Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-Z400 and procedures for its inspec- tion, service, and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
Page 3: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .............. 1- 2 GENERAL PRECAUTIONS ..............1- 2 SUZUKI LT-Z400K3 (2003-MODEL) ..........1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL AND OIL RECOMMENDATION ..........1- 4 FUEL .................... 1- 4 ENGINE OIL.................. 1- 5 BRAKE FLUID ................1- 5 ENGINE COOLANT ..............1- 5...
Page 4: Warning/Caution/Note
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 mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 5 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv- alent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
Page 6: Suzuki Lt-Z400K3 (2003-Model)
) method or 91 octane or higher rated by the Research Method. • SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. • Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.
Page 7: Engine Oil
Use an antifreeze designed for aluminum radiator. SUZUKI recommends the use of SUZUKI COOLANT antifreeze. if this is not available, use an equivalent antifreeze for aluminum radiators.
Page 8: Break-Ln Procedures
GENERAL INFORMATION BREAK-lN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-lN” before subjecting the engine to maximum stresses.
Page 9: Information Labels
GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-03 E-28 E-33 ¡ ¡ — Certification plate ¡ — — Information label ¡ ¡ ¡ Tire air pressure label " ¡ — — Tire air pressure label and warning no-passenger label ¡...
Page 10: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............1 830 mm (72.0 in) Overall width ............1 165 mm (45.9 in) Overall height............1 160 mm (45.7 in) Wheelbase ............1 245 mm (49.0 in) Front track............935 mm (36.8 in) Rear track ............910 mm (35.8 in) Ground clearance ..........
Page 11 GENERAL INFORMATION CHASSIS Front suspension..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Front wheel travel..........215 mm (8.5 in) Rear wheel travel ..........230 mm (9.1 in) Caster..............8.5° Trail ..............36 mm (1.42 in) Toe-in ..............
Page 12: Country And Area Codes
1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas. CODE COUNTRY OR AREA E-03 E-28 Canada E-33 California (USA)
Page 13 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 14 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl Measure in voltage range. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. 99000-25030 (USA) Measure in resistance range. 99000-25010 (Others) Apply SUZUKI SILICONE GREASE.
Page 15 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ..........2- 2 PERIODIC MAINTENANCE CHART ...........2- 2 MAINTENANCE AND TUNE-UP PROCEDURES .......2- 3 AIR CLEANER ................2- 3 EXHAUST PIPE NUTS AND MUFFLER BOLTS ......2- 4 VALVE CLEARANCE ..............2- 5 SPARK PLUG ................2-10 FUEL HOSE .................2-11 THROTTLE CABLE PLAY ............2-11 ENGINE IDLE SPEED ..............2-11...
Page 16: Periodic Maintenance Schedule
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 kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are use under severe conditions.
Page 17: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER 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.
Page 18: Exhaust Pipe Nuts And Muffler Bolts
PERIODIC MAINTENANCE * 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 is to operate the engine with- out the element or with torn element.
Page 19: Valve Clearance
PERIODIC MAINTENANCE VALVE CLEARANCE Inspect initially at 1 month and every 6 months there- after. 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.
Page 20 PERIODIC MAINTENANCE • Remove the valve timing inspection plug 1 and generator cover cap 2. NOTE: * The piston must be at top dead center (TDC) on the compres- sion stroke in order to check or adjust the tappet clearance. * The tappet clearance should only be checked when the engine is cold.
Page 21 After rotating the crankshaft, check the tappet clearance again to make sure that it is within specification. • When installing the cylinder head cover, apply SUZUKI BOND “1207B” to the cam end caps of the cylinder head cover gas- ket.
Page 22 PERIODIC MAINTENANCE INTAKE SIDE...
Page 23 PERIODIC MAINTENANCE EXHAUST SIDE...
Page 24: Spark Plug
2-10 PERIODIC MAINTENANCE SPARK PLUG Inspect every 6 months. Replace every 18 months. • Disconnect the spark plug cap 1 and remove the spark plug. Hot type Standard Cold type CR6E CR7E CR8E DENSO U20ESR-N U22ESR-N U24ESR-N 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.
Page 25: Fuel Hose
PERIODIC MAINTENANCE 2-11 SPARK PLUG INSTALLATION 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.
Page 26: Engine Oil And Oil Filter
2-12 PERIODIC MAINTENANCE • Connect the electric tachometer or the multi circuit tester to the high-tension cord. • Start the engine and set the engine idle speed between 1 400 and 1 600 r/min by turning the throttle stop screw 1. % Engine idle speed: 1 500 ±...
Page 27: Engine Oil Hoses
PERIODIC MAINTENANCE 2-13 OIL FILTER REPLACEMENT • Drain the engine oil as described in the engine oil replace- ment procedure. • Remove the oil filter cap 1 and oil filter 2. • Replace the oil filter with a new one. •...
Page 28: Engine Coolant
2-14 PERIODIC MAINTENANCE 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 B lines on the engine coolant reservoir. • If the level is below the lower line, add engine coolant until the level reaches the upper line.
Page 29: Radiator Hoses
PERIODIC MAINTENANCE 2-15 • 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. Repeat the above procedure several times and make sure the radiator is filled with engine coolant to the upper line of the engine coolant reservoir.
Page 30: Clutch
2-16 PERIODIC MAINTENANCE CLUTCH Inspect initially at 1 month and every 6 months there- after. • Loosen the locknut 1. • Turn the adjuster 2 in or out to obtain the correct play. • Tighten the locknut 1. % Clutch lever play A: 10 – 15 mm (0.4 – 0.6 in) BRAKES Inspect initially at 1 month and every 3 months there- after.
Page 31 PERIODIC MAINTENANCE 2-17 • Adjust the brake switch so the brake light comes on when the brake pedal is depressed 7 – 10 mm (0.3 – 0.4 in). PARKING BRAKE Parking brake adjustment may be required if the parking brake does not work properly.
Page 32: Brake Fluid
2-18 PERIODIC MAINTENANCE • Turn the parking brake adjuster 2 clockwise until it stops. • Then turn the adjuster 2 ( – ) back. • Tighten the adjuster locknut 1 while holding the adjuster 2 in position with a screw driver. "...
Page 33 PERIODIC MAINTENANCE 2-19 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 cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 34: Brake Hoses
2-20 PERIODIC MAINTENANCE BRAKE HOSES Inspect every 6 months. Replace every 4 years. • Check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones. TIRES Inspect every 3 months. 4.0 mm TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease...
Page 35: Steering
PERIODIC MAINTENANCE 2-21 To minimize the possibility of tire damage from over-inflation, we strongly recommended that a man- ual type air pump be used rather than a high pressure air compressor as found in service stations. When fill- ing air into the tires, never exceed 70 kPa (0.7 kgf/cm², 10 psi).
Page 36: Drive Chain
2-22 PERIODIC MAINTENANCE DRIVE CHAIN Inspect drive chain each time the motorcycle is rid- den. Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) * Loose pins * Excessive wear...
Page 37: Drive Chain Slack
PERIODIC MAINTENANCE 2-23 • 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 mm (12.57 in) ADJUSTING •...
Page 38: Suspensions
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is a RK 520KZO SUZUKI recommends to use this standard drive chain as a replacement.
Page 39: Chassis Bolts And Nuts
PERIODIC MAINTENANCE 2-25 CHASSIS BOLTS AND NUTS Tighten initially at 1 month and every 3 months there- after. Check that all chassis nuts and bolts are tightened to their specified torque. (Refer to page 2-26 and 2-27 for the locations of the following nuts and bolts.) Item N·m kgf-m...
Page 40 2-26 PERIODIC MAINTENANCE...
Page 41 PERIODIC MAINTENANCE 2-27...
Page 42: General Lubrication
2-28 PERIODIC MAINTENANCE GENERAL LUBRICATION Lubricate initially 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. 1Brake lever holder 5Brake cam Grease 2Throttle lever...
Page 43: Compression Pressure Check
PERIODIC MAINTENANCE 2-29 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 mainte- nance records kept at your dealership should include compression readings for each maintenance service. % Compression pressure: Standard: 1 000 kPa (10.0 kgf/cm², 142 psi) (Automatic decompression actuated)
Page 44: Oil Pressure Check
2-30 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. % Oil pressure: Above 20 kPa (0.2 kgf/cm², 2.8 psi) Below 60 kPa (0.6 kgf/cm², 8.5 psi) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE * Clogged oil filter...
Page 45 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2 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 REMOUNTING ..............3- 7 ENGINE DISASSEMBLY ..............3- 9 ENGINE COMPONENTS INSPECTION AND SERVICE .....3-19 CYLINDER HEAD ................3-19...
Page 46: Engine Components Removable With Engine In Place
ENGINE 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 SIDE PARTS REMOVAL INSTALLATION...
Page 47: Engine Removal And Remounting
ENGINE 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. (!2-14) • Remove the engine under cover 1. •...
Page 48 ENGINE • Remove the fuel tank. (!4-3) • Disconnect the spark plug cap 1 oil tank overflow hose 2 and breather hose 3. • Remove the engine coolant inlet hose 4 and disconnect the outlet hose 5. • Disconnect the breather hose 6 and remove the oil return tank 7 with hose 8.
Page 49 ENGINE • Remove the engine sprocket cover. • Remove the clutch cable bracket 1. • Disconnect the clutch inner cable 2 from the cam lever. • Disconnect the generator lead wire couplers 3 and neutral switch lead wire coupler 4. •...
Page 50 ENGINE • Loosen the muffler clamp bolt 1. • Remove the muffler 2. • Remove the radiator lower mounting bolt 3 and push lower of the radiator forward. • Remove the thermostat cover 4 and thermostat. • Remove the exhaust pipe 5. •...
Page 51: Engine Remounting
ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. Pay attention to the following points: 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.
Page 52 ENGINE • Install the engine sprocket with drive chain after loosening the chain adjuster bolts. NOTE: The letter A on the engine sprocket should face to the outside. • Apply THREAD LOCK SUPER “1303” to the sprocket bolts. $ 99000-32030: THREAD LOCK SUPER “1303” •...
Page 53: Engine Disassembly
ENGINE ENGINE DISASSEMBLY • Remove the clutch release arm 1. • Remove the starter motor 2. • Remove the spark plug. & 09930-10121: Spark plug wrench set • Remove the spring holder bolt 3 of the can chain tension adjuster with spring. •...
Page 54 3-10 ENGINE • Remove the valve timing inspection plug 1 and generator cover cap 2. • Turn the generator rotor until the “T” 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.
Page 55 ENGINE 3-11 • Remove the cylinder head bolts, and then remove the cylinder head. NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic mallet. • Remove the cylinder head gasket 1 and dowel pins 2. •...
Page 56 3-12 ENGINE • Remove the starter drive gear cover and starter drive gear 1. • Remove the generator rotor cover. • Remove the starter driven gear 2, dowel pins 3, and gasket • Remove the clutch cover. A: Bolt with washer •...
Page 57 ENGINE 3-13 • Hold the generator rotor using a 27-mm offset wrench. • Loosen the clutch spring set bolts working in diagonal stages. • Remove the bolts and springs. • Remove the clutch pressure plate, clutch drive plates, and clutch driven plates. •...
Page 58 3-14 ENGINE • Remove the primary driven gear assembly 1 and washer 2. • Remove the coller 3. • Remove the cam chain tensioner 4 and cam chain 5. • Remove the oil pipe 6. • Remove the oil pump idle gear 7 and oil pump driven gear •...
Page 59 ENGINE 3-15 • Remove the gearshift shaft 1 by removing the snap ring 2. • Remove the gearshift pawl lifter 3 and gearshift cam driven gear 4. • Remove the gearshift cam stopper arm 5. • Remove the gearshift cam driven gear bolt. •...
Page 60 3-16 ENGINE • Remove the key 1, balancer drive gear 2 and pin. • Hold the generator rotor using a 27-mm offset wrench, and then remove the generator rotor nut. • 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.
Page 61 ENGINE 3-17 • Remove the neutral switch 1. • Remove the O-ring 2, switch contacts 3 and springs 4. • Remove the left crankcase securing bolts. • Remove the right crankcase securing bolts. • Separate the crankcase using the special tool. &...
Page 62 3-18 ENGINE • Remove the reverse idle gear with its shaft. • Remove the countershaft assembly 1 and driveshaft assem- bly 2. • Remove the balancer shaft. • Remove the crankshaft from the crankcase using the special tool. & 09920-13120: Crankcase separating tool...
Page 63: Engine Components Inspection And Service
ENGINE 3-19 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD DISASSEMBLY " Identify the position of each removed part. Organize the parts in their respective groups (i.e., exhaust or intake) so that they can be installed in their original positions. • Remove the intake pipe. •...
Page 64 3-20 ENGINE • Compress the valve springs, and then remove the valve cot- ters 1 from the valve stem using the special tools. & 09916-14510: Valve spring compressor 09916-14910: Attachment 09916-84511: Tweezers • Remove the valve spring retainer 2 and valve spring 3. •...
Page 65 ENGINE 3-21 CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance read- ings at several places. If any clearance reading exceeds the ser- vice limit, replace the cylinder head with a new one. &...
Page 66 3-22 ENGINE VALVE STEM DEFLECTION Lift the valve about 10 mm (0.39 in) from the valve seat. Mea- sure the valve stem deflection in two directions, “X” and “Y”, per- pendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, determine whether the valve or the guide should be replaced with a new one.
Page 67 ENGINE 3-23 • Oil the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer and attachment. & 09916-44310: Valve guide remover/installer 09916-53360: Valve guide installer attachment " Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head.
Page 68 3-24 ENGINE VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45°. Intake Exhaust 45° N-128 N-128 15° — N-121 30° N-128 — 60°...
Page 69 ENGINE 3-25 INITIAL SEAT CUT • Descale and clean up the seat using the 45° cutter. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. 45˚ • If the valve seat is pitted or burned, use the 45° cutter to con- dition the seat some more.
Page 70 3-26 ENGINE FINAL SEAT CUT Contact area too low and • If the contact area is too low or too narrow, use the 60° cutter too narrow on face of valve to raise and widen the contact area. If the contact area is too high or too wide, use the 15°...
Page 71 ENGINE 3-27 VALVE SPRING The force of the coil spring keeps the valve seat tight. A weak- ened spring results in reduced engine power output and accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
Page 72: Camshaft/Automatic Decompression Assembly
3-28 ENGINE • Install the valve spring retainer by pressing down the spring using the valve lifter. Fit the cotter halves to the stem end and release the lifter to allow the cotter 1 to wedge between the retainer and the valve stem. Make sure that the rounded lip 2 of the cotter fits snugly into the groove 3 in the stem end.
Page 73: Camshaft Runout
ENGINE 3-29 CAMSHAFT JOURNAL WEAR Measure the oil clearance, with the camshaft installed, using the plastigauge. & 09900-22301: Plastigauge 09900-22302: Plastigauge % Camshaft journal oil clearance (IN & EX) Service Limit: 0.150 mm (0.0059 in) • Tighten the camshaft journal holder bolts evenly and in diago- nal stages to the specified torque.
Page 74: Cam Chain Tension Adjuster And Tensioner
3-30 ENGINE CAM CHAIN TENSION ADJUSTER AND TEN- SIONER Check that the push rod slides smoothly when unlocking the ratchet mechanism 1. If push rod does not slide smoothly, replace the cam chain ten- sion adjuster with a new one. Check the contacting surface of the cam chain tensioner and cam chain guide.
Page 75: Piston And Piston Ring
ENGINE 3-31 PISTON AND PISTON RING PISTON DIAMETER Measure the piston diameter using the micrometer at 15 mm (0.6 in) from the skirt end. If the piston diameter is less than the service limit, replace the piston with a new one. 15 mm &...
Page 76 3-32 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using the vernier calipers, first, and then fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any measurement exceeds the service limit, replace the piston ring with a new one.
Page 77: Conrod
ENGINE 3-33 CONROD CONROD SMALL END I.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. & 09900-20605: Dial calipers % Conrod small end I.D.
Page 78: Balancer Shaft And Balancer Driven Gear
3-34 ENGINE BALANCER SHAFT AND BALANCER DRIVEN GEAR DISASSEMBLY • Disassemble the balancer shaft as shown in the illustration. Balancer shaft " Balancer driven gear Spring (4 pcs.) Pin (2 pcs.) INSPECTION Inspect the balancer shaft and balancer driven gear for wear or damage.
Page 79: Starter Clutch
ENGINE 3-35 STARTER CLUTCH • Hold the rotor using a 27-mm offset wrench and remove the bolts. • Install the starter clutch in the proper direction as shown. NOTE: When installing the starter clutch onto the rotor, make sure that the flange side A in the bearing faces to the rotor.
Page 80: Starter Torque Limiter
" The oil pump case securing screw 3 is applied with SUZUKI THREAD LOCK SUPER “1303”. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
Page 81: Clutch
ENGINE 3-37 • When installing the outer rotor, face the punched mark 1 on the outer rotor to the outside. CLUTCH CLUTCH DRIVE PLATES Measure the thickness of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
Page 82: Gearshift Fork And Gear
3-38 ENGINE GEARSHIFT FORK AND GEAR GEARSHIFT-FORK-TO-GEARSHIFT-FORK GROOVE CLEARANCE Clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process. Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. If the clearance exceeds specification, replace the fork, its respective gear, or both.
Page 83: Transmission
ENGINE 3-39 TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown. Countershaft 5th drive gear " 3rd drive gear 4th drive gear 2nd drive gear Driveshaft & 2nd driven gear 4th driven gear 3rd driven gear 5th driven gear Reverse driven gear 1st/reverse dog 1st driven gear Reverse idle gear shaft...
Page 84 3-40 ENGINE REASSEMBLY Reassemble the transmission in the reverse order of disassem- bly. Pay special attention to the following points: NOTE: Before installing the gears, apply engine oil to the inner surface of each gear and bushing. " * 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.
Page 85 ENGINE 3-41 • When installing the reverse driven gear bushing, align the its oil hole with the driveshaft oil hole. Countershaft Driveshaft...
Page 86: Crankcase
3-42 ENGINE CRANKCASE OIL SUMP FILTER • Remove the oil sump filter. • Clean the oil sump filter using compressed air. • Align the oil passage holes when installing the oil sump filter. OIL JET • Remove the oil jet. •...
Page 87 ENGINE 3-43 OIL PUMP IDLE GEAR SHAFT AND GEARSHIFT ARM STOPPER • Remove the oil pump idle gear shaft 1. • Apply THREAD LOCK “1342” to the gearshift arm stopper. • Tightening the gearshift arm stopper 2 to the specified torque.
Page 88 3-44 ENGINE BEARING INSTALLATION • Install the crankcase bearings using the special tool. & 09913-70210: Bearing installer set • Apply a small quantity of THREAD LOCK SUPER “1303” to the bearing retainer screws, and tighten them securely. $ 99000-32030: THREAD LOCK SUPER “1303” OIL SEAL INSPECTION Damage to the lip of the oil seal may result in leakage of the engine oil.
Page 89 • Install the oil seals into the crankcase. Pay attention to the fol- lowing points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seals. ) 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 90: Clutch Cover
3-46 ENGINE CLUTCH COVER OIL FILTER !2-13 WATER PUMP !5-13 OIL CHECK VALVE • Remove the bushing 1, oil check valve ball 2 and spring 3. • Install the spring 3, oil check valve ball 2 and bushing 1 to the clutch cover 4 as shown.
Page 91: Engine Reassembly
ENGINE 3-47 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling the engine. CRANKSHAFT Bearing Crankshaft (R) " Conrod Bearing Crank pin...
Page 92: Gearshift Cam, Fork And Reverse Lock Shaft
3-48 ENGINE GEARSHIFT CAM, FORK AND REVERSE LOCK SHAFT Gearshift fork No.1 Gearshift fork No.2 " Gearshift fork shaft Gearshift cam Gearshift fork No.3 & Reverse lock shaft Spring • Install the gearshift forks into the gearshifting grooves in the correct position and direction.
Page 93: Crankcase
• Install the dowel pins 1 to the left crankcase. • Apply engine oil to the conrod big end and to the transmission gears. • Apply SUZUKI BOND “1207B” or “1215” to the mating surface of the right crankcase as shown. * 99104-31140: SUZUKI BOND “1207B” (USA) + 99000-31110: SUZUKI BOND “1215”...
Page 94: Starter Clutch And Generator Rotor
3-50 ENGINE • After the crankcase bolts have been tightened, check if the crankshaft, countershaft, and driveshaft rotate smoothly. If a large resistance is felt to rotation, try to free the shafts by tap- ping them with a plastic mallet. STARTER CLUTCH AND GENERATOR ROTOR •...
Page 95: Primary Drive Gear And Balancer Gear
ENGINE 3-51 PRIMARY DRIVE GEAR AND BALANCER GEAR • Install the pins 1. • Install the balancer drive gear 2. • Install the key 3 and cam chain drive sprocket 4. • Apply engine oil to the thread and inside surface of the nut. •...
Page 96: Gearshift Cam Driven Gear
3-52 ENGINE GEARSHIFT CAM DRIVEN GEAR • Tighten the gearshift cam driven gear bolt to the specified torque. # Gearshift cam driven gear bolt: 24 N·m (2.4 kgf-m, 17.5 lb-ft) • Install each pawl lifter into the gearshift cam driven gear. The large shoulder A must face to the outside.
Page 97: Oil Pump
ENGINE 3-53 OIL PUMP • Before mounting the oil pump, apply engine oil to the sliding surfaces of the oil pump case, outer rotor, inner rotor, and crankcase. • Apply a small quantity of THREAD LOCK “1342” or THREAD LOCK SUPER “1322” to the oil pump mounting screws, and then tighten them securely.
Page 98: Clutch
3-54 ENGINE CLUTCH Clutch release camshaft Bolt " Spring retainer Spring Pressure plate Drive plate (7 pcs) & Driven plate (7 pcs) Drive plate (1 pc) Bearing Push piece Washer Clutch sleeve hub Washer Primary driven gear assembly Spacer Push rod Clutch sleeve hub nut ITEM N·m...
Page 99 ENGINE 3-55 • Bend the tongue of the washer securely. • Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order. NOTE: * Be sure to install the drive plate with an inside diameter of 122.5 mm (4.82 in), first.
Page 100: Neutral Switch
3-56 ENGINE NEUTRAL SWITCH • Install the springs 1, contacts 2 and new O-ring 3. • Install the neutral switch and tighten the bolts to the specified torque. # Neutral switch bolt: 6.5 N·m (0.65 kgf-m, 4.7 lb-ft) GENERATOR ROTOR COVER •...
Page 101: Piston Ring
ENGINE 3-57 PISTON RING • Install the oil ring first, the 2nd ring second, and the 1st ring last. NOTE: * The 1st 1 and 2nd 2 piston rings differ in shape. * The 1st and 2nd piston rings should be installed with the mark facing up.
Page 102: Piston And Cylinder
3-58 ENGINE PISTON AND CYLINDER • Apply molybdenum oil solution onto the piston pin and small end of the conrod. NOTE: Install the piston with the punch mark 1 on the piston head fac- ing toward the exhaust side. • 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.
Page 103: Cylinder Head
ENGINE 3-59 • Install the cam chain guide 1. NOTE: Make sure that the guide 1 is inserted properly or binding of the cam chain and guide may result. • Install the dowel pins 2 and new gasket 3. " Use a new cylinder head gasket to prevent gas leak- age.
Page 104: Camshaft/Automatic Decompression Assembly
3-60 ENGINE CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY • Turn the generator rotor until the “T” line on the generator rotor is aligned with the center of the hole in the generator cover. " If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch between crank- case and cam chain drive sprocket.
Page 105 ENGINE 3-61 • With the “T” 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 arrow marked “1” 1. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.
Page 106: Cylinder Head Cover
CYLINDER HEAD COVER • Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover. • Apply SUZUKI BOND “1207B” to the end caps of the cylinder head cover gasket as shown. * 99104-31140: SUZUKI BOND “1207B” (USA) * 99000-31140: SUZUKI BOND “1207B”...
Page 107: Cam Chain Tension Adjuster
ENGINE 3-63 CAM CHAIN TENSION ADJUSTER • Apply engine oil to the push rod. • Unlock the ratchet mechanism 1 and push the push rod 2 all the way. • Install the new gasket and cam chain tension adjuster to the cylinder.
Page 108: Fuel System
FUEL SYSTEM FUEL SYSTEM CONTENTS FUEL TANK ..................4- 2 CONSTRUCTION .................4- 2 FUEL LINE INSPECTION ............4- 3 REMOVAL ..................4- 3 REMOUNTING ................4- 3 FUEL VALVE ..................4- 4 REMOVAL AND INSPECTION ............4- 4 FUEL STRAINER .................4- 4 REMOUNTING ................4- 4 CARBURETOR ..................4- 5 CONSTRUCTION .................4- 5 SPECIFICATIONS ................4- 6 I.D.
Page 109: Fuel Tank
FUEL SYSTEM FUEL TANK CONSTRUCTION Insert the breather hose Steering stem head cover No. 2 into the steering Breather hose No.1 stem shaft. " Breather hose No.2 Fuel tank cap Fuel tank Fuel valve & Fuel hose Duct cover Air cleaner duct Frame Cushion Steering stem shaft...
Page 110: Fuel Line Inspection
FUEL SYSTEM FUEL LINE INSPECTION Inspect the fuel lines, fuel tank 1, fuel tank breather hoses 2 and fuel tank cap 3 for damage, clogging and leakage of fuel. If any damages are found, replace the defective parts with the new ones. Steering head cover REMOVAL •...
Page 111: Fuel Valve
FUEL SYSTEM FUEL VALVE REMOVAL AND INSPECTION • Remove the fuel tank. (!4-3) • Drain fuel completely. • Remove the fuel valve. " Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. FUEL STRAINER If the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
Page 112: Carburetor
FUEL SYSTEM CARBURETOR CONSTRUCTION Spring Holder O-ring Spring Washer E-ring Spacer Washer Jet needle Diaphragm Ring Piston valve Vacuum hose Air vent hose Cover O-ring Diaphragm Diaphragm cover Starter plunger Pilot jet pipe Pilot jet Needle valve Needle jet O-ring Starter jet Needle jet holder Main jet ring...
Page 113: Specifications
FUEL SYSTEM SPECIFICATIONS SPECIFICATION ITEM E-03, 28 E-33 ← Carburetor type MIKUNI BSR36 ← Bore size 36 mm I.D. No. 07G0 07G1 ← Idle r/min 1 500 ± 100 r/min 13.0 ± 1.0 mm ← Float height (0.51 ± 0.04 in) Main jet (M.J.) #130...
Page 114: Removal
FUEL SYSTEM REMOVAL • Remove the fuel tank left side cover. (!6-4) • Disconnect the fuel hose 1 and vacuum hose 2. • Loosen the carburetor clamp screw. • Loosen the carburetor clamp screw. • Disconnect the air vent hose 3. •...
Page 115: Disassembly
FUEL SYSTEM • Disconnect the throttle cable 6. • Remove the O-ring 7. DISASSEMBLY • Remove the fuel hose a, over flow hose b and vacuum hose • Remove the throttle stop screw d. • Remove the carburetor top cap. Do not use compressed air on the carburetor body before removing the diaphragm;...
Page 116 FUEL SYSTEM • Remove the jet needle holder 4, O-ring 5, spring 6, washer 7, jet needle 8 and washer 9. • Remove the diaphragm cover 0. • Remove the diaphragm A. • Remove the float chamber.
Page 117 4-10 FUEL SYSTEM • Remove the O-ring B. Replace the removed O-ring with a new one to prevent leakage of fuel. • Remove the float pin C, float D and needle valve E. • Remove the valve seat F.
Page 118 FUEL SYSTEM 4-11 • Remove the following parts. G Main jet, main jet ring, needle jet holder and needle jet H Pilot screw I Starter jet J Pilot jet K Pilot air jet NOTE: Before removing the pilot screw H, its setting must be deter- mined.
Page 119: Cleaning
4-12 FUEL SYSTEM CLEANING " Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Page 120: Reassembly
FUEL SYSTEM 4-13 NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.
Page 121: Remounting
Replace the removed O-ring with a new one. THROTTLE STOP SCREW • Apply SUZUKI SUPER GREASE “A” to thread part of the throttle stop screw, then install the throttle stop screw to the carburetor.
Page 122: Cooling And Lubrication System
COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS COOLING SYSTEM ................5- 2 DESCRIPTION ................5- 2 ENGINE COOLANT ................5- 3 RADIATOR AND HOSES ..............5- 4 COOLING CIRCUIT INSPECTION ..........5- 4 RADIATOR CAP INSPECTION ...........5- 4 RADIATOR INSPECTION ............5- 4 RADIATOR HOSE INSPECTION ..........5- 5 RADIATOR REMOVAL ..............5- 5 RADIATOR REMOUNTING ............5- 6 RADIATOR RESERVOIR TANK ..........5- 6...
Page 123: Cooling System
COOLING AND LUBRICATION SYSTEM COOLING SYSTEM DESCRIPTION The engine is cooled by the forced circulation of engine coolant, using a high-capacity, centrifugal water pump, through water jackets formed in the cylinder and cylinder head, and through the radiator. The tube- and-fin type radiator is made of aluminum, which is characterized by lightness in weight and good heat dissi- pation.
Page 124: Engine Coolant
COOLING AND LUBRICATION SYSTEM 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. Anti-freeze Freezing point This 50:50 mixture will provide the optimum corrosion protection density and excellent heat protection, and will protect the cooling system –31˚C (–24˚F) from freezing at temperatures above –31°C (–24°F).
Page 125: Radiator And Hoses
COOLING AND LUBRICATION SYSTEM RADIATOR AND HOSES COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, check the following. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler.
Page 126: Radiator Hose Inspection
COOLING AND LUBRICATION SYSTEM RADIATOR HOSE INSPECTION • Remove the front fender. (%6-4) Any radiator hose found in a cracked condition or flattened must be replaced. Any leakage from the connecting section should be corrected by proper tightening. RADIATOR REMOVAL •...
Page 127: Radiator Remounting
COOLING AND LUBRICATION SYSTEM • Disconnect the engine coolant temperature switch lead wire coupler 1 and cooling fan motor lead wire coupler 2. • Disconnect the upper and lower radiator hoses. • Remove the three mounting bolts and radiator assembly. RADIATOR REMOUNTING •...
Page 128: Cooling Fan
COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the front fender. (%6-4) • Disconnect the cooling fan lead wire coupler. Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration. The voltmeter is for making sure that the battery applies 12 volts to the motor.
Page 129: Remounting
COOLING AND LUBRICATION SYSTEM • Remove the cooling fan. • Remove the cooling fan motor. REMOUNTING Remount the cooling fan in the reverse order of removal.
Page 130: Cooling Fan Thermo-Switch
COOLING AND LUBRICATION SYSTEM COOLING FAN THERMO-SWITCH The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo- switch. The thermo-switch remains open when the temperature of the engine coolant is low, but closes when the temperature reaches approximately 88°C (190°F) setting the cooling fan in motion.
Page 131: Inspection
5-10 COOLING AND LUBRICATION SYSTEM INSPECTION • Check the thermo-switch closing or opening temperatures by testing it at the bench as shown in the figure. Connect the thermo-switch 1 to a circuit tester and place it in the oil con- tained in a pan, which is placed on a stove.
Page 132: Engine Coolant Temperature Switch
COOLING AND LUBRICATION SYSTEM 5-11 ENGINE COOLANT TEMPERATURE SWITCH REMOVAL • Remove the front fender. (%6-4) • Drain a small amount of engine coolant. (%2-14) • Disconnect the engine coolant temperature switch lead wire coupler 1. • Remove the engine coolant temperature switch 2. INSPECTION •...
Page 133: Thermostat
5-12 COOLING AND LUBRICATION SYSTEM THERMOSTAT REMOVAL • Drain a small amount of engine coolant. (%2-14) • Place a rag under the thermostat case. • Remove the thermostat case. • Remove the thermostat. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.
Page 134: Water Pump
COOLING AND LUBRICATION SYSTEM 5-13 WATER PUMP CONSTRUCTION Water pump cover O-ring " Impeller Mechanical seal Oil seal O-ring & Bearing O-ring...
Page 135: Removal And Disassembly
5-14 COOLING AND LUBRICATION SYSTEM REMOVAL AND DISASSEMBLY • Drain engine coolant. (%2-14) • Drain engine oil. (%2-12) " * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
Page 136 COOLING AND LUBRICATION SYSTEM 5-15 • Remove the water pump cover. • Remove the snap ring 1, water pump driven gear 2, pin 3 and washer 4. • Remove the E-ring 5, impeller 6, and water pump body 7. • Remove the bearing using the special tool. &...
Page 137: Inspection
5-16 COOLING AND LUBRICATION SYSTEM • 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 nec- essary. The removed oil seal must be replaced with a new one. •...
Page 138: Reassembly And Installation
& 09913-70210: Bearing installer set NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. * 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 139 The paint marked side A of the mechanical seal ring faces the impeller. • Apply grease to the impeller shaft. * 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the impeller shaft to the water pump body.
Page 140 5-19 • Install the new O-rings 1 and 2. • Apply grease to the O-rings. * 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the water pump body with the impeller to the clutch cover.
Page 141 5-20 COOLING AND LUBRICATION SYSTEM • Install the new O-ring to the water pump cover. Use the new O-rings to prevent engine coolant leak- age. • Apply engine coolant to the O-ring. • Install the water pump cover to the clutch cover. •...
Page 142: Oil Tank And Hoses
COOLING AND LUBRICATION SYSTEM 5-21 OIL TANK AND HOSES CONSTRUCTION 23 N . m 2.3 kgf-m 16.5 lb-ft Oil tank hose, RH Oil tank hose, LH " Oil hose union bolt Gasket 12 N . m Bolt 1.2 kgf-m 8.5 lb-ft &...
Page 143: Removal
5-22 COOLING AND LUBRICATION SYSTEM REMOVAL • Remove the front fender. (%6-4) • Drain engine coolant. (%2-14) • Remove the radiator. (%5-5) • Drain engine oil. (%2-12) • Remove the oil tank protector 1. • Remove the engine protector 1. •...
Page 144: Remounting
COOLING AND LUBRICATION SYSTEM 5-23 • Remove the oil tank. REMOUNTING Remount the oil tank and hoses in the reverse order of removal. Pay attention to the following points. • When connecting the oil tank right hose, place the base of oil pipe against the stopper on engine.
Page 145: Lubrication System
5-24 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE %2-30 OIL FILTER %2-13 OIL SUMP FILTER %3-42 OIL PUMP %3-36...
Page 146: Engine Lubrication System Chart
COOLING AND LUBRICATION SYSTEM 5-25 ENGINE LUBRICATION SYSTEM CHART STARTER CLUTCH CYLINDER WALL PISTON LEFT CRANKSHAFT PISTON PIN IN & EX CAM FACE CONROD BIG END CAM CHAIN BEARING IN & EX CAMSHAFT JOURNAL ORIFICE CYLINDER HEAD CRANK PIN PISTON CYLINDER RIGHT CRANKSHAFT PISTON PIN...
Page 147 CHASSIS CONTENTS EXTERIOR PARTS ..................6- 2 CONSTRUCTION ................... 6- 2 REMOVAL ....................6- 4 REMOUNTING ..................6- 8 FRONT AND REAR WHEELS ................ 6- 9 CONSTRUCTION ................... 6- 9 REMOVAL ....................6-10 INSPECTION AND DISASSEMBLY ............6-11 REASSEMBLY AND REMOUNTING ............ 6-12 TIRES ......................
Page 148 CHASSIS FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ........6-48 REAR BRAKE ....................6-49 CONSTRUCTION ...................6-49 BRAKE PAD REPLACEMENT ..............6-50 BRAKE FLUID REPLACEMENT ............6-51 BRAKE CALIPER REMOVAL AND DISASSEMBLY ......6-52 BRAKE CALIPER INSPECTION ............6-54 BRAKE CALIPER REASSEMBLY AND REMOUNTING ......6-55 BRAKE DISC REMOVAL AND REMOUNTING ........6-58 BRAKE DISC INSPECTION ..............6-58 MASTER CYLINDER REMOVAL AND DISASSEMBLY .......6-59...
Page 149: Exterior Parts
CHASSIS EXTERIOR PARTS CONSTRUCTION...
Page 150 CHASSIS Rear fender Shield " Battery plate Rear fender bracket Cushion Before adhering the shield, Right mud guard degrease the front fender. reinforcement Left mud guard & reinforcement Right mud guard Left mud guard Foot rest 55 N . m (5.5 kgf-m, 40.0 lb-ft)
Page 151: Removal
CHASSIS REMOVAL SEAT • Remove the seat by pulling the lock release lever 1 which is located behind the rear fender. FRONT FENDER • Remove the seat. (!above) • Remove the fuel tank cap 1. • Remove the fuel tank top cover 2. •...
Page 152 CHASSIS • Remove the reverse lock release knob 4. • Remove the front fender mounting bolts. • Disconnect the headlight coupler 5. • Remove the front fender. • Remove the headlight assembly 6.
Page 153 CHASSIS FOOTREST MUD GUARD • Remove the mud guards 1. FOOTREST • Remove the footrest mud guards. (!above) • Remove the footrests.
Page 154 CHASSIS REAR FENDER • Remove the seat. (!6-4) • Remove the fasteners. • Remove the battery plate 1. • Remove the battery 2. • Disconnect the battery lead wire clamp 3. • Remove the starter relay 4. • Remove the rear fender mounting bolts. •...
Page 155: Remounting
CHASSIS REMOUNTING Remount the exterior parts in the reverse order of removal. Pay attention to the following points: FOOTREST • Apply THREAD LOCK “1342” to the bolts 1 and tighten bolts to the specified torque. " 99000-32050: THREAD LOCK “1342” # Footrest mounting bolt: 55 N·m (5.5 kgf-m, 40.0 lb-ft) MUD GUARD REINFORCEMENT •...
Page 156: Front And Rear Wheels
CHASSIS FRONT AND REAR WHEELS CONSTRUCTION Disc cover Front disc Spacer Dust seal Hub bearing Bearing spacer Front wheel hub Hub bearing Dust seal Spacer Washer Cotter pin Tire valve Front tire Front wheel rim Sprocket flange Sprocket Washer Rear wheel hub Washer Rear tire Rear wheel rim...
Page 157: Removal
6-10 CHASSIS REMOVAL FRONT AND REAR WHEELS • Place the vehicle on level ground. • Support the vehicle with a jack or wooden block. • Remove the wheel. • Remove the front hub plate 1. FRONT WHEEL HUB • Remove the front wheel. (!See above) •...
Page 158: Inspection And Disassembly
CHASSIS 6-11 REAR WHEEL HUB • Remove the rear wheel. (!6-10) • Remove the cotter pin and loosen the wheel hub nut by apply- ing the rear brake. • Remove the wheel hub nut and washer. • Remove the wheel hub 1. INSPECTION AND DISASSEMBLY DUST SEAL Inspect the dust seal lips for wear or damege.
Page 159: Reassembly And Remounting
CHASSIS REASSEMBLY AND REMOUNTING FRONT WHEEL HUB • Apply SUZUKI SUPER GREASE “A” to the hub bearing. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the hub bearings and spacer into the front wheel hub with the special tool.
Page 160 • Install the dust seals 4 into the front wheel hub with fabric portion facing to outside. • Apply SUZUKI SUPER GREASE “A” to the dust seal’s lip. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 161 6-14 CHASSIS REAR WHEEL HUB • Apply small amount of SUZUKI SUPER GREASE “A” to the wheel hub’s spline. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the rear wheel hub 1, washer and nut.
Page 162: Tires
CHASSIS 6-15 TIRES TIRE REPLACEMENT • Remove the front and rear wheels. (!6-10) • After removing the air valve cap, release the tire pressure by depressing the valve. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim by using a set of tire levers and rim protectors.
Page 163 6-16 CHASSIS NOTE: * For inspecting the tire, refer to page 2-20. * Inspect the valve core, before installation. * When installing the front tire, make sure that the arrow A on the side wall of the front tire points in the direction of rotation. * When installing the rear tire, make sure that the instruction “SIDE FACING INWARDS”...
Page 164: Front Brake
CHASSIS 6-17 FRONT BRAKE CONSTRUCTION Master cylinder reservoir cap Master cylinder mounting bolt Diaphragm Brake hose union bolt Master cylinder clamp Air bleeder valve Boot Brake caliper mounting bolt Piston/cup set Brake pad mounting pin Caliper holder pin Spring Caliper holder slide pin Master cylinder Brake disc bolt Brake hose No.1...
Page 165: Brake Pad Replacement
6-18 CHASSIS BRAKE PAD REPLACEMENT • Remove the front wheel. (!6-10) • Remove the brake caliper mounting bolts 1 and brake pad mounting pins 2. • Remove the brake pads. * Do not operate the brake lever during or after brake pad removal.
Page 166: Brake Fluid Replacement
CHASSIS 6-19 BRAKE FLUID REPLACEMENT • Place the vehicle on a level surface and keep the handlebar straight. • 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. * Specification and classification: DOT 4 •...
Page 167 6-20 CHASSIS • Remove the spring 1. • Place a rag over the brake caliper piston to prevent the piston from popping out and then force out the piston using com- pressed air. Do not use high pressure air to prevent brake caliper piston damage.
Page 168: Brake Caliper Inspection
CHASSIS 6-21 BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age.
Page 169: Brake Caliper Reassembly And Remounting
• Tighten the pin 2 to the caliper holder 1 to the specified torque. # Caliper holder pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Apply SUZUKI SILICONE GREASE to the brake caliper holder pin 2. + 99000-25100: SUZUKI SILICONE GREASE...
Page 170 CHASSIS 6-23 • Apply SUZUKI SILICONE GREASE to the brake caliper holder slide pin. + 99000-25100: SUZUKI SILICONE GREASE • Install the pin 1, washer 2 and caliper holder 3 to the cali- per. • Apply THREAD LOCK SUPER “1360” to the pin 1.
Page 171: Brake Disc Removal And Disassembly
6-24 CHASSIS BRAKE DISC REMOVAL AND DISASSEMBLY • Remove the front wheel. (!6-10) • Remove the front wheel hub. (!6-10) • Remove the brake disc. BRAKE DISC INSPECTION • Remove the front wheel. (!6-10) • Remove the caliper. (!6-19) Inspect the brake disc for cracks or damage and measure the thickness using the micrometer.
Page 172: Master Cylinder Removal And Disassembly
CHASSIS 6-25 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the vehicle.
Page 173: Master Cylinder Inspection
6-26 CHASSIS • Remove the piston/secondary cup, primary cup and spring. 7 Secondary cup 8 Piston 9 Primary cup 0 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
Page 174 CHASSIS 6-27 • Align the master cylinder holder’s mating surface A with the punch mark B on the handlebars and tighten the upper clamp bolt first. # Master cylinder clamp bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft) C Master cylinder D Master cylinder upper clamp bolt E Handlebar F Clearance...
Page 175: Front Suspension
6-28 CHASSIS FRONT SUSPENSION CONSTRUCTION Front shock absorber Upper wishbone arm " Lower wishbone arm Coller Dust seal Bearing & Dust cover Washer Dust seal Bearing Spacer Knuckle end Steering knuckle Tie rod end Tie rod kgf . m ITEM N·m lb-ft 43.5...
Page 176: Removal
CHASSIS 6-29 REMOVAL • Remove the front wheel. (!6-10) • Remove the front wheel hub. (!6-10) • Remove the brake caliper. (!6-19) • Remove the brake hose clamp 1. • Disconnect the brake hose at the hose clamp. • Remove the front disc cover 2. •...
Page 177: Inspection And Disassembly
6-30 CHASSIS • Remove the shock absorber 6. • Remove the cotter pins and nuts. • Remove the steering knuckle 7 with a commercially available ball bearing joint remover 8. INSPECTION AND DISASSEMBLY FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage. If any damages are found, replace the front shock absorber with a new one.
Page 178 Inspect the bushing and dust seal for wear or damage. If any damages are found, replace the shock absorber with a new one. • Apply SUZUKI SUPER GREASE “A” to the bushing and dust seals before remounting. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 179 6-32 CHASSIS WISHBONE ARM Inspect the wishbone arm for wear or damage. If any damages are found, replace the wishbone arm with a new one. WISHBONE ARM PIVOT BEARING • Remove the spacer and dust seal. Inspect the dust seal lips and spacers for wear and damage. If any damages are found, replace them with new ones.
Page 180: Reassembly And Remounting
CHASSIS 6-33 • Remove the needle bearing with the special tools. & 09923-73210: Bearing puller 09930-30104: Sliding hammer Do not reuse the removed bearing. BRAKE DISC COVER Inspect the brake disc cover for damage. If any damages are found, replace the brake disc cover with a new one. REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly.
Page 181 * When installing the sealed bearing that is used at the upper wishbone pivot, make sure that the stamped side of bearing faces to the spacer 1. • Apply SUZUKI SUPER GREASE “A” to the dust seals and bearing. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 182 CHASSIS 6-35 • Install the wishbone arms to the steering knuckle and tighten the knuckle end nuts to the specified torque. # Knuckle end nut: 43 N·m (4.3 kgf-m, 31.0 lb-ft) • Install the cotter pins. Replace the removed cotter pins with new ones. •...
Page 183: Suspension Setting
6-36 CHASSIS • Tighten the tie rod end nut to the specified torque. # Tie rod end nut: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Install the cotter pin. Replace the removed cotter pin with a new one. NOTE: When installing the tie rod end, install the washer 0 between the tie rod end A and steering knuckle B.
Page 184: Steering
CHASSIS 6-37 STEERING CONSTRUCTION Handlebar upper holder Handlebar lower holder " Steering shaft Steering shaft holder Dust seal Bushing & Dust seal O-ring Dust seal Washer Tie rod Steering head cover Handlebars Steering head cover bracket Tie rod end Sreering knuckle Handlebar clamp bolt Steering shaft holder bolt Steering shaft nut...
Page 185: Removal
6-38 CHASSIS REMOVAL HANDLEBARS • Remove the front fender. (!6-4) • Remove the master cylinder assembly 1 from the handle- bars. (!6-25) • Remove the throttle lever case 2. • Disconnect the rear brake cable 3 and the clutch cable 4. •...
Page 186 CHASSIS 6-39 • Remove the oil hose cover by removing two fasteners. • Disconnect the oil hoses 2 and breather hose 3. Do not reused the removed O-ring in order to prevent leakage of oil. • Remove the oil tank 4.
Page 187 6-40 CHASSIS • Remove the cotter pins and tie rod end nuts. Replace the removed cotter pins with new ones. • Remove the tie rods. • Remove the cotter pin and steering shaft nut 5, washer 6 and dust seal 7. Replace the removed cotter pins with new ones.
Page 188: Inspection And Disassembly
CHASSIS 6-41 • Remove the steering shaft 9. • Remove the dust seals 0 from the steering shaft. • Remove the steering shaft holder half A. • Remove the dust seal B from the steering shaft. INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebar distortion * Handlebar clamp wear DUST SEALS AND O-RING...
Page 189 6-42 CHASSIS TIE ROD END Inspect the tie rod ends for smooth movement. If there are any abnormalities, replace the tie rod end with a new one. Inspect the tie rod end boot for wear or damage. If any damages are found, replace the tie rod end with a new one.
Page 190: Reassembly And Remounting
Pay attention to the following points: STEERING SHAFT • Apply SUZUKI SUPER GREASE “A” to the O-ring, dust seals and steering shaft before remounting the steering shaft. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 191 6-44 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the dust seal lip and sliding surface of the steering shaft holders before remounting the steering shaft holders. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others)
Page 192 CHASSIS 6-45 NOTE: When installing the tie rod, make sure the narrow end 1 of the tie rod comes out. The locknuts 2 with a yellow finished surface have left-hand threads. Forward OIL TANK AND RADIATOR • Install the oil tank. (!5-53) •...
Page 193 6-46 CHASSIS • Install the handle switch box with the lug C on the switch half inserted into the hole D on the handlebars. NOTE: When installing the handlebars, make sure that the cable, wiring harness and brake hose routing are proper. (!8-11 to 8-20) •...
Page 194: Toe-In Adjustment
CHASSIS 6-47 TOE-IN 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. (!2-20) • Place 75 kg (165 lbs) of weight on the seat. Forward •...
Page 195: Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information
6-48 CHASSIS FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION...
Page 196: Rear Brake
CHASSIS 6-49 REAR BRAKE CONSTRUCTION Brake caliper holder Reservoir tank Parking brake ITEM N·m kgf-m lb-ft Reservoir tank hose Parking brake lever 16.5 Brake hose Adjuster Snap ring O-ring 13.0 Connector Gasket O-ring Boot Spring 13.0 Piston/cup set Brake hose union bolt 20.5 Push rod Brake master cylinder rod locknut...
Page 197: Brake Pad Replacement
6-50 CHASSIS BRAKE PAD REPLACEMENT • Flatten the lock washer 1, and then slightly loosen the pad mounting pins 2. • Loosen the locknut 3 and turn out the parking brake adjuster 4 several turns. • Remove the caliper. • Remove the brake pads by removing the pad mounting pins. * Do not operate the brake pedal while dismounting the pads.
Page 198: Brake Fluid Replacement
CHASSIS 6-51 • Tighten the caliper mounting bolts to the specified torque. # Brake caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft) • Adjust the parking brake. (!2-17) BRAKE FLUID REPLACEMENT • Place the vehicle on a level surface. •...
Page 199: Brake Caliper Removal And Disassembly
6-52 CHASSIS BRAKE CALIPER REMOVAL AND DISASSEMBLY • Disconnect the parking brake cable by removing the locknut 1 and lever 2. • Disconnet the brake hose 3 and allow the brake fluid to drain into a suitable receptacle. • Remove the parking brake housing 4. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
Page 200 CHASSIS 6-53 • Loosen the caliper holder slide pin 7, and then remove the caliper holder 8. • Remove the caliper holder slide pin 9. • Place a rag over the brake caliper piston to prevent the piston from popping out. •...
Page 201: Brake Caliper Inspection
6-54 CHASSIS BRAKE CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damages are found, replace the brake cal- iper with a new one. BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or other dam- age.
Page 202: Brake Caliper Reassembly And Remounting
• Tighten the pin 2 to the caliper holder 1 to the specified torque. # Caliper holder pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft) • Apply SUZUKI SILICONE GREASE to the brake caliper holder pin 2. + 99000-25100: SUZUKI SILICONE GREASE...
Page 203 6-56 CHASSIS • Apply SUZUKI SILICONE GREASE to the caliper holder slide pin. • Install the slide pin into the caliper. + 99000-25100: SUZUKI SILICONE GREASE • Install the pin 3, washer 4 and caliper holder 5 to the cali- per.
Page 204 CHASSIS 6-57 • When replacing the boot with a new one, apply SUZUKI SILI- CONE GREASE to the groove of parking brake axle. + 99000-25100: SUZUKI SILICONE GREASE • Loosen the locknut a and turn the adjuster b in completely, so that the cable play is maximum.
Page 205: Brake Disc Removal And Remounting
6-58 CHASSIS BRAKE DISC REMOVAL AND REMOUNTING • Remove the rear wheel. (!6-10) • Remove the rear axle. (!6-80) • Remove the brake disc. • Install the brake disc to the rear axle with the punch mark A showed up. NOTE: Make sure that the disc is free of any greasey matter.
Page 206: Master Cylinder Removal And Disassembly
CHASSIS 6-59 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (!6-51) • Place a rag underneath the brake hose union bolt on the mas- tercylinder to catch any split brake fluid. Remove the brake hose union bolt 1 and disconnect the brake hose 2. Immediately wipe off any brake fluid contacting any part of the vehicle.
Page 207: Master Cylinder Inspection
6-60 CHASSIS • Remove the connector 7 and O-ring 8 by removing the snap ring 9. • Remove the dust boot 0. • Remove the snap ring A. • Remove the push rod B, piston/primary cup C and spring D. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage.
Page 208: Master Cylinder Reassembly And Remounting
* Apply brake fluid to the master cylinder bore and all the component to be inserted to the bore. * Specification and classification: DOT 4 • Apply SUZUKI MOLY PASTE to the master cylinder rod. . 99000-25140: SUZUKI MOLY PASTE • Tighten the master cylinder rod locknut 1, master cylinder mounting bolts 2 and brake hose union bolt 3 to the speci- fied torque.
Page 209: Rear Shock Absorber
6-62 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION Rear shock absorber Rear shock absorber upper mounting nut Rear shock absorber lower mounting nut kgf . m ITEM N·m lb-ft 43.5 40.0 REMOVAL • Raise the rear wheel off the ground and support the vehicle with jack or wooden block.
Page 210 CHASSIS 6-63 • Remove the cushion rod lower bolt/nut. • Remove the rear shock absorber mounting bolts/nuts. • Remove the rear shock absorber by lifting up the swingarm.
Page 211: Inspection
6-64 CHASSIS INSPECTION Inspect the shock absorber body and rubber bushing for dam- age and leakage of oil. If any defects are found, replace the shock absorber with a new one. Do not attempt to disassemble the rear shock absorber. It is unserviceble. REAR SHOCK ABSORBER DISPOSAL * The rear shock absorber unit contains high-pressure nitrogen gas.
Page 212: Remounting
CHASSIS 6-65 REMOUNTING Remounting the rear shock absorber in the reverse order of removal. Pay attention to the following points: • Tigten each bolt/nut to the specified torque. # Rear shock absorber nut (Upper) 1: 60 N·m (6.0 kgf-m, 43.5 lb-ft) Rear shock absorber nut (Lower) 2: 55 N·m (5.5 kgf-m, 40.0 lb-ft) Rear cushion rod nut 3: 78 N·m (7.8 kgf-m, 56.5 lb-ft)
Page 213 6-66 CHASSIS 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 DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster clockwise.
Page 214: Rear Suspension
CHASSIS 6-67 REAR SUSPENSION CONSTRUCTION Swingarm Chain adjuster plate " Chain buffer Dust cover Washer Dust seal & Bearing Bushing Dust seal Collar Swingarm under cover Chain buffer Rear shock absorber Cushion rod Cushion lever Bearing Cushion lever cover Grease nipple Rear shock absorber upper mounting nut Rear shock absorber lower mounting nut Cushion rod nut...
Page 215: Removal
6-68 CHASSIS REMOVAL CUSHION LEVER AND CUSHION ROD • Place the vehicle on the level ground and support the vehicle with a jack or wooden block. • Remove the swingarm under cover 1. • Remove the cushion lever cover 2. •...
Page 216 CHASSIS 6-69 • Remove the parking cable guide 2. • Loosen the swingarm pivot nut and remove the swingarm pivot shaft. • Remove the swingarm assembly. • Remove the chain buffer 3.
Page 217: Inspection And Disassembly
6-70 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove the dust covers 1, washers 2 and spacers 3 from the swingarm. • Remove the spacers from the cushion lever and cushion rod. • Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones.
Page 218 CHASSIS 6-71 SWINGARM BEARING AND BUSHING Insert the spacer 1 into the bearing 2, bushing 3 and then check the play when moving the spacer up and down. If excessive play is noted, replace the bearing and bushing with a new one. •...
Page 219 6-72 CHASSIS CUSHION LEVER BEARING AND CUSHION ROD BEARING Insert the spacer into the bearing, and then check the play when moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. • Remove the dust seals. Do not reuse the removed dust seals.
Page 220 CHASSIS 6-73 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 (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) ( Swingarm pivot shaft runout: Service Limit: 0.3 mm (0.01 in) CUSHION LEVER AND ROD BOLT...
Page 221: Reassembly
' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Apply SUZUKI SUPER GREASE “A” to lip of the dust covers • Install the dust covers 1, washers 2 and spacers 3 to the swingarm.
Page 222 CHASSIS 6-75 SWINGARM PIVOT ASSEMBLY INFORMATION...
Page 223 4.5 mm (0.18 in) Cushion rod • Install the dust seals into the cushion rod/lever. • Apply SUZUKI SUPER GREASE “A” to the bearings and lips of dust seal. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) NOTE: * The stamped mark of dust seal must face outside.
Page 224: Remounting
CHASSIS 6-77 REMOUNTING Remount the cushion lever, cushion rod and swingarm in reverse order of removal. Pay attention to the following points: • Install the swingarm and pivot shaft. • Tighten the swingarm pivot nut to the specified torque. # Swingarm pivot nut: 84 N·m (8.4 kgf-m, 61.0 lb-ft) •...
Page 225 6-78 CHASSIS 60 N . m 6.0 kgf-m 43.5 lb-ft 78 N . m 7.8 kgf-m 56.5 lb-ft 78 N . m 7.8 kgf-m 56.5 lb-ft GREASE NIPPLE INSTALLATION Right Left 55 N . m 5.5 kgf-m 40.0 lb-ft VIEW OF H 78 N .
Page 226: Rear Axle
CHASSIS 6-79 REAR AXLE CONSTRUCTION Rear wheel right hub Rear axle kgf - m ITEM N·m lb-ft " Rear brake disc Dust seal 18.0 130.0 Bearing 16.5 Rear axle housing & Spacer Rear axle nut 53.0 Sprocket flange Disc bolt 10.0 72.5 Sprocket...
Page 227: Removal
6-80 CHASSIS REMOVAL • Place the vehicle on the level ground and support the vehicle with a jack or wooden block. SPROCKET • Remove the left rear wheel. (!6-10) • Remove the left rear wheel hub. (!6-11) • Remove the rear caliper. •...
Page 228: Inspection And Disassembly
CHASSIS 6-81 REAR AXLE HOUSING • Remove the axle housing bolts 1. • Remove the chain adjuster plate 2. • Remove the axle housing from the swingarm. • Remove the chain adjuster stud bolts 3 and boots 4. INSPECTION AND DISASSEMBLY SPROCKET Inspect the sprocket teeth for wear.
Page 229 6-82 CHASSIS DUST SEAL Inspect the dust seals for wear or damage. If any defect are founds, replace the dust seal with a new one. AXLE BEARINGS Inspect the play of the wheel bearings by finger while they are in the axle housing.
Page 230: Reassembly And Remounting
* The concave side of washer 3 must face to the sprocket. * The stamped mark 4 must face to left of the vehicle. AXLE HOUSING • Apply SUZUKI SUPER GREASE “A” to the bearings and dust seals before installing. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 231 6-84 CHASSIS • Install the bearings to the axle housing with the special tool. & 09941-34513: Bearing installer set 09913-70210: Bearing installer set * First install the right bearing 1 to the bottom, and then install the spacer and left bearing 2. * The sealed cover of the bearing must face outside.
Page 232 CHASSIS 6-85 • Install the chain adjuster stud bolts and boots. NOTE: The smaller diameter portion of the boot must face to the axle housing. • Install the axle housing into the swingarm. • Tighten the axle housing bolts temporarily. NOTE: The axle housing bolts are unequal in size.
Page 233 Make sure that the brake disc is clean and free of any grease matter. • Install the rear axle shaft into the axle shaft housing. • Apply SUZUKI SUPER GREASE “A” to the spline of the axle shaft. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
Page 234 CHASSIS 6-87 • Install the sprocket flange 2 to the axle shaft. • Apply SUZUKI BOND “1207B” or “1215” to the axle shaft. / 99104-31140: SUZUKI BOND “1207B” (USA) 0 99000-31110: SUZUKI BOND “1215” (Others) • Apply THREAD LOCK SUPER “1303” or “1322” to the thread portion of the rear axle shaft.
Page 235 6-88 CHASSIS • Install the rear wheel hubs. (!6-14) • Install the rear wheels. (!6-14) • Adjust the chain slack. (!2-22) • Tighten the rear axle housing bolts to the specified torque in the described order. (!2-23) # Rear axle housing bolt (M10) 6: 73 N·m (7.3 kgf-m, 53.0 lb-ft) # Rear axle housing bolt (M12) 7: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
Page 236: Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm And Rear Axle Shaft Reassembling Information
CHASSIS 6-89 REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWIN- GARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION...
Page 237 6-90 CHASSIS...
Page 238: Reverse Lock Release Cable
CHASSIS 6-91 REVERSE LOCK RELEASE CABLE REMOVAL • Remove the reverse lock release knob 1 from the front fender. • Remove the bracket. • Remove the cap 2. • Remove the screw 3 and washer 4. • Remove the knob 5. •...
Page 239: Remounting
Pay attention to the following points: • Install the spring with the spring end A matched the groove B on the housing. • Apply SUZUKI SUPER GREASE “A” to the O-ring 1. ' 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 240 CHASSIS 6-93 CABLE PLAY ADJUSTMENT After installing the reverse lock release cable, adjust the cable play. The cable adjuster is located at inside of the fuel tank right side cover. • Loosen the locknut 1. • Turn the adjuster 2 in or out until the cable play A should be 1 –...
Page 241: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............7- 2 CONNECTORS ................7- 2 COUPLERS .................. 7- 2 CLAMPS ..................7- 2 FUSES ..................7- 2 SEMI-CONDUCTOR EQUIPPED PARTS ........7- 2 BATTERY ..................7- 3 CONNECTING THE BATTERY ........... 7- 3 WIRING PROCEDURE ..............
Page 242: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.
Page 243: Battery
ELECTRICAL SYSTEM BATTERY • The MF battery used in this vehicle does not require mainte- nance (e.g., electrolyte level inspection, distilled water replen- ishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
Page 244: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Handlebar switch Ignition coil CDI unit Regulator/rectifier...
Page 245 ELECTRICAL SYSTEM Battery Engine coolant temp. switch ( 5-10) Main fuse Cooling fan thermo-switch ( 5-9) Starter relay Starter motor Ignition switch...
Page 246: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM Ignition switch Main fuse Battery Generator Regulator/rectifier TROUBLESHOOTING Battery runs down quickly. Accessories Check accessories which use excessive • Remove accessories are installed amounts of electricity. No accessories Check the battery for current leaks. Current leaks •...
Page 247 ELECTRICAL SYSTEM Measure the continuity of the generator coil. No continuity • Faulty generator coil or 7-9) disconnected lead wires Continuity Measure the generator no-load voltage. Incorrect • Faulty generator 7-10) Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier 7-10) Correct Incorrect Inspect the wires.
Page 248: Inspection
ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Remove the seat. (!6-4) • Turn the ignition switch to the “OFF” position. • Disconnect the - battery lead wire. Measure the current between - battery terminal and the - bat- tery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
Page 249 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the seat. (!6-4) • Start the engine, turn the ignition switch to LIGHT (') and the dimmer switch to HI and run the engine at 5 000 r/min. Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
Page 250 7-10 ELECTRICAL SYSTEM GENERATOR NO-LOAD PERFORMANCE • Disconnect the generator lead wire coupler. • Start the engine and run it at 5 000 r/min. Measure the AC voltage between the lead wires of the generator using the multi circuit tester. If the voltage is under the specified value, replace the AC gener- ator with a new one.
Page 251: Starter System
ELECTRICAL SYSTEM 7-11 STARTER SYSTEM Fuse Clutch Engine lever Starter Starter stop Ignition position motor switch button switch switch Starter relay TROUBLESHOOTING Starter motor will not run. Check if the starter motor runs when its terminal is connected The transmission is in neutral. Turn on the to the battery terminal (Do Clicks...
Page 252: Starter Motor Removal And Disassembly
7-12 ELECTRICAL SYSTEM Check the starter relay. Incorrect • Faulty starter relay 7-15) Correct • Improper starter relay contact The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the parking brake lever grasp firmly. Others Engine does not turn though the starter motor runs.
Page 253: Starter Motor Inspection
ELECTRICAL SYSTEM 7-13 • Disassembly the starter motor, as shown. ITEM N·m kgf-m lb-ft STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one.
Page 254: Starter Motor Reassembly And Remounting
Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...
Page 255: Starter Relay Inspection
ELECTRICAL SYSTEM 7-15 • Apply SUZUKI SUPER GREASE “A” to the O-ring . . 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) STARTER RELAY INSPECTION • Remove the seat. (!6-4) • Disconnect the battery - lead wire at battery terminal.
Page 256 7-16 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. # 09900-25008: Multi circuit tester set ) Tester knob indication: Resistance (Ω Ω Ω Ω ) &...
Page 257: Ignition System
ELECTRICAL SYSTEM 7-17 IGNITION SYSTEM Engine Ignition stop Fuse switch switch Ignition coil DC-DC converter Regulator /rectifier Ignition power source circuit Generator Wave form arrangement circuit Water Neutral temp. switch switch TROUBLESHOOTING Make sure the transfer is in the neutral position and the engine stop switch is in the “RUN”...
Page 258 7-18 ELECTRICAL SYSTEM Measure the ignition coil primary peak voltage. 7-19) Inspect the spark plug. Correct NOTE: The ignition coil peak voltage 2-10) inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Correct Incorrect Incorrect •...
Page 259: Inspection
ELECTRICAL SYSTEM 7-19 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the front fender, side cover, fuel tank. (!6-4) • Remove the spark plug cap. • Connect a new spark plug to spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged.
Page 260 7-20 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the front fender, side cover, fuel tank. (!6-4) • Disconnect the ignition coil lead wires and spark plug cap, and remove the ignition oil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester.
Page 261 ELECTRICAL SYSTEM 7-21 • Shift the transmission to the neutral position, turn the ignition Peak volt adaptor switch to the “ON” position. • Press the starter button and allow the engine to turn for a few seconds, and then measure the pickup coil and signal coil peak voltage.
Page 262: Indicator Light Position
7-22 ELECTRICAL SYSTEM INDICATOR LIGHT POSITION Neutral indicator light BI/B & O/G Speedometer cover Water temp. Reverse indicator light indicator light BI/R & O/G BI/W & O/G Blue/White mark Blue/Red mark Blue/Black mark WIRE COLOR Bl/B: Blue with Black tracer Bl/W:Blue with White tracer Bl/R: Blue with Red tracer O/G: Orange with Green tracer...
Page 263: Lamps
ELECTRICAL SYSTEM 7-23 LAMPS HEADLIGHT If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. HEADLIGHT BULB REPLACEMENT • Remove the cover. • Remove the socket. •...
Page 264: Brake Light/Taillight
7-24 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT Brake light/taillight: 12 V 21/5 W If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. BULB REPLACEMENT • Remove the socket. •...
Page 265: Switches
ELECTRICAL SYSTEM 7-25 SWITCHES Measure each switch for continuity using a multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one. # 09900-25008: Multi circuit tester set IGNITION SWITCH COOLING FAN THERMO SWITCH 5-10 Color Position...
Page 266: Battery
7-26 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX9-BS Capacity 12V, 28.8 kC (8 Ah)/10HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safty valve INITIAL CHARGING FILLING ELECTROLYTE •...
Page 267 ELECTRICAL SYSTEM 7-27 NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...
Page 268: Servicing
7-28 ELECTRICAL SYSTEM 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.
Page 269: Servicing Information
SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................ 8- 2 ENGINE ..................8- 2 RADIATOR ................... 8- 5 CARBURETOR ................8- 5 CHASSIS ..................8- 6 BRAKES ..................8- 7 ELECTRICAL ................8- 8 BATTERY ..................8- 9 WIRING DIAGRAM ................8-10 WIRING HARNESS, CABLE AND HOSE ROUTING ......
Page 270: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace. 4.
Page 271 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive tappet clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1.
Page 272 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.
Page 273: Radiator
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.
Page 274: Chassis
SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Handling is too heavy 1. Improper front wheel alignment. Adjust. or stiff. 2. Insufficiently lubricated. Lubricate. 3. Low air pressure in front tires. Adjust. 4. Tie rod ends tending to seize. Replace.
Page 275: Brakes
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Rear wheels wobble. 1. Distorted rear wheel rims. Replace. 2. Damage or worn rear axel housing bearings. Replace. 3. Defective or incorrect rear tires. Replace. 4. Loose rear wheel hub nuts. Tighten. 5.
Page 276: Electrical
SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective generator. Replace. 4. Defective CDI unit. Replace. 5. Defective pickup coil. Replace. Spark plug is wet or 1.
Page 277: Battery
SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces of cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check the generator, and regu- quickly.
Page 278: Wiring Diagram
8-10 SERVICING INFORMATION WIRING DIAGRAM...
Page 279: Wiring Harness, Cable And Hose Routing
SERVICING INFORMATION 8-11 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Battery terminal Throttle cable Wiring harness Clamp Clamp Fix the clamp Battery to the rear fender. Clamp Ignition coil Battery terminal Starter relay coupler Pass the starter motor lead wire Clamp and starter relay lead wire Generator...
Page 280 8-12 SERVICING INFORMATION Handlebar Clamp switch (L) Clamp Indicator light Handlebar switch (R) Throttle cable Headlight Ignition switch Handlebar switch (L) Starter cable Clutch cable Parking brake 20 mm Clamp cable Clamp Handlebar switch (L) Indicator light Clamp Ignition switch Ignition switch coupler Cooling fan coupler Indicator light...
Page 281: Cable Routing
SERVICING INFORMATION 8-13 CABLE ROUTING Pass the throttle cable between the frame and Throttle cable engine oil breather hose. Clamp Pass the throttle cable Parking brake cable in front of the handlebars. Reverse Clamp gear cable Rear brake hose Parking brake cable Parking brake cable guide Clutch cable Clutch cable...
Page 282 8-14 SERVICING INFORMATION Throttle cable Cable guide Clamp Starter cable Throttle cable Clutch cable Throttle cable Set the white mark of the clutch cable with the clamp. Clutch cable Parking brake Starter cable cable DETAIL A Set the both side of the reverse gear cable Reverse gear cable adjuster boot with the clamp.
Page 283: Fuel Hose Routing
SERVICING INFORMATION 8-15 FUEL HOSE ROUTING Fuel valve Steering stem Breather hose head cover No.2 Carburetor Insert the breather hose Fuel hose No. 2 into the steering stem shaft. UPPER 45˚ LOWER Clamp Carburetor UPPER Breather hose Air cleaner Carburetor LOWER Clamp Carburetor...
Page 284: Engine Oil Hose And Pipe Routing
8-16 SERVICING INFORMATION ENGINE OIL HOSE AND PIPE ROUTING...
Page 285 SERVICING INFORMATION 8-17 Breather hose White mark Breather hose Clip Clip Clip Engine oil return tank Clip Oil hose Clip...
Page 286: Cooling System Hose Routing
8-18 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING...
Page 287: Front Brake Hose Routing
SERVICING INFORMATION 8-19 FRONT BRAKE HOSE ROUTING...
Page 288: Rear Brake Hose Routing
8-20 SERVICING INFORMATION REAR BRAKE HOSE ROUTING...
Page 289: Seat Rail And Chain Roller Installation
SERVICING INFORMATION 8-21 SEAT RAIL AND CHAIN ROLLER INSTALLATION...
Page 290: Special Tools
8-22 SERVICING INFORMATION SPECIAL TOOLS 09900-00401 09900-00410 09900-06104 09900-06105 09900-06108 Hexagon wrench set Hexagon wrench set Snap ring pliers Snap ring pliers Snap ring pliers 09900-20202 09900-20204 09900-20205 09900-09004 09900-20101 Micrometer Micrometer Micrometer Impact driver set Vernier calipers (25 – 50 mm) (75 –...
Page 291 SERVICING INFORMATION 8-23 09915-64512 09915-74511 09913-50121 09913-70210 09915-63310 Compression Oil pressure gauge Oil seal remover Bearing installer set Adaptor gauge set 09916-20610 09915-74532 09916-10911 09916-14510 09916-14910 Seat cutter Adaptor Valve lapper set Valve lifter Attachment (N-121) 09916-21111 09916-22420 09916-22430 09916-24311 Valve seat Valve seat cutter Valve seat cutter...
Page 292 8-24 SERVICING INFORMATION 09930-73170 09930-73180 09924-84510 09930-30104 09930-31921 Starter torque Starter torque Bearing installer set Sliding hammer Rotor remover set limiter holder limiter socket 09930-10121 09941-34513 09941-50111 Spark plug wrench 09940-92450 Bearing installer Bearing remover Rear axle nut holder...
Page 293: Tightening Torque
SERVICING INFORMATION 8-25 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Cylinder head bolt (M10) 33.5 (M6) Cylinder head side bolt 10.0 Cylinder nut Camshaft journal holder bolt Balancer driven gear nut 36.0 Primary drive gear nut 14.0 101.5 Generator rotor nut...
Page 294: Chassis
8-26 SERVICING INFORMATION CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt 16.5 Steering shaft holder bolt 16.5 Steering shaft nut 35.5 Steering knuckle nut (Upper & Lower) 31.0 Tie rod end nut 43.5 Tie rod locknut 21.0 Front shock absorber mounting nut (Upper & Lower) 43.5 Wishbone arm pivot nut 47.0...
Page 295: Tightening Torque Chart
SERVICING INFORMATION 8-27 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A A A A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 0.15...
Page 296: Service Data
8-28 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.42) — (1.14) Tappet clearance (when cold) 0.10 – 0.20 — (0.0039 – 0.0078) 0.20 – 0.30 — (0.0078 – 0.0118) Valve guide to valve stem 0.010 –...
Page 297 SERVICING INFORMATION 8-29 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.320 – 36.370 36.020 (1.4299 – 1.4319) (1.4181) 35.200 – 35.250 34.900 (1.3858 – 1.3878) (1.3740) Camshaft journal oil clearance 0.019 – 0.053 0.150 IN. & EX. (0.0007 –...
Page 298 8-30 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring thickness 0.71 – 0.76 — (0.0280 – 0.0299) 1.08 – 1.10 — (0.0425 – 0.0433) 0.77 – 0.79 — (0.0303 – 0.0311) Piston pin bore 20.002 – 20.008 20.030 (0.7875 – 0.7877) (0.7886) Piston pin O.D.
Page 299 SERVICING INFORMATION 8-31 DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.960 (74/25) — Final reduction ratio 2.857 (40/14) — Gear ratios 2.538 (33/13) — 1.666 (30/18) — 1.238 (26/21) — 1.000 (23/23) —...
Page 300 8-32 SERVICING INFORMATION THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temper- 73.5 – 76.5 °C — ature (164 – 170 °F) Thermostat valve lift Over 6 mm (0.24 in) at 90°C (194 °F) — Radiator cap valve opening pres- 108 –...
Page 301 SERVICING INFORMATION 8-33 WATTAGE Unit: W ITEM SPECIFICATION Headlight 30 × 2 pcs. 30 × 2 pcs. Brake light/Taillight 21/5 Reverse indicator light Neutral indicator light Engine coolant temp. indicator light BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake pedal height 0 –...
Page 302: Tire Pressure
8-34 SERVICING INFORMATION ITEM STANDARD/SPECIFICATION LIMIT Wheel rim size Front 10 × 5.5 AT — Rear 9 × 8.0 AT — AT22 × 7R10 ✩✩ Tire size Front — AT20 × 10R9 ✩✩ Rear — Tire type Front DUNLOP: KT331 —...
Page 303 Prepared by March, 2002 Part No. 99500-43060-01E Printed in Japan...
Page 304 Printed in Japan...

Suzuki LT-Z400 Service Manual

General Information 1

Periodic Maintenance

Engine

Fuel System

Cooling and Lubrication System

Chassis

Electrical System

Servicing Information

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Suzuki LT-Z400

Summary of Contents for Suzuki LT-Z400