
Is the ignition coil OK?
YES
NO
Go to Step 6.
• Poor connection of the ignition coil
• Faulty ignition coil
Step 6
1) Measure the CKP sensor peak voltage and its resistance. (
9-25)
NOTE:
The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor.
Is the peak voltage and 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
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Remove the fuel tank. (
5-3)
• Disconnect the spark plug cap.
• Connect a new spark plug to the spark plug cap and ground it to the cylinder head.
NOTE:
* Check that all the couplers are connected properly.
* Check that the battery is fully charged.
Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure.
• Connect the multi circuit tester with the peak voltage adaptor as follows.
+ Probe: B lead wire
Probe: Ground
NOTE:
Do not disconnect the ignition coil lead wires.
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.
ECM
Peak volt adaptor
B
Ignition coil
New spark plug
Battery
9-24 ELECTRICAL SYSTEM
• Shift the transmission into neutral and turn the ignition switch
ON.
• Squeeze the clutch lever.
• Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.
• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage.
Ignition coil primary peak voltage: 200 V and more
Tester knob indication: Voltage (
)
While testing, do not touch the tester probes and spark plug to prevent receiving an electric shock.
If the peak voltage is lower than the specified value, inspect the ignition coil. (
Below)
IGNITION COIL RESISTANCE
• Remove the fuel tank. (
5-3)
• Disconnect the ignition coil lead wires and spark plug cap.
• Measure the ignition coil resistance in both the primary and secondary windings using the multi circuit tester.
If the resistance is not within the standard range, replace the ignition coil with a new one.
Ignition coil resistance
Primary: 2.9 – 4.1 Ω ( + Terminal – Terminal)
Secondary: 24.0 – 36.2 k Ω
( + Terminal – Spark plug cap)
09900-25008: Multi circuit tester set
Tester knob indication: Resistance ( Ω )
ELECTRICAL SYSTEM 9-25
CKP SENSOR PEAK VOLTAGE
NOTE:
* Check that all the couplers are connected properly.
* Check that the battery is fully charged.
• Remove the front seat. (
8-3)
• Disconnect the CKP sensor lead wire coupler 1 and connect the multi circuit tester with the peak volt adaptor as follows.
+ Probe: G lead wire
Probe: Bl lead wire
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.
• Squeeze the clutch lever.
• Press the starter button and allow the engine to crank for a few seconds, and then measure the CKP sensor peak voltage.
• Repeat the above test procedure a few times and measure the highest CKP sensor peak voltage.
CKP sensor peak voltage: 2.0 V and more ( + G – Bl)
09900-25008: Multi circuit tester set
09900-25009: Needle-point probe set
Tester knob indication: Voltage (
)
If the peak voltage is lower than the specified value, inspect for coupler connection and metal particles or foreign material being stuck on the CKP sensor and rotor tip.
If the peak voltage is within the specification, check the continuity between the CKP sensor coupler and ECM coupler.
Normally, use the needle-point probe to the backside of the lead wire coupler to prevent the terminal bend and terminal alignment.
CKP SENSOR RESISTANCE
• Measure the resistance between the lead wires and ground. If the resistance is not as specified, the CKP sensor must be replaced.
CKP sensor resistance: 420 – 620
Ω
(Bl – G)
∞ Ω
(Bl – Ground)
09900-25008: Multi circuit tester set
Tester knob indication: Resistance ( Ω )
CKP sensor
Bl
G
CKP sensor couper
Peak volt adaptor
Bl
G
CKP sensor
CKP sensor couper
9-26 ELECTRICAL SYSTEM
SPEEDOMETER
REMOVAL AND DISASSEMBLY
• Remove the speedometer. (
8-34)
• Disassemble the speedometer as shown.
1 Speedometer
2 Bracket
3 Bulb
4 Cover
ELECTRICAL SYSTEM 9-27
INSPECTION
Check the continuity between the lead wires using the multi circuit tester. If there is no continuity replace the respective parts.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (
)
Speedometer
High beam indicator light
Neutral indicator light
Turn signal indicator light
FI indicator light
Fuel indicator light
B: Turn signal (L)
Lg: Turn signal (R)
Bl/B: Neutral
O: Illumi, FI,
Neutral, Fuel
B/W: Illumi,
High beam
Y/B: Fuel
Bl/W: FI
Y: High beam
9-28 ELECTRICAL SYSTEM
DIODE (For speedometer)
• Remove the headlight. (
9-30)
• Remove the diode 1 .
Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.
C ,
A
B
+ 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.
FUEL LEVEL INDICATOR SWITCH (THERMISTOR)
• Remove the fuel pump assembly. (
5-7)
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
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.
* When the bulb turns off, immediately pick up the switch from kerosene.
* After the check has been completed, wash the switch with gasoline.
OFF
Test bulb
Battery
Battery
Kerosene
FUEL LEVEL INDICATOR LIGHT
Check that the fuel level indicator light immediately after turning the ignition switch to “ ” position.
If the fuel level indicator light does not light up, check the lead wires, couplers, check relay and ignition switch.
CHECK RELAY (For fuel level indicator light)
• Remove the front seat and right frame cover. (
8-3)
• Remove the check relay 1 .
First, check the insulation between A and B terminals with the multi circuit tester. Then apply 12 V to C and D terminals, + to
C and to D , and check the continuity between A and B .
If there is no continuity, replace the check relay with a new one.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (
)
ELECTRICAL SYSTEM 9-29
9-30 ELECTRICAL SYSTEM
LAMPS
HEADLIGHT
Headlight: 12 V 60/55 W 1
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
* Do not use bulb other than those with predetermined wattage.
* Remove the bulb when it gets cool, since it may be heated to an extremely high temperature when the headlight is turned ON.
HEADLIGHT BULB REPLACEMENT
• Remove the headlight mounting screws.
• Disconnect the headlight socket 1 .
• Remove the rubber cap 2 .
• Unhook the holder spring 3 and replace the headlight bulb
4 .
• When installing the headlight, hang the hook A of the headlight to the projection B of the housing.
HEADLIGHT BEAM ADJUSTMENT
• Adjust the headlight beam, both vertical and horizontal.
A : Vertical adjuster
B : Horizontal adjuster
ELECTRICAL SYSTEM 9-31
9-32 ELECTRICAL SYSTEM
BRAKE LIGHT/TAILLIGHT
Brake light/taillight: 12 V 21/5 W 1
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
* Do not use bulb other than those with predetermined wattage.
BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT
• Remove the lens by removing the screws.
• Push in on the bulb, turn it counterclockwise, and pull it out.
ELECTRICAL SYSTEM 9-33
TURN SIGNAL LIGHT
Turn signal light: 12 V 21 W 1
If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
* Do not use bulb other than those with predetermined wattage.
TURN SIGNAL LIGHT BULB REPLACEMENT
• Remove the lens by removing the screws.
• Push in on the bulb, turn it counter clockwise, and pull it out.
Do not overtighten the lens fitting screws.
9-34 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 9-20 for the side-stand relay and diode inspection.
SIDE-STAND RELAY
DIODE
TURN
SIGNAL
RELAY
MAIN RELAY
Main relay inspection is the same as that of the check relay.
9-29
CHECK RELAY
9-29
SWITCH
IGNITION SWITCH REMOVAL
• Remove the headlight. (
9-30)
• Disconnect the ignition switch lead wire couplers 1 .
• Remove the ignition switch mounting bolts using the special tools.
09930-11920: Torx bit (JT40H)
09930-11940: Torx bit holder
• Remove the ignition switch 2 .
IGNITION SWITCH INSTALLATION
Install the ignition switch in the reverse order of removal. Pay attention to the following points:
• Apply thread lock to the ignition switch mounting bolts.
When reusing the ignition switch mounting bolts, clean threaded part and apply the thread lock to them.
99000-32110: THREAD LOCK SUPER “1322” or equivalent
• Tighten the ignition switch mounting bolts using the special tools.
09930-11920: Torx bit (JT40H)
09930-11940: Torx bit holder
ELECTRICAL SYSTEM 9-35
9-36 ELECTRICAL SYSTEM
SWITCH INSPECTION
Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies withe new one.
09900-25008: Multi circuit tester set
Tester knob indication: Continuity test (
)
STARTER BUTTON
Color
O/W Y/G O/R Y/W
IGNITION SWITCH
Color
R
ON
C
OFF
LOCK
O O/Y B/W Gr Br O/W
DIMMER SWITCH
Color
Position
HI (
!
)
LO (
" )
W
TURN SIGNAL SWITCH
Color
Position
L
PUSH
R
Lg
ENGINE STOP SWITCH
Color
Position
OFF (
# )
RUN (
$ )
O/B
Y
Lbl
O/W
Y/W
B
PUSH
HORN BUTTON
Color
Position
B/Bl B/W
PUSH
FRONT BRAKE LIGHT SWITCH
Color
Position
B/R
OFF
ON
B/Bl
REAR BRAKE LIGHT SWITCH
Color
Position
OFF
ON
O W/B
CLUTCH LEVER POSITION SWITCH
Color
Position
B/Y
OFF
ON
B/Y
WIRE COLOR
B : Black
Br : Brown
Lbl : Light blue
Lg : Light green
Gr : Gray O : Orange
B/BI : Black with Blue tracer
B/R : Black with Red tracer
B/W : Black with White tracer
B/Y : Black with Yellow tracer
O/B : Orange with Black tracer
O/R : Orange with Red tracer
O/W : Orange with White tracer
O/Y : Orange with Yellow tracer
W/B : White with Black tracer
Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
R : Red
W : White
Y : Yellow
BATTERY
SPECIFICATIONS
Type designation
Capacity
1 Upper cover breather
2 Cathode plates
3 Stopper
4 Filter
YTX7L-BS
12 V, 21.6 kC (6 Ah)/10 HR
5 Terminal
6 Safety valve
7 Anode plates
8 Separator (Fiberglass plate)
INITIAL CHARGING
Filling electrolyte
• Remove the aluminum tape 1 sealing the battery electrolyte filler holes A .
NOTE:
When filling electrolyte, the battery must be removed from the motorcycle and must be put on the level ground.
• 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 4 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.
• Make sure air bubbles 5 are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
ELECTRICAL SYSTEM 9-37
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 20 minutes.
• Insert the caps 6 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
INCORRECT
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.
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 the 12.0 V (DC) and less, recharge the battery with a battery charger.
A Charging period
B Stop charging
* When recharging the battery, remove the battery from the motorcycle.
* Do not remove the caps on the battery top while recharging.
Recharging time: 3 A for 1 hour or 0.7 A for 5 to 10 hours
Be careful not to permit the charging current to exceed 3 A at any time.
• After recharging, wait for 30 minutes and more and check the battery voltage with a multi circuit tester.
• If the battery voltage is the 12.5 V and less, recharge the battery again.
• If battery voltage is still 12.5 V and less, 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.
12
11
10
(V)
14
13
(at 0 – 40 ˚C)
100 75 50 25
Battety charged condition
0 (%)
SERVICING INFORMATION
SERVICING INFORMATION 10-1
CONTENTS
FI SYSTEM MALFUNCTION CODE AND
DEFECTIVE CONDITION.................................................................... 10- 2
WIRING HARNESS, CABLE AND HOSE ROUTING................................ 10-12
WIRING HARNESS ROUTING............................................................ 10-12
THROTTLE CABLE ROUTING ........................................................... 10-15
SPEEDOMETER CABLE ROUTING................................................... 10-16
FRONT BRAKE HOSE ROUTING ...................................................... 10-17
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................... 10-18
CYLINDER HEAD RUBBER PAD INSTALLATION.................................. 10-19
EXHAUST SYSTEM CONSTRUCTION..................................................... 10-19
THROTTLE BODY AND FUEL PUMP INSTALLATION ........................... 10-20
REAR BRAKE PEDAL INSTALLATION ................................................... 10-21
TORQUE LINK INSTALLATION................................................................ 10-21
SIDE-STAND INSTALLATION .................................................................. 10-22
FRONT TURN SIGNAL LIGHT INSTALLATION....................................... 10-23
REAR TURN SIGNAL LIGHT INSTALLATION......................................... 10-23
FI SYSTEM AND INTAKE AIR SYSTEM ............................................ 10-28
TIGHTENING TORQUE CHART ......................................................... 10-29
10
10-2 SERVICING INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
(
4-26 to -28)
ENGINE
Complaint
Engine will not start or is hard to start.
Symptom and possible causes
Compression too low
1. Valve clearance out of adjustment
2. Worn valve guides or poor seating of valves
3. Mistiming valves
4. Excessively worn piston rings
5. Worn-down cylinder bore
6. Too slowly starter motor cranks
7. Poor seating of spark plug
Plug not sparking
1. Fouled spark plug
2. Wet spark plug
3. Defective ignition coil
4. Defective CKP sensor
5. Defective ECM
6. Open-circuited wiring connections
No fuel reaching the intake manifold
1. Clogged fuel mesh filter or fuel hose
2. Defective fuel pump
3. Defective fuel pressure regulator
4. Defective fuel injector
5. Defective ECM
6. Open-circuited wiring connections
Incorrect fuel/air mixture
1. TP sensor out of adjustment
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 ET sensor
9. Defective IAT sensor
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Remedy
Adjust.
Repair or replace.
Adjust.
Replace.
Replace.
See electrical section.
Retighten.
Clean.
Clean and dry.
Replace.
Replace.
Replace.
Repair or replace.
SERVICING INFORMATION 10-3
Complaint Symptom and possible causes
Engine idles poorly.
1. Valve clearance out of adjustment
2. Poor seating of valves
3. Defective valve guides
4. Worn rocker arms or cam surfaces
5. Too wide spark plug gap
6. Defective ignition coil
7. Defective CKP sensor
8. Defective ECM
9. Defective TP sensor
10. Defective fuel pump
Engine stalls often.
Incorrect fuel/air mixture
1. Defective IAP sensor or circuit
2. Clogged fuel mesh filter
3. Defective fuel pump
4. Defective fuel pressure regulator
5. Defective ET sensor
6. Defective IAT sensor
Fuel injector improperly operating
1. Defective fuel injector
2. No injection signal from ECM
3. Open or short circuited wiring connection
4. Defective battery or low battery voltage
Control circuit or sensor improperly operating
1. Defective ECM
2. Defective fuel pressure regulator
3. Defective TP sensor
4. Defective IAT sensor
5. Defective CKP sensor
6. Defective ET sensor
Engine internal parts improperly operating
1. Fouled spark plug
2. Defective CKP sensor or ECM
3. Clogged fuel hose
4. Valve clearance out of adjustment
Remedy
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Repair or replace.
Replace or recharge.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Clean.
Adjust.
10-4 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 rocker arms or cam surfaces
4. Worn and burnt camshaft journal bearings
Noise seems to come from piston
1. Worn down piston or cylinder
2. Carbon combustion chamber fouled with carbon
3. Worn piston pin or piston pin bore
4. Worn piston rings or ring grooves
Noise seems to come from timing chain
1. Stretched chain
2. Worn sprockets
3. Tension adjuster not working
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
Noise seems to come from crankshaft
1. Rattling bearings due to wear
2. Worn and burnt big-end bearing
3. Worn and burnt journal bearings
4. Too large thrust clearance
Noise seems to come from balancer
1. Weakened balancer driven gear springs
Noise seems to come from transmission
1. Worn or rubbing gears
2. Worn splines
3. Worn or rubbing primary gears
4. Worn bearings
Adjust.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Remedy
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
SERVICING INFORMATION 10-5
Complaint
Engine runs poorly in high speed range.
Symptom and possible causes
Defective engine internal/electrical parts
1. Weakened valve springs
2. Worn camshaft
3. Valve timing out of adjustment
4. Too narrow spark plug gap
5. Ignition not advanced sufficiently due to poorly working timing advance circuit
6. Defective ignition coil
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 STVA
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. Defective STP sensor or STVA
Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective IAP sensor
6. Defective ECM
7. TP sensor out of adjustment
8. Defective STP sensor and/or STVA
Replace.
Replace.
Adjust.
Adjust.
Replace ECM.
Replace.
Replace.
Replace.
Clean.
Clean and prime.
Replace.
Replace.
Replace.
Remedy
Replace.
Adjust or replace.
Adjust or replace.
Retighten or replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
10-6 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. Valve timing out of adjustment
4. Worn piston rings or cylinder
5. Poor seating of valves
6. Fouled spark plug
7. Incorrect spark plug
8. Clogged fuel injector
9. TP sensor out of adjustment
10. Clogged air cleaner element
11. Sucking air from throttle body joint
12. Too much engine oil
13. Defective fuel pump or ECM
14. Defective CKP sensor or ignition coil
15. Defective STP sensor or STVA
Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective IAP sensor
6. Defective ECM
7. TP sensor out of adjustment
8. Defective STP sensor and/or STVA
Remedy
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Adjust or replace.
Replace.
Adjust.
Replace.
Retighten or replace.
Drain out excess oil.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
SERVICING INFORMATION 10-7
Complaint
Engine overheats
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
Defective engine internal parts
1. Heavy carbon deposit on piston crown
2. Not enough oil in the engine
3. Defective oil pump or clogged oil circuit
4. Sucking air from throttle body joint
5. Use incorrect engine oil
Lean fuel/air mixture
1. Short-circuited IAP sensor/lead wire
2. Short-circuited IAT sensor/lead wire
3. Sucking air from throttle body joint
4. Defective fuel injector
5. Defective ET sensor
Other factors
1. Ignition timing is too advanced due to defective timing advance system (ET sensor, CKP sensor and ECM).
2. Drive chain is too tight.
1. Too much engine oil in the engine
2. Worn piston rings or cylinder
3. Worn valve guides
4. Scored or scuffed cylinder wall
5. Worn valve stems
6. Defective valve stem seals
7. Worn oil ring side rails
1. Clutch cable out of adjustment
2. Weakened clutch springs
3. Worn or distorted pressure plate
4. Distorted clutch plates or pressure plate
1. Clutch out of adjustment
2. Some clutch spring weakened while others are not.
3. Distorted pressure plate or clutch plates
1. Broken gearshift cam
2. Distorted gearshift forks
3. Worn gearshift pawl
1. Broken return spring on gearshift shaft
2. Rubbing or stickily gearshift shaft
3. Distorted or worn gearshift forks
1. Worn shifting gears on driveshaft or countershaft
2. Distorted or worn gearshift forks
3. Weakened gearshift cam stopper spring
4. Worn gearshift cam stopper plate or gearshift pawl
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Remedy
Clean.
Add oil.
Replace or clean.
Retighten or replace.
Change.
Repair or replace.
Repair or replace.
Retighten or replace.
Replace.
Replace.
Replace.
Adjust.
Check with inspection window, drain out excess oil.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Replace.
10-8 SERVICING INFORMATION
CHASSIS
Complaint
Heavy steering
Wobbly handlebars 1. Loss of balance between right and left front forks
2. Distorted front fork
3. Distorted front axle or crooked tire
4. Loose steering stem nut
5. Worn or incorrect tire or wrong tire pressure
6. Worn bearing/race in steering stem
Wobbly front wheel 1. Distorted wheel rim
2. Worn front wheel bearings
3. Defective or incorrect tire
4. Loose front axle or axle pinch bolt
5. Incorrect front fork oil level
6. Incorrect front wheel weight balance
Front suspension too soft
Symptom and possible causes
1. Overtightened steering stem nut
2. Broken bearing in steering stem
3. Distorted steering stem
4. Not enough pressure in tires
Front suspension too stiff
Noisy front suspension
Wobbly rear wheel
Rear suspension too soft
1. Weakened springs
2. Not enough fork oil
3. Wrong weight fork oil
1. Too viscous fork oil
2. Too much fork oil
3. Bent front axle
1. Not enough fork oil
2. Loose bolts on suspension
1. Distorted wheel rim
2. Worn rear wheel bearings
3. Defective or incorrect tire
4. Loosen rear axle nut
5. Worn swingarm pivot bushings
6. Loose nuts on rear suspension
7. Incorrect rear wheel weight balance
1. Weakened shock absorber springs
2. Leakage of oil from shock absorber
3. Improperly set rear spring pre-load adjuster
Rear suspension too stiff
Noisy rear suspension
1. Bent shock absorber shaft
2. Bent swingarm pivot shaft
3. Worn swingarm pivot bushings and shock absorber bushings
4. Improperly set rear spring pre-load adjuster
1. Loose nuts on rear suspension
2. Worn swingarm pivot bushings and shock absorber bushings
Adjust.
Retighten.
Replace.
Remedy
Adjust.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Adjust.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Retighten.
Adjust.
Adjust.
Replace.
Replenish.
Replace.
Replace.
Drain excess oil.
Replace.
Replenish.
Retighten.
Replace.
Replace.
Replace.
Retighten.
Replace.
Retighten.
Adjust.
Replace.
Replace.
Adjust.
Replace.
Replace.
Replace.
SERVICING INFORMATION 10-9
BRAKES
Complaint
Insufficient brake power (Front)
Insufficient brake power (Rear)
Brake squeaking
(Front)
Brake squeaking
(Rear)
Excessive brake lever stroke
(Front)
Symptom and possible causes
1. Leakage of brake fluid from hydraulic system
2. Worn disc or pads
3. Friction surfaces of pad are dirty with oil or dust
4. Air in hydraulic system
5. Not enough brake fluid in the reservoir
1. Worn drum or shoes
2. Excessive brake pedal play
3. Friction surfaces of shoes are dirty with oil or dust
1. Carbon adhesion on pad surface
2. Tilted pad
3. Damaged wheel bearings
4. Loosen front wheel axle
5. Worn pads
6. Foreign material in brake fluid
7. Clogged return port of master cylinder
1. Carbon adhesion on shoe surface
2. Tilted shoe
3. Damaged wheel bearings
4. Loosen rear axle nut
5. Brake shoe surface glazed
6. Worn shoes
1. Air in hydraulic system
2. Insufficient brake fluid
Excessive brake pedal stroke
(Rear)
3. Improper quality of brake fluid
1. Worn brake cam lever
2. Excessively worn drum or shoes
3. Incorrect adjustment of rear brake
Leakage of brake fluid (Front)
1. Insufficient tightening of connection joints
2. Cracked hose
3. Worn piston and/or cup
Brake drags (Front) 1. Rusty part
2. Insufficient brake lever pivot lubrication
Brake drags (Rear) 1. Rusty part
2. Insufficient brake pedal pivot lubrication
3. Broken brake shoe springs
4. Incorrect adjustment of rear brake
Remedy
Repair or replace.
Replace.
Clean disc/pads or replace.
Bleed air.
Replenish.
Replace.
Adjust.
Clean drum/shoes or replace.
Repair surface with sandpaper.
Correct pad fitting or replace.
Replace.
Retighten.
Replace.
Replace brake fluid.
Disassemble and clean master cylinder.
Repair surface with sandpaper.
Correct shoe fitting or replace.
Replace.
Retighten.
Repair surface with sandpaper.
Replace.
Bleed air.
Replenish fluid to specified level; bleed air.
Replace with correct fluid.
Replace.
Replace.
Adjust.
Tighten to specified torque.
Replace.
Replace piston and/or cup.
Clean and lubricate.
Lubricate.
Clean and lubricate.
Lubricate.
Replace.
Adjust.
10-10 SERVICING INFORMATION
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.
Symptom and possible causes
1. Defective ignition coil
2. Defective spark plug
3. Defective CKP sensor
4. Defective ECM
5. Defective TO sensor
6. Open-circuited wiring connections
1. Mixture too rich
2. Idling speed set too high
3. Incorrect gasoline
4. Dirty air cleaner element
5. Too cold spark plug
1. Worn piston rings
2. Worn piston or cylinder
3. Excessive clearance of valve stems in valve guides
4. Worn valve stem seals
1. Too hot spark plug
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
Inspect FI system.
Adjust air screw.
Change.
Replace.
Replace with hot type plug.
Replace.
Replace.
Replace.
Remedy
2. Overheated engine
3. Loose spark plug
4. Too lean mixture
1. Open- or short-circuited lead wires, or loose lead connections
2. Short-circuited, grounded or open generator coil
3. Short-circuited or punctured regulator/rectifier
1. Lead wires tend to get shorted or open-circuited or loosely connected at terminals.
2. Grounded or open-circuited generator coil
3. Defective regulator/rectifier
4. Defective cell plates in the battery
1. Internal short-circuit in the battery
2. Damaged or defective regulator/rectifier
3. Poorly grounded regulator/rectifier
1. Lead wire insulation frayed due to vibration, resulting in intermittent short-circuiting.
2. Internally shorted generator
3. Defective regulator/rectifier
1. Run down battery
2. Defective switch contacts
3. Brushes not seating properly on starter motor commutator
4. Defective starter relay/starter interlock switch
5. Defective main fuse
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.
Clean and tighten ground connection.
Repair or replace.
Replace.
Replace.
Repair or replace.
Replace.
Repair or replace.
Replace.
Replace.
SERVICING INFORMATION 10-11
BATTERY
Complaint
“Sulfation”, acidic white powdery substance or spots on surface of cell plates
Battery runs down quickly.
Battery “sulfation”
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. Trouble in the charging system
2. Cell plates have lost much of their active material as a result of overcharging.
3. Internal short-circuit in the battery
4. Too low battery voltage
5. Too old battery
1. Incorrect charging rate
(When not in use batteries should be checked at least once a month to avoid sulfation.)
2. The battery was left unused in a cold climate for too long.
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.
Replace the battery if badly sulfated.
10-12 SERVICING INFORMATION
WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING
Clamp
Handlebar switch (RH)
Clamp
Wiring harness *4
*1
Clamp
Rear turn signal (RH)
*1, *6
Handlebar switch (LH)
Clamp
*1
*3 *5
Wiring harness
Rear turn signal (LH)
Rear combination
Clamp
Clamp
Wiring harness
Clutch cable
Guide
Wiring harness
Clutch cable
*2
Clamp
Wiring harness
STVA
STP sensor
Clamp
Clamp
Wiring harness
Generator
Neutral switch
Side-stand switch
20 mm
(0.8 in)
*6
*7
Wiring harness
Starter motor
Clamp
8 N.m (0.8 kgf-m, 6.0 lbf-ft)
1 ECM
2 Relay (Check or Main)
3 Regulator/Rectifier
4 Taping clamp
5 Wiring harness
6 Clutch cable
*1 Cut off the excess end of clamp.
*2
The tip of clamp must face upward.
*3 Pass the wiring harness outside of the air cleaner bracket.
*4
Set the fuel pump coupler at the right side of IAT sensor.
Do not pinch the fuel pump lead wire coupler between the fuel tank and frame, when installing the fuel tank.
*5
Pass the neutral switch lead wire and generator lead wire inside of the air cleaner bracket.
*6
Before clamping the lead wire, draw the protector tube to the rear turn signal lead wire coupler.
*7 Pass every wiring harness inside of the relay.
Clamp
Wiring harness
Speedometer
White tape
SERVICING INFORMATION 10-13
Clamp
Ignition switch
Handlebar switch (LH & RH)
Turn signal (LH & RH)
Clamp
Starter motor
Throttle cables
*2
*1
*3
*4
Clamp
*5
Brake light switch
Battery +
Clamp
Starter motor
Clamp
Fender brace
Rear fender
Weld clamp
*8
*7
*6
Rear combination light
Grommet
15 – 20 mm
(0.6 – 0.8 in)
1 Horn lead wire
2 HO2 sensor coupler
3 Rear combination socket
*3 Pass the wiring harness outside of the battery
*4
lead wire.
Pass the HO2 sensor lead wire and brake light switch lead wire in front of the bridge.
4 Rear combination light lead wire *5 Pass the HO2 sensor lead wire into the hook of battery holder.
*1
*2
Pass the starter motor lead wire most up.
Pass the wiring harness outside of the battery + lead wire.
*6 Do not contact the ground lead wire and bracket.
*7
Cut off the excess end of clamp. The end of clamp must face upward.
*8 Do not slack the rear combination light lead wire.
10-14 SERVICING INFORMATION
160 N.m (16.0 kgf-m, 115.5 lbf-ft)
*1
*2
*5
*3
0 ± 10˚
*4
1 Generator lead wire
2 Battery terminal
3 Clamp
4 Neutral switch
5 CKP sensor
6 Stator coil
7 Stator coil lead wire
8 Clamp
9 Generator cover
*1 Pass the generator lead wire inside of the breather hose.
*2 Contact the battery terminal onto the crankcase.
*3 Bent the oil seal retainer.
*4
Pass the stator coil lead wire between the boss and rib.
Do not pinch the stator coil lead wire with the clamp, boss and rib.
*5
Do not pinch the stator coil lead wire with the boss of generator cover and CKP sensor.
THROTTLE CABLE ROUTING
*1
*2
SERVICING INFORMATION 10-15
*3
0 mm
(0 in)
0 mm
(0 in)
90˚
1 Throttle cable No.1
2 Throttle cable No.2
3 Starter motor lead wire
4 Cable guide
5 Clutch cable
6 Clutch release arm
7 Clutch cable stopper
*4
8 Wiring harness
*1 Pass the throttle cable No.2 over the throttle cable No.1.
*2 Pass the throttle cables outside of the brake hose.
*3 Pass the throttle cable No.1 under the throttle cable No.2.
*4
Set the protector of clutch cable inside of the cable guide.
Pass the clutch cable outside of the wiring harness.
10-16 SERVICING INFORMATION
SPEEDOMETER CABLE ROUTING
FWD
45 ± 15˚
*1
90 ± 5˚
90 ± 5˚
1 Front fork
2 Brake hose
3 Speedometer cable
4 Cable guide
5 Clamp
6 Cable guide
7 Speedometer gearbox
1*
Bind the speedometer cable and hose guide with the clamp.
Cut off the excess end of clamp.
FRONT BRAKE HOSE ROUTING
*1
SERVICING INFORMATION 10-17
*2
20 – 30˚
*2
1 Throttle cable No.1
2 Throttle cable No.2
3 Speedometer cable
4 Clamp
5 Brake hose
6 Clamp
*4
*3
7 Front fender
*1 Do not contact the brake hose and upper bracket.
*2 Attach the brake hose to the hose guide firmly.
*3
After the brake hose union has contacted the stopper, tighten the union bolt.
*4 Insert the hose clamp to the hole of front fender firmly.
10-18 SERVICING INFORMATION
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
*1
0 – 2 mm
(0 – 0.08 in)
*3
*2
10 N.m
(1.0 kgf-m, 7.0 lbf-ft)
1 Match mark (White)
2 Match mark (Yellow)
3 PAIR control solenoid valve
*1 Do not clamp the clip at the nipple of PAIR pipe.
*2 To air cleaner
*3 To PAIR pipe
CYLINDER HEAD RUBBER PAD INSTALLATION
SERVICING INFORMATION 10-19
DIRECTION OF RUBBER
PAD INSERT
DIRECTION
OF RUBBER
PAD INSERT
NOTE:
Insert the rubber pads at 0 – 4 mm (0 – 0.16 in) depth from the fin ends.
A 40 mm (1.6 in)
B 46 mm (1.8 in)
C 118 – 122 mm (4.6 – 4.8 in)
D 32 – 34 mm (1.26 – 1.34 in)
E 70.5 – 72.5 mm (2.78 – 2.85 in)
EXHAUST SYSTEM CONSTRUCTION
50 N.m (5.0 kgf-m, 36.0 lbf-ft)
23 N.m (2.3 kgf-m, 16.5 lbf-ft)
25 N.m
(2.5 kgf-m,
18.0 lbf-ft)
23 N.m
(2.3 kgf-m, 16.5 lbf-ft)
23 N.m
(2.3 kgf-m, 16.5 lbf-ft)
1 Exhaust pipe gasket
2 Exhaust pipe cover
3 HO2 sensor
*1
4 N.m (0.4 kgf-m, 3.0 lbf-ft)
20 – 30˚
4 Muffler connector
5 Muffler cover
*1 The tip of clamp must face inside of the exhaust pipe cover.
10-20 SERVICING INFORMATION
THROTTLE BODY AND FUEL PUMP INSTALLATION
10 N.m (1.0 kgf-m, 7.0 lbf-ft)
3
5
1, 6
*1
2
4
10 N.m (1.0 kgf-m, 7.0 lbf-ft)
UP
45˚
6 N.m
(0.6 kgf-m, 4.5 lbf-ft)
UP
10 – 20˚
1 Fuel feed hose
2 Match mark (White)
3 Fuel pump
4 Throttle body
5 Intake pipe
6 Outlet tube clamp
*1
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.
REAR BRAKE PEDAL INSTALLATION
SERVICING INFORMATION 10-21
1 Rear brake pedal
2 Rear brake rod
3 Rear brake cam lever
4 Rear brake adjuster nut
5 Cotter pin
A 20 mm (0.8 in)
B 30 mm (1.2 in)
C 65.5 mm (2.58 in)
TORQUE LINK INSTALLATION
D 90 mm (3.5 in) a Free travel adjustable range
16 N.m
(1.6 kgf-m, 11.5 lbf-ft)
16 N.m
(1.6 kgf-m, 11.5 lbf-ft)
1 Torque link 2 Swingarm 3 Brake panel
10-22 SERVICING INFORMATION
SIDE-STAND INSTALLATION
55 N.m
(5.5 kgf-m, 40.0 lbf-ft)
50 N.m
(5.0 kgf-m, 36.0 lbf-ft)
FRONT TURN SIGNAL LIGHT INSTALLATION
SERVICING INFORMATION 10-23
13 N.m
(1.3 kgf-m, 9.5 lbf-ft)
1 Front turn signal light 2 Headlight bracket
REAR TURN SIGNAL LIGHT INSTALLATION
*1
*1
UP
15 N.m
(1.5 kgf-m, 11.0 lbf-ft)
13 N.m
(1.3 kgf-m, 9.5 lbf-ft)
1 Rear fender
2 Rear turn signal bracket
3 Clamp
4 Rear turn signal light
1*
After the edge of bracket has contacted the frame, tighten the bracket mounting bolt.
10-24 SERVICING INFORMATION
SPECIAL TOOLS
09900-06107
Snap ring remover
(Open type)
09900-18710
Hexagon socket
(12 mm)
09900-20101
Vernier calipers
(150 mm)
09900-20202
Micrometer
(25 – 50 mm)
09900-20203
Micrometer
(50 – 75 mm)
09900-20205
Micrometer
(0 – 25 mm)
09900-20530
Cylinder gauge set
09900-20602
Dial gauge
09900-20605
Dial calipers
(10 – 34 mm)
09900-20607
Dial gauge
09900-20701
Dial gauge chuck
09900-20803
Thickness gauge
09900-20805
Tire depth gauge
09900-21304
V blocks
09900-22403
Small bore gauge
(18 – 35 mm)
09900-25008
Multi circuit tester set
09900-25009
Needle-point probe set
09900-26006
Engine tachometer
09900-28630
TP Sensor lead
09904-41010
SUZUKI Diagnostic system set
09910-20116
Connecting rod stopper
09910-32812
Crankshaft installer
09910-32840
Crankshaft installer adaptor
09910-34510
Piston pin puller
09913-50121
Oil seal remover
SERVICING INFORMATION 10-25
09913-70210
Bearing installer set (10 – 75
)
09915-63210
Compression gauge adaptor
09915-64512
Compression gauge
09915-74511
Oil pressure gauge (600 kPa)
09916-10911
Valve lapper set
09916-14510
Valve lifter
09916-14910
Valve lifter attachment
09916-34542
Reamer handle
09916-34550
Valve guide reamer (5.5 mm)
09916-34561
Valve guide reamer (11.3 mm)
09916-44910
Valve guide installer & remover
09916-84511
Tweezer
09917-14910
Tappet adjust driver
09917-47011
Vacuum pump gauge set
09920-13120
Crankshaft remover
09920-31020
Extension handle
09920-53740
Clutch sleeve hub holder
09921-20240
Bearing remover set
09923-74511
Bearing remover
09924-84510
Bearing installer set
09924-84521
Bearing installer set
09930-10121
Spark plug wrench set
09930-11920
Torx bit (JT40H)
09930-11940
Torx bit holder
09930-11950
Torx wrench
(5 mm)
10-26 SERVICING INFORMATION
09930-30104
Rotor remover sliding shaft
09930-34960
Rotor remover
09930-44521
Rotor holder
09930-82720
Mode selection switch
09940-14911
Steering stem nut socket wrench
09940-30230
Hexagon socket
(17 mm)
09940-34520
T type handle
09940-34561
Front fork assembling attachment (D)
09940-40211
Fuel pressure gauge adaptor
09940-40220
Fuel pressure gauge attachment
09940-52861
Front fork oil seal installer set
09940-60113
Spoke nipple wrench
09941-34513
Bearing installer
09941-50111
Wheel bearing remover set
09941-54911
Bearing outer race remover
09941-74911
Steering race installer
09943-74111
Front fork oil level gauge
99565-01010-020
CD-ROM Ver.20
NOTE:
When order the special tool, please confirm whether it is available or not.
SERVICING INFORMATION 10-27
TIGHTENING TORQUE
ENGINE
ITEM
Engine mounting bolt
Engine mounting upper plate nut
Engine mounting lower plate nut
Exhaust pipe bolt
Muffler mounting bolt
Muffler connecting bolt
Exhaust pipe cover screw
Cylinder head cover bolt/nut
Cylinder head nut
Camshaft sprocket bolt
Primary drive gear nut
Crank balancer bolt
Cam chain tension adjuster bolt
Cam chain tensioner bolt
Generator rotor nut
Starter clutch bolt
TDC plug
Generator cover plug
Valve clearance adjusting screw lock-nut
Oil gallery plug
Oil drain plug
Engine sprocket nut
Clutch sleeve hub nut
Clutch spring set bolt
Clutch cover bolt
Crankcase bolt
Generator cover bolt
PAIR pipe bolt/nut
Oil pump mounting bolt
Spark plug
Gearshift cam stopper plug
Gearshift arm stopper
Gearshift lever mounting bolt
Front
Rear
(M6)
(M5)
11
6
10
10
55
10
11
11
18
23
19
10
100
40
10
10
160
26
21
15
15
23
23
90
23
23
50
23
N·m
41
40
28
4
11
37
10
40.0
7.0
8.0
8.0
8.0
4.5
7.0
7.0
13.0
16.5
13.5
7.0
72.5
29.0
7.0
7.0
115.5
19.0
15.0
11.0
11.0
16.5
16.5
65.0
lbf-ft
29.5
29.0
20.0
16.5
16.5
36.0
16.5
3.0
8.0
27.0
7.0
1.1
0.6
1.0
1.0
5.5
1.0
1.1
1.1
1.8
2.3
1.9
1.0
10.0
4.0
1.0
1.0
16.0
2.6
2.1
1.5
1.5
2.3
2.3
9.0
kgf-m
4.1
4.0
2.8
2.3
2.3
5.0
2.3
0.4
1.1
3.7
1.0
10-28 SERVICING INFORMATION
FI SYSTEM AND INTAKE AIR SYSTEM
ITEM
Air cleaner box mounting bolt
Air cleaner box lower mounting bolt
Fuel pump mounting bolt
TP sensor mounting screw
STP sensor mounting screw
ET sensor
HO2 sensor
CHASSIS
ITEM
Steering stem head bolt
Steering stem nut
Front fork cap bolt
Front fork upper clamp bolt
Front fork lower clamp bolt
Front axle
Front axle pinch bolt
Handlebar clamp bolt
Front brake hose union bolt
Front brake caliper air bleeder valve
Front brake caliper mounting bolt
Front brake disc bolt
Front brake master cylinder holder bolt
Front brake lever pivot bolt
Front brake lever pivot bolt lock-nut
Rear brake cam lever nut
Clutch lever holder bolt
Rear sprocket nut
Rear axle nut
Swingarm pivot nut
Torque link nut (Front & Rear)
Damper rod bolt
Rear shock absorber nut (Upper and Lower)
Front footrest bolt
Side-stand nut
Side-stand bolt
Side-stand switch mounting bolt
Seat rail bolt (M8)
(M12)
Spoke nipple
Regulator/rectifier mounting bolt
Turn signal light mounting nut (Front & Rear)
Rear turn signal bracket mounting bolt
N·m
10
6
10
3.5
3.5
18
25 kgf-m
1.0
0.6
1.0
0.35
0.35
1.8
2.5
lbf-ft
7.0
4.5
7.0
2.5
2.5
13.0
18.0
50
8
26
85
20
29
39
55
3
10
13
15
60
65
65
16
6
6
10
10
N·m
65 kgf-m
6.5
lbf-ft
47.0
45 N·m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/4 – 1/2
23 2.3
16.5
23
33
2.3
3.3
16.5
24.0
7.5
39
23
10
65
23
16
23
6.5
2.3
1.6
2.3
0.75
3.9
2.3
1.0
47.0
16.5
11.5
16.5
5.5
28.0
16.5
7.0
0.6
0.6
1.0
1.0
6.0
6.5
6.5
1.6
2.0
2.9
3.9
5.5
5.0
0.8
2.6
8.5
0.3
1.0
1.3
1.5
14.5
21.0
28.0
40.0
36.0
6.0
19.0
61.5
4.5
4.5
7.0
7.0
43.5
47.0
47.0
11.5
2.0
7.0
9.5
11.0
SERVICING INFORMATION 10-29
TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:
Bolt Diameter
A (mm)
10
12
14
16
18
6
8
4
5
Conventional or “4” marked bolt
N·m kgf-m lbf-ft
1.5
3
0.15
0.3
1.0
2.0
5.5
13
29
45
0.55
1.3
2.9
4.5
4.0
9.5
21.0
32.5
65
105
160
6.5
10.5
16.0
47.0
76.0
115.5
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
lbf-ft
1.5
3.0
7.0
16.5
36.0
61.5
97.5
152.0
173.5
Conventional bolt “4” marked bolt “7” marked bolt
10-30 SERVICING INFORMATION
SERVICE DATA
VALVE + VALVE GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
Valve spring tension
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
STANDARD
34
(1.3)
29
(1.1)
0.03 – 0.08
(0.001 – 0.003)
0.08 – 0.13
(0.003 – 0.005)
0.025 – 0.052
(0.0010 – 0.0020)
0.040 – 0.067
(0.0016 – 0.0026)
5.500 – 5.512
(0.2165 – 0.2170)
5.460 – 5.475
(0.2150 – 0.2156)
5.445 – 5.460
(0.2144 – 0.2150)
—
—
—
—
0.9 – 1.1
(0.035 – 0.043)
—
—
185 – 219 N
(18.9 – 22.3 kgf, 41.7 – 49.2 lbs) at length 36.0 mm (1.42 in)
—
—
—
—
Unit: mm (in)
LIMIT
—
—
—
—
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
2.1
(0.08)
—
0.03
(0.001)
39.3
(1.55)
—
SERVICING INFORMATION 10-31
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
EX.
IN. & EX.
IN. & EX.
STANDARD
33.84 – 33.89
(1.332 – 1.334)
33.30 – 33.35
(1.311 – 1.313)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.983 – 11.994
(0.4718 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 200 – 1 400 kPa
(12 – 14 kgf/cm², 171 – 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
0.020 – 0.030
(0.0008 – 0.0012)
72.000 – 72.015
(2.8346 – 2.8352)
71.975 – 71.990
(2.8337 – 2.8342)
Measure at 10 mm (0.4 in) from the skirt end.
—
Piston ring free end gap
1st N Approx. 10.0 (0.39)
2nd N
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
1st N
2nd N
1st
2nd
1st
2nd
Oil
Approx. 11.0 (0.31)
0.10 – 0.22
(0.004 – 0.009)
0.22 – 0.34
(0.009 – 0.013)
—
—
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
Unit: mm (in)
LIMIT
850 kPa
(8.5 kgf/cm 2 ,
121 psi)
0.120
(0.0047)
Nicks or
Scratches
71.880
(2.8299)
0.05
(0.002)
8.0
(0.31)
8.8
(0.35)
0.50
(0.020)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
Unit: mm (in)
LIMIT
33.54
(1.320)
33.00
(1.299)
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
10-32 SERVICING INFORMATION
ITEM
Piston ring thickness
Piston pin bore I.D.
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
1st
2nd
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
0.975 – 0.990
(0.0384 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
18.002 – 18.008
(0.7087 – 0.7090)
17.992 – 18.000
(0.7083 – 0.7087)
STANDARD
18.006 – 18.016
(0.7089 – 0.7093)
—
0.10 – 0.65
(0.004 – 0.026)
20.95 – 21.00
(0.825 – 0.827)
59.9 – 60.1
(2.36 – 2.37)
—
STANDARD
30 – 70 kPa
(0.3 – 0.7 kgf/cm², 4.3 – 10.0 psi) at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
No. 1
No. 2
No. 1 and 2
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)
—
43.0
(1.69)
LIMIT
—
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.59)
0.10
(0.004)
40.9
(1.61)
LIMIT
—
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
LIMIT
18.040
(0.7102)
3.0
(0.12)
1.0
(0.04)
—
—
0.080
(0.0031)
SERVICING INFORMATION 10-33
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Shift fork to groove clearance
No. 1, 2 and 3
Shift fork groove width
No. 1, 2 and 3
Shift fork thickness
Drive chain
No. 1, 2 and 3
Type
Links
20-pitch length
Drive chain slack (on side-stand)
STANDARD
3.238 (68/21)
2.866 (43/15)
2.636 (29/11)
1.687 (27/16)
1.200 (24/20)
0.952 (20/21)
0.818 (18/22)
0.20 – 0.40
(0.008 – 0.016)
4.25 – 4.35
(0.167 – 0.171)
3.95 – 4.05
(0.156 – 0.159)
DID520V
108 links
—
10 – 20
(0.4 – 0.8)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.60
(0.024)
—
—
—
—
323.8
(12.75)
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating set pressure
SPECIFICATION
Approx. 10.5 Ω at 20 °C (68 °F)
Approx. 33.3 ml (1.13 US oz) and more/10 sec.
Approx. 294 kPa
(2.94 kgf/cm², 41.8 psi)
NOTE
10-34 SERVICING INFORMATION
FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor output voltage
ET sensor input voltage
ET sensor output voltage
ET sensor resistance
IAT sensor input voltage
IAT sensor output voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
Fuel injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor output voltage
STV actuator resistance
PAIR control solenoid valve resistance
HO2 sensor output voltage
HO2 sensor resistance
SPECIFICATION
420 – 620
Ω
2.0 V and more (When cranking)
4.5 – 5.5 V
Closed
Opened
1.5 – 3.5 V at idle speed
4.5 – 5.5 V
Approx. 0.6 V
Approx. 3.8 V
4.5 – 5.5 V
0.1 – 4.6 V
1.95 – 4.18 k
Ω
at 20 – 40 °C (68 – 104 °F)
4.5 – 5.5 V
0.15 – 4.84 V
Normal
Approx. 2.45 k Ω at 20 °C (68 °F)
16.5 – 22.3 k
Ω
0.4 – 1.4 V
Leaning
65°
3.7 – 4.4 V
Battery voltage
200 V and more (When cranking)
Closed
Opened
4.5 – 5.5 V
Approx. 0.5 V
Approx. 3.9 V
Approx. 6.5
Ω
Approx. 22
Ω
at 20 °C (68 °F)
0.3 V and less at idle speed
0.6 V and more at 5 000 r/min
Approx. 8.0
Ω
at 23 °C (73 °F)
NOTE
Bl – G
+ : G – : Bl
+ : W/Bl –
: B/Br
+ : V –
: B/Br
+ : B/Bl –
: Ground
+ : Y/R –
: Ground
+ : Br –
: B/Br
+ : B –
: Ground
+ : Y –
: B
+ : B –
: Gr
W – W
SERVICING INFORMATION 10-35
THROTTLE BODY
ITEM
Bore size
I.D. No.
Fast idle r/min
Idle r/min
Throttle cable play
SPECIFICATION
32 mm
26GA
1 800 – 2 300 r/min
1 300 ± 100 r/min
2.0 – 4.0 mm
(0.08 – 0.16 in)
ELECTRICAL
Spark plug
ITEM
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(When engine is cold)
Starter motor brush length
Regulated voltage
Starter relay resistance
Battery Type designation
Fuse size
Capacity
Headlight
Horn
Ignition
Signal
ECM
Main
Type
Gap
SPECIFICATION
NGK: DR8EA
DENSO: X24ESR-U
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
420 – 620 Ω
2.0 V and more (When cranking)
Primary 2.9 – 4.1
Ω
Secondary 24.0 – 36.2 k Ω
200 V and more
0.1 – 1.5
Ω
60 V (AC) and more at 5 000 r/min
Standard
Limit
12 (0.47)
8.5 (0.33)
13.5 – 15.5 V at 5 000 r/min
2 – 6
Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
10 A
10 A
10 A
10 A
10 A
30 A
Unit: mm (in)
NOTE
Bl – G
+ : G – : Bl
+ Terminal –
Terminal
+ Terminal –
Plug cap
+ : B –
: Ground
B – B
10-36 SERVICING INFORMATION
WATTAGE
ITEM
Headlight
Brake light/Taillight
Turn signal light
Speedometer light
High beam indicator light
Neutral indicator light
Turn signal indicator light
Fuel injection indicator light
Fuel level indicator light
HI
LO
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake disc thickness
Brake disc runout
Brake drum I.D.
Brake master cylinder bore
Brake master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Wheel rim runout
Wheel rim size
Wheel axle runout
Front
Front
Rear
Front
Front
Front
Front
Axial
Radial
Front
Rear
Front
Rear
Unit: W
STANDARD/SPECIFICATION
60
55
21/5
21
1.7
1.7
3.4
1.7
3
3.4
STANDARD
20 – 30
(0.8 – 1.2)
20 – 30
(0.8 – 1.2)
4.8 – 5.2
(0.19 – 0.20)
—
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
30.230 – 30.306
(1.1902 – 1.1931)
30.150 – 30.200
(1.1870 – 1.1890)
—
—
18 × 1.85
18 M/C × MT 2.50
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
Unit: mm (in)
LIMIT
—
—
4.5
(0.18)
0.30
(0.012)
130.7
(5.15)
—
—
SERVICING INFORMATION 10-37
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Cold inflation tire pressure
(Dual riding)
Tire size
Tire type
Tire tread depth
(Recommended depth)
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD
175 kPa
(1.75 kgf/cm², 25 psi)
200 kPa
(2.00 kgf/cm², 29 psi)
175 kPa
(1.75 kgf/cm², 25 psi)
225 kPa
(2.25 kgf/cm², 33 psi)
90/90-18 M/C 51S
110/90-18 M/C 61S
CHENG SHIN C-6009
CHENG SHIN C-822
—
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring, outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork inner tube O.D.
Rear shock absorber spring adjuster
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
120
(4.7)
345.2
(13.59)
72
(2.8)
SUZUKI FORK OIL SS-08 or an equivalent fork oil
411 ml (13.9 US oz)
37
(1.5)
3/5 position
95
(3.7)
—
Unit: mm (in)
LIMIT
—
338
(13.3)
—
—
—
—
—
—
0.6
(0.02)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
10-38 SERVICING INFORMATION
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Including reserve
Fuel level indicator light lighting
12.0 L
(3.2 US gal)
Approx. 2.5 L
(0.7 US gal)
SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
1 400 ml
(1.5 US qt)
Filter change
Overhaul
1 500 ml
(1.6 US qt)
1 900 ml
(2.0 US qt)
NOTE
EMISSION CONTROL INFORMATION 11-1
EMISSION CONTROL INFORMATION
CONTENTS
EMISSION CONTROL SYSTEMS .............................................................. 11- 2
FUEL INJECTION SYSTEM................................................................. 11- 2
CRANKCASE EMISSION CONTROL SYSTEM.................................. 11- 3
EXHAUST EMISSION CONTROL SYSTEM........................................ 11- 4
HO2 SENSOR INSPECTION ............................................................... 11- 5
HO2 SENSOR REMOVAL AND INSTALLATION ............................... 11- 5
NOISE EMISSION CONTROL SYSTEM.............................................. 11- 5
PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL
PAIR REED VALVE ............................................................................. 11- 6
PAIR CONTROL SOLENOID VALVE.................................................. 11- 7
PAIR (AIR SUPPLY) SYSTEM DIAGRAM ................................................. 11- 9
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ...................................... 11- 9
11
11-2 EMISSION CONTROL INFORMATION
EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
TU250X 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. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC. Adjusting, interfering with, improper replacement, or resetting of any of the fuel injection components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission level limits.
1 Fuel tank
2 Fuel pressure regulator
3 Fuel delivery pipe
4 Fuel injector
5 Fuel feed hose
6 Fuel mesh filter
7 Fuel pump
A Pressurized fuel
B Before-pressurized fuel
C Relieved fuel
EMISSION CONTROL INFORMATION 11-3
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
1 PAIR control solenoid valve
2 PCV hose
A FRESH AIR
B FUEL/AIR MIXTURE
C EXHAUST GAS
D BLOW-BY GAS
E SEPARATED RETURN OIL
11-4 EMISSION CONTROL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of the PAIR system, HO2 sensor and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ETS, IATS, IAPS and CKPS.
1 PAIR control solenoid valve
2 PAIR reed valve
3 Air cleaner box
4 Fuel injector
5 ECM
6 Three-way catalyst
7 HO2 sensor
A FRESH AIR
B EXHAUST GAS
EMISSION CONTROL INFORMATION 11-5
HO2 SENSOR INSPECTION
(
4-64)
HO2 SENSOR REMOVAL AND INSTALLATION
(
4-72)
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following acts or the causing thereof:
1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated 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.
11-6 EMISSION CONTROL INFORMATION
PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM
INSPECTION
PAIR HOSES
• Inspect the PAIR hoses and PAIR pipe for wear or damage.
• Inspect the PAIR hoses and PAIR pipe for secure connection.
PAIR REED VALVE
REMOVAL
• Remove the PAIR control solenoid valve. (
11-7)
• Remove the PAIR reed valve cover 1 and PAIR reed valve
2 .
INSPECTION
• Inspect the reed valve for the carbon deposit.
• If the carbon deposit is found in the reed valve, replace the
PAIR reed valve with a new one.
INSTALLATION
• Install the PAIR reed valve 1 and PAIR reed valve cover 2 .
• Apply thread lock to the screws and tighten them securely.
99000-32110: THREAD LOCK SUPER “1322” or equivalent
• Install the PAIR control solenoid valve.
PCV HOSE
• Inspect the PCV hose for wear and damage.
• If it is worn or damaged, replace the PCV hose with a new one.
EMISSION CONTROL INFORMATION 11-7
PAIR CONTROL SOLENOID VALVE
REMOVAL
• Disconnect the PAIR control solenoid valve coupler 1 and
PAIR hose 2 .
• Disconnect the PAIR hose 3 and remove the PAIR control solenoid valve 4 .
NOTE:
PAIR control solenoid valve can be checked without removing it.
(
4-67)
11-8 EMISSION CONTROL INFORMATION
INSPECTION
• 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 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.
PAIR control solenoid valve resistance:
Approx. 22 Ω at 20 °C (68 °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
Installation is in the reverse order of removal.
• Connect the PAIR control solenoid valve coupler and PAIR hoses securely. (
10-18)
PAIR (AIR SUPPLY) SYSTEM DIAGRAM
EMISSION CONTROL INFORMATION 11-9
1 PAIR control solenoid valve
2 PAIR reed valve
3 Air cleaner
A FRESH AIR
B EXHAUST GAS
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
(
10-18)
WIRING DIAGRAM
Wiring diagrams wire color, refer to section “WIRE COLOR”.
CHECK
RELAY
HANDLEBAR SWITCH (RH)
SPEEDOMETER
ENGINE
STOP
SWITCH
OFF
RUN PUSH
STARTER
BUTTON
FRONT BRAKE
LIGHT SWITCH
OFF
ON
IGNITION SWITCH
ON
C
OFF
LOCK
REAR BRAKE
LIGHT SWITCH
ON
OFF
FUEL PUMP
M
IGNITION COIL
PAIR
CONTROL
SOLENOID
VALVE
STVA
DIODE
ECM
FRONT TURN SIGNAL LIGHT (RH)
Lg
B/W
HEADLIGHT
FRONT TURN SIGNAL LIGHT (LH)
B
B/W
B
B/W
Lg
B/W
Br
B/W
W/B
B
B/W
B
B/W
Br
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (RH)
REAR COMBINATION LIGHT
REAR TURN SIGNAL LIGHT (LH)
1
1: HEAD HI, LO 10 A
FUSE
BOX 1
HORN
2 3 4 5
PUSH
L
PUSH
HORN
R
BUTTON TURN SIGNAL
SWITCH
HI
LO
DIMMER
SWITCH
FREE
CLUTCH
LEVER
POSITION
SWITCH
2: HORN 10 A
3: IGNITION 10 A
FUSE
BOX 2
4: SIGNAL 10 A
5: ECU 10 A
FUSE
BOX 3
HANDLEBAR SWITCH (LH)
RELAY BOX
NEUTRAL
SWITCH
FREE
PUSH
SIDE-STAND
SWITCH
MAIN
RELAY
TP
SENSOR
STP
SENSOR
REGULATOR/
RECTIFIER
1
GENERATOR
STARTER
MOTOR
1: MAIN FUSE (30 A)
STARTER
RELAY
FUEL
INJECTOR
BATTERY
HO2
SENSOR
TO
SENSOR
ET
SENSOR
IAP SENSOR
IAT SENSOR
12
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Key Features
- 1. Compact and lightweight design for easy maneuverability
- 2. Fuel-efficient engine for economical rides
- 3. Comfortable upright riding position for enhanced comfort
- 4. Durable construction for long-lasting performance
- 5. Responsive handling for precise control
- 6. Stylish design that turns heads
- 7. Low maintenance requirements for hassle-free ownership
- 8. Affordable pricing for excellent value
- 9. Trusted Suzuki quality and reliability