Page 1 RMX450Z SERVICE MANUAL 9 9 5 0 0 - 4 4 0 9 0 - 0 1 E...
Page 2 FOREWORD This manual contains an introductory description on the SUZUKI RMX450Z and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
Page 6 CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
Page 7 Precautions: 00-2 • Use a torque wrench to tighten fasteners • Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber •...
Page 8 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blows, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
Page 9 Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
Page 10 00-5 Precautions: When checking system circuits including an electronic 4) Using continuity inspect or voltage check procedure control unit such as ECM, etc., it is important to perform as described below, inspect the wire harness careful check, starting with items which are easier to terminals for open circuit and poor connection.
Page 11 Precautions: 00-6 Voltage check Short circuit check (Wire harness to ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect the negative (–) cable from the battery. check can be used as circuit check. 2) Disconnect the connectors/couplers at both ends of 1) With all connectors/couplers connected and voltage the circuit to be checked.
Page 12 Using The Multi Circuit Testers side of the lead wire coupler and connect • Use the Suzuki multi circuit tester set. the probes of tester to them. • Use well-charged batteries in the tester.
Page 13: Table Of Contents
Throttle Cable Play Inspection and Symbols .............. 0A-1 Adjustment ............0B-12 Abbreviations ............0A-1 Hot Starter Lever Clearance Inspection and SAE-to-Former SUZUKI Term ......0A-2 Adjustment ............0B-13 Vehicle Side View ..........0A-3 Throttle Body Inspection ........0B-13 Vehicle Identification Number ......0A-3 Crankcase Breather (PCV) Hose Inspection..0B-13...
Page 14 Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
Page 15 J1930 terms and abbreviations which may be used in (TPS) this manual in compliance with SAE recommendations, as well as their former SUZUKI names. Voltage Regulator (VR): Voltage Regulator Ex. SAE term (Abbreviation): Former SUZUKI term Air Cleaner (ACL): Air Cleaner, Air Cleaner Box...
Page 16 PERFORMANCE 4 MOTOR OIL or an equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.
Page 17 Suzuki recommends the use of SUZUKI COOLANT anti- freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
Page 18 0A-5 General Information: Wire Color Symbols BA02J20101010 Symbol Wire color Symbol Wire color Black Black with Yellow tracer Blue Bl/B Blue with Black tracer Brown Bl/R Blue with Red tracer Dark green Br/W Brown with White tracer Green Green with Black tracer Gray Green with White tracer Orange...
Page 19 General Information: 0A-6 Component Location Electrical Components Location BA02J20103001 IA02J1010005-07 1. Fuel pump 6. Speedometer 11. IAP sensor 2. ECT sensor 7. Ignition switch 12. TO sensor 3. Ignition coil 8. Headlight relay 13. Speed sensor 4. Starter button 9. Fuse (Sub/Spare) 5.
Page 20 0A-7 General Information: 23, 24 IA02J1010007-09 13. Engine stop switch 18. Starter relay 23. Crankshaft rotation signal sensor 14. IAT sensor 19. ECM 24. Magneto 15. Battery 20. Condenser 25. GP switch 16. Fuse box (Main) 21. Starter motor 26. TP sensor 17.
Page 21 General Information: 0A-8 Specifications Specifications BA02J20107001 NOTE These specifications are subject to change without notice. Dimensions and curb mass Item Specification Overall length 2 185 mm (86.0 in) Overall width 840 mm (33.1 in) Overall height 1 265 mm (49.8 in) Wheelbase 1 485 mm (58.5 in) Ground clearance...
Page 22 0A-9 General Information: Chassis Item Specification Front suspension Telescopic, coil spring, oil damper Rear suspension Link type, coil spring, oil damper Front fork stroke 310 mm (12.2 in) Rear wheel travel 310 mm (12.2 in) Caster 28° 10’ Trail 122 mm (4.8 in) Steering angle 45°...
Page 23 Plastigage (0.051 – Small bore gauge (18 Multi circuit tester set Needle-point probe Engine tachometer 0.152 mm) – 35 mm) 09904–41010 09910–20115 09910–32812 09910–60611 09911–11310 SUZUKI Diagnostic Piston holder Crankshaft installer Universal clamp Crankshaft installer system set wrench attachment C...
Page 24 0A-11 General Information: 09913–10750 09913–50121 09913–70210 09914–61010 09915–64512 Compression gauge Oil seal remover Bearing installing set Gear holder Compression gauge (10 – 75 Φ) adapter 09915–74511 09915–74521 09915–77331 09916–10911 09916–14510 Oil pressure gauge Adapter hose Oil pressure gauge Valve lapper set Valve lifter (600 kPa) (1000 kPa)
Page 25 General Information: 0A-12 09924–84510 09924–84521 09925–18011 09930–10121 09930–11950 Bearing installer set Bearing installer set Bearing installer Spark plug wrench set Torx wrench (T25H) 09930–30104 09930–34932 09930–35010 09930–40210 09930–70220 Rotor remover sliding Rotor remover Rotor remover Rotor holder Starter torque limiter shaft socket 09930–73170...
Page 26: General Description
0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance BA02J20200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.
Page 27 Maintenance and Lubrication: 0B-2 Scheduled Maintenance Periodic Maintenance Chart BA02J20205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. C = Clean. R = Replace. T = Tighten. L = Lubricate. Initial Initial 150 Every 1 000 Every 2 000 Item Remarks...
Page 28 A. Lightweight oil such as WD-40 or penetrating oil B. Aerosol type Chain Lube C. SUZUKI SUPER GREASE “A” (or equivalent grease) or Water-proof wheel bearing grease IA02J1020001-04 Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.
Page 29 Maintenance and Lubrication: 0B-4 Repair Instructions Spark Plug Replacement 3) After finishing the spark plug inspection, reinstall the BA02J20206001 removed parts. Replace spark plug Electrodes Condition Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 month) 1) Remove the spark plug.
Page 30 0B-5 Maintenance and Lubrication: 3) Fill a washing pan large enough to hold the element 2) If the air cleaner heat guard has play, retighten the air cleaner heat guard mounting screws as following with a non-flammable cleaning solvent “A”. Immerse the element in the solvent and wash it.
Page 31 Maintenance and Lubrication: 0B-6 3) Remove the engine oil level check bolt (1). At this time, if oil comes out from this bolt hole, the engine can be started for oil level check. IA02J1020004-03 5) Repeat the procedures from 2) to 3). 6) Tighten the oil check bolt to the specified torque.
Page 32 0B-7 Maintenance and Lubrication: 6) Depress the kick starter lever 10 times and more or press the starter button to crank the engine for a few seconds. NOTE To avoid turning on the engine, push along the engine stop switch while depressing the kick starter lever or pressing the starter button.
Page 33 Maintenance and Lubrication: 0B-8 6) Install the oil filter cap and tighten the bolts (5) to the 3) Inspect the oil strainer No. 1 for clogging or any specified torque. damage. If necessary, clean it with compressed air or replace it with a new one. Tightening torque Oil filler cap bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) IA02J1020013-01...
Page 34 0B-9 Maintenance and Lubrication: Oil Pump No. 2 Strainer Inspection 1) Remove the oil pump No. 2 strainer. Refer to “Oil Pump No. 2 Removal and Installation” in Section 1E (Page 1E-5). 2) Inspect the oil pump No. 2 strainer for clogging or any damage.
Page 35 Maintenance and Lubrication: 0B-10 4) Place a pan below the water pump, and then drain Air Bleeding from the Cooling Circuit the engine coolant by removing the drain plug (2). 1) Hold the motorcycle in an upright position on a level surface.
Page 36: Clutch Lever Clearance Inspection And Adjustment
0B-11 Maintenance and Lubrication: Radiator Hose Inspection Inspect radiator hoses Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 months) 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-5). 2) Inspect the radiator hoses for damage and engine coolant leakage.
Page 37 IA02J1020082-01 2) Apply oil to the throttle cable. “ a ” 3) Apply grease to the throttle cable spool. : Grease 99000–25010 (SUZUKI SUPER IA02J1020028-01 GREASE “A” or equivalent) Throttle Cable Adjustment 1) Loosen the lock-nut (1). 2) Turn adjuster (2) so the throttle grip has 2 – 4 mm (0.08 –...
Page 38: Adjustment
0B-13 Maintenance and Lubrication: Hot Starter Lever Clearance Inspection and 4) Check that the hot starter lever moves smoothly from full open to full close. If it does not move smoothly, Adjustment BA02J20206011 lubricate the hot starter cable. Inspect hot starter lever clearance Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 months) Inspect and adjust the hot starter lever clearance “a”...
Page 39: Fuel Hose Inspection
Maintenance and Lubrication: 0B-14 Fuel Hose Inspection 3) Remove the TO sensor bracket bolt and nut (1). BA02J20206014 4) Remove the cylinder head cover (2). Inspect fuel hose Initially 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 months) Replace fuel hose Every 4 years Inspect the fuel hose in the following procedures:...
Page 40 0B-15 Maintenance and Lubrication: 7) Insert the thickness gauge between each tappet and 3) Check the figures printed on the shim. These figures cam. If the clearance is out of specification, adjust it indicate the thickness of the shim, as illustrated. to the specified range.
Page 41 Maintenance and Lubrication: 0B-16 (INTAKE SIDE) IA02J1020063-02...
Page 42 0B-17 Maintenance and Lubrication: (EXHAUST SIDE) IA02J1020064-01...
Page 43: Exhaust Pipe Bolt And Muffler Bolt Inspection
Maintenance and Lubrication: 0B-18 6) Install the intake or exhaust camshaft. Refer to Spark Arrester Cleaning BA02J20206017 “Engine Top Side Assembly” in Section 1D (Page 1D-30). Clean spark arrester Every 1 000 km (600 miles, 6 months) thereafter 7) Rotate the engine so that the tappet is depressed fully.
Page 44 Spark arrester mounting bolt (a): 5.5 N·m (0.55 IA02J1020100-04 kgf-m, 4.0 lbf-ft) IA02J1020098-03 IA02J1020097-01 7) Install the muffler tail cover (1). 8) Apply bond to the holes of the muffler body as shown. CAUTION Dry the adhesive completely. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent)
Page 45: Drive Chain Inspection And Adjustment
Maintenance and Lubrication: 0B-20 Drive Chain Inspection and Adjustment BA02J20206018 Inspect drive chain Clean lubricate and inspect each time the motorcycle is ridden Drive Chain Visual Check “B” “A” 1) With the transmission in neutral, support the motorcycle using a jack. 2) Visually check the drive chain for the possible defects listed as follows.
Page 46: Drive Chain Cleaning And Lubricating
0B-21 Maintenance and Lubrication: 5) After adjusting the drive chain, tighten the axle nut Crankcase Driveshaft Oil Seal Inspection BA02J20206020 (1) to the specified torque. Inspect crankcase driveshaft oil seal Tightening torque Initially 150 km (100 miles, 1 month) and every 1 000 Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lbf-ft) km (600 miles, 6 months) thereafter 6) Tighten both chain adjuster lock-nuts (2) securely.
Page 47: Drive Chain Buffer, Guide And Roller Inspection
Maintenance and Lubrication: 0B-22 Drive Chain Buffer, Guide and Roller Inspection WARNING BA02J20206022 Inspect drive chain buffer, guide and roller • The brake system of this motorcycle is Inspect each time the motorcycle is ridden filled with a glycol-based brake fluid. Do not use or mix different types of fluid such Replace the chain buffer (1), guide (2), guide defence (3) as silicone-based and petroleum-based...
Page 48 0B-23 Maintenance and Lubrication: Brake Pad Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pads. When “a” the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad Replacement”...
Page 49: Front Fork Inspection
Maintenance and Lubrication: 0B-24 Air Bleeding from Brake Fluid Circuit Rear Suspension Inspection BA02J20206025 Refer to “Air Bleeding from Brake Fluid Circuit” in Section 4A (Page 4A-3). Inspect rear suspension Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 month) thereafter Front Fork Inspection BA02J20206024...
Page 50: Steering System Inspection
0B-25 Maintenance and Lubrication: 2) Inspect the wheel rim runout. Refer to “Front Wheel Related Parts Inspection” in Section 2D (Page 2D-5) and “Rear Wheel Related Parts Inspection” in Section 2D (Page 2D-12). IA02J1020089-01 Tire Pressure Inspection Inspect front and rear tire pressure. IA02J1020068-03 Tire pressure (cold) 70 –...
Page 51: Kick Starter Lever Inspection And Lubrication
Maintenance and Lubrication: 0B-26 Kick Starter Lever Inspection and Lubrication BA02J20206028 Inspect kick starter lever Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 months) thereafter Lubricate kick starter lever Initially at 150 km (100 miles, 1 month) and every 1 000 km (600 miles, 6 months) thereafter Inspect the kick starter lever for smooth movement and lubricate it periodically.
Page 52: Compression Pressure Check
0B-27 Maintenance and Lubrication: IA02J1020076-01 IA02J1020079-01 Swingarm pivot nut 70 N⋅m (7.0 kgf-m, 50.5 lbf-ft) Rear sprocket nut 30 N⋅m (3.0 kgf-m, 21.5 lbf-ft) Seat rail bolt/nut (Upper and Lower) 23 N⋅m (2.3 kgf-m, 16.5 lbf- IA02J1020080-01 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) IA02J1020077-02 Brake caliper air bleeder valve (Rear) 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
Page 53 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-22) Grease SUZUKI SUPER GREASE “A”...
Page 54: Special Tool
0B-29 Maintenance and Lubrication: Special Tool BA02J20208002 09900–20101 09900–20803 Vernier calipers (150 mm) Thickness gauge (Page 0B-20) (Page 0B-15)
Page 55: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data BA02J20307001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 31.0 (1.22) — 0.09 – 0.16 (0.004 – 0.006) — Valve clearance (When cold) 0.17 –...
Page 56: 0C-2 Service Data
0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure Approx. 400 kPa (4.0 kgf/cm , 57 psi) and more — (Automatic decomp. actuated) Piston to cylinder clearance 0.035 – 0.045 (0.0014 – 0.0018) 0.120 (0.0047) Nicks or Cylinder bore...
Page 57 Service Data: 0C-3 Radiator + Engine Coolant Unit: mm (in) Except ratio Item Standard Limit 20 °C Approx. 2.58 kΩ — (68 °F) 50 °C Approx. 0.77 kΩ — (122 °F) ECT sensor resistance 80 °C Approx. 0.28 kΩ — (176 °F) 110 °C Approx.
Page 58 0C-4 Service Data: FI Sensors Item Specification Note 150 – 280 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more Crankshaft rotation signal sensor 0.2 – 0.6 Ω resistance Crankshaft rotation signal sensor 3.0 V and more peak voltage IAP sensor input voltage 4.5 –...
Page 59 Service Data: 0C-5 Electrical Unit: mm (in) Item Specification Note Ignition timing 4° B.T.D.C. at 2 000 r/min. Type NGK: CR8EIB-10 Spark plug 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. 150 – 280 Ω CKP sensor resistance R –...
Page 60 0C-6 Service Data: Brake + Wheel Unit: mm (in) Item Standard Limit Brake lever adjuster length 11 – 15 (0.4 – 0.6) — Rear brake pedal height 0 – 10 (0 – 0.4) — 3.0 ± 0.2 (0.118 – 0.008) Front 2.5 (0.10) Brake disc thickness...
Page 61 Front fork oil capacity (each leg) Damper rod oil 193 ml (6.5/6.8 US/lmp oz) quantity SUZUKI REAR SUSPENSION OIL SS-25 Rear shock absorber oil type or an equivalent suspension oil Rear shock absorber oil capacity 383 ml (13.0/13.5 US/lmp oz)
Page 62 0C-8 Service Data: Tightening Torque List BA02J20307002 Engine Item N⋅m kgf-m lbf-ft Cylinder head cover bolt 10.0 Spark plug Initial 18.0 Cylinder head bolt Final 37.0 Cylinder head base bolt Cylinder base bolt Camshaft journal holder bolt (L45 & L45) Oil gallery bolt (Journal holder) Primary drive gear nut 65.0...
Page 63 Service Data: 0C-9 FI system and Intake Air System Item N⋅m kgf-m lbf-ft Throttle cover screw CKP sensor mounting bolt 0.55 IAP sensor mounting screw 0.15 IAT sensor mounting screw 0.13 0.95 TP sensor mounting screw 0.35 GP switch mounting bolt 0.65 Fuel pump mounting bolt Fuel pipe mounting screw...
Page 64 0C-10 Service Data: Item N⋅m kgf-m lbf-ft Rear wheel rim lock 10.0 Swingarm pivot nut (engine mounting) 50.5 Rear shock absorber mounting nut (Upper and Lower) 36.0 Rear shock absorber compression adjuster assembly 21.0 Rear cushion lever nut (Upper and Lower) 58.0 Rear cushion rod nut (Front and Rear) 58.0...
Page 65 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “41” (P0230): FP Relay Circuit Malfunction............1A-65 Precautions............. 1-1 DTC “63” (P1771): Crankshaft Rotation Precautions for Engine.......... 1-1 Signal Circuit Malfunction........1A-67 Engine General Information and Specifications .............1A-70 Service Data............1A-70 Diagnosis ..........
Page 66 1-ii Table of Contents Service Data............1C-7 Transmission Oil Seal / Bearing Removal and Tightening Torque Specifications......1C-8 Installation ............1D-65 Clutch Release Camshaft Oil Seal / Bearing Special Tools and Equipment ......1C-8 Inspection............1D-66 Recommended Service Material ......1C-8 Clutch Release Camshaft Oil Seal / Bearing Special Tool ............1C-8 Removal and Installation.........1D-66 Engine Mechanical ........
Page 67 Table of Contents 1-iii Repair Instructions ..........1F-4 Ignition Coil and Plug Cap Inspection ....1H-4 Cooling Circuit Inspection ........1F-4 CKP Sensor Inspection ........1H-6 Radiator Cap Inspection ........1F-4 Crankshaft Rotation Signal Sensor Inspection ..1H-7 Radiator Inspection and Cleaning ....... 1F-4 CKP Sensor / Crankshaft Rotation Signal Radiator Removal and Installation ......
Page 68 1-iv Table of Contents Battery Runs Down Quickly ........ 1J-3 Recommended Service Material ....... 1J-10 Special Tool ............1J-11 Repair Instructions ..........1J-3 Battery Current Leakage Inspection....1J-3 Exhaust System........1K-1 Regulated Voltage Inspection ......1J-4 Precautions............1K-1 Generator Inspection........... 1J-4 Precautions for Exhaust System ......1K-1 Generator Removal and Installation....
Page 69: Precautions
Precautions: Precautions Engine Precautions Precautions for Engine BA02J21000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2).
Page 70: 1A-1 Engine General Information And Diagnosis
1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description BA02J21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
Page 71 Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.
Page 72 1A-3 Engine General Information and Diagnosis: Self-diagnosis Function The self-diagnosis function is incorporated in the ECM. It can be notified by using the FI indicator light assy (option). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the tool is necessary to read the DTC (Diagnostic Trouble Code) that identify malfunction location.
Page 73: Schematic And Routing Diagram
Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram BA02J21102001 Main fuse (15A) Condensor Sub fuse (15A) Regulator/ rectifier Crankshaft Ignition rotation switch signal sensor CKP sensor FI indicator light (Option) Fuel indicator light Battery TP sensor R/Bl Fuel...
Page 74: Ecm Terminal
1A-5 Engine General Information and Diagnosis: ECM Terminal BA02J21102002 IA02J1110005-01 Terminal No. Circuit Terminal No. Circuit Power source (+B) — TO sensor signal (TOS) Map select 1 (MAP1) CKP sensor signal (CKP+) FI indicator GP switch signal (GP) ECT sensor signal (ECT) TP sensor signal (TPS) —...
Page 75: Component Location
Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location BA02J21103001 IA02J1110006-06 “A”: ECM “D”: Fuel pump “G”: IAP sensor “B”: Ignition coil “E”: ECT sensor “C”: TO sensor “F”: Fuel injector IA02J1110007-04 “A”: ECM “I”: TP sensor “K”: Crankshaft rotation signal sensor “H”: IAT sensor “J”: CKP sensor...
Page 76: Diagnostic Information And Procedures
1A-7 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis BA02J21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guides or poor seating of Repair or replace.
Page 77 Engine General Information and Diagnosis: 1A-8 Condition Possible cause Correction / Reference Item Engine stalls often (Fuel Defective fuel injector. Replace. injector improperly No injection signal from ECM. Repair or replace. operating) Open or short circuited wiring Repair or replace. connection.
Page 78 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine runs poorly in Weakened valve springs. Replace. high speed range Worn camshaft. Replace. (Defective engine internal/ Valve timing out of adjustment. Adjust. electrical parts) Incorrect spark plug gap. Replace.
Page 79: Self-Diagnostic Procedures
Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Engine overheats (Lean Short-circuited IAP sensor/lead wire. Repair or replace. fuel/air mixture) Short-circuited IAT sensor/lead wire. Repair or replace. Sucking air from throttle body or intake Repair or replace. pipe joint.
Page 80 Removal and Installation” in Section 9D (Page 9D- 2) Set up the SDS tools. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic system set) (B): 99565–01010–021 (CD-ROM Ver.21) IA02J1110089-01 4) Start the engine or crank the engine for more than 4 seconds.
Page 81: Use Of Sds Diagnosis Reset Procedures
Engine General Information and Diagnosis: 1A-12 Use of SDS Diagnosis Reset Procedures 6) Follow the displayed instructions. BA02J21104003 NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.
Page 82: Show Data When Trouble (Displaying Data At The Time Of Dtc)
1A-13 Engine General Information and Diagnosis: Show Data When Trouble (Displaying Data at the Time of DTC) BA02J21104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.
Page 83 Engine General Information and Diagnosis: 1A-14 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I831G1110017-01...
Page 84: Sds Check
1A-15 Engine General Information and Diagnosis: SDS Check BA02J21104005 Using SDS, sample the data at the time of new and periodic inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data helps to improve the accuracy of troubleshooting since they can indicate the condition of motorcycle functions that has changed with time.
Page 85 Engine General Information and Diagnosis: 1A-16 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. XX °C IA02J1110077-03 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open IA02J1110078-03...
Page 86 1A-17 Engine General Information and Diagnosis: Data of intake negative pressure during idling (90 °C) Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. 90 °C IA02J1110079-03 Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure.
Page 87 Engine General Information and Diagnosis: 1A-18 Example of Trouble Three data (one current data and two past data) can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring.
Page 88: Dtc Table
1A-19 Engine General Information and Diagnosis: DTC Table BA02J21104006 EXAMPLE: When CKP sensor and TO sensor defective (DTC No.12 and 23) FI light Code No.12 Code No.23 Code No.12 Code No.23 0.3 0.3 0.3 0.3 Time (sec.) I933H1110010-02 In the FI light, the DTC is indicated from small code to large code. Code FI light flashing pattern Malfunction part...
Page 89: Fail-Safe Function Table
Engine General Information and Diagnosis: 1A-20 Code FI light flashing pattern Malfunction part Remarks (Page Injector signal (FI) Fuel injector 1A-62) MCODE00C32-0-02 Fuel pump control system (FP control (Page system) 1A-65) MCODE00C41-0-01 (Page Crankshaft rotation signal sensor 1A-67) MCODE00C63-0-01 Fail-Safe Function Table BA02J21104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
Page 90: Fi System Troubleshooting
1A-21 Engine General Information and Diagnosis: FI System Troubleshooting BA02J21104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model:...
Page 91: Malfunction Code And Defective Condition Table
Engine General Information and Diagnosis: 1A-22 Visual Inspection Prior to diagnosis using the FI indicator light assy or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of FI indicator light assy or SDS.
Page 92 1A-23 Engine General Information and Diagnosis: DTC No. Detected Item Detected Failure Condition Check For The sensor voltage should be the following for 5 seconds. and more. TO sensor, lead wire/coupler 0.3 V ≤ sensor voltage < 4.5 V connection. In other than the above value, 23 (P1651) is indicated.
Page 93: Dtc "12" (P0335): Ckp Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-24 DTC “12” (P0335): CKP Sensor Circuit Malfunction BA02J21104010 Detected Condition and Possible Cause Detected condition Possible cause The signal does not reach ECM for 1 second or more, • Metal particles or foreign material being stuck on the after receiving the IAP sensor input signal.
Page 94 1A-25 Engine General Information and Diagnosis: Step Action 1) Turn off the ignition switch. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor/crankshaft rotation signal sensor lead wire coupler (1) for loose or poor contacts. If OK, then measure the CKP sensor resistance.
Page 95 Engine General Information and Diagnosis: 1A-26 Step Action 4) If OK, then check the continuity between each terminal Go to Step 2. Replace the CKP and ground. sensor with a new one. Special tool (A): 09900–25008 (Multi circuit tester set) CKP sensor continuity ∞...
Page 96: Dtc "14" (P0120-H/L): Tp Sensor Circuit Malfunction
1A-27 Engine General Information and Diagnosis: DTC “14” (P0120-H/L): TP Sensor Circuit Malfunction BA02J21104011 Detected Condition and Possible Cause Detected condition Possible cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
Page 97 Engine General Information and Diagnosis: 1A-28 14 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the fuel tank. Refer to “Fuel Tank Removal and coupler (terminal “13”...
Page 98 1A-29 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. Y wire shorted to VCC or B/Br wire open. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 99 Engine General Information and Diagnosis: 1A-30 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. Y wire shorted to VCC and Installation” in Section 1C (Page 1C-1). or B/Br wire open. 7) Check the continuity between Y wire “C” and terminal “5”.
Page 100 1A-31 Engine General Information and Diagnosis: P0120-L (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. Y or R/Bl wire open, or Y wire shorted to 2) Remove the fuel tank. Refer to “Fuel Tank Removal and ground.
Page 101 Engine General Information and Diagnosis: 1A-32 Step Action 7) Check the continuity between Y wire “C” and terminal Go to Step 2. Y or R/Bl wire open, or “5”. Y wire shorted to Also, check the continuity between R/Bl wire “A” and ground.
Page 102 1A-33 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TP sensor lead wire • Y, R/Bl or B/Br wire If check result is not coupler. open or shorted to satisfactory, replace TP ground, or poor “5”, sensor with a new one.
Page 103: Dtc "15" (P0115-H/L): Ect Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-34 DTC “15” (P0115-H/L): ECT Sensor Circuit Malfunction BA02J21104012 Detected Condition And Possible Cause Detected condition Possible cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.1 V ≤...
Page 104 1A-35 Engine General Information and Diagnosis: 15 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the exhaust pipe. Refer to “Muffler / Exhaust coupler.
Page 105 Engine General Information and Diagnosis: 1A-36 P0115-H (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. G/Y or G/R wire open. 2) Remove the exhaust pipe. Refer to “Muffler / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K- 3) Check the ECT sensor coupler (1) for loose or poor contacts.
Page 106 1A-37 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. • G/Y wire shorted to ground. 2) Remove the exhaust pipe. Refer to “Muffler / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K- •...
Page 107 Engine General Information and Diagnosis: 1A-38 Step Action 6) Connect the ECT sensor coupler. Go to Step 2. • G/Y wire shorted to ground. 7) Insert the needle-point probes to the lead wire coupler. • If wire is OK, go to 8) Turn on the ignition switch.
Page 108 1A-39 Engine General Information and Diagnosis: Step Action 1) Turn off the ignition switch. • G/Y or G/R wire open Replace the ECT or shorted to ground, sensor with a new one. 2) Connect the ECM coupler and disconnect the ECT or poor “22”...
Page 109: Dtc "17" (P0105-H/L): Iap Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-40 DTC “17” (P0105-H/L): IAP Sensor Circuit Malfunction BA02J21104013 Detected Condition and Possible Cause Detected condition Possible cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
Page 110 1A-41 Engine General Information and Diagnosis: 17 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the fuel tank. Refer to “Fuel Tank Removal and coupler.
Page 111 Engine General Information and Diagnosis: 1A-42 P0105-H (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 112 1A-43 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the G/B wire “C” and Go to Step 3. G/B wire shorted to terminal “6”. VCC, or B/Br wire open. If OK, then check the continuity between the B/Br wire “B”...
Page 113 Engine General Information and Diagnosis: 1A-44 P0105-L (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. R/Bl and G/B wire open, G/B wire shorted to the 2) Remove the fuel tank. Refer to “Fuel Tank Removal and ground.
Page 114 1A-45 Engine General Information and Diagnosis: Step Action 7) Check the continuity between the R/Bl wire “A” and Go to Step 2. R/Bl and G/B wire open, terminal “13”. Also, check the continuity between the G/ G/B wire shorted to the B wire “C”...
Page 115 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn off the ignition switch. Go to Step 4. • Open or short circuit in the G/B wire. 2) Connect the ECM coupler and IAP sensor coupler. • If the wire is OK, 3) Insert the needle-point probes to the lead wire coupler.
Page 116 1A-47 Engine General Information and Diagnosis: Step Action 1) Turn off the ignition switch. • G/B, R/Bl or B/Br wire If check result is not open or shorted to satisfactory, replace IAP 2) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “6”, sensor with a new one.
Page 117: Dtc "21" (P0110-H/L): Iat Sensor Circuit Malfunction
Engine General Information and Diagnosis: 1A-48 DTC “21” (P0110-H/L): IAT Sensor Circuit Malfunction BA02J21104014 Detected Condition and Possible Cause Detected condition Possible cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.2 V ≤...
Page 118 1A-49 Engine General Information and Diagnosis: 21 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. Go to Step 2. • Loose or poor contacts on the ECM 2) Remove the seat. Refer to “Exterior Parts Removal and coupler.
Page 119 Engine General Information and Diagnosis: 1A-50 P0110-H (Use of SDS) Step Action 1) Turn off the ignition switch. Connect the ECM Dg or B/Br wire open. coupler and go to step 2) Remove the seat. Refer to “Exterior Parts Removal and Installation”...
Page 120 1A-51 Engine General Information and Diagnosis: P0110-L (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. • Dg wire shorted to ground. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-1). •...
Page 121 Engine General Information and Diagnosis: 1A-52 Step Action 9) Measure the output voltage between the Dg wire “A” and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi circuit tester set) (B): 09900–25009 (Needle-point probe set) Tester knob indication...
Page 122: Dtc "23" (P1651-H/L): To Sensor Circuit Malfunction
1A-53 Engine General Information and Diagnosis: DTC “23” (P1651-H/L): TO Sensor Circuit Malfunction BA02J21104015 Detected Condition and Possible Cause Detected condition Possible cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 seconds and more, after •...
Page 123 Engine General Information and Diagnosis: 1A-54 C23 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the fuel tank. Refer to “Fuel Tank Removal and “TO Sensor Removal Installation”...
Page 124 1A-55 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. Br/W wire shorted to VCC, or B/Br wire open. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 125 Engine General Information and Diagnosis: 1A-56 Step Action 7) Check the continuity between Br/W wire “C” and terminal Go to Step 2. Br/W wire shorted to “2”. Also, check the continuity between B/Br wire “B” and VCC, or B/Br wire open. terminal “24”.
Page 126 1A-57 Engine General Information and Diagnosis: P1651-L (Use of SDS) Step Action 1) Turn off the ignition switch. Go to Step 2. R/Bl or B wire open, or Br/W wire shorted to the 2) Remove the fuel tank. Refer to “Fuel Tank Removal and ground.
Page 127 Engine General Information and Diagnosis: 1A-58 Step Action 7) Check the continuity between R/Bl wire “A” and terminal Go to Step 2. R/Bl or B wire open, or “13”. Br/W wire shorted to the Also, then check the continuity between Br/W wire “C” ground.
Page 128 1A-59 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • Br/W, R/Bl or B/Br • Loose or poor wire open or shorted contacts on the ECM 2) Insert the needle-point probes to the lead wire coupler. to ground, or poor “2”, coupler.
Page 129: Dtc "24" (P0351): Ignition Coil Circuit Malfunction
Engine General Information and Diagnosis: 1A-60 DTC “24” (P0351): Ignition Coil Circuit Malfunction BA02J21104016 NOTE Refer to “No Spark or Poor Spark” in Section 1H (Page 1H-3) for details. DTC “31” (P0705): GP Switch Circuit Malfunction BA02J21104017 Detected Condition and Possible Cause Detected condition Possible cause No GP switch voltage...
Page 130 1A-61 Engine General Information and Diagnosis: Step Action 1) Turn off the ignition switch. • P wire open or • P or B/W wire open, shorted to ground. or P wire shorted to 2) Remove the fuel tank. Refer to “Fuel Tank Removal and ground.
Page 131: Dtc "32" (P0201): Fuel Injector Circuit Malfunction
Engine General Information and Diagnosis: 1A-62 DTC “32” (P0201): Fuel Injector Circuit Malfunction BA02J21104018 Detected Condition and Possible Cause Detected condition Possible cause CKP signal is produced but fuel injector signal is • Fuel injector circuit open or short. interrupted by 8 times or more continuity. •...
Page 132 1A-63 Engine General Information and Diagnosis: Step Action 1) Turn off the ignition switch. Go to Step 2. Replace the fuel injector with a new one. Refer to 2) Remove the fuel tank. Refer to “Fuel Tank Removal and “Fuel Injector / Fuel Installation”...
Page 133 Engine General Information and Diagnosis: 1A-64 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the fuel injector and ground. with a new one. Refer to “Fuel Injector / Fuel Special tool Delivery Pipe / T-joint (A): 09900–25008 (Multi circuit tester set) Removal and...
Page 134: Dtc "41" (P0230): Fp Relay Circuit Malfunction
1A-65 Engine General Information and Diagnosis: DTC “41” (P0230): FP Relay Circuit Malfunction BA02J21104019 Detected Condition and Possible Cause Detected condition Possible cause No voltage is applied to fuel pump although FP relay is • FP relay circuit open or short. turned ON.
Page 135 Engine General Information and Diagnosis: 1A-66 C41 (Use of FI indicator light) Step Action 1) Turn off the ignition switch. • FP relay (ECM) Open or short circuit in malfunction. the O/G wire. 2) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation”...
Page 136: Dtc "63" (P1771): Crankshaft Rotation Signal Circuit Malfunction
1A-67 Engine General Information and Diagnosis: DTC “63” (P1771): Crankshaft Rotation Signal Circuit Malfunction BA02J21104020 Detected Condition and Possible Cause Detected condition Possible cause The signal does not reach ECM for 30 seconds and • Metal particles or foreign material being stuck on the more.
Page 137 Engine General Information and Diagnosis: 1A-68 Step Action 1) Turn the ignition switch. Go to step 2. Replace the crankshaft rotation signal sensor 2) Check the CKP sensor/crankshaft rotation signal sensor with a new one. lead wire coupler (1) for loose or poor contacts. If OK, then measure the crankshaft rotation signal sensor resistance.
Page 138 1A-69 Engine General Information and Diagnosis: Step Action 4) If OK, then check the continuity between each terminal Go to step 2. Replace the crankshaft and ground. rotation signal sensor with a new one. Special tool (A): 09900–25008 (Multi circuit tester set) Crankshaft rotation signal sensor resistance ∞Ω...
Page 139: Specifications
Engine General Information and Diagnosis: 1A-70 Specifications Service Data BA02J21107001 Injector Item Specification Note 10.5 ± 0.53 Ω at 24 °C (75.2 °F) Injector resistance FI Sensors Item Specification Note 150 – 280 Ω CKP sensor resistance CKP sensor peak voltage 5.0 V and more Crankshaft rotation signal sensor 0.2 –...
Page 140: Special Tools And Equipment
(Page 1A-52) / (Page 1A-64) / (Page 1A-66) / (Page 1A-52) / (Page 1A-54) (Page 1A-68) 09904–41010 09917–47011 SUZUKI Diagnostic system Vacuum pump gauge set (Page 1A-11) / (Page 1A-47) (Page 1A-15) 99565–01010–021 CD-ROM Ver.21 (Page 1A-11) / (Page 1A-15)
Page 141: Emission Control Devices
Emission Control Devices: 1B-1 Emission Control Devices Engine Precautions Precautions for Emission Control Devices BA02J21200001 Refer to “General Precautions” in Section 00 (Page 00-1). Repair Instructions Crankcase Breather (PCV) Hose Inspection Crankcase Breather (PCV) Hose Removal and BA02J21206001 Installation Inspect the crankcase breather (PCV) hose in the BA02J21206002 following procedures: Removal...
Page 142: Engine Electrical Devices
1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device BA02J21300001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). Component Location Engine Electrical Components Location BA02J21303001 Refer to “Electrical Components Location”...
Page 143: Iap Sensor Inspection
Engine Electrical Devices: 1C-2 Installation TP Sensor Removal and Installation BA02J21306008 Install the CKP sensor/crankshaft rotation signal sensor Removal in the reverse order of removal. Refer to “Generator 1) Remove the exhaust pipe cover (1). Removal and Installation” in Section 1J (Page 1J-5). IAP Sensor Inspection BA02J21306005 Refer to “DTC “17”...
Page 144: Tp Sensor Adjustment
• Align the throttle shaft end “A” with the groove “B” of the TP sensor. • Apply grease to the throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) Special tool : 09930–11950 (Torx wrench (T25))
Page 145: Iat Sensor Inspection
Engine Electrical Devices: 1C-4 5) Turn on the ignition switch. 10) Tighten the TP sensor mounting screw to the specified torque. 6) Measure the TP sensor output voltage between the Y wire terminal (+) and B wire terminal (–). Tightening torque TP sensor mounting screw: 3.5 N·m (0.35 kgf- Special tool m, 2.5 lbf-ft)
Page 146: Ect Sensor Removal And Installation
1C-5 Engine Electrical Devices: 3) Disconnect the IAT sensor coupler (1) under the fuel tank protector. IA02J1130015-02 IA02J1130014-01 1. IAT sensor mounting screw 4. Air cleaner box 4) Remove the IAT sensor (2). 2. O-ring 5. IAT sensor bracket 5) Remove the IAT sensor bracket (3) from the air 3.
Page 147: Ect Sensor Inspection
Engine Electrical Devices: 1C-6 Installation Special tool Install the ECT sensor in the reverse order of removal. (A): 09900–25008 (Multi circuit tester set) Pay attention to the following points: Tester knob indication • Tighten the ECT sensor to the specified torque. Resistance (Ω) CAUTION Temperature sensor specification...
Page 148: Gp Switch Inspection
1C-7 Engine Electrical Devices: Installation • Install the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-5). Install the TO sensor in the reverse order of removal. Pay attention to the following points: GP Switch Inspection •...
Page 149: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J21308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1C-3)
Page 150: Engine Mechanical
1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram BA02J21402001 IA02J1140124-01...
Page 151: Throttle Cable Routing Diagram
Engine Mechanical: 1D-2 Throttle Cable Routing Diagram BA02J21402002 “A” “B” IA02J1140125-06...
Page 152 1D-3 Engine Mechanical: “ a ” “ a ” IA02J1140126-04 1. Throttle cable set 8. Wiring harness. 2. Lock-nut “A”: Pass the clutch, throttle and hot starter cables over the radiator hose. 3. Clutch cable “B”: Align the punch marks before tightening the nut. 4.
Page 153: Diagnostic Information And Procedures
Engine Mechanical: 1D-4 Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 5) Shift the transmission to the neutral, turn on the BA02J21404001 ignition switch and grasp the clutch lever. Refer to “Engine Symptom Diagnosis” in Section 1A 6) Keep the throttle grip in the fully-opened position. (Page 1A-7).
Page 154: Repair Instructions
1D-5 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place BA02J21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
Page 155 Engine Mechanical: 1D-6 Engine Right Side Item Removal Inspection Installation Refer to “Clutch Removal” in Refer to “Clutch Installation” Clutch cover — Section 5C (Page 5C-7). in Section 5C (Page 5C-8). Refer to “Clutch Parts Refer to “Clutch Removal” in Refer to “Clutch Installation”...
Page 156 1D-7 Engine Mechanical: Engine Left Side Item Removal Inspection Installation Refer to “Generator Removal Refer to “Generator Refer to “Generator Removal Generator and Installation” in Section Inspection” in Section 1J and Installation” in Section 1J (Page 1J-5). (Page 1J-4). 1J (Page 1J-5). Refer to “Engine Sprocket Refer to “Drive Chain Refer to “Engine Sprocket...
Page 157: Air Cleaner Element Removal And Installation
Engine Mechanical: 1D-8 Air Cleaner Element Removal and Installation Installation BA02J21406002 Installation in the reverse order of removal. Pay attention Removal to the following point: 1) Open the air cleaner box cover (1). • When installing the new air cleaner cap gasket (1), apply adhesive to position “A”...
Page 158: Throttle Cable Removal And Installation
1D-9 Engine Mechanical: 3) Remove the air cleaner box mounting bolts (2). Throttle Cable Removal and Installation BA02J21406005 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-5). 2) Remove the throttle cable as shown in the cable routing diagram.
Page 159 • Connect the hot starter cable (3) to the lever. the hot starter cable. • Apply grease to the end of starter cable. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1140245-01 5) Remove the hot starter cable (5) from its lever.
Page 160: Throttle Body Components
1D-11 Engine Mechanical: Throttle Body Components BA02J21406008 IA02J1140137-02 1. TP sensor 6. Cushion seal 11. IAP sensor Apply engine oil. 2. O-ring 7. O-ring 12. O-ring : Do not reuse. 3. Starter knob/idle screw 8. L-joint : 3.5 N⋅m (0.35 kgf-m, 2.5 lbf-ft) 4.
Page 161: Throttle Body Construction
Engine Mechanical: 1D-12 Throttle Body Construction BA02J21406009 “A” “a” “B” IA02J1140233-02 1. IAT sensor “A”: The claw part of the IAT sensor coupler should : 1.5 N⋅m (0.15 kgf-m, 1.0 lbf-ft) face right side. 2. Air cleaner box “B”: Clamp end should face downward. “a”: 12.5°...
Page 162 1D-13 Engine Mechanical: “D” “C” “E” (1), (6) IA02J1140140-03 5. Fuel feed hose “E”: When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque in the ascending order of numbers. 6.
Page 163: Hot Starter Lever Construction
Engine Mechanical: 1D-14 Hot Starter Lever Construction BA02J21406010 IA02J1140253-03 1. Hot starter lever 2. Hot starter lever cover : Fit the cover to the lever positively. Throttle Body Inspection 3) Set the engine idle speed sensor between 1 900 and BA02J21406011 2 100 r/min by turning the idle air screw (1).
Page 164: Throttle Body Removal And Installation
1D-15 Engine Mechanical: Throttle Body Removal and Installation BA02J21406013 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 1G-5). 2) Disconnect the TP sensor coupler (1) and fuel injector coupler (2). IA02J1140258-01 6) Disconnect the hot starter cable (5) from the throttle body.
Page 165 Engine Mechanical: 1D-16 9) Remove the hot starter valve (8) and spring (9) from • Connect the throttle pulling cable (1) and throttle the hot starter cable. returning cable (2) to the pulley. NOTE The throttle pulling cable has “xxxx” mark. IA02J1140148-01 Installation Install the throttle body assembly in the reverse order of...
Page 166: Throttle Body Disassembly And Assembly
1D-17 Engine Mechanical: Throttle Body Disassembly and Assembly 4) Remove the L-joint (4). BA02J21406014 Refer to “Throttle Body Removal and Installation” (Page 1D-15). Disassembly 1) Remove the fuel hose (1). 2) Remove the starter knob/idle screw (2). CAUTION Be sure to disconnect the fuel hose (1) by hand.
Page 167 Engine Mechanical: 1D-18 8) Remove the condenser bracket (10). Assembly Assemble the throttle body in the reverse order of disassembly. Pay attention to the following points: • Tighten the condenser bracket bolts to the specified torque. CAUTION Replace the condenser bracket bolts with new ones.
Page 168 1D-19 Engine Mechanical: • Apply thin coat of engine oil to new cushion seal (3) • Tighten the fuel pipe mounting bolts to the specified and O-ring (4). torque. Tightening torque CAUTION Fuel pipe mounting bolt (c): 3.5 N·m (0.35 kgf-m, Replace the cushion seal and O-ring with 2.5 lbf-ft) new ones.
Page 169: Throttle Body Inspection And Cleaning
• Apply grease to the throttle shaft end “C” if Some carburetor cleaning chemicals, necessary. especially dip-type soaking solutions, are very corrosive and must be handled carefully. : Grease 99000–25010 (SUZUKI SUPER Always follow the chemical manufacturer’s GREASE “A” or equivalent) instructions on proper use, handling and Special tool storage.
Page 170 1D-21 Engine Mechanical: 6) Disconnect the battery (–) lead wire. 11) Disconnect the radiator hoses (2) and (3). 12) Remove the crankcase breather (PCV) hose (4). Refer to “Crankcase Breather (PCV) Hose Removal and Installation” in Section 1B (Page 1B-1). 13) Disconnect the ECT sensor coupler (5) and engine ground lead wire (6).
Page 171 Engine Mechanical: 1D-22 17) Disconnect the clutch cable (11). 21) Remove the gearshift lever (15). NOTE NOTE Loosen the clutch cable adjuster on the Mark the gearshift shaft head at which the clutch lever fully when disconnecting the gearshift lever slit set for correct cable.
Page 172 1D-23 Engine Mechanical: 25) Remove the front engine mounting brackets (21) and 27) Remove the swingarm pivot shaft nut and washer. upper engine mounting brackets (22), left and right. 26) Remove the engine mounting bolt and nut (23). IA02J1140263-02 28) Extract three quarters of the swingarm pivot shaft (24) so as to keep the swingarm in position.
Page 173: Engine Assembly Installation
Engine Mechanical: 1D-24 Engine Assembly Installation CAUTION BA02J21406017 Install the engine in the reverse order of removal. Pay The engine mounting nut is the self-lock type attention to the following points: and cannot be used repeatedly. If the self- lock effect is lose, replace it with a new one. •...
Page 174 1D-25 Engine Mechanical: IA02J1140229-04 1. Upper engine mounting bracket (RH) 10. Swingarm pivot shaft 2. Upper engine mounting bracket (LH) 11. Washer 3. Front engine mounting bracket (RH) 12. Swingarm pivot nut 4. Front engine mounting bracket (LH) : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft) 5.
Page 175 Engine Mechanical: 1D-26 • Install the engine sprocket (13) and snap ring (14). • Install the gearshift lever (18) in the correct position. CAUTION Replace the snap ring with a new one. Seat the snap ring in the groove and locate its end as shown in the illustration.
Page 176: Engine Top Side Disassembly
1D-27 Engine Mechanical: Engine Top Side Disassembly 2) Turn the crankshaft counterclockwise to bring the BA02J21406018 line “A” on the magneto rotor to the grooves “B” on CAUTION the cap hole thread. Identify the position of each removed part. NOTE Organize the parts in their respective groups The piston must be at top dead center (TDC) (e.g., intake, exhaust) so that they can be...
Page 177 Engine Mechanical: 1D-28 6) Remove the camshaft journal holder. Cylinder Head 1) Remove the exhaust pipe (1) and gasket. Refer to CAUTION “Muffler / Exhaust Pipe Removal and Installation” in Be sure to loosen the camshaft journal Section 1K (Page 1K-2). holder bolts evenly by shifting the wrench in the descending order of numbers.
Page 178 1D-29 Engine Mechanical: 6) Remove the cylinder head base bolts (5). Cylinder 7) Loosen the cylinder base bolt (6). 1) Remove the cylinder (1) by removing the cylinder base bolt. CAUTION Do not drop the cam chain into the crankcase. NOTE If the cylinder does not come off easily, lightly tap it with a plastic hammer.
Page 179: Engine Top Side Assembly
• Thoroughly wipe off oil from the fitting surface of the crankcase. • Apply bond to the crankcase as shown in the figure. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) IA02J1140204-01 • Place a clean rag over the cylinder base to prevent the piston pin circlip (1) from dropping into the crankcase, and then install new piston pin circlip (1).
Page 180 1D-31 Engine Mechanical: • Install the dowel pins and cylinder gasket (1). Cylinder Head • Temporarily tighten the cylinder base bolt (1). CAUTION • Insert the end of cam chain guide No. 1 “A” into the Use a new gasket to prevent oil leakage. recess “B”...
Page 181 Engine Mechanical: 1D-32 • Place the cylinder head (3) on the cylinder. • After tightening the cylinder head bolts to specification, tighten the cylinder head base bolts (4) NOTE and cylinder base bolt (5) to the specified torque. When installing the cylinder head (3), keep Tightening torque the cam chain taut.
Page 182 1D-33 Engine Mechanical: • Install the throttle body. Refer to “Throttle Body Removal and Installation” (Page 1D-15). • Connect the radiator inlet hose (8). • Install the exhaust pipe (9). Refer to “Muffler / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-2).
Page 183 • Unlock the ratchet mechanism (1) and push the push camshaft journal holder. rod (2) all the way. CAUTION Use new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1140221-01 • Install new gasket (3). CAUTION Use a new gasket to prevent oil leakage.
Page 184 CAUTION properly by checking the slack of cam chain. Use new O-rings to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) • Tighten each plug to the specified torque. Tightening torque TDC plug (c): 14 N·m (1.4 kgf-m, 10.0 lbf-ft)
Page 185: Valve Clearance Inspection And Adjustment
• Apply bond to the end caps of the cylinder head cover Valve Clearance Inspection and Adjustment BA02J21406020 gasket as shown in the figure. Refer to “Valve Clearance Inspection and Adjustment” in : Sealant 99000–31140 (SUZUKI BOND Section 0B (Page 0B-14). No.1207B or equivalent) Camshaft Inspection CAUTION BA02J21406021 Refer to “Engine Top Side Disassembly”...
Page 186 1D-37 Engine Mechanical: Camshaft Bearing Inspect the bearings for play and smooth movement. If there is anything unusual, replace the camshaft assembly. (A), (B) IA02J1140005-01 2) Install the camshaft journal holder. 3) Tighten the camshaft journal holder bolts evenly in the ascending order of numbers.
Page 187: Cam Chain Tension Adjuster Inspection
Engine Mechanical: 1D-38 5) If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or cylinder head depending upon which one exceeds the specification.
Page 188: Cam Chain Tensioner Inspection
1D-39 Engine Mechanical: Cam Chain Tensioner Inspection 6) Reinstall the magneto rotor and starter idle gears. BA02J21406024 Refer to “Starter Torque Limiter / Starter Idle Gear / Inspect the cam chain tensioner in the following Starter Clutch Removal and Installation” in Section 1I procedures: (Page 1I-10).
Page 189 Engine Mechanical: 1D-40 3) Install the sleeve protector between the valve spring 7) Remove the valve stem oil seal (7) and spring seat and cylinder head. (8). 4) Using the special tools, compress the valve spring and remove the two cotter halves (3) from the valve stem.
Page 190 IA02J1140022-04 • Apply grease to new O-ring of the intake pipe. CAUTION Replace the O-ring with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1140118-01 • Install the valve spring seat (3). • Apply molybdenum oil to new valve stem oil seal (4), and press-fit it into position.
Page 191 Engine Mechanical: 1D-42 • Insert the valve, with its stem coated with molybdenum oil all around and along the full stem length without any break. CAUTION When inserting the valve, take care not to damage the lip of the valve stem oil seal. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) IA02J1140027-01...
Page 192: Cylinder Head Related Parts Inspection
1D-43 Engine Mechanical: Cylinder Head Related Parts Inspection Valve Head Radial Runout BA02J21406026 Place the dial gauge at a right angle to the valve head Refer to “Cylinder Head Disassembly and Assembly” face and measure the valve head radial runout. If it (Page 1D-39).
Page 193 Engine Mechanical: 1D-44 Valve Stem and Valve Face Wear Condition Valve Stem Wear Visually inspect each valve stem and valve face for wear Measure the valve stem O.D. using the micrometer. If it and pitting. If it is worn or damaged, replace the valve is out of specification, replace the valve with a new one.
Page 194 1D-45 Engine Mechanical: Valve Spring Valve Seat Width The force of the coil spring keeps the valve seat tight. A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve.
Page 195: Valve Guide Replacement
Engine Mechanical: 1D-46 Valve Seat Sealing Condition NOTE 1) Clean and assemble the cylinder head and valve • Discard the removed valve guide sub- components. assemblies. 2) Fill the intake and exhaust ports with gasoline to • Only oversized valve guides are available check for leaks.
Page 196: Valve Seat Repair
1D-47 Engine Mechanical: 7) Drive the guide into the guide hole using the valve NOTE guide installer. • Be sure to cool down the cylinder head to ambient air temperature. CAUTION • Insert the reamer from the combustion Failure to oil the valve guide hole before chamber and always turn the reamer driving the new guide into place may result in handle clockwise.
Page 197: Cylinder Inspection
Engine Mechanical: 1D-48 Cylinder Bore CAUTION Inspect the cylinder wall for any scratches, nicks or other • The valve seat contact area must be damage (Measure the cylinder bore diameter at six inspected after each cut. places). If any defects are found, replace the cylinder with a new one.
Page 198: Piston Ring Removal And Installation
1D-49 Engine Mechanical: Piston Ring Removal and Installation BA02J21406030 Removal “A” 1) Remove the piston. Refer to “Engine Top Side Disassembly” (Page 1D-27). 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it.
Page 199: Piston And Piston Ring Inspection
Engine Mechanical: 1D-50 Piston and Piston Ring Inspection Piston ring-to-groove clearance BA02J21406031 Service limit: (1st): 0.180 mm (0.007 in) Refer to “Piston Ring Removal and Installation” Piston ring groove width (Page 1D-49). “a”: Standard: (1st): 0.78 – 0.80 mm (0.0307 – 0.0315 Piston Diameter “b”: Standard: (1st): 1.30 –...
Page 200: Engine Bottom Side Disassembly
1D-51 Engine Mechanical: Piston Ring Free End Gap and Piston Ring End Gap Measure the piston ring free end gap using the vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.
Page 201 Engine Mechanical: 1D-52 Magneto Cover Magneto Rotor / Starter Driven Gear Remove the magneto rotor (1). Refer to “Generator 1) Remove the magneto cover (1). Removal and Installation” in Section 1J (Page 1J-5). IA02J1140049-01 IA02J1140052-01 2) Remove the dowel pin and gasket (2). Cam Chain Tensioner / Cam Chain Remove the cam chain tensioner (1), cam chain guide retainer (2) and cam chain (3).
Page 202 1D-53 Engine Mechanical: Gear Position Switch 2) Remove the primary drive gear nut (1) and washer Remove the gear position switch (1). Refer to “Gear (2). Position (GP) Switch Removal and Installation” in CAUTION Section 5B (Page 5B-11). The primary drive gear nut has left-hand threads.
Page 203 Engine Mechanical: 1D-54 Oil Pump No. 1 2) Remove the crankcase bolts. Remove the oil pump No. 1 component parts (1). Refer 3) Remove the oil strainer No. 1 (3). Refer to “Oil to “Oil Pump No. 1 Removal and Installation” in Section Strainer Inspection”...
Page 204: Engine Bottom Side Assembly
1D-55 Engine Mechanical: Transmission Remove the transmission component parts. Refer to “Transmission Removal and Installation” in Section 5B (Page 5B-3). IA02J1140067-01 IA02J1140065-01 Crankshaft Remove the crankshaft with the special tool. CAUTION Be careful not to damage the thread part of the crankshaft.
Page 205 “Transmission Removal and Installation” in Section 5B (Page 5B-3). IA02J1140070-01 Left Crankshaft Oil Seal • Apply grease to new oil seal lip. CAUTION Replace the removed oil seal with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1140073-01...
Page 206 • Apply grease to the oil seal lip and new O-rings (4). CAUTION Replace the removed O-rings with new ones. IA02J1140074-02 : Grease 99000–25010 (SUZUKI SUPER • Fit the right crankcase on the left crankcase. GREASE “A” or equivalent) • Tighten the crankcase bolts to the specified torque.
Page 207 IA02J1140080-01 The washer (4) is directional. Assemble the Primary Drive Gear / Clutch washer (4) as shown in the illustration. • Apply SUZUKI moly paste to the clutch release CAUTION camshaft. The primary drive gear nut has left-hand : Moly paste 99000–25140 (SUZUKI MOLY threads.
Page 208 1D-59 Engine Mechanical: • Install the clutch component parts. Refer to “Clutch Installation” in Section 5C (Page 5C-8). “A” • Hold the crankshaft immovable with the special tool and tighten the primary drive gear nut (5) to the specified torque. Special tool (A): 09914–61010 (Gear holder) Tightening torque...
Page 209 Engine Mechanical: 1D-60 Cam Chain / Cam Chain Tensioner Starter Idle Gear / Starter Torque limiter Install the starter idle gears and starter torque limiter. • Install the cam chain (1) to the crankshaft sprocket. Refer to “Starter Torque Limiter / Starter Idle Gear / •...
Page 210: Oil Pump No. 1 Inspection
1D-61 Engine Mechanical: Starter Motor Conrod Small End I.D. Install the starter motor (1). Refer to “Starter Motor Measure the conrod small end inside diameter with the Removal and Installation” in Section 1I (Page 1I-4). dial calipers. If conrod small end inside diameter exceeds the service limit, replace the conrod.
Page 211: Crankshaft Oil Seal / Bearing Inspection
Engine Mechanical: 1D-62 Conrod Big End Side Clearance Crank Web to Web Width Push the big end of the conrod to one side and measure Measure the width between crankshaft webs “a”. the side clearance using a thickness gauge. If the Width between crankshaft webs “a”...
Page 212: Crankshaft Oil Seal / Bearing Removal And Installation
1D-63 Engine Mechanical: Bearing 4) Remove the snap ring (3). Rotate the bearing inner race by finger to inspect for Special tool abnormal play, noise and smooth rotation while the : 09900–06108 (Snap ring remover (Close bearings are in the crankcase. type)) Replace the bearing if there is anything unusual.
Page 213 Engine Mechanical: 1D-64 7) Remove the left crankcase bearing (6) using the special tool. Special tool (B): 09913–70210 (Bearing installing set (10 – 75 Φ)) IA02J1140112-01 2) Install the right crankcase bearing (2) using the special tool. Special tool (A): 09913–70210 (Bearing installing set (10 –...
Page 214: Transmission Oil Seal / Bearing Inspection
Transmission Oil Seal / Bearing Removal and Installation BA02J21406043 IA02J1140115-01 Refer to “Transmission Oil Seal / Bearing Removal and 6) Apply grease to the oil seal lip. Installation” in Section 5B (Page 5B-8). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent)
Page 215: Clutch Release Camshaft Oil Seal / Bearing Inspection
Engine Mechanical: 1D-66 Clutch Release Camshaft Oil Seal / Bearing CAUTION Inspection the removed bearings must be replaced with BA02J21406044 Refer to “Clutch Release Camshaft / Oil Seal / Bearing new ones. Inspection” in Section 5C (Page 5C-5). NOTE Clutch Release Camshaft Oil Seal / Bearing Stamped mark side of the bearings should Removal and Installation face upward.
Page 216: Specifications
1D-67 Engine Mechanical: Specifications Service Data BA02J21407001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 31.0 (1.22) — 0.09 – 0.16 (0.004 – 0.006) — Valve clearance (When cold) 0.17 – 0.24 (0.007 – 0.009) —...
Page 217 Engine Mechanical: 1D-68 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit Compression pressure Approx. 400 kPa (4.0 kgf/cm , 57 psi) and more — (Automatic decomp. actuated) Piston to cylinder clearance 0.035 – 0.045 (0.0014 – 0.0018) 0.120 (0.0047) Nicks or Cylinder bore...
Page 218 1D-69 Engine Mechanical: Tightening Torque Specifications BA02J21407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Cable adjuster lock nut 0.21 (Page 1D-16) Condenser bracket bolt (Page 1D-18) IAP sensor mounting screw 0.15 (Page 1D-18) Fuel pipe mounting bolt 0.35 (Page 1D-19) L-joint mounting screw 0.35 (Page 1D-19)
Page 219: Special Tools And Equipment
(Page 1D-41) / (Page 1D-56) / (Page 1D-57) / (Page 1D-58) / (Page 1D-58) / (Page 1D-65) Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1D-58) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1D-30) / (Page 1D-31) /...
Page 220: Special Tool
1D-71 Engine Mechanical: Special Tool BA02J21408002 09900–06107 09900–06108 Snap ring remover (Open Snap ring remover (Close type) type) (Page 1D-22) / (Page 1D-63) / (Page 1D-26) (Page 1D-65) 09900–20101 09900–20202 Vernier calipers (150 mm) Micrometer (25 – 50 mm) (Page 1D-43) / (Page 1D-37) (Page 1D-45) / (Page 1D-51)
Page 221 Engine Mechanical: 1D-72 09900–22302 09900–22403 Plastigage (0.051 – 0.152 Small bore gauge (18 – 35 (Page 1D-37) (Page 1D-38) / (Page 1D-51) 09900–26006 09910–32812 Engine tachometer Crankshaft installer (Page 1D-14) (Page 1D-56) 09911–11310 09913–10750 Crankshaft installer Compression gauge adapter attachment C (Page 1D-56) (Page 1D-4) 09913–50121...
Page 222 1D-73 Engine Mechanical: 09916–34550 09916–34580 Valve guide reamer (5.5 Valve guide reamer (10.8 (Page 1D-47) (Page 1D-46) 09916–44310 09916–53360 Valve guide installer & Valve guide installer remover attachment (Page 1D-46) / (Page 1D-47) (Page 1D-47) 09916–84511 09919–28610 Tweezer Sleeve protector (Page 1D-40) / (Page 1D-39) / (Page 1D-42)
Page 223: Engine Lubrication System
Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil BA02J21500001 Refer to “Fuel and Oil Recommendation” in Section 0A (Page 0A-3). Schematic and Routing Diagram Engine Lubrication System Chart Diagram BA02J21502001 CAMSHAFT BEARINGS PISTON IN. & EX. CAM FACES CONROD SMALL END CAM SPROCKETS CAMSHAFT JOURNALS...
Page 224: Diagnostic Information And Procedures
1E-2 Engine Lubrication System: Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis BA02J21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Incorrect engine oil. Change.
Page 225: Repair Instructions
Engine Lubrication System: 1E-3 6) Stop the engine and remove the oil pressure gauge and attachment. 7) Reinstall the main oil gallery plug (1) and tighten it to the specified torque. CAUTION Use a new gasket to prevent oil leakage. Tightening torque Oil gallery plug (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft) IA02J1150003-01...
Page 226 1E-4 Engine Lubrication System: 3) Remove the snap ring (1). Installation Install the oil pump No. 1 in the reverse order of removal. Special tool Pay attention to the following points: : 09900–06107 (Snap ring remover (Open type)) CAUTION 4) Remove the oil pump idle gear (2). The removed snap ring and O-ring must be replaced with new ones.
Page 227: Oil Pump No. 2 Components
Engine Lubrication System: 1E-5 • Install the oil pump idle gear (5) and snap ring (6). IA02J1150013-01 4) Remove the oil pump No. 2 shaft (2), pin (3), inner IA02J1150033-01 • Reinstall the clutch. Refer to “Clutch Installation” in rotor (4) and outer rotor (5). Section 5C (Page 5C-8).
Page 228: Oil Pump Inspection
1E-6 Engine Lubrication System: Installation • Install the oil pump No. 2 strainer (5) and snap ring (6). CAUTION The removed snap ring must be replaced with a new one. • Install the pin (1) and inner rotor (2) to the oil pump No.
Page 229: Oil Relief Valve Removal And Installation
Engine Lubrication System: 1E-7 Oil Pump No. 2 1) Remove the oil pump No. 2. Refer to “Oil Pump No. 2 Removal and Installation” (Page 1E-5). 2) Inspect the oil pump parts for any defects or wear. If any defects are found, replace the defective parts with a new one.
Page 230: Oil Reed Valve Inspection
1E-8 Engine Lubrication System: Installation Install the oil reed valve and assemble the crankcase. Refer to “Engine Bottom Side Assembly” in Section 1D (Page 1D-55). Oil Reed Valve Inspection BA02J21506014 Inspect the oil reed valve in the following procedures: • Remove the oil reed valve. Refer to “Oil Reed Valve Removal and Installation”...
Page 231: Special Tools And Equipment
Engine Lubrication System: 1E-9 Special Tools and Equipment Recommended Service Material BA02J21508001 NOTE Required service material is also described in the following. “Oil Pump No. 1 Components” (Page 1E-3) “Oil Pump No. 2 Components” (Page 1E-5) Special Tool BA02J21508002 09900–06107 09900–06108 Snap ring remover (Open Snap ring remover (Close...
Page 232: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System Engine Precautions Precautions for Engine Cooling System BA02J21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
Page 233: General Description
Engine Cooling System: 1F-2 General Description Engine Coolant Description Fig.1: Engine coolant density-freezing point curve BA02J21601001 CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. •...
Page 234: Water Hose Routing Diagram
1F-3 Engine Cooling System: Water Hose Routing Diagram BA02J21602002 “A” “C” “C” “ a ” “E” “F” “F” “D” “B” “C” “B” “G” “D” “H” IA02J1160033-04 1. Reservoir tank “A”: Face the hose clamp end forward. “F”: White marking 2. Reservoir tank inlet hose “B”: Face the screw head to the right side.
Page 235: Repair Instructions
Engine Cooling System: 1F-4 Repair Instructions Cooling Circuit Inspection Radiator Cap Inspection BA02J21606001 BA02J21606002 Inspect the radiator cap in the following procedures: WARNING 1) Remove the radiator cap. • Do not open the radiator cap when the 2) Attach the radiator cap (1) to the radiator tester (2) engine is hot, as you may be injured by as shown in the figure.
Page 236: Radiator Removal And Installation
1F-5 Engine Cooling System: 3) Reinstall the radiator covers, left and right. Radiator Cleaning 1) Remove the radiator covers, left and right. Refer to “Exterior Parts Removal and Installation” in Section 9D (Page 9D-1). 2) Blow out any foreign matter that is stuck in the radiator fins using compressed air.
Page 237: Water Hose Inspection
Engine Cooling System: 1F-6 Water Hose Inspection Installation BA02J21606005 1) Install the water hose as shown in the water hose Inspect the water hoses in the following procedures: routing diagram. Refer to “Water Hose Routing 1) Remove the radiator covers, left and right. Refer to Diagram”...
Page 238: Ect Sensor Removal And Installation
1F-7 Engine Cooling System: Installation 4) Install the protector. 1) Connect the hoses as shown in the water hose ECT Sensor Removal and Installation routing diagram. Refer to “Water Hose Routing BA02J21606009 Diagram” (Page 1F-3). Refer to “ECT Sensor Removal and Installation” in 2) Install the reservoir tank (1).
Page 239: Water Pump Removal And Installation
Engine Cooling System: 1F-8 Water Pump Removal and Installation 7) Remove the rear brake pedal. Refer to “Rear Brake BA02J21606013 Pedal Removal and Installation” in Section 4A Removal (Page 4A-16). NOTE 8) Remove the kick starter lever. Refer to “Kick Starter Removal and Installation”...
Page 240 IA02J1160024-02 IA02J1160021-01 • Apply grease to the oil seal lips. Installation : Grease 99000–25010 (SUZUKI SUPER Install the water pump in the reverse order of removal. GREASE “A” or equivalent) Pay attention to the following points: • Apply thread lock to the outer surface of new oil seal.
Page 241 Engine Cooling System: 1F-10 • Apply engine oil to the water pump shaft. • Install the dowel pins and oil filter (3). • Hold the water pump shaft with a wrench and tighten • Install the spring (4) and a new gasket (5). the impeller to the specified torque.
Page 242: Water Pump Related Parts Inspection
1F-11 Engine Cooling System: Water Pump Related Parts Inspection Oil Seal BA02J21606014 Visually inspect the oil seal for damage, with particular Refer to “Water Pump Removal and Installation” attention given to the lip. (Page 1F-8). Replace the oil seal that shows indications of leakage. Impeller and Water Pump Shaft Inspect the impeller and water pump shaft for damage.
Page 243: Special Tools And Equipment
Engine Cooling System: 1F-12 Special Tools and Equipment Recommended Service Material BA02J21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1F-9) equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1F-7) / (Page 1F- “1322”...
Page 244: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System BA02J21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...
Page 245: Diagnostic Information And Procedures
Fuel System: 1G-2 Diagnostic Information and Procedures Fuel System Diagnosis BA02J21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.
Page 246: Repair Instructions
1G-3 Fuel System: Repair Instructions Fuel Pressure Inspection 4) Turn on the ignition and check the fuel pressure. BA02J21706001 Fuel pressure WARNING Approx. 294 kPa (2.94 kgf/cm , 42psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...
Page 247: Fuel Discharge Amount Inspection
Fuel System: 1G-4 Fuel Discharge Amount Inspection 6) Connect proper lead wires to the fuel pump lead wire BA02J21706003 coupler (fuel pump side) and apply 12 V to the fuel WARNING pump (between (+) R wire and (–) B wire) for 10 seconds and measure the amount of fuel •...
Page 248: Fuel Tank Components
1G-5 Fuel System: Fuel Tank Components BA02J21706007 IA02J1170016-01 1. Fuel tank : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Fuel pump : Apply grease. 3. O-ring : Do not reuse. 4. Fuel feed hose Fuel Tank Removal and Installation BA02J21706008 Removal WARNING •...
Page 249: Fuel Injector / Fuel Delivery Pipe / T-Joint Removal And Installation
Fuel System: 1G-6 4) Disconnect the fuel pump coupler (1). 5) Place a rag under the fuel feed hose (2) and disconnect the fuel feed hose (2) from the fuel pump. CAUTION • Be sure to disconnect the fuel feed hose (2) by hand.
Page 250: Specifications
• Install a new O-ring and apply grease to it. Tightening torque Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 CAUTION lbf-ft) Replace the O-ring with a new one. 1, 6 : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1170015-01 IA02J1170014-01 Specifications Service Data BA02J21707001...
Page 251: Special Tools And Equipment
Fuel System: 1G-8 Special Tools and Equipment Recommended Service Material BA02J21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1G-7) equivalent NOTE Required service material is also described in the following. “Fuel Tank Components” (Page 1G-5)
Page 252: Ignition System
1H-1 Ignition System: Ignition System Engine Schematic and Routing Diagram Ignition System Diagram BA02J21802001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Ignition coil Regulator /rectifier CKP sensor Magneto Engine Crankshaft rotation stop signal sensor switch sensor sensor switch IA02J1180018-03 Ignition System Components Location...
Page 253: Diagnostic Information And Procedures
Ignition System: 1H-2 Diagnostic Information and Procedures Ignition System Symptom Diagnosis BA02J21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug cap. Replace. Damaged spark plug. Replace. Fouled spark plug. Clean or replace. Wet spark plug. Clean and dry or replace.
Page 254: No Spark Or Poor Spark
1H-3 Ignition System: No Spark or Poor Spark BA02J21804002 Troubleshooting NOTE Check that the transmission is in neutral. Check that the fuse is not blown and the battery is fully- charged before diagnosing. Step Action Check the ignition system couplers for poor connections. Go to step 2.
Page 255: Repair Instructions
Ignition System: 1H-4 Repair Instructions Spark Plug Cap and Spark Plug Removal and Installation BA02J21806001 Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch. 1) Turn off the ignition switch. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 256 1H-5 Ignition System: 4) Insert the needle-point probes to the ignition coil lead 6) Measure the ignition coil primary peak voltage in the wire coupler (1). following procedures: CAUTION WARNING Use the special tool to prevent the rubber of Do not touch the tester probes and spark the water proof coupler from damage.
Page 257: Ckp Sensor Inspection
Ignition System: 1H-6 3) Measure the ignition coil resistance in both the 2) Connect the multi circuit tester with the peak voltage primary and secondary coils. If the resistance is not adaptor as follows: within the standard range, replace the ignition coil CAUTION with a new one.
Page 258: Crankshaft Rotation Signal Sensor Inspection
1H-7 Ignition System: CKP Sensor Resistance 1) Disconnect the CKP sensor/crankshaft rotation signal sensor lead wire coupler (1). IA02J1180007-02 2) Connect the multi circuit tester with the peak voltage adaptor as follows: IA02J1180007-02 CAUTION 2) Measure the resistance between the lead wires and ground.
Page 259: Ckp Sensor / Crankshaft Rotation Signal Sensor Removal And Installation
Ignition System: 1H-8 5) If the peak voltage is within the specification, check CKP Sensor / Crankshaft Rotation Signal the continuity between the CKP sensor/crankshaft Sensor Removal and Installation rotation signal sensor lead wire coupler and ECM BA02J21806006 Refer to “Generator Removal and Installation” in Section coupler.
Page 260: Engine Stop Switch Removal And Installation
1H-9 Ignition System: Engine Stop Switch Removal and Installation Ignition Switch Inspection BA02J21806008 BA02J21806009 Removal Refer to “Speedometer Construction” in Section 9C (Page 9C-2). 1) Turn off the ignition switch. 2) Remove the fuel tank. Refer to “Fuel Tank Removal Ignition Switch Removal and Installation and Installation”...
Page 261: Specifications
Ignition System: 1H-10 Specifications Service Data BA02J21807001 Electrical Unit: mm (in) Item Specification Note Type NGK: CR8EIB-10 Spark plug 0.9 – 1.0 (0.035 – 0.039) Spark performance Over 8 (0.3) at 1 atm. Crankshaft rotation signal sensor 3.0 V and more (+): B/R, (–): R/W peak voltage Crankshaft rotation signal sensor...
Page 262: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram BA02J21902001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). Clutch Starter lever Starter Ignition relay switch button switch Fuse (15A) Fuse (15A) Starter motor IA02J1190050-04 Component Location Starting System Components Location BA02J21903001...
Page 263: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run BA02J21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to step 2. Go to step 3. 2) Grasp the clutch lever, turn on the ignition switch and listen for a click from the starter relay when the starter button is pushed.
Page 264: Repair Instructions
1I-3 Starting System: Repair Instructions Starter Motor Components BA02J21906001 IA02J1190069-01 1. O-ring 6. Brush holder set : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 2. Housing end (Inside) 7. O-ring : Apply grease. 3. Square-ring 8. Housing end (Outside) : Apply moly paste to sliding surface. 4.
Page 265: Starter Motor Removal And Installation
Pay attention to the following points: • Apply grease to the O-ring. Disassembly Disassemble the starter motor as shown in the starter : Grease 99000–25010 (SUZUKI SUPER motor components diagram. Refer to “Starter Motor GREASE “A” or equivalent) Components” (Page 1I-3).
Page 266: Starter Motor Related Parts Inspection
3.5 lbf-ft) IA02J1190004-02 • Apply a small quantity of moly paste to the armature IA02J1190008-02 shaft. : Moly paste 99000–25140 (SUZUKI MOLY Starter Motor Related Parts Inspection PASTE or equivalent) BA02J21906004 Refer to “Starter Motor Disassembly and Assembly” (Page 1I-4).
Page 267: Starter Relay Removal And Installation
Starting System: 1I-6 Commutator Bearing Inspect the commutator for discoloration, abnormal wear Check the bearing of housing end for damage. or undercut “A”. If any damage is found, replace the housing end. If the commutator is abnormally worn, replace the armature.
Page 268: Starter Relay Inspection
1I-7 Starting System: 4) Disconnect the starter relay lead wire coupler (1), 3) Measure the relay coil resistance between the starter motor lead wire (2) and battery (+) lead wire terminals using the multi circuit tester. If the (3). resistance is not within the specified value, replace the starter relay with a new one.
Page 269 Starting System: 1I-8 3) Check the continuity between Bl and B lead wires 7) Measure the voltage between P and B/W lead wires with the transmission in neutral. using the multi circuit tester when shifting the gearshift lever from 1st to top. Special tool : 09900–25008 (Multi circuit tester set) Special tool...
Page 270: Starter Torque Limiter / Starter Idle Gear / Starter Clutch Components
1I-9 Starting System: Starter Torque Limiter / Starter Idle Gear / Starter Clutch Components BA02J21906008 IA02J1190058-02 1. Bushing 5. Starter driven gear : Apply molybdenum oil solution. 2. Starter Torque limiter 6. Starter clutch : Apply thread lock. 3. Starter Idle gear No. 2 : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft) : Do not reuse.
Page 271: Starter Torque Limiter / Starter Idle Gear / Starter Clutch Removal And Installation
Starting System: 1I-10 Starter Torque Limiter / Starter Idle Gear / 6) Remove the magneto rotor. Refer to “Generator Removal and Installation” in Section 1J (Page 1J-5). Starter Clutch Removal and Installation BA02J21906009 7) Hold the magneto rotor with the special tool and Removal remove the starter clutch bolts.
Page 272: Starter Torque Limiter Inspection
1I-11 Starting System: • Install the guide to the generator rotor. NOTE The arrow mark “C” must face the generator rotor side. “C” IA02J1190018-01 • Install the starter idle gears. • Apply molybdenum oil solution to the starter torque limiter bushings and idle gear holes on the generator cover.
Page 273: Starter Clutch Related Parts Inspection
Starting System: 1I-12 2) Turn the starter torque limiter with a torque wrench and check the slip torque. If the slip torque is not within the specification, replace the starter torque limiter with a new one. Starter torque limiter slip torque Standard: 9 –...
Page 274: Starter Button Inspection
1I-13 Starting System: Installation 3) Inspect the starter button for continuity with the Install the starter driven gear bearing in the reverse order tester. If any abnormality is found, replace the handle of removal. switch assembly with a new one. Refer to “Handlebars Removal and Installation”...
Page 275: Kick Starter Components
Starting System: 1I-14 Kick Starter Components BA02J21906014 IA02J1190026-02 1. Oil seal 8. Kick starter idle gear 2. Return spring : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3. Spring guide : 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft) 4. Kick starter drive gear : Apply grease.
Page 276: Kick Starter Removal And Installation
1I-15 Starting System: Kick Starter Removal and Installation 10) Remove the kick starter idle gear (8) and wave BA02J21906015 washer (9). Removal 1) Drain engine oil. Refer to “Engine Oil Inspection and Replacement” in Section 0B (Page 0B-5). 2) Drain engine coolant. Refer to “Cooling System Inspection”...
Page 277 Starting System: 1I-16 13) Remove the kick starter guide (19). • Install the spring guide (5) onto the kick starter shaft. NOTE Align the concave of spring guide “A” with kick starter hole “B”. “B” IA02J1190046-02 Installation “A” Install the kick starter in the reverse order of removal. Pay attention to the following points: •...
Page 278 1I-17 Starting System: • Install the washer (8) and spring (9) onto the kick starter shaft. IA02J1190041-04 • Reassemble the clutch component parts. Refer to “Clutch Installation” in Section 5C (Page 5C-8). IA02J1190038-03 • Install the kick starter shaft assembly onto the •...
Page 279: Kick Starter Related Parts Inspection
Starting System: 1I-18 • Align the truncated splines and install the kick starter Inspect the kick starter component parts for any lever to the shaft. damage. If necessary, replace the defective parts with a new one. IA02J1190044-01 • Apply thread lock to the kick starter lever hole and IA02J1190052-01 tighten it to the specified torque.
Page 280: Specifications
Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-5) equivalent Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 1I-5) Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1I-11) / (Page 1I- Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 281: Special Tool
Starting System: 1I-20 Special Tool BA02J21908002 09900–06107 09900–06108 Snap ring remover (Open Snap ring remover (Close type) type) (Page 1I-15) / (Page 1I- (Page 1I-12) 09900–20102 09900–25008 Vernier calipers (200 mm) Multi circuit tester set (Page 1I-5) (Page 1I-6) / (Page 1I-7) (Page 1I-7) / (Page 1I-...
Page 282: Charging System
1J-1 Charging System: Charging System Engine Schematic and Routing Diagram Charging System Diagram BA02J21A02001 Regulator/Rectifier Ignition switch Generator Load IA02J11A0018-04 Component Location Charging System Components Location BA02J21A03001 Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
Page 283: Diagnostic Information And Procedures
Charging System: 1J-2 Diagnostic Information and Procedures Charging System Symptom Diagnosis BA02J21A04001 Condition Possible cause Correction / Reference Item Generator does not Open- or short-circuited lead wires, or Repair, replace or connect properly. charge loose lead connections. Short-circuited, grounded or open Replace.
Page 284: Battery Runs Down Quickly
1J-3 Charging System: Battery Runs Down Quickly BA02J21A04002 Troubleshooting Step Action Check accessories which use excessive amounts of Remove accessories. Go to Step 2. electricity. Are accessories being installed? Check the battery for current leakage. Refer to “Battery Go to Step 3. •...
Page 285: Regulated Voltage Inspection
Charging System: 1J-4 Regulated Voltage Inspection 2) Measure the resistance between the three lead BA02J21A06002 wires. Inspect the regulated voltage in the following If the resistance is out of specified value, replace the procedures: stator with a new one. Also, check that the generator 1) Remove the seat.
Page 286: Generator Removal And Installation
1J-5 Charging System: 4) Using the multi circuit tester, measure the voltage 5) Remove the magneto cover (3). between three lead wires. If the tester reads under the specified value, replace the generator with a new one. Special tool : 09900–25008 (Multi circuit tester set) : 09900–26006 (Engine tachometer) Tester knob indication Voltage (~)
Page 287 Charging System: 1J-6 9) Remove the magneto rotor assembly with the NOTE special tool. Be sure the grommet (1) is set to the generator cover. Special tool (B): 09930–34932 (Rotor remover) Tightening torque Generator stator bolt (a): 5.5 N·m (0.55 kgf-m, 4.0 CAUTION lbf-ft) Do not hit the magneto rotor with a hammer,...
Page 288: Regulator / Rectifier Removal And Installation
1J-7 Charging System: • Apply molybdenum oil solution to the idle gear shaft holes and starter torque limiter bushing (2). “D” M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) “C” “D” IA02J11A0012-03 • Route the CKP/crankshaft rotation signal sensor and generator lead wires. Refer to “Wiring Harness Routing Diagram”...
Page 289: Regulator / Rectifier Inspection
Charging System: 1J-8 Regulator / Rectifier Inspection BA02J21A06006 Inspect the regulator/rectifier in the following procedures: 1) Remove the regulator/rectifier. Refer to “Regulator / Rectifier Removal and Installation” (Page 1J-7). 2) Measure the voltage between the terminals using the multi circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
Page 290: Battery / Battery Protector Removal And Installation
1J-9 Charging System: 2) Measure the battery voltage using the multi circuit Battery / Battery Protector Removal and tester. Installation If the voltage reading is less than the 12 V (DC), BA02J21A06009 Removal recharge the battery with a battery charger. 1) Remove the seat.
Page 291: Battery Visual Inspection
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J21A08001 Material SUZUKI recommended product or Specification Note Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7)
Page 292: Special Tool
1J-11 Charging System: Special Tool BA02J21A08002 09900–25008 09900–26006 Multi circuit tester set Engine tachometer (Page 1J-3) / (Page 1J- (Page 1J-4) / (Page 1J- 4) / (Page 1J-4) / (Page 1J-5) / (Page 1J- 09930–34932 09930–40210 Rotor remover Rotor holder (Page 1J-6) (Page 1J-5) / (Page 1J-...
Page 293: Exhaust System
Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System BA02J21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 294: Muffler / Exhaust Pipe Removal And Installation
1K-2 Exhaust System: Muffler / Exhaust Pipe Removal and Installation 5) Remove the muffler (4) by removing the mounting BA02J21B06002 bolts. Removal NOTE 1) Loosen the muffler connecting bolt (1). Support the muffler to prevent it from falling. IA02J11B0001-01 2) Remove the exhaust pipe (2) by removing the IA02J11B0012-01 exhaust pipe bolt and nut.
Page 295: Exhaust System Inspection
Exhaust System: 1K-3 • Install new muffler connector (2). NOTE • When installing new connector, remove the old sealer from the exhaust pipe and muffler. Apply the exhaust gas sealer to both the inside and outside of the new connector. •...
Page 296: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-3)
Page 297 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Cushion Rod Removal and Installation .....2C-18 Cushion Rod Inspection ........2C-18 Precautions............. 2-1 Cushion Rod Bearing Removal and Precautions for Suspension ........2-1 Installation ............2C-19 Suspension General Diagnosis....2A-1 Swingarm Removal and Installation....2C-20 Swingarm Related Parts Inspection ....2C-23 Diagnostic Information and Procedures....2A-1 Swingarm Bearing Removal and Installation ..2C-24...
Page 298: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension BA02J22000001 Refer to “General Precautions” in Section 00 (Page 00-1). WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 299: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis BA02J22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.
Page 300: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components BA02J22206001 IA02J1220063-03 1. Compression damper nut 12. Push rod 23. Axle holder bolt 2. Air bleeder valve 13. Fork spring : 30 N⋅m (3.0 kgf-m, 21.5 lbf-ft) 3. O-ring 14.
Page 301: Front Fork Removal And Installation
Front Suspension: 2B-2 Front Fork Removal and Installation 7) Hold the fork body and loosen the fork lower clamp BA02J22206002 bolts (5). Removal 8) Remove the front fork. 1) Place the motorcycle on a block to lift front wheel off the ground.
Page 302: Front Fork Disassembly
2B-3 Front Suspension: 2) Tighten the fork lower clamp bolts (1), upper and lower alternately, repeating this procedure in more than two times, to the specified torque. Tightening torque Fork lower clamp bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) IA02J1220007-04 8) Install the front wheel assembly.
Page 303 Front Suspension: 2B-4 1) Set rebound and compression damper settings to 5) Place a drain pan under the front fork and drain fork the minimum settings (softest) before disassembling. oil. Record the setting before turning the adjuster. NOTE Face the oil hole “A” on the sub-tank downward.
Page 304 2B-5 Front Suspension: 9) Compress the outer tube by hands and install the special tool between the axle holder bottom (2) and lock-nut (4). Special tool (B): 09910–20115 (Piston holder) IA02J1220065-01 13) Loosen the fork cap bolt (sub-tank) (6) and remove the sub-tank (6) along with the damper and assembly (7).
Page 305 Front Suspension: 2B-6 17) Separate the inner tube (11) out of the outer tube. 21) Loosen the compression damper unit (18). “B” IA02J1220016-01 IA02J1220022-02 18) Remove the slide bushing (12) from the inner tube 22) Remove the compression damper unit (18) from the (11).
Page 306: Front Fork Assembly
2B-7 Front Suspension: Front Fork Assembly 6) Insert the inner tube into the outer tube. BA02J22206004 CAUTION Clean all fork parts before reassembling. Replace the O-rings, oil seal and dust seal with new ones. Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and sliding parts.
Page 307 Front Suspension: 2B-8 9) Attach the dust seal (1) with the special tool. 3) Apply fork oil to the O-ring (1). 4) With the damper rod held immovable in fully Special tool extended position, gently install the compression (A): 09940–52861 (Front fork oil seal damper unit (2) to the sub-tank (3).
Page 308 2B-9 Front Suspension: 7) Tighten the lock-nut (4) by hand completely. 10) With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. 11) If the inner rod is not extend, repeat the procedures 1) to 9).
Page 309 Front Suspension: 2B-10 16) Temporarily tighten the fork cap bolt (6) (sub-tank). 21) Slowly tighten the center bolt (9) until resistance is felt and check the clearance between the lock-nut (4) and center bolt (9) to provide 1 mm (0.04 in) and more.
Page 310: Front Fork Parts Inspection
2B-11 Front Suspension: 24) Loosen and remove the fork cap bolt (10) (sub-tank) Front Fork Parts Inspection BA02J22206005 from the outer tube and slowly slide down the outer Refer to “Front Fork Disassembly” (Page 2B-3) and tube. “Front Fork Assembly” (Page 2B-7). Special tool (C): 09941–53630 (Front fork cap socket Center Bolt...
Page 311: Front Suspension Adjustment
Front Suspension: 2B-12 Inner and Outer Tube Fork Spring Measure the fork spring free length. If it is shorter than • Inspect the inner tube for scratches. If it has the service limit, replace it with a new one. scratches, replace it with a new one. •...
Page 312 2B-13 Front Suspension: • Turn the adjust screw (1) counterclockwise and the Adding the fork oil 8th click is the standard position. • Remove the air bleeder valve (1). Compression damping force adjuster • Add the fork oil with a injector from the air bleed hole. Standard setting: 8 clicks turn back : Fork Oil (FORK OIL SS-19 or equivalent) “...
Page 313 Front Suspension: 2B-14 Reducing the fork oil • Avoid scratching or damaging the inner tube or the oil seal. Use a mild detergent or • Remove the front forks. Refer to “Front Fork Removal car wash soap and sponge out dirt with and Installation”...
Page 314: Specifications
2B-15 Front Suspension: 7) Slide down the outer tube. Spring Change 8) Pour the specified amount of fork oil into the outer • Remove the dumper rod assembly and fork spring. tube as shown in the fork oil quantity table. Refer to “Front Fork Disassembly”...
Page 315 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J22208001 Material SUZUKI recommended product or Specification Note Fork Oil FORK OIL SS-19 or equivalent — (Page 2B-7) /...
Page 316: Special Tool
2B-17 Front Suspension: Special Tool BA02J22208002 09900–20607 09900–20701 Dial gauge Dial gauge chuck (Page 2B-12) (Page 2B-12) 09900–21304 09910–20115 V blocks Piston holder (Page 2B-12) (Page 2B-5) / (Page 2B- 09940–52861 09941–53630 Front fork oil seal installer Front fork cap socket wrench (50 mm) (Page 2B-7) / (Page 2B-...
Page 317: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Shock Absorber Components BA02J22306001 IA02J1230102-02 1. Damper rod assembly 8. Compression adjuster assembly 2. Spring seat : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) 3. Spring : 44 N⋅m (4.4 kgf-m, 32.0 lbf-ft) 4.
Page 318: Cushion Rod / Cushion Lever Components
2C-2 Rear Suspension: Cushion Rod / Cushion Lever Components BA02J22306002 IA02J1230103-02 1. Dust seal 6. Cushion rod 2. Bearing 7. Washer 3. Spacer : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft) 4. Collar : Apply grease. 5. Cushion lever : Do not reuse.
Page 319: Swingarm Components
Rear Suspension: 2C-3 Swingarm Components BA02J22306003 IA02J1230104-01 1. Dust seal 5. Swingarm : Apply thread lock to the thread part. 2. Bearing 6. Chain buffer : Apply grease. 3. Spacer 7. Chain guide : Do not reuse. 4. Bearing/Washer : 70 N⋅m (7.0 kgf-m, 50.5 lbf-ft)
Page 320: Rear Suspension Assembly Construction
2C-4 Rear Suspension: Rear Suspension Assembly Construction BA02J22306004 Left Right “ c ” “ a ” “ b ” “ b ” IA02J1230003-04 1. Rear suspension linkage bolt : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) “a”: 4.5 mm (0.18 in) : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft) “b”: 6.0 mm (0.24 in) : Apply grease.
Page 321: Rear Shock Absorber Removal And Installation
Rear Suspension: 2C-5 Left Right IA02J1230105-01 2. Swingarm pivot shaft : Apply grease. : 70 N⋅m (7.0 kgf-m, 50.5 lbf-ft) Rear Shock Absorber Removal and Installation 5) Remove the rear shock absorber upper mounting BA02J22306005 bolt and nut. Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 322: Rear Shock Absorber Disassembly
2C-6 Rear Suspension: 6) Remove the rear shock absorber lower mounting • Pass the wiring harness and clamp them securely. bolt and nut. Refer to “Wiring Harness Routing Diagram” in Section 9A (Page 9A-2). Rear Shock Absorber Disassembly BA02J22306006 Bearing 1) Remove the spacers (1).
Page 323 Rear Suspension: 2C-7 4) Remove the needle roller bearing cage (4) with the Damper Rod special tool. 1) Turn the rebound damping force adjuster and compression adjuster to the softest position. Special tool (A): 09921–20240 (Bearing remover set) IA02J1230016-01 2) Drain the shock absorber oil and bleed out nitrogen IA02J1230013-01 gas.
Page 324: Rear Shock Absorber Assembly
2C-8 Rear Suspension: 6) Depress the seal case (2) with a screwdriver until the 10) Extract the damper rod assembly from the shock circlip (3) is fully exposed. absorber body. 11) Remove the piston ring (teflon coating metal) (5) and O-rings (6) if necessary.
Page 325 Rear Suspension: 2C-9 4) Fit the stopper (3) to the shock absorber body. 7) Pressure the shock absorber unit with nitrogen gas. Refer to “Rear Suspension Oil Replacement” (Page 2C-11). Gas pressure 784 kPa (8.0 kg/cm , 113.8 psi) Spring 1) Install the following parts to the shock absorber.
Page 326: Rear Suspension Inspection
Bearing / Dust Seal 5) Install the spacers (1) (right side) and (2) (left side). 1) Press the new needle roller bearing cage with the : Grease 99000–25010 (SUZUKI SUPER special tool and a suitable size socket wrench. GREASE “A” or equivalent)
Page 327: Rear Suspension Oil Replacement
Rear Suspension: 2C-11 Damper Rod / Shock Absorber Body Spacer / Dust Seal Inspect the spacers and dust seals for damage. If any 1) Inspect the damper rod for bends and smooth defects are found, replace the defective parts with a new movement.
Page 328 2C-12 Rear Suspension: 1) Following tools and equipment are required to perform oil replacement. IA02J1230040-01 5) Remove the compression adjuster assembly (11) with the special tool from the rear shock absorber. Special tool (A): 09941–53660 (RCU socket wrench (24 mm)) IA02J1230039-02 1.
Page 329 Rear Suspension: 2C-13 9) Pour the fresh specified rear suspension oil as 14) Apply rear suspension oil to the O-rings and tighten shown while moving the rod. the compression adjuster assembly (12) to the specified torque with the special tool. NOTE CAUTION Be sure to extend the rod after filling the oil.
Page 330: Rear Suspension Adjustment
2C-14 Rear Suspension: Rear Suspension Adjustment Rebound Damping Force Adjustment BA02J22306011 Compression Damping Force Adjustment NOTE To set the adjuster, you must gently turn the NOTE adjust screw clockwise until it stops, then To set the adjuster, you must gently turn the back it out the recommended number of adjust screw or bolt clockwise until it stops, turns.
Page 331: Cushion Lever Removal And Installation
Rear Suspension: 2C-15 Spring Pre-load (Set Length) Adjustment Spring Change • Support the motorcycle with a jack. • Remove the spring. Refer to “Rear Shock Absorber Disassembly” (Page 2C-6). • Remove the muffler. Refer to “Muffler / Exhaust Pipe Removal and Installation” in Section 1K (Page 1K-2). •...
Page 332: Cushion Lever Inspection
2C-16 Rear Suspension: Installation Install the cushion lever in the reverse order of removal. Pay attention to the following point: • Tighten each nut to the specified torque. Tightening torque Cushion lever nut (a): 80 N·m (8.0 kgf-m, 58.0 lbf- Cushion rod nut (b): 80 N·m (8.0 kgf-m, 58.0 lbf-ft) Rear shock absorber mounting nut (c): 50 N·m ( 5.0 kgf-m, 36.0 lbf-ft)
Page 333: Cushion Lever Bearing Removal And Installation
Rear Suspension: 2C-17 Cushion Lever Bearing Removal and Installation BA02J22306014 Removal 1) Remove the needle roller bearings. “ a” “ b ” “a” IA02J1230062-01 “c” 2) Install the needle roller bearings. “ c” “ b ” “a” “ b ” IA02J1230060-01 “a”...
Page 334: Cushion Rod Removal And Installation
2C-18 Rear Suspension: 4) Apply grease to the bearings and dust seal lips. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1230068-01 Cushion Rod Inspection BA02J22306016 Refer to “Cushion Rod Removal and Installation” IA02J1230066-01 5) Install the cushion lever. Refer to “Cushion Lever (Page 2C-18).
Page 335: Cushion Rod Bearing Removal And Installation
Rear Suspension: 2C-19 Cushion Rod 3) Remove the cushion rod bearing with the special Inspect the cushion lever for damage. If any defect is tool. found, replace the cushion rod with a new one. Special tool (A): 09921–20240 (Bearing remover set) IA02J1230071-01 IA02J1230074-02 Cushion Rod Bearing Removal and Installation...
Page 336: Swingarm Removal And Installation
4) Remove the rear brake caliper (2) from the swing IA02J1230101-01 arm. 4) Apply grease to the bearings and dust seal lips. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1230079-01 5) Remove the cushion rod bolt and nut.
Page 337 Rear Suspension: 2C-21 8) Remove the swing arm pivot nut (3) and washer (4). 12) Remove the plates (8) left and right. IA02J1230081-02 IA02J1230084-01 9) Down the rear brake pedal (5) and remove the pivot 13) Remove the following parts from the swingarm. shaft (6).
Page 338 The removed oil seals and dust seals must be replaced with new ones. • Apply grease to the dust seals, bearings and oil seals. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1230088-01 • Install the following parts into the swingarm.
Page 339: Swingarm Related Parts Inspection
Rear Suspension: 2C-23 • Tighten the cushion lever nut (11), cushion rod nut Bearing (12) and rear shock absorber mounting nut (13) to the 1) Insert the spacers into bearings. specified torque. 2) Check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a Tightening torque new ones.
Page 340: Swingarm Bearing Removal And Installation
• Thrust bearing (4) • Dust seal (5) • Spacer (6) IA02J1230099-01 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1230097-01 2) Remove the swingarm pivot bearings (7) using the special tool. Special tool (A): 09921–20240 (Bearing remover set)
Page 341: Specifications
Rear Suspension: 2C-25 Specifications Service Data BA02J22307001 Suspension Unit: mm (in) Item Standard Limit Note 8.5 mm (0.34 in) Rear shock absorber spring set 256.5 (10.10) — compressed from length spring free length Rear shock absorber spring rate 53.9 N/mm (5.5 kgf/mm) —...
Page 342: Special Tools And Equipment
2C-26 Rear Suspension: Special Tools and Equipment Recommended Service Material BA02J22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 2C-10) / equivalent (Page 2C-18) / (Page 2C-20) / (Page 2C-22) / (Page 2C-24)
Page 343 Rear Suspension: 2C-27 09941–53660 RCU socket wrench (24 (Page 2C-9) / (Page 2C- 12) / (Page 2C-13)
Page 344: Wheels And Tires
2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire BA02J22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...
Page 345: Repair Instructions
Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components BA02J22406001 IA02J1240044-02 1. Front axle 7. Collar 13. Speed sensor : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) 2. Dust seal 8. Front axle nut 14. Dust seal : Apply grease. 3. Bearing 9.
Page 346: Front Wheel Assembly Construction
2D-3 Wheels and Tires: Front Wheel Assembly Construction BA02J22406002 “ a ” IA02J1240042-01 1. Front axle nut “a”: Clearance : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) 2. Front axle holder bolt : 35 N⋅m (3.5 kgf-m, 25.0 lbf-ft) : Apply grease. 3.
Page 347 After removing the front wheel, fit the calipers temporarily to the original positions. IA02J1240031-01 2) Apply grease to the lip of dust seal. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) 3) Install the speed sensor (2) to the front wheel. IA02J1240022-01 6) Remove the speed sensor (4) (RH only).
Page 348: Front Wheel Related Parts Inspection
2D-5 Wheels and Tires: 5) Hold the front axle with the special tool and tighten Front Wheel Related Parts Inspection BA02J22406004 the front axle nut (3) to the specified torque. Refer to “Front Wheel Assembly Removal and Special tool Installation” (Page 2D-3). (A): 09944–28321 (Hexagon socket (19 mm)) Tire...
Page 349: Front Wheel Dust Seal / Bearing Removal And Installation
Wheels and Tires: 2D-6 Wheel Front Wheel Dust Seal / Bearing Removal and Installation 1) Remove the brake pads. Refer to “Front Brake Pad BA02J22406005 Replacement” in Section 4B (Page 4B-2). 2) Make sure that the wheel runout checked as shown Removal in the figure does not exceed the service limit.
Page 350 Installation CAUTION The removed snap ring, dust seal and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) “ a ” IA02J1240038-02 1. Spacer “a”: Clearance 2.
Page 351 Wheels and Tires: 2D-8 4) Install the speed rotor (3) and snap ring (4). 5) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE “A” or equivalent) Replace the snap ring (4) with a new one.
Page 352: Rear Wheel Components
2D-9 Wheels and Tires: Rear Wheel Components BA02J22406006 IA02J1240001-02 1. Rear axel nut 8. Spacer : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 2. Spacer 9. Rear wheel : 19.8 N⋅m (2.6 kgf-m, 19.0 lbf-ft) 3. Dust seal 10. Tire : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft) 4.
Page 353: Rear Wheel Assembly Construction
Wheels and Tires: 2D-10 Rear Wheel Assembly Construction BA02J22406007 “a” IA02J1240043-02 1. Rear axle nut “a”: Clearance : 30 N⋅m (3.0 kgf-m, 21.5 lbf-ft) 2. Rear brake disc bolt : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) : Apply grease. 3. Rear sprocket nut : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft) : Apply thread lock to the thread part.
Page 354: Rear Wheel Spoke Construction
2D-11 Wheels and Tires: Rear Wheel Spoke Construction BA02J22406008 IA02J1240046-01 1. Rear wheel spoke (Inner) L=194 mm (7.64 in) : 6 N⋅m (0.6 kgf-m, 4.5 lbf-ft) 2. Rear wheel spoke (Outer) L=192 mm (7.56 in) : 14 N⋅m (1.4 kgf-m, 10.0 lbf-ft) Rear Wheel Assembly Removal and Installation 4) Remove the rear wheel by disengaging the drive BA02J22406009...
Page 355: Rear Wheel Related Parts Inspection
Wheels and Tires: 2D-12 Installation Sprocket Refer to “Drive Chain Related Components” in Section 1) Install the spacers (1). 3A (Page 3A-2). Spoke Nipple and Rim Lock Refer to “Wheel and Tire Inspection” in Section 0B (Page 0B-24). Dust Seal Inspect the each dust seal lip for wear or damage.
Page 356: Rear Wheel Dust Seal / Bearing Removal And Installation
2D-13 Wheels and Tires: Wheel 1) Remove the rear brake pads. Refer to “Rear Brake Pad Replacement” in Section 4C (Page 4C-1). 2) Make sure that the wheel runout checked as shown in the figure does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings.
Page 357 IA02J1240013-01 Installation CAUTION The removed snap ring, dust seal and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER “A” GREASE “A” or equivalent) “ a ” I649G1240019-02 “A” 2) First install the left wheel bearings with the special IA02J1240015-04 tool, using the suitable spacer “A”...
Page 358: Specifications
(C): 09913–70210 (Bearing installer set) IA02J1240018-01 IA02J1240017-01 6) Apply grease to the each dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1240019-01 7) Install the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation”...
Page 359: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J22408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 2D-4) /...
Page 360 2D-17 Wheels and Tires: 09913–50121 09913–70210 Oil seal remover Bearing installing set (10 – 75 Φ) (Page 2D-6) / (Page 2D- (Page 2D-7) / (Page 2D- 09921–20240 09924–84510 Bearing remover set Bearing installer set (Page 2D-6) / (Page 2D- (Page 2D-7) 09941–34513 09944–28321 Bearing installer...
Page 361 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Sprocket Removal and Installation.....3A-4 Drive Chain Guide Removal and Installation ..3A-5 Precautions............. 3-1 Drive Chain Roller Removal and Installation..3A-5 Precautions for Driveline / Axle ......3-1 Drive Chain Buffer Removal and Installation ..3A-5 Drive Chain Related Parts Inspection ....3A-5 Drive Chain / Drive Train / Drive Shaft...
Page 362: Precautions
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is DID 520MXV. Suzuki recommends to use this standard drive chain as a replacement.
Page 363: Diagnostic Information And Procedures
Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis BA02J23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.
Page 364: Repair Instructions
3A-2 Drive Chain / Drive Train / Drive Shaft: Repair Instructions Drive Chain Related Components BA02J23106001 “A” IA02J1310018-06 1. Drive chain 5. Snap ring : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) 2. Engine sprocket 6. Front chain guide plate : Apply thread lock to thread part. 3.
Page 365: Drive Chain Roller Construction
Drive Chain / Drive Train / Drive Shaft: 3A-3 Drive Chain Roller Construction BA02J23106002 IA02J1310017-01 1. Chain roller (upper) 4. Washer 2. Frame : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 3. Chain roller (lower) Engine Sprocket Removal and Installation 4) Remove the engine sprocket cover (3) and front BA02J23106003 chain guide plate (4).
Page 366: Rear Sprocket Removal And Installation
3A-4 Drive Chain / Drive Train / Drive Shaft: 5) Remove the snap ring (5) and remove the engine • Install the engine sprocket cover (4). sprocket (6). • Apply thread lock to the engine sprocket cover bolts (5) and tighten them to the specified torque. : Thread lock cement 99000–32050 (THREAD LOCK CEMENT “1342”...
Page 367: Drive Chain Guide Removal And Installation
Drive Chain / Drive Train / Drive Shaft: 3A-5 Installation Installation Install the rear sprocket and rear sprocket mounting Install the chain guide in the reverse order of removal. drum in the reverse order of removal. Pay attention to the following points: Drive Chain Roller Removal and Installation BA02J23106006 •...
Page 368: Drive Chain Replacement
3A-6 Drive Chain / Drive Train / Drive Shaft: Chain Roller Rotate the chain roller by hand and check that it moves smoothly. If it does not move smoothly, replace the chain roller assembly. I649G1310023-02 Drive Chain Cutting 1) Set up the special tool as shown in the figure. IA02J1310011-01 Chain Buffer and Chain Guide Inspect the chain buffer and chain guide for damage and...
Page 369 Drive Chain / Drive Train / Drive Shaft: 3A-7 2) Place the drive chain link being disjointed on the Drive Chain Connecting chain holder (8) of the tool. WARNING 3) Turn in both the adjuster bolt (6) and pressure bolt [A] (3) so that each of their end hole fits over the Do not use joint clip type of drive chain.
Page 370 3A-8 Drive Chain / Drive Train / Drive Shaft: 4) Apply grease on the recessed portion of the joint 8) Continue pressing the joint plate until the distance plate holder (3) and set the joint plate (10). between the two joint plates comes to the specification.
Page 371: Specifications
Drive Chain / Drive Train / Drive Shaft: 3A-9 2) Stake the joint pin by turning (approximately 7/8 turn) the pressure bolt [A] (3) with the bar until the pin end diameter becomes the specified dimension. CAUTION • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.
Page 372: Special Tools And Equipment
3A-10 Drive Chain / Drive Train / Drive Shaft: Special Tools and Equipment Recommended Service Material BA02J23108001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT “1342” or P/No.: 99000–32050 (Page 3A-4) equivalent NOTE Required service material is also described in the following.
Page 373 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Special Tools and Equipment ......4A-17 Recommended Service Material .......4A-17 Precautions............. 4-1 Special Tool ............4A-18 Precautions for Brake System ......4-1 Brake Fluid Information ......... 4-1 Front Brakes ..........4B-1 Brake Control System and Diagnosis ...
Page 374: Precautions
4-1 Precautions: Precautions Brake Precautions Precautions for Brake System BA02J24000001 Refer to “General Precautions” in Section 00 (Page 00-1). Brake Fluid Information BA02J24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 375: Brake Control System And Diagnosis
Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram BA02J24102001 “A” “C” “B” “B” IA02J1410044-03 1. Front brake hose “C”: Pass the front brake hose in front of the cables. 2.
Page 376: Rear Brake Hose Routing Diagram
4A-2 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram BA02J24102002 “A” “A” “ a ” IA02J1410041-02 “A” After the brake hose union set between the stoppers, tighten the union : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) bolt. “a” Outside...
Page 377: Diagnostic Information And Procedures
Brake Control System and Diagnosis: 4A-3 Diagnostic Information and Procedures Brake Symptom Diagnosis BA02J24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.
Page 378 4A-4 Brake Control System and Diagnosis: 2) Fill the reservoir with brake fluid to the upper line “A”. 7) Repeat this process until the fluid flowing into the Place the reservoir cap to prevent dirt from entering. receptacle no longer contains air bubbles. NOTE While bleeding the brake system, replenish the brake fluid in the reservoir as necessary.
Page 379: Brake Fluid Replacement
Brake Control System and Diagnosis: 4A-5 2) Fill the reservoir with brake fluid to the upper line “A”. 3) Fill the reservoir with brake fluid to the upper line “A”. Place the reservoir cap to prevent dirt from entering. “A” “A”...
Page 380 4A-6 Brake Control System and Diagnosis: 6) Loosen the air bleeder valve and pump the brake Rear Brake lever until the old brake fluid flows out of the brake 1) Place the motorcycle on a level surface. system. 2) Remove the reservoir cap and diaphragm. 3) Suck up the old brake fluid as much as possible.
Page 381: Front Brake Hose Removal And Installation
Brake Control System and Diagnosis: 4A-7 7) Close the air bleeder valve and disconnect the clear Rear Brake Hose Removal and Installation BA02J24106007 hose. Removal Tightening torque 1) Drain brake fluid. Refer to “Brake Fluid Air bleeder valve (Rear caliper): 6 N·m (0.6 kgf- Replacement”...
Page 382: Front Brake Master Cylinder Components
4A-8 Brake Control System and Diagnosis: Front Brake Master Cylinder Components BA02J24106008 IA02J1410043-01 1. Reservoir cap 4. Front brake hose : Do not reuse. 2. Diaphragm : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 3. Piston/cup set : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
Page 383: Front Brake Master Cylinder Assembly Removal And Installation
Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Assembly Removal and Installation BA02J24106009 Removal “B” 1) Drain brake fluid. Refer to “Brake Fluid Replacement” (Page 4A-5). 2) Place a rag underneath the brake hose union bolt (1) on the master cylinder to catch any spilt brake fluid. 3) Remove the brake hose union bolt (1).
Page 384: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly
• Apply grease to the brake lever pivot bolt (1). • Apply grease to the contact point between the piston and brake lever. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) IA02J1410018-01 3) Remove the washer (5) and piston/cup set (6).
Page 385: Front Brake Master Cylinder Parts Inspection
Brake Control System and Diagnosis: 4A-11 • Tighten the pivot bolt (1) and lock-nut (2) to the Piston / Rubber Parts specified torque. Inspect the piston surface for any scratches or other damage. Tightening torque Inspect the primary cup, secondary cup and dust boot Brake lever pivot bolt (a): 6 N·m (0.6 kgf-m, 4.5 for wear or damage.
Page 386: Rear Brake Master Cylinder Components
4A-12 Brake Control System and Diagnosis: Rear Brake Master Cylinder Components BA02J24106012 IA02J1410023-02 1. Reservoir cap 5. Push rod : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Diaphragm 6. Dust boot : Apply silicone grease. 3. Master cylinder : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Apply brake fluid.
Page 387: Rear Brake Master Cylinder Disassembly And Assembly
Brake Control System and Diagnosis: 4A-13 4) Place a rag under the brake hose union bolt (3) to • Install the master cylinder rod pin (4), washer and new catch spilled brake fluid. cotter pin (5). 5) Remove the rear brake master cylinder by removing the union bolt (3).
Page 388: Rear Brake Master Cylinder Parts Inspection
I947H1410038-01 BA02J24106016 • Apply grease to the push rod end. Removal 1) Removal the brake lever boot (1). : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) IA02J1410032-01 2) Remove the brake lever (2) by removing the pivot IA02J1410030-02 bolt and nut.
Page 389: Rear Brake Pedal Construction
Pay attention to the following points: • Apply grease to the brake lever, pivot bolt and contact point between piston and brake lever. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) • Tighten the brake lever pivot bolt (1) and lock-nut (2) to the specified torque.
Page 390: Rear Brake Pedal Removal And Installation
Installation is in the reverse order of removal. Pay attention to the following points: • Apply grease to the dust seals and brake pedal pivot bolt groove. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1410039-02 Specifications Service Data...
Page 391 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-5) /...
Page 392: Special Tool
4A-18 Brake Control System and Diagnosis: Special Tool BA02J24108002 09900–06108 Snap ring remover (Close type) (Page 4A-10) / (Page 4A-13)
Page 393: Front Brakes
Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components BA02J24206001 IA02J1420021-07 1. Seal set : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft) : 11 N⋅m (1.1 kgf-m, 8.0 lbf-ft) 2. Piston and seal set : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) : Apply thread lock to the thread part.
Page 394: Front Brake Pad Inspection
4B-2 Front Brakes: Front Brake Pad Inspection WARNING BA02J24206002 Refer to “Brake System Inspection” in Section 0B After replacing the brake pads, pump the (Page 0B-22). brake lever several times to check for proper brake operation and then check the brake Front Brake Pad Replacement fluid level.
Page 395: Front Brake Caliper Disassembly And Assembly
Front Brakes: 4B-3 3) Remove the brake caliper by removing its mounting • Bleed air from the brake system after installing the bolts (2). caliper. Refer to “Air Bleeding from Brake Fluid Circuit” in Section 4A (Page 4A-3). • Check the brake fluid leakage and brake operation. CAUTION Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
Page 396 7) Remove the dust seals (6) and piston seals (7). I649G1420013-02 • Install the springs and boots. IA02J1420010-02 • Apply SUZUKI SILICONE GREASE to the caliper axles. Assembly Assemble the caliper in the reverse order of : Grease 99000–25100 (SUZUKI SILICONE disassembly.
Page 397: Front Brake Caliper Parts Inspection
Front Brakes: 4B-5 • Install the brake pads and temporarily tighten the pad Boot mounting pin (3). Inspect the boots for damage and wear. If any defects are found, replace it with a new one. IA02J1420012-01 IA02J1420015-01 Front Brake Caliper Parts Inspection Brake Pad Spring BA02J24206006 Refer to “Front Brake Caliper Disassembly and...
Page 398: Front Brake Disc Inspection
4B-6 Front Brakes: Installation Brake disc thickness Install the front brake disc in the reverse order of Service limit (Front): 2.5 mm (0.10 in) removal. Pay attention to the following points: • Make sure that the brake disc is clean and free of any grease.
Page 399: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-4) /...
Page 400: Rear Brakes
4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components BA02J24306001 IA02J1430019-02 1. Seal set 5. Rear caliper guard : 5 N⋅m (0.55 kgf-m, 4.0 lbf-ft) : Apply thread lock to the thread part. 2. Piston and seal set 6.
Page 401: Rear Brake Caliper Removal And Installation
Removal 1) Remove the disc cover (1) and caliper protector (2). IA02J1430002-01 3) Install new brake pads. 4) Apply SUZUKI SILICONE GREASE to the O-ring. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) IA02J1430005-01 2) Place a rag under the brake hose union bolt to catch spilled brake fluid.
Page 402: Rear Brake Caliper Disassembly And Assembly
Install the brake caliper in the reverse order of removal. Refer to “Brake Fluid Replacement” in Section 4A Pay attention to the following points: (Page 4A-5). • Apply SUZUKI SILICONE GREASE to the caliper axles. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent)
Page 403: Rear Brake Caliper Parts Inspection
Rear Brakes: 4C-4 5) Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. 6) Apply low-pressure air into the caliper through the hole to remove the piston. WARNING Fingers can get caught between piston and caliper body when removing the piston.
Page 404: Rear Brake Disc Removal And Installation
4C-5 Rear Brakes: Brake Caliper Piston Rear Brake Disc Removal and Installation BA02J24306007 Inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, Removal replace the piston with a new one. 1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation”...
Page 405: Rear Brake Disc Inspection
Rear Brakes: 4C-6 Rear Brake Disc Inspection Brake Disc Distortion BA02J24306008 1) Remove the rear brake disc. Refer to “Rear Brake Brake Disc Thickness Disc Removal and Installation” (Page 4C-5). Check the brake disc for damage or cracks and measure 2) Measure the rear brake disc distortion.
Page 406: Special Tools And Equipment
4C-7 Rear Brakes: Special Tools and Equipment Recommended Service Material BA02J24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-4) / (Page 4C- Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 4C-2) / (Page 4C-...
Page 407 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Tightening Torque Specifications......5B-18 Special Tools and Equipment ......5B-18 Precautions............. 5-1 Recommended Service Material .......5B-18 Precautions for Transmission / Transaxle..... 5-1 Special Tool ............5B-19 Manual Transmission......5B-1 Clutch ............5C-1 Diagnostic Information and Procedures....5B-1 Precautions............5C-1 Manual Transmission Symptom Diagnosis ..
Page 408: Precautions
5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle BA02J25000001 Refer to “General Precautions” in Section 00 (Page 00-1).
Page 409: Manual Transmission
Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis BA02J25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gears. Replace. seems to come from the Worn countershaft splines. Replace countershaft.
Page 410: Repair Instructions
5B-2 Manual Transmission: Repair Instructions Transmission Components BA02J25206001 IA02J1520059-04 1. Countershaft/1st drive gear 11. 5th driven gear 21. Gearshift shaft 2. 2nd drive gear 12. Gearshift cam : 8.5 N⋅m (0.85 kgf-m, 6.0 lbf-ft) 3. 3rd drive gear 13. Gearshift cam stopper plate : 24 N⋅m (2.4 kgf-m, 17.5 lbf-ft) 4.
Page 411: Transmission Removal And Installation
Manual Transmission: 5B-3 Transmission Removal and Installation Installation BA02J25206002 1) Install the countershaft assembly (1) and driveshaft Removal assembly (2). 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal” in Section 1D (Page 1D-20). 2) Remove the engine top side. Refer to “Engine Top Side Disassembly”...
Page 412 5B-4 Manual Transmission: 3) Install the gearshift cam (6). 6) Install new O-rings (8) and engine sprocket spacer (9). 4) Install the gearshift fork shafts (7). CAUTION NOTE Turn the gearshift cam to the neutral position • The removed O-rings must replace with and confirm that the driveshaft and new ones.
Page 413: Transmission Construction
Manual Transmission: 5B-5 Transmission Construction BA02J25206003 IA02J1520009-01 1. Countershaft 2. Driveshaft...
Page 414: Countershaft Gear / Driveshaft Gear Disassembly And Assembly
5B-6 Manual Transmission: Countershaft Gear / Driveshaft Gear Disassembly and Assembly “A” BA02J25206004 Refer to “Transmission Removal and Installation” (Page 5B-3). Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups “B” (i.e., drive or driven) so that they can be I649G1520049-02 reinstalled in their original positions.
Page 415: Transmission Related Parts Inspection
Manual Transmission: 5B-7 Transmission Related Parts Inspection Gearshift Fork Thickness BA02J25206005 Measure the gearshift fork thickness using the vernier Refer to “Transmission Removal and Installation” calipers. (Page 5B-3) and “Countershaft Gear / Driveshaft Gear Special tool Disassembly and Assembly” (Page 5B-6). (A): 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) Gearshift Fork to Groove Clearance...
Page 416: Transmission Oil Seal / Bearing Inspection
5B-8 Manual Transmission: Transmission Oil Seal / Bearing Inspection 2) Remove the engine sprocket spacer (1) and O-rings BA02J25206006 (2). Refer to “Transmission Removal and Installation” (Page 5B-3). Oil Seal Inspect the oil seal lips for wear or damage. If any defects are found, replace the oil seal with new ones.
Page 417 5B-9 2) Apply grease to the oil seal lip. Bearing Removal : Grease 99000–25010 (SUZUKI SUPER 1) Remove the transmission assembly. Refer to GREASE “A” or equivalent) “Transmission Removal and Installation” (Page 5B- 2) Remove the driveshaft oil seal (1) with the special tool.
Page 418 5B-10 Manual Transmission: 5) Remove the left driveshaft bearing (4) and right countershaft bearing (5) using the special tool. Special tool (B): 09913–70210 (Bearing installing set (10 – 75 Φ)) “C” “B” “A” IA02J1520019-01 “B” IA02J1520017-02 6) Remove the left countershaft bearing (6), left gearshift cam bearing (7) and right driveshaft bearing (8) using the special tool.
Page 419: Gear Position (Gp) Switch Inspection
IA02J1520057-01 4) Remove the engine sprocket cover (2). Refer to “Engine Sprocket Removal and Installation” in Section 3A (Page 3A-3). IA02J1520023-02 6) Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1520025-01 IA02J1520024-01...
Page 420: Gearshift Shaft / Gearshift Cam Plate Components
Replace the O-ring with a new one. 6. Gearshift cam driven gear : Apply thread lock to thread part. 7. Gearshift cam driven gear : Apply grease. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) 8. Gearshift cam stopper : Do not reuse. plate •...
Page 421: Gearshift Construction
Manual Transmission: 5B-13 Gearshift Construction 5) Remove the right crankcase cover. Refer to “Kick BA02J25206011 Starter Removal and Installation” in Section 1I (Page 1I-15). 6) Remove the clutch component parts. Refer to “Clutch Removal” in Section 5C (Page 5C-7). 7) Remove the gearshift shaft (2) and washer (3). IA02J1520029-04 1.
Page 422 5B-14 Manual Transmission: 10) Remove the gearshift pawls (8), pins (9), springs Installation (10) and gearshift roller (11). Install the gearshift shaft/gearshift cam plate in the reverse order of removal. Pay attention to the following points: • Apply a small quantity of thread lock to the gearshift arm stopper (1) and tighten it to the specified torque.
Page 423 Manual Transmission: 5B-15 • Instal the springs (8), pins (9), pawls (10) and gearshift roller (11) to the gearshift cam driven gear (12). NOTE Wider side “D” of pawl should be positioned outside. “A” IA02J1520040-02 • Check the gearshift cam stopper moves smoothly. •...
Page 424: Gearshift Linkage Inspection
5B-16 Manual Transmission: • Apply a small quantity of thread lock to the pawl lifter • Align the matching mark on the gearshift shaft head screws (14), and tighten them to the specified torque. with slit of the gearshift lever. •...
Page 425: Gearshift Shaft Oil Seal / Removal And Installation
/ Gearshift Cam Plate Removal and Installation” (Page 5B-13). IA02J1520054-01 • Apply grease to the oil seal lip. 2) Remove the gearshift shaft oil seal (1). : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1520053-01 IA02J1520055-01 Specifications Service Data...
Page 426: Tightening Torque Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 5B-9) /...
Page 427: Special Tool
Manual Transmission: 5B-19 Special Tool BA02J25208002 09900–06107 09900–20102 Snap ring remover (Open Vernier calipers (200 mm) type) (Page 5B-13) (Page 5B-7) / (Page 5B- 09900–20803 09913–50121 Thickness gauge Oil seal remover (Page 5B-7) (Page 5B-9) 09913–70210 09921–20240 Bearing installing set (10 – Bearing remover set 75 Φ) (Page 5B-10) /...
Page 428: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System BA02J25300001 Refer to “General Precautions” in Section 00 (Page 00-1). Diagnostic Information and Procedures Clutch System Symptom Diagnosis BA02J25304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline.
Page 429: Clutch Cable Inspection And Adjustment
Clutch: 5C-2 Clutch Cable Inspection and Adjustment 5) Remove the clamps. BA02J25306002 Refer to “Clutch Lever Clearance Inspection and Adjustment” in Section 0B (Page 0B-11). Clutch Cable Removal and Installation BA02J25306003 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation”...
Page 430: Clutch Control System Components
5C-3 Clutch: Clutch Control System Components BA02J25306004 IA02J1530044-04 1. Clutch lever 5. Oil seal : 4 N⋅m (0.4 kfg-m, 3.0 lbf-ft) 2. Quick adjuster 6. Bearing : Apply moly paste. 3. Clutch cable 7. Bearing : Apply grease. 4. Clutch release camshaft : 4 N⋅m (0.4 kfg-m, 3.0 lbf-ft) : Do not reuse.
Page 431: Clutch Cable Adjuster Construction
Installation BA02J25306006 removal. Pay attention to the following points: Removal • Apply SUZUKI MOLY PASTE to the clutch release 1) Drain engine oil. Refer to “Engine Oil Inspection and camshaft. Replacement” in Section 0B (Page 0B-5). : Moly paste 99000–25140 (SUZUKI MOLY 2) Remove the clutch pressure plate and push rod.
Page 432: Clutch Release Camshaft / Oil Seal / Bearing Inspection
5C-5 Clutch: Clutch Release Camshaft / Oil Seal / Bearing Inspection BA02J25306007 Refer to “Clutch Release Camshaft Removal and Installation” (Page 5C-4). Clutch Release Camshaft Inspect the clutch release camshaft for abnormal deflection and damage. If any defects are found, replace the clutch release camshaft with a new one.
Page 433: Clutch Components
Clutch: 5C-6 Clutch Components BA02J25306008 IA02J1530010-02 1. Primary driven gear 7. Spring washer 13. Spring 2. Clutch sleeve hub 8. Drive plate No. 2 : 90 N⋅m (9.0 kgf-m, 65.0 lbf-ft) 3. Push rod 9. Drive plate No. 1 : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 4.
Page 434: Clutch Removal
5C-7 Clutch: Clutch Removal 6) Remove the clutch drive plates (4) and driven plates BA02J25306009 (5). 1) Drain engine oil. Refer to “Engine Oil Filter Replacement” in Section 0B (Page 0B-7). 2) Remove the rear brake pedal. Refer to “Rear Brake Pedal Removal and Installation”...
Page 435: Clutch Installation
Clutch: 5C-8 9) Remove the push rod (10). 13) Remove the thrust washer (13) and primary driven gear assembly (14). NOTE If it is difficult to pull out the push rod (10), use a magnetic hand or a wire. IA02J1530020-02 14) Remove the primary driven gear bearing (15) and spacer (16).
Page 436 5C-9 Clutch: 3) Install the primary driven gear assembly (3) and thrust washer (4). IA02J1530024-02 8) Make sure the clutch sleeve hub for smooth movement. IA02J1530035-02 4) Install the clutch sleeve hub (5) and new washer (6). 9) Bend the tongue of the washer (6) securely. NOTE The removed washer must be replaced with a new one.
Page 437 Clutch: 5C-10 13) Install the spring washer seat (10) and spring washer NOTE (11) onto the clutch sleeve hub correctly. Two kinds of the driven plate (No. 1 and No. 2) are equipped in the clutch system, they can be distinguished by color. The No.
Page 438: Clutch Parts Inspection
5C-11 Clutch: 19) Install the clutch cover (18) and tighten its bolts to Measure the claw width of drive plates with a vernier the specified torque. calipers. Replace the drive plates found to have worn down to the limit. Tightening torque Clutch cover bolt: 11 N·m (1.1 kgf-m, 8.0 lbf-ft) Special tool (A): 09900–20102 (Vernier calipers (1/20 mm,...
Page 439 Clutch: 5C-12 Clutch Spring Push Rod Measure the free length of each coil spring with a vernier Inspect the push rod for wear and damage. calipers, and compare the length with the specified limit. If any defects are found, replace the push rod with a new Replace all the springs if any spring is not within the one.
Page 440: Specifications
SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 5C-4) equivalent Moly paste SUZUKI MOLY PASTE or equivalent P/No.: 99000–25140 (Page 5C-4) NOTE Required service material is also described in the following. “Clutch Control System Components” (Page 5C-3) “Clutch Components” (Page 5C-6)
Page 441: Special Tool
Clutch: 5C-14 Special Tool BA02J25308002 09900–20102 09900–20803 Vernier calipers (200 mm) Thickness gauge (Page 5C-11) / (Page 5C-11) (Page 5C-11) / (Page 5C-12) 09900–25008 09920–31020 Multi circuit tester set Extension handle (Page 5C-1) (Page 5C-8) / (Page 5C- 09920–53740 Clutch sleeve hub holder (Page 5C-8) / (Page 5C-...
Page 442 5C-15 Clutch:...
Page 443 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Handlebars Inspection ........6B-5 Steering Components .........6B-6 Precautions............. 6-1 Steering Removal and Installation ......6B-7 Precautions for Steering ........6-1 Steering Related Parts Inspection.......6B-9 Steering System Inspection ........6B-9 Steering General Diagnosis....6A-1 Steering Stem Bearing Removal and Diagnostic Information and Procedures....6A-1 Installation ............6B-9...
Page 444: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering BA02J26000001 Refer to “General Precautions” in Section 00 (Page 00-1).
Page 445: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis BA02J26104001 Condition Possible cause Correction / Reference Item Heavy steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.
Page 446: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebars Components BA02J26206001 “A” “A” IA02J1620001-01 1. Handlebars 4. Throttle grip “A”: Apply handle grip bond. 2. Handle grip 5. Handlebar holder : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft) 3. Throttle case 6.
Page 447: Handlebar Construction
Steering / Handlebar: 6B-2 Handlebar Construction BA02J26206002 “ h ” “ d ” “ a ” “ e ” “ c” “ g ” “ b ” “ f ” IA02J1620035-02 1. Marking “d”: 15° 2. Velcro fastening: “e”: 175 mm (6.9 in) Position the velcro fastening side of the handlebar pad cover backward.
Page 448: Handlebars Removal And Installation
6B-3 Steering / Handlebar: Handlebars Removal and Installation 4) Disconnect the clamps. BA02J26206003 5) Remove the starter button (5) and front brake master cylinder (6). Removal 1) Remove the handlebar pad (1). CAUTION Do not turn the front brake master cylinder upside down.
Page 449 Steering / Handlebar: 6B-4 7) Remove the throttle cables (8) and throttle grip (9). Installation Install the handlebars in the reverse order of removal. Pay attention to the following points: • Set the mark “A” on the handlebar holder forward. “A”...
Page 450: Handlebars Inspection
IA02J1620015-02 • Apply grease to the end of starter cables (4). • Check the wiring harness routing and cable routing. : Grease 99000–25010 (SUZUKI SUPER Refer to “Wiring Harness Routing Diagram” in Section GREASE “A” or equivalent) 9A (Page 9A-2) and “Throttle Cable Routing Diagram”...
Page 451: Steering Components
Steering / Handlebar: 6B-6 Steering Components BA02J26206005 IA02J1620017-03 1. Steering stem head nut 10. Spacer 2. Steering stem upper bracket 11. Handlebar holder 3. Steering stem nut : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 4. Washer : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 5.
Page 452: Steering Removal And Installation
6B-7 Steering / Handlebar: Steering Removal and Installation 9) Remove the steering stem nut (6) and washer (7) BA02J26206006 with the special tool. CAUTION NOTE Make sure that the motorcycle is supported When loosening the stem nuts, hold the securely. steering stem lower bracket to prevent it from falling.
Page 453 Bearing “ b ” Apply grease to the steering stem bearings before remounting the steering stem. : Grease 99000–25010 (SUZUKI SUPER GREASE “A” or equivalent) IA02J1620026-03 Steering stem upper bracket Install the front forks and steering stem upper bracket in...
Page 454: Steering Related Parts Inspection
6B-9 Steering / Handlebar: 3) Tighten the steering stem head nut (2). Tightening torque Steering stem head nut (a): 100 N·m (10.0 kgf- m, 72.5 lbf-ft) IA02J1620030-01 IA02J1620027-02 4) Temporary install the handlebars and tighten the handlebar bolts (3) to the specified torque. Tightening torque Handlebar holder bolt (b): 45 N·m (4.5 kgf-m, 32.5 lbf-ft)
Page 455 Steering / Handlebar: 6B-10 3) Remove the steering stem lower bearing and inner Outer race race using a chisel. Press in the upper and lower outer races using the special tool. Special tool (A): 09941–34513 (Bearing installer) (B): 09913–70210 (Bearing installing set (10 – 75 Φ)) I649G1620033-02 4) Remove the steering stem upper and lower bearing...
Page 456: Specifications
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List” in Section 0C (Page 0C-8). Special Tools and Equipment Recommended Service Material BA02J26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE “A” or P/No.: 99000–25010 (Page 6B-5) /...
Page 457 Steering / Handlebar: 6B-12 09941–34513 Bearing installer (Page 6B-10)
Page 458 6B-13 Steering / Handlebar:...
Page 459 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Repair Instructions ..........9C-2 Speedometer Construction .........9C-2 Precautions............. 9-1 Speed Sensor Harness Routing Diagram ...9C-3 Precautions for Electrical System ......9-1 Speedometer Removal and Installation ....9C-4 Component Location ..........9-1 Speedometer Inspection ........9C-4 Electrical Components Location ......
Page 460: Precautions
9-1 Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System BA02J29000001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00 (Page 00-2). Component Location Electrical Components Location BA02J29003001 Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
Page 461: Wiring Systems
Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram BA02J29102001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-5). IA02J1910901-09...
Page 462: Wiring Harness Routing Diagram
9A-2 Wiring Systems: Wiring Harness Routing Diagram BA02J29102002 “A” IA02J1910909-02 1. Clamp 6. Steel clamp : Bind the engine stop switch lead wire. Set the tip of clamp foreword. : Fix the steel clamp toward the front side. Clamp the fuse box lead wire, ignition switch lead wire, speedometer lead wire and speed sensor lead wire.
Page 463 Wiring Systems: 9A-3 “ b ” “B” “ a ” “A” IA02J1910910-03 1. Cable clamp “A”: Pass the battery (–) lead wire left side of the starter motor lead : Pass the throttle cables, clutch cable and starter button lead wire inside the wire and ECT sensor lead wire.
Page 464 9A-4 Wiring Systems: “E” “A” “G” “F” “ a ” “C” “B” “D” IA02J1910911-05 1. Clamp “D”: Face the fuse box over the lead wire and clamp the lead wire : Clamp the lead wire at tube part of the lead wire and set the tip of clamp right with the clamp.
Page 465 Wiring Systems: 9A-5 “G” “H” “C” “ a ” “B” “F” “D” “E” VIEW A “ a ” IA02J1910912-05 1. Cable clamp 11. Engine sprocket cover : Pass the engine stop switch lead wire, hot starter cable and wiring harness : Do not pinch the lead wire when installing the engine inside the clamp from top side.
Page 466 9A-6 Wiring Systems: “ a ” “A” IA02J1910906-04 1. Gear position switch lead wire “A”: Pass the gear position switch lead wire between the engine sprocket cover and crankcase. 2. Starter motor lead wire : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 3.
Page 467: Specifications
Wiring Systems: 9A-7 Specifications Service Data BA02J2910S001 Electrical Unit: mm Item Specification Note Main 15 A Fuse size 15 A Tightening Torque Specifications BA02J2910S002 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram” (Page 9A-2) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List”...
Page 468: Lighting Systems
9B-1 Lighting Systems: Lighting Systems Body and Accessories Repair Instructions Headlight Construction BA02J29206001 IA02J1920001-02 1. Headlight assembly 3. Headlight beam adjusting screw 5. Headlight bulb (12 V 35W) 2. Headlight cover 4. Nut : Set the flat side forward.
Page 469: Headlight Cover Construction
Lighting Systems: 9B-2 Headlight Cover Construction BA02J29206002 “A” E-28 IA02J1920002-02 1. Headlight cover 4. Front fender 2. Lower headlight cover 5. Front side reflex reflector bracket (E-28 only) 3. Cushion “A”: Set the headlight cover cushions to the ribs on the front fender. Headlight Removal and Installation 2) Disconnect the headlight coupler (1) and fuel BA02J29206003...
Page 470: Headlight Bulb Replacement
9B-3 Lighting Systems: 4) Remove the headlight lower cover (4). 1) Remove the headlight cover side bolts. IA02J1920006-03 IA02J1920003-02 5) Remove the headlight (5) by removing the screws. 2) Disconnect the headlight coupler (1). 3) Turn the bulb (2) counterclockwise and remove it. IA02J1920018-01 IA02J1920020-01 Installation...
Page 471: Tail Light Construction
Lighting Systems: 9B-4 Tail Light Construction BA02J29206006 “ a ” UPPER IA02J1920012-05 1. Rear fender 5. Clamp : Install the clamps as shown in the illustration. 2. Tail light 6. Cushion 3. Rear reflex reflector (E-28 only) “a”: 50 mm (2.0 in) 4.
Page 472: Tail Light Removal And Installation
9B-5 Lighting Systems: Tail Light Removal and Installation Installation BA02J29206007 Install the tail light in the reverse order of removal. Pay Removal attention to the following point: 1) Remove the left frame cover. Refer to “Exterior Parts • Tighten the tail light screws in the ascending order of Removal and Installation”...
Page 473: Reflex Reflector Construction (E-28 Only)
Lighting Systems: 9B-6 Reflex Reflector Construction (E-28 only) BA02J29206008 IA02J1920016-05 1. Front side reflex reflector : 1.8 N⋅m (0.18 kgf-m, 1.3 lbf-ft) 2. Rear reflex reflector : 12 N⋅m (1.2 kgf-m, 8.5 lbf-ft) 3. Rear side reflex reflector...
Page 474: Headlight Relay Inspection
9B-7 Lighting Systems: Headlight Relay Inspection If there is no insulation, replace it with a new one. BA02J29206009 Special tool 1) Remove the headlight relay (1). : 09900–25008 (Multi circuit tester set) Tester knob indication set Continuity test ( “C” “A”...
Page 475: Combination Meter / Fuel Meter / Horn
Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Speedometer System Description BA02J29301001 The LCDs indicate followings: Speed / Average speed, Clock / Timer, Odo / Trip 1 / Trip 2 / Voltage and Tire diameter calculator. IA02J1930001-02 1.
Page 476: Repair Instructions
9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Speedometer Construction BA02J29306001 “A” IA02J1930012-03 1. Speedometer meter : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) 2. Ignition switch : 4.5 N⋅m (0.45 kgf-m, 3.5 lbf-ft) “A”: Pass the combination meter harness through the hole of the bracket.
Page 477: Speed Sensor Harness Routing Diagram
Combination Meter / Fuel Meter / Horn: 9C-3 Speed Sensor Harness Routing Diagram BA02J29306002 “D” “C” “C” “D” Inside Inside Inside Outside Outside Outside “B” “A” IA02J1930013-03 1. Speed sensor 6. Ignition switch 2. Guide “A”: Stopper part of the speed sensor 3.
Page 478: Speedometer Removal And Installation
9C-4 Combination Meter / Fuel Meter / Horn: Speedometer Removal and Installation 3) Raise the front wheel off the ground and support the BA02J29306003 motorcycle with a jack or a wooden block. Removal 4) Connect a 12 V battery (between O/R and B/W), 10 1) Remove the battery (–) lead wire.
Page 479: Fuel Level Indicator Light Inspection
Combination Meter / Fuel Meter / Horn: 9C-5 Fuel Level Indicator Light Inspection 3) When the switch is immersed in kerosene, the bulb BA02J29306007 should go out. If the bulb remains lit, replace the fuel Check that the fuel level indicator light (1) lights on for pump with a new one.
Page 480: Ignition Switch Inspection
9C-6 Combination Meter / Fuel Meter / Horn: Ignition Switch Inspection 3) Inspect the ignition switch for continuity with the BA02J29306010 tester. If any abnormality is found, replace the Inspect the ignition switch in the following procedures: ignition switch with a new one. 1) Remove the headlight cover.
Page 481: Exterior Parts
Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Exterior Parts Removal and Installation Seat BA02J29406001 Removal Radiator Cover Remove the seat by removing the bolts. Removal NOTE The right radiator covers are installed symmetrically and therefore the removal/ installation procedure for one side is the same as that for the other side.
Page 482 9D-2 Exterior Parts: Frame Cover Installation Install the protector in the reverse order of removal. Pay Removal attention to the following point: Remove the frame cover (1) (LH/RH) by removing the bolts. • Make sure that the radiator reservoir tank hoses are routed properly.
Page 483: Body Structure
Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction BA02J29506001 IA02J1950003-01 1. Frame 8. Upper engine mounting bracket (LH) : 40 N⋅m (4.0 kgf-m, 29.0 lbf-ft) 2. Seat rail 9. Front engine mounting bracket (RH) : 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 3.
Page 484: Seat Rail Removal And Installation
9E-2 Body Structure: Seat Rail Removal and Installation 5) Remove the muffler. Refer to “Muffler / Exhaust Pipe BA02J29506002 Removal and Installation” in Section 1K (Page 1K-2). 6) Loosen the throttle body clamp screw (air cleaner Removal box side). Refer to “Throttle Body Removal and 1) Remove the battery.
Page 485: Footrest Bracket Construction
Body Structure: 9E-3 Footrest Bracket Construction BA02J29506003 IA02J1950001-02 1. Right footrest bracket : 35 N⋅m (3.5 kgf-m, 25.5 lbf-ft) 2. Left footrest bracket Side-stand Construction BA02J29506004 “A” IA02J1950002-01 1. Side-stand 3. Inner spring : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft) : Apply grease.
Page 486: Side-Stand Removal And Installation
9E-4 Body Structure: Side-stand Removal and Installation BA02J29506005 Removal 1) Support the motorcycle with a jack or wooden block. CAUTION Do not support the motorcycle with the exhaust pipes. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction” (Page 9E-3). Installation Install the side-stand as shown in the side-stand construction.
Page 487 Prepared by October, 2009 Part No. 99500-44090-01E Printed in Japan...
Page 488 Printed in Japan...

Suzuki RMX450Z Service Manual

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