FOREWORD This manual contains an introductory description ‘on the SUZUKI GSX1400 and procedures far its inspection/service and overhaul of its main cont ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa miliarize yoursel! with the motoreycle and its main- tenance. Use this section as well as other sections to use as.a guide for proper inspection and senvice. This manual wilthelp you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service. * This manual has been prepared on the basis of the Jatest specifications at the time of pub- Heation.. modtiications have been mace since then, differences may exist between the con- tent of this manual and the actual motorcycle. Itustrations in this manual are used to show the basic principles of operation and work pro- cedures, They may not represent the actual motorcyele exactly in detail This manual is written for persans who have ‘enough knowledge, skills and tools, including Special tools, for servicing SUZUKI motor- cycles. If you do not have the proper knowl ‘edge and tools, #sk your authorized SUZUKI matoreyole dealer to help you. Inexperienced mechanics or mechanics with- out the proper tools and equipment may not be able to properly perform the services de- scribed in this manual. Improper repair may result in injury tothe mechanic and may ren- der the motorcycle unsafe for the rider and passenger. SUZUKI MOTOR CORPORATION Overseas Service Department ‘©COPYRIGHT SUZUKI MOTOR CORPORATION 2001 GENERAL INFORMATION E a PERIODIC MAINTENANCE Ez ENGINE E I FISYSTEM Z a OIL COOLING AND LUBRICATION SYSTEM Ez CHASSIS E 7 ELECTRICAL SYSTEM Ea SERVICING INFORMATION EZ ZHOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1.The text of this: manual is divided into sections. 2.The section titles are listed in the GROUP INDEX. 8.Holding the manual as shown at the right will allow you to find the first page of the section easily. 4.Tho contents are listed on the first page of each section to help find the iter 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! ather service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel oO TEM | Wem @_| 100 B 23SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. ‘Apply oll. Use engine ail unless otherwise specified. ‘Apply THREAD LOCK SUPER, ‘Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) ‘Apply or use brake fiuid. Apply SUZUKI SUPER GREASE “A”. 99000-25010 Measure in voltage range. ‘Apply SUZUKI MOLY PASTE. 99000-25140 Apply SUZUKI BOND 12078". 99000-31140 Measure in current range. Measure in diode test range. Apply SUZUKI BOND "12168" 99000-31230 Apply THREAD LOCK SUPER "1303". 99000-32030, ‘Measure in continuity test range. Use special tool. ‘Apply THREAD LOCK SUPER "1922", 99000-32110 Indication of service data. Apply THREAD LOCK 1342", 99000-32050ABBREVIATIONS MAY BE USED IN THIS MANUAL A ABDC : Aller Bottom Dead Center ac Alternating Current ACL Air Cleaner, Air Cleaner Box API = American Petroleum Institute TOC After Top Dead Cantor ATM Pressure: Atmospheric Pressure ‘Atmospheric Pressure ‘Sensor (APS, AP Sensor) NE + Air Fuol Moture 8 BDC : Bofore Bottom Dead Canter BTDC : Before Top Dead Center Be : Battery Positive Voltage: c CKP Sensor: Crankshaft Position Sensor (CKPS) KT 2 Circuit CLP Switch: Clutch Lever Position Switch (Clutch Switch) CMP Sensor; Camshatt Position Sensor (MPS) co = Carbon Monaxide cpu Central Processing Unit D ie : Direct Current DMC : Dealer Made Coupler DOHC : Double Qver Head Camshaft DAL : Daytime Running Light ECM EOT Sensor EVAP EVAP Ganister Fi FP FPR FP Relay GEN GND GP Switch Ho ' IAP Sensor 1AT Sensor is co LED LH Engine Control Module Engine Control Unit (ECU) (FI Control Unit) : Engine Oil Temperature: ‘Sensor (EOTS), Oil Temp. Sensor (OTS) : Evaporative Emission Evaporative Emission Canister (Canister) : Fuel! injection, Fuel injector Fuel Purip Fuel Pressure Regulator + Fuel Pump Relay : Generator Ground : Gear Position Switch : Hydrocarbons t Intake Air Pressure Sensor (IAPS) ¢ Intake Air Temperature ‘Sensor (IATS) Ignition = Liquid Crystal Dispiay + Light Emitting Diode (Maifunction Indicator Lamp) Left HandMAL-Code Max MIL Min SAE STC System STP Sencor ST Valve STV Actuator ‘TO Sensor ‘TP Sensor : Malfunction Code (Diagnostic Code) ‘Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshatt Oil Pressure Switch Positive Crankcase Ventilation (Crankcase Breather) light Hand Read Only Memory Society of Automotive Engineers. Secondary Throttle Control System (sTes) : Secondary Throttlo Position Sensor (sTPs) Secondary Throttle Valve (STV) : Secondary Thrattle Valve Actuator (STVA) Tip Over Sensor (TOS) 1: Throttie Position Sensor (rps)GENERAL INFORMATION. 1-1 Se ela] CONTENTS WARNING/CAUTION/NOTE .. GENERAL PRECAUTIONS SUZUKI GSX1400K2 (2002-MODEL) SERIAL NUMBER LOCATION FUEL AND OIL RECOMMENDATION. FUEL ENGINE OIL. BRAKE FLUID FRONT FORK OIL. BREAK-IN PROCEDURES. CYLINDER IDENTIFICATION INFORMATION LABELS SPECIFICATIONS COUNTRY AND AREA CODES... s SVADARHADAANNHD1:2_ GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize spacial information, the symbol and the words WARNING, GAUTION and NOTE have special meanings. Pay special attention to the mes- sagas highlighted by these signal words. PROGINS Indicates. a potential hazard that could result in death or injury. CAUTION indicates a potential hazard that could result in metoreyele damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover al potential hazards relating to the servicing, or lack of servicing, of the motorcyole. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. if you are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad- vice. GENERAL PRECAUTIONS PROGINS * Proper service and repair procedures are Important for the safety of the service mechanic and | the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas Is forced outdoors, * When working with toxic or flammable materials, make sure that the area you work in is well~ ‘ventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avold getting burned, do not touch the engine, engine oll, radiator and exhaust system until they have cooled. * After servicing the fuel, oll, engine coolant, exhaust or brake systems, check all lines and fit- tings related to the system for IGENERAL INFORMATION 1-3 (CAUTION “If parts replacement 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 orderly manner so that they may be reinstalled In the proper ordor. * 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 pesitive cable. * When reconnecting the battery, connect 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 crankease 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, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces, * Never reuse a circlip, When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe otf grease and oll It a thread Is. smeared with them. ‘+ After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawtully dispose of used motor all, engine coolant and other fluids: batteries, and tires. * To protect the earth’s natural resources, properly dispose of used motorcycles and parts.44 GENERAL INFORMATION SUZUKI GSX1400K2 (2002-MODEL) LEFT SIDE * Difference between photograrh and actual motorcycle depends on the markets, SERIAL NUMBER LOCATION ‘The frame serial number or V.LN. (Vehicle Identification Number) @ is stamped on the right side of the steering head pipe, The engine serial number (B is located on the rear side of the crank- case. These numbers are required especially for registering the ‘machine and ordering spare parts.GENERAL INFORMATION 1-5 FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 81 olane (Research Method) or higher. An unleaded gasoline is recom- mended, ENGINE OIL Use a premium quality 4-stroke motor ail to ensure: longer sor- vice life of your motorcycle. Use only oils which are rated SF or SG under the AP! service classification. Tho recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the following chart. BRAKE FLUID Use DOT brake fluid. PONS Since the brake system of this motorcycle is filled with a glycol-based brake fluld by the manufac- turer, do not use or mix different types of fluld such as sillcone-based and petroleum-based fluld for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oll LO1 or an equivalent fork cil.14 GENERAL INFORMATION BREAK-IN PROCEDURES. During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but itis stil necessary to allow the moving parts to “BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early fe. The general rules are as follows. + Keep to these break-in procedures; Initial 800 km ( 500 miles}: Below 4500 r/min Upto 1600km (1 000miles): Below 6 700 r/min Over to 1600km (1000 -miles): Below 9000 r/min + Upon reaching an odometer reading of 1 600 km (1.000 miles) you can subject the motoreycle to full throttle operation. However, do net exceed 9 000 rimin at any time, CYLINDER IDENTIFICATION Tho tour cylindors of his engine are identified as No.1, No.2, No and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat).GENERAL INFORMATION 1-7 INFORMATION LABELS @ Noise label @ Fuel caution label1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width... Overall NEIGH eer Wheelbase - Ground clearance Seat height ENGINE Type. Number of eylinders Bore ... x stroke. Piston displacement Compression ratio Fuel system Air cleaner: Starter system... Lubrication system, Idle speed TRANSMISSION Clute Transmission... Gearshift pattorn Primary reduction AHO wm Gear rails, LOW nese 2nd .. rd ath... sth. Top Final reduction ratio... Drive chain... 2 160 mm (85.0 in) 810 mm (31.9 in) 1140 mm (44.9 in) - 1.520 min (59.8 in) 130 mm (5.1 in) 790 mm (31.1 in) 228 kg (502 Ibs} Four-stroke, air-cooled with SACS, DOHC .4 81.0 mm (3.189 in) 68.0 mm (2.677 in) 1 402.¢m* (85.5 cu. in) 85:1 Fuel injection system Non-woven fabric element Eloctric Wet sump 1100+ 100 nmin Wet multi-plate type 6-speed constant mesh t-down, 5-up 1.509 (89/55) 2.916 (95/12) 1.937 (31/16) 1.526 (29/19) 1.285 (27/21) 1.136 (25/22) 1.000 (24/24) 2.277 (A1/18) Rk GBS0GSVZ3, 116 linksGENERAL INFORMATION 1.9 CHASSIS: Front suspension .. Telescopic, coil spring, oll damped Rear suspension nono. ‘Swingarm, coil spring, oll damped Front suspension stroke .. Rear wheel travel ovnnene 190 mm (5.1 in) 123 mm (4.7 in) Caster .... . 26° Trail. z 105 mm (4.1 inp Steering angle .. 97° (right and left) Turning radius 2am(O2t) Front brake . Dise brake, twin Rear Brae son Disc brake Front tre size... 120/70 ZANT (58 W), tubeless Rear tre size 190/50 ZRI7 (73 W), tubeless ELECTRICAL, Ignition type Electronic ignition (Transistorized} Ignition timing 7° BT... at 1 100 rimin Spark PUD nn NGK CREEK DENSO U24ETR Battery ... ~ 12V 43.2 kG (12 Ahy10 HAL Generator. Threa:phase A.C, generator Main fuse S0A Fuse ... 1ONO/SI5/10/10 A Headlight 12 V 60/55 W (Ha) Position Hight... 12V 5W...... Excopt E24 Tur signal ight... 12V21W Brake lightTailight 12V 215 Wx2 Speedometer fiGMt. anor LED Tachometer light... LED Leo LeD LeD LEO LED Turn signal indicator light Neutral indicator light... High beam indicator light Oil pressure indicator light Ful injection warning light CAPACITIES Fual tank, including reserve Engine oil, oil change .. with filter change. 22 L (6.8/4.8 US/Imp- gal) 4.200 mi (4.4/3.7 US/Imp at) 4800 mil (5.1/4.2 US/imp qt) overhaul “ 5 700 mi (6.05.0 US/Imp at) Front fork oil (each leg)... coectnnnnnes — G48 ml (21 :8/22.8 USimp 02) These specifications are subject to change without notice,41-10_GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and areat-s). MODEL CODE COUNTRY or AREA E02 UK. @sx1400 E19 EU E24 Australia Gsxi4ooun | E-19 EUPERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS Ez PERIODIC MAINTENANCE SCHEDULE.. - PERIODIC MAINTENANCE CHAR} LUBRICATION POINTS.. MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER... SPARK PLUG .... VALVE CLEARANCE ENGINE OIL AND OIL FILTER FUEL HOSE. ENGINE IDLE SPEED THROTTLE VALVE SYNCHRONIZATION... THROTTLE CABLE PLAY... CLUTCH... DRIVE CHAIN BRAKE. TIRE . STEERING .. FRONT FORK REAR SUSPENSION... EXHAUST PIPE BOLT AND NUT CHASSIS BOLT AND NUT. COMPRESSION PRESSURE CHECK OIL PRESSURE CHECK22 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and menths, and are dependant on whichever comes first NOTES: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART Interval [km 1000] 6000 [ 12000 [ 18000 | 24000 miles 600_| 4000 7500 | 11000 | 15000 tem ‘months 1 6 12 18 24 Air cleanar element - I I i Spark plugs 2 1 R T A Valve clearance - = = = 1 Engine oil R RB a BR a | Engine oi fiter R = = R - Fuel tine : i i L i hose every 4 year L ‘and lubficate every 7 000 km (600 | | T T Replace every 4 Exhaust pipo bolts and muffier bolt and nut Chassis bolts and nuts, inspect and adjust, clean, lubricate or replace as necessary. A= Replace T= TightenPERIODIC MAINTENANCE 23. LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Conte sten pt afoares Sereda NOTE: * Before fubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject fo rust, with a rust preventative spray, especially whenever the: motoreyole has been operated under wet or reiny conditions.24 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item ‘mentioned in the Periodic Maintenance chart, AIR CLEANER * Remove the fuel tank. + Remove the fuel tank bracket, + Remove the air cleaner element by removing the screws, + Carefully use air hose to blow the dust from the cleaner ale- ‘ment CAUTION Always use alr pressure on the outside of the air cleaner element. If air pressure Is used on the inside, dirt will be forced into the pores of the air cleaner element thus re- stricting air flow through the air cleaner element, + Reinstall the cleanad or new air cleaner element in the reverse onder of removal. 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 ail times. The life of the engine de- pends largely on this component! ‘+ Remove the drain plugs from the air cleaner box to allow any water to drain out,SPARK PLUG SPARK PLUG AND SPARK PLUG CAP REMOVAL * Romove the seat + Remove the fuel tank. ((7"4-48} + Remove all spark plug caps. * Remove the spark plugs with a spark plug wrench HEAT RANGE * Chock ta see the hoat range of the plug. If the electrode of the plug is wet appearing or dark color, re- place the plug with hotter type one. I itis white or glazed ap- pearing, replace the plug with colder type one. NGK DENSO Standard CABER U24ETR Colder type CRSEK Us7ETR NOTE: “°R® type spark plug has a resistor located at the center electrode to prevent radio noise. CARBON DEPOSITS * Check to see if there are carbon deposits-on the spark plug. * If carbon is deposited, remove it using a spark plug cleaner machine or carafully use a too! with a pointed end. SPARK PLUG GAP * Measure the spark plug gap using a thickness gauge. * If out of specification, regap the spark plug. [EME Spark plug gap: Standard: 0. mm (0.028 ~ 0.031 in) ( 09900-20803: Thickness gauge Gap: 07 = 0.8mm . © (e.can 0.091 in)24 PERIODIC MAINTENANCE ELECTRODE’S CONDITION + Check the condition of the electrode. + ifitis extremely wom or bumt, replace the spark plug. Replace the spark plug ifit has a.broken insulator, damaged thread, otc. (Check the thread sizeand reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the spark plug hole and engine damage may result, SPARK PLUG AND SPARK PLUG CAP INSTALLATION * Install the spark plugs to the cylinder head by finger tight, and then tighten them to the specified torque. (8) Spark plug: 41 Nem (1.1 kgm, 8.0 Ib=ft) Te avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper VALVE CLEARANCE * Remove the fuel tank, ((7"4-48) * Remove the spark plug caps, + Remove the ignition coil brackets. Remove the ignition coils. * Disconnect the cam pesition sensor coupler. * Disconnect the PAIR hoses. + Remove the PAIR valve.+ Remove the engine oil cooler bolts. + Remove the engine oil cooler hose clamp, * Move the angine oil cooler forward. * Disconnect the cooling fan lead wire coupler. * Remove the oil hose clamp bolts. * Remove the cylinder head cover bolts. * Remove the cylinder head cover.2-4 PERIODIC MAINTENANCE. ‘The valve clearance specification is different for intake and ex- haust valves. Valve clearance must be checked.and adjusted, 1) at the time of periodic 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, ® or ®, im order to check the valve clearance, oF to adjust tappet clearance. Clearance read- ings should not be taken with the cam in any ether position than these two positions. * The clearance specication és for COLD state. * To turn the crankshaft for clearance checking, be sure to use a wrench, and rotate in the normal running direction. Alt spark plugs should be removed, + Rlamove the signal generator cover «Turn the crankshaft clockwise until the signal generator rotor line aligns on the signal generator sensor tip © Check the exhaust and intake camshaft line positions,+ When the lines face each other, measure * marked valve clear ances, * Tum the crankshaft 360° and measure « marked valve clears ances, + Measure the valve clearances with a thickness gauge. (BB) 09900-20803: Thickness gauge VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker of thinner shim, + Remove the intake or exhaust camshatts. ((7" 3-12) * 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 a replacement shim that will provide a clearance within the specified range, Fer 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 tappel. Be sure to check shim size with micromater to ensure its size. Reter to the tappet shim selection table (772-11, 2-12} for details. 1.70 re2:10_ PERIODIC MAINTENANCE NOTE: * Bo sure to apply engine oil fo tappet shim top and bottom faces. * When seating the tanpet shim, be sure to face figure printed surface to the tappet CAUTION Reinstall the camshafts as the specified manner. (ors) * After replacing the tappet shim and camshafts, rotate the en- gine $0 that the tappot is depressed fully. This wil squeeze out oil trapped between the shim and the tappet that could cause am incorreet measurement, then check the clearance again to ccenfirm that itis within the specified range. + After finishing the valve clearance adjustment, reinstall the fol- fowing parts. * Camshatts ... * Signal generator cover ... * Cylinder head cover .... F378 ore crs-7auu OBA posh eget ozs WHS, uw 02's OMS WHYS oso uw zo 8 ouRROp aN aera “uuinyon PERIODIC MAINTENANCE 2-11 ee et wpa aU SURED Le = Seapprretenehannys a 709 acne. oom oxen a aref is ve we 2 | 002, ALMVHO SIHL ISM OL MOH fore [ore Weare [ore rz] cra [ore | cow sre [ore [we [oor ‘ore [soe | ooe | aoa ‘ore we were, WEE] sre fore Gr] se [ere | se Wzlee| sre fore [soe [we art [sae [ont [ase sn [eon [| ose ort [sen foot [ore wees | @2orpa[erlar ore [eo | oe [ont [ost [sat [ore ‘oot [ert [ort [ort [orn [wt] oes] ea [OP ‘or [ore [ove ore [oc [ort | een orn wee} er2| ore | coe] ove | err | ora | cos | oe [ces [arn] cor | ont | ces Jorn Jews [avn | cea | oct | cee | et joan” aa] cot | sie | onz | sae | on | sor | oat | sen | ons | sea | ocr | son Nozes0-00e2)) 148 WIS 4Bdev (xxx-00090-26921) (ON WIHS Ladd, (SotvLNi] S76 NOLLOSTSS WIHS L3dd¥L peace aes On ove | ser | oer | sex | os |xans (INTAKE SIDE)212_PERIODIC MAINTENANCE WU Og —_pOsN oq oF a7 WS wu oz" 28 WUE IUPERid Wu EEO AUELBOID aNEA arawxs ‘uuureoo lore Feworuoy wy azs uiys wueseud yen uuyOD FEOHOR Uj BOUEIEOR REN tI) ae ‘928 ugys yuasosd aunseoyy ae 3 Ber] cre | ore| soz 07709 SI SNIONS. ‘B2UNWEP BHBA auNEwOIY "| eel ar [are tee tar SWEWHO SIHL BEM OLMON ‘sre | ove | soe | one | sox we|ooe |e for] a we less fort [eon] ort Brae wer fon fetter part ore [ore owt [oon | ort [sre [oct sro1z0 Te] sie | ore | soz Tor [sre [ore | ao ‘or08e0 We sve ore | soz | ove ‘ore [sen fort [sor | ore so0190 Bez] G2 | ove | se | oo | oa ot [or [ar cid We] ere fore [coe] oe | eon | oe or [er fore Sro1e0 are ore [ewe | coe err ort are cama) ‘are [oor [owe [sat er pert fore OID ery er oe [son foo [ser een poce ore [scr fore semEO (EXHAUST SIDE) ‘GRBNOSK LGR DY ONSON TESTO O: we forearms [ea en a CN a =r we woe | oo [owe ten | oo we eer fore [are er oor seu] ore| ses} ace | $05 09s | 354] cos | ars fort (o2as0-008zH) 135 VHS 13devi (xXx-00080-2692H) (ON WIHS Lda LisnvHxal 31¥L NOLLOT3S WIHS 13dd¥LENGINE OIL AND OIL FILTER Oil should be changed while the engine is warm. Oil fter replace- ment at the specified intervals, should be done together with the engine oil change. ENGINE OIL REPLACEMENT * Koop the motorcycle upright. * Place an oil pan below the engine, and drain oll by removing the oll drain plug © and filer cap * Tighten the drain plug @to the specified torque, and pour fresh oil through the oilfillar. The engine will hold about 4.2 L (4.43.7 USiimp at) of oil, Use an API classification of SF or SG oil with SAE 10W/40 viscosity. () oll rain plug: 23 N-m (2.3 kgt-m, 16.5 Ib-ft) + Start up the engine and allow it to: nin for several minutes at Idling speed. * Tum off the engine and wait about three minutes, then check the oil level through the inspection window. Ifthe level is below mark “L', add oil to "F"lovel. If the lovel is above mark “F”, drain il to F level. OIL FILTER REPLACEMENT * Drain the engine cil as described in the engine oil replacement procedure. * Remove the oll filter @ using the special tool. (09915-40810: Oi filter wrench * Apply engine oil lightly to the gasket af the new oil filter before installation,214 PERIODIC MAINTENANCE * Install the new oil fiter. Turn it by hand until you feel that the oil filler gasket has contacted the oil fiter mounting surface. Then, tighten the ail iter two full turns using the special too. NOTE: 7o properly tighten the oil filter, use the special fool. Never tighten the oil fiter by hand. + Add new engine oll and check the oil level as described in the engine oll replacenent procedure. NECESSARY AMOUNT OF ENGINE OIL: Oll change: 4.2L (4.4/3.7 US/imp qt) .8L (5.1/4.2 US/mp qt) Engine overhaul: 5.7L (6.0/5.0 US/Imp qt) CAUTION ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FIL- TER. Other manufacturer's oll filters may differ in thread specifications (thread diameter and pitch), fering per- formance and durability which may lead to engine dam- age or oil leaks. Also, do not use-a genuine Suzuki auto- mobile oil filter on this motorcycle. FUEL HOSE Inspect the fuol hose @ for damage and fuel leakage. If any de- fects are found, the hoses must be replaced. ENGINE IDLE SPEED NOTE: Make this adjustment when the engine is hot. + Start the engine, turn the throttle stop screw and set the engine idle speed as follows. GEE Engine idle speed: 1 100+ 100 rpm (gasket, tighten 2 turne,PERIODIC MAINTENANCE _ 2-15 THROTTLE VALVE SYNCHRONIZATION Inspect throttle valve synchronization periodically. (74-66) THROTTLE CABLE PLAY Adjust the thratlo cable play @) as follows. MINOR ADJUSTMENT Ast step: * Loosen the locknut @ of the throttle retuming cable (2 and fully tum in the adjuster ®. 2nd stop: * Loosen the locknut @) of the throttle pulling cable * Turn the adjuster @ in or out until the thoitle cable play (at the throttle grip) @ is between 2.0 = 4.0 mm (0.08 = 0.16 in), * Tighten the locknut @) while hokjing the adjuster ©), Throttle cable play A: 2.0 ~ 4.0 mm (0.08 ~ 0.16 in) 3rd step: * While holding the throttle grip atthe fully closed position, stowly turn out the adjuster @) of the throttle returning cable @ until resistance is fol * Tighten the locknut @D while holding the adjuster @, After the adjustment is completed, check that handlebar movement does not raise the engine idie speed and that the throttle grip returns smoothly and automatically, NOTE: ‘Major adjusiment can be made at the thrattlo body side adjustor.216 PERIODIC MAINTENANCE MAJOR ADJUSTMENT * Lift and support the fuel tank with its prop stay. (7° 4-48) + Loosen the lock nuts (D of the thrattle returning cable @ + Tum the returning cable adjuster @ to obtain proper cable play. * Loosen the lock nuts @ of the throttle pulling cable @. + Tum the pulling cable adjuster ®in or out until the thrattle cable play @ should be 2.0 ~ 4.0 mm (0.08 ~ 0.16 in) at the throttie grip. + Tighten the lock nuts @) securely while holding the adjuster ©). [EY Thrattie cable play @: 2.0— 4.0 mm (0.08 = 0.16 in) + While holding the throttle grip at the fully closed position, slowly tum the returning cable adjuster @) to obtain a cable slack of 1.0 mm (0.04 in). + Tighten the lock nuts @ escuraly. ‘After the adjustment is completed, check that handlebar mavement does not raise the engine idle speed and that the throttle grip returns smoothly and automaticall CLUTCH CLUTCH FLUID LEVEL * Keep the motorcycle upright and place the handlebars straight, '* Check the clutch fluid level by observing the lower limit line on the clutch fluid reservoir ‘+ I the level is found to be lower than the lower mark, replenish with BRAKE FLUID thal the following specification, B Specification and Classification: DOT 4 The clutch system of this motorcycle Is filled with a gly- col-based brake fluid. Do not use or mix different types of fluid such as sillcone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stared for a long periods. Check the clutch hose and hose joints for cracks and fluid leakage.BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT The elutch fluid circuit may be purged of air in the following man- ner. * Keep the motorcycle upright and place the handlebars straight. * Fill up the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dirt. Attach a pipe to the bleeder valve and insert the free end of the pipe into a receptacle, ‘Squeeze and release the clutch levar several times in rapid succession, and squeeze the lever fully without releasing it, Loosen the bleeder valve by turning it a quarter of a turn 80 that the fluid runs into the receptacie; this will remove the ten- sion of the cliteh lever causing ito touch the handlobar ip. ‘Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the ‘luid flowing into the receptacle no longer contains air bubbles, * Close the bleeder valve, and disconnect the pipe. Fill he reser- voir with brake fluid to the upper end of the inspection window, [BJ Air bleedier valve: 8 N-m (0.8 kgt-m, 6.0 Ib-ft) DRIVE CHAIN Visually check the drive chain for the possible defects listed be- low. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) * Loose pins + Excessive wear Damaged rollers. * Improper chain adjustment Dry or rusted links * Missing O-ring seals * Kinkod or binding links W any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace ihe arive chain anc sprockets as a set2:19 _PERIODIC MAINTENANCE CHECKING * Loosen the axle nut, + Loosen the chain adjuster lock nuts @. + Loosen the torque link nut (Fear) @. * Tense the drive chain fully by turning both chain adjusters ©. * Count out 21 pins (20 pitches) on the chain and maasure the distance between the two points. If the distance exceeds the ‘service limit, the chain must be replaced, Drive chain 20-pitch length: Service limit: 319.4 mm (12.87 In) ADJUSTING + Loosen or tighten both chain adjuster nuts (D until there is 20 — 30 mm(0.8= 1.2 in) of stack at the middle of the chain between the engine and rear sprockets as shown. The reference marks ® on both sides of the swingarm and the edge of each chain ‘adjustor must be aligned te eneure thatthe front and roar whos are correctly aligned, (BHI Drive chain slack: Standard: 26 ~ 30 mm (0.8 = 1.2 in) + Place the motorcycle on its side-stand for accurate adjustment * After adjusting the drive chain, tighten the axle nut @ and the torque link nut (Rear) @ to the specified torque. + Tighten both chain adjuster nuts @ securely (Ey Rear axle nut: 110 Nem (11.0 kgm, 79.6 Ibett) Torque link nut (Rear): 34 Nm (3.4 kgfim, 24.6 lb-ft) + Recheck the drive chain stack after tightening the axle nutPERIODIC MAINTENANCE 2-19 CLEANING AND LUBRICATING * Clean the drive chain with kerosina. If the drive chain tends to rust quickly, the intervals must be shortened, (CAUTION Do not use trichloroethylene, gasoline or any similar soivent. These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain. * Alfer washing and drying the chain, oil it with a heavyweight motor oil * Do not use any oll sold commercially as “drive chain oil". Such ol can damage the O-rings. * The standard drive chain is a RK GBS0GSVZ3 Suzuki recommends to use this standard drive chain as a re- placement. BRAKE BRAKE FLUID LEVEL CHECK + Keep the motorcycle upright and place the handlebars straight. * Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. + When the level is below the lowerlimit line, replenish with brake fluid that meets the following specification, B Spccification 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 petroleur- 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 Jong period of time. Ke fluld, Hf it leaks, will Interfore with sate running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and fluld leak- age before riding.220 PERIODIC MAINTENANCE BRAKE PADS FRONT BRAKE + The extent of brake pad waar can be checked by observing the grooved limit line ® on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (76-50) Replace the brake pads as a set, otherwise braking per- formance will be adversely affected. REAR BRAKE * The extent of brake pad wear can be checked by observing the grooved limit line @ an the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (cor 6-58) CAUTION Replace the brake pads as a set, otherwise braking per- formance will be adversely affected. BRAKE PEDAL HEIGHT + Loosen the locknut ©. + Tum the push rod @ until the brake pedal is 35 ~ 45mm (1.4 — 1.8 in} @ bolow the top of the footrest, + Tighten the locknut (D securely. [8] Rear brake master cylinder rod locknut: 18 Nem (1.8 kgtm, 13.0 ib-tt) GME Brake pedal height @: Standard: 3545 mm (1.4 = 1.8 in)BRAKE LIGHT SWITCH * Adjust the rear brake light switch so that the brake light will come on just before pressure is feit when the brake pedel is depressed. AIR BLEEDING THE BRAKE FLUID CIRCUIT Ar trapped in the brake fluid circult acts like @ cushion to abssorts a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake-caliper, The presence of air is indicated by “sponginess" of the brake lever and also by lack of braking force, Considering the danger to which such trapped air exposes the machine and rider, it is essential that alter remounting the brake and restoring the brake: system to the normal condition, the brake fluid circuit be purged of air in the following manner: FRONT BRAKE * Fil the master cylinder reservoir to the top of the inspection window, Replace the reservoir cap to prevent dirt fram enter- ing. * Attach a hose to the air bleoder valve and insert the froe ond of the hose into a receptacie. * Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bieader valve by turning ita quarter of a tum so ‘that the brake fluid runs into the receptacte, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the ai bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until fluid flow ing into the receptacte no longer contains air bubbles. NOTE: While bleeding the brake system, replenish the brake fluid in the resenoir as necessary. Make sure that there is always:some fluid Visiole in the reservoir.222 PERIODIC MAINTENANCE * Close the air bleeder valve and disconnect the hose: Fill the ‘reservoir with brake fluid to the top of the inspection window. (7) Air bieeder valve: 8 N-m (0.8 kat'm, 6.0 Ib-ft) REAR BRAKE * Blood air from the rear brake system as the same manner of front brake. NOTE: The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. TIRES TIRE TREAD CONDITION Oparating the motoreycle with excessively wom tires will decrease riding stability and consequently invite a dangerous situation. Itis highly recomended to replace a tire when the remaining depth of tire tread reaches the following specification. (09900-20805: Tire depth gauge Tire tread depth: Service Limit: FRONT 1.6 mm (0.06 in) REAR 2.0 mm (0.09 in}PERIODIC MAINTENANCE 223 ‘TIRE PRESSURE If the tire pressure is too high of too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadabilty and a longer tre life Cold infiation tire pressure is as follows, Cold inflation tire pressure Solo riding: Front: 250 kPa (2.50 kgt/em*, 36 psi) Rear: 250 kPa (2.50 kgticm’, 36 psi) Front: 250 kPa (2.50 kgticm®, 36 psi) Rear: 290 kPa (2.90 katlem?, 42 psi) Dual ridi (CAUTION. The standard tire fitted on this motorcycle is a 120/70 R17 (68W) for the front and a 190/50 ZR17 (73W} for the rear. The use of tires other than those specified may cause Instability. ts highly recommended to use the specified tires. TIRE TYPE BRIDGESTONE (BT020F F.....Front, BTO20R.....Rear) STEERING The steering should be adjusted property far smooth turning of the handlebars and safe operation. Qvertight steering prevents smooth turning of the handlebars and too loose stearing will cause poor stability. Check that there is no play in the front fork. Support the motorcycie so that the front whee! is off the ground, With the wheel facing straight ahead, grasp the loner fork tubes near the axle and pul forward. If play is found, readjust the steering. (7 6-31)224 PERIODIC MAINTENANCE FRONT FORK Inspect the front forks for ell leakage, scoring or scratches on the cuter surface of the inner tubes. Replace any defective parts. i necessary. (7 6-13) REAR SUSPENSION Inspact the rear shock absorbers for oil leakage and check that there is no play in the swingarm, Replace any defective parts if necessary. (7 6-41) EXHAUST PIPE BOLT AND NUT + Tighten the exhaust pipe bolts, muffler maunting bolt and nut to the: specified torque, [i] Exhaust pipe bolt @: 23 Nem (2.3 kgtm, 16.5 Ib-ft) Muffler connecting bolt 2: 24 Nom (2.4 kgf-m, 17.5 lb-ft) Muffler mounting bolt @: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) Exhaust pipe connecting bolt: 20 Nem (2.0 kgtim, 14.4 bf)PERIODIC MAINTENANCE 2.25 CHASSIS BOLTS AND NUTS Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle.:(7F°2-26 item Nem kgt-m No-ft Sisering siem head nut 65 65 470 Staoring stem lock nut 80 80 58.0 Front fork. upper clamp bor 2a 2g 165 @ Front fork lower clamp bolt 23 23 165 @ Front axle 100 10.0 725 © Front axle pinch bolt 23 23 16.5 @ Handlebar set bolt 23 23 16.5 @ Handlebar clamp bot 95 95 685 @ Front brake master cylinder mounting bolt 10 10 7.0 @ Front brake caliper mounting bolt 26 26 19.0 @ Brake hose union bolt (Front & roar) 23 23 165 {@ Caliper air bieader vatve (Front & Rear) 8 OB 6.0 (® Brake disc bolt 23 23 16.5 @ Rear brake caliper mounting bot 26 28 20.0 Rear brake master cylinder mounting bolt 410 1.0 73 lear brake master cylinder rod lock nut 18 18 413.0 &@ Front footrest bracket mounting bolt 26 26 19.0 @ Swingarm pivot nut 100 10.0 725 Torque link bolt and nut (Front) 28 28 20.0 Torque link bolt and nut (Rear) 34 34 24.6 ) Rear shock absorbar (Upper) 23 23 165 @ Rear shock absorber (Lower) Ea 34 245 @ Rear axle nut 100. 10.0 725 Rear sprocket nut 60. 6.0 43.5PERIODIC MAINTENANCE 2:27 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator ot its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- ance records kept at your dealorship should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit Difference 1180 kPa 880 kPa 200kPa ("' 8 tater) (ss sate) ( ) 168 psi 125 psi Low compression pressure can indicate any of the following conditions: * Excessively worn cylinder walls * Worn piston or piston rings * Piston rings stuek in grooves * Poor valve seating * Ruptured or otherwise defective cylinder head gasket Overhaul the engine in the following cases: * Compression pressure in one of the cylinders is less than 900 kPa (9 kg/om®, 128 pai). * The difference in compression pressure betwoan any two cyl- inders is more than 200 kPa (2 kgl/cm’, 28 psi). * All comprassion pressure readings are below 1 100 kPa (14 kat/om*, 156 psi) evan when they measure more than 900 kPa (8 kgttcm®, 128 psi) COMPRESSION TEST PROCEDURE NOTE: * Before resting the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted. * Mave tha engine warmed up before testing. * Make sure that the battery is fully-charged. Remove the related parts and test the compression pressure in the following manner. * Lift and support the fuel tank. (C7" 4-48) + Remove all the spark plugs. (7 2-5) * Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight, * Koop the throttle grip in the fully opened position, * Press the starter button and crank the engine for a few sec- nds. Record the maximum gauge reading as the cylinder com- pression. * Repeat this procedure with the othar eylindors, (09915-64510: Compression gauge set 09913-10760: Adaptor228 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts, OIL PRESSURE SPECIFICATION 300 ~ 600 kPa (3. 6.0 kgticm’, 43 — 85 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) H the oil pressure is: lower or higher than the specification, the following causes may be considered. LOw OIL PRESSURE * Clogged oi fiter * Gil leakage from the ail passage * Damaged O-ring * Defective oll pump * Combination of the above items HIGH OIL PRESSURE ~ Engine oil viscosity is too high * Clogged off passage * Combination of the above iterns OIL PRESSURE TEST PROCEDURE Start the: engine and check if the oil pressure indicator light is turned on, If the light stays on, check the oil pressure indicator light circuit. If the: circuit is:OK, check the oil pressure in the fol- owing manner. * Flemove the main oll gallery plug, + Install the oil pressure gauge and adaptor into the main il gal- lery. + Warm up the engine as fellows: ‘Summer: 10min. at 2 000 nimin. Winter: 20 min. at 2.000 rimin. * After warming up, increase the engine speed to 3 000 rifmin. (observe the tachometer), and read the oil pressure gauge. (09915-74520: Oil pressure gauge hose 09915-74540: Oll pressure gauge attachment (09915-77390: Meter (for high pressure) [7] oll galtery plug (M16): 35 N-m (3.5 ktm, 25.5 Ib-M)ENGINE 31 CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE iN PLACE... ENGINE REMOVAL AND INSTALLATION. ENGINE REMOVAL ... ENGINE INSTALLATION. ENGINE DISASSEMBLY .. ENGINE COMPONENTS INSPECTION AND SERVICE PAIR VALVE CYLINDER HEAD COVER CAMSHAFT. CAM CHAIN TENSION ADJUSTER... CAM CHAIN TENSIONER/CAM CHAIN GUID! CYLINDER HEAD AND VALVE: 3-26 CYLINDER... PISTON AND PISTON RING CLUTCH... GEARSHIFT SYSTEM. GENERATOR OL PUMP OIL PRESSURE REGULATOR/OIL STRAINER: CRANK BALANCER TRANSMISSION .. CRANKSHAFT AND CONROD. 345 CRANKCASE/OIL PAN 3-53 ENGINE REASSEMBLY 3-5632_ ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ‘The parts listed below can be removed and reinstalled without removing the engine trom the frame. Rater to- page listed in each section for removal and reinstallation instructions. ENGINE CENTER EM REMOVAL, INSPECTION | REINSTALLATION Gil cooler Cras — crs40 Exhaust pipe and mutter crs4 — rss PAIR valve ren craze cree Gylinder head cove ren 7323 73-78 ‘Cam chain tansion adjuster ors crs76 [Camshatt ors Cylinder Head ora ree Cylinder Piston Sreatar cover Oll temperature sensor Grank balancer ENGINE RIGHT SIDE ‘Signal generator cover crs — ors Signal generator rotor Crt — corse ‘Signal generaion(CKP sensor) CFs rT r363 Coating fan switeh CFs 75-10 orem hutch ever CFG = Css Gutch (plates) ors oraa7 ores Gearshift shat ora crs29 cre-6s Gilpump driven gear Cre — P35 ENGINE LEFT SIDE Goarshit' arma ras — ores Engine Sprocket cra? — cree Starter moior Crea CrTis r370 ‘Generator(Cover) crsis corsa corse Siarter ile gear Crate — Cre (Generator rotoriSiarter clutch Gear positon sensor Glich release oylinder CreesENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using aa steam cleaner. Engine removal is sequentially exptained in the following steps, Reinstall the engine by reversing the removal pro- cedure. * Remove the seat, ((7°6-3) + Remove the frame side cover. (776-2) + Remove the fuel tank. (774-48) + Remove the tray. + Remove the battery . * Drain engine oil. ENGINE 3934_ ENGINE OIL COOLER + Remove the cooling fan coupler (2P). ‘+ Remove the oil hose union and oll hose guide. * With the oil cooler bolts removed, detach the oil cooler and cool- ing fan, EXHAUST PIPE AND MUFFLER * Loosen the muttler connecting bolts, @ and @. * With the muffler mounting nuts (@ and @) removed, remove the: mutters (R, L). + With the exhaust pipe bolts and exhaust pipe mounting bolt () removed, remove the exhaust pipe assembly.IGNITION COIL * With the ignition ceil couplers and plug caps disconnected, re- ‘move the ignition coil brackets (RL). * Disconnect the CMP sensor. * Disconnect the breather hose. + Remove the throttie body assembly. (74-55) ELECTRIC PARTS * Disconnect the oil temperature sensor coupler (2P)D. * Disconnect the signal generator (CKP sensoryoll pressure switch coupler (SP) @). * Disconnect the cooling fan switch coupler (2°). * Disconnect the ground lead wire coupler.346 _ ENGINE * Disconnect the gear position switch coupler (3) @ and side- stand switch coupler (2P) 2. * Flemove the starter motor lead wire. GEARSHIFT LEVER * Disconnect the gearshift lever linkage, ENGINE SPROCKET * Remove the engine sprocket cover. * Disconnect the generator coupler (3) ®. + Remove the clutch release cylinder housing. Do not operate the clutch lever after removing the clutch release housin:ENGINE 37 + Remove the clutch push rod ®. * Remove the speed sensor rotor 2. + Remove the engine sprocket nut @) and the washer, * Remove the cotter pin. (For E-03, 28, 33) * Loosen the rear axle nut and the rear torque link nut + Loosen the left and right chain adjusters, * Push the rear wheel forward and make sure that the drive chain has enough slack. * Disangage the drive chain from the rear sprocket, * Remove the engine sprocket. ENGINE MOUNTING * Support the engine using an engine jack. * With each engine mounting bolts and nuts remaved.detach the frame dawn tube: * Draw aut the engine mounting shafts and remove the engi assembly from frame.34_ ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: NOTE: Hang the drive chain on the driveshaft when insialing the engine, ENGINE MOUNT * Install the engine and tighten the engine mounting bolts and nuts. ‘0d 99000-32050: THREAD LOCK “1342” Teu | Nm | ighm [in OBO 50 5.0 37 O8 55 55 | at ® 23 23. | 1 @ 88 88 65 o 85 as | 63* Apply a small quantity of THREAD LOCK to the drive shaft thread portion and tighten the engine sprocket nut @ to the specified torque. +i} 99000-32050: THREAD Lock “1342 () Engine sprocket nut: 115 Nem (11.5 kgfm, 83.2 Ib-ft) * Tighien the speed sensor rotor bolt @ to the specified torque. (¥] speed sensor rotor bolt: 20 Nom (2.0 kgt-m, 14.8 Ibeft) * Apply grease to the clutch push rod and clutch release piston, and install it. AG@x 99000-25010; SUZUKI SUPER GREASE “A” CLUCH RELEASE CYLINDER * Install the clutch release cylinder housing. (7) clutch rolease cylinder housing bo! 10 Nem (1.0 kgt-m, 7.4 lb-ft) GEARSHIFT LEVER * Install the engine sprocket cover and the gearshift lever. Gearshift lever hight: 40 — 50 mm (1.6 — 2.0 In)3410 _ ENGINE EXHAUST PIPE/ MUFFLER * Install the exhaust pipes and mutfiers as shown in illustration. CAUTION Replace the gaskets with new anes. Maun 2augim, 65m) 23.Nm (23 hat, 165 Bet) 20 teen 20 kgten, 18.4.0) OIL COOLER + Fit a new O-ring. * Install the oil cooler hoses. 7] oll cooter union bolt: 10 N-m (1.0 katm, 7.4 Ib-ft) + Install and acjust the following items. * Engine oil (72-13) * Throttle valve synchronization (7-466) * Throttle cable play (C7"2-15) * Idling adjustment (7"2-14) * Drive chain siack (32-17) * Wiring hamess, cables and hoses (7"8-16 - 29)eNGNE 311 ENGINE DISASSEMBLY CAUTION. Identify the position of each removed part. Organize the parts in their respective groups (¢.g., intake, exhaust) 50 | tet trey cals be veliekalie in thekr crigioal postfone: | CYLINDER HEAD COVER * Remove the PAIR reed vaive cover and reed valve. * Remove the oil hoses. + Remove the spark plugs. (72-5) + Remove the cylinder head cover. * Remove the dowel pins and O-rings, SIGNAL GENERATOR COVER * Remove the signal generator cover and gasket312_ ENGINE + Set the #1 cylinder at TDC. ‘Turn the crankshaft to bring the "T"line on the rotor tothe tip of signal generator, and the lines:on camshaft facing outside. + Remove the cam chain tension adjuster cap, the washer, the spring and the steel ball * Remove the cam chain tension adjuster. * Remove the oil pipe ©. + Remove the cam chain guide @ and camshaft journal holders. CAUTION Be cure to loosen + Remove the cam chain guide,CYLINDER HEAD * Remove the ail hese, Loosen the cylinder nut ®. + Remove the cylinder head bolts (M6). + Remove the cylinder head bolts and nuts. NOTE: When loosening tne eylinder head bolts and nuts, loosen each bolt tle by title diagonally. * Ramove the eylindar head. CYLINDER * Draw out the oll return pipes (R, L). + Remove the cylinder nut @.14_ ENGINE ‘+ Flomove the cylinder head gasket and dewel pins. * With both end cf cylinder evenly rised, remove the cylinder. PISTON + Putthe rag under the piston so as not to drop the parts into the crankcase, remove the piston pin circlip, + Draw out the piston pin, remove the piston. + Remove the gasket and dowel pins. OIL TEMPERATURE SENSOR + Remove the oil temperature sensor D. STARTER MOTOR * Remove the starter motor, BREATHER COVER + Remove the breather cover.SIGNAL GENERATOR * With the rotor held, remove the signal generator rotor bolt. * Flemove the signal generator. + Remove the oll pressure switch @. OIL FILTER + Remove the oi fiter. ( 09915-40610: O11 titer wrench COOLING FAN SWITCH + Remove the cooling fan switch.3416 _ ENGINE CLUTCH + Remove the clutch cover, + With the clutch spring bolts removed, detach the clutch springs and clutch pressure pl + Remove the clutch push piece (, the bearing 2) and the thrust washer @), + Remove the clutch push rod @, NOTE: If its difficult to pull out the push rod @. use a magnetic hand or a wire. + Remove the clutch drive plates and the driven pla + Remove the spring washer and the spring washer seat. * Unlock the clutch sleeve hub nut. * Hold the clutch sleeve hub with the special tool. (09920-53740: Clutch sleeve hub holder + Remove the clutch sleeve hub nut,* Remove the wave washer @, the back torque limiter @ and the clutch sleeve hub, * Remove the washer (@) and the primary driven gear assernbly + Remove the spacer, the bearing and the washer. OIL PUMP DRIVEN GEAR + Remove the ciclip @) and the washer @ * Remove the oll pump driven gear, NOTE: De not drop the eirelip, the pin and the washer into the erank- casa, + Remove the pin @ and the washer @). GEARSHIFT SHAFT * With the circlip removed, remove the gearshift shaft assembly. * Romove the gearshift cam plate (D and the gearshift cam stop- per @.318 _ ENGINE GENERATOR COVER + Remove the generator cover. * Remove the starter idle gear and its shaft. GENERATOR ROTOR/STARTER CLUTCH * Hold. the generator rotor ‘with the special tool and remave the generator rotar bolt, (By 09920-44530: Rotor holder ‘+ Remove the generator rator with the special tact (BB 09930-30450: Rotor remover (09930-44530: Rotor holder GEAR POSITION SENSOR + Remove the gear position sensor. ‘+ Remove the switch contacts and the springs.ENGINE 3419 OIL PAN * Remove the oil pan. * Remove the oll pressure regulator. + Remove the oil pipes, @ and @. + Remove the crank balancer guard @). * Remove the oll strainer @) and its O-ring, CRANK BALANCER * With the balancer lever bolt removed, draw out the crank bal- ancer shaft and remove the crank balancer,320_ ENGINE CRANK CASE + Rlemove the lower crankcase bolts, (6 mm) and (& mm). ‘+ Remove the upper crankcase bolts, (6 mm) and (8 mm). + Remove the erank journal bolts (9 mm). NOTE: Loosen the erank journal bolts in the descending order of the number on crankcase. + Remove the lower crankcase, GEARSHIFT CAM AND GEARSHIFT FORK + With the screws removed, draw out the gearshift fork shatt and remove the gearshift fork, Ol PUMP. + Remove the oil pump.+ Flerove the O-rings and the dowel pins, CRANKSHAFT + Romove the crankshaft thrust bearings @. + Remove the crankshaft together with the cam chain, TRANSMISSION + Remove the countershatt and the driveshaft, * Remove the G-ring @ and the dowel pins @.322_ ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CAUTION Identity the position of each removed part. Organize the parts in their respective groups (/.¢.,intake, exhaust,No.1 or No.2) so that they can be installed in their original locations. PAIR VALVE REMOVAL AND INSTALLATION Remove the fuel tank (74.22) + Disconnect the PAIF valve hases and remove the PAIR valve. INSPECTION PAIR REED VALVE HOSE * Inspect the PAIR valve hose for damage and connection. PAIR REED VALVE * Inspect the reed valve for the carbon deposit, + If the carbon deposit is found in the reed valve, replace the PAIR control valve with a new one. PAIR CONTROL VALVE * Inspect that air flows through the PAIR control valve air inlet port to the air outlet ports. * If air does not fiow out, replace the PAIR valve with a new one. * Connect the vacuum pump gauge to the vacuum port of the Control valve as shown in the photograph, * Apply negative pressure slowly to the control valve and inspect the air flow, « If air does not flow oul, the control valve is in normal condition. * If the control valve does not function within the specification, replace the control valve with a new one, Negative pressure range (Standard): 38.7 — $3.3 kPa (280 - 390 mmHg) (09917-47010: Vacuum pump gauge CAUTION hand operated vacuum pump gauge to prevent the contro! valve damage.CYLINDER HEAD COVER CAM POSITION SENSOR * Inspect the cam position sensor for abnormal condition. + With the grease applied to the O-ring, install the cam position sensor, (¥) Cam position sensor bolt: 10 N-m (1.0 kgf-m, 7.4 Ib-ft) ‘Fix, 99000-25010; SUZUKI SUPER GREASE OL GALLERY PLUG * Inctall the gasket and the oil gallery plug. (7 Ol gallery plug: 14 N-m (1.4 kgf-m, 10 Ib-tt) CAMSHAFT CAMSHAFT IDENTIFICATION The exhaust camshaft can be distinguished from that of the intake by the embossed letters "EX" (tor exhaust) as against letters “IN” (for intake). CAM WEAR * Check the camshaft for wear or damage. * Measure the cam height @ with a micrometer. 09900-20202: micrometer (25-50 mm) [EZ) Cam height @: a e Service Limit; (IN,) : 34.98 mm (1.378 In} (EX,) : 33.88 mm (1.939 In) CAMSHAFT RUNOUT * Measure the runout using the dial gauge. + Replace the camshaft if the runout exceeds the limit. (5) 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand (09900-21304: V-block set (100 mm) Camshaft runout: Service Limit (IN & EX): 0.10 mm (0.004 in)24_ ENGINE CAMSHAFT JOURNAL WEAR * Determine whether or nat each journal is worn down to the limit by measuring the oll clearance with the camshatl installed in place. * Use the plastigauge to read the clearance at the widest por- tion, which is specified as- follows Camshaft journal oll clearance: Standard: (IN & EX): 0.022 - 0.066 mm {0.0013 —0.0026 In) Service Limit: (IN & EX): 0.150 mm (0.0059 in) (09900-22301; Piastigauge 09900-22302: Plastigauge « Tightan the camshatt journal holder bolts evenly and diago- nally to the specified torque, [8] camshaft journal holder bolt: 10 N-m (1.0 kgm, 7.4 lb-ft) NOTE: Do not rotate the camshaft with the plastigauge in place. Flemove the camshaft holders, and read the width of the om- pressed plastigauge with envelope scale. © This measurement should be taken at the widest part, If the camshaft journal oll clearance measured exceeds the lini, measure the inside diameter of the camshatt journal holder and outside diameter of the camshaft journal. Roplace the camshaft or the cylinder head depending upon which one exceeds the specification. Journal holder 1.0: Standard: (IN & EX}: 24.012 - 24.025 mm (0.9454 —0.9459 in) (09000-20602: Dial gauge (1/1000, 1 mm) (09900-22403: Small bore gauge (18 - 35 mm) Camshaft journal 0.0. Standard (IN & EX): 23.959 - 23.980 mm (0.9433 - 0.9481 In) (BB 09900-20205: Micrometer (0 — 25 mm)ENGINE 325 CAM SPROCKET * Inspect the sprocket teeth for vrear. * If they:are worn, replace the sprockel/camshaft assembly and cam chain asa sot * Install the cam sprocket to the camshaft. ((7°9-75) * Apply a small quantity of thread lock to the cam sprocket bolt and tighten it to the specified torque. ‘eZ 99000-22090: THREAD Lock "1303" [F) cam sprocket bolt: 25 N-m (2.5 kgm, 18 lb-ft} CAM CHAIN TENSION ADJUSTER INSPECTION ‘+ Remove the cam chain tension adjuster cap bolt. “* Check that the push rod slides smoothly when releasing stop- per. ‘© If it does not slide smosthly, replace the cam chain tension ad- te, juster with a new one. CAM CHAIN TENSIONER \ INSPECTION Q * Check the contacting surface of the cam chain tensioner. ER * Ifitis worn or damaged, replace it with a new one. ES oy CAM CHAIN GUIDE INSPECTION % * Check the contacting surfaces of the cam chain quides. * I they are worn or damaged, replace them with the naw ones,26 ENGINE CYLINDER HEAD AND VALVE VALVE AND VALVE SPRING DISASSEMBLY + Remove the tappets and shims by fingers or magnetic hand. Identify the position of each removed part. * Using special tools, compress the valve springs and remove the two cotter halves (D from valve stem. (By 09916-14510: valve lifter (09916-14521: Valve lifter attachment (24 mm) 09916-84511: Tweezers CAUTION Be careful not to damage the tappet sliding surface with the special tool. * Remove the valve spring retainer 2) and valve springs @). ee * Pull out the valve @) from the other side, % € + Remove the spring seat &, OO @ @ * Remove the oil seal ®) CAUTION Do not reuse the removed oll seal. CYLINDER HEAD DISTORTION + Decarbonize the combustion chambers. * Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading al several places indicated. + It the largest reading at any position of the straightedge ex- ceeds the limit, replace the cylinder head. (09900-20803: Thickness gauge Cylinder head distortion: Service Limit: 0.20 mm (0.008 in)ENGINE 327 VALVE STEM DEFLECTION * Lift the valve about 10 mm (0.39 in) from the valve seat. + Measure the valve siem deflection in two directions, pempen- dicular to each other, by positioning the dial gauge as shown. + If the detiection measured exceeds the limit, then determine whether the valve or the guide should be replaced with a new one. (09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand Valve stem deflection (IN & EX): Service Limit: 0.35 mm (0.014 In) VALVE STEM WEAR * Ifthe valve stem is worndoven to the limit, as measured with a micrometer, replace the valve * I the stem is within the limit, then replace the guide. * Affor replacing valva or guida, be sure to recheck the dotiec= tion. (8 09900-20205: Micrometer (0 - 25 mm) Valve stem 01 Standard (IN) : 4.475 - 4.490 mm (0.1762 — 0.1768 in) (EX): 4.455 4.470 mm (0.1754 — 0.1760 In} NOTE! It valve guides have to be removed for replacement alter inspect- ing relatad parts, carry out the steps shown in vaive guide servic- ing. (F°3-29) VALVE STEM RUNOUT * Support the valve using V-blocks and check its runout using the dial gauge as shown, + Ifthe runout exceeds the service limit, replace the valve. (09900-21304: V-biock set (100 mm) Valve stem runout: Service Limit: 0.05 mm (0.002 In) VALVE HEAD RADIAL RUNOUT * Place the dial gauge ata right angle to the valve head face and measure the valve head radial runout, * I it measures more than the service limit, replace the valve, Valve head radial runout: ‘Service Limit: 0.03 mm (0.001 in) VALVE FACE WEAR + Visually inspect each valve face for wear. Replace any valve with an abnormally worn face: The thickness of the valve face decreases as the face wears, Measure the valve face (D, I itis out of specification, replace the valve with @ new one, ( 09900-20102: Vernier calipers Valve head thickness (D: Service Limit: 0.5 mm (0.02 in)$28 ENGINE, VALVE SPRING The force of the coll springs keeps the valve seat tight, Weakened springs result in reduced engine power output, and often account for ttre chattering noise coming from the vaive mechanism. * Check the valve springs for proper strength by measuring their free length and also by the forée required to compress them, * If the-spring length is less than the service limit, or if the force ‘required to compress the spring does not fall within the range ‘specified, replace both the inner and outer springs as a set (B 09900-20102: Vernier calipers Vaive spring free length (IN & EX): Service limit: Inner: 38.6 mm (1.52 in) Outer: 40.6 mm (1.60 In) BAZ Vaive spring tension (IN & EX): Standard: Inner: 49 ~ 59 N, 4.9 ~ 5.9 kgf 23.9 mm (10.8 — 13.0 Iss 1.18 in) Outer: 136 ~ 156 N, 13.6 - 15.6 kgt/ 93.4 mm (30.0 ~ 34.4 Ibs! 1.31 in)ENGINE 329 VALVE GUIDE SERVICING * Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust camshaft side. (62 09916-59310: Vaive guide removeriinstaller NOTE: * Discard the removed vaive guide subassembties. * Only oversized valve guides are available as replacement parts. (Part No. 11545-18072) * Refinish the valve guide holes in cylinder head with the reamer and handle. (09916-24561: Valve guide reamer 09916-34842: Reamer handle (cAUTIO! When refinishing or removing the reamer from the valve guide hole, always tum it clockwise. + Apply engine oll to the valve guide hole. * Drive the valve guide into the hole using the special tool ( 09916-49210: Valve guide Installer/remover NOTE: Install the valve guide until the ring ® contacts with the eylinder head. (CAUTION Failure to oll the vaive guide hole betore driving the new guide into place may result in a damaged guide or head. * After installing the valve guides, refinish their quiding bores us- ing the reamer. * Clean and oi the guides after reaming. (09916-3310: Valve guide reamer 09916-34542: Valve gulde reamer handle NOTE: Insert the reamer from the combustion chamber and always tum the reamer hanale clockwise.$90_ ENGINE. VALVE SEAT WIDTH INSPECTION * Visually check for valve seat width on each valve face. + Ifthe valve face has worn abnormally, replace the vaive. * Coat the valve seat with Prussian Blue and set the valve in place, Rotate the valve with light pressure, + Check that the transferred blue on the valve face is uniform all around and in center of the valve face. (2) 09916-10911; Valve rapper set If the seat width @ measured exceeds the standard value, or ‘seat width is not uniform raface the seat using the seat cutter. GE Vaive seat wicth ‘i: Standard: 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) H the valve seat is out of specification, recut the seat. VALVE SEAT SERVICING The vaive seats for both the intake and exhaust valves are ma- chined to four different angles. The seat contact surface Is. cut at 45° EXHAUST emmaust (09916-21111: Valve seat cutter set (09916-20630: Valve seat cutter (N-126) (09916-20640: Solid pilot (N-100-4.5) NOTE: The valve seat cuttars (N-121), (NN-122) and (N-111) are included (nthe valve seat cutter set (09916-21111). CAUTION The valve seat contact area must be inspected after each cut, + When installing the solid plot @, rotate it sight eedENGINE 3431 INITIAL SEAT CUT * Install the 45° cutter @, attachment @ and Thandle @). * Using the 45* cutter, descale and clean up the seat. totate the cotter one or two tums. + Measure the valve seat width (® after every cut. * Ifthe valve seat is pitted or burned, use the 45° cutter to condi- tion the seat some more. NOTE: Cut only the minimum amount necessary from the seat to pre- vent the possibilty of the valve stem becoming too clase to the camshatt. ‘TOP NARROWING CUT * Ifthe contact area (is too high on the valve, or iit is too wide, use the 15° (for the exhaust side) and the 30° (for the intake side) to lower and narrow the contact area. Contact area to high aed 109 eon ta of valve 1569 30° (i)$32 ENGINE. BOTTOM NARROWING CUT (IN.) © If the contact area (is too wide or too low, use the 60° cutter to narrow and raise the contact area. FINAL SEAT CUT * Ifthe contact area (is too low or too narrow, use the 45° cutter to raise and widen the contact area, NOTE: After cutting the 15% 30° and 60° angies, itis possible that the valve seat (45°) is too namow. I so, recut the valve seat to the comect wich. * Alter the desired seat position and width Is achieved, use the 445° cutter very lightly to clean up any burrs caused by the pre- vious cutting operations. ‘CAUTION Do not use lapping compound atter the final cutis made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surtace for the final seating of the valve which will occur during the first few seconds of engine operation NOTE: Alter servicing the valve seats, be sure to check the vaive clear- ance after the cylinder head has been reinstalled. (2-6) + Cloan ang assemble the head and valve components, Fill the intake and exhaust ports with gasoline to-check for leaks. * If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the vaive from sealing. PCN Always use extreme caution when handling gasoline.