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2001-2002 SUZUKI GSX-R600 SERVICE MANUAL 99500-35080-018 GROUP IND | GENERAL INFORMATION Ez a PERIODIC MAINTENANCE Bi | ENGINE El FI SYSTEM AND INTAKE AIR SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ma ELECTRICAL SYSTEM ra SERVICING INFORMATION | 8 | WIRING DIAGRAM za Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properiy pertorm 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. SUZUKI MOTOR CORPORATION Moto ycle Service Departme HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 41.The text of this manual is divided into sections. 2.The section titles are listed in the GROUP INDEX, 8.Holding the manual as shown at the right will allow you to find the first page of the saction easly 4.The contents are listed on the first page of each section to halp find the hem 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 tarque, lubricating points and locking agent paints, are provided. Example: Frant wheel / HHH ti t gE if ii i it Front iM |_Nem_| kghm a0 100 a | 2a 3 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic- log, The meaning of each symbol is also included in the table SYMBOL | DEFINTION | SYMBOL DEFINITION Torque control required. | Apply THREAD LOCK SUPER Data beside it indicates specified "1360" torque | 99000-32130 Apply oil. Use engine oil unless Use engine coolant A Aa otherwise spe 99000-89032-11K Apply molybdenum oll solution Use tork oil (Mixture of engine oll and SUZUKI 98000-89001-SS8 MOLY PASTE in a ratio of 1:1) (8000-38044-106) Apply SUZUKI SUPER GREASE “A” 98000-25010 Apply or use brake fiuid Agply SUZUKI MOLY PASTE. 99000-25140 Measure in voltage range. Apply SUZUKI BOND "12076". 99000-31140 Ee] A] Ee C Measure in current range. Apply SUZUKI BOND “1215 99000-31110 i Measure in diode test range, Apply THREAD LOCK SUPER 41303" 98000-32030 a Measure in continuity test range. Apply THREAD LOCK SUPER "1322" 98000-32110 B Use special tool, Apply THREAD LOCK "1342". 99000-32050 Indication of service data. ABBREVIATIONS MAY BE USED IN THIS MANUAL A ABDC After Bottom Dead Genter AG Alternating Current ACL Air Cleaner, Alt Cleaner Box APL American Petroleum Institute aATDG “Alter Top Deed Center ATM Pressure; Atmospheric Pressure Atmospheric Pressure Sensor (APS, AP Sensor} AF Alr Fue! Mixture 8 BBDC + Before Bottom Dead Canter BTDC + Belore Top Dead Center B Battery Positive Voltage c ‘KP Sensor: Crankshaft Position Sensor (CKPS) cK Circuit CLP Switch Clutch Lever Position Switch (Clutch: Swatch) GMP Sensor: Camshaft Position Sensoe (CMPS) co Carbon Monoxide cpu Central Processing Unit D pe Direct Currant DMG Dealer Mode Coupler DOHC Double Over Head Camshaft DAL : Daytime Running Light = ecm Engine Gontral Module - Engine Control Unit (ECU) (FI Contra Unit) ECT Sensor: Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) evap + Evaporative Emission EVAP Canister ; Evaporative Emission Canister (Canister) F Fi Fuel Injection, Fue! Injector FP =Fusl Pump FPR Fusl Pressure Regulator FP Relay Fuel Pump Relay 6 GEN Generator - GND Ground GP Switch Gear Prsition Switch H He : Hydrocarbons - ' IAP Sensor: Intake Air Pressure ‘Sensor (APS) WAT Sensor Intake Air Temperature Sensor (IATS) ie ‘Ignition L 4 Leo Liquid Crystal Display LED + Light Emitting Diode (Mattunction Indicator Lamp) tH Lett Hand - + MAL-Code Max MIL Min NOx onc ops FH ROM SAE STC System STC Unit STP Sensor ST Valve STV Actuator TO Sensor TP Sansor =; Maltunction Code (Diagnastic Code) : Maximum ¢Mttunction Indicator Lamp (LED) = Minimum Nitrogen Oxides : Over Head Camshatt + Oil Pressure Switch : Positive: Crankease Ventilation (Crankcase Breather) Right Hand Read Only Memory 2 Saciely of Automotive Engineers Secondary Thrattie Gontral System (sTes) © Secondary Throttis Gontrat Unit (STU) : Seoondary Throttle Position Sensor (sTPS) Secondary Throttle Valve (STV) Secondary Throttle Valve Actuator (sta) Tip Over Sensor (TOS) | Throttie Postion Sensor (TPS) GENERAL INFORMATION. 1-1 Ser ee ee ele) ——— CONTENTS WARNING/CAUTION/NOTE ..... GENERAL PRECAUTIONS .. SUZUKI GSX-R600K1 (2001-MODEL). SERIAL NUMBER LOCATION ......... ae FUEL, OIL AND ENGINE COOLANT RECOMMENDATION............ 1- FUEL, sossisssisei ENGINE OIL... BRAKE FLUID FRONT FORK OIL ENGINE COOLANT. WATER FOR MIXING ANTI-FREEZE/ENGINE COOLANT.. LIQUID AMOUNT OF WATER/ENGINE COOLANT BREAK-IN PROCEDURES... CYLINDER IDENTIFICATION INFORMATION LABELS SPECIFICATIONS ..... COUNTRY AND AREA CODES SVAAsAanHHnaaaeann 12 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. Ta emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention fo the mes- sages highlighted by these signal words. CeCOn Indicates a potential hazard that could result in death or injury. A CAUTION | Indicates potential hazard that could result in matoreyele damage. NOTE: Indicates special infoomation to make maintenance easier or instructions cleaves, Please note, havevet, that the warnings and cautions cantained in this: manual cannot possibly caver all potential hazards relating to the servicing, of 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 @ more experienced mechanic fat ad- wie 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 ig 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 well- ventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning salvent. * To avoid getting bumed, do not touch the engine, engine olf, radiator aid exhaust system until they have cooled. After servicing the fuel, oll, engine caolat tings related to the system for leaks. exhaust or brake systems, check all lines and tite GENERAL INFORMATION 13 (a CAUTION if ports repiacomont is necessary, replace the parts with Suzuki Genuine Parts or their equiva-_ Tent. When removing parts that are to be reused, keep them arranged in an arderly manner so that they may be reinstalled in the proper order. 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, connoct the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power: When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cater 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 tram the mating surfaces. | Nover reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to stip the circlip over the shaft. After installing a civelip, always ensure that it is | completely seated in its groove and securely fitted. Use a torque wrench to tighten fasteners to the specitied torque. Wipe off grease and oil if a thread Is smeared with them. After reassembling, check parts for tightness and proper operation. To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires. To protect the earth's natural resources, properly dispase of used motorcycles and parts, | 14 GENERAL INFORMATION SUZUKI GSX-R600K1 (2001-MODEL) * Dilarence berwoen photograph and actual metorcyeia depends on the markste SERIAL NUMBER LOCATION The frame serial number or VI.N. (Vehicle Identification Number) i is stamped on the right side of the steering head pipe. The engine serial number ‘B is located on the reair side af the crank- case. These numbers are required especially for registering the mashing and ordering spare parts. (GENERAL INFORMATION 15 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (FOR USA AND CANADA) Use only unleaded gasoline of at laast 87 pump octane (93M) or 81 octane or higher ratad by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Etner), less than 10% ethanol, ar jas than 5% methanol with appropriate Cosalvenis and ecrrosion inhibitor is permissible FUEL (FOR THE OTHER COUNTRIES) Gasoline used should be graded 94 octane (Research Method) or higher. An unleadad gasoline is recom- mended. ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL of an oll which is rated SF of SG under the API (American Petroleum Institute) service classification. The recom= mended viscosity is SAE 10Wid0. If an SAE 10W/40 oil is not available, select and allemative according to the right chart ENGINE OIL (For the other models) Use a premium quality 4-stroke motar ol! fo ensure longer ser- vie lite of your motoreycie. Use anly olis which are rated SF or ‘SG under the AP| service classification. The recommended viscosity is SAE 10W-40. Hl an SAE 10W~40 ‘rotor oll i not available, select an allemative according to the following chart BRAKE FLUID Use DOT brake fluid. Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu- facturer, 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 nat use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over fram a previous servicing, which has been stored for a jong period FRONT FORK OIL Use fork oll S5-8 (#10) of an equivalent fork oil, 1-6 _ GENERAL INFORMATION ENGINE COOLANT Use an antitreeze’engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only Water other than distilad water ean corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT ‘The engine coolant perform as a corrosion and rust inhabit as weil as: anti-freeze. Therefore, the engine coolant should be used at all times even thaugh the aimospheric temperature in your area does nat.go dawn 1 freezing point. ‘Suzuki recommends the use of SUZUKI COOLANT ant-treeze/engine coolant. H this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): 2400 mi (2.5/2.1 US/imp qt) For engine coolant mixture information, refer to cooling system section. (<- 5-2) ‘A CAUTI Mixing of anti-freezefengine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. lf the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced, Be sure to mix It above S0% even though the atmospheric temperature does hat go down to the freezing paint. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts ara finished to a very high standard but itis still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine ta maximium stresses, The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The goneral rules are as follows. * Keep ta these break-in procedures: Initial 800 km {500 miles): Below 7000 r/min Upta 1600. km (1000 miles): Below 10 500 r/min ‘Over to 1600 km (1 000 mites): Below 14 000 r/min * Upon reaching an adometer reading of 1 600 km (1 000 miles) you can subject the motoreycle to full trots (operation. However, de not exceed 14 000 r/min at any time: CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No.1, No.2. No.3 and No.4 cylinder, as counted from lett to right (as viewed by te ridor on the seat) GENERAL INFORMATION 1-7 INFORMATION LABELS (GSX-REOO GSx-RE00UD [| GSx-REOQUF 7, Noise label © For E-03, 24, 33. © Information label (0 For E-03, 28. 33 Vacuum hose routing taba | © For E-33 4) Fuel caution label O Fer E-02, 24 5) Manual notice label O For E-03, 43 Frame caution label 3 o 5 D Screen warming label a o o Steering waming tabel a o © © Tire pressure label a o o ‘13 Warning saiety label a o 5 3) ICES Canada label For £28 @ AD plate ‘For E02. 18, 24 o o & E-19 1D label ° i Salary plate, O For E03, 28, 33 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase . Ground clearnoe Seat height... Ory mass Number af cylinders. Valve clearance IN... x. BORE nr SHOHE essen Piston displacement ‘Compression ratio Fuel SY8EEM enero Air cleaner. Starter system. Lubrication system .. TRANSMISSION GUAR at Transmission . Gearshift pattern . Primary reduction ratio Gear ratios, Low .. 2nd.. ard. ain. Sth... Top Final reduction ratio Drive sysiam 2.040 mm (20.3 in) 715 mm (28.1 in) 1.435 mm (44.7 in) 4810 mm (55.5 in) 130mm (6.1 in) 830 mm (82:7 in) 163 kg (959 fos)... For E33 164 kg (367 ts)... For the others Four-stroke, Liquid-cooled, DOHC. 4 0.10 ~0.20 mm (0,004 — 0.008 in) 0.20 - 0.30 mm (0.008 - 0.012 in) 67.0 mm (2.636 in} 42.5 mm (1.673 in) 589 om? (36.5 cu. in} 12:1 Fuel injection Non-woven fabric: element Electric Wet sump Wet multi-plate type E-speed, constant mesh tedown, Sup 1.925 (79/41) 2.785 (39/14) 2.000 (32/18) 1.600 (32/20) 1.363 (30/20) 1.208 (29/24) 1.086 (25/23) 2.812 (45/16) RK 525SMOZB, 110 links GENERAL INFORMATION 1-9 CHASSIS: Front suspension 0 Fear SUSPENSION 1... Caster. Trail... " Steering angle .. ne rte Frant brake Rear brake ... Front tire size Roar tire size ELECTRICAL Aghition YP pone Ignition timing Spark PIU mo Battery reals Generator . Main fuse Fuse Headlight... Position light... Turn signat light Brake: lightTailigh Neutral indicator light High beam indicator light Turn signal indicator light Fue! injection wasrmning fight. oe FUOII pressure/Engine coolant temp. indicator light... CAPACITIES Fuel tank, Including reserve nnn ma Engine oil, all change with fitter change OVOMBU onsen ‘Coolant, Front fork oi (each leg) .. Telescopic, coll spring, oll damped, spring pre-load fully adjustable, rebound and compression damp ing foree fully adjustable. Link type.oll damped, coil spring, spring pre-road fully adjustable, rebound damping force and com- pression damping force fully adjustable, aan 96 mm (3.8 in} 25° (right & lett) 32m (105 f) Disc brake, twin Dise brake 120/70 2R17 (58 W), tubeless 180/55 2A17 (73 W), tubeless Electronic ignition (Transistorized) 4 BID. at 1 300 rimin NGK CRSE, DENSO U27ESA-N 12V 36.0 kO(@ Any/TOHR ‘Three-phase AG. Generator 308 18/15/18/15/10/10A 12V 85+55/55W (H7) 12V 8W........ Except for E-03, 24, 28, 33 models sv 21 12V 215W x2 LED LED LED LED LED 18 L (4.8/4.0 US/imp gal) 2 800 mi (3.0/2.5 US/imp qt} 3.100 mi (3.327 USiimp at) 3-400 mi (3.6/3.0 USiimp gt} 2.400 mi (3.2/2.6 USiimp qt) 52a mi (17.8/18.6 USiimp 02) “These specifications are subject to change without notice, 440_ GENERAL INFORMATION COUNTRY AND AREA CODES ‘The following codes stand for the applicable country(-ies) and area-s) MODEL | CODE COUNTRY or AREA E02 UK. E03 USA (Except tor catiorniay B19 a SORE eee Australia E28 Canada Esa | Caitforia (USA) Gsx-Requb| E19 | a GSX-REOOUF| E19 Eu PERIODIC MAINTENANCE 2-1 fe 6m eae = CONTENTS PERIODIC MAINTENANCE SCHEDULE... PERIODIC MAINTENANCE CHART. LUBRICATION POINTS....... : MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER... SPARK PLUG VALVE CLEARANCE ENGINE OIL AND OIL FILTER FUEL HOSE..... ene a onn ENGINE IDLE SPEED. 25 THROTTLE VALVE SYNCHRONIZATION 215 THROTTLE CABLE PLAY. 216 CLUTCH... 217 COOLING SYSTEM. 218 DRIVE CHAIN. 2-20 BRAKE 222 TIRE... 225 STEERING 2-26 FRONT FORK. ‘ 2.27 REAR SUSPENSION... 227 EXHAUST PIPE BOLT AND NUT .. 227 CHASSIS BOLT AND NUT, 2:28 COMPRESSION PRESSURE CHECK... 2-30 OIL PRESSURE CHECK 231 22_ PERIODIC MAINTENANCE, PERIODIC MAINTENANCE SCHEDULE ‘The chart below lists the recommended intervals for all the requires periodic service work necessary to keep the motorcycle operating at peak performance and ecanamy. Maintenance intervals are expressed in {terms of kilometer, miles and months, and are dependant on whichever comes fist NOTES: Mare frequent servicing may be pertermed an motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval | km 4.000, 6000 42 000 18 000 24000 miles 600 4000 7500 41.000. 15 000 Item months 4 & 16 24 Avr cleaner element = I ‘Spark plugs _ : 1 R Valve clearance Engine oll BR Engine ol fiter B - Fue! fine Ltt Replace fuel hose every 4 years. lle speed 1 4 i 1 Throttle valve synchronization ' 2 i # T A T Evaporative emission control systam = = 1 s I (E-33 only) Floplace vapor hose every 4 years, |_PAIF (air supply) system = i ~ Tt i t I | Cue i 1 | Aladiaiar hoses: = i 1 | Engine coolant Replace every 2 years. Brive chain 1 | L 1 i | ‘Clean and lubrieate every 1 O60 km (600 miles), Brakes i 1 D i — Brake hoses : t i i T Brake tid : 1 I Tires - ft 1 i i | Steering - 4 = i Front forks = = 1 i Rear suspension [ss = 1 i Exhaust pipe bolts and muffler Bolt and nut) 1 = T = T Chassis bolts and nuts T T T T | Inspect and adjust, clean, lubricate or repiace as necessary. Fea Replace T= Tighten PERIODIC MAINTENANCE 23 LUBRICATION POINTS Proper lubrication Is important for smoath operation and long Iife of each working part of the matorcysie, Major lubrication points are indicated below, Bip Brake lovertoer NOTE: * Before lubricating each part, clean off any rusty spots and uipe off any grease, ail, dirt or grime. * Lubricate exposed parts which are subject to rust, with 2 rust preveniative spray, especially whenever the motorcycle has been opetated under wet ar rainy conditions. 244 PERIODIC MAINTENANCE. MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and Foplace every 18 000 km (11,000 miles, 18 months). ‘+ Remove the front and rear seats. (> 6-6) ‘+ Lift end support the fuel tank. (C7 4-52) ‘+ Remove the sir cleaner element by removing the screws. * Carefully use air hose to blow the dust from the cleaner ele- ment. ‘A CAUTION | Always use air pressure on the outside of the air cleaner Gloment. If alr pressure is used on the inside, dirt will be forced into the pores of the air cleaner element thus re- stricting alr flow through the air cleaner element. * Reinstall tho cleaned or now air cleaner element in the re- ‘verse order of removal A CAUTION It 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 ‘orto use a tom element, Make sure that the air cleaner is In good condition at all times. The life of the engine de- pends largely on this component! * Remove the drain plugs trom the alr elganer box to allew any water to drain out SPARK PLUG Inspect every € 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months! SPARK PLUG AND IGNITION COILIPLUG CAP REMOVAL * Flemove the front and rear seal. ("7 6-6) * Lift and support the fue! tank. ((<7" 4-52) = Remove the air cleaner box (1), (C77 4-62) * Disconnect all of the fead wire couplers from each ignitian coll” plug cap, a CAUTI Do not remove the ignition coll/plug cap belore discon- | necting its lead wire coupler. * Fiemave all of tne ignition coils/plug caps. 4 CAUTION * Do not pry up the ignition coil/plug cap with a driver or a bar te avoid Its damage. * Be careful not to drop the ignition coil/plug cap to pre- vent the short or open the circuit of its. » Remove the spark plugs with a spark plug wench, 28 PERIODIC MAINTENANCE. HEAT RANGE * Check to see the heat range af the plug. It the electrode of the plug is wet appearing or dark color, re= place the plug with hotter type one. if it is whits or glazed ap- pearing, repiace the plug with colder type one —— NGK DENSO | Hotter type GREE U2aESA-N Standard CROE LU27ESA-N Golder type CRIOE | UStESA-N NOTE: “FT type spark plug has a resistor located at the center electrode to prevent radia noise. CARBON DEPOSITS * Check to see if there are carbon deposits on the spark plug “Il carbon is deposited, remove it using a spark plug cleaner machine or caratully use a tool with a pointed end. SPARK PLUG GAP + Monsure the spark plug gap using'a thickness gauge. * If out of specification, regap the spark plug. Spark plug gap: Standard: 0.7 = 0.8 mm (0.028 = 0.031 in) (09900-20809: Thickness gauge (0.928 0.031 in) ELECTRODE’S CONDITION * Chock the condition of the electrode. © itits extremely woen or burnt, replace the spark plug, Replace the spark plug If ithas a broken insulator, damaged thread, etc. 4 CAUTION | Cheek the thread size and reach when replacing the spark plug. If the reach is too shart, carbon will be deposited ‘on the screw portion of the spark plug hole and engine | damage may result, SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION * Install the spark plugs to the ayinder head by finger tight, and then tighten tem to the specified torque (7) Spark plug: 11 Nm (1.1 kaf-m, 8.0 lb-ft) [a CAUTION | To avoid damaging the cylinder head threads, first fin- ger tighten the spark plug and then tighten it ta the proper torque using the spark plug wrencl * Install the ignition colls/plug caps and connect their tead wire couplers. iON Bo not strike the ignition colljplug cap with a plastic hammer when installing It * When installing the Ignition colliplug cap, place its coupler not to contact with the cylinder head cover. INCORRECT mooRREct 2.8 PERIODIC MAINTENANCE VALVE CLEARANCE 24 000 km (15 000 miles, 24 months). | Inspect + Remove the right under cowiing. (3 6-3) + Remove the front and rear seats. (CF 6-6) + Lift and support the tual tank. (Ca 4-52) * Remove the spark plugs. (IF 2-5) Remove the cylinder head covers. ((<7" 3-15) ‘The valve clearance specification is different for intake and ex- haust valves. Valve clearance must be checked and adjusted, 1) at the time ot Penodic inspection, 2) when the valve mechanism is. serviced, and 3) when the camshafts are disturbed by removing them for servicing Valve clearance (when cold): Standard: IN. : 0.10 ~ 0.20 mm (0.004 ~ 0.008 in) EX.: 0.20 — 0.30 mm (0.008 - 0.012 in} NOTE: * The cam must be at positions, A) or @, in order to cheek the vaive clearance, or 1a adjust tappet clearance. Clearance read- ings shout not be faken with the cam in any other position than these two positions, * The clearance specification Is for GOLD state. * To tum the erankshaf for clearance checking, bo sure to use 8 wrench, and rotale in ihe normal cunning direction. Alt spark plugs should be removed, + Remove the valve timing inspection cap ‘© Tum the crankshatt 10 bring the “Top” line on the starter clutch to the index mark and also to bring the notches 'A) on the left ‘ends of both camishatis (Ex and In) to the positions as shown, ‘In this condition, read the valve clearance: at the valves ‘B? (In and Ex of No.d cylinder, Ex of No and In of No.2). It the clearance is out of specification, adjust the clearance. (co 2-10) (09900-20803; Thickness gauge + urn the crankshaft 960 degrees (ane rotation) to bring the “TOP” ine on the starter clutch to the intiex mari of valve tim ing inspection hole and algo to bring the notches (®) to the position as shawn, + Road the clearance at the remaining valves (© and adjust the clearance if necessary. (C7 2-10) Notch (& position Cam position Exhaust Camehat | Intake Camshat ® eFront (O) + Front © c Front ©) Front 2.10 _ PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by @ thicker or thinner shim, * Riemave the intake or exhaust camshafts. (C7 3-16) + Remove the tappet.and shim by fingers or magnetic hand, * (Check the: figures printed on the: shim. These figures indicate the thickness of the shim, as illustrated. * Select's replacement shim that will provide a clearance within the specified range. Far the purpose of this adjustment, a total of 25 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward lappet. Be sure fo check shim size with micrometer 1o ensure its size. Reter to the tap- pet shim selection table (72-11, 2-12) tor details NOTE: * Be sure-to apply engine oll to tappet shim top and bottom faces. ” When seating the tappet shim, be sure to face figure printed surface to the tappet, A CAUTION | Reinstall the camshafts as the specified mann (cor 391) + Alter replacing the tappéet shim arid camshafts, rotate the en- gps oo thar the tappet is depressed fully This will squeeze out oll trapped between the shim and the tappet that could cause an incomect measurement, then check the clearance again to confirm that it is within the specitied range * After finishing the valve clearance adjustment, reinstall the fot- lowing itams. Page * Cylinder head cover eee ons 396 * Spark plug and plug cap : BF * Valve timing inspection IQ cranes 30 170mm PERIODIC MAINTENANCE 2411 aw g@4 poem ag of 02 unas unm oe 6218 ums wesc ww gz @9UEHEEP aNEA, anna ‘uuinyoo UOTUCK UI OFS Uni Os (gM LALIIGD feoRNAN LBL KEEN ‘228 Liye guosaud aINECOWY .0709 $1 SION, BouRIBEAD aNeEA aiTsbeR 1 face | wwe | ove} wae | one | sev | ow] uy | awe | se sai} ons | set] ove | avs | ov | ace cs | se {oen60-D08e1) 135 WHS L3da¥L (xxx-00060-2682 1) (ON WIHS Laddvi [@yWINI) SN@VL NOLLOTTAS WIHS LadawL (INTAKE SIDE) anu oR} BET Bq Oy 22 MaRS ww ost forye ys wai lun grrO BOURNE aAEA maw “uwuniaa waco 2s Lees _UisAd Yay ULUTYOD FEI BOKER UERY “RTI LNs UPON aANSHORY ih -C109 $1 ANION, sHUEIBE! eNYeR airw—RY HLWWH SAL ASN OL MOH en | 001 | ost int | sea wa | ca [ iio ooeei) aS We baa | 2:12_ PERIODIC MAINTENANCE. (EXHAUST SIDE} (XX-00050-26821) ‘ON WHS LadewL LusNVHxal a76Wi NOLLOS 1S IIHS LaddWi aa sans ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (Ol FILTER) | Replace initially at 1 000 km (600 miles, 1 month) and every 18 000 km (11 000 miles, 18 months) thereafter. ‘Oi should be changed while the enging is warm, Oa! fter replace- ment at the above intervals, should be done together with the engine oil change. ENGINE OIL REPLACEMENT + Keep tha matorcyele upright, + Place an oil pan below the engine, and drain oll by ramoving the oll drain plug “f) and filer cap'2 ‘© Tighten the drain plug (Dt0 the specified torque, and pour fresh oil though the il filer. The engine will hold about 2.8 L (3.0! 2.5 US/imp qt) of oil, Use an AP) classification al SF or SG oil with SAE 10W/40 viscostty. (7) Oil drain plug: 23 Nim (2.3 kat-m, 16.5 lb-ft) * Start up the engine and allow it to run for several minutes at idling speed, + Turn off the engine and wait about three minutes, then check the oi! level through the Inspection window. Ifthe level is botow mark "L’, add oll to "F level. I the level is above mark °F’, drain oll 10"F* level PERIODIC MAINTENANCE 2-13 2.14 _ PERIODIC MAINTENANCE OIL FILTER REPLACEMENT * Drain the engine oll as described in the engine ll replacement procedure * Remove the oll fiter “using the special toot (09915-40610: Oi! filter wrench * Apply engine oil lightly to the gasket of the new of filter before installation, * Install the new cil fer, Turn it by hand until you feet that the ail titer gasket has contacted the ail filter mounting surface. Then, tighten the ci ftir two full turns using the special tot. NOTE: ‘To property tighten the oit titer, use the special toot, Never tighten the oil fiter by hand, * Add new engine oil and check the oil level as described in the engine oil replacement procedure, NECESSARY AMOUNT OF ENGINE OIL: Ot change: 2.84 (3.0/2.5 US/Imp at) Oil and filter change: 3.1L (3.9/2.7 US/Imp qt) Engine overhaul: 3.4L. (3.6/3.0 USAmp at) A CAUTION) ONLY USE A GENUINE SUZUKI MOTORCYCLE OlL FiL- TER. Other manufacturer's ol filters may differ in thread speci- fieations (thread diameter and pitch), filtering perfor- mance and durability which may lead to engine damage oroil leaks, Also, do not use a genuine Suzuki automo- bile oil filter on this motorcycle. Aer contacting the (pastel, tighten 2 tums, PERIODIC MAINTENANCE 2-15, FUEL HOSE Inspect the fuel hose “for damage and fuel leakage. If any defects are found, the hoses must be replaced. ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and | every 6 000 km (4 000 miles, § months) thereafter NOTE: Make this adjustment when the engine is hot + Start the engine, turn the throitle stop screw and set the engine die speed as tollows. Engine idle speed: 1 300 + 100 rpm THROTTLE VALVE SYNCHRONIZATION | Inspect initially at 1 000 km (600 miles, 1 monthE-33 | only) and every 12 900 km (7 500 miles, 12 months). (cr 473) 246 PERIODIC MAINTENANCE THROTTLE CABLE PLAY ns eee Inspect initially at 1 000 km (600 miles, 1 month) and |_every 6 000 km (4.000 miles, 6 months) thereafter, Adjust tho trons cable play ® as follows MINOR ADJUSTMENT tat stop: * Loosen the locknt P of the thrattle returning cable @ and tully tum in the adjuster 2nd step: * Loosen the locknut 4) of the thrattis pulling cable ‘5 + Tormthe adjuster © in or out until the throttle cable play (at tho throttle grip) 2 is between 2.0 ~4.0 mm (0.08 ~ 0.16 in), + Tighten the locknut @ while holging the aduster (6 EAD Throttle cable play A): 2.0 = 4.0 mm (0.08 = 0.16 Inj 3rd step: + Whiig holding the throte grip at the fully clased position, slowly turn out the adjuster (2) of the thrattle returning cable @ until resistance Is felt * Tighten the locknut «) while holding the adjuster 3 After the adjustment is completed, check that handlebar maverent dees not raise the engine idle speed and thi the thrattle grip returns smoothly and automat NOTE: Major adjustment can be made at the throttle body side adjuster PERIODIC MAINTENANCE 2.17 MAJOR ADJUSTMENT + Litt and support the fuel tank with ts prop stay. (7° 4-52) * Loasen the fock nuts @ af the throttle returning cable 2 * Turn the returning cable adjuster J) to obtain proper cable play. * Loosen the lock nuts @) of the thattle pulling cable 5 + Tum the pulling cable adjuster (in or out until the throttle ‘cable play (®P should be 2.0 — 4.0 mim (0.08 — 0.16 in) at the thratie grip. + Tighten the lock nuts @) securely while holding the adjuster 6 Throttle cable play (A): 2.0 —4.0 mm (0.08 ~ 0.16 in) ‘+ While holding the throttie grip at the fully closed position, stowly tum the returning cable adjuster (D to obtain a cable slack of 1.0 mm {0.04 in), * Tighten the lock nuts (P securely. After the adjustment is completed, cheek thet handie- | har mavement does not raise the engine idle speed and that the throttle grip returns smoothly and automat) cally. CLUTCH Inspect Every 6 000 km (4 000 miles, 6 months). + Flemave the lett under cowling. (76-3) * Turn in the adjuster CP all the way into the clutch lever assem: bi. * Rlemave the clutch release cover, * Loosen the lock nut (2! and turn out the adjusting screw ‘J! two oo three rotations. *» From that position, slowly turn in the adjusting screw 1 leet resistance, * From this position. turn out the adjusting screw @ ‘a rotations, and tighten the lock nut * Laosen the lock nut @, and tum the cable adjuster ‘1a ob- tain 10-15 mm (0.4 —0.6 in) of free play @ at the clutch lever end. + Tighten the Jock nuts :4 ‘Clutch lever play ‘®: 10 ~ 15 mm (0.4 ~ 06 in) ‘Clutch release screw: 14 tums out oy 218 PERIODIC MAINTENANCE COOLING SYSTEM | Inspect every 6 000 km (4 000 mites, 6 months). |_ Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK Keep the motorcycle upright © Check the enging coclant lave! by observing the full and lower lines on the engine coolant reserve tank. ® Fullling & Lower tine “If the level is below the lowering, remove the left under cowl- ing (7°69), and ada engine coolant to the full line from the engine coolant reserve tank filler. ENGINE COOLANT CHANGE + Remove the under cowling. (7 6-3) * Remove the radiator cap * Drain engine coolant by dissonnesting the radiator hose @ from the puma, ns | + Do not open the radiator cap when the engine is hot, ‘85 You may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed or if it comes in contact with skin of eyes. If engine coolant gets into the eyes or in contact with the skin, flush tharoughly with plenty of water. If swallowed, induce vomiting and call physician immediately! * Flush the radiator with fresh water if necessary. * Connect the radiator hose @) securely. * Pour the specifiad engine coolant up to the radiator inlet. CE] Engine coolant capacity (without reservoir): 2.150 ml (2.3/1.9 Usiimp at) * Bleed the air from the engine coolant cirauit as follewing pro cedure, (72-19) ENGINE COOLANT INFORMATION: —7°5-2 AIR BLEEDING THE COOLING CIRCUIT * Add engine coolant up to the radiator inlet + Support the motorcycle upright. = Stowly swing the motorcycle, right and ieft, to bleed the air trapped in the coating circuit © Add engine cootant up to the radiator inlet. Start up the engine and bleed alr from the radiator inlet com- pletely, ‘+ Add engine coolant up to the radiator intet ‘= Repeat the above procedure until bleed no air from the radia tor inte * Loosen the air bleeding bolt () and check the engine coolant flow out [F) Air bleeding bolt: 5.5 Nem (0.55 kgh-m, 4.0 tb-ft) * Close the radiator cap securely. ‘After warming up and cooling down the engine several mes, add the engine coolant up to the full lovel of the reserve tank. Repeat the above procedure several times and make ‘sure that the radiator Is filled with engine coolant up to the reserve tank full level 1) Engine coolant capacity (Without reservoir): 2.150 mil (2.9/1.9 USAmp at) RADIATOR HOSES: ‘© Flomove the under cowlings. (7-6-3) * Check to see the radiator hoses for crack, damage or engine coolant leakage, ++ I any defects are found, replace the radiator hoses with new ones. PERIODIC MAINTENANCE 2-19 2.20_ PERIODIC MAINTENANCE DRIVE CHAIN | Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereatter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain far the passible defects listed be- low. (Support the motorcycle by a jack and a wooden block, turn the rear wheel siowly by hand with the transmission shifted 10 Neutral) * Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Diy oF rusted links * Missing O-ring seals * Kinked ar binding links WW any delects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a sat. CHECKING ‘+ Remove the axle catter pin. (For E-03, 28 and 33) * Loosen the axte nut © * Loosen the chain adjuster lock nuts © * Loosen the torque link nut (Rear) @. ‘+ Tense tha drive chain fully by turning both chain adjusters 4, + Count out 21 pins (20 pitches) on the chain and measure the distanee between the two points. if the distance exceeds the service limit, the chain must be replaced [2D Drive chain 20-piteh length: Service limit: 319.4 mm (12.57 in) ADJUSTING + Loosen of tighten both chain aidjuster nuts [D until there is: 20 20 mm (0.8 = 1.2 in) of slack at the middie of the chain tween the engine and rear sprockets as shown. The reter- ence marks & on both sides of the swingarm and the edga of each chain adjusier must be aligned to ensure that the front and rear wheels are correctly aligned. [EMD Drive chain slack: Standard: 20 ~ 30 mm (0.8 - 1.2 In) © Place the motorcycle on its side-stand for accurate adjustment. ‘= Alter adjusting the drive chain, tighten the axle nut 2 and the torque link nut (Rear) (2 to the specified torque, + Tighten both chain adjuster nuts 4) securely, (©) Rear axie nut: 110 Nem (11.0 kgf-m, 79.6 Ib-ft) For E-03, -28, -33 120 Nem (12.0 kg-m, 86.8 Ib-ft) “ For the others Torque link nut (Rear): 34 Nem (3.4 kgf'm, 24.6 Ib-f) « Install a new cotter pin, (For E-03, 28, 33) + Recheck the drive chain slack after tightening the axle nut. CLEANING AND LUBRICATING » Clean the drive chain with kerosina, it the drive chain tends to rust quickly, the intervats must be shortened, Do not use trichleroethytene, gasoline or any similar solvent. These fluids: have too great a dissolving power for this chain and they can damage the O-rings. Use [only Kerasine to clean the drive chain. * After washing and drying the chain, olf it with @ heavyweight motar oil CAUTI * Da not use any oll sold commercially a “drive chain | oll”, Such oll can damage the O-rings. * The standard drive chain is a AK S25SMOZ6 Suzuki recommends to use this standard drive chain as. a replacement 2:22 _ PERIODIC MAINTENANCE BRAKE (BRAKE) Inspect initially at 1.000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fiuid every 2 years. BRAKE FLUID LEVEL CHECK + Kaop the motorcycle upright and place the handlebars straight. * Check the brake fluid level by observing the lower limit lines oon the front and naar brake fiuid reservoirs. “ When the level is below the lower limit ing, replenish with brake fluid that meets the following specification IB 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 re-use brake fluid left over from the last servicing or stored for a tong period af 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 leak- age before riding. BRAKE PADS FRONT SRAKE + The extant of brake pad wear can be checked by observing the grooved limit line 4 on the pad. When tha wear excasds the grooved limit fine, replace the pads with new ones (> 6-58) ‘A CAUTION = - Replace the brake pads as a set, atherwise braking per- formance will be adversely affected. REAR BRAKE ‘+ The extent of brake pad wear can be checked by obser the grooved limit ine A on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones, (cr 6-63) A CAUTION | Ropia rake pads as.a set, otherwise braking per- BRAKE PEDAL HEIGHT + Loosen the locknut (J Turn the push red (2 until the brake pedal is 50 — 60 mm (2.0 ~2.d\in) ® below the top of the footrest. + Tighten the lacknut securely. [2] Rear brake master cylinder rod locknut: 18 Nem (1.8 kat, 19.0 Ibeft) EXO) Brake pedal height ©: Standard: 50 = 60 mm (2.0 = 2.4 in) BRAKE LIGHT SWITCH ‘+ Adjust the raar brake light switch sa that the brake light will come On just betore pressure is felt When the brake pedal is depressed. 2:24 _ PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Alrtrappad in the brake fluid circuit acts like @ cushion to absorb a large proportion of the pressure developed by the master cy- Inder and thus interleras with the full braking performance of the brake caliper. The presence of air is indicated by “sponginass” ot the brake lever and alsa by lack ot braking farce. Considering the danger to which such trapped air exposes the machine and rider, iis e5sential that afier remounting the brake and restoring the brake system fo the normal condition, the Brake fluid circuit be purged of air in the follawing manner: FRONT BRAKE * Fill the master cylinder reservoir to the top of the Inspection swindow. Replace the reservoir cap to prevent dit from entar- ing. * Attach a hose to the air bleeder valve and insert the tree end ‘of thie hose into receptacie, * Squeeze and release the brake lever several times in rapict succession and squeeze the lever fully without refeasing it Loosen the air bleader valve by tuming it @ quarter of 2 turn 50 that the brake tluid runs into the receptacle, this wil re- move the tansion of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until fluid flowing into the receptacle no longer contains air bubbles, NOTE: While bleeding the brake sysiam, 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 lap of the inspection window, [) Air bieeder valve: 8 Nm (0.8 kgfm, 6.0 Ib-ft) AUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc. PERIODIC MAINTENANCE 2.25 REAR BRAKE ‘ Blsed air from the rear brake system as the same manner of front brake, NOTE: ‘The only ditterence between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal TIRES ] | inspect every 6 000 km (4.000 miles, 6 months). 3 TIRE TREAD CONDITION Operating the motoreycle with excessively wor tires will decrease riding stability and consequently invite a dangerous situation. tt Is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. (09900-20805; Tire depth gauge [EXE Tire tread depth: Service Limit: FRONT 1.6 mm (0.06 in) REAR 2.0 mm (0.08 in) 2.98 _ PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- ‘versely affected and tire wear yril increase. Thersfore, maintain the correct tire pressure for good roadability and a longer tire Me. Cold inflation tre pressure is as follows. Cold inflation tire pressure Sola riding: Front: 250 kPa (2.50 kgtfcm*, 36 psi) Rear; 250 kPa (2.50 kgticm*, 36 psi) ‘ront: 250 kPa (2.50 kglfom?, 36 psi) Re 250 kPa (2.50 kgt/em?, 96 psi) Bual riding: A CAUTION ‘The standard tire fitted on this motoreycie is @ 12070 ZR17 (58W) for the front and a 180/55 ZAI7 (73W) for the rear. The use of tires other than these specified may cause Instability. It is highly recommended to use the specitied tires, ESD TRE TYPE DUNLOP (D207FU.....Front, D207U.....Rear) -- E-03, 24, 28, 33 PIRELLI(MTR21S corsa....Front, MTR22S corsa....Rear) » The others STEERING Inspect initially st 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 manths) thereafter. The steering should be adjusted properly for smoath turing of the handiobars and safe operation, Overtight steering prevents: smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is na play in the front fark. Support the motorcycle 66 that the front wheel is off the ground. ‘With the whee! facing straight ahead, grasp the lower tork tubes near the axle and pull forward, play is found, readjust the stear- ing (> 6-29) PERIODIC MAINTENANCE 2:27 FRONT FORK very 12.000 km (7 500 miles, 12 months! Ins Inspect the front forks for ail leakage, scoring or scratches on the outer surface of the inner tubes. Replace any detective parts, if necessary. (C7 6-13) REAR SUSPENSION |_ inspect every 12 000 km (7 500 miles, 12 months). Inspect the rear shock absorbers for ail leakage and check that there is:no play in the swingarm. Replace any detective parts i necessary (C7 6-41, 6-45) EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and | every 12 000 km (7 500 miles, 12 months) thereatte + Tighton the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque. Mane (ieee, 228 PERIODIC MAINTENANCE, CHASSIS BOLTS AND NUTS | Tighten initially at 1-000 km (600 miles, 1 month) and every 6 000 km (4 G00 miles, 6 months) thereafter, Check that all chassis bolts and nuts are tightened to their specified torque. The locatians of the following Ruts and bolts on the motorayele, 7°2-29 item Nm _kgtm itt @ Steoring siem head nut T 80 90 65.0 & Steering stem lock nut { 80 8.0 58.0 @ Front fork upper clamp ball | 23 23 16.5. @) Front fork lower clamp bot 23 [ 2.3 165 5) Front fork cap bolt 36 | 35 25.5 6 Front axis 100 10.0 t 72.5 D Front axe pinch batt 23 23 16.5. & Handlebar set bot 10 10 7.0 © Handlebar clamp bolt 23 2a 16.5 ©) Front brake master cylinder mounting batt 10 1.0 7.0 {© Front brake caliper mounting bolt 25 25 16.1 | Front brake caliper housing bolt 2t “24. 15.2 3 Brake hase union bolt (Front & Rear} 23 23 16.5 Score weenie (Front & Rear) B O8 6.0 Brake disc bolt (Front) 23 23 16.5 ® Brake dise tot (Rear) 35. 35 25.5 {Rear brake caliper mounting bolt 25 25 18.1 | Fleas brake caliper housing bolt = | 3.0 21.5 ‘Fear brake master cylinder mounting bolt 10. 7.0 i Rear brake master cylinder rod lock nut 18 13.0 !) Front footrest bracket mounting bolt 2a 16.5 swingarm pivot hut 100 725 {D Swingarm pivot lock nut 90. 65.0 Torque link bolt and nut (Front) 2a 20.0 @ Torque link bolt and nut (Rear) 34 24.6 Rar shock absorber bracket nut 15 #32 2 Rear sh af MOurtir Mt pret lie ounting bott/nt 50 36.0 @ Rear cushion leverirod mounting nut 7 78 565 & Rear axle nut |_For E-03, 28, 33, v0 414.0 738 For the others 120 12.0 6.5 © Rear sprocket nut 80 6.0 43.5 3 Swering camper boitinut i 23 23 I 165 2:30_ PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure eating of 2 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 mainta- nance recomis kept at your dealership should include compression readings for each maintenance service, COMPRESSION PRESSURE SPECIFICATION ‘Standard [__Dilfere 7100 — 1 500 kPa 900 kPa 200kPa 11-15 kglter® \| —/ @ kgHem® | (2 kote? 156 = 213 psi 128 psi_} \_ 28 psi Low compression pressure can indicate any of the following conditions: * Excessively worn cylinder walls * Wom piston oF piston rings * Piston rings stuck in grooves: * Poor valve seating * Ruptured or otherwise detective cylinder head gasket ‘Overhaul the engine in the following cases: * Compression pressure in one af the cylinders is less than S00 kPa (8 kgicm’, 128 psi) * The ditference In compression pressure between any two ey inders is more than 200 KPa (2 kgticm?, 28 psi). * All compression prassure readings ars below 1 100 KPa (11 kglfom, 156 psi) even when they measure more than 900 kPa (2 kgtiem®, 128 psi) COMPRESSION TEST PROCEDURE NOTE: * Belare testing the engine for compression pressure, make sure that the cylinder head nuts are lightened to the spacified torque values and the valves are properly adjusted * Have the engine warmed up betore testing, * Make sure that the battery is fully-charged, Fiomove the related parts and test the camprassion pressure in the following manner. * Lift and support the fuel tank. (C7" 4-52) * Remove all the spark plugs. ((7" 2-5) * Install the compression gauge and adaptor in the spark: plug hole. Make sute that the connection is tight + Kaep the throttle grip in the fully opened position + Press the starter button and crank the engine for a few se fonds, Record the maximum gauge reading a5 the cylinder com- pression, + Flepeat this procedure with the other cylinders ‘Compression gauge set 09913-10750; Adaptor PERIODIC MAINTENANCE 2-31 OIL PRESSURE CHECK heck tha engine oll pressure periodically. This will give @ good indication of the condition of the maving parts, OlL PRESSURE SPECIFICATION 200 ~ 500 kPa (2.0 ~ 5.0 kgt/em*, 26 ~ 71 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) II tha oil pressure is lower or higher than the specification, the fallowing causes may be considered LOW OIL. PRESSURE * Clogged off filter * Oil leakage from the oll passage * Damaged O-ring * Detective oll pump * Combination of the above items HIGH OIL PRESSURE * Engine oil viscosity is too high > Clogged oll passage * Combination of the above items OIL PRESSURE TEST PROCEDURE Start the engine and check if the ail pressure indicator fight is tumed on. if the fight stays an, check the oll pressure indicator light circutt. if the circuit is OK, check the oil pressure in the foie lowing manner. + Remove the main oil gatlery plug @ * Install the oll pressure gauge and adaptor ino the main ol gallery. + Warm up the engine as follows: ‘Summer: 10 min, at 2 000 «min. Winter; 20 min, at 2 090 r'min. ‘= After warming up. increase the engine speed to 3 000 «imin. [observe the tachometer), and resd the oll pressure. gauge, 09915-74520: Oil pressure gouge hose 99915-74540; Oil pressure gauge attachment 0915-77330: Meter (for high pressure) (©) ol! gattery plug (0416): 95 N-m (3.5 kgf-m, 25.5 tb-ft) ENGINE 34 ENGINE CONTENTS a ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE..... sii ENGINE REMOVAL AND REINSTALLATIO! nai BS ENGINE REMOVAL ..... +s ENGINE REINSTALLATION. a4 ENGINE DISASSEMBLY .. on BIS ENGINE COMPONENTS INSPECTION AND SERVICE 3-28 PAIR VALVE occoero scene 3-28 CYLINDER HEAD COVER 3-29 CAMSHAFT 3-29 CAM CHAIN TENSION ADJUSTER. 331 CAM CHAIN TENSIONER +31 CAM CHAIN GUIDE CYLINDER HEAD AND VALVE. eLUTGH OIL PUMP... STARTER CLUTCH GENERATOR .. WATER PUMP... 343 GEARSHIFT SYSTEM 344 OIL PRESSURE REGULATOR 3-45 OIL STRAINER... 345 TRANSMISSION... 3-46 CYLINDER 3-49 PISTON AND PISTON RING 3-50 CRANKCASE.. +53 CRANKSHAFT AND GONROD....... 3-59 CRANKSHAFT JOURNAL BEARING 3-62 CRANKSHAFT THRUST BEARING..... 3-64 ENGINE REASSEMBLY .. +66 32_ ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ‘The parts listed below can be removed and reinstalled without removing the engine tram the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER TEM FENOVAL INSPECTION REINSTALLATION PAIR valve: ras ore Cra? Starter motor crsis CFT crss7 Breather cover cr 328 — erst | Thermostat | cra so soo Cylinder head cover Cras rss rae Camshatt cra Ers25 Crs [ntake pipe —- =—— Creat (Gi filter crs2d =—_ Cr376 (Oil cooler corsa — crs76 Gil pan EP325 —_— Er3-75 ENGINE RIGHT SIDE TEM REMOVAL INSPECTION REINSTALLATION Exhaust pips end mulier crs — Cr at4 Cam chain tension adjuster Crs orsst Cr se4 Clutch cower Cra18 — cree Clutch (plates) | craw Crs-42 erase Primary dilven gaat cra — | raee Om pump. cFs20 Crs43 Crae4 Gearshift shaft 320 ra erase ‘Starter idle goar cover crs22 — cr 3-82 Siarler ile gear Craze — rset ‘Starter clutch cover Crse2 | —— Cr3-81 Btarier clutch D Cras Cras cre CKP sensor Crses cor 435 C380 Primary drive gear crs23 —— cra Cam chain and cam chain tensioner Cr322 Crsat CP380 Cam chain guide cr322 orsn C7320 ENGINE LEFT SIDE TEM REWOVAL INSPECTION EINSTALLATION Engine sprockel ora — ers Gear pusition sensor rao an cra Generator (cover) (328 ra crear Generator rotor crses —_— cra79 Water pur Cree cra ENGINE 3-3 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Belore 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 tha removal pra- cedure + Flemave the under cowlings. (7° 6-8) * Remove the front and rear seats (seat tall coven), + Flomave the fuel tank, ((F°4-52) F 66) = Disconnect the battery © lead wire. * Drain engine oll. (oF 2-13) + Drain engine coolant. ([" 2-18) S4_ ENGINE + Femove the ait cleaner box. (C7 4-62) + Flemave the throttie body, (2° 4-63) RADIATOR * Disconnect the reserve tank hose. © Disconnect the radiator inlet hoses, ‘+ Disconnact the cooling fan thermo-switch coupler ‘) and cool ing tan coupler (2 + Disconnect the harn coupler ‘+ Remove the radiator bolt ‘+ Remove the radiator and horn, i CAUTION Be careful not to bent the radiator fi + Romove the frant engine cover. EXHAUST PIPE AND MUFFLER + omove the exhaust pipe bolts = Figmove the muffler mounting bolt and nut ‘+ Remove the exhaust pipe/muttier. ENGINE 35 34_BIGINE + Remove the radiator mounting bracket ‘f ELECTRIC PARTS * Disconnect the oil pressure switch lead wire (2) and remove it {from the clamps. * Disconnect the starter motor lead wire 2 * Disconnect the graund lead wire * Disconnect the crankshaft position sensor caupler @). Disconnect the gear position switch coupler § Disconnect the engine coolant temperature sensor coupler @ [Disconnect the generator coupler (7 © Disconnect the lead wire couplers from each ignition coiliplug cap and camshaft position sensor. Do not remove the ignition collplug cap before discon- necting its lead wire coupler. + Remove the ignition colls‘plug caps. Do not pry up the Ignition cailplug cap with a driver ar a bar to avold its damage. * Be careful not to drop the ignition coil/plug cap to pre- vent its short or open circuit, ‘+ Remove the reservor tank, ENGINE SPROCKET AND GEAR SHIFT LEVER ‘+ Remove the speed sensor. + Flemove the gearshift lever. * Remove the engine sprocket cover. = Remove the clutch push rod 7 38_ ENGINE NOTE: Jack up the motorcycle and fix it for safery * Remove the speed sensor rotor + Remove the engine sprocket nut (2) and the washer. * Remove the cotter pin. (For E-03, 28, 33) * Loosen the rear axle nut and the rear tongue fink nut 4 * Loosen the Jelt and right chain adjusters * Push the rear whee! forward and make sure thatthe drive chain has enough slack. * Oisengage the drive chain trom the rear sprocket + Remove the engine: sprocket © ENGINE ‘+ Support the engine using an engine jack. ‘+ Remove the engine mounting bolts ?), 2 * Loosen the engin mounting pinch bolts © Flemove the engine mounting bolts 4 + Remove the engine mounting nut 5 + Romove tho angina mounting thrust adjuster lockrut @) with the special toot * Loosen the engine maunting thrust adjuster ¢: fully with he special tool (09940-14990: Engine mounting thrust adjuster socket wrench S10_ ENGINE + Remove the engine mounting nut @ * Loasen the engine mounting thrust adjuster iocknut + Loasen the engine mounting thrust adiuster @ NOTE: ‘Do not remove the engine mounting bolts at this stage. *+ Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft, + Remove the engine assembly. ENGINE 311 ENGINE REINSTALLATION Aeinstall the engine in the reverse order of engine removal Pay attention to the following points: NOTE: Be careful not to damage the frame and engine when installing the engine. + Betore installing the engine, install the spacer * Beloce installing the engine, install the engine mounting thrust adjusters 2) and * Install all engine maunting bolts, spacers and tighten them tem- porary (CF 3-12) CAUTION Be care(ul nat to catch the wiring hamess between the frame and the engine. 19 thrust adjusters to the specified «Tighten the engine moi torque with the special tool (09840-14990; Engine mounting thrust adjuster socket wrench (Engine mounting thrust adjuster: 23 Nem (2.3 kgt-m, 16.5 Ib-ft) + Tighten the engine mounting thrust adjuster tock puts 10 the specified torque with the special tool (09940-12990: Engine mounting thrust adjuster socket wrench I Engine mounting thrust adjuster tocknut: 45 Nom (4.5 keg, 92.5 Ib-ft) + Tighten all engine mounting. boits and nuts to the specified torque. (7 3-42) NOTE: The engine mounting auts are seltecking. Once the quts have bean removed, they are no longer of any use. ‘Tighten the engine mounting pinch bolt to the specitied torque. (F312) 212_ ENGINE eee 55 388 fre a ae 75 75 80) ee (ee tm | 23 a 365 BE ais | a 10 10 7a ‘Spacer 2 30.5 ee | 4s 45 925 Adjuster | DD 4 | ENGINE 343 * install he engine sprocket and the washer * Apply a smail quantity of THREAD, LOCK '1342" to the drive shal thread portion sofa) 99000-32050: THREAD LOCK “1342” * Tighten the engine sprocket nut to the specified torque. {© Engine sprocket nut: 115 Nem (11.5 kgt-m, 83.2 Ib-ft) ‘Install the speed sensor rotor + Tighten the speed sensor rotor Bolt to the specified torque. [F Speed sensor rotor bolt: 20 Nem (2.0 kghm, 14.4 th-tt) + Apply grease to the cluten push rod and install i SESH 99000-25010: SUZUKI SUPER GREASE “A” * Align the hole at the clutch release cylinder with the end of the clutch push rod when installing the engine sprocket cover, + Tighten the speed sensor bolt 7) to the specttied torque. (8) Speed sonsior bolt: 4:5 Nim (0.45 kgf-m, 3.0 tb-ft) * Install the engine sprocket covar and the gearshift lever 52- 62mm (2.05 = 2.44 inp * Install the radiator mounting bracket (P + Install the exhaust pipeimutier ‘@ CAUTION Replace the gaskets with new anes. 23m (2B hgh, 185 tet 23Nm (BB gt, 165 tt) Bann (23 igh, 165m) * Install and adjust the following items, * Engine oil (7 2-12) * Engine coolant (=F 2-19) * Throttle cable play (“7 2-16) * Glutch (F" 2-17) * Idling adjustment (C7 2-15) * Throttle valve synchronization ([—7" 4-73) * Drive chain slack (7 2-20) * Wiring harness. cables and hoses. ((7"8-14 ~ 22) ENGINE 3.15 ENGINE DISASSEMBLY “a CAUTION | Identity the position of each removed part. Organize the parts in thelr respective groups (e.g. intake, exhaust) 50 that they can be reinstalled in their original positions. + Remove the spark plugs. (7° 2-5) STARTER MOTOR * Remove the starter motor. PAIR VALVE + Remove the PAIR valve CYLINDER HEAD COVER * Flemove the cylinder head cover and its gaskets, + Remove the dowel pins and O-rings. ENGINE CAMSHAFTS © Remove the valve timing inspection cap + Turn tha crankghatt to bring the ling ‘) on the staner elutch to the index mark ‘8 of the valve timing inspection hole and also to bring the cams to the position as shown, + Remove the cam chain tension adjuster cap bolt union bolt @ and oll hase. + Fomove the spring, ball and cam chain tension adjuster. * Remove the carn chain guide @ * Remove the intake camshatt journal holder ‘3 + Remave the exhaust camshaft journal holder 4 ‘@ CAUTION Be sure to loosen the camshaft journ: |_ evenly by shifting the wrench diagonally, holder bolts: * Remove the intake camshait (]) + Remove the exhaust camshatt 2) CYLINDER HEAD * Remove the water hose * Flemove the thermostat cover (2 and thermostat, ‘THERMOSTAT INSPECTION: (75-10 + Remove the engine coolant temp. gauge (>, ENGINE COOLANT TEMP, GAUGE INSPECTION: (7'5-8 * Remove the cylinder head side bot @) and \ts gasket. ‘A CAUTION | When removing the cylinder head side bolt, pull the cam | chain upward, or the chain will be caught between the cylinder head and the side bolt. + Remove the cylinder head bolts (M6) 5). + Remove the cylinder head bolts and washers NOTE: When loosening the cylinder head batts, loosen each bott title ty fitia ckagonaly. + Remove the eylinder head. S48 ENGINE CLUTCH + Remove the cluteh cover, + Hold the clutch housing with the special tool A CAUTION Be careful not to damage the clutch housing of eluteh | plates. (09920-53740: Clutch sieeve hub holder + Remove the clutch springs. NOTE: Loasen the clutch spring sat bots Jtte by ittte and diagonally. * Remove the pressure plate, clutch pistes, spring washer and washer, ‘+ Remove the clutch push piece 4). the bearing ‘2 and the thrust washer @. «Remove the sluteh push rod NOTE: fits ditticull to pull aut the push rad @), use a magnetic hand ar a wire, ENGINE 349 Unlock the eiutch sieeve hub nut. * Hold the clutch sloowe hub with the special tool (09920-53740: Clutch sleeve hub holder * lermove the clutch sleeve hub nut. «= Remove the wave washer 7) washer (2), clutch sleeve hub | and washer, ‘+ Remove the primary driven gear assembly @ NOTE: itis dificult 10 remove the primary driven gear. rotate the crank- shat + Remove the spacer 5 and bearing (8. ‘= Remove the thrust washer 320_ENGINE lL PUMP * Remove the circtip @ * Rlemave the ail pump driven gear (2 NOTE: Do not drop the circiip (i), the pin and the washer 9) into the crankcase, * Remave the pin and the washer 4 + Remove the oil pump GEAR SHIFT SYSTEM * With the circlip @ removed, remove the gearshift shaft assom- bly 2 * Remove the gearshift cam plate bott (2). and gearshittcam plate a + Ramave the gearshitt cam stoner ‘8 STARTER IDLE GEAR + Flomave the starter idle gear caver. ‘= Remove the shaft (), wave washer @ washer ( starter idle gear Not @, besring © and washer 6 ‘= Remove the starter clutch cover. + Remove the wave washer 7), the starter Idle gear No2 2 and its shat 322_ ENGINE STARTER CLUTCH + Hold the starter cluich with the special tool 09920-38830: Starter clutch holder + Flemove the starter clutch bolt and washer. + Flemave the starter clutch assemnly. CAM CHAIN, CAM CHAIN TENSIONER, CAM CHAIN GUIDE + Flemove the cam chain tensioner (f) and cam chain guide 2 * lemave the cam chain @) and cam chain drive sprockat CKP SENSOR KP SENSOR INSPECTION:7-7-24 ‘+ Remove the GKP sensor. GENERATOR COVER + Remove the ganerator cover, GENERATOR ROTOR: * Hold the generator rotar with the:special too! 09930-44520: Rotor holder ‘* Remove the generator rator bolt. * Install a suitable bot A) to the left end of crankshat SUITABLE BOLT & [M112, length: 28 - 38 mm] + Remove the generator rotor with the special toot 09930-34980: Rotor remover WATER PUMP = Remove the water hose (, @ and iniet cover + Remove the water pump @. WATER PUMP SERVICING: ("5-11 3.24 ENGINE GEAR POSITION SWITCH * Rlemove the gear position switch. * Remove the switch contacts and springs: BREATHER COVER * Remove the breather cover, OWL FILTER jemove the oll iter with the special tool, (=7* 2-14) (09915-40610: Oil filter wrench OIL COOLER + Remove the oil cooler, OIL PAN ‘+ Flemave the cowling brackets {D). ‘* Flamove the oil pan. OIL PRESSURE REGULATOR + Ramave the oll pressure regulator 7). OIL PRESSURE SWITCH + Flomave the oll pressure switch 2 OlL STRAINER + Remove the oil strainer ) and O-ring. LOWER CRANK CASE «Remove the lawer crankcase bolts (6 mm). ‘+ Remove the lower crankcase bolts (8 mm). + Rlemave the lower crankcase assembly, TRANSMISSION « Hemave the transmission and O-rings. S26 _ ENGINE MIDDLE CRANKCASE > Remove the crankcase botts (6 mm} NOTE: Loosen the crankcase bolts diagonally and the smater sizes first. ‘+ Remove the crankease boits (8 mm). CRANKSHAFT + Remove the O-ring + Loosen the bearing cap bolts by using 10 mm, 12 point socket Wrench, and tap the bearing cap bolt lightly with plastic ham- merto remove the bearing cap. + Remove the crankshaft and thrust washers ©) PISTON AND CONROD + Push the confad to upward and remove the pisten and cantod from the upper crankcase, , CAUTION | Be careful not to damage the cylinder wall by the conrod. + Flemove the piston pin circip, + Separate the piston and conrod by driving out the piston pin. NOTE: Scribe the cylinder number on the head af the piston, 3.28 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE ‘A CAUTION Kdentity the position of each removed part. Organize the ] parts in their respective groups ((.e., intake, exhaust, No.1 or No.2) so that they can be Installed In their original locations. PAIR VALVE PAIR REED VALVE + Remove the PAIR valve cover. * Inspect the reed valve for the carbon deposit, * It the carbon deposit is found in the reed valve, replace the PAIR control valve with @ new one. PAIR CONTROL VALVE + Inspect that ait flows through the PAIR contra valve air inlet port to the air outlet ports. * Mair does not low out, replace the PAIR valve with a now one. * Connact the vacuum pump gauge to the vacuum port of the contro! valve as shown in the photograph. * Apply negative pressure of the specification slowly to the con- trol valve and inspect the air tlow. * Pair does not flow out, the contral valve is in narmal conaition. * If the contrat vale does not function within the specification, replace the control valve with a new ona. [EMS Negative pressure range: More than 66.6 kPa (491 mmHg) : Vacuum pump gauge (09917-4701 CAUTION | Use a hand operated vacuum pump to prevent the con- trol valve damage. CYLINDER HEAD COVER CAM POSITION SENSOR: + Install the oll seal 7) and cam position sensor “2 NOTE: When installing, clean the cam position sensors face. {F) cam position sensor bolt: 8 N-m (0.8 kgf'm, 5.8 Ib-ft) CAMSHAFT (CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters "EX" (lor exhaust) as against fetters “IN (or intake), ‘CAM WEAR * Check the camshatt lor wear or damage: ‘* Measure the cam height Bi with a miceometer, (5) 09900-20202: Micrometer (25 - 50 mm) ‘Cam height Service Limit: (IN.) : 36.28 mm (1.428 in) (EX) : 94.98 mm (1.417 in) $30_ ENGINE CAMSHAFT JOURNAL WEAR * Determine whethes or not each journal is worn down 10 the limit by measuring the ol clearance with the camshaft installed in place. * Use the plastigauge fo read the clearance at the widest par. tion, which is specified as folio Camshatt journal oil clearance: Service Limit: (IN & EX): 0.150 mm (0.0059 in) 09800-22302: Plastigauge NOTE: Install camshaft journal holders to their ariginal positions. or 399 * Tighten the camshaft journal hokier bolts evenly and disgo- nally to the specified torque. [EB camshatt journal holder bolt: 10 N-m (1.0 Keg, 7.0 Ib-tt) NOTE: (Do not rotate the camshatt with the piastigauge in placa, * Remove the camshaft holders, and read the width of the eqm- pressed plastigauge with envelope scale. * This measurement should be taken at the widest part * Ht the camshaft journal olf clearance measuted exceeds the limit, measure the inside diameter af the camshaft journal halder and autside.dhameter of the camshaft journal * Replace the camshatt or the cylinder head depending upon which one exceeds tha specification EES Journal holder 1.D.: Standard: (IN & EX}: 24.012 — 24.025 mm (0.9454 - 0.9459 in) (5 09900-20602: Dial gauge (1/1000, 1 mm) 99000-22403: Small bore gauge (18 — 35 mm) Camshaft journal 0.0.: Standard (IN & EX): 23.959 — 23,980 mm (0.9433 — 0.9441 in) licrameter (0 ~ 25 mm) (09900-20205: CAMSHAFT RUNOUT * Measure the runout using the dia! gauge. ‘= Replace the camshatt # the runout exceeds the limit (09900-20606: Diat gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-black set (100 mm) Camshaft runout: Service Limit (IN & EX): 1-10 mm (0.004 in) ‘CAM SPROCKET * Ingpect the sprocket teeth for wear. + Ifthey are worn, replace the sprockeVlcarishatt assembly and cam chain as a set. CAM CHAIN TENSION ADJUSTER INSPECTION + Remeve the cam chain tension adjuster cap bolt * Chack that tne push rod sides smoothly when releasing stop- per * fit does not slide smoothly, replace the cam chain tension ad- luster with a new one. CAM CHAIN TENSIONER INSPECTION + Check the contacting surtace of the cam chain tensioner. + tft is war or damaged. replace it with a new one. (CAM CHAIN GUIDE INSPECTION © Chack the eentacting surfaces of the cam chain guides. * If they are worn or damaged, repiace them with the new ones. 382 ENGINE CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY + Hemave the tappets ( and shims 2 by fingers or magnetic hand. (A CAUTION | Identity the position of each removed part. * Using special tools, compress the valve springs and remove the two cotter halves ‘3 trom valve. stem. (By 09916-14510: Vaive lifter 09916-14521: Valve lifter attachment (IN.) 09916-14830: Valve lifter attachment (EX.) 09916-84511: Tweezers & CAUTION Be careful nat te damage the tappet sliding surface with the speciat tool, SE * Remove the valve spring retainer @) and valve springs (5 * PUll out the valve from the other side. + Remove the ail seal ‘f) and the spring seat (2 “& CAUTION Do not reuse the removed oll seal + Remove the other valves in the same manner as described previousty. CYLINDER HEAD DISTORTION + Décarbonize the caribustion chambers. + Check the gaskated surtace of the cylintier head for distortion with 2 straightedge and thickness gauge, taking a clearance reading at several places indicated. + if the lacgest reading at any position of the straighiedge ex- ceeds the limit, replace the cylinder head (09900-20803: Thickness: gauge [EES Cylinder head distortion: Service Limit: 0.20 mm (0.008 in) VALVE STEM RUNOUT * Support the valve using Vsblocks and check its runout using the dial gauge as shoven * Ifthe runout exceeds the service limit, replace the valve. 02900-20606: Dial gauige (1/100 mm) (99900-20701; Magnetic stand (09900-21304: V-biack set (100 mm) FEY} valve stem runout: Service Limit: 0.05 mm (0.002 in) VALVE HEAD RADIAL RUNOUT * Place the dial gauge at s right angle to the valve head face and measure the valve head radial runout + Itt measures more than the service limit, replace the valve. (09900-20606: Dial gauge (1/100 mm) (09900-20701: Magnetic stand (09900-21304: block set (100 mm) FQ) Valve head radial runout: ‘Service Limit: 0.03 mm (0.091 In) VALVE FACE WEAR + Vigually inspect sach valve face for wear. Replace any valve with ant abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve face I itis out of specication, replace tha valve with a new one. (5 09900-20102: Vernier calipers. QD) Valve head thickness T: Service Limit: 0.5 mm (0.02 in) 334_ENGINE VALVE STEM DEFLECTION + Lift the valve about 10 mm (0.39 in) from the valve seat. + Measure the valve stem deflection in two directions, perpen- Gicular to each other, by positioning the dial gauge as shown. + It the deflection measured exceeds the limit, than determine whether the valve or the guide should be replaced with a new one. (© 09900-20606: Dial gauge (1/100 mmy 09900-20701: Magnetic stand ‘Valve stem deflection (IN & EX): Service Limit: 0,35 mm (0.014 in) VALVE STEM WEAR * Ith valve stem is wom down to the limit, as measured with a micrometer, replace the valve * Ifthe stem is within the Imi, then replace the guid * Ate replacing valve or guide, be sure io recheck the detiac- tion. (09900-20205: Micrometer (0 ~ 25 mm) Valve stem 0.0.: Standard (IN) : 3.875 ~ 3.990 mm (0.1585 - 0.1871 in) (EX): 8.955 - 3.970 mn (0.1557 — 0.1583 in) NOTE: \tvalve guides have 10 be removed lor replacement after inspect- ing related parts, earry out the steps shown in valve guide servic- ing. (3-35) ENGINE 3435 VALVE GUIDE SERVICING + Using the valve guide remover, drive the valve guide out to- ward the intake ot exhaust carishaft side. (09016-53310: valve guide removerfinstalter NOTE: * Discard the removed vaive guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No. 11115-11D70) © Fie-tinish the valve guide holes in cylinder head with the reamer and handle, (09916-49030: Valve guide reamer 109516-34542: Reamer handle a CAUTION | | When rafinishing or removing the reamer from the valve Guide hale, always turn It clockwise. | + Apply engine oil to the valve guide hole, * Drive the valve guide into the hole using the valve guide ine staier D and attachment @ (09916-53310: Valve guide installer/remover @ 09916-43220: Attachment 2 NOTE: Install the valve quide until the attachment contacts with the oy: inder head 2 A CAUTION lure to oil the valve guide hole before driving the new * After installing the valve guides, restinish their guiding bores using the reamer. * Clean and ail the guides after reaming (09016-33310: Valve guide reamer (09816-34542: Valve guide reamer handle NOTE: insert the reamer from the combustion chamber and alvayis turn the reamor handle clockwise. 335 ENGINE VALVE SEAT WIDTH INSPECTION * Visually check for valve Seat width on each valve face. * It the valve face has worn abnormally, replace the valve + Coat the vaive seat with Prussian Blue and set the valve in place. Flotate the valve with light pressure * Check that the transferred biue of the valve face is unitorm all around and in center of the valve face, (09916-10911: Valve lapper set * If the seat width {) measured exceeds the standard value, or seal width is not uniform reface tha seat using the saat cutter. EW) Valve seat width (i Standard: 0.9 — 1.1 mmm (0.095 - 0.043 in) I ha valve seat is out of specification, ré-cut the seat, WALVE SEAT SERVICING + The valve seats for both the intake and exhaust valves are ‘machined to four citferent angles, The seat contact surface is cul at 45" [intake EXHAUST = {, Mae ‘Yao eat a [Ns 45" [Nee Tar) 60) Natt nant (CB 09916-21111: Valve seat cutter set (09916-20630: Valve seat cutter (N-126) 09916-20650: Solid pilot (N-100-4.0) oO Q g a NOTE: The vaive seat cutters (N-121), (N-122} and (N-111) ave included in the valve seat cutter set (09916-21111) @ CAUTION ‘The valve seal contact area must be inspected after each + When installing the solid pilot (rotate it slightly Seat the pilot snugly Install the 45° cutter, attachment and handle INTIAL SEAT CUT * Using the 45° cutter, descale and clean up the saat. Rotate the ceutlar one or twa turns. ¢ Maasura tha valve coat width {R-ahar every cu * Ifthe valve seat is pitted or burned, use the 45° cutterto condi- tion the seat same more. NOTE: CUt only the minimum amourrt necessary from the seat to pre- vent the possibilly af the valve stem becoming too clase to the camshatt TOP NARROWING CUT + Ifthe contact area @ is too high on the valve, or if it is 100 wide, use the 18° (for the exhaust side) and the 30° (for the intake 5id2) 10 lower and narrew the contact area, BOTTOM NARROWING CUT + tf tha contact area W is too wide or too low, use the 60° cutter to narrow and raise the contact area (Contact are too figh and t20 wele on foe of vale a< 1Silerhaust) 30 neske) 338 ENGINE FINAL SEAT CUT ‘= ttthe contact area JP is too low oF too narrow, use the 45° cutter to-nise and widen the contact area. NOTE: After cutting the 15°, 30° ang 60° angles, itis possible that the wale Seat (5°) is:foo narrow. lf $a, ré-cut the valve seat to the correct wich, + After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the pee- vious cutting aparations. “A CAUTION 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.cheak the valve olear- ance affer the cylinder head has bean reinstalled. (7 2.8) * Cigan ang assemble the head and valve components. Fil the intake and exhaust ports with gasoline to chock far leaks. ‘+ It any leaks occur, inspect the valve seat and tace for burrs or other things that could prevent the valve from sealing. use extreme caution when handling gasoline. ‘Contact iba too low and too ‘serow on ace of vale Ss VALVE STEM END CONDITION ‘© Check the valve stem end face for pitting and wear, VALVE SPRING ‘The force of the col springs keeps the valve seat tight. Weak- ened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism ‘© Check the valve springs for proper strength by measuring their {ree length and also by the farce required to compress them, = ifthe spring length is less than the service limit, or tthe force Fequired to compress the spring does not fall within the range specified, replace both the inner and outer springs as a set. (09900-20102: Vernier calipers: [EE Vaive spring free length (IN & EX): Service limit: 37.8 mm (1.49 in) Valve spring tensi Standard: (IN & EX): 173 ~ 199 N/32.85 mm (fee Ks I.29 n) 38.8 = 44.8 Ibs: VALVE AND VALVE SPRING REASSEMBLY * Install the valve spring seats. * Apply molybdenum il salution to each oll seal, and press-ft them into position with the valve quice install. (09916-44310: Valve guide removerfinstaller “Fy Motvspenum oil SOLUTION a CAUTION | Do not reuse the remaved oil seal * Insert the valves, with their stems coated win molybdenum oil solution all around and along the full stem length without any break (a CAUTION | [ When inser eoch vive. take coe nt to camo tne | lip of the oil seal “Fy mouvepenum oit soLuTION * Install the valve springs with the: smal-piteh partion (lacing cylinder head Bi Large-pitch portan © Put on the valve spring retainer @), and using the valve lifer, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cottar 2 ta wedge in between ‘etainer and stem, Be sure that the rounded lip (8) af the cotter fits snuply into the groove ‘Bin the stem end. (By 09916-14510: Valve lifter Valve lifter attachment Be sure to restore each spring and valve to their original positions. ee + Install the tappet ahims and the tappets to their original post- tion NOTE: * Apply engine oil to the shim and tappet before fitting them, * When seating the tappet shim, be sure the figure printed sur- face faces the tappet. INTAKE PIPE * Install the intake pipe in the following procedure. * Apply THREAD LOOK °1342" to the screw and install the: in- take pipes, AZ 99000-32050: THREAD LOCK “1542” WATER BYPASS UNION * Apply SUZUKI BOND "12078" to the thread part of the water bypass union and tighten it to the specified torque. Gq 99000-31140: SUZUKI BOND "12078" (Water bypass union: 14 N-m (1.4 kgfm, 10.0 Ib-tt) Hi2_ ENGINE CLUTCH CLUTCH DRIVE PLATES INSPECTION NOTE: Wipe off engine oF trom the clutch drive plates with a clean rag © Measure the thickness of drive plates with a vernicr calipars, * If each drive plate is not within the standard range, replace it with & new one, Drive plate thickness (No. 1,2 & 3): Standard; 2.92 ~ 9.08 mm (0,115 — 0,121 in) (09900-20102: Vernier calipers: * Measure the claw width of drive plates with a vernier calipers. * Replace the drive plates found to have warn down to the: limit, (EGS Drive plate ctaw width (No.1, 2 & 3): Service Limit: 12.9 mm (0.508 in) (09900-20102: Vernier calipers CLUTCH DRIVEN PLATES INSPECTION NOTE: Wipe off engine oll from the clutch driven plates with a clean rag. + Measure each diven plate for distortion with a thickness gauge and surtace plate, + Replace driven plates which exceed the limit Driven plate distortion (No.1 and No.2): Service Limit: 0.10 mn (0.004 in) (03900-20803: Thickness gauge CLUTCH SPRING INSPECTION » Measure the free jength of each coll spring with a varnier call ers, and compare the fengtn with the specified limit. + Replace all the springs if any spring is nat within the limit. FEMS Clutch spring free length: Service Limit: 45.4 mm (1.787 In) (09900-20102: Vernier calipers ‘CLUTCH BEARING INSPECTION * Inspect the clutch release bearing tor any abnormality, particu- larly cracks. to decide whether it can be reused or should be replaced. * Smooth engagement and disengagement of the clutch depends (on the condition of this bearing. OIL PUMP: INSPECTION “+ Flotate the oll pump by hand and check that it moves smoothly. ‘+ IF it does not move smoothly, replace the oll pump assembly. STARTER CLUTCH INSPECTION ‘ Install the starter driven gear onto the starter clutch, ‘= Turn the starter driven gear by hand, + Inspect the starter clutch for a smooth movement. * Inspect that the gear tums ane: direction only Ifa large resistance is felt for rotation, inspect the starter clutch bearing or the starter clutch contacting surface on the starter driven gear for wear and damage. Itthey are found to be damaged, replace them with naw anes. (GENERATOR INSPECTION: 7-10 REASSEMBLY ‘© When installing the generator stator set baits, tighten them to the specified torque, [F) Generator stator set bolt 1:10 N-m (1.0 kgf-m, 7.0 lb-ft) NOTE: Be sure to install the grommet to the generator cover, WATER PUMP (51) #44 ENGINE: GEARSHIFT SYSTEM GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY * Remove the following parts from the gearshif! shaftigearshitt arm, D Washer ® Plate rewm spring 2 Girclip ® Washer @ Gearshift shaft retum spring = 7) Circlip, @ Gearshift cam drive plate (3 09000-06107: Snap ring pliers GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION * Inspect the gearshift shatt{gearshift arm for vrear or bend. * Inspect tha retum springs for damage or fatigue, + Replace the arm or spring it there is anything unusual GEARSHIFT SHAFT/GEARSHIFT ARM REASSEMBLY + Install the following parts to the gearshift shaf/gearshitt arm as shown in the right llustration, D Washer @ Plate return spring 2 Circlip @ Washer D Gearshin shaft reum spring =D Girelip @ Gearshift cam drive piate (5 09900-06107: Snap ring pliers NOTE: When mstaliing the gearshift shatt return spring, pasition the stop- per Bi of the gearshift arm between the shaft return spring ends R OIL PRESSURE REGULATOR * Inspect the operation of the oll pressure regulator by pushing ‘on the piston with a proper bar. + ithe piston does not operate, replace the cil pressure regula tor with a new one. OIL STRAINER + Inspect the oll strainer body for damage, ++ Clean the oil strainer if necessary, S46 ENGINE TRANSMISSION » Disassemble the countershaft and drive shaft, Pay attention to the following point. (3 09900-06104: Snap ring pliers + Remove the 6th drive gear circlip from its groove and slide it towards the Sraiath drive gear + Slide the 6th @ and 2nd 2 drive gears toward the ard/ath drive gears, then remove the 2nd drive gear circlip (2 sik) e228 {Sth ctiven gaat $B tnt avan gear ENGINE 47 REASSEMBLY "Assemble the countershalt and driveshall in the reverse order of disassembly: Pay attention to the following points: NOTE: * Rotate the bearings by hand to inspect for smooth rotation. Fle- place the bearings if there Js anything unusual. * Before installing the gears, apply engine ail to the driveshalt and countershatt * Before instating the olf seal, apply grease to oll seat foe 99000-25010: SUZUKI SUPER GREASE “A* A CAUTION * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be Installed. * When installing a new circlip, do not expand the end gop larger than required to slip the circlip over the shaft. * After installing a circlip, make sure that itis completely sented in its groove and securely fitted. NOTE: When reassembling the tansmissian, attention must be given to the locations and postions of washers and circlips. The cross Sectional view shows the correct position af the gears, bushings, washers and-crclips. (3-49) ‘+ When installing & new circlip, pay attention to the direction of the circlip. Fit it to the side where the thrust is as shown in the ustratton, CAUTION When installing the gear bushing onto the shaft, the shaft cil hole 7) with the bushing oil hole 2, Trust {4 Sharp wage S48 ENGINE TRANSMISSION PARTS LOCATION CYLINDER CRANKCASE SERVICING: (73-54 CYLINDER DISTORTION + Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge. taking a clearance reading at several places as indicated + It the largest reading at any position of the straightedge ex- ceeds the limit, replace the cylinder. (08800-20803: Thickness gauge Cylinder distortion: Service Limit: 0:20 mm (0.008 in) CYLINDER BORE * Inspect tha cylinder wall for any scratches, nicks or other darn age, ‘+ Measure the cylinder bore diameter at six places, (EM cylinder bore: ‘Standard: 67.000 ~ 67,015 mm (2.6378 ~ 2.6384 In) (09900-20508: Cylinder gauge set ¥50_ ENGINE PISTON AND PISTON RING PISTON DIAMETER + Using a micrometer, measure the piston outside diamater at ‘+ mm (0.6 in) from the piston skirt and. + Ht the measurement is less than the limit, replace the piston, Piston diameter: Service Limit: 66.880 mm (2.6331 In) at 15 mm (0.6 in) from the skirt end (09900-20203: Micrometer (50 — 75 mm) PISTON TO CYLINDER CLEARANCE + Subtract tha piston dismeter from the cylinder bore diameter. 09900-20102: Vernier calipers (GEARSHIFT FORK THICKNESS. * Measure the gearshift fork thickness using the vernier calipers. (ED) sshitt fork thickness: ‘Standard: 4.8 ~ 4.9 mm (0.189 - 0.193 in) ‘09900-20102: Vernier calipers QS 54 ENGINE * Inspect the gearshift cam bearing for abnarmal noise and ‘smooth rotation. * Flepiace the bearings if there is anything unusual * Inspect the gearshitt cam bearing @, gearshift fork bearing (2) ‘and gearshift shaft bearing ) for abnormal noise and smooth ‘rotation while they are in the crankcase, * Replace a bearing if there is anything unusual. Besring removal = Flemove the gearshift fork bearing Using the special tool, + Remove the gearshift cam bearing using the special toats 09921-20220; Bearing remover set (09910-20115: Conrod stapper CAUTION * Don't damage the crankcase by the conrod stopper, * Be careful not to lean the bearing remover. © Remove the ail seal, + Remove the gearshift shaft bearing using the special tool. Installation * install the bearings using the special tool, 00013-70210; Bearing installer set NOTE: ‘The staniped mark side of the gearshift shaft bearing faces out= side. * Install the oll seal, + Install the gearshift cam with the bearing. NOTE: Tha stamped mark side of the gearshift cam bearing faces out side, ‘ESB ENGINE * Install the gearshitt forks and their shafts as shown, @ For Srd/ath drive gears 2 For 6tn driven gear © For Sth driven gear «Apply a small quantity of THREAD LOGK “1342" to the bearing retainer screws and the shit fork shai retainer bolt, * Tighten them ta the specified torque. J 99000-32050: THREAD LOCK “1342” (0) Bearing retainer screw: 10 N-m (1.0 kgfm, 7.0 lb-ft) (Gearshift fork shaft retainer bolt: 19 N-m (1.8 kgtsm, 13:7 Ibeft) Ol JET. Remaval + Remove the piston cooling oil jets (f) fram the upper cranke case. + Flemave the oil jt (for transmission) from the lower crankcase. Inspection and cleaning * Check the oil jets for clogging. ‘+ If they are clogged, clean their oll passage with a proper wire and compressed air. @ Piston cooling oil jet D Oil et (#14) (For transmission) 358 _ ENGINE Installation + Fit the new O-rings

3-85) ENGINE 245 [ET Thrust bearing selection table Clearance betore inserting left-side Ester Tinea beri Thrust clearance thrust bearing (arta) | thiclenost 2.560 — 2.585 mm ‘white 2.475 - 2500 mm 0.060 - 0.110 mm (2.1008 -0.1018 in)_| _(72228-17E00-0FO) | (0.0974-0.0984 in) | (0.0024 - 0.0043 in "2.535 — 2.560 mm Yellow 2450-2475 mm G0s0-O110mm — | (0.0998 - 0.1008 in) | (12228-17E00-0E0) | (0.0985- 0.0974 in) | (0.0024 - 0.0043 in) 2510 — 2.595 mm Green ‘2.425 — 2.450 mm 0.060 - 0.110 mm (0.0968 ~ 0.0998 in)_|_(12228-17E00-0D0) | (0.0955-0.0085 in) | (0.0024 - 0.0043 in) 2495 —2.510 mm Blue 2400 - 2.425 mm 0.060 — 0.110 mm (9.0978 ~ 0.0988 in) | (12228-17E00-0C0) | (0.0945- 0.0955 in)_| (0.0024 ~ 0.0049 in) 2.460 ~2.485 mm Black 2375 —2.400 mm 0.060 - 0.110 mm (0.0869 ~ 0.0978 in) | (12228-17EO.080) | (0.0935 0.0045 in)_| (0.0024 - 0.0049 in) 2.490 — 2.460 mm Red 7350-2375 mm 0.088 ~ 0.110 mm (0.0857 ~ 0.0868 in) | _(12228-17ED0.0A0) | (0.0925~0.0835 in) | (0.0022 - 0.0043 in) + After selecting a left-side thrust beating, insert it and again perform the thrust clearance measurement fo make sure it falls within the standard range. NOTE: Right-side thrust bearing has the same specitication as the GREEN (12228-17E00-G00) of ett-side thrust bearing. Clare E66 _ ENGINE: ENGINE REASSEMBLY + Reessemble the engine in the reverse order of disassenibiy, + The following stens require special attention or precauslonary measures should be taken NOTE: Apply engine oil to each running and sliding part before reas- -sembling. *+ Be sure to install the following llams to the crankcase. * Crankshatt journal bearing (7 3-62) * Gearshitt fork (7" 3-56) * Gearshift fork shaft (7° 3-56) * Gearshitt shaft bearing (7" 3-55) * Gearshitt cam bearing (I 8-55) * Gearshift fork bearing (9° 3-55) * Gearshitt cam (7 3-55) * Bearing retainer (7 3-56) * Olljets (CF 3-58) PISTON AND GONROD * Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that tha gaps ate 50 lo- cated ‘+ lub a small quantity of molybdenum ail solution onto each pis- ton pin. “Py movrevenum on © Assemiis the piston and canrod. NOTE: * When instaling the pistons, the indent (A) on the piston head must be laced to another side of ID cada 'B on conrod tace, * install the: pistons. NOTE: Be sure to instal! the pistons in the oylindars from which they weve removed in disassembiy: refer to the ylinder numbers, “7” through 4", scribed an the piston. ‘= Install the piston pin circtips A CAUTION, End gap of the circlip shauid not be aligned with the cutaway in the piston pin bore. * Apply engine oll to the sliding surface of the pistons and cyline der walls. ‘+ Install the pistons and conrods into the cylinders from upside, NOTE: When installing the pistons, the indent &) of the piston head must be faced fo each extaust side, ‘A CAUTION |_Becarefull not to damage the cylinder wall by the conrod, ‘= Check that iD code @ on the each conrods taces toward intake side, (& CAUTION Be sure to clean the conrod big end. * Apply molybdenum oll solution to the crank pin bearings sur- face. “Pi movvevenum om soLution ‘348 ENGINE CRANKSHAFT + Position the Na.2 and No.3 cenrod big ends teward same side land the No.t and No.4 conred big ends toward opposite side ot Noz and Nos. ‘+ Sot the crankshatt fo the conrods and unper crankcase © Apply molybdenum oii solution to the crank pin and bearing surface. “Fi movyscenum ol SOLUTION & CAUTION) Be sure to clean the canrod big end. * When fiting the conrod cap, make sure that 1.0. code ‘Bon each conrod taces toward intake valve side. * Appiy-angine oil to ne beanng cap baits. * Tighten the bearing cap bolt by using a 10 mm, 12 point socket wrench as following two steps CE) Conrod beating eap bolt: Initial: 15 Nm (1.5 kat-m, 17.0 tb-tt) Final: 80° (74 turn) + Apply engine oil to the conrod big end side surfaces, + Check the conrod movement for smooth turning ‘CRANKSHAFT * Apply molybdenum cil solution to each crankshaft journal bear- ing lightly “Ty movvepenum olL SOLUTION ‘+ Insert the right and let-thrust bearings with oll groove ‘facing the erank web, NOTE; ight-theust bearing has green painting, CRANKCASE + Clean the mating surfaces of the crenkcases. * Install the dowel pins“) and O-ring @ to the upper crankcase. 370_ ENGINE * Apply SUZUKI BOND to the mating surtace of tha middle crank- case, Gg 99109-31140: SUZUKI BOND “12078” (For USA) GET] 99000-31110; SUZUKI BOND “1215" (For the athers) NOTE: Use of SUZUKI BOND is as follows: * Make surtaces tree from moisture, oll, dust and other foreign materials, * Spread on surtaces thinly fo form an even layer, and assemble the crankeases within few minutes, * Take extreme care not to apply any BOND to the oi hote, oll groove and bearing. * Apply to distorted surfaces as It forms a comparatively: thick ‘firm mae Align the gearshift forks with the each gear, * Tighten the crankcase bolt (8 mm) in ascending order of num- bers assigned to these bolts. Tighten each bolt a little at a time to equalize the pressure. (7) Crankcase bolt: (M3) initial: 18 Nom (1.8 kgfm, 13.0 b-ft) Final; 32 Nom (3.2 kgfm, 23.0 Ib-ft) * Tighten the other crankcase bolts a littia at a time to equalize the pressure. @) crankcase bolt: (16) initial: 6 Nom (0.8 kgm, 4.5 It) Final: 11 Nem (1.1 kgfm, 8.0 lb-ft) NOTE: Fit the clamp to the crankcase bot‘. ‘NOTE: Fil the gasket la the crankcase bott NOTE: ‘After the crankcase bolts have been tightened, check i the erank- shatt rotates smoothly 372 _ ENGINE ‘TRANSMISSION : © Install the bearing pins (7) and the C-ring @ on the upper crank- case. * Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove on the bearing and the: bearing pin with the indent on the bearing. + Install the driveshafi assembly on the upper crankcase, NOTE. Align the beanng ring with the groove an the crankcase ant the bearing pin with the indent on the bearing. + Install the olf seal ‘= Turn the bearings to install the bearing dowel pins @ in the respective positions. * Install the O-rings. > Install the dowel pins {® ENGINE 3-73 * Apply SUZUKI BOND to the mating surface of the lower crank- case GH] 99104-31140: SUZUKI BOND "12078" (For USA) sq] 99000-31110; SUZUKI BOND “1215” (For the others) NOTE: Use of SUZLIKI BOND is as follows: * Make surtaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even ayer, and assemble the crankcases within few minutes. * Take extreme care not to apply any BOND to the oi! hole, oi groove and bearing. * Apply to distorted surfaces as it forms a comparatively thick thir, ‘+ Match the middle and lower crankcases, NOTE. Align the gearshift forks with their grooves, 4 7_ ENGINE * Tighten the crankcase bolts a little at a lime to equaliz pressure, {© Crankcase bolt:(Mé) initial: 6 Nom (0.6 kgtm, 4.5 ib-ft) Final :11 Nem (1.1 kgf-m, 8.0 Ib-ft) (MB) initial: 15 Nem (1.5 kgf, 10.8 Ib-ft) Final : 26 Nem (2,6 kgf, 19.0 tb-tt} NOTE: * Fit the copper waisher to tha crankcase bolts ®). * Fit the gasket washer fo the crankcase bolts i. * Check the driveshait and countershatt to rotate smoothly OIL STRAINER + instal the O-ring. NOTE: Apply grease to the O-ring. Af 99000-25010; SUZUKI SUPER GREASE “A” CAUTION |_ Use the new O-ring to prevent oll leakag ‘Install the oll strainar as shown. [7] ol strainer bott: 10 Nem (1.0 kgt-m, 7.0 Ibeft) OIL PRESSURE REGULATOR ‘= Apply grease to the O-ring and press in the oil prassure taguta- tor to the crankcase, fax 99000-25010: SUZUKI SUPER GREASE “A” CAUTION Use the new O-ring to prevent oil leakage. OIL PAN © Install the gasket 4 CAUTION. Use the new gaskel to prevent oll leakage. * Install the off pan, NOTE Fit the gasket washer to the oll pan bott B + Tighten the oil pan bolts diagonally to the specified torque. (7) Ol! pan bolt: 10 N-m (1.0 kgt-m, 7.0 lb-ft) * Install the cowling brackets and 2 3.76_ENGINE Ol. PRESSURE SWITCH Apply SUZUKI BOND "12076" to the thread part of the oil pres- sure switch (D) and tighten ito the specified torque, Gj 99000-31140; SUZUKI BOND "12078" (7) Oil pressure switch: 14.N-m (1.4 kgf-m, 10.0 Ib-tt) NOTE: Be careful nat to apply SUZUKI BOND "12078" to the hate of the thread end, OlL COOLER * Apply the grease to the O-ring Sf 99000-25010: SUZUKI SUPER GREASE “A” ‘@ CAUTION | Use the new O-ring to prevent oll leakage. ++ Install the oll cooler as shown. 1) Ol cooler bolt: 19 Nem (1.0 kgt-m, 7.0 Ib-ft) OW FILTER * Install the oil titer using the special toot, (C7 2-14) (09915-40610: OFF filter wrench ENGINE 377 * Install the gasket. «Install the breather eover. () Breather cover bolt: 10 N-m (1.0 kgf-m, 7.0 tb-tt) GEAR POSITION SWITCH ‘Install the gear position switch contacts () and the springs (2, * Apply the grease to the O-ring 93 99000-25010: SUZUKI SUPER GREASE “A” + Install the gear position switch as shown. ‘78 ENGINE WATER PUMP + Apply grease to the O-ring A CAUTION Use the new O-ring to prevent oll leakage. Jak 99000-25010; SUZUKI SUPER GREASE “A” © Tighten the water pump mounting bolts to the specified torque, (©) water pump mounting bolt: 10 N-m (1.0 kgf-m, 7.0 lb-ft) NOTE: Pass through the gear position swlich lead wire under the warter pump it. * Apply the engina coolant to the O-ring + Install the water inlet cover, [E) Water inlet cover bolt: 10 Nem (1.0 kgt-m, 7.0 Ib-tt) ‘+ Install the radiator hoses. (-7"8-24) ENGINE 379 GENERATOR ROTOR, = Degraase the tapered portion af the generator rotor and also the crankshaft. Use nanfiammable cleaning solvent ta wipe off oily or greasy matter and make these surfaces completely cry, * Install the generator rotor onto the crankshaft * Install the rotor bolt with the washer + Holding the generator rotor with the special too! and tighten its bolt to the specified torque, (09930-44520: Rotor halder [F] Generator rotor bolt: 120 Nem (12.0 kgtm, GENERATOR COVER * Apply SUZUKI BOND “12078" lightly fo the mating surfaces at the parting line between the upper and lower crankeases as shown, "€22] 99000-31140: SUZUKI BOND “12078" * Install the dowel pins and new gasket ([ 4 CAUTION | Use the new gaskets to prevent oil leakage. * Install the generator cover and tighten the generator cover botts to the specified torque. (© Generator cover bolt: 10 Nm (1.0 kaf-m, 7.0 Ib-ft) Be careful not topinch the tinger between the generator cover and the crankcase, NOTE: Fit the gasket washer to the bois ® 0 ENGINE = Install the CKP sensor, * Apply SUZUKI BOND "12078" light to the groove of the signal generator lead wire gromet 7] 99000-21140: SUZUKI BOND "12078" CAM CHAIN DRIVE SPROCKET * Install the cam chain drive sprocket onto the crankshaft NOTE: Align the punched! mark (K) on the cam chain drive sprocket with the punched mark f on the crankshan CAM CHAIN TENSIONER AND CAM CHAIN GUIDE * Install the cam chain, © Apply a small quantity of THREAD LOCK ~1342" to ie cam chain tensioner bolt and cam chain guide bol. * Install the cam chain tensioner <), washer @ and cam chain gui Zl 99000-32050; THREAD Lock "1342" {Ei cam chain tensioner bolt: 10 N-m (1.0 kgf-m, 7.0 lb-ft) (Cam chain guide bolt: 10 N-m (1.0 kgfm, 7.0 lb-ft) ENGINE 3.81 STARTER CLUTCH * Install the washer 7 * Install the starter clutch assembly onto the crankshatt NOTE: Align ttre engraved line ®) on the starter clitch with the punched markiB on the crankshaft * Install the starter clutch bolt with the washer. + Hold the starter clutch with special tool and tighten its ott to the specified torque. (09920-34820: Starter clutch (F Starter clutch bolt: 55 Nem (5.5 kgt-m, 40.0 tb-ft) ‘STARTER IDLE GEAR * Install the starter idle gear No.2) its shatt ‘2 and the wave washer + Apply SUZUK! BOND 12078" lightly 1a the mating surtaces ® ‘at the parting line between the upper and lower crankcases ‘and surlace (B: as shown. 29 99000-31140: SUZUKI BOND "12078" $42_ ENGINE * Install the new gasket (D) and the dowel pins. A CAUTION | |_ Use a new gasket to prevent oil leakage. “Install the starter clutch cover and tighten its batt as shown. NOTE: * Fit the wive clamp to the starter clulch cover bolt ®) as shown, * Fit the new gasket washer to the starter ciutch cover bolt 8) as shown. @ CAUTION Use the new gasket washer to prevent oil leakage. [P) starter idle gear cover: 10 Nem (1.0 kkgttm, 7.0 Ibeft) + Install the starter idle gear'Ne.t shaft (D and the tirust washer 2 the bearing (3) and the starteridle gear No.1) the washor and the wave washer ‘5 * Install the dowel pins and the new gasket 7: _& CAUTION "Use a new gasket to prevent ail leakage. install the starter idle gear cover and tighten its bolts to the Specie’ toraue (© Starter idie gear cover: 10 Nem (1.0 kaf-m, 7.0 Ib-ft) NOTE: Fit the gasket washer to the bait GEARSHIFT SYSTEM * Install the gearshitt cam stopper ‘f), its bolt 2, the washer 2 and the return spring @). NOTE: Apply 4 small quantity of THREAD LOCK “1342"fo the gearshift cam stopper bolt) and tighten it fo the specified torque, Gq 99000-32050: THREAD LOCK "1342" (8) Gearshift cam stopper bolt: 10 Nem (1,0 kgf-m, 7.0 It-ft) NOTE. ‘Hook the return spring end to the stopper ‘t + Confirm the gearshift cam stopper movement + Check the neutral position, * Install the gearshift cam stopper plate after aligning the gear- shift cam pin ) with the gearshift cam stopper plate hole + Apply small quantity of THREAD LOCK "1342" to the gaar- shift cam stopper plate bolt and tighten itto the spocified torque. Zl 29000-32050: THREAD LOCK “1342” (F) Gearshift cam stopper plate bolt: 10 Nom (1.0 kgtm, 7.0 lb-ft) S44 ENGINE + Install the gearshift shattigearshitt arm ) with the washers as shown. NOTE: Pinch the gearshift arm stopper (2 with return spring ends () + Install the washer) and circlip @). Ol PUMP * Install the O-ring to the ail pump and apply grease to i. “da CAUTION __Use the new O-ring to prevent oil leakage. Sfx 99000-25010: SUZUKI SUPER GREASE “A” NOTE: ‘Set the oll pump shaft end to the water pump stat. + Install the oll pump with the three bolts and then tighten them 10 the specitied torque, (aii pump mounting bolts: 10 Nem (1.0 kgf-m, 7.0 Ib-tt) © Install the washer @ and the pin (2. NOTE: Be careful not to crap the washer }) and the pin into the cramke case, ‘© Install the oll pump driven gear * Install the circtip @ (© 09000-26107: snap ring pliers CLUTCH * Install the thrust washer onto the countershatt | NOTE: ‘The chamier sido & ofthe thrust washer faces crankcase sige. | + Install the oll pump drive gear () to the primary driven gear assembly. NOTE: Be careful not to contact the primary driven gear with the crankwab when installing the clutch housing + Install the bearing @ and spacer 2 and apply engine ail to them, + Install the primary driven gear assembly. 386 ENGINE * Install the thrust washer install the clutch sleeve hub (2: orto the countershatt, * Install the washer 'Si.and spring washer NOTE: The convex side of the washer @ faces eutsiae, * Install the clutch sieeve hub nut * Hold the clutch sleeve hub using the special tool (& 09020-53740: Clutch sleeve nub holder * Tighten the clutch sleeve nub nut to the specitied torque () clutch sieeve hub aut: 180 N-m (15.0 kafm, 108 Ib-ft) *# Lock the clutch sleeve hub nut with a eenter punch, CLUTCH « Insert the washer (f) and spring washer 2: = + Insert the clutch detve plates and driven pistes one by one into the clutch sleeve hub in the prescribed ordes NOTE: Insert the outermost drive plate claws ® to the other sits ®) of clutch housing as shown, WORIVE PLATE Ne. 1 (40 itn pes) :7 pes bb DRIVE PLATE No 2 (48 frictan es) 1 pe © DRIVE PLATE No.3 (With damoer) <1 pe @POAVEN PLATE No Theses: 26mm). 6-6 pes DRIVEN PLATE No.2 Total pos {Thickrass: 23:mm): 0-2 poe Freon pec + Install the clutch push tad () into the countershalt * Install the clutch push piece 2, the bearing “and the thrust ‘washer @) to the countershatt NOTE: Thrust washer @ is located between the pressure plate and the bearing @ 38 ENGINE * Install the clutch pressure plate. * Install the clutch springs * Hold the clutch housing using the special toot. “& CAUTION “Be careful not to damage the clutch housing or clutch | plates, (3 09920-53740: Clutch sleeve hub holder ‘+ Tighten the clutch spring set bolts to the specitied torque. {8 Clutch spring set bolt: 10 Nem (1.0 kgf-m, 7.0 tb-ft) Non Tighten the clutch spring set bolts eagonaily CLUTCH COVER + Apply SUZUK! BOND "1/2078" lightly to the mating surtaces at the parting line between the upper, middle and lower crank- cases as shown, GE] 99000-31140: SUZUKI BOND “12075” * Install the gasket Gand the dowel pins, ‘A CAUTION Use the new gasket to prevent oll leakage, + Install the clutch cover and tighten its bolis to the specified torque. clutch cover bolt: 10 N-m (1.0 kgfm, 7.0 Ibeft) NOTE: * Fit the clamp to the boit ®) as shown. * Fit the gaskets to the bolts as shown, ENGINE 3489 CYLINDER HEAD * Fit the dowel pins and the new cylinder head gasket ({) to the cylinder. 4 CAUTION | Use the new gasket to prevent gas leakage. + Place the cylinder head on the cylinder. + Install the cylinder head side bol and gasket 3) and tighten It to the specified torque. [F) cytinder head side bolt: 14 N-m (1.4 kat-m, 10.0 Ib-tt) NOTE: * The metal side of the gasket ® faces out. * Install the cylinder head side bolt between the cam chain. NOTE: When installing the cyfinder head, keep the cam chain taut. * Tighten the cylinder head bolts (M10) to the specified two-step torque with a torque wrench sequentially and diagonally, [) cylinder head bolt (M10): Initial: 25 Nem (2.5 kgfom, 18.0 Ib-ft) Final: 46 Nem (4.6 kgf, 33.3 thet) NOTE: * Install the washers fo the cylinder head botts (M10) as shown, * Apply engine ofl to the washers and thread partion of the bolts before installing the cylinder head bolts. + Tighten the cylinder head bolts to the specified torque. (7) cylinder head ott (Nae); 10 Nm (1.0 kam, 7.0 tb-Fi) * Fit the gasket 7) and tighten the water temp. gauge. (7) Water temp. gauge: 18 N-m (1.8 kgt-m, 13.0 Ib-tt) + Install the thermostat. (75-10) * Install the thermostat cover, (Thermostat cover bolt: 10 N-m (1.0 kgfm, 7.0 lb-ft) NOTE: Fit the clamp to she bolt ®. + Install the water hose. ([—7'B-24) CAMSHAFT + Tum the crankshaft counterclockwise with the box wrench and align the line & on the starter olutch with the index mark '® of the valve timing inspection hole while keeping the cam chain pulled upward Pull the cam chain upward, or the chain will be caught between crankcase and cam drive sprocket. & CAUTION To adjust the camshaft timing correctly, be sure to align the line & with the index mark & and hold this position | when installing the camshaits, | * The cam shafts are identified by the embossed letters * Before placing the camshaits on cylinder head, apply molyb- denum ail solution to their journals and cam faces. + Apply engine oll fo the camshaft journal holders Ti mouvapenum on so.ution NOTE: Before installing the camshatt, check that the tappets are inétallod correctly, * Pull the cam chain tightly * The exhaust camshatt sprocket has an arrow marked “1" Turn the exhaust camshalt so that the arrow is aligned with the gasket surtace of tne cylinder head + Engage the carn chain with the exhaust camshalt sprocket * Bind the cam chain and the sprocket with a proper wire clamp 4) to prevent the cam chain disengagement while installing the camshaft journal halders + The other arrow marked “2" (Bi should naw be pointing straight up. Starting from the roller pin that Is directly above the arrow marked "2", count out 14 roller pins (Irom the exhaust cam shalt side going towards the intake camshaft side). * Engage the 14 rollar pin ‘C) on the cam chain with the asrow marked “3" on the intake sprackat + Bind the cam chain and the sprocket with 4 proper wire clamp 1 to prevent the cam chain disengagement while installing the camshaft journal holders. 382 ENGINE NOTE! The cam chain should now be on ail three Sprockets. Ba careful ‘Rot to move the crankshaft until the camshatt journal halders and cam chain tension adjuster are secured. + Install the dowel pins. © Install the camshatt journal holders, intake and exhaust and cam chain guide. ‘+ Fasten the camshaft journal nokders evenly by tightening the camshatt journal holder bolts sequentially and diagonally. NOTE: * Damage to head or camsnalt journal holder thrust surfaces may resuttfthe camishat journal hakders are nat drawn down evenly. * Each camshaft journal holder is kientified with a cast-an tetters a © Tighten the camshatt jaurnal holder bolts in ascending order of numbers (see below) to the specified torque. (©) camshaft journal holder bolt: 10 Nem (1.0 kgf, 7,0 Ib-ft) & CAUTION ‘The camshaft journal holder bolts are made of a special material and much superior in strength, compared with other types of high strength bolts. ‘Take special care not to use other types of bolts. 4 ENGINE ‘Cam chain tension adjuster ‘+ Retract the push rod by pushing the rach * |nstall the bail @) to the cam chain tension adjuster, Sy * Install the new gasket 2). (A CAUTION | Use the new gasket to prevent oil leakage. | * Install the cam chain tension adjuster and tighten the mounting bolts. {F) cam chain tension adjuster mounting bolt: 10 Nm (1.0 kgfom, 7.0 theft) * Install the spring D. © Install the oll hase as shown in illustratioit. (CoFNext page) ‘Install the gaskets and tighten the union bolt {8 Oi hose union bolt: 12 Nem (1.2 kgm, 8.7 Ib-tt) ‘+ Install the gaskets and the cam chain tension adjuster cap bolt, NOTE: Glick sound is heard when the cam chain tension adjuster cap bolt fs installed. * Tighten the cam chain tension adjuster cap bolt to the speci- fied torque. [F) cam chain tension adjuster cap bolt: 23 Nem (2.3 kat-m, 16.5 Ib-ft) CAUTION After installing the cam chain tension adjuster, check to be sure thot the adjuster work properly by checking the slack of cam chain, * Cut the wire clamps. * After installing the cam chain tension adjuster, rotate the eranik- shaft (some tums), and recheck the pasitions of the camshats. (3-98) 35 6a. Hi a (wa eeu 21) & es fa) /. uo un odo ‘hur Eo: Sa in Wa oe wba) ‘No! “wo a 990 29) eu on i pe Botinas S ‘uo/SUR HEE UNE yo sana we UBhY 48 ENGINE * Tighten the valve timing Inspection plug @ to the specified torque. {© Valve timing inspection plug: 11 N-m (1.1 kgm, 8.0 lb-ft) CYLINDER HEAD COVER * Pour engine oil in each oll pocket in the cylinder head. NOTE, Be sure to check the vaive clearance. (J 2-8) © Install the dowel pins * Install the O-rings. * Install the new gaskets to the cylinder head cover, + Apply SUZUKI BOND ~1207B"to the cam end caps of the oas- kats as shown, eq] 99000-31140: SUZUKI BOND “12078” ‘4 CAUTION Use the new gaskets to prevent oil leakage. + Plaoe the cylinder head cover on the cylinder head, Fit the new gaskets to-sach hasd cover bolt. ‘a CAUTION © Tighten the head cover bolts to the specified torque. [Head cover bolt: 14 Nim (1.4 kgm, 10.0 [bf ENGINE 347 PAIR VALVE * Install the PAIR reed valve T), (Co> 8-22) * Apply THREAD LOGK ta the bolts, instal the PAIR valve ane! hose. (78-22) ‘f@2} 99000-32050; THREAD LOCK "1342" [F)PAIR reed valve cover bolt: 10 Nem (1.0 kgt+m, 7.0 tht) STARTER MOTOR «Apply the groase to the O-ring, SG 99000-25010: SUZUKI SUPER GREASE "A" * Install te starter motor (© Starter motor mounting bolt: 10 Nem (1.0 kgt+m, 7 tb-ft) * Install the spark plugs. (2 FI SYSTEM AND INTAKE AIR SYSTEM CONTENTS PRECAUTIONS IN SEAVICING ... FI SYSTEM TECHNICAL FEATURE: INJECTION TIME .. COMPENSATION OF INJECTION TINE... INJECTION STOP CONTROL .. FUEL DELIVERY SYSTEM. FUEL PUMP ... FUEL PRESSURE REGULATOR FUEL INJECTOR... FUEL PUMP CONTROL SYSTEM ECM (Fl CONTROL UNIT)... INJECTION TIMING .. SENSORS. INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM OPERATION ... 4-21 FI SYSTEM PARTS LOCATION 4-22 FI SYSTEM DIAGRAM. 4-24 FI SYSTEM WIRING DIAGRAM. SELF-DIAGNOSIS FUNCTION USER MODE .. DEALER MODE FAIL-SAFE FUNCTION FI SYSTEM TROUBLE CUSTOMER COMPLAINT ANALYSIS. SELF-DIAGNOSTIC PROCEDURES SELF-DIAGNOSIS RESET PROCEDURE... MALFUNCTION CODE AND DEFECTIVE CONDITION. "C11" CMP SENSOR CIRCUIT MALFUNCTION. "C12" CKP SENSOR CIRCUIT MALFUNCTION. JAP SENSOR CIRCUIT MALFUNCTION... “TP SENSOR CIRCUIT MALFUNCTION ECT SENSOR CIRCUIT MALFUNCTION. "IAT SENSOR CIRCUIT MALFUNCTION .. "AP SENSOR GIRGUIT MALFUNCTION TO SENSOR CIRCUIT MALFUNCTION “C24”, "C25", C26" or “C27” IGNITION SYSTEM MALFUNCTION....... - C28” STV ACTUATOR CIRCUIT MALFUNCTION “C29” STP SENSOR CIRCUIT MALFUNCTION “C30” STC UNIT CIRCUIN MALFUNCTION ... est GEAR POSITION SWITCH CIRCUIT MALFUNCTION "633", “C34” or “C35” FUEL INJECTION MALFUNCTION. “C41” FP RELAY CIRCUIT MALFUNCTION. “€42" IG SWITCH CIRCUIT MALFUNCTION. FISYSTEMANDINTAKE AIRSYSTEM 4-1 FUEL SYSTEM... FUEL TANK LIFT-UP FUEL TANK REMOVAL .. 4-52 FUEL TANK INSTALLATION. 4-52 FUEL PRESSURE INSPECTION. 4-53 FUEL PUMP INSPECTION... 4-54 FUEL PUMP RELAY INSPECTIOI 4-56 FUEL PUMP AND FUEL FILTER REMOVAL 4-56 FUEL MESH FILTER INSPECTION AND CLEANING 4-58 FUEL PUMP AND FUEL MESH FILTER INSTALLATION. 4-58 THROTTLE BODY AND STV ACTUATOR 2 461 CONSTRUCTION... 4-61 AIR CLEANER 8OX ANO THROTTLE BODY REMOVAL . 4-62 THROTTLE BODY DISASSEMBLY .. THROTTLE BODY CLEANING INSPECTION... THROTTLE BODY REASSEMBLY THROTTLE BODY INSTALLATION STP SENSOR ADJUSTMENT.. FUEL INJECTOR INSPECTION FUEL INJECTOR REMOVAL.. FUEL INJECTOR INSTALLATION ... FAST IDLE ADJUSTMENT... THROTTLE VALVE SYNCHRONIZATION | THROTTLE POSITION SENSOR (TPS) SE THROTTLE CABLE ADJUSTMENT. SENSORS.......... IAP SENSOR INSPECTION. JAP SENSOR REMOVAL/INSTALLATION. TP SENSOR INSPECTION..... TP SENSOR REMOVAL/INSTALLATION KP SENSOR INSPECTION........... CKP SENSOR REMOVAL/INSTALLATION CMP SENSOR INSPECTION... CMP SENSOR REMOVAL/INSTALLATION IAT SENSOR INSPECTION IAT SENSOR REMOVAL/INSTALLATION .. ECT SENSOR INSPECTION .. ECT SENSOR REMOVAL/INSTALLATION AP SENSOR INSPECTION... AP SENSOR REMOVAL/INSTALLATIO! TO SENSOR INSPECTION... TO SENSOR REMOVALIINSTALLATION STP SENSOR INSPECTION . z STP SENSOA REMOVALIINSTALLATION (£2 FISYSTEMANDINTAKE AIRSYSTEM PRECAUTIONS IN SERVICING When handling the Fl component parts or servicing the Fl sys- ‘tam, obsarve the following points for the salety of the system, CONNECTOR/COUPLER + When connecting & connector, be sure to push it m until a click is fet. * With a lock type coupler, be sure to release the lock when dis- ‘connecting, and push ft in fully til the lock works when cone necting it. ‘= When disconnecting the coupler, be sure to hold the coupler tbody and da not pull the lead wires. ‘= Inspect each terminal on the connectoricoupler tor looseness ‘or bending ‘+ Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material ‘which could impede proper terminat contact. Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace, + When taking measurements at electrical connectors using a tester probs, he sure to insert the probe from the wire hamess side (backside) of the connactoricoupler. * When conhecting meter probe from the terminal side of the ‘coupler (connection trom harass side not being passible), use extra: care not to force and cause the male terminal to bend or the temale terminal 1o open, Connect the prabe as shown to avaid opening of female termi- pal. Never push in the probe whore male terminal is supposed fa fn. + Check the male connector for bend and female connector for excessive opening, Also check the coupler for lacking (leose- ness), corrasion, dust. etc: otek @ x ae D coupier (@D Probe. D yrmeremaie: | Mein is FUSE + When a fuse blows, always investigate the cause, correct it and then replace ths fuse, + Do not use a fuse of a cifterent capacity + Do not use wire or any other substitute for the fuse. ECM/VARIOUS SENSORS + Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and instalation, + Be carstul not to touch the electrioal terminals of the EGM. ‘The static electricity from your body may damage this part. * When disconnecting and connecting the ECM couplers, make sure fa turn OFF the ignition switch, or electronic parts may get damaged. + Batiery connection in reverse polarity is strictly prohibited. Such wrong connecticn wil damage the compenents of the Fl ays- tem instantly when reverse pawer is applied. FISYSTEMANO INTAKEAIR SYSTEM £3 4 FISYSTEMANDINTAKE AIRSYSTEM. + Removing any battery terminal of a running engine is strietty prohipites, ‘The moment such removal is made, damaging counter electro- ‘motive force will be applied to the ECM which may result in Serious damage. * Before measuring voltage at eacn terminal, check to make sure that battery voltage is 11V or higher. Terminal woHlage ‘check at low battery voltage will lead to erroneous diagnasis. + Newer connect any tester (voltmeter, ohmmeter, ar whatever) to the ECM when its coupler is disconnected, Otherwise, dam- age to ECM may result, » Never connect an chmmator to the ECM with its coupler con nected, If attempted, damage ta ECM or sensors may result. * Be sure fo use a specified voltmetariohmmeter Otherwise, ac- curate measurements may not be obtained and personal injury may resutt ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there: are various. methods for electrical circult inspection, described here is 2 general method to check for open and short ‘cireult using an chmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause can exist In the connectoricoupler or terminal, thay need to be chistked carelully, * Loose connection af connesteticcupler * Poor contact af terminal (due 16 dirt, corrosion oF rust. paor contact tension, entry of foreign object etc:) * Wire hamess being open + Poor tarminahto-wire connection FISYSTEMAND INTAKE AFISYSTEM 45 + Discannect the negative cable trom the battery. + Chack each connectar/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler tock tt equipped. * 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.).Atthe same time, check to make sure that each terminal is fully inserted in the coupler and locked Ireontact tension is not enough. reetity the contact to increase tension or replece. ‘The terminals must be clean and tree of any foreign material which could impede proper terminal contact. + Using continuity inspect or voltage check procedure as de- ‘scribed below, inspect the vrire hamess terminals for open cir- ‘cuit and poor connection, Locate abnormality, if any. ‘Continuity check + Measure resisiance across coupler ‘8 (between ‘A’ and © in ‘the figure}, If no continuity is indicated {infinity or over limit}, the circuit is open between terminals (and, * Disconnect the coupler and measure resistance between couplers @ and Be If no continuity is indicated, the circuit is open between cous plers A and (If continuity Is indicated, there is an open cir- cuit between couplers 1 and © or an abnormality in coupler @ of coupler hack cra enaion by inserting Z rier A, crack each erat or bene are proper alignment Dic Doven SD Tie i few tract et 444 FISYSTEM AND INTAKE ARSYSTEM VOLTAGE CHECK I voltage is supolied to tho circuit being checked, voltage check can be used as ciroult check. * With all connectorsicouplars cannected and voltage applied to the circuit being checked, measure vollage between each ter- minal and body ground, Imeasurements were taken as shown in the figure at the right ‘and results are as listed below, it means that the circuit is pen between terminals 4 and 6. Voltage Between: and body ground: Approx. SV © and body ground: Approx. 5V ® and bady ground: ov Also, if measured values are as listed below, a resistance {ab- narmaiity) exists which causes the voltage drop in the circuit between terminals ® and ‘i and body ground: Approx, SV ‘and body ground: Approx. SV—— PV voltage drop A and body ground: Approx. aV— ey SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) * Disconnect the negative cable {ram the battory * Disconnect the connectors/counlers at bath ends of the circuit to be checked. Nore: I the circuit ta be checked branches 1o other parts as shown, disconnect all connectors‘couplers of these parts. Otherwise, di- agnosis will be misled, + Moasure resistance between terminal at one end of circurt (1) terminal in figure) andl body ground. I continuity is indicated, there is a short clroutt to ground between terminals A and °C FISYSTEMANO INTAKE AIRSYSTEM 47 * Disconnect the connectoricoupler included in circuit (coupler 4) and measure resistance between terminal ® and body oraun, If continuity is indicated, the circuit is. shorted to the ground between terminals) and Eb USING TESTERS * Use the Suzuki multi-circuit tester (09900-25008). * Use well-charged batteries in the tastar, + Be sure fo set the tester to the carrect testing range. Using the tester * Incorrectly connecting the @ and © probes may cause ine inside of the tester to burnout * it he voltage and current are nat known, make measurements using the highest range. * Reset the pocket tester 1a 02 belore measuring each resis: tance or after changing the resistance range. * When measuring the resistance with the mult-circuit tester, also ‘measure the resistance with no-load. Sub-tract that resistance from the resistance measured undar lad in order to get the true resistance, (Measured _ (No-load fesistance) resistance) = When measuring the resistance with the muti-circuit tester, « will ba Shawn 88 10,00MQ and “1” flashes in the display. ‘+ Check that no voltage is agpliad before making the measure- ment. It voltage IS applied, the testar may be damaged. * After using the tester, tum the power off (1 09900-25008: Multi-circuit tester NOTE: * When connecting the mult ercuit tester, install fixe copper wires (C20 is bolow 0.5 mm) to the back side of the laad wire coupier and connect the probes of tester to therm. * Use a fine copper wire, the outer diameter being below 0.5 ‘mm. to prevent the rubber of ihe water proof coupler feom damn age. = (True resistance) [ Maer-cincur TESTER 48 FISYSTEMANDINTAKE AIR SYSTEM. Fl SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) ‘The factors to determine the injection time include the basic fuel injection time which is basis of the intake air pressure, engi ulated on the speed and throtle opening angle, and various compensations which ‘are datermined according ta the signals fram varlous Sensors that detect the engine and driving conditions SSeS ECM ————— ————— | Intake Air Pressure intake air pressure | | Sensor {IAP Sensor) signal "| | Basic GCrankshatt Position Engine speed | tut ‘Sensor (CKP Sensor) signal | * injectian | time Throtie Position Sensor (TP Sensor) |_Throtie opening | signal Various Various signals Sener = >) Compensation Utinate ————— te le! Injection signal Injectors - Injection time FISYSTEMANO INTAKE AIRSYSTEM 48 COMPENSATION OF INJECTION TIME (VOLUME) The following ditferent signals are output fram the respective sensors for compensation of the tuel injection time (volume). DESCRIPTION NAL ATMOSPHERIC PRESSURE SENSOR SIG. | When atmospheric pressure |s low, the sensor sends the signal to the ECM and reduce the injaction time (voluma). ENGINE COOLANT TEMPERATURE SEN- SOR SIGNAL When engine coolant temperature is low, injection time (vol ume) Is increased INTAKE AIR TEMPERATURE SENSOR SIG- NAL When intake air temperature Is tow, Injection time (volume) ‘s increased. BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time, it monitors the votage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low wattage, ENGINE RPM SIGNAL STARTING SIGNAL | ACCELERATION SIGNAL’ DECELERATION SIGNAL At high speed, the injection time (volume) is increased, This is the compensation of the SAAD. When starting engine, additional [uel is injected during crank: ing engine. During acceleration, the fuel injection time (volume) is ine creased, in accordance wrth the throttle opening speed and | engine rpm. During deceleration, the fuel injection time (wae uma) is decreased INJECTION STOP CONTROL SIGNAL DESCRIPTION TIP OVER SENSOR SIGNAL ‘When the motorcycle tips over, the tip over sensor sends a (FUEL SHUT-OFF) ‘signal to the ECM. Then, this sighal cuts OFF current sup- plied to the tual pump, tue! injectors and ignition coils. OVER-AEV, LIMITER SIGNAL ‘The fuel injectors stop operation when engine rpm reaches te. limit rpm 410_FISYSTEM AND INTAKE AIRSYSTEM FUEL DELIVERY SYSTEM The fual delivery system consists of the fuel tank, fuel pump, fuel fiers, Tuel feed hose, {ust delivery pipe {including fuel injectors) and fuel pressure regulstor. There is no fue! return hose. The fuel in the fuel tank is Pumped up by the fuel pump and pressurized fuel to flow into the injector Installed in the tuel delivery pipe. Fuel pressure is regulated by the tuel pressure regulator As the fuel pressure: applied to the fuel injector (the fuel pressure in the fuel delivery pipe) is always kept absolute Tuel pressure of 3.0 kgtiom* (300 KPa, 43 psi), the fuel Is injected into the throttle body in conic dispersion when the injector opens according to the Injection signal from tha ECM, The tuo! relieved by the fuel pressure regulator flaws Out to the tue! tank, Ful td basa > el mest titer (Fer low pressure) File purrs si ee He ccurses fio! Fllieved tuo < Behre pressurized hie! FISYSTEM ANDINTAKE AIRSYSTEM 41 FUEL PUMP The electric fuel pup is mounted at the bottom cf the fuel tank. which consists of the armature, magnet, impeller, brush, check valve and relief waive. The ECM controls its ON/OFF operation a5 controlled under the FUEL PUMP CONTROL SYSTEM. ‘When elecirical energy is supplied to the fuel pump, the motor in the pump runs and sa.does the impeller. This ‘CaUSES a pressure difference fo occur betwean both sides of the impeller as there are many grooves around ft. Then the fuel is drawn through the inlet port, and with its pressure increased, it ia discharged through the: ‘outlet port. The fuel pump has-a check valve to Keep some pressure in the tuel feed hose even when the fuel pump is stepped, Also, the reliel valve 's equipped in the fuel pump, which releases pressurized tuel to the fue! tank when the outlet of the tue! pressure Nas increased up to 4.5.~ 6.0 kat/om* (450 ~ 800 kPa, 64-85 psi) Rate cane Magret poser When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the bide groove as viewed in angular direction due to fluid friction. This process continuously takes place causing fuel pressure to be built up. The pressurized fuel is then let out from the pump chamber and iischarped through the motor section and the chack valve. Blade cxner in pate 4-32. FISYSTEMAND PVTAKE AIRSYSTEM. FUEL PRESSURE REGULATOR ‘The fuel pressure reguiator consists of the spring and vaive. It keaps absolute fuel pressure of 3.0 kgticm® (900 kPa, 43 psi) applied to the injector at all times, When the jus! pressure rises more than 3.0 kgt/cm* (400 KPa, 43 psi), tha fuel pushes the valve in the Fequlator open and exc695 fue! returns to the fuel tank. at at | coo | FUEL INJECTOR ‘The tue! injector consists of the solenoid coll, plunger, needle valve and filer Iris an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM, When! the-solencid coll of the injector is energized by the ECM, it becomes.an electromagnet and attracts the plunger. At the same lime, the needle valve incorporated with the plunger opens and the injectar which is unger the fuel pressure injects fuel in conic dispersion. AS the lift stroke of the needle valve of the injector is set Constant, the volume of the fue! injected at one time is determined by the length of time during which the solenoid coll is energized (injection time), FISYSTEM ANDINTAKE AR SYSTEM. 419, FUEL PUMP CONTROL SYSTEM When the ignition switch is tured an, current from the battery flows to the fuel pump motor through the side-stand relay and the fue! pump relay causing tha motor to tum. Since the ECM has a timer function, the fuel pump motor stops turing in three seconds after the switch has been tuned on, ‘Thoteatter, when the crankshatt is turned by the starter motor ar the engine has been started, the engine revolving signal is input to the ECM. Than, current flows to the fuel purtp motot from the battery through the side-stand relay and the fal pump relay sa that the pump continues to funetion. A tip over Sensor is provided in the fuel pump sentiol circuit. By this provision, anytime the motorcycle tips ‘over, the tip over sensor sends a signal to the ECM to turn off power to the fue! pump retay, causing the fuel pump motor to stop. At the same time, current to the tuel injectors as well as the ignition coil is interrupted, which then stops the angina. \a.swrex ae cia on l ioe ewes eRe tester nae seems Sweat (414 FISYSTEMAND INTAKE AIRSYSTEM ECM (FI CONTROL UNIT) The ECM is located under the seat. The ECM consists of CPU (Gentral Processing Unit), mamory (HOM) and VO (InpuvOutput} sections. The signal from each sensor is sent to the input section and then sent to CPU, Qn the basis of signal information received, (CPU calculates the volume of fuel necessary for injection using maps programmed for varying engine conditions, ‘Then, the operation signal of the fuet injection is sent from the output section to the fue! injector, The eight kinds of independent program maps are programmed in the ROM. ‘These eight kinds of maps are designed to compensate for differences ot the intaka/exhaust systems and voting performance. LIGHT LOAD: When the engine is running in @ light load, the fue! injected volume (time) is determined the ‘basis of the intake air pressure and engine speod. HEAVY LOAD: When the engine is running ih a heavy load, the fuel injected volume: (time) is determined the basis of the thratbe valve opening and engine speed, FISYSTEMANDINTAKE AIRSYSTEM 4-15, INJECTION TIMING ‘The system employs 4 sequential, four-cylinder independent injection type, using the: crankshalt position sensor (signal generator) to determine the piston position (injection timing and ignition timing) and the ‘camshait position sensor to identity the cylinder during operation, and these information are sent to the ECM. This makes it possible to inject the optimum volume of tuel in the best timing for the engine operating sonditions. When the crankshaft begins to turn at the time of starting, the ECM sends the signals-to the four injectors, 1M, #2, #3 and #4 to have them inject fuel simultaneously, From the second turn onward, the sequential four-cylinder independent injection occurs as exptained above. cKP signal ley. 20. e230 whey Ignition ‘irwing Cermak angie we Os igor 720° Tuening 2 3 4 5 TUANS Toc. lea ‘416 SYSTEM AND INTAKE AIR SYSTEM SENSORS: INTAKE AIR PRESSURE SENSOR (IAP SENSOR) ‘The intake air pressure sensor is incated at the rear side ot the air cleaner box and its vacuum hose is cannected to the thrattie body. The sensor detects the intake: alr pressure, which is then con verted into: voltage signal and sant to the ECM, The basic fuel injection time (volume) is determined according to the voltage signal (output voage) ‘The voltage signal increases when the intake air pressure is high. Intake a prassutetrenet) i-— ha Low High an wezaur Thaw vacuum) THROTTLE POSITION SENSOR (TP SENSOR) ‘The throttle position sensor is installed on the No.4 throttle body. ‘The throttle postion sensor is a kine of variable resistor which dotects the throttis opening angie. The battery voltage in the sensor is changed to the throttle posi- tion voltage which is then sent fo the ECM. ‘The basic fuel injection time (volume) is determined according to the voltage signal (output voltage) ‘The voltage signal increases as the throttle is opened wider. Cua Throte rahe Lopeninpibegr2a) ve FISYSTEMANO INTAKE AIR SYSTEM £17 CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal rotor is mounted on the right end of the erankshatt and the crankshaft position sensor (Pick-up call) is installed on the right side of the middie crankcase. The sensor generates the pick-up signal 10 be supy ECM. The ECM calculates and decides bath the fuel injection timing ‘and ignition timing. ‘The injection volume incteases when the engine rpm is high to the CAMSHAFT POSITION SENSOR (CMP SENSOR} ‘The signal rotor is Matalled on the intake camshaft. and the cam- shaft position sensor (Pick-up coil} is installed on the cylinder head cover. The sensor generates the pick-up signal to be supplied to the ECM, The ECM calculates and decides the cylinder Identity and se- ‘auential injection timing INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) The intake alr tomperature sensor is installed at the right side of the air cleaner box The sensor detects the intake alt temperature in thermistor resis- lance valve. With this resistance value converted to voltage sig- Pal, the signal is sent to the ECM. The injection volume increases as intake air temperature decreases The thermistor resistance value increases when the intake alr temperature is low, and decreases when the intake air tempera ture is high Thormstor Lim 2—e High Se 4.18 FISYSTEM AND INTAKE AIRSYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) ‘The engine coolant temperature sensor is installed at the rear ide of the cylinder head ‘The sensor detects the engine coolant temperature in thermistor resistance value, which is then converted to voliage signal and sent to the ECM, Ths injection volume increases as coolant tem- perature decreases. ‘The thermistor resistance value increases when the engine cool lant temperature is low, and decreases when the engine cootant temperature is high asinine vaca — ne 3 f \ : Thecmisioe 5 cr Core engh Terese ATMOSPHERIC PRESSURE SENSOR (AP SENSOR) ‘The atmospheric pressure sensor is located over the EGM. ‘The sensor detects the atmospheric pressure, The detected pres: ure is converted into voltage signal and sent to the ECM. The injection time (volume) is controlled according to ms voltage signal (output voltage}, ‘The voliage signal increases as the atmospheric pressure rises. Mrssmnete fae rami) FISYSTEMAND NTAKE ARRSYSTEM 419 TIP OVER SENSOR (TO SENSOR) The tip aver serisor is located in ahead of the battery holder The sensor detects the leaning of the motoroyele, When it leans more than 43°, the mechanical switch tums ON and a signal is sent to the ECM. At the same time, this signal cuts OFF current supply to the fue! pump, fue! injectors and ignition calls. SECONDARY THROTTLE POSITION SENSOR (STP SENSOR) The secondary throttie position sensor is installed an the No.4 throttle body. The secondary throttle position sensor is a kind of variable re. sistor which detects the secondary throttle opening angie. ‘The STP sensor detects the STV actuator movement by the vol ‘age signal which is then sent to the ECM. The ECM determines the ST valve angle based on the opera- tion map. ‘The voltage signa! increases 5 the secondary throtile is opaned wider. Canaan = ™ f | : 1 5 Toto valve 5 opening Deqse6) ral ——= Lange £20_FISYSTEMANDINTAKE AR.SYSTEM INTAKE AIR SYSTEM SECONDARY THROTTLE CONTROL SYSTEM ‘The secondary throttle contro! system (STC system) consists of tha secondary throttle valve (ST valve), secondary throttie valve actuator (STV actuator) and secondary throttie position sensar (STP sensor) ST vahe is installed in each thratie body. STV actuator and STP sensor are installed! an the right side of the throttle body assembly. The ST valve is turned by the STV actuator, This system is designed ta control the volume and the velocity of intake ait s as to improve angina output power. The system produces more seamless and linear throttle respanse. This is performed by opening or closing the throttle botly intake port according 10 the gear positions and engine rpm. When the engine is: running in a low speed range, the intake part is almost closed for controlled intake air volume, This improves the effect to intake alr Now pu'sation so that the engine can output higher power in this speed range. As the engine spoed grows faster, the intake port are gradually pen for guiding the proper volume sf ait into the thrattle bodies so that the engine can produce the maximum power in each speed range. ~ ™ Secondary thotle position sensar (STPS) ‘Secondary thraste valve ‘sry Seconaery throttle vate actuator TVA} FISYSTEM ANDINTAKE AIRSYSTEM 421 OPERATION Tha secondary throttle control system (STC system) operates on the signal supplied from the ECM. The ‘apen’close operation of tha sacondary throttle valve (ST valve) is performed by the secondary throttle valve actuatar (STV actuator) which is controlled by the STC: unit to change the eurrent direction into the matar of the STV actuator. ‘The STP sensor detects the STV actuator movement by measuring vallage and the ECM determines the ST valve angle based on the operation map. ‘When turning the ignition switch ON, every time the STV actuator automatically drives the ST valve and ‘checks tully close and open position voltage and rétum to original position to confirm each ST vaive position voltage Secondary throne vaten (STV) Secondary thats poster serany (STS) ‘Secondary throtle valve ‘euator (STV) FISYSTEM AND INTAKE AIR SYSTEM £23, 4:28 SYSTEM AND IVTAKE AIRSYSTEM Fl SYSTEM DIAGRAM FISYSTEMANDINTAKE AIRSYSTEM 425 FISYSTEM WIRING DIAGRAM 4:25 SYSTEM AND IVTAKE AIRSYSTEM SELF-DIAGNOSIS FUNCTION ‘The self-diagnosis function is incorporatad in the ECM. The function has two modes, “User moda’ and “Depler mode”, The user can only be notified by the LCD (DISPLAY) panel and LED (Fi light). To chack the function of the individual Fi system devices, the dealer mode is prepared, In this check, the special tool is necessary to read the code of the malfunction items, USER MODE LCD (DISPLAY) FLUIGHT MALFUNCTION INGICRION NoierGON INDICATION MODE “NO” Coolant Temp. — = ee Coolant Tamp. and Filight tums ON. | Each 2 sec. Temp. “FI letters, or FF is indicated. a Engine can start Engine can not start | “FT letter Fi light turns ON “FT is indicated 2 and blinks. continupaisy. 4 When one of the signals is not recelved by ECM, the fail-safe circuit works and injection is not stopped. in this case, “FI' and coolant temp. are indicated in the LCD panel and motorcycle can run. Et ‘The injection signal is stopped, when the camshatt position sensor signal, crankshatt position sensor signal, tip aver sansor signal , #1/#2, #3 and #4 ignition signals. #1, #2, #3 and #4 injector signals, fuel pump retay signal ar ignition switch signal is not sent to ECM. In this case, “Fl” is indicated in the LCD panel. Motorcycle dees not run, “CHEC*: Tha LCD panel indicates “CHEC™ when no communication signal from the ECM is received for 5 seconds. For Example: ‘The ignition siteh is turned ON, and the engine stop switch is tured OFF: in this case, he speed- ‘ameter does not receive any signal from the ECM, and the panel indicates “CHEC". It CHEC is indicated, the LCD does not indicate the trouble coda. It is neoassary to check the wiring hares between ECM and speadometer couplers. ‘The possible cause of this indloation is as follows: Engine stop switch is in OFF pasition, Side-stand/ignition inter-lock system és not working: Ignition fuse is burnt, NOTE: Uniti starting the engina, the Flight turns ON. The FI light fs also turned GN when engine femperature is high, or olf pressure i low: FISYSTEMAND INTAKE AI SYSTEM $27 DEALER MODE ‘The detective function is memorized in the computer. Use the special teof's coupler to connect to the dealer mode coupler. The mamorized maifunchon code i$ displayed on LOD (DISPLAY) panel, Mattunction means that the ECM does not receive signal from the devices. These alfected devices are indicated in the code form, (09990-82710: Mode select switch ‘CAUTION Before checking the malfunction code, do not disconnect the ECM lead wire couplers. If the couplers trom the ECM are disconnected, the malfunction code memory is erased and the |_maifunetion eode ean not checked. | LED (DISPLAY) MALEUNCTION UOMICN FILIGHT INDICATION | INDICATION MODE “NGF 00 = 7 code is indicated — Fon crval nomarito. | Fight tums OFF: For sich 2 eee, cae moon indicated. 4:28_FISYSTEM AND INTAKE AIRSYSTEM CODE MALFUNCTION FART REMARKS: 200 | None No detective part C11 | Camshatt position sensor (CMP sensor) 12 | Crankshatt position sensor (CKP sensor) Pick-up oil signal, signal generator 13 | Intake sir pressure sensor (IAP sensor) 14 | Throttle positian sensor (TP sensor) 3 £15. | Engine coalant temp, sensor (ECT sensor) cat Intake air temp. sensor (IAT sensor) 22 | Atmospheric pressure sansor (AP Sansor} €23 | Tip over sensor (TO sensor) 24 | ignition signal #1 (1G coll #1) For #1 cylinder 25 | Ignition signal #2 {IG coll #2) | For #2 cylinder €26 | Ignition signal #3 (1G coll #3) For #3 cylinder 27 | Ignition signal #4 (1G coil) For #4 cylinder 28 | Secondary throttle valve actuator (STW actuator) 229. | Secondary throttie pusition sensor (STP sensor) ¢30 | Secondary throttie contro! unit (STC unit} 231 | Gear position signal (GP switch) 682 | Injector signal #1 (FI #1) For #1 cylinder 633 | Injector signal #2 (Fi #2) For #2 eylinder 654 | Injector signal #3 (Fl #3) For #3 cylinder 1635. | Injector signal ed (Fi #4) For #4 cylinder Fug! pump control system (FP contro| system) Fus! pump, Fue! pump relay | Ignition switch signal (IG switch signal) Antisthett In the LOD (DISPLAY) panel, the malfunction code is indicated from small code to large code. 3 To get the proper signal trom the throttle position sensor, the sensor basic position is indicated in the LCD (DISPLAY) panel. The maltunction code is indicated in three digits. in front of the three digits, a line appears in any of the position, upper, migdte or lower fing. the indication is upper o lower line when engine rpm is 1.300 ram, sightly tum the throttle position sensor and bring the line to middle. In the normal condition, the throttle valve stop screw pushes throttle valves sfightly, and indication point is middle line Setting procedure: 1.Adjust the engine rpm to 1 300 rpm. (= 2-15) 2.Slop the engine and connect the special lool (Mode ‘select switch) to the dealer mods coupler at the wiring hamess. 4.1 the throttle position sensor adjustment is necessary, joosen the screws and tun the thrattle position sensor and bring the tine 10 middle 4. Then, tighten the screws to fix the throttle pasition sensor, (09930-11960: Torx wrench SCO | = ieoreet - COG | — Correct position zc00 | The LOD indicates 0.4 sec.jime, and two times show the cor rect position, where itis fixed. Inearrect FISYSTEMANDINTAKE AIRSYSTEM 429 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 malunction condition. [Tem FAICSAFE MODE | STARTING ABILITY | AUNNING ABILITY, Camshatt position | When camshait position ees sensor signathas faled during running, NO" “ves” | he ECM determines cyinder | Motoreyeie an run, but ohe engine stops, engine as # belors occurrence of | can not start. such a failure Grankshalt positon | The motorcycle stops, . cone sensor NOE __ Intake air pressure | inlake Sir pressure i ined z ae sensor 19 760 mmbg. WES abe Thratile postion |The throttle opening Is sensor fixed to full open position. "ES" "YES" dh ing is also fixed. Engine coolant | Engine coolant temperature a temperature sensor| value is fixed to 60°C. ae es intake alr intake air temperature - : temperature sensor| value is fixed to 40°C, “yES" “vES' ‘imaspheric ‘Almospheric pressure iS 7 pressure sensor _|{ixed to 760 mmHg. ES XE Ignition wi lepnensn ES" YES* = signal eres [92.93 #4 cylinders can run. YES" es" #2 | [Fenian #1, #98 Ma oylindere can run 3 | #3 tgnition-off Le tem n Geers 1, #2 & WS cylinders can Tun “YES "YES" 4 | Fei iprttoneatt Wi, #2 8 85 cylinders can run. Teen “YES ES || St heeces 32, #3 B #4 cylinders can run, leek "VES" ES a2 [Pe Roane 1, #3. #4 cylinders can ran "YES" ES #3. | #3 Fusteut #1, #2 & #4 cylinders can nun. "YES" ES [eee ecco Hy, #2 & W3 cyinders can fun, Secondary voile | Secondary twrotta vale e wes “yes” valve actuator _| fixed to half open position. ‘Secondary throtte | Secondary throta valve le oe position sensor _| fixed to full open position. es: ne ‘Secondary thratie | Secondary thratie valve i a control unit fixed to full open position. Bid NEE ‘Gear position signal) Gear position signal is fixed ] a to 6th gear. = tes "Yes" means that the engine can start and can run evan If the above signal is not received from each sensar. But, the engine sunning condition is not complete, providing onty emergency help (by fail-safe ciccuit} In this caso, it ls necessary to bring the matorcycle to the workshop lor complete repair When two ignition signals or two injector signals are not received by ECM, the tall-sale circuit ean not work and ignition oF injection is stopped 42-90. FISYSTEM AND INTAKE AIRSYSTEAE Fl SYSTEM TROUBLE SHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as: described by the customer. Far {his purpose, use of such an inspection form will facilitate collacting information to the point required tor proper analysis and diagnosis EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Woda Ne Date of eve: ato Flea, [Date of problem Mileage: Waltunelion indicator lamp candition (LED) Waltunetion User mode] No display 1 Malfunction dlepiay ( 7 displaylcode (LCD) Dealer maveTi No code 1 Malfunction code. } PROBLEM SYMPTOMS DiPoor Driveability Hesitation on acceleratiin CBack frei After fre CLack of pawer Always ON [) Sometimes QN [J AWways OFF Cl Good condition Osurging Abnormal knocking DOther DEngine Stall when Poor fast Idle Dimmediately after start ‘Abnormal idling speed Thraitle valve is opened (CHigh Clow) { — ofmin) OThrotle valve is closed (Unstable Load is applied Hunting timin. 12min) Botner Dorner, TGTHERS: MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition ‘Weather Fair O Cloudy Cl Rain 6 Snow Always © Other ‘Temperature Hot C1 Warm (Cool ©) Cold ( “Fi °C) DAlways Frequency | ClAlWays Sometimes times’ day, manth) C1 Only once Under certain condition Road Urban C1 Suburb O Highway C! Mountainous (CI Uphill CI Downhill) OTarmacadam [Gravel 0 Other Motoreycie condition Engine DCold Warming up phase ClWarmed up [Aways [J Other at starting candition Climmediately ater start C1 Racing without load Cl Engine speed ( simi) | Motorcycle During driving: (J Constant speed (] Accelerating () Decelerating condition CO Right hand corner © Lefthand corner 1 When shifing (Gear position ) CIAtstop Cl Motoreycle speed when problem occurs { kmh, Mish) 1 Other, NOTE: Tha above form 8 a standard sample it should be modified according to conditions characteristic of each market. SELF-DIAGNOSTIC PROCEDURES + Don't disconnect couplers trom ECM, battery cable rom bat- tery, ECM ground wire hamess trom engine oF main fuse be- fore confirming malfunction coca (sel-dkagnostic trauble code} stored in memory. Such disconnection will erase memorized information in ECM memory. + Maltunction code stored in ECM memory can be checked by the special tao}, * Before checking maifunction code. read SELF-DIAGNOSIS FUNCTION “USER MODE and DEALER MODE (>> 4-26 and -27) carefully to have good understanding as to what func+ tions are available and how t0.use it, * Be sure to read ‘PRECAUTIONS for Electrical Circuit Service” (C7 4-4) betore inspection and otserve what Is written there. Remove the rear set Connect the special tool to the dealer mods coupler 4) st the witing harness, and start the engine or crank the engine for mora than 4 seconds. * Tum the special too!'s switch ON and check the malfunction ode fo determine the malfunction part, (09930-82710: Mode select switch ‘SELF-DIAGNOSIS RESET PROCEDURE * Aftor repairing the trouble, turn OFF tho ignition switch and tum ON again. I the maitunction code indicates (c00), the malfunction is cleared + Disconnect the special tool from the dealer mode coupler. FISYSTEMANDINTAKEAR SYSTEM $31 (99090-50710 Made seaet swt 442_AISYSTEM AND INTAME-AIR SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION | DeteeTeD ITEM DETECTED FAILURE CONDITION CODE CHECK FOR a0 NO FAULT Camshalt position ‘The signal does not reach ECM tor more than 4 see. after re- sensor the starier signal en ‘The camshatt position sensor wiring and mechanical parts. (Camshaft positon sensor, intake cam pin, wiring/coupler con nection) Crankshaft position | The signal does not reach ECM for more than 4 sec. after re- sensor | ceiving the starler signal te ‘The crankshaft position sensor wiring and mechanical parts, (Crankshalt position sensor, wiring/coupler connection) Intake ait pressure | The sensar should produce following voltage. e138 sensor (0.5 V = sensor voltage < 4.85 V) the above range, c1S is indicated =| intake air pressure sensor, wiring'coupler connection. ‘Thrattle position ‘The sensor should produce tollowing voltage. old sensor (0.2 V & sensor vollage < 4.8 V) | With above range, ct. ed _ - ‘Throttle position sensor, wiring/coupler connection. Engine coolant —_| The sensor voltage shuld te the following, ae temperature sensor | (0.15 < sensar voltage < 4.85 V) [Witnaut the above range. c1S is indicated, [ Engine coolant temperature: sensor, wiring/coupler connection intake air ‘The sensor voltage should be the following. at temperature sensar | (0.15 V S sensor voltage < 4.65 V) Without the above range, c21 is indicated. Intake air temperature sensor, wiring’coupler connection. | Atmospheric ‘The sensor voltage should be the following. 22 pressure sensor | (0.5'V sensor voltage < 4.85 V) Without the above range, c22 is indicated. Atm. pressure sensor, wiring/coupler connection, Tip over sensor ‘The sensor voltage should be less than the following for mare: than 2 sec, after ignition switch turns ON. c23 (0.25 = sensor voltage < 4.85 V) | Without the abave value, ¢23 is indicated. 7 ‘Tip over sensi, wiringicoupler connection | Ignition signal Crankshaft position sensar (pick-up coll) signal is produced but eee | signal from ignition coil is interrupted continuous by two times or 26 oF cot | ror. mis cae th ode 2, Soe erika. Ignition coil, wiring/coupler connection, power supply trom the battery. FISYSTEMANDINTAKE ARISYSTEM 4:33 c28 | Secondary throttle valve actuator When no actuator contro! signal ts supplied from the ECM or ‘communication signal does nat reach EGM or operation vol -age does not reach STV actuator, 28 is indicated, STV actua- STV actuator lead wireicoupler. 029 | Secondary throttle | position sensor [Secondary throttle pasion eansor, wiring/Gcupier connection. The sensor shauld produce following voltage. (0.2 V = sensor vohage < 4.8 V) [Without the above range, 229 is indicated. 30 | Secondary throttle control unit ‘When no communication signal is supplied from the ECM or [STC unit, witing’coupler connection, power supply to STC uni cat Gear position signal ‘Gear position signal voltage should be higher than the fallow- ing for more than 3 seconds. (Gear position sensor voltage > 0.60 ¥) Without the above value, ¢31 i indicated. ‘Gear position sensor, witing/coupler conection, Gearshifi cam etc 632, 089, cot or ea Fue! injector signal When fuel injection signal stops, the ¢32, ¢33, ¢34 ar 035 is indicated Injector, wiring/coupier connection, power supply 19 the in-| Jsstor. Fuel pump relay signal | When no signal is supilled from fuel pump relay. C41 is indicated | Fue! pump relay, connacting lead, power soures to fuel pump relay. | Ignition switch signal [Honition switch signal is not input in the ECM. 494_FISYSTEM AND INTAKE AIR SYSTEM “C11" CMP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION IBLE CAUSE No CMP sensor signal for @ seconds at engine | = Metal particles or foreign material being cranking attached on the CMP sensor and rotor tip = CMP sensor circuit open or short «CMP sensor matfunction. + ECM malfunction, INSPECTION * Lift and support the tual tank with its prop stay. (4-52) + Remove the air cleanor bax, ({"F"462) T] Turn the ignition switch OFF. ‘Check the CMP sensor coupler for loose or poor contacts WOK, then measure the CMP sensor resistance. Disconnect the CMP sensor coupler and measure the re-| sistance. | EM. cmp sensor resistance: 0.9 - 1.7 kQ j (Terminal ~ Terminal) IF OK, then check the continuity between each terminal and ground, [EEA cup sensor continuity: =f (Infinity) | (Terminal - Ground) GB 09900-25008: Multi circuit tester GE! Tester knob indication: Resistance (£2) No_, Replace the GMP sensor with a-new one. + Yes Disconnact the CMP sensor coupler, (Crank the engine 2 lew seconds with the starter motor. and. ‘measure the CMP sensor peak vollage at the sensor. CMP sensor peak voltage: More than 0.7 V (BI - Br} Repeat the above test procedure a few times and mea- Suré the highest peak voltage. ILOK, then measure the CMP sensor peak voltage at the| ECM terminals, (GwG- or 28) | |G 09900-25008: Mult! circuit tester \ fp! Tester knob indication: Voltage (= _No_, Loose or poor contacts on the CMP sensor coupler or ECM coupler, | Replace the CMP sanzor with a yes new ane. B/¥ or Br wire open or sharted to ground, or poor & ar @ oe connection. (<3 4-25} If wire and connection are OX, intormittent trouble or faulty ECM Recheck each terminal and wire hamess for open circuit and commis And) aM Soles Replace the ECM with a naw one, and inspect it again, — FISYSTEMANDINTAKE AIRSYSTEM 4435 “C12" CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No CKP sensor signal for 4 seconds at engine | » Meial particles or foreign material being cranking, attached on the CKP sensor and rotor tps. * CKP sensor circult open or short * GKP sensor mattunction + ECM malfunction INSPECTION «Litt and support the fuel tank with its prop stay. (C* 4-62) “Tum the ignition switch OFF Check the CKP sensor coupler for loase or poor contacts. OK, thon measure the CKP sensor resistance. Disconnect the CKP sensor coupler and measure the 16: | sistance. (EM ck sensor resistance: 70 - 220 0 (Black — Green) Hf OK, then check the continuity between each terminal and ground. (BA ckP sensor continuity: £2 (Infinity) Black — Ground \Green - Ground & 09900-25008: Multi circuit tester fe) Tester knob Indication: Resistance (Q) No, Replace the CKP sensor | with a new tes ih anew ane, [2! Disconnect the CKP sensor coupler. Crank the engine & few seconds with the starter motor, and measure the GKP sensor peak voltage at the coupler | BRE CKP sensor peak voltage: More than 0.5 V (Black ~ Green) Ropeat the above test procedure a few times and mea sure the highest peak voltage Hf OK, then measure the CKP sensor peak voltage at the | ECM terminals. (NN or Gv) | 09200-25008: Multi circuit tester ‘Ge! Tester knob indication: Voltage (=) [No Loose or poor contacts on the CKP sensor coupler or ECM coupler. = Replace the CKP sensor with ves Tewone. Black or Green wire open or shorted to ground, or poor @ or connection. (7 4-25) | twire and connactian are OX, intermittent trouble ar faulty ECM, Racheck each terminal and wire harness for open circuit and | poor connection. (°F" 44) Replace the ECM with a new ono, ‘and inspect It again. ECMocugtors 4.35 FISYSTEMAND INTAKE ARSYSTEM “C13” IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE. Low pressure and low voltage. © Clogged vacuum passage between throttle High pressure and high voltage, body and IAP sensor, (O89 = Senco votage < 485 Al being drawn trom vacuum passage without the above range, between throttis body and IAP sensor, NOTE: + Red wire circuit open or shorted to ground. Note hat atmospheric pressure vanes depending | » B/Br or G’B wire circut shortest ta ground, (on weather conditions as well as afktuce, AP sensor mattunction, Jake that into consideration when vowage.| + ECM malfunction. INSPECTION + -Liff and support the fuel tank with its prop stay. (—7" 4-52) [1] Turn the ignition switch OFF ] Check the IAP sensor coupler far loose or poor contacts. If OK, then measure the IAP sensor input voltage. Disconnect the IAP sensor coupler, Turn the ignition switch ON, Measure the voltage at the Fed wire and ground. IfOK, then measure the voltage at the Fled wire ard BB wire (EXD Ap sensor input voltage: 4.5 ~5.5V - ( Red — =Ground ) 1 @Red - BiB | v (@& 09900-25008: multi circuit tester iy fe) Tester knob indication: Voltage 2» Loose or peor contacts on the ECM coupler. Open or short circuit in 1 the Red wire or B/Br wire = ie [2] Connect the IAP sensor coupler. Insert the copper wires to the lead wire coupler Start the engine at idling speed. Measure the IAP sensor autput voltage at the wire side ‘coupler (between G/B and B/Br wires) [XUIIAP sensor output voltage: Approx. 1.32 V at idle speed (G/B — = B/Br) (& 09900-25008: Mult circuit tester | fe) Tester knob indication: Voltage (=) | Ni j-—*" > Gheck the vacuum hase for crack or damage, Open or short circuit in the G/B wira Rioplace the IAP sensor with & new ane, FISYSTEM ANDINTAKE AR'SYSTEM 437 [3] Remove tne tAP sensor. Connect the vacuum pump gauge to the vacuum port at the IAP sensor Arrange 3 new 1.5 V batteries in series (check that total valiage is 4.5 — 5.0 V) and connect =) terminal to the) graund terminal and & terminal to the Woo terminal, ‘Chack the voltage between Vout and ground. Also, check! if voltage reduces when vacuum is applied up to 40 cmHg| ‘by using vacuum pump gauge. (See table below.) (GB 09917-47010: vacuum pump gauge (09900-25008: Multi circuit tester (BD Tester knob indication: Voltage (=) No Hf check result is not satistactory [replace IAP sensor with a new ¥ Yes One | Red, GIB or BVBr wire open or shorted to ground. or poor #8. & of @ connection. (IF 4-25) wire and connection are OK, intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection, (<7 4-4), = Replace the ECM with a new one, and inspect it-agai Output voltage (Vee voltage 4.5 - 5.0'V, ambient temp. 20 - 30°C, 68 - 86°F) ALTITUDE, ATMOSPHERIC | OUTPUT (Relerence) PRESSURE _| VOLTAGE tm) tmmig) [a | a a 760 100 | | | 31-36 2000 610 707 aa 2001 en 707 aa | | | | 28-34 soo | 1524 aaa a5 3001 1525 4 55 | | | | 26-31 goo | 2438 567 76 8001 2499 367 76 t | I | 24-29 10000 } 3048 526 70 4-98 FISYSTEMAND INTAKE AIRSYSTEM “C14” TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal vottage low or high ° TP sensor maladjusted. Difference between actual throttle opening and | * TP sensor circuit open ar short opening calculated by ECM in larger than spacified| « TP sensor mattunction. valug. + ECM malfunction. ((SeY ss Sermonthtaye <8 ¥ without the abave range. INSPECTION ‘Litt and support the fusl tank with its prop stay, (7° 4-82) Turn the ignition switch OFF Chack the TP sensor coupler for joose or poor contacts. WOK, then measure the TP sensor input voltage. Disconnect the TP sensor coupier ‘urn the ignition switch ON. Measure the voltage at the Red wire and ground | 1OK, then measure the votage af the Fled wire and B/Br wiv | BRE) TPS sonsor input voltage: 4.5 - 5.5V (a8: Ground) | Rod ~ =8/6r | 09900-25008: Multi circuit tester fe! Tester knob indication: Voltage No, Loose-orpoorcantactsan the ECM coupier. Open at short circuit inthe Ried wire or BVBr wire: Yes 42! Tum the ignition switch OF Disconnect the TP sensor coupler Check the continuity between Yellow wire and ground FEN TP sensor continuity: =f (Infinity) | (Yellow wire ~ Ground) i¥.OK, then measure the TP sensor resistance at the cou | let between Yellow and Black wires) ‘Turn the throttle grip and measure the resistance. |GBEVTF censor resistance | Throttle valve is closed: Approx. 1.1 kQ Throttle valve is opened: Approx. 4.3 | ©} 09900-25008; Multi circuit tester bx! Tester knob indication: Resistance (Q) —— NO» Reset the TP sensor position correctly. Replace the TP sensor y Yes with @ naw one: FISYSTEMANO INTAKE ARSYSTEM 429 [8] connect tne TP sensor coupler. Insert the copper wires to the lead wire coupler Tuff the ignition switch ON. Measure the TP sensor cutput voltage at the couplr (be- ween Yellow and Black wires) by turning the thrattle grip. EXES TP sensor output voltage Throttle valve is closed: Approx. 1.1 V Throttle valve is opened: Approx. 4.3 V (Cy 09900-25008: Multi circuit tester ‘fe! te knob ication: Voltage (=} NO. it-check result is not satistactory, replace TP sensor with a new one. Yes | ed, PIG or BYBr wire apen or shorted to ground, er poor, | | or S connection. ((—* 4-25) [Hite and connection are OX, inleritient rouble or tauty ECM Recheck aach terminal and wire hamess for opon clreuit and poor connection. (C7 4-4) = Heplace the ECM with a new one, and pect it again, 42:40, FISYSTEM ANDINTAKE AIRSYSTEM “C15” ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE High engine coolant temp. (Low voltage—Low | » BB circuit shorted to ground. resistance) * BIBr circuit open. Low engine coolant temp. (High voltage—High | + ECT sensor matftunction. resistance) + ECM malfunction INSPECTION + Lift and support the fuel tank with its prop stay, (C= 4-52) +L tum the jonition switch OFF | Check the ECT sensor coupler tor loose or poor contacts. IFOK, then measure the EGT sensor voltage at the ware side coupler. Disconnect the coupler and turn the ignition switch ON. Measure the voltage between B/B! wire terminal and ground. ITOK, than measure the voltage between G/B! wire term- ral and B/Br wire terminal, [BREVECT sensor voltage: 4.5-55V_ (= 8/8 - = BiB (® 09900-25008: Multi circuit tester fg! Tester knob indication: Voltage No, Loose or poor contacts on the ECM coupler. ‘Open or short circuit in the ‘es BIBI wire: or BAB wire. the ignition switch OFF 2) tun Measure the ECT sensor resistance. TAQVECT sensor resistance: 2.3 - 2.6 kQ at 20°C (68°F) (Terminal - Terminal) (09900-25008; muti circuit tester Ga! Tester knob indication: Resistance (@) Reler to page 56 for details, | No, Replace the EGT sensor fies Withha naw one. BIBI oF B/BF wire Open oF shafted to ground, of poor or] eanhection. (7 4-25) HF wire and cannection are OK, intermittent trouble or faulty ECM.| [Engine Coolant Alecheck each terminal and wire hamess for open circuit and Temp. Resistance peer ce meee, (=F 44) 20°C ( 68°F) | Approx 2.45 kdl LS Replace the ECM with a new one BOG (12°F) | Approx O81 kal and Inspect it again BOC (176°F) | Approx 0.318 kA Ee ce? CORSTIT) | [fiero ea0°Fy [Approx 0.742 ka [oo a ECM couplers FISYSTEMANDINTAKEARRSYSTEN 441 “C21” IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION | POSSIBLE CAUSE High intake air temp. (Low vatage — Low * Dg circuit shorted to ground! resistance) + BIBr circuit opan Low intake alr temp. (High vohage — High + IAT sensor mattunction. resistance) + ECM matfunction INSPECTION + Litt and support the fuel tank wi [1] Turn the ignition switch OFF Check the IAT sensor coupler far loose or poor contacts WOK. then measure the IAT sensor voltage at the wire side coupler. Disconnect the coupler and tum the ignition switch ON. Measure the voltage between Dg wire terminal and ground HVOK, then measure the voltage between Dg wire termi- nal and B/Br wire terminal, FEB) at sensor voltage: 4.5-5.5V @0g- = Dg - = B/Br ( oa900-25008: multi circuit tester ‘Gg! Tester knob indication: Voltage ( No, Loose of poor eontacts on the ECM coupler. ‘Open of short circuitin the Dg wire or EVBr wire. Yes Turn the ignition switch OFF ] Measure the IAT sensor resistance. BREN iAT sensor resistance: 2.2 - 2.7 k(t at 20°C (68°F) (Terminal — Terminal) (> 09900-25008: Multi circuit tester |) Tester knob indication: Resistance (0) | Replace the IAT sensor we. with a new one, |Dg or BYBr wire open or shorted ta ground. oF poor Sor & connection. (e=7" 4-25) |Ifwire and connection are GK, intermittent trouble or faulty ECM. | Recheck each terminal and wire hamess for open circuit and) [Intake Aw Temp. | Alesisiance [poor connection. (7" 4-8) | [TR CTSe°F) Approx, 245 ko L___ Replace the ECM with a new one, 50°C (122°) | Approx. 0.808 Ki? and inspect it again, [eo°C (76 "F) | Approx. 0.322 ko 110°C (290°F) | Approx: 0.148 hit NOTE: JAT sensor resistance measurement mathod is the same way as that of the EGT sensor Refer lo page 5-8 for detais 4:42 FISYSTEM AND INTAKE AIRS STEM “C22” AP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION fr POSSIBLE CAUSE Low pressure and iow voltage, + Clogged alr passage with dust High pressure and high voltage. + Fed wire circuit open oF shorted to ground, (05 Sonsor Votage < 4.5V + BIBr oF GY wire circu shorted to ground. without the above range © AP sensor malfunction: NOTE: + ECM malfunction. Note that atmospheric pressure varies depending on weather conditions as well as altitude. Take that into consideration when inspecting voltage. INSPECTION + Remove the front seat, (776-8) [1] sum the ignition switch OFF Check the AP sensor coupler for loose or poor contacts. | OK, then measure the AP sensor input voltage. Turn the ignition switch ON Disconnect the AP sensor coupler. Measure the voltage between Fled wire and ground. MOK, then measure the voltage between Red wire and B/Br wire AP sensor Input voltage: 4.5 ~ 5.5 V_ (2aes- Red — | 09000-25008: mult! circuit tester G2 Tester knob indicatian: Voltage (= Ground Br | No, Loose ar poor cantacis an the ECM coupier: Open orshort circuitin the Raed wate or B/Br wre, oes 2 Connect the AP sensor coupler, Ineert the cooper wes tothe lead wire coupe | Tum the ignition switch ON Measure the AP sensor autput voltage at the wire sida coupler between GY and B/Br wires [XIN AP sensor output voltage: Approx. 3.6 V at 760 mmHg (100 kPa) | (2GN¥ - = 8/6) (> 09900-25008: Multi circuit tester | [BI Tester knob indication: Voltage (=) Roa | Nos: nec sha passage for clagaing, ‘Open or short circuit inthe GY wire Replace the AP sensor ‘with a new ono, ¥ Yos FISYSTEM ANDINTAKE ARRSYSTEM 443 [3] Remove the AP sensor. ] ‘Connect the vacuum pump gauge to the air passage port ol the AP sensor Arrange 3 new 1.6 V batteries in series (check tnat total voltage Is 4.5 — 5,0 ¥) and connect © terminal to the| ground terminal and ® terminal to the Voc terminal. ‘Check the voltage between Vout and ground. Also, check) it voltage reduces when vacuum iS applied up to 40 cmHg| | __ by using vacuurn pump gauge. (See table below} (& 09917-47010: vacuum pump gauge (09900-25008: Multi circuit tester {{@) Tester knob Indication: Voltage {- H check result Is not satistactory. replace AP sensor with a new one. Red, G/Y or B/Br wire open or shorted to ground, or poor 8, & of @ connection, (C7 4-25) It wire and connection ate OK, intermittent trouble ar faulty ECM. Flecheck sach terminal and wire harness for open circult and) poor connection. (=7" 4-4) > Replace the ECM with a new one, and inspect tt again, Qutput voltage (Vee voltage 4.5 — 5.0 V, ambient temp. 20 - 30°C, 68 ~ 86°F} ALTITUDE: ATMOSPHERIC | OUTPUT (Reterence} PRESSURE VOLTAGE i) (mb (mmHg) kPa (vy) a o 760 100 | | | 1-36 2.000 610 707 94 2001 eit | 707 3a | t | 28-34 sooo | 1524 aaa 85 3 001 ass 4 85 | | | l 28-31 sooo | 2438 567 76 eon | 24a9 567 76 | | | | 24-29 30000 | 3048 526 mw a] Graind EC couplers 4444_ FISYSTEM AND INTAKE AIR SYSTEM “C23"TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No TO sensor signal for mare than 2 seconds. | + TO sensor circuit open or short. alter ignition switch tums ON. | + 70 sensor mattunetion. Sansoe voltage high, + ECM maitunction. ( 0.25 V = Sensor Voltage < 4.85 Y without the abave range. INSPECTION + Lift and support the fuel tank with its prop stay LU Turn the ignition switch OFF ‘Check the TO sensor coupler tor loase or poor contacts. 1 OK, then measure tne TO sensor resistance Disconnect tne TO sensor coupler. Measure the resistance between Black and BW wie ter- minais. TO sensor resistance: 60-64 kQ (Black — B/W) (> 09000-25008: Multi circuit tester GB) Tester knob indication: Resistance (2) F 4-52) No, Replace the TO sensor ‘rath & new one. = }2) Connect the TO sensor coupler. Insart the copper wires to the wire lead coupler ‘Turn the ignition switch ON. Measure the voltage at the wire side coupler betwoan Bisck and B/Br wires. | BENTO sensor voltage: Approx. 2.5 (Black ~ B/Br) ‘Aisa, measure the voltage when leaning of the motorcycle. Dismount the TO sensor ftom its bracket and measure the voltage when it is leaned more than 43°, lett an right, from the horizontal level | EEXTO sensor voltage: 0'V (Black ~ B/Br) (08900-25008: Multi circuit tester fe) Tester knob indication: Voltage No_, Loose or poor contacts on the ECM coupler, ‘Open or short circuit inthe Black wire or BBr wire Replage the TO sensor ‘with & new one, __¥ Yes [Black or BBr wire open oF shorted to ground, or poor G or & ‘cannection, (7 4-25) tvaire and connection are OK, intermittent trouble or fauty ECM. | Recheck each terminal and wire hamess for open circuit and] +4) » — Replace the ECM with a new one, and inspect it again, |FLSYSTEM AND INTAKE AIR SYSTEM 4.45 “C24”, "C25", “C26” or "C27" IGNITION SYSTEM MALFUNCTION “Reter to the IGNITION SYSTEM for details. (77-17) “C28” STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ‘The operation voltage does not reach the STV | STV actuator maltunction actuator. + STV actuator circuit open or short ECM does not receive communication signal from | + STVA motor maltunction. the STC unit INSPECTION © Lit and support the fuel tank with its prop stay, ([7" 4-52} + Remove the air cleaner element. [LT urn the ignition switch OFF Gheck the STV actuator lead wire coupler for loose or poar| contacts, Tur the ignition switch ON. Check the operation of the STV actuator by the STV move. ment, {Operating order: Half open —+ Full close — Full apen | Half open) | ——** + Locee or poor contacts on Yes the STC unit coupler Open or short crcuitin the Rod or Black wee — —___¥_ Turn the ignition switch OFF Disconnect the STV actuator lead wire coupler. ‘Check the continuity between Red wire and ground FEY TY actuator continuity: =£2 (Infinity) WOK, then measure the STV actuator resistance, (between Red and Black wives) EM STV actuator resistance: Approx. 5.6 0 (= Red - > Black) (© 09900-25008: Multi circuit tester (fe)! Tester knob indication: Resistance (Q) |_No_. pepiace the STV actuator with anew one. yes, Loose of poor contacts an the STV actuator coupler or STC unit coupler. it wire and connection are OK, intermittent trouble or taulty STG unit. Recheck each terminal and wire harness for open clreut and poor connection. (7-4-4) |___s Replace the ST unit with few one, and inspect it again ¢H45_FISYSTEMANDINTAKE AIRSYSTEM “C29" STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE _ Signal voltage law or high + STP sensor maladjusted. Ditferencs between actual throtwe opening and | * STP: sensor circuit open or short. ‘opening calculated by ECM in larger than specified| + STP sensor malfunction. value * STC unit maitunction {ina Ree son ce) + ECM malfunction without the above range. INSPECTION + Lift and support the fuel tank with its prop stay (=F 4-62) [2] turn the ignition switch OFF Check the STP sensor coupler for laose or poor contacts, WOK, then measure the STP sensor input voltage. Disconnect the STP sensor coupler Turn the Ignition switch ON. Measure the voltage at the BIUe wire and ground WOK, then measure the voltage at the Blus wire and Black! wre, (RAY sTP sensor input voltage: 4.5 ~5.5V | ( Blue — Ground Blue - GB 09900-25008: Multi circuit tester ‘Ga! Tester knob indication: Voltage | ___NO. Loase-or poor contacts. on i the ECM coupler, Y Open or short circuitin the: | ‘te: Blue wire or Black wire. Turn the ignition switch OFF Flemove the sir cleaner element Disconnect the STP sensor coupler. Check the continuity between ‘allow wire and ground ‘[EXSSTP sensor continuity:e£ (Infinity) (Yellow wire ~ Ground) HOK, then measure the STP sensor resistanos al the coupler (between Yellow and Black wires) Close the secondary throttle vaive by finger and measure the valve closing resistance. Turn the ignition switch ON and measure the Valve opening resistance. ‘EGQQ)sTP sensor resistance Secondary thrattie valve is closed: Approx. 0.8 ka Secondary thrattle valve is opened: Approx. 3.9 ki } 0e900-25008; Multi circuit tester )) Testor knob Indication: Resistance (9) = Reset the STP sensor position correctly rer) Roplace the STP sensor with a new one. ] FISYSTEMANDINTAKE AIRSYSTEM 2.47, 13! Turn the ignision switen OFF: Connect the STP sensor coupler Insert the copper wires to the: lead wire coupler Turn the ignition switch ON, Measure the STP sensor output voltage at the coupler (between Yallow and Black wires) by turning the second: ary throttle vaive (close and open) with a finger EMI STP sensor output voltage Throttle valve is closed: Approx. 0.8 ¥ Throttle valve is opened: Approx. 4.0 08900-25008: Multi circuit tester Gi) Tester knob indication: Voltage ( [No it chack result is not satistactory, replace STP sensor with.a new one. Yos ‘Blue, Yellow or Black wire pen or shorted to ground, or poor] i connection. (C=7" 4-25) | I wire and connection are OK, intermittent trouble or STC unit! faulty or faulty ECM Rlocheck each terminal and wire hamess for open circuit ang} poor cannection, (F 4-4) Replace the STC unit or ECM with a ew one, and inspect it again. ECM coupiors 448 SYSTEM AND INTAKE AR SYSTEM “C30” STC UNIT CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE | The power source does not reach the STC unit TC unit malfunction. ECM does not recive communication signal trom | « STG unit cireuit open or short. the STC unit. INSPECTION + Remove the frame cover. (7 [1] Turn the ignitan switch OFF Cheek the STC. unt lead wire coupler tor loose or poor contacts. if OK, then measure the STC unit input voltage incon the copper wires to the lead wico coupler Tum the ignition switch ON, and measure the voltage be- tween the O/W wire and ground. OK, then measure the voltage between the OW wire] and BW wire. | RQQsTc unit input vottage: Battery voltage (5 09900-25008; multi circuit tester (ai! Tester knob indication: Voltage (=) No. Open or short circuit in the OW wire or BAY wire, ves [OW BAW oF Dor wie open or shoried to ground, or poor i] Joonnection, (7 4-25) Measure the STC unit voltage with the mult citoult fester. (I°7- 22) [twit and connection are OK, intermittent trouble or STC unit ity or faulty ECM, locheck each terminal and wire hamess for open circuit and! poor connection. 44) + Replace the STC unit with a new one, and inspect it again. EctAcoumiers FISYSTEMAND INTAKE AIR SYSTEM 49 $A __ FSSA INTAKE AIR SYSTEM 49 “C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION | POSSIBLE CAUSE No Gear Position switeh voltage * Gear Position switch circuit open or short. Switch voltage low. * Gear Position switch malfunction (Senege os + ECM malfunction without the above range. INSPECTION + Litt and support the fuel tank with is prop stay: (4-52) Turn the ignitian switch OFF: ‘Check the GP switch coupler tor loose or poor contacts. OK, then measure the GP switch voltage. ‘Support the motorcycle with a jack. Turn the side-stand to up-right position: Turn the enaine stop switch ON Insert the copper wire to the lead wire coupler Tur the ignition switch ON. Measure the voltage at the wire side coupler between| Pink wire and ground, when shitting the gearshift lever from 1st to Top, GP switch voltage: More than 0.6 V (Pink ~ Groung) (09900-25008: Mult! circuit tester ‘fe! Tester knob indication: Voltage (=) | No | pen or short circuit in the Pink wire Replace the GP switch with a new one, Pink wire open or shorted to ground, or poor ‘=: connection |r 4-25) wire and connection are OK, intermittent trauble-or faulty ECM. Recheck each terminal and wire harness for open circuit and [poor connection, (I 4-4) Replace the EOM with a new one, | sand inspect it again ECM coupler: -$50_FISYSTEM ANDIVTAKE AR SYSTEN “C32", “C33”, “C34” or "C35" FUEL INJECTION MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No injector current. * injector circuit open or short. + Injector maltunetion * ECM malfunction, INSPECTION [Lit and support the fuel tank with its prop stay. (7 4-82) [1] Turn the ignition switch OFF: (Check the injector caupler for loose or paor contacts. WOK, then measure the injector resistance Disconnect the coupler and measure the resistance be- tween teeminals Injector resistance: 1 = 16 0. at 20°C (68°F) (Terminal ~ Terminal) IPOK, then check the continuity between each terminl |__ and ground. Injector continuity: =f (Infinity) | (Terminal = Ground) GB 09900-25008; Muti circult tester BD) Tester knob indication; Resistance (2) ee ee eee eres | N Cm Replace the injector with anew one. (7° 4-64) be +2] Turn the igaition witch ON Measure the injector vollage between WR wire and] | ground. (YR = Ground) NOTE: Injector voltage can be detected only 3 seconds after ig- nition switch 1s tured ON. (09900-25008: Multi circuit tester | {@)! Tester knob indication: Voltage P Injector voltage: Battery voltage -_N2__» open circuit in the Yellow! Fed wire | vos + , GriB, Griy, Gr or ¥/R wire open or shorted to ground, oF poor 4), i, 6) (7) oF # connection. (7° 4-25) Ihwire and connection are OK, intermittent trouble or faulty ECM, Recheck each terminal and wire harness for apen circuit and poor connection. ("7 4-4) |g Replace the ECM with a naw one. and inspect it again FISYSTENLAND INTAKEAIR SYSTEM 4-51 “C41" FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No signal from fue! pump relay. © Fuel pump relay circuit open ar short. * Fuel pump relay malfunction, = &CM maifunction. INSPECTION ‘* Fomave the front seat + Lift and support the fuel tank with its prop stay (C- Tuen the ignition switch OFF ‘Check the FP relay coupler for loose oF paor contacts. OK, then check the insulation and continuity, Refer to page 4-55 tor details, 4-52) No f —S Replace the FP relay with a pew one 1 Yes {YIB or OM wire open or shorted to ground, oF pact ® or ® connection. ((F* 4-25) wire and connection are-Ok, intermittent trouble oF faulty ECM. Recheck each terminal and wire harass for open circuit |___ and poor connection. (7" 4-4) compos ooo Tit Tort \——+ Replace the ECM with a new one, ot do and inspect it again. : ECM covples “C42” IG SWITCH CIRCUIT MALFUNCTION * Refer to the IGNITION SWITCH INSPECTION for dotalls. © Remove the right under cowling. (7 6-3) * Inspect the ignition switch. (3° 7-31) £52. SYSTEM ANDIOTIAKE AR SYSTEM. FUEL SYSTEM FUEL TANK LIFT-UP = Flemove the front seat. * Flemove the fuel tank mounting bolts. * Lift and support the fuel tank wrth the fuel tank prop stay FUEL TANK REMOVAL + Liftand support the fuel tank with the fuel tank prop stay (See above) + Disconnect the tusl pump lead wire coupler (f + Place a rag under the fue! feed hose and remave the fuel feed hose @ @& CAUTION | When removing the fuel tank, do not remain the fuel feed hose ‘2 at the fuel tank side. [Gasoline is highly flammable and explosive. | Keep heat, spark and flame away. = Remove the fuel tank bracket mounting bolts, * Remove the fuel tank FUEL TANK INSTALLATION * Installation i in the reverse order ot removal FISYSTEM ANDIVTAKE ARSYSTEM 4-53 FUEL PRESSURE INSPECTION * Lift and support the fuel tank with its prop stay. (4-52) * Place a rag under the fuel feed hose. (7-462) * Remove the tus! feed hose and install the special tools be- tween the fuel tank and fuel delivery pipe 19940-40211: Fuel pressure gauge adaptor 09940-40220: Fuel pressure gauge hose attachment 09915-77390: Oil pressure gauge 0995-74520; Oi pressure gauge hose Turn the ignition switch ON and check the tue! pressure. Fuel pressure: Approx. 300 kPa (3.0 kgticm?, 43 psi) {the fue! pressure is lower than the specified, inspect the fol- owing ems: * Fuel hose leakage * Clogged fuel titer * Pressure regulator > Fuel pump Whe fuel pressure is higher than the specified, inspect the fol. lowing items: * Fuel pump check valve * Pressure regulator POI * Before removing the special tools, turn the ignition | Mand release the fuel pressure * Gasoline is highly flammable and explosive. Keep heat, sparks and flame away: To huel diivery sine a {{54_FISYSTEM AND INTANE AIR SYSTEM FUEL PUMP INSPECTION Tum the igrition switch ON and sheck that the fuel pump oper: ates for few seconds. Hf the fuel pump motor does nat make operating sound, replace 5 the fual pump assembly or inspect the fuel pump relay and tip over sensor FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive. | Keep heat, spark and flame away, ++ Lift and support the tuel tank with its prop stay: ((7"4-82) ** Disconnect the fuel feed hase (7) fram the fuel pump, * Connect a proper fuel nose 2 to the fuel pump. * Disconnect the ECM lead wire coupler * Push the ook (A) 10 pull ou! the power source lead wire (Yellow ‘with red tracer 2), ECM couple | FISYSTEM ANDINTAKE AIR SYSTEM 4-55, * Place the measuring cylinder and inseit the: hiel hase end into tha measuring oyinder. * Apply 12 volts 1o the fuel pump for 20 seconds and measure the amount af fuel discharged Battery © terminal — Power source lead wire (Veliow with red tracer) Ifthe discharge amount is not specified i means that the fue! pump is defective or thal the fuel fter s clogged. (EM) Fuel discharge amount: Approx. 1200 mi/30 sec. (1.3/1.1 USAmp 0230 sec. NOTE: The battery must be in fully charged condition. (£55_FISYSTEM ANDINTAKEARR SYSTEM FUEL PUMP RELAY INSPECTION Fuel pump relay is located in ahead of the battery. « Remove the front an rear seats: * Lift and support the fuel tank with its prop stay. ((7"4-52) + Remove the fue! pump relay, First, check the insulation between () and 2 terminals with pocket taster. Then apply 12 volts to Zi and @ terminals, # to 3 and © to @, and check the continuity between) and 2 there Is no continuity, replace it with @ naw one, FUEL PUMP AND FUEL FILTER REMOVAL CONSTRUCTION a {) Fuel pessire regulator 2 Fos! pure case Fue! tar [EN [etm | et cantioge i 16] 70 (Forregh pressure) SBntoure 4) Fuel mesh tar (Foriow pressure) Thermistar F O-mg FISYSTEMANDIVTAKE AIRSYSTEM 4-57 REMOVAL * Flemove the fuel tank, (7°4-52) + Remove the fuel pump assembly by removing its: mounting otis diagonally. | Gasoline is highly flammable and explosive. Keep heat, spark and flame away. * Remove the nuts. + Remove the screws, * Blemove the fuel pump assy from the fuel pump plate + Remove the tuel pump holder (£58 FISYSTEM AND INTAKE AIRSYSTEM. * Remove the fuel mesh filter * Remove the fuel pressure regulator holder 7) and the fue! pressure regulator FUEL MESH FILTER INSPECTION AND CLEANING ff the fuel mesh filter is clogged with sediment or nist, fuel will ‘not flow smoothly and Joss in engine power may result Blow the fuel mesh fiter with compressed air, NOTE: If the fuel mesh fiter is clogoed with many seaiment or rust, replace the el titer cartridge with a new one. FUEL PUMP AND FUEL MESH FILTER INSTALLATION Install the fuel pump and fuel mesh fiter in the reverse order of removal, and pay attention to the following points: ‘Install the new O-rings to the fuel pressure regulator and fuel pipe * Apply thin coat of the engine oil to the O-rings: a CAUTION FISYSTEMAND INTAKE ARSYSTEN 4.59 ‘+ Pass thraugh the wires behind the thermistors. | thecretar for hightever | Thirst toe tow fava - So. *+ Be sure to connect the wires fo the proper terminals, A @ terminal for fuel pump ~ Therristor for lov level _ Therrtistor for high level pee Pass mrough tne wires baled Be thermistor (460_FISYSTENAND INTAKE AIRSYSTEM * Install the O-ring and apply grease to it gow 99000-25010: SUZUKI SUPER GREASE "A" ‘The O-ring must be replaced with a new one to prevent | fuel leakage. + When installing the fuel pum: assembly. lightly tighten ail the fuel pump assembly mounting bolts in the ascending order of humbers, and then tighten them to the specified torque in the above manner. [¥] Fuct pump mounting bolt: 10 Nem (1.0 kgf-m, 7.0 Ib-tt) NOTE: Apply a small quantity of the THREAD LOCK "1342"to the thread portion of the fuel pump mounting voit. AGS) 99000-32050: THREAD LOCK “1342” FISYSTEM ANDINTAKE AIR SYSTEM £41 THROTTLE BODY AND STV ACTUATOR CONSTRUCTION | TP sensor | SSTP sensor 7STVadhustngectew Look rut {) STV balance adusting screw 3 Throtie etop sora { Fastice-cam #2 Fast ize adjusting screw Thro cable drum a Dane Mann eee (Oe hates 20 oS o ss ‘wisn {Os tgm 97m) Manm [ties Soin Meum f Cee ioe Mf mm (O3Skohm 25teH) | lazkghm 1.5 th 2a (02 bgt 1.5 A) |U62_FISYSTEM ANDINTAKE AIR SYSTEM AIR CLEANER BOX AND THROTTLE BODY REMOVAL AIR CLEANER BOX © Lift and support the tus! tank with its prop stay. ([—F-4-82) + Disconnect the IAT sensor coupler (f) and PAIR hose: (2 * Rleméve the IAP sensor @) along with the vacuum hose * Disconnect the crankcase breather hose * Loosen the throttia body clamp screws, © Remove the air cleaner box mounting bolt * Remove the air cleaner box FISYSTEM AND INTAKE AIRSYSTEM 4-63 THROTTLE BODY * Disconnect tha thrattle cables trom their drum, * Disconnect the fast idle cable trom its cam. ‘After disconnecting the throttle cables, do not snap the | throttle valve from full open to full close. It may cause | damage to the throttie valve and throttle bod + Place a rag under the fuel feed hose and disconnect the fuel feed hose from the fuel tank. + Disconnect the vacuum hase 7) from the PAIR valve. + Discorinect the fuel injector lead wire coupler @ * Loosen the throttle body clamp screws at the intake pipe side. * Remove the throttle body assembly {L54_FISYSTEM AND INTAKE AIR SYSTEM “ THROTTLE BODY DISASSEMBLY * Disconnect the respective vaccum hoses trom each throttle body. + Remove the lead wire clamps. * Disconnect the TP sensor lead wire coupler (f), STP sensor lead wire coupler 2, STVA motor lead wire coupler @) and fuel injoctor lead wire couplers 2) * Remove the fuel delivery pipe assembly (6) by removing its ‘mounting screws. + Remove the fuel injectors + Separate the four throtte bodies respectively by removing thelr connecting bolts. * Remove the TP sensor (i! with the special tool (00990-11960: Torx wrench FAISYSTEMAND INTAKE AIRSYSTEM 445, + Remove the STVA motor cover 4) along with the STP sensor 2 NOTE: Prior to disassembly, mark the STP sensor's original position with a paint or scribe for accurate seinstallation. + Remave the STVA motor lead wh the screw, connector by removing ‘+ Remove the STVA motor yoke ® along with STVA motor 5), ‘Never remove the STVA motor frame 5 Avold removing the STV adjuster 4 unless absolutely necessary. a CAUTION | | Never remove the secondary throttle vaive and throttle: _ valve. 465. FISYSTEMANO INTAKE AIRSYSTEM THROTTLE BODY CLEANING ‘Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled caretully. Always follow the chemical | manufacturer's instructions on proper use, handling and storage. * Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air cA Do not use wire to clean passageways. Wire ean dam- age passageways. Ifthe components cannot be cleaned with a spray cleaner it may be necessary to use 5 dip- type cleaning solution and allow them to soak. Always follow the chemical manutacturer's instructions for | proper use and cleaning of the throttle body compo- nents. De not apply carburetor cleaning chemicals to the rubber and plastic materials. INSPECTION Check following items (or any damage or clogging. * O-ring * Fuel injector titer * Throttle shaft bushing and seal * Injector cushion seal * Throtite valve * Injector dust seal * Secondary throtile valve * Vacuum hose THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- by Pay attension to the following points: * Install the STVA motor yoke 7) along with the STVA motor 2 (©) STVA motor yoke mounting bolt:3.5 Nm (0.35 kat-m, 2.5 Ib-tt) + Align the groove ® on the:secondary throtile shat end with tha lip of the STP sensor. NOTE: Apply grease “A” to the groove ®) if necessary. (E)STVA motor cover nut: 2.0 Nem (0.2 kgf-m, 1.5 lb-ft) NOTE: It the STP sensor adjustment is necessary refer to page 4-71 for STP sensor setting procedure * Align the groove (© on the throws shat end with the: ti the TP sensor (09930-11960: Torx wrench NOTE: Apply grease “A’ to the groove ©) W necessary. TP sensor setting procedure (“74.28 * Pasition the TV contral lever @) between the TV synchronizing serew Zand spring as shown, Set each'TV to the same opening by turning the balance screws 2 * Position the STV control lever @) between the STV synchra- nizing screw @ and spring () as shown, Place the throttie body assemiily on the surlace plate and tighten the connecting boits. (7) Throttle body connecting bolt:5 Nm (0.5 kgtm, 3.7 Ib FISYSTEM ANDINTARE AIR SYSTEM £67 (V6 FISYSTEM ANDINTAKEAIR SYSTEM + Apply thin coat of the engine oil ta the new fuel injector cust Jon seals @), and install them to each fual injector, (A CAUTION Replace the cushion seal with a new one. * Install the seats (2) and O-rings ‘3 to each fuel injector. * Apply thin coat of the engine oil fa the new O-rings (5 * Install the fusl injectors by pushing them straight 1a each throttle body, ‘A CAUTION Replace the dust seal and O-ring with the new ones. Never turn the injector while pushing It. | * Install the fuel delivery pipe assembly to the thratile body as- sembly. A CAUTION Never turn the fuel injectors while installing them. + Tighten the fuel delivery pipe mounting screws () Fue! delivery pipe mounting screw: 5 Nm (0.5 kgfim, 3.7 Ibeft) + Connect the fuel injector couplers to each {uel injects WIRE COLOR No.1 coupler: Gray, WIE No.2 coupler: Gray, Black Nod coupler: Gray, Yellow Not coupler: Gray, Green + With the STV fully opened and using a proper scale, set the No 4 and No. 3 ST walves to the same opening by turning the balance screw (7) Jj) 4-70_FIS¥STEM AND INTAKE AFRSYSTEM STPS couptar (ATS coupler THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay al the following points: + Connectthe thrattle pulling cable (P)and throttle returning cable 2'to the throttle cable drum. * Adjust the throttle cable play with the cable adjusters (J) and Rieter to page 4-76 for details © Connect the fast idie cable 5! and agjust the fast idle cable play with the cable adjuster tion to FISYSTEMANDITAKE ARSYSTEM 471 STP SENSOR ADJUSTMENT it the STP sensor adjustment is necessary, measure’ the sensor resistance and adjust the STP sensor positioning as follows: * Disconnect thie STP sensor coupler. ‘+ Sat the ST valve to fully close position by finger and measure the resistance between yellow and black wires. [BES STP sensor setting resistance ST valve is fully closed: Approx. 0.8 ka (® Yellow ~ = Black) 09900-25008: Multi circuit tester fi! Tester knob indication: Resistance (a) ‘© Loosen the STP sensor mounting screws. + Adjust the STP sensor until resistance is. within specification and tighten the STP sensor mounting screws. (09930-11960: Torx wrench (STP sensor mounting screw:2.0 Nm (0.2 kgt-m, 1.5 tb-tt) I the measured resistance is not within specification, adjust the: STV adjuster 7) as follows: + Under above candition, loosen the lock 2 and tum in or out the STV adjuster until the resistance becomes specified value. it the measured resistance is not obtain, replace the STF sen- or with a new one, and adjust the STP sensor posit again (STV adjuster lock nut: 1.0 Nem (0.1 kgfm, 0.73 Ib-ft) NOTE: Aiter adjusting the STV adjuster, apply THREAD LOCK "1342" to the fock mit THROTTLE BODY CLAMP POSITION ead ] MIEW OF TOP To IAP sonar 272 _F1SYSTEM AND INTAKE AIR SYSTEW FUEL INJECTOR INSPECTION ‘The fuet injector ean be checked without removing it trom the throttle body, Reler to page 4-50 tor details FUEL INJECTOR REMOVAL + Litt and support the fuel tank with its prop stay. ((2 * Remove the air clesnet box. (C7 4-62) * With battery negative cable disconnected, disconnect tha ins Jector couplers. + Remove the fuel delivery pipe assembly. (> 4-64) + Remove the fuel injectors No.1, No.2, No.3 and Na. (or 464) INSPECTION Check tuel injector fiter for evidence of dirt and contamination, It present, clean and check for presence of cit in the fuel tines anct fuel tank. 483) FUEL INJECTOR INSTALLATION * Apply thin coat of the engine oil to new injector cushion seals and O-rings. * Install the injector by pushing it straight to the throttle ody, Never turn the injector while pushing it. ((=7" 4-68} FAST IDLE ADJUSTMENT Tha fast idle system is a kind of starter system, which opens ‘rata valve by the fast idle cam mechanically, The tast idle cam is turned by the tast idle cable and the cam pushes throttie valve shalt bracket. The bracket then opens trwattle valve a litle 19 in- ‘erease the engine speed, and al the fully:pulled condition the engine speed rises to 3 900 rpm when warmed up. + Connect a tachameter * Start Up the engine and run it in idle condition for warming up. + Sat tha idle spsed to 1 200 rpm. * Tum the last idie lever (choke lever) (fully and check the fast ide setting rpm. the engine speed is notin the specified range adjust itto 3 000 rpm as explained in the fasowing procedures: 4)Li. and support the fuel tank with its prop stay ([=7-4-52) 2)Start up ine engine and keep tne fast idle lever in fully-pulled ‘cpndition, 3)Adjust the fast lala engine speed to 3 000 mpm by turing the Yast idle adjusting screw (2. (Fast idle adjusting screw :2) is focated behing the throttle cable drum.) ‘After adjusting the fast idle speed, set the idle speed to 1 300 rpm (EMD) Fast idle setting rpm ; 3.000 rpm (When the engine is warmed.) Engine idle rpm: 1300 rpm (When the engine warmed.) Fl SYSTEM AND INTAKE AIR SYSTEM 4-73 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among four cylinders. CALIBRATING EACH GAUGE * Lift and support the fuel tank. (9° 4-52) * Start up the engine and run it in idling condition for warming up. * Stop the warmed-up engine. * Disconnect the IAT sensor coupler T) and remave the |AT sen sor from the air cleaner Dex. * Connact the removed IAT sensor to its coupler and place it on the frame. * Remove the IAP sensor mounting screw 2 + Remove the air cleanor Dox. (7 4-62) + Disconnect tha vacuum hose 3) fram the No throttle body, © Connect proper rubber cap “4 to the nipple on the No.3 throttle body. 4:74 _F1SYSTEM AND INTAKE AIR SYSTEM + Connect ane of the four nubber hoses af the vacuum balancer gauge to the nipple (7) on the No.{ throttle body (09819-13121; Vacuum balancer gauge * Connect a tachomater, * Start up the engine and keep it running at 1 300 rpm by turning ‘tyottie stop screw 2 UTION | Avoid drawing dirt into the throttle body while running * Turn the air sorew (3) of the gauge so that the wacuum aeting on {he tube of tat nose will bring the stee! ball in the tube to the center iine NOTE: The racuurn gauge 8 positioned approx. 30° front the horizontal love. * Alter making sure that the steel ball stays steady at the center line, disconnect the hose from the No.1 throttle body nipple and connect the next hose to this nipple. * Turn air screw to bring the other stee| ball) to the center ling, * Repeat the above process an tha third and fourth hoses. The balancer gauge is now ready for use in balancing the throttle valves. Fl SYSTEM AND INTAKE AIA SYSTEM 4-75, ‘THROTTLE VALVE SYNCHRONIZATION * Tosynchroniza thwoitie valves, remove the rubber caps ‘fy and vacuum hase @ trom each vacuum nipple and connect the vacuum balanear gauge hoses to the vacuum nipples respec- tively 09913-13121: Vacuum balancer gauge * Connect tachometer and start up the engine, * Bring the engine rpm to 1 300 rpm by the throttle sto screw. * Check tha vacuum of the four cylinders and balance the four throttle valves The vacuum gauge is positioned approx. 30° from the horizontal level, and in this position the four balls should be within one ball dia. 11 the diifarence is larger than one ball, turn the balance ad- justing screw on the throttle body and bring the ball to the same level: A correctly adjusted throttle valve synchronization has the tals Inthe No, 1 through 4 at the same level 4 CAUTION | Avoid drawing dirt inte the throttle body while running the engine without alr cleaner box. Dirt drawn into the engine will the internal engine parts, NOTE: * During balancing the throttle valves. always Sef the engine ypm at 1 300 rpm, using throttle stop screw: * Alter balancing the-four valves, set the idle rpm to 1 300 rpm by the throttle stop screw after instafing the air cleaner box. 4£-76_FLSYSTEM ANO INTAKE AiR SYSTEM THROTTLE POSITION SENSOR (TPS) SETTING Aftar all adjustments are completed, check or adjust the TPS set- ting concfition (Reter to page 28 tor TPS setting procedure) THROTTLE CABLE ADJUSTMENT NOTE: ‘Minor adjustment can be made by the throtife gp side adjuster. (> 216) MAJOR ADJUSTMENT + Loosen the lock nuts ©) of the thrattie retuming eable (2 + Turnthe returning cable adjuster () to obtain proper cable play. * Loosen the lock nuts @ of the thrattie pulling cable + Tum the pulling cable adjustar in or out until the throttle cable Play ® should be 2.0 - 4:0 mm (0.08 ~ 0.16 in} at the throttla a. ‘+ Tighten the lock nuts @ securely while holding the adjuster ‘While holding the throttle grip a! the fuly closed position, slowly turn the returning cable adjuster @) ta abtain a cable siack Bi of 41.0 mm (0.04 in) Tighten the look nuts

4~tt) IAT SENSOR REMOVAL/INSTALLATION * Litt and support the fuel tank, (2 4-52) * Disconnect the IAT sensor coupler (7) and remove the IAT sen- sor from the air cleaner bor. ‘+ [Installation is in the reverse order af removal (EIAT sensor: 18 N-m (1.8 kam, 13.0 Ib-ft) 4-78_F1SYSTEM AND INTAKE AIR SYSTEM ECT SENSOR INSPECTION Ths engine coolant temperature: sensor is installed al the rear side af the cylinder head. (I 4-40 and 5-8) ECT SENSOR REMOVAL/INSTALLATION (7 5-8 ang -9) AP SENSOR INSPECTION ‘The atmospheric pressure sensor is locatect aver the: ECM. (I~ 442) AP SENSOR REMOVAL/INSTALLATION + Remove the front seat: (=7"6-6) © Disconnect the coupler ‘ + Rlemove the AP sensor + Installation is in the reverse order of removal TO SENSOR INSPECTION The tip over sensor is located in ahead of the battery holder, TO SENSOR REMOVAL/INSTALLATION * Remove the front seat, ((7"6-6) * Lift and support the fuel tank. (¢7"4-52) * Disconnect the coupler (j) and remove the TO sensor from the fuel tank bracket, ‘ Insiallation (s in tha reverse order of removal NOTE: Whee installing the TO sensor, bring the "UPPER" Jaiter on it to the top. ‘STP SENSOR INSPECTION The secondary throttle position sensor is installed on the STV actuator, (74-46) STP SENSOR REMOVAL/INSTALLATION * Lift and support the fuel tank. (4-52) * Flemove the STP sensor setting screws ‘P and disconnect tha coupler 2 + Install the STF sensorto the STV actuator, Refer to page 4-71 for STP sensor setting procedure. COOLING AND LUBRICATION SYSTEM 51 COOLING AND LUBRICATION SYSTEM al CONTENTS — ENGINE COOLANT... COOLING CIRCUIT .. COOLING CIRCUIT INSPECTION. RADIATOR AND WATER HOSES... RADIATOR REMOVAL ..... RADIATOR CAP INSPECTION ........0 RADIATOR INSPECTION AND CLEANING RADIATOR REMOUNTING WATER HOSE INSPECTION .... COOLING FAN REMOVAL INSPECTION .. INSTALLATION je. .cerse COOLING FAN THERMO-SWITCH ...... REMOVAL INSPECTION .. INSTALLATION és COOLING FAN CONTROL RELAY INSPECTION ... on ENGINE COOLANT TEMPERATURE SENSOR. REMOVAL INSPECTION ... INSTALLATION. THERMOSTAT. REMOVAL INSPECTION INSTALLATION. WATER PUMP WO SSHSEVIYNNRODABVGHNHARAR GON REMOVAL AND DISASSEMBL 5-11 INSPECTION ..... 514 REASSEMBLY AND INSTALLATION 515 LUBRICATION SYSTEM. 5-18 OIL PRESSURE... 518 OIL FILTER ... 518 OIL PRESSURE REGULATOR . 518 OlL STRAINER Ol JET. OlL PUMP .. OlL PRESSURE SWITCH .... 5-18 ENGINE LUBRICATION SYSTEM CHART. #19 ENGINE LUBRICATION SYSTEM... 5-20 $2 COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manulacture, the cooling system is filed with a 50:50 mixture of distilied water and ethylene glycol anti-freeze. This: 0:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will proteet the cooling system fram freezing at temperatures abova ~34°C (-24°F) It the motorcycle is to ne exposed to temparatures below ~21°C (-24°F), this mixing ratio shauld be increased up 10.55% or 60% according to the figure. 4 CAUTION "Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix sn alcohol base antifreeze and different brands of anti-freeze. * Do not put in more than 60% anti-freeze or less than 50%. (Refer to Right figure.) * Do not use a radiator antiteak addi 50% Engine coolant including reserve tank capacity Aniitigeze | Freezing point 50% =30°C 24°F) 55% 406 FF Be 55°C 67 Antitreeze [1200 mi (3.1726 USimp. pt) Water [4200 mi (9.172.6 USAmp. pl} 0 40 a 80 100 Denaiy (5) Fig Engine coca conatyrazing rr ey Get") aco 180) 2ee 49] 18 ee 130) 7 os os ‘Gauge proseine lie poi g 8 0 0m wm 4 8 oO Deity (5) Fig2 Engine coolant density:boiing point curve. * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way otf. * The engine must be cool betore servicing the cooling system. * Coolant is harmful: + Iitcomes in contact with skin or eyes, flush with water. + I swallawed accidentally, induce vomiting and call physician immediately. + Keop it away from children, COOLING AND LUBRICATION SYSTEM _ 5.3 COOLING CIRCUIT [RESERVE OSTAT| ENGINE COOLANT] a THERMOSTAT | CYLINDER HEAD f= TEMPERATURE SENSOR COOLING FAN THERMO =o aoiator| | evumoen |_“'swirey WATER | —— = COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant. inspect tne egoling circuit for tightness. + Hemove the under cowling. (6-3) * Hemove the radiator cap ?) and connect the tester 2) to the filler. Do not remove the radiator cap when the engine is hot. | Give a pressure of about 120 kPa (1.2 kgtiem’, 17 psi) and see if the system holds this pressure for 10 seconds. pressure should tall during this 10-second interval, it means that thers is a leaking point in the sysiem. in such a case, inspect the entire system and replace the leaking com- panent or part POO When removing the radiat cap tester, put arag on the | | Do not allow the pressure to exceed the radiator cap re- jease pressure, or the radiator can be damaged. 54 COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSES: RADIATOR REMOVAL * Remove the under cowling. ( = [ED Cooling fan thermo-switch operating temperature ‘Standard (OFF—+ON): Approx. 105°C (221°F) (ON-OFF); Approx, 100°C (212°F) ‘@ CAUTION * Take special care when handling the thermo-switch. may cause damage if It gets a sharp impact, * Bo not contact the cooling fan thermo-switch 7) and the column thermometer 2 with a pan. INSTALLATION * Install the O-ring * Tighten the cooling fan thetmo-switch to the specified torque. {F) Cooling fan thermo-switeh: 17 N-m (1.7 kegfm, 12.5 lb-ft) a © Pour engine coolant. (772-18) © Install the under eowling (C7"6-3) $8 _ COOLING AND LUBRICATION SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL + Remove the front seat. (7°6-6) © Remove the tual tank, (74-52) * Remove the air cleaner box. ([=7" 4-62} * Remove the throttle body. ([<7 4-63) * Remove the left side intake pipes. + Disconnect the angife coolant temperature switch lead wire coupler. * Keep the motorcycle upright. + Place a rag under the sensor and remove the engine eolant amperature sansoe (f INSPECTION * Check the engine coolant temperature sensor by testing i at the bench as shown in the figure. Connect the temperature Sensor 1) to a circuit tester and place it in the of contained in a an, which (s placed on a stave, * Heat the oll to raise its temperature slowly and read the column, theemameter and the ohmmeter. + lt the temperature sensor ohmic value does not change in the proportion indicated, replace it with anew one, ‘Temperature sensor specification __Temperature. Standard resisiance 20°C ( 68°F) AppIOK. 2.45 kG 50°C (122°F) Approx. O81 kot BO'C (176°F) Approx. 0.918 kid 110°C (230"F) ‘Approx. 0.142 KO 130°C (266°F) ‘Approx. 01088 kid it the resistance noted to shaw infinity ar too much dierent resis. tance value, raplace the temperature sensor with a new ane. * Take special care when handling the temperature-sen- sor, It may cause damage if it gets a sharp impact. | * Do nat contact the engine coolant temperature sensor ‘D and the eo! COOLING AND LUBRICATION SYSTEM 5-9 INSTALLATION + Tighten the engine coolant temperature switen ta the specitied rorque, [8] Engine coolant temperature sensor: 18 N-m (1.8 kgtm, 13.0 Ib-ft) AUTION may cause damage it it gets + Install the thrattle body. * Install the alr cleaner box. * Install the tuel tank, (—7-4-52) * Install the front seat. THERMOSTAT REMOVAL * Flemove the front seat, (776-6) * Remove the fusl tank. (774-52) + Place @ rag under the thermostal case. * Remove the thermostat case. + Rlemave the thermostat () $10 _ COOLING AND LUBRICATION SYSTEM INSPECTION Inspect the thermostat pellet for signs of cracking. “Test the thermostat at the bench for contra! action, in the flow ing manner. + Pass a string between flange, as shown in the illustration, + Immerse the thermostat in the water contained in a beaker, as shown in the ilustration. Note that the immersed thermostat is in suspension. Heat the water by placing the beaker on a stove and chserve the rising temperature on a thetmometer. * Read the thermameter just when opening the thermostat, This reading, which is the temperature level at which the thermastat valve begins to open, should be within the standard value, EX) Thermostat valve opening temperature Standard: Approx. B2°C (180°F) * ‘Kean on heating the watar to raise its temperature. * Just when the water temperature reaches. specified value, the ‘thermostat valve should have lifted by at least 8.0 mm (0.31 in). (EQ) Thermostat vaive litt Standard: Over 6.0 mm at 95°C (Over 0.31 in at 203°F) ‘+ A thermostat falling to satisfy either of the two requitements (start-to-open temperature and valve lift) must be replaced. INSTALLATION + Install the thermostat NOTE: The jiggle vaive ® of the thermastat taces upside. — © 2 * Install the thermostat case, NOTE: Fit the clamp to the thermastat case bolt 4) * Tighten tha thermostat case bolt to the specified torque. [F) Thermostat case bolt: 10 Nem (1.0 kgf-m, 7.0 Ib-ft) + Install the fuel tank, (=F 4-52) + Install the front seat. WATER PUMP REMOVAL AND DISASSEMBLY * Remove the under coming. (7"6-2) * Drain engine coolant, (72-18) + Drain engine oil. (72-13) NOTE: Belore draining engine oif and engine coolant, inspect engine oll and coolant leakage between the water pump and crankcase. It engine oil is leaking, visually inspect the oll seal and O-ring. It engine coolant is leaking, visually inspect the mechanical seal and seal washer (> 5-14) * Remove the reserve tank 4). COOLING ANO LUBRICATION SYSTEM 5-11 512 COOLING AND LUBRICATION SYSTEM ‘+ Remove the engine sprocket cover (f ‘= Disconnect the water hoses + Remove the water pump, + Remove the water pump caver. + Remove the impeller securing bolt (2 by holding the impellar Shaft with a water pump pliers, COOLING AND LUBRICATION SYSTEM 5-13 ‘+ Remove the mechanical seat ring @ ang the rubber seal trom the impeller. © lamove the impeller shatt 2 ‘+ Remove the bearing using the special toot. 09921-20220: Bearing remover set (0 10) NOTE: If 70 abnormal noise, Bearing removal Is not necessary & CAUTION | ‘The removed bearing must be replaced with a new one. * Remove the mechanical seat using the special tool, (00921-20220: Bearing remover set (0 12) NOTE: Ina abnormal, the mechanical seal removal is not necessary. a GAUTION | ‘The removed mechanical seal must be replaced with new one. + Remove the oll seal using a suftable bar, NOTE: Ifo atmormel, the oil seal removal is not necessary. 514 COOLING AND LUBRICATION SYSTEM INSPECTION BEARING ‘+ Inspect the play of the bearing try hand while it is in the water pump case. ‘+ Rotate the inner race by hand to inspect for abnormal noise land smocth rotation, + Replace the bearing if there is anything unusual. MECHANICAL SEAL * Visually inspect the mechanical seal for damage, with particu- lar attention given to the sealing face. “ Replace the mechanical seal that shows indications of leak- lage. Also replace the seal ring if necessary. OIL SEAL + Visually inspect the oil seal for damage, with particular atten- tion given to the tip, + Replace the oll seal that shows indications of leakage. BUSHING Visually inspect the bushing for damage. '* Replace the water pump body ll necessary, SEAL WASHER * Visually inspect the seal washer for damage, with particular attention given to-the sealing face. * Replace the seal washer that shows indications of leakage, CODLING AND LUBRICATION SYSTEM 5-18 REASSEMBLY AND INSTALLATION Install the oi! seal using the special tool. )09913-70210: Bearing installer set (¢ 20) NOTE: The stamped mark on the oil Seal faces outside. + Apply a small quantity of the SUZUKI SUPER GREASE “A” io tne oll seat lip. G5} 99000-25010: SUZUKI SUPER GREASE “A” © Install the new mechanical seal using a suitable size socket wrench NOTE: ‘The new mechanical seal has been appiled the sealer ®). + Install the new bearing using the special tool (09913-70210: Bearing installer set (0 25) NOTE: The stamped mark on the bearing faces crankcase side, 5418 COOLING AND LUBRICATION SYSTEM * Apply grease ta the Impeller shatt. Sy 99000-25010: SUZUKI SUPER GREASE “A” + Install the impeller shaft to the water pump body, * Afier wiping off the olly or greasy matter from the mechanical seal ring; install tito the iepalier. * Install the rubber seal) inio the impeller. NOTE: ‘The marked side &) of the mechanical seat ring faces the impel- fer “Install the seal washer andthe washer onto the impeller secur- ing bot 2, ® NOTE: \ ‘The metal side of the seal washer and the convex side © of the washer face the impeller securing bolt head. install the impeller & and its securing boit 2 onto the shat. + Tighten the impeller securing bolt @ to the specified torque. [F Impetier securing bolt: 8 N-m (0.8 kgt-m, 6.0 Ib-tt) NOTE: Before instaling the impeller securing bott, apply a-smali quantity of the THREAD LOCK "1342" to it. Zi 29000-32050; THREAD LOCK “1342” + Install the new O-rings, 7) and 2: “A CAUTION | Use the new O-rings to prevent engine coolant feskage. NOTE: * Apply engine coolant to the O-ring * Apaly grease to the O-ring gx 99000-25010: SUZUKI SUPER GREASE “A” + Tighten the water pump cover screws ta the specified torqui {8 Water pump cover screw: 6 Nim (0.6 kgtm, 4.5 lb-ft) + Install the water pump and tighten its mounting bolt to the specified torque. {8 Water pump mounting bolt: 10 N-m (1.0 kgm, 7.0 lb-ft) NOTE: Set the water pump shatt end (A to the ol pump-shaft Bi as shown in the following istration, (7- 5-18) Connect the water hoses, (C=7"8-19) Install the engine sprocket cover. Install the reserve tank Pour angina coolant. (72-18) Pour engine oil (72-13) Install the under coming, 5:18 _CODLING AND LUBRICATIONSYSTEM Mane (saisie) a Bt wt inaTER PUMP ou Pte LUBRICATION SYSTEM OIL PRESSURE mres1 OIL FILTER cre OIL PRESSURE REGULATOR Fas OIL STRAINER CF aS OIL JET or3s7 OiL PUMP F343 OIL PRESSURE SWITCH ora COOLING ANDLUBAICATIONSYSTEM 518 ENGINE LUBRICATION SYSTEM CHART TAKE CANA CARRAL HOLDER | « [antsearr JOURNALS, [tar nares Jenna causnar} EAST CARAT omar cine -—_ssmnems SUB-GALLERY bp gu] em ene 7 T ‘ aa —- ees] EE] ese] Le] fecal] [Si'sama| aatieawo] (Simcoe nh 7 7 7 7 Pro | | | ah MAIN-GALLERY r i ie Ses! 1 ; 1 ae 1 : i LEP SDE A ARES i LL ee | | oe T aaa elieeed — 1 H te | ae Te (eee | Sara eo stenct | | Sains A, ah 7 7 OIL PAN {5.20 ODQUNG ANDLUBRIGATIONSYSTEM ENGINE LUBRICATION SYSTEM CHASSIS CONTENTS —— EXTERIOR PARTS 6&2 FASTENER REMO' 62 SCREEN... 62 BODY COWLING COVER 63 RIGHT AND LEFT UNDER COWLINGS &3 BODY COWLING &4 RIGHT AND LEFT AIR INTAKE PIPES 65 COWLING BRACE 6&5 FRONT SEAT .. &6 REAR SEAT A & 6 FRAME COVER. & 6 FRONT WHEEL .. 6-7 CONSTRUCTIO! 6 7 REMOVAL 6&8 INSPECTION AND DISASSEMBLY. 6 3 REASSEMBLY AND REMOUNTING 6-10 FRONT FORK .. 6-13 CONSTRUCTI 6-13 REMOVAL AND DISA 6-14 INSPECTION... 6-17 REASSEMBLY AND REMOUNTING . 6-18 SUSPENSION SETTING... 6-23 STEERING DAMPER ... 624 CONSTRUCTION 624 REMOVAL 6-24 INSPECTIO! 624 REMOUNTIN 6-24 STEERING .. 6-25 CONSTRUCTION .. 6-25 REMOVAL AND DISASSEMBLY 6-25 INSPECTION AND DISASSEMBLY 627 REASSEMBLY AND REMOUNTING 6-27 STEERING TENSION ADJUSTMENT. 6-29 HANDLEBAR . 6-30 CONSTRUCT 6-30 REMOVAL AND DISASSEMBLY . 6-30 REASSEMBLY AND REMOUNTING 6-31 REAR WHEEL 6-33 CONSTRUCTION 6-33 REMOVAL. 6-34 INSPECTION AND DISASSEMBLY . 6-35 REASSEMBLY AND REMOUNTING 6-37 REAR SHOCK ABSORBER 6-41 CONSTRUCTION 6-41 REMOVAL .. 6-42 INSPECTION ... 6-42 REAR SHOCK ABSORBEA SCRAPPING PROCEDUR: 6-43 REMOUNTING.. 6-43 SUSPENSION SETTING 6d CHASSIS 6.1 REAR SUSPENSION CONSTRUCTION REMOVAL. INSPECTION AND DISASSEMBLY... REASSEMBLY REMOUNTING 6-52 FINAL INSPECTION AND ADJUSTM 6-53 FRONT BRAKE . CONSTRUCTION .. BRAKE PAD REPLACEMENT. BRAKE FLUID REPLACEMENT ........ CALIPER REMOVAL AND DISASSEMBLY CALIPER INSPECTION... CALIPER REASSEMBLY AND REMOUNTING.. BRAKE DISC INSPECTION .. MASTER CYLINDER REMOVAL AND DISASSEMBLI MASTER CYLINDER INSPECTION. MASTER CYLINDER REASSEMBLY AND REMOUNTING... REAR BRAKE CONSTRUCTION .. BRAKE PAD REPLACEMENT. BRAKE FLUID REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER INSPECTION... CALIPER REASSEMBLY Al MASTER CYLINDER REMOVAL AND DISASSEMBLY. MASTER CYLINDER INSPECTION. MASTER CYLINDER REASSEMBLY AND REMOUNTING 6-67 TIRE AND WHEEL. TIRE REMOVAL 6-68 INSPECTION ... 6-68 VALVE INSPECTIO! 6-69 VALVE INSTALLATION .. TIRE INSTALLATION BALANCER WEIGHT . &2_CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND REINSTALLATION FASTENER @) REMOVAL + Depress the head of fasteners center piece “f «Pull out the tastaner INSTALLATION * Let the center place stick out toward the head so that the pawis 2 close. * Insert the fastener into the installation hole NOTE: To prevent the paw! ®) from damage, insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face. FASTENER & REMOVAL * Pull the head of fastener center piece + Pull out the fastener, INSTALLATION * Let the center piece stick out toward the head so'that the pawls clase + Ingert the fastener into the installation hale, « Push in the head of canter piece. SCREEN + Remove the bolts and nuts. * Remove the screen. =~ CHASSIS: BODY COWLING COVER * Remove the body cowling cover 7) by removing the tasteners, RIGHT AND LEFT UNDER COWLINGS * Remove the fastener, + Remove the fastener, * Rlemave the right under cowling. * Disconnect the tum signal fight lead wire coupler. = Remove the lett under cowiing, * Disconnect the turn signal light lead wire coupler. 64 CHASSIS BODY COWLING REMOVAL * Remove the rear view mirrors, * Remove the fasteners + Remove the bolts. + Femove the bady cowling by disconnecting the lead wire cou- piers. REMOUNTING NOTE: When vemounting the body cowiing, install the hooks ®) fo the cowling brace holes. CHASSIS 65 RIGHT AND LEFT AIR INTAKE PIPES © Remove the body cawiing. + Remove the bolt and fastener, + Remove the right air intake pipe + Remove the bolt and fastener + Hemove the lett air intake pipa 2 COWLING BRACE REMOVAL + Remove the body coling, (C + Remove the cowling brace, 4) REMOUNTING * Tighten the cowling brace bolts and nut (F) Cowling brace bolt and nut : 23.N-m (2.3 kgt-m, 16.5 tb-tt) * Clamp the wire hamess and the brake hose. (["8-14, 15, 20) 56 CHASSIS FRONT SEAT + Remove the front seat by removing the bolts. REAR SEAT AND SEAT TAIL COVER + Remove the rear seat (sest tall cover) with the ignition kay, FRAME COVER + Remove the seats, ‘= Remove the bolts. + Remove the fasteners © Disconnect the rear combination light lead wire coupler, + Remave the frame cover. CHASSIS 67 FRONT WHEEL CONSTRUCTION &_ CHASSIS REMOVAL ‘© Remove the brake calipers. ‘A CAUTION | Do not operate the brake lever while removing the call cae. | *» Loosen two axle pinch balts |?) on the right frant fork leg * Loosen the front axle @ * Raise the front wheel off the ground and support the motor- cycte with a jack or a wooden block. 4 CAUTIO! Do not work by using side stand. Do not support the motorcycle with exhaust pipe. Make sure that the motor- cycle is supported securely. ‘+ Remove the tront axle and the front whee! NOTE. After removing the front wheel, fit he calipers temporarily to the original positions * Loosen two axle pinch batts @ on the ieft front fork leg and remove the spacer nut @ INSPECTION AND DISASSEMBLY TIRE INSPECTION: > 6-68 + Remove the brake disc BRAKE DISC INSPECTION: [> 6-58 — Continued on next page — + Remove both side dust seals by using the oil seal remover 09913-50121: Ol: seal remover be replaced with new AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it the runout exceeds the mit, (5 09900-20606: Dial gauge (1/100) (09900-20701; Magnetic stand 08800-21304: Veblock set (100 mm) Axle shaft runout Service Limit: 0.25 mm (0.010 in) WHEEL Make sure that the wheel runout checked as shawn does not exceed the service limit. An excessive runout is usually due to warn or loosened wheel bearings and can be reduced by 1é- placing the beanngs. |t bearing replacement fails to reduce the funout, replace the wheel ‘Wheel runout Service Limit (Axial and Radial): 2.0 mm (0.08 in) WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in tha wheel, Rotate the Innier race by finger to Inspect for abnormal noise and smooth rotation. Replace tne bearing in the following procadure if thete is any- thing unusual, * Remove the whee! bearings by using the special tool, (6 09921-20220: Bearing remover set replaced with new removed bearings should ones. 10 CHASSIS REASSEMBLY AND REMOUNTING Reassembie and remount the from! wheel in the reverse order of removal and disassembly. Pay attention to the following paints bat go =D Riot me BNm WBS hatin, 10.1 oe Wasnim BS kote, . m M Oy sod (iaeagtm, testo TBshghm, 16:5 bt b zane [23 4ghen, 165 | WHEEL BEARING * Apply grease to the wheel bearings. Jaq 99000-25010; SUZUKI SUPER GREASE “A ‘Install the whee! bearings as follows by using ihe special tools. (65 09941-34513: Bearing/Steering race installer set A CAUTION | First install the left wheel bearing, then install the right wheel bearing. The sealed caver of the bearing must face outside. CHASSIS 6-11 ada bag nga Dae BRAKE DISC ‘Make sure that the brake disc is clean and tree of any greasy matter, + Apply THREAD LOCK SUPER 360"to the disc mounting bolts and tighten them to the specified torque. (©) Brake disc bolt (Front): 23 Nem (2.3 kgt-m, 16.5 Ib-fi) AZ 09000-32130: THREAD LOCK SUPER “1360” 612_CHASSIS SPACER NUT ter touching the lange of spacer nut being contact with the left {ront fork lag. tighten the two axle pinch balts-on the let front fork. Jeg to the specified torque. (©) Front axte pinch bolt: 25 Nem (2.3 kgt-m, 16.5 lb-ft) WHEEL Install the front wheel with the front axle and hand-tighten the front axle temporarily. ‘The directional arrow on the tire should point ta the wheel rotation, when remounting the wheel BRAKE CALIPER * Tighten the brake caliper mounting bolts ta the specified torque. () Front brake caliper mounting bolt: 25 Nm. (25 kgt-m, 18.1 lb-ft) NOTE: Push the pistons all the way into the caliper and remount the calipers. FRONT AXLE * Tighten the front axle to the specified torque. (F) Front axte: 100 N-m (10.0 kgftm, 72.5 lb-ft) NOTE: Before tightening the two axie pinch bolts on the right front fork log, mave the front fork up and down 4 or 5 times. * Tighten two axle pinch bolts on the right front fork lag to’ the specttiog torque (8) Front axie pinch bolt: 23 Nem (2.3 kgf-m, 16.5 Iib-ft) CHASSIS. 613 FRONT FORK CONSTRUCTION Eid CHASSIS REMOVAL AND DISASSEMBLY + Remove the front wheel. ((7"6-8) * Disconnect the braka hoses + Remove tne tront tencier * Loosen the front fork upper clamp bolt (f NOTE: Slightly Joasen the front fork cap bolts (2) bafore ioosening the ower clamp batts to faciitate later disassembly, + Loosen the handlebar clamp bolt * Remove the handlebar set bolt & NOTE: Place the rags under each hanalebar to prevent scratching the upper fairing and the air intake pipes. * Loosen the front fork set bolts. NOTE: Be careful not to drop the front fark when loosening the bolts + Remave the protecter (5 + Loosen the front fork cap bolt 1) and remove the spring seat a + Remove the front fork cap bolt with spring adjuster by holding the inner rod lock nut, + Remove the spacer ), washers @, and spring 5, + Invert the fork and stroke it several times to drain out fork oil. * Hold the fork inverted for a faw minutes to deain oll, * Remove the dust seal, + Remove the ol seal stopper ring. S18 CHASSIS + Remove the damper rod bolt, * Remove the damper rod. * Extract the auter tube from the inner tube. NOTE: Be caret! not to damage the inner tube. CAUTION ‘The slide metals, oil seal and dust seal must be replaced with new ones when reassembling the frant fork. + Flomove the following parts, ‘1 Ol seat @ O4 seal retainer | Antistiction metal (Guter tube) @ Antitriction metal (Inner tube) 5 Oil look piece ‘+ Remove the compression damping force adjuster, NOTE: ‘Never disassemble the compression damping force adjuster CHASSIS 6417 DAMPER ROD DISASSEMBLY + Loosen the inner red lock nut (7). + Flemove the spring adjuster, A CAUTION Replace the O-rings with new ones, INSPECTION INNER AND OUTER TUBES Inspect the Inner tube: sliding surface and auter tube sliding sur- face for scutting, FORK SPRING Measure the fork spring {ree length. Wit is Shorter than the service limit, replace it with a new one EEX Front fork spring tree lengthy Service limit : 243 mm (8.6 in) DAMPER ROD Mave the inner rod by hand to examine it for smoothness, 618 CHASSIS: REASSEMBLY AND REMOUNTING Reassembe and remount the front ‘ork in the reverse arder af removal and disassembly, Pay attension to the fallowing points: ‘COMPRESSION DAMPING FORCE ADJUSTER * Tighten the compression damping force adjuster to the speci- fled torque. [) compression damping torce adjuster: 18 Nem (1.8 kgm, 13.0 lb-ft) & CAUTION DAMPER ROD * Install the rebound damping force adjuster 7 into the spring adjuster 2. + Adjust the height & of the rebound damping force adjuster at 1.5 mm (0.06 in), *+ Keep the above position and turn in the rebound damping force adjuster fully into the inner rod * Tighten the inner rad lock nut |) to the specified torque by holding the spring adjuster, Dinner rod tock nut: 20 N-m (2.0 kgfm, 14.5 Ist) ‘TUBE METALS AND SEALS + Hold the inner tube vertically and clean the metal groove and install the ANTI-FRICTION metal by hand as shown. CAUTION Use special care to prevent damage to the-Teflon" coated surface of the Anti-friction inner tube metal when mouint- ing it. ++ Install the oil lock piece @) onto the inner tube. & CAUTION | * Do not use solvents for washing to prevent oll seal damage. * Apply fork oil to the Antiriction metals, lip of oil seal and dust seal, *+ Apply fork oll to the oil saat lip lightly before instaling it ZB 29000-29001-8S8; SUZUKI FORK OIL SS-08 (#10) * Install the following parts as shown, 1 OW seal 2 Oil seal retainer 3) Antirietion metal (Quter tue) ® Anii-friction metal (Inner tube) 5 Dust seal 8) Ol seal stopper ring ‘+ Insert the inner tuba into the outer tube and fit the oll seal and dust seal with the special toot (5) 00040-52861: Front fork ail seal installer DAMPER ROD BOLT * Tighten the damper rod bolt to the specified torque. (F) Damper rod bolt: 35 Nem (3.5 kgf-m, 25.5 lb-ft) _A CAUTION | Use @ new damper rod bolt gasket to prevent oil leak- age. NOTE: If the damper rod turns with the damper rod bot, temporarily n= sal the fork spring, spacer and cap Balt. FORK OL * Ptace the front fork vertically without spring. + Compress i fly * Pour specifiad front fork oil up to the top leva! of the outer tube. + Move the innét rod slowly more than ten times until bubbles do not come aut fram the cil NOTE: Refill front fork oi! up to the top of the outer tube fo tind bubbies while bleeding air. + Refill specitied front fork oll up to the top level of the outer tube: again. Move the outer tube up and down several strokes until ‘bubbias do not come out from tne oil, * Keep the front fork vertically and wait 5 ~ 6 minutes. NOTE: * Always keep oil level over the cartridge top end, or air may ‘enter the cartridge during: this procedure. * Take extream attention fo purnp out air completely. * Hold the front fork wertically and adjust fork oll lave! with the special tool, NOTE: When adjusting the fork oil fevel, remove the fork spring and com: ‘press the inner tube fully (GS 09943-74111: Front fork oll level gauge Fork oll lavel: 102 mm (4.0 in) Fork oll type: $S-08 (#10) 5G) 99000-99001-SS8: SUZUKI FORK OIL $5-08 (#10) Capacity (each leg): 528 mi (17.818.6 US/imp oz) FORK SPRING * Install the fork spring, NOTE: The small end'®) of the fork spring should be at the battom of the front fork. FRONT FORK CAP BOLT Install the washers @) and spacer 2. * instal the front fork cap. * Install the spring retainer ©). + Apply fork oll lightly to the O-ring. (A CAUTION Use a new O-ring to prevent oil leakage. ] * Tighten the front fork cap bolt temporarily, + Install the front fork protectar. NOTE: Fil the projection of the front fork protecter to the depression of the front fork outer tube. 622 CHASSIS: * Set the upper surlace of the inner tube at 6.3 mm (0.25 in) height @ from the upper surtace of the steering stem upper bracket and tighten the front fork lower clamp bolts 7) to the specified torque. (F) Front fork lower clamp bolt: 23 N-m (2.9 kaf-m, 16.5 Ib-ft) * Tighten the handlebar set bolt (2 to the specified torque. (F) Handlebar set bolt: 10 N-m (1.0 kgtm, 7.0 theft) © Tighten the handlebar clamp bot @ + Tighten the front fork cap bolt @) to the specified torque and recheck the front fark outer tube upper surtace height 4) fram the upper surtace of the steering stem upper bracket (2) Handiebar clamp bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) Front fork cap bolt: 35 N-m (3.5 kgm, 25.5 lb-ft) * Tighten the front fori upper clamp tlt (©) Front tork upper clamp bolt: 23 Nem (2.3 kgf-m, 16.5 Ib-it) * Install the front fender. * Install the tront wheel. NOTE: Belore tightening the two axie pinch bolts on sight front fork leg. move the frant fork up and down 4 or 5 times; Bit) SUSPENSION SETTING After instaling the tront fork, adjust the spring pre-load and damp- ing farce as follows. SPRING PRE-LOAD ADJUSTMENT There are seven grooved lines on the side of the spring adjuster. Position 1 provides the maximum spring pre-load ant position 7 provides the minimum spring pre-load. (STO position: 4) (DAMPING FORCE ADJUSTMENT (Rebound side) Fully turn the damping force adjuster 7) clockwise. It is at stiffest Position and turn if out to standard setting position. (STD position: 1 and \4 turns aut [Fine-tune the adjuster by turn- (na it slightly wnt two punch marks align.J) (Compression side) Fully turn the camping force adjuster 2 clockwise. It is at stitfest position and tun it out fo standard setting position, (STD position: 1 and \% turns out [Fine-tune the adjuster by turn- ing it slightly untl two punch marks align J) STANDARD FRONT SUSPENSION SETTING FRONT ~ Spring pre-load] Damping force adjuster _ adjusier | Rebound | Compression Softer 4 [1 and te tums out |1 end yi tums out S| Sandard 4 [fend 9 ums out|t and 4 tus ot ning) sulfer 4 [tandems out) 4 turn out_| Dual riding | 4 hand Se tums out |f and tums ou POG "Be sure to adjust the spring pre-load and damping foree | of both front fork fegs equally. Compressign aide 624 CHASSIS STEERING DAMPER ‘CONSTRUCTION {Bienen aarcer ‘2-Dumt coal @ TEM | Nm | kghm | tot a 23 | 2a | 165 & | 2 | 20 | 165 REMOVAL + Remove the nut (f) by halding the nut + Remove the ott Zi and remove the steering dampar, INSPECTION Inspect the steering damper body, bearing and oll seal tor dam- ‘age and oil leaking, Move the steering damper rod by hand ta inspect for a smooth movement Hany defects are found, replace the steering dampar-with a new one. REMOUNTING * Install the steering damper and tighten the bait and nut (M steering damper bolt and nut: 23 Nm (23 kgi'm, 16.5 Ib-ft) * Apply grease to the bearings and dust seats, Jame 99000-25010: SUZUKI SUPER GREASE “A CHASSIS 625 STEERING CONSTRUCTION REMOVAL AND DISASSEMBLY + Flemove the front wheel. (7-6-8) © Hempve the front fork, (76-14) 6-25 CHASSIS * Remove the steering stam upper bracket by removing its head nul NOTE: I fs not necessary to remove the ignition switch, when anly re- placing the steering stern, (Ignition swrich removal: IF 7-30) + Remove the brake hose clamp bolt * Remave the steering stem lock nut, the washer and the stear- ing stem nut with the special tools (09940-14911: Steering stem nut wrench 09540-14560: Steering stem nut wrench socket * Draw out the steering siem lower bracket Nore Hold the steering ster tower bracket by hand ta prevent it Jroo ‘aing, + Remove the dust seal ‘D), the steering stem upper bearing in: er rage (2! and the bearing CHASSIS 627 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinalling > Bearing wear or damage * Abnormal noise at bearing {any abnormal points are found, replace defective parts with the new ones, * Remove the steering stem lower bearing inner race with a chisel ‘A CAUTION ‘The removed bearing outer race must be replaced with | Rew one. “ Drive out the steering stem bearing outer races, upper and lower, using a suitable wedge bat cal ‘The removed bearing outer race must be replaced with a new one, REASSEMBLY AND REMOUNTING eassemible and remount the stesring stem in the reverse order of removal and disassembly, Pay attention to the following points: OUTER RACE ‘* Press in the upper and iower bearing outer races with the spe lal teats, BS 09041-34513; Steering outer race installer sot INNER RACE ‘+ Press in the Iower bearing Inner raca with the spacial tool 08925-18011: Stoering bearing installer 628 CHASSIS BEARING * Apply grease to the bearings and bearing races. Sia 99000-25010: SUZUKI SUPER GREASE “A” * Install the lower bearing to the steering stem lower bracket. '= Install the upper bearing and bearing inner race. ‘STEM NUT * Install the dust seat + Tighten the steering stem nut to the specitied torque with the special tools (5) 09940-14911: Steering stem nut wrench (09940-14960: Steering stem nut wrench socket [F) Steoring stem nut: 48 Nem (4.5 kgm, 32.5 tbett) + Tum the steering stem lower bracket about tive or six times to the ltl and right so that the angular bell bearings willbe seated property + Loosen the stem nut by 1/4 — 1/2 turn NOTE: This adjustment will vary trom motorcycle to motorcycle. NOTE: When instalting tha washer, align the stepper lung to the gracve of the stearing stem. * Tighten the steering stem lock nut to the specilied torque with the special tools, (09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut wrench socket D2) Steering stom lock mut: 80 N-m (8.0 kgfm, 58.0 Ib-ft) FRONT FORK AND STEERING STEM UPPER BRACKET Install the front fork and steering stem upper bracket following steps 1) Install the upper bracket, washer 7) and steering stem head nut 2 temporary. 2) Set the front forks and tighten the steering stem ead rut 2 [F) stoering stem head nut: 90 N-m (9.0 kgfm, 65 Ib-ft) 3) Tighten the front fork upper and lower clamp bolts. (CF 6-22) * Install the handlebars. (C"6-31) ‘= Install the front wheel, (C'6-10) = Install the steering damper, (7"6-24) STEERING TENSION ADJUSTMENT Check the steering moverient in the follawing procedure, + By supporting the motoreycte with a jack, it the front whes! unti it off the flogr by 20 ~ 30 mm (0.6 — 1.2 i) + Remove the steering damper. (3° 6-24) = Check 19 make sure that the cables and wire hamesses are properly routed With the tront whee! in the straight ahead state, hitch the spring scale (special tool} on one handlebar grip end as shown la the figure and read the graduation when the handlebar starts mov- ing. Bo the same on the other grip end (EY) initial force: 200 - 500 grams (09940-92720: Spring scale * If the initial force read on the scale when the handlebar stars tuining is ether tao heavy or too light, adjust ttt it satisties the specitication, 1)First, loosen the frant fork upper and lawer clamp botts, steer ing stem head nut and steering stem lock nut, and then acfust the steering stem nut by loosening ar tightaning iL 2)Tighten the steering stem lock nut, stem head nut and front fork upper and lowar clamp bolts to the specified torque and re-check the initial foree with the spring scale agcording to the previously dasciibed procedure. 2)if the initial force is found within te specified range, adjust- ment has been completed. NOTE: Hold the trom fork Jags, move therm back and forth and make sure that the steering is not loose. &10_ CHASSIS HANDLEBAR CONSTRUCTION = 3 5 ~— 4 @ . aH | is Z ee of - a 2 ruspeteoe Oy coy rarale a w wp randie seen i - . » A nif) eM | Nm | ktm | A 7 a za | 23 | 165 & 10 io | 79 REMOVAL AND DISASSEMBLY RIGHT HANDLEBAR + Flemove the brake master cylinder ®) (I 6-59) © Remove the right handle switch 2 * Remove the handle balancer (3) © Remove the right handle grip @ LEFT HANDLEBAR: ‘* Remove the cluten lever holder (t), + Flamove the lett handie switch © ‘+ Fomove the handie balancer + Remove the let handle grip @ CHASSIS 6:31 * Loosen the handlebar clamp bolts + Remove thé handlebar set bats * Loosen the front fork upper clamp bolt + Flemove the steering stem upper bracket by removing the steer ing stem head nut * Draw out the handlebars to upward REASSEMBLY AND REMOUNTING Reaasemble and remount the handlebar in the reverse order of removal and disassembly. Pay altention to the following points: + Install the handlebars temporaly + Install the steering stam upper bracket. NOTE: If itis difficult 10 install the steering stem upper bracket, joosen the axle pinch bolts af right front fork + Tighten the steering stem head rut {H Steering stem head nut: 90 N-m (8.0 kgf-m, 65.0 lb-ft) + Tighten the front fork upper clamp bolts. {8 Front fork upper clamp bolt: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) 32 CHASSIS * Tighten the handlebar set bolts. {F) Hendiebar set bait: 10 N-m (1.0 kgm, 7.0 Ib-ft} * Tighten the handlebar clamp bolts (7) Handlebar clamp bolt: 23 N-m (2.3 kaf-m, 16.5 Ib-ft) * When remounting the clutch lever holder, align the fh mating surtace with punch mark ® on the handlebar. + When remounting the brake master cylinder, align the holders: ‘mating Surface with punch mark () on the handlebar. + When remounting the right and left handle switches, engage the stopper with the handlebar hole, * Apply the grease to the throttle cables and their holder. fa 99000-25010: SUZUKI SUPER GREASE “A” + Install the front biake master cylinder. (> 6:60) ba 2 i ee 34 of os sete, abe HUAI da SSA HaRTeEESSTD EO REAR WHEEL CONSTRUCTION § 3 oe] =e] @)o| @ | a}aj9) 2 | 8 Elalo| 2| = sla/3| 2] 8 Elwale| & 2\8)8) 2) 8 a) gl al f El clelosles le al = Be 4 CHASSIS REMOVAL * Remove the catier pin. (For Canada and USA) * Loosen the axle nut. * Raise the rear wheel off the ground and support the motor- veyole with a jack or wooden block, + Remove the axde nut and draw out the rear axle, * Remove the rear whee! by disengaging the drive chain i CAUTION Do not operate the brake pedal while removing the rear wheel. + Remove the collar ‘Draw out the rear sprockel mounting drum 2) from the wheel ub. ‘+ Remove the rear sprocket mounting drum retainer + Separate the rear sprocket from its mounting drum by remav- ing nuts. * Femove the dust sea! by using special tool, (09813-50121: Oil seal remover 4 CAUTION ‘The removed dust seal must be replaced with a new one. © Remove the collar 7 + Ramove the brake disc, INSPECTION AND DISASSEMBLY TIRE INSPECTION: (72-25 and 6-68 WHEEL INSPECTION: (7"6-9 and 68 REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. EM Axle shatt runout: Service Limit: 0.25 mm (0.010 in) (09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) WHEEL DAMPER, Inspect the damper far wear and damage. Replace the damper it there is. anything unusual ‘SPROCKET Sl Inspect the sprocket teeth for wear. It they are worn as shown, replace the two sprockets and drive chain as a Set ‘Nonna waar ENCASANE Wee £36 CHASSIS BEARINGS Inspect the play of the wheel and sprocket mounting drum bear- ings by hand whils they are in the wheel and drum. Rotate the inner race by hand to inspect far abnormal naise and smeoth rotation, Replace the bearing it here is anything unusual, + Remove the sprocket mounting drum bearing and whee! bear- ings by using the special tool. (09921-20220: Bearing remover set (9 30) A CAUTION | Tho removed bearings must be replaced with new ones. CHASSIS 6:37 REASSEMBLY AND REMOUNTING Reassembié and remount the rear wheel in the reverse order of removal and disassembly, Pay attention to the following paints: 25m Sexe” 25 kgm, 18.0.8) Ip 0k Oe aeanal: Mrshm Oem som For E03, 28, 93 633 CHASSIS < BEARINGS: © Apply grense to the bearings before installing, Say 99000-25010: SUZUKI SUPER GREASE “A" + Install the new bearing to the spracket mounting drum using the special to0l (09924-84510: Bearing installer set ** First install the right wheef bearing, tnen install the left whee! esting using the special taok (09941-94513: Bearing/Steering race installer set CAUTION - The sealed cover of the bearing must face outside, 7 DUST SEALS + Install the new dust seal using proper dift ‘+ Apply grease to the dust seal lip before assembling raar wheel. S@@w 99000-25010: SUZUKI SUPER GREASE “A” BRAKE DISC * Apply THREAD LOCK SUPER "1360" to the disc bolts. and ‘ighten them to the specified torque. NOTE: ‘(Make sure that the brake disc is clean and free of any greasy matter. AZ 99000-32130: THREAD LOCK SUPER "1360" () Brake disc bolt: 35 Nim (3.5 kgf-m, 25.5 Ib-ft) REAR SPROCKET * Tighten the sprocket mounting nuts to the specified torque, (©) Rear sprocket nut: 60 N-m (6.0 kat+m, 43.5 lb-ft) NOTE: Stamped mark on the sprocket should face outside + Install the rear sprocket mounting drum retainer @ + Install the rear sprocket mounting deum * Instalt the coltars @ and 640 CHASSIS REAR AXLE * Remount the rear wheel and rear axle shat, install the washer and rear axle nut 2 * Adjust the chain slack after rear whee! installation, (C7 2-20) * Tighten the rear axle nut ‘2 to the specified torque. (F) Rear axte nut: 110 N-m (11.0 kaf-m, 7.6 lb-ft) [For E-03, 28, 33] 120 Nem (12.0 kof'm, 86.8 Ib-ft) [For the others) © Tighten both chain adjuster look nuts Drive chain; 7 2-20 * Tire pressure: > 2-26 * Chassis bolts and nuts: 7" 2-28 St CHASSIS FRONT BRAKE CONSTRUCTION 4) Front brake fever 2 fox oon 3: Pazon oat Peon to | 3 Dist seal 3: Brake calor raion P Brake pao © brake pad eprng &@ Pid mounting pn Brake hose 2} Front master cyinoet moutting bot B Brake fogs Union bit © Galer mauntg bot Calin a blendor valve E-Gaiger housing oot * This brake system is filled with an ethylene glycolbased DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based oF patroloum-based, * Do not use any brake fluid taken trom old, used or unsealed containers. Never reuse brake fluid {oft 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 dise or brake pad reduces braking performance. Discard contaminated |_bads and lean the dise with high quality brake cleaner or neutral detergent. Handle brake fluid with care: © fluid reacts chemically with paint, plastics, rubber materials etc. BRAKE PAD REPLACEMENT + Remove the spring * Remove the brake pads by removing the clip 2) and pad maunt- ieg pin 3 i CAUTION | * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected. «Install the new brake pads, [F) Ped mounting pin: 16 N:m (1.6 kaf-m, 11.6 Ib-ft) woTe: After replacing the brake padis, pump the brake lever few times to. ‘check for proper brake operation and then check the brake tid level BRAKE FLUID REPLACEMENT + Place the motoreyels on a level surface and keep the handie- bars straight + Flemove the brake fluid reservoir cap and diaphragm. + Suck up the ld brake fluid as much as pessibie * Fill the reservoir with new brake fluid. » Connect a clear hose to the caliper alr bleeder valve and insert the other end of hose into a receptacie. * Loosen the air bleeder vaive and pump the brake lever until old brake fluid flows out of the blesder system. * Close the caliper air bleeder valve and disconnect a clear hose. Fill the reservoir with new fluid to the upper mark of the reser- voir & Specification and Classification: DOT 4 A CAUTION | | Bleed air from the brake system. (> 2-24) 655 CHASSIS CALIPER REMOVAL AND DISASSEMBLY + Remove the brake hose from the caliper by removing the union bbolt 7) and catch the brake uid in a suitable receptacle. NOTE: Place @ rag underneath the union boit on the brake caliper 10 catch any spilt brake Mud. * Remove the brake caliper by removing the caliper mounting bolts 2. NOTE: Slightly loosen the caliper housing bolts belore removing the cali- er mounting boits to faciltate later dlsasseminy. ‘A CAUTION | —— Never reuse the brake fluid left over from previous ser- viting and stored for long periods of time. Brake fluid, It it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. + Remove the brake pads. ([7" 6-55) ‘+ Separate the caliper halves to remove the caliper housing bolts. © Ramove the O-rings, Replace the O-rings with new ones, * Place a rag over the pistons to prevent it from poppiiig gut and than force out the pistons using compressed air. CHASSIS _65T + Remove the dust seals and piston seals, & CAUTION Do nat reuse the dust seals and piston seals to prevent fluid leakage. CALIPER INSPECTION BRAKE CALIPER, Inspect the brake caliper cylinder wall for nicks, scratches or ather damage BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage. CALIPER REASSEMBLY AND REMOUNTING eassemble the caliper in the reverse order of removal and dis- assembly Pay attention to the following points: = Wash the caliper bores and pistons with specified brake fluid, Particularly wash the dust Seal grooves and piston seal grooves, & Specification and Classification: DOT 4 Wash the caliper components with fresh brake fiuid | before reassembly. Never use cleaning solvent of gaso- line to wash them. * Donnot wipe the brake fluld off stter washing the cam- ponents. When washing the components, use the specified bbrake fluid. Never use different types of fluid or clean- ing solvent such as gasoline, kerosine or the others. * Replace the piston seals and dust seals with new ones ‘when reassembly. Apply the brake fluid to both seals ‘when installing them PISTON SEAL + Install the piston seals as shown in the right Hlustaton. O-ring * Install the O-rings and put caliper halves topsther, 658_CHASSIS * Tighten each bolt to the specified torque. {© Front brake caliper housing boit | 21 Nem (2.1 kat-in, 15.1 Ibeft) Front brake caliper mounting bott 2 25 Nem (2.5 kgf-m, 18.1 Ibstt) Front brake hose union balt ‘3): 23 Nom (2.3 kgf-m, 16.5 Ib-tt) NOTE: Botore remaunting the caliper, push the piston all the way into the caliper 4 CAUTION from the system after reassembling the caliper, 5) BRAKE DISC INSPECTION Visually check the brake disc for damage or cracks. Maasute the thickness with a micrometer. Replace the cise if the thickness is fess than the service limit orit damage is found Front disc thickness: Service Limit: 4.5 mm (0.18 in) (© 09900-20205: Micrometer (0-25 mm) + Remove the brake calipers, (7- 6-56) NMessure the runout with a dial gauge. Replace the disc if the runout exceeds the service limit FE) Front disc: runout: Service Limit: 0.30 mm (0.012 in} (09900-20608: Dial gauge (1/100 mm) 09900-20701: Magnetic stand * Brake disc removal (> 6-6) * Brake disc Installation ("7 6-11) MASTER CYLINDER REMOVAL AND DISASSEMBLY © Disconnect the front brake light switch lead wires. * Place @ mag underneath the union bolt on the master eylindar ip catch any spilt brake fluid. Remove the union bolt and discon- ect the brake hose, 4 CAUTION Immediately and completely wipe off any brake fluid con- tacting any part of the motorcycle. The fluid reacts chemi- cally with paint, plastics and rubber materials, etc. and will damage them severely. + Remove the master cylinder by removing the master cylinder bolts. * Remove the reservoir cap 1), insulator 2) and diaphragm + Flemave the brake lever 4) and brake switch 6.60 _ CHASSIS: * Pull out the dust boot ) and remove the circlip 2) 09900-06108: Snap ring pliers. ‘= Remove the piston/secandary cup, primary cup and return spring. ® Secondary cup & Piston § Primary cup @ Return spring * Remove the cireip 7, connector (Bt and O-ring @ MASTER CYLINDER INSPECTION i Inspect the master cylinder bore for any scratches-or ather dam age. Inspect the piston surface for any scratches or other damage Inspect the primary cup, secondary cup and dust seal for waar or damage MASTER CYLINDER REASSEMBLY AND [ = REMOUNTING Roassemble the master cylinder in the reverse order of removal and disassembly, Pay attention to the faliowing points: [a CAUTION * Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. * Do not wipe the components with a rag, * Apply brake fluid to the cylinder bore and all the com: ponent to be inserted inte the bor & Specification and Classification: DOT 4 © When femounting the brake master eyfinder onto the handia- har. align the master cylinder holder's mating surface with punched mark‘ on the handlebar and tighten the upper clamp bott first as shown [© Front brake master cylinder mounting bolt: 10 Nm (1.0 kgt+m, 7.0 tbett) aster cya Harojeoars | © Tighten the union boll (Brake hose routing: 7 8-20) [F] Brake hose union bolt: 23 Nim (2.3 kgfem, 16.5 theft} © Bleed air from the brake system. (77 2-24) INSPECTION AFTER REASSEMBLY © Front brake: 7" 2.22 6-42_CHASSIS REAR BRAKE CONSTRUCTION - I ' I! I ! | | | ' I Sete peda Piatnip sat 8 eT is ® | | 26 | wi | ee Totten Bb | i } 10 [70 | wet an & Bear bate caler maw bot Be | eee Bret Merwe aN iy oe Pos eae me nee eee E 301 96 | 21.5 | tom patcone = Hear orate oniper Sovslog Pat L * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petraleurn-based. * Do not use any brake fluid taken from old, used or unsealed containers, Never reuse brake fluid lett ovar from the last servicing of 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 wasting 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. |_Handie brake fluid with cara: the fluid reacts chemically with paint, plastics, rubber materials ete, BRAKE PAD REPLACEMENT + Remove the brake pad cover + Remove the clip + Remove the brake pads along with the shims by remaving tha brake pad mounting pins and springs [& CAUTION) * Do not operate the brake pedal while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected, | + Insiall the new brake pads and shims. 4 CAUTION) Be sure to install the shims properly a5 shown in m | NOTE: After replacing the brake pads, pump the brake pedal lew times fooperate the brake corectly and then check the brake fluid level BRAKE FLUID REPLACEMENT + Remowe the frame cover. (C= 6-6) + iomove the brake fluid reservoir cap, * Fleplace the brake fd in the same manner as the front brake: (or 688) & Specitication and Classification: DOT 4 @ CAUTION G4 CHASSIS CALIPER REMOVAL AND DISASSEMBLY = Remove the union bott @) and catch the brake fluid in a suitable receptacle ‘A CAUTION | Never reuse the brake fiuid left over from previous ser- vyieing and stored for long periods. Brake fluid, if it leaks, will interfere with safe running and jseolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. + Remove the brake caliper mounting bolts 2 and torque link bom NOTE: ‘Slightly loosen the caliper housing bolts @) to facilitate tater eis- assembly before removing the caliper mounting bolts * Remove the brake parts. (7° 6-63) * Remove the caliper housing bolts @ * Separate the caliper halves + Remove the O-ting Replace the O-ring with a new one. * Place a rag over the piston ta prevent it from popping out and then force out the pistons using compressed air. ‘A CAUTION Do not use high pressure air to prevent piston damage. * Remove the dust seats and piston seals ‘A CAUTION | Do not reuse the dust seals and piston seals to prevent |_ fluid leakage. CHASSIS 645 $A csis ss CALIPER INSPECTION CALIPER INSPECTION: (> 6-57 BRAKE DISC INSPECTION: [7" 6-58 [EWS Service Limit Rear disc thickness: 4.5 mm (0.18 in) Rear disc runout: 0.30 mm (0.012 in) CALIPER REASSEMBLY AND REMOUNTING Reassemible and remount the caliper in the reverse order of re- moval and disassembly, Pay attantion to the following points: a CAUTION | * Wash the caliper components with fresh brake fluid betore reassembly. Never use cleaning solvent or gaso- line to wash them. * Apply brake fluid to the caliper bore and piston to be Inserted into the bore, sification: DOT 4 ] PISTON SEAL * Install the piston seals as shown in the right itustraticn, Capa oy * Tighten each bolt to the specified torque, [] Brake nose union bolt}: 23 Nem (2.3 kgfm, 16.5 tb-ft) Rear brake caliper taunting bolt (2: 25 Nem (2.5 kgtm, 18.1 Ib-fy) Rear torque link nut 3): 34 Nem (3.4 kgm, 24.6 Ib-ft) Rear brake caliper housing bolt ': 30 Nm (8.0 kgm, 21.5 Ib-ft) @ CAUTION Bleed air from the system atter reassembling the caliper. _ (or 2-25) 645 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY * Remove the frame caver 66) + Remove the brake tluid reservoir tank mounting bat + Place rag undemeath the union bolt on the master cylinder ta catch spilled drops of brake fluid, Remave the union bolt 2 and disconnect the brake hase, © Loosen the Jack nut Remove tha mounting botts @ ‘A CAUTION Immediately and completely wipe off any brake fluid can- tacting any parts of the motorcycle. The fluid reacts ‘chemically with paint, plastic and rubber materials, ete, and wrill damage them severely. Disconnect the hase. Remove the master cylinder by turning the master eylinder rod Remove the reservoir cap and diaphragm ‘= Remove the connector by removing the screw, ‘Remove the O-ring @®, 4 CAUTION Replace the O-ring with anew ane. * Pull out the dust seal then remove the circlip with the spacial tool (Sy 09900-06108: Snap ring pliers + Remove the push rod, piston/primary cup and spring MASTER CYLINDER INSPECTION CYLINDER, PISTON AND CUP SET Inspect the eylinder bore wall for any scratches or other damage, Inspect the cup set end each rubber part for damage MASTER CYLINDER REASSEMBLY AND REMOUNTING Fleassemble and remount the master cylinder in the reverse oF der of removal and disassembly. Pay attention to the following points A CAUTION cylinder components with fresh brake Wash the mat fluid before reassembly. Never use cleaning solvent or | gasoline to wash them. * Apply brake fluid to the cylinder bore and all the com- ponent to be inserted into the bore. && specification and Classification: DOT 4 © Tighten each bolt to the specified torque. (Brake hose routing" 8-21) (©) Brake hose union bolt 1: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) Rear master cylinder mounting bolt 2 10 N-m (1.0 kgf-m, 7.0 tb-ft) Rear master cylinder rod lock nut (3): 18 Nem (1.8 kof, 13.0 tb-ft) * Bleed ait trom the brake system. (= 2-25) INSPECTION AFTER REASSEMBLY 668 CHASSIS TIRE AND WHEEL TIRE REMOVAL ‘The most critical factor of a tubsless tire is the seal between the wheel rim and the tire bead, For this reason, it is recommended fo use a fire changer that can satisty this sealing requirement ‘and can make the operation efficient as well as functional. For operating procedures, refer to the instructions supplied by the tie 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 ire is refitted to the original position after repair- ing puncture, the tire may have to be balanced again since such a repair can cause imbalance, INSPECTION WHEEL INSPECTION ‘Wipe the whee! clean and check for the follwing: * Distortion and crack + Nick or scraich on bead ‘+ Wheel rim runout (7° 6-13) TIRE INSPECTION Tire must be checked for the following points: * Nick and rupture on side wall = Thread remaining depth (7 2-25) * Separation of card * Abnormal, uneven waar on tread * Surlace damage on bead Localized tread wear due to skidding (Flat spot) Abnormal condition of inner finer VALVE INSPECTION Inspect the valve after the tire is temoved from the rim. Replace the valve with a new one if the saai rubber is peeling of has dam- age, NOTE: if the external appearance of the vaive shows no abnovmal con- dition, removing of the vaive is nat necessary Inspect the valve core I tha seal has abnormal deformation, replace the valve with a new ane. VALVE INSTALLATION ‘Any dust of rust around the valve hole must be cleaned off ‘Then install the valve in the rim, NOTE: To properly install ne valve info the vaive hole, apply a special tie lubricant or neutral soapy liquid to the valve & CAUTION TIRE INSTALLATION + Apply tire lubricant to th bead. ‘+ When installing the tire onta the wheal, observe the following points. A CAUTION Do not reuse the valve which has been once removed, ‘@ CAUTION | | Never use oil, grease or gasoline on the tire bead in place __of tire lubricant, 670_ CHASSIS ‘© When installing the tire, the airaw (1) on the side wall should point 0 the direction of whee! rotation * Align the chalk mark put on the tire at the time of removal with the valve position. + For installation procedure-of tie onto the wheel, fofow the in- structions given by the tire changer manufacturer + Bounce the tite several times while rotating. This makes the tire bead expand outward to contact the wheel, thereby facilitating si inflation. = Pump up the tire with ar & WARNING * Do not inflate the tire to more than 400 kPa (4.0kgt cm’).If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inftating. * In the case of preset pressure air inflstor, pay special care for the set pressure adjustment. * In this condition, chack the “rim ling” cast on the fire side wails. The line must be equicistant from the wheel rim ell around. i the distance between the rim line snd wheel rim varies, this cates that the bead is not property seated. If this is the case, Oshate the tire completely and unseat the bead for both sides. Coat the bead with lubricant and fit the tire again. * When the baad has been fitted property, inflate air and adjust the pressure ta specification. * AS necessary, adjust the tire balance. “a CAUTION | Do not run with a repaired tire at a high speed. [EW Cold inflation tire pressure Solo riding: Front: 250 kPa (2.50 kglicm’, 36 psi) Rear; 250 kPa (2.50 kgf/om’, 36 psi) 250 kPa (2.50 kgticm’, 36 psi) 250 kPa (2.50 kgt/em’, 36 psi) BALANCER WEIGHT + When installing the balancer weights to front wheel, set the two balancer weights on bath sides of wheat rim. Dual ridin (A CAUTION | | Weight.itfarence between the two balancer welghts must be less than 10 g. Frat whe ELECTRICALSYSTEM 7-1 ELECTRICAL SYSTEM = CONTENTS — CAUTIONS IN SERVICING. 7 7-2 LOCATION OF ELECTRICAL COMPONENTS... 74 CHARGING SYSTEM ..... 7-6 TROUBLESHOOTING. 76 INSPECTION .. a? STARTER SYSTEM AND SIDE: -STANDAGNITION INTERLOCK SYSTEM TROUBLESHOOTING .. STARTER MOTOR REMOVAL AND DISASSEMBLY .. STARTER MOTOR INSPECTION 712 STARTER MOTOR REASSEMBLY .. 7-12 STARTER RELAY INSPECTION. 7-13 SIDE-STANDIGNITION INTERLOCK SYSTEM PARTS INSPECTION .. 714 IGNITION SYSTEM. 717 TROUBLESHOOTING. FAT INSPECTION .. 7-19 COMBINATION METER ..... 7-23 DESCRIPTION. 7-23 REMOVAL AND DISASSEMBLY 7-24 INSPECTION 7-25 LAMPS... 7-29 RELAYS 7-30 ‘SWITCHES. 7-30 BATTERY... 7-32 ‘SPECIFICATIONS .. 732 INITIAL CHARGING . 732 SERVICING... . 733 RECHARGING OPERATION .. 7-34 72 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR = When connecting a connector, be sure to push it in until a click is fat. ‘ Inspect the connector for corrosion, contamination and break- age in its cover, COUPLER + With a lock type coupler. be sure to release the lock betore disconnecting it and push it in fully til the lock warks when ‘connecting it = When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires. inspect each terminal on the caupier for being loose or bent. inspect each terminal for corrosion and contamination CLAMP + Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING". (78-14 — 15) * Bond the ctamp properly so:that the wire harness is clamped securely © In clamping tha wire harness, use care not to allow it to hang down + Do notuse wire or any other substitute for the band type clamp. FUSE * When a fuse blows, always investigate the cause, correct it land then replace the fuse. * Do not use a fuse af a differant capacity. * Do not use wire of any othor substitute far the fuse. SEMI-CONDUCTOR EQUIPPED PART * Be carelul not to drop the part with a sami-conductor built in such as a ECM * When inspecting this part, follaw inspection instruction strictly, Neglecting proper procedure may cause damage to this part. ELECTRICAL SYSTEM 79 BA ERY © The MF battery used in this vehicte does not require maints- anes (@.g., electrolyte level inspection, distiled water replen- shment). ** During normal charging, no hydrogen gas Is produced. How- ‘var, If the battery is overcharged, hydrogen gas may be pro- duced. Therefore, be sure thera are no fire or spark sources (e.g.. short circuit) nearby when charging the battery. * Be sure to recharge the battery in a well-ventiated 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 disassem- bly 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. ‘+ Hf the terminal is corroded, remove the battery, pourwarm water over it and-clean it with a wire brush. ‘= Alter connecting the battery, apply a light coat of grease to the battery terminals. + Install the cover ower the > battery terminal WIRING PROCEDURE ‘+ Properly route the wire harness according to the "WIRE ROUT: ING" section. (78-14 ta 8-15) USING THE MULTI CIRCUIT TESTER * Properly Use the mult citcult tester > anci © probes. Improper use can cause damage fo the motorcycle and tester. ifthe voltage and current values are not known, begin mea- suring in the highest range. ‘= When measuring the resistance, make sure that no voltage is applied. if voltage is applied, the tester will be damaged. + After using the tester, be sure to turn the switch to the OFF position, 7-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS D Ignition coll (Not, 2, 3, 4) & ON pressure switch 2 Cam position sensor (74-95) {P Horn 3) Fuel injector (€="4-80) ® Turn signat/side-stand rolay ® intake air pressure sensor (7-4-6) & Fuse box 5} Engine coolant temp. sensor ((=7- 4-40) & intake air temp, sensor (C7"4-41) 7 Thratile position sensor (7-438) ® Starter motor ® Crankshalt pasition sensor ((“7'4-35) 1) Fuel level resister @ Battery 3) ECM (Engine Control Module) @ Starter relay/Main fuse e Fuel pump relay (74-51) 8) Tip aver sensor (F-4-44) guiator'Rectifier 1B! Mode selaction switch coupler 5) Secondary throttle control unit ‘Bi Cooling fan thermo-switch (7-5-7) ELECTRICAL SYSTEM 7-5 {) Cooling tan (75-6) @ Fust pump (7-4-4) © Fuel level switch Speedometer sensor ® Gear position switch i Side-stand switch 1? Generator 74 ELECTRICAL SYSTEM CHARGING SYSTEM ep.raor | rectar ca ee Generator K i eRe r TROUBLESHOOTING runs down quickly, Check accessories which use excessive | Accessories ——r *Remove accessories amounts of electricity ‘sre installed ———— No accessories ——— Check the battery for current | ——— Qurrent jaaks ———® «Short circult of wire harness leaks. (SF 7-7) ‘Faulty electrical equipment No current leaks ———— Measure the charging voltage between the battery terminals, Correct ————® Faulty battery (7-8) ‘= Abnormal driving condition (8 Incorrect ee, Measure the continuity ot the generator coil | ne continuity ——+ + Faulty generator cail or 78) disconnected Iead wires: — ft Continuity , Continued on next page ELECTRICAL SYSTEM 7.7 a Measure the generator no-load | voltage. (C3 7-8) | No good ———* + Faulty generator OK Inspect the reguiatorirectiier. |——————Na good © *Fauity regulatovrectifiar 7a) —No goad ————* + Short circuit of wire harness. *Poor contact of couplers + +Faulty battery Baitery overcharge * Faulty regulatorirectifier * Fautty battery + Poor contact of generator tead wire coupler INSPECTION BATTERY CURRENT LEAKAGE * emave the trant seat. (('6-6) * Turn the ignition switch to the OFF position, * Disconnect the battery © lead wire. Measure the cument between = battery terminal and the = bat- tery lead wire using the multi circuit tester. tthe reading exceeds the specified value, leakage is evident (09900-25008: Multi circuit tester set EX} Battery current (leak): Under 3 mA ‘fe! Tester knob indication: Current (=, 20 mA) [a CAUTION | * Because the current leak might be large, turn the tester to high range first to avoid tester damage. * Do not turn the ignition switch to the “ON” pasition whon measuring current, ‘When checking to find the excessive current leakage, remove the couplers and connectors, one by ane, checking each part ‘7 ELECTRICAL SYSTEM REGULATED VOLTAGE + Remove the front seat. (7-6-6) + Start the engine and keep it running at 5 000 rimin. with light ing switch tured ON and dimmer switch turned Hi position, Measure the DC voltage between the ! and = battery termi nals using the muti circuit tester. I the voltage is nat within the specified value, inspect the generator and regulatorirectifier FB and 7-8) NOTE: When making this test, be sure that the battery isin fuly-cherged conaitian, (&09900.25008: multi circuit tester set (Ge Tester knob indication: Voltage (=) Charging output (Regulated voltage): 14.0 — 15.0'V at 5 009 r/min, GENERATOR COIL RESISTANCE + Flemave the frame cover. (7°66) * Disconnect the generator coupler. Measure the resistance between the three lead wires, lf the resistance is not specified value. replace the stator with & new ane. Also, check thet the generator core Is insulated, (@ 09900-25008: Multi circuit tester set {fl Tester knob indication: Resistance (0) EEX Generator coil resistance: 0.2 — 1.5 Q (Black - Black) = @ (Black = Ground) NOTE: When making above fest, itis not necessary to remove the gen- erator. GENERATOR NO-LOAD PERFORMANCE * Start the engine and keep il running at 5 090 r/min Using the mutt circuit tester, measure the voltage between three lead wires, It the lester reads under the specified value, replace the gen- ‘orator with a new ane, 09900-25008: Multi circuit tester set a} Tester knob indication: Voltage (-) [EI Generator no-load performance: More than 65 V at § 000 r/min (When engine is cold) REGULATOR/RECTIFIER ‘+ Remove the frame cover, (776-6) + Disconnect the regulatorirectfier coupler. Measure the vollage between the fead wires using the multi cir- cuit tester as indicated in the table below. I the voltage is not wihin the specified value, replace the regulatarirectifier with a new one, (2 09900-25008: Multi circuit tester set 'GH)! Tester knob indication: Diode test (+) 2 Psbe of ear PX 3a Bt a a) BW on oa-0F 04-07 | os—12 SiPrabe ol lester i More than 1.4 ¥ (lester’s battery voliage) NOTE: If the tester reads undar 1.4 V when the tester probes are not connected, replace the battery of multi circuit fester, WIRE COLOR B: Biack, BF: Black wah Fed tracer, ‘BAW: Bch wh Wit truer ‘7 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine soe Igntion alien amish Faseis0n) ow F 8 starer va me oa Fue 1 potion | (158) sae 8 Ch ewer Sten Unsine G pain ewien sce stan rey ewe | % TROUBLESHOOTING Starter motor will not run. ‘The transmission is in neutral. Grasp the with the engine stop switch in the “RUN" | position and listen for a click from the Clicks ———* starter relay when the starter button is pushed, No click a Measure the starter relay voltage at the | starter relay connectors (between YG & |—— No voltaga———> and BY =) when the starter button is pushed Voltage , Continued on next page omic Check if the starter motor runs \when its terminal is connected to te btary trina (Do | nat use thin “wire” because a large amount of current thaws) T Runs Does not run | * Faully starter motor Faulty starter relay Loose or disconnected starter mator lead wire ‘Faulty ignition switch +Faulty engine stop switch ‘Faulty ciutch lever position switch *Faulty gear position switch +Faulty turn signal/side-stand relay, Faulty starter button ‘Poor contact of connector Open circuit in wire hamess. ELECTRICAL SYSTEM 7-11 Check the starter relay 7-13) Na good + Faulty starter relay |_________+. + Poor contact of the starter relay 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. Check the side-siand switch, [No good ——— + Faulty side-stand switch (or 714) OK —____________-+ + pen clroutt in wire hamess *Paor contact of connector c= Engine does not tun though | » Faulty starier clutch the starter motor runs, STARTER MOTOR REMOVAL AND DISASSEMBLY ‘+ Remove the starter motor, = Disassemble the starter molar as shown in the illustration, DO-ng 2 Houring end nai) 3 Siartar moto case @ Amature © Gras holder andepring PHoueingend voutsise) 712 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. it any damages are found, replace the brush assembly with a Rew ono, COMMUTATOR Inspect the commutatar for discoloration, abnormal year ar un- dercut Bi, | abnormal wear is found, replace the armature with a new one, It the commutator surface is discolored, polish it with #400 sand Paper and wipe Musing a clean dry cloth It there is: no undercut, scrape aut the insulator ) with a saw blage. ARMATURE COIL INSPECTION ‘Check for continulty between each segment and between each segment and the armature shat using the mult circuit tester If there iS no continuity between the segments or there is conti- nuity between the segments and shall, replace the armature with a maw one (5 09900-25006: Multi circuit tester set (fd Tester knob indication: Continuity test (#i}) OIL SEAL INSPECTION ‘Check the all seal lip for damage of leakage. IW any damage is found, replace the housing end STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly Pay attention to the follawing points: * Apply grease to the lip of the oil seal. AGH 99000-25010: SUZUKI SUPER GREASE “A” ELECTRICALSYSTEM 7.13, * Apply @ small quantity of SUZUKI MOLY PASTE to the arma- ture shaft Saw 99000-25140: SUZUKI MOLY PASTE * Align the match marks (P) on the starter motor case with th match mark on the housing end * Apply 2 small quantity of THREAD LOCK SUPER "1922" to the ‘starter motor housing batts. sf 29000-32110: THREAD LOCK SUPER "1322" ‘+ Apply SUZUKI SUPER GREASE “A” to the O-ring, Jy 99000-25010: SUZUKI SUPER GREASE “A” * Tighten the starter motor lead wire mounting nut ta the speci- ed torque. (F Lead wire mounting nut: 5 N-m (0.5 kgfim, 3.5 theft) STARTER RELAY INSPECTION + Remove the front seat and frame cover. (76-6) * Disconnect the tsttery © lead wire from the battery. + Remove the starter relay cover * Disconnect the starter motor leed wire tf), battery lead wire (2 and starter relay coupler ‘). * Remove the starter relay 4), Apply 12 V to ® and @ terminals and check for continuity be- tween the positive and negative terminals using the multi circuit fester. I the starter relay clicks and continuity ig found, the relay is.ak, (09900-25008: Mult! circult tester set (fB! Tester knob indication: Continuity test (of) ACAI Do nat apply « battery voltage to the starter relay for more than five seconds, since the relay coil may over heat and damaged. 7-14 _ ELECTRICAL SYSTEM Measure tha relay coll resistance between the terminals using the multi circuit toster. the resistance is not within the specified value, replace the starter relay with a new ane. (09900-25008; Multi circuit tester set EW Starter relay resistance: 3-50 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation, If tne interlock system does not operaie properly, check each component for damage or abnormalities. i any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH ‘The side-stand switch coupler is located upper the crankcase, + Lift the fuet tank, (CF 4-52) + Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White load wires (& 09900-25008: Mutti circuit tester set ‘& Tester knob indication: Diode test (14) == | eee Bacuvinis —|_(# Probe) ___(= Probe ON (Side-stand up) hood OFF More than 74 (Side-standt down) (Testers battery voltage) NOTE: Ii the tester reads under 1.4¥ when the fester probes are not connected, replace its battery. GEAR POSITION SWITCH + Lift the fuel tank: (C7" 4.52) * Disconnect the gear position switch coupler and check the-con- tintity between Blue and Black/White with the transmission in "NEUTRAL. Blue Black/White ‘ON (Neutral) oe ——— | OFF (Except neutral) I ELECTRICAL SYSTEM 7-15, A CAUTION | | When disconnecting and connecting the gear position ‘switch coupler, make sure to turn OFF the ignition switch, oF elactres parts may get damaged. * Connect the gear position switch coupler to the wiring hams '= Turn the ignition switch to “ON" position and side-stand to up~ right position, Measure the voltage between Pink and Biack'White lead wires using a mult circuit tester, when shitting the gearshit lever tram ow to top, (© 09900-25008: Multi circuit tester set ‘fi Tester knob indication: Voltage (=) Gear position switch voltage: More than 0.6V (: Low to top gear postion) (Pink ~ BW) * Except neutral position NOTE: * When connecting the mult eircut tester, install the eopper wire (O.D is below 0.5 mm) fo the back side of the lead wire coupler And connect the probes of tester to them. * Use the copper wira, ts outer diameter Is below 0.5 mm, to prevent the rubber of the water proaf coupier from damage. TURN SIGNAL/SIDE-STAND RELAY ‘The turn signaiiside-stand relay is composed of the turn signal relay, and the side-stand relay and diode © Remove the turn signal/side-stand ralay, 716 ELECTRICAL SYSTEM SIDE-STAND RELAY INSPECTION First check the insulation between 19) and terminals with the: tester. Then apply 12 to terminals (0: and & (@ tof) and to |G) and check the continumy between (D and ©. if thare is ne Continuity, replace the turn signallside-stand relay with a new ane. DIODE INSPECTION Measure the vattage between the terminals using the mull circuit tester. Flefer to the following table. Probe ol tester to: (08900-25008: Multi circuit tester set Unite W More than 1.4.V | asters banary vonage) Gey) Tester knob indication: Diode test (+) NOTE: it the mut circuit tester reads under 1.4V when the tester probes ate not connected, replace its battery @8eeocoo0 88 ELECTRICAL SYSTEM 7.17 IGNITION SYSTEM zou [ T Tess = See SS pee f ise ov SS Leal f Gan] Herth fee) 7 cH . lll awe Nee lin cut sty nen, t as a | a a) eae (ose || [oan es | (| fee] | | ee = h be NOTE: The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine. it engine rpm reaches 14 000 r/min, this circuit cuts off the ignition primary current for ail spark plugs, “a CAUTION Under no load, the engine can run over 14000 r/min, even if the ignition cut-off circuit is effective, and it may cause engine damage. Do not run the engine without load over 14.000 r/min at anytime. TROUBLESHOOTING * Check that the transmission is in neutral and the No spark or poor spark ‘engine stop switch is in the “RUN” position. Grasp the cluich lever. Check that the fuse is not biown and the battery is fully-charged before diagnosing. ‘Chack the Ignition system couplers for poor connections, T Correct + Continued on next page Looseness ———* * Poor connection of couplers 748 _ELECTRICAL SYSTEM + Measure the battery voltage between input laad wires (OW and B/W) at the ECM with the ignition suritch in the “ON" position. Incorrect ——* Faulty ignition evitch * Faulty turn signal/side-stand relay * Faulty engine stop switch Broken wite harness or poor connection of related circuit couplers Measure the ignition coil primary peak voltage. (F" 7-19, 20) NOTE: This inspection method is | applicabte only with the mutt circuit Jester and the peak voit adaptor. Incorrect Inspect the ignition colplug caps. | (oF 7-20) ——eP Correct pa, Measure the crankshatt position sensor peak voltage and fs resistancs. (oF 7-21, 2) NOTE: The crankshaft position sensor peak voltage inspection is applicable only with the multi cirouit testar and Correct —2—+ | Inspect the spark plugs. (28) Correct Incorrect, | \ 4 « Faulty spark plug (-8) * Poor connectian of the ignition collplug cap (5) ;—— Incoméct ———* «Faulty ignition coilslug cap (+8) Incorect ————* + Faulty crankshatt position sensor peak volt adaptor Pm ___ Correct > +Fautty ECM ‘*Poor connection of ignition couplers. ELECTRICAL SYSTEM 7.19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE + Remove the air cleaner box. (74-62) * Disconnect all the ignition coll/plug cap iaad wire couplers be- fore removing the ignition coiliplug caps. + Remove all of the ignition cailiplug caps. * Do not remove the ignition coil/plug cap before dis- connecting the lead wire coupler, or the lead wire will be damaged. * Do not pry up the ignition coiliplug cap with a screw- driver of a bar ta avoid damage. * Be careful not to drop the ignition coil/plug cap as it may open of short in 8 circult, *+ Connect the new four spark plugs to each ignition coilplug cap, ‘+ Connect all the ignition coi/plug cap lead wire couplers to the ignition colplug caps respectively, and ground them on the cylindes head (each spark plug hole). ‘Avoid grounding the spark plugs and suppling the olec- trical shock to the eylinder head cover (magnesium parts) to prevent the magnesium material from damage. NOTE: Be sure that al! coupiors and spark plugs are connected properly and the battery used Is in fully-charged conaftion. | s Inspect each ignition coil primary peak voltage at tha ignition coil! plug cap coupler. * Connect the multi circult tester with peak voltage adaptor as follows. No.1 ignition coiiplug cap: ‘WIBI terminal (3) Probe} ~ Ground (= Probe) terminal No2 ignition coilplug cap: B terminal (® Probe) ~ Ground (‘© Probe) terminal No ignition collpiug c Y terminal ( Probe) ~ Ground (= Probe) terminal No.4 ignition coulplug cap: G terminal ( Probe) ~ Ground (= Probe) terminal }09900-25908: Multi circuit tester set Taengre stop amis Betore using the multi circuit tester and peak volt adap- tor, be sure to refer to the appropriate instruction manual elated til eatedilact Zaha | 1 ccm Tab ELECTRICAL SYSTEM NOTE: * When connecting the mult circuit tester, insert the copper wires (Q.0i5 below 0.5 mm) to the back side of the ignition coll lead wire coupler and connect the tester probes fo thom. * Use the conper wire, ts outer atameter being betow 0.5 mm, to prevent the rubber of the water proof coupler from damage + Shift the transmission into neutral and turn ignition switch “ON © Crank the engine 5 few seconds with the startet motor by de pressing starter button and check the ignition coil primary peak voltage. Repeat the above inspection a faw times and measure the high- est peak voltage. GE) Tester knob indication: voltage FEE Ignition coil primary peak voltage: More than 80 V Do not touch the tester probes and spark plugs to pre- vent an olectrie shock while testing. if he peak vonage Is lower than the standard range, check the Ignition coilplug cap as foltaw IGNITION COIL/PLUG CAP RESISTANCE * Check the ignition eolV/plug cap for resistance in both primary and secondary windings. Ifthe resistance is not within the stan dard range, replace the ignition colvpiug cap win.a new ans. (09900-25008: Multi circult tester set Ga! Tester knob indication: Resistance (£2) FEES Ignition coitiplug cap resistance Primary: 0.8- 2.02 (® tap - © tap) Secondary : 8 ~ 15 kft (Plug cap ~ © tap) aT eae CKP SENSOR PEAK VOLTAGE © Remove the tront seat. ((—F" 6-6) NOTE: Be sure that all couplers are connected property and the battory used Js in fully charged condition. + Connect the multi circuit tester with peak voit adaptor as tol- lows. + Mensute the CKP sensor peak voltage between White and GreonWnie toad wires at the ECM coupler. White (() Probe} — Greennhite (= Probe) (09900-25008: Multi circuit tester set i CAUTION | Before using the multi circuit tester snd peak volt adap- tor, be sure to referte the appropriate instruction manual, © Shift the transmission into the neutral and turn ignition switch “ON, eee SM * Crank the engine a few seconds with the starter motor by de- Seen ee pressing starter button and check the CKP sensor peak vat- age. + Repeat the above test procedure a few times and moasure the highest peak voltage. ‘Tester knob indication: Voltage (=) CKP sensor peak voltage: More than 0.5,V H the peak voltage i tower than the standard range, check the peak voltage at the CKP sensor lead wire coupler. + Liftup the fuel tank. (—7" 4-52) © Disconnect the CKP sensor lead wire coupler and connect tha uit circuit tester with the peak volt adaptor. Black (® Probe} - Green (> Probe) ‘+ Moasure the CKP sensor peak voltage at the CKP sensor lead wire coupler [B) Tester knob indication: Voltage (=) CKP sensor peak voltage: More than 0.5 V 7-22_ ELECTRICAL SYSTEM tthe peak voltage is lower than the standard range, check each ‘coupler at both ends of the circuit or replace the CKP sensor and inspect it again. KP SENSOR RESISTANCE * Measure the resistance between the lead wires and ground. If the resistance is not specified value, the GKP sensor must be replaced. (5 08800-25008: Multi circuit tester set ‘GB! Tester knob indication: Resistance (2) EDI KP sensor resistance : 70 - 220 1 (Green - Black) (Green — Ground) SECONDARY THROTTLE CONTROL UNIT + Remove the frame cover. (7"6-6) ‘+ Remove the secondary throttle eantrot unit. Measure the voltage batween the terminals using the rhutti circuit lester, as indicated in the table below. If the valtage is not within the:specilied valve, réplace the its control unit with & new one, (29000-25008: Multi circuit tester set (Tester knob indication: Diode test («-) Unit: ¥ © Probe of taster to! J Anes Se NlatTetefolelele [Tu ne— 1a s-15)ro-15 [10-15] o5—101.0-1507-13 07-13] (05—1.0)10-15)7-13/07-19) (05-10) los 1.0) pl * | * | + |= E [p4~p9/o3-ng03-da)2-07 1.0-18i04-09/04- 09 F jtt—15)10—15]10-t5}t1-15 [10-1 a G b7~ 13/02 0802 -oah'o- 1503-14 Hor-1s]02-0602 -0a f=) Mote than 1.4 V (Tester's battery volt- age) NOTE: UF the marl circuit tester reads under 16 \, replace its battery when the tester probes are not connected. ‘ELECTRICAL SYSTEM 7-23 ‘COMBINATION METER DESCRIPTION This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and! LED (Light Emitting Diode}. This combination meter is light, thin and high response on those currentiy in use because of this composition, The rpm painter is driven by the stepping motor. ‘Tha LCDs indicate speed, Odo/Trip /Ttin2/Clock and engine coolant temp/Fl respectively, LED (Light Emitting Diode) LED is used for the iturnination fight and each jndicator fight. LED is maintenance free. LED |s less consuming electric power and stronger to vibration resistance cam pared to the bulb, ‘All LEDs light up immediately after turning the ignition switeh on. CI:LED (Speedometer int) Engine coolant tar, Ft J Select who a/tm 1 7tip 2¢Gock / 724 _ ELECTRICAL SYSTEM REMOVAL AND DISASSEMBLY * Remove the screw ()). ‘Draw out the hook (2 from the body coming. * Disconnect the lead wire coupler. + Flemove the combination meter. 4 CAUTION | When disconnecting and connecting the cambination meter coupler, make sure to tum OFF the ignition switch, fr electronic parts may get damaged. = Disassemble the combination meter 2s follows, ELECTRICAL SYSTEM 7.25 INSPECTION LED (LIGHT EMITTING DIODE) (Check that the LED lights. immediately after turning the ignition switch on, I the LED fails in operation, replace the combination meter unit with a new one ater checking its wire hamess/coupl STEPPING MOTOR Check that the pointer calibrates self immediately after turning the ignition switch on and stops at starting point. abnormal condition is found, replace the combination meter unit with a new one alter checking Its wire harness/couplet. » Peintor NOTE: The polnter may not return to the proper pesition éven turning the ignition switch oh under iow temperature condition. in that case, you can reset the pointer to the proper position iby following the instruction belawr 1) With the function switch ® pressed, tum the ignition switch on, 2) Release the function switch ‘A). 3 to 5 seconds after turning the ignition switch on. 2) Press the function switch @ twice (within 1 second). + Reset * Complete the operation within 10 seconds after the ignition switch has been turned an Time | Ignition switch | Adjuster swach @ |__| OFF PUSH Pointer will return to the starting point right alter the. completion of the operation. In the case ef the pointer nat returning to the proper position ater ding above, replace the combination meter unt, 7-26 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR Engine copiant temp. sensor inspection: (> 5-8 + Litt up the fuel tank. (IP 4-52) * Disconnect the engine coolant temperature sensor coupler ds CAUTION | | When connecting and disconnecting the engine coolant temp. sensor lead wire coupler, make sure to turn OFF ‘the ignition switch, or electronic parts may get damaged. © Connect the vatiable resister 'A) between the tetminats, + Tum the ignition switch ON, * Check the LCD and LED operetions when the resistance is adjusted fo the specified values, Resistance © [LED 1B] LOD © LCD Di|Water temperatura Over 2.45 nn] OFF [| — | under i9c ‘Approx. 0.811 Ki] Oi — | Approx. 60°C Approx 0.1 2 | Oi "| Flicker | 120-139 °C =} 2. Varlbie resister Engine ‘oatant far. OO (lumper'wirey| ON | “Hl [Flicker] Over 140°C either one ar all indications are abnormal, replace the combi- nation meter with a new one, NOTE: 10 the engine stop switch is turned OFF white the ignition switch (8 ON, he LCD displays “CHEC’. But itis not matunction. This codttion implies that combination meter recieves no signal ftom me ECM. Im that case, they ate restored fo ordinary indication by twrning the engine stop switch RUN. ELECTRICAL SYSTEM 7.27 FUEL LEVEL INDICATOR SWITCH INSPECTION © Remove and disassemble the fuel pump assembly, (4-57) * Connect 12 V battery and test bulb (12 V. 4.4 W) to the fuel fovel indicator switch as shewn in the right llustiapons, The buD should come on afer several seconds if the switch is in good condition + When the switch is immersed in water under the above cond tion, the butb should go out. it the bulb remains lit. replace the init with a new one. ane) FUEL LEVEL INDICATOR LIGHT INSPECTION I the fuel level indicator ight does nt function propery. check the fuel level ingicator switch and its lead wireicoupler IF the fuel lovel indicator switch and its lead wire'coupler are ail right, replace the combination meter with @ new-ane, FUEL LEVEL RESISTER INSPECTION = Measure the resistance between the terminats of each fuel level resister. f the resistance is not within the standard range, re- place the resister with a. new one, RED - BLACK, RED ~ WHITE (> 09900-25008; Multi circuit tester set GB) Testor knob indication: Resistance (02) [EXE Fuel level resister resistance: 65 - 75 12 ‘728 ELECTRICAL SYSTEM ‘SPEEDOMETER \tthe speedometer, odometer or trip meter does not funtion prop- ely, Inspect the speedometer sensor and connection af couplers. If the speedometer sensor and connection are all right. replace the meter with a new one, ‘SPEEDOMETER SENSOR ‘Remove the left under cowling. (7"6-3) * Disconnect speedometer sensor coupler, * Remove the speedometer senscr 1) by removing its mounting bolt. * Connect 12V battery, 10 kf2 resistor and the mult circuit tester as shown right illustration, BIR: Black with Red tracer BIW: Black with White tracer Bi Black (02000-25008: Multi circuit tester set B) Tester knob Indication: Voltage (=) + Under above condition, if'a suitable screwdriver touching the pick-up surtace of the speed sensor Is moved, the tester read ing woltage changes (OV—+124 or 12V-s0V). i the tester reag- ing vatage dees not change, replace the speedometer sensor with a now one, NOTE: The highest tester reading voltage (12V) while testing is same as battery vottage. ‘OIL PRESSURE INDICATOR NOTE: Setore inspecting the all pressure switch. check if the engine oil evel is enough. <7" 2-13) * Remove the right under cowling, (7° 6-3) *+ Disconnect the oil pressure switch lead wire from the oll pres- sure switch, + Turn the ignition switch ON. *# Check if the oll prossure indicator ® will ight and LOD @ will flicker, whan grounding the tead wine. | each indication are abnormal, replace the combination mater with a new ong after checking connection of couplers. eotpmanue eich Vee @ pray Ss a ELECTRICAL SYSTEM 7.28 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12. 55 W (HT) 12. 55 W(H7) 12 5 W dt (Except for £-03, 24, 28, 33) BRAKE LIGHT/TAILLIGHT 1vavew TURN SIGNAL LIGHT veiw A CAUTION | as | if you toueh the bulb with your bare hands, clean it with a cloth moistened with alechol or soapy water to prevent early failure. HEADLIGHT BEAM ADJUSTMENT + Remove the body cowiing cover, ((7"6-3} * Adjust the headight beam, both vertical and horizontal 8: Vertical adjuster (Using a screw driver ©) 8: Horizontal adjuster NOTE: Te adust the headlight beam, adiust the beam horizontaly first, then adjust the vertically 7a 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 op- eration of the tur signal light, hth tur signal light does not illuminate, inspect the bulb, tun signal switch and circuit connection, ifthe bull, turn signal switch and circult connection are OK, the turn signal relay may be fauity; therefore, replace the turn signal! side-stand relay witha new one. NOTE: * Mahe sure that the battery is tully charged. * Refer to the page 7-16 for the: side-stand relay and diode in- spection STARTER RELAY P73 FUEL PUMP RELAY crast SWITCHES IGNITION SWITCH REMOVAL + Remove the right under camiing. (7"6-3} + Disconnect the coupler Remove the ignition switch mounting bolts using the special tools. (09930-11940: Bit holder A CAUTION | When reusing the ignition switch balt, clean thread and apply the THREAD LOCK SUPER “1322” | fa) 99000-32110: THREAD LOCK SUPER 1322" ‘SIDE:STAND DIODE, ELECTRICAL SYSTEM 7.31 Inspect each switch for continuity with a tester. I any abnormality is found, replace tne respective switch assemblies with new ones. IGNITION SWITCH (For E-24) ry] STARTER BUTTON —ca6H OFF |. LOCK P LIGHTING SWITCH (Except for E-03, 24, 28 and 33) FRONT BRAKE SWITCH << PUSH A PASSING LIGHT SWITCH (Except for £-03, 28 and 33) on [eoawrt JOFF (R)) = RUN (3) —— yw | CLUTCH LEVER POSITION SWITCH coer leva BY ee |_ OFF _ ON DIMMER SWITCH OlL PRESSURE SWITCH [car] T x: w y ww wel ay «|S Ground a = leon Gr Sas cS O ON (eran {s g — ssionped} = {| - = OFF | NAL SWITCH 7 tg to 8 NOTE: Before inspecting the oil pressure switch. check if the engine ail level is enough. (=F 2-13) Black with Yellow tracer Black with Rod tracer Green with Yellow tracer Orange with Black tracer Orange with Blue tracer Orange with Groen tracer Orange with Red tracar Orange with White tracer : Orange with Yellow tracer White with Black tracer Yeliow with Green tracer + ¥ellow with White tracer S552238352522 782 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation FIX9-5 i Capacity 42V, 28.8 kC (8 Any 1OHR INITIAL CHARGING ling electrolyte ‘+ Remove the aluminum tape ‘) seating the battery electrolyte ‘ler holes. » Flemave the caps @ NOTE! * Atter filling the elactrofyte completely, use the removed cap (2 aS the sealed caps of battery-filer holes. * Do not remove or pierce the sealed areas “of the electralyie containar * Insert the nozzies of the slactralyte container into the bamery's btectrolyte filer holes, holding the container firmly so that it does ‘nat fal, Take precaution ot to allow any of the fie to spil + Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes. ELECTRICAL SYSTEM 7:33 NOTE: Ino air bubbles are coming up trom a filer part. tap the bottom of tha electrolyte container nwo or three times. Never remove the container from the battery + After confirming that the electrolyte has entered the battery compltely, remove the slectrolyte containers fromm the battery Wait for about 20 minutes. * Insert ihe caps into the file halas, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery's top cover. & CAUTI * Never use anything except the specified battery. * Once install the eaps to the battery; do not remove the caps. * Do not tap the caps with a hammer when installing them. TncoaREct ‘+ Using multi circum tester, measure the battery voltage. The taster should indicate more than 12.5 ~ 12.6V (DC) as shown in the Fig. Ifthe battery valtage is lawrer than the spenification, charge the battery with a battery charger. (Flefer to the recharging op- aration) “a CAUTION Do nat remove the caps on the battery top while charg- ling. NOTE: Inia! charging for a new battery is recommenced if nia years have elapsed since the dale of manufacture SERVICING Visually inspect the surtace af the battery container. H any signs ol cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one, Ifthe battery terminals are found to be costed with rust or an acidic white rows ery substance, then this can ba cleaned away with sandpanar $8 10 iMimdes} 7ot_ELECTRICAL SYSTEM RECHARGING OPERATION + Using the multi circuit tester, check the battery valtage. If the ‘voltage reading is less than the 12,0¥ (DC), recharge the bat- tery with a battery charger, ‘& CAUTION * When recharging the battery, remove the battery from the motorcycle. | * Do not remove the caps on the battery top while re- charging. | Recharging time: 4A for one hour or 0.94 for § to 10 hours Be careful not to permit the charging current to exceed aA time. * ‘After recharging, wait for mare than 30 minutes and check the banery voltage with a multi circult tester, + Ifthe battery voltage Is less than the 12.5\, recharge the bat- tery again. + If battory: voltage is: stil less than 12.54, ater recharging, re- place the battery with a new one + When the motorcycle is not used for a lang period, check the battery every 1 month to prevent the battery discharge. a oa) "Tim Miran) 7007560 25 Harley charged conden ‘SERVICING INFORMATION 6-1 SERVICING INFORMATION — CONTENTS TROUBLESHOOTING cscs eeeeenseneteineeiseeeene OB FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION... ENGINE... - RADIATOR (COOLING s Ys TEM) CHASSIS... 8-10 BRAKES... eit ELECTRICAL 8-12 BATTERY a3 WIRE HARNESS, CABLE AND HOSE ROUTING. 8-14 WIRE HARNESS ROUTING a4 CABLE ROUTING -....cccoe ae B17 FUEL TANK DRAIN HOSE ROUTING . a8 COOLING SYSTEM HOSE ROUTING 819 FRONT BRAKE HOSE ROUTING. 8-20 REAR BRAKE HOSE ROUTING. : B21 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .... 8-22 FUEL TANK SET-UP. 8-23 COWLING SETUP ..ce.ssccsssse 824 FRAME COVER SETUP......... 8-25 SIDE-STAND SET-UP..... 8-26 GEARSHIFT PEDAL SET-UP 8-26 SPECIAL TOOLS..... 8-27 TIGHTENING TORQUE .... 8-30 SERVICE DATA 8-34 8:2_ SERVICING INFORMATION TROUBLESHOOTING FLSYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION | DETECTED FAILURE CONDITION TECTED MEM }~———— SS cope pers I CHECK FOR 00) NO FAULT | Camshatt pasition | The signal does not reach ECM for mare than 2 see. after ra- sensor Losiving the starter sional. | en The camshafi position sensor wiring and mechanical parts (Camshat position sensor, intake cam pin, wiring/coupler con: nection) Crankshatt position | The signal does not reach ECM for more than 2 sec. after e-| sensor the starter signal | le © crankshaft position sensor wiring and mechanical parts. (Crankshatt position sansor, wiring/eoupler connection) Intake alr pressure | The sensor should produce following vattage. wit sensor | (05 V = sensor voltage < 4.85 V) | Wranout ne above range, £13 [Intake air pressure sensor, wiring'coupler connection Throttle position | The Sensor shauld produce following vattage. of sensor (02 V = sensor voltage < 4,8 V) | Without the above rates 014 4 Throttla position sensor, wiringleoupler connection. Engine coolant ‘The sensor voltage shauld be the foliowing, ae temperature sensor | (0.15 V = sensor voltage < 4.85 V) | Without the above range, 615 is indicated, _! Engine coolant temperature sensor, wiringicoupler connection | Intake air The sensor voltage should be tha following. i temperature sensor | (0.15 = sensor voltage < 4.88 V) e | Without the above range, c2t is indicated, Intake air temperature sensor, wiring/coupler connection. “Atmospharic ‘The Sensor voltage should be the following, a pressure sensor | (0.5 V = sensor voltage < 4.85 V) Without the above r Atm. pressure sensor, wirlnglcoupler connection 1 Tip over sensor —_| The serisor voltage should be less than the follwing for more than 3 580. affer ignition switch turns ON. 23, (0.25'V = sensor vohage < 4.85 V) YRIOUE tee ations wake C23 We inelenied 0.60 V) cat lithout the above value. c31 is indicated. j@ar position sensor, wiring’coupler connection, Gearshift cam atc. Fuel injector signal | When fuel injaction signal stops, tha ¢32, ¢33, c34 or 035 is 82, 033, 04 i ——— ‘or 35 Injector, wiring/coupler connection, power Supply t0 the in- | jector. Fuel pump relay | When no signal is supplied from fuel pump ratay 047 is maicated. | ca signal Fuel pump relay, connecting lead, power source to fuel pump relay. cae Jonttion switch signal | Ignition switch signal is not input in the ECM. Ba SERVICING INFORMATION ENGINE Complaint ‘Symptom and possible causes Remedy Engine will not start, | Compression too law fr Is hard to start. 1. Out of adjustment valve clearance. Adjust. 2. Wom vake guides or poor seating af wales opait or piace 3, Méstiming vatves. Adjust 44. Excessively warn piston rings. Replace. 5. Worn-dawn cylinder hores, Feeplace, 5, Too slowly starter motor evans. See electrical section 7. Poor seating of spark plugs. Retighten. Plugs not sparking 1 Fouled spark plugs Clean, 2 Wet spark plugs Glean and ary 3. Detective ignition ealvplug ap. Replace. 4. Delective CKP sensor Replace 5. Datoctve ECM Replace. 6 Open-eircuited wiring connections, FRpait or replace, No fuel reaching intake manifold 1. Clogged fuel fter oF tue! hese. Clean or replace 2 Detective tus! pump. Replace. 3 Delective fuel pressure regulator Replace. 4. Defective tue! ingector Repioce 5. Detective tuel pump relay Replace. 6 Dolective ECM, Replace 7. Open-tirculted witing connections, Cheek and repair Incorrect fuels mixture 1. Out! adjustment throttie positon sensi. Adjust. 2 Defective fuel pump Floplace. 3. Detective fuel pressure regulator. Replace 4. Detective trots position sensor Replace. 5 Detective eranksnatt postion sensor. Replace 6 Detective intake air pressure Eenear, Repiace. 7. Dolective aimosoheric pressure sensor Replace & Dolectiwe ECM, Replace 5. Detective engine coolant emp: sensor Replace. 10. Deleetive intake aie temp. sensor. apace, SERVICING INFORMATION. 8-5 ‘Complaint Symptom and possible causes Remedy Engine idles poorly, | 1 Gut of adjustment valve clearance. ‘Adjust. 2 Poor seating of valves. Flopiace or repair 3. Defective valre guides. Fisplace 4 Worn down camshaft Replace 5. Too wide spark plug gaps Adjust or replace ‘6. Detective igniion colipug cap. Rooplace, 7. Defective crankehan positon sensor Replace. 8. Detective ECM, Replace 9. Detective theotle position sensos Replace 10. Defective fuel pump, Replace. +14. Imbstaneed tneotle valve Adjust 12._Damaged or cracked vacuum hose. Freplace Incorrect fueVaie mbxture: 1 Detective intake air pressure sensor or circuit Repair or replace. 2 Clogged fue! tite. lean or replace } 3: Detective tue! pump Replace 4 Detective fue! pressure regulator Replace 5. Defective engine coolant temp. sensor Repiace 8, Defective thermostat. Repisce. 7. Detective intake air temp. sensor Replace | improperly working fuel Injector 1) Defective fue! inyecar Replace 2. Na injection signal from ECM, 3. Open or short eircutted wiring connection. 4. Delective battery or low battery voltage. Improperly working control circult or sensors: 1. Detective ECM. 2. Defective fupl pressure reiguiator, Defective throttle pasition sensor Defective iniake air temp. sensor Delective camshait position sensar Defective crankshah postion concer, Detective engine coolant temp. sensor Detective fuel pump relay. iproperly working engine internal parts Fouled spark plugs. Detective crankshaft position sensor or ECM. Clogged fuel hose Dut of adjustment tappet clearance. z pair or replace. Flepair or replace. Fleplace or recharge Replace: Replace: Replace: Replace: Roptace. Replace. Replace: Replace: Clean. Replace. Giean. Adjust $46 _ SERVICING INFORMATION Compiaint Symptom and possible causes: Remedy Noisy engine. Excessive vaive chatter 1, Too farge valve clearance. Adjust 2. Weakened or broken valve springs. Replace. 3. Wen tappet or cam suriace, Replace 4. Wom and burnt camshatt journal Froplace Noise seems to come trom piston 1. Worn down pistons or eyinders. Peoplace. 2, Fouled with carbon combustion chambers. Clean. 3. Worn piston pins or piston pin bore Feeplane 4, Worn piston rings or ring aranves. Replace [Noise seems to come from timing chain 1. Stratched chain, Replace, 2 Worn sprockots Replace. 3, Not working tension agjuster. Repair or replace. Noise seems to come from clutch 11, Worn spines of countershatt ar hub, Replace. 2. Worn taath of clutch plates: Replace. 3, Distorted clutch plates. driven and drive. Replace. 4, Wom chutch release bearing, place, 5. Weakened clutch dampers place the primary driven gear. Noise seems to come trom crankshaft 1. Due to wear rating bearings. Raplace 2. Worn and burt big-end bearings. Psplace 3. Worn and bumt journal bearings. Replace 4 Too largo thrust eisaranca, Replace thrust bearing, Noise seems to come trom transmission 11. Worn of rubbing gears. Replace. 2 Wor splines, Replace 3. Worn or rubbing primary gears Replace 4. Wor bearings Replace | Noise seems to.come from water pump 1, Tao much play on pump shatt bearing | Replace, 2 Worn oF damaged Impeller haf Replace. 3. Worn oF damaged mechanical sea Replace. _ 4. Touches pump case and impeller Replace Engine runs poorly | Betective engine intera/electrical parts inhigh speed range, | 1. Woaknnod valve eprings Replace 2. Wor camenats, Replace 3. Valve timing out of adjustment ‘Adjust 4. Too nasrow spark piug gaps, Adjust 5. Ignition not advanced suticiently dus to poorly Replace ECM working timing advance elreut 68. Delective ignition coil Replace, 7, Defective crankshaft position senso: Replace 8. Dielective ECM Replace 8. Clogged air cleaner stement. Clean 10. Clogged tust hose, resulting in inadequate tus! Clea and prime supply to Injecter 11. Defective tue! pump Replace 12 Detective throtia position sensor | Replace, Detective STC unit or STV aitustor Replace, Complaint Engine runs poorly In high speed range. | Detective Symptom and possible causes flow system 1. Clogged air cleaner element 2. Detective treme valve, 3. Detective secaundary throttie valve. 4, Sucking air trom throttle body joi 5. Delective ECM. Detective control circuit or sensor Clean oF replace. Adjust or replace, Adjust or replace, Repair ar replace, Replace, 1. Love fu! pressure Repair or raplace, 2. Delactive throttle position sensor Replace. 3. Detective intake air tomp. sensor Replace, 4. Detective camshaft position sensor Replace 5. Detective crankshalt position sensor. Replace 8. Delactive gear position sensor Replace, 7. Detective intake air pressure sensor Replace, A Detective atmosnheric pressure sensor, Replace, 9. Detective ECM, Replace, 10. imbalancing throtle vaive synenranization. Adjust 11. Detective STP sensor andior STV actuator, Replace, 12. Detective STC unit Replace Engine lacks power. | Befective engine internalielectrical parts, 1. Loss of valve clearance, Adjust 2. Weakened valve springs Replace. 3. Dut of adjustment valve timing, Adjust. 4, Worn piston rings or cyfinders Replace, 5. Poor seating of valves. Pepa 6. Fouled spark plug ‘Clean or replace. 7. Incomect spark plug ‘Agjust oF raplace.. 8. Clagged injector, ‘Giean, 9, Out of adiustment throttle position sensar. Adjust. 10. Clogged ait cleaner element ‘Clean, 11. Imbaiancing throttle valve synchronization, Adjust 12. Sucking air from throttle valve er vacuum hose. 13. Teo much engine ou, 14. Defective tel pump or ECM. 18. Defective crankshaft position sensor and Ignition oil, Defective contro! eircuit oF sensor Low fuel pressure Detective thrattle position sensor Detective intake as temp, senor. Detective camshatt position sansor Detective crankshalt position senso, Defective gear postion sensor Dtective intake air pressure sensor Detective atmospheric pressure sensor, 9. Defective ECM. 10. Imbalancing throttie valve synchronization 11. Defoctive STF sansor andler STV acuiaior. 12. Detective STC unit ‘Retighten or repiaca Drain out excess oll, Replace. Replace, Flopair oF replace: Fepiace. Ropiace. Foplace. Fepiace, Repiace, Roptace, Replace, Replace Adjust. Ropiace, Rispiace, 4 SERVICING INFORMATION Comptaint Symptom and possible causes i Remedy Engine overheats. Defective engine internat parts 1, Heavy carbon deposit on piston crowns. Clean, 2 Not enaugh olin the engine. Add oil, 4. Detective oll pump ar clogged oil circuit Replace or clean 4. Sucking air from intake pipes. Retighten or replace, 5. Use incorrect engine oll, Change. 6. Defective cooling aysiem See radiator section. [Lean fuel/air mixture 1, Shortcircuiteo intake ait pressure sensoriead Repair or replace, sue. 2 Short-ceulted intake air lemp. senso Repair or replace. 3. Sucking air from intake pipe joint Cloan or ropiace 4, Defective fuel ilector. Repair or replace, 5, Delectve engine caolant tamp. sensor, Replace ‘The other factors 1. Ignition timing is too advanced due ta defective Replace. fiming advance system (engine coolant temp, sensor, gear postion senor, erankshatt position sensor and ECM) 2. Brive chain is to0 tight Adjust. Dirty or heavy 1, Too much engine all in the engine. Check with inspection exhaust smoke. window drain out exces8 oll 2 Worn piston rings or evlinders. Replace, 3. Worn valve guides. Replace, 4, Scored oF seuted eyindar wan. Replace, 5. Worn valves stems Replace, 8. Defective stem Seal Replace. 7._Worn all ing side ras Replace. Slipping clutch. 1. Weakened chuich eprings. Replace. 2. Wom or cistorted pressure pinte Replace, 3. Distorted clutch plates or clutch plate, Replace, Dragging clutch. 1. Same clutch spring weakened whie others Replace, are nat 2. Distorted pressure plate or clutch plate Ropiaco, Transmission will 7. Broken gearshift cam Fopiace, not shift, 2. Distorted gearshit forks, opince. 3. Wom gearahit pawl opiate. Tranamission wi 1. Broken tetum spring on shitt shaft Replace. not shift back 2. Flubbing or sticky shift shaft Repair ot replace. 3._Distortod or wor gearshift forks Replace. 1. Worn shiting gears on driveshaft or Replace. ‘countershan, 2. Distorted or worn gearshit forks Replace 3. Weakened stopper spring on gearshift stopper Replace. L 4. Wor gearstitt carn plate. Replace. SERVICINGINFORMATION 8 RADIATOR (COOLING SYSTEM) Complaint ‘Symptom and possible causes Remedy Engine overheats, 7. Net enough engine coolant ‘Ads coolant 2 Glogged with dirt o¢ trashes radiator care. Ciean. 3. Fauity cooling tan, Repair or tenlace 4. Detective cooling fan therma-switch. Replace. 5. Clogged water passage. loan. 6. Air rapped in the cooling circut Biced out ai 7. Detect water pup: Roplace 8. Use incorrect coolant. Replace: 2, Detective thermostat Reptace: Engine overcoois. 7. Detective cooling fan termo-swach. Replace 2, Extremely cold weather Put on the radiator cover 3._ Detective thermostat Replace: :0_ SERVICING INFORMATION CHASSIS Complaint ‘Symptom and possible causes Fomody Heavy steering. 1. Gverighiened steering stem nut ‘Agjust 2. Broken bearing in steering stem Replace 3. Distorted storing stem. Replace 4. Net enough pressure in tires. Ajust. ‘Wobbly handlebars. 1, Loss of balance tietween right and left ont forks. Freplane 2. Distorted front fork Repair or replace, 3. Distorted front axle or moked bie, Replace, 4, Loose steering ster nut Adjust. 5. Wor or incorredt tire or wrong tire pressure. Adjust or replace. 6. Worn bearing'tace in steering stem, Asplace. Wobbiy front wheel. | 7 Disioried whos! im Replace. 2. Worn front whee! beatings. Replace. 3. Detective of incorrect tire Replace. 4, Loose axle or axle pinch bot Ratighton, | 5. tneoract tant fort level. Adjust. Front suspension 1. Weakened springs Replace too soft, 2. Not enough fork ol Replenish. 3. Wrong weight fork oi. Replace 4. Improperly set front fork spring adjuster, Adjust, 5, improperly set front fork damping foree axgustar. Adjust Front suspension 1. Too wiscous fork ot Replace, too stit 2. Too much fork of Drain excess ol 8, Improperly set frant fork apring adhuster Adjust. 4. Improperly eet front fork damping loree adjuster. Aust. 5, Bert vont are. Replace. Noisy front 1. Not enough tor ai Feeplenish suspension. 2 Loose bolls on suspension. atighten 7 ‘Weebly rear wheel. 1. Distorted wheel rim Replace. 2. Worn rear wheel baaring or swingarm bearings Replace, 3. Detective or incorrect tre Replace. 4, Worn swingarm and rear suspension bearings. Foplace, 5. Loose nuts of bolts on rear suspensians. Feetighton, Rear suspension 1, Weakenad spring et shock absarber. Replace. ‘90 soft, 2 Leakage oll or gas of shack absorb Repince. 3. Imprapediy set mar spring unit adjuster. Adjust 4. Impropeny sel rear suspension damping force Adjust - adjuster, Rear suapensian 1, Bent shock absorber shah Foopiace too att, 2 Bent swingarm. Ropince 3. Worn swingarm and rear suspansion beatings. Riopiace 4. Improperty set rear suspension adiuster Adjust SS. Imprapety set rear suspension damping force Aojust. adjuster. Noisy tear 1) Loose nuts ar botis on rear suspension Retghien ‘suspension. 2 Wom swingarm and suspension bearings Alspiace. SERVICING INFORMATION 6-11 BRAKES Complaint ‘Symptom and possible causes | Remedy Insufficient brake 1. Leakage of brake tia irom hydraulic aysiem Repair or replace. power. 2. Worn pads Replace 3. Olt adhesion of engaging surtace of parsishow Clean tise and pad. 4. Wan dae Replace 5. Ain hydenule system. Bleed ait 6. Not engugh take fui inthe resarvor, Foplanich Brake squeaking. 1. Garban adhesion on pad surtace Repair surface with sandpaper. 2. Tited pad Moxity pad fting or replace, 2, Damaged whee! pearing, Replace. 4, Loosen frnt-uhesl axe oF rear-whes! ile Toghten to specified torque. 8. Worn pads Replace. 6, Foreign material in bra Plt Replace brake ld 7, Clogged retum pom of master eyiner Disassemble and ‘oan master cyinder Excessive brake 1. Airin hydraulic system. - Bleed air lever stroke. 2. Insufficient brake fuid. Replenish fic to spe- ‘ed leva bleed alr. 3. Improper qualty of brake tid Replace with correct ud ‘Leakage of brake 1. Insufficient tightening of Connection oinia Tighien fo specited fala rorque. 2, Cracked hose, Replace. 3. Worn piston andior cup. Replace piston andior cup. Brake drags. 1 Flas park ‘lean and lubreain 2. Insufficient brake lever ar brake pedal pivot lubrication, Lubneate. 12_ SERVICING INFORMATION ELECTRICAL ‘Complaint ] ‘Symptom and possible causos Remedy No sparking or poor | 1, Delective ignition col/plug cap ar camahaft Raplace sparking. postion sancar 2 Detective spark plugs, Replace 8. Defective crankshalt position sensor Replace 4. Detective EOM Replace 5, Defective tip over sensor. Replace 6. Open-cireuted winng connections Check and repaie ‘Spark plug soon 1 Minture too rien Consult Fr ayster ‘become fouled with 2 Idling speed set to high Adjust ast idle or carbon, throtie stop serew. 23, tnearrect gasoline, Change. 4. Dirty element in air cloaner: Giean or mplace 5, Too cold spark plugs. Replace with hot type luge Spark plugs become fouled too soon. 7 Wem piston nae 2 Worn piston of cylinders. 8. Excessive clearanoa of valve stems in valve guides, ‘Worn stam at coat Replace, Replace, Replace Replace, Spark plug electrod- 25 overeat or bum. Joo fot spark plugs: Overhieated the engine |. Teo lean mixture. | Replace with cold type plugs Tune up Retighten, Consul system. 2 3. Loose spark plugs: 4 1 Generator does not ‘Open or short lead wires, or loose lead Repair orrepiace or charge, cannettions retighten. 2 Shorted. grounded or open generator ceils, Replace 3. Shorted or panctured requiatorirectiies, Replace, ‘Generator does 1. Lead wies tend to get shorted oF open-cireutied Repair or retighten, charge, but charging ‘9 loosely connected at terminate tate is below the 2 Grounded or open-circuited stator coils or Replace ‘specification, genenntor, 3. Defective regulatorreciier Replace. 4. Defective cell plates in the bstiery Replace tne barory Generator 7. Internal short-circut in the batiery Fieplace the battery overcharges. 2. Damaged ot detective regulstorrectiior, Replace, a Poorly grounded ragulator'actitie Repair, replace, oF connect proparly, Unstable charging. ‘Lead wire insulalion frayed doe to vibration, resulting in intermittent sherting Repair or replace. 2. Internat shorted generator. Replace, 3. Dotective reguiatorectifer Replace. Starter button isnot | 1. Fun Gown battery, Repair or replace cffective. 2. Defective snitch contacts Replace. 31 Not seating properly Brushes on commutator in Repair or replace starter motor 4. Defective: starter rolayiatarte’ interlock switch Replace. 5. Defective main hive Replace. SERVICING INFORMATION 813 BATTERY ‘Complaint Symptom and possible causes, Remedy “Bullation”, acidic 1, Cracked battery case, Replace the batlery nite powdery utr 2. Battery has been Jef in a run-down condition for Replace the battery stance of spots on satong time surtace of coll plates. Battery uns down 11 Not correct the charging systern. Chack the generator, quickly. requlatarrecttiar and citcutt connections and make necessary adjustments to obtain spocitied charging ‘operation 2, Cal pitas havo lost much of thair active Replace the battery, material as @ result of overcharging ‘and correct the charge ing yates 3, A-shor-cioutt condition exigta within the batery Replace the battery, 4, Too low battery voitage Recharge the batiory ‘uly, | 5 Teo ola batory Replace the battery Battery "sulfation". | 1, Incorrect charging rate Feplace the battery (When nat in use battanes should be checked at least once a month to avoid sulation,) 2. The battery was left un used in a cold elimate for too| Replace the battery it fong badly sulfated. Battery discharges 1. Dirty container top and sides. Cloan. 100 rapidly. B14 _ SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Set he witing harness 6 tho Fight wie of Reassight, and push i tothe groove othe paagight housing INSIDE OF THE BODY COWLING ene cane estar eae chy [ng rare ap Clam the wiring harness to ine frame, ‘Miring hams: SJ To matrant nan sigral gt ( Set the hanslebar wiih couplers under the wiring hnarhase afer connecting them Wiring haces [Wwstertsea Clamp Foce the clamp ena toomemward ass he side-ctand swich ‘ged wie vero oatery Press wire. | os rose ate box amp Sine veer maton / len Tana \ Wiring names: tery pa and wre rt he a uit re benvestbe eng coame Weng nemes| \, Miebelneen fcc re bypass hose and engnie cap {Bessie anor rey oe Startle nt Te sangor so at Pas tag near eee motor end wire behind of nenibber carseat Bosed lee Inaert 70 sensor up tothe oat of rear tensor securaly datr! teeth load wr tae ot ‘atthe injector coupler to inept peti wer Serectng eC ey pace pee soe laud wire belind the Bypass: bose wd breathar have (me (wns wii sob uN cot wa eq} wi STO) NSE if 8-16 _ SERVICING INFORMATION SERVICING INFORMATION 6.17 CABLE ROUTING ‘ice 2 thong a4 ane me OR oe an YBN SH) ; ges ys eg ree von onion ef FRO TON OMORUL — wjgeD ion ae oh eae oN ono 18 _ SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING SERVICING INFORMATION. 6-19 cach 1 4 on rm Burges on Ua { Hiei pein You UNS RL mE ney dump 94 19 HP BL COOLING SYSTEM HOSE ROUTING 8.20 _ SERVICING INFORMATION FRONT BRAKE HOSE ROUTING ‘3yON LAN ou LONG sedcOyS op OL suoun eso eye out NAP Hy oq due ug LO ‘amano Uo eps acy Baa yy ie OI A PRE sroy.aymq 344 YBMOR SEU SERVICING INFORMATION. 8.2t REAR BRAKE HOSE ROUTING q twain gaddons 48h ou Hump ogy Yea UPL ayy wap oksOns 08 ‘uoiun oom ae ut Bo. at 6:22 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR vate = )t0Nm 1 Oat. 7S) FAR claanerboss varia me | ——— PAIF valve noe (20 mint PD Air carer to SERVICING INFORMATION. 623 INNER SIDE COWLING SET-UP 6.24 SERVICING INFORMATION \ 9 ers wm ‘vcr a SERVICING INFORMATION. 6.25 FRAME COVER SET-UP HEAT SHIELD SET-UP a Left under coming Let unr comting. heat ahseld Nad _- Pight under coling heat shisla Not Left under coming 2 ‘ost chiets Noo SF Center under cowing heat shield Na ae ea Genler under coating nowt shia a2 7 £25 _ SERVICING INFORMATION SIDE-STAND SET-UP 400m (4.0 holm, 260 @ 08m (GO Kgtm, 36.2 mf 5 GEARSHIFT PEDAL SET-UP 52-62 mm (205-244 im) SERVICING INFORMATION $27 SPECIAL TOOLS 3200-08107 ‘Shaping lire ee00-06708 Snap ning piers Verner caligers 5 00-26 p900-20808 gevoe Daal colors (o=25 mm) Gyinger gauge est — | (vrGoomm, tm) | (1/106 rem. 1— 4 a) Dial gauge sson-2150 [vidrem, 10%) | Magnete stars Theokress gauge ‘ioc (100 rm = J HK esco.224i (10 t8rr ce13- 10750 tososz2e03| 8 35mm} | 99800-26008 uor0-20115 Garrgresson oxo ‘Smallore gape Coneoa hala ssaptor 2 oasisnaiat sat5-40810 ogas.68510 Cotarmtertstarcer sat | Of seal remover Bestmgincalorsct__| Oitorsronch Compression gauge 2428 _ SERVICING INFORMATION ff < ee eet | - eee oor 10 Ea a NN ~ pate 20080 Soldset ‘spats-se642 iNa80-49) earrertarae corre-aan10 oopre-sssi0 Ve gut Valve ge ouare-taz20 maaro-assit ier removerinwiaier | lacrrart & ‘So c.sa7-0 owas7-s7010 Gen eave ru vacuum pump gauge tole Na %& gane-04621 Steenng Seanng pean-11a20 | baaso-r aan Baarnginstwlersee | of attachment ‘este Fone bit ITOH | Bit bolder SEAVICINGINFORMATION £29 capda-n4971 a sve vecouo | mio aemace | an | Se ee ee Stzsring mut wrench | Swingarm pivot shat | Engiremouring mnt | Front lok easembing | Fuel pressure gauge = Breimien | Eero | 6 ite i Lp | : = SS Front fork: spring stop- | 99940-04930, ine PE an oad .34513 ‘Steering race instar sass-741 01 Fore el level gouges sate e020 evo! bea reg eorrcve NOTE: When ander the special tool, please confirm whether iis avaitable or aot $30 _ SERVICING INFORMATION TIGHTENING TORQUE ENGINE Trew Nem ]__ kgm Tbe Exhaust pipe bolt 23 23 18.5 Muffler maunting nut 23 23 165 Speed sensor raloe bol 20” 2.0 144 Engine sprocket nut 1s 115 632 Engine mounting bolt and nut (war) 75 75 54.0 . (we) | 35 5s ne Engine mounting thrust adjuster 23 23 16.5 ‘Engine maunting thrust adjuster lock rut 45 [45 [325 Engine mounting pinch bal 23 2a [165 (Cylinder head cover bolt 4 14 10.0 Spark plug W 1 80 ‘Cam chain guige bolt 10 1.0 To [Camshaft journal haider bo | 10 1.0 To ‘Cam chain tension adjuster cap bolt 23 2.3 16.5 | Cam chain tension adjuster mounting bart 10 | 1.0 7.0 [Cylinder mead side bolt 14 14 10.0 [Cam chain tensioner bolt 10 10 7.0 “Cylinder head bolt ii70) 46 46 EXE (M6) 10 0 70 PAIR raed valve cover bolt 10 10 70 ‘Water jacket a5 0.95 69 Water inlet cover bolt 10 1.0 70 Ciuich caver bolt 10 10 70 Clutch sleeve hub nut 150 15.0 108 Clutch spring set bolt 10 | 10 | 7.0 Starter clutch cover bolt i 10 41.0 7.0 Starter idie gear cover ball 10 40 7.0 Valve fiming inspection plug u it a0 Starter clutch bolt 55 55 40.0 Generator cover boit 10 10 7.0 ‘Generator rolar Bolt | 120 12.0 oa.5 Generator siaior sei bolt 10 1.0 7.0 Gearshift cam stopper bolt 10 10 7.0 Gearshift cam stopper plats bolt 10 1.0) 7.0 Ol pressure switch 14 14 | _10.0 ‘Crankcase bolt i 14 a0 26 26) +190 (M5) 32 32 23.0 ‘Oil gallery plog (Ws) (M10) 1 ii | _ ao - (16) 35 35. 26.5 Oil drain plug I 23 [23 16.5 SERVICING INFORMATION. 31 Trem Nem katm Tot Piston cooling ail jet batt 10 1.0 70 “Oil pump mounting bolt 10 1.0 7.0 ‘Contog bearing cap bot — intial) [15 5 10 (Fina) | (tum Besnng retainer screw 1 10 1.0 70 Breather cover bolt | 0. 1.0 70 ‘Oil strainer bolt i 10. 10 7.0 [_Oirpan bat 1 10. 1.0 Oil cooler bot 10, 1.0 FI SYSTEM AND INTAKE AIR SYSTEM \TEM I kgtm Ib-ft ‘Camenalt position Sensor mounting batt a8 6.0 Tnigke air lemperature sensor 18 13.0 Fuel delivery pipe mounting screw as a7 Fuel pump mounling bolt 1.0 7.0 Throtile Body connecting bait Os 35 STVA motor yoke mounting bolt — 0.38 25 STVA motor cover nut 92 rr COOLING SYSTEM ITEM Nem kghm Ibstt impeller securing bolt a 08 60 Water pump cover bolt 6 06 45 ‘Water pump mounting bok 0 1.0) 7.0 Cooling tan thermo-switch 7 id 128 Engine Coolant temperature sensor [18 ie 13.0 ‘Thermostat case bolt 10 10 7.0 2 _ SERVICING INFORMATION I CHASSIS: TEM tem kghm Tf Sieering stem head nut 90 90 65.0 ‘Steering sem lock nut 80 80 58.0 Steering damper bolt and nut 23 23 16.6 Front tork upper clamp tol 23 23 [18.5 Front fork lower clamp bolt | 23 23 | 185 Front fork cap bolt EY a5 25.5 Front fork inner rod lozk nut 20 20 145 Front fork damper rod bolt 38 35 25.5 Front axle 100 10.0 72.5 Front axle pinch bolt 23 23 16.5 Handlebar clamp bolt 23 as 16.8 Handlebar set bot - 10 1.0 7.0 Fioat brake master cylinder mounting bolt 10 1.0 7.0. Front brake caliper mounting bol 25. 25 16.1 Front brake caliper housing bolt Fa] 24 15.4 Brake hose union bal | 23 29 16.5 Clutch holder mounting bolt I 10 30 7.0 | Air bieedar valve BO OB 80, Brake disc boit (Front) 23 23 16.5 Brake dise bolt (Rear) 36 35 255 Rear brake caliper mounting bot 25 25 18.1 Rleat brake caliper housing bolt 30 30 as Rear _biake master eylindar mounting Bat 10 10 70 Rear brake master cylinder rod lock rut 78 18 15.0 Front footrest bracket meunting bot 23 [35 16.5 ‘Swingarm pivct shat 5 15 11.0 ‘Swingarm pivot nut 700 10.0 725 ‘Swingarm pivot lock nut 80 8.0) 65.0 Torque link nut (Front) 28 28 205, Torque link nut (Rear) 4 En 24.6 ‘Cuishion lever mounting hut 78 78 56.5 Cushion rod mounting nut 78 78 565 | Riear shack absorber mounting bo and nut (Upper and Lower} : ad §0 st Fear axle nut For £-03, 28, 33 no 11.0 For the others | 120 12.0 Rear sprocket nut 60 6.0 Side-stand mounting bracket bolt 50 5.0 Cowiing brace bolt and nut 33 23 | Rear shock absorber bracket nut 445 115 ‘Seat rail bol 23 23 SERVICING INFORMATION 639 TIGHTENING TORQUE CHART For other bolts and nuts listed previously, reter to this chart: Bat Diameter Conventional or "4" marked bor "7 marked bok ® mm) Nm | _'gtm et im gh be 4 15 | ons 10 23 0.23 15 5 3. | oa 20 45 045 30 8 55 055 40 10 10 70 8 13 13 a5 23 23 165 i 28 29 210 $0 50 360 12 45 45 325 a 85 615 14 85 a5 470 135 ws | 978 16 105 105 760 210 zo 1520 16 160 160 155 200 240 735 “# manked bok oT maka 834 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mim (ie) Tem STOISPEC. uni Valve diam 272 IN: (1.07) 22 Fi (087) Valve tiearance when cold) im og - 3%, i (0.008 — 01 020—0.90 uid {0.008 — 0.012) Valve guide fo valve stem iz 010 0.037 clearance {9.0004 — 0.0015) Ex. a Valve guide ID, = a (0.1575 — 0.1580) —_ Vane stem OD, i 3575 — 3.650 (0.1565 — 0.1571) ee 3.955 — 9.870 (0.1557 — 0.1583) Vale stem deflection TARE. ay Valve Siem runout eee ee, Vahe Read thickness l ween ey Valve seat widih ieee ae Valve Raed radial runout NER ee Valve spring free length: IN.B EX. | as : Wale sping tension ] i (Desa te | EEX. 38.8 — 44.8 bs —_ at fength 32.85 mm (1.29 in} CAMSHAFT + CYLINDER HEAD Unit: mn (in) TEM STOISPEC. Mir Gam halghi a 36.58 — 96.62 36.28 (1.440 — 1,449) (1.428) be. 36.28 — $5.52 34.08 (1-383 - 1381) Gain ‘Camshaft journal of clearance | wy g ex. 0.032 — 0.066 0.150 | __ (0.0073 - 0.0026) (2.0059) | ‘Camshaft journal holder [8 HEEL 24.012 — 24.005 (0.3454 — 0.9459) [SERVICING INFORMATION 8:5 Tem STDISPEC, cimir Gamshatt journal OD. | 23,959 - 23.980 _ SS (0.9438 ~ 0.9441) Camshaft runout —== 0.10 (9.008) | Gam chain pin (at arrow) 14th pin Gyiinder head distortion == 020 (9.008) CYLINDER + PISTON + PISTON RING ‘Unit: mim (in) Tem ‘STOSPEC. cmir Compression pressive 1 100 ~ 1 500 kPa 800 kPa (1, ‘saauer" Cigar 156 — 218 psi 128 si Compression pressure 200 kPa diference — 2 kglicm - 25 pa Piston to cylinder clearance 0.070 — 0.085 0.120 (0.00099 — 0.00738) | (0.0047) Cylinder tare 7.000 — 67.015 Nicks or (2.6378 — 2.6384) Scratches. Piston diam 166.970 — 66.985 (2.6906 — 2.6372) oS, Measure at 15 mm (0.6 in) irom the skint end. = Gyinder distartion 020 _ 9.008) Piston ring Free and gap 73 58 at | A ApoHox. (6.35) chy | 92 74 and | RN Apptox. (Gs) oe) Pision ing end gap 0.05 — 0.18 0.50 Tal Bt (0.003 ~ 0.008) (0.020) 8.06 — 0.18 050 a eat es (0.003 — 0.008) «o.720) Piston ring fo graove clearance 0.180 1g 10 9 ‘st (0.0071) 0.150 Ee (9.0059) Piston ring groove wid 101 1.03 im {0.0398 ~ 0.0406) ‘oat 083 ond (0.0319 ~ 0.0327) 731 1.53 ou (0.0894 — 0.0802) | Piston ring thickness i 097 ~ 059 (0.0382 ~ 0.0390) | O77 0.79 aa ___ (0.0303 = 0.0311) Piston pin bare 14.002 14.080 (0.5513 — 0.5515) _ (05524) Piston pn OD. 73.998 — 14,000 13,980 (0.5510 — 0.5512) 10.5504) 898 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) TEM STOSPEC, Mir Conred small end 44.010 - 14.018 14.080 (0.5515 — 0.5519) (0.5528) ‘Conred big end side clearance 010-020 0:30 u (0.004 — 0.008) (0.012) 1895 — 20.00 (0.7854 ~ 0.7874) Crank pin width 20.10 = 20.15 (0.7913 ~ 0.7939) Canred big end ol clarence 0.032 — 0.056 0.080 (0.9013 ~ 0.0022) (0.0031) Caank pin OB 30.978 - 37.000 | (1.2195 — 3.3208) Crankshaft journal el Gearance ‘0.016 - 0.080, 0.080 (0.0006 ~ 6.0016) (0.0031) Crarkshail journal OB. 31,978 ~ 92.000 (1.2588 — 1.2598) Crankshaft thrust bearing 2a25 ~ 2450 ‘thickness Rae sie | 0.0955 - 0.0965) 2.350 - 2.500 Lott sce | (0.0925 - 0.0984) Grankshaft trust clearance 0.055 - 0.110 (0.0022 - 9.0043) Crankehatt runout O08 (0.002) OlL PUMP STOISPEC. omit i pressure (at 60°C, 140°F) 200 - 500 kPa (20-50 kgliom®, 28 ~ 74 psi — at 3.000 rimin CLUTCH Unit: mm in) _ ITEM ‘STOISPEC. Limit | Gluten lever play 10-15 (0.4 - 06) Gulch release screw 3 tum back — Drive plate thickness Nat? 203-308 and 3 (0.145 — 0.121) Dive plate claw width No.t,2 137-148 i29 and 3 (0.540 — 0.543) (0.508) Tien plale dietorlion 0.10 — (0.00) Civieh Spring tree height #780 354 (1.882) (1.782) TRANSMISSION + DRIVE CHAIN SERVICING INFORMATION 6-37 Unit! mm (in) Except rato EM STDISPEC. twit Primary reduction ratio 1 1.826 (7841) — Final reduction ratio tT 2.812 (A516) _—— (Gear ratios Low 2.785 (99/14) — 2nd | 2,000 (92/18) — acd 1.600 (82/20) — ath 1.363 (8022) — sn | 1.208 (29724) = Top | = ‘Shif fork ta graove clearance 0.50 (0.020) ‘Shift fork groove width } (0.197 - 0.201) ‘Shift fork thickness 48-49 (0.189 - 0.193) | Deve chain Type RKS25SMOZE — Links: 110 inks 20-pitch kenath — Gasn Drive chain slack (on side-stand) 20-80 (0,79 - 1,18) Gearshift lever height 52-62 (2.05 ~ 2.44) THERMOSTAT + RADIATOR + FAN + COOLANT EM STDISPEC. Lana Thermostat valve opening temperature Approx. 82°C (180 °F) | Thermostat waive lit Over & frm (0.31 in) at 85°C (20°F) Enging coolant temperature ‘58n50r resistance er Approx. 2.45 kl = a Approx. 0.811 ki = Approx. 0.316 KE Approx. 0.142 ka (230°F) (a0) ‘Approx. 0.088 ki — Radiator cap valve opening 95 — 125 kPa pressure (0.95 - 1.25 kglicm!, 13.5 ~ 17.8 psi) ‘Cooling fan thermo-switch OFF — ON ‘Approx. 105°C (221°F) — operating temperatura JON — OFF! ‘Approx. 100°C (212"F) =——= Engine coolant type Use an antifrecze/coolant compatible with almi- num radiator, mixed with distilled water only, al the ratio of 50:50, Engine coolant Reserve Approx. 250 mi tank side (0.37.2 US/imp gi) Engine ‘Approx 2 150 ml — side (2.3/1.9 US/imp al) 5.38 _ SERVICING INFORMATION INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR en STOISPEG. NOTE Injector resistance 11 = 16 at 20°C (68°F) Fuel pump discharge amount Approx. 1.2 (1.3/1.1 US/imp ot) /30 886. Ee er eae opening Approx. 300 kPa (3.0 kaliem, 43 psi) FISENSORS + SECONDARY THROTTLE VALVE ACTUATOR Tem ‘STOISPEC. NOTE CMP sensor resistance Os-17kn GMP sensor peak voltage a More than 67 V CKP sensor resistance 70-220 CKP sensor peak voltage More than 0.5 V TAP sensor input voltage 4.5—55V JAP Sensor output voltage Approx. 1.32 V at idle speed TP sensor input voltage 45-55V TP sensor resistance Closet ‘Approx, 1.1 KE ‘Opened | ‘Approx, 4.5 KG ‘TP sensor output voltage Giosed | AE ‘Opened ECT sensor input voliage 45-55V ECT sensor resistance — 23-26 i al 20°C (68°F) IAT Sensor input voltage | 45-55V [TAT sengor resistance 22-27 kai 20°C (68F) Sensor input voltage 45-55V |AP sensor output voltage ‘Approx. 3.6 V ai 100 kPa (760 mmHg) “TO sensor resistance _ 60 - 64k TO sansar voltage Approx 2.5 V GP switch vaitage More than 0.6 V (From 1st 16 Top) injoctor voltage Batiery voltage Ignition coll primary peak voltage More than 80 V (When eranking) STP sensor input voltage 45-55V STP sensor resistance | Closed Aprox 0.8 KO | Opaned Apprax. 3.9 KO ‘STP Sensor output voltage Closed Approx 0.8 V Opened Approx 40V ‘STV actuaior resistance Approx 5.6 oF “| STC unit input voltage Battery voltage SERVICING INFORMATION 6:38 THROTTLE BODY TEM STDISPEC. Bore sie 36mm LD. No. 38 Fi (For E33), 39 FO (For the others) Tale afin 1-300 = 100 rimin. Fast idle rimin 2000 r’min, (After warming up) Throttle cable play 20-49mm (G08 - 0.16 in) ELECTRICAL Unit: mn (in) ~ Te ‘STOSPEC. NOTE Firing orc 1244 Spark plug NOR: ORGE |_ ee DENSO: U27ESR-N O7-08 Gap | __ (0.028 — 9.031) | Spark perormance ‘Gver 8 (0.3) at 1 aim CKP sensor resisianoe 70-2202 CP sensor peak voltage More than 0.5 V Ge a8 ‘onition coil resistance - Terminal Primary 08-200 steal - Plug cap = Seccndary a-15ka toe: ignition coll primary peak voltage ‘More than 60 V Generator col resistance: 02-152 Generator Max, output ‘Aaprox. 390 W at 5 000 «min. Ganeraior no-load voltage (when cold) More than 65 V (AC) at $ 000 r/min. Regulated voltage 14.0 — 15.0V at 6 000 vimin. Starter relay resistance 2-50 GP switch voliage More than 0:6 V (From ist to top) “Batiery | Type designation FTXO-BS ‘Capactly 12. 28.8 KG (8 Ahy/10 HA Fuse 2 | Heaciight HM 15a Lo 15a Signal 15 A Ignition 15a Fuel 1A Fan iA iain 304 340 SERVICING INFORMATION =e TSS WATTAGE nee E STDISPEC, £05, 24, 28-23 E02, 19 Headlight HI 55+55W = 10 sW I = Parking or position ght = BW Brake ightTalight 21eWxe - Turn aignal light 21Wea = Coibination meter fight LED = "Turn signal indicator ight LED = High beam indicator light teD = ‘Neutral indicator tight LED = Fl indicator light/Ol pressure Indicator ightEngine coolant LeD - temp, hisigatortignt Fuel level indicator ight ted = BRAKE + WHEEL Unit; mm fin) TEM ‘STOISPEC. uM Fisar brake pedal height 50— 60 ~ (1.97 — 2.38) Brake Gse thickness T 48-62 45 Een (0.189 — 6.208) (9.177) 48-52 43 Beat (0.189 - 0.205) (0.477) Brake diac runout oan, (0.012! Master cylinder Bore | ears {E70 — 18.515 (0.6248 — 0.8265) 12.700 — 12.743 eee {0.5000 — 0.5017) Masier vind piston diam, a {5827 — 15.854 (0.8231 — 0.6242) 12.657 — 12.664 Aeer (0.4983 — 0.4904) Brake caliper oylinder bore) 30.230 ~ 30280 ont Lees | (a.tg02 = 1.1921) 33.960 — 34010 Taling | (7.3570 — 1.3300) 38.180 - 38.086 i Rear (1.5031 - 1.5061) rake caliper piston diam 30.167 — 30.200 Front LOS"? | citazr— 1.1890) | 33.00] — 93.934 alleg (1.3345 7.3399) | aB.09e — 3.148 em (1.4999 — 7.5019) Brake fui pe DOT 4 — SERVICING INFORMATION 8-41 Tem cit Wheat rim runout 20 Axial ices) 20 (0.08) Whee rm size _ 7x Mit 380 | _ 7 x MT 550 | Wheel axle runout 025 (a.ar0y 025 Beer ——- (@.010) TIRE Unit: mm (in) Tem ‘STOSPEC. T__uiair Gold Infalion tre pressure fina 250 kPa (Solo riding) (2.50 kollem’, 36 psi | 250 kPa Rest (2.50. kgllom, 36 psi) ~ Gold Irflafion fre pressure eA 250 kPa (Dual nding) (2.50 kgfem’, 36 psi 250 kPa Feet (2.50 kgtfcr?, 36 psi Tie sue Front 120770 ZAYT (SBW) — Rear 190155 ZAY7 (73W) [| —— Tire type Front | PIRELLE MTR21s corsa (E-2, 19) | DUNLOP : D207FU (The others) Fear | PIRELLI: MTRz2s corsa (E-02, 19) DUNLOP ; D207U (The others) Tie Weed depih ra 1 (Recommended depth) 0.06) 20 Fer | | 1608) SUSPENSION: Unit: mm (in) Ten STOISPEC, Limit Front fork stroke 325 (4.52) Front fork epring free lengih 248.6 2a (5.73) (857) Front fork ail level (without apring.| 102 ular tuba fully compressed) | (4.02) Front fork all tyne SUZUKI Fork 61 55.08 (#10) oran equivalent fork of | —— Front fork olf capacity (each leg) 528 mi (37.818.6 USiImp 02) Front fork spring adjuster 4th groove trom ton — Front fork damping force Favound Vand is ws out = adjuster Campression| and turns out = Rear shock absorber sping vans pre-set length (7.538) Rear shock absorber damping | _Rlabound Tandy ums out —=— force adjuster Compression {and Yh tums out 542 _ SERVICING INFORMATION TTeM STDISPEC, “Rear wheel travel 7130. 1) ‘Swingarm pivot shaft runout FUEL + OIL TEM 'STDISPEC. Fuel type Use only unleaded gasoline of at least 87 pump octane (£2) or 97 octane or higher rated by the | reserch method. | Gasoline containing MTBE (Methyl Tertiary Butyl | Ether), less than 0% ethanol, or less than 5% | methanol with appropriate cosclvents and corro- sion inhibit is permissibi, Gasoline used should be graded 97 octane or higher. An unleaded gasoline is recommended. E-03, 28, 33 The others Fuel tank capacity ‘neludting wL reserve (4.8/4.0 US/imp gal) Foal level depres AL ce” (1.1/0.9 USiImp ga) Fuel level | Approx. 2.6 L or al | (0.691058 USimp gal) Engine cil type SAE 10W/40. API. SF or SG Engine oll capaciy 2aL Srasos (3.025 USimp at) ait Filter change (9927 USienp gb ‘Overhaul oa (2.63.0 USimp qt) GEE Be era’ WIRING DIAGRAM FI SYSTEM WIRING DIAGRAM sean Et Sain frie a bee —— ' 4 | Lune oyeee ae --4 ante WIRING DIAGRAM FOR E-03, 28, 33 T 7 oI = f (3 2 FOR E-02, 19 FOR E-24 Prepared by SUZUKI MOTOR CORPORATION Motorcycle Service Department September, 2000 Pant No. 99500-38080-01E PPrinied in Tapan =