FOREWORD This manual conans an inroductry easerpton ‘on the SUZUKI GSX1300R and procedures forts Jngpection’sarvice and overhaul of is main com ponents, ‘ther information considered as generally known [not included, Fea fo GENERAL INFORMATION section ff ‘milarize yoursel wih the motorcycle and ts manto- hance. Use tis saction as wel as othar sections to {Use as a guide for proper inspection and service, ‘This marisa! wil help you know the motoreyole bet: fer so that you can assure your customers of fast ‘and reliable service, * This manual has been prepared on the basis ofthe latest specifiations athe time of pub- ‘eation. if modifications have been made since then, ferences may exist betwoon the Content this manual and the actual motor eycle. * tistravons inthis manual are used 10 show the basic pnncples of operation and work pro (odures. Thay may not reprecent the actual ‘motoreycle exacty in dea. {Th manuel is writen for persons who have ‘enough kowiedge, skis and tools, iolud. | Ing special tools, for sorvieng SUZUKI mo- toreyeles.Iyeude not have the proper know ledge and tools, ask your authorized SUZUKI ‘motoraycle dealer to help you. FOCI inexparionced mechanics or mechanics ‘without the proper tools and equipment may Not be able to properly perform the services eseribed in this manuel. Improper repair may rosultin injury to the mechanic and ma render the motoreyele unsafe for the ri land passenger. IMPORTANT 7a! Suzuki motorcycles with engine is- placoment of 50 ce or greater are subject Ev ronmental Protection agency emission regulations Those regulations sot speci standards for exhaust emission output levels a6 well as paricular servc~ ing requirements. This manual includes speciio. infomation required to property inspect are ser ‘oe GSX1200F in accordance with ail EPA regua- lions. It's strongly recommended that the chapter fn Emission Cantal, Period Servicing and Carbu- fetion be thoroughly reviewed before any type of Sorvce work s performed, Furtner information concerning the EPA emission Fagulations and US. Suzukl' smiasion contol pro- ‘4 can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANLUAL/SEAVICE BULLE- TN. ‘SUZUKI MOTOR CORPORATION ‘Motoreycle Service Depariment (er lo I) 4 GENERAL INFORMATION EB PERIODIC MAINTENANCE eB ENGINE 13 FLSYSTEM AND INTAKE AIR Syeren COOLING AND LUBRICATION System CHASSIS | 6 ELECTRICAL SYSTEM EZ ‘SERVICING INFORMATION E I EMISSION CONTROL INFORMATIONHOWTO USE THIS MANUAL, TO LOCATE WHAT YOU ARE LOOKING FOR: 1.The text ofthis manual is divided into sections. 2.The section les are ised in the GROUP INDEX, Holding the manual as shown at the right will allow you to find the frst page ofthe section easy. 4.The contents are listed onthe fist page of each section tehelp find the fem and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each systom or unit, ists exploded view. Work instructions and other service information ‘such as the tghlening torgue, lubricating points and locking agent points, ae provided. Example: Front whee! Bate die Bima 8 bear Behm @rerewton @ Fox avo (B bn de ot Fan) Tem_[ kgtm [ 1b 00_| 100 | 725 23 [ea [ies | jale\al‘SYMBOL sted in the table below are the symbots indicating instructions and other information necessary for servio- ing. The meaning of each symbol is also included in the table. SvmeoL DERINTION SYMBOL DEFINITION : Torque contro equ, Use engine coolant Data bende tindeates species | MELE] torque oes va | SBS ‘Apply molybdenum oil solution. | ((Moxture of engine oll and SUZUKi MOLY PASTE in a ratio of 1:1) ‘Apply or use brake fi. 99000-25030 (For USA) 99000-25010 (For the other countries) ‘Apply SUZUKI MOLY PASTE, Measure in curtent range. 98000-25140 (enn) ‘Apply SUZUKI SUPER GREASE "A wy Measure in voltage range. 99104-81140 (for USA) Apply SUZUKI BOND 12078" Measure in diode test range. 99000-31140 (forthe othr counties) c Apply THREAD LOCK SUPER Measure in continuity test range. ‘Apply THREAD LOCK “1342, Use special tool 99000-32050 Apply THREAD LOCK SUPER Incicaton of service data. seo 99000-32130 AabahaGaaaABBREVIATIONS MAY BE USED IN ‘THIS MANUAL a H ‘ABDC. ‘Ator Bottom Dead Center He ac Alternating Current ACL Alt Cleaner, Air Cleaner Box APL ‘American Potroleum Instiule IAC Valve TOO. Alter Top Dead Center Actuator [ATM Pressure: Atmospheric Pressure ‘Atmospheric Pressure IAP Sensor ‘Sensor (APS) NF ‘Ar Fuel Mivture IAT Sensor B 6 BBDC Bolore Bottom Dead Center BTDC Botore Top Dead Conter L Be Battery Positive Votage Loo LED c ‘CKP Sensor : Crankshaft Position Sensor uy (CKPS) Mw xr Circuit MAL-Code GLP Switch: Clutch Lever Position Switch (Clutch Swich) Max CMP Sensor: Camshaft Position Sensor Mi (cs) co Carbon Monoxide Min cpu ental Processing Unit N D NOx oc Direct Current Duc Dealer Mode Coupler ° DoHe Double Over Head Camshaft = OHC DAL Daytime Funning Lignt OPS E Pp ECM Engine Control Module Pov Engine Control Unit (ECU) (1 Control Unit) ECT Sensor: Engine Coolant Temparoture ‘Sensor (ECTS), Water Temp. RH ‘Sensor (WTS) OM EVAP Evaporative Emission EVAP Canister : Evaporative Emission s Canister (Canister) SAE F FL Fuel Inlection, Fuel Injector = T FP. Fuel Pump TO Sensor FPR Fuel Pressure Regulator TP Sensor FP Relay Fuol Pump Relay 6 v GEN Generator vesv GND Ground v> GP Switch _: Gear Positon Switch vv Hydrocarbons Intake Ar Control Valve Actuator Intake Ar Pressure ‘Sensor (IAPS) Intake Air Temperature ‘Sensor (IATS) Ignition Liquid Crystal Display Light Emitting Diode (Malfunction Indicator Lamp) Left Hand Maifunction Code (Diagnostic Code) Maximum Maifunction Indicator Lamp (LED) Minium Nitrogen Oxides ‘Over Head Camshaft il Pressure Switch Positive Grankcase Ventilation (Crankcase Breather) Fight Hand Read Only Memory Socioty of Automotive Engineers Tip Over Sensor (TOS) Throttle Postion Sensor crs) Vacuum Control Solenoid Valve Vacuum Damper Vacuum Transmiting ValveSEA-TO-FORMER SUZUKI TERM(ONLY FOR U.S.A.) “This table lists SAE ( Society of Automotive Engineers)J1890 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as thelr former SUZUKI names. FULLTERW [ABBREVIATION FORMER SUZUKITERM x ‘Ai Cleaner ACL ‘Ar Cleaner, Ai Cleaner Box 8 Barometric Pressure BARO Barometric Pressure, Almospheri Pressure Battery Postve Votage ee Battery Voltage, +8. c Camshatt Positon Sensor CMP Sensor | Camshaft Postion Sensor(CMPS) Crankshaft Postion Sensor KP Sensor | Crankshaft Postion Sensor(CKPS), rank Angle . Data Link Connector pic Dealer Mode Coupler Diagnostic Test Mode om = Diagnostic Trouble Code ore Diagnostic Code, Malfunction Code E Electronic Ignition el = Engine Contro! Module ECM Engine Control Module (ECM) | Contro! Unt, Engine Control UniECU) Engine Coolant Level EOL Coolant Level Engine Coolant Temperature ecr Coolant Temperature, Engine Coolant Tem- perature Water Temperature Engine Speed RPM Engine Speed(RPM) Evaporative Emission EvAP Evaporative Emission Evaporative Emission Canister EVAP Canister] — (Canister) Purge Valve Purge Valve | Purge Valve(SP Valve) F Fan Control Fo _ Fuel Level Sensor — Fuel Level Sensor, Fuel Level Gauge Fuel Pump FP Fuel Pump(FP) 6 Generator GEN Generator Ground GND Ground(GNO,GRO)SAETERM FULLTERM [ABBREVIATION| FORMER SUZUKITERM ' Idle Speed Conti! Ignition Control Ignition Control Module Intake Air Tomporature M Maifunction indicator Lamp Manitol Absolute Pressure ‘Mass Air Flow ° (On-Board Diagnostic Open Loop Pp Programmable Read Only Mernory Pulsed Secondary Air Injection R Fandom Access Memory Read Only Memory s ‘Secondary Air Injection T Throtle Body ‘Throtle Body Fuel Injection ‘Throtle Position Sensor v Votage Regulator Volume Air Flow isc ic iow wr mL Map MAF 008 OL PROM PAIR AIR TB. Tet TP Sensor vA VAF Electronic Spark Advance(ESA) Intake Air Temperature(lAN), Air Temperature LED Lamp ‘Malfunction Indicator Lamp(MIL) Intake Air Pressure, Intake Vacuum Air Flow SeltDiagnosis Function Diagnostic Pulse Air Control (PAIR) Throttle Body(TB) “Throtle Body Fuel Injection(TBI) “TP Sensor(TPS) Voltage Regulator Air FlowGENERALINFORMATION. 11 GENERAL INFORMATION ——— contents ———_________ WARNING/CAUTION/NOTE .. GENERAL PRECAUTIONS ‘SUZUKI GSX1300RX ('99-MODEL). SERIAL NUMBER LOCATION .... FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .. FUEL ENGINE OIL. BRAKE FLUID. FRONT FORK Oll 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... SEVARMRHRAABRAMAHHHAANH‘12_ GENERAL INFORMATION. WARNING/CAUTION/NOTE Please read tis manual and folow Is instructions carefuly. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes: ‘sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained inthis manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, ofthe motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mecharical safety principles. If you ‘are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad- Vie. (GENERAL PRECAUTIONS “Proper service and repair procedures are Important for the 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 out- doors. * when working with toxic or flammable materials, make sure that the area you work in Is woll- Ventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system tuntil they have cooled. * ‘After servicing the fuel, oll, engine coolant, exhaust or brake systems, check all ines and fittings related to the system for leaks. fety of the service mechanicGENERAL INFORMATION 1-3 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or th lent. * When removing parts that are to be reused, Keep them arranged in an orderly manner so that they may be reinstaled in the proper order Be sure to use special toots when instructed. Make sure that all parts used in reassembly are clean. Lubricate them when specified. Use the specified lubricant, bond, or sealant. When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and 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, sel-locking nuts, cotter pins, ciclips, and certain other parts as specified, be sure to replace them with new tones. Also, bofore 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 itis completely seated in its groove and securely fitted. Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a throad is smeared with them. After reassembling, check parts for tightness and proper operatior quiver 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 dispose of used motorcycles and parts.414_GENERAL INFORMATION SUZUKI GSX1300RX ('99-MODEL) LEFT SIDE Diterence between photograph ae ata moteeeledepensson the mara SERIAL NUMBER LOCATION The frame serial number or VILN. (Vehicle Identification Num ber) @ is stamped on the right side of the steering head pipe The engine serial number @ is located on the rear side of the crankcase. These numbers are required especialy for register- ing the machine and ordering spare parts.GENERAL INFORMATION 1-5 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (For U.S.A. model) 1.Use ony unloaded gasoline ofa least 87 pump octane (E{M) method or 91 octane or higher rated by the research method. 2 2.Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3.Use of blended gasoline containing MTBE (Methy!Tertary Butyl Ether is permite. 4.Use of blended gasoline’alcohol fuel is permitted, provided thatthe fue contains not more than 10% etha- ‘al. Gasonelaicohol fuel may contain up to 5% methanal if appropriate cosolvents and corosion inhibitors fare present int 5. the performance ofthe vehicle is unsatisfactory while using blended gasolinelalcohol fuel, you should ‘wit to aleohol-ree unleaded gasoline. 6.Fallur to folow these guideline could possibly void applicable warranty coverage. Check with your fuel ‘supplier to make sure thatthe fuel you intend to use meets the requirements lsted above FUEL (For Canadian model) Use oiy unleaded gasoline of at least 87 pump octane (FM) method or 9 octane or higher rated bythe research method, FUEL (For the other models) ‘Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom- mended ENGINE OIL (For U.S.A. model) ‘SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Insitute) service classification. The rec- ‘ommended viscosity is SAE 1OW/40. an SAE 10WI40 al isnot available, select and alternative according to the right chart ENGINE OIL (For the other models) Use a premium quality 4-stroke motor oll to ensure longer ser- vies lif of your motoreyclo. Use only olls which are rated SF or ‘SG under the API service classification. ‘The recommended viscosity is SAE 10W-40. If an SAE 10W-40 ‘motor oil is not availabe, select an alternative according to the following chart BRAKE FLUID Use DOTS brake fui, Sica i hon naa? tan aS tana Wi a RETRO Ln TNT OF facture, donot tae or mi ferent ype ould suchas slleonebased and pettoleun-hased tld for retling the sytem, ctherwae serious damage wl esl ‘Done uo any bre fd abn fom olor ee or uwwobd octalre Never rvace bake ld aft over fom @ previous servicing, whi hasbeen stored fora fg pared FRONT FORK OIL ‘Use SUZUKI FORK OIL Lo1 or an equivalent fork oil1+8_GENERAL INFORMATION. ENGINE COOLANT Use an antsreeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only, WATER FOR MIXING Use cisiled water only. Water other than distiled water can corrode and clog the aluminum raciator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust Inhabit as well as ant-treeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): 2 950 mi (3.1/2.6 US/Imp qt) For engine coolant mixture information, refer to cooling system section. (<7 6-2) (@ CAUTION] _ Mixing of ant-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its _| ‘ficiency. the anti-reeze/engine coolant mixing rato Is below 0%, rust inhabiting performance is greatly reduced. Be sure to mix It above 50% even though the atmospheric temperature does not go down tothe freezing point 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 BREAKIN" before subjecting the engine 0 maximum stresses. The future performance and reliably of the engine depends on the care and restraint exercised during its early lite, The general rules are as follows, + Keep to these break-in procedures: Initial 800 km (500 miles): Below 5 500 r/min Up to 1.600km (1 000 miles): Below 8 000 r/min Over to 1 600 km (1 000 miles): Below 11 000 r/min ‘+ Upon reaching an edometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throtle ‘operation. However, do not exceed 11 000 rin at any time, CYLINDER IDENTIFICATION ‘The four cylinders of this engine are identilied as No.1, No2, No and No. cylinder, as counted from lft to right (as viewed by the rider on the seat)GENERAL INFORMATION 1-7 INFORMATION LABELS1:8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS ‘Overall length (Overall width Overall height Wheelbase Ground cleamee ‘Seat height Dry mass ENGINE Type. o Number of eylinders ‘Tappet clearance, IN ex Bore S08... Piston alsplacement.. Compression ratio Fue! system Air leaner. Starter system, Lubrication system TRANSMISSION Clute Transmission | Gearshift pattern Primary reduction rato Gear ratios, Low. 2nd ard 4th th Top Final reduction rato.. Drive system 2 180mm (85.8 in)... (For E-18 model) 2.140. mm (84.3)... (For the other mode's) 740 mm (28.1 in) 1155 mm (45.5 in) 1.485 mm (58.5in) 420mm (4.7) 805 mm (81.7 in) 216 kg (476 Ibs)... (For E-38 model) 215kq (473 Ib)... (For the other models) Four-stroke, Liquid-cooled, DOHC, TSCC, 4 (0.40-0.20 mm (0.004-0.008 in) (0.20-0.90 mm (0.008-0.012 in) 81,0 mm (2.188 in) 163.0 mm (2.480 in) 1.209 om? (79.3 cu. in) 0:1 Fuel injection system Non-woven fabric element Electric starter Wet sump ‘Wet mult-piate type ‘speed constant, mesh ‘down, 5-up 1.896 (83/52) 2.615 (94/13) 1.997 (a116) 1.526 (29/19) 41.285 (27/21) 1.436 (25/22) 1.048 (24/28) 2.952 (40/17) FK GBS0GSV 23, 112 linkscassis Front suspension FRear suspension Front fork stroke Fear whee! travel Steering ange .. Caster Trail Turning radius Front brake Fear brake Front tire size Rear tie size ELECTRICAL, Igaition type. Ignition timing... Spark plug.. Headlight “Turn signal ight. Position light. Brake lightTalight. License plate light. ‘Combination meter ight Neutral indicator ight High beam indicator light “Turn signal ingicator ligt. Ol pressure indicator light Fuel level indicator light. Engine coolant temp. incicator ight. FF Indicator light ‘CAPACITIES Fuel tank, including reserve. Engine ol, ol change: with fter change. overhaul Coolant Front fork cil each log) (GENERAL INFORMATION 1-9 Inverted telescopic, coil spring, oll damped, spring pre-load fully adjustable, compression damping force 13.way adjustable, rebound damping force ‘4eway adjustable. Link type systom, gasiol damped, coll spring, ‘spring pre-road fully adjustable, compression damping force 22-way adjustable, rebound damp: ing fore 22-way adjusiadle, 420 mm (4:7 in) 140 mm (8. in) 30° (right & let) 2a" 12 97 mm (3.8 in) 3.3 m (10.8 f) Disc brake, twin hydraulically operated Disc brake, hydraulically operated 120170 ZRI7 (68 W), tubeless 190150 ZAI (73 W), tubeless Electronic ignition (Transistoized) 4 BTDG, at 1 180 rimin NGK GR9E, DENSO U27ESR-N 12V 96.0 KC(10 Any/1OHR Three-phase A.C. Generator 0A, 15/15/15/15/10/108 12V 6545/55 tv aw 12V BW oo Except for E03, 24, 28, 83 models ray 215W2 rev sw ep LED LED LED LED LeD Leo Leo 20L (5.9/4.4 USIImp gal)... E-83 22 (5.8/4.8 US/Imp gal) 3 300 mi (3.5/2.9 US!imp gt) 3 500 mi (3.7/8.1 USiImp gt) 44.200 mi (4.43.7 USImp qi) 2 950 mi (3.1/2.6 USiimp at) 480 ml (16:2/16.9 USiImp 02) “These specifications are subject to change without notice.‘1110_GENERAL INFORMATION COUNTRY AND AREA CODES ‘The following codes stand for the applicable county(es) and area(s). (CODE ‘COUNTRY or AREA. E02 UK. E03 USA (Except for california) e418 Switzeriand E19 eu E24 Australia, 28 Canada E33 Caltoria (USA) paz BrazilPERIODIC MAINTENANCE 2. PERIODIC MAINTENANCE — CONTENTS PERIODIC MAINTENANCE SCHEDULE. | PERIODIC MAINTENANCE CHART... LUBRICATION POINTS x00 MAINTENANCE AND TUNE-UP PROCEDURES ... AIR CLEANER. SPARK PLUG TAPPET CLEARANCE. ENGINE OIL AND OIL FILTER wren FUEL HOSE.. ENGINE IDLE SPEED. THROTTLE VALVE SYNCHRONIZATION THROTTLE CABLE PLAY. CLUTCH COOLING SYSTEM. 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 iss the recommended intervals forall the required periodic service work necessary to keep the motoreycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, milas and months, and are dependant on whichever comes fist. nore: ‘More frequent servicing may be performed on motorcycles that are used under severe conditions. IMPORTANT: The periodic maintonance intervals and service requirements have been established in ac cordance with EPA regulations, Following these instructions will ensure thatthe rotorycio will not exceed ‘emission standards and it wil also ensure the reliabilly and performance ofthe motoreyele. PERIODIC MAINTENANCE CHART Tnterval [en 7000 | 6000 | 12.000 | 18.000_[ 94.000 miles 600 | 4000 | 7500 | 11.000 | 15.000 Item months 1 6 12 is 24 ‘Air leaner - 1 0 R 1] ‘Spark plugs 0 A i a [Tapper clearance : : = i Engine oll a a B B Engine ol iter R : = & 7 Fuel hase a c i n r Foplace overy 4 years Engine idle speed i i H T 1 “Trot valve syncronization v 7 “ i (€-33 ony) Evaporative emission contrl system : z i i i (€-38 only) place vapor hose every 4 years AIR (air suppiy) system (E-89 only) _ a feel i 7 “Throtle cable play i i 7 H mentee SS as ‘Clutch fiuid Sm alee Tadao Tass Sed ete Ege okt aaa aim tive ca a a ian a oat ray TOO (HO a i ee a Sas ae eee aie Sata i oo i Teac sen Dyas Ts Set Seth co t a SEES t ae eee 71 i Echua pp bot an $i a Gar otto Se [r= Inspect and adjust, loan, lubricate or replace as necessary.PERIODIC MAINTENANCE 2:3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcyclo. Major lubrication points are indicated below. FEB oe ever nlr Nore: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oi dirt or grime. * Lubricate exposed parts which are subject fo rust, witha rust preventative spray, especially whenever the ‘motorcycle has been operated under wet or rainy conditions24 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item ‘mentioned in the Periodio Maintenance chart AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months). + Remove the front and rear seats. (7° 6-11) + Lit and support the fuel tank. (=F 4-60) + Remove the ar cleaner element © by removing the sores, + Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION) ‘Always use air pressure on the outside ofthe air cleaner clement. I air pressure Is used on the inside, dirt will be forced into the pores of the thus stricting ar flow through the + Reinstall the cleaned or new air cleaner element in the re- verse order of removal(a CAUTION) If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element fr to use a torn element. Make sure that the air cleaner is In good condition at all times. The Ife of the engine de- pends largely on this component! eI ‘+ Remove the drain plugs @ trom the air cleaner box to allow any water to ain out. SPARK PLUG Inspect every 6 000 kr (4 000 mil replace every 12 000 km (7'500 mil {6 months) ane , 12 months). ‘SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL, + Remove the front and rear seat, (C7 6-11) * Lit and support the fuel tank. (> 4-50) + Remove the ar cleaner box ©D. (4-58) + Disconnect all ofthe lead wire couplers from each ignition coll plug cap and camshatt position sensor, o not remove the ignition coil/plug cap before discon- necting Its lead wire coupler. ‘+ Remove all ofthe ignition colsptug caps. ‘A CAUTION] * Do not pry up the ignition collplug cap with a driver (oF a bar to avoid Its damage. * Be careful not to drop the ignition coll/plug cap to Prevent the short or open the circuit ofits. PERIODIC MAINTENANCE 2526 _PERIODIC MAINTENANCE ‘+ Remove the spark plugs with a spark plug wrench, HEAT RANGE * Check to see the heat range of the plug, If the electrode of the plug is wet appearing or dark color, re- ‘lace the plug with hotter type one. I iis white or glazed ap- pearing, replace the plug with colder type one, GK DENSO Hotor type ‘cre: U2ESRN Standard (CAE U2TESR: Colder 198 ‘CAIOE USIESRAN, NOTE: "A" ype spark plug has a resistor located atthe center electrode {0 prevont 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 carefully use @ tol with a ponted end. ‘SPARK PLUG GAP ‘+ Measure the spark plug gap using a thickness gauge. + Hout of specification, regap the spark plug BBM spark plug gap Standard: 0.7 ~ 0.8 mm (0.028 - 0.031 in) 09900-2080: hickness gauge rr) —— K 07-08mm “Fes nw LeeannPERIODIC MAINTENANCE 27 ELECTRODE'S CONDITION * Check the concltion of the electrode + If itis extremely worn or burnt, replace the spark plug. Re- place the spark plug if it has a broken insulator, damaged thread, eto. [a CAUTION) CCheck the thread size and reach when replacing the spark plug. Ifthe reach is too short, carbon will be de- Posited on the screw portion of the spark plug hole land engine damage may result. ‘SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION + Install the spark plugs tothe cylinder head by finger ight, and then tighten them to the specified torque. [spark plug: 11 Nem (1.1 kgm, 8.0 tbe) [& CAUTION] ‘To avoid damaging the cylinder head threads, first fin- ger tighten the spark plug and then tighten It to the Proper torque using the spark plug wrench. * Install the ignition collsfplug caps and connect thelr lead wire couplers. [& CAUTION | * Do not strike the ignition collplug cap with a plastic hammer when instaling it * When installing the ignition collplug cap, place its coupler not to contact with the cylinder head cover.28 PERIODIC MAINTENANCE TAPPET CLEARANCE Inspect every 24 000 km (18 000 miles, 24 months). Remove the under coming. (6-8) Remove the front and rear seats. (7 6-11) Lit and support the fuel tank. (7° 4-60) Remove the spark plugs. ([=7" 2-8) Remove the throttle body assembly. ((F" 4-60) Remove the heat shiald rubber Remove the cowling bracket Flomove the cylinder head covers. (7° 3-23) ‘The tappet clearance specication is ifferent for intake and ex- haust valves. Tappet clearance must be checked and adjusted, 1) atthe time ‘of periodic inspection, 2) when the valve mechanism is serviced, land 3) when the camshals are disturbed by removing them for servicing, ‘Tappet 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, in order to check the tappet clearance, of to adjust tappet clearance, Clearance readings should not be taken withthe cam in any other posi- tion than these two position. * The clearance specication is for COLD state * To tum the crankshaft for clearance checking, be sure to use ‘wrench, and rotate in the normal running direction. All spark plugs should be removed. + Remove the starter clutch cover plug @ and the valve timing Inspection plug @.+ Turn the crankshaft o bring the “Topline on the starter clutch to the index mark of valve timing inspection hole and also to bring the notches @ on the left ends of both camshatts (Ex and In) to the postions as shown, + Inthis condition, read the teppet clearance at the valves @ (In ‘and Ex of No.4 oyiinder, x of No. and In of No.2). + the clearance is out of specification, adlust the clearance. (= 210) (3 09900-20803: Thickness gauge PERIODIC MAINTENANCE 29 + Turn the crankshatt 360 degrees (one rotation) to bring the "TOP" ine on the starter clutch tothe index mark of valve tim ing inspection hole and also to bring the notches @ to the positon as shown. ‘+ Read the clearance atthe remaining valves © and adjust the clearance if necessary. ((7* 2-10) Nich @ postion Exhaust Camshat | Intake Camshaft ® ‘Front © Front ©) © Front © Front Cam position2:10 PERIODIC MAINTENANCE ‘TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. + Remove the intake or exhaust camshatts. (7 3-23) ‘+ Romove the tappat and shim by fingers or magnetic hand, '+ Check the figures printed on the shim. These figures indicate the thickness ofthe shim, as ilusrated. + Solect a replacement shim that will provide @ clearance within the spect range. For the purpose of this adjustment, a total (of 25 sizes of tappet shim are available ranging from 2.90 to '3.50 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure ts size. Refer tothe tap- pet shim selection table (=F 2-11, 2-12) for detals. NTE: * 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 tothe tappet [a CAUTION Reinstall the camshafts (7 3122) the specified manner. | [ter replacing the tappet shim and camshafts, rotate the en ine so that the tappet is depressed fully Ths will squeeze out oll trapped between the shim and the tappet that could cause {an incorrect measurement, then check the clearance again to confirm that itis within the spectied range, [Alor finishing the tappet clearance adjustment, reinstall the folowing items. Page * oylinder head cover: 3129 * Spark plug and plug cap 27 * Valve timing inspection plug senna 8129 * Starter clutch cover BlUQ sn 3129 * Heat shield rubber Bt + Throttle body 465PERIODIC MAINTENANCE 2.11 wu og2 posh en 0 a6 wis wuer2 sae uas noses uw e201 sous ogee, mama aura eon uy eae wis wosad yn uuReDfearEN uy SOURIE LEE fe ways eo nso 47100 81 ANON, "soveraD ids anseON “LuvHO SIHL-367 OL. MOH me 18 S0-10 eel ort are ore [see oct] sel ore aE [ore ers | ore [aE [OEE [See ee | Te SFO=170 eae ose [SPE ore see ors [sce oce| sve ave. ‘are ore |ave ore set [ore] sec oze [sre ore ave ore ore eve]ors see tore| ree ore] sre [ore sot [ove ose|sve [ore |see|are| see ze] eve| ore| oe |ooe |o52| ov2| soz se |e | oe ee bse ar | sie o1e| sae one | sz | osz| sxe (OUTDO ISS WAS 13a] (INTAKE SIDE) (0006000 14-26821) ‘ON IIHS L3dd¥L [aywiNIl 316¥1 NOLES WHS 13d2:12 PERIODIC MAINTENANCE wore —_pesn 09 0126 ws iwuos2 es us wosELy uw eco eouseep tate, anaes “aunjeo co rewozyoy u 923 ways esa18 UK YUP ERI coURAEEE HEY THE OFE fans ulus wesed enseoyy 700 81 3NIONS, "20u89! fade INSHEN AMVHO SHEEN OLMOH ——acfore TIE [ooe sz Ta S62 [ose ce ore tee] See ore ore [set ]ore sre ore: BEE [oer see ore] 31 ee leeeoeel oreo 55 [ope [sa] ore rz ore] 5ez, Jose) se|ore| ses | oce| sze|aze| sre ore] soe| are| sez|ee) sez |owz| scz| orz| sez vz sz! alrdo (oroTDOeETTISS WINS T3AG¥I (00000-26824) (ON WIHS 13didvL Lisnviy3] 31a NOWOSTSS WHS Laddv (EXHAUST SIDE)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, § months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 month) and ‘every 18 000 km (11 000 miles, 18 months) thereafter il shouldbe changed while the engine is warm. Oil fiterreplace- ment at the above intervals, should be done together withthe ‘engine oll change. ENGINE OIL REPLACEMENT + Koop the metoreycle uoright + Place an ol pan below the engine, and drain ol by removing the ol arain plug D and filer cap @: * Tighten the drain plug @ to the specified torque, and pour {resh ol trough the ol filer. The engine will hold about 3:3 L (8.52.8 US/Imp qt) of oll. Use an API classification of SF or ‘SG oil with SAE 10W/40 viscosity. Toit drain plug: 23 Nm (2.3 kam, 16.5 Ib) * Start up the engine and allow i to un for several minutes at Icing speed. ‘+ Tum off the engine and wat about three minutes, then check the ol level through the inspection window . Ifthe level is below mark", add oll to"F'level If the lavel is above mark “F, ain ol to °F” level, PERIODICMAINTENANCE_ 2.19PERIODIC WAINTENANCE IL FILTER REPLACEMENT * Drain the engine oll as described in the engine ail replace- ‘ment procedure + Remove the oii iter © using the special too * Apply engine ol ight tothe gasket ofthe new ol fiter before installation. * Install the new oi fiterTurn iby hand untl you feel that the oil fiter gasket has contacted the ol fter mounting surface. Then, tighten the ol fiter two full turns using the special tol (62 09915-40610: OW fter wrenen NOTE: ‘To property tighten the oft, use the special tool. Never tighten the oi ter by hand, ‘+ Add new engine oil and check the oil level as described in the ‘engine ol replacement procedure NECESSARY AMOUNT OF ENGINE OIL Oil change: 3 300 mI (3.5/2.9 US/Imp qt) ll and filter change: 3 500 mi (3.7/3.1 USiimp qt) Engine overhaul: 4 200 mi (4.4/3.7 US/Imp at) [@ CAUTION} ‘ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FIL- TER. (Other manufacturer's oil filters may differ in thread speci- fications (thread diameter and pitch), filtering perfor- mance and durability which may lead to engine dam- ‘age or oil leaks. Also, do not use a genuine Suzuki au- tomobile oil filter on this motorcycle. ter contacting the gusto hier 2PERIODIC MAINTENANCE 2-15, FUEL HOSE Inspect every 6 000 km (4 000 miles,6 months). Replace every 4 years. Inspect the fuel feed hose @ and the fuel return 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 ev- ery 6 000 km (4.000 miles, 6 months) ther Nore: ‘Make this adlustment when the engine is hot. + Start the engine, turn the throttle stop serew and set the engine idle speed as follows. EMM Engine idle speed: 1180 +50 r/min 1150 4 100 rimin. For E-18 model For the other models THROTTLE VALVE SYNCHRONIZATION Pie tal ia Inspect initially at 1 000 km (600 miles, 1 month)E-33 only) and every 12 000 km (7 500 miles, 12 months). (467) EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 12 months). Replace vapor hoses every 4 years (94) PAIR (AIR SUPPLY) SYSTEM (E-33 ONLY) Inspect every 12 000 km (7 500 miles, 12 months). 97246 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 1 month) and ‘every 6 000 km (4 000 miles, 6 months) thereatter. ‘Adjust the throttle cable play @® as follows. MINOR ADJUSTMENT 18 step: + Loosen the locknut © of the throttle returning cable @ and fully tur in the adjuster . 2nd step: + Loosen the locknut @ ofthe thottie puling cable ‘+ Turn the adjuster @ in or out until the throttle cable pay (at the throttle grip) is between 2.0 — 4.0 mm (0.08 ~ 0.16 i). + Tighten the locknut @ while holding the adjuster 6. Throttle cable play : 2.0 ~ 4.0 mm (0.08 - 0.16 in) 34d step * While holding the throttle grip atthe fly closed postion, slowly tur out the adjuster @) of the trate returning cable @ unti resistance is fl. * Tighten the locknut while holding the adjuster. ‘After the adjustment is completed, check that handle- bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automati- cally Nore: ‘Major adjustment can be made atthe tote body side adjusterMAJOR ADJUSTMENT Lit and support the fuel tank with its prop stay. (I 4-50) + Loosen the locknuts (D ofthe throttle returning cable @.. + Turn the returning cable adjuster @ to obtain proper cable play. + Loosen the locknuts @ ofthe throttle puling cable ©. + Turn the pulling cable adjuster in or out until the throttle cable play @ should be 2.0 ~ 4.0 mm (0.08 ~ 0.16 in) at the throttle orp. + Tighten the lockruts @ securely while holding the adjuster ©. BINA Throttle cable play @: 2.0 ~ 4.0 mm (0.08 ~ 0.16 in) ‘While holding the throttle grip atthe fully closed position slowly tum the returning cable adjuster @ to obtain a cable slack ® Of 1.0 mm (0.04 in. Tighten the locknuts (D securely, PERIODIC MAINTENANCE 27248_PERIODIC WAWTENANCE CLUTCH (CLUTCH HOSE AND CLUTCH FLUID) Ingpect every 6 000 km (4.000 miles, 6 months). Replace hose every 4 years. Replace fluld every 2 years CLUTCH FLUID LEVEL + Keep the motoreyl upright and place the handlebars straight + Check the clute fui level by observing the lower limit line on the clutch Mid reservoir + Ifthe level is found to be lower than the lower mark, replenish with BRAKE FLUID thatthe folowing specification By specication and Clasitction: DOT 4 FOTN The clutch system of this motoreyele Is filled with a glycol-based brake tluld. Do not use or mix different types of fluid such as sillicone-based or petroleum- based. Do not use any brake fluid taken from old, used Cf unsealed containers. Never re-use brake fluid left over from the last servicing or stored for along periods. Check the clutch hose and hose joints for eracks and fluid akage. BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT “The clutch fuid circuit may be purged of ai inthe folowing man + lemove the left under cowling, (7° 6-8) + Keep the motorcycle upright and piace the handlebars straight. + Fil up the master eylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dit. Altach a pipe to the bleeder valve and insert the tree end of the pipe into a rocoptacle ‘Squeeze and release the clutch lever several times in rapid ‘succession, and squeeze the lever fully without releasing it Loosen the bleeder valve by turning ita quarter of a turn so thatthe fud runs into the receptacle; this will remove the ten ‘Son of the clutch lever causing it to touch the handlebar grip. “Then, cose the valve, pump and squeeze the lever, and open the valve. Repeat this process unti the fluid fowing into the receptacle no longer contains air bubbles. Close the bleeder valve, and disconnect the pipe. Fil the reser voir with brake fi tothe upper end ofthe inspection window, DDAir bieeder vaive: 7.5 N-m (0.75 kgftm, 6.5 Ib)PERIODIC MAINTENANCE 2-19 COOLING SYSTEM Ingpect every 6 000 km (4 000 miles, 6 months). Replace engine coolant every 2 years. ENGINE COOLANT LEVEL CHECK + Keep the motereycle upright. + Check the engine coolant level by observing the full and lower lines on the engine coolant reserve tank. @® Fullline ® Lower ine + Ifthe level Is below the lower line, add engine coolant to the full line fom the engine coolant reserve tank filer Nore: To remove the filer cap, remove the left under coving. «7 68) ENGINE COOLANT CHANGE ‘+ Remove the under cowing. (7" 6-8) ‘+ Remove the radiator cap ©. + Drain engine coolant by disconnecting the radiator hose @ from the pump, CEI * Do not open the radiator cap when the engine is hot, {as you may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If engine coolant gets into the eyes or in contact with the skin, flush thoroughly with plenty of water. if swallowed, induce voriting and call physician immediately! Flush the radiator with fresh water if necessary Connect the radiator hase @ securely Pour the spectid engine coolant up to the radiator inlet Bleed the air from the engine coolant circuit as following pro- cocure Nore: For engine coolant information, refer to page 52.220 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT + Add engine coolant up tothe radiator inlet + Support the motorcycle upright Slowly swing the motorcycle, right and let, to bleed the alr trapped in the cooling circuit. [Add engine coolant up to the radiator inlet Start up the engine and bleed air rom the radiator inet com- pletely ‘Add engine coolant up to the radiator inlet peat the above procedure until bleed no air from the radia tor inet. Close the radiator cap @ securely. + After warming up and cooling down the engine several times, add the engine coolant up to the full level ofthe reserve tank a CAUTION) Repeat the above procedure several times and make ‘ure that the radiator i filled with engine coolant up to the reserve tank full level. 1G Engine coolant capacity: 2 950 mi (3.12.6 USMImp at) RADIATOR HOSES + Remove the under cowing. ((F 6-8) * Check to s2e the radiator hoses for crack, damage or engine cooiant leakage, + any defects are found, replace the radiator hoses with newPERIODIC MAINTENANCE 221 DRIVE CHAIN Inspect initially at 1000 km (600 miles, 1 month) and ev- ‘ery 6 000 km (4 000 miles, 6 months) thereafter. Clean and lubricate every 1 000 km (600 miles). Visually check the drive chain for the possible defects sted bo- low. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the vansmission shifted to Newt) * Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Diy or rusted links“ Missing O-ing seals * inked or binding links It any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the dive chain and sprockets as a set ‘CHECKING + Remove the axle cater pin. (For E-08, 28 and 38 models) + Loosen the axle nut + Loosen the chain adjuster lock nuts @ + Loosen the torque tink nut Fear) @ + Tense the drive chain fully by turning both chain acjusters @). + Count out 21 pins (20 pitches) on the chain and measure the distance between the two points tthe distance exceeds the service limit, the chain must be replaced. [EIB Drive chain 20-pitch length Service limit: 319.4 mm (12.57 In)222 PERIODIC HANTENANCE. ‘ADJUSTING + Loosen or tighten both chain adjuster nuts © unt there is 20 = 30 mm (0.8 ~ 1.2 in) of slack at the middle of the chain betvieen the engine and rear sprockets as shown, The rater. ‘ence marks on both sides ofthe swingarm and the edge of ‘each chain adjuster must be aligned to ensure thatthe front and tear wheels are correty aligned, Drive chain slack Standard: 20 ~ 30 mm (0.8 ~ 1.2 in) + Place the motorcycle on its side-stand fr accurate agustment, + Alter adjusting the drive chain, tighten the axle nut @ and the torque link nut (Fear) @ to the spected torque + Tighten both chain adjuster nuts ® securely. (Roar axle nut: 100 Nim (10.0 kgm, 725 lb) Torque lnk nut (Roar: 35 Nm (3.5 kgm, 25.5 tbs) + Install @ new cotter pin. (For £03, 28, 39) + recheck the drive chain slack after tightening the axle nut CLEANING AND LUBRICATING + Clean the drive chain with kerosine. I the drive chaln tends to rust quickly, the intervals must be shortened. (& CAUTION) Do not use trichloroethylene, gasoline oF any similar solvent. 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. + After washing and drying the chain, oll it with a heavyweight motor ol ‘A CAUTION] * Do not use any oll sold commercially as “drive chain oll” Such oil can damage the O-ring * The standard drive chain is a RK GBSOGSV Z3 Suzuki recommends to use this standard drive chain as a replacement.BRAKE (BRAKE) 1spect initially at 1000 km (600 miles, 1 month) and ev- ‘ery 6 000 km (4 000 miles, 6 months) thereatte (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fluid every 2 years. BRAKE FLUID LEVEL CHECK + Keep the motorcycle upright and place the handlebars straight * Check the brake fluid level by observing the lower limit ines ‘on the front and rear brake fluid reservoks. ‘+ When the level is below the lower it ine, replenish with brake fluid that meets the folowing specication B specication and Classification: DOT & om * The brake system of this motorcycle is filed with a alycol-based brake fluid. Do not use or mix diferent types of fluld 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 long period of time. > Brake fluid, if it leaks, wll interfere with safe running and immediately discolor painted surtaces. Check the ‘brake hoses and hose joints for cracks and fluid leak- age before riding. PERIODIC MAINTENANCE 223 BRAKE PADS. FRONT BRAKE. + Remove the brake pad spring © by removing bolts. + The extent of brake pad woar can be checked by observing the grooved limit ine @ on the pad, When the wear exceeds ‘the grooved limit line, replace the pads with new ones. (664) CAUTION) [Replace the brake p224 PERIODIC MAINTENANCE: REAR BRAKE +The extent of brake pad wear can be checked by observing the grooved limit ne @) on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones, (672) CAUTION] Replace the brake pads as a set, otherwise braking per- formance will be adversely atfected. BRAKE PEDAL HEIGHT * Loosen the locknut ©. + Tum the push rod @ until the brake pedal is 65-65 mm (2.2 — 26 in) ® below the top of the footrest. + Tighien the locknut ( securely. ©) Rear brake master cylinder rod locknut 18 Nm (1.8 kgm, 13.0 bs) BRAKE LIGHT SWITCH + ‘Adjust the rear brake light switch so that the brake light wil ‘come on just before pressure is felt when the brake podal is depressed.AIR BLEEDING THE BRAKE FLUID CIRCUIT ‘Air trapped inthe brake fud circuit acts lke a cushion to absorb a large proportion of the pressure developed by the master cy Inder and thus interteres 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, is essential that after remounting the brake and restoring the brake system to the normal condition, the brake fui cicult bbe purged of air inthe folowing manner: FRONT BRAKE * Fil the master cyinder reservoir to the top ofthe inspection window. Replace the reservoir cap to prevent drt from enter ing, ‘+ Attach a hose tothe air bleeder valve and insert the free end cof the hose into a receptacle. ‘+ Squeeze and release the brake lever several times in rapid ‘succession and squeeze the lever fully without releasing it Loosen the air bleeder valve by turing ita quarter of a turn 0 that the brake fluid runs into the receptacte, this wil re ‘move the tension of the brake lever causing it to touch the ‘hanclebar grip. Then, close the alr bleeder valve, pump and ‘squeeze the fever, and open the valve. Repeat this process Lntl fluid flowing into the receptacle no longer contains air bubbles. NoTE: While bleeaing the brake system, replenish the brake fluid the reservoir as necessary. Make sure that there Is aways some fluid visible n the reservoir. + Close the air Bleeder valve and disconnect the hose. Fill the reservoir with brake fluid tothe top of the inspection window, 1 Air biceder vaive: 75 Nm (0.75 kom, 5.5 bs) Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, et. PERIODIC MAINTENANCE 2.25226 PERIODIC MAINTENANCE REAR BRAKE * Bleed ai from the rear brake system as the same manner of front brake, NOTE: The only difference between bleeding the frant and rear brakes fs that the rear master cylinder is actuated by a pedal TIRES ‘TIRE TREAD CONDITION Operating the motorcycle with excessively worn tres willdecrease riding stability and consequently invite a dangerous situation tis highly recommended to replace a tire when the remaining depth Ofte tread reaches the folowing spectication. (09000-20005: Tre depth gauge BID Tire tread depth (Recommend depth): Service Limit: FRONT 1.6 mm (0.06 in) REAR 2.0 mm (0.08 in)PERIODIC MANTENANCE 227 ‘TIRE PRESSURE It the tie pressure is 100 high oF too low, steering will be ad- versely affected and tio wear will increase. Therefore, maintain the correct tie pressure for ood roadabilty and a longer tie ite. Cold inflation tre pressure is as follows. Cold inflation tire pressure Solo riding: Front: 290 kPa (2.90 kgl/om®, 42 ps!) Rear: 290 kPa (2.90 kgticm, 42 psi) Dual riding: Front: 290 kPa (2.90 kgt/en®, 42 ps!) Rear: 290 kPa (2.90 kgtioms, 42 psi) (i CAUTION | “The standard tire fitted on this motoreycle Is @ 120/70 ZR17 (68W) for the front and a 190/50 ZR17 (73M) for ‘the rear. The use of tires other than those specified may cause instability. tis highly recommended to use the specified tires. GAA TRE TYPE BRIDGESTONE (BT56F J. ont, BTSER J....Rear) STEERING Tnapect initially at 1 000 kr (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter. ‘The steering should be adlusted property for smooth tuming of the hanclebars and safe operation. Overtight steering prevents smooth tung of the handlebars and too loose steering will cause poor stability. Check that there is no play n the front fork. ‘Support the motorcycle so that the front whe! is off the ground. \With the wheel facing straight ahead, grasp the lower fork tubes, ear the axle and pull forward If play is found, readjust the steer ing. (637)228 PERIODIC MANTENANGE FRONT FORK Inspect every 12 000 km (7 500 miles, 12 months). | Inspect the front forks for oil leakage, scoring or scratches on the outer surface ofthe inner tubes. Replace any defective part, necessary. (7 6-22) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months). Inspect the rear shock absorbers for ol leakage and check that there is no play in the swingarm. Replace any defective parts it necessary (F 6-50, 6-55) EXHAUST PIPE BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and ev- ery 12 000 km (7 500 miles, 12 months) thereafter. + Tighten the exhaust pipe bolts, nuts and muffler mounting bolts to the specified torque, IO is Fomures tei PE.) (este) oePERIODIC MAINTENANCE 229 CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque, (Refer to page 2-80 for the locations of the following nuts and bots on the motorcycle.) Tem im kgm rm @ Soaring stam Pead nut 30 20 5.0 ‘Steering stem lock nut 30) 80 58.0 (@ Front ork upper clamp bolt 23 23 16.5 (@ Front fork lower clamp bolt 23 23 165 ‘B Front fork cap bot 23 23 165 @ Front axle 00 700 R25 © Front axle pinch bal 23 23 165 ‘@ Handlebar clamp boil 10 10 7.0 (@ Handlebar holder mounting nut 35, 35 255 {@ Guuich master eyindor mounting Bott 10 1.0 7.0 {@ Front brake master cylinder mounting bot 10 10 7.0 (@ Front brake caliper mounting bot 3 39. 28.0 (Front brake caliper housing bolt Hl 2A 15.0 (3 Union bot 23 23 165 [[S Air bleoder valve 75 0.75 55 (Brake cise bolt (Front) 23 23 765 Brake csc bott (Rear) 35 35 25.5 (® Rear brake caliper mounting batt 28 26 10.0 (B Rear brake caliper housing bot 0 3.0 21s. {Rear brake master eyinder mounting bolt 10 10) 70 {) Rear brake master cylinder rod lock nut 18 18. 13.0 Front footrest bracket mounting bolt 26 26 19.0 1 Swingarm pivot nut 100 100 725, {@ Swingarm pivot lock nut 90. 9.0 65.0 1 Swingarm pivot shaft 5 15 11.0) (B Torque lnk nut (Front 28. 28 205 @ Torque lnk nut (Rear) 35, 35 25.5 {B Rear shock absorber mounting nut 50 5.0 36.0 {@ Cushion lever mounting nut 78 78. 565 ‘@ Cushion rod mounting nut 78 78 555 (Rear axle nut 100 70.0, 725 @ Rear sprocket Aut 60 60, 435 {Steering damper bolt 23 23, 16520_PERIODIC MAINTENANCE.PERIODIC MAINTENANCE 231 COMPRESSION PRESSURE CHECK “The compression pressure reading of a cylinder is @ good indicator ofits internal concition “The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service, ‘COMPRESSION PRESSURE SPECIFICATION ‘Standard mt Diference 7200-1 600 KPa | 900 KPa 200kPa (12—16 iiom®)) / 9kgliem? ) | (2 kaon) iz = 208 psi)| | 128 ps \ 28 psi_} Low compression pressure can Indicate any of the following conditions: * Excessively wor cinder walls * Worn piston or 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 ofthe cylinders is less then 900 kPa (9 kglemt, 128 ps) * The diference in compression pressure between any two cy! Inders is more than 200 kPa (2 kaon, 28 ps). * Al compression pressure reacings are below 1 200 KPa (12 kgifem®, 171 psi) even winen they measure more than 900 KPa (9 keller, 128 psi. COMPRESSION TEST PROCEDURE NOTE: * Before testing the engine for compression pressure, make sure thatthe cylinder head nuts are tightonod tothe specified torque values and the valves are properly adjusted. * Have the engine warmed up before testing. + Make sure that the battery is fuly-charged. Femove the related parts and test the compression pressure in ‘he folowing manner. * Lit and support the fuel tank. (7° 4-60) + Remove all he spark plugs. (F 2-5) “+ Install the compression gauge and adaptor in the spark plug hole. Make sure thatthe connection is tight. + Keep the thts grip inthe fully opened postion, + Press the starter button and erank the engine fora few sec- Conds. Record the maximum gauge reading as he cylinder com- pression. + opeat ths procedure withthe other cyinders. (00015-64510: Compression gauge set282 PERIODIC MAINTENANCE OIL PRESSURE CHECK CCheck the engine ol pressure periodically. This wil give a good Indication of the condition of the moving parts. IL PRESSURE SPECIFICATION ‘Above 200 kPa (2.0 kgtlem’,28 Ps!) at 3.000 rfmin., Oil temp. at 60°C (140°F) Below 500 kPa (5.0 kgt/em, 71 psi) {tthe ol pressure is lower or higher than the specication, the folowing causes may be considered, LOW OIL PRESSURE * Clogged ol fiter * Oil leakage from the oll passage * Damaged O-ring * Defective oll pump * Combination of the above tems HIGH OIL PRESSURE * Engine oll viscosity is too high + Clogged oil passage * Combination of the above items lL PRESSURE TEST PROCEDURE Start the engine and check if the oll pressure Indicator light Is turned on. I the light siays on, check the ol pressure incicator light circuit. the circuit s OK, check the oil pressure inthe fo lowing manner, * Remove the main ol gallery plug @. + Install the oll pressure gauge and adaptor into the main ol gal- lery + Warm up the engine as folows: ‘Summer: 10 min at 2.000 min, Winter: 20 min. at 2 000 rlmin, + Ator warming up, increase the engine speed to $ 000 r/min. (cbserve the tachometer) and read the ol pressure gauge. (6) 00015-74520: oll pressure gauge hose 09015-74540; Oil pressure gauge attachment 09915-77330: Meter (for high pressure) 1 ot gatiry plug (tt16): 35 Nm (8.5 kgf, 25.5 Ib-t)ENGINE 341 ENGINE ais ENGINE DISASSEMBL) CAM CHAIN TENSION ADJUSTER. a ea GEARSHIFT SYSTEM THE ENGINE IN PLACE. ENGINE INSTALLATION essen CAMSHAFT. CAM CHAIN GUIDE PISTON AND PISTON RING. on PUMP. WATER PUNP.. OIL STRAINER CRANKSHAFT JOURNAL BEARING TRANSMISSION.32_ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE “The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed inthis section for removal and reinstallation instructions. ENGINE LEFT SIDE PARTS: REMOVAL INSTALLATION Engine sprocket S10 316 Spoed sensor 340 346 Generator 9:96, 9-68 368, 3-105. ‘Crankshaft positon sensor 3:6, 9-68 8468, 94105 Clutch release cylinder ere 679 Water pump st 515, ENGINE RIGHT SIDE PARTS: REMOVAL INSTALLATION ‘clutch 31 3110 Primary oriven gear 383 3110 Gear postion switch 334 3108 Ol pump 338 3-108 il pressure swatch 3-83 3-83 Starter clutch 335 3107 Starter idle gears 3.26 34120 ENGINE CENTER PARTS REMOVAL INSTALLATION Throttle body 460 465 Cylinder head covers 323 3-129 Camshatts 323 3-122 Cam chain tension adjusters 328 3125 Thermostat 59 510 ol fiter 214 pad Starter motor 3.26 322 PAIR valve 3.22 3.190ENGINE 23 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine cut of the frame, wash the engine us: ing a steam cleaner. Engine removal is sequentially explained in the following steps. Reinsal the engine by reversing the removal procedure, + Remove the under comings. (I- 6-7) ‘+ Remove the front and rear seats (seat tall cover). (7 6-11) + Lit and support the fuel tank with the prop stay. (4-60) + Disconnect the batiry © lead wire. + Drain engine ol. (CF 2-13) + Drain engine coolant. (2° 2-19)4 ENGINE + Remove the alr cleaner box. (4-58) + Remove the throttle body. (> 4-60) + Remove the horn load wire couplers + Remove the hor with its bracket. + Remove the ol hoseENGINE 3-5 + Disconnect the radiator inlet hoses , @ + Remove the oll cooler mounting bot + Disconnect the reserve tank hose. + Remove the radiator mounting bolt @. + Disconnect the cooling fan thermo-switch lead wire and the cooling fan lead wire couplers. + Remove the radiator mounting bots @, + Remove the radiator with the oll cooler. [A CAUTION] Be careful not to bent the radiator fin and the oll cooler fin.95 ENGINE + Loosen the lef side exhaust pipe bott ©. ‘= Remove the left side muttier mounting bolt and nut ‘+ Remove the left side mutter. + Remove the exhaust pipe bolts ‘+ Flomove the right side mutfor mounting bolt and nut + Remove the exhaust pipe bots. + Remove the exnaust pipelmuttierENGNE 37 ‘+ Remove the radiator mounting bracket ©. + Remove the oll cooler mounting bracket 2 + Remove the PAIR valve vacuum hose @ and the PAIR valve air cleaner hose ®. + Disconnect the oll pressure switch lead wire ® and remove it from the clamps. + Disconnect the starter motor lad wire @. + Disconnect the ground lead wire ©. + Disconnect the generator lead wire coupler ®. + Disconnect the crankshaft postion sensor lead wire coupler ® + Disconnect the gear postion switch lead wire coupler @. * Disconnect the side-stand switch lead wire coupler .ENGINE + Disconnect the engine coolant temperature sensor lead wire * Disconnect the lead wire couplers trom each ignition col/slug ‘cap and camshaft postion sensor Do not remove the ignition colliplug cap before discon- necting its lead wire coupler. ‘+ Remove the ignition cois/plug caps. (a CAUTION] * Do not pry up the ignition collplug eap with a driver ‘oF a bar to avoid its damage. * Be careful not to drop the ignition coll/plug cap to prevent its short or open circ ‘+ Remove the reserve tank 2.ENGNE 39 + Remove the speed sensor + Remove the gearshift lever. ‘+ Remove the oll catch tank drain hose trom the clamp. + Remove the engine sprocket cover. + Remove the clutch push rod ©. Note: sack up the motorcycle and fix it for safety + Remove the side-stand with its bracket.$10_ ENGINE + Remove the speed sensor rotor D. Flomove the engine sprocket nut @ and the washer Remove the cotter pn. (For E-09, 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 Disengage the drive chain trom the rear sprocket. + Remove the engine sprocket ®.ENGINE 311 ‘Support the engine using an engine jack ‘+ Remove the engine mounting bolts ©, @. + Loosen the engine mounting pinch botts @. Reemave the engine mounting bots ®, + Loosen the engine mounting trust acjuster lock nut © wih the special ool + Loosen the engine mounting thrust adjuster @ fly withthe special oo {62 09040-14990: Engine mounting thrust adjuster sockot wrench42 ENGINE ‘+ Remove the engine mounting nuts @) and @ : Engine mounting nut @ : Engine mounting thrust adjuster lock nut © : Engine mounting thrust adjuster + Loosan the engine mounting thust adjuster lock nuts @, @ wit the spec took, + Loosen tha engine mounting thrust adjusters (fully with the special too 1683 09940-14990; Engine mounting thrust acjuster socket wrench NOTE: ‘Do not remove the engine mounting bolts at mis stage.ENGINE 3413 ‘+ Remove the engine mounting bolts and gradually lower the front side of the engine. Then, takeoff the drive chain from the driveshatt + Remove the engine assembly. ENGINE INSTALLATION Install the engine in he reverse order of engine removal Pay attention to the folowing points: NOTE: Be careful not to damage the frame and engine when intaling the engine. + Before instaling the engine, install the spacer D. + Before instaling the engine, install the engine mounting thrust, adjusters 2, @ and © we: + Gradually rise the rear side ofthe engine assembly, and then put the crive chain ®) on the diveshat. + Install all engine mounting bolts, spacers and tighten them temporary. (7 3-18) ‘A CAUTION)344 ENGINE ‘+ Tighten the engine mounting thrust adjusters to the specified torque with the special tool. (09040-14990: Engine mounting thrust adjuster socket wrench Wlenaine mounting thrust adjuster: 10N-m (10 katm, 79 tt) * Tate the engine mounting thrust acuser look nits tothe speced torque withthe special oo WEnaine mounting thrust adjuster locknut: 45 Nm (45 kof, 92.5 I>) + Tighten all engine mounting bolts and ruts to the spectied torque, (3-15) Nore: Te engine mounting nuts are sell-ocking. Once the nuts have been removed, they are no longer of any use. + Tighten the engine mounting pinch bal othe specified toraue (319)ENGINE 315 Right &> LeneTH Trew Tm i Tem [Nm | kgm | ibe elf ae: 0236 | 55 55 400) 8. ss_| 207 sor [|_@ | 320] 1260 coe | 45 325 oa aes eae | 10 10 73 © 30) 448 ‘oe 75 75 340 | | spacer | | 975 [148 © 35 35 255 STE Adjuster 3 i248 ENGNE + Install the engine sprocket and the washer. + Apply a small quantty of THREAD LOCK "1942" tothe drive shaft thread porto. 6H} 0000-22050: THREAD Lock "1342" + Tighten the engine sprocket nut @ to the spected torque Dlengine sprocket nut: 145 Nim (14.5 kgfim, 105 tbs) + Instal the speed sensor rotor + Apply a.small quantiy of THREAD LOCK “1542" tothe speed ‘sensor rotor bot. 98} 90000-32050: THREAD LOCK “1342" + Ton the speed sensor rotor bl to the specified torus W)speed sensor rotor bot 18 Nem (1.8 kgm, 12.0 bet) + just the cive chain sack. (F222) + Tighion the rear ade nut and the rear torque ink nu othe pected torque Rear axle nut: 100 Nm (10.0 kgtm, 725 ost) Rear torque ink nut: 35 em (9.5 kgf, 255 Ist)+ Apply a small quantty of THREAD LOCK "1342" tothe side stand bracket bots. $6} 90000-2050; THREAD LOCK “1942” + Tighten the side-stand mounting bracket bots tothe speciied torque. W)sidestand mounting bracket bolt: 95 Nm (85 kot, 68.5 Ib + Apply grease tote clutch push rod and intl. xi 99000-25020: SUZUKI SUPER GREASE + Align the hole of the clutch release cylinder withthe end @® ofthe clutch pusn rod when istaling the engine sprocket cover + Tighten the speed sensor bolt to the specified torque. W) speed sensor bolt: 4.5 Nm (0.45 kgfim, 3.0 lb-ft) + Install he engine sprocket cover and the gearshit lever. NOTE: Install the engine sprocket cover protector atthe boss ©)3418 ENGINE * Install the reserve tank. (7 8-25) * Install al ofthe ignition cos/plug cans (7 2-7) * Route wiring hamess, cables and hoses propery referring to tho sections for wire routing, cable routing and hose routing, (> 819) + Install the PAIR valve vacuum hose ( and the PAIR valve air cleaner hose @. (8-29) Install the radiator mounting bracket @: + Install the ol cooler mounting bracket @. Radiator mounting bracket (short) it cooler mounting bracket (long)ENGINE 3419 + Install the exnaust pipette. DExhaust pipe bolt: 23 Nim (23 kgm, 16.5 Ibs) Maflr mounting nut 2: 23 em (23 kgm, 16.5 Ist) ‘CAUTION | Foplace the gaskets with new ones. NoTE: Install the right side mutter frst Nore: Apply gas sealer to inside and outside ofthe exhaust pipe oon- hector EXHAUST GAS SEALER: PERMATEX 1372220 _ ENGINE + Install the radiator wit the oll cooler. (= 8-25) + Install the O-rings between the oll cooler and the ail hoses: ‘and apply grease to them. Au 99000-25030: SUZUKI SUPER GREASE “A’ (a CAUTION] Use the new O-rings to prevent ol leak + Install the O-rings between the engine and the oil hoses and apply grease to them: AB 99000-25030: SUZUKI SUPER GREASE “A + Tighten the ol cooler hose bolts to the specified torque, [oil cooler hose bolt: 10 Nem (1.0 kgt'm, 7.0 bt)ENGINE 321 * Install the throtle body. (=F" 4-65) + Adjust the following items, * Engine oll (<7 2-13) + Engine coolant ((—F" 2-18) Throttle cable play (=F 2-16) * Giutch (2-18) * Idling adjustment (—F- 2-18) “Throttle valve synchronization ((—F" 4-67) * Drive chain slack ((* 2:22) * Gear shaft lever height (7° 8-50)322_ENGINE ENGINE DISASSEMBLY [CAUTION | Idontiy the position of each removed par. Organize the parts In their respective groups (e.g, intake, exhaust) 40 that they can be reinstalled in their original posi- tions. + Remove the spark plugs. (7 2-5) + Disconnect the breather hose @ from the breather cover. + Remove the ol catch tank BREATHER COVER + Remove the breather cover, + Remove the gasket PAIR VALVE + Remove the PAIR valve ©.ENGINE $23 CYLINDER HEAD COVER + Remove the eylinder head cover and ks gaskets, ro 8-8. ol Coon + Remove the dowel pins. CAMSHAFTS + Remove the valve ting Inspection plug @ and the starter clutch cover plug 2 + Turn the crankshaft to bring the line @ on the starter clutch to the index mark @ ofthe valve timing inspection hole and also to bring the cams tothe position as shown,24_ ENGINE + Remove the oll pipe @. + Remove the cam chain guide @. + Remove the cam chain tension adjuster. NoTE: Loosen the cam chain tension adjuster cap bolt) to faciltate later reassembly. + Remove the gasketENGINE 925 ‘+ Remove the intake camshaft journal holder ©. + Remove the exhaust camshaft journal halder . Be sure to 16% fen the camshaft journal holder bolts ing the wrench diagonally. evenly by shi “+ Remove the dowel pins. ‘+ Remove the intak camshatt 3. + Remove the exhaust camshatt @. 9 + Remove the C-rings ©.228 ENGINE ‘STARTER MOTOR + Remove the starter motor ‘STARTER IDLE GEAR * Remove the startr idle gear cover ‘+ Remove the gasket © and the dowel pins, + Remove the wave washer @ and the washer ¢ + Romove the bearing @ and the starter idle gear No.t ®.ENGINE 927 + Remove the thrust washer @ and the shaft @. + Remove the starter clutch cover ‘+ Remove the gasket @ and the dowel pins. + Remove the wave washor @, the starter idle gear No2® and its shatt ©.226 ENGINE CYLINDER HEAD + Remove the oll hose ©. ‘+ Femove the water hose 2 + Remove the cylinder head side bolt © and its 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 sido bolt ©. ‘+ Remove the cyinder head bolts (ME) ®. ‘+ Remove the cylinder head bolt (Mé) ©. * Loosen the cylinder nuts ©.ENGINE 329 + Remove the cylinder head bolts and washers, NOTE: When loesening the cylinder head bolts, lesen each bolt litle by ite diagonally. + Remove the cylinder head. NOTE: Refer to page 3-48 for cylinder head servicing, + Remove the cylinder head gasket D, dowel pins @ and cam ‘chain guide ©.390_ENGINE CYLINDER, ‘+ Remove the water hose ©. + Remove the cylinder nuts. + Remove the oyiinder, * Remove the cylinder base gasket @ and the dowel pins @. PISTON ‘+ Remove the piston pin circips ©. Nore: Be careful not to drop the piston pin circips ®. + Remove the pistons @ by driving out the piston pine NOTE: SSorbe the cylinder number on the head of the piston. CAUTION] When turning the crankshaft, pull the cam chain up- Ward, or the chain will be caught between the crank- cease and the cam drive sprocket.ENGINE 331 CLUTCH COVER + Remove the clutch cover ©. NOTE: When removing the clutch outer cover, remove the three bolt. + Romove the gasket @ and dowel pins ® cuutcH + Hold the starter cluch withthe special tok 163 09020-24020: Starter clutch holder + Remove the dutch springs. Nore: Loosen the clutch spring set bots lite by litle and alagonaly. ‘+ Remove the pressure plate ©. + Remove the clutch push piece @), the bearing @ and the thrust washer @.392 _ ENGINE ‘+ Remove the clutch push rod ©. NOTE: Vitis iffcut to pull out the push rod ®, use @ magnetic hand or ‘+ Remove the clutch drive and driven plates. + Uniock the clutch stoeve hubnut @. fold the cutch sleeve hub withthe special tol (68) 09020-53740: clutch steeve hub holder ‘+ Remove the clutch sleeve hub nut + Remove the washer. ‘+ Remove the clutch sleeve hub @, the clutch drive cam @ and the clutch driven cam 6).ENGINE 933 ‘+ Flemove the thrust washer ©. ‘+ Remove the bearing @ and the spacer @. ‘+ Remove the primary driven gear assembly @. + Remove the oil pump drive gear‘ from the primary driven gear assembly @. + Remove the thrust washer 8.34 ENGINE om puMP. + Remove the oketlp ©. + Remove the oll pump driven gear @. NOTE: Do not drop the cicip ©, the pin® and the washer @ into the crankcase, + Femove the pin @ and the washer @. + Remove the oil pump ©. GEAR POSITION SWITCH ‘= Remove the gear position switch lead wire clamps @ ‘+ Remove the gear position switch 2 ‘+ Remove the switch contacts and the springs @)ENGINE 995 STARTER CLUTCH ‘Hold the starter clutch with the special too. (4 09020-04830: Starter clutch holder + Femove the starter otch bolt and washer. ‘+ Remove the starter clutch assembly ©. + Remove the washer @) ‘CAM CHAIN DRIVE SPROCKET ‘= Remove the cam chain © and the cam chain drive sprocket @395_ ENGINE CAM CHAIN TENSIONER “+ Remove the cam chain tensioner D. @® Cam chain tensioner ® Cam chain tensioner bot @ Wave washor GENERATOR COVER + Remove the generator cover @. NOTE: Refer to the page 3-68 for the generator cover servicing. + Remove the gasket @ and the dowel pins @.GENERATOR ROTOR + Hold the generator rotor with the special tot }09930-44530: Rotor holder + Remove the generator rotor bolt and the washer + Remove the generator rotor (6B 09930-30450: Rotor remover with the epecial tool. + Remove the key @. (WATER PUMP “= Femove the water pump ©. NOTE: Refer to the page 5-11 for the water pump servicing ENGINE 337298 ENGINE GEARSHIFT SYSTEM + Remove the geashitt cover ©. + Remove the gasket @ and the dowel pins ©. + Remove the gearshit shaft assembly ® and the washers ©. NoTE: Refer to the page 3-70 for the gearshit shaft servicing. + Rornove the goarshit cam plate bot ®. + Remove the gearshift cam plate ©.ENGINE 999 + Remove the following tems. © Gearshit cam stopper ® Gearshit cam stopper bolt Gearshit cam stopper spring @ Washer ol FILTER ‘+ Remove the oi fiter © with the special tool. ((7" 2-14) (4 09015-40610: 0 fiter wrench OW PIPE + Remove the ol pipe . + Remove the cushion ®. a) ceakease$40_ENGINE OL PAN + Remove the oll pan ©. ‘+ Remove the gasket 2) (OIL PRESSURE REGULATOR + Remove the ol pressure regulator @. OWL STRAINER + Remove the ol strainer ©. + Remove the O-ing 2ENGINE 341 BREATHER PIPE ‘+ Remove the breather pipe ©: CRANK BALANCER ‘+ Remove the balancer cover ©. + Remove the balancer shaft arm @: + Remove the balancer shaft ®. + Remove the crank balancer assembly @ wih the washers 6)242. ENGINE CRANKCASE + Remove the crankcase bolt + Romove the PAIR valve bracket ©. NOTE: Loosen the crankcase bots diagonally and he smaller sizes fst + Separate the crankcase into 2 parts, upper and lower. + Remove the dowel pins (CRANKSHAFT + Remove the crankshaft and the thrust washers @.‘TRANSMISSION + Remove the criveshatt assembly ( and the countershaft as- sembly @. ‘+ Remove the ol soal ®. + Remove the bearing pins @ and the C-ring248 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE (A CAUTION] ‘Identity the position of each removed part. Organize the parts In thelr respective groups (Le. intake, exhaust, No.1 of No.2) so that they can be installed in thelr erg nal locations. CAMSHAFT CAMSHAFT IDENTIFICATION ‘The exhaust camshaft can be distinguished from that ofthe intake by the embossed leters "EX" (for exhaust) as against letters "IN" (fr intake), ‘CAM WEAR a + Check the camshaft for wear or damage. ‘+ Measure the cam height @® with a micrometer (6) 09900-20202: micrometer (25 - 50 mm) [EM Cam height Service Limit: (Intake): 36.48 mm (1.436 in) (Exhaust): 36.18 mm (1.985 In)ENGINE 345 ‘CAMSHAFT JOURNAL WEAR * Determine whether or not each journal is wom down to the limit by measuring the olltearance with te camshal insted inplace + Use the plastgauge to read the clearance a the widest por ton, vhichf spectied as flows: ‘Camshaft journal oll clearance Service Limit (IN & EX): 0.150 mm (0.0059 in) (02000-22901: Piastigauge (09900-22302: Plastigauge NoTE: Install camshaft journal holders to the original positions. (> 34124, 34125) + Thon the camshaft journal holser bots evenly and lago- nally fhe specie torque Tl camshatt journal holder bolt: 10m (1.0 kam, 7.0 bs) Nore: ‘Do not rotate the camshaft wit the plastigauge in place. + Remove the camshalt holders, and read the width ofthe com pressed plastigauge with envelope scale. + This measurement should be taken at the widest part. + Ifthe camshalt journal ol clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal + Replace the camshatt or the cyfinder head depending upon wich one exceeds the specification. Journal holder 1.0. ‘Standard: (IN & EX): 24.012 ~ 24.025 mm (0.9484 ~ 0.9459 in) (09000-20602: Dial gauge (1/1000, 1 mm) (09900-22408: Small bore gauge (18 ~ 35 mm) BIA camshaft journal 0.0. Standard (IN & EX): 23.959 ~ 23.980 mm (0.3433 - 0.9441 in) (09000-20208: Micrometer (0 - 25 mm)346 ENGINE ‘CAMSHAFT RUNOUT + Measure the runout using the dial gauge. + Replace the camshaft i the runout exceeds the limit (65) 09900-20606: Dial gauge (1/100 mm) (09900-20701: Magnetic stand (09900-21304: Veblock set (100 mm) [EMI camshatt runout Service Limit (IN & E 10 mm (0.004 in) CAM SPROCKETIBEARING + Inspect the sprocket teeth for wear + Ifthey are worn, replace the sprocketlcamshaft assembly and ‘cam chain as a set + tate the bearing outer race by fingers, inspect for abnormal play, noise and smooth rotation. + itis unusual, replace the sprocket/camshaft assembly with a new one. Do not attempt to disassemble the cam sprocket or right-side bearing, They are unserviceable. CAM CHAIN TENSION ADJUSTER. INSPECTION ‘+ Remove the cam chain tension adjuster cap bolt + Retract the push rod with a sorewariver Check thatthe push rod slides smoothly when releasing i. Wit does not slide smoothly, replace the cam chain tension adjuster wih a new one. o@CAM CHAIN TENSIONER INSPECTION * Check the contacting surface ofthe cam chain tensioner. + Iritis wom or damaged, replace it with a new one, CAM CHAIN GUIDE INSPECTION * Check the contacting surfaces of the cam chain guides. + ftney are worn or damaged, replace them withthe new ones. ENGINE 3.473.8 ENG CYLINDER HEAD AND VALVE \VALVE AND VALVE SPRING DISASSEMBLY ‘+ Fomove the tappats and shims @ 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 @ from vaive stem. ve Iter (09916-14910: Valve lifer attachment (09016-84511: Tweezers ‘Be careful not to damage the tappet sliding surface with the special tool. ‘+ Remove the valve spring retainer @ and valve springs ©.ENGINE 349 + Pull out the valve trom the other side. + Remove the ol seal D and the spring seat @. Do not reuse the removed oil seal + Remove the other valves in the same manner as described previously, CYLINDER HEAD DISTORTION * Decaronize the combustion chambers. * Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated * Ifthe 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) VALVE STEM RUNOUT + Support the valve using Veblocks and check its runout using the dial gauge as shown. + Ifthe runout exceeds the service limit, replace the valve. (02000-20606: iat gauge (1/100 mm) 4 09900-20701: Magnetic stand a (09900-21904: Vblock set (100 mm) TEMA Vaive stem runout Service Limit: 0.05 mm (0.002 in) \VALVE HEAD RADIAL RUNOUT ** Place the dial gauge at a right angle to the valve head face | land measure the valve head racial runout + tit measures moce than the service mt, replace the valve (6) 09900-20608: pial gauge (1/100 mm) ‘09900-20701: Magnetic stand 09900-21308: \eblock set (100 mm) IE Vaive head racial runout Service Limit: 0.03 mm (0.001 in)250_ENGNE VALVE FACE WEAR, + Visual inspoctoach va face for wee. Replace ay valve with an abnormal worn face. The thickness of the valve face decreases asthe face wears. Measure th valve face. tis out of specication, replace te valve wth anew one (623 09000.20102: Verner calipers BHA Valve head thickness Service Limit 0:5 mm (0.02 in) VALVE STEM DEFLECTION + Lit the vaive about 10 mm (0.39 in) from the valve seat ‘+ Measure the valve stem deflection in two directions, perpen- lcular to each other, by postioning the dial gauge as shown. It the detection measured exceeds the limi, then determine wether the valve othe guide should be replaced with a new one. (6B 09000-20606: vial gauge (1/100 mm) [BAD vaive stem detiection (IN & EX) Sorvice Limit: 0.38 mm (0.014 in) VALVE STEM WEAR + Ifthe vale stem is worn down to the limit, as measured with a rmicrometer, replace the valve. + Ifthe tem i within the limi, then replace the guide. + After replacing valve or guid, be sure to recheck the difecton, (6 09000-20208: Micrometer (0-25 mm) TMD Vaive stom 00. Standara(N}: 4975 ~ 4.990 mm (0.1959 ~ 0.1965 in) (EX): 4,955 — 4.970 mm (0.1951 — 0.1957 in) Nore: 1 valve guides have to be removed for replacement ater in- ‘Spectng related pars, cary out the steps shown in valve guide senveing.ENGINE 251 VALVE GUIDE SERVICING . ~~ + Using the valve guide remover, crive the valve guide out to < ward the intake or exhaust camshaft side. & wo NOTE: * Discard the removed valve guide subassemblies, * Only oversized valve guides are available as replacement (parts (Part No, 11118-14071) + Re-tnish he valve guide holes In linger head wit the reamer and hand (07016-24500: ave guide 09916-04542: Reamer handle When refinishing of removing the reamer from the valve gulde hole, always turn it clockwise + Apply engine ol to the valve guide hole, + Dive the valve guide into the hole using the valve guide in- stalor @ and attachment @. (6) 00016-44310: Valve guide installerremover ‘09916-59960: Attachment 2 NOTE: Install the valve guido unt the attachmont contacts withthe cyl. Inder head ®. ‘CAUTION Failure to olf the valve guide hole before driving the new guide into place may result in a damaged guide or head. + After instaling the valve guides, re-fnish thelr guiding bores using the reamer + Clean and oi the guides atter reaming. (6) 00016-34570: Valve guide reamer (09916-84542: Valve guide reamer handle Nore: Insert the reamer from the combustion chamber and always turn the reamer handle clockwise.326 VALVE SEAT WIDTH INSPECTION iti, a + Visually check for valve seat width on each valve face. = + Ifthe valve face has worn abnormally, replace the valve. + Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with ight pressure. + Check that the transferred blue on the valve face is uniform all ‘around and in center of the valve face. (2) 00016-10911: Valve lapper set ‘ + Ifthe seat width @ measured exceeds the standard value, or ‘seat width i not uniform reflace the seat sing the seat cuter, EG vaive seat width Standard: 0.91.1 mm (0.036 ~ 0.043 in) I the valve seat is out of specification, re-cut the seat VALVE SEAT SERVICING + The valve seats for both the intake and exhaust valves ace ‘machined to four diferent angles. The Seat contact surface Is cut at 45°, INTAKE [| | __are = | _ 30" N28 45° Naa Na 60" Nata Nant (Gp o916-21141: vaive seat cuter set (09916-22420; Vaive seat cutter (N-114) 09916-22430: Valve seat cutter (N-128) 09916-24311: Solid pilot (N-1005.0) nore: “The valve saat cutters (N12), (N-122) and (N11) are ne ded in the valve seat cuter sat 090162111), * Uso the soli pilot (100.50) ) slang withthe valve seat cutters [@ CAUTION} ‘The valve seat contact area must be inspected after each cut. + When instaling the sold plot ©, rotate it sight. Seat the pilot snugly Insal the 45° cuter, attachment and handle.ENGINE 363 INMIAL SEAT CUT + Using the 45° cutter, descale and cl the cule one oF two tums ‘+ Measure the valve seat width @ ater every cut 1 up the seat. Rotate + I the vaive seat s pied or burned, use the 45° cutter to con- dition the seat some more. NoTE: (Cut only the minimum amount necessary from the seat to pre- vent the possibilty ofthe valve stam becoming too close to the ccamshart ‘TOP NARROWING CUT +f the contact area is too high on the valve, oF Ii 1s too Wide, use the 15° (forthe exhaust side) and the 20° (fer the Intake side) to lower and narrow the contact area, BOTTOM NARROWING CUT * Ine contact area @ is too wide or too low, use the 60° cutter to narrow and raise the contact area Capt fo gh an oo ® ‘wate ornate254_ENGNE FINAL SEAT CUT “Sout wnaivo wna + I the contact area @®) Is 100 low or too narrow, use the 45° | Sanow ons eftehen cutter to raise and widen the contact area Nore: ‘Alter cutting the 15°, 30° and 60° angles, It ls possible thatthe valve seat (45°) is too narrow. If so, re-cut the valve seat to the ccorect wiath ‘+ Altor the desired seat postion and width is achieved, use the ‘45% cutter very ight to clean up any burrs caused by the pre- vous cuting operations, [CAUTION] Do not use lapping compound after the final cutis made. ‘The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This wil provide a soft surtace for the final seating of the valve Which will occur during the first fow seconds of engine operation, NOTE: ‘Aterservicing the valve seats, be sure to check the tappet clear ‘ance ater the cylinder head has been reinstaled. (2-8) + Clean and assemble the head and valve components. Fil the intake and exnaust ports with gasoline to check for leaks, * I any leaks occur, inspect the valve seat and face for burs oF ther things that could prevent the valve from sealing,ENGINE 355 VALVE STEM END CONDITION * Check the valve stem end face for ping and wear. VALVE SPRING The fore of he col springs Keeps the valve seat tight Weak: ned springs resi in redated engine power output, end often tccount ortho chatirng nse coring rom the valve mech * Check the vate spring for proper strength by measuring her fre length and also by the force required 1 compress them. + if te ering ont is ls than the soviet, orf the force requied to compress the sping doos nt fal vitin the range spectid, replace both the inner and outer springs as a set 168 09000-20102: Vernier calipers IA Vavve spring fre length (WN & EX) Service limits INNER: 35:1 mm (138 in) OUTER: 45:2 mm (1.77 in) Valve spring tension Standard ( & EX) INNER: 3.1 - 05 kg9.1 mm (6.83 ~7:7 Ibs. in) OUTER: 155 — 179 kgl96.6 mm (0417 9948 Iba/.44 i) 81-95kGh & sam:258_ENGINE \VALVE AND VALVE SPRING REASSEMBLY Insta the vatve spring seats + Apply molybdenum ol solution to each oil seal @, and press- fit them into position with the valve guide installer. (6 09016-14910: Vaive guide removerinstaler x 99000-25140: SUZUKI MOLY PASTE (a CAUTION] Do not reuse the removed oll + Insert the valves, wth thr stems costed with melybdenum oi solution all round and along the ful stem length without any break. BCAUTION When inserting each valve, take care not to damage the lip ofthe oll sea Ax 99000-25140: SUZUKI MOLY PASTE + Insta he valve springs wih the smal-pich portion cylinder head. @: Large-ptch portionENGINE 257 + Put on the valve spring retainer and using the valve iter, press down the springs, fit the cotter halves to the stem end, ‘and release the Iftar to allow the cotter @ to wedge in be- tween retainer and stem. Be sure that the rounded lip ® ofthe cotter fis snugly into the groove (Bn the stem end. (By 00016-14510: Valve titer (09916-14910: Valve lifter attachment (09916-84511: Tweezers [CAUTION] Be sure to restore each spring and valve to their original positions. + Install the tappet shims and the tappets to their orginal pos- ton. NOTE: * Apply engine oll tothe shim and tappet before fting 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, * Aftor aligning the boss (® on the cylinder head withthe sit (® fon the intake pine, instal the intake pipe, + Tighten the ciamp screws as shown, * Install he throtle body side clamps as shown, PAIR PIPE + Install the gasket ©. Nore: Tho sea! side of the gasket must faces to the PAIR pipe. + Tighten the PAIR pipe nus to the spaced torque Pa pipe nut: 10 Nem (1.0 kgf, 7.0 bx) Nore: Fifer othe page 6:29 forth pipe poston.ENGINE 259 ENGINE COOLANT TEMPERATURE SENSOR + Tighten the coolant temperatura sonsor othe specified torque. Wlengine coolant temperature sensor: 18 Nem (1.8 kgm, 13.0 tb-tt) when handling the temperature sé .age if it gets a sharp impact. ‘THERMOSTAT + Install the thermostat NOTE: Tho jiggle valve (of the thermostat faces upside. + Tighten the thermostat case bolts along withthe clamp @ to the specified torque. [2] Thermostat case bolt: 10 N-m (1.0 kgf-m, 7.0 Ib-t) WATER BYPASS UNION ‘+ Apply SUZUKI BOND "12078" tothe thread part ofthe water bypass union ‘D and tighten it tothe spectied torque. s€2 99104-31140: SUZUKI BOND “12078" [E)Water bypass union: 14 Nem (1.4 kgtm, 10.0 Io-t)380 ENGINE CYLINDER: CYLINDER DISTORTION * Check the gasketed surface ofthe cylinder for dstortion with 2 staightedgo and thickness gauge, taking a clearance read ing at several places as Indicated + Ifthe largest reacing al any postion ofthe straightedge ex: coeds he mt, replace the cinder. (195 09900-20003: Thickness gauge EA cylinder distortion ‘Sorvice Limit: 0.20 mm (0,008 in) CYLINDER BORE + Ingpeet the ender w age. + Measure the cyiner bore lamer at sx paces. for any scratches, nicks or other dam BMA cytinder bore ‘Standard: 81.000 ~ 81.015 mm (3.1890 ~ 3.1896 in) (10900-20508: cylinder gouge setENGINE 361 WATER INLET CONNECTOR * Install the O-ring and apply engine coolant. Use the new O-ring to prevent the engine coolant leak- age. + Tighton the water inet connector bl to the spocod torque. [)Weter init connector bolt: 10 Nem (10 kat, 7.0 It) PISTON AND PISTON RING PISTON DIAMETER, + Using a micrometer, measure the piston outside diameter at 15 mm (06 in) @ from the piston skirt end + Ifthe measurement is less than the lim, replace the piston, AD Piston diameter Service Limit: 80.880 mm (3.1842 in) at 15 mm (0.6 in) from the skirt end (09900-20204: Micrometer (75 ~ 100 mm) PISTONTO CYLINDER CLEARANCE + Subiract the piston diameter from the cylinder bore diameter. (= 3-60) + Ifthe piston to oylinder clearance exceeds the service limit, replace the cyinder and the piston. M Piston to cylinder clearance: ‘Standard: 0.020 ~ 0.030 mm (0.0008 - 0.0012 In)3462_ ENGINE PISTON RINGTO GROOVE CLEARANCE * Measure the side clearances ofthe Yet and 2nd piston ngs Using te hekness gage. + Hany of te ceerancosexo2e0 the Int, rpiaoe both he ps ton and piston ngs. (60000020002: Thickness gauge 09000-20208: Micrometer (0 ~ 25 mm) Piston rng to groove clearance ‘Service Limit (1st): 0.18 mm (0.0071 in) (2nd): 0.15 mm (0.0058 in) IEAM Piston ring groove with Standard (Ist 121~123 mm (20476 - 0.0484 in) (2nd): 1.01 —1.09 mm (0.0998 0.0408 in) (Oi: 201 2.03 mm (0.0781 ~ 0.0799 in) Piston ring thickness Standard (tet); 1171.19 mm (0461 ~ 0.0469 in) (2nd): 097 0.99 mm (0.0382 ~ 0.0200 in PISTON RING FREE END GAP AND PISTON RING END GAP. + Measure the piston cng free and gap using veri clipes. *+ Nox fit tho piston ing squaely into the oyler and measure te piston ring end gap using the thickness gave. + Hf any ofthe measurements exceed the service Im, replace the piston ring wih a new one. (2) 09000-20102: Vernier calipers III Piston ring free end gap Service Limit (1st): 5.8 mm (0.23 in) (2nd): 6.4 mm (0.25 in) 1B} 02900-20003: Thickness gauge Piston ring end gap Service Limit (1st): 0.50 mm (0.020 in) (2nd): 0.50 mm (0.020 in)ENGINE 3463 PISTON RING REASSEMBLY + Install the piston rings inthe order of ol ring, 2nd ring and 1st ring +The first member to go into the ol ring groove is @ spacer D. ‘Aor placing the spacer, ft the two side rails 2. ‘NOTE: ‘Side designations, op and bottom, are not applied tothe spacer, and side rails: you can position each either way. ‘When installing the spacer, be careful not to allow its {two ends to overlap in the groove. + Install the 2nd ring @ and the 1st ring @ NOTE: ‘string and 2nd ring aiter in shape. + Ist ring and 2nd ring have letters “R" and “RIN’ marked on the ‘side, Be sure to bring the marked sido to the top when ting them to the piston. + Position the gaps ofthe thre rings as show. Before inserting ‘each piston into the cylinder, check thatthe gaps are so lo- ‘cated, ARRAY noo INCORRECT (om tog and C= = Up site Sasete64_ENGNE PISTON PINS AND PIN BORE ‘Measure the piston pin bore inside clameter using the small bore gauge + Ifthe measurements out of specications replace te piston. (6 09000-20602: iat gauge (1/1000 mm) (09900-22403: Small bore gauge (18 ~ 35 mm) BRA Piston pin bore 10. Service Limit: 20.030 mm (0.7886 in) + Measure the piston pln outside dameter at three postions {sing the micrometer. + tf any of the measurements are out of specication, replace the piston pin (62) 02000-20206: Micrometer (0~ 25 mm) [EH Piston pin 0. ‘Service Limit: 19.960 mm (0.7866 i) PAIR VALVE + Remove the PAIR valve mounting bracket. + Inspect the PAIR valve body for damage, PAIR REED VALVE. ‘+ Remove the PAIR valve cover + Inspect the reed valve forthe carbon deposit. + Ifthe carbon deposit is found in the reed valve, replace the PAIR contol valve with a new one. pSPAIR CONTROL VALVE, * Inspect that air flows through the PAIR contol valve air inlet port ® tothe air outlet parts + Ifar does not low out, repiace the PAIR valve with a new one. + Connect the vacuum pump gauge to the vacuum port ofthe ceniolvaive as show in the photograph + Apply negative pressure slowly to the control valve and spect the ae a + Hfairdoes ot fow out wtin the specication, the contr! valve isin normal condo. + ifthe eon valve does not funtion within the specication, replace the contol valve wih a new one IESG Negative pressure range: 44 ~ 65:3 kPa (830 - 490 mmHg) (01017-47010; Vacuum pump gauge Use a hand operated vacuum pump to prevent the con- {ol valve damas ENGINE 3.65