, MANUEL DU PROPRIETAIR: ‘ FAHRERHANDBUCH MANUAL DEL PROPIETARK * USO E MANOTENZIONE - HANDLEIDING —__a OWNER'S MANUAL This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instruc. tions which should be read carefully before operating the motorcycle. 99011-31D56-042 ENGLISHIMPORTANT BREAKIN (RUNNING-IN) INFORMA. TION FOR YOUR MOTORCYCLE The first 1600 km (1000 miles) are the most important in the life of your ‘motorcycle. Proper break-in operation during this time will help ensure max: imum life and performance from your new motorcycle. Suzuki parts are ‘manufactured of high quality materi als, and machined parts are finished to close tolerances. Proper break-in operation allows the machined sur faces to polish each other and mate smoothly, Motorcycle reliability and pertor- mance depend on special care and restraint exercised during the break in period. It is especially important that you avoid operating the engine inva manner which could expose the engine parts to excessive heat Please refer to the BREAKIN (RUNNING-IN) section for specific break-in recommendations. WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize ‘special information the words WARN ING, CAUTION and NOTE carry spe: clal meanings and should be carefully reviewed. ‘The personal safety of the rider may involved. Disregarding this infor. could result in injury to the rider. | “A CAUTION These instructions point out speci service procedures or precautions, that must be followed to avoid damag ing the machine. NOTE: This provides special infor- ‘mation to make maintenance easier or important instructions clearer. FOREWORD Motorcycling is one of the most ex- hilarating sports and to ensure your riding enjoyment, you should become ‘thoroughly familiar with the informs: tion presented in this owner's manu al before riding the motorcycle. The proper care and maintenance that your motorcycle requires is out- lined in this manual, By following these instructions explicitly you will ensure a long trouble free operating life for your motorcycle. Your autho- rized Suzuki dealer has experienced technicians that are trained to provide ‘achine with the best possible "e with the right tools and equipment, All information, illustrations, photo- ‘graphs and specifications contained in this manual are based on the latest, product information available at the ‘time of publication. Due to improve- ments or other changes, there may be some discrepancies in this manual Suzuki reserves the right to make changes at any time. Please note that this manual applies 10 all specifications forall respective destinations and explains all equip: mont. Therefore, your model may have different standard features than shown in this manual. SUZUKI MOTOR CORPORATION (© COPYRIGHT SUZUKI MOTOR CORPORATION 1996 TABLE OF CC ‘CONSUMER INFORMATION. . LOCATION OF PA CONTROLS KEY ‘Gurion swiTcH. INSTRUMENT PANE LEFT HANDLEBAR, AIGHT HANDLEBAR, FUEL TANK CAP. FUEL VALVE: CHOKE KNOB. GEARSHIFT_ LEVER REAR BRAKE PEDAL SEAT LOCK AND HE OLDERS. SIDE STAND ‘SUSPENSION ADU: FUEL AND ENGIN RECOMMENDATI BREAK-IN (RUNN' INSPECTION BEF RIDING RIDING TIPS. ENGINE. STARTING STARTING OFF USING THE TRANS RIDING OW HLS. STOPPING AND PAR INSPECTION AND MAINTENANCE, MAINTENANCE. SC TooLs. LUBRICATION POINT FUEL TANK REMOVE RAM COVER REMQ BATTERY. ‘NR CLEANER. ‘SPARK. PLUGS FUEL HOSE. ENGINE OL ‘CARBURETOR cuurca DRIVE CHAIN BRAKESTANT (RUNNING.IN) INFORMA. YOUR MOTORCYCLE M600 km (1000 miles) are important inthe life of your Proper break-in operation time wil help ensure max: land performance from your jeycle. Suzuki parts. are red of high quality materi- ichined parts are finished lerances. Proper break-in allows the machined sur. olh each other and mate Jo raliability and perfor: pend on special care and xercised during the break: Ie is especially important void operating the engine Jer which could expose the ts to excessive heat fer to the BREAK-IN IN) section for specific scommendations. WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information the words WARN- ING, CAUTION and NOTE carry spe- cial meanings and should be carefully reviewed, The personal safety of the rider may infor A CAUTION service procedures or precautions ‘that must be followed to avoid damag: ing the machine. NOTE: This provides special infor: ‘mation to make maintenance easier ‘or important instructions clearer. FOREWORD Motorcycling is one of the most ex: hilarating sports and to ensure your riding enjoyment, you should become thoroughly familar with the informa: tion presented in this owner's manu- al before riding the motorcycle. The proper care and maintenance that your motorcycle requires is out- lined in this manual. By following these instructions explicitly you will ensure a long trouble free operating, lite for your motorcycle. Your autho- rized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equipment. Al information, illustrations, photo- ‘graphs and specifications contained in this manual are based on the latest, product information available at the time of publication. Due to improve- ‘ments or other changes, there may be some discrepancies in this manui ‘Suzuki reserves the right to make changes at any tims Please note that this manual applies to ll specifications forall respective destinations and explains all equip ment. Therefore, your model_ may have different stendard features than shown in this manual ‘SUZUKI MOTOR CORPORATION © COPYRIGHT SUZUKI MOTOR CORPORATION 1998 TABLE OF CONTENTS ‘CONSUMER INFORMATION. ...... LOCATION OF PARTS. CONTROLS Key JGNITION switch INSTRUMENT PAWEL LEFT HANDLEBAR. FIGHT HANDLEBAR FUEL TANK CAP. FUEL _VALVE CHOKE. KNOB. GEARSHIFT LEVER. REAR BRAKE PEDAL. SEAT LOCK AND HELMET HOLDERS SIDE. STAND) SUSPENSION ADJUSTMENT... FUEL AND ENGINE OIL RECOMMENDATION BREAK-IN (RUNNING-IN), INSPECTION BEFORE RIDING RIDING TIPS. ENGINE. STARTING. ‘STARTING OF. USING THE TRANSMISSION. RIDING OW HILLS: ‘STOPPING AND PARKING INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE Toots: LUBRICATION POINTS: FUEL TANK REMOVAL. FRAM COVER REMOVAL BATTERY ‘AIR CLEANER. ‘SPARK PLUGS. FUEL HOSE ENGINE ot ‘CARBURETOR cuuTeH. DRIVE CHAIN BRAKES.te —— Tunes, - SPOKE NIPPLE TIGHTNESS. SIDE STANONGHTION INTERLOCK SWITCH. FRONT WHEEL REMOVAL REAR WHEEL REMOVAL... WINDSHIELD CLEANING... LIGHT BULB REPLACEMENT. FUSES. TROUBLESHOOTING MOTORCYCLE CLEANING. STORAGE PROCEDURE. SPECIFICATIONS 45 %6 a7 a7 9 2 50 50 34 35 37 38 ra CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS ‘There are a great variety of accesso: ries available to Suzuki owners. Suzu ki can not have direct control over the quality or suitability of accessories ‘you may wish to purchase. The addi tion of unsuitable accessories can lead to unsafe operating conditions. tis not possible for Suzuki to test each accessory on the market or ‘combinations of all the available ac Ccessories; however, your dealer can assist you in selecting quality acces: Sories and installing them correctly. Use extreme caution when selecting ‘and installing the accessories for your Suzuki. We have developed some ‘general guidelines which will aid you ‘when deciding whether, and how to equip your motorcycle. Never exceed the GVW (Gross Vehi- cle Weight) of this motorcycle. The GW is the combined weight of the machine, accessories, payload and riders. When selecting your accesso- fies, Keep in mind the weight of the riders as well as the weight of the ac- essories. The additional weight of the accessories may not only create ‘an unsafe riding condition but may also affect the steering ease GVW: 425 kg (935 Ibs) tthe the prasaue oid) Front: 2.09 ka/em* [28 psi Fear: 280 Kalen? (38 ps) Any time that additional weight or ‘aerodynamic affecting accessories are installed, they should be mount- ed as low as possible, as close to the ‘motoreycle and as near the center of ‘gravity as is feasible. The mounting brackets and other attachment hard= ware should be carefully checked to ‘ensure that it provides for a rigid, non- ‘movable mount. Weak mounts can al- low the shifting of the weight and cro ate a dangerous, unstable condition. Inspect for proper ground clearance and bank angle. An it properly mounted load could critic ly reduce these two safety factors. Also determine that the “‘load"” does not interfere with the operation of the. suspension, steering or other control operations. Accessories fitted to the handlebars fr the front fork area can create seri fous stability problems. This extra \weight will cause the motorcycle to be less responsive to your steering control. The weight may also cause ‘oscillations in the front end and lead to instability problems. Accessories ‘added to the handlebars or front fork ‘should be as light as possible and kept The motorcycle may be affected by a lifting condition or by an instability incross winds or when being passed or passing large vehicles. improperly ‘mounted or poorly designed accesso: fies can result in an unsafe riding con dition, therefore caution should be Used when selecting and installing all Certain accesso the rider from his or position. This limits movement of the ri his or her control al Additional electrical overload the existin tem. Severe overtog the wiring hamess o ous situation due to trical power during the motorcycle When carrying a lo ceycle, mount tas 1 as close as possible ‘An impropetly moun ate a high center of vvery dangerous and: cycle difficult to ha the “load” can als ‘dynamics and hand cycle. Balance the b right and left side 0 ‘and fasten it secur Modification Modification of the removal of original tender the motor illegalPPLE TIGHTNESS. sonGHITION 3K SWITCH EEL REMOVAL EEL REMOVAL, LD CLEANING. LB REPLACEMENT. SHOOTING CLE CLEANING PROCEDURE. "ATIONS CONSUMER INFORMATION ‘ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS ‘There are a great variety of accesso: ries available to Suzuki owners. Suzu kican not have direct control over the quality or suitability of accessories you may wish to purchase. The addi tion of unsuitable accessories can lead to unsafe operating condi It is not possible for Suzuki to test each accessory on the market or combinations of all the available ac. cessories; however, your dealer can ‘assist you in selecting quality acces- sories and installing them correctly, Use extreme caution when selecting ‘and installing the accessories for your Suzuki. We have developed some general guidelines which will aid you ‘when deciding whether, and how to equip your motorcycle Never excoed the GVW {Gross Vehi- cle Weight) of this motorcycle. The GW js the combined weight of the machine, accessories, payload and riders. When selecting your accesso- ries, keep in mind the weight of the riders as well as the weight of the ac cossories. The additional weight of the accessories may not only create an unsafe riding condition but may also affect the steering ease. GVW: 425 kg (935 Ibs) 2 the tke pressure (cold) Front: 2.00 kp/en* (29 psd Roar: 2:50 glen! (36 ps) Any time that additional weight or aerodynamic affecting accessories are installed, they should be mount- ed as low as possible, as close to the ‘motorcycle and as near the center of gravity as is feasible. The mounting brackets and other attachment hard- ware should be carefully checked to ensure that it provides fora rigid, non- movable mount. Weak mounts can al low the shifting of the weight and cre. ate 8 dangerous, unstable condition, Inspect for proper ground clearance and bank angle. An im- properly mounted load could critical- ly reduce these two safety factors. Also determine that the “load” does ‘ot interfere with the operation of the. suspension, steering or other control operations. Accessories fitted to the handlebars. or the front fork area can create seri ous stability problems. This extra weight will cause the motorcycle to be less responsive to your steering, control. The weight may also cause oscillations in the front end and lead. to instability problems. Accessories added to the handlebars o: front fork should be as light as possible and kept The motorcycle may be affected by allifting condition or by an instability in cross winds or when being passed or passing large vehicles. improperly ‘mounted or poorly designed accesso ries can result in an unsafe riding con: dition, therefore caution should be used when selecting and instaling all Cortal the ler fror accessories displace his or her normal riding position. This limits the freedom of ‘movement of the rider and may limit his or her control ability. Additional electrical accessories may, ‘overload the existing electrical sys- tem. Severe overloads may damaga| the wiring harness or create a danger ous situation due to the loss of elec- trical power during the operation of the motorcycle. When carrying a load on the motor. cycle, mount it as low as possible and as close as possible to the machine ‘An improperly mounted load can cre ate a high center of gravity whi very dangerous and makes the motor. difficult to handle. The size of cycle the “‘load’’ can also affect the ‘odynamics and handling of the motor cycle. Balance the load between the right and left side of the motorcycle ‘and fasten it securely. Modif Modification of the motorcycle, or removal of original equipment may render illegal the motorcycle unsafe orSAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS Motorcycle riding is great fun and an exciting sport. Motorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider and passenger. These procau- tions are: WEAR A HELMET Motorcycle safety equipment starts with a quality helmet. One of the ‘most serious injurias that can happen, is a head injury. ALWAYS woar a properly approved helmet. You should also wear suitable eye protection. RIDING APPAREL Loose, fancy clothing can be uncom. fortabie and unsafe when riding your motorcycle. Choose good quality motorcycle riding apparel when riding your motorcycle, INSPECTION BEFORE RIDING Review thoroughly the instructions in the “INSPECTION BEFORE RIDING” section of this manual. Do not forget, to perform an entire safety inspection to ensure the safety of the rider and its passenger FAMILIARIZE YOURSELF WITH THE MOTORCYCLE Your riding skill and your mechanical knowledge form tha foundation for safe tiding practices. We suggest that You practice riding your motoreycle in 2 non-traffic situation until you are ‘thoroughly familiar with your machine ‘nd its controls. Remember practice makes perfect KNOW YOUR LIMITS Ride within the boundaries of your ‘own skill at al times. Knowing these limits and staying within them will help you to avoid accidents. BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS. Riding on bad weather days, especial ly wet ones, requires extra caution Braking distances double on a rainy day. Stay off of the painted surface ‘marks, manhole covers and greasy ‘appearing areas as they can be espe cially slippery. Use extreme caution at railway crossings and on metal gratings and bridges. Whenever in doubt about road condition, slow down! SERIAL NUMBER LOCATION The frame and/or engine serial num: bers are used to register the motor cycle. They are also used to assist, your dealer when ordering parts or raferting to special service informa. tion. The frame number (is stamped ‘on the steering head. The engine seri- ‘al number @)is stamped on the crank- case assembly. Please write down the numbers in the box provided below for your future reference, Frame number [Engine number: aie |JDING RECOMMENDATION FORCYCLE RIDERS le riding is great fun and an Motorcycle riding also at some extra precautions to ensure the safety of the passenger. These precau HELMET fe safety equipment starts ality helmet. One of the Us injuries that can happen injury. ALWAYS wear a proved helmet. You should F suitable eye protection PPAREL, pey clothing can be uncom- ind unsafe when riding your le. Choose good quality leriding apparel when riding reycle. IN BEFORE RIDING Joroughly the instructions in >ECTION BEFORE RIDING’ this manual. Do nat forget van entire saiety inspection the safety of the rider and er NIZE YOURSELF WITH THE YCLE g skill and your mechanical e form the foundation for practices. We suggest that riding your motorcycle in fc situation until you are familar with your machine KNOW YOUR LIMITS: Ride within the boundaries of your ‘own skill at all times. Knowing these limits. and staying within them will help you to avoid accidents. BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days, especial ly wet ones, requires extra caution Braking distances double on a rainy day. Stay off of the painted surface ‘marks, manhole covers and greasy ‘appearing areas as they can be espe. cially slippery. Use extreme eaution at railway crossings and on metal gratings and bridges. Whenever in doubt about road condition, slow down! ‘SERIAL NUMBER LOCATION The frame and/or engine serial num. bors are used to register the motor cycle. They are also used to assist your dealer when ordering parts or referring to special service informa: tion, The frame number (Dis stamped on the steering head. The engine ser ‘al number @) is stamped on the crank case assembly Please write down the numbers in the box provided below for your future relerence,LOCATION OF PARTS @ Clutch lever D Spark plug ® Lett handlebar switches @ Fuel valve strument panel q font brake fluid reservoir Right handlebar switches @® Helmet holders Throttle grip @ Battery D Front brake lever 0) Fuses hoke knob & Tools 8) Fuel tank cap ® Gearshift lever © Ignition switch ©) Footrests @ Passenger footrestsTION OF PARTS Spark plug @ Fuel valve © Throttle stop screw 9) Air cleaner ) Gearshift lever Footrests Side stand ® Seat lock © Passenger footrestsCONTROLS “OFF” POSITION All electrical circuit Key engine will not sta removed. “ON" POSITION The ignition circuit the engine can nov key connot be ren sition, “LOCK” POSITION To lock the steering bars all the way down and tum ¢ This motorcycle comes equipped with | “LOCK” postion 8 pair of identical ignition keys. Keep | key. All electrical ci the spare key in a safe place. “P™ (Parking) POS ‘The key number is stamped on a plate | When parking the 1 provided with the keys. This number | the steering end tu is used when making replacement | "ppositien, The ke keys. Please write your key number } moved and the tal In the box provided for your future | This position is for ny reference, parking to increase ‘Key number: 5 | ree Before trang th @ Rear brake fluid reservoir the "Pari ® Rear brake light switch sition, stop the ® Engine oil filler cap ‘exrmion swrrcH place the motore 2) Rear brake pedal Stand @ Engine oil drain plug © Never attempt to & Engine oil filter ‘cycle when the st ‘or you may lose ‘The ignition switch has four positions: 10 "rake fluid reservoir rake light switch ail filler cop rake pedal oil drain plug ail fiter CONTROLS KEY This motorcycle comes equipped with 4 pair of identical ignition keys. Keep the spare key in a safe place. The key number is stamped on a plate provided with the keys, This number is used when making replacement keys. Please write your key number in the box provided for your future reference, Key number IGNITION SWITCH The ignition switch has four positions: “OFF” POSITION All electrical circuits are cut off. The tengine will not start. The key can be removed. “ON” POSITION The ignition circuit is completed and, the engine can now be started. The| key connot be temoved in this po sition, “LOCK” POSITION Tolock the steering, turn the handle bars all the way to the left. Push down and turn the key to the "LOCK" position and remove the key. Allelectrical circuits are cut off (Parking) POSITION When parking the motoreycle, lock the steering and turn the Key to the "P" position. The key can now be re- moved and the tailight will remain lit This position is for night time roadside parking to increase visibility, Before turning the ignition switch to the “P” (Parking) or "LOCK" po- cycle when the ster ‘or you may lose balINSTRUMENT PANEL SPEEDOMETER (2) The speedometer indicates the road speed in miles per hour andior klom- eters per hour, ODOMETER @ The odometer registers the total dis- tance that the motorcycle has been ridden, TRIP METER @) The trip meter isa resettable odome- ter located in the speedometer as- ‘sembly. ft can be used for indicating ‘the distance traveled on short trips ot between fuel stops, Turning the knob @® counterclockwise will return the meter to zero. ‘TACHOMETER () The tachometer indicates the engine speed in revolutions per minute (wimin), ‘TURN SIGNAL INDICATOR LIGHT @) When the turn signals are being oper- ated either to the right or to the let, the indicator will flash at the same time, NOTE: if tum signal ight is not oper. ‘ating properly due to bulb filament or circuit failure, the indicator light flick- ers more quickly to notice the rider of the existence of trouble. HIGH BEAM INDICATOR LIGHT @) The blue indicator light will be lit when the headlight high beam is turned on. NEUTRAL INDICATOR LIGHT @ ‘The green light will come on when the transmission is in neutral. The light will go out when you shift into any gear other than neutral LEFT HANDLEBAR DIMMER SWITCH @ "3D" Position The headlight low beam and tal light turn on. "3D" Position The headlight high beam and taillight, turn on. The high beam indicator light also turns on. HEADLIGHT FLASHER SWITCH Press the switch to light the head. light ‘TURN SIGNAL SWITCH @) Moving the switch to the <>" po- sition wil flash the left turn signals, Moving the switch to the “=> "po. sition will flash the right turn signals. The indicator light will also flash in- termittently. To cancel turn signal ‘operation, push the switch on, ‘Always use the turn signals when you intend to change lanes or make a turn Be sure to turn off the turn signals after completing the turn or lane ‘change, 13 HORN swiTcH “) Press the switch tc CLUTCH LEVER © ‘The clutch levers ing the drive to the starting the engin transmission gear lever disengages tdometer indicates the road les per hour and/or kilom- ‘hour ER ®@ peter registors the total dis- ¢ the motorcycle has been ER tor isa resottable odome- din the speedometer as- ‘ean be used for indicating ce traveled on short trips oF fuel stops. Turning the knob erclockwise will return the AETER ©) ometer indicates the engine » revolutions per minute INAL INDICATOR LIGHT © tuen signals are being oper tothe right or to the left, tor will flash at the same NOTE: If turn signal ight is not oper- ating properly due to bulb filament or circuit failure, the indicator ight lick: fers more quickly to notice the rider of the existence of trouble. HIGH BEAM INDICATOR LIGHT (7 The blue indicator light will be lit when the headlight high beam is tured on, NEUTRAL INDICATOR LIGHT ©) ‘The green light will come on when the transmission is in neutral. The light, will go out when you shift into any gear other than neutral. LEFT HANDLEBAR DIMMER SWITCH "30" Position The headlight low bear and taillight ("Position The headlight high bear and tai light turn on. The high beam indicator light also tums on, HEADLIGHT FLASHER SWITCH @) Press the switch to light the head. light TURN SIGNAL SWITCH @ Moving the switch to the “"<3”” po- sition will flash the left turn signals, Moving the switch to the "=>" po sition will flash the right turn signals. The indicator light will also flash in- tormittently. To cancel turn signal operation, push the switch on. ‘Always use the turn signals when you tend to change lanes or make a tur ure to turn off the turn signals after completing the turn or lane change, HORN SWITCH “b+” @ Press the switch to sound the horn CLUTCH LEVER @ The clutch lever is used for disengag- ing the drive to the reat wheel when starting the engine or shifting the, transmission gear. Squeezing thi levar disengages the clutch.RIGHT HANDLEBAR ENGINE STOP SWITCH SL" Position ‘The ignition circuit is off. The engine ‘cannot start or run. “Position The ignition circuit is on and the en- ‘gine can run FRONT BRAKE LEVER @ ‘The front brake is applied by squeez: ing the brake lever gently toward the throttle grip. This motorcycle is ‘equipped with disk brake system and excessive prossure is not required to slow the machine down properly. The brake light will be lit when the lover is squeezed inward UGHT SWITCH @ “<0%"* Position The headlight and taillight turn on. "6" Position ‘The position light and taillight turn on ++" Position The headlight and taillight turn off, ELECTRIC STARTER BUTTON ” @) " @ Sis button is used for operating the orton motor, With the. ignition Switch in the “ON” postion, tho on gine stop switch in the "(9 " past fon the ransmision in netral, push tho ect starter button to operate the starter motor and star the engine NOTE: This motorcycle is equipped with interlock switches for the igni: tion circuit and the starter circuit. The engine can only be startered if: ‘© The transmission is in neutral and the clutch is disengaged, or © The transmission is in gear, the side stand is fully up and the clutch ‘is disengaged. ~_ACAUTION | Do not engage the starter motor for | ‘moro than five seconds at a time as | check the fuel supply and ig |e torte te THOUBLESHOUT ING” section). THROTTLE GRIP ®) Engine spead is controlled by the po. sition of the throttle grip. Twist it toward you to increase engine speed. ‘Turn itaway from you to decrease the engine speed. FUEL TANK CAP To open the fuel tank cap, open the loki insert the ignition Koy into the lock and tn it cleckwwse, With the the key and open the fuel tank cap. To close the fel van cap, push the cap down key inserted, lft up wit firmly with the key in the cap lock ® Fuel lovel @ Filler neck ‘the ilustraton or ‘when the fuel he expands. (© When refu engine offELECTRIC STARTER BUTTON” @)"" FUEL TANK CAP This button is used for operating the starter motor. With the ignition switch in the "ON" position, the en- gine stop switch in the “"() posi tion, the transmission in neutral, push the electric starter button to operate the starter motor and start the engine. NOTE: This motoreyelo is equipped with interlock switches for the ign: tion circuit and the starter circuit. The engine can only be startered if: ‘© The transmission is in neutral and the clutch is disengaged, or @ Fuel level @ Filler neck PAWARNING | tart oF run. ‘© The transmission is in gear, the J0 not overfill the fuel A side stand & fully up and the clutch sping fal on the hat engin. Do | esition in argued ot fill the fue tank above the bo jon circuit is on and the en: tom of the fillor neck as shown in aoe ACAUTION __ when the fuel heats up later and expan: ‘© When refueling, always shut the ‘engine off and turn the ignition ‘ey to the “OFF” position Never | refuel near an open flame. the illustration or it may overflow | \KE LEVER @ Do not engage the starter motor for ‘more than five seconds at a time as ke lver gently toward the || it may everoat the wing harness ‘tie. This motoreycle is || and starter motor With disk brake system and || not start after several {ook snd tun Ikelockwise, With tha Pressure is not required to || check the fuel supply and ignition sys. | KY inserted, lift up with the key and machine down properly. The || tems. Refer to the "TROUBLESHOOT. | °PeN the fuel tank cap. To close the rT echine down propery: The = fuel tank cap, push the cap down pe will be lit when the I section). firmly with the key in the cap lock. To open the fuel tank cap, open the ‘ock lid, insert the ignition key into the 0d inward. L ) ‘THROTTLE GRIP ®) pociee Engine speed is controlled by the po- light and taillight turn on, | sition of the throttle grip. Twist estion toward you to increase engine speed. ‘Turnit away from you to decrease the on ight and taillight turn on. ‘ : engine speed.FUEL VALVE This motorcycle is equipped with a manually operated fuel valve. There are three positions: “ON,"” “RES' and "OFF." ON" POSITION ‘The normal operating position for the fuel valve lever is in the ““ON'" po. a: Res. "RES" (RESERVE) POSITION HH the fue! level in the tank is too low, turn the lever to the "RES" position . to use of reserve fuel supply. NOTE: After switching the fuel Valve lever t0 the “RES” pasition, rofl the fuel tank at the closest gaso: fine station. After rofueling, be sure to move the fuel valve to the “ON” position. “OFF” POSITION ‘Turn the lever to the "OFF position whenever stopping the engine for more than a few minutes. CHOKE KNOB The carburetor is equipped with a choke system to provide easy start: ing when the engine is cold. When starting the cold engine, pull the choke knob all the way toward you. The choke works best when the throttle is in the closed position. ‘When the engine is warm, you donot need to use the choke system for starting, NOTE: Refer t0 the RIDING TIPS section of this manual for the engine starting procedure. GEARSHIFT LEVER a This motorcycle has mission which opera shift properly, pull and close the thro time you operate th Lift the gearshift lev dopross the lever to tral is located betw gear. When neutral i or lift the lever halts and 2nd gear. A CAU 8 light is tiously release thee ly to determine ‘transmission i posit Reduce the motorey downshifting. Whe the engine speed sho bofore the clutch i Prevent unnecessar drive train compan tireVE joreycle is equipped with a ‘operated fuel vaive. There positions: “ON,” “RES” \ G t | U on osiTion pal operating position forthe lever isn the “ON” po Res RESERVE) POSITION evel in the tankis too low. lever to the “RES” position f reserve fuel supply After switching the fuel er to the “RES” position, fuel tank atthe closest gaso- n. After refueling, be sure the fuel valve to the “ON” orF “OFF” POSITION ‘Tut the lever to the “OFF” position whenever stopping the engine for more than a few minutes. CHOKE KNOB eg The carburetor is equipped with a ‘choke system to provide easy start- ing when the engine is cold, When starting the cold engine, pull the choke knob all the way toward you, The choke works best when the throttle is in the closed position. When the engine is warm, you do not need to use the choke system for starting. NOTE: Refer 10 the RIDING TIPS section of this manual for the engine starting procedure. GEARSHIFT LEVER ‘This motorcycle has a 6-speed trans. mission which operates as shown. To shift properly, pull the clutch lever and close the throttie at the same time you operate the gearshift lever. Lift the gearshift lever to upshitt and depress the lever to downshift. Neu: tral is located between low and 2nd gear. When neutrals desired, depress or lift the lever halfway between low ‘and 2nd gear. A CAUTION ‘When the transmission is in ‘the green ir ‘ment panel wil be it However, even though the light sly Reduce the motorcycle speed before downshifting. When downshitting, the engine speed should be increased before the clutch is engaged. This will prevent unnecessary wear on the drive train components and the rear tireTounlock the seat lock, insert the iG sie STAND NOTE: After riding the motorcycle ee nition key into the lock and turn it] aiceviousinemenamnait placate lock te sent. Heer lubricate the side stand pivot and in- Seat hook to the saat holding brack Aubrcate the s ‘and push down the seat frmiy un {il the seat snaps into the locked position. There are helmet holders u Ger the seat. To use them, remove t Seat, hook your helmet fastener ring to the holder and refit the seat. ‘SUSPENSION ADJUSTMENT ean suspension oo Sp Pa Aart uaa enh fs pon, Sree ascent foe os by er This motorcycle is equipped with a | authorized Suzuki dealer, since a spe- vscoouin bts te Depressing the rear brake pedal will ‘apply the rear disc brake. The brake light willbe illuminated when the rear SEAT LOCK AND HELMET eee The side stand/ignition_ interlock “itch works as follows: It the side stand is down and the ‘eansmission i in gear, the engine can not be started IF the engine is running and the transmission is shifted into gear withthe side stand down, the en gine wil stop running. * IF the engine is running and the side stand is put down with the transmission in gear, the engine will stop runnin, may come loose and interfer ah Greene interlock switch for proper operation | before riding, according tothe instruc: | ‘ions in the SIDE STANDJIGHITION IN- TERLOCK SWITCH section. If the switeh is not working and the sido stand is left down, it may interfere with rider control during a left turn, © Do not operate the motorcyc ‘with a helmet fastened to the . mot holder. The helmet may int fere withthe safe operation oft ‘motorcycle pall up on is securely latched. ftSPECIFICATIONS cLecTRICAL mtion tng Electronic ignition (CON e Pea 2365 mm (93.1 in) ... For Switzeriand and spark plug. 3, 8.7.0.6 above 4300 rimin ta “, eieeas £2230 mm (87.8) For ohors snare f) JA 43.24C172 amino HR Sa : ieieeteene eat ae eee 230 mm (9.1 in) 1 Brake, =. Seat height 1830 mm {36.0 n) I Bziw2 Sees Renee =r nae ae reo nestor ‘gh on a I ecarmae gasncogoel a a a eta q Teresa ee ‘Bore 105 mm (4.134 in) q “onal eee ape : 12v Ww Ss eer att cco meer Semi ee preeermetes enum Fears = ae gaan il sUsaa ‘Starter sya: St gece Genero wh fer he 2S° 1 200. 282.4 US tmp. peor? en ees nee rao =e ioe a oe eacey ae Pare aa ieee Babee iscthe Peed tee once oa age = Leone tr ee Sevthageemen patent at faa am fees Ht sae cores oe tae Zoey owe sre 1308017 68, ubeSTORAGE PROCEDURE the motorcycle is to be left unused {for extended period af time for wint storage or any other reason, the machine needs special servicing re {quiring appropriate materials, equip~ ‘ment and skill. For this reason, Suzuki recommends that you trust this main- tenance work to your Suzuki deale’ If you need to service the machine for storage yourself, follow the general guidelines as follows. ‘MOTORCYCLE Clean the entire motorcycle. Place the motoreycle on the side stand on a fiem, flat surface where it will not fall ‘over. Turn the handlebars all the way to the left and lock the steering, and remove the ignition key. FUEL © Fill the fuol tank to the top with fuel mixed with the amount of gasoline stabilizer recommended by the stabilizer manufacturer. ‘© Run the engine for a few minutes Until the stabilized gasoline fils the carburetors. NOTE: Make sure that the fuel valve is in “OFF” position. ENGINE '* Pour one tablespoon of motor oil into the spark plug holes. Reinstall ‘the spark plugs and crank the en gine a few times. ‘© Drain the engine oll thoroughly and fill the crankease with the fresh en- gine oil all the way up to the hole. BATTERY '@ Remove the battery from motorcycle. {A CAUTION ‘sure to remove the negative inal first, then remove the po ‘terminal. © Clean the outside of the batt ‘with a mild detergent and re ‘any corrosion from the termi ‘and wiring harness connecti ‘© Store the battery in @ room at ‘freezing. TIRES Inflate the tires to the normal spet cations. EXTERNAL ‘© Spray all vinyl and rubber with rubber preservative. ‘© Spray the unpainted surfaces rust preventative. ‘© Coat the painted surfaces wi PROCEDURE FOR RETURNING. SERVICE Clean the entire motorcycle. Reinstall the battery. A CAUTION Be sure to connect the positive ‘minal first, then connect the ‘terminal. fiemove the spark pugs. Turn the Sngine afew times by putting the ‘remission intop guar and tr tg tho roar wheel, Reinstall the Sor pgs. ran the engine oll thoroughy. Replace the ol fit with a now one and pour fresh of 36 outinad rrthe manual Adjust the pressure of tires as scribed inthe TIRES section, (Covina al places 8s netted inthis manual Bo the “Inepection Batre Fi as listed in this manual. eIgnition System Check 1. Remove two spark plugs and reattach one of them to the spark plug lead. 2. While holding the spark plug firm- ly against the engine, push the starter switch with the switch in the “ON” po: engine stop switch in the "” C) position, the transmission in neu- tral, and the clutch disengaged. HH the ignition system is operat- ing properly, a blue spark should jump across the spark plug gap. If there is no spark, consult your ‘Suzuki dealer for repairs. A WARNING Do not hold the spark plug close to the open spark plug hole in the cylinder head as gasoline vapor inside the cylinder could be ignited, creat: ing a fire hazard. To reduce the chance of electrical shock, hold the ‘metal shell of the spark plug against ‘an unpainted metal portion of th gine. Due eal. shock, condition or pacemaker should avoid this eheck. ENGINE STALLING 1. Check the fuel supply in the tank. 2. Check the ignition system for! termittont spark. 3. Check the idle speed. MOTORCYCLE. CLEANING: Woshing the Motorcycle hen washing the motorcycle, fol- \v the instruction below: Femove dirt and mud from the motorcycle with running water. You may use a soft sponge or brush. Do not use hard materials which can scratch the Wash the entire motorcycle with 2 mild. detergent or car wash soap using a sponge or soft cloth. The sponge or cloth should be frequently soaked in the soap solution ACAUTION | Oil cooler fins can be damaged by spraying high pressure water on ‘thom. Do not spray high pressure | water on the oil cooler fins. OTE: Avoid spraying oF allowing to flow over the following * ignition switch * Carburetors Brake master cylinders ‘Once the dirt has been complete- ly removed, rinse off the deter gent with running water. After rinsing, wipe off the motor cycle with a wet chamoise or cloth and allow it to dry in the shade. 5. Check carefully for damage to painted surfaces. If there is any damage, obtain “’touch-up"” paint-and ‘touch-up’ the ‘damage following the procedure below: 2. Clean all damaged spots and, allow them to dry. b. Stir the paint and "touch-up" the damaged spots lightly with a small brush. ©. Allow the paint to dry com: pletely. Waxing the Motorcycle ‘After washing the motorcycle, wax ing and polishing are recommended to further protect and beautify the paint. * Only use waxes and polishes of good quality. ‘© When using waxes and polishes, observe the precautions specified by the manufacturers, Inspection after Cleaning For extended life of your motorcycle, lubricate according to ‘“LUBRICA TION POINTS” section. ating the motorcycle with wet brakes can be hazardous. Wet brakes ‘may not provide as much stopping power as dry brakes. This could lead {to an accident. Test your brakes af- | ter washing the motorcycle, while rid- ing at slow speed. If necessary, apply brakes several times to let friction dry ‘out the fining, Follow the procedures in the Ne ‘SPECTION BEFORE RIDING” section to check your motorcycle for any problems that may have erisen dur- ing your last rideFe a sh fhe replacement bulb, Pu 4 Teng ution oh le using, FUSES 4 ‘The fuses are located unde the seat They re designed to open when a cit cuit overload exists in individual elec- trical system circuits. if any electrical system fails to operate, then the fuses must be checked. Spare fuses are provided inside the fuse box. Leet fe Ruways bo sure to replace blown fuse with the correct perage fuse. Never use a su tote for example, aluminum reir to ranace blown @ Ifa fuse blown out aot ‘time, it means that you have a major electrical prs Mow shuld canslt Your Su |___ seater immediatly. use ust ToS GA HAIN fe potecteal ea create 2, 308 DECOM fuse protects decompression system. a. Toa HEAD fuse provects neasight and high beam ¥ or ight 4. SOA'SIGNAL fuse protects turn signal ight, rm signal ‘Mtortghts and Brokelight 54 TROUBLESHOOTING NOTE: It is best to consult your Suzuki dealer before attempting to troubleshoot any problem. if the nachine is still within the warranty inen the Suzuki dealer should be con- sulted before any repairs are attempt od on the machine by yourself. Tampering with the machine while in warranty may affect warranty con- “eration Ifthe engine refuses to start, perform ihe following inspections to deter- ine the cause. Fuel Supply Check Make sure there is enough fuel in the fuel tank ‘Check that the fuel valve isin he ‘ON position, Make sure there is enough fuel reaching the carburetor from the fuel valve, 2, Loosen the drain screw locat- ed under the carburetar. Drain the fuel from the carburetor into a container. o not allow the fuel to spill, Catch ‘he fuel ina container. Do not allow el to come in contact with the ny smoking materials before forming this cheek, and stay away om any other fire or heat source. ». Place the empty container un- der the carburetor. Turn the fuel valve to the “OFF” posi tion and see if the fuel flows from the drain hole ©. Turn the fuel valve lever tothe 55 “ON” position. 4. Drain the fuel and tighten the drain screw. e. Push the electric starter but- ton for a several seconds to crank the engine reffering to the STARTING THE ENGINE, section. f. Loosen the drain screw and check that the carburetor is filled back up with fuel. 4. Tighten the drain screw. It fuel is reaching the carburetor, ignition system should be checked next.EEE EEE —————_ HEADLIGHT BEAM ADJUSTMENT ‘Tho headlight beam can be adjusted both horizontally and vertically if necessan ‘To adjust the beam horizontally: Turn the adjuster (@) clockwise or counterclockwise. ‘To adjust the beam vertically: Tum the adjuster @) clockwise or counterclockwise. ‘TURN SIGNAL LIGHT 1, Remove screws and the let 2. Pushin on the bulb, turn itt left, and pull it out. 3. To fit the replacement bulb it in and turn it to the right pushing [a cauTION” Fer sting te os, bert to overtghten the three | Screws lest the lens should 82 {AIL/BRAKE LIGHT To replace the tailbrake light bulb, follow the procedure below: 1. Loosen the screws and remove the lens Push in on the bulb, turn itto the loft, and pull it out ‘fit the replacement bulb, push in and turn it to the right while pushing. A CAUTION ‘ter setting the lens, be careful not 10 overtighten the two. securing ‘ovews lest the lens should break. LUcensePLare Licht replace the leense plate Ight bl folow the procedure below. 1. Remove two rubber caps @. 2 3. Pushin onthe bulb unit Sl, tur 40th left, and pull it out. “4‘When reinstalling the rear wheel, bbe sure to follow the procedure outlined in tho DRIVE CHAIN AD- JUSTMENT section. If you have found it necessary to LIGHT BULB REPLACEMENT The wattage rating of each bulb) shown on the chart below. Wh replacing a burned out bulb, lw Use the exact same wattage rati Using other than the specified rat ‘can result in overloading the elec cal system or premature failure HEADLIGHT tne procedure below: ‘fo replace the headlight bulb, follow smove the rear wheel, it is very | | bulb. orton thatthe nts and bo | tora te the proper spc Headlight T2v 60/58) el ca ! ‘and retorqued by your authorized Tail/Brake light 12 5/21" Stzuk eae, ? rconoe plat ght | 12V 5 Do not ride the motoreyele until | Remove four screws @ right & has been WINDSHIELD CLEANING LP Clean the windshield with a soft cloth ‘and warm water with a mild deter: ‘gent. If scratched, polish with a com mercially available plastic polish Replace the windshield if it becomes scratched or discolored so as to ob: Struct view. When replacing wind: Shield, use Suzuki replacement windshield left side) and remove the wind- shield. ctl Remove for vata ign it side) ‘and. slide the. eadi housing forwards ca 4. Unik te pele and pull out bulb ©. =o A CAUTION) Tis wot we lee eo ul, When replacing the head Halbert ach Sts bol rel bw be shortened. NOTE: When reinstalling the rubber ‘cap, make sure that its arrow mark faces upward.5. Unscrew the axle shaft, then draw it out. 7. To reinstall the wheel assem 8. After installing the wheel, 2 A CAUTION Never squeeze the front brake I with the front wheel removed. It very difficult to force the pads © the caliper assembly and br: fluid leakage may result. reverse described, the sequence the brake several times to res the proper lever stroke. © Do not ride the motorcycle the front brake lever has sumed” the pads and restore the pro lever stroke and firm feel © If the front wheel has to bo moved, it is very important have the loosoned nuts and {A CAUTION | Locate the speedometer box so that the cable 6. Slide the front wheel forward, ‘smoothly without an excessive REAR WHEEL REMOVAL 1, Place the motoreycle on the side Pace eycle on the sid 2. Remove the axle nut. Lift the rear end of the motorcy- cleup and place ajack or a block under the engine or chassis tubes. do not touch the het muffle nutter beaiyoae eee 4. Draw out het shat 5. With the weal moved forward femove, the chain tom the ‘sprocket. "he 6. Rill the veer wheel assembly rearward ___ A CAUTION ‘Never ‘eas oe ar el fone Nh very difficult to force Tac ame 7. Toroplacethe wheel reverse the envi seins ised iran te whee po thebrate several no ana they heck thatthe whee! otter _TIRE TREAD CONDITION Operating the motorcycle with exces: sively worn tires will decrease riding Stability and can lead to loss of con: trol. It is recommended that a tire be replaced when the remaining depth of tire tread becomes 4.0 mm (0.16 in) or loss, jhe standard tire on '90/90-21 54S. in front and a ¥30/80-17 65S on the rear. The use ‘of type which is other than original | ‘equipment can lead to stability problems. SPOKE NIPPLE TIGHTNESS Check the tension of spokes to fy the tightness of the spoke nippl The tension of the spokes can checked by squeezing the sp% ‘with your fingers. If 2 spoke nippl Toose, the spoke will bend more t the others. The tension can also: ‘checked by hitting the spokes wit small metal bar. If the spoke nipph foose, it’s sound will be dul. ‘To tighten the spoke nipples pr ly, tighten them equally to the sp fied torque. Loosened ‘overtightened spoke nipples ‘cause unequal tension of spokes. ‘may result in distortion of the wt fim, Contact your Suzuki dealer this service to be performed. SIDE STANDIIGNITION INTERLOCK switch Ccheck the side stand/ignition inter ck suite for proper operation as follows: |. Sit on the motoreyele in the nor- ‘mal riding position, with the side stand up, Shift into first gear, hold the clutch in, and start the engine. ‘While continuing to hold the clutch in, move the side stand to the down position, | the engine stops running when the sue stand Is moved to the down po- sion, then the side stand/ignition in- lock switch is working properly. If engine continues to run with the stand down and the transmission ‘ear, then the side stand/ignition ‘erlock switch is net working erly. Have your motorcycle in- ected by an authorized Suzuki deal- "oF @ qualified service mechanic, "ake sure that the side standigntion interlock switch is working property before riding. If the switeh working and the side stand is ‘own, it may interfere with rider con- ‘ol during a left turn, FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand. 2. Remove four bolts @ and remove the engine under guard, MG 3. Loosen the axle holder bolt @, 4. Lift the front end of the motorey- cle up and place a jack or a block under the chassis tubes or the engine.® Grooved wear limit line F A CAUTION Do not squeezeldepress the brake leveripedal wien the pas bho i" thoi postions tis fil to ps the ptns bok and rake hd ak la | REAR BRAKE PEDAL ADJUSTMI ‘The rear brake pedal position must properly adjusted at all times or disk brake pads will bear against disk causing damage to the pods to the disk surface. Adjust the b pedal position in the follo\ Loosen tock nut @, and ro sh rod © to locate the B16 mm (0.20.6 in) bol the top face of the footrest: Retighten lock nut @) to 806 push rod @ in the propee NOTE: After the rear brake pedal justment, check if the brake li lit when the rear brake is operated. ‘adjust the brake light switch, turn ‘adjuster so that the brake light. ‘come on just before a pressure ris felt when the brake pedal’ depressed. 44 EAR BRAKE LIGHT SWITCH » sdjust the brake light switch, turn switch body and raise or lower it tat the brake light will come on \ before a pressure rise is felt when brake pedal is depressed TIRES ‘he tires on your motorcycle form the link between your motorcycle ie road. Proper tire inflation pressure, condition, load "ype are important conditions for you ‘0 monitor. Failure to follow these vvarnings may result i ‘ue to tre failure or matarcyele con- «ol diffic ach day before you ri Do not overload your tires. © Replace tires when tread is worn ‘0 specified limits or if tires show visual evidence of damage, such a cracks or cuts. TIRE PRESSURE AND LOADING Proper tire pressure and proper tire loading are important factors. Over loading your tires can lead to tire failure and loss of motorcycle control. you ride, and be sure the pressur Correct for the motoreycle load ac. Cording to the table as follows. Tire pressure should only be checked and adjusted before riding, since riding will heat up the tires’ and lead to higher inflation pressure readings. Check tire pressure each day am Cold Tire Inflation Pressure SOLO] —TWOUF | ative | BE 175 kPa | 200 kPa FRONT | 1.75 kglem* | 2,00 ko/em= 25 psi 29.psi 200 kPa | 250 KPa REAR | 2.00 kgiem? | 2.60 kglem? [29'per 36 pat Under-inflated tires make smooth cor- rering difficult, and can result in rapia tire wear. Over-inflated tires have a ‘smaller amount of tire in contact with the road, which can contribute to skidding and loss of controlBRAKES ‘This motorcycle utilizes front and rear disc brakes. Properly operating brake systoms are vital to safe riding. Be sure to perform the brake inspection requirements as schedule BRAKE SYSTEM strongly advise you to have your ‘authorized Suzuki dealer perform ical manner. ¢ Disc brake systoms operate under extremely high pressures. For safety, the brake hase and brake ‘uid should be changed at inter vals of no longer than those scheduled in MAINTENANCE ‘SCHEDULE section of this manual Inspect your brake system for the fol lowing items daily: ‘© Inspect the front and rear brake system for signs of fluid leakage. ‘© Inspect the brake hose for leakage fr a cracked appearance, ‘© Check the wear of the disc brake pads. ‘© The brake lever and pedal should hhave the proper stroke and be firm ‘at all times. BRAKE FLUID layed or if it comes in contact skin or eyes. Contact your physic ‘A CAUTION "© This motorcycle uses. a p ‘serious damage will result to brake system. ‘© Never use any brake fluid that been stored in a used or un stored for long periods as absorbs moisture from the si. © Use only DOT 4 brake fluid. © Do not spill any brake fluid painted or plastic surfaces as ‘will damage the surface seve EAR heck the brake fluid level in both * and rear brake fluid reservoirs ‘the level in either reservoir is below ve lower mark, add DOTA brake fluid nd inspect brake pad w ‘and leaks. OTE: Rear brake fluid reservoir is chind the right frame cover. Check ® fluid level through the inspection indiow of the frame cover. BRAKE PAD Inspect the tron and rear brake pads by noting whether or nat te ton pads ara worn dovn othe grooved limit fine. If pad is worn to the aroove init inet ms be ropaces With « new one by your authored Suzuki ‘dealer or qualified service mechan il the brake lever pedal hi been “pumped” several times to ex: tend the pads and restore the proper leveripedal stroke and firm feel.Damage to he drive chain means that tho sprockots may also be damaged IRepact the sprockets forthe. fl lowing 2 Excessively worn tooth ® bBoken or darmaged teath * Loose sprocket mounting nuts {f you find any of these problems with ‘your sprocket, consult your Suzuki dealer. Worn Good DRIVE CHAIN CLEANING AND ‘OlLING ‘This drive chain has special 0" rings that permanently seal grease inside. Clean and oil the chain periodically, as follows: 1. Cleaning the chain with keroser i strongly recommended. If t chain tends to rust, the intervs must be shortened. Kerosene ‘ pattoleum product and will Vide some lubrication as well cleaning action. {- A CAUTION ‘areas fluids have a strong dissol ‘er that could damage the “O" ris See ‘chain would have to be replaced. 2. Allow the chain to dry, then lu cate the links with 3 drive chi lubricant or motor oil (Si 20W/50).. ‘A CAUTION solvents and additives which cout damage the “O" rings in your ch Use a drive chain lubricant cifically intended for use chains. DRIVE CHAIN ADJUSTMENT: Adjust the drive chain slack to the proper specification. The chain may require more frequent adjustments tnan itis with periodic maintenance Jepending upon your i Excessive chain slack could cause the chain to come off the sprockets and result in an accident or serious engine \iamage. The drive chain adjustment should be checked every time the machine is operated. 30-45 mm 0.251.819) $e The slack of the drive chain should be 30—45 mm (1.2—1.8 in) as meaured at the mid-point between the two sprockets. 1. Place the motoreycle on the side stand, 2. Loosen the axle nut (. 3. Turn the right and left adjuster @ to obtain the correct slack. at the same time, align both right ‘and left adjusters by referring to the reference marks @). 4. Tighten the axie nut securely NOTE: The two sprockets should be inspected for wear when a new ‘chain is installed and replace thern it necessary, NOTE: The chain is an endless type ‘chain tno master link) for maximum Strength. Chain replacement requires ‘that the swingarm be removed. Trust this work only to a qualified techni- ian, Never installa master Ink typees THROTTLE CABLE ADJUSTMENT | Pulling cable ploy The pulling cable should be adjust to have a cable play @ of 0.5—1 ‘mm (0,020.04 in) as shown in An twin throttle cable system is used in this motorcycle: One cable @)is for pling ond the other cable © for rata a adjust the cable play, | Fig. I the adjustment is necessa seen i returing cable fist end | exjust the cable playin the follow en adjust the poling cable way: _ 1, Turn the handlebars all the. to the lof 2. Loosen the lock nuts (®,), 3. Turn the adjuster (@) or move acjustor @ to obtain the ca ply, @. of 05-10 Returning cable play (0.02—0.04 in). 4, Tighten the lock nuts (©.@) courely. {A CAUTION After the adjustment is compl ‘The returning cable should be adjust: ed to havea thread length ©) of 2~3 ‘mm (0.080. 12 in| as shown in the Fig. If the adjustment is necessary, adjust the thread length in the follow: ing way: 1. Loosen lock nuts @) 2. Move the adjuster @) to obtain the thread length (2) of 2=3 mm Excessive cable play could cause ‘able ond come off and interfere | safe operation. After completing be adjustment, check that the hi (0.08-0.12 in). dlobars movement does not raise 3. Tighten the lock nuts @ se- ile sped and thatthe th curely ‘stip returns smoothly and a |S 38 cLuTcH 1048" (o4-05im ne play of the clutch lever should be )-18 mm (0.4=0.6 in) as meas- ted at the clutch lever end. If you the play of the clutch incorrect, st itn the following way. Loosen the lock nut (2) and tun in the adjuster @) as far as it will 90. Loosen the lock nuts @) and relo- cate the adjuster @ to obtain the correct play. Minor adjustment can be made with the clutch lever side ad- luster @. Tighten the lock nuts @ and @) A CAUTION Any maintenance of the clutch othar ‘han the eluteh eable play adjustment ‘hould be porermed by your Suzuki Coaler. DRIVE CHAIN This motorcycle has an endless drive chain constructed from spe ‘materials. It does not use a master link. We recommend that you take your motorcycle to an authorized ‘Suzuki dealer ifthe drive chain needs, replacing. The condition and adjust. ‘ment of the drive chain should be! checked each day before you ride, Al- ways follow the guidelines below for inspecting and servicing the chain, MGS For maximum safety, the drive chair ion abdadlueinent shui be coast pier fe orsotee ts mote Inspecting the Drive Chain When inspecting the chain, look for the following: © Loose pins © Damaged rollers © Dry oF rusted links inked or binding links © Excessive wear © Improper chain adjustment If you find anything wrong with the drive chain condition or adjustment, correct the problem if you know how. necessary, consult your authorizes Suzuki dealer.1. Remove the engine ol filer cap ®. 2. Place adrain pan under the drain plug. 3. Remove the drain plug @ with 2 wrench and drain out the engin« «il while holding the motorcycle vertically omperatare maybe Nigh enagh to burn you when the iain lo Toosened Wait unt ‘the drain plug is cool enough to touoh with bare han ‘© Be careful not to touch the ex is hot; a hot 4. 5 \ Refit the drain plug and gasket Tighten the plug securely with. Remove the bolts @ holding t 6. Replace the oil filter ©) wit new one. [A CAUTION Insert the filter with the open ond ‘the engine and make sure that t filter is seating property. Before fitting the engine oil filter cover, be sure to check that the filter spring @ and the "0" ring 7) are fitting correctly. OTE: Use a new “0” ring each ne the filter element is replaced. Tighton the bolts securely. Pour approximately 2700 mi (2.9/2.4 USiimp qt) of new oil through the filler hole and refit the filler cap. Bo sure to always use the specified engine oil With the engine running, look fully for leaks at the ol filter and drain plug. Run the engine at various speeds for 2 to 3 minute ‘Stop the engine and wait a few minutes. Check the oil level ‘again. Ifthe oll level is lower than the “F” line, add new oil until it reaches the “Fling. Check for leaks egain. CARBURETOR The carburetor is factory set for the best performance. Do not attempt to alter its setting. There are two items of adjustment, however, under your care: idle speed and throttle cable play. IDLE SPEED ADJUSTMENT 1. Start up the engine and let the engine run until it warms up fully 2. After engine warms up, turn the ‘throttle stop screw () located on the carburetor in or out so that engine may run at 1300+ 100 vimin,Plug Replacement Guide REMARKS, Ththe stendord plug wet in appearance or very dark in colour, replace with this ae Standord NGK DPREEA.S [DPROEA.S POG When replacing spark plugs, replac the right and left plugs at the same time and employ the same type of ‘lug for both sides. A CAUTION Do not overtorque or eros thread the spark plugs of the aluminum ‘threads of the cylinder head will bbe damaged. ' ‘© Do not allow contaminants to enter the engin through the spark plug holes when the plugs are temoved. ‘© The standard spark plug for this motoreycle has been carefully solace te all opera Spark plug eer inet that standard spark plug its est to consult your ‘alternate plug or heat range. The selection of an improper spark ‘plug can lead to severe engine FUEL HOSE ENGINE OIL {Long engine life depends much on the loction of a quality oll and the peri- sic changing of the engine oll, Daily ‘gine oil level checks and periodic Changes are two of the most impor- ant maintenance items to be per- ormed. ENGINE OIL LEVEL CHECK eck the engine oll evel with engine \ dipstick ( . The dipstick comes ‘together with the oll filer cap. The ine oil level should be between the F (full and “L" (low) level ines. To. eck the engine oil level, hold the otorycle vertically and insert the stick until the filer cap touches the or hole upper edge. A CAUTION ever operate the motorcycle if the ‘engine oi! level is below the “L" (low) in ine oil dipstick. Never ENGINE OIL AND FILTER CHANGE Change the engine oil and oi iter at the initial 1000 km (600 miles) and at each maintenance interval. The en- gine oil should be changed when the engine is hot so that the engine oll wi drain thoroughly from the engine. T? Procedure is as follows‘AIR CLEANER If the element has become clogged with dust, intake resistance will in- crease with a resultant decrease in power output and an increase in fuel coneumption. Check and clean the cleaner periodically according to the following procedure. 1. Remove the seat 2. Loosen the screws @ and take off the air cleaner element. 3. Carefully use an air hose to blow the dust from the air cleaner ‘element. If air pressure is usad on the inside, dirt will bo forced into the pores of the air cleaner element restricting the flow through the air cleaner 4. Refit the cleaned element or new air cleaner element in t reverse order of removal. Be solutely sure that the air clean ‘loment is securely in positios ‘A CAUTION If driving under dusty conditions, the air cleaner element must be leaned or replaced more. fre- ‘quontly than it is with periodic tion. The life of the engine de: pends largely on this single Component. SPARK PLUGS ‘A normally operating spark plugs are «ght brown. Ifthe standard plugs are rot suitable for your riding, change them according to the chart below: s OTE: This motoreycle is equipped vith two spark plugs for its one viinder. To remove the right side slug, the fuel tank must be removed. ‘he right side plug’s condition can be ‘resumed by inspecting the left side olug. 0.80.8 mm | pe 081 0.035 i) Remove the carbon deposits periodi- ly from the spark plug with a piece ‘of hard wire or pin. Readjust the spark plug gap to 0.80.9 mm {0.031—0.035 in} by using a spark plug gap thickness gauge. Whenever removing the carbon deposits, be sure to observe the oper ational color of each spark plug’s por celain tip. This color tells you whether ‘or not the standard spark plug is suita ble for your type of usage. A normal ‘operating spark plug should be light brown.‘A CAUTION When reinstalling the fuel tank, be careful not to damage the fuel hoses. | Fuel tan, satan tan covers mast be reinstalled securely. After rein lation, cheek that they are positioned without looseness. FRAME COVER REMOVAL Remove the seat 2. Remove the screws ©. 3. Unhook the frame cover hoot @ and remove the frame cove BATTERY ne battery is located under the seat. is battery is sealed type and re- wures no maintenance. Have your saler check the charging condition battery periodically. ‘A CAUTION _ lever charge a battery while stil in the machine as damage may result to the battery or regulator] rectifier. ‘© When disconnecting the battery torminals, be sure to remove the negative terminal first, then re- ver exceed ‘maximum charging rate © Never attempt to open the battery sealing caps even when charging the battery, A CAUTION Reversing the battery lead damage the charging system and bat. tery. The red lead must go to the (+) positive terminal and the black (or | black with white tracer) ead must go | to the (~) negative ter Ing tase comoctins wil damage the system and the battery.Too.s To assist you in the performance of periodic maintenance, @ tool kit is Supplied and located under the seat. LUBRICATION POINTS Proper lubrication is important f smooth operation and long lite each working part of your motoro} ‘le and also for safe riding. Itis ag practice to lubricate the motorc\ after a long rough ride and after ting it wet it in the rain or after wash ing it, Mejor lubrication points indicated as follows. (Clutch lever holder and clut ‘cable ‘Side stand pivot and spring he Drive chain Throttie cable ‘Brake lever holder “Brake pedal pivot ® Motor cil Grease FUEL TANK REMOVAL The fuel tank can be removed when servicing some parts of your motor- ‘yole. When removing the tank, fol ‘ow tho procedure below. 1. Stop the engine and turn the fuel valve to the “OFF” position, Remove the seat. screws @ (right & the screw @ and remove the fuel tank side covers. 4. Loosen two bolts @. NOTE: When removing the fuel tank side covers, take care not to break their hooks. 5. Loosen two bolts @, 6. Remove the fuel hose) from the fuel valve. avoid spilling fuol on a hot engine. Do ‘not smoke, and make sure there are ‘no open flames or sparks in the area. 7. Remove the fuel tank by sliding it rearward,INSPECTION AND MAINTENANCE, MAINTENANCE SCHEDULE ‘The chart indicates the intervals be- ‘tween periodic services in miles, kilometers and months. At the end of each interval, be sure to inspect, check, lubricate and service 2s in structed. If your motoreycle is used under high stress conditions such es continuous full throttle operation, or is operated in a dusty climate, certain services should be performed more to ensure reliability of the as explained in the main- tenance section. Your Suzuki dealer an provide you with further guide- ines. Steoring components, si sions and wheel components, items and require very special and Careful servicing. For maximum safe- ty we suggest that you have these items inspected and serviced by your ‘authorized Suzuki dealer or a qualified service mechanic. Proper breakin maintenance (600 ‘MANDATORY ___ A CAUTION Periodical inspoctions may reveal one ‘or more parts that may need rep ‘mont parts or Whether you are yourself mechanic, Suzuki mands that those itsms on the "MAIN- TEWANCE CHART” marked with at ‘the unmarked items by referring ‘the instructions in this seetion. MAINTENANCE CHART This interval should be judged by odometer reading or months, whichever omes first. Tiere) “ewe earance Spark pug “Trea able BBW i Taneee hain T t Fa hose Sah Auto decompression Engine of ae enging of ier Ske hoses ke fie ear auapension T ‘yindar Read nals on exioant pipe bois [1 = Chassis nts ae ol T NOTE: I= Inspect and clean, adjust, replace or lubricate as necessary, R=Replace, T= TightenWhen the engine is cold Pull the choke knob all the way Lup {full choke position) Close the throttle completely and ‘push the electric starter button. Immediately after the engine starts, return the choke knob halfway and warm up the engine. When ‘the engine become run smoothly without use of choke ssystom, return the choke knob all the way back to its normal dis ‘engaged position. When the egnine is warm: Close the throttle completely and push the electric starter button. Oper- ation of the carburetor choke system is not necessary when the engine is NOTE: Opening the throttle grip when starting the engine will make the engine hard to start. STARTING OFF 1 2 ‘Warm up the engine. Squeeze the clutch lever and depress the gearshift lever downward, Twist the throttle grip toward ‘you, At the same time release the Clutch lever gently and the motorcycle will move forward, ‘As speed increases, change up to the next higher gear. Close the throttle and squeeze the clutch lever simultaneously. Lift the ‘gearshift lever upward. Release the clutch lever gently and open the throttle grip again. NOTE: This motorcycle is equipps With @ side stand/ignition interlo witeh. If you shift the transmiss into gear when the side stand is down, the engine will stop running, USING THE TRANSMISSION ‘The transmission is provided to keer the engine operating smoothiy in its normal operating speed range. Tt gear ratios have been carefully ch fen to meet the characteristics of the tengine. The rider should always se the most suitable gear for the prevail ing conditions. Never slip the elute to control road speed, but rat downshift to allow the engine to rut within its normal operational range A CAUTION Never allow the engine to rev into red | zone in the tachometer in any gear. RIDING ON HILLS ‘© When climbing steep hills, the motorcycle may begin to. slo ‘er gear so that the engine wil ‘again be operating in its. norms ‘momentum. ‘© When riding down a steep hil, the ‘engine may be used for braking shifting to a lower gear, © Be careful, however, not to allo the engine to overrev. STOPPING AND PARKING ‘Turn the thrattle grip away from yourself to close the throttle completely. Apply the front and rear brakes evenly and at the same time. 3, Downshift through the gears as (disengaged position) just before ‘the motorcycle stops. Neutral po- sition can be confirmed by ob- ‘serving the neutral indicator ight. 4 WARNING As motorcycle speed increases, stopping distance incre Drogrssively. Be sure you have a safe stopping distance between id the vehicle or objoct head of you. © Using onl the front or rear brake is dangerous and can cause skid- ing and loss of contol © Apply the brakes lightly and with reat care on a wet highway pave- ment or other slipery surfaces and at all corners. Any abrupt braking on slippery or irregular roads ‘can cause loss of rider control VOTE: Reduce your road speed be- ‘ore downshifting. When downshift ‘ng, the engine speed should be vereased before the clutch is en- aged. This will prevent unnecessary vvear on the drivetrain components 2nd rear tire, 5. Park the motorcycle on a firm, level surface where it wil not fal over. ‘The muffler and exhaust pipe is very hot during and after operation. Avoid burns by being careful not to touch these ‘the motorcycle ‘where others are not likely to touch it. NOTE: If the motorcycle is to be parked on the side stand on a slight slope, the front end of the motorcy- Cle should face “yp” the incline to ‘avoid rolling forward off the side ‘stand. You may leave the motorcycle in 1st gear to help provent it from rol- ing off the side stand. Return to new tral before starting engine. 6. Tum the ignition key to the "OFF" position. 7. Turn the handlebars all the way to the left and lock the steering for security. 8. Remove the ignition key.INSPECTION BEFORE. RIDING Before riding the motorcycle, be sure to check the following items. Never underestimate the importance of these checks. Perform all of them be- fore riding the motorcycle. WHAT TO CHECK “Steering | © Smoothness 8 | 8 No'estnetion of No play oF looseness ‘© Covrect play in the throttle abl ‘© Smooth op ‘and positive return of the trate grip fo the closed position Ghatch | © Correct play in the able ‘© Smooth and progressive action Brakes | © Fluid lovel in tho feservoir to be above] ‘CHECK FOR: Throttle ‘8 No fhid leakage 1 Brake pads not to be ‘worn down to the Mit tine ‘© Correct pedal and lever play 1 No“eponginess! ‘Saapensions| Smooth movement Fuel Enough {vel for the planned distance of Drive chain | © Proper tension or ck © Adequate lubrication Correct pressure ‘Adequate treed depth No cracks or cut orrect level [Tires Ligniog «- | Operation of st sates, vaning | sna ncicators [Hom | Correct function Engine stop | Correct function switch, ‘Side stand} Proper operation ignition interiock ‘switch RIDING TIPS © If this is the first time that you have ridden @ machine of this ‘ype, we suggest that you practice ‘© One-hand riding is extremely dan- serous. Keep both hands firmly on the handlebars and both feat se- ‘curely on the footrests. Under no © Do not downshift in the midst of cornering. Slow down to a safe ‘spood before negotiating a corner. ‘© When the road surface is wet or © At side winds which may be ex. perienced at the exists of tunnels, by the cut of a hl overtaken by larg er vehicles, you should reduce spoed and ride alertly. © Obey the speed regulations at all times. ENGINE STARTING Never start the engine or let {indoors or where there is ltt ventilation. Exhaust gas contains car- bon monoxide, a potentially lethal gas that is col run too long er ing, or it will verhoat and ‘may damage internal engine com- The transmission is in neutral © The fuel valve is in the “ON po- sition. © The engine stop switch is in the Q)"" position NOTE: This motorcycle is equipped with interlock switches for the igni- tion circuit and the starter circuit. The engine can only be started if ‘© The transmission is in neutral and the clutch is disengaged, or © The transmission is in gear, the side stand is fully up and the clutch is disengaged.FUEL AND ENGINE OIL RECOMMENDATION FUEL Use unleaded gasoline with an octane rating of 91 or higher (Research method). Unleaded gasoline can ex- tend spark plug life and exhaust com- ponents life. If pinking oF knocking is experienced, ‘substitute higher octane grade gaso- line or another brand, because there are differences between brands. ENGINE OIL Use a premium quality 4-stroke mo- tor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF of SG under the API serv- ice classification. The recommended viscosity is SAE 10W-40. If a SAE 10W-40 motor oil is not available, select an alternative according to th following chart. cron || | Ter BREAK-IN (RUNNING- ‘The opening explain how impor proper break-i ‘explain proper break-in procedut MAXIMUM ENGINE SPEED RECOMMENDATION This table shows the maxim recommended engine speed duti the break-in period. ‘to achiaving ms avolD CONSTANT LOW SPEED Sporating the engine at constant low Speed (light load) can cause parts to sisze and not seat in. Allow the en- ‘ine to accelerate frealy through the {sars, without exceeding the recom: mended maximum limits. Do not, Swever, use full throttle for the first 11800 km (1000 miles} ALLOW THE ENGINE OIL TO CIRCU- LATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before VARY THE ENGINE SPEED The engine speed should be var ‘and not held at a constant speed. allows the parts to be “loade pressure, and then unloaded, al ing the parts to cool. This aids t mating process of the parts. itis sontial that some stress be placed ‘the engine components during break in to ensure this mating process. D ‘not, though, apply excessive load the engine. 800 kin nolying load or revving the engine. 'nitlal (500 miles) ns allows time for the lubricating ol [mere coat reach all critical engine com. 1600 km UP t© (1000 miles) | 5000 one 1600 ki Bolow Over (1000 miles) | 7500 ro Tr lo OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE The initial service (1000 km mainte- nance) is the most important service your motorcycle will receive. During break-in operation, all of the engine ‘components will have mated together ‘and seated. Maintenance required as| part of the initial service includes cor. rection ofall adjustments, tightening Of all fasteners and replacement of dirty oll. Timely performance of this service will help make sure you get the best service life and performance from the engine. ___ A CAUTION ‘The 1000 km (600 miles) service should be performed ‘and WARNING in that section,