Мануал для suzuki bandit 250

Brand: Suzuki
|
Category: Motorcycle
|
Size: 55.77 MB

• Section 1 Engine

  65

  • General Information

    16

  • Fuel and Oil Recommendation

    19

  • Vehicle Identification Number

    19

  • Cylinder Identification

    20

  • Maintenance and Lubrication

    32

  • Scheduled Maintenance

    32

  • Lubrication Points

    33

  • Table of Contents

    65

  • Precautions

    69

    • Precautions for Engine

      69

  • Engine General Information and Diagnosis

    70

  • General Description

    70

    • Injection Timing Description

      70

    • Self-Diagnosis Function

      71

  • Schematic and Routing Diagram

    73

    • FI System Wiring Diagram

      73

    • Terminal Alignment of ECM Coupler

      74

  • Component Location

    75

    • FI System Parts Location

      75

  • Diagnostic Information and Procedures

    76

    • Engine Symptom Diagnosis

      76

    • Self-Diagnostic Procedures

      80

    • Use of SDS Diagnosis Reset Procedures

      82

    • Show Data When Trouble (Displaying Data at the Time of DTC)

      83

    • SDS Check

      84

    • DTC Table

      87

    • Fail-Safe Function Table

      89

    • FI System Troubleshooting

      90

    • Malfunction Code and Defective Condition Table

      91

      • DTC «C12» (P0335): CKP Sensor Circuit Malfunction

        94

      • DTC «C13» (P0105-H/L): IAP Sensor (No.1) Circuit Malfunction

        97

      • DTC «C14» (P0120-H/L): TP Sensor Circuit Malfunction

        106

      • DTC «C15» (P0115-H/L): ECT Sensor Circuit Malfunction

        114

      • DTC «C17» (P1750-H/L): IAP Sensor (No.2) Circuit Malfunction

        121

      • DTC «C21» (P0110-H/L): IAT Sensor Circuit Malfunction

        129

      • DTC «C23» (P1651-H/L): to Sensor Circuit Malfunction

        136

      • DTC «C24» (P0351), «C25» (P0352), «C26» (P0353) or «C27» (P0354): Ignition System Malfunction

        142

      • DTC «C28» (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction

        142

      • DTC «C29» (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction

        146

      • DTC «C31» (P0705): GP Switch Circuit Malfunction

        154

      • DTC «C32» (P0201), «C33» (P0202), «C34» (P0203) or «C35» (P0204): Fuel Injector Circuit Malfunction

        156

      • DTC «C40» (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction

        160

      • DTC «C41» (P0230-H/L): FP Relay Circuit Malfunction

        166

      • DTC «C41» (P2505): ECM Power Input Signal Malfunction

        169

      • DTC «C42» (P1650): IG Switch Circuit Malfunction

        171

      • DTC «C44» (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction

        171

      • DTC «C49» (P1656): PAIR Control Solenoid Valve Circuit Malfunction

        177

      • DTC «C60» (P0480): Cooling Fan Relay Circuit Malfunction

        180

  • Specifications

    183

    • Service Data

      183

  • Special Tools and Equipment

    184

    • Special Tool

      184

  • Emission Control Devices

    185

  • Precautions

    185

    • Precautions for Emission Control Devices

      185

  • General Description

    185

    • Fuel Injection System Description

      185

    • Crankcase Emission Control System Description

      186

    • Exhaust Emission Control System Description

      187

    • Noise Emission Control System Description

      187

  • Schematic and Routing Diagram

    188

    • PAIR System Hose Routing Diagram

      188

  • Repair Instructions

    189

    • Heated Oxygen Sensor (HO2S) Removal and Installation

      189

    • Heated Oxygen Sensor (HO2S) Inspection

      189

    • PAIR Reed Valve Removal and Installation

      190

    • PAIR Control Solenoid Valve Removal and Installation

      190

    • PAIR System Inspection

      190

    • Crankcase Breather (PCV) Hose Inspection

      192

    • Crankcase Breather (PCV) Hose / Cover / Separator Removal and Installation

      192

    • Crankcase Breather (PCV) Cover Inspection

      193

  • Specifications

    194

    • Service Data

      194

    • Tightening Torque Specifications

      194

  • Special Tools and Equipment

    194

    • Recommended Service Material

      194

    • Special Tool

      194

  • Engine Electrical Devices

    195

  • Precautions

    195

    • Precautions for Engine Electrical Device

      195

  • Component Location

    195

    • Engine Electrical Components Location

      195

  • Diagnostic Information and Procedures

    195

    • Engine Symptom Diagnosis

      195

  • Repair Instructions

    195

    • ECM Removal and Installation

      195

    • CKP Sensor Inspection

      195

    • IAP Sensor (No.1) Removal and Installation

      196

    • IAP / TP / IAT Sensor Inspection

      196

    • IAP / TP / IAT Sensor Removal and Installation

      196

    • ECT Sensor Removal and Installation

      196

    • ECT Sensor Inspection

      197

    • TO Sensor Removal and Installation

      197

    • TO Sensor Inspection

      197

    • STP Sensor Inspection

      197

    • STP Sensor Adjustment

      198

    • STP Sensor Removal and Installation

      198

    • STV Actuator Inspection

      199

    • STV Actuator Removal and Installation

      199

    • ISC Valve Inspection

      199

    • ISC Valve Removal and Installation

      199

    • ISC Valve Preset and Opening Initialization

      200

    • HO2 Sensor Inspection

      200

    • HO2 Sensor Removal and Installation

      200

    • GP Switch Inspection

      200

    • GP Switch Removal and Installation

      200

  • Specifications

    201

    • Service Data

      201

    • Tightening Torque Specifications

      202

  • Special Tools and Equipment

    202

    • Recommended Service Material

      202

    • Special Tool

      202

  • Engine Mechanical

    203

  • Schematic and Routing Diagram

    203

    • Camshaft and Sprocket Assembly Diagram

      203

    • Throttle Cable Routing Diagram

      204

  • Diagnostic Information and Procedures

    205

    • Engine Mechanical Symptom Diagnosis

      205

    • Compression Pressure Check

      205

  • Repair Instructions

    206

    • Engine Components Removable with the Engine in Place

      206

    • Air Cleaner Element Removal and Installation

      208

    • Air Cleaner Element Inspection and Cleaning

      208

    • Air Cleaner Box Removal and Installation

      208

    • Throttle Cable Removal and Installation

      208

    • Throttle Cable Inspection

      209

    • Throttle Cable Play Inspection and Adjustment

      209

    • Throttle Body Components

      209

    • Throttle Body Construction

      210

    • Throttle Body Removal and Installation

      211

    • Throttle Body Disassembly and Assembly

      212

    • Throttle Body Inspection and Cleaning

      217

    • Throttle Valve Synchronization

      217

    • Engine Assembly Removal

      219

    • Engine Assembly Installation

      223

    • Tightening Torque

      224

    • Engine Top Side Disassembly

      226

    • Engine Top Side Assembly

      230

    • Valve Clearance Inspection and Adjustment

      238

    • Camshaft Inspection

      238

    • Camshaft Sprocket Inspection

      240

    • Camshaft Sprocket Removal and Installation

      240

    • Cam Chain Tension Adjuster Inspection

      241

    • Cam Chain Guide Removal and Installation

      241

    • Cam Chain Guide Inspection

      241

    • Cam Chain Tensioner Inspection

      242

    • Cylinder Head Disassembly and Assembly

      242

    • Cylinder Head Related Parts Inspection

      246

    • Valve Guide Replacement

      249

    • Valve Seat Repair

      250

    • Cylinder Disassembly and Assembly

      250

    • Cylinder Inspection

      252

    • Piston Ring Removal and Installation

      253

    • Piston and Piston Ring Inspection

      254

    • Engine Bottom Side Disassembly

      255

    • Engine Bottom Side Assembly

      263

    • Crank Balancer Disassembly and Assembly

      274

    • Crank Balancer Inspection

      275

    • Conrod Removal and Installation

      276

    • Conrod and Crankshaft Inspection

      277

    • Conrod Crank Pin Bearing Inspection and Selection

      278

    • Crankshaft Journal Bearing Inspection and Selection

      280

    • Crankshaft Thrust Clearance Inspection and Selection

      282

  • Specifications

    285

    • Service Data

      285

    • Tightening Torque Specifications

      286

  • Special Tools and Equipment

    287

    • Recommended Service Material

      287

    • Special Tool

      288

  • Engine Lubrication System

    291

  • Precautions

    291

    • Precautions for Engine Oil

      291

  • Schematic and Routing Diagram

    292

    • Engine Lubrication System Chart Diagram

      292

    • Oil Pan

      292

  • Diagnostic Information and Procedures

    293

    • Engine Lubrication Symptom Diagnosis

      293

    • Oil Pressure Check

      293

  • Repair Instructions

    294

    • Engine Oil and Filter Replacement

      294

    • Engine Oil Level Inspection

      294

    • Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation

      294

    • Oil Pressure Regulator / Oil Strainer Inspection

      296

    • Oil Cooler Removal and Installation

      297

    • Oil Pressure Switch Removal and Installation

      297

    • Oil Pressure Switch Inspection

      298

    • Oil Jet Removal and Installation

      298

    • Oil Gallery Jet Removal and Installation

      300

    • Oil Jet / Oil Gallery Jet Inspection

      300

    • Oil Pump Removal and Installation

      301

    • Oil Pump Inspection

      303

  • Specifications

    303

    • Service Data

      303

    • Tightening Torque Specifications

      303

  • Special Tools and Equipment

    304

    • Recommended Service Material

      304

    • Special Tool

      304

  • Engine Cooling System

    305

  • Precautions

    305

    • Precautions for Engine Cooling System

      305

    • Precautions for Engine Coolant

      305

  • General Description

    305

    • Engine Coolant Description

      305

  • Schematic and Routing Diagram

    306

    • Cooling Circuit Diagram

      306

    • Water Hose Routing Diagram

      307

  • Diagnostic Information and Procedures

    308

    • Engine Cooling Symptom Diagnosis

      308

  • Repair Instructions

    308

    • Cooling Circuit Inspection

      308

    • Radiator Cap Inspection

      309

    • Radiator Inspection and Cleaning

      309

    • Radiator / Cooling Fan Motor Removal and Installation

      309

    • Water Hose Inspection

      310

    • Water Hose Removal and Installation

      311

    • Radiator Reservoir Tank Inspection

      311

    • Radiator Reservoir Tank Removal and Installation

      312

    • Cooling Fan Inspection

      312

    • Cooling Fan Relay Inspection

      313

    • ECT Sensor Removal and Installation

      313

    • ECT Sensor Inspection

      313

    • Thermostat Connector / Thermostat Removal and Installation

      313

    • Thermostat Inspection

      315

    • Water Pump Components

      316

    • Water Pump Construction

      316

    • Water Pump Removal and Installation

      317

    • Water Pump Disassembly and Assembly

      318

    • Water Pump Related Parts Inspection

      321

  • Specifications

    322

    • Service Data

      322

    • Tightening Torque Specifications

      322

  • Special Tools and Equipment

    323

    • Recommended Service Material

      323

    • Special Tool

      323

  • Fuel System

    324

  • Precautions

    324

    • Precautions for Fuel System

      324

  • General Description

    325

    • Fuel System Description

      325

  • Schematic and Routing Diagram

    326

    • Fuel Tank Drain Hose and Breather Hose Routing Diagram

      326

  • Diagnostic Information and Procedures

    327

    • Fuel System Diagnosis

      327

  • Repair Instructions

    328

    • Fuel Pressure Inspection

      328

    • Fuel Pump Inspection

      328

    • Fuel Discharge Amount Inspection

      329

    • Fuel Pump Relay Inspection

      330

    • Fuel Hose Inspection

      330

    • Fuel Level Gauge Inspection

      330

    • Fuel Level Indicator Inspection

      330

    • Fuel Level Indicator Switch (Thermistor) Inspection

      330

    • Fuel Tank Construction

      331

    • Fuel Tank Removal and Installation

      332

    • Fuel Pump Components

      333

    • Fuel Pump Assembly / Fuel Level Gauge Removal and Installation

      334

    • Fuel Pump Disassembly and Assembly

      335

    • Fuel Mesh Filter Inspection and Cleaning

      337

    • Fuel Injector / Fuel Delivery Pipe / T-Joint Removal and Installation

      337

    • Fuel Injector Inspection and Cleaning

      337

  • Specifications

    338

    • Service Data

      338

    • Tightening Torque Specifications

      338

  • Special Tools and Equipment

    339

    • Recommended Service Material

      339

    • Special Tool

      339

  • Ignition System

    340

  • Schematic and Routing Diagram

    340

    • Ignition System Diagram

      340

    • Ignition System Components Location

      340

  • Diagnostic Information and Procedures

    341

    • Ignition System Symptom Diagnosis

      341

    • No Spark or Poor Spark

      342

  • Repair Instructions

    343

    • Ignition Coil / Plug Cap and Spark Plug Removal and Installation

      343

    • Spark Plug Inspection and Cleaning

      344

    • Ignition Coil / Plug Cap Inspection

      344

    • CKP Sensor Inspection

      346

    • CKP Sensor Removal and Installation

      347

    • Engine Stop Switch Inspection

      347

    • Ignition Switch Inspection

      348

    • Ignition Switch Removal and Installation

      348

  • Specifications

    350

    • Service Data

      350

    • Tightening Torque Specifications

      350

  • Special Tools and Equipment

    350

    • Special Tool

      350

  • Starting System

    351

  • Schematic and Routing Diagram

    351

    • Starting System Diagram

      351

  • Component Location

    351

    • Starting System Components Location

      351

  • Diagnostic Information and Procedures

    351

    • Starting System Symptom Diagnosis

      351

    • Starter Motor will Not Run

      352

    • Starter Motor Runs but Does Not Crank the Engine

      352

  • Repair Instructions

    353

    • Starter Motor Components

      353

    • Starter Motor Removal and Installation

      354

    • Starter Motor Disassembly and Assembly

      355

    • Starter Motor Inspection

      356

    • Starter Relay Removal and Installation

      357

    • Starter Relay Inspection

      357

    • Turn Signal / Side-Stand Relay Removal and Installation

      358

    • Side-Stand / Ignition Interlock System Parts Inspection

      358

    • Starter Clutch Removal and Installation

      360

    • Starter Clutch Inspection

      362

    • Starter Button Inspection

      363

  • Specifications

    363

    • Service Data

      363

    • Tightening Torque Specifications

      363

  • Special Tools and Equipment

    364

    • Recommended Service Material

      364

    • Special Tool

      364

  • Charging System

    365

  • Schematic and Routing Diagram

    365

    • Charging System Diagram

      365

  • Component Location

    365

    • Charging System Components Location

      365

  • Diagnostic Information and Procedures

    365

    • Charging System Symptom Diagnosis

      365

    • Battery Runs down Quickly

      366

  • Repair Instructions

    367

    • Battery Current Leakage Inspection

      367

    • Regulated Voltage Inspection

      367

    • Generator Inspection

      367

    • Generator Removal and Installation

      368

    • Regulator / Rectifier Construction

      372

    • Regulator / Rectifier Inspection

      372

    • Battery Components

      373

    • Battery Charging

      373

    • Battery Removal and Installation

      376

    • Battery Visual Inspection

      376

  • Specifications

    377

    • Service Data

      377

    • Tightening Torque Specifications

      377

  • Special Tools and Equipment

    378

    • Recommended Service Material

      378

    • Special Tool

      378

  • Exhaust System

    379

  • Precautions

    379

    • Precautions for Exhaust System

      379

  • Repair Instructions

    380

    • Exhaust System Construction

      380

    • Exhaust Pipe / Muffler Removal and Installation

      381

    • Exhaust System Inspection

      384

  • Specifications

    384

    • Tightening Torque Specifications

      384

  • Special Tools and Equipment

    384

    • Recommended Service Material

      384

• Section 2 Suspension

  385

  • Precautions

    386

    • Precautions for Suspension

      386

  • Suspension General Diagnosis

    387

  • Diagnostic Information and Procedures

    387

    • Suspension and Wheel Symptom Diagnosis

      387

  • Repair Instructions

    388

    • Front Fork Components

      388

    • Front Fork Removal and Installation

      389

    • Front Fork Inspection

      390

    • Front Fork Adjustment

      391

    • Front Fork Disassembly and Assembly

      391

    • Front Fork Parts Inspection

      396

  • Front Suspension

    388

  • Specifications

    397

    • Service Data

      397

    • Tightening Torque Specifications

      397

  • Special Tools and Equipment

    398

    • Recommended Service Material

      398

    • Special Tool

      398

  • Rear Suspension

    399

  • Repair Instructions

    399

    • Rear Suspension Components

      399

    • Rear Suspension Assembly Construction

      400

    • Rear Shock Absorber Removal and Installation

      401

    • Rear Suspension Inspection

      401

    • Rear Shock Absorber Inspection

      402

    • Rear Suspension Adjustment

      402

    • Rear Shock Absorber Disposal

      402

    • Cushion Lever Removal and Installation

      403

    • Cushion Lever Inspection

      404

    • Cushion Lever Bearing Removal and Installation

      404

    • Swingarm / Cushion Rod Removal and Installation

      405

    • Swingarm Related Parts Inspection

      407

    • Swingarm Bearing Removal and Installation

      408

  • Specifications

    410

    • Service Data

      410

    • Tightening Torque Specifications

      410

  • Special Tools and Equipment

    411

    • Recommended Service Material

      411

    • Special Tool

      411

  • Wheels and Tires

    412

  • Precautions

    412

    • Precautions for Wheel and Tire

      412

  • Repair Instructions

    413

    • Front Wheel Components

      413

    • Front Wheel Assembly Construction

      415

    • Front Wheel Assembly Removal and Installation

      417

    • Front Wheel Related Parts Inspection

      419

    • Front Wheel Dust Seal / Bearing Removal and Installation

      420

    • Rear Wheel Components

      423

    • Rear Wheel Assembly Construction

      425

    • Rear Wheel Assembly Removal and Installation

      427

    • Rear Wheel Related Parts Inspection

      428

    • Rear Wheel Dust Seal / Bearing Removal and Installation

      429

    • Tire Removal and Installation

      431

    • Wheel / Tire / Air Valve Inspection and Cleaning

      432

    • Air Valve Removal and Installation

      433

    • Wheel Balance Check and Adjustment

      434

  • Specifications

    434

    • Service Data

      434

    • Tightening Torque Specifications

      435

  • Special Tools and Equipment

    435

    • Recommended Service Material

      435

    • Special Tool

      435

• Section 3 Driveline / Axle

  437

  • Precautions

    438

    • Precautions for Driveline / Axle

      438

  • Diagnostic Information and Procedures

    439

    • Drive Chain and Sprocket Symptom Diagnosis

      439

  • Repair Instructions

    439

    • Drive Chain Related Components

      439

    • Engine Sprocket Removal and Installation

      440

    • Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation

      442

    • Drive Chain Related Parts Inspection

      443

    • Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation

      444

    • Drive Chain Replacement

      445

  • Drive Chain / Drive Train / Drive Shaft

    439

  • Specifications

    448

    • Service Data

      448

    • Tightening Torque Specifications

      448

  • Special Tools and Equipment

    449

    • Recommended Service Material

      449

    • Special Tool

      449

• Section 4 Brake

  451

  • Precautions

    453

    • Precautions for Brake System

      453

    • Brake Fluid Information

      453

  • Brake Control System and Diagnosis

    454

  • Schematic and Routing Diagram

    454

    • Front Brake Hose Routing Diagram

      454

    • Rear Brake Hose Routing Diagram

      458

  • Repair Instructions

    460

    • Brake Pedal Height Inspection and Adjustment

      460

    • Front Brake Light Switch Inspection

      460

    • Rear Brake Light Switch Inspection

      461

    • Rear Brake Light Switch Inspection and Adjustment

      461

    • Brake Fluid Level Check

      461

    • Brake Hose Inspection

      461

    • Air Bleeding from Brake Fluid Circuit

      461

    • Brake Fluid Replacement

      463

    • Front Brake Hose Removal and Installation

      465

    • Rear Brake Hose Removal and Installation

      466

    • Front Brake Master Cylinder Components

      467

    • Front Brake Master Cylinder Assembly Removal and Installation

      467

    • Front Brake Master Cylinder / Brake Lever Disassembly and Assembly

      468

    • Front Brake Master Cylinder Parts Inspection

      470

    • Rear Brake Master Cylinder Components

      471

    • Rear Brake Master Cylinder Assembly Removal and Installation

      471

    • Rear Brake Master Cylinder Disassembly and Assembly

      472

    • Rear Brake Master Cylinder Parts Inspection

      473

  • Diagnostic Information and Procedures

    460

    • Brake Symptom Diagnosis

      460

  • Specifications

    474

    • Service Data

      474

    • Tightening Torque Specifications

      474

  • Special Tools and Equipment

    475

    • Recommended Service Material

      475

    • Special Tool

      475

  • Front Brakes

    476

  • Repair Instructions

    476

    • Front Brake Components

      476

    • Front Brake Pad Inspection

      477

    • Front Brake Pad Replacement

      477

    • Front Brake Caliper Removal and Installation

      478

    • Front Brake Caliper Disassembly and Assembly

      479

    • Front Brake Caliper Parts Inspection

      481

    • Front Brake Disc Removal and Installation

      482

    • Front Brake Disc Inspection

      482

  • Specifications

    483

    • Service Data

      483

    • Tightening Torque Specifications

      483

  • Special Tools and Equipment

    484

    • Recommended Service Material

      484

    • Special Tool

      484

  • Repair Instructions

    485

    • Rear Brake Components

      485

    • Rear Brake Pad Inspection

      486

    • Rear Brake Pad Replacement

      486

    • Rear Brake Caliper Removal and Installation

      488

    • Rear Brake Caliper Disassembly and Assembly

      488

    • Rear Brake Caliper Parts Inspection

      490

    • Rear Brake Disc Removal and Installation

      491

    • Rear Brake Disc Inspection

      491

  • Rear Brakes

    485

  • Specifications

    492

    • Service Data

      492

    • Tightening Torque Specifications

      492

  • Special Tools and Equipment

    493

    • Recommended Service Material

      493

    • Special Tool

      493

  • Precautions

    494

    • Precautions for ABS

      494

    • ABS Information

      494

  • General Description

    494

    • Wheel Speed Sensor Description

      494

    • ABS Control Unit Description

      495

    • Hydraulic Unit (HU) Description

      497

    • Self-Diagnosis Function and ABS Indicator Light Description

      498

    • Fail-Safe Function Description

      499

  • Abs

    494

  • Schematic and Routing Diagram

    500

    • ABS Wiring Diagram

      500

    • ABS Unit Diagram

      501

    • Front Wheel Speed Sensor Routing Diagram

      502

    • Rear Wheel Speed Sensor Routing Diagram

      504

  • Component Location

    505

    • ABS Components Location

      505

  • Diagnostic Information and Procedures

    506

    • ABS Troubleshooting

      506

    • Pre-Diagnosis Inspection

      508

    • ABS Indicator Light Inspection

      510

    • DTC (Diagnostic Trouble Code) Output

      516

    • DTC (Diagnostic Trouble Code) Deleting

      518

    • SDS Check

      522

    • Active Control Inspection

      523

    • DTC Table

      527

      • DTC «13» (C1613): Wheel Speed Sensor Rotor Malfunction

        528

      • DTC «14» (C1614): Wheel Speed Sensor Rotor Malfunction

        530

      • DTC «22» (C1622): ABS Actuator Circuit Malfunction

        532

      • DTC «23» (C1623): ABS Actuator Circuit Malfunction

        534

      • DTC «25» (C1625): Wheel Speed Sensor Related Malfunction

        536

      • DTC «35» (C1635): ABS Motor Malfunction

        538

      • DTC «41» (C1641): Wheel Speed Sensor Signal Malfunction

        540

      • DTC «42» (C1642): Wheel Speed Sensor Circuit Open

        542

      • DTC «43» (C1643): Wheel Speed Sensor Circuit Short

        546

      • DTC «44» (C1644): Wheel Speed Sensor Signal Malfunction

        548

      • DTC «45» (C1645): Wheel Speed Sensor Circuit Open

        550

      • DTC «46» (C1646): Wheel Speed Sensor Circuit Short

        554

      • DTC «47» (C1647): Supply Voltage (Increased)

        556

      • DTC «48» (C1648): Supply Voltage (Decreased)

        558

      • DTC «55» (C1655): ABS Control Unit Malfunction

        560

      • DTC «61» (C1661): ABS Solenoid Malfunction

        562

  • Repair Instructions

    563

    • ABS Control Unit Coupler Disconnect and Connect

      563

    • Front Wheel Speed Sensor Removal and Installation

      564

    • Rear Wheel Speed Sensor Removal and Installation

      564

    • Front Wheel Speed Sensor Rotor Removal and Installation

      565

    • Rear Wheel Speed Sensor Rotor Removal and Installation

      566

    • Wheel Speed Sensor and Sensor Rotor Inspection

      567

    • ABS Control Unit/Hu Removal and Installation

      567

  • Specifications

    569

    • Tightening Torque Specifications

      569

  • Special Tools and Equipment

    569

    • Special Tool

      569

• Section 5 Transmission / Transaxle

  571

  • Precautions

    572

    • Precautions for Transmission / Transaxle

      572

  • Diagnostic Information and Procedures

    573

    • Manual Transmission Symptom Diagnosis

      573

  • Manual Transmission

    573

  • Repair Instructions

    574

    • Transmission Components

      574

    • Transmission Removal

      575

    • Transmission Installation

      577

    • Transmission Construction

      580

    • Countershaft Gear / Driveshaft Gear Disassembly and Assembly

      581

    • Transmission Related Parts Inspection

      584

    • Gear Position (GP) Switch Inspection

      584

    • Gear Position (GP) Switch Removal and Installation

      584

    • Gearshift Lever Construction

      585

    • Gearshift Lever Removal and Installation

      586

    • Gearshift Lever Height Inspection and Adjustment

      586

    • Gearshift Shaft / Gearshift Cam Plate Components

      586

    • Gearshift Construction

      587

    • Gearshift Shaft / Gearshift Cam Plate Removal and Installation

      587

    • Gearshift Linkage Inspection

      590

    • Gearshift Shaft Oil Seal / Bearing Removal and Installation

      591

  • Specifications

    592

    • Service Data

      592

    • Tightening Torque Specifications

      592

  • Special Tools and Equipment

    593

    • Recommended Service Material

      593

    • Special Tool

      593

  • Precautions

    594

    • Precautions for Clutch System

      594

    • Clutch Fluid (Brake Fluid) Information

      594

  • Clutch

    594

  • Schematic and Routing Diagram

    595

    • Clutch Hose Routing Diagram

      595

  • Repair Instructions

    596

    • Clutch Lever Position Switch Inspection

      596

    • Clutch Fluid Level Check

      596

    • Clutch Hose Inspection

      596

    • Air Bleeding from Clutch Fluid Circuit

      597

    • Clutch Fluid Replacement

      597

    • Clutch Hose Removal and Installation

      598

    • Clutch Control System Components

      599

    • Clutch Master Cylinder Assembly Removal and Installation

      600

    • Clutch Master Cylinder / Clutch Lever Disassembly and Assembly

      601

    • Clutch Master Cylinder Parts Inspection

      603

    • Clutch Release Cylinder / Push Rod Removal and Installation

      603

    • Clutch Push Rod (Left) Inspection

      604

    • Clutch Release Cylinder Disassembly and Assembly

      604

    • Clutch Release Cylinder Inspection

      604

    • Clutch Components

      605

    • Clutch Removal

      606

    • Clutch Installation

      607

    • Clutch Parts Inspection

      611

  • Diagnostic Information and Procedures

    596

    • Clutch System Symptom Diagnosis

      596

  • Specifications

    612

    • Service Data

      612

    • Tightening Torque Specifications

      612

  • Special Tools and Equipment

    613

    • Recommended Service Material

      613

    • Special Tool

      613

• Section 6 Steering

  615

  • Precautions

    616

    • Precautions for Steering

      616

  • Steering General Diagnosis

    617

  • Diagnostic Information and Procedures

    617

    • Steering Symptom Diagnosis

      617

  • Repair Instructions

    618

    • Handlebar Components

      618

    • Handlebar Construction

      619

    • Handlebar Removal and Installation

      620

    • Handlebars Inspection

      621

    • Steering Components

      622

    • Steering Removal and Installation

      623

    • Steering Related Parts Inspection

      626

    • Steering System Inspection

      626

    • Steering Stem Bearing Removal and Installation

      626

    • Steering Tension Adjustment

      627

  • Steering / Handlebar

    618

  • Specifications

    628

    • Tightening Torque Specifications

      628

  • Special Tools and Equipment

    629

    • Recommended Service Material

      629

    • Special Tool

      629

• Section 9 Body and Accessories

  631

  • Precautions

    633

    • Precautions for Electrical System

      633

  • Component Location

    633

    • Electrical Components Location

      633

  • Schematic and Routing Diagram

    634

    • Wiring Diagram (GSF1250)

      634

    • Wiring Diagram (GSF1250S)

      636

    • Wiring Diagram (GSF1250A)

      638

    • Wiring Diagram (GSF1250SA)

      639

    • Wiring Harness Routing Diagram

      641

  • Wiring Systems

    634

  • Specifications

    644

    • Service Data

      644

    • Tightening Torque Specifications

      644

  • Repair Instructions

    645

    • Headlight Components

      645

    • Headlight Removal and Installation

      646

    • Headlight Bulb Replacement

      647

    • Headlight Beam Adjustment

      649

    • Rear Combination Light Components

      649

    • Rear Combination Light Construction

      650

    • Rear Combination Light Removal and Installation

      650

    • Brake Light Bulb / Taillight Bulb Replacement

      651

    • License Plate Light Components

      651

    • License Plate Light Removal and Installation

      652

    • License Plate Light Bulb Replacement

      652

    • Turn Signal Light Components

      653

    • Front Turn Signal Light Removal and Installation

      653

    • Rear Turn Signal Light Removal and Installation

      654

    • Turn Signal Light Bulb Replacement

      654

    • Reflex Refractor Construction

      654

    • Turn Signal / Side-Stand Relay Inspection

      655

    • Turn Signal / Side-Stand Relay Removal and Installation

      655

    • Hazard Switch Inspection

      655

    • Turn Signal Switch Inspection

      655

    • Passing Light Switch Inspection

      656

    • Dimmer Switch Inspection

      656

  • Lighting Systems

    645

  • Special Tools and Equipment

    657

    • Special Tool

      657

  • Specifications

    657

    • Service Data

      657

    • Tightening Torque Specifications

      657

  • Combination Meter / Fuel Meter / Horn

    658

  • General Description

    658

    • Combination Meter System Description

      658

  • Repair Instructions

    659

    • Combination Meter Components

      659

    • Combination Meter Removal and Installation

      661

    • Combination Meter Disassembly and Assembly

      661

    • Combination Meter Inspection

      662

    • Engine Coolant Temperature Indicator Light Inspection

      662

    • Engine Coolant Temperature Removal and Installation

      663

    • Fuel Level Indicator Inspection

      663

    • Fuel Level Indicator Switch (Thermistor) Inspection

      664

    • Fuel Level Gauge Inspection

      665

    • Speedometer Inspection

      665

    • Speed Sensor Removal and Installation

      665

    • Speed Sensor Inspection

      666

    • Oil Pressure Indicator Inspection

      666

    • Oil Pressure Switch Removal and Installation

      667

    • Ignition Switch Inspection

      667

    • Ignition Switch Removal and Installation

      667

    • Horn Inspection

      667

    • Horn Removal and Installation

      668

  • Special Tools and Equipment

    669

    • Special Tool

      669

  • Specifications

    669

    • Service Data

      669

    • Tightening Torque Specifications

      669

  • Exterior Parts

    670

  • Schematic and Routing Diagram

    670

    • Seat Lock Cable Routing Diagram

      670

  • Repair Instructions

    671

    • Exterior Parts Construction

      671

    • Front Fender Construction

      673

    • Frame Cover Cushion Construction

      673

    • Engine Sprocket Outer Cover Cushion Construction

      674

    • Fastener Removal and Installation

      674

    • Exterior Parts Removal and Installation

      675

    • Seat Height Adjustment

      678

  • Body Structure

    679

  • Repair Instructions

    679

    • Body Frame Construction

      679

    • Engine Mounting Bracket Bushing Replacement

      679

      • Engine Mount Bushing Replacement

        680

      • Front Footrest Bracket Construction

        680

      • Side-Stand Construction

        681

      • Side-Stand Removal and Installation

        682

      • Center Stand Construction

        682

      • Center Stand Removal and Installation

        682

  • Specifications

    683

    • Tightening Torque Specifications

      683

  • Special Tools and Equipment

    683

    • Recommended Service Material

      683

Brand: Suzuki
|
Category: Motorcycle
|
Size: 36.41 MB

• Break-In (Running-In)

  2

• Table of Contents

  3

• Table of Contents

  4

• Consumer Information

  4

• Accessory Information and Precaution Safety Tips

  5

• Modification

  6

• Safe Riding Recommendation for Motorcycle Riders

  6

• Serial Number Location

  6

• Noise Control System (Australia Only)

  7

  • Location of Parts

    8

  • Vehicle View and Parts Identification

    8

  • Ignition Switch

    9

  • Instrument Panel

    10

    • Fuel Meter

      11

    • Odometer

      11

    • Tachometer

      11

    • Trip Meters

      11

    • Clock

      12

    • Fuel Injection System Indicator «FI»

      12

    • Coolant Temperature Indicator Light

      13

    • High Beam Indicator Light

      13

    • Oil Pressure Indicator Light

      13

    • Turn Signal Indicator Light

      13

    • Clutch Lever Adjustment

      14

    • Hazard Warning Switch

      14

    • Left Handlebar

      14

    • Turn Signal Light Switch

      14

    • Electric Starter Button

      15

    • Engine Stop Switch

      15

  • Right Handlebar

    15

  • Throttle Grip

    15

  • Fuel Tank Cap

    16

  • Gearshift Lever

    16

  • Rear Brake Pedal

    16

  • Seat Lock and Helmet Holders

    17

  • Stands

    17

    • Damping Force Adjustment

      18

    • Spring Pre-Load Adjustment

      18

  • Suspension Adjustment

    18

  • Fuel, Engine Oil and Coolant Recommendations

    19

  • Seat Height Adjustment

    19

  • Fuel Octane Rating

    20

  • Oxygenated Fuel Recommendation

    20

  • Engine Oil

    20

  • SAE Engine Oil Viscosity

    20

  • Coolant

    21

  • Anti-Freeze

    21

  • Required Amount of Water/Coolant

    21

  • Jaso T903

    21

  • Break-In (Running-In) and Inspection before Riding

    22

  • Maximum Engine Speed Recommendation

    23

  • Breaking in the New Tires

    23

  • Initial Service

    23

  • Riding Tips

    24

  • Starting the Engine

    25

  • Starting off

    25

  • Using the Transmission

    26

  • Riding on Hills

    26

  • Stopping and Parking

    26

  • Shifting Up/Down Schedule

    26

  • Inspection and Maintenance

    27

  • Maintenance Schedule

    28

  • Tool Kit Location

    29

  • Fuel Tank Removal

    29

  • Lubrication Points

    30

  • Battery

    31

  • Air Cleaner

    31

  • Air Cleaner Drain Tube

    32

  • Spark Plugs Removal

    33

  • Spark Plug Inspection

    33

  • Spark Plug Replacement Guide

    33

  • Engine Oil Level Check

    34

  • Fuel Hose

    34

  • Spark Plug Installation

    34

  • Engine Oil and Filter Change

    35

  • Engine Idle Speed Inspection

    36

  • Throttle Cable Adjustment

    37

  • Clutch

    37

  • Coolant Level

    38

  • Coolant Change

    38

  • Drive Chain

    38

  • Drive Chain Cleaning and Oiling

    39

  • Drive Chain Adjustment

    39

  • Brakes

    40

  • Brake Fluid

    40

  • Brake Pads

    40

  • Tires

    41

  • Rear Brake Light Switch

    41

  • Rear Brake Pedal Adjustment

    41

  • Tire Pressure and Loading

    42

  • Tire Condition and Type

    42

  • Cold Tire Inflation Pressure

    42

  • Side Stand/Ignition Interlock Switch

    43

  • Front Wheel Removal

    44

  • Rear Wheel Removal

    45

  • Light Bulb Replacement

    46

  • Headlight/Position Light

    46

  • Brake Light/Taillight

    47

  • Headlight Beam Adjustment

    48

  • License Plate Light

    48

  • Turn Signal Light

    48

  • Fuses

    49

  • Troubleshooting

    50

  • Fuel Supply Check

    51

  • Ignition System Check

    51

  • Engine Stalling

    51

  • Cleaning

    53

  • Washing the Motorcycle

    53

  • Waxing the Motorcycle

    53

  • Inspection after Cleaning

    53

  • Storage

    54

  • Procedure for Returning to Service

    54

  • Specifications

    55

  • Index

    56