Suzuki ltz 400 Service Manual
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Suzuki ltz 400 Service Manual

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Table of Contents

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This manual contains an introductory description on the SUZUKI LT-Z400 and procedures for its inspection/ser-
vice and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this
section as well as other sections to use as a guide for proper inspection and service.
This manual will help you know the vehicle better so that you can assure your customers of fast and reliable ser-
vice.
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content of this manual and the
actual vehicle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They
may not represent the actual vehicle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for
servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
!
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2008
FOREWORD
99500-43080-03E

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  • Page 1 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
  • Page 3 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
  • Page 6 CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
  • Page 7 Precautions: 00-2 • Use a torque wrench to tighten fasteners • Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber •...
  • Page 8 00-3 Precautions: • When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side • When a fuse is blows, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.
  • Page 9 Precautions: 00-4 • When disconnecting and connecting the coupler, • Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.
  • Page 10 00-5 Precautions: When checking system circuits including an electronic 4) Using continuity inspect or voltage check procedure control unit such as ECM, etc., it is important to perform as described below, inspect the wire harness careful check, starting with items which are easier to terminals for open circuit and poor connection.
  • Page 11 Precautions: 00-6 Voltage check Short circuit check (Wire harness to ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect the negative (–) cable from the battery. check can be used as circuit check. 2) Disconnect the connectors/couplers at both ends of 1) With all connectors/couplers connected and voltage the circuit to be checked.
  • Page 12 : 09900–25008 (Multi-circuit tester set) I705H1000009-02 “D”: To other parts Using the multi-circuit testers • Use the Suzuki multi-circuit tester set. • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Special tool (A): 09900–25008 (Multi-circuit tester set)
  • Page 13 Engine Idle Speed Inspection and Adjustment ..0B-10 Symbols .............. 0A-1 Throttle Body Inspection ........0B-10 Abbreviations ............0A-2 Throttle Cable Play Inspection and SAE-to-Former SUZUKI Term ......0A-2 Adjustment ............0B-10 Vehicle Side View ..........0A-3 Fuel Line Replacement ........0B-11 Vehicle Identification Number ......0A-3 Fuel Line Inspection ..........0B-11...
  • Page 14 Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply WATER RESISTANCE GREASE or equivalent.
  • Page 15 J1930 terms and abbreviations which may be used in CPU: Central Processing Unit this manual in compliance with SAE recommendations, as well as their former SUZUKI names. DC: Direct Current Ex. SAE term (Abbreviation): Former SUZUKI term DMC: Dealer Mode Coupler...
  • Page 16 Voltage Regulator (VR): Voltage Regulator Vehicle Side View I933H1010003-07 B933H20101004 NOTE Difference between illustration and actual vehicle may exist depending on the markets. SUZUKI LT-Z400 (2009-model) Right side “B” I933H1010004-01 Fuel and Oil Recommendation B933H20101006 Fuel (for USA and Canada)
  • Page 17 Use distilled water only. Water other than distilled water JASO. can corrode and clog the aluminum radiator. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and Anti-freeze / Engine coolant alternative according to the chart.
  • Page 18 0A-5 General Information: Country and Area Codes B933H20101009 The following codes stand for the applicable country(-ies) and area(-s). Code Country or area Effective frame No. LT-Z400K9 (E-19) E.U. LT-Z400K9 (E-28) Canada JSAAK4AA92 100001– LT-Z400K9 (E-33) U.S.A. Wire Color Symbols B933H20101010 Symbol Wire color Symbol...
  • Page 19 General Information: 0A-6 Warning, Caution and Information Labels Location B933H20101011 17 [E] [F] 11 [F] 8 [F] 6 [F] 4 [F] 9 [E] 7 [E] 1 [E],13 [E] 3 [E] 10 [E] 5 [E] 19 [B] [E], 20 [C] [F] 15 [F] 14 [E] 12 [E] [F], 16...
  • Page 20 0A-7 General Information: Component Location Electrical Components Location B933H20103001 I933H1010005-02 1. Battery 5. Ignition coil 9. Cooling fan fuse 2. Ignition fuse 6. Cooling fan relay 10. Cooling fan 3. Starter relay/Main fuse 7. TO sensor 11. IAT sensor 4. Fuel injector 8.
  • Page 21 General Information: 0A-8 I933H1010006-02 12. Mode select switch coupler 16. Regulator/Rectifier 20. GP switch 13. Fuel level gauge (Thermistor) 17. Fuel pump 21. CKP sensor 14. IAP sensor 18. ECT sensor 22. Generator 15. TP sensor 19. Starter motor...
  • Page 22 0A-9 General Information: Specifications Specifications B933H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Overall length 1 830 mm (72.0 in) Overall width 1 190mm (46.9 in) Overall height 1 145 mm (45.1 in) Wheelbase 1 245 mm (49.0 in) Front track...
  • Page 23 General Information: 0A-10 Chassis Item Specification 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 6.3° Trail 28.6 mm (1.13 in) Toe-out 6 mm (0.24 in)
  • Page 24 0A-11 General Information: Special Tools and Equipment Special Tool B933H20108001 09900–06107 09900–06108 09900–20101 09900–20102 09900–20202 Snap ring pliers Snap ring pliers Vernier calipers (1/15 Vernier calipers (1/20 Micrometer (1/100 mm, 150 mm) mm, 200 mm) mm, 25 – 50 mm) 09900–20204 09900–20205 09900–20508...
  • Page 25 General Information: 0A-12 09910–60611 09911–11310 09913–50121 09913–70210 09915–63311 Universal clamp Crankshaft installer Oil seal remover Bearing installer set Compression gauge wrench attachment attachment 09915–64512 09915–74511 09915–74521 09915–74533 09915–77331 Compression gauge Oil pressure gauge set Oil pressure gauge Oil pressure gauge Meter (for high hose attachment...
  • Page 26 0A-13 General Information: 09922–22711 09923–73210 09923–74511 09924–84510 09924–84521 Drive chain cutting Bearing remover Bearing remover Bearing installer set Bearing installer set and joining tool 09930–10121 09930–11950 09930–30104 09930–30721 09930–31921 Spark plug wrench set Torx wrench Rotor remover slide Rotor remover Rotor remover shaft 09930–44520...
  • Page 27 Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B933H20200001 The “Periodic Maintenance Schedule Chart” 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 for your convenience.
  • Page 28 0B-2 Maintenance and Lubrication: Scheduled Maintenance Periodic Maintenance Schedule Chart B933H20205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. C = Clean. L = Lubricate. Interval Item Initial 1 month Every 3 months Every 6 months Air cleaner element...
  • Page 29 Maintenance and Lubrication: 0B-3 Lubrication Points B933H20205002 Lubricate exposed parts 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 as follows. NOTE •...
  • Page 30 0B-4 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Cleaning 7) Remove the drain plug (1) of the air cleaner box to B933H20206001 allow any water to drain out. Air cleaner element cleaning Every 3 months Inspect and clean the air cleaner element in the following procedures: 1) Remove the air cleaner element.
  • Page 31 Maintenance and Lubrication: 0B-5 Valve Clearance Inspection and Adjustment 6) Remove the valve timing inspection plug (5) and B933H20206003 generator cover cap (6). Inspect valve clearance Initially at 1 month and every 6 months thereafter Inspection Tappet clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.
  • Page 32 0B-6 Maintenance and Lubrication: 8) Insert the thickness gauge between the tappet and 3) Check the figures printed on the shim. These figures the cam. If the clearance is out of specification, indicate the thickness of the shim, as illustrated. adjust it to the specified range.
  • Page 33 Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I933H1020010-03...
  • Page 34 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I933H1020011-02...
  • Page 35 Maintenance and Lubrication: 0B-9 6) Install the intake or exhaust camshafts. Refer to “Engine Top Side Assembly in Section 1D (Page 1D- 20)”. 7) Rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the specified range.
  • Page 36 0B-10 Maintenance and Lubrication: Spark Arrester Cleaning 3) Set the engine idle speed between 1 500 and 1 700 B933H20206006 r/min by turning the idle air screw (1). Spark arrester cleaning Engine idle speed Every 6 months 1 600 ± 100 r/min Clean the spark arrester in the following procedures: 1) Remove the spark arrester (1).
  • Page 37 Maintenance and Lubrication: 0B-11 3) Tighten the lock-nut (1) while holding the adjuster Engine Oil and Filter Replacement (2). B933H20206012 Replace engine oil 4) Install the boot correctly. Initially at 1 month and every 6 months thereafter Replace oil filter Initially at 1 month and every 6 months thereafter Oil should be changed while the engine is warm.
  • Page 38 0B-12 Maintenance and Lubrication: Oil filter replacement CAUTION When reassembling the oil filter, make sure that the oil filter is installed as properly. If the filter is installed improperly, serious engine damage may result. 1) Drain engine oil as described in the engine oil replacement procedure.
  • Page 39 Maintenance and Lubrication: 0B-13 6) Install the oil filter cap (1) and tighten the bolts Clutch Inspection and Adjustment securely. B933H20206014 Inspect clutch lever play NOTE Initially at 1 month and every 6 months thereafter Face the triangle mark “A” on the cap Inspect and adjuster the clutch lever play “a”...
  • Page 40 0B-14 Maintenance and Lubrication: 4) Flush the radiator with fresh water if necessary. 5) Tighten the drain plug (2) to the specified torque. CAUTION Replace the gasket with a new one. Tightening torque Engine coolant drain plug (a): 6 N·m (0.6 kgf-m, 4.5 lb-ft) I933H1020030-01 Engine coolant change...
  • Page 41 Maintenance and Lubrication: 0B-15 9) After warming up and cooling down the engine 3) After finishing the radiator hose inspection, reinstall several times, add the engine coolant up to the full the left side cover. level of the reservoir tank. Radiator Hoses Replacement CAUTION Replace radiator hoses...
  • Page 42 0B-16 Maintenance and Lubrication: Drive chain length inspection 3) Loosen or tighten the chain adjuster nut (2) until there is 30 – 40 mm (1.2 – 1.6 in) “a” of slack at the 1) Place the vehicle on level ground. middle of the chain between the engine and rear 2) Loosen the rear axle housing bolts (1).
  • Page 43 • Do not use any oil sold commercially as affected. “drive chain oil”. Such oil can damage the O-rings. Front • The standard drive chain is a RK520 SMOZ10S. SUZUKI recommends to use this standard drive chain as a replacement. “A” I933H1020041-01 Rear I933H1020040-01...
  • Page 44 0B-18 Maintenance and Lubrication: Brake pedal height inspection and adjustment 1) Loosen the parking brake adjuster lock-nut (1) while holding the adjuster (2) with a wrench. 1) Inspect the brake pedal height “a” between the pedal top face and footrest. 2) Loosen the adjuster (2).
  • Page 45 Maintenance and Lubrication: 0B-19 Brake fluid level check Front and rear brake hose inspection Inspect brake fluid level Inspect brake hose Every 3 months Every 6 months 1) Place the vehicle on a level ground and place the Inspect the brake hoses and hose joints for crack, handlebars straight.
  • Page 46 0B-20 Maintenance and Lubrication: Special tool Front and Rear Wheel Set Nuts Inspection : 09900–20805 (Tire depth gauge) B933H20206019 Tighten front and rear wheel set nuts Tire tread depth “a” (Service limit) Each time the vehicle is ridden Front: 4.0 mm (0.16 in) Rear: 4.0 mm (0.16 in) Tighten the front and rear wheel set nuts to the specified torque.
  • Page 47 Maintenance and Lubrication: 0B-21 Check that the rear axle nut is tightened to it specified 5) Apply thread lock to the rear axle nut bolt (3). torque. : Thread lock cement 99000–32110 If the specified torque is lower than specification, tighten (THREAD LOCK CEMENT SUPER 1322 or the rear axle nut and lock-nut as follows.
  • Page 48 0B-22 Maintenance and Lubrication: Suspensions Inspection Steering System Inspection B933H20206021 B933H20206022 Inspect suspensions Inspect steering system Every 6 months Initially at 1 month and every 3 months thereafter Inspect the suspensions in the following procedures: Steering should be adjusted properly for smooth turning of handlebars and safe running.
  • Page 49 Maintenance and Lubrication: 0B-23 Chassis Bolts and Nuts Inspection B933H20206023 Tighten chassis bolts and nuts Initially at 1 month and 3 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque. I933H1020066-01 Wishbone arm pivot nut (Upper & Lower) 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) I933H1020063-01 Handlebar clamp bolt 26N⋅m (2.6 kgf-m, 19.0 lb-ft)
  • Page 50 0B-24 Maintenance and Lubrication: I933H1020069-02 I933H1020072-02 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) Front brake pipe nut (Upper) 16 N⋅m (1.6 kgf-m, 11.5 lb-ft) Tie-rod end lock-nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) Footrest mounting bolt 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) Knuckle end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) I933H1020073-02 I933H1020070-02...
  • Page 51 Maintenance and Lubrication: 0B-25 I933H1020075-02 I933H1020077-04 Rear axle housing bolt 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) Rear shock absorber mounting nut (Upper) 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) Rear sprocket mounting nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) Seat rail mounting bolt (Lower) 66 N⋅m (6.6 kgf-m, 47.5 lb-ft) Rear axle nut 240 N⋅m (24.0 kgf-m, 173.5 lb-ft) Rear brake disc bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Rear axle lock-nut 240 N⋅m (24.0 kgf-m, 173.5 lb-ft)
  • Page 52 0B-26 Maintenance and Lubrication: Specifications Tightening Torque Specifications B933H20207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Exhaust pipe nut 16.5 (Page 0B-4) Muffler connecting bolt 16.5 (Page 0B-4) Muffler mounting bolt 16.5 (Page 0B-4) Spark arrester mounting bolt (Page 0B-10) Oil drain plug 15.0 (Page 0B-11)
  • Page 53 Maintenance and Lubrication: 0B-27 Special Tools and Equipment Recommended Service Material B933H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-19) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 0B-21) 1322 or equivalent NOTE Required service material is also described in the following.
  • Page 54 0C-1 Service Data: Service Data General Information Specifications Service Data B933H20307001 Valve + Valve guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 29.0 (1.14) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (When cold) 0.20 –...
  • Page 55 Service Data: 0C-2 Item Standard Limit 0.78 – 0.80 (0.0307 – 0.0315) — 1.30 – 1.32 (0.0512 – 0.0520) — Piston ring groove width 0.81 – 0.83 (0.0319 – 0.0327) — 2.01 – 2.03 (0.0791 – 0.0799) — 0.71 – 0.76 (0.0280 – 0.0299) —...
  • Page 56 0C-3 Service Data: Thermostat + Radiator + Fan + Coolant Item Standard Note Thermostat valve opening Approx. 76.5 °C (170 °F) — temperature Over 4.5 mm (0.18 in) and at 90 °C (194 °F) Thermostat valve lift — 20 °C Approx.
  • Page 57 Service Data: 0C-4 Throttle body Item Specification Bore size 36 mm (1.42 in) I.D. No. 33H0 1 600 ± 100 r/min Idle r/min Idle air screw 1-5/8 turns back Throttle cable play 3 – 5 mm (0.12 – 0.20 in) Electrical Unit: mm (in) Item...
  • Page 58 0C-5 Service Data: Item Standard Limit Front 2.8 – 3.2 (0.11 – 0.13) 2.5 (0.10) Brake disc thickness Rear 3.8 – 4.2 (0.15 – 0.17) 3.5 (0.14) Brake disc runout — 0.30 (0.012) Front 12.700 – 12.743 (0.5000 – 0.5017) —...
  • Page 59 Service Data: 0C-6 Tightening Torque Specifications B933H20307002 Engine Item N⋅m kgf-m lb-ft Cylinder head cover bolt 10.0 Spark plug Initial 18.0 (M10) Cylinder head bolt Final 33.5 (M6) Cylinder base nut Camshaft journal holder bolt Balancer driven gear nut 36.0 Primary drive gear nut 14.0 101.5...
  • Page 60 0C-7 Service Data: Cooling system Item N⋅m kgf-m lb-ft Water pump cover bolt Engine coolant drain plug ECT sensor Chassis tightening torque Item N⋅m kgf-m lb-ft Handlebar clamp bolt 19.0 Handlebar holder nut 43.5 Steering shaft holder bolt 16.5 Steering shaft nut 35.5 Steering knuckle end nut (Upper and Lower) 21.0...
  • Page 61 Service Data: 0C-8 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” (mm) N⋅m kgf-m lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55...
  • Page 62 0C-9 Service Data:...

  • Page 63: Table Of Contents

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C41” (P0230): FP Relay Circuit Malfunction............1A-63 Precautions............. 1-1 DTC “C60” (P0480): Cooling Fan Relay Precautions for Engine.......... 1-1 Circuit Malfunction...........1A-65 Engine General Information and Specifications .............1A-67 Diagnosis ..........1A-1 Service Data............1A-67 Special Tools and Equipment ......1A-68 General Description ..........1A-1...
  • Page 64 1-ii Table of Contents Service Data............1C-7 Specifications .............1D-60 Tightening Torque Specifications......1C-7 Service Data............1D-60 Tightening Torque Specifications......1D-61 Special Tools and Equipment ......1C-8 Recommended Service Material ......1C-8 Special Tools and Equipment ......1D-62 Special Tool ............1C-8 Recommended Service Material .......1D-62 Special Tool ............1D-62 Engine Mechanical ........
  • Page 65 Table of Contents 1-iii Radiator Reservoir Tank Removal and Ignition System Symptom Diagnosis....1H-2 Installation ............1F-9 No Spark or Poor Spark ........1H-3 Cooling Fan Inspection ........1F-9 Repair Instructions ..........1H-4 Cooling Fan Relay Inspection ......1F-10 Spark Plug Cap and Spark Plug Removal and ECT Sensor Removal and Installation ....
  • Page 66 1-iv Table of Contents Exhaust System........1K-1 Repair Instructions ..........1J-3 Battery Current Leakage Inspection....1J-3 Precautions............1K-1 Regulated Voltage Inspection ......1J-3 Precautions for Exhaust System ......1K-1 Generator Inspection........... 1J-4 Repair Instructions ..........1K-2 Generator Removal and Installation....1J-5 Exhaust System Construction ......1K-2 Regulator / Rectifier Inspection ......
  • Page 67 Precautions: Precautions Engine Precautions Precautions for Engine B933H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
  • Page 68 1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B933H21101001 Injection time (Injection volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

  • Page 69: Engine General Information And

    Engine General Information and Diagnosis: 1A-2 Compensation of injection time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.
  • Page 70 1A-3 Engine General Information and Diagnosis: 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. The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, ignition signal, injector signal, fuel pump signal or ignition switch signal is not sent to ECM.

  • Page 71: Fi System Wiring Diagram

    Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B933H21102001 I933H1110004-06...

  • Page 72: Terminal Alignment Of Ecm Coupler

    1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B933H21102002 I933H1110005-01 Terminal No. Circuit Terminal No. Circuit Power source — TO sensor signal (TOS) — CKP sensor signal (CKP+) FI/ECT indicator GP switch signal (GP) ECT sensor signal (ECT) TP sensor signal (TP) —...

  • Page 73: Component Location

    Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B933H21103001 “B” “D” “A” “C” “E” I933H1110006-01 “A”: Intake air temperature sensor (IATS) “C”: Engine coolant temperature sensor (ECTS) “E”: Cooling fan “B”: Ignition coil (IG COIL) “D”: Cooling fan relay “E”...

  • Page 74: Diagnostic Information And Procedures

    1A-7 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B933H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guides or poor seating of Repair or replace.
  • Page 75 Engine General Information and Diagnosis: 1A-8 Condition Possible cause Correction / Reference Item Engine stalls often Defective ECM. Replace. (Control circuit or sensor Defective fuel pump. Replace. improperly operating) Defective TP sensor. Replace. Defective IAT sensor. Replace. Defective CKP sensor. Replace.
  • Page 76 1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine lacks power Loss of tappet clearance. Adjust. (Defective engine internal/ Weakened valve springs. Replace. electrical parts) Valve timing out of adjustment. Adjust. Worn piston rings or cylinder. Replace.

  • Page 77: Self-Diagnostic Procedures

    Engine General Information and Diagnosis: 1A-10 Self-Diagnostic Procedures 3) Start the engine or crank the engine for more than 4 B933H21104002 seconds. Use of mode select switch 4) Turn the special tool’s switch ON. NOTE 5) Check the DTC to determine the malfunction part. Refer to “DTC Table (Page 1A-18)”.
  • Page 78 1A-11 Engine General Information and Diagnosis: Use of SDS NOTE • Do not disconnect the coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory.

  • Page 79: Use Of Sds Diagnosis Reset Procedures

    Engine General Information and Diagnosis: 1A-12 4) Start the engine or crank the engine for more than 4 Use of SDS Diagnosis Reset Procedures seconds. B933H21104003 NOTE 5) Check the DTC to determine the malfunction part. The malfunction code is memorized in the Refer to “DTC Table (Page 1A-18)”.
  • Page 80 1A-13 Engine General Information and Diagnosis: 6) Follow the displayed instructions. 7) Check that both “Current DTC” (3) and “Past DTC” (4) are deleted (NIL). I705H1110006-01 I705H1110008-01 8) Close the SDS tool and turn the ignition switch OFF. 9) Disconnect the SDS tool and install the left side cover.
  • Page 81 Engine General Information and Diagnosis: 1A-14 1) Click “Show data when trouble” (1) to display the data. I718H1110269-02 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I831G1110017-01...

  • Page 82: Sds Check

    1A-15 Engine General Information and Diagnosis: SDS Check B933H21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.
  • Page 83 Engine General Information and Diagnosis: 1A-16 Data at 3 000 r/min under no load Approx. 3 000 r/min Check the manifold absolute pressure. XXX kPa Check the engine coolant temperature. XX °C I933H1110075-01 Data at the time of racing Throttle: Quick wide open Throttle: Slowly open I933H1110076-01...
  • Page 84 1A-17 Engine General Information and Diagnosis: Data of intake negative pressure during idling (80 °C) Check the engine coolant temperature. 80 °C Check the manifold absolute pressure. XXX kPa I933H1110077-01 Example of trouble Three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in comparison by showing them in the graph.

  • Page 85: Dtc Table

    Engine General Information and Diagnosis: 1A-18 DTC Table B933H21104006 Code FI light flashing pattern Malfunction part Remarks None MCODE00C00-0-03 Pick-up coil signal, signal (Page Crankshaft position sensor (CKPS) generator 1A-23) MCODE00C12-0-02 (Page Throttle position sensor (TPS) 1A-26) MCODE00C14-0-02 (Page Engine coolant temperature sensor (ECTS) 1A-34) MCODE00C15-0-02 (Page...

  • Page 86: Fail-Safe Function Table

    1A-19 Engine General Information and Diagnosis: EXAMPLE: When CKP sensor and TO sensor defective (DTC No.12 and 23) FI light Code No.12 Code No.23 Code No.12 Code No.23 0.3 0.3 0.3 0.3 Time (sec.) I933H1110010-02 In the FI light, the DTC is indicated from small code to large code. Fail-Safe Function Table B933H21104007 FI system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum...

  • Page 87: Fi System Troubleshooting

    Engine General Information and Diagnosis: 1A-20 FI System Troubleshooting B933H21104008 Customer complaint analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model:...

  • Page 88: Malfunction Code And Defective Condition Table

    1A-21 Engine General Information and Diagnosis: 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 screen with the use of mode select switch or SDS.
  • Page 89 Engine General Information and Diagnosis: 1A-22 Malfunction Detected item Detected failure condition Check for code The sensor voltage should be the following. 0.2 V ≤ sensor voltage < 4.9 V IAT sensor, lead wire/coupler In other than the above range, C21 (P0110) is connection.

  • Page 90: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction

    1A-23 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B933H21104010 Detected condition and possible cause Detected condition Possible cause The signal does not reach ECM for 1 sec. or more, after • Metal particles or foreign material being stuck on the receiving the IAP sensor input signal.
  • Page 91 Engine General Information and Diagnosis: 1A-24 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. I933H1110013-01 3) Disconnect the CKP sensor coupler and measure the resistance.
  • Page 92 1A-25 Engine General Information and Diagnosis: Step Action 1) Press the starter button and allow the engine to crank for • Bl or G/W wire open • Inspect that metal a few seconds, and measure the CKP sensor peak or shorted to the particles or foreign voltage at the coupler.

  • Page 93: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-26 DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B933H21104011 Detected condition and possible cause Detected condition Possible cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
  • Page 94 1A-27 Engine General Information and Diagnosis: C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Remove the fuel pump mounting bolts and move the fuel coupler.
  • Page 95 Engine General Information and Diagnosis: 1A-28 P0120-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Y wire shorted to VCC or B/Br wire open. 2) Remove the fuel pump mounting bolts and move the fuel pump.
  • Page 96 1A-29 Engine General Information and Diagnosis: Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. Y wire shorted to VCC and Installation in Section 1C (Page 1C-2)”. or B/Br wire open. 7) Check the continuity between Y wire and terminal “5”. Also, check the continuity between B/Br wire and terminal “24”.
  • Page 97 Engine General Information and Diagnosis: 1A-30 Step Action 4) Disconnect the TP sensor coupler. Go to Step 2. Y or R wire open, or Y wire shorted to ground. 5) Check the continuity between Y wire and ground. Also, check the continuity between Y wire and B/Br wire. If sound is not heard from the tester, the circuit condition is OK.
  • Page 98 1A-31 Engine General Information and Diagnosis: Step Action 1) Correct the ECM coupler. Go to Step 3. Open or short circuit in the R wire or B/Br wire. 2) Turn the ignition switch ON. 3) Measure the input voltage between the R wire and ground.
  • Page 99 Engine General Information and Diagnosis: 1A-32 Step Action 4) If OK, then measure the TP sensor resistance at the test Go to Step 4. • Reset the TP sensor harness terminals (between terminal “A” (Y wire) and “C” position correctly. (B/Br wire)).
  • Page 100 1A-33 Engine General Information and Diagnosis: Step Action 1) Connect the test harness to TP sensor coupler. • Y, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Turn the ignition switch ON. ground, or poor “5”, sensor with a new one.

  • Page 101: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-34 DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B933H21104012 Detected condition and possible cause Detected condition Possible cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.2 V ≤...
  • Page 102 1A-35 Engine General Information and Diagnosis: C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Check the ECT sensor coupler for loose or poor coupler.
  • Page 103 Engine General Information and Diagnosis: 1A-36 P0115-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B/Bl or B/Br wire open. 2) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. I933H1110039-01 3) Disconnect the ECT sensor coupler.
  • Page 104 1A-37 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • B/Bl wire shorted to ground. 2) Check the ECT sensor coupler for loose or poor contacts. • If wire is OK, go to If OK, then check the ECT sensor lead wire continuity.
  • Page 105 Engine General Information and Diagnosis: 1A-38 Step Action 8) Measure the output voltage between B/Bl wire and Go to Step 2. • B/Bl wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication Voltage (...
  • Page 106 1A-39 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Bl or B/Br wire Replace the ECT open or shorted to sensor with a new one. 2) Connect the ECM coupler and disconnect the ECT ground, or poor “22”...

  • Page 107: Dtc "C17" (P1750-H/L): Iap Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-40 DTC “C17” (P1750-H/L): IAP Sensor Circuit Malfunction B933H21104013 Detected condition and possible cause Detected condition Possible cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
  • Page 108 1A-41 Engine General Information and Diagnosis: Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”.
  • Page 109 Engine General Information and Diagnosis: 1A-42 Step Action 1) Turn the ignition switch OFF. Go to Step 3. G/B wire shorted to VCC, or B/Br wire open. 2) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity. I933H1110027-01 3) Disconnect the IAP sensor coupler.
  • Page 110 1A-43 Engine General Information and Diagnosis: P0105-L for IAP sensor (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. R and G/B wire open, G/ B wire shorted to the 2) Check the IAP sensor coupler for loose or poor contacts. ground.
  • Page 111 Engine General Information and Diagnosis: 1A-44 Step Action 6) Check the continuity between the R wire and terminal Go to Step 2. R and G/B wire open, G/ “13”. Also, check the continuity between the G/B wire B wire shorted to the and terminal “6”.
  • Page 112 1A-45 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Check the vacuum hose for crack or 2) Connect the ECM coupler and IAP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...
  • Page 113 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace IAP 2) Remove the IAP sensor. Refer to “IAP Sensor Removal ground, or poor “6”, sensor with a new one.

  • Page 114: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction

    1A-47 Engine General Information and Diagnosis: DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B933H21104014 Detected condition and possible cause Detected condition Possible cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.2 V ≤...
  • Page 115 Engine General Information and Diagnosis: 1A-48 C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Loose or poor contacts on the ECM 2) Check the IAT sensor coupler for loose or poor contacts. coupler.
  • Page 116 1A-49 Engine General Information and Diagnosis: P0110-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to step 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity.
  • Page 117 Engine General Information and Diagnosis: 1A-50 P0110-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. • Dg wire shorted to ground. 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. •...
  • Page 118 1A-51 Engine General Information and Diagnosis: Step Action 8) Measure the output voltage between the Dg wire and Go to Step 2. • Dg wire shorted to ground. ground. • If wire is OK, go to Special tool Step 2. (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 119: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-52 DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B933H21104015 Detected condition and possible cause Detected condition Possible cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
  • Page 120 1A-53 Engine General Information and Diagnosis: C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the left side cover. Refer to “Exterior Parts “TO Sensor Removal Removal and Installation in Section 9D (Page 9D-4)”.
  • Page 121 Engine General Information and Diagnosis: 1A-54 P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Br/W wire shorted to VCC, or B/Br wire open. 2) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
  • Page 122 1A-55 Engine General Information and Diagnosis: Step Action 7) Check the continuity between Br/W wire and terminal Go to Step 2. Br/W wire shorted to “2”. Also, check the continuity between B/Br wire “C” and VCC, or B/Br wire open. terminal “24”.
  • Page 123 Engine General Information and Diagnosis: 1A-56 Step Action 5) Check the continuity between Br/W wire and ground. Go to Step 2. R or B wire open, or Br/ Also, check the continuity between Br/W wire and B/Br W wire shorted to the wire.
  • Page 124 1A-57 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and TO sensor coupler. • Br/W, R or B/Br wire • Loose or poor open or shorted to contacts on the ECM 2) Insert the needle pointed probes to the lead wire coupler. ground, or poor “2”, coupler.

  • Page 125: Dtc "C24" (P0351): Ignition Coil Circuit Malfunction

    Engine General Information and Diagnosis: 1A-58 DTC “C24” (P0351): Ignition Coil Circuit Malfunction B933H21104016 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-3)” for details. DTC “C31” (P0705): GP Switch Circuit Malfunction B933H21104017 Detected condition and possible cause Detected condition Possible cause No gear position switch voltage.
  • Page 126 1A-59 Engine General Information and Diagnosis: Troubleshooting NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”. Step Action 1) Turn the ignition switch OFF. • W wire open or •...

  • Page 127: Dtc "C32" (P0201): Fuel Injector Circuit Malfunction

    Engine General Information and Diagnosis: 1A-60 DTC “C32” (P0201): Fuel Injector Circuit Malfunction B933H21104018 Detected condition and possible cause Detected condition Possible cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 8 times or more continuity. •...
  • Page 128 1A-61 Engine General Information and Diagnosis: Troubleshooting NOTE • After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”. • Injector voltage can be detected only for 2 seconds after ignition switch is turned ON. Step Action 1) Turn the ignition switch OFF.
  • Page 129 Engine General Information and Diagnosis: 1A-62 Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Fuel Injector / Fuel Tester knob indication Delivery Pipe / L-joint Resistance (Ω) Removal and...

  • Page 130: Dtc "C41" (P0230): Fp Relay Circuit Malfunction

    1A-63 Engine General Information and Diagnosis: DTC “C41” (P0230): FP Relay Circuit Malfunction B933H21104019 Detected condition and possible cause Detected condition Possible cause No voltage is applied to fuel pump although FP relay is • FP relay circuit open or short. turned ON.
  • Page 131 Engine General Information and Diagnosis: 1A-64 C41 (Use of mode select switch) Step Action 1) Turn the ignition switch to OFF. • FP relay (ECM) Open or short circuit in malfunction. the red wire. 2) Remove the headlight. Refer to “Headlight Removal and Installation in Section 9B (Page 9B-2)”.

  • Page 132: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction

    1A-65 Engine General Information and Diagnosis: DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B933H21104020 Detected condition and possible cause Detected condition Possible cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
  • Page 133 Engine General Information and Diagnosis: 1A-66 Troubleshooting NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”. Step Action 1) Turn the ignition switch OFF. • O/Y and Y/B wire Replace the cooling fan open or shorted to relay with a new one.

  • Page 134: Specifications

    1A-67 Engine General Information and Diagnosis: 4) Click the “Operate” (2). At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. I933H1110080-02 5) Click the “Stop” (3) to check the operation properly. I933H1110081-02 Specifications Service Data...

  • Page 135: Special Tools And Equipment

    Engine General Information and Diagnosis: 1A-68 Special Tools and Equipment Special Tool B933H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-24) / (Page 1A-27) / (Page 1A-25) / (Page 1A-28) / (Page 1A-27) / (Page 1A-30) / (Page 1A-28) / (Page 1A-31) / (Page 1A-30) /...

  • Page 136: Emission Control Devices

    1B-1 Emission Control Devices: Emission Control Devices Engine Precautions Precautions for Emission Control Devices B933H21200001 Refer to “General Precautions in Section 00 (Page 00-1)”. Schematic and Routing Diagram Oil Return Tank Hose Routing Diagram B933H21202001 “ a ” Forward “A” “B”...

  • Page 137: Crankcase Breather (Pcv) Hose Removal And Installation

    Emission Control Devices: 1B-2 3) Inspect the PCV hoses (1) for wear or damage. If it is 3) Disconnect the breather hoses (1). worn or damaged, replace the PCV hoses with a 4) Remove the oil return tank (2). new ones. Check that the PCV hoses (1) is securely connected.

  • Page 138: 1C-1 Engine Electrical Devices

    1C-1 Engine Electrical Devices: Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B933H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B933H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.

  • Page 139: Repair Instructions

    Engine Electrical Devices: 1C-2 Repair Instructions ECM Removal and Installation IAP Sensor Inspection B933H21306001 B933H21306004 Removal Refer to “DTC “C17” (P1750-H/L): IAP Sensor Circuit Malfunction in Section 1A (Page 1A-40)”. 1) Remove the battery (–) lead wire. Refer to “Battery Removal and Installation in Section 1J (Page 1J- IAP Sensor Removal and Installation 12)”.
  • Page 140 1C-3 Engine Electrical Devices: TP Sensor Removal and Installation : Grease 99000–25160 (Water resistance B933H21306007 grease or equivalent) Removal Special tool 1) Remove the fuel pump mounting bolts (1) and move : 09930–11950 (Torx wrench) the fuel pump (2). “A” “B”...
  • Page 141 Engine Electrical Devices: 1C-4 TP Sensor Adjustment 7) If the TP sensor adjustment is necessary, loosen the B933H21306008 TP sensor mounting screw with the special tool. Adjust the TP sensor in the following procedures: Special tool 1) Warm up the engine and check the idling speed. : 09930–11950 (Torx wrench) Refer to “Engine Idle Speed Inspection and Adjustment in Section 0B (Page 0B-10)”.
  • Page 142 1C-5 Engine Electrical Devices: IAT Sensor Removal and Installation ECT Sensor Removal and Installation B933H21306010 B933H21306011 Removal Removal 1) Remove the seat. Refer to “Exterior Parts Removal 1) Drain engine coolant. Refer to “Cooling System and Installation in Section 9D (Page 9D-4)”. Inspection in Section 0B (Page 0B-13)”.
  • Page 143 Engine Electrical Devices: 1C-6 ECT Sensor Inspection TO Sensor Inspection B933H21306012 B933H21306013 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Refer to “DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction in Section 1A (Page 1A-34)”. Malfunction in Section 1A (Page 1A-52)”. Inspect the ECT sensor in the following procedures: TO Sensor Removal and Installation 1) Remove the ECT sensor.

  • Page 144: Specifications

    1C-7 Engine Electrical Devices: Specifications Service Data B933H21307001 FI Sensors Item Specification Note 400 – 600 Ω CKP sensor resistance CKP sensor peak voltage 1.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.

  • Page 145: Recommended Service Material

    Engine Electrical Devices: 1C-8 Special Tools and Equipment Recommended Service Material B933H21308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 1C-3) equivalent Special Tool B933H21308002 09900–25008 09900–28630 Multi-circuit tester set TPS test wire harness...

  • Page 146: Special Tool

    1D-1 Engine Mechanical: Engine Mechanical Engine Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 5) Disconnect the fuel pump lead wire coupler (1). B933H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-7)”. Compression Pressure Check B933H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 147: Repair Instructions

    Engine Mechanical: 1D-2 9) Press the starter button and crank the engine for a Low compression pressure can indicate any of few seconds. Record the maximum gauge reading the following conditions: as the cylinder compression. • Excessively worn cylinder wall Compression pressure specification •...
  • Page 148 1D-3 Engine Mechanical: Engine right side Item Removal Inspection Installation Refer to “Clutch Removal in Refer to “Clutch Installation Clutch cover — Section 5C (Page 5C-7)”. in Section 5C (Page 5C-9)”. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C...

  • Page 149: Air Cleaner Element Removal And Installation

    Engine Mechanical: 1D-4 Item Removal Inspection Installation Refer to “Generator Removal Refer to “CKP Sensor Refer to “Generator Removal CKP sensor and Installation in Section 1J Inspection in Section 1H and Installation in Section 1J (Page 1J-5)”. (Page 1H-6)”. (Page 1J-5)”. Refer to “Starter Torque Refer to “Starter Torque Refer to “Starter Torque...

  • Page 150: Throttle Cable Removal And Installation

    1D-5 Engine Mechanical: 4) Disconnect the IAT sensor coupler (4). Throttle Cable Removal and Installation B933H21406005 5) Remove the air cleaner box (5) by removing the air Removal cleaner box mounting bolts. 1) Remove the fuel tank and fuel tank lower cover. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.

  • Page 151: Starter Cable Removal And Installation

    Engine Mechanical: 1D-6 Starter Cable Removal and Installation Installation B933H21406008 Install the starter cable in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the front fender. Refer to “Exterior Parts • Install the starter cable as shown in the cable routing Removal and Installation in Section 9D (Page 9D- diagram.

  • Page 152: Throttle Body Components

    1D-7 Engine Mechanical: Throttle Body Components B933H21406009 I933H1140018-07 1. TP sensor 4. L-joint 7. Idle air screw : Apply engine oil. 2. IAP sensor 5. Fuel delivery pipe 8. Starter valve : Do not reuse. 3. Throttle body 6. Fuel injector : Apply water resistance grease.

  • Page 153: Throttle Body Construction

    Engine Mechanical: 1D-8 Throttle Body Construction B933H21406010 Upper Upper “ a ” Intake pipe clamp Outlet tube clamp “A” “A” “A” I933H1140241-07 1. Throttle body 5. Fuel vapor return hose “A”: White mark 2. Fuel valve 6. Air cleaner box “a”: 10 –...

  • Page 154: Throttle Body Inspection

    1D-9 Engine Mechanical: Throttle Body Inspection 7) Disconnect the throttle cable from drum. B933H21406011 Refer to “Throttle Body Inspection in Section 0B CAUTION (Page 0B-10)”. After disconnecting the throttle cable, do not snap the throttle valve from full open to full Throttle Body Removal and Installation close.

  • Page 155: Throttle Body Disassembly And Assembly

    Engine Mechanical: 1D-10 Installation 3) Remove the fuel injector (3) from the fuel delivery Install the throttle body in the reverse order of removal. pipe (2). Pay attention to the following points: NOTE When installing the throttle body, fit the concave part of the intake pipe onto the convex part of the throttle body.
  • Page 156 1D-11 Engine Mechanical: Assembly CAUTION Assembly is the throttle body in the reverse order of Avoid removing the idle air screw (8). removal. Pay attention to the following points: • Install the new O-ring (1). CAUTION Replace the O-ring with a new one. I933H1140030-01 CAUTION Never remove the throttle valve (9).
  • Page 157 Engine Mechanical: 1D-12 NOTE • Install the fuel injector (4) by pushing it straight to the delivery pipe (5). • Make sure the throttle valve smoothly open and close. CAUTION • For TP sensor setting procedure, refer to Never turn the injector (4) while pushing it. “TP Sensor Adjustment in Section 1C (Page 1C-4)”.

  • Page 158: Throttle Body Inspection And Cleaning

    1D-13 Engine Mechanical: • Install the L-joint (6) by pushing it straight to the Engine Assembly Removal delivery pipe (5). B933H21406015 Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is CAUTION sequentially explained in the following steps: Never turn the L-joint (6) while pushing it.
  • Page 159 Engine Mechanical: 1D-14 5) Remove the seat. Refer to “Exterior Parts Removal 12) Disconnect the fuel pump lead wire coupler (9) and and Installation in Section 9D (Page 9D-4)”. remove the fuel pump (10). 6) Disconnect the battery (–) lead wire. I933H1140046-01 13) Disconnect the ECT sensor coupler (11).
  • Page 160 1D-15 Engine Mechanical: 17) Disconnect the reverse lock release cable (15). 21) Remove the engine sprocket (22) with drive chain. Refer to “Gear Position (GP) Switch Removal and 22) Remove the gear shift lever (23) and spacers. Installation in Section 5B (Page 5B-12)”. NOTE Mark the gearshift shaft head at which the gearshift lever slit set for correct...

  • Page 161: Engine Assembly Installation

    Engine Mechanical: 1D-16 25) Remove the engine mounting bolts and nuts. • 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 to the engine sprocket bolts and tighten them.

  • Page 162: Engine Top Side Disassembly

    1D-17 Engine Mechanical: • After finishing the engine installation, check the Camshaft following items: 1) Remove the valve timing inspection plug (1) and – Throttle cable play generator cover plug (2). Refer to “Throttle Cable Play Inspection and Adjustment in Section 0B (Page 0B-10)”. –...
  • Page 163 Engine Mechanical: 1D-18 3) Remove the oil return tank. Refer to “Oil Return Tank Cylinder head Removal and Installation in Section 1B (Page 1B-2)”. 1) Remove the exhaust pipe (1). Refer to “Muffler / 4) Remove the cam chain tension adjuster cap bolt (3), Exhaust Pipe Removal and Installation in Section 1K washer and spring.
  • Page 164 1D-19 Engine Mechanical: 7) Remove the cylinder head. Cylinder 1) Disconnect the breather hose (1). NOTE 2) Remove the cam chain guide No. 1 (2) and cylinder • When loosening the cylinder head bolts, (3). loosen each bolt little by little diagonally. NOTE •...

  • Page 165: Engine Top Side Assembly

    “A” crankcase. • Apply bond to the crankcase “A” as shown in the figure. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) I933H1140074-01 • Place a clean rag over the cylinder base to prevent the piston pin circlip (1) from dropping into the crankcase, and then fit the piston pin circlip (1) with long-nose pliers.
  • Page 166 1D-21 Engine Mechanical: • Hold each piston ring and put it into the cylinder. Make • Place the cylinder head (3) on the cylinder. sure that the piston rings are caught by the cylinder NOTE skirt. When installing the cylinder head (3), keep NOTE the cam chain taut.
  • Page 167 Engine Mechanical: 1D-22 • After tightening the cylinder head bolts to • Install the throttle body. Refer to “Throttle Body specification, tighten the cylinder head bolts (4) and Removal and Installation (Page 1D-9)”. cylinder base nuts (5) to the specified torque. •...
  • Page 168 1D-23 Engine Mechanical: • Just before installing the camshaft into the cylinder • The other arrow marked “2” “B” should now be head, apply engine oil to the camshaft journals, cam pointing straight up. Starting from the roller pin that is faces and camshaft journal holders.
  • Page 169 Engine Mechanical: 1D-24 • Place each camshaft journal holders (1) and cam • Install the cam chain tension adjuster (4). chain guide No. 2 (2) into the correct position. NOTE NOTE Make sure that the “UP” mark “A” comes to Camshaft journal holders marked “EX”...
  • Page 170 • Apply bond to the end caps of the cylinder head cover gasket as shown in the figure. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) CAUTION Use a new gasket to prevent oil leakage.

  • Page 171: Valve Clearance Inspection And Adjustment

    Engine Mechanical: 1D-26 • Tighten the cylinder head cover bolts in diagonal Automatic decompression stages to the specified torque. Move the automatic decompression weight by hand to inspect if it is operating smoothly. If the automatic Tightening torque decompression weight does not operate smoothly, Cylinder head cover bolt: 14 N·m (1.4 kgf-m, 10.0 replace it with a new one.
  • Page 172 1D-27 Engine Mechanical: Camshaft journal wear Camshaft journal oil clearance (IN. & EX.) Inspect the camshaft journal wear in the following Service limit: 0.150 mm (0.0059 in) procedures: 1) Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.

  • Page 173: Cam Chain Tension Adjuster Inspection

    Engine Mechanical: 1D-28 Cam Chain Tension Adjuster Inspection 3) Remove the cylinder head cover. Refer to “Engine B933H21406021 Top Side Disassembly (Page 1D-17)”. The cam chain tension adjuster is maintained at the 4) Remove the cam chain guide No. 2 (2). proper tension by an automatically adjusted.

  • Page 174: Cam Chain Tensioner Inspection

    1D-29 Engine Mechanical: Cam Chain Tensioner Inspection 7) Reinstall the clutch components. Refer to “Clutch B933H21406024 Installation in Section 5C (Page 5C-9)”. Inspect the cam chain tensioner in the following 8) Reinstall the cylinder head. Refer to “Engine Top procedures: Side Assembly (Page 1D-20)”.
  • Page 175 Engine Mechanical: 1D-30 4) Using the special tools, compress the valve spring 8) Remove the other valves in the same manner as and remove the two cotter halves (4) from the valve described previously. stem. 9) Remove the ECT sensor (10). CAUTION To prevent damage of the tappet sliding surface with the special tool, use the sleeve...
  • Page 176 (2). I933H1140125-01 • Apply grease to the O-ring of the intake pipe. CAUTION Replace the O-ring with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I933H1140128-02 • Tighten the ECT sensor (3) to the specified torque. CAUTION Use the new O-ring (4) to prevent engine coolant leakage.
  • Page 177 Engine Mechanical: 1D-32 • Install the valve spring seat. • Put on the valve spring retainer (6), and using the special tools, press down the spring, fit the cotter • Apply engine oil to the oil seal (5), and press-fit it into halves (7) to the stem end, and release the lifter to position.

  • Page 178: Cylinder Head Related Parts Inspection

    1D-33 Engine Mechanical: • Install the other valves and springs in the same Valve stem runout manner as described previously. Support the valve using V-blocks, as shown in the figure, and check its runout using the dial gauge. If the runout •...
  • Page 179 Engine Mechanical: 1D-34 Valve face wear Valve stem wear Visually inspect each valve face for wear. Replace any Measure the valve stem O.D. using the micrometer. If it valve with an abnormally worn face. The thickness of the is out of specification, replace the valve with a new one. valve face decreases as the face wears.
  • Page 180 1D-35 Engine Mechanical: Valve spring Valve seat width The force of the coil spring keeps the valve seat tight. A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve.

  • Page 181: Valve Guide Replacement

    Engine Mechanical: 1D-36 Valve seat sealing condition 3) Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. 1) Clean and assemble the cylinder head and valve components. Special tool 2) Fill the intake and exhaust ports with gasoline to (A): 09916–44310 (Valve guide remover/ check for leaks.

  • Page 182: Valve Seat Repair

    1D-37 Engine Mechanical: 5) Cool down the new valve guides in a freezer for 8) After installing the valve guides, refinish their guiding about one hour and heat the cylinder head to 100 – bores using the reamer. Be sure to clean and oil the 150 °C (212 –...

  • Page 183: Cylinder Inspection

    Engine Mechanical: 1D-38 Cylinder bore CAUTION Inspect the cylinder wall for any scratches, nicks or other • The valve seat contact area must be damage (Measure the cylinder bore diameter at six inspected after each cut. places). If any defects are found, replace the cylinder with a new one.

  • Page 184: Piston Ring Removal And Installation

    1D-39 Engine Mechanical: Piston Ring Removal and Installation B933H21406030 Removal “A” 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-17)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it.

  • Page 185: Piston And Piston Ring Inspection

    Engine Mechanical: 1D-40 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 exceed the limit, replace both the piston and piston “C” “D” rings. Special tool (A): 09900–20803 (Thickness gauge) (B): 09900–20205 (Micrometer (0 –...

  • Page 186: Engine Bottom Side Disassembly

    1D-41 Engine Mechanical: Piston ring free end gap and piston ring end gap Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.
  • Page 187 Engine Mechanical: 1D-42 Starter torque limiter 2) Remove the oil filter (2) and O-ring (3). Remove the starter torque limiter (1). Refer to “Starter Torque Limiter / Starter Clutch Removal and Installation in Section 1I (Page 1I-8)”. I933H1140153-01 Clutch Remove the clutch component parts (1). Refer to “Clutch I933H1140150-01 Removal in Section 5C (Page 5C-7)”.
  • Page 188 1D-43 Engine Mechanical: Oil pump 5) Remove the outer rotor (7), inner rotor (8) and pin (9). 1) Remove the snap rings (1). NOTE Do not drop the snap ring (1) into the crankcase. Special tool : 09900–06107 (Snap ring pliers) 2) Remove the oil pump idle gear (2) and oil pump driven gear (3).
  • Page 189 Engine Mechanical: 1D-44 4) Remove the gearshift pawls (7), pins (8), springs (9) 2) Remove he washer (1), balancer driven gear (2) and and roller (10). pin (3). I933H1140161-01 I933H1140164-01 5) Remove the gearshift cam stopper plate bolt (11) Primary drive gear / Balancer drive gear and gearshift cam stopper plate (12).
  • Page 190 1D-45 Engine Mechanical: 4) Remove the pin (6). Gear position switch 1) Remove the gear position switch (1). 2) Remove the switch contacts (2) and springs (3). I933H1140167-01 Generator / Starter driven gear I933H1140170-01 1) Remove the generator rotor (1). Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”.
  • Page 191 Engine Mechanical: 1D-46 3) Separate the crankcase using the special tool. Transmission / Gearshift Remove the transmission component. Refer to Special tool “Transmission Removal and Installation in Section 5B (A): 09920–13120 (Crankcase separating (Page 5B-5)”. 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.
  • Page 192 1D-47 Engine Mechanical: Oil gallery plug Transmission oil seal / Bearing Remove the transmission oil seals and bearings if 1) Remove the oil gallery plugs (1) from the right necessary. Refer to “Transmission Oil Seal / Bearing crankcase. Removal and Installation in Section 5B (Page 5B-10)” and “Gearshift Shaft Oil Seal / Bearing Removal and Installation in Section 5B (Page 5B-18)”.

  • Page 193: Engine Bottom Side Assembly

    Engine Mechanical: 1D-48 Engine Bottom Side Assembly B933H21406033 Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. Oil pump idle gear shaft Install the oil pump idle gear shaft (1) and new snap ring (2).
  • Page 194 • Apply to distorted surfaces as it forms a comparatively thick film. I933H1140189-01 : Sealant 99000–31110 (SUZUKI BOND Oil sump filter No.1215 or equivalent) Align the oil passage holes when installing the oil sump filter (1).
  • Page 195 Engine Mechanical: 1D-50 • Tighten the crankcase bolts to the specified torque. Tightening torque Gear position switch mounting bolt (a): 6.5 N·m ( Tightening torque 0.65 kgf-m, 4.7 lb-ft) Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft) I933H1140195-02 I933H1140192-01 Generator / Starter driven gear •...
  • Page 196 1D-51 Engine Mechanical: Primary drive gear / Balancer drive gear Special tool (A): 09930–44520 (Rotor holder) • Install the pin (1) and balancer drive gear (2). Tightening torque Primary drive gear nut (a): 140 N·m (14.0 kgf-m, 101.5 lb-ft) I933H1140198-01 •...
  • Page 197 Engine Mechanical: 1D-52 Gearshift / Gearshift cam plate • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of thread lock to the gearshift • Locate the gearshift cam in the neutral position. arm stopper and tighten it to the specified torque. •...
  • Page 198 1D-53 Engine Mechanical: • Install the washer (15) and new snap ring (16). CAUTION The removed snap ring (16) must be replaced with a new one. Special tool : 09900–06107 (Snap ring pliers) I933H1140210-01 • Apply a small quantity of thread lock to the gearshift pawl lifter screws, and then tighten the specified torque.
  • Page 199 Engine Mechanical: 1D-54 • Apply a small quantity of thread lock to the oil pump Cam chain tensioner / Cam chain mounting screws. • Install the cam chain (1). : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or equivalent) Tighten the oil pump mounting screws to the specified torque.
  • Page 200 1D-55 Engine Mechanical: Oil filter Generator cover / Starter idle gear Install the starter idle gear (1) and generator cover (2). • Apply engine oil to the new O-rings (1). Refer to “Generator Removal and Installation in Section CAUTION 1J (Page 1J-5)”. Replace the new O-rings with new ones.

  • Page 201: Oil Sump Filter Inspection

    Engine Mechanical: 1D-56 Oil Sump Filter Inspection Conrod deflection B933H21406034 Wear On the big end of the conrod can be estimated by Refer to “Oil Sump Filter Inspection and Cleaning in checking the movement of the small end of the rod. This Section 1E (Page 1E-4)”.

  • Page 202: Balancer Shaft Inspection

    1D-57 Engine Mechanical: Crankshaft runout Balancer Shaft Inspection Support the crankshaft using V-blocks and measure the B933H21406038 Inspect the balancer shaft in the following procedures: crankshaft runout using the dial gauge, as shown. If the 1) Separate the crankcase, left and right. Refer to runout exceeds the service limit, replace the crankshaft “Engine Bottom Side Disassembly (Page 1D-41)”.

  • Page 203: Crankshaft Bearing / Balancer Shaft Bearing Removal And Installation

    Engine Mechanical: 1D-58 Crankshaft Bearing / Balancer Shaft Bearing Installation Removal and Installation CAUTION B933H21406040 Removal The removed bearings must be replace with 1) Disassemble the engine bottom side. Refer to new ones. “Engine Bottom Side Disassembly (Page 1D-41)”. 2) Remove the right crankcase bearings (1) using the NOTE special tool.

  • Page 204: Crankshaft Oil Seal Inspection

    Special tool a new one. (A): 09913–70210 (Bearing installer set) 2) Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I933H1140082-02 3) Install the clutch cover. Refer to “Clutch Installation in Section 5C (Page 5C-9)”.

  • Page 205: Specifications

    Engine Mechanical: 1D-60 Specifications Service Data B933H21407001 Valve + Valve guide Unit: mm (in) Item Standard Limit 36.0 (1.42) — Valve diam. 29.0 (1.14) — 0.10 – 0.20 (0.004 – 0.008) — Tappet clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —...

  • Page 206: Tightening Torque Specifications

    1D-61 Engine Mechanical: Item Standard Limit Piston pin bore I.D. 20.002 – 20.008 (0.7875 – 0.7877) 20.030 (0.7886) Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874) 19.980 (0.7866) Conrod + Crankshaft Unit: mm (in) Item Standard Limit Conrod small end I.D. 20.010 –...

  • Page 207: Special Tools And Equipment

    Engine Mechanical: 1D-62 Special Tools and Equipment Recommended Service Material B933H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-31) / equivalent (Page 1D-59) Water resistance grease or P/No.: 99000–25160 (Page 1D-6) /...
  • Page 208 1D-63 Engine Mechanical: 09900–20605 09900–20607 Dial calipers (1/100 mm, 10 Dial gauge (1/100 mm, 10 – 34 mm) (Page 1D-56) (Page 1D-33) / (Page 1D-33) / (Page 1D-34) / (Page 1D-56) / (Page 1D-57) 09900–20701 09900–20803 Magnetic stand Thickness gauge (Page 1D-33) / (Page 1D-33) / (Page 1D-33) /...
  • Page 209 Engine Mechanical: 1D-64 09915–64512 09916–10911 Compression gauge Valve lapper set (Page 1D-1) (Page 1D-35) 09916–14510 09916–14910 Valve spring compressor Valve spring compressor attachment (Page 1D-30) / (Page 1D-30) / (Page 1D-32) (Page 1D-32) 09916–34542 09916–34570 Reamer handle Valve guide reamer (5.0 (Page 1D-36) / (Page 1D-37) (Page 1D-37)
  • Page 210 1D-65 Engine Mechanical: 09930–44520 Rotor holder (Page 1D-44) / (Page 1D-44) / (Page 1D-51) / (Page 1D-51)

  • Page 211: Engine Lubrication System

    Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B933H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Oil Hose and Pipe Routing Diagram B933H21502001 “A” I933H1150035-03 1. Engine oil tank 5.

  • Page 212: Engine Lubrication System Chart Diagram

    1E-2 Engine Lubrication System: Engine Lubrication System Chart Diagram B933H21502002 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...

  • Page 213: Diagnostic Information And Procedures

    Engine Lubrication System: 1E-3 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B933H21504001 Condition Possible cause Correction / Reference Item Engine overheats Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Incorrect engine oil. Change.

  • Page 214: Repair Instructions

    1E-4 Engine Lubrication System: 6) Stop the engine and remove the oil pressure gauge and attachment. 7) Reinstall the main oil gallery plug (1) and tighten it to the specified torque. CAUTION Use a new gasket to prevent oil leakage. Tightening torque Main oil gallery plug (a): 18 N·m (1.8 kgf-m, 13.0 lb-ft)

  • Page 215: Oil Pump Components

    Engine Lubrication System: 1E-5 4) Remove the oil pump idle gear (2) and oil pump driven gear (3). I933H1150007-01 3) Install the oil sump filter. Refer to “Oil Sump Filter Removal and Installation (Page 1E-4)”. I933H1150009-02 5) Remove the pin (4) and washer (5). Oil Pump Components 6) Remove the oil pump assembly (6).

  • Page 216: Oil Pump Inspection

    1E-6 Engine Lubrication System: • When installing the oil pump driven gear, align the pin • Apply engine oil to the sliding surfaces of the oil pump (4) with the groove (5). inner rotor, outer rotor and shaft. • When installing the inner rotor (1), align the pin (2) with the groove (3).

  • Page 217: Engine Oil Hose And Pipe Construction

    Engine Lubrication System: 1E-7 Engine Oil Hose and Pipe Construction B933H21506008 I933H1150036-03 1. Oil tank overflow hose : 12 N⋅m (1.2 kgf-m, 8.5 lb-ft) 2. Engine oil pipe : Apply engine oil. 3. Oil tank : Do not reuse. 4. Engine oil level gauge...

  • Page 218: Oil Tank Inspection

    1E-8 Engine Lubrication System: Oil Tank Inspection 5) Remove the engine oil pipes. B933H21506009 Inspect the oil tank oil leaks. If any defects are found, replace the oil tank with a new one. Refer to “Oil Tank Removal and Installation (Page 1E-9)”. I933H1150020-01 I933H1150017-01 Engine Oil Pipe Removal and Installation...

  • Page 219: Oil Tank Removal And Installation

    Engine Lubrication System: 1E-9 Installation 5) Disconnect the overflow hose (2). Install the engine oil pipes in the reverse order of 6) Remove the engine oil pipes (3). removal. Pay attention to the following points: Apply engine oil to the O-rings. CAUTION Replace the O-rings with new ones to prevent oil leakage.

  • Page 220: Oil Pipe Removal And Installation

    1E-10 Engine Lubrication System: Installation 3) Remove the clutch primary driven gear assembly. Install the oil tank in the reverse order of removal. Pay Refer to “Clutch Removal in Section 5C (Page 5C- attention to the following points. 7)”. • Apply engine oil to the O-rings. 4) Remove the oil pipe No.2 (2).

  • Page 221: Oil Pipe Inspection

    Engine Lubrication System: 1E-11 Oil Pipe Inspection B933H21506013 Refer to “Oil Pipe Removal and Installation (Page 1E- 10)”. Make sure that the oil pipes are not clogged. If it is clogged, clean the oil passage using a wire of the proper size and compressed air.

  • Page 222: Special Tools And Equipment

    1E-12 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B933H21508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1E-6) 1322 or equivalent NOTE Required service material is also described in the following.

  • Page 223: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B933H21600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

  • Page 224: General Description

    1F-2 Engine Cooling System: General Description Engine Coolant Description Fig.1: Engine coolant density-freezing point curve B933H21601001 CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. •...

  • Page 225: Water Hose Routing Diagram

    Engine Cooling System: 1F-3 Water Hose Routing Diagram B933H21602002 I933H1160054-10 1. Radiator 4. Cooling fan 2. Reservoir 5. Yellow mark 3. Reservoir overflow hose 6. White mark...

  • Page 226: Diagnostic Information And Procedures

    1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B933H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

  • Page 227: Radiator Cap Inspection

    Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator cleaning B933H21606002 1) Remove the side covers, left and right. Refer to Inspect the radiator cap in the following procedures: “Exterior Parts Removal and Installation in Section 1) Remove the radiator cap. Refer to “Cooling Circuit 9D (Page 9D-4)”.
  • Page 228 1F-6 Engine Cooling System: 6) Disconnect the overflow hose (6) and reservoir tank (7). 7) Remove the cooling fan motor fuse box (8) and cooling fan assembly (9). I933H1160007-03 4) Disconnect the cooling fan motor lead wire coupler (3). I933H1160011-02 Installation Install the radiator in the reverse order of removal.

  • Page 229: Cooling Fan Motor Removal And Installation

    Engine Cooling System: 1F-7 Cooling Fan Motor Removal and Installation 5) Remove the cooling fan (6). B933H21606005 Removal 1) Remove the side covers, left and right. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. 2) Disconnect the cooling fan motor lead wire coupler (1) and cooling fan motor fuse box coupler (2).

  • Page 230: Water Hose Inspection

    1F-8 Engine Cooling System: Water Hose Inspection Radiator Cover Removal and Installation B933H21606006 B933H21606007 Inspect the water hose in the following procedures: Removal Remove the radiator covers, left and right (1). 1) Remove the side covers, left and right. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.

  • Page 231: Radiator Reservoir Tank Inspection

    Engine Cooling System: 1F-9 Radiator Reservoir Tank Inspection Installation B933H21606009 1) Install the reservoir tank (1). Inspect the radiator reservoir tank in the following 2) Apply thread lock to the reservoir tank mounting procedures: bolts and tighten them. 1) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- : Thread lock cement 99000–32110 4)”.

  • Page 232: Cooling Fan Relay Inspection

    1F-10 Engine Cooling System: NOTE “C” “A” • When making this test, it is not necessary to remove the cooling fan. • Make sure that the battery has a capacity enough to supply the motor with 12 V. With the motor running at full speed, the ammeter should indicate not higher than 5 “B”...

  • Page 233: Thermostat Inspection

    Engine Cooling System: 1F-11 Installation 4) Immerse the thermostat (1) in the water contained in a beaker and note that the immersed thermostat is in 1) Apply engine coolant to the rubber seal on the suspension. thermostat (1). 5) Heat the water by placing the beaker on a stove and 2) Install the thermostat (1).

  • Page 234: Water Pump Components

    1F-12 Engine Cooling System: Water Pump Components B933H21606018 I933H1160031-02 1. Water pump cover 4. Mechanical seal : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Do not reuse. 2. O-ring 5. Oil seal : Apply water resistance grease. 3. Impeller 6. Water pump driven gear : Apply engine coolant.

  • Page 235: Water Pump Removal And Installation

    Engine Cooling System: 1F-13 Water Pump Removal and Installation Installation B933H21606019 1) Apply grease to the O-rings. Removal CAUTION NOTE Replace the O-rings with new ones. Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and : Grease 99000–25160 (Water resistance crankcase.

  • Page 236: Water Pump Disassembly And Assembly

    1F-14 Engine Cooling System: Water Pump Disassembly and Assembly B933H21606020 Refer to “Water Pump Removal and Installation (Page 1F-13)”. Disassembly 1) Remove the water pump cover (1). I933H1160039-01 5) Remove the oil seal (6). NOTE If there is no abnormal condition, the oil seal removal is not necessary.
  • Page 237 Engine Cooling System: 1F-15 2) Apply a small quantity of the grease to the oil seal 4) Install the rubber seal (1) into the impeller. lip. 5) After wiping off the oily or greasy matter from the mechanical seal ring (2), install it into the impeller. : Grease 99000–25160 (Water resistance grease or equivalent) NOTE...

  • Page 238: Water Pump Related Parts Inspection

    1F-16 Engine Cooling System: 9) Fit the water pump cover and tighten the water pump Oil seal cover screws. Visually inspect the oil seal for damage, with particular attention given to the lip. Replace the oil seal that shows indications of leakage. I933H1160048-01 Water Pump Related Parts Inspection I933H1160050-01...

  • Page 239: Specifications

    Engine Cooling System: 1F-17 Specifications Service Data B933H21607001 Thermostat + Radiator + Fan + Coolant Item Standard Note Thermostat valve opening Approx. 76.5 °C (170 °F) — temperature 4.5 mm (0.18 in) and over at 90 °C (194 °F) Thermostat valve lift —...

  • Page 240: Special Tools And Equipment

    1F-18 Engine Cooling System: Special Tools and Equipment Recommended Service Material B933H21608001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 1F-13) / equivalent (Page 1F-15) / (Page 1F-15) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...

  • Page 241: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B933H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...

  • Page 242: General Description

    1G-2 Fuel System: General Description Fuel System Description B933H21701001 Fuel system The fuel delivery system consists of the fuel tank (1), fuel valve (2), fuel pump (3), fuel filter (4), fuel feed hoses (6) and (7), fuel delivery pipe (8), fuel injector (9), fuel pressure regulator (11). The fuel is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

  • Page 243: Schematic And Routing Diagram

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Hose Routing Diagram B933H21702001 “A” “D” “B” “ a” “D” “C” I933H1170037-03 1. Reverse gear cable 5. Fuel pump “B”: Face the tip of clip to left. 2. Fuel hose 6. Starter cable “C”: Face the tip of clip to right.

  • Page 244: Diagnostic Information And Procedures

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B933H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

  • Page 245: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Remove the ignition switch. Refer to “Ignition Switch B933H21706001 Removal and Installation in Section 1H (Page 1H- WARNING 7)”. 5) Connect the ignition switch lead wire coupler (2). • Keep away from fire or spark. •...

  • Page 246: Fuel Pump Inspection

    1G-6 Fuel System: Fuel Pump Inspection 3) Connect a proper fuel hose (2) to the fuel valve. B933H21706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder. operates for a few seconds.

  • Page 247: Fuel Pump Relay Inspection

    Fuel System: 1G-7 Fuel Pump Relay Inspection 4) Remove the fuel level indicator switch (thermistor) B933H21706004 cover (4). Refer to “DTC “C41” (P0230): FP Relay Circuit Malfunction in Section 1A (Page 1A-63)”. Fuel Hose Inspection B933H21706005 Refer to “Fuel Line Inspection in Section 0B (Page 0B- 11)”.

  • Page 248: Fuel Tank Construction

    1G-8 Fuel System: Fuel Tank Construction B933H21706009 I933H1170038-01 1. Fuel tank 5. Fuel hose 2. Fuel level indicator switch (Thermistor) : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3. O-ring : Do not reuse. 4. Fuel valve...

  • Page 249: Fuel Tank Removal And Installation

    Fuel System: 1G-9 Fuel Tank Removal and Installation 7) Disconnect the breather hose (6). B933H21706010 8) Place a rag under the fuel feed hoses (7) and fuel Removal hose (8). WARNING 9) Disconnect the fuel feed hoses (7) and fuel hose (8). 10) Remove the fuel tank.

  • Page 250: Fuel Valve Removal And Installation

    1G-10 Fuel System: • Full open the fuel valve screw (1) by turning the fuel 3) Remove the fuel valve (3) and O-ring (4). valve screw counter clockwise. “ a ” I933H1170017-08 4) Remove the fuel filters (5). I933H1170016-03 “a”: Full open: 5.5 mm (0.2 in) •...

  • Page 251: Fuel Filter Inspection And Cleaning

    Fuel System: 1G-11 • Tighten the fuel valve mounting bolts to specified torque. Tightening torque Fuel valve mounting bolt (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft) I933H1170020-02 4) Reinstall the fuel valve. Refer to “Fuel Valve Removal and Installation (Page 1G-10)”. 5) Reinstall the fuel tank.
  • Page 252 1G-12 Fuel System: 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation (Page 1G-9)”. 2) Disconnect the injector coupler (1). I933H1170025-06 • Apply thin coat of engine oil to the new cushion seal (1) and O-ring (2). I933H1170022-02 CAUTION 3) Remove the fuel delivery pipe (2) with the injector...

  • Page 253: Fuel Pump Removal And Installation

    Fuel System: 1G-13 8) Remove the fuel pump (8). CAUTION Never turn the fuel injector while installing it. • Tighten the fuel delivery pipe mounting screws and L- joint mounting screw. I933H1170031-01 Installation 1) Connect the fuel feed hose (1) to the fuel pump until it locks securely (a click is heard).

  • Page 254: Specifications

    1G-14 Fuel System: Specifications Service Data B933H21707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 9 – 17 Ω at 20 °C (68 °F) Injector resistance — Fuel pump discharge amount 84 ml (2.8/3.0 US/lmp oz) and more/10 sec. —...

  • Page 255: Ignition System

    Ignition System: 1H-1 Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B933H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Ignition Fuse sensor coil Ignition switch Fuse Battery sensor sensor switch I933H1180001-02 Ignition System Components Location B933H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.

  • Page 256: Diagnostic Information And Procedures

    1H-2 Ignition System: Diagnostic Information and Procedures Ignition System Symptom Diagnosis B933H21804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug cap. Replace. Damaged spark plug. Replace. Fouled spark plug. Clean or replace. Wet spark plug. Clean and dry or replace.

  • Page 257: No Spark Or Poor Spark

    Ignition System: 1H-3 No Spark or Poor Spark B933H21804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.

  • Page 258: Repair Instructions

    1H-4 Ignition System: Repair Instructions Spark Plug Cap and Spark Plug Removal and Spark Plug Inspection and Cleaning B933H21806002 Installation Refer to “Spark Plug Inspection and Cleaning in Section B933H21806001 0B (Page 0B-9)”. Removal WARNING Ignition Coil and Plug Cap Inspection B933H21806003 The hot engine can burn you.
  • Page 259 Ignition System: 1H-5 7) Connect the multi-circuit tester with the peak voltage 8) Measure the ignition coil primary peak voltage in the adaptor as follows: following procedures: CAUTION WARNING Before using the multi-circuit tester and peak Do not touch the tester probes and spark voltage adaptor, refer to the appropriate plug to prevent an electric shock while instruction manual.

  • Page 260: Ckp Sensor Inspection

    1H-6 Ignition System: CKP Sensor Inspection b) Press the starter button and allow the engine to B933H21806004 crank for a few seconds, and then measure the Refer to “Electrical Components Location in Section 0A CKP sensor peak voltage. (Page 0A-7)”. 5) Repeat the b) procedure a few times and measure the highest CKP sensor peak voltage.

  • Page 261: Ckp Sensor Removal And Installation

    Ignition System: 1H-7 CKP Sensor Removal and Installation Ignition Switch Removal and Installation B933H21806005 B933H21806008 Refer to “Generator Removal and Installation in Section Removal 1J (Page 1J-5)”. 1) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- Engine Stop Switch Inspection 4)”.

  • Page 262: Specifications

    1H-8 Ignition System: Specifications Service Data B933H21807001 Electrical Unit: mm (in) Item Specification Note NGK: CR7E Type DENSO: U22ESR-N Spark plug 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 400 – 600 Ω CKP sensor resistance CKP sensor peak voltage 1.0 V and more When cranking...

  • Page 263: Starting System

    Starting System: 1I-1 Starting System Engine Schematic and Routing Diagram Starting System Diagram B933H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop Ignition Starter switch switch relay Fuse (10A) Fuse (20A) Starter motor Starter button Clutch switch I933H1190001-01 Component Location...

  • Page 264: Starter Motor Will Not Run

    1I-2 Starting System: Starter Motor will not Run B933H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transfer to neutral. Go to step 2. Go to step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...

  • Page 265: Repair Instructions

    Starting System: 1I-3 Repair Instructions Starter Motor Components B933H21906001 I933H1190003-03 1. O-ring 7. Brush holder : Apply grease. 2. Housing end (Inside) 8. Housing end (Outside) : Apply water resistance grease. 3. O-ring : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Apply moly paste to sliding surface.

  • Page 266: Starter Motor Removal And Installation

    1I-4 Starting System: Starter Motor Removal and Installation • Tighten the starter motor mounting bolts (1) with the B933H21906002 battery (–) lead wire (2) and starter motor lead wire mounting nut (3) to the specified torque. Refer to Removal “Wiring Harness Routing Diagram in Section 9A 1) Turn the ignition switch OFF and disconnect the (Page 9A-3)”.

  • Page 267: Starter Motor Related Parts Inspection

    I933H1190012-01 • Apply a small quantity of moly paste to the armature Starter Motor Related Parts Inspection shaft. B933H21906004 : Moly paste 99000–25140 (SUZUKI Moly Refer to “Starter Motor Disassembly and Assembly paste or equivalent) (Page 1I-4)”. Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.

  • Page 268: Starter Relay Removal And Installation

    1I-6 Starting System: Starter Relay Removal and Installation Commutator B933H21906005 Inspect the commutator for discoloration, abnormal wear Refer to “Electrical Components Location in Section 0A or undercut “A”. (Page 0A-7)”. If the commutator is abnormally worn, replace the armature. Removal If the commutator surface is discolored, polish it with 1) Turn the ignition switch OFF position.

  • Page 269: Starter Relay Inspection

    Starting System: 1I-7 Starter Relay Inspection Gear Position (GP) Switch Inspection B933H21906006 B933H21906007 Inspect the starter relay in the following procedures: Refer to “DTC “C31” (P0705): GP Switch Circuit Malfunction in Section 1A (Page 1A-58)”. 1) Remove the starter relay. Refer to “Starter Relay Inspect the gear position switch in the following Removal and Installation (Page 1I-6)”.

  • Page 270: Starter Torque Limiter / Starter Clutch Removal And Installation

    1I-8 Starting System: Starter Torque Limiter / Starter Clutch Removal Starter clutch and Installation 1) Drain engine oil. B933H21906008 2) Remove the generator cover (1). Refer to “Generator Removal Removal and Installation in Section 1J (Page 1J-5)”. Starter torque limiter 1) Remove the starter torque limiter cover (1).
  • Page 271 Starting System: 1I-9 5) Remove the key (6) and starter driven gear (7). Installation Install the starter clutch in the reverse order of removal. Pay attention to the following points: Starter clutch • Apply engine oil to the one way clutch (1). •...
  • Page 272 1I-10 Starting System: • Apply thread lock to the bolts, and then tighten them • After installing the generator cover, pour engine oil. to the specified torque with the special tool. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or Starter torque limiter...

  • Page 273: Starter Torque Limiter Inspection

    Starting System: 1I-11 Starter Torque Limiter Inspection Starter Clutch Related Parts Inspection B933H21906009 B933H21906010 Inspect the starter torque limiter in the following Refer to “Starter Torque Limiter / Starter Clutch Removal procedures: and Installation (Page 1I-8)”. CAUTION Starter clutch 1) Install the starter driven gear onto the starter clutch. •...

  • Page 274: Starter Driven Gear Bearing Removal And Installation

    1I-12 Starting System: Starter Driven Gear Bearing Removal and Starter Button Inspection B933H21906012 Installation Inspect the starter button in the following procedures: B933H21906011 Removal 1) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Remove the starter driven gear.

  • Page 275: Specifications

    Starting System: 1I-13 Specifications Service Data B933H21907001 Unit: mm (in) Item Specification Note Standard 10 (0.39) Starter motor brush length Limit 6.5 (0.26) 3 – 6 Ω Starter relay resistance Tightening Torque Specifications B933H21907002 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Starter motor mounting bolt...

  • Page 276: Special Tools And Equipment

    1I-14 Starting System: Special Tools and Equipment Recommended Service Material B933H21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-5) equivalent Water resistance grease or P/No.: 99000–25160 (Page 1I-4) / (Page 1I-...

  • Page 277: Charging System

    Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B933H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B933H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B933H21A04001 Condition...

  • Page 278: Battery Runs Down Quickly

    1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. “Sulfation”, acidic white Cracked battery case. Replace the battery. powdery substance or Battery has been left in a run-down Replace the battery.
  • Page 279 Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B933H21A06001 B933H21A06002 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
  • Page 280 1J-4 Charging System: Generator Inspection No-load performance B933H21A06003 1) Connect the tachometer onto the spark plug high- Generator coil resistance tension cord. 1) Disconnect the generator coupler (1). 2) Disconnect the generator coupler (1). I933H11A0001-01 I933H11A0001-01 2) Measure the resistance between the three lead 3) Start the engine and keep it running at 5 000 r/min.
  • Page 281 Charging System: 1J-5 Generator Removal and Installation 8) Remove the gasket (5) and dowel pin. B933H21A06004 Removal 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”. 2) Disconnect the reverse lock release cable. (for transmission side) Refer to “Gear Position (GP) Switch Removal and Installation in Section 5B (Page 5B-12)”.
  • Page 282 1J-6 Charging System: 12) Remove the generator rotor assembly (8) with the Installation special tool. Install the generator in the reverse order of removal. Pay attention to the following points: Special tool • When installing the generator stator or CKP sensor, (B): 09930–31921 (Rotor remover) route the wire properly.
  • Page 283 Charging System: 1J-7 • Degrease the tapered portion “A” of generator rotor • Install the dowel pins and new gasket (2). assembly and also the crankshaft “B”. Use CAUTION nonflammable cleaning solvent to wipe off oily or greasy matter to make these surfaces completely dry. Use a new gasket to prevent oil leakage.
  • Page 284 1J-8 Charging System: • Install the generator cover (3) and tighten the • Route the CKP sensor and generator lead wire. Refer generator cover bolts. to “Wiring Harness Routing Diagram in Section 9A (Page 9A-3)”. WARNING • Tighten the fuel pump mounting bolts to the specified Be careful not to pinch the finger between the torque.
  • Page 285 Charging System: 1J-9 3) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication...
  • Page 286 1J-10 Charging System: 2) Remove the caps (2) from the electrolyte container. 5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for NOTE about more than 20 minutes. • Do not remove or pierce the sealed areas “B”...
  • Page 287 Charging System: 1J-11 8) Insert the caps (2) into the filler holes, pressing in CAUTION firmly so that the top of the caps do not protrude • For charging the battery, make sure to use above the upper surface of the battery’s top cover. the charger specially designed for MF CAUTION battery.
  • Page 288 1J-12 Charging System: 4) Install the battery to the vehicle. Refer to “Battery Installation Removal and Installation (Page 1J-12)”. Install the battery in the reverse order of removal. Pay attention to following point: CAUTION Never use anything except the specified battery.
  • Page 289 Charging System: 1J-13 Specifications Service Data B933H21A07001 Electrical Unit: mm Item Specification Note 0.1 – 1.5 Ω Generator coil resistance Generator maximum output 200 W at 5 000 r/min Generator no-load voltage 55 V (AC) and more at 5 000 r/min (When engine is cold) Regulated voltage 13.5 –...
  • Page 290 1J-14 Charging System: Special Tools and Equipment Recommended Service Material B933H21A08001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 1J-7) equivalent Molybdenum oil MOLYBDENUM OIL SOLUTION — (Page 1J-7) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110...
  • Page 291 Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B933H21B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
  • Page 292 1K-2 Exhaust System: Repair Instructions Exhaust System Construction B933H21B06001 I933H11B0012-03 1. Exhaust pipe 5. Muffler mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Muffler 6. Muffler connecting bolt : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft) 3. Connector 7. Spark arrester : Apply muffler seal.
  • Page 293 Exhaust System: 1K-3 Muffler / Exhaust Pipe Removal and Installation NOTE B933H21B06002 Support the exhaust pipe to prevent it from falling. Removal 1) Loosen the muffler connecting bolt (1). I933H11B0004-07 I933H11B0001-01 7) Remove the exhaust pipe gasket (5). 2) Remove the muffler (2) by removing the mounting bolts.
  • Page 294 1K-4 Exhaust System: • Install the new muffler connector (2). Exhaust System Inspection B933H21B06003 Inspect the exhaust pipe connection and muffler NOTE connection for exhaust gas leakage and mounting When installing new connector, remove the condition. If any defect are found, replace the exhaust old sealer from the exhaust pipe and muffler.
  • Page 295 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-4)
  • Page 296 1K-6 Exhaust System:...
  • Page 297 Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ..........2-1 Repair Instructions ..........2C-1 Rear Suspension Components ......2C-1 Precautions............. 2-1 Rear Suspension Assembly Construction...2C-2 Precautions for Suspension ........2-1 Rear Shock Absorber Removal and Suspension General Diagnosis....2A-1 Installation ............2C-3 Rear Suspension Inspection .......2C-4 Diagnostic Information and Procedures....2A-1 Rear Shock Absorber Inspection ......2C-4...

  • Page 298: Precautions

    2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B933H22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

  • Page 299: Suspension General Diagnosis

    Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B933H22104001 Condition Possible cause Correction / Reference Item Tires rapidly or unevenly Worn or loose front wheel hub bearings. Replace. wear Improper front wheel alignment. Adjust.

  • Page 300: Front Suspension

    2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Suspension Components B933H22206001 I933H1220001-14...

  • Page 301: Front Suspension / Steering Assembly Construction

    Front Suspension: 2B-2 1. Front shock absorber 12. Snap ring 23. Front hub plate 2. Upper wishbone arm 13. Knuckle end : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Lower wishbone arm 14. Tie-rod end : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 4.

  • Page 302: Front Shock Absorber Removal And Installation

    2B-3 Front Suspension: Front Shock Absorber Removal and Installation 3) Apply thread lock to the front shock absorber B933H22206003 mounting bolts and tighten the nuts to the specified torque. CAUTION : Thread lock cement 99000–32110 Make sure that the vehicle is supported (THREAD LOCK CEMENT SUPER 1322 or securely.

  • Page 303: Front Suspension Adjustment

    Front Suspension: 2B-4 Bush / Dust seal Maximum Minimum Standard Inspect the bushing and dust seal for wear or damage. If (Softest) (Stiffest) any damages are found, replace the front shock 288.5 mm 295.5 mm 281.5 mm “a” absorber with a new one. (11.36 in) (11.63 in) (11.08 in)

  • Page 304: Front Shock Absorber Disposal

    2B-5 Front Suspension: Compression damping force adjustment Gas pressure release After installing the front suspension, adjust the spring Make sure to observe the following precautions: pre-load and damping force as follows. WARNING NOTE • Never apply heat or disassemble the shock •...

  • Page 305: Front Wheel Hub / Steering Knuckle Removal And Installation

    Front Suspension: 2B-6 Front Wheel Hub / Steering Knuckle Removal and Installation B933H22206008 Removal 1) Remove the cotter pin (1) and loosen the hub nut (2). 2) Remove the front wheel assembly (3). Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-2)”.
  • Page 306 2B-7 Front Suspension: Installation • Apply grease to the dust seal lips, collar and spacer. Install the front wheel hub and steering knuckle in the : Grease 99000–25160 (Water resistance reverse order of removal. Pay attention to the following grease or equivalent) points: •...

  • Page 307: Front Wheel Hub Parts Inspection

    Front Suspension: 2B-8 • Install the front wheel hub (6), washer (7) and front Front Wheel Hub Parts Inspection wheel hub nut (8). B933H22206009 Refer to “Front Wheel Hub / Steering Knuckle Removal • Install the brake caliper (9). Refer to “Front Brake and Installation (Page 2B-6)”.

  • Page 308: Steering Knuckle Inspection

    2B-9 Front Suspension: Steering Knuckle Inspection 3) Remove the hub bearings (2) with the special tool. B933H22206010 Special tool Refer to “Front Wheel Hub / Steering Knuckle Removal (B): 09921–20240 (Bearing remover set) and Installation (Page 2B-6)”. Inspect the steering knuckle for damage. If any defects are found, replace the steering knuckle with a new one.

  • Page 309: Front Suspension Upper / Lower Wishbone Arm Removal And Installation

    Front Suspension: 2B-10 2) First install the right hub bearing, then install the 4) Apply grease to the lip of dust seals. spacer (1) and left hub bearing with the special tool. : Grease 99000–25160 (Water resistance Special tool grease or equivalent) (A): 09913–70210 (Bearing installer set) (B): 09924–84510 (Bearing installer set) CAUTION...
  • Page 310 2B-11 Front Suspension: 5) Disconnect the front brake hose (3) and remove the Installation upper wishbone arm (1) by removing the upper Install the front suspension upper/lower wishbone in the wishbone arm bolts and pivot nut (4). reverse order of removal. Pay attention to the following points.

  • Page 311: Knuckle End Boot Inspection

    Front Suspension: 2B-12 • Install the front wheel hub. Refer to “Front Wheel Hub 3) Remove the knuckle end (2) with the special tool. / Steering Knuckle Removal and Installation Special tool (Page 2B-6)”. (A): 09913–70210 (Bearing installer set) • Install the front wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-2)”.

  • Page 312: Front Suspension Wishbone Arm Dust Seal / Bearing Removal And Installation

    2B-13 Front Suspension: Front Suspension Wishbone Arm Dust Seal / 4) Remove the dust seals (5). Bearing Removal and Installation B933H22206015 Removal 1) Remove the front suspension upper/lower wishbone arm. Refer to “Front Suspension Upper / Lower Wishbone Arm Removal and Installation (Page 2B- 10)”.

  • Page 313: Front Suspension Wishbone Arm Related Parts Inspection

    Front Suspension: 2B-14 • Apply grease to the bearings. • Apply grease to the dust covers (2). : Grease 99000–25160 (Water resistance : Grease 99000–25160 (Water resistance grease or equivalent) grease or equivalent) • Install the washers (3) and dust covers (2). I933H1220056-01 I933H1220059-03 Inside...
  • Page 314 2B-15 Front Suspension: Lower wishbone arm Dust seal Inspect the knuckle end boot and lower wishbone arm Inspect the dust seal lips for wear or damage. for wear or damage. If any defects are found, replace the If any defects are found, replace the dust seal with the lower wishbone arm with a new one.

  • Page 315: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H22208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 2B-3) /...

  • Page 316: Special Tool

    2B-17 Front Suspension: Special Tool B933H22208002 09900–06107 09910–60611 Snap ring pliers Universal clamp wrench (Page 2B-12) / (Page 2B-4) (Page 2B-12) 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 2B-9) (Page 2B-10) / (Page 2B-10) / (Page 2B-12) / (Page 2B-12) / (Page 2B-14) 09921–20240...

  • Page 317: Rear Suspension

    Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B933H22306001 I933H1230001-07 1. Rear shock absorber 9. Swingarm : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Cushion rod 10. Chain buffer : 95 N⋅m (9.5 kgf-m, 68.5 lb-ft) 3. Cushion lever 11.

  • Page 318: Rear Suspension Assembly Construction

    2C-2 Rear Suspension: Rear Suspension Assembly Construction B933H22306002 “a ” “ b ” “ b ” “C” “C” “C” “C” I933H1230067-05 1. Rear shock absorber mounting nut (Upper) 5. Cushion rod nut (Upper) : Apply water resistance grease. 2. Rear shock absorber mounting nut (Lower) : 60 Nm (6.0 kgf-m, 43.5 lb-ft) “a”: 45°...

  • Page 319: Rear Shock Absorber Removal And Installation

    Rear Suspension: 2C-3 Rear Shock Absorber Removal and Installation Installation B933H22306003 1) Apply thread lock to the rear shock absorber mounting bolts and tighten the nuts to the specified Removal torque. 1) Remove the cushion rod and cushion lever. Refer to : Thread lock cement 99000–32110 “Cushion Rod / Cushion Lever Removal and (THREAD LOCK CEMENT SUPER 1322 or...

  • Page 320: Rear Suspension Inspection

    2C-4 Rear Suspension: Rear Suspension Inspection Spring pre-load length B933H22306004 Maximum Minimum Refer to “Suspensions Inspection in Section 0B Standard (Softest) (Stiffest) (Page 0B-22)”. 234.8 mm 238 mm 227.5 mm (9.24 in) (9.37 in) (8.96 in) Rear Shock Absorber Inspection B933H22306005 Inspect the rear shock absorber in the following procedures:...

  • Page 321: Rear Shock Absorber Disposal

    Rear Suspension: 2C-5 Rebound side Gas pressure release Turn the damping force adjuster (1) to the desired Make sure to observe the following precautions: position. WARNING STD position 1 and 1/4 turns out from stiffest position • Never apply heat or disassemble the shock absorber unit since it can explode or oil can splash hazardously.

  • Page 322: Rear Wheel Hub Removal And Installation

    2C-6 Rear Suspension: Rear Wheel Hub Removal and Installation 3) Install the washer (2) and hub nut (3). B933H22306008 NOTE Removal The conical side of washer (2) faces outside. 1) Remove the cotter pin (1) and loosen the hub nut (2). Refer to “Rear Suspension Assembly Construction (Page 2C-2)”.

  • Page 323: Cushion Rod / Cushion Lever Removal And Installation

    Rear Suspension: 2C-7 3) Place the vehicle on the level ground and support the vehicle with a jack. 4) Remove the cushion rod (1). I933H1230017-01 Cushion Rod / Cushion Lever Removal and Installation I933H1230021-01 B933H22306010 5) Remove the cushion lever (2). Removal 1) Remove the cushion lever cover (1).

  • Page 324: Cushion Lever Dust Seal / Bearing Removal And Installation

    2C-8 Rear Suspension: 3) Tighten the cushion rod nuts (3) to the specified 5) Tighten the cushion lever cover bolts (5) to the torque. specified torque. Tightening torque Tightening torque Cushion rod nut (c): 78 N·m (7.8 kgf-m, 56.5 lb- Cushion lever cover bolt (d): 5.5 N·m (0.55 kgf- m, 4.0 lb-ft) I933H1230024-03...
  • Page 325 Rear Suspension: 2C-9 4) Remove the bearings (4) with the special tools. “ b ” Special tool “ a ” (A): 09923–73210 (Bearing remover) (B): 09930–30104 (Rotor remover slide shaft) “ a ” “ a ” “ b ” I933H1230033-02 “a”: 4 mm (0.16 in) “b”: 4.5 mm (0.18 in) 3) Install the dust seals with the special tool.

  • Page 326: Cushion Rod Dust Seal / Bearing Removal And Installation

    2C-10 Rear Suspension: Cushion Rod Dust Seal / Bearing Removal and Installation Installation CAUTION B933H22306012 The removed dust seals and bearings must Removal be replaced with new ones. 1) Remove the cushion rod. Refer to “Cushion Rod / Cushion Lever Removal and Installation (Page 2C- NOTE 7)”.

  • Page 327: Cushion Lever / Cushion Rod Related Parts Inspection

    Rear Suspension: 2C-11 3) Install the dust seals with the special tool. Special tool (B): 09913–70210 (Bearing installer set) 4) Apply grease to the oil seal lip. : Grease 99000–25160 (Water resistance grease or equivalent) I933H1230043-01 3) Install the spacers and collars. Dust seal 1) Remove the collars and spacers.

  • Page 328: Swingarm Removal And Installation

    2C-12 Rear Suspension: Bearing Cushion rod / Cushion lever Inspect the cushion rod / cushion lever for damage. If 1) Remove the dust seals. Refer to “Cushion Lever any defect is found, replace them with new ones. Dust Seal / Bearing Removal and Installation (Page 2C-8)”...
  • Page 329 Rear Suspension: 2C-13 4) Remove the swingarm by removing the pivot shaft Installation and nut (3) and washer (4). Install the swingarm in the reverse order removal. Pay attention to the following points. • Apply grease to the dust covers lip. : Grease 99000–25160 (Water resistance grease or equivalent) I933H1230052-01...

  • Page 330: Swingarm Dust Seal / Bearing Removal And Installation

    2C-14 Rear Suspension: Swingarm Dust Seal / Bearing Removal and Installation Installation CAUTION B933H22306015 Refer to “Rear Axle Assembly Construction in Section The removed dust seals, bushings and 3A (Page 3A-3)”. bearings must be replaced with new ones. Removal NOTE 1) Remove the swingarm.

  • Page 331: Swingarm Related Parts Inspection

    Rear Suspension: 2C-15 4) Apply grease to the dust seal lips. Chain buffer Inspect the chain buffer for wear and damage. If any : Grease 99000–25160 (Water resistance defect is found, replace the chain buffer with a new one. grease or equivalent) I933H1230062-01 I933H1230060-02 5) Install the spacers (1).

  • Page 332: Specifications

    2C-16 Rear Suspension: Cushion lever / Rod bolt Special tool Inspect the cushion lever/rod bolts for damage and (A): 09900–20607 (Dial gauge (1/100 mm, 10 bend. If any defects are noted, replace them with new mm)) ones. (B): 09900–20701 (Magnetic stand) (C): 09900–21304 (V-block (100 mm)) Swingarm pivot shaft runout Service limit: 0.3 mm (0.01 in)

  • Page 333: Special Tools And Equipment

    Rear Suspension: 2C-17 Special Tools and Equipment Recommended Service Material B933H22308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 2C-6) / (Page 2C- equivalent 9) / (Page 2C-9) / (Page 2C-10) / (Page 2C-11) /...

  • Page 334: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B933H22400001 WARNING • Proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. •...

  • Page 335: Front / Rear Wheel Removal And Installation

    Wheels and Tires: 2D-2 Front / Rear Wheel Removal and Installation Front B933H22406002 CAUTION Make sure that the vehicle is supported “A” securely. Removal 1) Place the vehicle on level ground. 2) Support the vehicle with a jack or wooden block. 3) Remove the wheel (1).

  • Page 336: Tire Removal And Installation

    2D-3 Wheels and Tires: Tire Removal and Installation Installation B933H22406003 CAUTION 1) Remove the wheel from vehicle. Refer to “Front / Rear Wheel Removal and Installation (Page 2D-2)”. Do not reuse the valve which has been once 2) After removing the air valve cap, release the tire removed.
  • Page 337 Wheels and Tires: 2D-4 3) Mount the tire on the rim by hand or tire levers and 4) Inflate the tire to seat the tire bead. rim protectors. CAUTION CAUTION Place the tire under a protective tire cage or The standard tire fitted on this vehicle is similar protective covering device before AT22 x 7R10 for the front and AT20 x...

  • Page 338: Wheel / Tire Inspection

    2D-5 Wheels and Tires: Wheel / Tire Inspection 5) Adjust the tire pressure to the specified pressure. B933H22406004 Refer to “Tire Removal and Installation (Page 2D-3)”. CAUTION Before inflating the tire, check the MAXIMUM Wheel OPERATING PRESSURE rating of the tire. Inspect the sealing portion of the rim for contamination This is indicated by a “...
  • Page 339 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Drive Chain Related Parts Inspection ....3A-8 Drive Chain Replacement ........3A-8 Precautions............. 3-1 Drive Chain Roller Construction......3A-11 Precautions for Driveline / Axle ......3-1 Drive Chain Roller Inspection......3A-12 Drive Chain / Drive Train / Drive Shaft...

  • Page 340: Precautions

    • Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK 520SMOZ10S. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 341: Drive Chain / Drive Train / Drive Shaft

    Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B933H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 342: Repair Instructions

    3A-2 Drive Chain / Drive Train / Drive Shaft: Repair Instructions Drive Chain / Rear Axle Related Components B933H23106001 I933H1310044-03 1. Stopper ring 8. Dust seal : 240 N.m (24.0 kgf-m, 173.5 lb-ft) 2. Rear axle lock-nut 9. Bearing : 60 N.m (6.0 kgf-m, 43.5 lb-ft) 3.

  • Page 343: Rear Axle Assembly Construction

    Drive Chain / Drive Train / Drive Shaft: 3A-3 Rear Axle Assembly Construction B933H23106002 “ a ” “a” “ c” “ b ” “c ” “ b ” “ b ” “ a ” I933H1310045-04 1. Swingarm pivot nut 9. O-ring : Apply thread lock to the thread part.

  • Page 344: Engine Sprocket Removal And Installation

    3A-4 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 4) Loosen the chain adjuster nut (4) and rear axle B933H23106003 housing bolts (5) to provide additional chain slack. Removal 1) Remove the engine sprocket cover (1). I933H1310004-01 5) Remove the engine sprocket (6) with drive chain.

  • Page 345: Rear Sprocket Removal And Installation

    Drive Chain / Drive Train / Drive Shaft: 3A-5 2) Apply thread lock to the sprocket bolts and tighten Rear Sprocket Removal and Installation them. B933H23106004 : Thread lock cement 99000–32030 Removal (THREAD LOCK CEMENT SUPER 1303 or 1) Place the vehicle on the level ground and support equivalent) the vehicle with a jack or wooden black.
  • Page 346 3A-6 Drive Chain / Drive Train / Drive Shaft: 9) Loosen the rear axle housing bolts (6) and chain Installation adjuster nut (7). Install the rear sprocket in the reverse order of removal. Pay attention to the following point. 10) Disengage the drive chain (8) from the rear sprocket. •...

  • Page 347: Rear Axle Nut And Lock-Nut Tightening Torque

    Drive Chain / Drive Train / Drive Shaft: 3A-7 • Install the rear sprocket assembly (1) to the axle shaft. • Tighten the rear axle lock-nut to the specified torque with the special tool. Refer to “Rear Axle Nut and •...

  • Page 348: Drive Chain Related Parts Inspection

    3A-8 Drive Chain / Drive Train / Drive Shaft: Drive Chain Related Parts Inspection Special tool B933H23106006 : 09922–22711 (Drive chain cutting and joining Refer to “Engine Sprocket Removal and Installation tool) (Page 3A-4)” and “Rear Sprocket Removal and Installation (Page 3A-5)”. Rear sprocket flange Inspect the rear sprocket flange for damage and wear of spline.
  • Page 349 Drive Chain / Drive Train / Drive Shaft: 3A-9 2) Place the drive chain link being disjointed on the Drive chain connecting holder part (8) of the tool. WARNING 3) Turn in both the adjuster bolt (6) and pressure bolt [A] (3) so that each of their end hole fits over the Do not use joint clip type of drive chain.
  • Page 350 3A-10 Drive Chain / Drive Train / Drive Shaft: 4) Apply grease on the recessed portion of the joint Joint pin staking plate holder (3) and set the joint plate (10). 1) Set up the special tool as shown in the figure. NOTE When positioning the joint plate (10) on the tool, its stamp mark must face the joint plate...

  • Page 351: Drive Chain Roller Construction

    Drive Chain / Drive Train / Drive Shaft: 3A-11 3) Adjust the drive chain slack, after connecting it. Refer to “Drive Chain Inspection and Adjustment in Section 0B (Page 0B-15)”. “a” I649G1310036-03 Drive Chain Roller Construction B933H23106008 I933H1310048-02 1. Drive chain roller 3.

  • Page 352: Drive Chain Roller Inspection

    3A-12 Drive Chain / Drive Train / Drive Shaft: Drive Chain Roller Inspection Rear Axle Housing Removal and Installation B933H23106009 B933H23106011 Inspect the drive chain roller bearings for abnormal noise and smooth rotation. Replace the drive chain control Removal roller bearings if there is anything unusual. Refer to 1) Remove the rear sprocket.

  • Page 353: Rear Axle Related Parts Inspection

    Drive Chain / Drive Train / Drive Shaft: 3A-13 6) Remove the boot (5). • Temporarily tighten the rear axle housing bolts. NOTE The rear axle housing bolts are different length. “A” I933H1310030-01 7) Remove the snap ring (6), washer (7) and nut (8). Special tool : 09900–06107 (Snap ring pliers) “B”...

  • Page 354: Rear Axle Dust Seal / Bearing Removal And Installation

    3A-14 Drive Chain / Drive Train / Drive Shaft: Boot Rear Axle Dust Seal / Bearing Removal and Inspect the boot for wear or damage. If any defects are Installation found, replace the boot with a new one. B933H23106013 Removal 1) Remove the rear axle housing.
  • Page 355 Drive Chain / Drive Train / Drive Shaft: 3A-15 Install the rear axle dust seal / bearing in the reverse • Install the dust seals with the special tool. order of removal. Pay attention to the following points. NOTE • First install the right bearing, then install the spacer (1) and left bearings with the special tools.

  • Page 356: Specifications

    3A-16 Drive Chain / Drive Train / Drive Shaft: Specifications Service Data B933H23107001 Drive train Unit: mm (in) Item Standard Limit Final reduction ratio 2.857 (40 / 14) — Type RK520SMOZ10S — Drive chain Links — 20 pitch length — 319.4 (12.57) Drive chain slack (on center stand) 30 –...

  • Page 357: Special Tools And Equipment

    Drive Chain / Drive Train / Drive Shaft: 3A-17 Special Tools and Equipment Recommended Service Material B933H23108001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 3A-6) / (Page 3A- equivalent Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
  • Page 358 3A-18 Drive Chain / Drive Train / Drive Shaft:...
  • Page 359 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Repair Instructions ..........4B-1 Front Brake Components ........4B-1 Precautions............. 4-1 Front Brake Pad Inspection.........4B-2 Precautions for Brake System ......4-1 Front Brake Pad Replacement......4B-2 Brake Fluid Information ......... 4-1 Front Brake Caliper Removal and Installation..4B-3 Brake Control System and Diagnosis ...
  • Page 360 4-ii Table of Contents Parking Brake Removal and Installation .....4D-2 Tightening Torque Specifications......4D-4 Parking Brake Inspection ........4D-3 Special Tools and Equipment ......4D-4 Specifications............4D-4 Recommended Service Material ......4D-4...

  • Page 361: Precautions

    Precautions: Precautions Brake Precautions Precautions for Brake System B933H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B933H24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.

  • Page 362: Brake Control System And Diagnosis

    4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B933H24102001 “ a ” “ a ” “E” “ b ” “ b ” Right side Left side “B” “F”...

  • Page 363: Rear Brake Hose Routing Diagram

    Brake Control System and Diagnosis: 4A-2 Rear Brake Hose Routing Diagram B933H24102002 “ b ” “ a ” “A” “B” “C” “ c ” “D” Forward “B” “C” “F” “E” Outside I933H1410056-05 1. Parking brake cable “B”: After the brake hose union has contacted the stopper, tighten the bolt to the specified torque. 2.

  • Page 364: Hose And Cable Routing Diagram

    4A-3 Brake Control System and Diagnosis: Hose and Cable Routing Diagram B933H24102003 “A” “B” “C” I933H1410057-05 1. Throttle cable 5. Reverse gear cable “A”: Pass the throttle cable inside the steering cover. 2. Starter cable 6. Reverse cable adjuster “B”: Pass the starter cable inside the steering cover. 3.
  • Page 365 Brake Control System and Diagnosis: 4A-4 “A” “B” “C” I933H1410058-01 1. Throttle cable 5. Parking brake cable “B”: Pass the starter cable between fuel hose and reverse gear cable. 2. Reverse gear cable 6. Starter cable “C”: Set the reverse gear cable between the oil filter case and engine sprocket cover.

  • Page 366: Diagnostic Information And Procedures

    4A-5 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B933H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads or disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Worn disc.

  • Page 367: Rear Brake Light Switch Inspection

    Brake Control System and Diagnosis: 4A-6 Brake Fluid Level Check Rear Brake Light Switch Inspection B933H24106005 B933H24106003 Inspect the rear brake light switch in the following Refer to “Brake System Inspection in Section 0B procedures: (Page 0B-17)”. 1) Remove the fuel tank cover. Refer to “Exterior Parts Brake Hose Inspection Removal and Installation in Section 9D (Page 9D- B933H24106006...
  • Page 368 4A-7 Brake Control System and Diagnosis: 2) Attach a hose to the air bleeder valve, and insert the 8) Fill the reservoir with brake fluid to the upper mark of free end of the hose into a receptacle. the reservoir. 3) Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.

  • Page 369: Brake Fluid Replacement

    Brake Control System and Diagnosis: 4A-8 • Fill the reservoir with brake fluid to the upper mark of 3) Fill the reservoir with new brake fluid. the reservoir. BF: Brake fluid (DOT 4) 4) Connect a clear hose to the air bleeder valve (1) and insert the other end of the hose into a receptacle.

  • Page 370: Brake Hose Removal And Installation

    4A-9 Brake Control System and Diagnosis: Rear brake 7) Close the air bleeder valve (1) and disconnect the clear hose. 1) Remove the fuel tank cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- Tightening torque 4)”.

  • Page 371: Front Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-10 Front Brake Master Cylinder Components B933H24106010 I933H1410060-04 1. Reservoir cap 6. Brake lever : Apply silicone grease. 2. Diaphragm 7. Brake lever pivot bolt : Apply brake fluid. 3. Master cylinder : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Do not reuse.

  • Page 372: Front Brake Master Cylinder Assembly Removal And Installation

    4A-11 Brake Control System and Diagnosis: Front Brake Master Cylinder Assembly Removal and Installation B933H24106011 Removal 1) Drain brake fluid. Refer to “Brake Fluid Replacement “C” (Page 4A-8)”. 2) Place a rag underneath the brake hose union bolt (1) on the master cylinder to catch any spilt brake fluid. 3) Remove the brake hose union bolt (1) and “B”...

  • Page 373: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-12 Front Brake Master Cylinder / Brake Lever 4) Remove the piston/cup set (7) and spring (8). Disassembly and Assembly B933H24106012 Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-11)”. Disassembly 1) Remove the reservoir cap (1) and diaphragm (2). I933H1410028-03 Assembly Assemble the master cylinder in the reverse order of...

  • Page 374: Front Brake Master Cylinder Parts Inspection

    • Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever. I933H1410033-01 : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) Piston and rubber parts Inspect the piston surface, primary/secondary cup and dust boot for any scratches, wear or damage.

  • Page 375: Rear Brake Pedal Construction

    Brake Control System and Diagnosis: 4A-14 Rear Brake Pedal Construction B933H24106014 “ a” I933H1410061-01 1. Brake pedal 5. White mark : Do not reuse. 2. Brake light switch : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) “a”: 5 mm (0.2 in) 3.

  • Page 376: Rear Brake Pedal Removal And Installation

    4A-15 Brake Control System and Diagnosis: Rear Brake Pedal Removal and Installation 6) Remove the rear brake pedal (9) and O-rings (10). B933H24106015 Removal 1) Remove the right footrest mud guard. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.

  • Page 377: Rear Brake Master Cylinder Components

    Brake Control System and Diagnosis: 4A-16 Rear Brake Master Cylinder Components B933H24106016 I933H1410062-06 1. Reservoir tank 6. Piston/cup set : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) 2. Brake hose union bolt 7. Push rod : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3.

  • Page 378: Rear Brake Master Cylinder Assembly Removal And Installation

    4A-17 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal 5) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-8)”. and Installation B933H24106017 6) Remove the reservoir mounting bolt (5). Removal 1) Remove the fuel tank cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 4)”.

  • Page 379: Rear Brake Master Cylinder Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-18 4) Remove the connector (6) and O-ring (7) by removing the snap ring (8). Special tool : 09900–06108 (Snap ring pliers) I933H1410040-03 • Bleed air from the brake system after reassembling the master cylinder. Refer to “Air Bleeding from Brake Fluid Circuit (Page 4A-6)”.

  • Page 380: Rear Brake Master Cylinder Parts Inspection

    Inspect the master cylinder bore for any scratches or BF: Brake fluid (DOT 4) other damage. I649G1410036-02 • Apply grease to the push rod end. I933H1410048-05 : Grease 99000–25100 (SUZUKI SILICONE Piston GREASE or equivalent) Inspect the piston surface for any scratches or other damage. Rubber parts Inspect the primary cup, secondary cup and dust boot for wear or damage.

  • Page 381: Service Data

    Brake Control System and Diagnosis: 4A-20 Specifications Service Data B933H24107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 0 – 10 (0 – 0.4) — Front 12.700 – 12.743 (0.5000 – 0.5017) — Master cylinder bore Rear 14.000 –...

  • Page 382: Special Tools And Equipment

    4A-21 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B933H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-8) / (Page 4A- 9) / (Page 4A-12) / (Page 4A-19) Grease SUZUKI Silicone Grease or P/No.: 99000–25100...

  • Page 383: Front Brakes

    Front Brakes: 4B-1 Front Brakes Brake Repair Instructions Front Brake Components B933H24206001 I933H1420001-07 1. Front brake caliper 8. Front brake disc : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 2. Piston seal 9. Brake pad spring : Apply thread lock to the thread part. 3.

  • Page 384: Front Brake Pad Inspection

    4B-2 Front Brakes: Front Brake Pad Inspection 5) Clean up the caliper especially around the caliper B933H24206002 piston. Refer to “Brake System Inspection in Section 0B 6) Install the new brake pads. (Page 0B-17)”. CAUTION Front Brake Pad Replacement Replace the brake pads as a set, otherwise B933H24206003 braking performance will be adversely 1) Remove the front wheel assembly.

  • Page 385: Front Brake Caliper Removal And Installation

    Front Brakes: 4B-3 9) Tighten the brake caliper mounting bolts (2) to the 4) Remove the brake caliper by removing the brake specified torque. caliper mounting bolts (2). Tightening torque Brake caliper mounting bolt (a): 26 N·m (2.6 kgf- m, 19.0 lb-ft) 10) Tighten the front brake pad mounting pins (1) to the specified torque.

  • Page 386: Front Brake Caliper Disassembly And Assembly

    4B-4 Front Brakes: • Bleed air from the brake system after installing the 4) Remove the dust seal (2) and piston seal (3). caliper. Refer to “Air Bleeding from Brake Fluid Circuit in Section 4A (Page 4A-6)”. • Install the front wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-2)”.
  • Page 387 • Apply silicone grease to the brake caliper holder slide I933H1420013-02 pin. 9) Remove the rubber boots (9). : Grease 99000–25100 (SUZUKI SILICONE NOTE GREASE or equivalent) If there is no abnormal condition, the rubber • Set the rubber boot onto the brake caliper holder slide boots removal is not necessary.

  • Page 388: Front Brake Caliper Parts Inspection

    4B-6 Front Brakes: • Tighten the brake caliper holder slide pin (1) to the • Apply the brake fluid to piston seal (4) and dust seal specified torque. (5). Tightening torque CAUTION Front brake caliper holder slide pin (b): 23 N·m ( Replace the piston seal (4) and dust seal (5) 2.3 kgf-m, 16.5 lb-ft) with new ones.
  • Page 389 Front Brakes: 4B-7 Brake caliper piston Brake caliper holder slide pin Inspect the brake caliper piston surface for any Inspect the brake caliper holder slide pin for wear or scratches or other damage. If any damage is found, damage. If any damage is found, replace it with a new replace the piston with a new one.

  • Page 390: Front Brake Disc Removal And Installation

    4B-8 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B933H24206007 B933H24206008 Brake Disc Thickness Removal 1) Dismount the front brake caliper. Refer to “Front 1) Remove the front wheel assembly. Refer to “Front / Brake Pad Replacement (Page 4B-2)”. Rear Wheel Removal and Installation in Section 2D 2) Inspect the brake disc for damage or cracks and (Page 2D-2)”.

  • Page 391: Front Brake Disc Cover Inspection

    Front Brakes: 4B-9 Front Brake Disc Cover Inspection B933H24206009 Inspect the front brake disc cover in the following procedures: 1) Remove the front brake disc cover. Refer to “Front Wheel Hub / Steering Knuckle Removal and Installation in Section 2B (Page 2B-6)”. 2) Inspect the brake disc cover for damage.

  • Page 392: Special Tools And Equipment

    4B-10 Front Brakes: Special Tools and Equipment Recommended Service Material B933H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-6) / (Page 4B- Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 4B-5) / (Page 4B-...

  • Page 393: Rear Brakes

    Rear Brakes: 4C-1 Rear Brakes Brake Repair Instructions Rear Brake Components B933H24306001 I933H1430001-09 1. Rear brake caliper 8. Front brake disc : Apply thread lock to the thread part. 2. Piston seal 9. Stopper ring : Apply thread lock to the thread part. 3.

  • Page 394: Rear Brake Pad Inspection

    4C-2 Rear Brakes: Rear Brake Pad Inspection 4) Remove the brake pads (5) by removing the pad B933H24306002 mounting pins (1) and lock washer (6). Refer to “Brake System Inspection in Section 0B (Page 0B-17)”. NOTE When removing the pads, push the piston all Rear Brake Pad Replacement the way into the brake caliper.

  • Page 395: Rear Brake Caliper Removal And Installation

    Rear Brakes: 4C-3 7) Install the new lock washer (6) and temporarily Rear Brake Caliper Removal and Installation tighten the pad mounting pins (1). B933H24306004 8) Apply a small quantity of thread lock to the brake Removal caliper mounting bolts (4). 1) Drain brake fluid.

  • Page 396: Rear Brake Caliper Disassembly And Assembly

    4C-4 Rear Brakes: Installation 4) Install the parking brake. Refer to “Parking Brake Removal and Installation in Section 4D (Page 4D- 1) Apply a small quantity of thread lock to the brake 2)”. caliper mounting bolts (1). 5) Bleed air from the brake system. Refer to “Air : Thread lock cement 99000–32030 Bleeding from Brake Fluid Circuit in Section 4A (THREAD LOCK CEMENT SUPER 1303 or...
  • Page 397 Rear Brakes: 4C-5 4) Remove the caliper holder pin (5). 6) Place a rag over the brake caliper piston to prevent the piston from popping out. NOTE 7) Force out the piston by pushing the piston pin (7). If there is no abnormal condition, the caliper holder pin removal is not necessary.
  • Page 398 • Apply silicone grease to the brake caliper holder pin • Apply the brake fluid to O-ring (1), piston seal (2) and and caliper holder slide pin. dust seal (3). : Grease 99000–25100 (SUZUKI SILICONE CAUTION GREASE or equivalent) Replace the O-ring (1), piston seal (2) and dust seal (3) with new ones.

  • Page 399: Rear Brake Caliper Parts Inspection

    Rear Brakes: 4C-7 • Apply thread lock to the brake caliper holder slide pin Rear Brake Caliper Parts Inspection (5). B933H24306006 Refer to “Rear Brake Caliper Disassembly and : Thread lock cement 99000–32030 Assembly (Page 4C-4)”. (THREAD LOCK CEMENT SUPER 1303 or equivalent) Brake caliper cylinder Inspect the brake caliper cylinder wall for nicks,...

  • Page 400: Rear Brake Disc Removal And Installation

    4C-8 Rear Brakes: Brake pad mounting pin Brake caliper holder Inspect the brake pad mounting pins for wear or • Inspect the brake caliper holder and pin for damage. If damage. If any defects are found, replace the mounting any damage is found, replace it with a new ones. pin with new ones.
  • Page 401 Rear Brakes: 4C-9 5) Push the rear brake disc plate housing (3) and • Install the stopper ring (1). remove the stopper ring (4). CAUTION 6) Remove the rear brake disc plate housing (3) from the rear axle. The removed stopper ring must be replaced with a new one.

  • Page 402: Rear Brake Disc Inspection

    4C-10 Rear Brakes: Rear Brake Disc Inspection B933H24306008 Brake disc thickness Inspect the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if defect is found. Special tool (A): 09900–20205 (Micrometer (0 –...

  • Page 403: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-6) /...

  • Page 404: Parking Brake

    4D-1 Parking Brake: Parking Brake Brake Repair Instructions Parking Brake Inspection and Adjustment B933H24406001 Refer to “Brake System Inspection in Section 0B (Page 0B-17)”. Parking Brake Cable Removal and Installation B933H24406002 Removal 1) Loosen the parking brake cable adjuster lock-nut (1) while holding the adjuster (2).

  • Page 405: Parking Brake Lock / Knob Removal And Installation

    1) When replacing the boot with a new one, apply B933H24406004 grease to the groove of parking brake axle. Refer to “Clutch Lever Removal and Installation in Section 5C (Page 5C-3)”. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) Parking Brake Removal and Installation B933H24406005 Removal 1) Loosen the lock-nut (1) and remove the parking brake adjuster (2).

  • Page 406: Parking Brake Inspection

    4D-3 Parking Brake: 4) Loosen the lock-nut (4) and turn the adjuster (5) in 8) Connect the parking cable (9). completely, so that the cable play is maximum. 9) Install the adjuster (10) and the lock-nut (11). I933H1440009-01 I933H1440012-03 5) Set the parking brake shaft (6) in neutral position by 10) Adjust the parking brake.

  • Page 407: Special Tools And Equipment

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H24408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SILICONE GREASE or P/No.: 99000–25100 (Page 4D-2)
  • Page 408 4D-5 Parking Brake:...
  • Page 409 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Specifications .............5B-19 Service Data............5B-19 Precautions............. 5-1 Tightening Torque Specifications......5B-19 Precautions for Transmission / Transaxle..... 5-1 Special Tools and Equipment ......5B-20 Manual Transmission......5B-1 Recommended Service Material .......5B-20 Special Tool ............5B-20 Diagnostic Information and Procedures....5B-1 Manual Transmission Symptom Diagnosis ..

  • Page 410: Precautions

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B933H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 411: Manual Transmission

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B933H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gears. Replace. seems to come from the Worn countershaft splines. Replace countershaft.

  • Page 412: Reverse Lock Cable Removal And Installation

    5B-2 Manual Transmission: Reverse Lock Cable Removal and Installation 5) Draw out the reverse lock release knob (6). B933H25206002 6) Disconnect the reverse lock cable (7) by remove the Removal rotor (8). 1) Remove the reverse lock release knob (1) from the front fender.
  • Page 413 Manual Transmission: 5B-3 Installation • Connect the reverse lock cable (3) to the rotor (4) Install the reverse lock cable in the reverse order of through the hole of the housing. removal. Pay attention to the following points: • Apply grease to the end of the reverse lock cable (3) •...

  • Page 414: Transmission Components

    5B-4 Manual Transmission: Transmission Components B933H25206003 I933H1520014-05...

  • Page 415: Transmission Removal And Installation

    Manual Transmission: 5B-5 1. Countershaft 11. Reverse driven gear 21. Reverse lock shaft 2. Top drive gear 12. 1st/reverse dog 22. Gear position switch 3. 3rd drive gear 13. 1st driven gear 23. Gearshift cam stopper plate 4. 4th drive gear 14.
  • Page 416 5B-6 Manual Transmission: Installation Reverse idle gear assembly / Driveshaft assembly / Countershaft assembly 1) Install the countershaft assembly (1) and driveshaft assembly (2). I933H1520022-01 I933H1520019-02 2) Install the reverse idle gear (3) and shaft (4). 3) Install the wave washer (5) and washer (6). I933H1520023-01 2.

  • Page 417: Transmission Construction

    Manual Transmission: 5B-7 Transmission Construction B933H25206005 I933H1520025-03 1. Countershaft 2. Driveshaft Countershaft Gear / Driveshaft Gear / Reverse Assembly Assembly the transmission in the reverse order of Idle Gear Disassembly and Assembly disassembly. Pay attention to the following points: B933H25206006 Refer to “Transmission Removal and Installation (Page 5B-5)”.

  • Page 418: Transmission Related Parts Inspection

    5B-8 Manual Transmission: CAUTION • Never reuse a snap ring. After a snap ring has been removed from the shaft, it should be discarded and a new snap ring must be installed. • When installing a new snap ring, do not expand the end gap larger than required to “A”...
  • Page 419 Manual Transmission: 5B-9 Gearshift cam bearing Inspect the gearshift cam bearings, left and right for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to “Transmission Oil Seal / Bearing Removal and Installation (Page 5B-10)”. I649G1520056-03 Gearshift fork groove width Measure the gearshift fork groove width using the...

  • Page 420: Transmission Oil Seal / Bearing Inspection

    5B-10 Manual Transmission: Transmission Oil Seal / Bearing Inspection Transmission Oil Seal / Bearing Removal and B933H25206008 Installation Refer to “Transmission Removal and Installation B933H25206009 (Page 5B-5)”. Removal Oil seal 1) Remove the transmission assembly. Refer to Inspect the oil seal lips for wear or damage. If any “Transmission Removal and Installation (Page 5B- defects are found, replace the oil seal with new ones.
  • Page 421 Manual Transmission: 5B-11 5) Remove the gearshift cam right bearing (5). Installation CAUTION The removed oil seals and bearings must be replaced with new ones. 1) Install the bearings using the special tool. Special tool (A): 09913–70210 (Bearing installer set) CAUTION •...

  • Page 422: Gear Position (Gp) Switch Inspection

    5B-12 Manual Transmission: 2) Install the gearshift cam right bearing (1). 6) Apply grease to the oil seal lips. : Grease 99000–25160 (Water resistance CAUTION grease or equivalent) The stamped mark side of bearing face inside. I933H1520044-02 7) Install the oil seal retainer (4). I933H1520042-01 3) Install the bearing retainers (2).
  • Page 423 Manual Transmission: 5B-13 3) Loosen the reverse lock release cable lock-nut (1) 7) Remove the switch contacts (6) and springs (7). and adjuster (2). I933H1520051-01 I933H1520047-01 Installation 4) Disconnect the reverse lock release cable (3) by Install the gear position switch in the reverse order of removing the mounting bolt.

  • Page 424: Gearshift Shaft / Gearshift Cam Plate Components

    5B-14 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Gearshift Shaft / Gearshift Cam Plate Removal Components and Installation B933H25206012 B933H25206014 Removal 1) Remove the engine sprocket cover. Refer to “Engine Sprocket Removal and Installation in Section 3A (Page 3A-4)”. 2) Remove the gearshift lever (1).
  • Page 425 Manual Transmission: 5B-15 5) Remove the gearshift return spring (7). 8) Remove the gearshift cam stopper plate bolt (14) and gearshift cam stopper plate (15). 9) Remove the gearshift cam stopper (16), washer and spring. I933H1520058-01 6) Remove the gearshift pawl lifter (8) and gearshift cam driven gear (9).
  • Page 426 5B-16 Manual Transmission: • Install the gearshift cam stopper (1), bolt (2), washer • Tighten the gearshift cam stopper plate bolt to the (3) and return spring (4). specified torque. • Tighten the gearshift cam stopper bolt (2). Tightening torque Gearshift cam stopper plate bolt (b): 24 N·m (2.4 NOTE kgf-m, 17.5 lb-ft)

  • Page 427: Gearshift Linkage Inspection

    Manual Transmission: 5B-17 • Apply a small quantity of thread lock to the gearshift • Install a new snap ring (14). pawl lifter screws, and then tighten the specified CAUTION torque. The removed snap ring (14) must be replaced : Thread lock cement 99000–32110 with a new one.

  • Page 428: Gearshift Shaft Oil Seal / Bearing Removal And Installation

    5B-18 Manual Transmission: Gearshift shaft oil seal 3) Remove the gearshift shaft oil seal (1). Inspect the gearshift shaft oil seal lip for damage or 4) Remove the bearing (2) with the special tools. wear. If any defect is found, replace the oil seal with a Special tool new one.

  • Page 429: Specifications

    Manual Transmission: 5B-19 Specifications Service Data B933H25207001 Transmission + Drive chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 2.960 (74/25) — Final reduction ratio 2.857 (40/14) — 2.538 (33/13) — 1.666 (30/18) — 1.238 (26/21) — Gear ratios 1.000 (23/23) —...

  • Page 430: Special Tools And Equipment

    5B-20 Manual Transmission: Special Tools and Equipment Recommended Service Material B933H25208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 5B-3) / (Page 5B- equivalent 3) / (Page 5B-12) / (Page 5B-13) / (Page 5B-18)

  • Page 431: Clutch

    Clutch: 5C-1 Clutch Transmission / Transaxle Precautions Precautions for Clutch System B933H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B933H25304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline.

  • Page 432: Clutch Cable Inspection And Adjustment

    5C-2 Clutch: Clutch Cable Inspection and Adjustment 4) Move the fuel pump (6). B933H25306002 5) Remove the clutch cable bracket (7) and disconnect Refer to “Clutch Inspection and Adjustment in Section the clutch cable (8). 0B (Page 0B-13)”. Clutch Cable Removal and Installation B933H25306003 Removal 1) Loosen the cable adjuster lock-nut (1) and adjuster...

  • Page 433: Clutch Lever Components

    Clutch: 5C-3 Clutch Lever Components B933H25306004 I933H1530008-03 1. Clutch lever 3. Parking knob : Apply grease. 2. Parking lock 4. Clutch lever position switch Clutch Lever Removal and Installation 2) Disconnect the clutch lever position switch coupler B933H25306005 (3). Removal 1) Disconnect the clutch cable (1) and parking brake cable (2).
  • Page 434 5C-4 Clutch: 4) Remove the screw (5), washer (6), parking knob (7) Installation and spring (8). Install the clutch lever in the reverse order of removal. Pay attention to the following points: • Apply grease to the clutch lever pivot bolt (1) and parking lock spacer (2).

  • Page 435: Clutch Release Camshaft Removal And Installation

    Clutch: 5C-5 Clutch Release Camshaft Removal and Installation Install the clutch release camshaft in the reverse order of Installation removal. Pay attention to the following points: B933H25306006 Removal CAUTION 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D The removed bearing and oil seal must be (Page 1D-13)”.

  • Page 436: Clutch Components

    5C-6 Clutch: Clutch Components B933H25306007 I933H1530021-02 1. Clutch pressure plate 6. Spring washer 11. Primary driven gear assembly 2. No. 3 drive plate 7. Spring washer seat 12. Push rod 3. No. 2 drive plate 8. Release bearing : 70 N⋅m (7.0 kgf-m, 50.5 lb-ft) 4.

  • Page 437: Clutch Removal

    Clutch: 5C-7 Clutch Removal 6) Remove the clutch springs and clutch pressure plate B933H25306008 (4). 1) Drain engine oil and coolant. Refer to “Engine Oil NOTE and Filter Replacement in Section 0B (Page 0B-11)” and “Cooling System Inspection in Section 0B Loosen the clutch spring set bolts little by (Page 0B-13)”.
  • Page 438 5C-8 Clutch: 8) Remove the clutch drive plates (5) and driven plates 12) Hold the clutch sleeve hub with the special tool. (6). Special tool (B): 09920–53740 (Clutch sleeve hub holder) 13) Remove the clutch sleeve hub nut. I933H1530027-01 9) Remove the spring washer (7) and its seat (8). I933H1530031-01 14) Remove the washer (11) and clutch sleeve hub (12).

  • Page 439: Clutch Installation

    Clutch: 5C-9 Clutch Installation 6) Install the clutch sleeve hub nut (6). B933H25306009 NOTE 1) Install the spacer (1). The concave side of clutch sleeve hub nut (6) 2) Apply engine oil to the spacer (1) and bushing of the faces inside.
  • Page 440 5C-10 Clutch: 11) Install the spring washer seat (9) and spring washer NOTE (10) onto the clutch sleeve hub correctly. Three kinds of the drive plate (No. 1, No. 2 and No. 3) are equipped in the clutch system, they can be distinguished by the inside diameter “D”.

  • Page 441: Clutch Parts Inspection

    Clutch: 5C-11 17) Install the clutch springs. 21) Connect the radiator outlet hose (19) securely. Refer to “Water Hose Routing Diagram in Section 1F 18) Tighten the clutch spring set bolts securely in (Page 1F-3)”. diagonal stages. I933H1530049-01 I933H1530046-01 22) Install the rear brake pedal. Refer to “Rear Brake 19) Install the gasket (17) and the dowel pins.
  • Page 442 5C-12 Clutch: Special tool Clutch release bearing (A): 09900–20102 (Vernier calipers (1/20 mm, Inspect the clutch release bearing for play, wear and 200 mm)) damage. Move the inner race by finger and inspect for smooth movement. If any defects are found, replace the Clutch drive plate claw width clutch release bearing with a new one.

  • Page 443: Specifications

    Clutch: 5C-13 Specifications Service Data B933H25307001 Clutch Unit: mm (in) Item Standard Limit Clutch cable play 5 – 10 (0.2 – 0.4) — No. 1, No. 2 & Clutch drive plate thickness 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) No.

  • Page 444: Special Tools And Equipment

    5C-14 Clutch: Special Tools and Equipment Recommended Service Material B933H25308001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 5C-5) equivalent NOTE Required service material is also described in the following. “Clutch Lever Components (Page 5C-3)”...
  • Page 445 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Handlebars Removal and Installation ....6B-3 Handlebars Inspection ........6B-5 Precautions............. 6-1 Steering Shaft / Tie-rod Removal and Precautions for Steering ........6-1 Installation ............6B-5 Steering General Diagnosis....6A-1 Steering Parts Inspection ........6B-10 Toe-out Adjustment...........6B-11 Diagnostic Information and Procedures....6A-1 Specifications .............6B-11...

  • Page 446: Precautions

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B933H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 447: Steering General Diagnosis

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B933H26104001 Condition Possible cause Correction / Reference Item Handling is too Heavy or Improper front wheel alignment. Adjust. Stiff Insufficiently lubricated. Lubricate. Low air pressure in front tires Adjust.

  • Page 448: Steering / Handlebar

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Steering / Handlebars Components B933H26206001 “A” “A” I933H1620001-09 1. Handlebar upper holder 10. Dust seal “A”: Apply handle grip bond. 2. Handlebars 11. Bushing : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 3.

  • Page 449: Handlebar Construction

    Steering / Handlebar: 6B-2 Handlebar Construction B933H26206002 “A” “C” “B” I933H1620048-02 1. Punch mark “A”: Align the edge of throttle case upper with punch mark on handlebars. 2. Handlebars “B”: Align the edge of clutch lever holder with punch mark on handlebars. 3.

  • Page 450: Handlebars Removal And Installation

    6B-3 Steering / Handlebar: Handlebars Removal and Installation 5) Remove the clutch lever assembly (4) and handlebar B933H26206003 switch box (5). Refer to “Front Suspension / Steering Assembly Construction in Section 2B (Page 2B-2)”. Removal 1) Remove the throttle lever case (1). I933H1620005-03 6) Remove the left grip (6) and starter lever (7).
  • Page 451 Steering / Handlebar: 6B-4 10) Remove the handlebar lower holder nuts and washer • Align the punch mark “B” on the handlebars with the (12). mating surface of handlebar holder. 11) Remove the handlebar lower holder (13). • First tighten the bolts (1) to the specified torque and then tighten the bolts (2) to the specified torque.

  • Page 452: Handlebars Inspection

    6B-5 Steering / Handlebar: • Connect the starter cable (3) to the starter lever. Handlebars Inspection B933H26206004 • Apply grease to the end of starter cable (3). Refer to “Handlebars Removal and Installation (Page 6B-3)”. : Grease 99000–25160 (Water resistance Inspect the handlebars for distortion or damage.
  • Page 453 Steering / Handlebar: 6B-6 9) Remove the steering shaft holders (7) and dust seals (8). I933H1620016-01 6) Disconnect wheel side tie-rod ends using the special tool. I933H1620020-01 10) Draw out the steering shaft (9). Special tool 11) Disconnect each tie-rod ends using the special tool. (A): 09942–72410 (Tie-rod end remover) Special tool (A): 09942–72410 (Tie-rod end remover)
  • Page 454 6B-7 Steering / Handlebar: 14) Remove the steering shaft (14). “A” I933H1620026-01 Installation I933H1620023-02 15) Remove the dust seal (15) from the steering shaft. Install the steering shaft/tie-rod in the reverse order of removal. Pay attention to the following points: •...
  • Page 455 Steering / Handlebar: 6B-8 • Temporarily install the lock-nuts (4), (5) and tie-rod • Apply grease to the dust seal lip and steering shaft end (6) to the tie-rod (7). holders before remounting the steering shaft holders. : Grease 99000–25160 (Water resistance NOTE grease or equivalent) The lock-nuts (4) have left-hand threads.
  • Page 456 6B-9 Steering / Handlebar: • Apply grease to the O-rings (8), and dust seal (9). • Install the new cotter pins (11). CAUTION CAUTION Replace the O-rings (8) with new ones. Replace the cotter pins (11) with new ones. : Grease 99000–25160 (Water resistance grease or equivalent) I933H1620036-03 I933H1620034-03...

  • Page 457: Steering Parts Inspection

    Steering / Handlebar: 6B-10 • Install the handlebars. Refer to “Handlebars Removal Tie-rod end and Installation (Page 6B-3)”. Inspect the tie-rod ends for smooth movement. If there are any abnormalities, replace the tie-rod ends with new • Check the steering moves smoothly. ones.

  • Page 458: Toe-Out Adjustment

    6B-11 Steering / Handlebar: Steering shaft bushing 3) Temporarily tighten the four lock-nuts. Inspect the steering shaft bushing for wear or damage. If 4) Check that the distance “C” and “D” are equal, as any defects are found, replace the steering shaft bushing shown.

  • Page 459: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H26208001 Material SUZUKI recommended product or Specification Note Grease Water resistance grease or P/No.: 99000–25160 (Page 6B-5) /...
  • Page 460 6B-13 Steering / Handlebar:...
  • Page 461 Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ..........9-1 Fuel Level Indicator Switch (Thermistor) Inspection............9C-2 Precautions............. 9-1 Engine Coolant Temperature Indicator Light Precautions for Electrical System ......9-1 Inspection............9C-3 Component Location ..........9-1 Engine Coolant Temperature Removal and Electrical Components Location ......

  • Page 462: Precautions

    9-1 Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B933H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B933H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”.

  • Page 463: Wiring Systems

    Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B933H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”.
  • Page 464 9A-2 Wiring Systems: I933H2910901-04...

  • Page 465: Wiring Harness Routing Diagram

    Wiring Systems: 9A-3 Wiring Harness Routing Diagram B933H29102002 “A” I933H1910903-08 1. Clamp 6. Clamp 11. Engine sprocket cover : Bind the wiring harness with the clamp. : Bind the brake light / taillight with the clamp. 2. Clamp 7. Clamp 12.
  • Page 466 9A-4 Wiring Systems: I933H1910904-01 1. Clamp 5. Starter motor : Bind the brake switch with the clamp. 2. Clamp 6. Wiring harness : Bind the handlebar switch (L), starter cable and clutch lever position switch. with the clamp. 3. Clamp 7.
  • Page 467 Wiring Systems: 9A-5 “ a ” “ b ” “ c ” I933H1910905-02 1. Starter motor lead wire 6. CKP sensor : 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft) 2. Battery ground wire : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft) 3.

  • Page 468: Specifications

    9A-6 Wiring Systems: Specifications Service Data B933H29107001 Electrical Unit: mm Item Specification Note Ignition 10 A Fuse size Cooling fan 10 A Main 20 A Tightening Torque Specifications B933H29107002 NOTE The specified tightening torque is also described in the following. “Wiring Harness Routing Diagram (Page 9A-3)”...

  • Page 469: Lighting Systems

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B933H29206001 I933H1920014-02 1. Headlight bulb (12 V 35/35 W)

  • Page 470: Headlight Removal And Installation

    9B-2 Lighting Systems: Headlight Removal and Installation 1) Remove the left side cover. Refer to “Exterior Parts B933H29206002 Removal and Installation in Section 9D (Page 9D- Removal 4)”. 1) Remove the headlight bulb. Refer to “Headlight Bulb 2) Remove the headlight adjusting bolt (1). Replacement (Page 9B-2)”.

  • Page 471: Headlight Beam Adjustment

    Lighting Systems: 9B-3 Headlight Beam Adjustment B933H29206004 Adjust the headlight beam in the following procedures: 1) Loosen the headlight adjusting bolt (1). 2) Move the headlight up or downwards and adjust the headlight beam vertically. I933H1920006-04 3) Tighten the headlight adjusting bolt (1). Rear Combination Light Components B933H29206005 I933H1920015-02...

  • Page 472: Rear Combination Light Removal And Installation

    9B-4 Lighting Systems: Rear Combination Light Removal and Rear Combination Light Bulb Replacement B933H29206007 Installation Replace the rear combination light bulb in the following B933H29206006 procedures: Removal 1) Disconnect the rear combination coupler (1) and CAUTION clamp. • When 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.

  • Page 473: Dimmer Switch Inspection

    Lighting Systems: 9B-5 Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a tester. B933H29206008 If any abnormality is found, replace the handlebar Inspect the dimmer switch in the following procedures: switch assembly with a new one. 1) Disconnect the headlight coupler (1). Refer to Refer to “Handlebars Removal and Installation in “Headlight Bulb Replacement (Page 9B-2)”.

  • Page 474: Combination Meter / Fuel Meter / Horn

    9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories Repair Instructions Indicator Light Components B933H29306001 I933H1930011-02 1. 12 V 1.7 W 2. 12 V 3.4 W Indicator Light Removal and Installation B933H29306002 CAUTION When disconnecting and reconnecting the...

  • Page 475: Indicator Light Replacement

    Combination Meter / Fuel Meter / Horn: 9C-2 2) Remove the steering head cover (2). Indicator Light Inspection B933H29306004 Check that the indicator lights (Fuel level indicator light and FI indicator light / Engine coolant temperature indicator light) immediately light up for two seconds when the ignition switch is turned to ON.

  • Page 476: Engine Coolant Temperature Indicator Light Inspection

    9C-3 Combination Meter / Fuel Meter / Horn: 3) When the switch is immersed in kerosene, the bulb 2) Connect the variable resistor (2) between the should go out. If the bulb remains lit, replace the unit terminals. with a new one. NOTE •...

  • Page 477: Ignition Switch Inspection

    Combination Meter / Fuel Meter / Horn: 9C-4 Ignition Switch Inspection 3) Inspect the ignition switch for continuity with a tester. B933H29306010 If any abnormality is found, replace the ignition Inspect the ignition switch in the following procedures: switch with a new one. 1) Remove the left side cover.

  • Page 478: Exterior Parts

    9D-1 Exterior Parts: Exterior Parts Body and Accessories Repair Instructions Exterior Parts Construction B933H29406001 I933H1940023-08 1. Fuel tank cover 4. Side cover (LH) 2. Side cover (RH) : 12 N⋅m (1.2 kgf-m, 8.5 lb-ft) 3. Front fender : Apply thread lock to thread part.
  • Page 479 Exterior Parts: 9D-2 I933H1940024-03 1. Rear fender 3. Mudguard (LH) 2. Mudguard (RH) : Apply thread lock to thread parts.

  • Page 480: Fuel Tank Cover Cushion Installation

    9D-3 Exterior Parts: Fuel Tank Cover Cushion Installation B933H29406002 I933H1940025-09...

  • Page 481: Fastener Removal And Installation

    Exterior Parts: 9D-4 Fastener Removal and Installation Exterior Parts Removal and Installation B933H29406003 B933H29406004 Removal Seat 1) Depress the head of fastener center piece (1). Removal 2) Pull out the fastener (2). Pull the seat lock lever (1) upward and remove the seat (2).
  • Page 482 9D-5 Exterior Parts: 2) Disconnect the ignition switch coupler (4). 7) Remove the front fender bracket (11), left and right. 3) Remove the screw (5). I933H1940010-01 I933H1940004-02 Installation 4) Remove the reverse selection knob (6) and screw Install the side cover and front fender in the reverse (7).
  • Page 483 Exterior Parts: 9D-6 Fuel tank cover Installation Removal 1) Install the mud guard reinforcement (1). 2) Apply thread lock to the mud guard reinforcements CAUTION mounting bolt (2), rear fender mounting screw (3) To prevent the fuel tank from contamination and footrest mounting bolt (4).
  • Page 484 9D-7 Exterior Parts: Rear fender 5) Disconnect the ignition fuse assembly (5), starter motor lead wire coupler (6) and clamp. Removal 6) Remove the rear fender (7). 1) Remove the seat. 2) Remove the fasteners (1) and screws (2). I933H1940019-01 I933H1940015-01 Installation Install the rear fender in the reverse order of removal.

  • Page 485: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H29408001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9D-5) /...

  • Page 486: Body Structure

    9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B933H29506001 I933H1950014-01 1. Frame 4. Rear grip 7. Battery plate 2. Seat rail 5. Seat rail mounting bolt : 66 N⋅m (6.6 kgf-m, 47.5 lb-ft) 3. Front grip 6.

  • Page 487: Footrest Removal And Installation

    Body Structure: 9E-2 Footrest Removal and Installation Installation B933H29506002 Install the front grip in the reverse order of removal. Removal Remove the footrests (1), left and right. Rear Grip Removal and Installation B933H29506004 Removal Remove the rear grip (1). I933H1950001-01 Installation 1) Install the footrest (1).

  • Page 488: Seat Rail Removal And Installation

    9E-3 Body Structure: Seat Rail Removal and Installation B933H29506005 Removal 1) Remove the seat and rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. 2) Remove the muffler. Refer to “Muffler / Exhaust Pipe Removal and Installation in Section 1K (Page 1K-3)”. 3) Remove the rear combination light.

  • Page 489: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-6)”. Special Tools and Equipment Recommended Service Material B933H29508001 Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 9E-2) /...
  • Page 492 Prepared by March, 2008 Part No. 99500-43080-03E Printed in Japan...

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