1 Suzuki_Ltr450_Workshop_Repair_Manual_ Suzuki Ltr450 Workshop Repair Manual

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GENERAL INFORMATION 1-1

CONTENTS

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1- 2
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.......................1- 5
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1- 6
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1- 7
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1- 8
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1- 8
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1- 8
................................................................................................ 1- 9
.........................................................................................1- 9
..........................................................................................
1- 9

WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKl LT-R450K6 ('06-MODEL)
SERIAL NUMBER LOCATION
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
FUEL (FOR OTHER COUNTRIES)
ENGINE OIL (FOR USA)
ENGINE OIL (FOR OTHER COUNTRIES)
BRAKE FLUID
ENGINE COOLANT
BREAK-IN PROCEDURES
INFORMATION LABELS
SPECIFICA TIONS
DIMENSIONS AND DRY MASS
ENGINE
DRIVE TRAIN
CHASSIS
ELECTRICAL
CAPACITIES

COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s)
CODE
E-19
E-28
E-33

COUNTRY or AREA
E.U.
Canada
California (U.S.A.)

EFFECTIVE FRAME NO.
JSAAL41A 62100001 JSAAL41A 62100001
JSAAL41A 62100001

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING. CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

Indicates a potential hazard that could result i n death or injury.

I CAUTION I
lndicates a potential hazard that could result i n vehicle damage.

NOTE:
Indicates soecial information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the sewicing, or lack of servicing, of the vehicle. In addition to the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS
Proper service and repair procedures are Important for the safety of the service mechanic and
the safety and reliability of the vehicle.
When 2 or more persons work together, pay attention to the safety of each other.
When it i s necessary to run the englne indoors, make sure that exhaust gas i s forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in i s wellventilated and that you follow ail of the material manufacturer's instructions.
Never use gasoline as a cleaning solvent.
' T o avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related
to the system for leaks.

If parts replacement is necessary, replace the parts with Suzuki Genulne Parts or their equivalent.
When removlng parts that are t o be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientatlon.
* Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean. Lubricate them when specifled.
Use the specified lubricant. bond, or sealant.
* When removing the battery, dlsconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
When tightening the cylinder head or case bolts and nuts, tlghten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
Never reuse a circlip. When installing a new circllp, take care not to expand the end gap larger
than required to slip the clrclip over the shaft. After Installing a circlip, always ensure that it is
completely seated in its groove and securely fltted.
' Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
After reassembling, check parts for tightness and proper operation.

' T o protect the environment,

do not unlawful\y dispose of used motor oil, engine coolant and
other fluids: batteries and tlres.
' To protect Earth's natural resources, properly dispose of used vehicle and parts.

1-4

GENERAL INFORMATION

SUZUKI LT-R450K6 ('06-MODEL)

Difference between photograph and actual vehicle may exist depending on the markets.

SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) (1) is stamped on the right side of the
steering head pipe. The engine serial number la is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 90 pump octane (Rl2 + Ml2).
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible.

FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recommended.

ENGINE OIL (FOR USA)
Oil quality is a major contributor to your engine's performance and life. Always select good quality engine oil.
Suzuki recommends the use of SUZUKl PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of
SFISG or SHISJ 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 an
alternative according to the following chart.

ENGINE OIL (FOR OTHER COUNTRIES)
Oil quality is a major contributor to your engine's performance
and life. Always select good quality engine oil. Use of SF/SG or
SHISJ in API with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil. I f SAE
10W-40 engine oil is not available, select an alternative according to the right chart.

BRAKE FLUID
Specification and classification: DOT 4

Since the brake system of this vehicle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid tor refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6

GENERAL INFORMATION

ENGINE COOLANT
Use an anti-freezelengine coolant compatible with an aluminum radiator, mixed with distilled water only.

WATER FOR MIXING
Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZUENGINE COOLANT
The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKl COOLANT anti-freezelengine coolant. I f this is not available, use
an equivalent which is compatible with an aluminum radiator.

LIQUID AMOUNT OF WATERlENGlNE COOLANT
Solution capacity (total): Approx. 1 400 ml (1.511.2 USllmp qt)
For engine coolant mixture information, refer to cooling system section in page 6-2.

CAUTION
Mixing of anti-freezelengine coolant should be limited to 60%. Mixing beyond it would reduce
its efficiency. If the anti-freezelengine coolant mixing ratio is below 50% rust inhabiting performance i s greatly reduced. Be sure t o mix it above 50% even though the atmospheric temperature does not go down t o the freezing polnt.

BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
Keep to these break-in engine speed limits:
Break-In englne speeds
Initial 10 hours: Less than % throttle
After the engine has been operated for 10 hours the engine to full throttle operation, for short periods of
time.

GENERAL INFORMATION

INFORMATION LABELS
NO

LABEL or PLATE NAME

APPLIED SPECIFICATION
E-19

E-28

E-33

(3' Tire air pressure label (Warning no-passenger) :E,

(41 Tire air pressure label (Warning no-passenger) lr'

0
0
0

(51 General warning and Age,l6 label 'E:

'61 General warning label F '

0
0

(11

Certlf~callonpalo IE'

(2' Information label ,EN

~~~

'I1

Warning no-passenger
-. mark (El

'I0

Manual nolice label 'B

(11'

ICES Canada label !E 'F;

(81

Waming no-passenger mark 8 1Fi

9 ' Age, 16 label iFI

o Z Comoliance label 'D
1
'3

Chain adjuslmenl
label {Fi
.-

t14
-

0
0

Chain adjuslment label 'El
EC approval mark

'$6 Fuel information label :E'!F
Fuel information label E',

\
@
R g hl
l side of frame

eH side of frame

Swingarm

U m e r sutlace
o i i u e ~tank cover

1-7

1-8 GENERAL INFORMATION

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................... 1 845 mm (72.6 in)
Overall width ........................................................1 245 mm (49.0 in)
Overall height .............
......
............................. 1 085 mm (42.7 in)
Wheelbase ........................................................... 1 285 mm (50.6 in)
Front track ............................................................1 045 mm (41.1 in)
Rear track .........................................................
985 mm (38.8 in)
Ground clearance .....................
.
.
...................
240 mm (9.4 in)
Seat height ...................... .
.
.
............................. 780 mm (30.7 in)
Dry mass ..............................................................
167 kg (368 Ibs)

ENGINE

.
.
.
.

Type ....................
.......................................Four stroke, liquid-cooled, DOHC
Number of cylinders ............................................. 1
Bore .....................................................................
95.5 mm (3.760 in)
Stroke...................................................................62.8 mm (2.472 in)
450 cm3 (27.5 cu. in)
Displacement .......................................................
Compression ratio .............................................
11.7: 1
Fuel system........................................................
Fuel injection
Air cleaner ............................................................
Polyurethane foam element
Starter system ...................................................... Electric
Lubrication system ............................................... Dry sump
Idle speed ..................................................
1 800 100 rlmin

DRIVE TRAIN

Clutch...................................................................
Wet multi-plate type
. . . ........
Transm~ss~on
.....
................................. 5-forward
Gearshift pattern ..................................................
1 down 4 up, foot operated
Primary reduction ratio ......................................... 2.851 (77127)
Gear ratios, Low ............................................... 2.076 (27113)
....................
2nd.. ...................
1.647 (28117)
3rd ..................................................
1.333 (28121)
4th ................................................... 1.095 (23121)
Top ..............................................
0.913 (21123)
Final reduction ratio ............................................. 2.571 (36114)
Drive chain ...........................................................
RK 520SMOZlOS. 96 Links

...

GENERAL INFORMATION 1-9

CHASSIS
Front suspension ................................................. Independent, double wishbone, coil spring, oil damped
Rear suspension ...................
.
.
......................... Swingarrn type, coil spring, oil damped
Front wheel travel ................................................ 254 rnm (10.0 in)
Rear wheel travel ...................
.................. 277 mm (10.9 in)
Caster .................................................................. 8.0"
Trail ....................
.......
.................................. 30 mm (1.18 in)
Toe-in .................................................................. 0 mm
Camber .................... .
.
.................................... -3.0"
Steering angle ................................... .. .............. 41"
Turning radius .....................
..................... 3.5 m (11.5 fl)
Front brake .......................................................... Disc brake, twin
Rear brake ...................
.
.
.
............................
Disc brake
Front tire size ....................................................
AT20 x 7 RlO.>{f , tubeless

.
.
.
.

ELECTRICAL
Electronic ignition (Transistorized)
8" B.T.D.C. at 1 800 rlmin
Spark plug ........................................................... NGK CR8EB
Battery ................................................................. 12 V 21.6 k c (6 Ah)/lO HR
Generator ............................................................Three-phase A.C. generator
Main fuse................
.
.
....................................... 20 A
Fan fuse
10 A
Ignition fuse .........................................................10 A
Headlight.............................................................12 V 40140 W
Brake lightrraillight .............................................. LED
Neutral indicator light ......................................
12v3.4 W
Fuel indicator light ............................................... 1 2 v 3 . 4 W
Coolant tempereturel
Fuel injection warning light ................
...........

CAPACITIES
Fuel tank, including reserve ................................ 10.0 L (2.612.2 USIlmp gal)
Engine oil, oil change ......................................... Oil tank 1 200 ml (1.311.1 USIlrnp qt)
Engine 400 ml (0.410.4 USIlmp qt)
with filter change ............................... Oil tank 1 300 ml (1.411.1 USIlmp qt)
Engine 400 ml (0.410.4 USllmp qt)
overhaul ......................................... Oil tank 1 400 ml (1.511.2 USllmp qt)
Engine 400 ml (0.410.4 USllmp qt)
Coolant ................................................................1.4 L (1.511.2 USllmp qt)
These specifications are subject to change without notice.

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

rque control required.

pply oil. Use engine oil unless

ixture of engine oil and SUZUKl

Apply or use brake fluid.

easure in voltage range.

Apply SUZUKI SILICONE GREASE.

a
a

Measure in resistance range.

Apply SUZUKI BOND "1215"
or equivalent bond.
99000-31 110

Measure in diode test range.

Apply SUZUKI BOND "1216B".
99000-31230

Measure in continuity test range.

APPB THREAD LOCK SUPER '1303''.
99000-32030

Apply THREAD LOCK SUPER "1322"
or equivalent thread lock.
99000-321 10

special tool,

Indicates sewice data

ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC
AC
ACL
API
ATDC
AIF

: After Bottom Dead Center
: Alternating Current
: Air Cleaner. Air Cleaner Box
: American Petroleum Institute
: After Top Dead Center
: Air Fuel Mixture

: Hydrocarbons

I
IAP Sensor
IAT Sensor

IG
BBDC
BTDC
B+

: Before Bottom Dead Center
: Before Top Dead Center
: Battery Positive Voltage

IAS

: Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
: Intake Air Temperature Sensor
(IATS)
: Ignition
: Idle air screw

: Left Hand

C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT
: Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO
: Carbon Monoxide
: Central Processing Unit
CPU

D
DC
DMC
DOHC
DRL
DTC

Max
MIL
Min

: Direct Current
: Dealer Mode Coupler
: Double Over Head Camshaft
: Daytime Running Light
: Diagnostic Trouble Code

NOX

ECT Sensor

: Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
: Engine Coolant Temperature
Sensor (ECTS), Water Temp
Sensor (WTS)

: Nitrogen Oxides

0
OHC

: Over Head Camshaft

P
PCV

E
ECM

: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
: Minimum

: Positive Crankcase
Ventilation (Crankcase Breather)

R
RH
ROM

: Right Hand
: Read Only Memory

S
F
F1
FP
FPR
FP Relay

: Fuel Injection. Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay

G
GEN
GND
GP Switch

: Generator
: Ground
: Gear Posilion Switch

SAE
SDS

: Society of Automotive Engineers
: Suzuki Diagnosis System

T
TO Sensor
TP Sensor

: Tip-Over Sensor (TOS)
: Throttle Position Sensor (TPS)

PERIODIC MAINTENANCE 2-1

CONTENTS

........................................... 2 - 2
.......................................... 2 - 2
.............................. 2 - 3
............................................................................ 2 - 3
....................... 2 - 4
.............................................................. 2 - 5
............................................................................. 2-10
................................................................................. 2-11
.............................................................................. 2-11
.......................................................... 2-11
................................................................ 2-12
......................................................................2-12
................................................... 2-12

PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
EXHAUST PIPE NUTS AND MUFFLER BOLTS
VALVE CLEARANCE
SPARK PLUG
FUEL LINE
FUEL FILTER
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
THROTTLE BODY
ENGINE OIL AND OIL FILTER
ENGINE OIL HOSE ....................................................................
ENGINE COOLANT
RADIATOR
RADIATOR HOSE
SPARK ARRESTER ...................................................................
CLUTCH CABLE PLAY
BRAKES
BRAKE FLUID
BRAKE HOSE
TIRES
STEERING
DRIVE CHAIN
SUSPENSIONS
FRONT AND REAR WHEEL SET NUTS
REAR AXLE NUT AND LOCK-NUT
CHASSIS BOLTS AND NUTS
GENERAL LUBRICA TION
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
OIL PRESSURE CHECK
OIL PRESSURE TEST PROCEDURE
SDS CHECK

2-14
2-15
2-16
2-16
2-17
2-18
2-78
2-21
2-23
2-23
2-24
2-25
2-28
2-28
2-29
2-30
2-33
2-34
2-34
2-35
2-35
2-36

..............................................................
......................................................................................
............................................................................
.............................................................................
........................................................................................
..................................................................................
.............................................................................
...........................................................................
....................................
...........................................
....................................................
.........................................................
................................................
........................................

.....................................................................
........................................
........................................................................................

2.2

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of
months

NOTE:
More frequent servicing may be performed on vehicles that are use under severe conditions

PERIODIC MAINTENANCE CHART
Interval
Item

3 months
C
T

6 months

Fuel line
Fuel filter
Engine oil and oil filter

Tires
Suspensions
Front and rear wheel set nuts
Rear axle nut and lock-nut
Steering
Chassis bolts and nuts
General lubrications

1 month

Spark arrester
Idle speed
Throttle cable play
Throttle body

Brake hose

Every

T
I

Spark plug

Brakes fluid

Every

Air cleaner element
Exhaust oioe nuts and muffler bolts
Valve clearance

Enaine coolant
Radiator
Radiator hose
Drive chain
Drive chain buffer
Brakes

Initial

C
T

I
I

Replace
every 18 months.
-

I
I

I
I
Replace every 4 years.
Replace every 4 years.

Reolace evew 2 vears.
I

C
I
I
I
I

I
I
Clean, lubricate and inspect each time the vehicle is ridden.
Inspect each time the vehicle is ridden.
I
I
I
I
I
I
I
Replace every 2 years.
I
Replace every 4 years.
I
I
I
Tighten each time the vehicle is ridden.
T
I
T
I
T
L
I
I
I
T
T
T
L
L
L

NOTE:
I= lnspect andadjust, clean, lubricate, or replace as necessary.
R = Replace
C = Clean
T = Tighten
L =Lubricate

PERIODIC MAINTENANCE 2.3

MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned in the Periodic Maintenance chart.

AIR CLEANER
c

Clean every 3 months.
If the air cleaner is clogged with dust, intake resistance will be
increased, with a resultant decrease in power output and an
increase in fuel consumption, Check and clean the air cleaner
element in the following manner.
Remove the seat. ( p 7 - 6 )
Remove the air cleaner case cover (7:).
Remove the air cleaner element

Separate the polyurethane foam element

m and element holder.

3,
element frame

0
@
I

Fill a wash pan of a proper size with a non-flammable cleaning solvent. Immerse the air cleaner element in the cleaning
solvent and wash it.
Press the air cleaner element between the palms of both
hands to remove the excess solvent: do not twist or wring the
element or it will tear.
lmmerse the element in motor oil, and then squeeze out the
excess oil leaving the element slightly wet.
Non-flammable cleaning solvenl
[Bi MOTUL AIR FILTER OIL or equivalent filter oil

2-4

PERIODIC MAINTENANCE

PAUTIONA
" Inspect the air cleaner element for tears.

A torn ele-

ment must be replaced.

* If driving under dusty conditions, clean the air
cleaner element more frequently. The surest way to
accelerate engine wear i s to operate the engine without the element or with torn element. Make sure that
the air cleaner element i s i n good condition at all
times. Life of the engine depends largely on this
component!
Remove the drain cap
water to drain out.

m of the air cleaner box to allow any

,
$

EXHAUST PIPE NUTS AND MUFFLER
BOLTS
Tighten initially at 1 month and every 3 months thereafter.
Tighten the exhaust pipe nuts (71, muffler connection bolt (2,
and muffler mounting bolt d to the specified torque.

[Z1 Exhaust pipe nut:

23 N.m (2.3 kgf-m, 16.5 lb-ft)
Muffler connection bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)
Muffler mounting bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)

, ' ,

,..

,2,..-

" 4
,

F -9'
\

PERIODIC MAINTENANCE 2-5

VALVE CLEARANCE
Inspect initially at 1 month and every 6 months thereafter.
Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power.
Check the intake and exhaust valve clearances at the distances
indicated above and adjust the valve clearances to specification.
if necessary.
Remove the seat. ( U 7 - 6 )
Remove the side covers, fuel tank cover and front fender.

(-7-6)

Remove the fuel tank and fuel tank lower cover. ( W 5 - 4 )
* Remove the spark plug cap and spark plug. ( D 2 - 1 0 )
* Disconnect the breather hose rtl and oil tank over-flow hose (3,

Remove the cylinder head cover 0).
The valve clearance specification is different for intake and
exhaust valves.
Valve clearance must be checked and adjusted, I ) at the time of
periodic inspection. 2) when the valve mechanism is serviced,
and 3) when the camshafts are removed for servicing.

Remove the valve timing inspection plug (41 and generator
cover cap (3.
NOTE:
The piston must be at top dead center (TDC) on the cornpression stroke in order to check or adjust the tappet clearance.
* The tappet clearance should only be checked when the engine
is cold.

,''<

./ '

-;
\,

.
,

.L--

2-6

PERlOOiC MAINTENANCE

Rotate the crankshaft with a box wrench to set the piston at
TDC on the compression stroke. (Rotate the crankshaft until
the "T line on the generator rotor is aligned with the triangle
mark on the generator cover.)

Insert a thickness gauge between the tappet and the cam. If
the clearance is out of specification, adjust it to the specification as follows.
09900-20803: Thickness gauge
Valve clearance (when cold)
IN: 0.10 0.20 mm (0.0039 0.0079 in)
EX: 0.20 0.30 mm (0.0079- 0.01 18 in)

NOTE:
The cam must be at position [A), when checking and adjusting
the valve clearance. Clearance readings should not be taken
with the cam in any other position than this position.

ADJUSTMENT
The clearance is adjusted by replacing the existing tappet shim
with a thicker or thinner shim.
Remove the intake or exhaust camshafts. (-3-13)
Remove the tappet and shim by hand or with a magnet.

(W3-25)

PERIODIC MAINTENANCE 2-7

Check the numbers printed on the tappet shim. These numbers indicate the thickness of the tappet shim, as illustrated.
Select a replacement tappet shim that will provide the proper
clearance. Tappet shims are available in 25 sizes, ranging
from 2.30 to 3.50 mm (0.09 to 0.14 in) in increments of 0.05
mrn (0.002 in). lnstall the selected shim a , l ! at the valve stem
end, with the numbers facing towards the tappet. Be sure to
measure the shim with a micrometer to ensure that it is of the
proper size.
Refer to the tappet shim selection table for details.

NOTE:
" B e sure to apply molybdenum oil solution to the top and bottom faces of the tappet shim.
* When installing the tappet shim, make sure that the side with
the numbers face towards the tappet.

Install the camshafts as specified. (-3-76)

After replacing the tappet shim and camshafts, rotate the
crankshaft so that the tappet is depressed fully (this will
squeeze out any oil trapped between the tappet shim and the
tappet that could cause an incorrect measurement). After
rotating the crankshaft, check the valve clearance again to
make sure that it is within specification.
When installing the cylinder head cover, apply SUZUKI BOND
"12168" to the cam end caps of the cylinder head cover gasket.

a99000-31230: SUZUKI BOND "1216B"

Tighten the generator cover cap and valve inspection plug.
(W3-76)
Apply engine oil to both sides of the washers.
Tighten the cylinder head cover bolts to the specified torque.
(W3-79)
Cylinder head cover bolt:
Initial 10 N.m (1.0 kgf-m, 7.0 lb-ft)
Final 14 N.m (1.4 kgf-rn, 10.0 lb-ft)

2-8

PERIODIC MAINTENANCE

INTAKE

PERIODIC MAINTENANCE 2-9

EXHAUST SIDE

2-1 0

PERIODIC MAINTENANCE

SPARK PLUG
Inspect every 6 months.
Replace every 18 months.
Remove the fuel tank and fuel tank lower cover. ( W 5 - 4 )
Disconnect the spark plug cap (11and remove the spark plug.

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Hot type

Standard

Cold type

CR7EB

CREE0

CR9EB

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CARBON DEPOSITS
Check to see if there are carbon deposits on the spark plug. If
carbon is deposited, remove it using a spark plug cleaner
machine or carefully use a tool with a pointed end.
SPARK PLUG GAP
Measure the spark plug gap using a thickness gauge. If the
spark plug gap is out of specification, adjust the gap.
Standard
Spark plug gap: 0.7

- 0.8

mm (0.028

- 0.031 in)

09900-20803: Thickness gauge
ELECTRODE
Check the condition of the electrode.
If the electrode is extremely worn or burnt, replace the spark
plug with a new one.
Also, replace the spark plug if it has a broken insulator, damaged threads, etc.

EA:UTI
ON
Check the thread size and reach when replacing the
spark plug. If the reach is too short, carbon will be
deposited on the screw portion of the spark plug hole
and engine damage may result.
SPARK PLUG INSTALLATION

E ~ ~ ~ m
To avoid damaging the cylinder head threads; first,
finger tighten the spark plug, and then tighten it to the
specified torque using the spark plug wrench.
Insert the spark plug and finger tighten it to the cylinder head
and then, tighten it to the specified torque.
Spark plug: 11 N.m (1.1 kgf-m, 8.0 lb-ft)

(0.028 - 0.031 in)

PERIODIC MAINTENANCE 2-11

FUEL LINE
lnspect every 3 months.
Replace every 4 years.
lnspect the fuel hose for damage and fuel leakage. If any
defects are found, replace the fuel hoses with new ones.

FUEL FILTER
Replace every 4 years.
lnspect the fuel f~lterfor damage and rust. If any defects are
found, blow the fuel f~lterwith compressed air or replace the fuel
filter, 0 - r ~ n gand fuel filter cap with a new one. (-5-9)

THROTTLE CABLE PLAY

lnspect initially at 1 month and every 3 months thererafter.
Adjust the throttle cable play (521 as follows.
Loosen the lock-nut @of the throttle cable.
Turn the adjuster (2) in or out to oblain the correct play.
Throttle cable play: 3

- 5 mm (0.12 - 0.20 in)

After adjusting the throttle cable play, tighten the lock-nut (i:).

J-

2-12

PERIODIC MAINTENANCE

ENGINE IDLE SPEED
lnspect initially at 1 month and every 3 months thereafter.

NOTE:
Make this adjustment when the engine is hot.

Connect the tachometer to the high-tension cord.
Start the engine and set the engine idle speed between 1 700
and 1 900 rlmin by turning the idle air screw (11.
Engine idle speed: 1800 + 100 rlmin

THROTTLE BODY

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lnspect every 3 months.
Inspect the throttle body for dirt.
Clean the throttle body if necessary.

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2-14

PERIODIC MAINTENANCE

* install the new 0-rlng (3'.
install the spring '.Zjand new O-ring (5).

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Apply engine oil t o the O-rings.
Replace the oil filter cap and tighten the bolts securely.

NOTE:
Face the triangle mark [A') on the cap rearward.

Add new engine oil and check the oil level as described in the
engine oil replacement procedure.
Engine oil capacity (oil tank side)
Oil change:
1.2 L (1.3 US qt,
Oil and filter change: 1.3 L (1.4 US qt,
Engine overhaul:
1.4 L (1.5 US qt,
Engine oil capacity (engine side)
0.4 L (0.4 US qt,
Oil change:
Oil and filter change: 0.4 L (0.4 US qt,
Engine overhaul:
0.4 L (0.4 US qt,

1.1 Imp qt)
1.1 imp qt)
1.2 imp qt)

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0.4 imp qt)
0.4 Imp qt)
0.4 imp qt)

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When reassembling the oil filter, make sure that the oil
filter i s installed as shown above. If the filter is
Installed improperly, serious engine damage may
result.

ENGINE OIL HOSE
lnspect initially at 1 month and every 3 months thereafter.
Inspect the engine oil hoses for damage and oil leakage. If any
delects are found, replace the engine oil hoses with new ones.

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PERIODIC MAINTENANCE 2-15

ENGINE COOLANT
Replace the engine coolant every 2 years.
ENGINE COOLANT LEVEL CHECK
Check the engine coolant level by observing the upper (A) and
lower 031 lines on the engine coolant reservoir.
If the level is below the lower line, remove the front fender
(-7-6), add engine coolant until the level reaches the
upper line.

ENGINE COOLANT REPLACEMENT
Remove the front fender. (-7-6)
Remove the radiator cap il' and engine coolant reservoir cap
12;).

Place a pan below the water pump, and then drain the engine
coolant by removing the drain plug (3).

* Do not open the radiator cap when the engine i s hot,

as you may be injured by escaping hot llquid or
vapor.
' Engine coolant may be harmful if swallowed or if it
comes in contact with the skin or eyes. If engine
coolant gets into the eyes or contacts the skln. flush
the eyes or wash the skin thoroughly, with plenty of
water. It engine coolant i s swallowed, induce vomlting and call a physiclan immediately.
Flush the radiator with fresh water, if necessary.
Tighten the drain plug securely.
Pour the specified engine coolant into the reservoir.

NOTE:
For engine coolant information, refer to page 6-2.

YT-

2-16

PERIODIC MAINTENANCE

Install the radiator cap securely.
After warming up and cooling down the engine, add engine
coolant until the level is between the upper and lower lines on
the engine coolant reservoir.
-

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8

Repeat the above procedure several times and make
sure the radiator i s filled with engine coolant t o the
upper line of the engine coolant reservoir.
Engine coolant capacity (including reserve):
1 400 ml (1.5 US qt, 1.2 Imp qt)

RADIATOR
lnspect every 3 months.
lnspect the radiator for dirt.
Clean the radiator if necessary.

RADIATOR HOSE
lnspect every 6 months.
lnspect the radiator hoses for damage and engine coolant leakage. If any defects are found, replace the radiator hoses with
new ones.

PERIODIC MAINTENANCE 2-17

SPARK ARRESTER
Clean every 6 months.
Disconnect the brake lightltaillight coupler.

Remove the brake lightitaillight cover 17.') and rear brake light
(21.

Remove the spark arrester cover ( 3 .

Remove the spark arrester pipe (41.
Remove the gasket 151.

Clean the spark arrester pipe by brush
Reinstall the spark arrester pipe.
Reinstall the spark arrester cover.
Reinstall the brake IighWtaillight and brake lightitaillight cover.
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Only clean the spark arrester In an open area away
from combustible materials. Exhausted hot carbon
particles can start a fire.

2-18

PERIODIC MAINTENANCE

CLUTCH CABLE PLAY
lnspect initially at 1 month and every 3 months thereafter.
Adjust the clutch cable play as follows:

MAJOR ADJUSTMENT
Loosen the lock-nut t i ; .
Turn adjuster f? so the clutch lever has 10 - 15 rnrn (0.4 - 0.6
in) play at the clutch lever end before pressure is felt.
Tighten the lock-nut (0.

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MINOR ADJUSTMENT
Turn adjuster 13 so the clutch lever has 10 - 15 mm (0.4 - 0.6
~ nplay
)
at the clutch lever end before pressure IS felt.
Clutch lever play ti\): 10

- 15 mm (0.4 - 0.6 in)

BRAKES
Inspect lnltially at 1 month and every 3 months thereafter.
BRAKE PADS
Remove the front wheels. (-7-10)
The extent of brake pad wear can be checked by observ~ngthe
limit line (A7 on the brake pads. When the wear reaches the limit
,
line, replace the pads with new ones. ( W 7 - 1 9 -55)

Replace the brake pads as a set, otherwise braking
performance will be adversely affected.

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PERIODIC MAINTENANCE 2-19

FRONT BRAKE LEVER ADJUSTMENT
Adjust the brake lever position as follows:
Loosen the lock-nut ii).
Turn in or out adjuster (21to obtain the proper brake lever
position.
The standard adjuster length @> is 11 15 mm (0.4 - 0.6 in).
Tighten the lock-nut (i!securely.
Front brake lever adjuster lock-nut:
5 N.m (0.5 kgf-m, 3.5 ib-ft)

REAR BRAKE PEDAL AND LEVER
The procedure for adjusting the rear brake pedal and brake
lever is as follows:

NOTE:
First adjust the brake pedal, and then adjust the brake lever.

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Brake pedal helght 0:
0 10 mm (0

- 0.4 in)

Rear brake master cylinder rod lock-nut:
18 N m (1.8 kgf-rn, 13.0 ib-ft)

Adjust the rear brake light switch so that the brake light will
come on just before pressure is felt when the brake pedal is
depressed.

PARKING BRAKE
Parking brake adjustment may be required if the parking brake
does not work properly. Evely time the brake pads are replaced,
adjust the parking brake.
Loosen the parking brake adjuster lock-nut (I)
while holding
the adjuster (21 with a tool.
Loosen the adjuster (2).

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Brake pedal
Turn the adjuster (i, in or out unt~lthe pedal height
specification, after loosening the lock-nut (2).
Make sure to tighten the lock-nut (27 securely.

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2-20

PERIODIC MAINTENANCE

Loosen the parking brake cable adjuster lock-nut '3.

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Turn the cable adjuster (4) so that the cable length :d is 49
53 rnrn (1.9 2.1 in).

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Tighten the adjuster lock-nut ($1.

Turn the parking brake adjuster (3 clockwise until it stops.
Then, turn out the adjuster 12)118 114.
* Tighten the adjuster lock-nut (0while holding the adjuster IB
with a tool.

,--

Parking brake adjuster lock-nut:
18 N.rn (1.8 kgf-m, 13.0 lb-ft)

After adjusting the parking brake, check that there i s
n o dragging when turning the rear wheel wlth the
wheel off the ground.

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PERIODIC MAINTENANCE 2-21

BRAKE FLUID
Inspect every 3 months.
Replace every 2 years.
BRAKE FLUID LEVEL
Place the handlebar straight.
Check the brake fluid level by observing the lower limit lines
on the front and rear brake fluid reservoirs.
When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.
Specification and classification: DOT 4

' The brake system of this vehlcle is filled with a glycol-based brake fluid. Do not use or mix dlfferent
types of fluid such as slllcone-based and petroleum-based fluids. Do not use any brake fluld taken
from old, used or unsealed containers. Never re-use
brake fluid left over from the last servicing or stored
for a long period of time.
Brake fluid, if it leaks, will Interfere with safe running
and immediately dlscolor palnted surfaces. Check
the brake hoses and hose joints for cracks and fluid
leakage before riding.

AIR BLEEDING THE BRAKE FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion absorb a
large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by "sponginess"
of the brake lever and also by lack of braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

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2-22

PERIODIC MAINTENANCE

Fill the front or rear brake reservoir with the specified brake
fluid to the top of the inspection window or upper limit line.
Replace the reservoir cap to prevent dirt from entering.
Attach a hose to the air bleeder valve, and insert the free end
of the hose into a receptacle.
Squeeze and release the brake lever or brake pedal several
times in rapid succession and squeeze the lever or pedal fully
without releasing it. Loosen the air bleeder valve by turning it
a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to
touch the handlebar grip or brake pedal reaching bottom of
the stroke. Then, close the air bleeder valve, pump and
squeeze the lever or pedal, and open the valve. Repeat this
process until the fluid flowing into the receptacle no longer
contains air bubbles.

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NOTE:
While bleeding the brake system, replenish the brake fluid in the
reservoir as necessary. Make sure that there is always some
fluid visible in the reservoir.

Close the air bleeder valve, and disconnect the hose. Fill the
reservoir with brake fluid to the top of the inspection window
or upper limit line.
Air bleeder valve: 6 N.m (0.6 kgf-m, 4.5 lb-ft)

1cAUTloq
Handle brake fluid wlth care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

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PERIODIC MAINTENANCE 2.23

BRAKE HOSE
lnspect every 6 months.
Replace every 4 years.
lnspect the brake hoses for leakage, cracks, wear and damage.
If any defects are found, replace the brake hoses with new ones.

TIRES
lnspect every 3 months.

TIRE TREAD CONDITION
Operating the vehicle with excessively worn tires will decrease
riding stability and consequently invite a dangerous situation. It
is highly recommended to replace a tire when the remaining
depth of the tire tread reaches the following specification.
09900-20805: Tire depth gauge

Service Llmlt
Tire tread depth: Front 4.0 mm (0.16 in)
Rear 4.0 mrn (0.16 in)

2-24

PERIODIC MAINTENANCE

TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear will increase. Therefore, rnaintain the correct tire pressure for good roadability and a longer
tire life. Cold inflation tire pressure is as follows.
Cold inflation tire pressure
Front: 45 kPa (0.45 kgflcm2, 6.5 psi)
Rear : 45 kPa (0.45 kgflcm7, 6.5 psi)
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

To minimize the posslbillty of tire damage from
over-inflation, we strongly recommended that a manual type air pump be used rather than a high pressure
air compressor as found in service stations. When filling air into the tires, never exceed 50 kPa (0.5 kgf/cm2,
7 psi).

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ATZOx7RlOi?**
for the front and AT18~10RB.,"il"iII.
for the rear. The use of tires other than those specified
may cause instability. It is highly recommended t o use
the ~ ~ e c i f i tires.
ed

STEERING
Inspect initially at 1 month and every 3 months thereafter.
Steering system should be adjusted properly for smooth rnanipulation of the handlebars and safe running.

PERIODIC MAINTENANCE 2-25

TOE
Place the vehicle on level ground.
Make sure the tire pressure for right and left tires is the same
and set to the proper specification.
Set the front wheels in the straight position.
Place a load of 75 kg (165 lbs) on the seat.
Measure the distance (& and i@
of the front wheels with a
toe-in gauge as shown and calculate the difference between
(A) and (Ri.
id:, (A1= Toe-in

Toe-in: 0

+ 4 mm ( 0 * 0.16 in)

If the toe-in is out of specification, bring it into the specified
range. ( D 7 - 5 2 )

DRIVE CHAIN
Clean, lubricate and Inspect each time the vehicle is
ridden.
Visually check the drive chain for the possible defects listed
below. (Support the vehicle by a jack and a wooden block, turn
the rear wheel slowly by hand with the transmission shifted to
Neutral.)

' Loose pins

' Excessive wear
Damaged rollers
Improper chain adjustment
+ Dry or rusted links
" Missing O-ring seals
Kinked or binding links
If any defects are found, the drive chain must be replaced.
NOTE:

When replacing the drive chain, replace the drive chain and
sprockets as a set.

CHECKING
Place the vehicle on a level ground.
Loosen the rear axle housing set nuts.

Forward

-1

2.26

PERIODIC MAINTENANCE

* lnsert a tool into the rear sprocket hole and adjuster hole
Tense the drive chain fully by turning rear axle holder '1 1.

* Count out 21 pins (20 pitches) on the chain and measure the
distance between the two points. If the distance exceeds the
service limit, the chain must be replaced.
Drive chain 20-pitch length
Service limit: 319.4 mrn (12.57 in)

ADJUSTING
Insert a tool in the rear sprocket hole and adjuster hole.
Turn rear axle holder O).Until there is 45 - 55 mm (1.8 - 2.2
in) of slack at the middle point between the chain buffer and
the rear sprocket as shown.
Drive chain slack:
Standard: 45 55 mrn (1.8

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- 2.2 in)

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(1.8

- 2.2 in)

After adjusting the drive chain, tighten the rear axle housing
set nuts in ascending order and to the specified torque.

Rear axle housing set nut: 28 N.rn (2.8 kgf-rn, 20.0 lb-ft)

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-PERIODIC MAINTENANCE 2.27

CLEANING AND LUBRICATING
Clean the drive chain with kerosine. If the drive chain tends to
rust quickly, the intervals must be shortened.

1-NO-

Do not use trlchloroethylene, gasoline or any similar
solvent. These fluids have too great a dissolving
power for this chain and they can damage the O-rings.
Use only kerosine to clean the drive chaln.

After washlng and drylng the cham,
motor 011.

011it

wlth a heavyweight

CAUTION]

Do not use any oil sold commercially as "drive chain
oil". Such oil can damage the O-rings.
* T h e standard drive chaln i s a RK 520SMOZlOS.
Suzuki recommends to use this standard drive chain
as a replacement.

DRIVE CHAIN BUFFER

Inspect each tlme the vehicle I s ridden.

The extent of chain buffer wear can be checked by observing
the limit line 1"3 on the chain buffer. When the wear reaches the
limit line, replace the chain buffer with a new one.

(W7-85)

2-28

PERIODIC MAINTENANCE

SUSPENSIONS

Inspect every 6 months.

* Support the vehicle with a jack or wooden blocks.
Remove the front and rear wheels. ( p 7 - 1 0 )
lnspect the suspension arm and bearing for scratches, wear.
or damage. If any defects are found, replace the suspension
arm or bearing with a new one. ( W 7 - 7 8 )
lnspect the swinging arm, rear axle and bearing for scratches,
wear or damage. If any defects are found, replace them with a
new one. ( W 7 - 8 6 , -94)
lnspect the front and rear shock absorbers for oil leakage or
damage. If any defects are found, replace them with a new
one. ( p 7 - 6 9 , -73)

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FRONT AND REAR WHEEL SET NUTS
Tighten each time the vehicle is rldden.
Tighten the front and rear wheel set nuts to the specified
torque.

Wheel set nut (Front and Rear):
66 N.m (6.6 kgf-m, 47.5 lb-ft)

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PERIODIC MAINTENANCE

2-29

REAR AXLE NUT AND LOCK-NUT
Tighten initially at 1 month and every 3 months thereafter.
Loosen the axle lock-nut (1) and axle nut r2) with the special
tools.
09940-92460: Rear axle nut wrench set

Apply THREAD LOCK "SUPER 1322" to the thread portion of
the axle nut holder.
Tighten the axle nut (2) to the specified torque with the special
tool.
Rear axle nut: 240 N
-99000-32110:

m (24.0 kgf-rn, 173.5 lb-ft)

THREAD LOCK SUPER "1322"
(or equivalent thread lock)

09940-92460: Rear axle nut wrench set

NOTE:
When tightening the axle nut with the special tool, the reading
torque on the torque wrench is smaller than actual torque that is
applied to the axle nut. Therefore convert the tightening torque.
(V7-101)

~ p p l THREAD
y
LOCK SUPER "1322~
to the thread portion of
the axle nut holder.

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m 9 9 0 0 0 - 3 2 1 1 0 : THREAD LOCK SUPER "1322"
(or equivalent thread lock)

Tighten the axle lock-nut (I!to the specified torque with the
special tools.
Rear axle lock-nut: 240 N.m (24.0 kgf-m, 173.5 lb-ft)

09940-92460: Rear axle nut wrench set

NOTE:
When tightening the axle lock-nut with the special tool, the reading torque on the torque wrench Is smaller than actual torque
that is applied to the axle lock-nut. Therefore convert the tightening torque. ( C 3 7- 101)

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2-30

PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS
Tighten initially at 1 month and every 3 months thereafter.
Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-31. -32 for the
locations of the following nuts and bolts on the vehicle.)

PERIODIC MAINTENANCE

2-31

PERIODIC MAINTENANCE

2-33

GENERAL LUBRICATION
Lubricate inltlally at 1 month and every 3 months
thereafter.
Proper lubrication is important for smooth operation and long life of each working part of the vehicle.
Major lubrication points are indicated below.

I
1l:Brake lever holder
"2)Throttle lever
(3:Steering shaft holder

#&rake pedal and rod link
:5:Rear axle joint spline

ll Grease
Motor oil

NOTE:
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt, or grime.
Lubricate exposedparfs which are subject to rust, with a rust preventative spray, especially whenever the
vehicle has been operated under wet or rainy conditions.

2-34

PERlOOlC MAINTENANCE

COMPRESSION PRESSURE CHECK
The compression pressure reading of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings lor each maintenance service.
Compresslon pressure:
Standard: 800 kPa (8.0 kgf/cm2,114 psi)
(Automatic decompression actuated)
Low compression pressure can indicate any of the following conditions:
Excessively worn cylinder wails
Worn piston or piston rings
' Piston rings stuck in grooves
Poor valve seating
Ruptured or otherwise defective cylinder head gasket
NOTE:
When the compression pressure goes below specification, check the engine for conditions listed above.

COMPRESSION TEST PROCEDURE
NOTE:
'Before testing the eng~nefor compression pressure, make
sure that the cylinder head nuts are tightened to the specified
torque values and the valves are properly adjusted.
" Have the engine warmed up before testing.
Make sure that the battery is fully-charged.

'
p.

Remove the related parts and test the compression pressure in
the following manner.
Remove the fuel tank and fuel tank lower cover. ( D 5 - 4 )
* Remove the spark plug. ( W 2 - 1 0 )
Disconnect the fuel pump lead wire coupler (3.
Install the compression gauge and adaptor in the spark plug
hole. Make sure that the connection is tight.
Keep the throttle lever in the fully open position.
Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder
compression.
09915-64512: Compression gauge set
09913-10750: Adaptor

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PERIODIC MAINTENANCE 2-35

OIL PRESSURE CHECK
Check the engine oil pressure periodically. This will give a good indication of the condition of the moving
pal-ts.
Oil pressure:
10 kPa (0.1 kgflcm2, 1.4 psi) at 3 000 rlmin, Oil temp. at 60 "C (140 O F )

If the oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE
" Clogged oil filter
+ Oil leakage from the oil passage
^ Damaged O-ring
Defective oil pump
" Combination of the above items

HIGH OIL PRESSURE
Engine oil viscosity is too high
Clogged oil passage
' Combination of the above items

OIL PRESSURE TEST PROCEDURE
Connect the tachometer onto the spark plug high-tension
cord.
Remove the main oil gallely plug (TI.
Install the oil pressure gauge and adaptor into the main oil
gallery.
Warm up the engine as follows:
Summer: 10 minutes at 2 000 rtmin
Winter: 20 minutes at 2 000 rlmin
After warming up the engine, increase the engine speed to
3 000 rlmin (observe the tachometer), and read the oil pressure gauge.
~.
09915-74511: 011pressure gauge
09940-40211: Adaptor

Apply engine oil to both sides of the main oil gallery plug
washers.
Tighten the main oil gallery plug to the specified torque.
Main oil gallery plug: 10 N m (1.0 kgf-m, 7.0 lb-ft)

2-36

PERIODIC MAINTENANCE

SDS CHECK
Using SDS, take the sample of data from the new vehicle and at the time of periodic maintenance at your
dealership.
Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for
troubleshooting as they can be compared periodically with changes over time or failure conditions of the
vehicle.
For example, when a vehicle is brought in for service but the troubleshooting is difficult, comparison with the
normal data that have been saved or filed can allow the specific engine failure to be determined.

* Set up the SDS tool. ( W 4 - 2 4 )

@ 09904-41010: SDS set tool
99565-01010-007: CD-ROM Ver. 7
NOTE:
Before taking the sample of data, check and clear the Past DTC. p 4 - 2 5 )
' A number of different data under a fixed condition as shown below should be saved or filed as sample
+

SAMPLE:
Data sampled from cold starting through warm-up

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1 idle alr screw sccllon

Check the engine rimin.
xxxx rimin

Check the engine rtmin.

PERIODIC MAINTENANCE 2-37

Data at 3 000 rlmin under no load

absolute pressure.

Data at the time of racing
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. 4 #.# " m < , l

1-r .

Throttle:
Quick wide open
v

*.,"#,I

.,.,..,,,..

2-38 PERIODIC MAINTENANCE

Data of intake negative pressure during idling (100 "C)
I,. Y^.
1.1.

,...
1

, ,,. . , .

.,,..

, . , ~

...

---~

:I
I
d
.,.,.""
Fr.l
:!I..,
,,,."",,*,,. ,,",
Check the mantiold absolute
=

pressure.
Approx. XXX kPa ( X X X mmHg)

CONTENTS
ENGINE COMPONENTS REMOVABLE WITH ENGINE
3-2
IN PLACE
ENGINE LEFT SIDE
3-2
ENGINE RIGHT SIDE ................................................................. 3 - 2
ENGINE CENTER
3-2
ENGINE REMOVAL AND REMOUNTING
3-3
ENGINE REMOVAL
3-3
ENGINE INSTALLATION ............................................................ 3 - 8
ENGINE DISASSEMBLY
3-11
ENGINE COMPONENTS INSPECTION AND SERVICE .................... 3-24
CYLINDER HEAD
3-24
AUTOMATIC DECOMP
3-33
CAMSHAFT
3-33
CAM CHAIN TENSION ADJUSTER AND TENSIONER ............ 3-36
CYLINDER
3-36
PISTON AND PISTON RING
3-37
CONROD
3-39
CRANKSHAFT
3-40
BALANCER SHAFTAND BALANCER DRIVEN
3-41
AND DRIVE GEAR
STARTER CLUTCH
3-41
GENERATOR
3-43
STARTER TORQUE LIMITER
3-43
OIL PUMP
3-44
CLUTCH
3-45
GEARSHIFT FORK AND GEAR
3-47
TRANSMISSION
3-48
OIL STRAINER
3-51
CRANKCASE
3-51
RIGHT CRANKCASE COVER
3-56
GEARSHIFT SHAFT
3-57
ENGINE REASSEMBLY
3-58

....................................................................

......................................................................
....................................................................
..............................................................................
....................................................
...................................................................................
......................................................................................
.................................................
.........................................................................
...........................................................................
..............................................................................
....................................................
...................................................................
.....................................................................

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
The parts listed below can be removed and installed without removing the engine from the frame. Refer to
the page listed in each section for removal and installation instructions.

ENGINE LEFT SlDE
PARTS

Engine sprocket
Starter driveldriven gear
Generator rotor
Starter clutch
Gear position switch
Oil pump No.2
Balancer crank
Cam chain tensioner

REMOVAL

INSTALLATION

3-6
3-14. -15
3-21
3-21
3-1 1
3-21
3-22
3-21

3-9
3-71
3-63
3-62
3-79
3-62

REMOVAL
3-4

INSTALLATION
3-10

3-15
3-16, -17

3-70
3-68. -69

3-17
3-17
3-20
3-18
3-18
3-18
3-19
3-19
3-19
3-20

3-67
3-67
3-63
3-66, -67
3-66
3-65

REMOVAL

INSTALLATION

5-14
3-11
3-12
3-11

5-18
3-79
3-78
3-79

3-13
3-13
3-13
3-14

3-76
3-75
3-74
3-73
3-62
3-74

3-62

ENGINE RIGHT SlDE
PARTS
Exhaust pipelmuffler
Oil filter
Clutch pressure plate, drive plates, and driven plates
Clutch sleeve hub
Primary driven gear assembly
Primary drive gear
Oil pump idle gear and driven gear
Oil pump No.1
Gearshift shaft
Gearshift cam driven gear
Gearshift cam stopper plate
Gearshift cam stopper
Balancer driveldriven gear

3-65
3-64
3-64
3-63. -64

ENGINE CENTER
PARTS
Throttle body
Starter motor
Cam chain tension adjuster
Cylinder head cover
Camshaft/automatic decompression assembly
Cylinder head
Cylinder
Piston
Cam chain
Cam chain guide

3-21
3-13

ENGINE REMOVAL AND REMOUNTING
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine
using a steam cleaner. Engine removal is sequentially explained
in the following steps.
Drain engine coolant. ( W 2 - 1 5 )
Drain engine oil. (-2-1
3)
Remove the fuel tank and fuel tank lower cover. ( p 5 - 4 )
Remove the oil return tank. (-6-23)
Remove the oil tank. (-6-22)

Disconnect the engine coolant inlet hose (.4j, brather hose (51
and engine coolant outlet hose @.

1
L..

Remove the throttle body assembly. ( W 5 - 1 4 )

3.4

ENGINE

Disconnect the ECT sensor coupler

Loosen ther mufflerclamp bolt.

Remove the exhaust plpe (7,.
Remove the gasket (8).

Remove the muffler

.. ??,

"I'

pi++f
*. .
:;
Disconnect the motor lead wire.

,;
,

* Remove the starter motor lead wire
and wiring harness 03
from the clamp.
Disconnect the ground lead wire coupler @I.

1 L -\-

Remove the parking brake cable 03' from the bracket.

bd
Disconnect the generator startor coupler ii4), CKP sensor 051
and gear position switch coupler @?I.
Remove the generator lead wire and gear position switch lead
wire from the clamp.

Remove the rear brake switch O and brake pedal (lW
(W7-67)

Remove the rear brake switch wire OP from the clamp

Remove the engine sproket cover W)

Remove the gearshift lever (1D.

Remove the clutch cable bracket OD.
Remove the clutch release arm @31 along with the clutch cable.

.y.

%.z
~ A .

Remove the engine sprocket TO with drive chain.

'Li
Remove the engine mounting lower brackets.
Remove the engine mounting upper brackets.
Remove teh engine mounting bolts and nuts.

Remove the swingarm pivot shaft nut and washer.

i
'

Extract three quarters of the swlngarm p~votshaft so as to
keep the swingarm IS position.

NOTE:
The swingarm will come off when the swingarm pivot shaff is
completely removed.
Remove the engine from the right side.

- & $
f-

fl .
,

-.,

,. ,

V:,

i
I

-v

ENGINE INSTALLATION
Install the engine in the reverse order of engine removal.
Pay attention to the following points:
Tighten the swingarm pivot shaft nut to the specified torque.

NOTE:
* The engine mounting nuts are self-locking.
Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them
to the specified torque.

lnstall the engine sprocket with drive chain.
NOTE:
The letter

on the engine sprocket should face to the outside,

Apply THREAD LOCK SUPER "1303" to the sprocket bolts.
-99000-32030:

THREAD LOCK SUPER "1303"

Tighten the engine sprocket bolts to the specified torque.
Engine sprocket bolt: 10 N.rn (1.0 kgf-rn, 7.0 lb-ft)

Install the clutch release arm 11) as shown in the illustration.

lnstall the gearshift lever (2'1 in the correct position.
Gearshift lever height !R: 5

- 10 mm (0.2 - 0.4 in)

Gearshift lever bolt: 10 N.m (1.0 kgf-m, 7.0 lb-ft)
Install the brake pedal and rear brake switch. ( W 7 - 6 7 )

Footresl

3-10

ENGINE

Install the muffler (3;~and exhaust pipe (41.

WJ
Use new gaskets to prevent exhaust gas leakage.
Muffler rnountlng bolt: 23 N.rn (2.3 kgf-rn. 16.5 lb-ft)
Exhaust pipe bolt: 23 N.rn (2.3 kgf-rn, 16.5 lb-ft)
Muffler connecting bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)

, ,

'3,

~.1
I

Install the throttle body assembly. ( W 5 - 1 8 )
Install the oil tank. (-6-23)
Install the oil return tank. (C76-23)
Install the fuel tank. ( W 5 - 4 )
After installing the engine, route the wiring harness, cables
and hoses properly. (179-15)
Adjust the following items.

' Engine oil W 2 - 1 3
Engine coolant W 2 - 1 5
' Throttle cable play W 2 - 1 1
Engine idle speed W 2 - 1 2
Clutch cable play W 2 - 1 8
' Drive chain slack -2-26
Brake pedal height CZ72-19
" Rear brake switch W 2 - 1 9

ENGINE DISASSEMBLY
STARTER MOTOR
Remove the starter motor O.

/
A

GEAR POSITION SWITCH
Remove the gear position switch (Ti.
Remove the O-ring (2'1, switch contacts

t5 and springs i l l .

Remove the spark plug.
09930-10121: Spark plug wrench set

CYLINDER HEAD COVER
Remove the cylinder head cover bolts, and then remove the
cyl~nderhead cover Ci).

CAMSHAFT
Remove the valve tlming lnspectlon plug ' 1 1 and generator
cover cap (2).

Turn the generator rotor until the '7" line on the generator
rotor is aligned with the center of the hole in the generator
cover.

NOTE:
Before removing the camshaft journal holders, the piston must
be at TDC of the compression stroke.

Remove the spring holder bolt 6)of the can chain tension
adjuster with spring (4).

Remove the cam chain tension adjuster 151and gasket (6).

Remove camshaft journal holders (7).

NOTE:
Loosen the camshaftjournal holder bolts diagonally.

Remove the dowel pins, ~ntakecamshaft (81,exhaust camshaft (91 and C-rings 007.

ION]
Do not drop the dowel pins, cam chain and C-rings
into the crankcase.

CYLINDER HEAD
Remove the cylinder head bolts (I).
Loosen the cylinder hase bolt 12,.

Remove the four cylinder head bolts in diagonal stages, and
then remove the cylinder head.
NOTE:
If the cylinder head does not come off easily, lightly tap it using a
plastic mallet.

CYLINDER
Remove the cylinder head gasket O and dowel pins.

Remove the cam chain guide (2).
Remove the cylinder base bolt, and then remove the cylinder.

NOTE:
If the cylinder does not come off easily, lightly tap it using a plas.
tic mallet.

Remove the cylinder gasket ( 3 1 and dowel pins.
1

.PISTON
Place a clean rag over the cylinder base to prevent the piston
pin circlip from dropping into the crankcase.
Remove the piston pin circlip.

~~p

_
I
.
-

.\
i- ,.

Draw out the piston pin (0and remove the piston (2).

..*

GENERATORROTORCOVER
Remove the starter torque l~miterassembly cover (1).

Remove the collars (21, washers (3) and starter torque limiter
assembly (4).

.-~
.

Remove the generator rotor cover

Remove the shaft 0,
starter idle gear (9, gasket (61 and dowel
pins.

Remove the oil filter QJ and O-ring (3

CLUTCH COVER
Remove the clutch cover K
l.

,-. .! -0
L-- .*-. .<
fl

d&.#,.b

OIL FILTER
Remove the oil filter cap 0.

.-.

Remove the gasket i21.

RIGHT CRANKCASE COVER
Remove the right crankcase cover l i r .

Remove the gasket (2>, dowel pins and oil seal :TI.

NOTE:
If there is no wear or damage at oil seal lip, the oil seal (3)
removal is not necessary.
0

CLUTCH
Hold the generator rotor using the special tool.
Loosen the clutch spring set bolts working in diagonal stages.
Remove the bolts and springs.

09930-44520: Rotor holder

:' 0

"-1 I.
, ,

.
,,.'.
,

;

.;u
-.

Remove the clutch pressure plate O.

Remove the drive plates @! and driven plates i 3 l .
Remove the spring washer and spring washer seat.

- - _--

? ,,
/

~,,

/El

.' b

'
,

4
Ql

Y',
*, .

.
,-. .
I,.

*.;
.- ,,

2ii&

2 + \

- .

Remove the push piece (41 and push rod (5'
Flatten the lock washer '6).

Hold the clutch sleeve hub using the special tool, and then
remove the clutch sleeve hub nut.

09920-53740: Clutch sleeve hub holder

Cd -

@
J/

=c
T

Remove the washer (8) and primary driven gear assembly 9.

.*
. 1

. #f

Remove the lock washer @) and clutch sleeve hub 0.

,-+at

-.@

7%
T/

,-* :
:

-3

Remove the spacer 5101.

OIL PUMP (No.1)
Remove the oil pump idle gear (ii and oil pump driven gear

iz?.
09900-06107: Snap ring pllers

*.
r

.. . . .

Remove the pin (3,washer (a and oil pump assembly (51.

'-7

Remove the following parts from the oil pump assembly.
Outer rotor (61
Inner rotor (3
Pin Cs?
Oil pump body @)
Oil pump shaft (i@!

GEARSHIFT SHAFT
Remove the gearshift shaft

I-

09900-06107: Snap ring pliers

--fl

y.
.\.!'

.
c

by removing the snap ring @I.

.&'

Q-,

;

!'I

Remove the gearshift pawl lifter (3'1 and gearshift cam driven
gear (.K).
NOTE:
Be careful not to drop the pins and springs when removing the
gearshift cam driven gear.

x
1.
{1

Remove the gearshift pawls iR,pins ( 6 and springs !TI

Remove the spring OD.
Remove the gearshift cam stopper bolt (10, gearshift cam
stopper (12and washer I@.

--.~.

Remove the gearshift cam driven gear pin (8'1 and gearshift
cam stopper plate 9).

1
?p
'

GENERATOR ROTOR
Hold the generator rotor using the special tool, and then
remove the balancer driven gear nut.

09930-44520: Rotor holder

%'K/\.!..

k
.
'
,

4 ,I
,C-

ENGINE

3-20

Remove the washer (Ibalancer
!,
driven gear (2).
Remove the pin 15).

Hold the generator rotor using the special tool, and then
remove the primary drive gear nut.

;

,c*"T,
ooNli
,-

The primary drive gear nut has left-hand threads.

@ 09930-44520: Rotor holder

Remove the washer

,--

'a and primary drive gear (51.

1
C

1
LI

Remove the key (6) and balancer dr~vegear fli.

77,

-L

\-,

Hold the generator rotor using the special tool, and then
remove the generator rotor nut.
09930-44520: Rotor holder

Remove the generator rotor using the special tool.
09930-31921: Rotor remover
NOTE:
Temporarily install the generator rotor nut to the crankshaft, and
then remove the generator rotor using the special tool.

p5iiuzm
Do not hit the generator rotor wlth a hammer, otherwise
the rotor may be damaged.
Remove the generator rotor key Bl.
Remove the starter driven gear (9).

CAM CHAIN
Remove the cam cha~ntensioner (72, washer 12)and cam
cha~n13J.

OIL PUMP (No.2)
Remove the oil pump assembly (1)

Remove the pin 0,
inner rotor (3 and outer rotor (a).

-5C

BALANCERCRANK
Remove the balancer crank ~ i i

CRANKCASE
Remove the retainer (ii.
Remove the spacer (2).
Remove the gearshift fork shaft retainer 3.

F5EW1
at this point
Do not pull out the gearshift fork shafl
because the gearshift fork comes off in the crankcase.

Remove the left crankcase bolts and engine oil drain plugs 6).
-

-0,
:.~,
.

a **a' 0
6.@
"

-0

a
0.

Separate the crankcase using the special tool

09920-13120: Crankcase separating tool

NOTE:
Fit the crankcase separating tool to the right crankcase, so that
the tool plate is paralleled with the end face of the crankcase.

ti9
.;
.-;~
,
'0

. /
(51~
. .0s
Remove the right crankcase bolts

c 9

Remove the dowel pins.
Remove the oil strainers 14;.

Remove the gearshift fork shafts (5,gearshift forks
and
gearshift cam 171.
Remove the countershaft assembly I R ' j and driveshaft assembly (9).
'

(7)

Remove the crankshaft from the crankcase using the special
tool

09920-13120: Crankcase separatlng tool

3-24

ENGINE

ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD
DISASSEMBLY

ICAUTION1
the parts In their respective groups (i.e., exhaust or
intake) so that they can be installed in their original

Remove the intake pipe (1;).

Remove the ETC sensor from the cylinder head.

-a

,
,:.r

.. ..

,,,

---

3
--<

I,.

Remove the thermostat cover

2 1

and thermostat i3i.

Remove the tappets
hand.

and shims

i51 by fingers or magnetic
1

WoN_I

,/ .

Identify the position of each removed part.

;,-.-

r
'.-A

ja :4 ,.

'-9

-.;:'

. -L

Using the special tools, compress the valve spring and
remove the two cotter halves (6, from the valve stem.

* - - 3 - '~(6,

& 09916-14510: Valve lifter
09916-14521: Valve lifter attachment (Exhaust side)
09916-14910: Valve llfter attachment (Intake side)
09916-8451 1: Tweezers

TIO ON]
Be careful not to damage the tappet slidlng surface
with the sDeclal tool.

Remove the valve spring retalner i f ) and valve spring tW

Pull out the valve

from the combustin chamber side.

--4

s f ,-.\
-

3-26

ENGINE

Remove the oil seal 11Ql and sprlng seat

in).
6
,
.

Do not reuse the removed oil seal.
Remove the other valves in the same manner as described
previously.

CYLINDER HEAD DISTORTION
Decarbonize the combustion chambers.
Check the gasket surface of the cylinder head for distortion with
a straightedge and thickness gauge, taking a clearance reading
at several places indicated. If the largest reading at any position
of the straightedge exceeds the limit, replace the cylinder head.
Cylinder head distortion:
Service Limit: 0.05 mm (0.002 in)
09900-20803: Thickness gauge
VALVE STEM RUNOUT
Support the valve using V-blocks and check its runout using the
dial gauge as shown. If the runout exceeds the service limit,
replace the valve.
Valve stem runout:
Servlce Llmit: 0.05 mm (0.002 in)
09900-20607: Dlal gauge (11100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)

BAUTION]
-~

Be careful not to damage the valve and valve stem
when handllng It.
VALVE HEAD RADIAL RUNOUT
Place the dial gauge at a right angle to the valve head face and
measure the valve head radial runout. If it measures more than
the service limit, replace the valve.
Valve head radial runout:
Service Limit: 0.03 mm (0.001 in)

@ 09900-20607: Dial gauge (11100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)

~CAUT~ON
Be careful not t o damage the valve and valve stem
when handling It.

.'n
,,

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h

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I,.
;.
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,

ENGINE 3-27

VALVE STEM AND VALVE FACE WEAR CONDITION
Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one.

VALVE STEM DEFLECTION
Lift the valve about l o mm (0.39 in) from the valve seat.
Measure the valve stem deflection in two directions, perpendicular to each other, by positioning the dial gauge as shown.
If the deflection measured exceeds the limit, then determine
whether the valve or the guide should be replaced with a new
one.
Valve stem deflection (IN & EX):
Servlce Limit: 0.25 mm (0.010 in)
09900-20607: Dial gauge (11100 mm)
09900-20701: Magnetic stand
VALVE STEM WEAR
If the valve stem is worn down to the limit, as measured with a
micrometer, replace the valve.
If the stem is within the limit, then replace the guide.
Afler replacing valve or guide, be sure to recheck the deflection.
Valve stem O.D.:
Standard (IN) : 5.475
(EX): 5.455

- 5.490 mm (0.2156 - 0.2161 in)
- 5.470 mm (0.2148 - 0.2154 in)

09900-20205: Micrometer (0

- 25 mm)

NOTE:
If valve guides have to be removed for replacement after
inspecting related parts, carry out the steps shown in valve
guide servicing. (C73-28)

ENGINE

3-28

VALVE GUIDE SERVICING
Using the valve guide remover, drive the valve guide out
toward the intake or exhaust camshaft side.

09916-44910: Valve guide removerlinstaller

NOTE:
Discard the removed valve guide subassemblies.
Only oversized valve guides are available as replacement
parts. (Part No. 1 1115-45670)

Re-finish the valve guide holes in cylinder head with the
reamer and handle.
09916-34580: Valve guide reamer (10.8 mm)
09916-34542: Reamer handle

I ~ f i
When rellnishing or removing the reamer from the
valve guide hole, always turn it clockwise.

Cool down the new valve guides in a freezer for about one
hour and heat the cylinder head to 100 150 "C (212 - 302
"F) with a hot plate.

LCAUION]

Do not use a burner t o heat the valve guide hole to
prevent cylinder head distortion.
Apply engine oil to the valve guide hole.
Drive the valve guide into the hole using the valve guide
installer ii!and attachment (2.
09916-44310: Valve guide removerlinstaller 'i:)
09916-53360: Attachment (2'

NOTE:
Install the valve guide until the attachment contacts with the cylinder head (3).

Failure t o oil the valve gulde hole before driving the
new guide into place may result in a damaged guide or
head.

12.2rnrn

ENGINE 3-29

After installing the valve guides, re-finish their guiding bores
using the reamer.
Clean and engine oil the guides after reaming.
09916-34550: Valve guide reamer (5.5 mm)
09916-34542: Reamer handle

NOTE:
Be sure to cool down the cylinder head to ambient air temperature.
' Insert the reamer from the combustion chamber and always
turn the reamer handle clockwise.
VALVE SEAT WIDTH INSPECTION
Visually check for valve seat width on each valve face.
If the valve face has worn abnormally, replace the valve.
Coat the valve seat with a red lead (Prussian Blue) and Set
the valve in place. Rotate the valve with light pressure.
Check that the transferred red lead (blue) on the valve face is
uniform all around and in center of the valve face.
09916-10911: Valve lapper set

If the seat width '@hmeasured exceeds the standard value or
seat w~dthIS not uniform, refuse the seat using the seat cutter.

Valve seat width (WI:
Standard: 0.9 - 1.1 mm (0.035

- 0.043 in)

If the valve seat is out of specification, correct the seat by servicing it as follows:

VALVE SEAT SERVICING
The valve seats ( 1 1 for both the intake valve 121 and exhaust
valve 0)are machined to three different angles. The seat contact surface is cut at 45'.

seat angle
seat width
valve diameter
valve guide I.D.

INTAKE
30", 45", 6 0
0.9 1.1 mm
(0.035 - 0.043 in)
36 m m (1.42 in)

EXHAUST
15". 45", 60"
0.9 - 1.1 mm
(0.035 - 0.043 in)
29 mm (1.14 in)

5.500 5.512 mm
5.500 - 5.512 mm
(0.2165 - 0.2170 in) (0.2165 0.2170 in)

The valve seat contact area must be inspected after
each cut.

Do not use lapping compound after the final cut i s
made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few
seconds of engine operation.

The titanium valves are coated with an oxidized rnernbrane treatment t o resist wear but the membrane tend
t o be removed if lapped after valve seat servicing.
NOTE:
After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. ( D 2 - 5 )
Clean and assemble the head and valve components. Fill the
intake and exhaust ports with gasoline to check for leaks.
If any leaks occur, inspect the valve seat and face for burrs or
other things that could prevent the valve from sealing.

Always use extreme caution when handling gasoline.

"-mL,2
.J

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f
\

VALVE SPRING
The force of the coil spring keeps the valve seat tight. Weakened spring results in reduced engine power output, and often
accounts for the chattering noise coming from the valve mechanism.
Check the valve spring for proper strength by measuring its free
length and also by the force required to compress it.
If the spring length is less than the service limit, or if the force
required to compress the spring does not fall within the range
specified, replace the spring.
Valve sprlng free length:
Servlce Ilmlt: (IN.) 34.0 mm (1.34 in)
(EX.) 33.3 mm (1.31 in)
09900-20102: Vernier calipers
Valve spring tension:
Standard:
(IN.) Approx. 119 - 137 N, 11.9 13.7 kgf130.9 mm
(26.2 30.21bsl1.22in)
(EX.) Approx. 78.5 N, 7.85 kgf130.9 rnm
(17.3 lbs/ 1.22in)

REASSEMBLY
Install the valve spring seat.
Apply MOLYBDENUM OIL SOLUTION to the oil seal i )and
,
press-fit it into position.
MOLYBDENUM OIL SOLUTION

rCAUTION]
-

Do not reuse the removed oil seal.

Insert the valve, with its stem coated with MOLYBDENUM
OIL SOLUTION all around and along the full stem length without any break.

When inserting the valve, take care not to damage the
lip of the oil seal.

MOLYBDENUM OIL SOLUTION

lN.Approx 119- 137 N (11.9- 13.7 kgl)
EX. Approx 78.5 N (7.85 kgf)

I
IN. 30.9 rnm (1.22 in)
EX. 30.9 mm (1.22 in)

I
I

Install the valve spring with the small-pitch portion (AI facing
cylinder head.

iB1 Large-pitch portion
~1

UPWARD
Paint

Put on the valve spring retainer 'a, and using the valve lifter,
press down the spring, fit the valve cotter halves to the stem
end, and release the lifter to allow the valve cotter (31 to
wedge in between retainer and stem.

09916-14510: Valve lifter
09916-14521: Valve lifter attachment (Exhaust slde)
09916-14910: Valve lifter attachment (Intake side)
09916-8451 1: Tweezers

Be sure that the rounded lip E: of the cotter fits snugly into the
groove if) in the stem end.
Install the other valves and springs in the same manner as
described previously.

Be sure t o restore each spring and valve to their
original positions.
Be careful not t o damage the valve and valve stem
when handling it.
( 2 ) Valve spring retainer
(3) Valve cotter

Install the tappet shims and the tappets to their original positions.

NOTE:
Apply engine oil to the stem end, shim and tappet before fitting
them.
When seating the tappet shim, be sure the figure printed surface faces the tappet.

L
a*-P'
+' ,.--T
,.
-. .

,3
'h_

.
6

A
-'

.. .
.*

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,
..

, A T4
.

Install the ETC sensor. ( p 6 - 1 1 )
Apply SUZUKl SUPER GREASE to the O-ring.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

purj

The removed O-ring must be replaced with a new one.

. --

/y==yq
.
..

+a.S m
..

-~- d-q;:-& .

Apply THREAD LOCK SUPER "1303" to the intake pipe bolts.
Install the intake pipe.

NOTE:
Make sure that the "up mark"(A1 comes to the upper side.

=).j

$
..* ~ *-~. P bs -3
~

99000-32030: THREAD LOCK SUPER "1303"

- !n
A

;:,

,
,1 ,

AUTOMATIC DECOMP.
Check the decomp. cam moves smoothly and shaft (D rotates
together. If any abnormal condition are found, replace the camshaft assembly.

CAMSHAFT

~FAUTIONJ
-.
Do not attempt t o disassemble the camshatUautomatic decomp. assembly. It i s not sewiceable.

CAM SPROCKET
Inspect the sprocket teeth for wear. If they are worn, replace the
camshafts, crankshaft and cam chain as a set.

m-a
=,>**.
-$-, -I+--

3.34

ENGINE

CAMSHAFT BEARING
Inspect the bearings for play, discoloration, wear and seizure.
Move the outer race by finger and inspect for smooth movemerit. If there is anything unusual, replace the camshaft assembly.

-'+---

I , .i , ,
---T-.''

rrJ

---

.=-,

CAM WEAR
Check the camshaft for wear or damage.
Measure the cam height HI with a m~crometer.
Cam height $31
Service Limlt (IN.) 32.264 rnrn (1.2702 In)
(EX.) 33.151 mm (1.3052 in)
09900-20202: Micrometer (25 - 50 mm)

CAMSHAFT JOURNAL WEAR
Determine whether or not each journal is worn down to the
limit by measuring the oil clearance with the camshaft
installed in place.
Use the plastigauge to read the clearance at the widest portion, which is specified as follows:
09900-22301: Plastlgauge
09900-22302: Plastigauge

NOTE:
InstaN the camshaftjournal holders to their original positions.

a-. - a

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3m

', f

- "s$'-'1pm
,.*

Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.

Camshaft journal holder bolt: 10 N.m (1.0 kgf-rn, 7.0 lb-ft)

... ;:'*I
,

NOTE:
Do not rotate the camshan with the plastigauge in place.

Remove the camshaft journal holders, and read the width of
the compressed plastigauge with envelope scale. This measurement should be taken at the widest part.
Camshaft journal oll clearance:
Service Limit (IN. & EX.): 0.150 rnm (0.006 in)

r- ?

, <

)

ENGINE 3-35

If the camshaft journal oil clearance measured exceeds the
limit, measure the inside diameter of the camshaft journal
holder and outside diameter of the camshaft journal.
Replace the camshaft or the cylinder head depending upon
which one exceeds the specification.
Camshaft lournal holder 1.0.:
Standard: (IN & EX): 22.012 - 22.025 mm
(0.8667 0.8671 In)

09900-20602: Dlal gauge (111000,l mm)
09900-22403: Small bore gauge (18 35 mm)

Camshaft JournalO.D.:
Standard (IN & EX): 21.959
(0.8645

- 21.980 mm
- 0.8653 in)

@ 09900-20205: Micrometer (0 - 25 mm)

r
l
I
W
I

3-36

ENGINE

CAM CHAIN TENSION ADJUSTER AND
TENSIONER

-d/

Check that the push rod sl~dessmoothly when unlock~ngthe
ratchet mechan~sm' 1 r.
If push rod does not sl~desmoothly, replace the cam cha~ntenslon adjuster w~tha new one

%
' %,

I11

Remove the cam chain gu~de121 from cylinder head cover.

Check the contacting surface of the cam chain tensioner and
cam chain guides.
If any defects are found, replace it with a new one.

CYLINDER
CYLINDER DISTORTION
Check the gasket surface of the cylinder for distortion with a
straightedge and thickness gauge, taking a clearance reading at
several places indicated.
If the largest reading at any position of the straightedge exceeds
the limit, replace the cylinder head.
Cylinder distortion:
Service Limit: 0.05 mm (0.002 In)
09900-20803: Thickness gauge

F
+
‘
,

1,.
,~

ENGINE

CYLINDER BORE
Inspect the cylinder wall for any scratches, nicks or other damage. Measure the cylinder bore diameter at six places.
If any one of the measurements exceed the limit, replace the cylinder.
Cylinder bore
Standard: 95.500

- 95.515 m m (3.7598 - 3.7604 in)

rn09900-20530: Cylinder gauge set
09900-20513: Rod (94 mm)

PISTON AND PISTON RING
PISTON DIAMETER
Using a micrometer, measure the piston outside diameter at 10
mm (0.4 in) (A) from the piston skirt end.
If the measurement is less than the limit, replace the piston.
Piston diameter:
Servlce Limit: 95.380 mm (3.7551 in)
at 15 mm (0.6 in) from the skirt end

rn09900-20204: Micrometer (75 - 100 mm)

PISTON-TO-CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter.
(Wabove)
If the piston-to-cylinder clearance exceeds the service limit.
replace the cylinder or the piston, or both.
Plston-to-cyllnder clearance:
Service Limit: 0.120 mm (0.0047 In)

=-1

3-37

PISTON PIN AND PIN BORE
Measure the piston pin bore diameter using the small bore
gauge. If the measurement is out of specifications replace the
piston.
Piston pin bore I.D.:
Servlce Limit: 19.030 mm (0.7492 in)
09900-20602: Dial gauge (111000 mm)
09900-22403: Small bore gauge (18 - 35 n'tm)
Measure the piston pin outside diameter at three positions using
the micrometer. If any of the measurements are out of specification, replace the piston pin.

Piston pin O.D.:
Servlce Limit: 18.980 mm (0.7472 in)

09900-20205: Micrometer (0 - 25 mm)

PISTON-RING-TO-GROOVE CLEARANCE
Measure the side clearances of the 1st and 2nd piston rings
using the thickness gauge. If any of the clearances exceeds the
limit, replace both the piston and piston rings.
09900-20803: Thickness gauge
09900-20205: Micrometer (0 25 mm)

Piston.ring-to-groove clearance
Service Limit:
1st: 0.180 mm (0.007 in)
2nd: 0.150 mm (0.006 in)
Piston ring groove width
Standard:
1st: 0.78 0.80 mm (0.0307 - 0.031 5 in)
1.30 1.32 mm (0.051 2 0.0520 in)
2nd: 0.81 - 0.83 mm (0.0319 0.0327 in)
Oil: 2.01 2.03 mm (0.0791 - 0.0799 In)

r r.

ENGINE 3.39

Piston rlng thickness
Standard:
1st: 0.71 0.76 mm (0.0280 0.0299 in)
1.00- 1.10 mm (0.0425-0.0433 in)
2nd: 0.77 0.79 mm (0.0303 - 0.0311 in)

PISTON RING END GAP

Fit the piston ring squarely into the cylinder and measure the
piston ring end gap using the thickness gauge.
If any of the measurements exceeds the service limit, replace
the piston ring with a new one.
Piston rlng end gap:
Service Llmit:
1st: 0.50 mm (0.020 in)
2nd: 0.50 m m (0.020 in)

@ 09900-20803: Thlckness gauge

CONROD
CONROD SMALL END I.D.
Using a small bore gauge, measure the inside diameter of the
conrod small end. If the inside diameter of the conrod small end
exceeds the limit, replace the conrod.
Conrod small end I.D.:
Servlce Limit: 19.040 mm ( 0.7496 In)
09900-20602: Dial gauge (111 000 mm, 1 mm)
09900-22403: Small bore gauge (18 35 mm)

3-40

ENGINE

CONROD DEFLECTION AND BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be estimated by checking
the movement of the small end of the rod. This method can also
be used to check the extent of wear on the parts of the conrod
big end.
Conrod deflection
Service Limit: 3.0 mm (0.12 In)

09900-20701: Magnetic stand
09900-20607: Dial gauge (11100 mm)
09900-21304: V-block set (100 mm)
Push the big end of the conrod to one side and measure the
side clearance using a thickness gauge. If the clearance
exceeds the service limit, replace the crankshaft assembly with
a new one or bring the deflection and the side clearance within
the service limit by replacing the worn parts (conrod, big end
bearing, crank pin, etc.) with new ones.
Conrod big end side clearance
Service Limlt: 1.0 rnm (0.04 in)

@ 09900-20803: Thickness gauge
CRANKSHAFT
CRANKSHAFT RUNOUT
Support the crankshaft using V-blocks and measure the crankshaft runout using the dial gauge, as shown. If the runout
exceeds the service limit, replace the crankshaft with a new one.
NOTE:
' Place the crankshaft onto the V-blocks so that it becomes horizontally.
Measure the runout from the tips of the crankshaft.
Crankshaft runout
Service Llmit: 0.080 mm (0.003 in)

09900-20607: Dial gauge (11100 mm)
09900-20701: Magnetic stand
09910-21304: V-block set (100 mm)

''.
''

3.42

ENGINE

Tighten the bolts while holding the rotor using the special tool.
Starter clutch bolt: 10 N.m (1.0 kgf-m, 7.0 lb-ft)

@
\2

09930-44520: Rotor holder

~~.
I

STARTER DRIVEN GEAR BEARING INSPECTION
Inspect the starter driven gear bearing for any damages.

STARTER DRIVEN GEAR BEARING REPLACEMENT
Remove the bearing using the special tool.
09913-70210: Bearing Installer set

Install the bearing using the special tool.

@ 09913-70210: Bearing Installer set

~
m
.-

CAUTION]
L~
1
The removed bearing must be replaced with a new
one.
I

NOTE:
The stamped mark on Me bearing must face crankcase side.

,:\/ . . ....

ENGINE 3.43

9\qg1.aa,,.~..
r

GENERATOR

----rr.

@is*.
d'
02

INSPECTION ( W E - 9 ,-21)
Remove the generator stator O, CKP sensor Ti), bracket bl
and grommet i4i.

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4 C-"i

lb.::d

51,~
i<
63,.0:e
-

When replacing the generator stator or CKP sensor, route the
wire properly.

3h?+?.
. ( 1 ' ' -- L
'1

Apply a small quantity of THREAD LOCK SUPER "1303 to
the generator stator mounting bolts, and tighten them
securely.

a99000-32030:THREAD LOCK SUPER "1303

STARTER TORQUE LIMITER

~C~UTION

Do not attempt to disassemble the starter torque limiter. It Is unserviceable.
Check the slip torque of the starter torque limiter using the special tools and vise as shown, if the slip torque is not within the
specified torque, replace the starter torque limiter with a new
one.

09930-73170:Starter torque limiter holder
09930-73120: Starter torque limiter socket
Slip torque:

20.5-36.0 N.m (2.05-3.6 kgf-m, 14.6 -26.0 lb-ft)

.-.-I

-4

.'
A

3-44

ENGINE

OIL PUMP
INSPECTION
Inspect the outer rotor (1) and inner rotor Bl for any scratches or
other damage. If any damages are found, replace them with new
ones.

,.'
j

) r/;

Rotate the oil pump by hand and check that it moves smoothly
If it does not move smoothly, replace the 011pump assembly.

1Do not attempt to disassemble the oll pump assembly.
The oll pump Is avallable only as an assembly.

a
/"

ENGINE 3-45

CLUTCH
CLUTCH DRIVE PLATE

NOTE:
Wipe off engine oil from the clutch drive plates with a clean rag,
Measure the thickness of drive plates using the vernier calipers.
If the drive plate thickness is found to have reached the limit.
replace it with a new one.
Drive plate thickness (No.1 & No.2):
Service Limit: 2.77 mm (0.109 in)

@ 09900-20101: Vernier calipers
Measure the claw width of drive plates using the vernier calipers. Replace the drive plates found to have worn down to the
limit.
Drive plate claw width (No.1 & No.2):
Service Llmit: 13.35 mm (0.528 in)

@ 09900-20101: Vernler callpers

CLUTCH DRIVEN PLATE

NOTE:
Wipe off engine oil from the clutch driven plates with a clean rag.
Measure each driven plate for distortion with a thickness gauge
and surface plate. Replace driven plates which exceed the limit.
Drlven plate distortion:
Service Limit: 0.10 mrn (0.004 in)
09900-20803: Thickness gauge
CLUTCH SPRING
Measure the tree length of each coil spring with a vernier calipers, and compare the length with the specified limit.
Replace all the springs if any spring is not within the limit.
Clutch spring free length:
Service Limit: 50.4 mm (1.98 in)
09900-20101: Vernler calipers

PUSH ROD
lnspect the push rod for wear and damage.
If any defects are found, replace the push rod with a new one.

,
.

RELEASE BEARING
lnspect the release bearing for play, wear and damage.
Move the inner race by finger and inspect for smooth movement.
If any defects are found, replace the release bearing with a new
one.

RELEASE BEARING REPLACEMENT
Remove the release bearing using the special tool.
09913-70210: Bearing installer set

Press the bearings using the special tool,

09913-70210: Bearing installer set

CLUTCH SLEEVE HUBlPRlMARY DRIVEN GEAR ASSEMBLY
Inspect the slot of the clutch sleeve hub and primary driven gear
assembly for damage or wear caused by the clutch plates. If
necessary, replace it with a new one.

.
. .

- '

,
.
I

ENGINE 347

GEARSHIFT FORK AND GEAR
GEARSHIFT FORK-TO-GROOVE CLEARANCE
Using a thickness gauge, check the gearshift fork clearance in
the groove of its gear.
The clearance tor each gearshift fork plays an important role in
the smoothness and positiveness of the shifting action.
Shift fork-to-groove clearance:
Service Limit: 0.5 mm (0.020 In)
09900-20101: Vernier calipers
09900-20803: Thickness gauge

If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.
GEARSHIFT FORK GROOVE WIDTH
Measure the gearshift fork groove width using the vernier calipers.
Shift fork groove width:
Standard: 4.8 - 4.9 mm (0.189

- 0.193 In)

09900-20101: Vernier calipers

GEARSHIFT FORK THICKNESS
Measure the gearshift fork thickness using the vernier calipers.

Shift fork thlckness:
Standard: 4.6 4.7 mm (0.181

- 0.185 in)

09900-20101: Vernier calipers

GEARSHIFT CAM
Inspect the gearshift cam groove for abnormal wear and damage. If any defects are found, replace the gearshift cam with a
new one.

3-40

ENGINE

TRANSMISSION
DlSASSEMBLY
Disassemble the transmission gears as shown in the illustration

(5 Countershaft

(51 2nd drive gear

i 9 i 3rd driven gear

121 5th drive gear

( 6 ) Driveshaft

(lor 5th driven gear

13i 3rd drive gear

17, 2nd driven gear

(4) 4th drive gear

181

4th driven gear

1st driven gear

ENGINE 3-49

REASSEMBLY
Reassemble the countershaft and driveshaft in the reverse order
of disassembly. Pay attention to the following points:

NOTE:
Before installing the gears, apply engine oil to the inner surface
of each gear and bushing.
'Apply molybdenum oil solution to the surface of countershaft
and inner surface of 5th drive gear li).
MOLYBDENUM OIL SOLUTION

* Never reuse a snap ring. After a snap ring has been
removed from a shaft, it should be discarded and a
new snap ring must be installed.
'When installlng a new snap ring, do not expand the
end gap larger than required t o sllp the snap ring
over the shaft.
' After Installing a new snap ring, make sure that It Is
completely seated in its groove and securely fitted.
NOTE:
When reassembling the transmisslon, attention must be given to
the locations and positions of the washers and snap rings. The
cross sectional view shows the correct position of the gears.
bushings, washers, and snap rings. (CSP3-50)
When installing a new snap ring, pay attention to the direction.
Fit it to the side where the thrust is as shown in the illustration.

~ AThrust
I
16)Sharp edge

When installing the 3rd driven gear bushing Ci), align the its oil
hole with the driveshaft oil hole.

-El'

3.50

ENGINE

1 7 Countershalt

If21

I Driveshaft

ENGINE 3-51

OIL STRAINER
Clean the oil strainers using the compressed air.

,P1 * Z ! i

CRANKCASE

, 37,

GEARSHIFT ARM STOPPER
Remove the gearshift arm stopper Cii and washer C21.
Apply a small quantity of THREAD LOCK SUPER "1303 to
the gearshift arm stopper.
Install the washer
and tightening the gearshift a n stopper
fl) to the specified torque.

-99000-32030:

THREAD LOCK SUPER "1303"

Gearshift arm stopper: 32 N.m (3.2 kgf-m, 23.0 lb-ft)

0 .

OIL SEAL INSPECTION
Inspect the oil seal lips for wear or damage. If any defects are
found, replace the oil seal with new ones.

OIL SEAL REMOVAL
Remove the crankcase plate tD.

Remove the oil seals (21

3-52

ENGINE

OIL SEAL INSTALLATION
Install the oil seals (1) using the special tool.

The removed 011 seals must be replaced with new
ones.

09913-70210: Bearing installer set

.
.

Apply SUZUKI SUPER GREASE " A to the lip of the oil seals.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)
Install the crankcase date.

BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for abnormal
play, noise and smooth rotation while the bearings are in the
crankcase.
Replace the bearing in the following procedure if there is anything unusual.

BEARING REMOVAL
Remove the oil seals. ( V 3 - 5 1 )
Remove the bearing retainers.

Q)
.

Remove the bearings using the special tool.
09913-70210: Bearing installer set
Bearing m: r:, 22 Attachment
Bearing (3J: I!, 25 Attachment
Bearlng (6), C8): 4 30 Attachment
Bearing t i ) , (3,(i):r,'j 35 Attachment
Bearing (2': 0 42 Attachment

Remove the bearings using the special tool.
09921-20240: Bearing remover set
Bearlng 19'1: Remover 17 mm
Bearing (10): Remover 25 mm

Remove the bearing (Ti).
09921-20210: Bearing remover
09930-301 04: Sliding shaft

INSTALLATION
Press the bearings using the special tool
Bearing (n): (b 20 Attachment
(%!: cli 32 Attachment
Bearing (3
Bearing @I: ri, 40 Attachment
Bearing 16), (61: ($ 42 Attachment
Bearing
$1 52 Attachment
Bearing (1): (/, 62 Attachment
(5): 4 72 Attachment
Bearing

09913-70210: Bearing Installer set

The removed bearlngs must be replaced with new
ones.

NOTE:
The stamped mark side of the bearing faces fl) outside.
The stampedmark side of the bearing faces ((2). (3). ($1, 6).
6).
m. (6). @) inside.
The sealed side of the bearing faces (Q), (9J) outside.

Apply a small quantity of THREAD LOCK SUPER "1303" to
the bearing retainer screws, and tighten them securely.
a 9 9 0 0 0 - 3 2 0 3 0 : THREAD LOCK SUPER "1303"

ENGINE 3-55

CLUTCH RELEASE CAMSHAFT INSPECTION
Rotate the clutch release camshaft by finger to inspect for
abnormal noise or smooth movement.
If any defects are found, replace the clutch release camshaft or
bearings with new ones.

CLUTCH RELEASE CAMSHAFT AND BEARING
REPLACEMENT
Remove the 011seal retainer 1).

Remove the following parts.
Oil seal
(2) Washer
138 Upper bearing
(4;Clutch release camshaft
(1

Remove the lower bearing (3).

3.56

ENGINE

Apply engine oil to the bearings.
Apply grease to the oil seal lip.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)
Install the clutch release camshaft correctly.

I CAUTION I
I

The removed bearings and oil seal must be replaced
with new ones.

NOTE:
The stamped mark side of the bearing faces upside

RIGHT CRANKCASE COVER
WATER PUMP

W6-16
OIL SEAL INSPECTION
Inspect the oil seal lip for wear or damage.
If any defects are found, replace the oil seal with a new one.

OIL SEAL REPLACEMENT
Remove the retainer (1 1.
Remove the oil seal using the special tool.
09913-501 21 : 011 seal remover

Install the oil seal using the special tool.
09913-70210: Bearing Installer set

~ C A U- ~ N

The removed oil seal must be replaced with a new one.
Apply grease to the oil seal lip.
99000-25010: SUZUKI SUPER GREASE "A"
(or equivalent grease)

@
\J

96' /3
7

ENGINE 3-57

GEARSHIFT SHAFT
DISASSEMBLY
Remove the following parts from the gearshift shaft 1 1I.
121 Sh~m
131 Snap ring
141 Return spring

09900-06107: Snap ring pliers

INSPECTION
Inspect the gearshift shaft for bend or damage.
Inspect the return spring for damage or fatigue.
Replace the defective parts with a new one if necessary.

REASSEMBLY
Reassemble the gearshift shaft in the reverse order of disassembly. Pay attention to the following points:

NOTE:
When installing the gearshift shaft return spring, position the
stopper (A) of gearshill arm between the shaft return spring ends
CBI.

ENGINE REASSEMBLY
Reassemble the engine in the reverse order of disassembly. The following steps require special attention or
precautionary measures should be taken.

NOTE:
Apply engine oil to each running and sliding part before reassembling
CRANKSHAFT
I

Bearing
(5:j Crank pin
(61 Crankshaft (L)

Bearing
1.2: Crankshaft (R)
( 3 , Conrod

(41

ti>

Determine the width between the webs referring to the figure
when rebuilding the crankshaft.
Crank-web-to-web-width
Standard: 62.0 0.1 rnm (2.441

* 0.004 in)

When mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase by using the special
tools.
09910-32812: Crankshaft installer Ti,
09911-11310: Attachment (21
09913-70210: Bearing installer set (3)
(inner drlver attachment (fi 35)

fnI Bearing

ENGINE 3-59

Never fit the crankshaft into the crankcase by striking
it with a plastic hammer.
Always use the special tool, otherwise the accuracy of
the crankshaft alignment will be affected.

COUNTERSHAFT/DRIVESHAFT
lnstall the countershaft assembly and driveshaft assembly.

GEARSHIFT CAM, FORK AND SHAFT
Install the gearshift forks into the gearshifting grooves in the
correct position and direction.
31Gearshift fork No.1
(21 Gearshift fork No.2
(3; Gearshift fork No.3

Install the gearshift cam (7).
Install the gearshift fork shaft

m,iQii.

NOTE:
'After the gearshift fork shaft and gearshift forks have been fitted, make sure that the gears engage normally.
Set the transmission gears to the neutral position.

CRANKCASE
Thoroughly remove the sealant material and oil stains on the
mating surface of the right and left crankcases.
lnstall the dowel pins to the left crankcase.
install the oil strainers (0.
Apply engine oil to the conrod big end and to the transmission
gears.

3-60

ENGINE

Apply SUZUKl BOND "1215" to the mating surface of the right
crankcase as shown.

99000-311 10: SUZUKI BOND "121 5"
(or equivalent bond)

NOTE:
Use of SUZUKl BOND "1215"is as follows:
Make surfaces free from moisture, oil, dust and other foreign
materials.
Spread on surfaces thinly to form an even layer, and assemble
the crankcases within few minutes.
Take extreme care not to apply any BOND "1215" to the oil
hole, oil groove and bearing.
A p p l y to distorted surfaces as it forms a comparatively thick
film.

Tighten the crankcase bolts and engine oil drain plug '21to the
specified torque.

Crankcase bolt: 11 N.rn (1.1 kgf-rn, 8.0 lb-ft)
Engine oil draln plug: 18 N.rn (1.8 kgf-rn, 13.0 lb-ft)

After the crankcase bolts have been tightened, check if the
crankshaft, countershart, and driveshaft rotate smoothly.

Apply a small quantity of THREAD LOCK SUPER "1303 to
the gearshift fork shaft retainer screw, and tighten it securely.

-9900092030:

THREAD LOCK SUPER "1303"

Install the spacer O and retainer (4).
Install the balancer crank.

OIL PUMP No.2
Install the pin (2, to oil pump No.2 shaft (7).
Install the inner rotor 1%to oil pump No.2 shaft (i).
NOTE:
Fit the slot

of the inner rotor on the pin (2

Apply engine oil to the outer rotor.
Install the outer rotor 14;to the left crankcase.
Apply engine oil to the oil pump shaft and inner rotor.

FAUTION]

The punch mark iB! o n the outer rotor must face to the
crankcase side.

lnstall the oil pump No.2 6).
Tighten the oil pump No.2 mounting bolts to the specified
torque.

'\"T
n

Oil pump No.2 mounting bolt: 10N.m (1.0 kgf-m, 7.0lb-ft)
8.

CAM CHAIN
Install the cam chain (71onto the sprocket.
Install the cam chain tensioner (2) and washer (3).
Tighten the cam chain tensioner mounting bolt
to the specified torque.

la!

Cam chain tensloner mountlng bolt:
10 N.m (1.0 kgf-m, 7.0 lb-ft)

STARTER CLUTCH AND GENERATOR ROTOR
Apply engine oil to the starter driven gear bearing and crankshaft.

T-

.
.-9

Install the starter driven gear $1.
Degrease the tapered portion of generator rotor and also the
crankshaft. Use nonflammable cleaning solvent to wipe off
oily or greasy matter and make these surfaces completely
dry.
Install the key 0.

,\
,

:
.

3$3
,

,-\q

..
.

'
1

Install the generator rotor.
Tighten the generator rotor nut to the specified torque using
the special tool.

A.,,*t
9 *. - y . ~

Generator rotor nut: 120 N.rn (12.0 kgf-rn, 87.0 lb-ft)
09930-44520: Rotor holder

PRIMARY DRIVE GEAR AND BALANCER GEAR
lnstall the balancer dr~vegear 11:.
Install the key (2)

lnstall the primary drive gear (ij, and washer rT).

NOTE:
lnstall the washer#) as shown in the illustration

':c
.

3.64

ENGINE

Hold the generator rotor using the special tool, and then
tighten the primary drive gear nut to the specified torque.

c?L-~" .

Primary drive gear nut: 140 N.rn (14.0 kgf-rn, 101.5 lb-fl)

..a111

,:,<--

NOTE:

- .. ' ;'y.
I, :
i

This nut has left-hand thread.

,\"

09930-44520: Rotor holder

Install the pin 6i.
Install the balancer driven gear (6) by aligning the matching
marks
Install the washer (8).

Balancer driven gear nut: 50 N.rn (5.0 kgf-rn, 36.0 lb-fl)

' 51

(.n.

Hold the generator rotor using the special tool, and then
tighten the balancer driven gear nut to the specified torque.

. a-

1,'-

'
-

GEARSHIFT CAM DRIVEN GEAR
Install the washer ill and gearshift cam stopper (2) to the
gearshift cam stopper bolt 13.
Apply a small quantity of THREAD LOCK SUPER "1303"to
the gearshift cam stopper bolt.
Tighten the gearshifi cam stopper bolt.
Install the spring (8.
-99000-32030:

,
e

..
\

.
-

THREAD LOCK SUPER " 1 3 0 3

Align the pin groove lizi with the pin i,b when installing the
stopper plate (5).

,d
%\.

/
I

' *

ENGINE 3-65

Apply a small quantity of THREAD LOCK SUPER "1303 to
the gearshift cam driven gear bolt.
Tighten the gearshift cam driven gear bolt to the specified
torque.

-k

;

v'-P
b, -

.cr*,
L

99000-32030: THREAD LOCK SUPER "1303"

. -1.

Install each pawl lifter ~ n t othe gearsh~ftcam dr~vengear. The
large shoulder 0 must face to the outside.

With the pawls held in pushed position, install the pawl lifter

6).

Apply a small quantity ol THREAD LOCK SUPER "1303 to
the pawl lifter screw, and then tighten the screw and nut
securely.

99000-32030: THREAD LOCK SUPER "1303"

Install the gearshift shaft.

NOTE:
Align the center teeth on the gearshift shaft wrth the center teeth
on the gearshift cam driven gear.

&&
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c.9'

,\--

--*ffl-. -*a,
,

4c.

3-66

ENGINE

lnstall the washer ;CI and new snap ring 8)
09900-06107: Snap ring pliers

OIL PUMP No.1
lnstall the oil pump body C2', Inner rotor r31 and pln (4 to
pump shaft ill.

.
.
.
0

011

NOTE:
Fit the slot (Ai of the inner rotor on the pin (41.

The slit must face to the crankcase side.

Apply engine oil to the outer rotor.
Install the outer rotor (51to the right crankcase.
Apply engine oil to the oil pump shaft and inner rotor.

..@_

-I

~ AU T I -O N ~

The punch mark (s;j on the outer rotor must face to the
oll pump body.

..\m--

-ig

lnstall the oil pump No.? (61.
lnstall the washer (7)and pin @.

* When installing the oil pump driven gear
with the groove 0.
09900-06107: Snap ring pliers

ce), align the pin 63

.
a
-

F7b,

L .

',\

:,wL,-.
;.
. \

.,*.,v,.

: .' *c.:

' i

'.!
-t-~*
:I

-7'
-t ' /

lnstall the oil pump idle gear ill.

@ 09900-06107: Snap ring pliers

CLUTCH
Apply engtne 011to the spacer.
Install the spacer ill.

Install the primary driven gear assembly 171.
Install the washer r3'.

Install the clutch sleeve hub
clutch sleeve hub nut (6).

new lock washer 61and

NOTE:
The concave side of clutch sleeve hub nut faces inside.

Clutch sleeve hub nut: 90 N.m (9.0 kgf-m, 65.0 lb-ft)
09920-53740: Clutch sleeve hub holder

.,\

Hold the clutch sleeve hub using the special tool, and then
tighten the clutch sleeve hub nut to the specified torque.

- "t.-.
-,?, .. .
,
r
#
.
, . .;

- *
L
.

t$s

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-~~

3-68

ENGINE

Bend the tongue of the washer securely.

lnstall the push rod (3and push piece :8,

Install the spring washer seat (9) and spring washer 00 onto
the clutch sleeve hub correctly.

Apply engine oil to the drive plates ifi) and driven plates (12,.
Install the clutch drive plates and driven plates one by one
into the clutch sleeve hub in the prescribed order as show in
illustration.

---.on

,f-.

.
$1'

.. L

Direction at ouls~de

Apply englne oil to the release bearing 1131.
Install the clutch pressure plate (id).

Hold the generator rotor using the special tool.
Tighten the clutch spring Set bolts securely in diagonal
stages.

& 09930-44520: Rotor holder

Apply engine oil to the lip of the oil seal.
Install the oil seal iiS, dowel pins and gasket (1@.

pGi10q
Use a new oil seal and gasket to prevent oil leakage.

g j

'--

- - - . -~

Tighten the right crankcase cover bolts securely

Install the gasket ill!.

!cnuTloN]

Use a new gasket to prevent oil leakage.

-fl

>".'

Tight the clutch cover bolts securely
, C : Bolt with clamp

OIL FILTER
Apply engine oil to the O-ring.
Install the O-ring (5 and oil filter (2).

.A.

Use a new O-ring to prevent oil leakage.

Apply englne 011to the 0 - r ~ n g
lnstall the 0 - r ~ n g3 1 and sprlng (4)

-1
Use a new O-ring to prevent oil leakage.

'
I
A

Replace the oil filter cap and tighten the bolts securely
NOTE:
Face the triangle mark (kl on the cap rearward.

GENERATOR ROTOR COVER
Before install~ngthe starter idle gear, apply molybdenum oil
solution to the hole of starter idle gear shaft.
MOLYBDENUM OIL SOLUTION

Install the starter idle gear i:i),shaft (21, dowel pins and gasket
(3,.

(

Use a new gasket t o prevent oll leakage.

Tighten the generator rotor cover bolts securely
:A': Bolt with clamp
rer:Bolt with lead wire
(C): Bolt wtth bracket

Before installing the starler torque limiter assembly, apply
molybdenum oil solution to the collarsI.@ of starter torque limiter assembly shaft.
Install the collars a)),washers (5, and starter torque limiter
assembly 1%.

MOLYBDENUM OIL SOLUTION

3-72

ENGINE

Apply engine oil to the O-ring (7,.
Install the starter torque limiter assembly cover 61.

PISTON RING
Install the piston rings in the order of oil ring, 2nd ring and 1st
ring.
The first member to go into the oil ring groove is a spacer 171.
After placing the spacer, fit the two side rails (2).

NOTE:
Side designations, top and bottom, are not applied to the spacer
and side rails: you can position each either way.

When installing the spacer, be careful not t o allow its
two ends to overlap In the groove.

(Al INCORRECT
(6) CORRECT

Install the 2nd ring tj? and the 1st ring i41 to the piston.

NOTE:
1st ring and 2nd ring differ in shape.

Be sure to bring the concave side of 1st ring to the top when
fitting it to the piston.
2nd ring has letter "R" marked on the side. Be sure to bring
the marked side ring to the top when fitting it to the piston.

Position the gaps of the three ring as shown. Before inserting
each piston into the cylinder, check that the gaps are so
located.
,A:

Exhaust side

' 6 Intake side

( 5 2nd ring and lower side rail

6 Upper side rail
17 1st ring and spacer

PISTON AND CYLINDER
Apply molybdenum oil solution onto the piston pin and small
end of the conrod.

NOTE:
Instali the piston with the punch mark
ing toward the exhaust side.

on the piston head fac-

MOLYBDENUM OIL SOLUTION

Place a clean rag over the cylinder base to prevent the piston
pin circlip from dropping into the crankcase, and then fit the
piston pin circlip with long-nose pliers.

1 CAUTION_J
Use a new piston pin circlip to prevent circlip failure
wlth a bent one.

NOTE:
End gap 01 the circlip should not be aligned with the cutaway in
the piston pin bore.
Thoroughly wipe off oil from the fitting surface of the crankcase.
Apply SUZUKl BOND "1215 to the crankcase as shown.
99000-31110: SUZUKl BOND "1215"

(or equivalent bond)

3-74

ENGINE

Apply molybdenum oil solution to the sliding surface of the
piston and piston rings.
Install the dowel pins and gasket ii)onto the crankcase.

FAU T I O ~ ~

Use a new gasket to prevent oil leakage.

MOLYBDENUM OIL SOLUTION

NOTE:
When mounting the cylinder, after attaching the camshaft drive
chain. keep the camshaft drive chain taut. The camshaft drive
chain must not be caught between the cam drive chain
sprocket and crankcase when the crankshaft is rotated.

Install the dowel pins and gasket i
3
.

Use a new gasket to prevent gas leakage.

J,,

r,'
..

:-y

Install the cam chain guide (2).

NOTE:
Make sure that the guide (2) is inserted properly or binding of Me
cam chain and guide may result.

Hold each piston ring with the piston ring sections positioned
correctly and put it into the cylinder. Make sure that the piston
rings are caught by the cylinder skirt.

,
.
I
.
'

9?‘&..
.
.

..., +.

. .>,,..
2

.
\

b
.

ENGINE 3-75

CYLINDER HEAD
With the head snugly seated on the cylinder, secure it by
tightening the bolts in diagonal stages. Tighten the cylinder
head bolts diagonally to the specified torque.

rn Cylinder head bolt

Initlal: 25 N.m (2.5 kgf-rn, 18.0 lb-ft)
Final: 47 N.m (4.7 kgf-rn, 34.0 lb-ft)

NOTE:
'Apply engine oil to the threaded parts of the cylinder head
bolts and both sides of the its washers.
' Be sure to install the washer with rounded side facing up.

Use new copper washers t o prevent oil leakage.

After tightening the cylinder head bolts to specification, tighten
the cylinder head bolts (i) and cylinder bolts 14 to the specified torque.

b
t3

rn Cylinder head bolt: 10 N m (1.0 kgf-rn, 7.0 lb-ft)
Cylinder bolt:

10 N.rn (1.0 kgf-rn. 7.0 lb-ft)

CAMSHAFTlAUTOMATlC DECOMP. ASSEMBLY
Turn the generator rotor unt~ithe '7" l~neon the generator
rotor is aligned with the center of the hole in the generator
cover

p
-

~@it~
@* - , 15

1If the crankshaft is turned without drawing the cam
chain upward, the cam chain will catch between crankcase and cam chaln drive sprocket.

1 r

4
-s

-',c
fl.

Just before installing the camshaft into the cylinder head,
apply engine oil to the camshaft journals, cam faces, camshaft journal holders and camshaft bearings.

With the '7" line aligned with the center of the hole, hold the camshaft steady and lightly pull up the cam
chain to remove any slack between the cam chain drive sprocket and exhaust camshaft sprocket.
The exhaust camshaft sprocket has an punch marked iii).Turn the exhaust camshaft so that the punch is
aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust camshaft
sprocket.
should now be pointing straight up. Starting from the roller pin that is directly
The other punch marked
above the punch marked :B!, count out 15 roller pins (from the exhaust camshaft side going towards the
intake camshaft side).
Engage the 15th roller pin on the cam chain with the punch marked (0 on the intake sprocket. Refer to the
following illustrations.
NOTE:
The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaftjournal holders and cam chain tensioner are secured.
Make sure that the punch mark (D) is aligned with the gasket surface of the cylinder head.

1st pin

15th pin

ENGINE 3-77

* Install the dowel pins and C-ring (1).
Place each camshaft journal holders into the correct position.
NOTE:
Camshaft journal holders marked " E X are for the exhaust side
and those marked nIN"arefor the intake side.

Tighten the camshaft journal holder bolts to the specified
torque.
Camshaft journal holder bolt: 10 N.m (1.0 kgf-m, 7.0 lb-ft)

NOTE:
When tightening the camshaft journal holder bolts, the piston
position must be at TDC on the compression stroke.
Tighten the camshaft journal holder bolts diagonally.
+

CAM CHAIN TENSION ADJUSTER
Unlock the ratchet mechan~smc l and
~
push the push rod (2' all
the way

Install the gasket $(1
inder.

and cam chain tension adjuster to the cyl-

"1
-

~A-LITION]

Use a new gasket to prevent oil leakage.

Tighten the cam chain tension adjuster mounting bolts to the
specified torque.
Cam chain tension adjuster mounting bolt:
10 N.m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Make sure that the 'bp markMS)comes to the upper side.

3-78

ENGINE

Install the spring 14).
Tighten the spring holder bolt to the specified torque.
Cam chain tension spring holder bolt:
30 N,m (3.0 kgf-m, 21.5 lb-ft)

I
After installing the cam chaln tension adjuster, check
t o be sure that the adjuster works properly by checking the slack of cam chain.
After installing the cam chain tension adjuster, rotate the
crankshaft (two turns), and recheck the positions of the camshafts. (-3-76)
Apply grease to the O-ring 151.
T~ghtenthe generator cover cap (6-1 and valve timing inspec.
tion plug (3.
Generator cover cap: 15 N.m (1.5 kgf-m, 11 lb-ft)
Valve timing inspectlon plug:
23 N.m (2.3 kgf-m, 16.5 lb-ft)

CYLINDER HEAD COVER
Thoroughly wipe off oil from the fitting surfaces of the cylinder
head and cover.
Apply SUZUKl BOND "12166 to the end caps of the cylinder
head cover gasket as shown.

a99000-31230: SUZUKl BOND "1216B"
I CAUTION]

Use a new gasket to prevent oll leakage.

Apply engine oil to both sides of the washers 11 .
Lightly tighten the cylinder head cover bolts and then tighten
them to the specified torque.

fl Cylinder head cover bolt
Initial: 10 N.rn (1.0 kgf-m, 7.0 lb-ft)
Final: 14 N.m (1.4 kgf-m, 10.0 lb-ft)

ci"

6.:

;,
.

LCAU%&N]

Use new washers to prevent oil leakage.
Tighten the spark plug. (-2-10)
GEAR POSITION SWITCH
Apply grease to the O-ring.
Install the O-ring @, springs (2) and contacts O!.

P
(4)

;.J

~ m o ~ 7
Use a new O-ring t o prevent oll leakage.

99000-25010: SUZUKl SUPER GREASE "A"
(or equlvalent grease)

Install the gear position switch (4) and tighten the bolts to the
specifled torque.
Gear position switch bolt: 6.5 N m (0.65 kgf-m, 4.7 lb-ft)
STARTER MOTOR
Apply grease to the O-ring.
Install the starter motor (TI.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

..
i
t,%

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*
*

I,'

0
-,J

FI SYSTEM DIAGNOSIS

CONTENTS

..................................................................4 - 3
...........................................................................4 - 3
...................................................................................................... 4 - 4
...................................................................
4-4
..........................4 - 6
.................................................4 - 9
.........................................................4-10
...........................................4-10
...........................4-11
...........................................................4-11
...........................................................4-12
............................................................4-14
..........................................................................................4-15
...................................................................4-16
.........................................................................................4-16
.....................................................................................4-17
.............................................4-18
...............................................................................4-19
...............................................................................4-20
.............................................................4-21
............................................. 4-21
...........................................................................4-22
............................................... 4-23
............................................4-23
....................................... 4-24
...............................4-25

PRECAUTIONS IN SERVICING
ELECTRICAL PARTS
FUSE
ECMNARIOUS SENSORS
ELECTRICAL CIRCUIT INSPECTION PROCEDURE
USING THE MULTI-CIRCUIT TESTER
FISYSTEM TECHNICAL FEATURES
INJECTION TlME(INJECTI0N VOLUME)
COMPENSATION OFINJECTION TIME (VOLUME)
INJECTION STOP CONTROL
Fl SYSTEM PARTS LOCATION
Fl SYSTEM WIRING DIAGRAM
ECM TERMINAL
SELF-DIAGNOSIS FUNCTION
USER MODE
DEALER MODE
DIAGNOSTIC TROUBLE CODE TABLE
TPS ADJUSTMENT
FAIL-SAFE FUNCTION
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
VISUAL INSPECTION
SELF-DIAGNOSTIC PROCEDURES
SELF-DIAGNOSIS RESET PROCEDURE
USE OF SDS DIAGNOSTIC PROCEDURES
USE OF SDS DIAGNOSIS RESET PROCEDURE
SHOW DATA WHEN TROUBLE
(DISPLAING DATA AT THE TIME OF DTC)
MALFUNCTION CODE AND DEFECTIVE CONDITION
"C12" (P0335) CKP SENSOR CIRCUIT MALFUNCTION
"C13" (PO105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
"C14" (PO120-H/L) TP SENSOR CIRCUIT MALFUNCTION
"C15" (POI 15-H/L) ECT SENSOR CIRCUIT MAL FUNCTION
"C21" (PO1 10-H/L) IAT SENSOR CIRCUIT MALFUNCTION
"C23" (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION
"C24" (P0351) IGNITION SYSTEM MALFUNCTION
"C31"(P0705) GP SWITCH CIRCUIT MALFUNCTION
"C32" (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION
"C41" (P0230) FP RELAY CIRCUIT MALFUNCTION
"C60" (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION .....

........................................ 4-26
......................4-27
...................4-29
..............4-31
............... 4-37

............. 4-42
.............. 4-46
...............4-50

........................... 4-53
....................... 4-54
...............4-56
......................... 4-58
4-59

4-2

FI SYSTEM DIAGNOSIS

CONTENTS
SENSORS .................................................................................................... 4-60
CKP SENSOR INSPECTION
4-60
CKP SENSOR REMOVAL AND INSTALLA TlON
4-60
IAP SENSOR INSPECTION
4-60
4-60
IAP SENSOR REMOVAL AND INSTALLATION
TP SENSOR INSPECTION
4-60
TP SENSOR REMOVAL AND INSTALLATION
4-60
TPS ADJUSTMENT
4-60
ECT SENSOR INSPECTION
4-60
ECT SENSOR REMOVAL AND INSTALLATION
4-60
IAT SENSOR INSPECTION .................................................................. 4-61
IAT SENSOR REMOVAL AND INSTALLATION .................................. 4-61
TO SENSOR INSPECTION
4-61
TO SENSOR REMOVAL AND INSTALLATION
4-61

................................................................

................................

FI SYSTEM DIAGNOSIS 4-3

PRECAUTIONS IN SERVICING
When handling the component parts or servicing the FI system.
observe the following points for the safety of the system.

ELECTRICAL PARTS
CONNECTORICOUPLER
When connecting a connector, be sure to push it in until a
click is felt.

Wilh a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.
When disconnecting the coupler, be sure to hold the coupler
body and do not pull the lead wires.
lnspect each terminal on the connector/coupler for looseness
or bending.
lnspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
lnspect each lead wire circuit for poor connection by shaking it
by hand lightly. If any abnormal condition is found, repair or
replace.

......

When taklng measurements at electrical connectors us~nga
tester probe, be sure to Insert the probe from the wlre harness
s~de(backside) of the connector/coupler.

( 1 ) Coupler

(2) Probe

FI SYSTEM DIAGNOSIS 4-5

When disconnecting and connecting the ECM, make sure to
turn OFF the ignition switch (71, or electronic parts may get
damaged.

Battery connection in reverse polarity is strictly prohibited.
Such a wrong connection will damage the components of the
FI system instantly when reverse power is applied.

Removing any battery terminal of a running engine is strictly
prohibited.
The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in
serious damage.

Before measuring voltage at each terminal, check to make
sure that battely voltage is 11 V or higher. Terminal voltage
check with a low voltage battery will lead to erroneous diagnosis.

Never connect any tester (voltmeter, ohmmeter, or whatever)
to the ECM when its coupler is disconnected.
Otherwise, damage to ECM may result.
Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to ECM or sensors may result.
Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained and personal
injury may result.

ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various methods for electrical circuit inspection.
described here is a general method to check for open and short
circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK
Possible causes for the open circuits are as follows. As the
cause can exist in the connector/coupler or terminal, they need
to be checked carefully.
* Loose connection of connector/coupler.
Poor contact of terminal (due to dirt, corrosion or rust, poor
contact tension, entry of foreign object etc.).
Wire harness being open.
Poor terminal-to-wire connection.
9

Disconnect the negative cable from the battery.
Check each connector/coupler at both ends of the circuit
being checked for loose connection. Also check for condition
of the coupler lock if equipped.

1 1 1 Sensor
121 ECM

'1 Check for loose connection.

1 -

Using a test male terminal, check the female terminals of the
circuit being checked for contact tension.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust, entry of foreign object, etc.). At
the same time, check to make sure that each terminal is fully
inserted in the coupler and locked.
If contact tension is not enough, rectify the contact to increase
tension or replace.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
'1 Check contact tension by inserting and removing.
'2 Check each terminal for bend
and proper alignment.
Using continuity inspect or voltage check procedure as
described below, inspect the wire harness terminals for open
circuit and poor connection. Locate abnormality, if any.

(A) Looseness of crimping
ii3)

Open

ic) Thin wire (a few strands left)

4
6
r

FI SYSTEM DIAGNOSIS 4.7

Continuity check
Measure resistance across coupler (ej (between tW and i
'in
the figure).
If no continuity is indicated (infinity or over limit), the circuit is
open between terminals !A) and (Cb.

(1)ECM
Disconnect the coupler B' and measure resistance between
couplers (A) and iE).
If no continuity is indicated, the circuit is open between couplers $0 and tbj. If continuity is indicated, there is an open circuit between couplers (B:' and !CI or an abnormality in coupler
(BY or cou~ler6.

VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
With all connectorslcouplers connected and voltage applied
to the circuit being checked, measure voltage between each
terminal and body ground.

If measurements were taken as shown in the figure at the right
and results are as l~stedbelow, it means that the circuit is open
between terminals [Ai and ( 6 1 .
Voltage Between:
iCl and body ground: Approx. 5 V
8 1 and body ground: Approx 5 V
(A) and body ground:
0V

Also, if measured values are as listed below, a resistance
(abnormality) exists which causes the voltage drop in the circuit
between terminals tW and @.
Voltage Between:
(12)and body ground: Approx. 5 V
(0) and body ground: Approx. 5 V J2 V voltage drop
(Gand body ground:
3V

4-8

F1 SYSTEM DIAGNOSIS

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)
Disconnect the negative cable from the battery.
Disconnect the connectors/couplers at both ends of the circuit
to be checked.

NOTE:
If the circuit to be checked branches to other park as shown,
disconnect all connectors/couplers of those parts. Otherwise,
diagnosis will be misled.
Measure resistance between terminal at one end of circuit (tk
terminal in figure) and body ground. I f continuity is indicated,
there is a short circuit to ground between terminals RIand 10.

KJ Other parts
'1 To other parts

Disconnect the connector/coupler included in circuit (coupler
I@) and measure resistance between terminal A
' 1 and body
ground.
If continuity is indicated, the circuit is shorted to the ground
between terminals rfii and (81.

!:aECM
'1 To other parts

FI SYSTEM DIAGNOSIS 4-9

USING THE MULTI-CIRCUIT TESTER
Use the Suzuki multi-circuit tester set (09900-25008)
Use well-charged batteries in the tester.
Be sure to set the tester to the correct testing range.

USING THE TESTER
Incorrectly connecting the [ii and i,?)probes may cause the
inside of the tester to burnout.
If the voltage and current are not known, make measurements using the highest range.
When measuring the resistance with the multi-circuit tester iiI ,
will be shown as 10.00 MQ and "1" flashes in the display.
Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.
After using the tester, turn the power off.

@ 09900-25008:Multi-circuit tester set
NOTE:
" When connecting the multi-circuit tester, use the needle
pointed probe to the back side of the lead wire coupler and
connect the probes of tester to them.
' Use the needle pointed probe to prevent the rubber of the
water proof coupler from damage.

@ 09900-25009:Needle pointed probe set

ti,.&

.:;

4-10

FI SYSTEM DIAGNOSIS

F1 SYSTEM TECHNICAL FEATURES
INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the
basis of intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine
and driving conditions.

Intake Air Pressure
Sensor (IAP Sensor)

Intake air pressure
signal

Basic

Crankshaft Position
Sensor (CKP Sensor)
Throttle Position
Sensor (TP Sensor)

- ! f i g ? E 3 ? @ ! ! ! ! s~gnal

co
:i;tn
tlmw

Throttle opening
slgnal

I
Various
Sensors

Injector

t-Various signals

Compensation

L
I
1
I
I

Injection signal

1 I

injection
time

1
2i

FI SYSTEM DIAGNOSIS 4-11

COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensation of the fuel injection
time (volume).

SIGNAL
DESCRIPTION
ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (voiume) is increased.
SOR SIGNAL
When intake air temperature is low, injection time (volume)
INTAKE AIR TEMPERATURE SENSOR
is increased.
SIGNAL
ECM operates on the battery voltage and at the same time.
BATTERY VOLTAGE SIGNAL
it monitors the voltage signal for compensation of the fuel
injection time (volume). A longer injection time is needed to
adjust injection volume in the case of low voltage.
During acceleration, the fuel injection time (volume) is
ACCELERATION SIGNAU
increased in accordance with the throttle opening speed and
DECELERATION SiGNAL
engine rpm. During deceleration, the fuel injection time (volume) is decreased.

INJECTION STOP CONTROL
SIGNAL
TIP-OVER SENSOR SIGNAL
(FUEL SHUT-OFF)
OVER-REV. LIMITER SIGNAL

DESCRIPTION
When the vehicle tips over, the tip-over sensor sends a signal to the ECM. Then, this signal cuts OFF current supplied
to the fuel pump, fuel injector and ignition coil.
The fuel ignition stop operation when engine rpm reaches
rev. limit rpm.

4-12

FI SYSTEM DIAGNOSIS

FI SYSTEM PARTS LOCATION

(A1 Intake alr temperature sensor (IATS)

~ CEng~ne
I
coolant temperature sensor (ECTS)
(El Cooling fan

!@' Ignition c o ~(IG
l COIL)
IDSCoollng fan relay

FI SYSTEM DIAGNOSIS 4.13

(F) Fuel pump relay (FP RERAY)

!HIIntake air pressure sensor (IAPS)
(J) Throttle position sensor (TPS)
tiL Crankshaft position sensor (CKPS)

Tip-over sensor (TOS)
( 1 ) Fuel injector
KJ Fuel pump (FP)
@ Gear position switch

Crankshaft position sensor
(CKP

1
Thronle position sensor
(TPS)

Intake air pressure
sensor (IAPS)

Clutch lever position

Eng~necoolant
temperature sensor
(ECTS)

Intake air temperature
sensor (IATS)

Starter motor

FI SYSTEM DIAGNOSIS 4-15

ECM TERMINAL

1171

118

Fuel indicator
Ignition coil

(35)
061

Ground (€01)
Ground (E02)

4-16

FI SYSTEM DIAGNOSIS

SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECM. The function has two modes, "User mode" and
"Dealer mode". The user can only be notified by the FI light. To check the function of the individual FI system
devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items.

USER MODE
MALFUNCTION
"NO
"YES"
Engine can start
Engine can not start

FI LIGHT INDICATION

FI light turns ON.
'1
FI light turns ON and blinks.
'2

'1
When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In
this case, FI light is lighted in the indicator panel and vehicle can run.
'2
The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, ignition
signal, injector signal, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, FI light
is lighted and blinked in the indicator panel. Vehicle can not run.

When ignition switch is turned ON, FI light is lit for 2 seconds and therealter remains unlit.
The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the indicator panel
does not receive any signal from ECM, and the indicator panel does not light "FI light".
If FI light is not lighted when turning the ignition switch to ON, the FI light does not indicate the trouble code.
It is necessary to check the wiring harness between ECM and indicator panel couplers.
The possible cause of this indication is as follows;
Engine stop switch is in OFF position, Ignition fuse is burnt.

NOTE:
The F/ light blinks quickly two times a second when the engine coolant temperature becomes too high.

FI SYSTEM DIAGNOSIS 4-17

DEALER MODE
The defective function is memorized in the computer. Use the special tool's coupler to connect to the dealer
mode coupler. The memorized malfunction code is displayed on FI light. Malfunction means that the ECM
does not receive signal from the devices. These affected devices are indicated in the code form.

09930-82720: Mode select switch

R A U ~
Before checking the malfunction code, do not disconnect the ECM lead wire couplers and turn
the ignition switch OFF.
If the couplers from the ECM are disconnected, the malfunction code memory is erased and the
malfunction code can not be checked.

MALFUNCTION
"NO
"YES

FI LIGHT INDICATION
FI light turns OFF.
FI light turns ON and blinks.
(Code is indicated from small numeral to
large one.)

INDICATION MODE

Refer to "DIAGNOSTIC TROUBLE
CODE TABLE" ( W 4 - 1 8 )

4-18

FI SYSTEM DIAGNOSIS

DIAGNOSTIC TROUBLE CODE TABLE

*
Code No.21

Code No.13

e atr pressure sensor

Tip-over sensor (TOS)
24

Ignition signal (IG coil)

Gear position signal
(GP switch)

32
41

Jid
JhIfIL

Injector signal (FI)

mihi

Fuel pump control system
(FP control system)

Fuel pump relay

Cmling fan control system

Cooling fan relay

In the FI light, the malfunction code is indicated from small code to large code.

Code No.21

FI SYSTEM DIAGNOSIS 4-19

TPS ADJUSTMENT
1. Adjust the engine rpm to 1 800 rlmin. ( W 2 - 1 2 )
2.If the throttle position sensor adjustment is necessary, remove
the fuel tank cover (-7-6), fuel pump (-5-6)
and follow

the procedure below.
3. Loosen the screw and turn the throttle position sensor (1:) and
connect the TP sensor coupler 1:2) to the test harness.
4. Turn the ignition switch ON.
5.Adjust the TP sensor (7) until the output voltage comes within
the specified value.
6.Then, tighten the screw to fix the throttle position sensor.

TP sensor output voltage: 0.58 0.62 V
( ( + J Yellow - (3BIBr)

@ 09900-25008:Multi-circuit tester set
09900-28630:TPS test wire harness
09930-11950: Torx wrench
7.Check the engine idle speed. (-2-12)

4-20

FI SYSTEM DIAGNOSIS

FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum
performance necessary even under malfunction condition.
ITEM
IAP sensor
TP sensor

ECT sensor

IAT sensor
Gear position signal

FAIL-SAFE MODE
Intake air pressure is fixed to 101
kPa (768 rnmHg).
The throttle opening is fixed to close
position.
Ignition timing is also fixed.
Engine coolant temperature value is
fixed to 80 "C (176 O F ) .
Cooling fan is fixed on position.
Intake air temperature value is fixed
to 40 "C (104 OF).
Gear position signal is fixed to Neutral gear.

STARTING
ABILITY

RUNNING
ABILITY

"YES"

"YES

The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the vehicle to the workshop for complete repair.

FI SYSTEM DIAGNOSIS 4-21

FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form such as below will facilitate collecting information required for
proper analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM
User name:
Date of issue:
Malfunction indicator
lamp condition
Malfunction indicator
lamp/code

O Dlfflcult Starting
q No cranking
NOinitial combustion
No combustion
I? Poor starting at
(0cold q warm
Other

I Model:
1 Date Reg.

IVIN:
Date of problem:

q Always ON

Sometimes ON

I Mileage:

Always OFF

Good condition

User mode: q No indicator lamp
Malfunction indicator lamp (
Dealer mode: q No code
Malfunction code (
)

always)

Poor Idling
Abnormal idling speed
( 0 High
Low) (
rimin)
Unstable
Hunting (
rlmin to
rlmin)
Other
OTHERS:

PROBLEMSYMPTOMS
U Poor Driveability
Hesitation on acceleration
13 Back fire10 After fire
I3 Lack of power
Surging
13 Abnormal knocking
Engine rpm jumps briefly
q Other
Engine Stall when
q Immediately after start
q Throttle valve is opened
Throttle valve is closed
Load is applied
Other

Weather
Temperature
Frequency
Road

VEHlCLElENVlRONMENTAL CONDITION WHEN
- PROBLEM OCCURS
Environmental condition
Fair
Cloudy
Rain n Snow n Always
Other
Hot
Warm
Cool
Cold (
"C1
"F) n Always
0 Always
Sometimes (
times1
day, month)
Only once
Under certain condition
Urban
Suburb
Highway
Mountainous (0Uphill
Downhill)
Tarmacadam
Gravel
Other
Vehicle condition

Engine condition

Cold
Warming up phase
Warmed up
Always
Other at starting
Immediately after start
Racing without load
Engine speed ( rlmin)
Vehicle condition During driving:
Constant speed
Accelerating
Decelerating
Left hand corner
Right hand corner
13 At stop
Vehicle speed when problem occurs (
kmih,
milelh)
Other
NOTE:
The above form is a standard sample. The form should be modified according to conditions and characteristics of each market.

VISUAL INSPECTION
Prior to diagnosis using the mode select switch 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 indicator panel with the use of mode select switch or SDS.
Engine oil level and leakage (-2-13)
" Engine coolant level and leakage ( 0 2 - 1 5 )
Fuel level and leakage (-2-1
1 and 8-25)
Clogged air cleaner element (C72-3)
Battery condition ( 0 8 - 3 1 )
Throttle cable play ( W 2 - 1 1 )
Vacuum hoses looseness, bend and disconnection
Burnt fuse
FI light operation (-4-16
and 8-23)
Each warning light operalion ( W 8 - 2 3 to -25)
+ Exhaust gas leakage and noise ( C 7 2 - 4 )
Each coupler disconnection
+ Clogged radiator fins ( p 6 - 6 )

FI SYSTEM DIAGNOSIS 4-23

SELF-DIAGNOSTIC PROCEDURES
NOTE:
Do not disconnect couplers from the ECM, the battery cable
from the battery, ECM ground wire harness from the engine or
main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will
erase the memorized information in ECM memory.
' Malfunction code stored in ECM memory can be checked by
the special tool.
' Before checking malfunction code, read SELF-DIAGNOSIS
FUNCTION "USER MODE and DEALER MODE" 0 4 - 1 6 ,
-17) carefully fo have good understanding as to what functions
are available and how to use it.
' Be sure to read "PRECAUTIONS IN SERVICING" M 4 - 3 )

before inspection and observe what is written there.
Connect the special tool to the dealer mode coupler at the wiring harness, and start the engine or crank the engine for more
than 4 seconds.
Turn the special tool's switch ON and check the malfunction
code to determine the malfunction part.

@ 09930-82720: Mode select switch

SELF-DIAGNOSIS RESET PROCEDURE

After repalring the trouble, turn OFF the ignition switch and
turn ON again.
If the malfunction code does not indicate, the malfunction is
cleared.
Disconnect the special tool from the dealer mode coupler.
NOTE:
Even though the malfunction code (FI light blinks) is not indicated. the previous malfunction history code still remains
stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS.
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.

' rd

4-24

FI SYSTEM DIAGNOSIS

USE OF SDS DIAGNOSTIC PROCEDURES
Do not disconnect couplers from ECM, the battery cable from
the battery, ECM ground wire harness from the engine or main
fuse before confirming the malfunction code (self-diagnostic
trouble code) stored in memory. Such disconnection will erase
the memorized information in ECM memory.
' Malfunction code stored in ECM memory can be checked by
the SDS.
' Be sure to read "PRECAUTIONS IN SERVICING" 0 4 - 3 )
before inspection and observe what is wrilten there.
Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
Read the DTC (Diagnostic Trouble Code) and show data
when trouble (displaying data at the time of DTC) according to
instructions displayed on SDS.
Not only is SDS used for detecting Diagnostic Trouble Codes
but also for reproducing and checking on screen the failure
condition as described by customers using the trigger.
* How to use trigger. (Refer to the SDS operation manual for
further details.)

e09904-41010:
set to01
99565-01010-007:
Ver.
SDS
CD-ROM

~14

,,.
:-1

FI SYSTEM DIAGNOSIS 4-25

USE OF SDS DIAGNOSIS RESET
PROCEDURE

After repairing the trouble, turn OFF the ignition switch and
turn ON again.
Click the DTC inspection button !i?.
Check the DTC.
The previous malfunction history code (Past DTC) still
remains stored in the ECM. Therefore, erase the history code
memorized in the ECM using SDS tool.
control

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.
Click "Clear" i21 to delete history code (Past DTC).

D ' I -~ NIL
. . . .
Past DTC-.- 2
.
Manifold
_PO'O?-H_L-absolute
PO1 15-H
I Enpine- coolant
te~
-Current
.
.
.

-- -

Follow the displayed instructions.
I

Check that both "Current DTC"
deleted (NIL).

0)and

'Past DTC" (3) are

-File

Vievv

Help

Clear

Code
Descr>dti7/&
Current DTC - NIL

4-26

FI SYSTEM DIAGNOSIS

SHOW DATA WHEN TROUBLE
(DISPLAING DATA AT THE TIME OF DTC)
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. This data is called "Show data when trouble".
Therefore, it is possible to know engine and driving conditions (e.g.. whether the engine was warm or not,
where the vehicle was running or stopped) when a malfunction was detected by checking the show data
when trouble. This show data when trouble function can record the maximum of two Diagnostic Trouble
Codes in the ECM.
Also, ECM has a function to store each show data when trouble for two different malfunctions in the order as
the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have
been detected. Its use is helpful when rechecking or diagnosing a trouble.

C.3ill.11
e a

PO115-H

Engine cwknt /oil tewrature circuit malfunction

Item
El-cine r p e ~ d

Pre-detect Detect poi... ( Post-detc ...
II
n
0

0.5

T1..ottle psition

ldanifnld aboolufe presswe 1
~

-30.0

Engine cwlant J oil temperature
v

0.5

~ 1003

100.9

-30.0

Fix wint
0

(

0.5
. -100.3

-30.0
'1

Click "Show data when trouble" to display the data. By clicking the drop down button (2), either "Failure
# I " or "Failure # 2 can be selected.

F.?il~.~t?
$2
Data monitor
-

DTC inspection

PO1 10-H

-I\ *.~..
Intake air 1e1

:CICZIJI~ Imelfunctioc

-1

,
@

Item

El-cine 61
llaottle po.:ition
Mmifold &scrlutp pressure 1

E r r ins cwlant / oil temperature
1C.
~

[

Pre-d

FI SYSTEM DIAGNOSIS 4-27

MALFUNCTION CODE AND DEFECTIVE CONDITION
DETECTED
DETECTED FAILURE CONDITION
ITEM
CKP sensor The signal does not reach ECM for 1
sec. or more, after receiving the IAP
sensor input signal.

DTC No.
C12
PO335

IAP sensor
C13

PO105

L
TP sensor

C14

POI 20
L
ECT sensor
C15

PO115

L
IAT sensor

C21

PO110

H
L

The sensor should produce following
voltage.
0.5 V I
sensor voltage c 4.4 V
In other than the above range. C13
(POI 05) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
The sensor should produce following
voltage.
0.5 V 5 sensor voltage < 4.8 V
In other than the above range. C14
(PO120) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
The sensor voltage should be the following.
0.1 V 5 sensor voltage < 4.8 V
In other than the above range, C15
(PO1 15) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
The sensor voltage should be the following.
0.2 V 5 sensor voltage < 4.8 V
In other than the above range. C21
(POI 10) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.

CHECK FOR
CKP sensor wiring and rnechanical parts
CKP sensor, lead wirelcoupler
connection
IAP sensor, lead wirelcoupler
connection

iAP sensor circuit shorted to
VCC or ground circuit open
IAP sensor circuit open or
shorted to ground or VCC circuit
open
TP sensor, lead wirelcoupler
connection

TP sensor circuit shorted to
VCC or ground circuit open
TP sensor circuit open or
shorted to ground or VCC circuit
open
ECT sensor, lead wirelcoupler
connection

ECT sensor circuit open or
ground circuit open
ECT sensor circuit shorted to
ground
IAT sensor, lead wirelcoupler
connection

IAT sensor circuit open or
ground circuit open
IAT sensor circuit shorted to
ground

4-28

FI SYSTEM DIAGNOSIS

DETECTED
DETECTED FAILURE CONDITION
ITEM
The sensor voltage should be the folTO sensor
lowing for 1 sec. and more, after ignition switch is turned ON.
C23
0.3 V j sensor voltage < 4.6 V
In other than the above value, C23
(P1651) is indicated.
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
PI651
value.
L
DTC No.

C24

lgnition signal

PO351
C31

Gear position signal

PO705
Fuel injector
C32
PO201
C41
PO230
C60
PO480

Fuel pump
relay
Cooling fan
relay

CHECK FOR
TO sensor, lead wirelcoupler
connection

TO sensor circuit shorted to
VCC or ground circuit open
TO sensor circuit open or
shorted to ground or VCC circuit
open
CKP sensor (pick-up coil) signal is pro- lgnition coil, wiringlcoupler connection, power supply from the
duced, but signal from ignition coil is
battery
interrupted 5 times or more continuously. In this case, the code C24
(P0351) is indicated.
Gear position signal voltage should be GP switch, wiringlcoupler conhigher than the following for 3 seconds nection, gearshift cam, etc.
and more.
Gear position switch voltage D 0.9 V
If lower than the above value, C31
(P0705) is indicated.
CKP sensor (pickup coil) signal is pro- Fuel injector, wiringlcoupler conduced, but fuel injector signal is inter- nection, power supply to the
rupted 8 times or more continuously. In injector
this case. the code C32 (P0201) is
indicated.
Fuel pump relay signal is not input to
Fuel pump relay, lead wirelcouECM.
pler connection.
Cooling fan relay signal is not input to Cooling fan relay, lead wirelcoupler connection
ECM.

FI SYSTEM DIAGNOSIS 4.29

"C12" (P0335) CKP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
The signal does not reach ECM for 1 sec. or more,
after receiving the IAP sensor input signal.

POSSIBLE CAUSE
Metal particles or foreign material being stuck on
the CKP sensor and rotor tip
CKP sensor circuit open or short
CKP sensor malfunction
ECM malfunction

ECM

CKP sensor

i
'

INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the CKP sensor coupler for loose or poor contacts.
If OK, then measure the CKP sensor resistance.

3) Disconnect the CKP sensor coupler and measure the resistance.
CKP sensor resistance: 155 - 232 Q
(White - Blue)

CKP+

CKP-

FI SYSTEM DIAGNOSIS

4-30

4) If OK, then check the continuity between each terminal and

ground.
CKP sensor resistance:

52 (Infinity)
(White Ground)
(Blue -Ground)

'\ .

09900-25008: Multi-circuit tester set

L
B Tester knob indication: Resistance (R)

Are the resistance and continuity OK?

.
,

-:*

/Go to step 2.
Replace the (:KP sensor with a riew one.
. .
.
5)After repairing the trouble, clear tne U l C using SDS tool.
(-4-25)
YES
NO

Step 2
1) Crank the engine a few seconds with the starter motor, and
measure the CKP sensor peak voltage at the coupler.
2) Repeat the above test procedure a few times and measure
the highest peak voltage.

! ,.

CKP sensor peak voltage: 0.5 V and more
((+> White 4 - 1 Blue)

!!) Peak volt adaptor

09900-25008: MUM-circu~ttester set

.mTester knob indication: Voltage (-)
Is the voltage OK?

YES

G/W or 81 wire open or shorted to ground.
Loose or poor contacts on the CKP sensor coupler or ECM coupler (terminal 13;or (91).
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the ECM with a known good one, and
inspect it again.
Inspect that metal particles or foreign material
stuck on the CKP sensor and rotor tip.
If there are no metal particles and foreign material, then replace the CKP sensor with a new
one.

'icXUi0q
When uslng the multi-circuit tester, do not storongly touch the terminal of the ECM coupler
with a needle pointed tester probe t o prevent the terminal damage or terminal bend.
3) After repairing the trouble, clear the DTC using SDS tool.
(-4-25)

FI SYSTEM DIAGNOSIS 4.31

"C13" (P0105-HIL) IAP SENSOR CIRCUIT MALFUNCTION
C13

DETECTED CONDITION
IAP sensor voltage is not within the following range.
0.5 V 5 Sensor voltage s 4.4 V

POSSIBLE CAUSE

Clogged vacuum passage between throttle body
and IAP sensor.
Air being drawn from vacuum passage between
throttle
body and IAP sensor.
NOTE:
IAP sensor circuit open or shorted to ground.
N~~~that atmospheric pressure varies
IAP
malfunction.
depending on weather conditions as
ECM malfunction.
well as altitude.

Take that into considerat~on when
inspecting voltage.
PO105
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.

IAP sensor circuit shorted to VCC or ground circuit open.
IAP sensor circuit open or shorted to ground or
VCC circuit open.

ECM

IAP sensor

0 vcc
BlBr

IAP

INSPECTION
Step 1 (When indicating C13:)
1) Turn the ignition switch OFF.
2) Remove the rear fender. (-7-8)
3) Check the IAP sensor coupler for loose or poor contacts.
IfOK, then measure the IAP sensor input voltage.

El
-.

-.
- =-

4-32

FI SYSTEM DIAGNOSIS

4) Disconnect the IAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire and ground.
7) If OK, then measure the voltage at the Red wire and BIBr
wire.

IAP sensor input voltage: 4.5 5.5 V
(17, Red (3Ground)
((+) Red O BIBr)

P,t.
'

09900-25008: Multi-circult tester set

Is the voltage OK?

Go to Step 2.
Loose or poor contacts on the ECM coupler
(terminal (13; or f@).
Open or short circuit in the Red wire or BlBr
wire.

Step 1 (When lndlcatlng P0105-H:)
1) Turn the ignition switch OFF.
2) Remove the rear fender. ( W 7 - 8 )
3) Check the IAP sensor coupler for loose or poor contacts.
If OK, then check the IAP sensor lead wire continuity.

4) Disconnect the IAP sensor coupler.
5) Check the continuity between Red wire cA) and GW wire iB).
If the sound is not heard from the tester, the circuit condition
is OK.

\!!
> \

Tester knob indication: Voltage (-)

:;w
YES

yvm

FI SYSTEM DIAGNOSIS 4-33

6) Remove the headlight assembly 0~)
and disconnect the headlight coupler (21.

,
.

!.'

7) Disconnect the ECM coupler.
8) Check the continuily between GIB wire $1 and terminal !Bi.
9) IfOK, then check the continuity between B/Br wire (C) and terminal i2Q.
IAPS lead wire continuity: Continuity (-11))
09900-25008: Multl-circuit tester set
09900-25009: Needle pointed probe set

Tester knob indication: Continuity test (4))

ECM coupler (Harness side)

When using the multi-circuit tester, do not storongly touch the terminal of the ECM coupler
with a needle pointed tester probe t o prevent the terminal damage or terminal bend.
Is the continuity OK7
YES
NO

)GOto Step 2.
/GI8 wire shorted to VCC, or BlBr wire open.

10)ARer repairing the trouble, clear the DTC using SDS tool.

(C74-25)
Step 1 (When indicating P0105-L:)
1) Turn the ignition switch OFF.
2) Remove the rear fender. ( W 7 - 8 )
3) Check the IAP sensor coupler for loose or poor contacts.
If OK, then check the IAP sensor lead wire continuity.

4) Disconnect the IAP sensor coupler.
5) Check the continuity between G/B wire i.W and ground.
6) Also, check the continuity between G/B wire (El and BlBr wire
(0.If the sound is not heard from the tester, the circuit condition is OK.

FI SYSTEM DIAGNOSIS

4-34

7) Remove the headlight assembly. ( W 4 - 3 3 )
8) Disconnect the ECM coupler.
9) Check the continuity between Red wire CA) and terminal W.
10)Also, check the continuity between GiB wire :B; and terminal
@.

IAPS lead wire continuity: Continuity (.I)))

,, ,. ,, , :

@ 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indication: Continulty test (-11))

When using the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe t o prevent the terminal damage
or terminal bend.
Is the continuity OK?
YES

Go to Step 1 ( W 4 - 3 1 ) and go to Step 2.
Red wire or GIB wire open, or G/B wire shorted to
ground

11)After repairing the trouble, clear the DTC using SDS tool
(W4-25)
Step 2
1) Connect the IAP sensor coupler and ECM coupler.
2) lnsetl the needle pointed probes to the lead wire coupler.
3) Start the engine at idle speed and measure the IAP sensor
output voltage at the wire side coupler (between GIB and
B/Br wires).

IAP sensor output voltage: Approx. 2.7 V at idle speed
((+I GI6
(-) BIBr)

09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indication: Voltage (-)

Is the voltage OK?
YES

Go to Step 3.
Check the vacuum hose for crack or damage.
Open or short circuit in the GIB wire
If vacuum hose and wire are OK, replace the
IAP sensor with a new one.

4)After repairing the trouble, clear the DTC using SDS tool.
(-4-25)

ECM coupler (Harne!ss side)

FI SYSTEM DIAGNOSIS 4-35

Step 3
1) Turn the ignition switch OFF.
2) Remove the IAP sensor.
3) Connect the vacuum pump gauge to the vacuum port of the
IAP sensor.
Arrange 3 new 1.5 V batteries in series ii)(check that total
voltage is 4.5 - 5.0 V) and connect terminal to the ground terminal i2) and GI terminal to the VCC terminal 1%.
4) Check the voltage between Vout !4r and ground. Also, check
if voltage reduces when vacuum is applied up to 53 kPa (400
mmHg) by using vacuum pump gauge. ( W 4 - 3 6 )

09917-47011: Vacuum pump gauge
09900-25008: Multi-circuit tester set

,jm

Tester knob indication: Voltage (-)

Is the voltage OK?

YES

G/B, Red or BlBr wire open or shorted to
ground, or poor 161, (0)or i2fl connection
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the ECM with a known good one. and
inspect it again.
If check result is not satisfactory, replace the IAP
sensor with a new one.

When using the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe t o prevent the terminal damage
or terminal bend.
5) After repairing the trouble, clear the DTC using SDS tool
(-4-25)

4
ECM coupler (Harness side)

4-36

FI SYSTEM DIAGNOSIS

Output voltage (VCC voltage 4.5
30 "C, 68 - 86 "F)

- 5.0 V, amblent temp. 20 -

FI SYSTEM DIAGNOSIS

4-37

"C14" (P0120-HIL) TP SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION
loutput voltage is not with~nthe following *
range.
Difference between actual throttle opening and opening calculated by ECM is
larger than specified value.
0.5 V S Sensor voltage c 4.8 V
PO120
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
L
value.

C14

POSSIBLE CAUSE
TP sensor maladjusted
TP sensor circuit open or short
TP sensor malfunction
ECM malfunction

TP sensor circuit shorted to VCC or ground circuit
open
TP sensor circuit open or shorted to ground or
VCC circuit open

0 VCC

6)TP
@

B/Br

INSPECTION
Step 1 (When lndicatlng C14:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank cover. ( W 7 - 6 )
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
4) Dtsconnect the TP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Red wire 1R) and ground.
7) If OK, then measure the voltage at the Red wire iKl and B/Br
wire a).
TP sensor input voltage: 4.5

- 5.5 V

((G Red - G Ground)
(\TI Red

- O BIBr)

@ 09900-25008: Multi-circuit tester set

fimTester knob indication: Voltage (-)
Is the voltage OK?
YES

Go to Step 2.
Loose or poor contacts on the ECM coupler
(terminal 03' or m).
Open or short circuit in the Red wire or B/Br
wire.

ECM

TP sensor

4.38

FI SYSTEM DIAGNOSIS

Step 1 (When indicating P0120-H:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank cover. (-7-6)
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.

4) Disconnect the TP sensor coupler.
5) Check the continuity between Yellow wire (%i and Red wire

(6).
If the sound is not heard from the tester, the circuit condition
is OK.

6) Remove the headlight assembly. ( W 4 - 3 3 )
7) Disconnect the ECM couoier.
8) Check the continuity betieen Yellow wire 0 and teminal,.
9) Also, check the continuity between B/Br wire (B) and terminal

i3o.
TPS lead wire continuity: Continuity

(.I)))

@ 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set

Pw Tester knob indication: Continuity test (.))I)
When using the multi-circult tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe t o prevent the terminal damage
or termlnal bend.
Is the continuity OK?
YES
NO

/ G Oto Step 2.

I Yellow wire shorted to VCC, or B/Br wire open

10)After repairing the trouble, clear the DTC using SDS tool
(W4-25)

FI SYSTEM DIAGNOSIS 4-39

Step 1 (When indicating P0120-L:)
1) Turn the ignition switch OFF.
2) Remove the fuel tank cover. ( W 7 - 6 )
3) Check the TP sensor coupler for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.

4) Disconnect the TP sensor coupler.

5) Check the continuity between Yellow wire
and ground.
6) Also, check the continuity between Yellow wire (0and BlBr
wire @). If the sound is not heard from the tester, the circuit
condition is OK.

7) Remove the headlight assembly. ( W 4 - 3 3 )
8) Disconnect the ECM coupler.
9) Check the continuity between Yellow wire (C) and terminal '5).
10)Also. check the continuity between Red wire (,XI
and terminal

(0).

TPS lead wire continuity: Continuity (-11))

09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indicatlon: Continuity test (.)I))

~
-. ~ U T I O ~
--

When using the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe t o prevent the terminal damage
or terminal bend.
Is the continuity OK?
YES

Go to Step 1 (-4-37) and go to Step 2.
Red wire or Yellow wire open, or Yellow wire
shorted to ground

11)After repairing the trouble, clear the DTG using SDS tool
(D4-25)

ECM coupler (Harness side)

4-40

FI SYSTEM DIAGNOSIS

Step 2
1) Turn the ignition switch OFF.
2) Disconnect the TP sensor coupler and ECM coupler.
3) Check the continuity between terminal 0.9 V

POSSIBLE CAUSE
Gear Position switch circuit open or short
Gear Position switch malfunction
ECM malfunction

ECM

GP switch

Neutral indicator
light

Ignition
switch
1
I
I
-

T
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the GP switch coupler for loose or poor contacts.
If OK, then measure the GP switch voltage.

.
.
3) Insert the needle pointed probes to the lead wire coupler.
4) Turn the ignition switch ON.
5) Measure the voltage at the wire side coupler between Pink
wire and B/W wire, when shifting the gearshift lever from 1st
to Top.
GP switch voltage: 0.9 V and more
( ( + I Pink - c-' BBMI)

09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indlcatlon: Voltage (x)

, ..

. --

Is the voltage OK?

1
-

YES

Pink wire open or shorted to ground
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the ECM with a known good one, and
inspect it again.
Pink or BIW wire open, or Pink wire shorted to
ground
Loose or poor contacts on the ECM coupler
(terminal :4j or ( 6 ) )
If wire and connection are OK, replace the GP
switch with a new one.
-

When uslng the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler wlth a needle
pointed tester probe to prevent the terminal damage
or termlnal bend.
6) After repairing the trouble, clear the DTC using SDS tool.

(W4-25)

ECM coupler (Harness side)

4-56

FI SYSTEM DIAGNOSIS

"C32" (P0201)FUEL INJECTOR CIRCUIT MALFUNCTION
DETECTED CONDITION
CKP signal is produced but fueiinjector signal is
interrupted by 8 times or more continuously.

ECM

@ #ll

POSSIBLE CAUSE
lnjector circuit open or short
Injector malfunction
ECM malfunction

Fuel pump relay

-GrN--

Ignition
switch

slop switch

-,
Fuel Injector

INSPECTION
Step 1
1) Turn the ignition switch to OFF.
2) Remove the fuel tank cover. (-7-6)
3) Check the injector coupler for loose or poor contacts.
If OK, then measure the injector resistance.

4) Disconnect the injector coupler and measure the resistance
between terminals.
Injector resistance: 9 - 17 52 at 20 'C (68 O F )
(Terminal -Terminal)

- ;4 q ?
...
?. ?- 'M-,
.',

h'
:,A-p
&.

-~ ./-

FI SYSTEM DlAGNOSlS 4-57

5) If OK, then check the continuity between each terminal and
ground.
Inlector resistance:

n (Infinity)

09900-25008: Multi-circuit tester set

i:mTester knob indication: Resistance ( 0 )
Are the resistance and continuity OK?
-

YES
NO

1 GO to Step 2.
I ~ e p l a c ethe injector with a new one. ( W 5 - 1 8 )

6) After repairing the trouble, clear the DTC using SDS tool.
(-4-25)

Step 2
1) Turn the ignition switch to ON.
2) Measure the injector voltage between OIG wire and ground.
Injector voltage: Battery voltage
((+I OIG (3Ground)

NOTE:
injector voltage can be detected only 3 for seconds after ignition
switch is turned ON.

@ 09900-25008: ~ u l t l - c i r c u itester
t
set

im Tester knob indication: Voltage (r)
Is the voltage OK?

YES

GrlW wire open or shorted to ground, or poor cis!
connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the ECM with a known good one, and
inspect it again.
Open circuit in the OIG wire

When uslng the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe t o prevent the terminal damage
or terminal bend.

3) After repairing the trouble, clear the DTC using SDS tool.
(04-25)

ECM caupler (Harness side)

4-58

FI SYSTEM DIAGNOSIS

"C41" (P0230)FP RELAY CIRCUIT MALFUNCTION
POSSIBLE CAUSE
Fuel pump relay circuit open or short
ECM malfunction

DETECTED CONDITION
Fuel pump relay signal is not input to ECM.

Engine stop
ew~tch

@ FP Relay

switch

om-

-YIBI

-r
-

relay

INSPECTION
Step 1 (When lndlcating C41:)
1) Turn the ignition switch OFF.
2) Remove the front fender. (-7-6)
3) Check the FP relay coupler for loose or poor contacts.
If OK, then check the FP relay. ( W 5 - 8 )

!,(,

m..

I
8

Is the FP relay OK?
O/W or Y/BI wire open or shorted to ground, or
poor it0 connection
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection.
Replace the ECM with a known good one, and

YES

inspect it again.
Replace the FP relay with a new one.

When uslng the multl-circuit tester, do not storongly
touch the terminal of the ECM coupler wlth a needle
pointed tester probe to prevent the terminal damage
or terminal bend.
4) After repairing the trouble, clear the DTC using SDS tool

(W4-25)

ECM coupler (Harness side)

FI SYSTEM DIAGNOSIS 4.59

"C60" (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION
DETECTED CONDITION
Cooling fan relay signal is not input to ECM.

ECM

POSSIBLE CAUSE
Cooling fan relay circuit open or short
ECM malfunction

Cooling fan
relay
Y/8

Ignition
switch

-mo

Cooling fan

motor

I
A

INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Remove the front fender. ( P 7 - 6 )
3) Check the cooling fan relay coupler for loose or poor contacts.
If OK, then check the cooling fan relay. (-6-10)

.
'b,

Is the cooling fan relay OK?

YES

OIY and Y/B wire open or shorted to ground, or
poor 4,33 connection
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for
open circuit and poor connection
Replace the ECM with a known good one, and
inspect it again.
Replace the cooling fan relay with a new one.

When using the multi-circuit tester, do not storongly
touch the terminal of the ECM coupler with a needle
pointed tester probe to prevent the terminal damage
or terminal bend.
4) After repairing the trouble, clear the DTC using SDS tool.

(W4-25)

ECM coupler (Harness side)

SENSORS
CKP SENSOR INSPECTION
The crankshaft position sensor is installed at the inside of the
generator cover. ( 1 7 4 - 2 9 )

.&*,c.,2~.

" '

CKP SENSOR REMOVAL AND INSTALLATION

A*,

C*{

- 0

,'c

-ii

Remove the generator cover. ( W 3 - 1 5 )
Remove the CKP sensor. ( W 3 - 4 3 )
Install the CKP sensor in the reverse order of removal.

The Intake alr pressure sensor 1s installed at the left s~deof the
seat rail. ( D 4 - 3 1 )

'-8

b7: - 6 -,

e v* d m.y,,4
,9\
,'

IAP SENSOR INSPECTION

c . '

'+fi>,

- L-

-.=-

IAP SENSOR REMOVAL AND INSTALLATION
Remove the rear fender. (-7-8)
Remove the IAP sensor from the seat rail.
Install the IAP sensor in the reverse order of removal.
,...

TP SENSOR INSPECTION
The throttle position sensor is installed at the left side of the
throttle body. ( W 4 - 3 7 )

TP SENSOR REMOVAL AND INSTALLATION
Remove the fuel tank cover. ( W 7 - 6 )
Remove the fuel pump. ( W 5 - 6 )
Remove the TP sensor. (-5-14)
Install the TP sensor in the reverse order of removal.

h
k

f '

@w?
YP
.<

~=-.

-.r

- -"i
C
\

..,;
. 1,
. . . ,‘i
"

.>%

TPS ADJUSTMENT
Adjust the TP sensor. ( W 4 - 1 9 )

ECT SENSOR INSPECTION
The engine coolant temperature sensor is installed on the right
side of the cylinder. ( D 4 - 4 2 )
G-

ECT SENSOR REMOVAL AND INSTALLATION
Remove the ECT sensor. ( D 6 - 1 0 )
Install the ECT sensor in the reverse order of removal.
ECT sensor: 12 N.m (1.2 kgf-rn, 8.5 lb-ft)

FI SYSTEM DIAGNOSIS 4-61

IAT SENSOR INSPECTION
The intake air temperature sensor is installed at the right side of
the air cleaner box. (-4-46)

IAT SENSOR REMOVAL AND INSTALLATION
Remove the seat. (C77-6)
Remove the IAT sensor (7) from the air cleaner box.
Install the IAT sensor in the reverse order of removal.

TO SENSOR INSPECTION
The tip-over sensor is located in rear of the headlight assembly.
(-4-50)

TO SENSOR REMOVAL AND INSTALLATION
Remove the front fender. ( W 7 - 6 )
Remove the TO sensor from the bracket.
Install the TO sensor in the reverse order of removal.
NOTE:
When instali~ngthe TO sensor, the avow mark f i t
pointed upward.

must b e

FUEL SYSTEM AND THROTTLE BODY 5-1

CONTENTS

..........................................................................5 - 2
.............................................................................................
5-3
........................................................................
5-3
...............................................................5 - 4
..........................................................5 - 5
....................................................................5 - 6
...............................................................5 - 6
...................................................................5 - 6
....................................... 5 - 7
......................................................5 - 8
.................................................................5 - 9
......................................................... 5-11
.......................................................................................5-12
............................................................................. 5-12
.............................................................................................
5-13
.....................................................................................5-14
............................................................................................5-16
.........................................................................................
5-16
......................................................................................5-16
.....................................................................................5-18
................................................................5-18
............................................................5-18
.......................................................5-18
............................... 5-18

FUEL DELIVERY SYSTEM
FUEL SYSTEM
FUEL TANK REMOVAL
FUEL TANK INSTALLATION
FUEL PRESSURE INSPECTION
FUEL PUMP REMOVAL
FUEL PUMP INSTALLATION
FUEL PUMP INSPECTION
FUEL DISCHARGE AMOUNT INSPECTION
FUEL PUMP RELAY INSPECTION
FUEL VALVE.FOEL FILTER
FUEL PRESSURE REGULATOR
THROTTLE BODY
CONSTRUCTION
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
REASSEMBLY
INSTALLATION
FUEL INJECTOR REMOVAL
FUEL INJECTOR INSPECTION
FUEL INJECTOR INSTALLATION
THROTTLE POSITION SENSOR (TPS) SETTING

Gasoline must be handled carefully in an area well ventilated and away
from fire or s ~ a r k .s

5-2

FUEL SYSTEM AND THROTTLE BODY

FUEL DELIVERY SYSTEM
The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hoses, fuel delivery pipe
(including fuel injector) and fuel pressure regulator. There is fuel return hose. The fuel in the fuel tank is
pumped up by the fuel pump and pressurized fuel flows into the injector installed in the luel delivery pipe.
Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the
fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 2.94 kgf/cm7 (294 kPa,
41.81 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to
the injection signal from the ECM.
The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

iT! Fuel tank
(2) Fuel filter (For fuel valve)
-(3) Fuel hose
(4'1 Fuel return hose
151 Fuel pressure regulator

6 Fuel delivery pipe
(I>Fuel injector
(8) Fuel feed hose
(9) Fuel vapor return hose
(r0' Fuel filter (For fuel pump)

011 Fuel p i
R) Pressu
(0) Before-pressurized fuel
iC) Relieved fuel
iD) Fuel vapor

FUEL SYSTEM AND THROTTLE BODY 5-3

FUEL SYSTEM
FUEL TANK REMOVAL
Remove the front fender. ( W 7 - 6 )
Remove the fuel valve screw cap 01.
Close the fuel valve screw (ii
by turning the fuel valve screw
clockwise.

e:
L

.,*<
.

lcsl

b
Remove the fuel pipe cap (3.
Place a rag under the fuel hose (41 and disconnect the fuel
hose (47 from the fuel pipe (3.
Install the fuel pipe cap (3to the fuel pipe m.

. _ - :

-1

2 3. -* : -

.-.-;I

. .,
,

-,l

:.<;I:.

s :

prevent fuel leakage.
Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
151 to

Disconnect the fuel level gauge coupler .

' '\

. \ ,

Install the special tools between the fuel pressure regulator
and fuel delivery pipe.
09940-40211: Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge hose attachment
09915-77331: Oil pressure gauge
09915-74521: 011 pressure gauge hose
Turn the ignition switch ON and check the fuel pressure.
Fuel pressure: Approx. 294 kPa (2.94 kgf/cm2,41.81 psi)
If the fuel pressure is lower than the specification, inspect the
following items:
Fuel hose leakage
Clogged fuel filter
+ Pressure regulator
e Fuel pump
If the fuel pressure is higher than the specification, inspect the
following items:
Fuel pump
Pressure regulator

' Before removing the special tools, turn the ignition
switch to OFF position and release the fuel pressure
slowly.
'Gasoline is hlghly flammable and explosive. Keep
heat, sparks and flame away.

it?

To fuel pressure regulator
To fuel delivery pipe

5-5

5-6

FUEL SYSTEM AND THROTTLE BODY

FUEL PUMP REMOVAL
Close the fuel cock by turning the fuel cock clockwise.
(US-3)
Remove the fuel pump mounting bolts.

.11

,\j

, ,.

Disconnect the fuel pump lead wire coupler ii). fuel vapor
return hose 3,fuei feed hose @j and fuel hose 1 4 from the
fuel pump and remove the fuel pump ($1.

(4)

FUEL PUMP INSTALLATION
Install the fuel pump in the reverse order of removal. Pay attention to the following points:
Tighten the fuel pump mounting bolts to the specified torque.

Fuel pump mounting bolt: 9 N.m (0.9 kgf-m, 6.5 lb-R)
'

FUEL PUMP INSPECTION
Turn the ignition switch ON and check that the fuel pump operates for few seconds.
If the fuel pump motor does not make operating sound, inspect
the fuel pump circuit connections or inspect the fuel pump relay
and tip-over sensor.
If the fuel pump relay, tip-over sensor and fuel pump circuit connections are OK, the fuel pump may be faulty, replace the fuei
pump with a new one.

FUEL SYSTEM AND THROllLE BODY

FUEL DISCHARGE AMOUNT INSPECTION
Gasoline i s highly flammable and explosive.
Keep heat, spark and flame away.

Remove the fuel tank cover. (-7-6)
* Place a rag under the fuel feed hose and disconnect the fuel
feed hose (ii from the fuel pressure regulator.

,\\
,
I:

Connect a proper fuel hose ' 2 to the fuel pressure regulator.

PI;ace the measuring cylinder and insert the fuel hose end into
the measuring cylinder.

-%.

5-7

5-8

FUEL SYSTEM ANDTHROTTLE BODY

Connect a proper lead wire into the fuel pump lead wire coupler (fuel pump side) and apply 12 volts to the fuel pump
(between terminal CA) and terminal ( 0 ) ) for 10 seconds and
measure the amount of fuel discharged.
Battery (?) terminal -terminal
!A:) (OIGwire)
Battery (-1 terminal -terminal 10)( B N wire)
If the pump does not discharge the amount specified, it means
that the fuel pump or fuel pressure regulator is defective or that
the fuel filter is clogged.
Fuel discharge amount:
Approx. 83 ml(2.812.9 USllmp oz) and morel10 sec.

NOTE:
The battery must be in fully charged condition.

FUEL PUMP RELAY INSPECTION
Fuel pump relay is located in back of the headlight assembly.
Remove the front fender. ( W 7 - 6 )
Remove the fuel pump relay ($1.
First, check the insulation between (A) and @I terminals with
pocket tester. Then apply 12 volts to {Cland ibl terminals, i+! to
(C, and - 1 to ;DJ, and check the continuity between
and i01.
If there is no continuity, replace it with a new one.

' b,

.!.

.h
J

FUEL SYSTEM AND THROTTLE BODY

FUEL VALVEIFUEL FILTER
FUEL VALVE REMOVAL AND DISASSEMBLY
Remove the front fender. ( W 7 - 6 )
Drain the fuel com~letelv.
Remove the fuel tank. ( W 5 - 4 )
Disconnect the fuel vapor return hose :ljand fuel inlet hose
(21and remove the fuel valve (3).

.-.~
.-

Gasoline is highly flammable and explosive.
Keep heat, spark and flame away.
Remove the rubber cushion i4).

Remove the fuel filter cap (9 by removing its mounting screws
diagonally.

Remove the fuel filter

(a.

5-9

5-10

FUEL SYSTEM AND THROTTLE BODY

FUEL FILTER INSPECTION AND CLEANING
If the fuel filter is clogged with sediment or rust, fuel will not flow
smoothly and loss in engine power may result.
Blow the fuel filter with compressed air.

NOTE:
If the fuel filter is clogged with many sediment or rust, replace
the fuel filter, O-ring and fuel filter cap with a new one.

FUEL VALVE REASSEMBLY AND INSTALLATION
Reassemble and install the fuel valve in the reverse order of
removal and disassembly. Pay attention to the following points:
Align the groove
of fuel filter holder with the stopper iB1 and
install the fuel filter to the fuel valve.

_I-

Tighten the fuel filter cap mounting screws to the specified
torque.

NOTE:
Tighten the fuel filter cap mounting screws diagonally.
Fuel fllter cap mounting scerw: 2 N.m (0.2 kgf-m, 1.5 lb-ft)

Apply thin coat of the engine oil to the O-ring

The removed O-ring must be replaced with a new one.

FUEL SYSTEM AND THROllLE BODY

FUEL PRESSURE REGULATOR
REMOVAL
Remove the front fender. ( p 7 - 6 )
Drain the fuel completely.
Remove the fuel tank. ( 0 5 - 4 )
Disconnect the fuel return hose (0.
Remove the fuel pressure regulator (21.

m~
- ~ &

-,y
;!

Gasoline is highly flammable and explosive.
heat, spark and flame away.

INSTALLATION
Install the fuel pressure regulator in the reverse order of
removal.

"8;

.r-

d=l.'

..,

5-11

5-12

FUEL SYSTEM AND THROTTLE BODY

THROTTLE BODY
CONSTRUCTION

ll'l

TP sensor

Throttle body
! 3 ! Fuel delivery pipe
14.1 O-ring
1,51 Fuel injector
161 Injector seal
(21

O! Vacuum hose
Starter valve
Throttle cable cover
'A) Fuel delivery pipe mounting screw
16) Fuel injector mounting screw
!C1 TP sensor mounting screw
i8)
\9!

(C!

3.5
3.5

0.35
0.35

2.5
2.5

FUEL SYSTEM AND THROTTLE BODY

REMOVAL

Remove the front fender. (-7-6)
Remove the fuel tank and fuel tank lower cover. (-5.4)
Disconnect the fuel injector coupler Cil and TP sensor coupler

5-13

(2.

Disconnect the IAP hose

a).

D~sconnectthe throttle cable from drum

E A ~ ]

After disconnecting the throttle cables, do not snap
the throttle valve from full open t o full close. It may
cause damage to the throttle valve and throttle body.

-7
Loosen the throttle body clamp screws and remove the throttle body assembly.

--.

5.14

FUEL SYSTEM AND THROTTLE BODY

Disconnect the starter cable from the throttle body assembly.

&&"Q

- :$,

-a

Remove the starter valve (9 and spring
cable.

from the starter

'.
DISASSEMBLY
Remove the fuel feed hose O

Remove the TP sensor CZ with the special tool.

"DF.';~

09930-11950: Torx wrench
NOTE:

Prior to disassembly, mark the sensor original position with a
paint or scribe for accurate reinstallation.

,+A
4

7
-

,,_ I.
,J

?#
Remove the fuel delivery pipe m.

., :21

FUEL SYSTEM AND THROTTLE BODY 5.15

Remove the fuel injector (4-1.

.
LAU~O~
b v o i d removing the idle air screw (51.

Never remove the throttle valve 161.

@AUTTi?ji
Avoid removlng the throttle lever stopper screw (91.

-- -

r-\
rc

5-16

FUEL SYSTEM AND THROTTLE BODY

CLEANING

dip-type soaking solutions, are very corrosive and
must be handled carefully. Always follow the chemical
manufacturer's instructions on proper use, handling
and storage.
Clean all passageways with a spray-type carburetor cleaner
and blow dry with compressed air.

Do not use wlre to clean passageways. Wire can damage passageways. If the components cannot be
cleaned with a spray cleaner it may be necessary to
use a dip-type cleaning solution and allow them to
soak. Always follow the chemical manufacturer's
instructions for proper use and cleaning of the throttle
body components. Do not apply carburetor cleaning
chemicals to the rubber and plastic materials.

INSPECTION
Check following items for any damage or clogging.
* O-ring
' Throttle valve
" Idle air screw
Vacuum hose

REASSEMBLY
Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:
Apply thin coat of the engine oil to the injector seal.
Install the fuel injector by pushing it straight to throttle body.
.b

L W
'The removed injector seal must b e replaced with a
new one.
Never turn the inlector while pushlng It.

FUEL SYSTEM AND THROTTLE BODY

Tighten the fuel injector mounting screws to the specified
torque.

rn Fuel injector mounting screw:

3.5 N.m (0.35 kgf-m, 2.5 lb-ft)
1.

,, '

Apply thin coat of the engine oil to the O-rings.
Install the fuel delivery pipe (0to the injector (2).

EXIT?
*The removed O-rings must be replaced with new
ones.
Never turn the fuel delivery pipe while pushing it.

Ir,.

Tighten the fuel delivery pipe mounting screws to the specified torque.

[ZJ Fuel delivery pipe mounting screw:
3.5 N.m (0.35 kgf-m, 2.5 lb-ft)

With the throttle valve fully closed, install the TP sensor (3,
and tighten the TP sensor mounting screw to the specified
torque.

mEF_1
The removed O-ring must be replaced with a new one.

NOTE:
Apply thin coat of the engine oil to the O-ring.
Align the throttle shaft end 60 with the groove (ij) of TP sensor.
" Apply grease to the throttle shaft end Cn! ifnecessary.

rn TP sensor mounting screw: 3.5 N.m (0.35 kgf-m, 2.5 lb-ft)

99000-25010: SUZUKI SUPER GREASE "A"
(or equivalent grease)
09930-11950: Torx wrench

NOTE:
" Make sure the throttle valve open or close smoothly.
TP sensor setting procedure. m 4 - I S )

+ Y-W

@'~~

&\
I'
/

5-17

5.18

FUEL SYSTEM AND THROTTLE BODY

INSTALLATION
Install the throttle body assembly in the reverse order of
removal. Pay attention to the following points:
Align the groove of starter valve with the starter cable end.

,.:

Align the lug on the throttle body with the intake pipe's cutout.
1)
Adjust the throttle cable play. (-2-1
Adjust the idle speed. (-2-12)
Adjust the TP sensor setting condition. ( W 4 - 1 9 )

v"*.
*.=.q

FUEL INJECTOR REMOVAL
Remove the front fender. ( D 7 - 6 )
Remove the fuel tank and fuel tank lower cover. ( W 5 - 4 )
With battery negative cable disconnected, disconnect the
injector coupler.
Remove the fuel delivery pipe. ( W 5 - 1 4 )
Remove the fuel injector. (-5-15)

FUEL INJECTOR INSPECTION
Check fuel injector filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in the fuel lines and
fuel tank.
The fuel injector can be checked without removing it from the
throttle body.
Refer to page 4-56 for details.

FUEL INJECTOR INSTALLATION
Apply thin coat of the engine oil to injector seal.
Install the injector by pushing it straight to the throttle body
Never turn the injector while pushing it. (-5-16)
lnstall the fuel delivery pipe. ( V 5 - 1 7 )

THROTTLE POSITION SENSOR (TPS) SETTING
After all adjustments are completed, check or adjust the TPS setting condition.
(Refer to page 4-19 for TPS setting procedure.)

..>

CONTENTS

.....................................................................................
6-2
...................................................................................6 - 3
........................................................ 6 - 3
................................................................6 - 4
.........................................................................
6-4
............................................................6 - 6
........................................6 - 6
...............................................................6 - 6
...............................................................6 - 7
...........................................................
6-7
............................................................................................
6-8
............................................................................................. 6 - 8
..................................................................................6 - 9
....................................................................................... 6 - 9
..................................................6-10
..............................................................................................6-10
.............................................................................................
6-10
.........................................................................................
6-10
.....................................................................................
6-11
............................................................................................
6-12
............................................................................................. 6-12
.........................................................................................6-12
.....................................................................................6-13
.............................................................................................
6-14
.........................................................6-14
.........................................................................................6-16
..................................................6-17
...........................................6-20
..............................................................................6-20
........................................................................................... 6-21
..............................................................................
6-23
............................................................................6-24
....................................................................................
6-24
........................................................................................... 6-24
........................................
6-24
.............................................................................................. 6-24
..........................................6-25
ENGINE COOLANT
COOLING CIRCUIT
COOLING CIRCUIT INSPECTION
RADIATOR AND WATER HOSE
RADIATOR REMOVAL
RADIATOR CAP INSPECTION
RADIATOR INSPECTION AND CLEANING
RADIATOR INSTALLATION
WATER HOSE INSPECTION
RADIATOR RESERVOIR TANK
COOLING FAN
REMOVAL
INSTALLATION
INSPECTION
COOLING FAN RELAY INSPECTION
ECTSENSOR
REMOVAL
INSPECTION
INSTALLATION
THERMOSTAT
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND INSTALLATION
OIL TANK. OIL RETURN TANK AND HOSES
CONSTRUCTION
OIL TANK
OIL RETURN TANK
LUBRICATION SYSTEM
OIL PRESSURE
OIL FILTER
OIL STRAINER
OIL PUMP
ENGINE LUBRICATION SYSTEM CHART

6-2

COOLING AND LUBRICATIONSYSTEM

ENGINE COOLANT
At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene

glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above -31 "C (-24 "F).
If the vehicle is to be exposed to temperatures below -31 "C (-24 "F), this mixing ratio should be increased
up to 55% or 60% according to the figure.
Anti-freeze density
50%

Freezing point
-30 "C (-24 "F)

* 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.
* Do not put in 60% and more anti-freeze or 50% and less. (Refer t o below figure.)
' Do not use a radiator anti-leak additive.
50% Engine coolant including reserve tank capacity
700 ml (1.5!1.2 US/lmp.pt)
700 m1 (1.511.2 US!lrnp.pt)

Anti-freeze
Water
('F)
32
14

E 4
o
a -22

('C)
0

("F) ('C)

-10
-20

-30

(kgftcrnz)

302 150
284 140

1.5

X 266 130

0.9

C
.-

-40

-58

-50

-76

-60

230 110

-94

-70

212 100

C
.-

Fig. 1 Engine coolant density-freezing
point curve

0.5

% 248 120

20 40 60 80 100
Density ("to)

20 30 40 50
Dens~ty(%)

Fig. 2 Engine coolant density-boiling
point curve

You can be injured by scalding fluid or steam if you open the radiator cap when the engine i s
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.
*The engine must be cool before servicing the cooling system.
* Coolant i s harmful;
If It comes i n contact with skin or eyes, flush with water.
If swallowed accidentally, induce vomiting and call physlclan Immediately.
Keep it away from children.

COOLING AND LUBRICATION SYSTEM

6-3

COOLING CIRCUIT

RAD'ATO
WATER PUMP

COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant.
inspect the cooling circuit for tightness.
Remove the side cover (R). ( p 7 - 6 )
Remove the radiator cap 1
9 and connect the tester (2) to the
filler.

Do not remove the radiator cap when the engine i s
hot.

Give a pressure of about 120 kPa (1.2 kgf/cmz, 17 psi) and
see if the system holds this pressure for 10 seconds.
If the pressure should fall during this 10-second interval, it
means that there is a leaking point in the system. In such a
case, inspect the entire system and replace the leaking component or part.

the filler to prevent spouting of engine coolant.
~A~TION]
Do not allow the pressure t o exceed the radiator cap
release pressure, or the radlator can be damaged.

6-4

COOLING AND LUBRICATION SYSTEM

RADIATOR AND WATER HOSE
RADIATOR REMOVAL
Remove the front fender. ( D 7 - 6 )
Drain engine coolant. ( W 2 - 1 5 )
Remove the oil return tank. ( W 6 - 2 3 )
Remove the fuel tank and fuel tank lower cover. ( 0 5 - 4 )
Remove the cooling fan. ( p 6 - 8 )
Remove the radiator reservoir tank. ( P 6 - 7 )
Remove the b a n e y holder. (-6-21)
Remove the cooling fan luse (3) from the radiator.
Disconnect the inlet hose MI.
Disconnect the outlet hose !j'.
* Disconnect the rear brake switch coupler :4j.
Remove the rear brake switch wire harness from the clamp

Remove the main harness '5) from the clamp

Remove the radiator cover mounting bolts

COOLING AND LUBRICATION SYSTEM

Remove the radiator mounting bolts, and then radiator 'GI
from the body of a vehicle.
I, r

flem0ve the radiator cover Cil from the bodv of a v ~ h i r l e

Disconnect the siphon hose is)

6-5

6-6

COOLING AND LUBRICATION SYSTEM

RADIATOR CAP INSPECTION
Remove the radiator cap I !from the radiator.
Fit the cap (1) to the radiator cap tester 1.21.
Build up pressure slowly by operating the tester. Make sure
that the pressure build-up stops at 108 - 137 kPa (1.08 - 1.37
kgflcm'. 15.4 - 19.5 psi) and that. with the tester held standstill, the cap is capable of holding that pressure for at least 10
seconds.
Replace the cap if it is found not to satisfy either of these two
requirements.
Radiator cap valve opening pressure
Standard: 108 - 137 kPa
(1.08 - 1.37 kgflcm2,15.4 19.5 PSI)

RADIATOR INSPECTION AND CLEANING
Road dirt or trash stuck on the f~nsmust be removed.
Use of compressed air is recommended for this clean~ng.

Fins bent down or dented can be repaired by straightening them
with the blade of a small screwdriver.

7----------

...---,

---.-._mIR(

"@:

RADIATOR INSTALLATION
lnstall the radiator in the revers order of removal. Pay attention
to the following points:
Align the grooves on the radiator covers with the boss on the
radiator.
Install the radiator cover to the radiator.
Install the radiator.
Route the siphon hose and radiator hoses. ( D 9 - 2 0 )
* Pour engine coolant. (-2-13)

-,
I+

COOLING AND LUBRICATION SYSTEM

WATER HOSE INSPECTION
Remove the side covers (R & L). ( W 7 - 6 )
Any water hose found in a cracked condition or flattened must
be replaced.
Any leakage from the connecting section should be corrected
by proper tightening.

RADIATOR RESERVOIR TANK
REMOVAUREMOUNTING
Remove the side cover (L). (-7-6)
Remove the reservoir tank mounting bolts and disconnect the
siphon hose from the reservoir tank and drain engine
coolant.
.
Install the reservoir tank in the reverse order of removal.
Pour engine coolant. ( W 2 - 1 5 )

a.
'

6-7

6-8

COOLING AND LUBRICATION SYSTEM

COOLING FAN
REMOVAL
Remove the front fender. (-7-6)
Remove the fuel tank and fuel tank lower cover. ( D 5 - 4 )
Disconnect the cooling fan motor lead wire coupler :i).
Remove the rear brake switch wire harness i 2 ~from the
clamp.

Remove the cooling fan unit

6~.

Remove the cushion (4)

Remove the cooling fan (51.

)t,

.*.

, ..

COOLING AND LUBRICATION SYSTEM

INSTALLATION
Install the cooling fan unit in the reverse order of removal. Pay
attention to the following points:
Apply a small quantity of the THREAD LOCK SUPER "1303"
on the cooling fan motor shaft.
Tighten the cooling fan nut.

6-9

9
-

99000-32030: THREAD LOCK SUPER "1303"
8

INSPECTION
v,

Remove the front fender. (-7-6)
Disconnect the cooling fan coupler (0.
Test the cooling fan motor for load current with an ammeter
connected as shown in the illustration.

i
The voltmeter is for making sure that the battery (2) applies 12
volts to the cooling fan motor (3. With the cooling fan motor
with electric motor fan running at full speed, the ammeter iS)
should be indicating not 5 amperes and more.
If the fan motor does not turn, replace the motor assembly
with a new one.

NOTE:
When making above test, it is not necessary to remove the cooling fan unit,

6-10

COOLING AN0 LUBRICATION SYSTEM

COOLING FAN RELAY INSPECTION

Cooling fan relay is located in rear of the headlight assembly.
Remove the front fender. ( W 7 - 6 )
Remove the cooling fan relay 0).
First check the insulation between i@
and (Bi terminals with
tester. Then apply 12 volts to (0and iD\ terminals, I+) to :c? and
5 to 0,
and check the continuity between 1x1 and is?.
If there is no continuity, replace it with a new one.

!'*
' b4, ,
/.

I.(

.... .h

09900-25008: Multi-circuit tester set

i:mTester knob indication: Continuity test (-111)

ECT SENSOR
REMOVAL

Remove the fuel tank and fuel tank lower cover. ( W 5 - 4 )
D~sconnectthe ECT sensor coupler (II.
Place a rag under the ECT sensor and remove the ECT sensor

.,-

r
INSPECTION
Check the ECT sensor by testing it at the bench as shown in
the figure. Connect the ECT sensor (1'1 to a circuit tester and
place it in the oil (2 contained in a pan, which is placed on a
stove.
Heat the oil to raise its temperature slowly and read the column thermometer (3) and the ohmmeter.

COOLING AND LUBRICATION SYSTEM

I f the ECT sensor ohmic value does not change in the proportion indicated, replace it with a new one.
Temperature sensor specification
Temperature
20 "C (68 "F)
50 "C (122 "F)
80 OC (1 76 "F)
110 *C (230 OF)

Standard resistance
Approx. 2.6 kc2
Approx. 0.772 k n
Approx. 0.279 kiL
Approx. 0.1 18 k i l

Cooling fan operating temperature:
Standard (OFF-ON): Approx. 98 "C (208 "F)
(ON-OFF): Approx. 93 "C (199 T)

If the resistance is noted to show infinity or too much different
resistance value, replace the ECT sensor with a new one.

WFON_I
may cause damage if It gets a sharp impact.
Do not contact the ECT sensor and the column thermometer with a pan.

INSTALLATION
Apply engine coolant to the O-ring.
Tighten the ECT sensor to the specified torque

ECT sensor: 12 N m (1.2 kgf-m, 8.5 lb-ft)

I- C

Take special care when handllng the ECT sensor. It
may cause damage If it gets a sharp impact.
Connect the ECT sensor coupler.
Install the fuel tank lower cover and fuel tank.
Check the engine coolant level. (-2-15)

6-1 l

6-12

COOLING AND LUBRICATIONSYSTEM

THERMOSTAT
REMOVAL
Dra~nthe engine coolant. (137-15)
Place a rag under the thermostat case
Remove the thermostat case ( 1 ) .

Remove the thermostat :2.

INSPECTION
Inspect the thermostat pellet for signs of cracking.
Test the thermostat at the bench for control action, in the following manner.
Pass a string O between flange (2of thermostat, as shown.

Immerse the thermostat in the water contained in a beaker, as
shown in the illustration. Note that the immersed thermostat is
in suspension. Heat the water 81 bv. placinq
.
- the beaker on a
stove (4, and observe the rising temperature on a thermometer (51.
Read the thermometer just when opening the thermostat. This
reading, which is the temperature level at which the thermostat valve begins to open, should satisfy the standard value.
Thermostat valve opening temperature
Standard: Approx. 76.5 "C (169.7 O F )

COOLING AND LUBRICATION SYSTEM

Keep on heating the water to raise its temperature.
Just when the water temperature reaches specified value, the
thermostat valve should have lifted by at least 4.5 mm (0.18
in).
Thermostat valve lift (A)
Standard:
4.5 mrn and over at 90 "C (0.18 i n and over at 194 O F )
A thermostat failing to satisfy either of the two requirements
(start-to-open temperature and valve lift) must be replaced.

INSTALLATION
Install the thermostat in the reverse order of removal.
Apply engine coolant to the rubber seal on the thermostat.
After installing the thermostat and thermostat case, be sure to
add engine coolant. (-2-15)

6-13

6-14

COOLING AND LUBRICATION SYSTEM

WATER PUMP
'7-

REMOVAL AND DISASSEMBLY
NOTE:
Before draining engine oil and engine coolant, inspect engine oil
and coolant leakage between the water pump and crankcase. If
engine oil is leaking, visually inspect the oil seal and O-ring. If
engine coolant is leaking, visually inspect the mechanical seal
and seal washer. p 6 - 16)

Drain engine coolant. (-2-15)
Drain engine oil. ( C 7 2 - 1 3 )
D~sconnectthe rad~atorhose 11 and breather hose 121.

Remove the rear brake switch
(-7-67)

and brake pedal

1%.

Remove the right oil tank hose.

COOLING AND LUBRICATION SYSTEM

Remove the clutch cover (51.

Remove the right crankcase cover (6).

Remove the water pump cover il)

Remove the snap ring Q), water pump driven gear (91, pin
and washer 63.

(a>

:91 tg?k

09900-06107: Snap ring pliers

110)

..
-,

Remove the impeller (li: and water pump body 63.
Remove the O-ring fl41 and il9.

-*-,~+

-6

6.15

E-16

COOLING AND LUBRICATION SYSTEM

Remove the mechanical seal using the special tool.
09921-20240: Bearlng remover set
NOTE:
If there is no abnormal condition, the mechanical seal removal is
not necessay.

&,':,:spj
g!,
7

Place a rag over the water pump.
Remove the oil seal using a suitable bar

NOTE:
If there is no abnormal condition. the oil seal removal is not neo
essary.

Remove the mechanical seal ring
from the impeller.

fib and the rubber seal dl!

INSPECTION
MECHANICAL SEAL
Visually inspect the mechanical seal for damage, with particular attention given to the sealing face.
Replace the mechanical seal that shows indications of leakage.

OIL SEAL
Visually inspect the oil seal for damage, with particular attention given to the lip.
Replace the oil seal that shows indications ol leakage.

COOLING AND LUBRICATION SYSTEM

IMPELLER SHAFT JOURNAL
Visually inspect the journal for damage or scratch.
Replace the water pump body if necessary.

IMPELLER
Visually inspect the impeller and its shaft for damage.

REASSEMBLY AND INSTALLATION
Install the oil seal using the special tool.
09913-70210: Bearing installer set
NOTE:
The stamped mark on the oil seal faces outside.

The removed oil seal must be replaced with a new one.

Apply a small quantity of the SUZUKl SUPER GREASE " A to
the oil seal lip.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

6-17

6-10

COOLING AN0 LUBRICATION SYSTEM

lnslall the mechanical seal using a suitable size socket
wrench.
NOTE:
On the mechanical seal, the sealer iN has been applied.

The removed mechanical seal must be replaced with a
new one.

Install the rubber seal ti^) into the impeller.
After wiping off the oily or greasy matter from the mechanical
seal ring, install it into the impeller.
NOTE:
The paint marked side (6) of the mechanical seal ring faces the
impeller.

* Apply grease to the impeller shaft.

%99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

Apply grease to the 0-r~ngs.
Install the 0-r~ngs12:and (3'1.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

EA~ION]
The removed O-rings must be replaced wlth new ones.

\(2)

COOLING AND LUBRICATION SYSTEM

lnstall the impeller shaft to the water pump body.
Install the water pump body w~ththe impeller to the clutch
cover.

Install the washer !;I)pin
, 61,water pump driven gear (61and
snap ring (71.
09900-06107: Snap ring pliers

Apply engne coolant to the O-ring.
lnstall the O-ring to the water pump cover.

A
-.

The removed O-ring must be replaced with a new one.

lnstall the water pump cover

to the right crankcase cover.

lnstall the right crankcase cover. ( p 3 - 7 0 )
lnstall the clutch cover. ( m 3 - 7 0 )
lnstall the right oil tank hose. ( U 6 - 2 3 )
* lnstall the brake pedal (-7-67)
and rear brake switch.
Connect the breather hose and radiator hose.
Pour engine oil. (-2-13)
Pour engine coolant. ( W 2 - 1 5 )
Adjust the brake pedal. ( W 2 - 1 9 )
* Adjust the rear brake switch. (-2-19)

.>Y

6-19

6-20

COOLING AND LUBRICATIONSYSTEM

OIL TANK, OIL RETURN TANK AND HOSES
CONSTRUCTION

Oil tank hose (R)
Oil tank hose (L)
i.3) O-ring
(4) Oil tank over-flow hose
(5) Oil tank

(6'1 Oil level gauge
i7i Oil return tank

(81 Breather hose
( A Oil tank hose mounting bolt
(6)

Drain plug

ITEM

kgf-rn

lb-ft

COOLING AND LUBRICATION SYSTEM

OIL TANK
REMOVAL
Remove the front fender. ( W 7 - 6 )
Drain englne oil. ( p 2 - 1 3 )
Remove the oil return tank. (-6-23)
Remove the fuel tank and fuel tank lower cover. ( 0 5 - 4 )
Remove the battery. (-8-3)
Remove the oil return tank bracket Oi.

Remove the battery holder (2).

Disconnect the oil tank over-flow hose.

Remove the oil return tank mounting bolts.

6-21

6-22

COOLING AND LUBRICATIONSYSTEM

Remove the oil tank hose mounting bolts. and then remove
the oil tank and right and left oil tank hoses from the body of a
vehicle.

REMOUNTING
Remount the oil tank and oil tank hoses in the reverse order of
removal. Pay attention to the following points.
Apply engine oil to the O-rings.
Install the O-rings to the right and left hoses.

Use the new O-rings to prevent engine coolant leak-

COOLING AND LUBRICATION SYSTEM

Tighten the oil tank hose mounting bolls to the specified
torque.
Oil tank hose mounting bolt:

10 N.m (1.0 kgf-m, 7.0 lb-ft)

,? I* 'i

.?S>~:$Y@

* Install the oil tank.
Pour engine oil. ( W 2 - 1 3 )

OIL RETURN TANK
REMOVAL AND DISASSEMBLY
Remove the oil return tank mounting bolt.

Disconnect the breather hoses ti:),
remove the oil return tank I@.

@)'

and

6) and then.

INSPECTION
Inspect the oil return tank for damage.
Clean the oil return tank.

INSTALLATION
Install the oil return tank in the reverse order of removal.

' v -

6.23

6-24

COOLING AND LUBRICATION SYSTEM

LUBRICATION SYSTEM
OIL PRESSURE
W2-35

OIL FILTER
-2-1

OIL STRAINER
C33-51

OIL PUMP
-3-44

COOLING AND LUBRICATION SYSTEM

6.25

ENGINE LUBRICATION SYSTEM CHART

CAM FACE (IN & EX)

9
CRANK PIN

RIGHT CRANKSHAFT
1)

PISTON PIN
CYLINDER WALL
I..,

OIL NOZZLE

STARTER CLUTCH

RIGHT CRANKCASE

-------.-

OIL FILTER

BY-PASS

I--i
OIL PUMP (NO, I )

SPACER

I GENERATYR COVER 1

G
?

OIL PUMP (NO. 2)

OIL PUMP (FOR RETURN)

OIL PAN

d=
OIL STRAINER (FRONT)

CONTENTS
I

..............................................................................................
7-3
.......................................................................................
7-3
.....................................7 - 5
..................................................................................................
7-6
..........................................................................................
7-8
.............................................................................7 - 9
...................................................................................
7-9
.................................................................................................
7-10
........................................................
7-11
.......................................................7-12
...................................................................................................................
7-15
................................................................................
7-15
....................................................................................................
7-18
.......................................................................................
7-18
...................................................................
7-19
...........................................................7-20
................................7-20
................................................................
7-22
.........................7-23
.......................................7-24
.......................................................................
7-24
................................7-25
...........................7-25
.......................................................7-26
....................7-27
.........................................................................................
7-29
.......................................................................................
7-29
..................................................................................................
7-30
...........................................................
7-31
.......................................................7-35
.................................................7-38
............................................................................
7-38
.....................................................................................................
7-40
.......................................................................................
7-40
..................................................................................................
7-41
..............................................................................................
7-41
..........................................................................................
7-42
............................................................................................................
7-44
.......................................................................................
7-44
.................................................................................................. 7 4 5
..........................................................7-47
.......................................................7 4 9
...................................................................................
7-52
......................................................................7-53
......................................................................................................
7-54
.......................................................................................
7-54
...................................................................
7-55
................................................................7-56

EXTERIOR PARTS
CONSTRUCTION
FASTENER REMOVAL AND REINSTALLATION
REMOVAL
INSTALLATION
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
TIRES
TIRE REPLACEMENT
FRONT BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND INSTALLATION
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND INSTALLATION
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND INSTALLATION
FRONT SUSPENSION
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
FRONT SHOCK ABSORBER DISPOSAL
SUSPENSION SETTING
HANDLEBARS
CONSTRUCTION
REMOVAL
INSPECTION
INSTALLATION
STEERING
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
TOE ADJUSTMENT
FRONT WHEEL. FRONTBRAKE, FRONTSUSPENSION AND STEERING
REASSEMBLING INFORMATION
REAR BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT

CONTENTS

................................7-57
................................................................7-59
......................... 7-60
.......................................7-63
......................................................................7-63
........................... 7-64
......................................................7-65
.................... 7-65
....................................................................................................
7-67
..................................................................................................
7-67
..........................................................................................
7-67
................................................................................
7-68
.......................................................................................
7-68
..................................................................................................
7-68
.......................................................7-69
.....................................................7-77
...................................................7-72
............................................................................7-73
.............................................................
7-75
.......................................................................................
7-75
..................................................................................................
7-76
...........................................................7-76
.......................................................
7-80
.
......................................................7-82
..........................................................................................................
7-83
.......................................................................................
7-83
..................................................................................................
7-84
...........................................................
7-86
...........................................................................................
7-89
..........................................................................................
7-90
.........................................................................................................
7-97
.......................................................................................
7-91
.................................................................................................
7-92
...........................................................7-94
......................................................7-96
...... 7-102
......................................................................................................
7-103
........................................................................7-103
..................................................................7-104
...................................................................7-107
......................................................................................
7-107
.................................................................................................
7-107
............................................................................................
7-107
.........................................................................................
7-108

BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND INSTALLATION
BRAKE DISC REMOVAL AND INSTALLATION
BRAKE DISC INSPECTION
MASTER
REMOVAL AND DISASSEMBLY
. . .CYLINDER
-~
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND INSTALLATION
BRAKE PEDAL
REMOVAL
INSTALLATION
REAR SHOCK ABSORBER
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
REAR SHOCK ABSORBER DISPOSAL
SUSPENSION SETTING
CUSHION ROD AND CUSHION LEVER
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
CUSHION ROD CUSHION LEVER AND
REAR SHOCK ABSORBER INFORMATION
SWINGARM
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY
INSTALLATION
REAR AXLE
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
REAR WHEEL. REAR BRAKE, REAR SUSPENSION.
REARS WINGARM AND REAR AXLE REASSEMBLING INFORMATION
DRIVE CHAIN
DRIVE CHAIN CUTTING
DRIVE CHAIN CONNECTING
DRIVE CHAIN CONTROL ROLLER
CONSTRUCTION
REMOVAL
INSPECTION
INSTALLATION
.

CHASSIS

EXTERIOR PARTS
CONSTRUCTION

:1:) Fuel tank cover

iAi Front fender mounting screw

ti, Side cover
0)Front fender
14'1 Headlioht cnver

(a') To front fender
ib' To frame

7-3

7-4

CHASSIS

(1) Rear fender

3 Cushion (Rear)
(31 Cushion (Front)
14) Mud guard reinforcement

I :5;I Footrest mud auard

Rear fender mounting screw
(6) Mud guard mounting screw
ial To fuel tank cover
(br To seat rail
iA1

CHASSIS

FASTENER REMOVAL AND
REINSTALLATION
REMOVAL
Depress the head of fastener center plece (1)
Pull out the fastener.

INSTALLATION
Let the center piece stick out toward the head so that the
pawls (i)close.
Insert the fastener into the installation hole.

NOTE:
To prevent the pawl from damage, insert the fastener all the
way into the installation hole.

7-5

7-6

CHASSIS

REMOVAL
SEAT

Remove the seat f!) by pulling the lock release cable which is
located behind the rear fender.

'1
I -I

SIDE COVER, FRONT FENDER AND FUEL TANK COVER
Remove the seat ( W a b o v e )
Remove the slde covers (1 1, left and r~ght

Remove the fuel tank cap (5.
Remove the fuel tank cover iS)

Remove the front fender (6) by removing the fasteners.

!"!&Z
-17
;-

Remove the brackets T )from the front fender (61.

FRONT GRIP
Remove the front grip (3).

FOOTREST MUD GUARD AND
MUD GUARD REINFORCEMENT
Remove the footrest mud guards ('TI),lefl and right.

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--.

Remove the mud guard reinforcements in, left and right.

FOOTREST
Remove the mud guard reinforcements. ( W a b o v e )
Remove the footrests (0,
left and right.

7-8

CHASSIS

REAR FENDER
Remove the seat. (-7-6)
Remove the fuel tank cover. ( W 7 - 6 )
Remove the rear fender (1) by removing the mounting screws.

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INSTALLATION
Install the exterior parts in the reverse order of removal. Pay
attention to the followina- .points:
FOOTREST
* Apply THREAD LOCK "1342" to the bolts and tighten bolts to
the specified torque.

.,
-'

a 9 9 0 0 0 - 3 2 0 5 0 : THREAD LOCK "1342"

..-\

Footrest mounting bolt: 55 N.rn (5.5 kgf-m, 40.0 ib-ft)

=~
-

MUD GUARD REINFORCEMENT
Apply THREAD LOCK SUPER "1 322" to the mud guard reinforcement mounting bolts.
I

a 9 9 0 0 0 - 3 2 1 1 0 : THREAD LOCK SUPER "1322"
(or equivalent thread lock)

REAR FENDER AND FOOTREST MUD GUARD
Apply THREAD LOCK SUPER "1322" to the rear fender
mounting screws and footrest mud guard mounting screws.
(-7-4)
-99000-32110:

THREAD LOCK SUPER "1322"
(or equivalent thread lock)

.,. ,
,

..-- -.

CHASSIS

7-9

FRONT AND REAR WHEELS
CONSTRUCTION
I

7-10

CHASSIS

REMOVAL
FRONT AND REAR WHEELS
Place the vehicle on level ground.
Support the vehicle w ~ t ha jack or wooden block.
Remove the wheels by removing the wheel set nuts
Remove the front hub plate 11,).

" 7-

d'@

FRONT WHEEL HUB
Remove the front brake caliper 'l!.( W 7 - 2 0 )
Remove the cotter pin, and then loosen the wheel hub nut.
Remove the wheel hub nut and washer.
Remove the front wheel hub :2).

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D o not operate the brake lever while removing the caliper.

(2)

Remove the brake disc. (-7-24)
Remove the collar (3) and spacer (4.;

REAR WHEEL HUB
Remove the rear wheel. ( W 7 - 1 0 )
Remove the cotter pin and loosen the wheel hub nut by applying the rear brake.
Remove the wheel hub nut and washer.
Remove the wheel hub (7).

Tx,,y'r,

,..

".',:.:k: 45 kPa (0.45 kgflcm2,6.5 psi)

7.18

CHASSIS

FRONT BRAKE
CONSTRUCTION

(Z]
--ITEM

ili:

N.m
10
23
6
26
18
18
23
16

ill

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IB~

16,
1

, Fi

1D
nut

kgf-m
1.O

2.3
0.6
2.6
1.8
1.8
2.3
1.6
2.3

lb-ft
7.0
16.5
4.5
19.0
13.0
13.0
16.5
11.5
16.5

CHASSIS 7-19

' This brake system i s filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mlx
different types of fluid, such as silicone-based or petroleum-based.

' Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or which has been stored for a long periods of time.

'When storing brake fluid, seal the container completely and keep it away from children.
When replenishing brake fluid, take care not to get dust into the fluid.

' When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake dlsc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

m o q
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage them severelv.

BRAKE PAD REPLACEMENT
Remove the front wheel and front hub plate. ( W 7 - 1 0 )
Remove the brake caliper mounting bolts (9 and brake pad
mounting pins 12).

Remove the brake pads.

pad removal.

' Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
Install the new brake pads.

NOTE:
Before installing the new pads, inspect the pad mounting pins
for wear. If excessive wear is found, replace them with new
ones.
Apply THREAD LOCK SUPER "1360" to the brake caliper
mounting bolts @I.

99000-32130: THREAD LOCK SUPER "1360"

Tighten the brake pad mounting pins (27 and brake caliper
mounting bolts t i ) to the specified torque.
Brake pad mounting pin: 18 N.m (1.8 kgf-m, 13.0 lb-ft)
Brake caliper mounting bolt:
26 N.m (2.6 kgf-m, 19.0 lb-ft)
NOTE:
After replacing the brake pads. pump the brake lever several
times to check for proper brake operation and then check the
brake fluid level.

7-20

CHASSIS

BRAKE FLUID REPLACEMENT

Place the vehicle on a level surface and keep the handlebar
straight.
Remove the master cylinder reservoir cap and diaphragm.
Suck UD the old brake fluid as much as ~0sSible.
Fill the reservoir with new brake fluid.

6 Specification and classlfication: DOT 4

Connect a clear hose to the alr bleeder valve and insert the
other end of the hose into a receptacle.
Loosen the air bleeder valve and pump the brake lever until
the old brake fluid is completely out of the brake system.
Close the air bleeder valve and disconnect the clear hose. Fill
the reservoir with new brake fluid to the upper mark of the resewoir.

m Brake air bleeder valve: 6 N.m (0.6 kgf-m, 4.5 lb-ft)

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LCPUTloN
' Never

reuse the brake fluid left over from previous
servicing and whlch has been stored for long periods of time.
Bleed air from the brake system.
(cz72-21)

.~
.

.. ,

BRAKE CALIPER REMOVAL AND
DISASSEMBLY

Remove the front wheel and front hub plate. ( W 7 - 1 0 )
Disconnect the brake hose from the brake caliper by removing the brake hose union bolt (7) and allow the brake fluid to
drain into a suitable receptacle.
Remove the brake caliper by removing the brake caliper
mounting bolts i21.
Remove the brake pads. (W7-19)

Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose,
brake pipe and hose joints tor cracks and leakage of
brake fluid.

-7
.,

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-

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i

2.4

CHASSIS 7.21

Remove the spring 3 1

Remove the brake caliper holder 14).

Remove the rubber Darts.

Place a rag over the brake caliper piston to prevent the piston
from popping out and then force out the piston using compressed air.

l,e

Do not use high pressure air t o prevent brake callper
piston damage.

Remove the dust seals (9 and piston seals is':.
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Do not reuse the dust seals and piston seals t o prevent fluid leakage.

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7-22

CHASSIS

BRAKE CALIPER INSPECTION
BRAKE CALIPER
lnspect the brake callper cyl~nderwall for n~cks,scratches or
other damage. If any defects are found, replace the brake call~ ewr~ t ha new one

BRAKE CALIPER PISTON
lnspect the brake callper plstons for any scratches or other damage. If any defects are found, replace the plston wtth new ones

RUBBER PARTS
lnspect the rubber parts for damage. If any defects are found,
replace them with new ones.

CALIPER HOLDER
Inspect the caliper holder (D and caliper holder pin tij for damage. Ifany defects are found, replace them with new ones.

$.~/@

BRAKE CALIPER REASSEMBLY AND
INSTALLATION
Reassemble and install the brake caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
Clean the caliper bores and pistons with the specified brake
fluid. Thoroughly clean the dust seal grooves and piston seal
grooves.
B-Speclflcation and classlficatlon: DOT 4

LC~TION~
-

Clean the brake caliper components with fresh brake
fluid before reassembly.
Do not wipe the brake fluld off after cleanlng the
components.
'When cleanlng the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine or others.
' Replace the removed piston seals and dust seals
with new ones.
Apply brake fluid to all of the seals, brake callper
bores and pistons before reassembly.

PISTON SEAL
Install the piston seals ,TI and dust seals (2) as shown.

BRAKE CALIPER HOLDER
Apply SUZUKl SILICONE GREASE to the brake caliper
holder pins.

& 99000-25100: SUZUKl SILICONE GREASE
b

7-24

CHASSIS

Apply THREAD LOCK SUPER "1360 to the brake caliper
mounting bolts 1
2
.

-99000-32130:

THREAD LOCK SUPER "1360"

Tighten the brake pad mounting pins (7.1,brake caliper mounting bolts (2) and brake hose union bolt (3) to the specified
torque.

18 N.m (1.8kgf-rn, 13.0 lb-ft)
Brake pad mounting pin:
Brake caliper mounting bolt:
26 N m (2.6 kgf-m, 19.0 lb-ft)
23 N.m (2.3kgf-m, 16.5 lb-ft)
Brake hose union bolt:

0
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For assembly procedure of brake hose. ( U 9 - 2 2 )
NOTE:
Before remounting the brake caliper, push the brake caliper pistons all the way into the caliper.

The removed brake hose washers should be
replaced wlth new ones in order t o prevent leakage
of brake fluid.
' Bleed air from the system after reassembling the
brake caliper. ( W 2 - 2 1 )
Install the front hub plate and front wheel. (-7-14)

-- - -- - -- - .

BRAKE DISC REMOVAL AND
DISASSEMBLY
Remove the front wheel. (C37-10)
Remove the front wheel hub. ( D 7 - 1 0 )
Remove the brake disc.

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. +a
BRAKE DlSC INSPECTION
Remove the front wheel and front hub plate. (-7-10)
Remove the caliper. (-7-20)

Inspect the brake disc for cracks or damage and measure the
thickness using the micrometer. If any defects are found or if the
thickness is less than the service limit, replace the brake disc
with a new one.

09900-20205:Micrometer (0- 25 rnrn)
Brake disc thickness
Servlce Llrnlt: 2.5 mm (0.098in)

@
''

CHASSIS

7-25

Measure the runout using the dial gauge. If the runout exceeds
the service limit, replace the brake disc with a new one.
09900-20607: Dial gauge (1H00 mm)
09900-20701: Magnetic stand

Brake disc runout
Servlce Limit: 0.3 mm (0.012 in)
If either measurement exceeds the service limit, replace the
brake disc with a new one.
Install the caliper. ( V 7 - 2 4 )
Install the front hub plate and front wheel. (-7-14)

BRAKE DISC REASSEMBLY AND
INSTALLATION
Reassemble and install the brake disc in the reverse order of
removal and disassembly. Pay attention to the following points:

- - -- --.
-

Apply THREAD LOCK SUPER "1360 to the brake disc bolts
and tighten them to the specified torque.

c - -

NOTE:
Make sure that the disc is clean and free of any greasy matter.
-99000-32130:

THREAD LOCK SUPER "1360"

Brake disc bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)

0-7

****(;'

Install the front wheel hub and front wheel. ( D 7 - 1 3 , 14)

MASTER CYLINDER REMOVAL AND
DISASSEMBLY

p
*

.
.

Place a rag underneath the brake hose union bolt on the master cylinder to catch any split brake fluid. Remove the brake
hose union bolt and disconnect the brake hose.

Is.
IpEiGjTj
contacting any part of the vehlcle. The brake fluld
reacts chemically wlth paint, plastics, rubber materials, etc., and will damage them severely.
Remove the master cylinder assembly.
Disconnect the brake switch coupler.

-9

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,

CHASSIS

7.26

Remove the brake lever

and brake switch (21

Pull the dust boot (3out and remove the snap ring 6:.

09900-06108: Snap ring pliers

Remove the piston assembly C f l

MASTER CYLINDER INSPECTION
MASTER CYLINDER
Inspect the master cylinder bore for any scratches or damage. If
any defects are found, replace the master cylinder with a new
one.

PISTON AND RUBBER PARTS
Inspect the p~stonsurface, prlmarylsecondary cup and dust boot
for any scratches, wear or damage. If any defects are found,
replace the plston set w ~ t ha new one.

.--

st'::;wr~(rn'(\\

MASTER CYLINDER REASSEMBLY AND
INSTALLATION
Reassemble and install the master cylinder in the reverse order
of removal and disassembly. Pay attention to the following
points:

EA@T~
'Clean the master cylinder components with fresh
brake fluid before reassembly.
Do not wipe the brake fluid off after cleaning the
components.
'When cleaning the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine or others.
' Apply brake fluid t o the cylinder bore and all the
component to be Inserted into the bore.

fi Specification and classification: DOT 4
Align the convex part (A) of brake switch with the hole iB, of
master cylinder when installing the brake switch.

,&.

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..-,
.-

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Apply SUZUKl SILICONE GREASE to the brake lever bolt.
Apply SUZUKl SILICONE GREASE to the contact point
between piston and brake lever.
99000-25100: SUZUKl SILICONE GREASE

(

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,

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4
~.. 4

CHASSIS

FRONT SUSPENSION
CONSTRUCTION
1

7.29

7-30

CHASSIS

REMOVAL
Remove the front wheel. ( W 7 - 1 0 )
Remove the front wheel hub. (-7-10)
Remove the brake caliper. (-7-20)
Remove the brake hose clamp 171.
Disconnect the brake hose at the hose clamp

Remove the front d ~ s ccover (21.

Remove the cotter pin and tie rod end nut.

Remove the tie rod end (3) from the steering knuckle (4)with a
commercially available ball bearing joint remover (5).

Remove the front shock absorber lower mounting bolt (W.
Remove the wishbone arm assembly (7).

T,
1-

. i

Remove the front shock absorber i8') by removing the upper
mounting bolt.

Remove the cotter pins, nuts @I, spring washer 03)and washer
(11).

Remove the steer~ngknuckle 02 with a commerc~allyava~lable
ball bearing jo~ntremover f31.
(

INSPECTION AND DISASSEMBLY
FRONT SHOCK ABSORBER
Inspect the shock absorber body for oil leakage or damage. If
any defects are found, replace the shock absorber with a new
one.

c:--

CAUTIO~

Do not attempt to disassemble the front shock
absorber. It is unserviceable.
FRONTSHOCKABSORBERDUSTSEAL
Remove the collars.

Inspect the dust seal lips and collars for wear or damage.
If any defects are found, replace the dust seals and collars w~th
new ones.

7,
# !

Remove the dust seals.

The removed dust seals must be replaced with new
ones.

e
,
.
,
-

--.

FRONT SHOCK ABSORBER BEARING
Inspect the bearings for abnormal noise and smooth movement.

1 q r - q -

Remove the needle roller bearings.

Remove the bearing cages with the special tool.

09921-20240: Bearing remover set

1- C

A
.

]

The removed bearing cages must be replaced with
new ones.

;.-

STEERING KNUCKLE
Inspect the steerlng knuckle for damage. If any defects are
found, replace the steering knuckle with a new one.

a
I

KNUCKLE END
lnspect the knuckle end boot for wear or damage. If any defects
are found, replace the knuckle end with a new one.
lnspect the knuckle end for smooth movement. If there are any
abnormalities, replace the wishbone arm with a new one.

LOWER WISHBONE ARM
lnspect the knuckle end boot and lower wlshbone arm for wear
or damage If any defects are found. replace the lower w~shbone
arm wlth a new one.
lnspect the knuckle end smooth movement. If there are any
abnormalttles, replace the knuckle end w~tha new one.

WISHBONE ARM DUST SEAL
Remove the collars.

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--*.

UPPER WISHBONE ARM
lnspect the upper wishbone arm for wear or damage. If any
defects are found, replace the upper wishbone arm with a new
one.

., ,

'~4'
,.

7-34

CHASSIS

Inspect the dust seal lips and collars for wear and damage. If
any defects are found, replace them with new ones.

Remove the dust seals.

WISHBONE ARM PIVOT BEARING
Inspect the bearings for abnormal noise and smooth movement.

Remove the needle roller bearings.

Remove the bearing cages with the spec~altools.
09923-73210: Bearing puller
09930-30104: Sliding
- hammer

I~TION~
The removed bearing cages must be replaced with
new ones.

CHASSIS 7-35

BRAKE DISC COVER
Inspect the brake d~sccover for damage. If any defects are
found, replace the brake disc cover with a new one.

REASSEMBLY AND INSTALLATION
Reassemble and install the front susoension in the reverse order
of removal and disassembly. Pay attention to the following
points:
WISHBONE ARM
Press fit the bearing cages with the special tool and a suitable
size socket wrench.

@ 09924-84521: Bearlng Installer set
NOTE:
Position the bearings by referring to the illustration of page 7-53.
Apply grease to the needle roller bear~ngs.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

Apply grease to the dust seal lips and collars.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

.--

Install the dust seals and collars into the upper wishbone arm
and lower wishbone arm.
NOTE:
* Stamped mark on the dust seal must face outside.
Position the dust seals by referring to the illustration of page

7-53.
FRONT SHOCK ABSORBER
Press fit the bearlng cages w~ththe special tool and a su~table
slze socket wrench.
09924-84510: Bearing installer set

NOTE:
Position the bearings by referring to the illustration of page 7-53.

Apply grease to the needle roller bearings.

& 99000-25010: SUZUKl SUPER GREASE "A"

{ \
'--

Handlebar clamp bolt: 26 N.m (2.6 kgf-m, 19.0 lb-ft)

NOTE:
The higher portion of handlebar holder must face forward, so
that the clearance 0of holder is in back of the handlebars.

Apply the grease to the end of starter cable

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)
When remounting the left handle switch. engage the stopper
0with the handlebar hole

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I.:

P'
-

Ad-

Align the punch mark IF) on the handlebars with the mating
surface i G of clutch lever holder.
Tighten the clutch lever holder clamp bolts to the specified
torque.
Clutch lever holder clamp bolt:
10 N.m (1.0 kgf-rn, 7.5 lb-ft)

HIClearance
Align the punch mark
on the handlebars with the mating
surface I J ) of throttle lever case.
Tighten the throttle lever case bolts to the specified torque.

rn Throttle lever case bolt: 5 N.rn (0.5 kgf-rn, 3.5 lb-ft)
Install the brake master cylinder. ( W 7 - 2 8 )

7-44

CHASSIS

STEERING
CONSTRUCTION

CHASSIS 7-45

REMOVAL
Remove the front wheel. (-7-10)
Remove the side covers, fuel tank cover and front fender.

(-7-6)
Remove the handlebars. ( W 7 - 4 1 )
Remove the handlebar holder nuts, washers and handlebar
holder (D.

Remove the tie rod end (2) with a commercially available ball
bearing joint remover (3).
4

@
,.

Loosen the steering arm plate bolt ciil.
Remove the cotter pin and steering shaft nut
steering arm plate
and dust seal (8).

(9,
washer el,

Remove the cotter pins, tie rod end nuts and spring washers.

Remove the steering arm plate i l j with a commercially available ball bearing joint remover (3).

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\\

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C

' 8

Remove the brake pipe joint mounting bolt (9.
Remove the cable guide (i@.

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,
,

Remove the steering shaft holder bolts.
Remove the steering shaft plate KO.

Remove the steering shaft @.
Remove the steering shaft holder 03) and collars (:@.
Remove the steering shaft holder bushing (19 from the steering shaft.
I

CHASSIS 7.47

INSPECTION AND DISASSEMBLY
STEERING SHAFT HOLDER BUSHING
lnspect the bushing for wear or damage. If any defects are
found, replace the bushing with a new one.

TIE ROD
lnspect the tie rod for distortion or damage. If any defects are
found, replace the tie rod with a new one.

('71Tie rod end

d ) Lock-nut
(31Lock-nut
(41 Tie rod

IU!TloNI
I The lock-nuts (2)have left-hand threads.
TIE ROD END
lnspect the tie rod ends for smooth movement. If there are any
abnormalities, replace the tie rod ends with new ones.
lnspect the tie rod end boots for wear or damage.
If any defects are found, replace the tie rod ends with new ones.

STEERING SHAFT
lnspect the steering shaft for distortion or bend. If any defects
are found, replace the steering shaft with a new one.

STEERING SHAFT HOLDER
Inspect the steerlng shaft holders for wear or damage If any
defects are found, replace the steerlng shaft holders with new
ones.

STEERING SHAFT BUSHING AND DAST SEAL
Inspect the steerlng shaft bushing IJ
and dust seals @ for wear
and damage. If any defects are found, replace them w~thnew
ones.

i
)f'

Remove the steering shaft bushing and dust seals with the
special tools and a suitable size socket wrench.
09924-84521: Bearing installer set
09930-30721: Rotor remover

Install the steering shaft bushing and dust seal with the special tool.
09924-84521: Bearing installer set

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- --

CHASSIS 7-49

REASSEMBLY AND INSTALLATION
Reassemble and install the steering shaft in the reverse order of
removal and disassembly. Pay attention to the following points:
STEERING SHAFT
Apply grease to the steerlng shaft holder bushtng.

,!&99000-25010: SUZUKI SUPER GREASE "A"

(or equivalent grease)
Install the steering shaft holder bushing to the steerlng shaft.

Apply grease to the steering shaft and O-ring.

Replace the O-ring with a new one.

99000-25010: SUZUKI SUPER GREASE " A
(or equivalent grease)

NOTE:
When installing the steering to the vehicle, turn the recess
the spline part of steering shaft to the forward of the vehicle.

k./

d
l

Apply grease to the bushing and dust seal.

99000.25010: SUZUKI SUPER GREASE "A"
(or equivalent grease)
*'
.,

Apply grease to the steering shaft holders before remounting
the steering shaft holders.

99000-25010: SUZUKl SUPER GREASE " A
(or equivalent grease)

5-,
--

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26
9:

[CAFO~

To prevent the entry of dirt, the dust seal end 63)must
face rearward when Installing the dust seal to the
steerinq shaft.

. "
. .'

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.

r-.

-I

7.50

CHASSIS

-k?T

Tighten the steering shaft holder bolts to the specified torque.
Steering shaft holder bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
Make sure that the wiring harness, cables and brake hose routing are properly. (C39-15, 78 and 22)

Apply grease to the dust seal.
Install the dust seal to the steering shaft

When installing the steering arm plate, align the wide spline
iC) of steering shaft with slit (Dl of steering arm plate.

* Apply THREAD LOCK SUPER "1322" to the thread part of
steering shaft.
-99000-32110:

THREAD LOCK SUPER "1322"
(or equivalent thread lock)

Tighten the steering shaft nut iii to the specified torque.

rn Steering shaft nut: 120 N.m (12.0 kgf-m, 87.0 lb-ft)

Apply THREAD LOCK SUPER "1322" to the thread part of
steering arm plate boil (2) and tighten it to the specified
torque.
a 9 9 0 0 0 - 3 2 1 1 0 : THREAD LOCK SUPER "1322"
(or equivalent thread lock)

rn Steering arm plate bolt: 29 N.m (2.9 kgf-m, 21.0 lb-R)
Install the cotter pin.

Replace the removed cotter pin wlth a new one.

..
:

(.-j

CHASSIS 7-51

TIE ROD
Tighten the tie rod end nuts to the specified torque
Tie rod end nut: 23 N.m (2.3 kgf-m, 16.5 lb-ft)
Install the cotter pins.

W~ONJ
E e p l a c e the removed cotter pins wlth new ones.

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3

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fl

NOTE:
When installing the tie rod, make sure the narrow end (1) of the
tie rod comes out.

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The lock-nuts Qj surface have left-hand threads.

8 Forward
HANDLEBAR HOLDER
Set the handlebar holder 171 with facing the projection @ forward.
Tighten the handlebar holder nut to the specified torque.

fl Handlebar holder nut: 60 N.m (6.0 kgf-m, 43.5 ib-ft)
Reinstall the handlebars. ( W 7 - 4 2 )
Reinstall the front fender.
Reinstall the front wheel. ( W 7 - 1 4 )

TOE ADJUSTMENT
Adjust the toe-in as follows:
Place the vehicle on level ground and set the handlebars
straight.
Make sure all the tires are inflated to the standard pressure.
(D2-24)
Place 75 kg (165 lbs) of weight on the seat.
Loosen the lock-nuts ((0,
tl)on each lie rod.

NOTE:
Hold the concave part (a') of tie rod with a wrench.

The lock-nuts (2) have left-hand threads.

Measure the distances (iiii and (8)) between the front wheels.
Subtract the measurements of (& from the measurements of
(B to find the toe-in. If the toe-in is not within specification,
adjust the tie rod to the right or left until the toe-in is within the
specified range.
(0. - (68 = Toe-in
Toe-In
Standard: 0

* 4 rnrn (0 1: 0.16 In)

Temporarily tighten the four lock-nuts.
Check that the distances (10
and td) are equal, as shown. If
the distances are not equal, adjust the tie rod lo the right or
lett until the toe-in is within specification. Check the toe-in
again by measuring distances iA) and Cb!.
If the toe-in is not within specification, repeat the adjustment
as above until the proper toe-in is obtained and distances 'Cl
and (D! become equal.
After adjustment has been made, tighten the four lock-nuts (1)
to the specified torque.

NOTE:
Hold the concave part @I of tie rod a wrench.
Tle rod lock-nut: 29 N.m (2.9 kgf-m, 21.0 lb-ft)

FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND
STEERING REASSEMBLING-INFORMATION

I
-

REAR BRAKE
CONSTRUCTION

I
Reservoir tank
2 1 Reservoir tank hose
(31 Brake hose
14) Snao rino
(I!

1
'1lj I Brake caliper holder
(16) Piston seal

ria! Parking brake

!Is) Parking brake lever
f2Oi Adjuster

120 0-rina

I (J) I Brake caliper mounting bolt
I 'K, I Disc bolt

2.3

16.5

* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix

different types of fluid such as silicone-based or petroleum-based.
Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake
fluid left over from the last servicing or stored for long periods.
" When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
' When cleaning brake components, use fresh brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

. -- ~.
CAUTION/
-

Handle brake fluid with care: the fluid reacts chemically wlth paint, plastics, rubber materials
etc. and will damage them severely.

BRAKE PAD REPLACEMENT

.-.bFp-.

.-' . ,,

Flatten the lock washer (,I, and then slightly loosen the pad
mounting pins (2).

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7 ,,

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Loosen the lock-nu! (3 and turn out the parking brake adjuster
@I several turns.

Remove the caliper mounting bolts.
Remove the brake pads by removing the pad mounting pins.
-

-..

(

1-1

CAUTION
the pads.
Replace the brake pads as a set, otherwlse braking
performance will be adversely affected.

Install the new brake pads.
NOTE.
+ Before installing the new pads, inspect the pad mounting pins
for wear. If excessive wear is found, replace them with new
ones.
+ B e sure to loosen the parking brake adjuster before installing
the i ads.

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,.

7.56

CHASSIS

Apply THREAD LOCK SUPER"1360 to the callper mountlng
bolts

'
1

99000-32130: THREAD LOCK SUPER " 1 3 6 0

(

Tighten the caliper mounting bolts to the specified torque.

rn Brake caliper rnountlng bolt: 26 N.m (2.6 kgf-rn, 19.0 lb-ft)
Tighten the pad mounting pins 15) to the specified torque, and
then bend the lock washer.

-4mpqIlJ!,

rn Pad mounting pin: 18 N.m (1.8 kgf-m, 13.0 lb-ft)

NOTE:
After replacing the brake pads, pump the brake pedal several
times to check for proper brake operation and then check the
brake fluid level.

Adjust the parking brake. ( D 2 - 1 9 )

'
1

BRAKE FLUID REPLACEMENT
Place the vehicle on a level surface.
Remove the seat. ( W 7 - 6 )
Remove the master cylinder reservoir cap and diaphragm.
Suck up the old brake fluid as much as possible.
Fill the reservoir with new brake fluid.

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Specification and classlflcation: DOT 4

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A
1PJ
b
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-4

Connect a clear hose to the air bleeder valve and insert the
other end of the hose into a receptacle.
Loosen the air bleeder valve and pump the brake pedal until
the old brake fluid is completely out of the brake system.
Close the air bleeder valve and disconnect the clear hose. Fill
the reservoir with new brake fluid to the upper level.

rn Brake air bleeder valve: 6 N.m (0.6 kgf-m, 4.5 lb-ft)

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' Never

reuse the brake fluid left over from previous
servicing and which has been stored for long periods of time.
Bleed air from the brake system.
(c3-2-21)

I.:.

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''';

BRAKE CALIPER REMOVAL AND
DISASSEMBLY
Loosen the lock-nut Ti) and remove the parking brake
adjuster (2).
Remove the spring 13) and disconnect the parking brake
cable (4).
* Remove the parking brake lever :%.

Disconnect the brake hose by removing the brake hose union
bolt (6)and allow the brake fluid to drain into a suitable receptacle.
Remove the parking brake housing CT' and gasket (0).

Brake fluid, if it leaks. will interfere with safe runnlng
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.
Remove the brake caliper by removing the caliper mounting
bolts.

NOTE:
Before removing the caliper, sllghtly loosen the caliper holder
slide pin @) to facilitate later disassembly.

Remove the pads. ( W 7 - 5 5 )
Remove the pad spring m.

Remove the callper holder sl~depin (m, and then remove the
caliper holder IT and washer fl51.

7-58

CHASSIS

Remove the rubber parts.

Place a rag over the brake caliper piston to prevent the piston
from popping out.
Force out the piston by pushing the piston pin 'a'.

Remove the dust seal %', p~stonseal (16, and 0 - r ~ n g117,.

Do not reuse the dust seal, piston seal and O-ring t o
prevent leakage of brake fluid.
Do not a t t e m ~to
t remove the retainer 18.

BRAKE CALIPER INSPECTION
BRAKE CALIPER
lnspect the brake callper cyltnder wall for nlcks, scratches or
other damage If any defects are found, replace the brake callper wtth a new one.

-7
f

BRAKE CALIPER PISTON
lnspect the brake caliper piston for any scratches or other damage. If any defects are found, replace the piston with a new one.

RUBBER PARTS AND SLIDE PIN
lnspect the rubber parts for damage. If any defects are found.
replace them with new ones.
lnspect the slide pin il) for damage. If any defects are found.
replace it with a new one.

CALIPER HOLDER
lnspect the caliper holder m and callper holder pin Qr for damage. If any defects are found, replace them w ~ t hnew ones.

PARKING BRAKE
lnspect the parking brake for damage and smooth rotatton by
turn~ngthe axle. If there is anything unusual, replace the parktng
brake wtth a new one.

a?@

7.60

CHASSIS

BRAKE CALIPER REASSEMBLY AND
INSTALLATION
Reassemble and install the brake caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
Clean the caliper bore and piston with the specified brake
fluid. Thoroughly clean the dust seal grooves and piston seal
grooves.
Specification and classificatlon: DOT 4
CAUTION I

" Clean the brake caliper components wlth fresh brake
fluid before reassembly.
* Do not wipe the brake fluid off with a rag after cleaning the components.
When cleaning the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine or others.
Replace the removed piston seals and dust seals
wlth new ones.
* Apply brake fluld t o all of the seals, brake caliper
bores and pistons before reassembly.

PISTON SEALS
Install the piston seal (I),
dust seal (21and 0-r~ng131 as shown
In ~llustration.

BRAKE CALIPER HOLDER
Apply SUZUKl SILICONE GREASE to the brake callper
holder pln and callper holder sl~depin.

& 99000-25100: SUZUKl SILICONE GREASE

-.
\.

Apply THREAD LOCK SUPER "1303 to the caliper holder
slide pin (11.

a 9 9 0 0 0 - 3 2 0 3 0 : THREAD LOCK SUPER "1303"

a),

Install the caliper holder slide pin
washer i2) and caliper
holder (3, to the caliper.
Tighten the caliper holder slide pin fllito the specified torque.

[T1 Caliper holder slide pin: 23 N.m (2.3 kgf-m,

16.5 lb-ft)

Install the pad spring and pads. ( W 7 - 5 5 )
NOTE:
When installing !he caliper holder slide pin (I
and
rwasher
) 12).the
convex of washer must face slide pin as shown in illustration.
Apply THREAD LOCK SUPER "1360 to the caliper mounting
bolts and tighten the them to the specified torque.

99000-32130: THREAD LOCK SUPER "1360"

Brake caliper mounting bolt: 26 N.m (2.6 kgf-m. 19.0 lb-ft)

-J7"m!

. .
I"

-99000-32130:

THREAD LOCK SUPER "1360"

m Brake hose union bolt: 23 N.m (2.3 kg4-m, 16.5 lb-ft)

p!-'?y"-A
a,
-.
1
,.

'The removed brake hose washers should be
replaced with new ones In order t o prevent leakage
of brake fluld.
Bleed air from the system after reassembling the
brake caliper. (-2-21)

%
'

.,.

FUTION]

99000-25100: SUZUKl SILICONE GREASE

t-.?%-

Parking brake housing bolt: 28 N.m (2.8 kgf-m, 20.0 lb-ft)

When repiaclng the boot w~tha new one, apply SUZUKl SILICONE GREASE to the groove of parklng brake axle.

NOTE:
Before remounting the brake caliper, push the brake caliper piston all the way into the caliper.

Tighten the brake hose union bolt.
Install the parking brake housing GR and new gasket.
Apply THREAD LOCK SUPER "1360" to the parking brake
bolts and tighten them to the specified torque.

""1'

-.-

I
!

Loosen the lock-nut (5)and turn the adjuster (61in completely,
so that the cable play is maximum.

,.$A

Set the parking brake shaft II' in neutral position by rotating
the shaft.
Install the parking lever @~! onto the parking brake shaft i f )
with the punch mark (61 aligned with corner of hexagon on the
parking brake shaft
so that parking lever (6:' is at angle of
i as shown in illustration.
approx. 90 degrees to the line W

(a,

Hook the return spring (9)on the parking lever with the spring
end faced the caliper.
Connect the parking cable
Install the adjuster (iD and the lock-nut !i?.
Adjust the parking brake. ( W 2 - 1 9 )

(m.

CHASSIS 7-63

BRAKE DlSC REMOVAL AND INSTALLATION
REMOVAL
Remove the rear wheel. ( D 7 - 1 0 )
Remove the rear axle. ( W 7 - 9 2 )
Remove the brake disc.
INSTALLATION
lnstall the brake disc to the rear axle.

NOTE:
Make sure that the disc is free of any greasy matter.
Apply THREAD LOCK SUPER "1360"to the brake disc bolts
and tighten them to the specified torque.

-99000-32130:

THREAD LOCK SUPER "1360

C] Brake disc bolt: 23 N.m (2.3 kgf-rn, 16.5 lb-tt)
Install the rear axle. ( W 7 - 9 8 )
Install the rear wheel. (-7-14)

?\\Y

BRAKE DlSC INSPECTION
Inspect the brake disc for cracks or damage and measure the
thickness using the micrometer. If any defects are found or if the
thickness is less than the service limit, replace the brake disc
with a new one.

& 09900-20205:Micrometer (0- 25 mm)
Brake disc thickness
Servlce Limit: 3.5 mm (0.138in)

Remove the brake caliper. ( W 7 - 5 7 )
Measure the runout using the dial gauge. If the runout exceeds
the service limit, replace the brake disc with a new one.

09900-20607:Dial gauge (11100mm)
09900-20701:Magnetic stand
Brake dlsc runout
Servlce Llmlt: 0.3 mm (0.012In)
Install the brake caliper. ( W 7 - 6 1 )

I
,
'
?

? '7'
n'

--~

z.-a.

MASTER CYLINDER REMOVAL AND
DISASSEMBLY
Drain the brake fluid. ( W 7 - 5 6 )
Place a rag underneath the brake hose union bolt and reservoir tank hose connector on the master cylinder to catch any
split brake fluid. Remove the brake hose union bolt and disconnect the brake hose and reservoir tank hose.

I?
,.

i
,'.
+

contacting any part of the vehicle. The brake fluld
reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
Remove the master cylinder rod pin. (-7-67)
Remove the master cylinder mounting bolt.
Remove the master cylinder (11.

Remove the connector 32) and O-r~ng
151 by removtng the snap
ring (4).
09900-06108: Snap ring pllers

Remove the dust boot (5).
Remove the snap ring (6'1.
09900-06108: Snap ring pliers

T..

Remove the push rod '77,
p~stonassembly 18)

MASTER CYLINDER INSPECTION
MASTER CYLINDER
lnspect the master cylinder bore for any scratches or damage. If
any defects are found, replace the master cylinder with a new
one.

PISTON AND RUBBER PARTS
Inspect the piston surface, primarylsecondary cup and dust boot
for any scratches, wear or damage. If any defects are found.
replace them with a new one,

MASTER CYLINDER REASSEMBLY AND
INSTALLATION
Reassemble and install the master cylinder in the reverse order
of removal and disassembly. Pay attention to the followinq point:

Clean the master cylinder components with fresh
brake fluid before reassembly.
'Do not wipe the brake fluid off after cleanina
.
, the
components.
When cleanlng the components, use the specified
brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine or others.
'Apply brake fluid t o the cyllnder bore and all the
component to be inserted into the bore.

fi Specificatlon and classification: DOT 4

7-66

CHASSIS

Apply SUZUKl MOLY PASTE to the push rod.

& 99000-25140: SUZUKl MOLY PASTE

Install the master cylinder rod pin. (-7-67)
Tighten the master cylinder mounting bolts O!.
Master cylinder mountlng bolt:
10 N.m (1.0 kgf-m, 7.0 lb-ft)

~--\.

Tighten the brake hose union bolt (2 to the specified torque.
Connect the reservoir tank hose.
Brake hose union bolt :2j: 23 N.m (2.3 kgf-rn, 16.5 lb-ft)

NOTE:
After contacting the brake hose union to the stopper, tighten the
union bolt.

pEip5q
replaced with new ones.
Bleed air from the system after reassembling the
brake master cylinder. ( W 2 - 2 1 )
Adjust the brake pedal height. ( W 2 - 1 9 )

i '

...

CHASSIS 7.67

BRAKE PEDAL
REMOVAL
Remove the c l ~ p'1).
Remove the cotter pln (2) and washer (31

Remove the master cylinder rod pin a).
Remove the brake pedal pivot bolt (51.
Remove the return spring iC> and rear brake switch spring (7')
from the brake pedal Wi.

INSTALLATION
Apply grease to the oil seal and brake pedal pivot bolt.
99000-25010: SUZUKl SUPER GREASE "A"
(or equlvalent grease)

Install the return spring and rear brake switch spring properly.

(-9-26)

Tighten the brake pedal pivot boll to the specified torque.
Brake pedal pivot bolt: 29 N.m (2.9 kgf-rn, 21.0 lb-ft)
Install cotter pins and clip.

~ T Z T N ~
Replace the removed cotter pin with a new one.

Adjust the brake pedal height. (-2-19)

--..

.2:

7-68

CHASSIS

REAR SHOCK ABSORBER
CONSTRUCTION

ID Rear shock absorber
(2, Collar
!3! Dust seal
(4:'

(51 Collar

Rear shock absorber mounting nut

,XI

I
IA~ 1

ITEM

N.m
60

I
1

kgf-m
6.0

Ib-ft

43.5

Bearing

REMOVAL
Ra~sethe rear wheel off the ground and support the vehicle
with jack or wooden block.
Remove the cushion rod lower boltlnut.

jm!gF'. -

:s.

Remove the rear shock absorber mounting boltslnuts.

- ..
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Remove the rear shock absorber.

INSPECTION AND DISASSEMBLY
REAR SHOCK ABSORBER
Inspect the shock absorber body for 011leakage or damage.
If any defects are found, replace the shock absorber w~tha new
one.

CAUTION]
L-

Do not attempt t o disassemble the rear shock
absorber. It is unserviceable.
REAR SHOCK ABSORBER DUST SEAL
Remove the collars.

lnspect the dust seal lips and collars for wear or damage.
If any defects are found, replace the dust seals and collars with
new ones.

w
&-'

.
I

7.70

CHASSIS

Remove the dust seals

1- '
The removed dust seals must be replaced with new
ones.

i@
)

REAR SHOCK ABSORBER BEARING
Inspect the bearings for abnormal noise and smooth movement

Remove the needle roller bearings.

Remove the bearing cage with the special tool.
09921-20240: Bearing remover set

Lcnfifioq
The removed bearing cage must be replaced with a
new one.

REASSEMBLY AND INSTALLATION
Reassemble and install the rear shock absorber in the reverse
order of removal and disassembly. Pay attention to the following
points:
Press fit the bearing cage with the special tool and a suitable
size socket wrench.
09924-84521: Bearlng installer set

NOTE:
Position the bearings by referring to the illustration of page 7-82.

%> .
-

Apply grease to the needle roller bearings.

-.. fa-

99000-25010: SUZUKl SUPER GREASE "A"
(or equlvalent grease)

Apply grease to the dust seal lhps and collars
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)
Install the dust seals (TJ and collars (2) lnto the rear shock
absorber

T~ghteneach bolvnut to the spec~f~ed
torque
Rear shock absorber nut (Upper) '31:
60 N m (6.0 kgf-m, 43.5 lb-ft)
Rear shock absorber nut (Lower) (41:
60 N.m (6.0 kgf-m, 43.5 lb-ft)
Rear cushion rod nut f51:78 N.m (7.6 kgf-m, 56.5 lb-ft)

..*

7.72

CHASSIS

REAR SHOCK ABSORBER DISPOSAL
The rear shock absorber unit contains high-pressure
nitrogen gas.
Mishandling can cause explosion.
'Keep away from fire and heat. High gas pressure
caused by heat can cause an explosion.
Release gas pressure before disposing.

GAS PRESSURE RELEASE
The rear cushion damper unit contains high-pressure nitrogen
gas. Make sure to observe the following precautions.

since it can explode or oil can splash hazardously.
When discarding the rear cushion unit, be sure to
release gas pressure from the unit following the procedures below.
Mark the drill center at the location @ using a center punch.
Wrap the rear cushion unit with a vinyl bag and fix it on a vise as
shown.
Drill a 2 - 3 mrn (0.08 - 0.1 2 in) hole at the marked drill center
using a drilling machine and let out gas while taking care not to
get the vinyl bag entangled with the drill bit.

Be sure to wear protective glasses since drilling
chips and oll may fly off with blowing gas when the
drill bit has penetrated through the body.
' Make sure to drill at the specified position. Otherwise, pressurized oil may spout out forcefully.

SUSPENSION SETTING
After installing the rear suspension, adjust the spring pre-load
and damping force as follows.
SPRING PRE-LOAD ADJUSTMENT
The set length 222 mm (8.7 in) provides the maximum spring
ore-load.
The set length 236 mm (9.3 in) provides the minimum spring
pre-load.

STD length: 299 mm (11.8 in)

LcAUTION_J
-

Do not set the spring length out of the specified range.
Remove the rear shock absorber. ( W 7 - 6 8 )
Loosen the lock-nut iT).
Adjust the spring set length by turning the adjuster h).
Tighten the lock-nut (71 to the specified toraue.

Rear shock absorber lock-nut:

30 N.m (3.0 kgf-m, 21.5 lb-ft)
Remount the rear shock absorber. ( p 7 - 7 1 )

DAMPING FORCE ADJUSTMENT
The rebound and compression damping force are adjustable for
rider's preference, rider's weight and field condition.

NOTE:
Do not turn the adjuster screws more than given position, or the
adjuster may be damaged.
Rebound slde
Fully turn the damping force adjuster (ijclockwise. It is at stiffest
position and turn it out to standard setting position.
STD position: 7 clicks out from stiffest posltlon
[Fine-tune the adjuster by turning it slightly until two punch
marks align.]
NOTE:
Make sure to check the 1st click position by last sound when
turning in the adjuster.

-A
'

-~
\
- .\*
' _

7-74

CHASSIS

Compression side
(Low-side)
Fully turn the damping force adjuster i21 clockwise. It IS at stiffest
position and turn it out to standard setting position.

STD position (Low speed compression):
8 clicks out from stiffest position
(High-side)
Fully turn the damp~ngforce adjuster 131clockwise. It is at stiffest
position and turn it out to standard setting position.

STD position (High speed compression):
314 turns out from stiffest position

[Fine-tune the adjuster by turning it slightly until two punch
marks align.]
Standard suspension setting

Spring set length

Standard

299 mm (1 1.8 in)

REAR
Damping force adjuster
Rebound
Compression
8 clicks out from stiffest
Low speed
position
7 clicks out from stiffest
position
3/4 turns out from stiffest
High speed
position

CHASSIS

CUSHION ROD AND CUSHION LEVER
CONSTRUCTION

(1) Rear shock absorber

(2) Cushion rod
(3) Cushion lever

(4) Bearing

Washer
(81 Collar
Rear shock absorber mount'A'
ing nut

(51 Spacer

(g) Cushion rod nut

Dust seal

(Ci Cushion lever nut

7-75

7-76

CHASSIS

REMOVAL
Place the vehlcle on the level ground and support the veh~cle
w ~ t ha lack or wooden block
Remove the drive chain control roller 1.1).

?Fv
.

r?f
A
IR

Remove the cushion rod (21.

Remove the cushion lever 13)

INSPECTION AND DISASSEMBLY

SPACER
Remove the collars, washers and spacers lrom the cushlon
lever.
Remove the spacer from the cush~onrod

Inspect the spacers for damage. If any defects are found.
replace the spacers with new ones.

a
0

'
,,

\
- ~0
0
\\

DUST SEAL
Inspect the dust seal lips for wear or damage. If any defects are
found, replace them with new ones.

Remove the dust seals.

The removed dust seals must be replaced with new
ones.

4)
/k

BEARING
Inspect the bearings for abnormal noise and smooth movement.

Remove the needle roller bearings.

CHASSIS

Remove the needle bearing cages with the special tools.
09921-20240: Bearing remover set
09923-73210: Bearing puller
09930-30104: Sliding hammer

The removed bearing cages must be replaced with
new ones.

TIP,$9
*'

d1~\
CUSHION ROD AND CUSHION LEVER
Inspect the cushion rod and cushion lever for damage and distortion. If any defects are found, replace them with new ones.

7-79

7-80

CHASSIS

REASSEMBLY AND INSTALLATION
Reassemble and install the cushion rod and cushion lever in the
reverse order of removal and disassembly. Pay attention to the
following points:
Press fit the bearing cages with the special tool and a suitable
size socket wrench.
09924-84521: Bearing installer set

NOTE:
Position the bearings by referring to the illustration of page 7-82.

Apply grease to the dust seal lips, spacers, collars and needle
roller bearings.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

NOTE:
The stamped mark on the dust seals must face outside.

_fl

.~7

Tighten the rear shock absorber mounting boltlnul and cushion lever bolUnut to the specified torque.
Rear shock absorber nut (Lower) t i ) :
60 N.m (6.0 kgf-rn, 43.5 lb-ft)
Cushion lever nut 12:78 N.rn (7.8 kgt-rn, 56.5 lb-ft)

p'..

/,,C

F-7

Is>-

- ~ ~ - .

Tighten the cushion rod boltstnuts to the specified torque.
Cushion rod nut 6):
78 N.rn (7.8 kgf-rn, 56.5 lb-ft)
Install the drive chain control roller. (-7-107)
. b'

7-82

CHASSIS

CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER
INFORMATION

5.75 rnrn (0.23in)

SWINGARM
CONSTRUCTION

7.84

CHASSIS

REMOVAL

Place the vehicle on the level ground and support the vehicle
with a jack or wooden block.
Remove the rear wheels. ( W 7 - 1 0 )
Remove the rear wheel hubs. (-7-10)
Remove the rear axle. ( W 7 - 9 2 )
Remove the axle housing. ( U 7 - 9 4 )
Remove the rear brake disc cover ii~.

7,
>.-

~3 "

p .

Remove the sprocket guard 12).

Remove the brake hoselparking brake cable guides.

Remove the cushion rod upper boltlnut and rear shock
absorber lower mounting bolt/nut.

!!m

. ..
'

Loosen the swingarm pivot nut and remove the washer and
swingarm pivot shaft.
Remove the swingarm assembly.

I<,)
y
;
.

7-rn5:'-'
.

'ih\
CI

Remove the chain buffer 0)and chain slider (4).

Remove the rear axle housing set bolts/nuts and chain
adjuster rubber seal (5).

-.
-..,

(.JG

' r n
..

Remove the E-ring
and rear brake caliper bracket bush~ng
(7).
Remove the rear brake caliper bracket stopper (8'.

'W'

---

' 0

4
-3

*CI

7-86

CHASSIS

INSPECTION AND DISASSEMBLY
Remove the following items from the swingarm:
Outer dust seals !i)
Thrust washers (21
Thrust bearings t31
Outer spacers ;4':
Inner spacers (3

SPACER
lnspect the spacers for damage. If any defects are found.
replace the spacers with new ones.

ye,

DUST SEAL
lnspect the dust seal lips for wear or damage. If any defects are
found, replace them wtth new ones.

.'-

THRUST BEARING AND THRUST WASHER
lnspect the thrust washers (1) and thrust bear~ngs(2) for damage. Ifany defects are found, replace them w ~ t hnew ones.

BEARING
Insert the inner spacers into bearings and check the play
when moving the inner spacers up and down. If excessive
play is noted, replace the bearings with new ones.
lnspect the bearings for abnormal nolse and smooth movement.

Remove the bearings (outer) with special tools.

09921-20240: Bearing remover set

The removed bearings must be replaced wlth new
ones.

-a

Remove the dust seals (inner).
Remove the bearings (inner) with special tool.
09913-70210: Bearing installer set

The removed bearings must be replaced with new
ones.

SWINGARM PIVOT SHAFT
Using a dial gauge, check the pivot shaft runout. If the runout
exceeds service limit, replace the pivot shaft with a new one.

09900-20607: Dial gauge (11100 mm, 10 mm)
09900-20701: Magnetic stand
09900-21304: V-block (100 rnm)

Swingarm pivot shaft runout:
Service Limit: 0.3 rnm (0.01 in)
SWINGARM
lnspect the swingarm for cracks and damage. If any defects are
found, replace the swingarm with a new one.

CHAIN BUFFER
Inspect the cha~nbuffer for wear and damage. If any defects are
found, replace the chain buffer w ~ t ha new one.

7-88

CHASSIS

REAR BRAKE DISC COVER
lnspect the rear brake disc cover for damage.

SPROCKET GUARD
lnspect the sprocket guard for damage.

CHAIN SLIDER
lnspect the chain slider for wear and damage. If any defects are
found, replace the chain slider with a new one.

CHAIN GUIDE AND CHAIN GUIDE PLATE
lnspect the chain guide for wear and damage.
lnspect the chain guide plate for damage.

CHAIN ADJUSTER RUBBER SEAL
lnspect the chain adjuster rubber seal for wear and damage.

REASSEMBLY
Reassemble the swingarm in the reverse order of disassembly.
Pay attention to the following points:

CHASSIS 7-89

-,*-

BEARING
Press f ~the
t bear~ngswith the speclal tool and a sultable slze
socket wrench.

09924-84510: Bearing installer set

NOTE:
" The stamped mark on the bearings must face outside.
Position the bearings by referring to the illustration of page
7-102.

-39

* -6

Apply grease to the bearings.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

'.,

DUST SEAL
Apply grease to the dust seal Ihps.

& 99000-25010: SUZUKl SUPER GREASE "A"

(or equlvalent grease)

NOTE:
The stamped mark on the dust seals inner must face outside.

Apply grease to the spacers.

99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)
Install the spacers Into the swlngarrn.

6,"

6
-1

w'-

'
?

INSTALLATION
lnstall the swingarm in reverse order of removal. Pay attention to
the following points:
CALIPER BRACKET STOPPER
Apply THREAD LOCK SUPER "1303"to the callper bracket
stopper and t~ghtenit.

a99000-32030:THREAD LOCK SUPER "1303"

lnstall the swingarm and pivot shaft.
Tighten the swingarrn pivot nut to the specified torque.
Swingarm pivot nut: 95 N.m (9.5kgf-rn, 68.5 lb-ft)

7
,

:/( " i

f.
I*

fl
I
b

Install the rear shock absorber and cushion rod. ( D 7 - 7 1 )
Apply THREAD LOCK SUPER "1322"to disc cover mounting
bolts.

99000-32110:THREAD LOCK SUPER "1322"
(or equivalent thread lock)
lnstall the axle housing and rear axle. (-7-98)
lnstall the wheel hubs. (-7-13)
lnstall the rear wheels. ( W 7 - 1 4 )
FINAL INSPECTION AND ADJUSTMENT
After installing the rear suspension and wheel, the following
adjustments are required before driving.
* Drive chain (-2-26)
+ Parking brake ( W 2 - 1 9 )

: '

e
.%.,,v
a , ?'
.-

--.'>.

3C
..

.>.. ':,'-

. ,a

-I .,

-7

CHASSIS 7-91

REAR AXLE
CONSTRUCTION
I

-,
-YO)- Dust seal
ill)

(12'

03)
041

ti51

Bearing
Axle housing
Spacer
Dust seal
O-ring

.. .

Rear wheel hub (Left)
(A) Brake disc bolt
iB) Sprocket mounting nut
(C) Axle nut
ib, Axle lock-nut
Rear axle housing set nut

REMOVAL
Place the vehicle on the level ground and support the vehicle
with a jack or wooden block.
Remove the rear wheels. ( W 7 - 1 0 )
Remove the rear wheel hubs. (-7-10)
Remove the bracket 1.71,chain guide plate 121and chain guide i5!.

wn..-

!~.

Loosen the rear axle housing set nuts c4).
* Move the rear axle forward and make sure that the drive chain
has enough slack. (-2-26)

~t
C ,

.-,C\

REAR AXLE
Loosen the axle lock-nut ri'r and axle nut (2) with the special
tool by applying the rear brake.

(4!

-7

-.-

,.'

09940-92460: Rear axle nut wrench set

1,.

Remove the axle lock-nut (11.

/
(11

Loosen the axle nut (2) completely and push the axle nut
holder (3.
Remove the C-ring fi'.

Remove the axle nut (21 (along with the axle nut holder (9).
Remove the washers (9
and ('6).

,I*..

-$,

.,?

$ v-,,?
L

j-.
~

.= <

:- *;.,-I3

-L

Disengage the drive chain (3from the rear sprocket.
Remove the sprocket flange (8 (along with the rear sprocket).

-,-

..>

,\+,,

#---

..,. .:.

1 .. - ~ ~ .

Remove the rear sprocket 19) from the sprocket flange Si.

Remove the brake caliper. ( W 7 - 5 7 )
Draw out the rear axle cb
l to the right side

Remove the brake disc.

.,
1.7

Push the rear brake disc plate housing cii! and remove the
C-ring $4.
Remove the rear brake disc plate housing (iT, from the rear
axle.

6..

PF
./,

a',.
,

.,@

7,
"

7.94

CHASSIS

REAR AXLE HOUSING
Remove the snap rings (1\.

09900-06107: Snap ring pliers
Remove the rear brake caliper bracket (2:

Remove the axle housing (3 and washer (4'.

INSPECTION AND DISASSEMBLY
SPROCKET
Inspect the sprocket teeth for wear. If they are worn as shown.
replace the engine sprocket, rear sprocket and drive chain as a
set.

pfEq
Normal wear

REAR AXLE
Measure the rear axle runout. If the runout exceeds the service
limit, replace the rear axle with a new one.
Rear axle runout
Service limit: 6.0 mm (0.24 in)

09900-20607: Dial gauge (11100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
NOTE:
When measuring the runout, support the rear axle at 35 mm
(1.38 in) diameter of the rear axle as shown in illustration.
Measure the runout at 40 mm (1.57 in) diameter of Me rear axle
as shown in illustration.

Excessive wear

657'

Dlal gauge

REAR BRAKE DISC PLATE HOUSING AND SPROKET
FLANGE
Inspect the rear brake disc plate housing and sprocket flange for
damage and wear of spline. If any defects are found, replace the
rear brake disc plate housing or sprocket flange with a new one.

'.fi

REAR BRAKE CALIPER BRACKET
inspect the rear brake caliper bracket for distortion or damage.
If any defects are found, replace the rear brake caliper bracket
with a new one.

DUST SEAL
Inspect the dust seal lips for wear or damage If any defects are
found, replace the dust seals wlth new ones.

Remove the dust seals with the special tool.
09913-501 21: 011 seal remover

1C A U T I ~
-

The removed dust seals must be replaced with new
ones.

BEARING
inspect the play of the axle bearings by hand while they are in
the axle housing. Rotate the inner race by hand to inspect for
abnormal noise and smooth rotation.
If there is anything unusual, replace the bearings with new ones.

.-/

7-96

CHASSIS

Remove the left bearings (inner and outer) with appropriate
and remove the spacer O.
bar !I)

1 CAUTION]

The removed bearings must be replaced with new
ones.

Remove the right bearing in the same manner as the left
bear~ng.

AXLE HOUSING
Inspect the axle houslng for damage. if any defects are found,
replace the axle housing w~tha new one.

REASSEMBLY AND INSTALLATION
Reassemble and install the rear axle and rear axle housing in
the reverse order of removal and disassembly. Pay attention to
the following points:
AXLE HOUSING
Apply grease to the bearings.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

CHASSIS

7-97

Install the bearings to the axle housing with the special tool.
09913-70210: Bearing installer set
09924-84510: Bearing installer set
09941-34513: Bearing installer set

[cnuTloNJ
First lnstall the right bearings iSi to the bottom, and
then install the spacer and left bearings (2,.
'When installing the hub bearings to the axle housing, the sealed cover of inner bearing must face
inside, and the sealed cover of outer bearing must
face outside.

Q Right

-4-

Clearance

Install the dust seals with the special tool.

09913-70210: Bearing installer set

NOTE:
The stamped mark on the dust seals must face outside.

7-98

CHASSIS

* Apply grease to the dust seal lips.
99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

.l-

Apply englne 011to the 0-r~ngs

I CAUTION I
Replace the O-rings wlth new ones.
Install the 0-rlngs to the axle houslng and

r3k&%

Apply grease to the O-ring and install the O-ring.

pGFi6iT

FT'
a . -

99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

;[

Install the axle housing and washer into the swingarm.

* Apply grease to the contact surface of the rear caliper
bracket.

& 99000-25010: SUZUKl SUPER GREASE "A"
(or equivalent grease)

09900-06107: Snap rlng pliers

Replace the O-ring with a new one.

Install the snap rings to the axle housing.

7
r
x

,-;
i. 6 .!
fl

,'I .

'.,
,

CHASSIS 7-99

REAR AXLE
Apply grease to the O-ring and spline of rear brake disc plate
housing.

ICAUTION

Replace O-ring with a new one.

)i& 99000-25010: SUZUKI SUPER GREASE "A"
(or equivalent grease)
Apply grease to the spline of rear axle.

ji&

99000-25010: SUZUKI SUPER GREASE " A
(or equivalent grease)

Install the C-ring and rear brake disc plate housing to the rear
axle.

7 %../-.9
,

Apply THREAD LOCK SUPER "1360 to the brake disc bolts
and tighten them to the specified torque.

-99000-32130:

THREAD LOCK SUPER "1360"

Brake disc bolt: 23 N.m (2.3 kgf-m, 16.5 lb-ft)

NOTE:

a- !..
(

.
"

Make sure that the brake disc is clean and free of any grease
matter.

,
2s'

Insert the rear axle through the axle housing and drive chain.
Install the brake caliper. ( W 7 - 6 1 )

Apply grease to the O-ring and spline of sprocket flange

Replace the O-ring with a new one.

)i& 99000-25010: SUZUKI SUPER GREASE "A"
(or equivalent grease)

7-100

CHASSIS

Tighten the sprocket mounting nuts to the specified torque.
Sprocket mounting nut: 60 N.m (6.0 kgf-m, 43.5 lb-ft)
NOTE:
The stamped mark @! must Face to right side of the vehicle.

,-; ,

'fi

Rm'--%

Apply grease to the spl~neof rear axle

/&99000-25010: SUZUKl SUPER GREASE "A"
(or equlvalent grease)

Install the sprocket flange fi to the axle shaft.
Engage the drive chain (2) from the rear sprocket.

Install the washer (thick)
washer (thin) 0,
axle nut (5) and
C-ring (6).
Apply THREAD LOCK SUPER "1322" to the thread portion of
the axle nut holder.

99000-321 10: THREAD LOCK SUPER "1322"
(or equivalent thread lock)

Tighten the axle nut O to the specified torque with the special
tool.
Rear axle nut: 240 N.m (24.0 kgf-m, 173.5 lb-ft)

09940-92460: Rear axle nut wrench set
NOTE:
When tightening the axle nut with the special tool, the reading
torque on the torque wrench is smaller than actual torque that is
applied to the axle nut. Therefore convert the tightening torque.
p7-101)

Apply THREAD LOCK SUPER "1322" to the thread portion of
the axle nut holder.

99000-32110: THREAD LOCK SUPER "1322"
(or equivalent thread lock)

Tighten the axle lock-nut c6? to the specified torque with special tool.
Rear axle lock-nut: 240 N-m (24.0 kgf-m, 173.5 ib-ft)
09940-92460: Rear axle nut wrench set

NOTE:
When tightening the axle lock-nut with the special tool, the reading torque on the torque wrench is smaller than actual torque
that is applied to the axle lock-nut. Therefore converl the tightening torque. (C7below)
Install the rear wheel hubs and wheels. ( W 7 - 1 3 ,14)
After installing the rear axle, adjust the chain slack and parking brake cable. ( W 2 - 1 9 , 26)
Tighten the rear axle housing set nuts in ascending order and
to the specified torque.
Rear axle housing set nut: 28 N.m (2.8 kgf-rn, 20.0 lb-ft)

REAR AXLE NUT TIGHTENING TORQUE
Measure the effective length L of the torque wrench.
Calculate the reading torque on the torque wrench by use of the
formula shown below.

L x Ts
L + LS
T: Reading torque on the torque wrench
Ts: Specified torque
Ls: 0.060 m (2.36 in)
Off-set of the specified special tool (09940- 92460)
L: Effective length of the torque wrench

09940-92460: Rear axle nut wrench set

7-102

CHASSIS

REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR
SWINGARM AND REAR AXLE REASSEMBLING INFORMATION

4.5 mrn

OUT SIDE

L
A

ITEM
.A#

1
/

N.rn
95

I kgf-rn I

9.5

lb-fl
68.5

ITEM

N.m

kgf-m

lb-ft

$1)

121
28

12.1
28

20.0

87.5

DRIVE CHAIN
1

Use the special loo1 in the following procedures, to cut and rejoin
the drive chain.
09922-22711: Drive chain cutting and joining tool set

NOTE:
When using the special tool, apply a smaN quantity of grease to
the threadedparts of the special fool.

DRIVE CHAIN CUTTING
Set up the special tool as shown in the illustration.
a J TOOI body
h)Grip handle
13: Pressure bolt " A
i4! Pressure bolt "B"
(57 Bar
16) Adjuster bolt (with through hole)
17) Pin remover
is, Chain holder (engraved mark 500)
with reamer bolt M5 x 10

NOTE:
The tip of pin remover (9) should be posifioned inside approximately 5 mm (0.2 in) from the end face of pressure bolt ' W " ( 3 as
shown in the illustration.

5 rnrn (0.2 in)

7-104

CHASSIS

Place the drive chain link being disjointed on the holder part

c81of the tool.
Turn in both the adjuster bolt (6'1 and pressure bolt " A (31 so
that each of their end hole fits over the chain joint pin properly.
Tighten the pressure bolt " A (3) with the bar.

Turn in the pressure bolt "B" 141with the bar iS) and force out
the drive chain joint pin (0.

lCAUTlON
Continue turning in the pressure bolt "8" 141until the
joint pin has been completely pushed out of the chain.

NOTE:
After the joint pin Wi is removed, loosen the pressure bolt "B'r4)
and then pressure bolt 'flAY31.
Remove the joint pin (3)of the other side of joint plate.

Never reuse Joint pins, O-rings and plates. After joint
pins, 0-rlngs and plates have been removed from the
drive chain, the removed joint pins, O-rings and plates
should be discarded and new ioint plate, O-rings and
plate must be installed.

DRIVE CHAIN CONNECTING

JOINT PLATE INSTALLATION
Set up the special tool as shown in the illustration.
11 1 Tool body
6 )Adjuster bolt
i2! Grip handle
(without hole)
6)Pressure bolt "A"
13) Joint plate holder
(engraved mark "C520)
(77 Bar
($1 Wedge holder & wedge pin
Connect both ends of the drive chain with the joint pin
inserted from the inside iR as installed on the motorcycle.
(9) O-ring ... 4 pcs.
rlD Joint plate
Joint set part number
RK: 27620-43820

Do not use jolnt cllp type of drive chain. The joint clip
may have a chance t o drop whlch may cause severe
damage to motorcycle and severe injury.

Apply grease on the recessed portion of the joint plate holder
131 and set the joint plate ibl.

NOTE:
When positioning the joint plate IWon the tool, its stamp mark
must face the joint plate holder in side.

Set the drive chain on the tool as illustrated and turn in the
adjuster bolt 15) to secure the wedge holder & wedge pin ($1.
Turn in the pressure bolt "A" (61 and align two joint pins (I!)
properly with the respective holes of the joint plate
Turn in the pressure bolt " A !GI further using the bar C;i) to
press the joint plate over the joint pins.

Continue pressing the joint plate until the distance between
the two joint plates come to the specification.
Joint plate distance specification (WI

of the joint plate be made excessively
beyond the specified dimension, the work should be
redone using the new joint parts.
JOINT PIN STAKING
Set up the special tool as shown in the illustration.
'1 1 Tool body
(21 Grip handle
i3> Pressure bolt " A
Adjuster bolt (without hole)
(5, Staking pin (stowed inside grip handle behind rubber cap)
(6) Bar

NOTE:
Before staking the joint pin, apply a small quantity of grease to
the staking p ~ (9.
n

7106

CHASSIS

Stake the jolnt pln by turning (approximately 718 turn) the
pressure bolt " A (3 wlth the bar until the pin end diameter
becomes the specifled dimenslon.
Pin end diameter specification ID\

' After joining of the chain has been completed, check
to make sure that the link is smooth and no abnormal
condition is found.
' Should any abnormal condition be found, reassemble the chain link using the new joint parts.

Adiust the drive chain, after connectina it. ( D 2 - 2 6 )

CHASSIS 7-107

DRIVE CHAIN CONTROL ROLLER
CONSTRUCTION

11 Washer
-

(2)
(3) Spacer

(4~)

Drive chain control roller
(Lower)
Drive chain control mounting
bolt

REMOVAL
Remove the drive chain control roller, upper and lower.

INSPECTION
lnspect the drive chain control roller bearings (lower) for
abnormal noise and smooth rotation.
Inspect the drive chain control for damage.

PI
ITEM
IA'

N.m
31

(

kgf-m
3.1

Ib-ft

22.5

7.108

CHASSIS

w
l
-

INSTALLATION

-4

Tighten the drive chain control mounting bolts.
Drive chain control mounting bolt:
31 N.m (3.1 kgf-m, 22.5 lb-ft)

- j -f.(l

c X.,.\

*rrl.,

NOTE:
The concave side of chain control roller (upper) faces inside.

p2r+

, , '..

'-zss

. .!

I
.,

CONTENTS
8-2
..........................................................................
.........................................................................................
8-2
...............................................................................................
8-2
...................................................................................................
8-2
.......................................................................................................
8-2
................................................8 - 3
...............................................................................................
8-3
..............................................................
8-3
...........................................................................8 - 3
...............................................8 - 4
.......................................... 8 - 5
..................................................................................
8-7
............................................................................
8-7
..........................................................................................8 - 8

CAUTIONS IN SERVICING
CONNECTOR
COUPLER
CLAMP
FUSE
SEMCCONDUCTOR EQUIPPED PART
BATTERY
CONNECTING THE BATTERY
WIRING PROCEDURE
USING THE MULTI-CIRCUIT TESTER
LOCATION OF ELECTRICAL COMPONENTS
CHARGING SYSTEM
TROUBLESHOOTING
INSPECTION
STARTER SYSTEM AND SIDE-STAND/
IGNITION INTERLOCK SYSTEM
TROUBLESHOOTING
STARTER MOTOR REMOVAL
STARTER MOTOR DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY
STARTER RELAY INSPECTION
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
INDICATOR LIGHT
INSPECTION
LAMPS
HEADLIGHT BRAKE LIGHT/TAILLIGHT
RELAYS
STARTER RELAY
FUEL PUMP RELAY
COOLING FAN RELAY
SWITCHES INSPECTION
BATTERY
SPECIFICA TIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION

................................................................
8-71
............................................................................8-11
..............................................................
8-12
..................................................8-13
...................................................8-13
.......................................................8-14
...........................................................8-15
......................................................................................
8-17
............................................................................8-17
.........................................................................................8-19
......................................................................................8-22
..........................................................................................
8-23
.........................................................................................................8-26
.............................................8-26
.......................................................................................................
8-27
..............................................................................
8-27
.......................................
8-27
..........................................................................
8-27
......................................................................8-28
.....................................................................................................8-29
..................................................................................
8-29
...............................................................................
8-29
............................................................................................
8-31
.................................................................
8-31

8.2

ELECTRICAL SYSTEM

CAUTIONS IN SERVICING
CONNECTOR
When connecting a connector, be sure to push it in until a
click is felt.
lnspect the connector for corrosion, contamination and breakage in its cover.

COUPLER
With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.
When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
lnspect each terminal on the coupler for being loose or bent.
lnspect each terminal for corrosion and contamination.

CLAMP
Clamp the wire harness at such positions as indicated in
"WIRING HARNESS ROUTING". ( W 9 - 1 5to -17)
Bend the clamp properly so that the wire harness is clamped
securely.
In clamping the wire harness, use care not to allow it to hang
down.
Do not use wire or any other substitute for the band type
clamp.

FUSE
When a fuse blows, always investigate the cause to correct it
and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use wire or any other substitute for the fuse.

CORRECT

INCORRECT

ELECTRICAL SYSTEM

SEMI-CONDUCTOR EQUIPPED PART
Be careful not to drop the part with a semi-conductor built in
such as a ECM.
When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.

BATTERY
The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water
replenishment).
During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g.. short circuit) nearby when charging the battery.
Be sure to recharge the battery in a well-ventilated and open
area.
Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.

CONNECTING THE BATTERY
When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the i-battery
)
lead
wire, first.
When connecting the battery lead wires, be sure to connect
the i.+)
battery lead wire, first.
If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the
battery terminals.

WIRING PROCEDURE
Properly route the wire harness according to the "WIRING
HARENESS ROUTING" section. ( U 9 - 1 5to -1 7)

INCORRECT

8-3

USING THE MULTI-CIRCUIT TESTER

Properly use the multi-circuit tester + I and 1-J probes.
Improper use can cause damage to the motorcycle and
tester.
If the voltage and current values are not known, begin measuring in the highest range.
When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
After using the tester, be sure to turn the switch to the OFF
position.
09900-25008: Multi-circuit tester set

I CAUTION]
I -

Before using the multi-circuit tester, read its instruction manual.

NOTE:
* When connecting the multi-circuit tester, use the needle
pointed probe to the back s ~ d eof the lead wlre coupler and
connect the probes of tester to them.
Use the needle pointed probe to prevent the rubber of the
water proof coupler from damage.
09900-25009: Needle pointed probe set

ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

(i)Fuel level switch (~-?.8-25)

Cooling fan ( W 6 - 8 )
13'1 Fuse (Fan)
XI RegulatorIRectifier
(51 ECM (Engine Control Module)
16) TO sensor (-4-50)
Mode selection switch coupler (-4-23)

pump relay (c:,? ' 5 - 6 )
Cooling fan relay ( p 6 - 1 0 )
00) IAT sensor ( W 4 - 4 6 )
"1) IAP sensor (-4-31)
(18 Ignition coil
tf3! ECT sensor ( p 4 - 4 2 )
f l Fuel

(9'

8-5

8-6

ELECTRICAL SYSTEM

Oa Fuel injector ( m 4 - 5 6 )

99) Starter relay ( U 8 - 1 5 )

65) TP sensor ( W 4 - 3 7 )

QO, Generator

iis, Fuel pump ( D 5 - 6 )

01) CKP sensor (-4-29)
(23 GP switch ( D 8 - 2 4 )
09 Starter motor

hD Battery
ri8, Fuse (Main, Ignition)

ELECTRICALSYSTEM

8-7

CHARGING SYSTEM

M
Regulator/Rectif~er

Generator

r----------

TROUBLESHOOTING
Battery runs down quickly
Step 1
1) Check accessories which use excessive amounts of electricity.
Are accessories being installed?
YES
NO

(Remove accessories.
GO to Step 2.

Step 2
1) Check the battery for current leaks. (-8-8)
Is the battery for current leaks OK?
YES
NO

Go to Step 3.
Short circuit of wire harness
Faulty electrical equipment

Step 3
1) Measure the regulated voltage between the battery terminals. (-8-9)
Is the regulated voltage OK?
YES

Faulty battery
Abnormal driving condition
Go to Step 4.

Step 4
1 ) Measure the resistance of the generator coil. ( W 8 - 9 )
Is the resistance of generator coil OK?
YES
NO

Go to Step 5.
Faulty generator coil
Disconnected lead wires

8-8

ELECTRICAL SYSTEM

Step 5
1) Measure the generator no-load performance. ( D 8 - 1 0 )
Is the generator no-load performance OK?
YES
NO

]Go to Step 6.
/Faulty generator

Step 6
1) lnspect the regulatorlrectifier. (C78-10)
Is the regulatorlrectifier OK?

1 Go to Step 7.

YES
NO

/Faulty re~ulator/rectifier

Step 7
1) lnspect wirings.
Is the wirings OK?
Faulty battery
Short circuit of wire harness
Poor contact of couplers

YES
NO

Battery overcharges
Faulty regulator/rectifier
Faulty battery
Poor contact of generator lead wire coupler

INSPECTION
BATTERY CURRENT LEAKAGE
Remove the battery holder cover.
Turn the ignition switch to the OFF position.
Disconnect the battery Fl lead wire.
Measure the current between I-)
battery terminal and the ( --

,',?!-

(a,

ELECTRICAL SYSTEM

8-17

IGNITION SYSTEM

ECM

NOTE:
The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine
speed reaches 16 000 r/min. this circuit cuts off fuel at the fuel injector.

TROUBLESHOOTING
No spark or poor spark
NOTE:
Check that the transmission is in neutral and the engine stop switch is in the "RUNWposition.Grasp the
clutch lever. Check that the fuse is not blown and the battery Is fully-charged before diagnosing.

Step 1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition system couplers?

YES
NO

] G O to step 2.
Poor connection of couplers

Step 2
1 ) Measure the battery voltage between input lead wires ( O M and BNV) at the ECM with the ignition switch
in the "ON" position.
Is the voltage OK?

YES
NO

Go to Step 3.
Faulty ignition switch
Faulty engine stop switch
Broken wire harness or poor connection of related circuit couplers

8-16 ELECTRICAL SYSTEM

Step 3
1) Measure the ignition coil primary peak voltage. (-8-1

NOTE:
This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor.
Is the peak voltage OK?
YES
NO

( G Oto step 4.

1 GO to step 5.

Step 4
1) lnspect the spark plug. ( p 2 - 1 0 )
Is the spark plug OK?
YES
NO

/ G Oto Step 5.

I Faulty spark plug.

Step 5
1) lnspect the ignition coil. (-8-20)
Is the ignition coil OK?
YES
NO

Go to Step 6.
Poor connection of the ignition coil.
Faulty ignition coil.

Step 6
1) Measure the crankshaft position sensor peak voltage and its resistance. ( W e - 2 1 )
NOTE:
The crankshaft position sensor peak voltage inspection is applicable only with the multi-circuit tester and
peak volt adaptor.

Is the peak voltage and resistance OK?
YES

Faulty ECM
Open or short circuit in wire harness
Poor connection of ignition coupler

Faulty CKP sensor
Metal particles or foreign material being stuck on the CKP sensor and rotor tip

ELECTRICAL SYSTEM

8.19

INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
Remove the front fender, side covers and fuel tank.
( W 5 - 3 and 7-6)
Disconnect the fuel pump coupler (7).

Remove the spark plug cap.
Connect a new spark plug to spark plug cap and ground it to
the cylinder.

LCAUTION]

Avoid grounding the spark plugs and suppling the
electrical shock to the cylinder head cover (magneslum parts) to prevent the magnesium material from
I

NOTE:
Make sure that fhe spark plug cap and spark plug are connected
properly and the battery is fully-charged.
Measure ignition coil primary peak voltage using the multi-circuit
tester in the following
- .procedure.
Insert the needle pointed probes iK! to the lead wire coupler.

TT
I
.
i;-

P=mm
Use the special tool, to prevent the rubber of the water
proof coupler from damage.
09900-25009: Needle pointed probe set
Connect the multi-circuit tester with the peak voltage adaptor
as follows.

6)Probe: BlackhVhite lead wire
Probe: WhitelBlue lead wire

NOTE:
Do not disconnect the ignition coil lead wire coupler.
09900-25008: multl-circuit tester set

.-,.*.'.

-*.=iu,:,.

8,,,

,. .
-_._
?

8-20

ELECTRICAL SYSTEM

piuToNI
When using the multl-clrcult tester and peak volt
adaptor, refer t o the appropriate instruction manual.
Shift the transfer to the neutral position and turn the ignition
switch to the "ON" position.
Push the starter button and allow the engine to crank for a few
seconds, and then measure the ignition coil primay peak voltage.
Repeat the above procedure a few times and measure the highest ignition coil primay peak voltage. If the voltage is lower than
the standard values, inspect the ignition coil. ( W b e l o w )

Tester knob indlcation: Voltage

(7)

lgnition call primary peak voltage: 150 V and more

While testing, do not touch the tester probes and
spark plug to prevent recelvlng an electric shock.

NOTE:
After checking the ignition coil primary peak voltage, clear the
DTC using SDS tool.
IGNITION COIL RESISTANCE
Remove the front fender, side cover and fuel tank.
(C75-3and 7-6)
Disconnect the ignition coil lead wire coupler and spark plug
cap.
Measure the ignition coil resistance in both the primary and
secondary windings using the multi-circuit tester. If the resistance in both the primary and secondary windings is close to
the specified values, the windings are in sound condition.

a
:iw

09900-25008: multi-circuit tester set

Tester knob indlcation: Resistance (Q)
lgnition coil resistance
Primary:
0.1 - 1.0 R (WIBI - E N )
Secondary: 8 15 kc> (Spark plug cap

- WIBI)

.., ,

-h.

, +

b'il1.

L...-.A

ELECTRICAL SYSTEM

CKP SENSOR PEAK VOLTAGE
Dtsconnect the CKP sensor coupler 11).

Connect the multi-circuit tester with the peak volt adaptor as
follows.
(Ci probe: White
P probe: Blue
09900-25008: multi-circuit tester set

1 CAUT~ONI
When using the multi-circuit tester and peak volt
a d a ~ t o r refer
,
to the aDDroDriate instruction manual.
Shift the transmission to the neutral position, turn the ignition
switch to the "ON" position.
Push the starter button and allow the engine to turn for a few
seconds, and then measure the CKP sensor peak voltage.
Repeat the above procedure a few times and measure the
highest CKP sensor peak voltage.

Peak volt adaptor

Generator

Tester knob Indication: Voltage (--)
CKP sensor peak voltage: 0.5 V and more

NOTE:
Affer checking the CKP sensor peak voltage, clear the DTC
using SDS tool.
If the peak voltage is within the specification, check the continuity between the CKP sensor coupler and ECM coupler.

WTIC~N
i
Normally, use the needle pointed probe to the backside of the lead wlre coupler to prevent the terminal
bend and terminal alignment.

CKP SENSOR RESISTANCE
Disconnect the CKP sensor coupler.
Measure the resistance between the lead wires usinq
- the
multi-circuit tester. If the resistance is not within the specified
value, the CKP sensor must be replaced.

@ 09900-25008: multi-clrcuit tester set

Tester knob indication: Resistance (Q)
CKP sensor redstance: 155

- 232
.

0
'4.-.

k .'

When the switch is immersed in kerosine under the above
condition, the bulb should go out. If the bulb remains it,
replace the switch with a new one.

-*\

i
Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel
level indicator switch as shown in the right illustrations. The
bulb should come on after several seconds if the switch is in
good condition.

8-25

bulb

C-

.
'

8-26

ELECTRICAL SYSTEM

LAMPS
HEADLIGHT, BRAKE LIGHTITAILLIGHT
HEADLIGHT
12 V 40140 W ii)

BRAKE LIGHTFAILLIGHT: LED

1 E~UTIONJ
If you have touched and the bulb with your bare hands, clean It wlth a cloth moistened wlth
alcohol or soapy water to maintain lens clarity.

ELECTRICAL SYSTEM

+ C."

RELAYS
STARTER RELAY
W8-15

FUEL PUMP RELAY
ir;-5-8

COOLING FAN RELAY
V'6-10

,-*

-L-

8-27

8-28

ELECTRICAL SYSTEM

SWITCHES INSPECTION
Inspect each switch for continuity with a tester. If any CLUTCH SWITCH
Color
abnormality is found, replace the respective switch
B
Posfion
assemblies with new ones.
ncc

DIMMER SWITCH

t'os1t10n \I

I
LO (-n)
1
HI ( D)

FRONT BRAKE SWITCH
h

ENGINE STOP SWITCH
REAR BRAKE SWITCH

OFF
STARTER BUTTON
Color
Positlon

PUSH

VIE

IGNITION SWITCH

OFF

B
I

WIRE COLOR
B
Gr
810
BIR
Bff
O N
WIB
YIB

:Black
~r : ~ r o w n
:Gray
0 : Orange
: Black with Orange tracer
: Black with Red tracer
:Black withYellow tracer
:Orange with White tracer
:White with Black tracer
:Yellow with Black tracer

BIV

ELECTRICAL SYSTEM 8-29

BATTERY
SPECIFICATIONS
Type designation
Capacity

FTX7A-BS
12 V, 21.6 k c (6 Ah)/lO HR

!I.: Upper cover breather
:2: Cathode plates

(3)Stopper
(4) Filter

'51 Terminal
16) Safety valve
17'Anode plates
18)Separator (Fiberglass plate)

INITIAL CHARGING
Filling electrolyte
Remove the aluminum tape
filler holes !A).

ti) sealing the battery electrolyte

NOTE:
When filling electrolyte, the battery must be removed from the
vehicle and must be put on the level ground.

Remove the caps (2).

NOTE:
After filling the electmlyfe completely, use the removed cap (2,
as sealing caps of batlery-filler holes.
Do not remove orpierce the sealed areas '3;
of the electrolyte
container.

Insert the nozzles of the electrolyte container (4) into the battery's electrolyte filler holes, holding the container firmly so
that it does not fall. Take precaution not to allow any of the
fluid to spill.

Make sure air bubbles 6)are coming up each electrolyte container, and leave in this position for about more than 20 minutes.

8-30

ELECTRICAL SYSTEM

NOTE:
If no air bubbles are coming up from a filler port, tap the bottom
of the electrolyte container two or three times,
Never remove the container from the battery.

* I

After confirming that the electrolyte has entered the battery
completely, remove the electrolyte containers from the battety. Wait for about 20 minutes.

Insert the caps 16) ~ntothe f~lierholes, presslng in flrmly so that
the top of the caps do not protrude above the upper surface of
the battery's top cover

p5EEiGJ
' Never use anything except the specified battery.
' Once the caps have been installed to the battery, do
not remove the caps.
* D o not tap the caps with a tool such as hammer
when installing them.

For initial charging, use the charger specially designed for MF battery.

For charging the battery, make sure t o use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life.
* Do not remove the cap during charging.
Position the battery with the cap facing upward during charging.

ELECTRICAL SYSTEM

8-31

Measure the battery voltage using rnulti circuit tester. The tester
should indicate more than 12.5 - 12.6 V (DC) as shown in the
Fig. If the battery voltage is lower than the specification, charge
the battery with a battery charger. (Refer to the recharging operation)

Do not remove the caps on the battery top while
charglng.

iTimc6

10 (M~nutes)

NOTE.
Initial charging for a new battery is recommended if two years
have elapsed since the date of manufacture.

SERVICING
Visually inspect the surface of the battery container. If any signs
of cracking or electrolyte leakage from the sides of the battery
have occurred, replace the battery with a new one. If the battery
terminals are found to be coated with rust or an acidic white
powdery substance, clean the battery terminals with sandpaper.

RECHARGING OPERATION
Using the multi-circuit tester, check the battery voltage. If the
voltage reading is the 12.0 V (DC) and less, recharge the battery with a battery charger.
cAi Charging period

('J
18
17
16
15
14

(El Stop charging

When recharging the battery, remove the battery
from the vehicle.
Do not remove the caps on the battery top while
recharglng.
Recharging tlme: 0.7 A for 5 to 10 hours or 3 A for 1 hour

L~oN]
Be careful not to permit the charging current to
exceed 3 A at any time.
After recharging, wait for 30 minutes and more and check the
battery voltage with a multi-circuit tester.
If the battery voltage is the 12.5 V and less, recharge the battery again.
If battery voltage is still 12.5 V and less, after recharging.
replace the battery with a new one.
When the vehicle is not used for a long period (especially during the winter season), check the battery every 1 month to
prevent the battery discharge.

20 30
Time

60
(Mlnules)

CONTENTS

..................................................................................
...
..................................................................................................
......................................................
................................................................................................
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.........................................................................................
...............................................................................................
...................................
...............................................................
..............................................................................
.........................................................
................................................
.............................................................................
......................................................
.......................................................
......................................................
................................................................
..........................................................

TROUBLESHOOTING
9-2
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION 9- 2
ENGINE
9-4
RADIATOR (COOLING SYSTEM)
9-10
CHASSIS
9-10
BRAKES
9-12
ELECTRICAL
9-13
BATTERY
9-14
WIRING HARNESS, CABLE AND HOSE ROUTING
9-15
WIRING HARNESS ROUTING
9-15
CABLE ROUTING
9-18
FUEL SYSTEM HOSE ROUTING
9-19
COOLING SYSTEM HOSE ROUTING
9-20
OIL HOSE ROUTING
9-21
FRONT BRAKE HOSE ROUTING
9-22
REAR BRAKE HOSE ROUTING
9-23
T H R O n L E BODY INSTALLATION
9-24
FUEL TANK INSTALLATION
9-25
BRAKE PEDAL INSTALLATION
9-26
FRONT SIDE REFLEX REFLECTOR INSTALLATION (For E-28) ....... 9-27
BRAKE LlGHTfTAlLLlGHT INSTALLATION (For others)
9-28
BRAKE LIGHTfTAILLIGHT INSTALLATION (For E-28)
9-29
DRIVE CHAIN ROLLER INSTALLATION
9-30
SPECIAL TOOLS
9-31
TIGHTENING TORQUE
9-34
ENGINE
9-34
Fl SYSTEM AND INTAKE AIR SYSTEM
9-35
COOLING SYSTEM
9-35
CHASSIS
9-36
TIGHTENING TORQUE CHART
9-37
SERVICE DATA
9-38

9-2

SERVICING INFORMATION

TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION

sensor input signal.

0.5 V 5 sensor voltage c 4.4 V

shorted to ground or VCC circuit

0.5 V $ sensor voltage

4.8 V

shorted to ground or VCC circuit

0.1 V 5 sensor voltage c 4.8 V
In other than the above range. C15

0.2 V 2 sensor voltage c 4.8 V
In other than the above range, C21
H

PO110

Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.

IAT sensor circuit open or
ground circuit open
IAT sensor circuit shorted to
ground

SERVICING INFORMATION 9.3

on switch is turned ON.
.3 V 5 sensor voltage < 4.6 V
other than the above value, C23

duced, but signal from ignition coil
ously. In this case, the code C24

Gear position switch voltage > 0.9 V

he code C32 (P0201) is

9-4

SERVICING INFORMATION

ENGINE
Symptom
and possible causes
complaint
.---Engine will not start Compression too low
1. Valve clearance out of adjustment
or i s hard to start.
2. Worn valve guides or poor seating of valves
3. Mistirning valves
4. Excessively worn piston rings
5. Worn-down cylinder bore
6. Too slowly starter motor cranks
7. Poor seating of spark plug
8. Broken, cracked or damaged piston

Remedy
Adjust.
Repair or replace.
Adjust.
Replace.
Replace.
See electrical section.
Retighten.
Replace.

Plug not sparking
1. Fouled spark plug
2. Wet spark plug
3. Defective ignition coil
4. Defective CKP sensor
5. Defective ECM
6. Open-circuited wiring connections

Clean.
Clean and dry.
Replace.
Replace.
Replace.
Repair or replace.

No fuel reaching the intake manifold
1. Clogged fuel filter or fuel hose
2. Defective fuel pump
3. Defective fuel pressure regulator
4. Defective fuel injector
5 . Defective fuel pump relay
6. Defective ECM
7. Open-circuited wiring connections

Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.

Incorrect fuellair mlxture
1. TP sensor out of adjustment
2. Defective fuel pump
3. Defective fuel pressure regulator
4. Defective TP sensor
5. Defective CKP sensor
6. Defective IAP sensor
7. Defective ECM
8. Defective ECT sensor
9. Defective IAT sensor

Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

SERVICING INFORMATION 9-5

Complaint
-Engine idles poorly.

Engine stalls often.

Symptom and possible causes
1. Valve clearance out of adjustment
2. Poor seating of valves
3. Defective valve guides
4. Worn down camshafts
5. Too wide spark plug gap
6. Defective ignition coillplug cap
7. Defective CKP sensor
8. Defective ECM
9. Defective TP sensor
10. Defective fuel pump
11. Damaged or cracked vacuum hose
Incorrect fuellalr mixture
1. Defective IAP sensor or circuit
2. Clogged fuel filter
3. Defective fuel pump
4. Defective fuel pressure regulator
5. Defective ECT sensor
6. Defective thermostat
7. Defective IAT sensor
8. Damaged or cracked vacuum hose

Remedy
Adjust.
Replace or repair.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Clean or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

Fuel injector improperly operatlng
1. Defective fuel injectors
2. No injection signal from ECM
3. Open or short circuited wiring connection
4. Defective battery or low battery voltage

Replace.
Repair or replace.
Repair or replace.
Replace or recharge.

Control circuit or sensor Improperly operating
1. Defective ECM
2. Defective fuel pressure regulator
3. Defective TP sensor
4. Defective IAT sensor
5. Defective CKP sensor
6. Defective ECT sensor
7. Defective fuel pump relay

Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

Englne internat parts improperly operating
1. Fouled spark plug
2. Defective CKP sensor or ECM
3. Clogged fuel hose
4. Out of adjustment tappet clearance

Clean.
Replace.
Clean.
Adjust.

9-6

SERVICING INFORMATION

Complaint
Noisy engine

Remedy

Symptom and possible causes
Excessive valve chatter
1. Too large tappet clearance
2. Weakened or broken valve springs
3. Worn tappet or cam surface
4. Worn and burnt camshaft journal

Adjust.
Replace.
Replace.
Replace.

Noise seems t o come from plston
1. Worn down piston or cylinder
2. Carbon combust~onchamber fouled with carbon
3. Worn piston pins or piston pin bore
4. Worn piston rings or ring grooves

Replace.
Clean.
Replace.
Replace.

Nolse seems t o come from timing chain
1. Stretched chain
2. Worn sprockets
3. Tension adjuster not working

Replace.
Replace.
Repair or replace.

Noise seems t o come from clutch
1. Worn splines of counlershafl or hub
2. Worn teeth of clutch plates
3. Distorted clutch plates, driven and drive
4. Worn clutch release bearing
5. Weakened clutch damper

Replace.
Replace.
Replace.
Replace.
Replace the primary
driven gear.

Nolse seems to come from crankshaft
1. Rattling bearings due to wear
2. Worn and burnt big-end bearings
3. Worn and burnt journal bearings

Replace.
Replace.
Replace.

Noise seems t o come from balancer
1. Worn and burnt journal bearings

Replace.

Noise seems to come from transmission
1. Worn or rubbing gears
2. Worn splines
3. Worn or rubb~ngprimary gears
4. Worn bearings

Replace.
Replace.
Replace.
Replace.

Noise seems t o come from water pump
1. Too much play on pump shaft bearing
2. Worn or damaged impeller shaft
3. Worn or damaged mechanical seal
4. Contact between pump case and impeller

Replace.
Replace.
Replace.
Replace.

SERVICING INFORMATION 9-7

Complaint
Symptom and possible causes
Engine runs poorly Defective engine internal/electrical parts
In high speed range. 1. Weakened valve springs
2. Worn camshafts
3. Valve timing out of adjustment
4. Too narrow spark plug gap
5. Ignition not advanced sufficiently due to poorly
working timing advance circuit
6. Defective ignition coil
7. Defective CKP sensor
8. Defective ECM
9. Clogged air cleaner element
10. Clogged fuel hose, resulting in inadequate fuel
supply to injector
11. Defective fuel pump
12. Defective TP sensor

Remedy
Replace.
Replace.
Adjust.
Adjust.
Replace ECM.
Replace.
Replace.
Replace.
Clean.
Clean and prime.
Replace.
Replace.

Defective alr flow system
1. Clogged air cleaner element
2. Sucking air from throttle body joint
3. Defective ECM

Replace.
Repair or replace.
Replace.

Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective GP sensor
6. Defective IAP sensor
7. Defective ECM
8. TP sensor out of adjustment

Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

9.8

SERVICING INFORMATION

Complaint
Symptom and possible causes
Defective
engine internallelectrical parts
Engine lacks power.
1. Loss of tappet clearance
2. Weakened valve springs
3. Valve timing out of adjustment
4. Worn piston rings or cylinder
5. Poor seating of valves
6. Fouled spark plug
7. Incorrect spark plug
8. Clogged fuel injector
9. TP sensor out of adjustment
10. Clogged air cleaner element
11. Sucking air from throttle valve or vacuum hose
12. Too much engine oil
13. Defective fuel pump or ECM
14. Defective CKP sensor and ignition coil
Defective control circuit or sensor
1. Low fuel pressure
2. Defective TP sensor
3. Defective IAT sensor
4. Defective CKP sensor
5. Defective GP sensor
6. Defective IAP sensor
7. Defective ECM
8. TP sensor out of adjustment

Remedy
Adjust.
Replace.
Adjust.
Replace.
Repair.
Clean or replace.
Adjust or replace.
Replace.
Adjust.
Replace.
Retighten or replace.
Drain out excess oil.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Adjust.

SERVICING INFORMATION 9-9

Complaint
Engine overheats

Symptom and possible causes
Defective engine internal
1. Heavy carbon deposit on piston crowns
2. Not enough oil in the engine
3. Defective oil pump or clogged oil circuit
4. Sucking air from intake pipe
5. Use incorrect engine oil
6. Defective cooling system

Clean.
Add oil.
Replace or clean.
Retighten or replace.
Change.
See radiator section.

Lean fuellair mixture
1. Short-circuited IAP sensorllead wire
2. Short-circuited IAT sensor/lead wire
3. Sucking air from intake pipe joint
4. Defective fuel injector
5 . Defective ECT sensor

Repair or replace.
Repair or replace.
Repair or replace.
Replace.
Replace.

Remedy

Other factors
1. Ignition timing is too advanced due to defective
Replace.
timing advance system (ECT sensor, GP sensor,
CKP sensor and ECM).
2. Drive chain is too tight.
Adjust.
Dirty or heavy
1. Too much engine oil in the engine
Check with inspection
exhaust smoke
window, drain out excess
oil.
2. Worn piston rings or cylinder
Replace.
3. Worn valve guides
Replace.
4. Scored or scuffed cylinder wall
Replace.
5. Worn valves stems
Replace.
6. Defective stem seal
Replace.
7. Worn oil ring side rails
Replace.
Slipping clutch
1. Weakened clutch springs
Replace.
2. Worn or distorted pressure plate
Replace.
3. Distorted clutch plates or pressure plate
Replace.
Dragging clutch
1. Some clutch spring weakened while others
Replace.
are not.
2. Distorted pressure plates or clutch plates
Replace.
Transmission wlll
1. Broken gearshift cam
Replace.
not shift.
2. Distorted gearshift forks
Replace.
Replace.
3. Worn gearshift pawl
1. Broken return spring on shift shaft
Transmission will
Replace.
not shlfl back.
2. Rubbing or stickily shift shaft
Repair or replace.
3. Distorted or worn gearshift forks
Replace.
Transmission jumps 1. Worn shifting gears on driveshaft or
Replace.
out of gear.
countershaft
2. Distorted or worn gearshift forks
Replace.
3. Weakened stopper spring on gearshift stopper
Replace.
Replace.
4. Worn gearshift cam plate
5. Gear dogldog hole worn
Replace.

9.10

SERVICING INFORMATION

RADIATOR (COOLING SYSTEM)
Complaint
Engine & e r h i i t s

2.
3.
4.

Engine overcools

5.
6.
7.
8.
9.
10.
1 1.
1.
2.
3.
4.
5.

Symptom and possible causes
Not enough engine coolant
Radiator core clogged with dirt or scale
Faulty cooling fan
Defective cooling fan relay, or open- or shortcircuited
Defective ECM
Defective ECT sensor
Clogged water passage
Air trapped in the cooling circuit
Defective water pump
Use incorrect coolant
Defective thermostat
Defective ECT sensor
Extremely cold weather
Defective thermostat
Defective cooling fan relay, or open- or shortcircuited
Defective ECM

Remedy
Add coolant.
Clean.
Repair or replace.
Repair or replace.

Symptom and possible causes
Improper front wheel alignment
Insufficiently lubricated
Low air pressure in front tires
Tie rod ends tending to seize
Linkage connections tending to seize
Unequally inflated tires
Loose front wheel hub nuts
Damaged or worn front wheel hub bearings
Worn or loose tie rod ends
Defective or incorrect front tires
Damaged or worn wishbone arms and related
bearings
Distorted front wheels
Loose chassis nuts and bolts.
Unequally inflated tires
Improper front wheel alignment
Worn front wheel hub bearings
Distorted frame or wishbone
Defective shock absorber
High tire pressure
Worn steering linkage connections
Loose suspension system bolts

Remedy
Adjust.
Lubricate.
Adjust.
Replace.
Repair or replace.
Regulate.
Tighten.
Replace.
Replace or tighten.
Replace.
Replace.

Replace.
Replace.
Clean.
Bleed air.
Replace.
Replace.
Replace.
Replace.
Put on the radiator cover.
Replace.
Repair or replace.
Replace.

CHASSIS
Complaint
Handling is too
heavy or stiff.

Steering wobbles.

Steering pulls to
one side.

1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.

7.
8.
1.
2.
3.
4.

Shocks felt in the
steering.

5.
1.
2.
3.

Replace.
Tighten.
Regulate.
Adjust.
Replace.
Repair or replace.
Replace.
Regulate.
Replace.
Tighten.

SERVICING INFORMATION 941

Complaint
Tires rapidly or
unevenly wear.
teer ring too noisy.

Front suspension
too soft.

Front suspension
too stiff.

Front wheels wobble.

Suspension too
noisy.
Rear suspension
too soft.

Rear suspenslon
too stiff.

Rear wheels wobble.

Symptom and possible causes
Worn or loose front wheel hub bearings
Improper front wheel alignment
Loose nuts and bolts
Damaged or worn front wheel hub bearings
Insufficiently lubricated
Weakened spring of shock absorber
Leakage oil or gas of shock absorber
Improperly set front spring pre-road adjusters
4. Improperly set damping force adjusters
1. Worn upper or lower wishbone arms and
related bearings
2. Bent shock absorber rod
3. lmproperly set front spring pre-road adjusters
4. Improperly set damping force adjusters
1. Distorted front wheel rims
2. Damage or worn front wheel hub bearings
3. Defective or incorrect front tires
4. Loose front wheel hub nuts
5. Damaged or worn wishbone arms and related
bearings
6. Front shock absorber leaks oil
7. Loose chassis nuts and bolts
1. Loose suspension system bolts
2. Worn wishbone arms and related bearings
3. Worn swingarm and suspension bearings
1. Weakened spring ol shock absorber
2. Leakage oil or gas of shock absorber
3. Improperly set rear spring pre-load adjuster
4. Improperly set damping force adjuster
1. Bend shock absorber rod
2. Bent swingarm pivot shaft
3. Worn swingarm and rear suspension bearings
4. Improperly set rear spring pre-load adjuster
5, Improperly set damping force adjuster
6. Improper chain adjustment
1. Distorted rear wheel rims
2. Damage or worn rear axel housing bearings
3. Defective or incorrect rear tires
4. Loose rear wheel hub nuts
5. Distorted rear axle
6. Loosen rear axle housing mounting bolts
7. Improper rear brake adjustment
8. Damaged or worn rear swingarm and related
bearings
9. Rear shock absorber leaks oil
10. Loose rear swingarm nut

1.
2.
1.
2.
3.
1.
2.
3.

Remedy
Replace.
Adjust.
Tighten.
Replace.
Lubricate.
Replace.
Replace.
Adjust.
Adjust.
Tighten.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Tighten.
Replace.
Replace.
Tighten.
Tighten.
Replace.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Adjust.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Tighten.
Replace.
Tighten.
Adjust.
Replace.
Replace.
Tighten.

9-12

SERVICING INFORMATION

BRAKES
Complaint
Insufficient brake
power

Brake squeaking

1.
2.
3.
4.
5.
6.
7.
1.

Symptom and possible causes
Leakage of brake fluid from hydraulic system
Worn pads
Oil adhesion of engaging surface of padslshoe
Worn disc
Air in hydraulic system
Not enough brake fluid in the reservoir
Improper parking brake adjustment
Carbon adhesion on pad surface

2. Tilted pad
3. Loosen front wheel axle or rear wheel axle
4. Worn pads

5. Foreign material in brake fluid
6. Clogged return port of master cylinder

Excessive brake
lever stroke

Leakage of brake
fluid
Brake drags

1. Air in hydraulic system
2. Insufficient brake fluid

Improper quality of brake fluid
Insufficient tightening of connection joints
Cracked hose
Worn piston andlor cup
Rusty part
Insufficient brake lever or brake pedal
pivot lubrication
3. Improper parking brake adjustment

3.
1.
2.
3.
1.
2.

Remedy
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replenish.
Adjust.
~ e p a i surface
r
with
sandpaper.
Correct pad fitting or
replace.
Tighten to specified
torque.
Replace.
Replace brake fluid.
Disassemble and
clean master cylinder.
Bleed air.
Replenish fluid to specified
level: bleed air.
Replace with correct fluid.
Tighten to specified torque.
Replace.
Replace piston andlor cup.
Clean and lubricate.
Lubricate.
Adjust.

SERVICING INFORMATION 9.13

ELECTRICAL
Complaint
No sparking or poor
sparking

Spark plug soon
become fouled with
carbon.

Spark plug become
fouled too soon.

Spark plug electrodes overheat or
burn

Generator does not
charge.

Generator does
charge, but charging rate i s below the
specification.

Symptom and possible causes
1. Defective ignition coils

2. Defective spark plugs
3. Defective CKP sensor
4. Defective ECM
5. Defective TO sensor
6. Open-circuited wiring connections
1. Mixture too rich
2. Idling speed set too high
3. Incorrect gasoline
4. Dirty air cleaner element
5. Too cold spark plugs
1. Worn piston rings
2. Worn piston or cylinder
3. Excessive clearance of valve stems in valve
guides
4. Worn stem oil seal
1. Too hot spark plugs
2.

3.
4.
1.
2.
3.
1.

2.
3.
4.

Generator overcharges

Unstable charging

1.
2.
3.
1.

2.
3.

Starter button i s not
effective.

1.
2.
3.
4.
5.

Remedy
Replace.
Replace.
Replace.
Replace.
Replace.
Check and repair.
inspect Fl system.
Adjust idle air screw.
Change.
Replace.
Replace with hot type plug.
Replace.
Replace.
Replace.

Replace.
Replace with cold type
plugs.
Tune up.
Overheated the engine
Retighten.
Loose spark plugs
Inspect FI system.
Too lean mixture
Open- or short-circuited lead wires, or loose lead Repair or replace or
retighten.
connections
Short-circuited, grounded or open generator coil Replace.
Replace.
Short-circuited or punctured regulatorlrectifier
Lead wires tend to get shorted or open-circuited Repair or retighten.
or loosely connected at terminals.
Replace.
Grounded or open-circuited generator coil
Replace.
Defective regulatorirectifier
Replace the battery.
Defective cell plates in the battery
Replace the battery.
internal short-circuit in the battery
Replace.
Damaged or defective regulatorlrectifier
Clean and tighten ground
Poorly grounded regulatorlrectifier
connection.
Repair or replace.
Lead wire insulation frayed due to vibration.
resulting in intermittent short-circuiting.
Replace.
Internally shorted generator
Defective regulatortrectifier
Replace.
Repair or replace.
Run down battery
Defective switch contacts
Replace.
Repair or replace.
Brushes not seating properly on starter motor
commutator
Defective starter relay
Replace.
Replace.
Defective main fuse

9-14

SERVICING INFORMATION

BATTERY
Complaint
"Sulfation", acidic
white powdery substance or spots on
surface of cell
plates
Battery runs down
quickly.

Symptom and possible causes
1. ~rackedbatterycase
2. Battery has been left in a run-down condition for
a long time.

Remedy
Replace the battery.
Replace the battery.

I.Trouble in the charging system

Check the generator, regulatorlrectifier and circuit
connections and make necessary adjustments to
obtain specified charging
operation.
Replace the battery and
correct the charging system.
Replace the battery.
Recharge the battery fully.
Replace the battery.
Replace the battery.

2. Cell plates have lost much of their active

material as a result of overcharging.

Battery "sulfation"

Battery discharged
too polarity

3. Internal short-circuit in the battery
4. Too low battery voltage
5. Too old battery
1, Incorrect charging rate
(When not in use batteries should be checked at
least once a month to avoid sulfation.)
2. The battery was left unused in a cold climate for
too long.
1. Dirty container top and sides.
2. Old battery.

Replace the battery if badly
sulfated.
Clean.
Replace the battery.

SERVICING INFORMATION

WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING

9-15

9-16

SERVICING INFORMATION

Wiring harness

Rear brake switch lead wire

Rear brake sw~lchlead wire

SERVICING INFORMATION

9.17

9.18

SERVICING INFORMATION

CABLE ROUTING

Pass the throttle and clutch cables through
downside of the high-tension cord.
Pass the starter cable between the frame and
'2 . .
wlrlng harness.
Pass the starter cable through upside of the wiring harness.
Pass the clutch cable through downside of the
'4
lever.
Clamp the starter cable and left handle switch
'5 . .
wlrtng harness.

Pass the starter cable through rearward of the
parking brake cable.
Pass the starter cable through upside of the
'7 ,
s~phonhose.
Pass the starter cable through upside of the fuel
'8
hose.
Pass the throttle and clutch cables through
*'
upside of the breather hose.
Pass the clutch cable through forward of the
'lo
throttle body and inside of the ignition coil.

SERVICING INFORMATION 9.19

FUEL SYSTEM HOSE ROUTING

Fuel hose
(2' Fuel return hose
(3' Fuel hose
'4) Fuel vapor return hose
I

(51 Fuel pump
(61

'71

Fuel pressure regulator
Fuel feed hose

9-20

SERVICING INFORMATION

COOLING SYSTEM HOSE ROUTING

~ a r k i n g(White)

"
'2
ti)
(21

(5
14)

Pass the siphon hose through the upside of the
cables.
Run this hose straightly down.
Clamp
Siphon hose
Reservoir tank over-flow hose
Water pump

~ A r k i n g(Yellow)

!5! Thermostat
Inlet radiator hose
1.7) Radiator cover
(8) Radiator
191 Outlet radiator hose
ilOi Water pump driven gear
iBi

SERVICING INFORMATION 9-21

OIL HOSE ROUTING

ID-

i " P F$@
/@

.; .

,..

Q
~. 1
,;

\ FA
*?$).,.

Install the oil tank cushion to the both sides of the .
(6) Breather hose
011tank.
iii Oil level gauge
Q Breather hose
(2) Oil return tank
(81 Oil hose (R)
(3) Oil tank
;91Oil hose (L)
(4) Breather hose
iA1 Matching mark
!5) Oil tank over-flnw hncs
'1

9-22

SERVICING INFORMATION

FRONT BRAKE HOSE ROUTING

RIGHT BRAKE HOSE

'1 The brack paint is forward.

LEFT BRAKE HOSE

After the brake hose union has contacted the
' 5 under surface of master cylinder, tighten the
union bolt.

After the under surface of brake pipe joint has
After the brake hose union has contacted the
"2 contacted the end face of hose braket of frame, '6
stopper, tighten the union bolt.
tighten the pipe joint mounting bolt.
'3 Clamp the brake hose firmly.
(2, Stopper
Fit the brake hose with brake hose sleeve shape
'4
correctly fitted inside clamp.

SERVICING INFORMATION 9-23

REAR BRAKE HOSE ROUTING

9.24

SERVICING INFORMATION

THROTTLE BODY INSTALLATION
UPPER

LOWER
INTAKE PIPE

UPPER

LOWER
OUTLET TUBE

(C1 12 N.m
(1.2 kgl-m. 8.5 lb-ft)

4.5 N.m
(0.45 kgf-m.
3.3 1b4)

(41 Fuel feed hose No.2
'1 Face the clamp ends left side.
Pass the fuel vapor return hose through left side
Intake pipe
'2
of the wiring harness.
Install the fuel feed hose No.2 with the white
Throttle body
'3
r6,
paint side to the fuel pump.
(1;) IAT sensor
(I, Air cleaner
(8) IAP sensor
(2) Fuel vapor return hose
(91 Fuel pump
(3) Fuel feed hose No.1

SERVICING INFORMATION 9-25

FUEL TANK INSTALLATION

1 ) Fuel tank breather hose
121 Fuel tank cap

(71 Fuel valve
6 )Fuel valve cushion

1.3) Fuel tank cushion
(6, Fuel tank

191 Fuel pressure regulator

(51 Fuel vapor return hose

(11) Fuel tank lower cover

16) Fuel hose

(lm Fuel return hose

9-26

SERVICING INFORMATION

BRAKE PEDAL INSTALLATION

'i/ Cotter pin

-(21Brake pedal pivot bolt
131 Rear brake switch

-r4i

Rear brake switch spring

15'i Brake pedal spring
16) Brake pedal

SERVICING INFORMATION 9-27

FRONT SIDE REFLEX REFLECTOR INSTALLATION (For E-28)

1
1

(1) Front grip

$21 Reflex reflector

1
1\41I stopper

1\31 Reflex reflector bracket

9.28

SERVICING INFORMATION

BRAKE LIGHT/TAILLIGHT INSTALLATION (For others)

I Brake l gnliTa l lgnt

B r a ~ eI g n f l a i ignr cover

SERVICING INFORMATION 9-29

BRAKE LlGHTKAlLLlGHT INSTALLATION (For E-28)

rn 6

N.m (0.6 kgf-m. 4.5 Ib-ft)

rn 1.0 N.m

I
(21 I Brake l ~ g h f l a ~ l l ~cover
ght
(1) Brake I~ghVTa~ll~ght

(0.18 kgf-m. 1.3 ib-ft)--+

1
I(4) I Reflex reflector bracket

1\31 Reflex reflector

SERVICING INFORMATION

9-30

DRIVE CHAIN ROLLER INSTALLATION

1 kgl-m.

UPPER

31 N.m (3.1 kgl-m,

LOWER

(1-1 C h a m roller

1(2' F r a m e

SERVICING INFORMATION 9-31

SPECIAL TOOLS

9-32

SERVICING INFORMATION

09915-64512
Compression
09913-70210
gauge set
Bearing
installer
set
-

0991 5-74511
Oil pressure gauge
set

09915-74521
Oil pressure gauge
hose

09915-77331
Meter (for high pressure)

09916-14521
09916-14910
Attachment

0991 6-34542
Reamer handle

09916-34550
Valve guide reamer
(5.5 mm)

09916-10911
Valve lapper set

09916-14510
Valve lifter

separating tool

holder
-

09923-73210
Bearing remover

09930-10121
09924-84521
Spark plug wrench
09924-84510
Bearing installer set Bearing installer set set

Drive chain cutting
Bearing remover

Bearing remover set and joining tool

09930-11950
Torx wrench

SERVICING INFORMATION 9-33

09930-301 04
Sliding hammer

09930-30721
Rotor remover

09930-31 921
Rotor remover

09930-73120
Starter torque
limiter socket

09930-44520
Rotor holder

/-rr

h6 $ ::

..
2

,~nv -

\1.,

&i
09930-73170
Starter torque
limiter holder
-

09930-82720
Mode selection
switch

09940-4021 1
Adaptor

09941-34513
Bearing Installer

09904-41 010
SDS Set

99565-01010-007
CD-ROM Ver. 7

09940-40220
Fuel pressure gauge
hose attachment

09940-92460
Rear axle nut
wrench set

9-34

SERVICING INFORMATION

TIGHTENING TORQUE
ENGINE

SERVICING INFORMATION 9-35

FI SYSTEM AND INTAKE AIR SYSTEM
ITEM
CKP sensor mounting bolt
IAT sensor mounting screw
Fuel delivery pipe mounting screw
Fuel pump mounting bolt
TP sensor mounting screw

N.m

3.5

kgf-m
0.65
0.18
0.35
0.9
0.35

Ib-ft
4.7
1.3
2.5
6.5
2.5

N.m

kgf-m

Ib-ft

10
10
5.5
12
10

1.O

7.0
7.0
4.0
8.5
7.0

6.5
1.8
3.5
9

COOLING SYSTEM
ITEM
Water pump cover screw
Water pump cover bolt
Engine coolant drain plug
ECT sensor
Thermostat cover bolt

1.O
0.55
1.2
1.O

9-36

SERVICING INFORMATION

CHASSIS

Swingarm pivot nut
Rear shack absorber mounting nut (Upper & Lower)
Cushion lever nut
Cushion rod nut
Drive chain control mounting bolt
Throttle lever case bolt
Clutch lever hold mounting bolt

68.5
9.5
95
43.5
6.0
60
78
56.5
7.8
78
56.5
7.8
31
22.5
3.1
5
3.5
0.5
10
1.O
7.5

SERVICING INFORMATION 9-37

TIGHTENING TORQUE CHART
For other nuts and bolts not listed in the preceding page, refer to this chart:

Conventional boll

" 4 marked bolt

9-38

SERVICING INFORMATION

SERVICE DATA
VALVE

+ GUIDE
ITEM

Unit: m m (in)

STANDARD

LIMIT

Valve stem runout

IN. & EX.

0.05
(0.002)

Valve head thickness

IN. & EX.

0.5
(0.02)

)valve seat width

(I IN. & EX. II

Valve head radial runout

Valve spring tension

- 1.1

.,..,--,

IN. & EX.

Valve spring tree length

0.9

~n
\.,.,-- nsr, - n n ~ s r

IN
EX.

0.03
lO.OOl\

34.0
(1.34)

IN.

119-137N
(1 1.9 - 13.7 kgf, 26.2 - 30.2 IbS)
at lenath 30.9 mm (1.22 in)
(7.85 kgf, 17.3 lbs)
at length 30.9 mm (1.22 in)

SERVICING INFORMATION 9-39

CAMSHAFT + CYLINDER HEAD
ITEM
Cam height

STANDARD
IN.

EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Cam chain pin
Cylinder head distortion

Unit: rnm (in)

IN. & EX.

IN. & EX.
IN. & EX.

32.564 - 32.604
(1.2820 - 1.2836)
33.451 - 33.491
(1.3170 - 1.3185)
0.032 - 0.066
(0.0013 - 0.0026)
22.012 - 22.025
(0.8666 - 0.8671)
21Yk9 -21.980
(0.8645 - 0.8653)
15th pin
-

LIMIT
32.264
(1.2702)
33.151
(1.3052)
0.150
(0.0059)

0.05
(0.002)

9-40

SERVICING INFORMATION

ITEM
Piston ring thickness
1st

2nd

STANDARD
0.71 - 0.76
(0.0280 - 0.0299)
1.08- 1.10
(0.0425 0.0433)
0.77 0.79
(0.0303 - 0.031 1)
19.002 19.008
- 0.7483)
(0.7481
-.
18.994 - 19.0%
(0.7478 0.7480)

Piston pin bore
Piston pin O.D.

CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.

LIMIT

19.030
(0.7492)
18.980
(0.7472)

Unit: mm (in)
. .
STANDARD
19.010- 19.018
(0.7484 - 0.7487)

LIMIT
19.040
(0.7496)

0.30 - 0.65
(0.012 - 0.026)
21.75 - 21.80
(0.8563 0.8583)
62.0 i 0.1
(2.441 + 0.004)

1.O
(0.04)

0.08
(0.003)

STANDARD
10 kPa (0.1 kgflcrn', 1.4 psi)
at 3 000 rlmin

LIMIT

Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout

OIL PUMP
ITEM
Oil pressure (at 60"C, 140°F)

CLUTCH

Unit: mm (in)
ITEM

Clutch cable play

Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(NO. 1 & NO. 2)
Driven plate distortion
Clutch spring free length

STANDARD
10 - 15
(0.4 0.6)
3.07 - 3.23
(0.120-0.127)
13.85 - 13.95
(0.545 - 0.549)

53.06
13

nn)

LIMIT
-

2.77
(0.109)
13.35
(0.528)

(1
50?1clR\

SERVICING INFORMATION 9-41

THERMOSTAT + RADIATOR + FAN + COOLANT

I
Engine coolant including reserve

se an antifreezelcoolant
num radiator, mixed with distilled water only, at the
ratio of 50:50.
Approx. 1 400 ml
(1.5 - 1.2 USIlmp qt)

1.42

SERVICING INFORMATION

NJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
SPECIFICATION

ITEM
Injector resistance
Fuel pump discharge amount

9 - 17 L! -at-20
'C (68 "F)
-A p p r o ~83
. ml (2.81 2.9 USIlmp oz) and more
110 sec.

Fuel pressure regulator operating
set pressure

Approx. 294 kPa (2.94 kgflcmz. 41.81 psi)

NOTE

Fl SENSORS
SPECIFICATION

ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltacji
TP sensor resistance

TP sensor output voltage

155 - 232 L l
0.5 V and more
4.5 5.5 V
Approx. 2.7 V at idle spec
4.5 - 5.5 V
Aoorox.
4.5 kR
, ,

GP switch voltage
Injector voltage
Ignition coil primary peak voltage

Closed
Opened
Closed
Opened

I
1

Aoorox.
1.4 kc!
, ,
Approx. 4.2 kc2
Aoorox.
0.6 V
, ,
Approx. 3.8 V

ITEM

I.D. No.
Idle rlmin
Idle air screw
Throttle cable play

I
1

0.15 - 4.85 V
Approx. 2.6 kf2 at 20 "C (68 "F)

Approx. 2.6 ki2 at 20 "C (68 "F)
i n -36nko
Normal

0.4

- 1.4V

Leaning

3.7

- 4.4 V

0.9 V and more
Batterv voltane
150 V and more

THROTTLE BODY

I1 Bore size

-When cranking

ECT sensor input voltage
ECT sensor output voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor output voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage

NOTE

SPECIFICATION
43 mm
45G0
1 800 i 100 rlmin
1-518 turns back
3-5mm
10.12 - 0.20 in)

When
leaning 65"
From 1st to Top
When cranking

SERVICING INFORMATION 9-43

ELECTRICAL

Unit: mm (in)

ITEM

Spark plug

CKP sen^-. ,-Ignition coil resistance

Primary

Capacity
Ignition
Fan
Main

Fuse size

TYP~

SPECIFICATION
NGK: CR8EB

0.1 - 1.0

12 V 21.6 k c (6 Ah)llO HR
10 A
10 A
70 A

WATTAGE

NOTE

Terminal

Unit: w
ITEM

Headlight

HI
LO

Brake lighflaillight
Fuel indicator light
Neutral indicator light
Engine coolant temp. FI warning
indicator light

SPECIFICATION
40
40
LED
3.4
3.4

3.4

9-44

SERVICING INFORMATION

BRAKE +WHEEL
ITEM
Rear brake pedal height

STANDARDlSPEClFlCATlON
0 - 10
(0 0.4)
25.40 25.45
(1.oooo
- 1.0020)
-3396 34.01
(1.3370 - 1.3390)
25.318 - 25.368
(0.9968 - 0.9987)
33.878 - 33.928
(1.3338 - 1.3357)
DOT 4
2.8 - 3.2
(0.1 10 - 0.126)

Brake caliper cylinder bore

Front
Rear

Brake caliper piston diam.

Front
Rear

Brake fluid type
Brake disc thickness

Front

Rear

Brake disc runout (Front & Rear)
Front
Rear
Master cylinder piston diam.

Front
Rear

Turning radius
Toe-in (with 75 kg. 165 lbs)

2.5
(0.098)

0.30
10.0121
>-..-,

Master cylinder bore

Unit: mm (in)
LIMIT

12.700 - 12.743
(0.5000 - 0.5017)

12.700 - 12.743
(0.5000 - 0.5017)
12.657.
(0.4983 12.657 - 12.68
(0.4983 - 0.499 ,
3.5 m (1 1.5 ft)
0*4
(0 i 0.1 6)
3.0"
8.0"

Wheel rim runout

Front
Rear

Wheel rim size
Tire size
Tire type
Tire tread depth

Wheel axle runout

Front
Rear
Front
Rear
Front
Rear

2.0
(0.081
\-.--,

2.0
(0.08)

lOx5.5AT
8 x 8.0 AT
AT20 x 7R10 f;i:-*
AT18 x 10RB I?&&
DUNLOP: KT381
DUNLOP: KT385

Front

Rear

4.0
(0.16)
4.0
10.161
6.0
(0.24)

SERVICING INFORMATION 9-45

TIRE PRESSURE

VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)

SUSPENSION
ITEM
Front shock absorber s,~ r i n o
pre-set length
Front shock absorber damping
force adjuster

STANDARDlSPEClFlCATlON
274.5
(10.8)
Rebound
1-112 turns out from stiffest position
Compression1 2-114 turns out from stiffest position
Rear shock absorber spring pre-set
299
length
(11.8)
l
4
e
a
y
s
h
o
cRebound
k
7 clicks out from stiffest position
force adjuster
8 clicks out from stiffest position
(Low speed)

(Highspeed)
Front wheel travel
Rear wheel travel

LIMIT

314 turn out from stiffest position
254
(10.0)
277
(10.9)

FUEL + OIL

Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%

EMISSION CONTROL INFORMATION

CONTENTS

...............................................................10- 2
..................................................................10- 2
...................................10- 3

EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
CRANKCASE EMISSION CONTROL SYSTEM

10-1

10-2

EMISSION CONTROL INFORMATION

EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
LT-R450 vehicles are equipped with a fuel injection system for emission level control.
This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable
emission limits. With a view to reducing CO. NOX and HC, all of the fuel injection volumes are stringently
controlled with the programmed injection maps in the ECM by varying engine conditions. Adjusting, interfering with, improper replacement, or resetting of any of the fuel injection components may adversely affect
injection performance and cause the vehicle to exceed the exhaust emission level limits, if unable to effect
repairs, contact the distributor's representative for further technical informaiton and assistance.

'1; Fuel tank

i6! Fuel delivery pipe

8.11' Fuel pump

(2' Fuel filter (For fuel valve)

i71 Fuel injector

t A Pressurized fuel

( 3 ; Fuel hose
14: Fuel return hose
15) Fuel pressure regulator

(8) Fuel feed hose

1 6 Before-pressurized fuel

(91
i101

Fuel vapor retur~
Fuel filter (For fuel pump)

Relieved fuel
Fuel vapor

EMISSION CONTROL INFORMATION 10-3

CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle
body.

PCV (breather) hose
: A BLOW-BY GAS
! B FRESH AIR

[:I!

rcl

FUEUAIR MIXTURE
;D; EXHAUST GAS
:E) SEPARATED RETURN OIL

F l OVER-FLOW OIL

WIRING DIAGRAM
Wrrlnq d ~ a g r a mwire color, rmer to

seclmn "WIRE C O L O R
HhNOtEEhRSWnCH
M W E C m P

tLL!7CH

swlrc*

SWRCR

YVIIIALWT~~~LW~

Wm
S
H cF HA

L I Wsmrcr
~

IUVW

,*I
#4,TLYm,mL.oKI

~ I X I LCWT
A

- - . ..
I r

. m

-.-.

I';

I !

I
- . -

-I

I I

.-.I

I
I
I

, I

Y a m

1'11B1

IWnmY swrcw

SFHSOR

LCr

llT

SSWR

5 f N W

I
I

., .-

wrCma

aEWEFXTIla

Ill,
.-

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