Сузуки интрудер сервис мануал

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Suzuki VS800 Intruder

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  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Motorcycle
  5. Intruder VZR1800
  6. Service manual
  • Contents

  • Table of Contents

  • Troubleshooting

  • Bookmarks

Related Manuals for Suzuki Intruder VZR1800

Summary of Contents for Suzuki Intruder VZR1800

  • Page 1
    VZR1800 9 9 5 0 0 — 3 9 2 9 0 — 0 1 E…
  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI VZR1800 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

  • Page 4
    Use engine oil unless otherwise speci- 99000-99032-11X fied. Apply molybdenum oil solution. Use fork oil or equivalent. (Mixture of engine oil and SUZUKI 99000-99044-L01 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent. Apply or use brake fluid.
  • Page 5: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Fuel Injection, Fuel Injector : Alternating Current : Fuel Pump : Air Cleaner, Air Cleaner Box : Fuel Pressure Regulator : American Petroleum Institute FP Relay : Fuel Pump Relay ATDC : After Top Dead Center : Air Fuel Mixture…

  • Page 6
    : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor…
  • Page 7
    WIRE COLOR : Black : Green : Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer…
  • Page 8: Table Of Contents

    GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE…………….. 1- 2 GENERAL PRECAUTIONS …………….1- 2 SUZUKI VZR1800K6 (’06-MODEL) ………….. 1- 4 SERIAL NUMBER LOCATION …………..1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ……. 1- 5 FUEL (FOR USA AND CANADA)…………1- 5 FUEL (FOR OTHER COUNTRIES) …………1- 5 ENGINE OIL (FOR USA)…………….

  • Page 9: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.

  • Page 10
    GENERAL INFORMATION » * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  • Page 11: Suzuki Vzr1800K6 (’06-Model)

    GENERAL INFORMATION SUZUKI VZR1800K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.

  • Page 12: Fuel, Oil And Engine Coolant Recommendation

    Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

  • Page 13: Front Fork Oil

    Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

  • Page 14: Break-In Procedures

    GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.

  • Page 15: Information Labels

    GENERAL INFORMATION INFORMATION LABELS VZR1800 VZR1800UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label 6 Manual notice label A (For E-03, 33) 7 Tire information label…

  • Page 16: Specifications

    GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………2 450 mm (96.5 in) ..For E-03, 33 2 480 mm (97.6 in) ..For others Overall width …………875 mm (34.4 in) Overall height …………1 185 mm (46.7 in) Wheelbase …………

  • Page 17: Chassis

    1-10 GENERAL INFORMATION CHASSIS Front suspension ……….Inverted telescopic, coil spring, oil damped Rear suspension ……….Link type, coil spring, oil damped Front fork stroke……….. 130 mm (5.1 in) Rear wheel travel ……….118 mm (4.6 in) Caster …………..31° 15’ Trail …………..

  • Page 18: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………… 2- 2 PERIODIC MAINTENANCE CHART…………. 2- 2 LUBRICATION POINTS ……………. 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ……..2- 4 AIR CLEANER………………2- 4 EXHAUST PIPE BOLTS AND MUFFLER BOLTS ……. 2- 6 EXHAUST CONTROL VALVE …………..

  • Page 19: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.

  • Page 20: Lubrication Points

    PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Brake lever holder Throttle cable Brake pedal pivot Clutch lever holder Side-stand pivot and Gearshift link pivot spring hook NOTE:…

  • Page 21: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months). •…

  • Page 22
    PERIODIC MAINTENANCE • Carefully use air hose to blow the dust from the cleaner ele- ment. » Always use air pressure on the center air cleaner side of the air cleaner element. If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.
  • Page 23: Exhaust Pipe Bolts And Muffler Bolts

    PERIODIC MAINTENANCE EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque.

  • Page 24: Exhaust Control Valve

    PERIODIC MAINTENANCE EXHAUST CONTROL VALVE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Remove the rubber cover 1. Check the exhaust control valve actuator 2 for its movement when the ignition switch is turned on.

  • Page 25: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Remove the frame head covers and radiator covers. ($9-6) • Remove the air cleaner chamber. ($6-13) •…

  • Page 26
    PERIODIC MAINTENANCE • Remove the secondary gear case cover. ($3-6) • Remove the generator cover cap 4, valve timing inspection plug 5 and generator cover plug 6. • Turn the crankshaft to set the #1 (Rear) cylinder at TDC of compression stroke.
  • Page 27
    2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. ($3-14 to -15 and 3-17 to -18) • Remove the tappet and shim by fingers or magnetic hand. •…
  • Page 28
    PERIODIC MAINTENANCE 2-11 (INTAKE SIDE)
  • Page 29
    2-12 PERIODIC MAINTENANCE (EXHAUST SIDE)
  • Page 30: Spark Plug

    PERIODIC MAINTENANCE 2-13 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). replace every 12 000 km (7 500 miles, 24 months). #2 (FRONT) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) •…

  • Page 31
    2-14 PERIODIC MAINTENANCE #1 (REAR) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Disconnect lead wire coupler 1 from ignition coil/plug cap. » Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler dam- age.
  • Page 32
    PERIODIC MAINTENANCE 2-15 HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.
  • Page 33: Fuel Line

    2-16 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION • Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque. # Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) » Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

  • Page 34: Engine Oil And Oil Filter

    PERIODIC MAINTENANCE 2-17 ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.

  • Page 35
    Oil and filter change : 3.6 L (3.8/3.2 US/Imp qt) Engine overhaul : 4.7 L (5.0/4.1 US/Imp qt) » ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
  • Page 36: Final Gear Oil

    PERIODIC MAINTENANCE 2-19 FINAL GEAR OIL Replace initially at 1 000 km (600 miles, 2 months) and inspect every 12 000 km (7 500 miles, 24 months) thereafter. • Keep the motorcycle upright. • Place an oil pan under the final gear case. •…

  • Page 37: Throttle Valve Synchronization

    2-20 PERIODIC MAINTENANCE THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). Inspect the throttle valve synchronization periodically. ($6-23) COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years.

  • Page 38
    PERIODIC MAINTENANCE 2-21 • Drain engine coolant by disconnecting the radiator hose 2 from the radiator. * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes.
  • Page 39: Clutch Cable Play

    2-22 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the fuel tank. ($6-3) • Remove the frame head covers, radiator covers and radiator bottom cover. ($9-6) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones.

  • Page 40: Brake

    PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.

  • Page 41
    2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ($9-52) «…
  • Page 42
    PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Turn the push rod 2 until the brake pedal height becomes 25 – 35 mm (1.0 – 1.4 in) A below the top of the footrest. • Tighten the lock nut 1 securely. # Rear brake master cylinder rod lock nut: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) % Brake pedal height A:…
  • Page 43
    2-26 PERIODIC MAINTENANCE AIR BLEEDING FROM BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
  • Page 44: Tires

    PERIODIC MAINTENANCE 2-27 REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. # Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft) NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal.

  • Page 45: Steering

    2-28 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. % Cold inflation tire pressure Solo riding: Front: 250 kPa (2.50 kgf/cm , 36 psi)

  • Page 46: Rear Suspension

    PERIODIC MAINTENANCE 2-29 REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months). • Remove the under cover. ($9-41) Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary.

  • Page 47
    2-30 PERIODIC MAINTENANCE…
  • Page 48: Compression Pressure Check

    PERIODIC MAINTENANCE 2-31 COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

  • Page 49: Oil Pressure Check

    2-32 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 400 – 700 kPa (4.0 – 7.0 kgf/cm , 57 – 100 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) If the oil pressure is lower or higher than the specification, the following causes may be considered.

  • Page 50: Sds Check

    PERIODIC MAINTENANCE 2-33 SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

  • Page 51: Data At The Time Of Racing

    2-34 PERIODIC MAINTENANCE Data at 3 000 r/min under no load Approx. 3 000 r/min Check the water temperature. XX ˚C ˚ Check the manifold absolute pressure #1. XX mmHg Data at the time of racing ˚ Check the manifold absolute pressure #1 in according with the throttle valve opening.

  • Page 52
    PERIODIC MAINTENANCE 2-35 Data of intake negative pressure during idling (100 °C) ˚ Check the water temperature. Approx. 100 ˚C Check the manifold absolute pressure #1. XX mmHg Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure #1. XX mmHg Check the manifold absolute pressure #2.
  • Page 53
    ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION……….3- 3 ENGINE REMOVAL …………….3- 3 ENGINE INSTALLATION …………..3- 9 ENGINE DISASSEMBLY …………….3-13 ENGINE COMPONENTS INSPECTION AND SERVICE……3-29 CYLINDER HEAD COVER…………..3-29 CAMSHAFT ……………….
  • Page 54: Engine Components Removable With Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION !12-6…

  • Page 55: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Drain engine oil. (!2-17) •…

  • Page 56
    ENGINE • Disconnect the ECT sensor lead wire coupler 4. • Disconnect the ignition coil/plug cap lead wire couplers and remove the ignition coils/plug caps. (!2-13 and -14) » * Do not remove the ignition coil/plug cap before dis- connecting its coupler. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.
  • Page 57
    ENGINE • Remove the right footrest 8. • Disconnect the starter motor lead wire 9. • Disconnect the oil cooler hose 0. • Remove the oil pressure switch lead wire A.
  • Page 58
    ENGINE • Disconnect the cooling fan coupler B and horn lead wire cou- plers C. • Remove the left frame lower side cover D. • Remove the secondary gear case cover E. • Disconnect the generator lead wire coupler F. •…
  • Page 59
    ENGINE • Remove the clutch cable K. • Support the engine with an engine jack. • Remove the left footrest L and gearshift lever M. • Remove the ground lead wire N. • Disconnect the GP switch lead wire coupler O. •…
  • Page 60
    ENGINE • Slightly move the frame down tube by removing its bolts P, bolts and nuts Q. • Remove the caps. • Remove the engine mounting bracket bolts R. • Remove the engine mounting bolts and nuts S. • Remove the the engine assembly.
  • Page 61: Engine Installation

    ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the boot and universal joint. NOTE: Make sure that the “UP” mark A faces up. • Gradually raise the engine, and then engage the secondary driven gear shaft to the universal joint.

  • Page 62
    3-10 ENGINE • Install the frame down tube and tighten the bolts 2, bolts and nuts 3 to the specified torque. NOTE: The frame down tube nuts are self-locking. Once the nuts have been removed, they are no longer of any use. # Frame down tube bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •…
  • Page 63
    ENGINE 3-11 NOTE: The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. Right Left 3 Bushing Engine mounting nut 4 Bushing Spacer ITEM N·m kgf-m lb-ft 40.0 • Install the gearshift lever and tighten the mounting bolts to the specified torque.
  • Page 64
    3-12 ENGINE • Tighten the right front footrest mounting bolts to the specified torque. # Right front footrest bolt: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Install the rear brake master cylinder cover 4. (!9-72) • Install the throttle body. (!6-21) •…
  • Page 65: Engine Disassembly

    ENGINE 3-13 ENGINE DISASSEMBLY » Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the front and rear spark plugs. STARTER MOTOR •…

  • Page 66
    3-14 ENGINE REAR CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the rear cylinder head cover 2 and its gasket. REAR CAMSHAFT • Remove the generator cover cap 1. • Remove the valve timing inspection plug 2 and generator cover plug 3.
  • Page 67
    ENGINE 3-15 • Turn the crankshaft to bring the “R I T” line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown. NOTE: At the above condition, the rear cylinder is at TDC of compres- sion stroke and also the engraved lines A on the camshafts are parallel with the mating surface of the cylinder head cover.
  • Page 68
    3-16 ENGINE REAR CYLINDER HEAD • Remove the cylinder head bolts and washers. NOTE: Loosen the cylinder head bolts little by little diagonally with the smaller sizes first. • Remove the cylinder head 1. REAR CYLINDER • Remove the cylinder head gasket 1, dowel pins 2 and cam chain guide No.
  • Page 69
    ENGINE 3-17 FRONT CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the front cylinder head cover 2 and its gasket. FRONT CAMSHAFT • Turn the crankshaft to bring the “F I T” line mark on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown.
  • Page 70
    3-18 ENGINE • Remove the cam chain guide No. 3 5. • Remove the camshaft journal holder 6. • Remove the dowel pins. » Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
  • Page 71
    ENGINE 3-19 • Remove the cylinder nuts. • Remove the cylinder 5. NOTE: Firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose.
  • Page 72
    3-20 ENGINE • Remove the clutch push rod 5 and clutch push rod release ball 6. NOTE: If it is difficult to pull out the push rod 5 and ball 6, use a long- bar. • Unlock the clutch sleeve hub nut. •…
  • Page 73
    ENGINE 3-21 • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the needle roller bearing C and spacer D. REAR CAM CHAIN TENSION ADJUSTER • Unlock the ratchet 1 and insert the special tool. % 09917-62430: Chain tensioner lock tool •…
  • Page 74
    3-22 ENGINE • Remove the cam chain No. 2 4, rear cam chain idler sprocket 5 and cam chain No. 1. REAR CAM CHAIN DRIVE SPROCKET • Hold the generator rotor and remove the rear cam chain drive sprocket bolt. «…
  • Page 75
    ENGINE 3-23 NOTE: When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. • Remove the generator rotor assembly with the special tool. % 09930-30721: Rotor remover •…
  • Page 76
    3-24 ENGINE • Remove the cam chain tensioner No. 1 6. • Remove the cam chain No. 2 7, front cam chain idler sprocket 8 and cam chain No. 1 9. • Remove the front cam chain tension adjuster No. 1 0. SECONDARY DRIVEN GEAR •…
  • Page 77
    ENGINE 3-25 • Remove the gearshift cam plate 3. • Remove the gearshift cam stopper 4. SECONDARY DRIVE GEAR • Shift the gear position to 1st or 2nd. • Hold the primary driven gear with the special tool. % 09930-44541: Rotor holder •…
  • Page 78
    3-26 ENGINE • Remove the oil pump drive gear 5 and pin 6. GEAR POSITION SWITCH • Remove the gear position switch 1. OIL FILTER • Remove the oil filter with the special tool. % 09915-40610: Oil filter wrench OIL COOLER/OIL PRESSURE SWITCH •…
  • Page 79
    ENGINE 3-27 OIL PAN • Remove the oil pan 1 and stay 2. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainers 2 and O-rings 3. UPPER CRANKCASE • Remove the breather cover 1. •…
  • Page 80
    3-28 ENGINE NOTE: * The crankshaft and transmission components should remain in the upper crankcase half. * If it is difficult to separate the crankcase halves, set the proper bolts and nuts to the crankcase by separating the upper and lower crankcase halves, as shown in the illustration.
  • Page 81: Engine Components Inspection And Service

    ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE » Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER DISASSEMBLY •…

  • Page 82
    3-30 ENGINE CAM WEAR • Check the camshaft for wear or damage. • Measure the cam height H with a micrometer. $ Cam height H: Service Limit: (IN. & EX.): 40.580 mm (1.5976 in) % 09900-20202: Micrometer (25 – 50 mm) CAMSHAFT JOURNAL WEAR •…
  • Page 83: Camshaft Runout

    ENGINE 3-31 • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. $ Camshaft journal holder I.D.: Standard: (IN.

  • Page 84: Cam Chain Tension Adjuster

    3-32 ENGINE CAM CHAIN TENSION ADJUSTER INSPECTION • The cam chain tension adjusters are maintained at the proper cam chain tension automatically. • Unlock the ratchet A, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or ratchet mech- anism is faulty, replace the cam chain tension adjuster assembly with a new one.

  • Page 85
    ENGINE 3-33 CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
  • Page 86
    3-34 ENGINE • Remove the valve spring retainer 4 and valve spring 5. • Pull out the valve 6 from the combustion chamber side. • Remove the oil seal 7 and spring seat 8. » Do not reuse the removed oil seal. •…
  • Page 87
    ENGINE 3-35 VALVE STEM AND VALVE FACE WEAR CONDITION • Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one. VALVE STEM DEFLECTION • Lift the valve about 10 mm (0.39 in) from the valve seat. •…
  • Page 88
    3-36 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side. % 09916-46020: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts.
  • Page 89
    ENGINE 3-37 VALVE SEAT WIDTH INSPECTION • Visually check for valve seat width on each valve face. • If the valve face has worn abnormally, replace the valve. • Coat the valve seat with a red lead (Prussian Blue) and set the valve in place.
  • Page 90
    3-38 ENGINE • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. • If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Always use extreme caution when handling gasoline.
  • Page 91
    ENGINE 3-39 • Install the valve spring with the small-pitch portion A facing cylinder head. B Large-pitch portion C UPWARD D Paint • Put on the valve spring retainer 3, and using the valve lifter and protector 4, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter 5 to wedge in between retainer and stem.
  • Page 92
    3-40 ENGINE CAM CHAIN TENSIONER • Inspect the cam chain tensioner for damage. If any damage are found, replace the cam chain tensioner with a new one. • Install the cam chain tensioner 1, washers 2 and nuts 3. • Tighten the cam chain tensioner nuts to the specified torque. # Cam chain tensioner nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft) WATER JACKET PLUG •…
  • Page 93: Cylinder

    ENGINE 3-41 CYLINDER CYLINDER DISTORTION • Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. • If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.

  • Page 94: Piston And Piston Ring

    3-42 ENGINE PISTON AND PISTON RING PISTON DIAMETER • Using a micrometer, measure the piston diameter at 10 mm (0.4 in) A from the piston skirt end. • If the measurement is less than the limit, replace the piston. $ Piston diameter: Service Limit: 111.880 mm (4.4047 in) at 10 mm (0.4 in) from the skirt end % 09900-20210: Micrometer (100 –…

  • Page 95: Piston Ring Groove Width

    ENGINE 3-43 PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. % 09900-20803: Thickness gauge 09900-20205: Micrometer (0 –…

  • Page 96: Clutch

    3-44 ENGINE CLUTCH CLUTCH PLATE THICKNESS NOTE: Wipe off engine oil from the clutch plates with a clean rag. • Measure the thickness of drive and driven plates with a ver- nier calipers. If each plate is not within the service limit or standard range, replace it with a new one.

  • Page 97
    ENGINE 3-45 CLUTCH RELEASE BEARING • Inspect the clutch release bearing for any abnormality, partic- ularly cracks, to decide whether it can be reused or should be replaced. • Smooth engagement and disengagement of the clutch depends on the condition of this bearing. CLUTCH PUSH ROD •…
  • Page 98: Gearshift Cover

    REASSEMBLY • Install the bearing 1 and oil seal 2 with the special tool. % 09913-70210: Bearing installer set (22 mm) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent «…

  • Page 99: Starter Clutch

    ENGINE 3-47 STARTER CLUTCH STARTER DRIVEN GEAR INSPECTION • Turn the starter driven gear by hand. • Inspect the starter clutch for a smooth movement. • Check that the gear turns only in one direction. • Inspect the starter driven gear bushing for any damage. If necessary, replace it with a new one.

  • Page 100: Oil Pump

    3-48 ENGINE • Apply THREAD LOCK SUPER to the bolts, and then tighten them to the specified torque. # Starter clutch bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft) * 99000-32030: THREAD LOCK SUPER “1303” or equivalent OIL PUMP REMOVAL • Remove the oil pump assembly 1 with oil return pump. DISASSEMBLY •…

  • Page 101
    ENGINE 3-49 REASSEMBLY • Apply engine oil to the sliding surfaces of the oil pump inner rotor, outer rotor and shaft. • When installing the inner rotor 1, align the pin 2 with the groove 3. • When installing the inner rotor and outer rotor, face the punched marks A on the rotors to the outside.
  • Page 102: Starter Torque Limiter

    3-50 ENGINE STARTER TORQUE LIMITER STARTER TORQUE LIMITER INSPECTION » * Do not attempt to disassemble the starter torque lim- iter. * The starter torque limiter is available only as an assembly. • Check the slip torque with the special tools. $ Slip torque Standard: 31 –…

  • Page 103: Clutch Release Camshaft

    • Remove the clutch push rod cap 7 and oil seal 8. » The removed oil seal must be replaced with new one. REASSEMBLY • Apply SUZUKI SUPER GREASE “A” the release camshaft 1, new bearing 2 and oil seal 3 before installing. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…

  • Page 104: Water Pump

    3-52 ENGINE WATER PUMP !8-15 GEARSHIFT GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY • Remove the following parts from the gearshift shaft/gearshift arm. 1 Washer 4 Gearshift cam drive plate 2 Snap ring 5 Plate return spring 3 Gearshift shaft return spring GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION •…

  • Page 105: Oil Pressure Regulator

    ENGINE 3-53 OIL PRESSURE REGULATOR • Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar. • If the piston does not operate, replace the oil pressure regula- tor with a new one. OIL STRAINER •…

  • Page 106: Transmission

    3-54 ENGINE TRANSMISSION CONSTRUCTION 1 Countershaft/1st drive gear 7 2nd driven gear 2 5th drive gear 8 3rd driven gear 3 4th drive gear 9 4th driven gear 4 3rd drive gear 0 5th driven gear 5 2nd drive gear A 1st driven gear 6 Driveshaft…

  • Page 107
    ENGINE 3-55 DISASSEMBLY » Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Drive” and “Driven”, so that each will be restored to the original location during assembly. Countershaft •…
  • Page 108
    3-56 ENGINE • Remove the snap ring D, washer E, 5th drive gear F and 5th drive gear bushing G. Driveshaft • Remove the bearing 1, washer 2 and 1st driven gear 3. • Remove the 1st driven gear bushing 4, washer 5 and 5th driven gear 6.
  • Page 109
    Replace the bearings if there is anything unusual. * Before installing the gears, apply engine oil to the driveshaft and countershaft. * When installing the oil seal, apply SUZUKI SUPER GREASE “A” to it. ) 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 110
    3-58 ENGINE • When installing a new snap ring, pay attention to its direction. Fit it to the side where the thrust is as shown in the illustration. A Thrust B Sharp edge » When installing the gear bushing onto the counter- shaft 1 and driveshaft 2, align the shaft oil hole 3 with the 3rd drive gear bushing oil hole 4 and 4th driven gear bushing oil hole 5.
  • Page 111
    ENGINE 3-59 TRANSMISSION PARTS LOCATION 1 Countershaft 2 Driveshaft…
  • Page 112: Crankcase

    3-60 ENGINE CRANKCASE GEARSHIFT FORK AND GEARSHIFT CAM Removal • Remove the gearshift cam bearing retainer screws 1 and gearshift fork shaft retainer plug 2 from the lower crankcase. • Remove the gearshift fork shafts 3 and gearshift forks 4 from the lower crankcase.

  • Page 113
    ENGINE 3-61 GEARSHIFT FORK GROOVE WIDTH • Measure the gearshift fork groove width using the vernier cali- pers. $ Shift fork groove width: Standard: 5.0 – 5.1 mm (0.197 – 0.201 in) % 09900-20102: Vernier calipers GEARSHIFT FORK THICKNESS • Measure the gearshift fork thickness using the vernier cali- pers.
  • Page 114
    3-62 ENGINE • Remove the gearshift cam bearing with the special tools. % 09923-74511: Bearing remover 09930-30104: Sliding shaft Installation • Install the bearings with the special tool. % 09913-70210: Bearing installer set (1 +20) (2 +32) NOTE: The stamped mark side of the gearshift shaft bearing 1 and gearshift cam bearing 2 faces outside.
  • Page 115
    ENGINE 3-63 • Apply a small quantity of THREAD LOCK to the bearing retainer screws 8 and gearshift arm stopper bolt 9. • Tighten the bearing retainer screws 8, gearshift arm stopper bolt 9 and gearshift fork shaft retainer plug 0 to the specified torque.
  • Page 116
    3-64 ENGINE Inspection and cleaning • Check the oil jets for clogging. • Inspect the operation of the oil jet by pushing on the piston with a proper bar • If they are clogged or piston does not opreat, clean their oil passage with a proper wire and compressed air or replace the oil jet with a new one.
  • Page 117
    ENGINE 3-65 • Remove the oil gallery plugs 2 (for upper crankcase side). • Remove the oil gallery plugs 3 (for lower crankcase side). • Remove the oil gallery plugs 4 (for oil pan).
  • Page 118
    3-66 ENGINE Installation • Apply THREAD LOCK to the water jaket plugoil gallery plugs 1 and oil gallery plugs (2, 3). & 99000-32050: THREAD LOCK “1342” or equivalent NOTE: It is not require to apply THREAD LOCK when installing the other removed oil gallery plugs.
  • Page 119: Balancer Driven Gear

    ENGINE 3-67 BALANCER DRIVEN GEAR BALANCER DRIVEN GEAR INSPECTION Visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. BALANCER DRIVEN GEAR DISASSEMBLY • Remove the balancer shaft with the special tool. % 09913-70210: Bearing installer set •…

  • Page 120
    3-68 ENGINE • Hold the balancer driven gear No. 2 3 with the special tool. % 09920-53740: Clutch sleeve hub holder • Turn the balancer driven gear No. 1 4 and align the holes. • Apply THREAD LOCK SUPER to the bolts (5, 6). * 99000-32030: THREAD LOCK SUPER “1303”…
  • Page 121: Crankshaft And Conrod

    ENGINE 3-69 CRANKSHAFT AND CONROD CONROD SMALL END I.D. • Using a small bore gauge, measure the inside diameter of the conrod small end. $ Conrod small end I.D.: Service Limit: 23.040 mm (0.9071 in) % 09900-20602: Dial gauge (1/1 000 mm, 1 mm) 09900-22403: Small bore gauge (18 –…

  • Page 122
    3-70 ENGINE • Remove the conrods, and mark them to identify the cylinder position. • Inspect the bearing surfaces for any sign of fusion, pitting, burn, or flaws. If any, replace them with a specified set of bearings. CONROD-BIG END BEARING SELECTION •…
  • Page 123
    ENGINE 3-71 • Check the corresponding conrod I.D. code number (“1” or “2”) • Check the corresponding crank pin O.D. code number (“1”, “L” “2” or “3”) B. $ Bearing selection table Crank pin O.D. B Code Green Black Brown Conrod “R”…
  • Page 124
    3-72 ENGINE $ Crank pin O.D. Code O.D. specification 54.992 – 55.000 mm (2.1650 – 2.1654 in) 54.984 – 54.992 mm (2.1647 – 2.1650 in) 54.976 – 54.984 mm (2.1644 – 2.1647 in) % 09900-20202: Micrometer (25 – 50 mm) $ Bearing thickness Color code Color (Part No.)
  • Page 125: Crankshaft Journal Bearing

    ENGINE 3-73 • Apply engine oil to the bearing cap bolts. • Tighten the bearing cap bolts as following two steps. # Conrod bearing cap bolt (Initial) : 35 N·m (3.5 kgf-m, 25.5 lb-ft) (Final) : After tightening the bolts to the above torque, tighten them 1/4 of a turn (90°).

  • Page 126
    3-74 ENGINE • Remove the lower crankcase and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the com- pressed plastigauge. $ Crankshaft journal oil clearance: Standard: 0.016 – 0.034 mm (0.0006 – 0.0013 in) Service Limit: 0.080 mm (0.0031 in) •…
  • Page 127
    ENGINE 3-75 $ Crankshaft journal O.D. specification Code O.D. specification 54.994 – 55.000 mm (2.1651 – 2.1654 in) 54.988 – 54.994 mm (2.1649 – 2.1651 in) 54.982 – 54.988 mm (2.1646 – 2.1649 in) % 09900-20203: Micrometer (50 – 75 mm) $ Bearing thickness specification Color (Part No.) Thickness…
  • Page 128: Crankshaft Thrust Bearing

    3-76 ENGINE CRANKSHAFT THRUST BEARING • With the crankshaft and thrust bearing 1 inserted in the upper crankcase, measure the thrust clearance by using the thickness gauge. $ Thrust clearance: Standard: 0.100 – 0.200 mm (0.0039 – 0.0078 in) % 09900-20803: Thickness gauge •…

  • Page 129
    ENGINE 3-77 $ Thrust bearing selection table Clearance before Color Thrust bearing inserting left-side Thrust clearance (Part No.) thickness thrust bearing 2.400 – 2.450 mm 2.250 – 2.300 mm 0.100 – 0.200 mm (0.0944 – 0.0965 in) (12228-48G00-0A0) (0.0886 – 0.0906 in) (0.0039 –…
  • Page 130: Engine Reassembly

    3-78 ENGINE ENGINE REASSEMBLY • Reassemble the engine in the reverse order of disassembly. • The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. CRANKSHAFT •…

  • Page 131
    ENGINE 3-79 • Turn the bearing to install the bearing dowel pin C in the posi- tion. • Install the oil seal 1. TRANSMISSION • Install the countershaft assembly on the upper crankcase. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.
  • Page 132
    3-80 ENGINE • Install the O-rings 1. • Apply SUZUKI SUPER GREASE “A” to the O-rings. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent » Use a new O-ring to prevent oil leakage. • Install the dowel pins 2.
  • Page 133
    ENGINE 3-81 • Apply SUZUKI BOND to the mating surface of the lower crankcase. , 99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 134
    3-82 ENGINE • Tighten the crankcase bolts a little at a time to equalize the pressure. NOTE: * Fit the new copper washers to the crankcase bolts B. * Fit the new gasket washers to the crankcase bolts C. # Crankcase bolt: (M6): 11 N·m (1.1 kgf-m, 8.0 lb-ft) (M8): 26 N·m (2.6 kgf-m, 19.0 lb-ft) (M10) Initial: 30 N·m (3.0 kgf-m, 21.5 lb-ft) Final: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
  • Page 135
    ENGINE 3-83 • Apply SUZUKI BOND to the mating surface of the breather cover. — 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 136
    Align the oil strainer C with the lower crankcase hole D. OIL PRESSURE REGULATOR • Apply SUZUKI SUPER GREASE “A” to the O-rings and press in the oil pressure regulator 1 to the lower crankcase. ) 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 137
    ENGINE 3-85 OIL PAN • Apply SUZUKI BOND to the mating surface of the oil pan. , 99000-31110: SUZUKI BOND “1215” or equivalent NOTE: Use of SUZUKI BOND is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials.
  • Page 138
    , 99000-31110: SUZUKI BOND “1215” or equivalent # Oil pressure switch: 14 N·m (1.4 kgf-m, 10.0 lb-ft) NOTE: Be careful not to apply SUZUKI BOND to the hole of thread end. OIL COOLER • Apply engine oil to the O-ring.
  • Page 139
    • Install the oil pump driven gear 3. • Install the snap ring 4. GEAR POSITION SWITCH • Apply SUZUKI SUPER GREASE “A” to the O-ring. NOTE: Align the gear position switch pin A with the gearshift cam hole ) 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 140
    3-88 ENGINE GEARSHIFT • Install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. NOTE: Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt 2 and tighten its to the specified torque. &…
  • Page 141
    • Install the dowel pins and gasket 1. » Use new gasket to prevent oil leakage. • Install the gearshift cover and tighten its bolts. NOTE: Apply grease to the oil seal lip before installing the gearshift cover. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
  • Page 142
    3-90 ENGINE SECONDARY DRIVEN GEAR • Install the shims 1 onto the secondary driven gear case. (!4-11) • Fit the O-ring 2 and apply engine oil. » Use the new O-ring to prevent oil pressure leak. • Install the secondary driven gear case 3 with the bolts and then tighten them to the specified torque.
  • Page 143
    • Align the groove A on the cam idler sprocket with the embossed line B on the upper crankcase. (!3-94) • Apply SUZUKI MOLY PASTE to the idler shaft 2 and install the idler shaft. ( MOLYBDENUM OIL SOLUTION…
  • Page 144
    3-92 ENGINE • Install the cam chain guide No. 1 3. • Apply a small quantity of THREAD LOCK SUPER to the bolts and tighten its to the specified torque. * 99000-32030: THREAD LOCK SUPER “1303” or equivalent # Cam chain guide No. 1 bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft) •…
  • Page 145
    • Align the groove A on the cam idler sprocket with the embossed line B on the upper crankcase. (!3-94) • Apply SUZUKI MOLY PASTE to the idler shaft 1 and install the idler shaft. ( MOLYBDENUM OIL SOLUTION…
  • Page 146
    3-94 ENGINE • After unlocking the ratchet, push the cam chain tension adjuster rod. • Insert the special tool between the ratchet and the adjuster body. % 09917-62430: Chain tensioner lock tool • Install the rear cam chain tension adjuster No. 1 with the bolts and tighten its bolts to the specified torque.
  • Page 147
    ENGINE 3-95 CLUTCH • Install the needle bearing 1 and spacer 2 onto the counter- shaft. • Apply engine oil to them. • Install the primary driven gear assembly 3 onto the counter- shaft. • Install the thrust washer 4. •…
  • Page 148
    3-96 ENGINE Outside DRIVE PLATE: A Drive plate No. 1 …5 pcs. B Drive plate No. 2 …1 pc. Wave plate C Wave washer D Wave washer seat DRIVEN PLATE: a Driven plate No. 1 …4 pcs. b Driven plate No. 2 …2 pcs. 3.6 mm (0.14 in) 2.6 mm (0.10 in) A Drive plate No.
  • Page 149
    ENGINE 3-97 • Install the drive plate No. 2 7, spring washer 8 and spring washer seat 9 onto the clutch sleeve hub correctly. NOTE: The conical curve side of spring washer 8 faces outside. • Insert the clutch drive plates and driven plates one by one to the clutch sleeve hub after applying engine oil to the them.
  • Page 150
    3-98 ENGINE • Tighten the clutch spring set bolts securely while holding the generator rotor. NOTE: Tighten the clutch spring bolts diagonally. PISTON RING • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. •…
  • Page 151
    ENGINE 3-99 • Position the gaps of the three ring as shown. Before inserting each piston into the cylinder, check that the gaps are so 120 ¡ located. 120 ¡ 120 ¡ C 2nd ring and lower side rail D Upper side rail E 1st ring and spacer •…
  • Page 152
    3-100 ENGINE CYLINDER • Fit the dowel pins and new gaskets 1 to the crankcase front and rear. » Use the new gaskets to prevent oil leakage. • Apply a small quantity of MOLYBDENUM OIL SOLUTION to the sliding surface of the pistons and cylinder walls. “FR”…
  • Page 153
    ENGINE 3-101 • Fit the dowel pins and new cylinder head gaskets 2 to the cylinders, front and rear. » Use the new gaskets to prevent gas leakage. Rear NOTE: “F” The cylinder heads can be distinguished by the embossed-let- ters, “F”…
  • Page 154
    3-102 ENGINE • Tighten the front and rear cylinder nuts to the specified torque. # Cylinder nut: 13 N·m (1.3 kgf-m, 9.5 lb-ft) Front Rear FRONT CAMSHAFTS • Turn the crankshaft counterclockwise approx. 1-1/3 turns (486°) with the box wrench and align “F I T” line A on the crankshaft with the index marks B of the upper crankcase hole while keeping the camshaft drive chain pulled upward.
  • Page 155
    ENGINE 3-103 • Pull the cam chain lightly. • The exhaust camshaft sprocket has an arrow marked “1” C. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the exhaust camshaft sprocket. •…
  • Page 156
    3-104 ENGINE • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust 1, and cam chain guide No. 3 2. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers.
  • Page 157
    ENGINE 3-105 REAR CAMSHAFTS • From the position where the front camshafts have now been installed, rotate the generator rotor approx. 2/3 turn (234°) and align the “R I T” line A on the crankshaft with the index marks B of the upper crankcase hole. «…
  • Page 158
    3-106 ENGINE • Pull the cam chain lightly. • The intake camshaft sprocket has an arrow marked “1” C. Turn the intake camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • Engage the cam chain with the intake camshaft sprocket. •…
  • Page 159
    ENGINE 3-107 • Install the dowel pins. • Install the camshaft journal holders, intake and exhaust 1, and cam chain guide No. 3 2. • Have the camshaft journal holders seated evenly by tighten- ing the camshaft journal holder bolts lightly, in the ascending order of numbers.
  • Page 160
    3-108 ENGINE • Install the gasket 5 and cam chain tension adjuster cap bolt NOTE: Click sound is heard when the cam chain tension adjuster cap bolt is installed. • Tighten the cam chain tension adjuster cap bolt to the speci- fied torque.
  • Page 161
    NOTE: Be sure to check the valve clearance. (!2-8) • Install the new gaskets to the cylinder head covers. • Apply SUZUKI BOND to the cam end caps of the gaskets as shown. — 99104-31140: SUZUKI BOND “1207B” or equivalent «…
  • Page 162
    3-110 ENGINE • Tighten the head cover bolts in ascending order of numbers to the specified torque. # Head cover bolt (Front and Rear): 11 N·m (1.1 kgf-m, 8.0 lb-ft) GENERATOR COVER • Install the dowel pins and gasket 1. «…
  • Page 163
    ENGINE 3-111 • Apply engine oil to the new O-ring and install the generator cover plug. » Use the new O-ring to prevent oil leakage. • Tighten the generator cover plug 2 and valve timing inspec- tion plug 3 to the specified torque. # Generator cover plug: 16 N·m (1.6 kgf-m, 11.5 lb-ft) Valve timing inspection plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
  • Page 164
    • Install the thermostat assembly 1 and connect the water hoses 2. • Tighten the thermostat assembly bolt. INTAKE PIPE • Apply SUZUKI SUPER GREASE “A” to the O-ring. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the intake pipes.
  • Page 165
    ENGINE 3-113 STARTER MOTOR • Apply SUZUKI SUPER GREASE “A” to the O-ring. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the starter motor 1 bolts to the specified torque. # Starter motor bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft)
  • Page 166
    DRIVELINE/AXLE DRIVELINE/AXLE CONTENTS SECONDARY BEVEL GEARS …………..4- 2 CONSTRUCTION ……………… 4- 2 REMOVAL ………………… 4- 4 DISASSEMBLY ………………4- 4 INSPECTION ………………4- 6 REASSEMBLY ………………4- 8 SECONDARY GEAR SHIMS ADJUSTMENT ……..4-10 FINAL BEVEL GEARS ………………. 4-13 CONSTRUCTION ………………
  • Page 167: Secondary Bevel Gears

    DRIVELINE/AXLE SECONDARY BEVEL GEARS CONSTRUCTION 1 Driven bevel gear coupling 8 Shims E Driven bevel gear bearing 2 Oil seal 9 O-ring A Driven bevel gear coupling nut 3 Oil seal housing 0 Secondary gear case B Secondary driven bearing stopper 4 Bearing housing set A Output cam dog C Secondary driven bearing housing bolt…

  • Page 168
    DRIVELINE/AXLE Backlash 0.03 – 0.15 mm (0.001 – 0.006 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-26D00-030 0.30 mm (0.012 in) 24945-26D00-035 0.35 mm (0.014 in) 24945-26D00-040 0.40 mm (0.016 in) 24945-26D00-050 0.50 mm (0.020 in) 24945-26D00-060…
  • Page 169: Removal

    DRIVELINE/AXLE REMOVAL The secondary bevel gear service requires engine removal and disassembly. Refer to the engine removal and the engine disas- sembly sections for secondary bevel gear assembly removal. Engine removal «3-3 DISASSEMBLY SECONDARY DRIVE BEVEL GEAR («3-28) SECONDARY DRIVEN BEVEL GEAR •…

  • Page 170
    DRIVELINE/AXLE • Remove the shims 5. • Using a chisel, unlock the nut. • Remove the driven bevel gear coupling nut with the special tool. # 09924-64510: Final drive gear coupling holder • Remove the washer 6 and the driven bevel gear coupling 7. •…
  • Page 171: Inspection

    DRIVELINE/AXLE • Remove the bearing housing 8, secondary driven gear 9, output cam dog 0, damper spring A, spring cam stopper B and shaft C. INSPECTION * Driven bevel gear damage or wear * Improper tooth contact * Output cam dog wear or damage * Shaft damage or wear.

  • Page 172
    DRIVELINE/AXLE • Remove the oil seal with the special tool. # 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. • Remove the driven gear stopper with the special tool. # 09913-70210: Bearing installer set (30 mm) •…
  • Page 173: Reassembly

    # 09913-70210: Bearing installer set (42 mm) NOTE: When installing the bearing, stamped mark on the bearing must face outside. • Apply SUZUKI BOND to the mating surface of the bearing housing and oil seal housing. & 99000-31140: SUZUKI BOND “1207B” or equivalent NOTE: * Make surfaces free from moisture, oil, dust and other foreign materials.

  • Page 174
    DRIVELINE/AXLE • Install the oil seal with the special tool. # 09913-70210: Bearing installer set (62 mm) • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent SECONDARY DRIVEN BEVEL GEAR •…
  • Page 175: Secondary Gear Shims Adjustment

    4-10 DRIVELINE/AXLE • Install the secondary driven gear assembly 3. • Apply a small quantity of the THREAD LOCK SUPER to the bearing housing bolts and tighten it to the specified torque. ( 99000-32030: THREAD LOCK SUPER “1303” or equivalnet ! Secondary driven bering housing bolt: 28 N·m (2.8 kgf-m, 20.0 lb-ft) •…

  • Page 176
    DRIVELINE/AXLE 4-11 • If the backlash is not within specification, the shims (Driven bevel gear side) must be changed and the backlash should be re-checked until correct. Refer to the chart for appropriate changes. NOTE: When changing the shims (Driven bevel gear side), measure the thickness of old shims.
  • Page 177
    4-12 DRIVELINE/AXLE 3 INCORRECT (Contact at tooth root) • If tooth contact is found to be incorrect, the shims of the sec- ondary drive bevel gear and secondary driven bevel gear must be changed, tooth contact should be re-checked until correct.
  • Page 178: Final Bevel Gears

    DRIVELINE/AXLE 4-13 FINAL BEVEL GEARS CONSTRUCTION 1 Oil seal A Final drive bavel gear K Oil seal 2 Final gear bearing case B Shims L Propeller shaft 3 Shims C Washer M Universal joint 4 Final driven gear bearing D Final drive bevel gear bearing A Final gear case bolt (M8) 5 Final driven bevel gear E Oil seal…

  • Page 179
    4-14 DRIVELINE/AXLE Standard clearance A: 1.00 mm (0.039 in) Shim 3 – Gear case cover clearance: 0.1 mm (0.004 in) Shim 1 size table Shim 3 size table Part number Thickness Part number Thickness 27445-24A01-030 0.30 mm (0.012 in) 27327-38B00-035 0.35 mm (0.014 in) 27445-24A01-035 0.35 mm (0.014 in)
  • Page 180: Final Gear Case Removal

    DRIVELINE/AXLE 4-15 FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. • Drain final gear oil. («2-19) • Remove the rear wheel. («9-34) • Remove the final gear case nut, spring washer and final gear case 1.

  • Page 181
    4-16 DRIVELINE/AXLE • Remove the propeller shaft 4 and spring 5. • Using a chisel, unlock the nut. • Remove the final drive gear coupling nut with the special tool. # 09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •…
  • Page 182
    DRIVELINE/AXLE 4-17 • Remove the bearing with the inner race from the final drive bevel gear with the special tool. # 09913-60910: Bearing puller The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. •…
  • Page 183
    4-18 DRIVELINE/AXLE • Remove the shim A and final driven bevel gear B. • Remove the shims C. • Using two bolts or suitable bars, remove the final driven bevel gear bearing from the bevel gear. NOTE: If no abnormal noise the bearing removal is not necessary. The removed bearing must be replaced with a new one.
  • Page 184
    DRIVELINE/AXLE 4-19 • Remove the final driven gear bearing D and oil seal E with the special tools. # 09941-64511: Bearing remover 09930-30104: Sliding shaft The removed bearing and oil seal must be replaced with new ones. • Remove the final drive gear bearing with the special tools. # 09923-74511: Bearing remover 09930-30104: Sliding shaft The removed bearing must be replaced with a new one.
  • Page 185: Final Gear Shims Adjustment

    (M10): 50 N·m (5.0 kgf-m, 36.0 lb-ft) NOTE: (M10) It is not necessary to apply SUZUKI BOND “1207B” and THREAD LOCK to the matching surface and bolts at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.

  • Page 186
    DRIVELINE/AXLE 4-21 BACKLASH After assembling the final gear case («4-24), measure the final bevel gear backlash as follows. • Install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in photo. # 09924-34510: Backlash measuring tool (27 – 50 mm) 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand •…
  • Page 187
    4-22 DRIVELINE/AXLE Shims 2 specifications Part number Shim thickness 27327-38B00-035 0.35 mm (0.014 in) 27327-38B00-040 0.40 mm (0.016 in) 27327-38B00-050 0.50 mm (0.020 in) 27327-38B00-060 0.60 mm (0.024 in) The shims 2 are available as a set (27327-38810). EXAMPLE: Final gear to case shims 1; 1.45 mm + 1.40 mm = 2.85 mm Final gear bearing to bearing case shims 2, 0.35 mm + 0.60 mm = 0.95 mm Original total measurement = 3.80 mm…
  • Page 188
    DRIVELINE/AXLE 4-23 • Remove the final gear bearing case and final driven bevel 3 INCORRECT (Contact at tooth root) gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right: • If the tooth contact pattern is incorrect, as shown in 1, a thin- ner shim 4 is needed between the final drive bevel gear bearing and final gear case.
  • Page 189: Final Gear Case Reassembly

    * Use a new oil seal to prevent oil leakage. * The lip and spring of the oil seal A should face to the driven bevel gear side. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…

  • Page 190
    • Install a new oil seal to the final gear bearing case with the special tool. # 09951-16310: Final gear case oil seal installer • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent •…
  • Page 191
    • Install the correct shims 9 to the final drive bevel gear and install the bevel gear to the final gear case. Shim adjustment («4-23) • Apply SUZUKI SUPER GREASE “A” to the O-ring and the lip of oil seal. • Install the bearing stopper 0.
  • Page 192
    • Install the dust seal with the special tool. # 09940-51410: Steering bearing installer 09925-18011: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the lip of the dust seal. Use a new dust seal to prevent oil leakage. ‘ 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 193: Final Gear Case Installation

    4-28 DRIVELINE/AXLE • Apply SUZUKI BOND to the mating surface of final gear case. & 99000-31140: SUZUKI BOND “1207B” or equivalent • Install the stopper plate F to the final gear case. When installing the plate, fit the protrusion B of plate to the one of the bearing stopper grooves.

  • Page 194
    DRIVELINE/AXLE 4-29 • Install the final gear case. • Tighten the final gear case bolts to the specified torque. ! Final gear case nut: 40 N·m (4.0 kgf-m, 29.0 lb-ft) • Install the rear wheel. («9-39) • Pour final gear oil. («2-19)
  • Page 195: Fi System Diagnosis

    FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING …………..5- 3 ELECTRICAL PARTS …………….5- 3 FUSE…………………. 5- 4 ECM/VARIOUS SENSORS …………..5- 4 ELECTRICAL CIRCUIT INSPECTION PROCEDURE……5- 6 USING THE MULTI-CIRCUIT TESTER……….5- 9 FI SYSTEM TECHNICAL FEATURES…………5-10 INJECTION TIME (INJECTION VOLUME) ………..

  • Page 196
    FI SYSTEM DIAGNOSIS FI SYSTEM DIAGNOSIS CONTENTS “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION………………5-68 “C40” (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION………………5-70 “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION ….5-76 “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION …… 5-78 “C44”…
  • Page 197: Precautions In Servicing

    FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.

  • Page 198: Fuse

    FI SYSTEM DIAGNOSIS • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.

  • Page 199
    FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
  • Page 200: Electrical Circuit Inspection Procedure

    FI SYSTEM DIAGNOSIS ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

  • Page 201
    FI SYSTEM DIAGNOSIS Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 202
    FI SYSTEM DIAGNOSIS SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 203: Using The Multi-Circuit Tester

    FI SYSTEM DIAGNOSIS USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and — probes may cause the inside of the tester to burnout.

  • Page 204: Fi System Technical Features

    5-10 FI SYSTEM DIAGNOSIS FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 205: Compensation Of Injection Time (Volume)

    FI SYSTEM DIAGNOSIS 5-11 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.

  • Page 206: Fi System Parts Location

    5-12 FI SYSTEM DIAGNOSIS FI SYSTEM PARTS LOCATION A Tachometer B ISC valve (ISCV) C Intake air pressure sensor #2 (IAPS) D Ignition coil #1 (IG COIL) E Secondary throttle position sensor (STPS) F Throttle position sensor (TPS) G Secondary throttle valve actuator (STVA) H PAIR control solenoid valve (For E-02, 19, 24) I Ignition coil/plug cap #2 J HO2 sensor #2 (HO2S) [For E-02, 19, 24]…

  • Page 207
    FI SYSTEM DIAGNOSIS 5-13 A Speedometer B Intake air temperature sensor (IATS) C PAIR control solenoid valve D Fuel injector #1 E Fuel injector #2 F Intake air pressure sensor #1 (IAPS) G Fuel pump H Ignition coil/plug cap #1 I Tip-over sensor (TOS) J Fuel pump relay (FP RELAY) K Cooling fan relay…
  • Page 208: Fi System Wiring Diagram

    5-14 FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM…

  • Page 209: Ecm Terminal

    FI SYSTEM DIAGNOSIS 5-15 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT STVA signal (STVA. 2A) STVA signal (STVA. 2B) STVA signal (STVA. 1A) STVA signal (STVA. 1B) EXCVA power (MO–) STP sensor signal (STP) EXCVA power (MO+) Ignition switch signal EXCVA position sensor (MPS) TO sensor signal (TOS) Serial data for speedometer GP switch signal (GP)

  • Page 210
    5-16 FI SYSTEM DIAGNOSIS TERMINAL TERMINAL CIRCUIT CIRCUIT ISC signal (ISC, 2A) ISC signal (ISC, 2B) ISC signal (ISC, 1A) ISC signal (ISC, 1B) — — — — Fuel pump relay (FP Relay) — — — HO2 sensor heater (HO2, H) Mode select switch Starter relay Neutral switch…
  • Page 211: Self-Diagnosis Function

    FI SYSTEM DIAGNOSIS 5-17 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

  • Page 212: Dealer Mode

    5-18 FI SYSTEM DIAGNOSIS DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

  • Page 213
    FI SYSTEM DIAGNOSIS 5-19 CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, Generator Intake air pressure sensor #2 (IAPS #2) For Front cylinder Throttle position sensor (TPS) Engine coolant temp. sensor (ECTS) Intake air pressure sensor #1 (IAPS #1) For Rear cylinder Intake air temp.
  • Page 214: Tps Adjustment

    5-20 FI SYSTEM DIAGNOSIS TPS ADJUSTMENT 1. Warm up the engine and check the engine idle r/min. Adjust the engine rpm to 900 r/min if necessary. (#6-22) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. 3.

  • Page 215: Fail-Safe Function

    FI SYSTEM DIAGNOSIS 5-21 FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760…

  • Page 216: Fi System Troubleshooting

    5-22 FI SYSTEM DIAGNOSIS FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

  • Page 217: Visual Inspection

    FI SYSTEM DIAGNOSIS 5-23 MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous (…

  • Page 218: Self-Diagnostic Procedures

    5-24 FI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

  • Page 219: Use Of Sds Diagnostic Procedures

    FI SYSTEM DIAGNOSIS 5-25 USE OF SDS DIAGNOSTIC PROCEDURES * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

  • Page 220: Use Of Sds Diagnosis Reset Procedure

    5-26 FI SYSTEM DIAGNOSIS USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.

  • Page 221: Show Data When Trouble (Displaing Data At The Time Of Dtc)

    FI SYSTEM DIAGNOSIS 5-27 SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

  • Page 222: Malfunction Code And Defective Condition

    5-28 FI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

  • Page 223
    FI SYSTEM DIAGNOSIS 5-29 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
  • Page 224
    5-30 FI SYSTEM DIAGNOSIS DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve ISC valve motor current is higher than ISC valve circuit shorted to specified value. BATT or ground circuit open P0505 ISC valve motor circuit is open. ISC valve circuit open or BATT circuit open Idle speed is lower than the desired…
  • Page 225
    FI SYSTEM DIAGNOSIS 5-31 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1657) is indicated.
  • Page 226: C12″ (P0335) Ckp Sensor Circuit Malfunction

    5-32 FI SYSTEM DIAGNOSIS “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip. •…

  • Page 227
    FI SYSTEM DIAGNOSIS 5-33 6) If OK, then check the continuity between each terminal and ground. $ CKP sensor continuity: ∞ Ω (Infinity) (Blue – Ground) (Green – Ground) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
  • Page 228: C13″ (P1750-H/L) Or «C17» (P0105-H/L) Iap Sensor Circuit Malfunction

    5-34 FI SYSTEM DIAGNOSIS “C13” (P1750-H/L) or “C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C13/C17 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.5 V Sensor voltage <…

  • Page 229
    FI SYSTEM DIAGNOSIS 5-35 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire 3 and ground. 7) If OK, then measure the voltage at the Red wire 3 and B/Br wire 4.
  • Page 230
    5-36 FI SYSTEM DIAGNOSIS Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (#6-13) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total — voltage is 4.5 –…
  • Page 231
    FI SYSTEM DIAGNOSIS 5-37 Step 1 (When indicating P1750-H for IAP sensor #2) (When indicating P0105-H for IAP sensor #1) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity.
  • Page 232
    5-38 FI SYSTEM DIAGNOSIS 8) Check the continuity between P/B wire B and terminal 9 (#2), and G/B wire B and terminal P (#1). 9) If OK, then check the continuity between B/Br wire C (#1 and #2) and terminal S. «…
  • Page 233
    FI SYSTEM DIAGNOSIS 5-39 7) Disconnect the ECM coupler. (#5-37) 8) Check the continuity between Red wires A (#1 and #2) and terminal A. 9) Also, check the continuity between P/B wire B and terminal 9, and G/B wire B and terminal P. «…
  • Page 234
    5-40 FI SYSTEM DIAGNOSIS Step 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Reinstall the fuel tank and lift up the fuel tank. 3) Insert the needle pointed probes to the lead wire coupler. 4) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler.
  • Page 235: C14″ (P0120-H/L) Tp Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 5-41 “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION 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 open- • TP sensor malfunction ing and opening calculated by ECM is •…

  • Page 236
    5-42 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0120-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 237
    FI SYSTEM DIAGNOSIS 5-43 Step 1 (When indicating P0120-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 238
    5-44 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler and ECM coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground. $ TP sensor continuity: ∞ Ω (Infinity) (Terminal A –…
  • Page 239
    FI SYSTEM DIAGNOSIS 5-45 Step 3 1) Connect the TP sensor coupler 1 to the test harness. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + P/B and — B/Br) by turning the throttle grip. $ TP sensor output voltage Throttle valve is closed: Approx.
  • Page 240: C15″ (P0115-H/L) Ect Sensor Circuit Malfunction

    5-46 FI SYSTEM DIAGNOSIS “C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short range. • ECT sensor malfunction P0115 0.15 V Sensor voltage < 4.85 V •…

  • Page 241
    FI SYSTEM DIAGNOSIS 5-47 Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
  • Page 242
    5-48 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then measure the output voltage. 4) Disconnect the ECT sensor coupler.
  • Page 243
    FI SYSTEM DIAGNOSIS 5-49 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ECT sensor coupler. 3) Measure the ECT sensor resistance. $ ECT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Refer to page 8-9 for details.
  • Page 244: C21″ (P0110-H/L) Iat Sensor Circuit Malfunction

    5-50 FI SYSTEM DIAGNOSIS “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short range. • IAT sensor malfunction P0110 0.15 V Sensor voltage < 4.85 V •…

  • Page 245
    FI SYSTEM DIAGNOSIS 5-51 Step 1 (When indicating P0110-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
  • Page 246
    5-52 FI SYSTEM DIAGNOSIS Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
  • Page 247
    FI SYSTEM DIAGNOSIS 5-53 Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. $ IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Is the resistance OK? ECM coupler (Harness side) •…
  • Page 248: C23″ (P1651-H/L) To Sensor Circuit Malfunction

    5-54 FI SYSTEM DIAGNOSIS “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON.

  • Page 249
    FI SYSTEM DIAGNOSIS 5-55 Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 250
    5-56 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the fuel tank. (#6-3) 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 251
    FI SYSTEM DIAGNOSIS 5-57 Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Black and B/Br wires.
  • Page 252: C28″ (P1655) Stv Actuator Circuit Malfunction

    5-58 FI SYSTEM DIAGNOSIS “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction ECM does not receive communication signal from • STVA circuit open or short the STVA. •…

  • Page 253
    FI SYSTEM DIAGNOSIS 5-59 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. $ STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between Black wire A and Pink wire B) and (between Green wire C and W/BI wire D).
  • Page 254
    5-60 FI SYSTEM DIAGNOSIS ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.
  • Page 255: C29″ (P1654-H/L) Stp Sensor Circuit Malfunction

    FI SYSTEM DIAGNOSIS 5-61 “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted range. • STP sensor circuit open or short Difference between actual throttle open- • STP sensor malfunction ing and opening calculated by ECM is •…

  • Page 256
    5-62 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1654-H:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. STP sensor lead wire coupler: Black 4) Disconnect the STP sensor coupler.
  • Page 257
    FI SYSTEM DIAGNOSIS 5-63 Step 1 (When indicating P1654-L:) 1) Turn the ignition switch OFF. 2) Remove the right air cleaner box. (#6-13) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. STP sensor lead wire coupler: Black 4) Disconnect the STP sensor coupler.
  • Page 258
    5-64 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner chamber. (#6-13) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground. $ STP sensor continuity: ∞ Ω (Infinity) (Terminal –…
  • Page 259
    FI SYSTEM DIAGNOSIS 5-65 Step 3 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler and install the test har- ness. 3) Disconnect the STVA lead wire coupler. 4) Turn the ignition switch ON. 5) Measure the STP sensor output voltage at the terminals (between + terminal A Y/W wire and — terminal C B/Br wire) by turning the secondary throttle valve (close and open) with a finger.
  • Page 260: C31″ (P0705) Gp Switch Circuit Malfunction

    5-66 FI SYSTEM DIAGNOSIS “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage • Gear Position switch circuit open or short Switch voltage is not within the following range. • Gear Position switch malfunction Switch voltage >…

  • Page 261
    FI SYSTEM DIAGNOSIS 5-67 Is the voltage OK? ECM coupler (Harness side) • Pink wire open or shorted to ground (Black) (Gray) • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
  • Page 262: C32″ (P0201) Or «C33» (P0202) Fuel Injector Circuit Malfunction

    5-68 FI SYSTEM DIAGNOSIS “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by 4 times or more. • Injector malfunction. •…

  • Page 263
    FI SYSTEM DIAGNOSIS 5-69 5) If OK, then check the continuity between each terminal and ground. $ STP sensor continuity: ∞ Ω (Infinity) ! 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
  • Page 264: C40″ (P0505-H/L Or P0506 And P0507) Isc Valve Circuit Malfunction

    5-70 FI SYSTEM DIAGNOSIS “C40” (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE ISC valve motor current is higher than • ISC valve circuit shorted to BATT or ground circuit P0505 the specified value. open •…

  • Page 265
    FI SYSTEM DIAGNOSIS 5-71 INSPECTION Step 1 1) Remove the fuel tank. (#6-3) 2) Turn the ignition switch OFF. 3) Check the ISC valve coupler for loose or poor contacts. 4) If OK, then check the ISC valve lead wire continuity. 5) Disconnect the ISC valve coupler and ECM coupler.
  • Page 266
    5-72 FI SYSTEM DIAGNOSIS Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ISC valve coupler. 3) Check the continuity between terminals 1 and 3, terminals 2 and 4. $ ISC valve continuity: Approx. ∞ Ω (Infinity) (Terminal 1 – Terminal 3) (Terminal 2 –…
  • Page 267
    FI SYSTEM DIAGNOSIS 5-73 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 1. 5) Check that the “Spec”…
  • Page 268
    5-74 FI SYSTEM DIAGNOSIS Check 2 1) Click the button 1 and decrease the “Spec” 2 to 800 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. At the same time, check that the number of steps in the ISC valve position decreases 3) Click the button 4 and increase the “Spec”…
  • Page 269
    FI SYSTEM DIAGNOSIS 5-75 Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 200 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC valve position increases «…
  • Page 270: C41″ (P0230-H/L) Fp Relay Circuit Malfunction

    5-76 FI SYSTEM DIAGNOSIS “C41” (P0230-H/L) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump • Fuel pump relay circuit open or short although fuel pump relay is turned ON, • Fuel pump relay malfunction or voltage is applied to fuel pump, •…

  • Page 271
    FI SYSTEM DIAGNOSIS 5-77 Step 1 (When indicating P0230-H:) 1) Turn the ignition switch OFF. 2) Remove the right frame side cover. (#9-5) 3) Check the FP relay coupler for loose or poor contacts. If OK, then check the FP relay. (#6-6) Is the FP relay OK? ECM coupler (Harness side) •…
  • Page 272: C42″ (P01650) Ig Switch Circuit Malfunction

    5-78 FI SYSTEM DIAGNOSIS “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Ignition switch signal is not input to the ECM. • Ignition system circuit open or short • ECM malfunction INSPECTION * Refer to the IGNITION SWITCH INSPECTION for details. (#10-42)

  • Page 273: C44″ (P0156/P0161) Or «C64» (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (For E-02, 19, 24)

    FI SYSTEM DIAGNOSIS 5-79 “C44” (P0156/P0161) or “C64” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24) DETECTED CONDITION POSSIBLE CAUSE C44/C64 HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0156/ to ECM during engine operation and •…

  • Page 274
    5-80 FI SYSTEM DIAGNOSIS 6) Disconnect the ECM coupler. (#5-37) 7) Check the continuity between W/G or W/Bl wire A and termi- nal B, E. 8) Also, check the continuity between B/Br wire B and terminal » When using the multi-circuit tester, do not strongly (Gray) (Black) touch the terminal of the ECM coupler with a needle…
  • Page 275
    FI SYSTEM DIAGNOSIS 5-81 Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to (Black) (Gray) ground, or poor B, E or S connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM.
  • Page 276
    5-82 FI SYSTEM DIAGNOSIS Step 2 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W/B wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
  • Page 277: C46″ (P1657-H/L Or P1658) Excv Actuator Circuit Malfunction

    FI SYSTEM DIAGNOSIS 5-83 “C46” (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation signal does not reach the • EXCVA maladjusted EXCV actuator. • EXCVA circuit open or short EXCVA position sensor voltage low or •…

  • Page 278
    5-84 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1657-H:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
  • Page 279
    FI SYSTEM DIAGNOSIS 5-85 Step 1 (When indicating P1657-L:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA position sensor coupler for loose or poor contacts. If OK, then check the EXCVA position sensor lead wire conti- nuity.
  • Page 280
    5-86 FI SYSTEM DIAGNOSIS Step 1 (When indicating P1658:) 1) Turn the ignition switch OFF. 2) Remove the lower frame cover. (#7-8) 3) Check the EXCVA motor coupler for loose or poor contacts. Is the contacting OK? Go to Step 6. Loose or poor contacts on the EXCV motor cou- pler 4) After repairing the trouble, clear the DTC using SDS tool.
  • Page 281
    FI SYSTEM DIAGNOSIS 5-87 Step 3 1) Turn the ignition switch OFF. 2) Check the continuity between Yellow wire and ground. $ Position sensor continuity: ∞ Ω (Infinity) 3) If OK, then measure the position sensor resistance. 4) Connect the position sensor coupler. 5) Set the EXCVA to adjustment position.
  • Page 282
    5-88 FI SYSTEM DIAGNOSIS Step 4 1) Turn the ignition switch OFF. 2) Connect the position sensor coupler. 3) Measure the position sensor output voltage at fully close posi- tion and fully open position. 4) Insert the needle pointed probes to the back side of the posi- tion sensor lead wire coupler.
  • Page 283
    FI SYSTEM DIAGNOSIS 5-89 Step 5 1) If the position sensor output voltage is 0.5 V and less at fully close position, adjust the output voltage to specified by turn- ing out the No. 1 cable adjuster 1. 2) Repeat the above procedure (Step 4) until the out put voltage becomes specified value.
  • Page 284
    5-90 FI SYSTEM DIAGNOSIS Step 6 1) Turn the ignition switch OFF. 2) Disconnect the motor lead wire coupler of the EXCVA. 3) Apply 12 volts to the terminal and check the operation of EXCVA. 12 V 4) Then, swap the wires supplied 12 volts and check the opera- tion of EXCVA.
  • Page 285
    FI SYSTEM DIAGNOSIS 5-91 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Exhaust valve operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the EXCVA, the function is normal.
  • Page 286: C49″ (P1768) Or «C61» (P1656) Pair Control Solenoid Valve Circuit Malfunction

    5-92 FI SYSTEM DIAGNOSIS “C49” (P1768) or “C61” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short ECM. • PAIR control solenoid valve malfunction •…

  • Page 287
    FI SYSTEM DIAGNOSIS 5-93 Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/B wire and ground. $ PAIR valve voltage: Battery voltage (+ O/B – — Ground) ! 09900-25008: Multi-circuit tester set & Tester knob indication: Voltage (‘) Is the voltage OK? ECM coupler (Harness side) •…
  • Page 288: C60″ (P0480) Cooling Fan Relay Circuit Malfunction

    5-94 FI SYSTEM DIAGNOSIS “C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short • ECM malfunction Side-stand Ignition Cooling fan relay switch relay To Side-stand…

  • Page 289
    FI SYSTEM DIAGNOSIS 5-95 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click the operate button 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal.
  • Page 290
    5-96 FI SYSTEM DIAGNOSIS 6) Click the off button 4 to check the cooling fan relay and cooling fan motor operation. NOTE: This inspection should be begun from when the engine coolant temperature is below 50 °C (122 °F). Check that the cooling fan relay operates for a few seconds as the engine coolant temperature arrives each at 50 °C (122 °F), 70 °C (158 °F) and 90 °C (194 °F) / above 4 000 r/min.
  • Page 291: Sensors

    FI SYSTEM DIAGNOSIS 5-97 SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the right and left side of the air cleaner box. (#6-13) IAP SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the IAP sensors from the air cleaner chamber. •…

  • Page 292: Stp Sensor Inspection

    5-98 FI SYSTEM DIAGNOSIS STP SENSOR INSPECTION The secondary throttle position sensor is installed on the No. 2 throttle body. (#5-61) STP SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the right air cleaner box. (#6-13) •…

  • Page 293: Iat Sensor Inspection

    FI SYSTEM DIAGNOSIS 5-99 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the front left side of the air cleaner box. (#5-50) IAT SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank. (#6-3) • Remove the IAT sensor from the air cleaner chamber. •…

  • Page 294: Ho2 Sensor Inspection (For E-02, 19, 24)

    5-100 FI SYSTEM DIAGNOSIS HO2 SENSOR INSPECTION (FOR E-02, 19, 24) The heated oxygen sensor is installed on the pre-muffler. (#5-79) HO2 SENSOR REMOVAL AND INSTALLATION (FOR E-02, 19, 24) • Remove the HO2 sensor unit. Do not remove the HO2 sensor while it is hot. «…

  • Page 295: Fuel System And Throttle Body

    FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL DELIVERY SYSTEM…………….6- 2 FUEL SYSTEM………………… 6- 3 FUEL TANK REMOVAL……………. 6- 3 FUEL TANK INSTALLATION …………… 6- 3 FUEL PRESSURE INSPECTION …………6- 4 FUEL PUMP INSPECTION …………..6- 5 FUEL DISCHARGE AMOUNT INSPECTION ……..

  • Page 296: Fuel Delivery System

    FUEL SYSTEM AND THROTTLE BODY FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

  • Page 297: Fuel System

    FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM FUEL TANK REMOVAL • Remove the left and right frame side covers. («9-5) • Remove the fuel tank mounting bolt. • Lift and support the fuel tank about 10 cm (3.94 in) with the proper stay.

  • Page 298: Fuel Pressure Inspection

    FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE INSPECTION • Lift and support the fuel tank. («6-3) • Place a rag under the fuel feed hose. • Disconnect the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.

  • Page 299: Fuel Pump Inspection

    FUEL SYSTEM AND THROTTLE BODY FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.

  • Page 300: Fuel Pump Relay Inspection

    FUEL SYSTEM AND THROTTLE BODY FUEL PUMP RELAY INSPECTION Cooling fan relay is located in front of the battery. • Remove the right side frame cover. («9-5) • Remove the fuel pump relay 1. First check the insulation between A and B terminals with tester.

  • Page 301: Fuel Pump And Fuel Level Gauge Removal

    FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Thermistor 5 O-ring 2 Fuel pump 6 Fuel level gauge ITEM N·m kgf-m lb-ft 3 Fuel mesh filter A Fuel pump mounting bolt 4 Filter cover…

  • Page 302: Fuel Level Gauge Inspection

    FUEL SYSTEM AND THROTTLE BODY REMOVAL • Remove the fuel tank. («6-3) • Remove the fuel tank shield 1. A: Clamp • Remove the fuel pump assembly 2 mounting bolts diago- nally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. •…

  • Page 303: Fuel Pump Disassembly

    FUEL SYSTEM AND THROTTLE BODY FUEL PUMP DISASSEMBLY • Disconnect the fuel pump coupler 1. • Remove the band 2 and clamp 3. • Remove the hose 4 and filter cover 5. • Remove the clamp 6 and thermistor 7. •…

  • Page 304: Fuel Mesh Filter Inspection

    6-10 FUEL SYSTEM AND THROTTLE BODY FUEL MESH FILTER INSPECTION • Disconnect the clamp 1 and rubber boot 2. If the fuel mesh filter is clogged with sediment or rust, replace the fuel filter with a new one. FUEL PUMP AND FUEL LEVEL GAUGE REASSEMBLY AND INSTALLATION Install the fuel pump and fuel level gauge in the reverse order of removal and disassembly.

  • Page 305
    FUEL SYSTEM AND THROTTLE BODY 6-11 • Apply thin coat of the engine oil to the bushing. • Install the fuel pump 1. • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. ) 99000-25010: SUZUKI SUPER GREASE “A” or equivalent The O-ring must be replaced with a new one to prevent fuel leakage.
  • Page 306: Throttle Body

    6-12 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY CONSTRUCTION Only for E-33 1 TP sensor 8 Cushion seal 2 STP sensor 9 Air screw 3 STVA 0 ISC valve 4 Fuel delivery pipe A Vacuum hose ITEM N·m kgf-m lb-ft 5 IAP sensor A Fuel delivery pipe mounting screw 6 O-ring…

  • Page 307: Air Cleaner Box Removal

    FUEL SYSTEM AND THROTTLE BODY 6-13 AIR CLEANER BOX REMOVAL • Remove the fuel tank. («6-3) • Remove the bolts. *: Hooked part • Disconnect the drain hose 1. • Loosen the clamp screw 2. • Remove the right air cleaner box. •…

  • Page 308
    6-14 FUEL SYSTEM AND THROTTLE BODY • Disconnect the PCV hose 8. • Loosen the throttle body clamp screws at the air cleaner chamber side. • Disconnect the PAIR lead wire couplers 9 and hoses 0. • Remove the air cleaner chamber. For E-03, 28, 33 For the others •…
  • Page 309: Throttle Body Disassembly

    FUEL SYSTEM AND THROTTLE BODY 6-15 • Disconnect the clamp and fuel injector lead wire couplers D. • Loosen the throttle body clamp screws at the intake pipe side. • Disconnect the throttle cables from their drum. • Remove the throttle body assembly. Do not snap the throttle valve from full open to full close after disconnecting the throttle cables.

  • Page 310
    6-16 FUEL SYSTEM AND THROTTLE BODY • Remove the fuel injectors 5. • Remove the TP sensor 6 and STP sensor 7 with the special tool. $ 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation.
  • Page 311: Throttle Body Cleaning

    FUEL SYSTEM AND THROTTLE BODY 6-17 THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean passageways (except for main bore) with a spray-type carburetor cleaner and blow dry with compressed air.

  • Page 312: Isc Valve Removal

    6-18 FUEL SYSTEM AND THROTTLE BODY ISC VALVE REMOVAL Disconnect the hoses and remove the ISC valve 1. INSPECTION Check the ISC valve for wear or damage, replace it with a new one if necessary. ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal.

  • Page 313: Throttle Body Reassembly

    * Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary. ) 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 314
    6-20 FUEL SYSTEM AND THROTTLE BODY • Apply thin coat of the engine oil to the new cushion seal 3, and the O-ring 4. Replace the cushion seal and O-ring with the new ones. • Install the fuel injector 5 by pushing it straight to the delivery pipe 6.
  • Page 315: Air Cleaner Chamber And Throttle Body Installation

    FUEL SYSTEM AND THROTTLE BODY 6-21 AIR CLEANER CHAMBER AND THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position. The color on each lead wire refers to the appropriate fuel injector.

  • Page 316: Stp Sensor Adjustment

    6-22 FUEL SYSTEM AND THROTTLE BODY STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the air cleaner chamber. («6-13) • Disconnect the STVA coupler. («6-14) •…

  • Page 317: Fuel Injector Installation

    FUEL SYSTEM AND THROTTLE BODY 6-23 FUEL INJECTOR INSTALLATION • Apply thin coat of the engine oil to new injector cushion seals and O-rings. («6-20) • Install the injector by pushing it straight to the throttle body. Never turn the injector while pushing it. («6-20) THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders.

  • Page 318: Throttle Position Sensor (Tps) Setting

    6-24 FUEL SYSTEM AND THROTTLE BODY Step 2 • Warm up the engine as follows: Summer: approx. 5 min at idle r/min Winter: approx. 8 min at idle r/min • Water temperature should be more than 80 °C (176 °F) and then wait 30 second.

  • Page 319: Exhaust System

    EXHAUST SYSTEM EXHAUST SYSTEM CONTENTS EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE)……….7- 2 EXCVA AND EXCV REMOVAL …………. 7- 2 EXCVA INSPECTION…………….7- 3 EXCV INSPECTION …………….7- 3 CABLE INSPECTION …………….7- 3 EXCVA AND EXCV INSTALLATION…………. 7- 3 EXCVA ADJUSTMENT …………….

  • Page 320: Excva (Exhaust Control Valve Actuator) And Excv (Exhaust Control Valve)

    EXHAUST SYSTEM EXCVA (EXHAUST CONTROL VALVE ACTUATOR) AND EXCV (EXHAUST CONTROL VALVE) EXCVA AND EXCV REMOVAL • Turn the ignition switch OFF. • Remove the left frame side cover. (!9-5) • Connect the special tool (Mode select switch) to the dealer mode coupler.

  • Page 321: Excva Inspection

    EXHAUST SYSTEM • Disconnect the No. 2 cable 3 and then No. 1 cable 4 from the pulley. • Remove the EXCVA 5. • Remove the EXCV cover 6 from the EXCV pulley. • Disconnect the No. 1 7 and No. 2 8 cables. EXCVA INSPECTION !5-83 EXCV INSPECTION…

  • Page 322: Excva And Excv Installation

    EXHAUST SYSTEM EXCVA AND EXCV INSTALLATION Install the EXCVA and EXCV in the reverse order of removal. Pay attention to the following points: • Connect the EXCV cables temporarily to the EXCV pulley. • Adjust the clearance A between the adjuster end and EXCV pulley to provide 4 mm (0.16 in) and more.

  • Page 323
    EXHAUST SYSTEM • Check the EXCVA to adjustment position. (!7-2) Do not use the adjustable wrench to turn EXCVA pul- ley so as not to cause damage to the internal gear of EXCVA. • Install the pulley 8 to the shaft 9. NOTE: Make sure that the shaft’s line D and cable slots E facing upward as shown.
  • Page 324: Excva Adjustment

    EXHAUST SYSTEM EXCVA ADJUSTMENT 1st step: • Set the EXCVA to adjustment position. (!7-2) • Make sure that the No. 2 cable and No. 1 cable are fixed into the clamp. 2nd step: • Turn the mode select switch OFF. •…

  • Page 325
    EXHAUST SYSTEM • To set the EXCV to fully close position, apply 12 volts to A and B terminals. Positive wire –– A (Pink wire) terminal Negative wire –– B (Gray wire) terminal To prevent the motor damage, stop applying 12 V as soon as the EXCV reaches fully close position.
  • Page 326: Exhaust Pipe And Muffler

    EXHAUST SYSTEM Measure the position sensor output voltage at fully open posi- tion. % Position sensor output voltage EXCV is fully open: 3.5 output voltage 4.5 V (+ Yellow – — B/Br) If the measured voltage is more than specification, adjust the No.2 cable adjuster as follows: •…

  • Page 327
    EXHAUST SYSTEM • Disconnect the front and rear HO2 sensor lead wire couplers. (For E-02, 19, 24) • Remove the muffler cover 3. • Remove the No. 1 muffler 4. • Remove the right frame lower cover 5. NOTE: “ ( ” indicates hook location.
  • Page 328: Installation

    7-10 EXHAUST SYSTEM • Remove the exhaust pipes 6 and the No. 2 muffler 7. INSTALLATION Install the exhaust pipe and muffler in the reverse order of removal. Play attention to the following points: • Install the exhaust pipes 1 with the No. 2 muffler 2. Replace the gaskets with new ones.

  • Page 329
    EXHAUST SYSTEM 7-11 • Install the No. 1 muffler 3. • Tighten the No. 1 muffler bolts and muffler connecting bolts. $ Muffler mounting bolt : 23 N·m (2.3 kgf-m, 16.5 lb-ft)
  • Page 330
    7-12 EXHAUST SYSTEM 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler (#1) Muffler (#2) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) HO2 sensor (For E-02, 19, 24) 4.0 mm (0.16 in) and more 8.5 –…
  • Page 331: Cooling And Lubrication System

    COOLING AND LUBRICATION SYSTEM COOLING AND LUBRICATION SYSTEM CONTENTS ENGINE COOLANT ………………8- 2 COOLING CIRCUIT ………………8- 3 COOLING CIRCUIT INSPECTION…………8- 3 RADIATOR AND WATER HOSE…………..8- 4 RADIATOR REMOVAL AND DISASSEMBLY ……..8- 4 RADIATOR DISASSEMBLY …………..8- 5 RADIATOR CAP INSPECTION………….

  • Page 332: Engine Coolant

    COOLING AND LUBRICATION SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat pro- tection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).

  • Page 333: Cooling Circuit

    COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT RESERVOIR ENGINE COOLANT THERMOSTAT TEMPERATURE CYLINDER HEAD TANK SENSOR CYLINDER RADIATOR WATER PUMP COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the fuel tank. (#6-3) •…

  • Page 334: Radiator And Water Hose

    COOLING AND LUBRICATION SYSTEM RADIATOR AND WATER HOSE RADIATOR REMOVAL AND DISASSEMBLY • Remove the fuel tank. (#6-3) • Remove the frame head covers and radiator covers. (#9-6) • Drain the engine coolant. (#2-20) • Disconnect the reservoir hose 1 and cooling fan lead wire coupler 2.

  • Page 335: Radiator Disassembly

    COOLING AND LUBRICATION SYSTEM RADIATOR DISASSEMBLY • Remove the reservoir tank 1. • Remove the coolong fan 2 and shield 3. • Remove the radiator guard 4. RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. •…

  • Page 336: Radiator Inspection And Cleaning

    COOLING AND LUBRICATION SYSTEM RADIATOR INSPECTION AND CLEANING • Road dirt or trash stuck on the fins must be removed. • Use of compressed air is recommended for this cleaning. • Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver.

  • Page 337: Water Hose Inspection

    COOLING AND LUBRICATION SYSTEM WATER HOSE INSPECTION • Remove the fuel tank. (#6-3) • Remove the frame head covers and radiator covers. (#9-6) • Remove the left and right air cleaner boxs. (#6-13) • Remove the secondary gear case cover. (#3-6) •…

  • Page 338: Cooling Fan

    COOLING AND LUBRICATION SYSTEM COOLING FAN INSPECTION • Remove the right frame head cover and right radiator cover. (#9-6) • Disconnect the cooling fan coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. •…

  • Page 339: Ect Sensor

    COOLING AND LUBRICATION SYSTEM ECT SENSOR REMOVAL • Drain the engine coolant. (#2-20) • Remove the air cleaner chamber and throttle body. (#6-13) • Disconnect the ECT sensor coupler 1. • Remove the rear intake pipe and thermostat assembly. (#3-13) •…

  • Page 340: Installation

    8-10 COOLING AND LUBRICATION SYSTEM If the resistance is noted to show infinity or too much different resistance value, replace the ECT sensor with a new one. * Take special care when handling the ECT sensor. It may cause damage if it gets a sharp impact. * Do not contact the ECT sensor and the column ther- mometer with a pan.

  • Page 341: Thermostat

    COOLING AND LUBRICATION SYSTEM 8-11 THERMOSTAT REMOVAL • Remove the left air cleaner box. (#6-13) • Place a rag under the thermostat cover. • Remove the thermostat cover 1. • Remove the thermostat 2. INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner.

  • Page 342: Installation

    8-12 COOLING AND LUBRICATION SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8 mm (0.31 in). $ Thermostat valve lift A Standard: 8.0 mm and over at 100 °C (0.31 in and over at 212 °F) •…

  • Page 343: Water Pump

    COOLING AND LUBRICATION SYSTEM 8-13 WATER PUMP REMOVAL AND DISASSEMBLY NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal washer.

  • Page 344
    8-14 COOLING AND LUBRICATION SYSTEM • Remove the water pump cover 3. • Remove the impeller securing bolt by holding the impeller with a water pump pliers. • Remove the mechanical seal ring 4 and rubber seal 5 from the impeller. •…
  • Page 345: Inspection

    COOLING AND LUBRICATION SYSTEM 8-15 • Remove the oil seal 9. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one. INSPECTION MECHANICAL SEAL •…

  • Page 346: Reassembly And Installation

    % 09913-70210: Bearing installer set ()22) NOTE: The stamped mark on the oil seal faces mechanical seal side. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. * 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 347
    COOLING AND LUBRICATION SYSTEM 8-17 • Apply SUZUKI SUPER GREASE “A” to the impeller shaft and O-ring. Use the new O-ring to prevent engine oil leakage. * 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the impeller shaft 1, washer 2 and O-ring 3 to the water pump body.
  • Page 348
    8-18 COOLING AND LUBRICATION SYSTEM • Install the new O-ring 9. Use the new O-ring to prevent engine coolant leakage. NOTE: Apply engine coolant to the O-ring. • Tighten the water pump cover screws. • Install the water pump. NOTE: Set the water pump shaft end E to the oil pump shaft F as shown.
  • Page 349: Engine Lubrication System Chart

    COOLING AND LUBRICATION SYSTEM 8-19 ENGINE LUBRICATION SYSTEM CHART…

  • Page 350
    CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ………………9- 3 FASTENER REMOVAL AND INSTALLATION……..9- 3 FRONT AND REAR SEAT …………..9- 4 FRAME SIDE COVER …………….9- 5 REAR FRAME COVER …………….. 9- 5 FRAME HEAD COVER AND RADIATOR COVER ……. 9- 6 FRONT WHEEL ……………….
  • Page 351
    CHASSIS CHASSIS CONTENTS REASSEMBLY ………………9-46 INSTALLATION………………9-49 SUSPENSION SETTING …………… 9-50 FRONT BRAKE……………….. 9-51 CONSTRUCTION ……………… 9-51 BRAKE PAD REPLACEMENT …………. 9-52 BRAKE FLUID REPLACEMENT …………9-53 CALIPER REMOVAL …………….9-54 CALIPER DISASSEMBLY …………..9-55 CALIPER INSPECTION ……………. 9-56 CALIPER REASSEMBLY …………..
  • Page 352: Exterior Parts

    CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION FASTENER (Type A) Removal • Depress the head of fastener center piece 1. • Pull out the fastener a. Installation • Let the center piece stick out toward the head so that the pawls 2 close.

  • Page 353: Front And Rear Seat

    CHASSIS Installation • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole. • Push in the head of center piece. FRONT AND REAR SEAT REMOVAL •…

  • Page 354: Frame Side Cover

    CHASSIS FRAME SIDE COVER REMOVAL • Remove the front seat. (!9-4) • Remove the left frame side cover 1. NOTE: “»” indicates hook location. • Disconnect the seat lock cable 2. • Remove the right frame side cover 3. NOTE: “»”…

  • Page 355: Frame Head Cover And Radiator Cover

    CHASSIS FRAME HEAD COVER AND RADIATOR COVER REMOVAL • Remove the fuel tank. (!6-3) • Remove the right frame head cover 1 and left frame head cover 2. • Remove the right radiator cover 3 by removing the bolt 4 and fastener 5.

  • Page 356
    CHASSIS INSTALLATION Install the frame head covers and radiator covers in the reverse order of removal. Pay attention to the following points: • Install the radiator bottom cover 1. NOTE: Pass the breather hose A in the hole B of a radiator bottom cover.
  • Page 357: Front Wheel

    CHASSIS FRONT WHEEL CONSTRUCTION 1 Brake disc 5 Collar 2 Dust seal 6 Front wheel ITEM N·m kgf-m lb-ft 3 Bearing A Front axle 10.0 72.5 4 Spacer B Brake disc bolt 23.0 16.5…

  • Page 358: Removal

    CHASSIS REMOVAL • Remove the brake calipers 1, left and right. Do not operate the brake lever while removing the cal- ipers. • Loosen the two axle pinch bolts 2 on the right front fork leg. • Loosen the front axle with the special tool. % 09900-18740: Hexagon socket (24 mm) •…

  • Page 359
    9-10 CHASSIS WHEEL • Make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.
  • Page 360: Reassembly And Installation

    Left Right 23 N·m (2.3 kgf-m, 16.5 lb-ft) 23 N·m (2.3 kgf-m, 16.5 lb-ft) 100 N·m (10.0 kgf-m, 72.5 lb-ft) WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…

  • Page 361
    The sealed cover of the bearing must face outside. Clearance • Install the dust seal with the special tool. % 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent BRAKE DISC •…
  • Page 362
    CHASSIS 9-13 WHEEL • Install the collar 1 in the left side. • Install the front wheel with the front axle and tighten the front axle with hand temporarily. The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. FRONT AXLE •…
  • Page 363: Front Fork

    9-14 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 6 Oil seal stopper ring A Front fork cap bolt 2 Spacer 7 Dust seal B Inner rod lock nut 3 Outer tube 8 Spring C Damper rod bolt 4 Oil seal retainer 9 Inner rod/Damper rod (cartridge) D Front axle pinch bolt 5 Oil seal…

  • Page 364: Removal And Disassembly

    CHASSIS 9-15 REMOVAL AND DISASSEMBLY • Remove the front wheel. (!9-9) • Remove the bolts, left and right and front fender. • Remove the fasteners 1 and bolts 2. • Remove the head light assembly and disconnect the cou- plers. •…

  • Page 365
    9-16 CHASSIS • Remove the front fork cap bolt 5 from the inner rod by loos- ening the lock nut. • Remove the special tools. After removing the front fork cap bolt 5, avoid hold- ing the outer tube vertically by hand to prevent the inner tube from falling and damaged.
  • Page 366
    CHASSIS 9-17 • Remove the inner rod/damper rod (cartridge) 8. Do not disassemble the inner rod/damper rod (car- tridge). • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal 9 and oil seal stopper ring 0. •…
  • Page 367: Inspection

    9-18 CHASSIS INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with a new one. Do not remove the “ANTI-FRICTION”…

  • Page 368: Reassembly

    CHASSIS 9-19 REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1 Dust seal 2 Oil seal stopper ring 3 Oil seal…

  • Page 369
    • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube. + 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
  • Page 370
    CHASSIS 9-21 FRONT FORK INNER ROD LOCK NUT • Loosen the lock nut 1 to the bottom of inner rod threads. FORK SPRING • Install the fork spring as shown in the illustration. Upper side Lower side • Install the spring 1 and spacer 2. FRONT FORK CAP BOLT •…
  • Page 371: Installation

    9-22 CHASSIS INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Install the front fork to the steering stem and steering stem upper bracket. • Install the top of outer tube 5 mm (0.2 in) higher than the 5 mm upper surface of the steering stem upper bracket and tighten (0.2 in)

  • Page 372: Steering

    CHASSIS 9-23 STEERING CONSTRUCTION 1 Handlebar clamp 6 Dust seal B Handlebar holder bracket bolt 2 Handlebar clamp holder 7 Steering stem upper bearing C Steering stem head nut 3 Handlebar holder bracket 8 Steering stem lower bearing D Front fork upper clamp bolt 4 Steering stem upper bracket 9 Steering stem E Handlebar holder bolt 5 Steering stem nut…

  • Page 373: Removal

    9-24 CHASSIS REMOVAL • Remove the front forks. (!9-15) • Remove the handlebar. (!9-30) • Remove the tachometer. (!10-32) • Remove the turn signal mounting bolts 1, brake hose guide bolts 2 and brake hose mounting bolt 3. • Remove the steering stem head nut 4 and washer. •…

  • Page 374: Inspection And Disassembly

    CHASSIS 9-25 • Remove the handlebar holder 9 from the steering stem upper bracket. • Remove the following parts. 0 Bolt A Rubber cushion B Rubber washer C Washer INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Distortion of the steering stem.

  • Page 375: Reassembly

    Install the steering stem in the reverse order of removal. Pay attention to the following points: BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Install the upper bearing 1 to the steering stem.

  • Page 376
    CHASSIS 9-27 • Tighten the steering stem nut to the specified torque with the special tool. % 09940-14911: Steering stem nut wrench # Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft) • Turn the steering stem lower bracket about five or six times to the left and right so that the bearing will be seated properly.
  • Page 377: Steering Tension Adjustment

    9-28 CHASSIS Tighten the following points: • Tighten the handlebar bracket bolts to the specified torque. # Handlebar holder bracket bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Install the tachometer. (!10-32) • Install the handlebar. (!9-31) # Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) •…

  • Page 378: Handlebars

    CHASSIS 9-29 HANDLEBARS CONSTRUCTION 1 Handlebars 3 Left handlebar grip 5 Right handlebar grip 2 Grip end cap 4 Left handlebar switch 6 Right handlebar switch…

  • Page 379: Removal

    9-30 CHASSIS REMOVAL • Remove the right rear view mirror 1. • Remove the brake master cylinder 2. • Remove the throttle grip end cap 3. • Disconnect the front brake switch lead wire coupler 4 and remove the right handlebar switch 5. •…

  • Page 380: Installation

    CHASSIS 9-31 INSTALLATION Install the handlebar in the reverse order of removal. Pay atten- tion to the following points: • When setting the handlebar clamp to the handlebar holder, face the punched mark A to the forward. • Align the punched mark B on handlebars with the handlebar clamp mating surface as shown.

  • Page 381
    9-32 CHASSIS • Install the front brake master cylinder. (!9-61) • Apply the SUZUKI SUPER GREASE “A” to the throttle cables and their holder. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • When remounting the right and left handlebar switches, engage the stopper with the handlebar hole.
  • Page 382: Rear Wheel

    CHASSIS 9-33 REAR WHEEL CONSTRUCTION 1 Rear axle 7 Damper C Collar 2 Spacer 8 O-ring D Brake disc 3 Bearing 9 Spacer E Cotter pin (For E-03, 28, 33) 4 Lock washer 0 Bearing A Rear brake disc bolt 5 Driven joint stopper A Rear wheel B Rear axle nut…

  • Page 383: Removal

    9-34 CHASSIS REMOVAL • Remove the brake caliper bracket mounting bolt 1. • Remove the cotter pin 2. (For E-03, 28, 33) • Hold the rear axle with the special tool and remove the axle nut 3. % 09944-28320: Hexagon socket •…

  • Page 384: Inspection And Disassembly

    CHASSIS 9-35 • Remove the O-ring 2. INSPECTION AND DISASSEMBLY WHEEL DAMPER • Inspect the damper for wear or damage. • Replace the damper if there is anything unusual. • Remove the dampers with a screw driver. WHEEL (!9-73) WHEEL AXLE (!9-9) TIRE (!2-27 and 9-73) BRAKE DISC (!9-69) •…

  • Page 385: Reassembly And Installation

    9-36 CHASSIS • Remove the wheel bearings on both sides with the special tool. % 09921-20240: Bearing remover set (25 mm) The removed bearings should be replaced with new ones. REASSEMBLY AND INSTALLATION Reassemble and install the rear wheel in the reverse order of removal and disassembly.

  • Page 386
    The sealed cover of the bearing must face outside. Clearance • Install the dust seal with the special tool. % 09913-70210: Bearing installer set (52 mm) • Apply SUZUKI SUPER GREASE “A” to the dust seal lip. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
  • Page 387
    • Install the new O-ring 1 and driven hub joint 2. NOTE: * Apply SUZUKI SUPER GREASE “A” to the O-ring and the final gear spline before installing the driven joint. * Align the driven joint flat surface A with the screw holes B of wheel.
  • Page 388
    CHASSIS 9-39 REAR WHEEL • Install the spacer 1. • Apply SUZUKI SUPER GREASE “A” to the final gear spline before installing the rear wheel. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Remount the rear wheel, rear axle and coller.
  • Page 389: Rear Suspension

    9-40 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 6 Dust seal B Rear cushion rod mounting nut 2 Rear cushion rod 7 Swingarm pivot bearing C Rear cushion lever mounting nut 3 Spacer 8 Swingarm D Swingarm pivot shaft 4 Rear cushion lever bearing 9 Boot 5 Rear cushion lever…

  • Page 390: Removal

    CHASSIS 9-41 REMOVAL • Remove the exhaust pipe and muffler. (!7-8) • Remove the rear wheel. (!9-34) • Remove the final gear case. (!4-15) • Remove the under plate 1. • Remove the regulator/rectifier 2. • Remove the rear shock absorber front mounting bolt and nut. •…

  • Page 391: Inspection And Disassembly

    9-42 CHASSIS • Loosen the swingarm pivot pinch bolt 5. • Loosen the swingarm pivot shaft with the special tool. % 09944-28320: Hexagon socket • Draw out the swingarm pivot shaft. • Remove the rear suspension assembly. • Remove the cushion rods 6 and cushion lever 7. •…

  • Page 392
    CHASSIS 9-43 • Remove the swingarm pivot bearings 1 with the special tools. % 09923-74511: Bearing remover set 09930-30104: Sliding shaft The removed bearings must be replaced with new ones. CUSHION LEVER BEARING • Insert the spacer into bearings and check the play when mov- ing the spacer up and down.
  • Page 393
    9-44 CHASSIS CUSHION ROD BEARING • Insert the spacer into bearings and check the play when mov- ing the spacer up and down. • If excessive play is noted, replace the bearings with a new one. • Remove the cushion lever bearings 1 with the special tool. % 09913-70210: Bearing installer set (25 mm) The removed bearings must be replaced with new ones.
  • Page 394: Rear Shock Absorber Disposal

    CHASSIS 9-45 SWINGARM PIVOT SHAFT • Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. & Swingarm pivot shaft runout: Service limit: 0.3 mm (0.01 in) % 09900-20607: Dial gauge (1/100 mm, 10 mm) 09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) REAR SHOCK ABSORBER DISPOSAL…

  • Page 395: Reassembly

    9-46 CHASSIS REASSEMBLY Reassemble the rear suspension in the reverse order of disassembly and removal. Pay attention to the following points: NOTE: Tightening order are E to F . 1 1.0 mm (0.04 in) C Rear cushion lever lower nut 2 4.5 mm (0.17 in) D Rear cushion rod nut ITEM…

  • Page 396
    • Install the dust seals into the cushion lever with the special tool. % 09913-70210: Bearing installer set (35 mm) NOTE: Apply SUZUKI SUPER GREASE “A” to the dust seals. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent SWINGARM BEARING •…
  • Page 397
    9-48 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the spacers. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent…
  • Page 398: Installation

    CHASSIS 9-49 INSTALLATION Remount the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the following points. CUSHION ROD AND CUSHION LEVER • Install the cushion rods 1 and cushion lever 2 onto the swin- garm temporarily.

  • Page 399: Suspension Setting

    9-50 CHASSIS • Tighten the swingarm pivot pinch bolt. CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER • Assemble the cushion rod, cushion lever and rear shock absorber onto the swingarm. (!9-46) • Tighten the rear shock absorber front mounting nut to the specified torque.

  • Page 400: Front Brake

    CHASSIS 9-51 FRONT BRAKE CONSTRUCTION 1 Dust boot 9 Brake pad 2 Piston set 0 Brake pad spring ITEM N·m kgf-m lb-ft 3 Cap A Master cylinder mounting bolt 4 Diaphrapm B Brake caliper mounting bolt 28.0 5 Master cylinder C Brake caliper air bleeder valve 0.75 6 Piston seal…

  • Page 401: Brake Pad Replacement

    9-52 CHASSIS * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

  • Page 402: Brake Fluid Replacement

    CHASSIS 9-53 NOTE: * Install the brake pad shims 3 onto the new brake pad, as shown. * The arrow mark on the brake shim must face to the direction of brake disc rotation. • Install the new brake pads. •…

  • Page 403: Caliper Removal

    9-54 CHASSIS • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system. •…

  • Page 404: Caliper Disassembly

    CHASSIS 9-55 CALIPER DISASSEMBLY • Remove the pad spring 1. • Remove the caliper air bleeder valve 2. • Separate the caliper halves by removing the caliper housing bolts 3 with the special tools. % 09930-11920: Torx bit JT40H 09930-11940: Bit holder •…

  • Page 405: Caliper Inspection

    9-56 CHASSIS CALIPER INSPECTION BRAKE CALIPER • Inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace it with a new one. BRAKE CALIPER PISTON • Inspect the brake caliper piston surface for any scratches or other damage.

  • Page 406
    CHASSIS 9-57 PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal O-RING • Install the new O-ring 1 and reassemble caliper halves. Replace the O-ring with a new one. • Temporarily tighten the air bleeder valve 2. •…
  • Page 407: Caliper Installation

    9-58 CHASSIS CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the brake pads and brake caliper. (!9-53) • to the specified torque. # Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) * The seal washers should be replaced with the new ones to prevent brake fluid leakage.

  • Page 408: Master Cylinder Removal And Disassembly

    CHASSIS 9-59 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Drain the brake fluid. (!9-53) • Disconnect the front brake light switch lead wire coupler 1. • Place a rag underneath the union bolt 2 on the master cylin- der to catch any split brake fluid. Remove the union bolt and disconnect the brake hose.

  • Page 409: Master Cylinder Inspection

    9-60 CHASSIS • Remove the following parts. 0 Piston A Secondary cup B Primary cup C Return spring MASTER CYLINDER INSPECTION MASTER CYLINDER • Inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one.

  • Page 410: Master Cylinder Installation

    CHASSIS 9-61 • Apply SUZUKI SUPER GREASE “A” to the bolt and brake lever end. ‘ 99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the pivot bolt and nut. • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder.

  • Page 411: Rear Brake

    9-62 CHASSIS REAR BRAKE CONSTRUCTION 1 Piston/Cup set 7 Dust seal 2 Reservoir hose 8 Brake pad spring ITEM N·m kgf-m lb-ft 3 Brake hose A Caliper air bleeder valve 0.75 4 Brake pad B Brake hose union bolt 16.5 5 Piston C Brake master cylinder rod lock nut 13.0…

  • Page 412: Brake Pad Replacement

    CHASSIS 9-63 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

  • Page 413: Brake Fluid Replacement

    9-64 CHASSIS • Inspect the pad mounting pin for bent or damage. If any defects are found, replace the pad mounting pins with the new ones. • Install the new brake pads. • Install the brake caliper. • Tighten the rear brake caliper mounting bolt to the specified torque.

  • Page 414: Caliper Removal

    CHASSIS 9-65 • Connect a clear hose to the caliper air bleeder valve and insert the other end of hose into a receptacle. • Loosen the air bleeder valve and pump the brake pedal until old brake fluid flows out of the bleeder system. •…

  • Page 415: Caliper Inspection

    9-66 CHASSIS • Remove the caliper air bleeder valves 3. • Remove the rubber boots 4. • Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air. Do not use extremely high pressure to remove the brake caliper pistons, otherwise damage to the pis- tons will result.

  • Page 416
    CHASSIS 9-67 BRAKE CALIPER HOLDER • Inspect the brake caliper holder for wear and other damage. If any defects are found, replace the holder with a new one. RUBBER BOOT • Inspect the rubber boot for damage and wear. If any defects are found, replace the boots with new ones.
  • Page 417: Caliper Reassembly

    PISTON SEAL • Install the piston seals as shown in the illustration. Dust seal Caliper body Piston seal BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder. . 99000-25100: SUZUKI SILICONE GREASE or equivalent…

  • Page 418: Caliper Installation

    CHASSIS 9-69 RUBBER BOOT • Set the rubber boot onto the brake caliper. CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Install the brake pads and brake caliper. (!9-64) • Tighten brake hose union bolt to the specified torque. (Rear brake hose routing:!11-40) # Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) * The seal washers should be replaced with the new…

  • Page 419: Master Cylinder Disassembly

    9-70 CHASSIS • Temporarily tighten the master cylinder mounting bolts 2. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Remove the union bolt 3 and disconnect the brake hose. •…

  • Page 420: Master Cylinder Inspection

    CHASSIS 9-71 • Remove the push rod 8, piston/primary cup 9 and spring 0. MASTER CYLINDER INSPECTION CYLINDER, PISTON • Inspect the cylinder bore wall for any scratches or other dam- age. CUP SET • Inspect the cup set. MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disas- sembly.

  • Page 421: Master Cylinder Installation

    9-72 CHASSIS • Apply SUZUKI SILICONE GREASE to the push rod end. . 99000-25100: SUZUKI SILICONE GREASE or equivalent • Install the O-ring 1 and connector 2 to the master cylinder. MASTER CYLINDER INSTALLATION Install the master cylinder in the reverse order of removal. Pay attention to the following points: •…

  • Page 422: Tire And Wheel

    CHASSIS 9-73 TIRE AND WHEEL TIRE REMOVAL The most critical factor of tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

  • Page 423: Valve Inspection

    9-74 CHASSIS VALVE INSPECTION • Inspect the valve after the tire is removed from the rim. • Replace the valve with a new one if the seal A rubber is peel- ing or has damage. NOTE: If the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary.

  • Page 424: Tire Installation

    CHASSIS 9-75 TIRE INSTALLATION • Apply tire lubricant to the tire bead. • When installing the tire onto the wheel, observe the following points. * Do not reuse the valve which has been once removed. * Never use oil, grease or gasoline on the tire bead in place of tire lubricant.

  • Page 425: Balancer Weight Installation

    9-76 CHASSIS • In this condition, check the “rim line” B cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.

  • Page 426: Electrical System

    ELECTRICAL SYSTEM 10-1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING …………… 10- 3 CONNECTOR ………………10- 3 COUPLER……………….. 10- 3 CLAMP ………………..10- 3 FUSE………………..10- 3 SEMI-CONDUCTOR EQUIPPED PART ……….10- 4 BATTERY ……………….. 10- 4 CONNECTING THE BATTERY…………10- 4 WIRING PROCEDURE…………….

  • Page 427
    10-2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS LAMPS …………………. 10-39 HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT ………… 10-39 HEADLIGHT RELAY INSPECTION ………… 10-40 RELAYS ………………..10-41 TURN SIGNAL/SIDE-STAND RELAY ……….10-41 STARTER RELAY …………….10-41 FUEL PUMP RELAY …………….10-41 COOLING FAN RELAY……………
  • Page 428: Fuse

    ELECTRICAL SYSTEM 10-3 CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

  • Page 429: Semi-Conductor Equipped Part

    10-4 ELECTRICAL SYSTEM SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in INCORRECT such as a ECM. • When inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. BATTERY •…

  • Page 430: Using The Multi-Circuit Tester

    ELECTRICAL SYSTEM 10-5 USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and — probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •…

  • Page 431: Location Of Electrical Components

    10-6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 IAP sensor (#2) (!5-34) C Horn 2 IAP sensor (#1) (!5-34) D Turn signal/Side-stand relay 3 Fuel injector (#1) (!5-68) E Fuel pump relay (!6-6) 4 Fuel injector (#2) (!5-68) F Headlight relay 5 Ignition coil (#1) G Cooling fan relay (!8-8) 6 IAT sensor (!5-50)

  • Page 432
    ELECTRICAL SYSTEM 10-7 1 Fuel level gauge 0 PAIR control solenoid valve (!12-6) 2 Fuel pump (!6-8) A Regulator/Rectifier 3 Battery B Oil pressure switch 4 ECM (Engine Control Module) C Generator 5 Fuse box D CKP sensor (!5-32) 6 Ignition coil (#2) E Speedometer sensor 7 Mode selection switch coupler (!5-24) F Side-stand switch…
  • Page 433: Charging System

    10-8 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/Rectifier IG. switch Generator TROUBLESHOOTING Battery runs down quickly Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to Step 2. Step 2 1) Check the battery for current leaks. (!10-9) Is the battery for current leaks OK? Go to Step 3.

  • Page 434: Inspection

    ELECTRICAL SYSTEM 10-9 Step 5 1) Measure the generator no-load performance. (!10-11) Is the generator no-load performance OK? Go to Step 6. Faulty generator Step 6 1) Inspect the regulator/rectifier. (!10-11) Is the regulator/rectifier OK? Go to Step 7. Faulty regulator/rectifier Step 7 1) Inspect wirings.

  • Page 435
    10-10 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the front seat. (!9-4) • Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position. • Measure the DC voltage between the + and — battery termi- nals using the multi-circuit tester.
  • Page 436
    ELECTRICAL SYSTEM 10-11 GENERATOR NO-LOAD PERFORMANCE • Disconnect the generator coupler. (!10-10) • Start the engine and keep it running at 5 000 r/min. • Using the multi-circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the gen- erator with a new one.
  • Page 437: Starter System And Side-Stand/Ignition Interlock System

    10-12 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch Fuse (30 A) To Ignition coil Starter motor GP switch Fuse (15 A) (Neutral) Battery Starter relay Starter Turn signal/ button side-stand relay Clutch switch side-stand switch TROUBLESHOOTING Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.

  • Page 438
    ELECTRICAL SYSTEM 10-13 Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty engine stop switch •…
  • Page 439: Starter Motor Removal

    10-14 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL • Remove the right frame side cover. (!9-5) • Remove the exhaust pipe and muffler. (!7-8) • Remove the master cylinder cover 1. • Disconnect the battery — lead wire. • Disconnect the starter motor lead wire 2. •…

  • Page 440: Starter Motor Disassembly

    ELECTRICAL SYSTEM 10-15 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 O-ring 5 Brush holder 2 Housing end (inside) 6 Housing end (outside) ITEM N·m kgf-m lb-ft 3 Armature A Starter motor lead wire nut 4 Starter motor case B Starter motor mounting bolt…

  • Page 441: Starter Motor Inspection

    10-16 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Make sure that the length A is not less than 6.0 mm (0.24 in). If this length becomes less than 6.0 mm (0.24 in), replace the brush.

  • Page 442: Starter Motor Reassembly

    STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal and bearing. / 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 443: Starter Relay Inspection

    10-18 ELECTRICAL SYSTEM • Tighten the starter motor mounting lead wire bolts 5 and nut 6 to the specified torque. , Starter motor mounting bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft) Starter motor lead wire nut: 6 N·m (0.6 kgf-m, 4.5 lb-ft) STARTER RELAY INSPECTION •…

  • Page 444: Side Stand/Ignition Interlock System Parts Inspection

    ELECTRICAL SYSTEM 10-19 SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH •…

  • Page 445
    10-20 ELECTRICAL SYSTEM GEAR POSITION SWITCH • Remove the right frame side cover. (!9-5) • Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmis- sion in “NEUTRAL”. » 09900-25008: Multi-circuit tester set — Tester knob indication: Continuity test (.) Blue Black/White…
  • Page 446
    ELECTRICAL SYSTEM 10-21 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the left frame side cover. (!9-5) • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
  • Page 447: Ignition System

    10-22 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop switch Side- stand #1 (R) Power source relay circuit #1 (R) Fuse sensor Waveform arrangement Ignition circuit #2 (F) switch Fuse #2 (F) Battery sensor sensor switch NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 7 200 r/min, this circuit cuts off fuel at the fuel injector.

  • Page 448: Troubleshooting

    ELECTRICAL SYSTEM 10-23 TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.

  • Page 449
    10-24 ELECTRICAL SYSTEM Step 5 1) Inspect the ignition coil/plug caps and ignition coils. (!10-27 and -28) Is the ignition coil/plug cap and ignition coils OK? Go to Step 6. • Poor connection of the ignition coil/plug cap(-s) and ignition coils. •…
  • Page 450: Inspection

    ELECTRICAL SYSTEM 10-25 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the left frame side covers. (!9-5) • Remove the fuel tank. (!6-3) • Remove the frame head covers and right radiator covers. (!9-6) • Remove the front cylinder right head cover cap and rear cylin- der left head cover cap.

  • Page 451
    10-26 ELECTRICAL SYSTEM IGNITION COIL/PLUG CAP PRIMARY PEAK VOLTAGE Inspect each ignition coil primary peak voltage at the ignition coil/plug cap coupler. • Connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil/plug cap: W/Bl wire terminal (+ Probe) – Ground (- Probe) terminal #2 ignition coil/plug cap: Black wire terminal (+ Probe) –…
  • Page 452
    ELECTRICAL SYSTEM 10-27 IGNITION COIL PRIMARY PEAK VOLTAGE Peak volt adaptor Inspect each ignition coil primary peak voltage in the following procedure. Ignition • Connect the multi-circuit tester with peak voltage adaptor as coil Y or G follows. #1 ignition coil: + Probe: Yellow lead wire terminal spark plug — Probe: Ground…
  • Page 453
    10-28 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Disconnect the spark plug caps. (!10-25) • Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the stan- Ω dard range, replace the ignition coil with a new one. kΩ…
  • Page 454
    ELECTRICAL SYSTEM 10-29 CKP SENSOR RESISTANCE • Measure the resistance between the lead wires and ground. If the resistance is not within the standard range, replace the CKP sensor coupler CKP sensor with a new one. » 09900-25008: Multi-circuit tester set CKP sensor ( Tester knob indication: Resistance (Ω) $ CKP sensor resistance: 190 –…
  • Page 455: Speedometer And Tachometer

    10-30 ELECTRICAL SYSTEM SPEEDOMETER AND TACHOMETER DESCRIPTION This speedometer and tachometer mainly consists of the stepping motor (except for tachometer), LCD (Liq- uid Crystal Display) and LED (Light Emitting Diode). The speedometer pointer is driven by the stepping motor. The LCDs indicate Tachometer, Engine coolant and Oil pressure temp mark, Odo/Trip1/Trip2/FI and Clock, Fuel level respectively.

  • Page 456: Speedometer Removal And Disassembly

    ELECTRICAL SYSTEM 10-31 SPEEDOMETER REMOVAL AND DISASSEMBLY • Disconnect the speedometer lead wire coupler. (!6-3) • Remove the screw. • Remove the speedometer 1. NOTE: “2” indicates hook location. When disconnecting and reconnecting the speedome- ter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

  • Page 457: Tachometer Removal And Disassembly

    10-32 ELECTRICAL SYSTEM TACHOMETER REMOVAL AND DISASSEMBLY • Remove the handleber. (!9-30) • Remove the head light. (!9-15) • Remove the screws 1. • Disconnect the tachometer lead wire coupler and remove the tachometer 2. • Disassemble the tachometer as follows. Do not attempt to disassemble the tachometer unit 2.

  • Page 458: Inspection

    ELECTRICAL SYSTEM 10-33 INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (FI indicator light, Fuel level indicator light) immediately after turning the ignition switch on. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.

  • Page 459
    10-34 ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE METER AND INDICATOR ECT sensor inspection (!8-9) • Remove the right frame side cover. (!9-5) • Remove the right air cleaner box. (!6-13) • Disconnect the ECT sensor coupler 1. When connecting and disconnecting the engine cool- ant temperature sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
  • Page 460
    ELECTRICAL SYSTEM 10-35 FUEL LEVEL INDICATOR SWITCH INSPECTION • Remove and disassemble the fuel pump assembly. (!6-8) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel Battery Test level indicator switch as shown in the right illustration. The bulb bulb should come on after one minutes if the switch is in good condition.
  • Page 461
    10-36 ELECTRICAL SYSTEM FUEL LEVEL METER INSPECTION • Lift and support the fuel tank. (!6-3) • Disconnect the fuel pump lead wire coupler 1. • Connect variable resistor between the Light green and Black lead wires at the wire harness. •…
  • Page 462
    The highest voltage reading in this test will be the same as that of battery (12 V). (Battery voltage) • Apply SUZUKI SUPER GREASE “A” to the speedometer sen- sor O-ring before installing it. / 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 463
    10-38 ELECTRICAL SYSTEM OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check if the engine oil level is correct. (!2-17) • Disconnect the oil pressure switch lead wire from the oil pres- sure switch. • Turn the ignition switch ON. •…
  • Page 464: Position Light

    ELECTRICAL SYSTEM 10-39 LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W 1 POSITION LIGHT ….. (E-02, 19, 24) 12 V 5 W BRAKE LIGHT/TAILLIGHT LICENCE PLATE LIGHT 12 V 5 W 2 TURN SIGNAL/POSITION LIGHT (E-03, 28, 33) 12 V 21 W/5 W ×…

  • Page 465: Headlight Relay Inspection

    10-40 ELECTRICAL SYSTEM HEADLIGHT RELAY INSPECTION headlight relay is located in front of the battery. • Remove the right frame side cover. (!9-5) • Remove the headlight relay 1. First check the insulation between A and B terminals with tester. Then apply 12 volts to C and D terminals, + to C and — to D, and check the continuity between A and B.

  • Page 466: Relays

    ELECTRICAL SYSTEM 10-41 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

  • Page 467: Switches Inspection

    10-42 ELECTRICAL SYSTEM SWITCHES INSPECTION Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. PUSH HAZARD SWITCH HORN BUTTON Color Position Color B/Bl (OFF) Position (ON) PUSH…

  • Page 468: Battery

    ELECTRICAL SYSTEM 10-43 BATTERY SPECIFICATIONS Type designation FTZ16-BS Capacity 12 V, 64.8 kC (18 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •…

  • Page 469
    10-44 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
  • Page 470: Servicing

    ELECTRICAL SYSTEM 10-45 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.

  • Page 471: Servicing Information

    SERVICING INFORMATION 11-1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………….11- 3 FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION…………..11- 3 ENGINE ………………..11- 7 RADIATOR (COOLING SYSTEM) …………11-13 CHASSIS ………………… 11-14 SHAFT DRIVE ………………11-15 BRAKES ………………..11-15 ELECTRICAL ………………11-16 BATTERY ………………..

  • Page 472
    11-2 SERVICING INFORMATION SERVICING INFORMATION CONTENTS IGNITION COIL INSTALLATION …………11-51 SIDE-STAND INSTALLATION …………11-51 REAR TURN SIGNAL LIGHT, LICENSE LIGHT WIRE ROUTING ..11-52 SEAT LOCK CABLE ROUTING …………11-52 LICENSE LIGHT AND LICENSE PLATE INSTALLATION ….11-53 BRAKE LIGHT/TAILLIGHT INSTALLATION ……..11-53…
  • Page 473: Troubleshooting

    SERVICING INFORMATION 11-3 TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

  • Page 474
    11-4 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
  • Page 475
    SERVICING INFORMATION 11-5 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve ISC valve motor current is higher than ISC valve circuit shorted to specified value. BATT or ground circuit open P0505 ISC valve motor circuit is open. ISC valve circuit open or BATT circuit open Idle speed is lower than the desired…
  • Page 476
    11-6 SERVICING INFORMATION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Exhaust con- EXCVA position sensor produces fol- EXCVA, EXCVA lead wire/cou- trol valve lowing voltage. pler actuator 0.1 V sensor voltage < 4.9 V In other than the above range, C46 (P1675) is indicated.
  • Page 477: Engine

    SERVICING INFORMATION 11-7 ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Tappet clearance out of adjustment Adjust. 2. Worn valve guides or poor seating of valves Repair or replace. 3.

  • Page 478
    11-8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Tappet clearance out of adjustment Adjust. 2. Poor seating of valves Replace or repair. 3. Defective valve guides Replace. 4. Worn down camshafts Replace. 5. Too wide spark plug gaps Adjust or replace.
  • Page 479
    SERVICING INFORMATION 11-9 Complaint Symptom and possible causes Remedy Noisy engine Excessive valve chatter 1. Too large tappet clearance Adjust. 2. Weakened or broken valve springs Replace. 3. Worn tappet or cam surface Replace. 4. Worn and burnt camshaft journal Replace.
  • Page 480
    11-10 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal/electrical parts in high speed range. 1. Weakened valve springs Replace. 2. Worn camshafts Replace. 3. Valve timing out of adjustment Adjust. 4. Too narrow spark plug gaps Adjust.
  • Page 481
    SERVICING INFORMATION 11-11 Complaint Symptom and possible causes Remedy Engine lacks power. Defective engine internal/electrical parts 1. Loss of tappet clearance Adjust. 2. Weakened valve springs Replace. 3. Valve timing out of adjustment Adjust. 4. Worn piston rings or cylinders Replace.
  • Page 482
    11-12 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats Defective engine internal parts 1. Heavy carbon deposit on piston crowns Clean. 2. Not enough oil in the engine Add oil. 3. Defective oil pump or clogged oil circuit Replace or clean.
  • Page 483: Radiator (Cooling System)

    SERVICING INFORMATION 11-13 RADIATOR (COOLING SYSTEM) Complaint Symptom and possible causes Remedy Engine overheats 1. Not enough engine coolant Add coolant. 2. Radiator core clogged with dirt or scale Clean. 3. Faulty cooling fan Repair or replace. 4. Defective cooling fan relay, or open- or short- Repair or replace.

  • Page 484: Chassis

    11-14 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Not enough pressure in tires Adjust. Wobbly handlebars 1. Loss of balance between right and left front forks Adjust.

  • Page 485: Shaft Drive

    SERVICING INFORMATION 11-15 SHAFT DRIVE Complaint Symptom and possible causes Remedy Noisy shaft drive Noise seems to come from secondary bevel gear and final bevel gear assemblies. 1. Oil level too low Refill. (Check oil jet./Replace oil seal.) 2. Drive and driven bevel gears damaged or worn Replace.

  • Page 486: Electrical

    11-16 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coils Replace. sparking 2. Defective ignition coil/plug caps Replace. 3. Defective spark plugs Replace. 4. Defective CKP sensor Replace. 5. Defective ECM Replace. 6.

  • Page 487: Battery

    SERVICING INFORMATION 11-17 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates Battery runs down…

  • Page 488: Special Tools

    11-18 SERVICING INFORMATION SPECIAL TOOLS 09900-18740 09900-20101 09900-20202 09900-20205 09900-06108 Hexagon socket 09900-20102 Micrometer Micrometer Snap ring pliers (24 mm) Vernier calipers (25 – 50 mm) (0 – 25 mm) 09900-20210 09900-20602 09900-20605 09900-20607 Micrometer Dial gauge Dial calipers Dial gauge 09900-20701 (100 –…

  • Page 489
    SERVICING INFORMATION 11-19 09913-70210 09913-60910 09913-75821 09913-76010 09913-84510 Bearing installer set Bearing puller Bearing installer Bearing installer Bearing installer 09915-74511 09915-17410 09915-64512 09915-74521 09915-77331 Oil pressure gauge 09915-40610 Compression gauge Oil pressure gauge Meter attachment Oil filter wrench hose (for high pressure) 09916-14910 09916-37810 09916-10911…
  • Page 490
    11-20 SERVICING INFORMATION 09920-53740 09918-53810 Clutch sleeve hub 09921-20210 09921-20240 Chain tensioner 09919-28610 holder Bearing remover Bearing remover set lock tool Sleeve protector 09924-62410 09924-34510 09924-41830 Final drive gear 09924-62430 09923-74511 Backlash measur- Bearing retainer bearing holder 22 mm Long Bearing remover ing tool (!27 –…
  • Page 491
    SERVICING INFORMATION 11-21 09930-73170 09930-73180 09930-82720 09940-14911 09940-30221 Starter torque Starter torque Mode selection Steering stem nut Front fork assem- limiter holder limiter socket switch wrench bling tool 09940-40211 09940-40220 09940-52841 09940-52861 Fuel pressure Fuel pressure gauge Front fork inner Front fork oil seal 09940-51410 gauge adaptor…
  • Page 492: Tightening Torque

    11-22 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt Cylinder head cover cap bracket bolt Cylinder head bolt M: 6 M: 8 19.0 Initial 18.0 M: 10 Final 30.5 Cylinder nut Cylinder head plug (Water jacket plug) 19.0 Camshaft housing bolt Sprocket cam chain drive bolt…

  • Page 493: Fi System And Intake Air System

    SERVICING INFORMATION 11-23 ITEM N·m kgf-m lb-ft Gearshift cam stopper plate bolt Gearshift arm stopper bolt 13.5 Gearshift cam stopper bolt Gearshift lever shaft 36.0 Gearshift fork shaft retainer plug 25.5 Generator cover plug 11.5 Generator rotor bolt 16.0 115.5 Generator stator bolt Starter motor bolt Starter motor lead wire nut…

  • Page 494: Chassis

    11-24 SERVICING INFORMATION CHASSIS N·m kgf-m lb-ft ITEM Handlebar clamp bolt 16.5 Handlebar holder bolt 61.5 Handlebar bracket bolt 16.5 Front fork upper and lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork damper rod bolt 29.0 Front fork inner rod lock nut 11.0 Steering stem head nut 65.0…

  • Page 495: Tightening Torque Chart

    SERVICING INFORMATION 11-25 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 496: Service Data

    11-26 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.65) — (1.50) Tappet clearance (when cold) 0.09 – 0.16 — (0.004 – 0.006) 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem 0.010 –…

  • Page 497
    SERVICING INFORMATION 11-27 ITEM STANDARD LIMIT Camshaft runout 0.10 IN. & EX. — (0.004) Cam chain pin (at arrow “3”) 18th pin — Cylinder head distortion 0.05 — (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 –…
  • Page 498
    11-28 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 23.010 – 23.018 23.040 (0.9059 – 0.9062) (0.9071) Conrod big end side clearance 0.100 – 0.200 0.30 (0.0039 – 0.0078) (0.012) Conrod big end width 23.95 –…
  • Page 499
    SERVICING INFORMATION 11-29 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD LIMIT Thermostat valve opening Approx. 88 °C (190 °F) — temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) — Engine coolant temperature sensor 20 °C Approx.
  • Page 500
    11-30 SERVICING INFORMATION DRIVELINE/AXLE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Secondary bevel gear backlush 0.03 – 0.15 — (0.001 – 0.006) Final bevel gear backlush 0.08 – 0.16 — (0.003 – 0.006) Damper spring free length 64.6 — (2.54) Final gear oil type Hypoide gear oil SAE #90, API grade GL-5 —…
  • Page 501
    SERVICING INFORMATION 11-31 ITEM SPECIFICATION NOTE STP sensor output voltage Closed Approx. 0.6 V Opened Approx. 4.2 V Approx. 7 Ω STV actuator resistance EXCVA position sensor input 4.5 – 5.5 V voltage EXCVA position sensor resistance At adjustment Approx. 3.1 kΩ position EXCVA position sensor output Closed…
  • Page 502: Front Turn Signal/Position Light

    11-32 SERVICING INFORMATION ITEM SPECIFICATION NOTE Generator no-load voltage 70 V (AC) and more at 5 000 r/min (When engine is cold) Regulated voltage 14.0 – 15.5 V at 5 000 r/min 3 – 6 Ω Starter relay resistance Battery Type FTZ16-BS designation…

  • Page 503
    SERVICING INFORMATION 11-33 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 25 – 35 — (1.0 – 1.4) Brake disc thickness 5.0 ± 0.2 Front (0.197 ± 0.008) (0.18) –0.4 Rear (0.276 (0.25) –0.016 Brake disc runout 0.30 —…
  • Page 504: Fuel Tank Capacity

    Front fork oil level (without spring, inner tube fully — (5.2) compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) 684 ml — (23.1/24.1 US/lmp oz) Rear shock absorber spring —…

  • Page 505: Wiring Harness, Cable And Hose Routing

    SERVICING INFORMATION 11-35 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Wiring harness Face the lead wire Clamp to the lower. Clamp ISC valve Set the speedometer Wiring harness harness to the right side. Clamp Keep the clearance between wiring harness and fuel tank and frame.

  • Page 506
    11-36 SERVICING INFORMATION Pass the handlebar switch lead wire upper the brake switch coupler. Handlebar switch lead wire (R) To the Handlebar switch lead wire (L) tachometer Clamp Clamp Clamp Ignition coil high tension cord Pass the lead wire Wiring harness outside of the terminal.
  • Page 507: Engine Electrical Parts Lead Wire Routing

    SERVICING INFORMATION 11-37 ENGINE ELECTRICAL PARTS LEAD WIRE ROUTING Clamp Starter motor Battery ground wire Starter motor lead wire Generator lead wire Grommet Gear position switch Speedometer sensor CKP sensor Oil pressure switch Oil pressure switch lead wire Clamp Clamp…

  • Page 508: Cable Routing

    11-38 SERVICING INFORMATION CABLE ROUTING Pass the throttle cable between the handlebars and brake hose. Pass the throttle cables behind the right handlebar switch lead wire and brake switch coupler. VIEW A Front brake hose Throttle cable No.1 (pulling cable) Cable guide Throttle cable No.2 (returning cable) Throttle cable…

  • Page 509: Front Brake Hose Routing

    SERVICING INFORMATION 11-39 FRONT BRAKE HOSE ROUTING 21˚ 14˚ 14˚ 1 Stopper 8 Bolt 2 Brake master cylinder 9 Brake caliper (R) 3 Throttle cable 0 Brake caliper (L) Tighten the brake hose union bolt to the specified torque after touching 4 Cable guide the brake hose union to the stopper.

  • Page 510: Rear Brake Hose Routing

    11-40 SERVICING INFORMATION REAR BRAKE HOSE ROUTING 30˚ 14˚ 1 Stopper A Face the white paint on reservoir hose to forward. Tighten the hose guide bolt after positioning the stopper of 2 Reservoir hose guide to the swingarm. 3 Brake cylinder C Fix the grommet of brake hose to the hose guide.

  • Page 511: Throttle Body Hose Routing

    SERVICING INFORMATION 11-41 THROTTLE BODY HOSE ROUTING Rear cylinder 15˚ Front cylinder Air cleaner outlet clamp 15˚ – 25˚ Front cylinder 25˚ – 35˚ Rear cylinder Intake pipe clamp 1 ISC valve hose (R) 0 Bolt 2 ISC valve hose (L) *1 Yellow mark 3 Throttle body *2 Face the tip of clip to upper.

  • Page 512: Cooling System Hose Routing

    11-42 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Rediator cap Keep clearance between clamp and hose. 90˚ 90˚ Mark 90˚ Rediator Face the tip of clip to the inside. White mark Face the tip of clip to the backward. Red mark Oil cooler Yellow mark Clamp…

  • Page 513: Pair (Air Supply) System Hose Routing (For E-03, 28, 33)

    SERVICING INFORMATION 11-43 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR E-03, 28, 33) Set the PAIR hose to the concave of air cleaner tube. White mark Blue mark VIEW A Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

  • Page 514: Pair (Air Supply) System Hose Routing (For The Others)

    11-44 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR THE OTHERS) Set the PAIR hose to the concave of air cleaner tube. White mark Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

  • Page 515: Fuel Tank Installation

    SERVICING INFORMATION 11-45 FUEL TANK INSTALLATION Forward Outside 1 Heat shield 6 Fuel tank cushion 2 Fuel pump 7 Rear fender cover cushion 3 Clamp 8 Apply instant adhesive to the shaded portion. 4 Face the tip of clamp to the backward. 9 Fuel tank rear bracket Face the arrow mark to the forward, when install- Attach the front of fuel tank cushion to the rein-…

  • Page 516: Frame Head Cover And Radiator Cover Installation

    11-46 SERVICING INFORMATION FRAME HEAD COVER AND RADIATOR COVER INSTALLATION 1 Frame head cover (R) 6 Radiator lower cover (L) 2 Radiator cover (R) 7 Radiator bottom cover 3 Radiator lower cover (R) 8 Throttle cable No.1 (pulling cable) 4 Frame head cover (L) 9 Throttle cable No.2 (returning cable) 5 Radiator cover (L) 0 Clutch cable…

  • Page 517: Frame Head Cover Cushion Installation

    SERVICING INFORMATION 11-47 FRAME HEAD COVER CUSHION INSTALLATION 1 Cushion 3 Frame head cover (L) 2 Frame head cover (R) RADIATOR UPPER COVER CUSHION INSTALLATION 3 mm (0.1 in) 2 mm (0.08 in) 18 mm (0.7 in) 16 mm (0.6 in) 1 Radiator upper cover 3 Cushion 2 Frame…

  • Page 518: Left Frame Covers Installation

    11-48 SERVICING INFORMATION LEFT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower side cover 3 Rear side cover…

  • Page 519: Right Frame Covers Installation

    SERVICING INFORMATION 11-49 RIGHT FRAME COVERS INSTALLATION 1 Rear fender 4 Side cover 2 Rear fender cover 5 Lower cover 3 Rear side cover…

  • Page 520: Headlight Cover Installation

    11-50 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 4 Headlight cover brace 2 Headlight cover 5 Steering stem upper bracket 3 Headlight back cover 6 Steering stem lower bracket…

  • Page 521: Ignition Coil Installation

    SERVICING INFORMATION 11-51 IGNITION COIL INSTALLATION Forward 1 Ignition coil #1 3 Ignition coil bracket 2 Ignition coil #2 4 Spacer SIDE-STAND INSTALLATION…

  • Page 522: Rear Turn Signal Light, License Light Wire Routing

    11-52 SERVICING INFORMATION REAR TURN SIGNAL LIGHT, LICENSE LIGHT WIRE ROUTING License light and right and left rear turn signal lead wirres installtion order. Fix the right and left rear turn signal light lead wires Connect the license light and left rear turn and license light lead wire with clamp.

  • Page 523: License Light And License Plate Installation

    SERVICING INFORMATION 11-53 LICENSE LIGHT AND LICENSE PLATE INSTALLATION » 1 License light 4 Washer 2 License plate 5 Spacer ITEM N·m kgf-m lb-ft 3 Nut A License light nut BRAKE LIGHT/TAILLIGHT INSTALLATION 1 Rear frame cover 2 Brake light/Taillight…

  • Page 524: Emission Control Information

    EMISSION CONTROL INFORMATION 12-1 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS ………….. 12- 2 FUEL INJECTION SYSTEM…………..12- 2 CRANKCASE EMISSION CONTROL SYSTEM……..12- 3 EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) …. 12- 4 NOISE EMISSION CONTROL SYSTEM……….12- 5 PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION ………………..

  • Page 525: Emission Control Systems

    12-2 EMISSION CONTROL INFORMATION EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VZR1800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With a view to reducing CO, NOX and HC, all of the fuel injection volumes are stringently controlled with the programmed injection maps in the ECM by varying engine conditions.

  • Page 526: Crankcase Emission Control System

    EMISSION CONTROL INFORMATION 12-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atomo- sphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combus- tion chamber through the PCV (breather) hose, air cleaner and throttle body.

  • Page 527: Exhaust Emission Control System (Pair System)

    12-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system, exhaust control system and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve.

  • Page 528: Noise Emission Control System

    EMISSION CONTROL INFORMATION 12-5 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.

  • Page 529: Pair (Air Supply) System And Emission Control System

    12-6 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PAIR HOSES • Remove the frame head covers. (!9-6) • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses for secure connection. PAIR REED VALVE •…

  • Page 530
    EMISSION CONTROL INFORMATION 12-7 • Check the resistance between the terminals of the PAIR con- trol solenoid valve. » Resistance: 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) # 09900-25008: Multi-circuit tester set $ Tester knob indication: Resistance (Ω) INSTALLATION If the resistance is not within the standard range, replace the PAIR control solenoid valve with a new one.
  • Page 531: Pair (Air Supply) System Hose Routing (For E-03, 28, 33)

    12-8 EMISSION CONTROL INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR E-03, 28, 33) Set the PAIR hose to the concave of air cleaner tube. White mark Blue mark VIEW A Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

  • Page 532: Pair (Air Supply) System Hose Routing (For The Others)

    EMISSION CONTROL INFORMATION 12-9 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (FOR THE OTHERS) Set the PAIR hose to the concave of air cleaner tube. White mark Yellow mark White mark 1 PAIR control solenoid valve 2 PAIR reed valve…

  • Page 533: Heated Oxgen Sensor (Ho2S) Inspection (For E-02, 19, 24)

    12-10 EMISSION CONTROL INFORMATION HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) • Disconnect the HO2 sensor lead wire coupler. (!5-79) • Inspect the HO2 sensor and its circuit referring to flow table of malfunction code (P0156/P0161 P0130/P0135). • Check the resistance between the terminals of the HO2 sen- sor.

  • Page 534: Wiring Diagram

    WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. HANDLEBAR SWITCH (R) IGNITION IGNITION ENGINE STOP COIL/ COIL/ IGNITION IGNITION STARTER FRONT BRAKE SWITCH PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 BUTTON SWITCH SIDE STAND SPEEDOMETER…

  • Page 535
    E-03, 28, 33 HANDLEBAR SWITCH (R) IGNITION IGNITION COIL/ COIL/ IGNITION IGNITION ENGINE STOP STARTER FRONT BRAKE SWITCH PLUG CAP #1 PLUG CAP #2 COIL #1 COIL #2 BUTTON SWITCH SPEEDOMETER SIDE STAND TACHOMETER PUSH IGNITION SWITCH SWITCH FREE PUSH LOCK PAIR SOLENOID…
  • Page 536
    Prepared by January, 2006 Part No. 99500-39290-01E Printed in Japan…
  • Page 537
    Printed in Japan…
  • Page 538
    The following departments in your dealership should be notified of this information: Warranty Sales Accessories ⌧ ⌧ ⌧ ⌧ Management ⌧ ⌧ ⌧ ⌧ Service ⌧ ⌧ ⌧ ⌧ Parts ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter…
  • Page 539
    FUEL SYSTEM AND THROTTLE BODY FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL CONSTRUCTION 1 Regulator 5 O-ring 2 Fuel pump 6 Fuel level gauge ITEM N·m kgf-m lb-ft 3 Fuel mesh filter Thermistor 4 Filter cover Fuel pump mounting bolt…
  • Page 540
    ELECTRICAL SYSTEM 10-35 FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION • Remove and disassemble the fuel pump assembly. (!6-8) • Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel Battery Test level indicator switch as shown in the right illustration. The bulb bulb should come on after one minutes if the switch is in good condition.
  • Page 541
    MOTORCYCLE DIVISION 4-STROKE BULLETIN VS-VX-VZ-VL NO. 60 DATE: 1/4/2008 SUBJECT: SERVICE MANUAL CORRECTIONS — VALVE SPRING SPECIFICATIONS AND CLUTCH WASHER MODEL: VZR1800K6-K8 REFERENCE: VZR1800 SERVICE MANUAL (P/N 99500-39292-03E) Pages 3-38 and 11-26 VZR1800 SERVICE MANUAL (P/N 99500-39292-03E, prior to 08/07 revision) Pages 3-21 and 3-95 NOTICE: This bulletin contains service manual correction information for the VZR1800.
  • Page 542: Bearing

    ENGINE 3-21 • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the needle roller bearing C, spacer D and washer REAR CAM CHAIN TENSION ADJUSTER • Unlock the ratchet 1 and insert the special tool. % 09917-62430: Chain tensioner lock tool •…

  • Page 543: Spacer

    ENGINE 3-95 CLUTCH • Install the washer 1, spacer 2 and needle bearing 3 onto the countershaft. • Apply engine oil to them. • Install the primary driven gear assembly 3 onto the counter- shaft. • Install the thrust washer 4. •…

  • Page 544
    The following departments in your dealership should be notified of this information: Warranty Sales Accessories ⌧ ⌧ ⌧ ⌧ Management ⌧ ⌧ ⌧ ⌧ Service ⌧ ⌧ ⌧ ⌧ Parts ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter — 1/1 -…
  • Page 545
    2-22 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the fuel tank. (!6-3) • Remove the frame head covers, radiator covers and radiator bottom cover. (!9-6) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones.
  • Page 546
    PERIODIC MAINTENANCE 2-23 * Loosen the lock nut 3 and turn in the release screw 4 to feel resistance. * From that position, turn out the release screw 4 1 turn and tighten the lock nut 3 securely by holding the release screw «…
  • Page 547
    2-24 PERIODIC MAINTENANCE BRAKE FLUID LEVEL CHECK • Keep the motorcycle upright and place the handlebars straight. • Check the brake fluid level relative to the lower limit lines on the front and rear brake fluid reservoirs. • When the level is below the lower limit line, replenish with brake fluid that meets the following specification.
  • Page 548
    PERIODIC MAINTENANCE 2-25 Rear brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. (!9-63) Replace the brake pads as a set, otherwise braking performance will be adversely affected.
  • Page 549
    The following departments in your dealership should be notified of this information: ⌧ ⌧ Management ⌧ ⌧ Service Warranty Sales ⌧ ⌧ Parts Accessories ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ ⌧ American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV / Scooter — 1/24 -…
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  • Page 580
    Federal law requires that ALL vehicles affected by a safety recall campaign be corrected prior to sale or lease to a customer. You must verify this on the Suzuki «Certificate of Vehicle Pre- Delivery» form (99923-09823-005), which is to be completed for all new and used vehicle sales.
  • Page 581
    1) Check the repair status by checking the Vehicle History in the Suzuki Connect Service Menu. If the repair needs to be performed, you will see the message «CAMPAIGN NOT YET PERFORMED» displayed and the fuel delivery pipe assembly will need to be replaced.
  • Page 582
    Enter date of repair MILEAGE: Enter mileage on unit CAMPAIGN NUMBER: 2096 LABOR HOURS: 1.0 hrs SUZUKI AUTH. NUMBER: As approved by TECH-LINE PARTS REPLACEMENT PART NUMBER: NO PARTS REQUIRED FAILURE DESCRIPTION DESCRIPTION OF FAILURE: Replace Fuel Delivery Pipe Assy per…
  • Page 583
    FUEL DELIVERY PIPE ASSEMBLY REPLACEMENT PROCEDURE When working with the fuel system, work in a well ventilated area away from any flame or ignition sources. Store the motorcycle in an area away from any flame or ignition sources. NOTE: The fuel delivery pipe assembly can be removed from the throttle body without removing the throttle body assembly from the motorcycle.
  • Page 584
    Only your conscientious action at the dealership level can lead to a successful campaign conclusion. Please extend Suzuki’s apologies for any inconvenience this recall campaign may cause them. Refer to page 7 for detailed information regarding Customer Reimbursement.
  • Page 585
    Vehicle Safety Act. What is the reason for this notice? Suzuki Motor Corporation has decided that a defect that relates to motor vehicle safety exists in all 2006 and certain 2007 model year VZR1800/Z (M109R) motorcycles. According to our records, you are the owner of one of these affected VZR1800 (M109R) motorcycles.
  • Page 586
    Vehicle Identification Number ready when calling. If you believe that (1) Suzuki or your Suzuki dealer has failed to or is unable to perform the recall service without charge, or (2) Suzuki has failed to or is unable to perform the recall…

This manual is also suitable for:

Vzr1800

  • Page 1
    GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION Revised 09/07…
  • Page 3
    SUPPLEMENTS VL800K2 (’02- MODEL) VL800K3 (’03- MODEL) VL800K4 (’04- MODEL) VL800K5 (’05- MODEL) VL800TK5 (’05- MODEL) VL800/TK6 (’06- MODEL) VL800/TK7 & TK8 (’07&’08- MODEL ) VL800/C/TK9 (”09 MODEL) WIRING DIAGRAM…
  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

  • Page 5
    Use fork oil. otherwise specified. 99000-99001 SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 Apply SUZUKI MOLY PASTE.
  • Page 6
    Use fork oil. otherwise specified. 99000-99001-SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25010 Apply SUZUKI MOLY PASTE.
  • Page 7: General Information

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS…

  • Page 8: General Precautions

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.

  • Page 9
    GENERAL INFORMATION 1-3 » * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
  • Page 10: Serial Number Location

    ) method or 91 octane or higher rated by the Research Method. 2. Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.

  • Page 11: Brake Fluid

    Use an antifreeze designed for aluminum radiators. Suzuki recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.

  • Page 12: Cylinder Identification

    1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.

  • Page 13: Information Labels

    GENERAL INFORMATION 1-7 INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-02 E-03 E-19 E-24 E-28 E-33 Noise label – – – Information label – – – Vacuum hose routing label – – – – – Fuel caution label – –…

  • Page 14: Dimensions And Dry Mass

    1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………..2 510 mm (98.818 in) Overall width …………..985 mm (38.779 in) Overall height …………..1 110 mm (43.700 in) Wheelbase …………..1 650 mm (64.960 in) Ground clearnce …………140 mm ( 5.511 in) Seat height …………..

  • Page 15
    GENERAL INFORMATION 1-9 CHASSIS Front suspension …………Telescopic, coil spring, oil damped Rear suspension …………Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle ………….. 38° (right & left) Caster …………….33° 20’ Trail …………….141 mm (3.55 in) Turning radius ……………
  • Page 16
    1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 England (UK) E-03 E-19 E-24 Australia E-28 Canada E-33 California…
  • Page 17: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS…

  • Page 18: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, whichever comes first. IMPORTANT (USA only): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.

  • Page 19: Lubrication Points

    PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Throttle cable Brake lever holder Brake pedal pivot and brake rod link Clutch lever holder Side-stand pivot and spring hook…

  • Page 20: Air Cleaner

    2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER • Remove the screws and air cleaner case cover. • Remove the air cleaner element. • Carefully use air hose to blow the dust from the cleaner ele- ment.

  • Page 21
    PERIODIC MAINTENANCE 2-5 • Remove the spark plug caps. • Remove the spark plugs with a spark plug wrench. HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one.
  • Page 22: Spark Plug/Ignition Coil/Plug Cap Installation

    2-6 PERIODIC MAINTENANCE SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION • Install the spark plugs to the cylinder head with fingers, and then tighten them to the specified torque with a wrench. % Spark plug: 11 N . m (1.1 kgf . m, 8.0 Ib-ft) Do not crossthread or over tighten the spark plug, or the spark plug will damage the aluminum threads of the cyl- inder head.

  • Page 23
    PERIODIC MAINTENANCE 2-7 • Remove all the inspection caps. • Remove all the spark plugs. • Remove the generator cover plug 3 and the timing inspection plug 4. • Rotate the generator rotor to set the No.1 engine’s piston at TDC of the compression stroke.
  • Page 24: Engine Oil And Oil Filter

    2-8 PERIODIC MAINTENANCE Inspect the No.2 engine’s valve clearance as the same manner above. NOTE: FRONT Use the thickness gauge from the arrow marks as shown in the illustration. No. 2 Engine No. 1 Engine ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT •…

  • Page 25
    TER. Other manufacturer’s oil ilters may differ in thread specifications (thread diameter and pitch), filtering per- formance and durability which may lead to engine dam- age or oil leaks. Also, do not use a genuine Suzuki auto- mobile oil filter on this motorcycle.
  • Page 26: Fuel Hose

    2-10 PERIODIC MAINTENANCE FUEL HOSE Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, replace the fuel hose. ENGINE IDLE SPEED NOTE: Warm up the engine before adjusting the engine idle speed. • Start the engine, turn the throttle stop screw and set the engine idle speed as follows.

  • Page 27: Throttle Cable Play

    PERIODIC MAINTENANCE 2-11 THROTTLE CABLE PLAY Adjust the throttle cable play A as follows. MINOR ADJUSTMENT 1st step: • Loosen the lock nut 1 of the throttle returning cable 2 and fully turn in the adjuster 3. 2nd step: • Loosen the lock nut 4 of the throttle pulling cable 5. •…

  • Page 28
    2-12 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Remove the fuel tank. (!5-3) • Loosen the lock nuts 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play. • Loosen the lock nuts 4 of the throttle pulling cable 5. •…
  • Page 29: Cooling System

    PERIODIC MAINTENANCE 2-13 COOLING SYSTEM ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A Full line B Lower line • If the level is below the lower line, add engine coolant to the full line from the engine coolant reservoir filler.

  • Page 30
    2-14 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •…
  • Page 31: Final Gear Oil

    PERIODIC MAINTENANCE 2-15 FINAL GEAR OIL • Keep the motorcycle upright. • Place an oil pan under the final gear case. Remove the filler cap 1 and drain plug 2 to drain oil. • Refit the drain plug 2. Pour the specified oil (SAE 90 hypoid gear oil with GL-5 under API classification) through the filler hole until the oil level reaches the filler hole.

  • Page 32
    2-16 PERIODIC MAINTENANCE REAR BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Adjust the brake pedal height A by turning the adjuster 2. » Rear brake pedal height : 75 – 85 mm REAR BRAKE ADJUSTING • Adjust the free travel B to 20 – 30 mm by turning the adjusting nut 3.
  • Page 33
    PERIODIC MAINTENANCE 2-17 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
  • Page 34: Tire Tread Depth

    2-18 PERIODIC MAINTENANCE TIRES TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. ( 09900-20805: Tire depth gauge «…

  • Page 35: Front Fork

    PERIODIC MAINTENANCE 2-19 STEERING The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground.

  • Page 36: Chassis Bolts And Nuts

    2-20 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle. N . m kgf . m Item Ib-ft 1 Steering stem head nut 65.0 2 Steering stem lock nut 58.0…

  • Page 37
    PERIODIC MAINTENANCE 2-21…
  • Page 38: Compression Pressure Check

    2-22 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit…

  • Page 39: Oil Pressure Check

    PERIODIC MAINTENANCE 2-23 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 350 – 650 kPa (3.5 – 6.5 kgf/cm , 50 – 92 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered.

  • Page 40
    ENGINE ENGINE CONTENTS…
  • Page 41
    3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION…
  • Page 42: Engine Removal And Installation

    ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure.

  • Page 43
    3-4 ENGINE • Disconnect the neutral switch lead wire coupler 1. • Disconnect the generator lead wire coupler 2 and the signal generator lead wire coupler 3. • Disconnect the side-stand switch lead wire coupler 4. • Remove the clutch release mechanism. •…
  • Page 44
    ENGINE 3-5 • Remove the air cleaner box bracket. • Disconnect the negative pressure hose 1. • Remove the carburetor. Caburetor removal !5-15 • Remove the spark plug caps. • Remove the right frame cover. • Remove the No. 1 muffler.
  • Page 45
    3-6 ENGINE • Remove the No. 1 exhaust pipe and the No. 2 muffler. • Remove the No.2 exhaust pipe. • Remove the rear clutch cover. • Remove the cooling fan mounting bolts. • Remove the engine mounting bolt 1.
  • Page 46
    ENGINE 3-7 • Remove the frame down tube. • Support the engine with an engine jack. • Remove the engine mounting bolts and nuts. • Gradually lower the engine.
  • Page 47: Engine Installation

    3-8 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the universal joint. NOTE: Be sure to face the short portion A backward when installing it. • Install the boot. NOTE: Make sure that the “UP”…

  • Page 48
    ENGINE 3-9 NOTE: * The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. * Be sure to use new nuts and tighten them to the specified torque. 50 N . m (5.0 kgf .
  • Page 49
    » Gearshift lever height A Standard: 90 mm (3.5 in) • Apply grease to the push rod and install it. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Apply grease to the clutch release mechanism and install it.
  • Page 50: Engine Disassembly

    ENGINE 3-11 ENGINE DISASSEMBLY • Remove the PAIR pipes. • Remove the spark plugs. % 09930-10121: Spark plug wrench set • Remove the valve timing inspection plug 1 and the generator cover cap 2. • Position “RIT” mark on the generator with the center of the valve timing inspection hole.

  • Page 51
    3-12 ENGINE CYLINDER HEAD/CYLINDER • Loosen the water hose clamp screws. • Remove the cylinder head bolts. (Front cylinder) • Remove the cylinder head and cylinder. (Front cylinder) • After unlocking the ratchet, push the cam chain tension ad- juster rod fully. •…
  • Page 52
    ENGINE 3-13 • Remove the cylinder head bolt and nut. (Rear cylinder) • Push the cam chain tension adjuster rod and insert the special tool. % 09918-53810: Chain tensioner lock tool • Remove the cylinder head by removing the cylinder head bolts. •…
  • Page 53
    3-14 ENGINE STARTER MOTOR • Remove the starter motor cover. • Remove the starter motor. CLUTCH • Remove the clutch cover. • Remove the clutch spring mounting bolts and springs diago- nally. • Remove the pressure plate 1.
  • Page 54
    ENGINE 3-15 • Remove the thrust washer 1, bearing 2, push piece 3 and push rod. • Remove the clutch drive and driven plates. • Remove the spring washer 4 and spring washer seat 5. • Remove the clutch sleeve hub nut with the special tool. % 09920-53740: Clutch sleeve hub holder •…
  • Page 55
    3-16 ENGINE • Remove the primary driven gear assembly and the oil pump drive chain. • Remove the thrust washer 1 and spacer 2. OIL PUMP • Remove the oil pump by removing the circlip. % 09900-06107: Snap ring pliers •…
  • Page 56
    ENGINE 3-17 • Remove the gearshift cam plate 1. • Remove the gearshift cam stopper 2. PRIMARY DRIVE GEAR Remove the primary drive gear by removing the primary drive gear bolt with the special tool. % 09930-40113: Rotor holder & This bolt has left-hand thread.
  • Page 57
    3-18 ENGINE NEUTRAL SWITCH • Remove the neutral switch assembly. • Remove the oil pressure switch lead wire. GENERATOR • Remove the generator cover. • Remove the starter motor driven gear and the idle gear. • Loosen the generator rotor bolt. NOTE: When loosen the rotor bolt, do not remove it.
  • Page 58
    ENGINE 3-19 • Remove the cam chain tensioner and the chain. WATER PUMP • Remove the water pump cover. • Remove the water pump assembly. SECONDARY DRIVEN GEAR • Remove the secondary driven gear housing bolts. • Remove the secondary driven gear case.
  • Page 59
    3-20 ENGINE • Remove the secondary driven gear assembly. • Remove the bearing 1. • Remove the oil jet 2. OIL JET • Remove the oil jets. CRANKCASE • Remove the crankcase bolts. • Separate the crankcase into two parts with the special tool. % 09920-13120: Crankcase separator…
  • Page 60
    ENGINE 3-21 • Remove the crankshaft. • Remove the gearshift fork shafts and gearshift forks. • Remove the transmission. SECONDARY DRIVE BEVEL GEAR • Remove the over driving gear 1 and bush 2. • Remove the secondary drive bevel gear assembly.
  • Page 61: Engine Components Inspection And Servicing

    (0.4724 – 0.4731 in) % 09900-20605: Dial calipers REASSEMBLY • Apply SUZUKI MOLY PASTE to the rocker arms and their shafts. ‘ 99000-25140: SUZUKI MOLY PASTE ( Rocker arm shaft: 27 N . m (2.7 kgf . m, 19.5 lb-ft)

  • Page 62
    To properly measure the oi clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.
  • Page 63
    3-24 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. » Camshaft journal O.D. (Sprocket side) : 24.959 – 24.980 mm (0.9826 –…
  • Page 64: Cylinder Head

    ENGINE 3-25 CYLINDER HEAD VALVE AND VALVE SPRING DISASSEMBLY • Using special tools, compress the valve springs and remove the two cotter halves 1 from valve stem. % 09916-14510: Valve spring compressor 09916-14910: Valve spring compressor attachment 09916-84511: Tweezers • Remove the valve spring retainer, inner spring and outer spring. •…

  • Page 65
    3-26 ENGINE VALVE STEM RUNOUT Support the valve with “V” blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. » Valve stem runout Service Limit: 0.05 mm (0.002 in) % 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block…
  • Page 66
    ENGINE 3-27 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust rocker arm side. % 09916-44910: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
  • Page 67
    3-28 ENGINE VALVE SEAT WIDTH • Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
  • Page 68
    ENGINE 3-29 • Insert the solid pilot 1 (09916-24450: N-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
  • Page 69
    3-30 ENGINE BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. 60˚ (Intake only) FINAL SEAT CUT Contact area too low and too •…
  • Page 70
    ENGINE 3-31 VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit.
  • Page 71
    3-32 ENGINE • Insert the valves, with their stems coated with high quality mo- lybdenum disulfide lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break. ‘ 99000-25140: SUZUKI MOLY PASTE & When inserting each valve, take care not to damage the lip of the stem seal.
  • Page 72: Piston Diameter

    Service Limit: 83.085 mm (3.2711 in) % 09900-20508: Cylinder gauge set NOTE: When installing the water union to the cylinder, apply grease to the new O-rings. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig.

  • Page 73: Piston Ring Groove Width

    3-34 ENGINE PISTON-TO-CYLINDER CLEARANCE As a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. » Piston to cylinder clearance Service Limit: 0.12 mm (0.0047 in) Piston oversize: 0.5, 1.0 mm PISTON RING TO GROOVE CLEARANCE…

  • Page 74
    ENGINE 3-35 Oversize piston ring The following two types of oversize piston rings are used. They bear the following identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. 1.0 mm O.S. Oversize oil ring The following two types of oversize oil rings are available as op- 1.0 mm O.S.
  • Page 75
    3-36 ENGINE PISTON RING REASSEMBLY • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.
  • Page 76
    ENGINE 3-37 CONROD/CRANKSHAFT CONROD SMALL END I.D. Using a small bore gauge, measure the conrod small end inside diameter. ! Conrod small end I.D. Service Limit: 20.040 mm (0.7890 in) » 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22403: Small bore gauge (18 – 35 mm) If the conrod small end inside diameter exceeds the above men- tioned limit, replace the conrod.
  • Page 77
    3-38 ENGINE • Place plastigauge axially on the crank pin avoiding the oil hole, at TDC or BDC side as shown. • Tighten the bearing cap with two-step torque values. NOTE: When fitting the bearing cap to crank pin, be sure to discriminate between its two ends, I.D.
  • Page 78
    ENGINE 3-39 Conrod I.D. specification Code 1 I.D. specification 44.000 – 44.006 mm (1.7323 – 1.7325 in) 44.006 – 44.012 mm (1.7325 – 1.7328 in) 44.012 – 44.018 mm (1.7328 – 1.7330 in) Crank pin O.D. specification Code 2 O.D. specification 40.994 –…
  • Page 79
    1 first and press in the other end. • Apply molybdenum oil solution to the crank pin and bearing surface. % 99000-25140: SUZUKI MOLY PASTE • When mounting the conrod on the crankshaft, make sure that I.D. code 2 of the conrod faces rearward.
  • Page 80
    ENGINE 3-41 • Measure the crankshaft journal bearing I.D. 1 by using the special tool. ! Crankshaft journal bearing I.D. 1 Standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in) » 09900-20508: Cylinder gauge set If each crankshaft journal bearing I.D. is not within the standard range, replace them with new ones.
  • Page 81
    3-42 ENGINE CRANKSHAFT THRUST CLEARANCE Install the crankshaft in the right crankcase half after installing the thrust shim on the crankshaft. NOTE: The oil grooved face A of thrust shim 1 is faced to crankshaft web side. • Place the thrust washer, camshaft drive sprocket and primary drive gear on the right end of the crankshaft and tighten pri- mary drive gear bolt to the specified torque.
  • Page 82
    ENGINE 3-43 CLUTCH CLUTCH DRIVE AND DRIVEN PLATES NOTE: Wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one.
  • Page 83
    3-44 ENGINE GENERATOR/SIGNAL GENERATOR/ STARTER CLUTCH GENERATOR STATOR AND SIGNAL GENERATOR STATOR INSPECTION&8-8, 19, 20 GENERATOR STATOR AND SIGNAL GENERATOR STATOR SERVICING When replacing the generator stator or signal generator stator, route the wire properly. STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement.
  • Page 84: Oil Pump

    ENGINE 3-45 STARTER CLUTCH SERVICING • Hold the rotor with off-set wrench and remove the starter clutch securing bolts. • When fitting the one way clutch to the guide 1, position flange side A of one way clutch to the rotor side. •…

  • Page 85
    3-46 ENGINE TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. 1 Driveshaft bolt 2 Over driving gear 3 1st driven gear 4 4th driven gear 5 3rd driven gear 6 Driveshaft 7 5th driven gear 8 2nd driven gear 9 Counter haft/1st drive gear 0 4th drive gear A 3rd drive gear…
  • Page 86
    Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. % 99000-25140: SUZUKI MOLY PASTE * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
  • Page 87
    3-48 ENGINE When installing the 1st and 3rd driven gear bushings, align the bushing oil hole with the driveshaft oil hole. TRANSMISSION GEARS AND RELATED PARTS…
  • Page 88: Gearshift Fork

    ENGINE 3-49 GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.

  • Page 89
    • Remove the oil sump filter. • Clean the oil sump filter using compressed air. • When installing the O-ring, apply grease to it. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) OIL PIPE •…
  • Page 90
    ENGINE 3-51 • When installing the oil pipe, use the new O-rings. • Apply a small quantity of the THREAD LOCK “1342” to the oil pipe retainer bolts and tighten them securely. ) 99000-32050: THREAD LOCK “1342” OIL PRESSURE REGULATOR •…
  • Page 91
    » 09913-70210: Bearing installer set OIL PRESSURE SWITCH • Remove the oil pressure switch. • When installing the switch, apply SUZUKI BOND “1207B”. # Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘1207B”…
  • Page 92: Engine Reassembly

    ENGINE 3-53 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. SECONDARY DRIVE BEVEL GEAR •…

  • Page 93
    Use the new O-ring to prevent oil leakage • Clean the mating surfaces of the lef and right crankcase halves. • Apply SUZUKI BOND “1207B” to the mating surface of the right crankcase. * 99104-31140: SUZUKI BOND ‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”…
  • Page 94
    (For the others) • Clean the mating surfaces of the crankcase and the secondary gear case. • Apply SUZUKI BOND “1207B” to the mating surface of the sec- ondary gear case. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B” (For the others)
  • Page 95
    3-56 ENGINE • Tighten the secondary gear case bolts to the specified torque. # Secondary gear case bolt (Initial): 15 N . m (1.5 kgf . m, 11.0 lb-ft) (Final) : 22 N . m (2.2 kgf . m, 16.0 lb-ft) NOTE: Fit the washer to the bolt A .
  • Page 96
    ENGINE 3-57 • Install the new O-ring. • Install the water pump cover. NOTE: Fit the clamp to the bolt A . CAM CHAIN/CAM CHAIN TENSIONER • Install the cam chain tensioner and cam chain. # Cam chain tensioner bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) 1 For front cylinder 2 For rear cylinder NOTE:…
  • Page 97
    3-58 ENGINE • Install the starter driven gear and the idle gear. • Install the new gasket and dowel pins. • Install the generator cover. NOTE: Fit the new gaskets to the bolts A . NEUTRAL SWITCH • Install the springs and switch contacts. •…
  • Page 98
    ENGINE 3-59 OIL FILTER • Apply engine oil lightly to the gasket of the oil filter before in- stallation. • Install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface. Then tighten it 2 turns using the oil filter wrench.
  • Page 99
    3-60 ENGINE • Install the cam driven gear 1 after installing the springs, pins and gearshift pawls. • Install the cam guide and the pawl lifter. • Apply a small quantity of THREAD LOCK “1342” to the nuts. ) 99000-32050: THREAD LOCK “1342” •…
  • Page 100
    ENGINE 3-61 • Install the oil pump driven gear and the circlip. » 09900-06107: Snap ring pliers CLUTCH • Install the spacer 1 and the thrust washer 2. • Engage the chain with the oil pump drive gear. • Install the primary driven gear assembly and engage the chain with the oil pump driven gear.
  • Page 101
    3-62 ENGINE • Install the washer 1 and the clutch sleeve hub nut 2. NOTE: The convex side of the washer faces outside. • Tighten the clutch sleeve hub nut to the specified torque with the special tool. # Clutch sleeve hub nut: 60 N . m (6.0 kgf . m, 43.5 lb-ft) «…
  • Page 102
    ENGINE 3-63 • Install the wave washer seat 1 and the wave washer 2. • Install the clutch drive plate No.2 A first. • Install the drive and driven plate one by one into the clutch sleeve hub. • Install the push rod. •…
  • Page 103
    • Apply engine oil to the new O-ring and install the oil jets. PISTON • Apply a light coat of SUZUKI MOLY PASTE to the piston pins. % 99000-25140: SUZUKI MOLY PASTE • When installing the piston, the arrow mark on the piston head…
  • Page 104
    » 09918-53810: Chain tensioner lock tool # Cam chain tension adjuster mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Coat SUZUKI BOND “1207B” lightly to the mating surfaces among the crankcase mating surfaces. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”…
  • Page 105
    3-66 ENGINE CYLINDER HEAD • Install the cam chain guide. 1 For front cylinder 2 For rear cylinder • Fit the dowel pins and the new cylinder head gasket. Use a new gasket to prevent gas leakage. • Install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque.
  • Page 106
    Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket. • Before installing the camshafts onto each cylinder head, apply SUZUKI MOLY PASTE onto the camshaft journals. Also, apply engine oil onto the camshaft journal holders. % 99000-25140: SUZUKI MOLY PASTE NOTE: The camshaft is identified by the embossed letters “F”…
  • Page 107
    3-68 ENGINE • Align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. NOTE: Arrow marks are located to forward. Front Rear (No. 1) cylinder he d • Engage the chains on the cam sprockets with the locating pin holes A as shown in the photograph.
  • Page 108
    ENGINE 3-69 • Apply SUZUKI BOND “1216B” to the mating surface of the cyl- inder head cover. • Fit the camshaft end caps 1. • Apply grease to the O-ring 2 and install it. (Front cylinder only) 99000-31230: SUZUKI BOND “1216B”…
  • Page 109
    FRONT REAR NOTE: * Before installing the bolt 1 , apply SUZUKI BOND “1207B” to the thread of the bolt. * Allen bolt: 2 * Stainlessbolt: 1 , 3 , 4 . * Fit the gasket to the bolt 5 .
  • Page 110
    • Install the intake pipe. • Apply grease to the new O-ring and install the water outlet union. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Install the gasket and the breather cover.
  • Page 111
    3-72 ENGINE • Install the PAIR pipes. • Install the head cover caps 1. • Install the spark plugs. » 09930-10121: Spark plug wrench set…
  • Page 112: Shaft Drive

    SHAFT DRIVE SHAFT DRIVE CONTENTS…

  • Page 113
    4-2 SHAFT DRIVE SECONDARY BEVEL GEARS CONSTRUCTION A Secondary drive gear shaft nut 1 Bush B Secondary drive bevel gear 2 Overdriving driven gear 3 Circlip bearing retainer bolt C Secondary driven bevel gear 4 Output cam dog 5 Damper spring bolt 6 Secondary bevel gear set 7 Shims (5 kinds)
  • Page 114
    SHAFT DRIVE 4-3 0.05 – 0.32 mm Backlash (0.002 – 0.013 in) Standard clearance A: 1.00 mm (0.039 in) B: 1.00 mm (0.039 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-05A-0A0 0.30 mm (0.012 in)
  • Page 115
    4-4 SHAFT DRIVE REMOVAL SECONDARY DRIVE BEVEL GEAR The crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal.
  • Page 116
    SHAFT DRIVE 4-5 SECONDARY DRIVEN BEVEL GEAR • Remove the bearing stopper with the special tool. # 09921-21820: Bearing retainer wrench • Remove the oil seal. INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear…
  • Page 117
    NOTE: * Hollow portion A of the secondary driven bevel gear assembly faces inside. * It is not necessary to apply SUZUKI BOND “1207B” to the matching surface at this stage. • Measure the backlash as follows. • Set-up a dial gauge as shown in photo.
  • Page 118
    SHAFT DRIVE 4-7 • Adjust the dial gauge so that it touches the secondary drive bevel gear cam dog; hold the driven bevel gear securely, and turn the drive bevel gear in each direction, reading the total backlash on the dial gauge. % Secondary bevel gear backlash Standard: 0.05 –…
  • Page 119
    4-8 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • Remove the drive bevel gear assembly from the crankcase. •…
  • Page 120
    REASSEMBLY SECONDARY DRIVEN BEVEL GEAR • Apply grease to the lip of oil seal. & 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Tighten the bearing stopper to the specified torque with the special tool.
  • Page 121
    4-10 SHAFT DRIVE FINAL BEVEL GEARS CONSTRUCTION ITEM kgf.m lb-ft 16.5 29.0 10.0 72.5 A Final gear case bolt 1 Oil seal D Stopper plate (2 kinds) B Final driven beve gear bearing 2 Final gear bearing case E Final drive gear bearing 3 O-ring F Final drive bevel gear retainer screw…
  • Page 122
    SHAFT DRIVE 4-11 Standard clearance C: 1.00 mm (0.039 in) Shim 3 size table Part number Thickness Standard clearance A: 1.00 mm (0.039 in) 27327-34200 0.35 mm (0.014 in) Shim 1 size table 27327-34210 0.40 mm (0.016 in) 27327-34220 0.50 mm (0.020 in) Part number Thickness 27327-34230…
  • Page 123
    4-12 SHAFT DRIVE FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. NOTE: Refer to the following pages for the details of each step. •…
  • Page 124
    SHAFT DRIVE 4-13 1 Spring 2 Propeller shaft 3 Circlip • Using a chisel, unlock the nut. • Remove the final drive bevel gear coupling nut with the special tool. # 09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •…
  • Page 125
    4-14 SHAFT DRIVE • Remove the bearing from the final drive bevel gear with the bearing puller. The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. • Remove the final gear bearing case bolts. •…
  • Page 126
    SHAFT DRIVE 4-15 • Remove the bearing retainer screws, using an impact driver set. # 09900-09004: Impact driver set • Remove the final driven gear bearing and oil seal with the spe- cial tools. # 09941-64511: Bearing remover 09930-30102: Sliding shaft The removed bearing and oil seal must be replaced with new ones.
  • Page 127
    ! Final gear case bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) NOTE: It is not necessary to apply SUZUKI BOND “1207B” to the match- ing surface at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.
  • Page 128
    SHAFT DRIVE 4-17 If the backlash is not within the specification, adjust the shim thick- ness as follows: • Remove shims from final gear bearing case and final gear case, and measure total thickness. • In order not to change the clearance between final driven bevel gear and bearing, the total thickness of the shims installed af- ter a change is made must equal the original total thickness of shims.
  • Page 129
    4-18 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After backlash adjustment is carried out, the tooth contact must be checked. • Remove the bolts from the final gear bearing case, and remove the case with the two 5 mm screws. («4-14) Do not mis- place the shims.
  • Page 130
    SHAFT DRIVE 4-19 FINAL GEAR CASE REASSEMBLY Reassemble the final gear case in the reverse order of disassem- bly. Pay attention to the following points. • Install a new oil seal 1 and O-ring 2 to the bearing stopper. Use new O-ring and oil seat to prevent oil leakage. •…
  • Page 131
    4-20 SHAFT DRIVE • Install the needle roller bearing for the final driven bevel gear into the final gear case with the special tool. # 09913-76010: Bearing installer NOTE: The stamped ward on the bearing end should face to the driven bevel gear side.
  • Page 132
    SHAFT DRIVE 4-21 • Apply SUZUKI BOND “1207B” to the mating surface of the final gear case and final gear bearing case. Do not block the breather passage when applying SUZUKI BOND “1207B”. ( 99000-31140: SUZUKI BOND “1207B” • Apply THREAD LOCK “1342” to the final gear case bolts and tighten them to the specified torque.
  • Page 133
    • Apply grease to the lip of the oil seal and install it to the final drive bevel gear coupling. Use a new oil seal to prevent oil leakage. & 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (For USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (For the others)
  • Page 134: Final Gear Case Installation

    SHAFT DRIVE 4-23 • Install the stopper plate. When installing the plate, fit the protrusion A of plate to the one of the bearing stopper grooves. NOTE: Two kinds of plates are available to lock the stopper at the proper position.

  • Page 135: Fuel And Lubrication System

    FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM…

  • Page 136: Fuel Pump

    5-2 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM The fuel pump is operated by a vacuum force which is supplied from the carburetor intake pipe. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.

  • Page 137
    FUEL AND LUBRICATION SYSTEM 5-3 FUEL TANK/FUEL VALVE REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Remove the front seat. («7-2) • Remove the speedometer. • Disconnect the speedometer coupler. Be careful not to scratch the fuel tank. •…
  • Page 138
    5-4 FUEL AND LUBRICATION SYSTEM • Disconnect the fuel hose 1 and vacuum hose 2. • Remove the throttle stop screw. • Remove the fuel tank. • Remove the fuel valve. • Remove the fuel level gauge mounting bolts. • Remove the fuel level gauge 3. •…
  • Page 139
    FUEL AND LUBRICATION SYSTEM 5-5 INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel valve for cracks. REMOUNTING •…
  • Page 140
    5-6 FUEL AND LUBRICATION SYSTEM * Gasket 3 must be replaced with new ones to prevent fuel leakage. * Tighten the fuel level gauge bolts evenly. NOTE: mark A on the fuel level gauge forward. Face 10 N . m (1 0 kgf m, 7.0 lb-ft) Fuel tank FUEL PUMP REMOVAL…
  • Page 141
    FUEL AND LUBRICATION SYSTEM 5-7 • Disconnect the fuel hoses 1, 2 and vacuum hose 3. INSPECTION Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Disconnect the fuel hose 1, connect the suitable hose and insert the free end of the hose into a receptacle.
  • Page 142
    5-8 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap A Throttle stop screw 2 Spring B Pilot screw 3 Jet needle stopper C Float 4 O-ring D Pilot jet 5 E-ring E Main jet holder 6 Jet needle F Main jet 7 Diaphragm/Piston valve G Needle valve 8 Funnel…
  • Page 143
    FUEL AND LUBRICATION SYSTEM 5-9 SPECIFICATIONS SPECIFICATION ITEM E-02, 19, 24 E-03, 28 E-33 ← ← Carburetor type MIKUNI BDSR34 ← ← Bore size 34 mm I.D. No. 41F1 41F2 41F3 ← ← Idle r/min. 1 100 ± 100 r/min. Fuel level —…
  • Page 144: Diaphragm And Piston Operation

    5-10 FUEL AND LUBRICATION SYSTEM DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the venturi A.

  • Page 145: Slow System

    FUEL AND LUBRICATION SYSTEM 5-11 SLOW SYSTEM This system supplies fuel to the engine during engine operation with throttle valve 1 closed or slight opened. The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through #1 pilot air jet 4 and #2 pilot air jet 5.

  • Page 146: Main System

    5-12 FUEL AND LUBRICATION SYSTEM MAIN SYSTEM As the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve 2 moves upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel passes around main air bleed pipe 5, mixes with the air admitted through main air jet 6 to from an emulsion and emulsion fuel enters needle jet 7.

  • Page 147: Float System

    FUEL AND LUBRICATION SYSTEM 5-13 STARTER (ENRICHER) SYSTEM Pulling the starter (enricher) plunger 1 causes fuel to be drawn into the starter circuit from the float chamber The starter jet 3 meters this fuel. The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2.

  • Page 148: Accelerator Pump System

    5-14 FUEL AND LUBRICATION SYSTEM ACCELERATOR PUMP SYSTEM This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve) is slow and sucking volume of fuel is less.

  • Page 149
    FUEL AND LUBRICATION SYSTEM 5-15 REMOVAL • Remove the fuel tank. («5-3) • Loosen the air intake pipe clamp screws. • Disconnect the breather hose. • Move the air inlet pipe to forward. • Remove the throttle cables 1. • Disconnect the throttle position sensor coupler 2. •…
  • Page 150
    5-16 FUEL AND LUBRICATION SYSTEM • Loosen the clamp screw and remove the carburetor. • Remove the starter plunger. DISASSEMBLY • Remove the carburetor top cap 1. • Remove the spring 2 and piston valve 3 along with diaphragm • Pull out the jet needle holder 5.
  • Page 151
    FUEL AND LUBRICATION SYSTEM 5-17 • Remove the spring 1, washers 2, 3, retainer 4 and jet needle • Remove the float chamber 6. $ 09900-09004: Impact driver set • Remove the accelerator pump plunger 7. • Remove the O-ring 8. Use a new O-ring to prevent fuel leakage.
  • Page 152
    5-18 FUEL AND LUBRICATION SYSTEM • Use a %” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug.
  • Page 153
    FUEL AND LUBRICATION SYSTEM 5-19 • Remove the casting valve cover. • Remove the casting valve 1 and the spring 2.
  • Page 154: Carburetor Cleaning

    5-20 FUEL AND LUBRICATION SYSTEM CARBURETOR CLEANING Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 155
    FUEL AND LUBRICATION SYSTEM 5-21 CARBURETOR HEATER INSPECTION (for E02, E19) • Disconnect the carburetor heater terminal lead wires. • Connect the positive + terminal of a 12V battery to the termi- nal of the carburetor heater and the battery negative — termi- nal to the terminal.
  • Page 156
    5-22 FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT • Measure the float height A by using a calipers with the carbu- retor slanting at an angle of 45° (as shown in the right illustra- tion) and the float arm just contacting the needle valve. •…
  • Page 157: Reassembly And Reinstallation

    Replace the O-ring A with a new one. • Apply grease to the O-ring and install the accelerating plunger. For USA ‘ 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ‘ 99000-25010: SUZUKI SUPER GREASE “A” • Fit the seal rings securely to the float chamber and install the…

  • Page 158
    • Align the protrusion C of the carbureto top cap with the O-ring STARTER PLUNGER Apply a small quantity of grease to the starter plunger O-ring. For USA ‘ 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ‘ 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-rings with new ones.
  • Page 159
    FUEL AND LUBRICATION SYSTEM 5-25 THROTTLE POSITION SENSOR POSITIONING • Install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle posi- tion sensor. Ω 1 Ω Ω • Measure the resistance between the throttle position sensor terminals as shown in the illustration.
  • Page 160: Lubrication System Chart

    5-26 FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM CHART ROCKER ARM SHAFT (EX.) ROCKER ARM SHAFT (EX.) CAMSHAFT R. JOURNAL CAMSHAFT L. JOURNAL CAM FACES CAM FACES (IN. & EX.) (IN. & EX.) VALVES AND VALVES AND SPRINGS (IN. & EX.) SPRINGS (IN.

  • Page 161
    PAIR (AIR SUPPLY) SYSTEM 5-27 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING…
  • Page 162
    5-28 PAIR (AIR SUPPLY) SYSTEM PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VAVLE • Remove the PAIR valve cover. • Inspect the reed valve for the carbon deposit. •…
  • Page 163: Cooling System

    COOLING SYSTEM COOLING SYSTEM CONTENTS…

  • Page 164
    6-2 COOLING SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a Anti-freeze Freezing point 50:50 mixture of distilled water and ethylene glycol anti-freeze. density This 50:50 mixture will provide the optimum corrosion protection –30°C (–24°F) and excellent heat protection, and will protect the cooling system –40°C (–44°F) from freezing at temperatures above –31°C (–24°F).
  • Page 165: Cooling Circuit Inspection

    COOLING SYSTEM 6-3 RADIATOR AND WATER HOSE COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the fuel tank. (#5-3) • Remove the radiator cap 1 and connect the tester to the filler. «…

  • Page 166: Radiator Removal

    6-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the fuel tank. (#5-3) • Remove the frame head covers 1. • Disconnect the water hoses. • Drain engine coolant. • Remove the radiator cover 2. • Remove the radiator mounting bolts. • Remove the radiator.

  • Page 167: Radiator Cap Inspection

    COOLING SYSTEM 6-5 RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95–125 kPa (0.95–12.5 kgf/ , 13.5–17.8 psi) and that, with the tester held standstill, the cap is capable of holding that pressure for at least 10 seconds.

  • Page 168: Cooling Fan

    6-6 COOLING SYSTEM COOLING FAN INSPECTION • Disconnect the cooling fan lead wire coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • The voltmeter is for making sure that the battery applies 12 volts to the motor.

  • Page 169
    COOLING SYSTEM 6-7 INSTALLATION • Put the cooling fan between the down tube and the engine. • Tighten the down tube mounting bolts. (#3-9) • Tighten the cooling fan mounting bolts. • Install the radiator. (#6-5) COOLING FAN THERMO-SWITCH REMOVAL •…
  • Page 170
    Do not allow the switch to touch the pan, or false read- ing will result. • Apply grease to the O-ring ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Tighten the engine coolant temperature switch to the specified torque.
  • Page 171
    COOLING SYSTEM 6-9 THERMOSTAT REMOVAL • Drain engine coolant. (#2-13) • Remove the secondary gear case cover. • Remove the reserve tank 1 and water hose 2. • Remove the water pump case. • Remove the thermostat case. • Remove the thermostat. INSPECTION Inspect the thermostat pellet for signs of cracking.
  • Page 172: Water Pump

    6-10 COOLING SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the Valve lift thermostat valve should have lifted by at least 6.0 mm (0.24 in). $ Thermostat valve lift Standard: Over 6.0 mm at 90°C (Over 0.24 in at 194°F) •…

  • Page 173
    COOLING SYSTEM 6-11 • Remove the pin 1 and draw out the impeller shaft 2. • Remove the mechanical seal ring 3 and rubber seal 4. • Remove the bearing with the special tool. & 09921-20220: Bearing remover set NOTE: If no abnormal noise, bearing removal is not necessary.
  • Page 174: Reassembly And Installation

    • Install the oil seal. NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 175
    COOLING SYSTEM 6-13 • Install the new mechanical seal with a suitable size socket wrench and the special tool. NOTE: The new mechanical seal has been applied the sealer A . & 09924-84521: Bearing installer • Install the new bearing with the special tool. &…
  • Page 176
    6-14 COOLING SYSTEM • Apply grease to the O-ring. • Set the water pump shaft end A to the oil pump shaft B. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Install the water pump screws.
  • Page 177: Chassis

    CHASSIS CHASSIS CONTENTS…

  • Page 178: Exterior Parts

    7-2 CHASSIS EXTERIOR PARTS REMOVAL SEAT • Remove the rear seat by removing the bolts. Be careful not to scratch the rear fender. • Remove the rear seat grip band by removing the bolts. • Remove the seat. Be careful not to scratch the rear fender. FRAME COVER •…

  • Page 179
    CHASSIS 7-3 REAR FENDER • Remove the seat. («7-2) • Disconnect the coupler 1. • Remove the left or right side frame handle grip. • Remove the rear fender 2. Be careful not to scratch the rear fenders. NOTE: When installing the frame handle grip bolts, apply a small quan- tity of THREAD LOCK “1303”…
  • Page 180
    7-4 CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Bearing (R) 3 Front wheel 4 Spacer 5 Bearing (L) 6 Brake disc 7 Spacer A Front axle B Brake disc mounting bolt N . m kgf . m ITEM lb-ft 47.0 16.5 Left…
  • Page 181
    CHASSIS 7-5 REMOVAL AND DISASSEMBLY • Loosen the front axle pinch bolt 1. • Loosen the front axle 2 by using the special tool. % 09900-18710: Hexagon socket (12 mm) • Raise the front wheel off the ground with a jack or a wooden block.
  • Page 182
    7-6 CHASSIS INSPECTION WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 183
    Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings before in- stalling. For USA ‘ 99000-25030: SUZUKI SUPER GREASE “A”…
  • Page 184
    7-8 CHASSIS SPEED SENSOR • Apply SUZUKI SUPER GREASE “A” to the speed sensor dust seal. For USA ‘ 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ‘ 99000-25010: SUZUKI SUPER GREASE “A” • Align the grooves 1 on the speed sensor with the lugs 2 on the wheel hub.
  • Page 185
    CHASSIS 7-9 FRONT BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Caliper holder 7 Caliper 8 Pad set 9 Piston ITEM N·m kgf·m lb-ft 0 Piston and dust seal A Insulator A Master cylinder mounting bolt B Brake hose union bolt C Brake caliper mounting bolt * The brake system is illed with an glycol-based brake fluid, which is classified DOT 4.
  • Page 186: Brake Pad Replacement

    7-10 CHASSIS BRAKE PAD REPLACEMENT • Remove the guide hook A. • Remove the brake caliper by removing the brake caliper mount- ing bolts. • Remove the pin 1. • Remove the pad pin 2. • Remove the brake pads 3. * Do not operate the brake lever during or afte br ke pad removal.

  • Page 187: Brake Fluid Replacement

    CHASSIS 7-11 BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. • Remove as much old brake fluid as possible. • Fill the reservoir with new brake fluid. * Specification and classification: DOT 4 •…

  • Page 188: Brake Caliper Inspection

    7-12 CHASSIS • Remove the brake pads. («7-10) • Remove the insulator. • Remove the brake caliper holder. • Remove the spring. • Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using compressed air.

  • Page 189: Brake Caliper Reassembly And Remounting

    * Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEALS • Install the piston seals 1 and dust seals 2 as shown. BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder. + 99000-25100: SUZUKI SILICONE GREASE…

  • Page 190: Brake Disc Inspection

    7-14 CHASSIS • Tighten the brake caliper mounting bolts 1, and brake hose union bolt 2 to the specified torque. $ Brake caliper mounting bolt: 39 N . m (3.9 kgf . m, 28 lb-ft) Brake hose union bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) •…

  • Page 191: Master Cylinder Removal And Disassembly

    CHASSIS 7-15 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle.

  • Page 192: Master Cylinder Inspection

    7-16 CHASSIS • Remove the piston assembly. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary/secondary cup, and dust boo for any scratches, wear or damage.

  • Page 193
    CHASSIS 7-17 • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • When remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper clamp bolt first.
  • Page 194
    7-18 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 2 Front fork spring 3 Damper rod ring 4 Rebound spring 5 Damper rod 6 Inner tube cover 7 Rubber 8 Washer 9 Inner tube 0 Slide metal A Dust seal B Oil seal stopper ring C Oil seal D Oil seal retainer E Oil lock piece…
  • Page 195
    CHASSIS 7-19 REMOVAL AND DISASSEMBLY • Remove the front wheel. («7-5) • Remove the brake hose from the hose guide. • Remove the guide hook A. • Remove the front brake caliper by removing the bolts. • Remove the front fender by removing its mounting bolts. Be careful not to scratch the front fender.
  • Page 196
    7-20 CHASSIS • Remove the front fork inner tube cover 1, washer 2 and rub- ber 3. • Remove the inner tube cover stopper 4 by loosening the bolt. • Remove the inner tube cover guide 5. • Remove the front fork spring stopper nut 6 and fork spring 7. % 09900-18720: Hexagon socket (14 mm) •…
  • Page 197
    CHASSIS 7-21 • Remove the dust seal 1 and the oil seal stopper ring 2. • Remove the oil seal by slowly pulling out the inner tube. NOTE: Be careful not to damage the inner tube. The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork.
  • Page 198
    • Install the oil lock piece 1, slide metals 2, oil seal retainer 3 and oil seal 4 onto the inner tube. NOTE: Apply grease to the oil seal 4 lip lightly before installing it. For USA ‘ 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ‘ 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 199
    CHASSIS 7-23 NOTE: When installing the oil lock piece, insert the tapered end A of oil lock piece into the inner tube. • Insert the inner tube into the outer tube and install the oil seal 1 using the special tool. % 09940-52861: Front fork oil seal installer •…
  • Page 200
    7-24 CHASSIS FORK OIL • Pour the specified fork oil into the inner tube. Fork oil type: SUZUKI FORK OIL SS-08 (#10) or equivalent fork oil , 99000-99001-SS8: SUZUKI FORK OIL SS-08 & Front fork oil capacity (each leg): 412 ml (13.9/14.5 US/Imp oz)
  • Page 201
    CHASSIS 7-25 • Install the inner tube cover 1, rubber 2 and washer 3. • Remount the front fork and tighten the front fork lower clamp bolts temporarily. NOTE: Install the inner tube A until it seets to the flange part B of the steering stem upper bracket.
  • Page 202
    7-26 CHASSIS STEERING CONSTRUCTION 1 Handlebars 2 Handlebar balancer 3 Handlebar set bolt cap 4 Handlebar clamp/holder 5 Steering stem upper bracket 6 Steering stem nut 7 Dust seal 8 Steering stem upper bearing 9 Steering stem lower bearing 0 Steering stem A Fron fork upper cover B Head ight housing bracket A Handlebar set bolt…
  • Page 203
    CHASSIS 7-27 • Disconnect the front brake light switch lead wires 1. • Remove the front brake master cylinder 2. • Remove the right handlebar balancer 3, the right handlebar switch 4 and the throttle grip 5. • Disconnect the clutch lever position switch lead wires 6. •…
  • Page 204
    7-28 CHASSIS • Remove the steering stem head nut 1 and washer. • Remove the steering stem upper bracket 2 and the front fork upper cover 3. NOTE: Hold the front fork upper cover to prevent it from falling. • Remove the cable guide 4. •…
  • Page 205
    CHASSIS 7-29 • Remove the front turn signal light bracket. • Disconnect the front turn signal light lead-wire connector. • Remove the brake hose guide. • Remove the brake hose and speedo sensor lead-wire. («9- • Remove the head light housing. •…
  • Page 206
    7-30 CHASSIS • Remove the dust seal 1. • Remove the steering stem upper bearing 2. • Remove the steering stem lower bearing 3. • Remove the handlebar holders 4 from the steering stem up- per bracket. • Remove the handlebar bushes by using the proper tool and special tools.
  • Page 207
    CHASSIS 7-31 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal bearing noise * Distortion of the steering stem • Remove the steering stem lower bearing inner race by using a chisel.
  • Page 208
    • Apply grease to the upper and lower bearings before remount- ing the steering stem. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the bearings inner race and the dust seal.
  • Page 209
    CHASSIS 7-33 HANDLEBAR HOLDER • Install the handlebar holders and related parts to the steering stem head. • Tighten the handlebar holder nuts to the specified torque. $ Handlebar holder nut: 70 N . m (7.0 kgf . m, 50.5 lb-ft) STEERING STEM UPPER BRACKET •…
  • Page 210
    • Install the handlebar set bolt cap. Forward • Apply grease to the throttle cable end For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the front brake master cylinder. (‘7-17) $ Front master cylinder mounting bolt: 10 N .
  • Page 211: Steering Tension Adjustment

    CHASSIS 7-35 Master cylinder Handlebar Upper clamp bolt Punched mark Clearance • Install the clutch lever holder with the punch mark A aligned with the clutch lever holder clamp as shown. $ Clutch lever holder clamp bolt: 10 N . m (1.0 kgf .

  • Page 212: Rear Wheel

    7-36 CHASSIS REAR WHEEL CONSTRUCTION 1 Rear axle 2 Spacer (LH) 3 Lock washer 4 Driven joint stopper 5 Driven joint 6 Damper 7 O-ring 8 Bearing (LH) 9 Spacer 0 Bearing (RH) A Wheel rim B Brake shoe C Brake camshaft D Brake panel E Brake cam lever A Driven joint stopper bolt…

  • Page 213
    CHASSIS 7-37 Left Right For E-03, E-28, E-33 N . m kgf . m ITEM lb-ft 0.73 A Rear axle nut B Brake cam lever nut 25.5 C Rear torque link nut (F) D Rear torque link nut (R) 18.0…
  • Page 214
    7-38 CHASSIS REMOVAL • Remove the seat 1. (‘7-2) • Remove the rear fender 2. (‘7-3) NOTE: The rear fender removal is not necessary when the rear part of motorcycle can be lifted high enough to take the rear wheel out smoothly.
  • Page 215
    CHASSIS 7-39 • Remove the rear swingarm left cover. • Remove the rear axle shaft. DISASSEMBLY • Flatten the lock washers. • Remove the fitting bolts, washers and plates. • Pull off the driven joint 1. • Remove the O-ring 1. •…
  • Page 216
    Pay attention to the following points: WHEEL BEARING • Apply grease to the bearings before installation. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special ool.
  • Page 217
    Apply grease to the O-ring and the final gear spline before install- ing the driven joint. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Apply THREAD LOCK SUPER “1303” to the thread of driven joint stopper bolts.
  • Page 218: Rear Brake

    7-42 CHASSIS REAR BRAKE REMOVAL AND DISASSEMBLY • Remove the rear wheel. (‘7-38) • Remove the rear brake panel. • Remove the brake shoes. • Remove the rear brake cam lever 1 and rear brake cam 2 by removing bolt. •…

  • Page 219
    Replace the brake shoes as a set, otherwise braking per- formance will be adversely affected. REASSEMBLY AND REMOUNTING BRAKE CAMSHAFT • When installing the brake camshaft, apply SUZUKI SUPER GREASE “A” to the camshaft and cam face. For USA # 99000-25030: SUZUKI SUPER GREASE “A”…
  • Page 220: Rear Brake Rod

    7-44 CHASSIS • Tighten the brake cam lever bolt to the specified torque. $ Brake cam lever nut: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Install the rear wheel. (‘7-41) • Adjust the rear brake pedal free travel. (‘2-16) REAR BRAKE ROD REMOVAL AND DISASSEMBLY •…

  • Page 221: Reassembly Remounting

    • Apply grease to the rear brake link pivot bolt and tighten it to the specified torque. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” $ Rear brake link pivot bolt: 29 N m (2.9 kgf . m, 21 lb-ft) •…

  • Page 222
    7-46 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Rear cushion rod 3 Spacer 4 Rear cushion lever bearing 5 Rear cushion lever 6 Swingarm pivot bearing 7 Swingarm bea ing 8 Swingarm 9 B ot A Rear shock absorber mounting nut B Rear cushion rod mounting nut C Rear cushion lever mounting nut D Rear swingarm pivot bolt lock nut…
  • Page 223
    CHASSIS 7-47 Left Right 50 N m 5.0 kgf m 36 0 lb-f 1 mm 1 mm 78 N . m 7.8 kgf . m 56.5 lb-ft 1 mm 1 mm 100 N . m 10.0 kgf . m 100 N . m 72 5 lb-ft 10.0 kgf .
  • Page 224
    7-48 CHASSIS REMOVAL • Remove the rear wheel. (‘7-41) • Remove the final gear case with propeller shaft. • Remove the secondary gear case cover 1. • Remove the right frame lower cover 2, clutch rear cover 3. : hooked part •…
  • Page 225
    CHASSIS 7-49 • Remove the cushion lever mounting bolt and nut. • Remove the shock absorber upper mounting bolt and nut. • Remove the right side swingarm pivot bolt lock nut 1. • Remove the left and right side swingarm pivot bolts 2. NOTE: Slightly loosen the cushion rod mounting nuts and the shock ab- sorber lower mounting nut before removing the swingarm to fa-…
  • Page 226
    7-50 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove spacer from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into swingarm cushion rod upper side bearing and check the play to move the spacer up and down.
  • Page 227
    CHASSIS 7-51 CUSHION LEVER BEARING Insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. • Remove the cushion rod lower side bearing 1 by using the special tools.
  • Page 228
    When installing the bearings, stamped mark of bearing must face outside. • Apply grease to the spacers and bearings For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Assemble the shock absorber, cushion lever and cushion rods onto the swingarm.
  • Page 229
    • Install the swingarm assembly, its pivot bearings and bolts (1, NOTE: Apply grease to the swingarm pivot bearings. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” 1: For left side swingarm pivot bolt 2: For right side swingarm pivot bolt •…
  • Page 230
    $ Cushion lever mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) FINAL GEAR CASE • Install the plate to the final gear case 1. Apply SUZUKI BOND “1207B” to the mating surface of swingarm and final gear case For USA * 99104-31140: SUZUKI BOND ‘‘1207B”…
  • Page 231
    CHASSIS 7-55 NOTE: To install the final gear case easily, move the dust boot front and the universal joint back. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven bevel gear shaft. •…
  • Page 233: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS…

  • Page 234: Cautions In Servicing

    8-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 235: Connecting The Battery

    ELECTRICAL SYSTEM 8-3 BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water re- plenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.

  • Page 236
    8-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Ignition switch 5 Cooling fan 2 Ignition coil #2 6 Cooling fan thermo-switch 3 Fuel level gauge 7 Speedometer sensor 4 Rear brake switch…
  • Page 237
    ELECTRICAL SYSTEM 8-5 F Oil pressure switch 8 Ignition coil #1 G Generator 9 Throttle position sensor H Gear position switch 0 Starter relay/main fuse I Side-stand switch A Battery J Fuse box B Ignitor K Turn signal side-stand relay C Engine coolant temperature sensor L Regulator/rectifier D Horn…
  • Page 238: Charging System

    8-6 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator / rectifier Ig.switch Generator Fuse TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed amounts of electricity. No accessories Check the battery for current Current leaks • Short circuit of wire harness leaks.

  • Page 239
    ELECTRICAL SYSTEM 8-7 Measure the generator no-load voltage. (! 8-8) Incorrect • Faulty generator Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier (! 8-9) Correct Inspect wirings. Incorrect • Short circuit of wire harness Poor contact of couplers Correct • Faulty battery Others Battery overcharge •…
  • Page 240
    8-8 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the two seats. (!7-2) • Start the engine and keep it running at 5 000 r/min. with light- ing switch turned ON (except for E-03, 28, 24, 33 models) and dimmer switch turned HI position. Measure the DC voltage between the + and — battery termi- nals using the multi circuit tester.
  • Page 241
    ELECTRICAL SYSTEM 8-9 REGULATOR/RECTIFIER • Remove the secondary gear case cover. • Disconnect the regulator/rectifier couplers. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified valve, replace the regulator/rectifier with a new one.
  • Page 242
    8-10 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch To ignition Fuse(30A) coils and ignitor Starter motor Fuse Gear position Clutch lever (15A) witch position switch Starter relay Starter Turn signal/ button side-stand re ay side-stand switch TROUBLESHOOTING…
  • Page 243: Starter Motor Removal And Disassembly

    ELECTRICAL SYSTEM 8-11 Check the starter relay. Incorrect • Faulty starter relay (! 8-13) Correct • Poor contact of the starter relay The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.

  • Page 244: Starter Motor Inspection

    Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply grease to the lip of the oil seal. For U.S.A. — 99000-25030: SUZUKI SUPER GREASE “A” For the other countries — 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 245: Starter Relay Inspection

    ELECTRICAL SYSTEM 8-13 • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. . 99000-25140: SUZUKI MOLY PASTE • Align the tonque 1 on the brush holder with the groove 2 on the housing end. • Align the threaded parts 3 on the housing end.

  • Page 246
    8-14 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. » 09900-25008: Multi circuit tester set # Starter relay resistance: 3 – 7 Ω Ω SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation.
  • Page 247
    ELECTRICAL SYSTEM 8-15 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • Remove the secondary gear case cover. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
  • Page 248
    8-16 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop Side stand switch relay Ignition Fuse coil #2 Ignition switch ¹ Bl/W Ignitor Main Pickup gnition fuse coil coil #1 Generator Bl R/B G/Bl R Y B/Br Battery Gear Throttle position position switch sensor NOTE: The ignition cut-off circuit is incorporated in this ignitor to prevent over-running of engine.
  • Page 249
    ELECTRICAL SYSTEM 8-17 Measure the battery voltage between input lead wires (O/W and B/W) at the ignitor with the ignition switch in the Incorrect • Faulty ignition switch “ON” position. • Faulty turn signal/side-stand relay • Faulty engine stop switch Correct •…
  • Page 250
    8-18 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. (&5-3) • Disconnect the two spark plug caps. • Connect the new spark plugs to the each spark plug cap and ground them on the cylinder head. NOTE: Make sure that the each spark plug cap and spark plug are con- nected properly.
  • Page 251
    ELECTRICAL SYSTEM 8-19 IGNITION COIL RESISTANCE • Remove the fuel tank. (&5-3) • Disconnect the ignition coil lead wires and plug caps. Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
  • Page 252
    8-20 ELECTRICAL SYSTEM • Shift the transmission into the neutral, and then turn the igni- tion switch to the “ON” position. Ignitor Pickup coil coupler • Pull the clutch lever. coupler • Press the starter button and allow the engine to crank for a few seconds, and then measure the pickup coil peak voltage.
  • Page 253
    ELECTRICAL SYSTEM 8-21 SPEEDOMETER REMOVAL • Remove the screws. • Disconnect the cover and couple . When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Remove the speedometer.
  • Page 254
    8-22 ELECTRICAL SYSTEM PARTS NAMES 1 High beam indicator light 2 Engine coolant temperature indicator light 3 Turn signal indicator light 4 Oil pressure indicator light 5 Neutral indicator light 6 Fuel level meter 7 Speedometer/tripmeter/clock 8 SELECT button 9 ADJUST button OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD light up for three…
  • Page 255
    ELECTRICAL SYSTEM 8-23 CLOCK • Displays the time (hours and minutes) on a 12-hour clock. • Setting the time. Hold down the ADJUST button for two seconds while pressing The setting that is the SELECT button and then flashing the hour display. flashing can be changed.
  • Page 256
    8-24 ELECTRICAL SYSTEM INSPECTION ENGINE COOLANT TEMPERATURE INDICATOR LIGHT Engine coolant temperature sensor inspection: &6-8 • Remove the fuel tank. (&5-3) • Disconnect the engine coolant temperature sensor coupler. • Connect the jumper wire to the wire harness coupler. Check that the LED light immediately after turning the ignition switch on.
  • Page 257
    ELECTRICAL SYSTEM 8-25 FUEL LEVEL METER • Remove the fuel tank. (&5-3) • Connect the speedometer. • Connect each resistor between the Yellow/Black and Black/ White lead wire at the wire harness. • Turn the ignition switch “ON” position and wait for approx, 13 seconds.
  • Page 258
    • Install the O-ring and apply grease to it. For U.S.A. + 99000-25030: SUZUKI SUPER GREASE “A” For the other countries + 99000-25010: SUZUKI SUPER GREASE A” Use a new O-ring to prevent fuel leakage.
  • Page 259
    ELECTRICAL SYSTEM 8-27 SPEED SENSOR INSPECTION If the speedometer, odometer or tripmeter does not function prop- erly. Inspect the speed sensor and connection of couplers. If the speed sensor and connection is all right, replace the unit with a new one. •…
  • Page 260
    8-28 ELECTRICAL SYSTEM LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W ….For E-03, 24, 28, 33 12 V 60/55 W + 4 W ..For E-02,19 For E-02, 19 BRAKE LIGHT/TAILLIGHT 12 V 21/5 W TURN SIGNAL LIGHT Front 12 V 21/5 W ..
  • Page 261: Starter Relay

    ELECTRICAL SYSTEM 8-29 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

  • Page 262
    8-30 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. IGNITION SWITCH PUSH (For E-24) HORN BUTTON Color Color Position B/Bl Position PUSH LOCK FRONT BRAKE SWITCH…
  • Page 263: Initial Charging

    ELECTRICAL SYSTEM 8-31 BATTERY SPECIFICATIONS Type designation FTX12-BS Capacity 12V, 36 kC (10 Ah)/10HR INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 which seals the battery filler holes 2. • Remove the caps 3 from the electrolyte container. NOTE: * Do not remove or pierce the sealed areas 4 of the electrolyte container.

  • Page 264
    8-32 ELECTRICAL SYSTEM NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •…
  • Page 265: Recharging Operation

    ELECTRICAL SYSTEM 8-33 RECHARGING OPERATION • Measure the battery voltage using the multi circuit tester. If the voltage reading is less than the 12.0V (DC), recharge the bat- tery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.

  • Page 267: Servicing Information

    SERVICING INFORMATION SERVICING INFORMATION CONTENTS…

  • Page 268
    9-2 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace.
  • Page 269
    SERVICING INFORMATION 9-3 Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1.
  • Page 270
    9-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Valve clearance out of adjustment. Adjust.
  • Page 271
    SERVICING INFORMATION 9-5 Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.
  • Page 272
    9-6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut. Adjust. Replace. 2. Broken bearing in steering stem. 3. Distorted steering stem. Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. Adjust or replace.
  • Page 273
    SERVICING INFORMATION 9-7 BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi- 1. Leakage of brake fluid. Repair or replace. Replace. cient. 2. Worn brake pad/shoe. 3. Oil on brake pad surface. Clean brake disc and brake pads. 4. Worn brake disc. Replace.
  • Page 274
    9-8 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. Replace. sparking. 2. Defective spark plug. 3. Defective pick-up coil. Replace. 4. Defective ignitor unit. Replace. Spark plug is wet or 1.
  • Page 275
    SERVICING INFORMATION 9-9 BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check generator, regulator/ quickly.
  • Page 276
    9-10 SERVICING INFORMATION WIRING DIAGRAM For E-03, -28, -33…
  • Page 277
    SERVICING INFORMATION 9-11 For E-02, -19…
  • Page 278
    9-12 SERVICING INFORMATION For E-24…
  • Page 279: Wire Harness Routing

    SERVICING INFORMATION 9-13 WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING After clamping, cut the excessive end. 200 mm After clamping, cut Clamp the excessive end. Handlebar switch (L & R) Speed sensor Wiring harness Front turn signal light (L & R) Clamp Clamp Clutch cable…

  • Page 280
    9-14 SERVICING INFORMATION Fuel level gauge lead wire Fuel pump & carburetor hose Wiring harness Fuel pump vacuum hose Install between wiring harness and fuel pump vacuum hose. Pass the battery -lead wire To spe dometer under the starter relay. Frame head cover (L &…
  • Page 281
    SERVICING INFORMATION 9-15…
  • Page 282
    9-16 SERVICING INFORMATION CABLE ROUTING Throttle cable Throttle cable Throttle plate (returning) cabl cable Clutch (pulling) cable Brake hose Throttle cable (pulling) Reservoir hose Guide High-tension cord Wiring harness Clutch cable Throttle cable clip Fuel hose Reservoir hose Clamp Clutch cable Starter cable Clamp…
  • Page 283: Fuel Hose Routing

    SERVICING INFORMATION 9-17 FUEL HOSE ROUTING…

  • Page 284
    9-18 SERVICING INFORMATION COOLING HOSE ROUTING…
  • Page 285
    SERVICING INFORMATION 9-19 FRONT BRAKE HOSE ROUTING…
  • Page 286: Battery Protector

    9-20 SERVICING INFORMATION BATTERY PROTECTOR Battery protector 60 mm 90 mm 90 mm 65 mm 30 mm 30 mm 0 mm Battery protector SPEED SENSOR LEAD WIRE ROUTING 30 mm Speed sensor lead wire clamp Speed sensor guide hook Speed sensor lead wire…

  • Page 287
    SERVICING INFORMATION 9-21 SPECIAL TOOLS 09900-18710 09900-18720 09900-09004 Hexagon socket Hexagon socket 09900-06107 09900-06108 Impact driver set (12 mm) (14 mm) Snap ring pliers Snap ring pliers 09900-20102 09900-20202 09900-20203 09900 20204 09900-20205 Vernier calipers Micrometer Micrometer Micrometer Micrometer (200 mm) (25 –…
  • Page 288
    9-22 SERVICING INFORMATION 09916-14910 09915-77330 09916-21111 09916-14510 Valve lifter Meter (For high 09916-10911 Valve seat cutter set Valve lifter attachment Valve lapper set pressure) 09916-34550 09916-22430 09916-34580 09916-44910 09916-44920 Valve guide reamer Valve seat cutter Valve guide reamer Valve guide Valve guide installer (N-128) (5.5 mm)
  • Page 289
    SERVICING INFORMATION 9-23 09940-14911 09940-52861 Steering stem nut 09940-34520 09940-34531 Front fork oil seal 09940-92720 wrench T handle Attachment “A” installer Spring scale 09941-34513 09941-54911 09941-74911 09941- 4511 Steering outer race 09941-50111 Bearing outer race Steering bearing Bearing remover installer Bearing remover set remover installer…
  • Page 290
    9-24 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Rocker arm shaft 19.5 Cylinder head cover bolt 6 mm 8 mm 18.0 Cylinder head bolt and nut Initial 8 mm Final 18.0 Initial 18.0 10 mm Final 27.5 Cam sprocket bolt…
  • Page 291: Secondary And Final

    SERVICING INFORMATION 9-25 N . m kgf . m ITEM lb-ft Oil plug 6 mm 8 mm 13.0 10 mm 11.0 14 mm 16.5 16 mm 25.5 Engine mounting bolt 57.0 Engine mounting bracket bolt 16.5 Frame mounting bolt/nut 8 mm 16.5 10 mm 36.0…

  • Page 292
    9-26 SERVICING INFORMATION CHASSIS N . m kgf . m ITEM lb-ft Front axle 47.0 Front axle pinch bolt 24.0 Brake disc bolt 16.5 Front fork cap bolt 33.1 Front fork spring stopper nut 25.5 Front fork damper rod bolt 14.5 Front fork lower clamp bolt 24.0…
  • Page 293
    SERVICING INFORMATION 9-27 TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N . m kgf . m N . m kgf . m lb-ft lb-ft 0.15…
  • Page 294
    9-28 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.18) ——— (1.02) Valve clearance 0.08 – 0.13 ——— (when cold) (0.003 – 0.005) 0.17 – 0.22 ——— (0.007 – 0.009) Valve guide to valve stem 0.010 –…
  • Page 295
    SERVICING INFORMATION 9-29 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT 35.95 – 35.99 Cam height 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.58 –…
  • Page 296
    9-30 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring free end gap Approx. (0.38) (0.30) 11.8 Approx. (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring groove clearance 0.180 ———…
  • Page 297
    SERVICING INFORMATION 9-31 OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) Below 650 kPa (6.5 kgf/cm , 92 psi) ——— at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –…
  • Page 298
    9-32 SERVICING INFORMATION SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 ——— (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side ——— (0.001 – 0.025) Damper spring free length 58.5 ———…
  • Page 299
    SERVICING INFORMATION 9-33 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE 1 . 2 Firing order Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 –…
  • Page 300
    540.6 (21.73) (21.29) Front fork oil level (without spring) ——— (6.96) Front fork oil type SUZUKI FORK OIL SS-08 ——— or an equivalent fork oil Front fork oil capacity 412 ml (each leg) (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster ———…
  • Page 301
    SERVICING INFORMATION 9-35 TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front ——— (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear ——— (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front ———…
  • Page 303: Emission Control Information

    EMISSION CONTROL INFORMATION 10-1 EMISSION CONTROL INFORMATION CONTENTS…

  • Page 304
    The jet needle is also of special manufacture. Only one clip position is provided on the jet needle. If replace- ment becomes necessary the jet needle may only be replaced with an equivalent per orming replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best pos- sible performance and durability.
  • Page 305
    EMISSION CONTROL INFORMATION 10-3 EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA MODEL ONLY) Fuel tank Fuel valve Carburetor surge control valve Canister Fuel pump Intake pipe PAIR valve PTC valve Carburetors…
  • Page 306: Evaporative Emission Control System Inspection

    10-4 EMISSION CONTOROL INFORMATION CANISTER HOSE ROUTING 09404-06431 Clamp, air vent hose 13590-41F00 Air vent hose Valve comp, air vent 09401-09403 Clip, air vent valve hose Air vent hose 09355-40805 480 Hose, air vent valve vac 13595-41F00 Hose, air vent valve Air vent hose 13590-41F00 Valve comp, air vent…

  • Page 307
    EMISSION CONTROL INFORMATION 10-5 CARBURETOR SURGE CONTROL VALVE • Remove the carbretor surge control valve. • Connect the vacuum pump to the vacuum port as shown. • Apply the specified negative pressure to the carburetor surge control valve. • The specified negative pressure must be maintained. •…
  • Page 308
    10-6 EMISSION CONTOROL INFORMATION • Remove the vacuum pump and blow air through the air vent port A. • Air should flow through the carburetor surge control valve and out the canister port B. • Replace the carbretor surge control valve if air does not flow out the canister port B.
  • Page 309: Vl800K2 (’02- Model)

    VL800K2 (’02-MODEL) 11-1 VL800K2 (’02-MODEL) CONTENTS SPECIFICATIONS …………….11- 2 SERVICE DATA ……………..11- 4…

  • Page 310
    11-2 VL800K2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length …………..2 510 mm (98.818 in) Overall width …………..985 mm (38.779 in) Overall height …………..1 110 mm (43.700 in) Wheelbase …………..1 650 mm (64.960 in) Ground clearnce …………140 mm ( 5.511 in) Seat height …………..
  • Page 311
    VL800K2 (’02-MODEL) 11-3 CHASSIS Front suspension …………Telescopic, coil spring, oil damped Rear suspension …………Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle ………….. 38° (right & left) Caster …………….33° 20’ Trail …………….141 mm (3.55 in) Turning radius ……………
  • Page 312
    11-4 VL800K2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.18) ——— (1.02) Valve clearance 0.08 – 0.13 ——— (when cold) (0.003 – 0.005) 0.17 – 0.22 ——— (0.007 – 0.009) Valve guide to valve stem 0.010 –…
  • Page 313
    VL800K2 (’02-MODEL) 11-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT 35.95 – 35.99 Cam height 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.58 –…
  • Page 314
    11-6 VL800K2 (’02-MODEL) ITEM STANDARD LIMIT Piston ring free end gap Approx. (0.38) (0.30) 11.8 Approx. (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring groove clearance 0.180 ———…
  • Page 315
    VL800K2 (’02-MODEL) 11-7 OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) Below 650 kPa (6.5 kgf/cm , 92 psi) ——— at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –…
  • Page 316
    11-8 VL800K2 (’02-MODEL) SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 ——— (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side ——— (0.001 – 0.025) Damper spring free length 58.5 ———…
  • Page 317
    VL800K2 (’02-MODEL) 11-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE 1 . 2 Firing order Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 –…
  • Page 318
    540.6 (21.73) (21.29) Front fork oil level (without spring) ——— (6.96) Front fork oil type SUZUKI FORK OIL SS-08 ——— or an equivalent fork oil Front fork oil capacity 412 ml (each leg) (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster ———…
  • Page 319
    VL800K2 (’02-MODEL) 11-11 TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front ——— (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear ——— (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front ———…
  • Page 321
    VL800K3 (’03-MODEL) 12- 1 VL800K3 (’03-MODEL) This chapter describes service data, service specifications and servicing procedures which dif- fer from those of the VL800K2 (’02-MODEL). NOTE: * Please refer to the chapter 1 through 11 for details which are not given in this chapter. CONTENTS SPECIFICATIONS ………….
  • Page 322
    12-2 VL800K3 (’03-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length…………2 510 mm (98.8 in) Overall width …………985 mm (38.7 in) Overall height…………1 100 mm (43.3 in) Wheelbase …………1 655 mm (65.2 in) Ground clearnce ……….140 mm ( 5.5 in) Seat height…………
  • Page 323: Table Of Contents

    VL800K3 (’03-MODEL) 12-3 CHASSIS Front suspension……….Telescopic, coil spring, oil damped Rear suspension ……….Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle …………. 38° (right & left) Caster…………..33° 20’ Trail …………..141 mm (3.55 in) Turning radius ………….

  • Page 324
    12-4 VL800K3 (’03-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance 0.08 – 0.13 — (when cold) (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –…
  • Page 325
    VL800K3 (’03-MODEL) 12-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.58 –…
  • Page 326
    12-6 VL800K3 (’03-MODEL) ITEM STANDARD LIMIT Piston ring free end gap Approx. 9.6 (0.38) (0.30) Approx. 11.8 (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring groove clearance 0.180 —…
  • Page 327
    VL800K3 (’03-MODEL) 12-7 OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) — Below 650 kPa (6.5 kgf/cm , 92 psi) at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –…
  • Page 328
    12-8 VL800K3 (’03-MODEL) SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side — (0.001 – 0.025) Damper spring free length 58.5 —…
  • Page 329
    VL800K3 (’03-MODEL) 12-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 – 6 Ω Primary Terminal Plug cap –…
  • Page 330: Brake Light/Taillight

    (21.29) Front fork oil level (without spring) — (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 412 ml (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster —…

  • Page 331
    VL800K3 (’03-MODEL) 12-11 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height 75 – 85 — (3.0 – 3.3) Brake drum I.D. 180.7 Rear —…
  • Page 332
    12-12 VL800K3 (’03-MODEL) FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump R + M octane or 91 octane ( ) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-…
  • Page 333
    VL800K3 (’03-MODEL) 12-13 WIRING DIAGRAM For E-02, 19…
  • Page 334
    12-14 VL800K3 (’03-MODEL) For E-03, 28, 33…
  • Page 335
    VL800K3 (’03-MODEL) 12-15 For E-24…
  • Page 337
    VL800K4 (’04-MODEL) 13- 1 VL800K4 (’04-MODEL) This chapter describes servicing procedures which differ from those of the VL800K3 (’03-MODEL). NOTE: * Please refer to the chapters 1 through 12 for details which are not given in his chapter. CONTENTS SPECIFICATIONS ………………. 13- 2 SERVICE DATA …………
  • Page 338: Specifications

    13-2 VL800K4 (’04-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 510 mm (98.8 in) Overall width ………………985 mm (38.8 in) Overall height ………………1 100 mm (43.3 in) Wheelbase ………………1 655 mm (65.2 in) Ground clearance…………….140 mm ( 5.5 in) Seat height ………………

  • Page 339: Service Data

    VL800K4 (’04-MODEL) 13-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance 0.08 – 0.13 — (when cold) (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –…

  • Page 340
    13-4 VL800K4 (’04-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.58 –…
  • Page 341
    VL800K4 (’04-MODEL) 13-5 ITEM STANDARD LIMIT Piston ring free end gap Approx. 9.6 (0.38) (0.30) Approx. 11.8 (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring groove clearance 0.180 —…
  • Page 342
    13-6 VL800K4 (’04-MODEL) OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) — Below 650 kPa (6.5 kgf/cm , 92 psi) at 3 000 r/min CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –…
  • Page 343
    VL800K4 (’04-MODEL) 13-7 SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side — (0.001 – 0.025) Damper spring free length 58.5 —…
  • Page 344
    13-8 VL800K4 (’04-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 – 6 Ω Primary Terminal Plug cap –…
  • Page 345
    (21.29) Front fork oil level (without spring) — (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 412 ml (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster —…
  • Page 346
    13-10 VL800K4 (’04-MODEL) TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front — (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear — (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front —…
  • Page 347: Periodic Maintenance Chart

    VL800K4 (’04-MODEL) 13-11 PERIODIC MAINTENANCE CHART Interval 1 000 6 000 12 000 18 000 24 000 miles 4 000 7 500 11 000 15 000 Item months Air cleaner element — Spark plugs — Valve clearance — — Engine oil Engine oil filter —…

  • Page 348: Cooling Hose Routing

    13-12 VL800K4 (’04-MODEL) COOLING HOSE ROUTING…

  • Page 349: Rear Combination Light Installation

    VL800K4 (’04-MODEL) 13-13 REAR COMBINATION LIGHT INSTALLATION Clamp Clamp Inside of the rear fender Rear fende…

  • Page 350
    13-14 VL800K4 (’04-MODEL) WARNING DIAGRAM For E-03, 28, 33…
  • Page 351
    VL800K4 (’04-MODEL) 13-15 For E-24…
  • Page 353: Vl800K5 (’05- Model)

    CONTENTS SPECIFICATIONS ………………. 14- 2 ABBREVIATIONS USED IN THIS MANUAL ……….14- 3 SAE-TO-FORMER SUZUKI TERM …………14- 5 SERVICE DATA………………14- 7 PERIODIC MAINTENANCE CHART …………14-17 PRECAUTIONS IN SERVICING …………… 14-18 FI SYSTEM TECHNICAL FEATURES …..

  • Page 354: Specifications

    14-2 VL800K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 510 mm (98.8 in) Overall width ………………985 mm (38.8 in) Overall height ………………1 100 mm (43.3 in) Wheelbase ………………1 655 mm (65.2 in) Ground clearance…………….140 mm ( 5.5 in) Seat height.

  • Page 355: Abbreviations Used In This Manual

    VL800K5 (’05-MODEL) 14-3 ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center…

  • Page 356
    : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor…
  • Page 357: Sae-To-Former Suzuki Term

    14-5 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM…

  • Page 358
    14-6 VL800K5 (’05-MODEL) SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION ——- Idle Speed Control Ignition Control Electronic Spark Advance (ESA) Ignition Control Module ——- Intake Air Temperature Intake Air Temperature (IAT), Air Temperature Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp (MIL)
  • Page 359: Service Data

    VL800K5 (’05-MODEL) 14-7 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. —- (1.18) —- (1.02) Valve clearance (when cold) 0.08 – 0.13 —- (0.003 – 0.005) 0.17 – 0.22 —- (0.007 – 0.009) Valve guide to valve stem 0.010 –…

  • Page 360
    14-8 VL800K5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.52 –…
  • Page 361
    VL800K5 (’05-MODEL) 14-9 ITEM STANDARD LIMIT Piston ring free end gap Approx. 9.6 (0.38) (0.30) Approx. 11.8 (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring to groove clearance 0.180 —- (0.007)
  • Page 362
    14-10 VL800K5 (’05-MODEL) ITEM STANDARD LIMIT Crankshaft thrust bearing 1.925 – 2.175 —- thickness (0.0758 – 0.0856) Crankshaft thrust clearance 0.05 – 0.10 —- (0.002 – 0.004) Crankshaft runout 0.05 —- (0.002) OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60 °C, 140 °F) 350 –…
  • Page 363
    VL800K5 (’05-MODEL) 14-11 ITEM STANDARD LIMIT Shift fork groove width 5.50 – 5.60 No.1 —- (0.217 – 0.220) 4.50 – 4.60 No.2 —- (0.177 – 0.181) Shift fork thickness 5.30 – 5.40 No.1 —- (0.209 – 0.213) 4.30 – 4.40 No.2 —- (0.169 –…
  • Page 364
    14-12 VL800K5 (’05-MODEL) * INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE 11 – 13 Ω at 20 °C (68 °F) * Injector resistance * Fuel pump discharge amount Approx. 168 ml (5.7/5.9 US/lmp oz) and more/10 sec. * Fuel pressure regulator operating set Approx.
  • Page 365
    VL800K5 (’05-MODEL) 14-13 * THROTTLE BODY ITEM SPECIFICATION Bore size * 34 mm I.D. No. * 41F1 (For E-33), 41F0 (For the others) Idle r/min. * 1 100 ± 100 r/min. Fast idle r/min. * 2 100 r/min. (When cold engine) Throttle cable play 2.0 –…
  • Page 366
    14-14 VL800K5 (’05-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight 60 W ← ← 55 W Position/Parking light ← ← Brake light/Taillight 21/5 W Turn signal light 21/5 W (Front), ← 21 W 21 W (Rear) ←…
  • Page 367
    (21.73) (21.29) Front fork oil level (without spring) —- (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil —- Front fork oil capacity (each leg) 412 ml —- (24.0/25.0 US/Imp oz) Front fork inner tube outside diam.
  • Page 368
    14-16 VL800K5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion…
  • Page 369: Periodic Maintenance Chart

    VL800K5 (’05-MODEL) 14-17 PERIODIC MAINTENANCE CHART Interval miles 4 000 7 500 11 000 14 500 1 000 6 000 12 000 18 000 24 000 Item months Air cleaner element —- Spark plug —- Valve clearance —- —- Engine oil Engine oil filter —- —-…

  • Page 370: Precautions In Servicing

    14-18 VL800K5 (’05-MODEL) PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.

  • Page 371
    VL800K5 (’05-MODEL) 14-19 • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
  • Page 372
    14-20 VL800K5 (’05-MODEL) • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
  • Page 373: Electrical Circuit Inspection Procedure

    VL800K5 (’05-MODEL) 14-21 ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

  • Page 374
    14-22 VL800K5 (’05-MODEL) Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 375
    VL800K5 (’05-MODEL) 14-23 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 376
    14-24 VL800K5 (’05-MODEL) USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and — probes may cause the inside of the tester to burnout.
  • Page 377: Fi System Technical Features

    VL800K5 (’05-MODEL) 14-25 FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 378: Injection Stop Control

    14-26 VL800K5 (’05-MODEL) COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.

  • Page 379: Fi System Parts Location

    VL800K5 (’05-MODEL) 14-27 FI SYSTEM PARTS LOCATION A IAP sensor (Rear cylinder) F PAIR control solenoid valve B Ignition coil No.1 (Rear cylinder) G CKP sensor C ECT sensor H GP switch D Fuel injector (Rear cylinder) I FP relay E Fuel injector (Front cylinder)

  • Page 380
    14-28 VL800K5 (’05-MODEL) J HO2 sensor N STP sensor K TO sensor O TP sensor L STVA P IAP sensor (Front cylinder) M Speedometer Q Ignition coil No.2 (Front cylinder)
  • Page 381: Fi System Wiring Diagram

    VL800K5 (’05-MODEL) 14-29 FI SYSTEM WIRING DIAGRAM…

  • Page 382: User Mode

    14-30 VL800K5 (’05-MODEL) SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.

  • Page 383: Dealer Mode

    VL800K5 (’05-MODEL) 14-31 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

  • Page 384
    14-32 VL800K5 (’05-MODEL) CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) For Front cylinder Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air pressure sensor (IAPS) For Rear cylinder Intake air temperature sensor (IATS) Tip-over sensor (TOS)
  • Page 385: Tps Adjustment

    VL800K5 (’05-MODEL) 14-33 TPS ADJUSTMENT 1. Lift and support the fuel tank. ($14-93) 2. Adjust the engine rpm to 1 100 rpm. NOTE: Warm up the engine before adjustment. 3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness.

  • Page 386: Fail-Safe Function

    14-34 VL800K5 (’05-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”…

  • Page 387: Fi System Troubleshooting

    VL800K5 (’05-MODEL) 14-35 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

  • Page 388: Visual Inspection

    14-36 VL800K5 (’05-MODEL) MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill…

  • Page 389
    VL800K5 (’05-MODEL) 14-37 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in the memory. Such disconnection will erase the memorized information in ECM memory.
  • Page 390: Use Of Sds Diagnostic Procedures

    14-38 VL800K5 (’05-MODEL) SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • If the malfunction code indicates (C00), the malfunction is cleared. • Disconnect the special tool from the dealer mode coupler. NOTE: * Even though the malfunction code (C00) is indicated, the previ- ous malfunction history code still remains stored in the ECM.

  • Page 391
    VL800K5 (’05-MODEL) 14-39 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
  • Page 392: Show Data When Trouble

    14-40 VL800K5 (’05-MODEL) SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

  • Page 393
    VL800K5 (’05-MODEL) 14-41 • Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure #1” or “Failure #2” can be selected.
  • Page 394: Ecm Terminal

    14-42 VL800K5 (’05-MODEL) ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) Ignition switch signal (AT) IAT sensor signal (IAT) ECT sensor signal (ECT) Rear cylinder IAP sensor signal (IAP. R) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Blank Front cylinder IAP sensor signal (IAP.

  • Page 395: Malfunction Code And Defective Condition

    VL800K5 (’05-MODEL) 14-43 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts.

  • Page 396
    14-44 VL800K5 (’05-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection. 0.1 V sensor voltage < 4.6 V In other than the above range, C21 (P0110) is indicated.
  • Page 397
    VL800K5 (’05-MODEL) 14-45 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Gear posi- Gear position signal voltage should be GP switch, lead wire/coupler tion signal higher than the following for 3 seconds connection. Gearshift cam etc. and more. Gear position sensor voltage > 0.6 V If lower than the above value, C31 P0705 (P0705) is indicated.
  • Page 398
    14-46 VL800K5 (’05-MODEL) “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip. •…
  • Page 399
    VL800K5 (’05-MODEL) 14-47 5) Disconnect the CKP sensor coupler and measure the resis- tance. ! CKP sensor resistance: 184 – 276 Ω (Blue – Green) 6) Also, check the continuity between each terminal and ground. ! CKP sensor continuity: ∞ Ω (Infinity) (Blue –…
  • Page 400
    14-48 VL800K5 (’05-MODEL) Step 2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. ! CKP sensor peak voltage: 4.0 V and more (+ Green –…
  • Page 401
    VL800K5 (’05-MODEL) 14-49 “C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C13/C17 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.1 V Sensor voltage < 4.8 V •…
  • Page 402
    14-50 VL800K5 (’05-MODEL) Step 2 1) Connect the IAP sensor couplers and install the fuel tank. 2) Insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between G/B and B/Br wires or between G/W and B/Br wires).
  • Page 403
    VL800K5 (’05-MODEL) 14-51 Is the voltage OK? • G/B, G/W, R or B/Br wire open or shorted to ground, or poor L, 3, 6 or D connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •…
  • Page 404
    14-52 VL800K5 (’05-MODEL) “C14” (P0120) TP SENSOR CIRCUIT MALFUNCTION 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 open- • TP sensor malfunction. ing and opening calculated by ECM is •…
  • Page 405
    VL800K5 (’05-MODEL) 14-53 Step 1 (When indicating P0120-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 406
    14-54 VL800K5 (’05-MODEL) Step 1 (When indicating P0120-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 407
    VL800K5 (’05-MODEL) 14-55 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between Yellow wire and ground. ! TP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 4) If OK, then measure the TP sensor resistance at the termi- nals (between Yellow wire and Black wire).
  • Page 408
    14-56 VL800K5 (’05-MODEL) Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the TP sensor output voltage at the coupler (between + Bl/B wire and — B/Br wire) by turning the throttle grip.
  • Page 409
    VL800K5 (’05-MODEL) 14-57 “C15” (P0115) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. Sensor voltage < 4.6 V • ECM malfunction. P0115 Sensor voltage is higher than specified •…
  • Page 410
    14-58 VL800K5 (’05-MODEL) Step 1 (When indicating P0115-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
  • Page 411
    VL800K5 (’05-MODEL) 14-59 Step 1 (When indicating P0115-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler.
  • Page 412
    14-60 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. ! ECT sensor resistance: Approx. 2.3 – 2.6 kΩ at 20 °C (68 °F) (Terminal – Terminal) » 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) 3) Remove the ECT sensor.
  • Page 413
    VL800K5 (’05-MODEL) 14-61 “C21” (P0110) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. Sensor voltage < 4.6 V • ECM malfunction. P0110 Sensor voltage is higher than specified •…
  • Page 414
    14-62 VL800K5 (’05-MODEL) Step 1 (When indicating P0110-H:) 1) Remove the air cleaner box. ($14-103) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
  • Page 415
    VL800K5 (’05-MODEL) 14-63 Step 1 (When indicating P0110-L:) 1) Remove the air cleaner box. ($14-103) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
  • Page 416
    14-64 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. ! IAT sensor resistance: Approx. 2.6 kΩ at 20 °C (68 °F) (Terminal – Terminal) » 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Is the resistance OK? •…
  • Page 417
    VL800K5 (’05-MODEL) 14-65 “C23” (P1651) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short. ing for 2 sec. and more, after ignition • TO sensor malfunction. switch is turned ON. •…
  • Page 418
    14-66 VL800K5 (’05-MODEL) Step 1 (When indicating P1651-H:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 419
    VL800K5 (’05-MODEL) 14-67 Step 1 (When indicating P1651-L:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 420
    14-68 VL800K5 (’05-MODEL) Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Br/W and B/Br wires. ! TO sensor voltage: 0.4 –…
  • Page 421
    VL800K5 (’05-MODEL) 14-69 “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from • STVA circuit open or short. the STVA. • STVA motor malfunction. STV ACTUATOR STVA.
  • Page 422
    14-70 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each wire terminal and ground. ! STVA continuity: ∞ Ω (Infinity) 4) If OK, then measure the STVA resistance. (between Black wire terminal and Pink wire terminal) and (between Green wire terminal and W/B wire terminal) ! STVA resistance: Approx.
  • Page 423
    VL800K5 (’05-MODEL) 14-71 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from STVA, the function is normal.
  • Page 424
    14-72 VL800K5 (’05-MODEL) “C29” (P1654) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle open- • STP sensor malfunction. ing and opening calculated by ECM is •…
  • Page 425
    VL800K5 (’05-MODEL) 14-73 Step 1 (When indicating P1654-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
  • Page 426
    14-74 VL800K5 (’05-MODEL) Step 1 (When indicating P1654-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
  • Page 427
    VL800K5 (’05-MODEL) 14-75 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler. 3) Check the continuity between Yellow wire terminal and ground. ! STP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 6) If OK, then measure the STP sensor resistance at the coupler (between Yellow and Black wires).
  • Page 428
    14-76 VL800K5 (’05-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Y/W and — B/Br wires) when the secondary throttle valve is full closed and opened by moving the fast idle…
  • Page 429
    VL800K5 (’05-MODEL) 14-77 Is the voltage OK? • Y/W, R or B/Br wire open or shorted to ground, or poor 4, 6 or D connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
  • Page 430
    14-78 VL800K5 (’05-MODEL) “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage. • Gear Position switch circuit open or short. Switch voltage is not within the following range. • Gear Position switch malfunction. Switch voltage > 0.6 V •…
  • Page 431
    VL800K5 (’05-MODEL) 14-79 5) Support the motorcycle with a jack. 6) Fold the side-stand to up position. 7) Make sure the engine stop switch is in the “RUN” position. 8) Insert the needle pointed probes to the lead wire coupler. 9) Turn the ignition switch ON.
  • Page 432
    14-80 VL800K5 (’05-MODEL) “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted 4 times or more continuously. • Injector malfunction. •…
  • Page 433
    VL800K5 (’05-MODEL) 14-81 Step 2 1) Turn the ignition switch ON. 2) Measure the injector voltage between Y/R wire and ground. ! Injector voltage: Battery voltage (+ Y/R – — Ground) NOTE: Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.
  • Page 434
    14-82 VL800K5 (’05-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump, although fuel • Fuel pump relay circuit open or short. pump relay is turned ON, or voltage is applied to fuel •…
  • Page 435
    VL800K5 (’05-MODEL) 14-83 “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short. ECM. • PAIR control solenoid valve malfunction. •…
  • Page 436
    14-84 VL800K5 (’05-MODEL) Step 2 1) Connect the PAIR control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the PAIR control solenoid valve coupler. 4) Measure the voltage at the wire side coupler between Black wire and ground.
  • Page 437
    VL800K5 (’05-MODEL) 14-85 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details) 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
  • Page 438
    14-86 VL800K5 (’05-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19, 24) DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and •…
  • Page 439
    VL800K5 (’05-MODEL) 14-87 4) Disconnect the HO2 sensor coupler and ECM coupler. 5) Check the continuity between W/Bl wire A and terminal 7. 6) Also, check the continuity between W/Bl wire A and ground. If sound of the continuity is not heard from the tester, the cir- cuit condition is OK.
  • Page 440
    14-88 VL800K5 (’05-MODEL) Step 1 (When indicating C44/P0135:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the HO2 sensor coupler for loose or poor contacts. 4) Insert the needle pointed probes to the HO2 sensor coupler. 5) Turn the ignition switch ON and measure the heater voltage between W/B wire (ECM side) and ground.
  • Page 441
    VL800K5 (’05-MODEL) 14-89 Step 2 (When indicating C44/P0135:) 1) Turn the ignition switch OFF. 2) Disconnect the HO2 sensor coupler. 3) Check the resistance between the terminals (White – White) of the HO2 sensor. ! HO2 heater resistance: 6.5 – 8.9 Ω (at 23 °C/73.4 °F) (White –…
  • Page 442: Sensors

    14-90 VL800K5 (’05-MODEL) SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. ($14-46) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. ($3-18) • Install the generator cover in the reverse order of removal. IAP SENSOR INSPECTION The intake air pressure sensor is installed on the air intake pipe.

  • Page 443: Iat Sensor Inspection

    VL800K5 (’05-MODEL) 14-91 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the back side of the air cleaner box. ($14-61) IAT SENSOR REMOVAL AND INSTALLATION • Remove the air cleaner box. ($14-103) • Remove the IAT sensor from the air cleaner box. •…

  • Page 444: Fuel Delivery System

    14-92 VL800K5 (’05-MODEL) FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

  • Page 445: Fuel System

    VL800K5 (’05-MODEL) 14-93 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seat. ($7-2) • Remove the fuel tank mounting bolt 1. • Lift and support the fuel tank about 10 cm (3.94 in) with the prop stay. NOTE: Be careful not to lift the fuel tank more than about 10 cm (3.94 in), or hoses will be twisted.

  • Page 446: Fuel Pressure Inspection

    14-94 VL800K5 (’05-MODEL) FUEL PRESSURE INSPECTION • Lift and support the fuel tank. ($14-93) • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.

  • Page 447: Fuel Pump Inspection

    VL800K5 (’05-MODEL) 14-95 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor.

  • Page 448: Fuel Pump Relay Inspection

    14-96 VL800K5 (’05-MODEL) FUEL PUMP RELAY INSPECTION Fuel pump relay is located inside the secondary gear case cover. • Remove the secondary gear case cover. • Remove the fuel pump relay 1. First, check the insulation between A and B terminals with pocket tester.

  • Page 449
    VL800K5 (’05-MODEL) 14-97 FUEL PUMP CONSTRUCTION 1 Fuel pump 4 Fuel mesh filter cover 2 Plate assy 5 Fuel feed hose ITEM N·m kgf-m lb-ft 3 Fuel mesh filter A Fuel pump mounting bolt…
  • Page 450: Fuel Pump Removal And Disassembly

    14-98 VL800K5 (’05-MODEL) FUEL PUMP REMOVAL AND DISASSEMBLY • Remove the fuel tank. ($14-93) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the fuel mesh filter cover 2. •…

  • Page 451: Fuel Mesh Filter Inspection And Cleaning

    VL800K5 (’05-MODEL) 14-99 • Remove the fuel mesh filter 7 and rubber cushion 8. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air.

  • Page 452
    14-100 VL800K5 (’05-MODEL) FUEL PUMP REASSEMBLY AND INSTALLA- TION Install the fuel pump in the reverse order of removal and disas- sembly. Pay attention to the following points: • Install a new bushing 1 to the fuel pump. Use the new bushing to prevent fuel leakage.
  • Page 453
    VL800K5 (’05-MODEL) 14-101 • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. , 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) The O-ring must be replaced with a new one to prevent fuel leakage.
  • Page 454: Throttle Body

    14-102 VL800K5 (’05-MODEL) THROTTLE BODY CONSTRUCTION 1 STP sensor 9 Three way joint (only E33) 2 TP sensor 0 Hose (only E33) 3 IAP sensor A Vacuum hoses 4 STVA B Fast idle screw 5 Fuel delivery pipe C Throttle stop screw 6 O-ring A STP sensor mounting screw ITEM…

  • Page 455: Air Cleaner Box Removal

    VL800K5 (’05-MODEL) 14-103 AIR CLEANER BOX REMOVAL • Remove the fuel tank. ($14-93) • Remove the bolts 1 and lossen the clamp screw 2. NOTE: “✩” indicates hook location. • Disconnect the IAT sensor lead wire coupler 3. • Disconnect the PAIR hose 4. •…

  • Page 456: Throttle Body Removal

    14-104 VL800K5 (’05-MODEL) THROTTLE BODY REMOVAL • Remove the air intake pipe. ($14-103) • Disconnect the TP sensor lead wire coupler 1, STVA lead wire coupler 2 and STP sensor lead wire coupler 3. • Disconnect the fuel injector lead wire couplers 4. •…

  • Page 457: Throttle Body Disassembly

    VL800K5 (’05-MODEL) 14-105 THROTTLE BODY DISASSEMBLY • Remove the vacuum hose 1 and fuel feed hose 2. • Remove the clamp 3. • Remove the fuel delivery hose 4. • Remove the fuel delivery pipes 5. • Remove the fuel injectors 6 •…

  • Page 458
    14-106 VL800K5 (’05-MODEL) • Remove the STP sensor 8 with the special tool. » 09930-11950: Torx wrench NOTE: * Prior to disassembly, mark the STP sensor’s original position with a paint or scribe for accurate reinstallation. * TP sensor and STP sensor look very much alike. To avoid confusion, mark identifications when removing.
  • Page 459: Throttle Body Cleaning

    VL800K5 (’05-MODEL) 14-107 THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

  • Page 460
    NOTE: * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary. TP sensor setting procedure. ($14-118) , 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”…
  • Page 461
    VL800K5 (’05-MODEL) 14-109 • Install the O-ring and dust seal to each fuel injector. • Apply thin coat of the engine oil to the new O-ring and cushion seal. Replace the O-ring and cushion seal with the new ones. • Install the fuel injectors 3 by pushing them straight to each throttle body.
  • Page 462
    14-110 VL800K5 (’05-MODEL) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the TP sensor lead wire coupler 1. TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.
  • Page 463: Fuel Injector Removal

    VL800K5 (’05-MODEL) 14-111 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows: • Disconnect the STP sensor coupler. • Close the secondary throttle valve fully by moving the fast idle link, and measure the STP sensor resistance (between Yel- low wire terminal and Black wire terminal).

  • Page 464: Fuel Injector Inspection

    14-112 VL800K5 (’05-MODEL) FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. The fuel injector can be checked without removing it from the throttle body.

  • Page 465: Fast Idle

    VL800K5 (’05-MODEL) 14-113 FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.

  • Page 466
    14-114 VL800K5 (’05-MODEL) • Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened. Example: TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.08 V STV fully open 1.20 V Idle…
  • Page 467
    VL800K5 (’05-MODEL) 14-115 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders. USE OF DIGITAL VACUUM TESTER Step 1 • Lift and support the fuel tank. (!14-93) • Start up the engine and run it in idling condition for warming up. •…
  • Page 468
    14-116 VL800K5 (’05-MODEL) Step 3 • Turn in two idle air screws to the complete close position. • Check for difference of vacuum between front cylinder and rear cylinder. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.
  • Page 469
    VL800K5 (’05-MODEL) 14-117 • Connect a tachometer. • Start up the engine and keep it running at 1 100 rpm by turn- ing throttle stop screw 2. Avoid drawing dirt into the throttle body while running the engine without intake pipe and air cleaner box. Dirt drawn into the engine will damage the internal engine parts.
  • Page 470
    14-118 VL800K5 (’05-MODEL) THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS 1 setting condition.
  • Page 471: Emission Control Systems

    14-119 EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VL800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 Fuel tank…

  • Page 472
    14-120 VL800K5 (’05-MODEL) EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem (For E-02, -19, -24 and -33). The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve.
  • Page 473: Noise Emission Control System

    VL800K5 (’05-MODEL) 14-121 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.

  • Page 474: Pair (Air Supply) System And Emission Control System Inspection

    14-122 VL800K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PCV HOSE • Remove the PCV hose from the crankcase breather cover. • Inspect the PCV hose for wear or damage. • If it is worn or damaged, replace the PCV hose with a new one.

  • Page 475: Pair Control Solenoid Valve

    VL800K5 (’05-MODEL) 14-123 PAIR CONTROL SOLENOID VALVE • Lift and support the fuel tank. ($14-93) • Remove the PAIR control solenoid valve cover 1. • Disconnect the PAIR control solenoid valve lead wire coupler • Disconnect the PAIR hoses. • Remove the PAIR control solenoid valve 3. •…

  • Page 476: Evaporative Emission Control System Inspection (Only For E-33)

    14-124 VL800K5 (’05-MODEL) EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seats 1. ($7-2) • Remove the speedometer 2. ($5-3) • Remove the fuel tank 3. ($14-93) • Remove the fuel frame cover 4. ($7-2) HOSES (EVAP hose) Inspect the hoses for wear or damage.

  • Page 477: Tightening Torque

    VL800K5 (’05-MODEL) 14-125 TIGHTENING TORQUE CHASSIS N·m kgf-m lb-ft ITEM Front axle 47.0 Front axle pinch bolt 24.0 Brake disc bolt 16.5 Front fork cap bolt 33.1 Front fork spring stopper nut 25.5 Front fork damper rod bolt 14.5 *Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 24.0…

  • Page 478: Wiring Harness, Cable And Hose Routing

    14-126 VL800K5 (’05-MODEL) WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Wiring harness Front turn signal light (L & R) Regulator/Rectifier Handlebar switch (L & R) Speed sensor Clamp Clamp Clamp Wiring harness PAIR contr l solenoid valve leadwire Ignition oil leadwire To generator Clamp…

  • Page 479
    VL800K5 (’05-MODEL) 14-127 Injector To speedometer stoplamp switch To Horn Clamp TO sensor Pass through inside of the cover Clamp IAT sensor To HO2S sensor Wiring harness Frame Radiator…
  • Page 480
    14-128 VL800K5 (’05-MODEL)
  • Page 481
    VL800K5 (’05-MODEL) 14-129 CABLE ROUTING Throttle cable No.2 (Returning cable) Clamp Throttle cable No.1 Wiring (Pulling cable) harness Throttle cable No.2 Clutch cable Throttle White Brake cable No.1 tape Clutch hose Cable guide cable Clutch 0 – 2 mm (0 – 0.08 in) Wiring cable *3 harness…
  • Page 482: Cooling System Hose Routing

    14-130 VL800K5 (’05-MODEL) COOLING SYSTEM HOSE ROUTING…

  • Page 483
    VL800K5 (’05-MODEL) 14-131 SPEED SENSOR LEAD WIRE ROUTING Headlight housing Brake hose Speed sensor 30 mm lead wire (1.18 in) Clamp Speed sensor guide hook Speed sensor lead wire Speed sensor lead guide Pass through the speed sensor lead wire between the headlight housing and brake hose.
  • Page 484
    14-132 VL800K5 (’05-MODEL) FUEL TANK INSTALLATION Cut the clamp Frame…
  • Page 485: Brake Pedal Installation

    VL800K5 (’05-MODEL) 14-133 BRAKE PEDAL INSTALLATION 5 mm (0.20 in) 98 mm (3.86 in) *1 Apply an adhesive agent. HANDLEBAR BALANCER Throttle grip Handlebar Handle balancer expander Handlebar balancer Screw 5.5 N·m (0.5 kgf-m, 4.0 lb-ft) 1 mm (0.04 in): Right side 0 mm (0 in): Left side…

  • Page 486: Pair (Air Supply) System Diagram

    14-134 VL800K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM DIAGRAM 1 PAIR control solenoid valve *1 From air cleaner. 2 PAIR reed valve *2 To #1 cylinders. A FRESH AIR *3 To #2 cylinders.

  • Page 487: Pair (Air Supply) System Hose Routing

    VL800K5 (’05-MODEL) 14-135 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 1 PAIR control solenoid valve *2 Matching mark Throttle body Do not contact the hose and throttle cable drum. Bolt The sealant side should face PAIR pipe side. To air cleaner box. With the bolt lightly contacted with the PAIR pipe, tighten the bolt.

  • Page 488: Evap Canister Hose Routing (Only For E-33)

    14-136 VL800K5 (’05-MODEL) EVAP CANISTER HOSE ROUTING (Only for E-33) 1 Three way joint 5 EVAP Canister Wiring harness Pass through the purge hose over the wiring harness. 3 Frame *2 White paint mark should face upside. 4 Fuel shut-off valve *3 To three way joint.

  • Page 489: Fuel Feed Hose Routing

    VL800K5 (’05-MODEL) 14-137 FUEL FEED HOSE ROUTING 1 IAP sensor (Front cylinder) 2 IAP sensor (Rear cylinder) 3 PCV (Breather) hose 4 Fuel feed hose *1 Match mark (White)

  • Page 490: Special Tools

    14-138 VL800K5 (’05-MODEL) SPECIAL TOOLS 09900-25009 09913-13121 Needle pointed 09904-41010 99565-01010-004 Vacuum balancer 09930-11950 probe set SDS Set CD-ROM Ver.4 gauge Torx wrench 09940-40211 09940-40220 09930-82720 Fuel pressure gauge Fuel pressure gauge Mode select switch adaptor hose attachment NOTE: When ordering the special tool, please confirm whether it is available or not.

  • Page 491
    VL800K5 (’05-MODEL) 14-139 WIRE COLOR : Black : Gray : Red : Blue : Light blue : White : Brown : Light green : Yellow : Dark green : Orange : Green : Pink B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer…
  • Page 493: Vl800Tk5 (’05- Model)

    VL800TK5 (’05-MODEL) 15- 1 VL800TK5 (’05-MODEL) This chapter describes service specifications, service data and servicing procedures which dif- fer from those of the VL800K5 (’05-MODEL). NOTE: * Any differences between the VL800K5 (’05-MODEL) and VL800TK5 (’05-MODEL) in specifi- cations and service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 14 for details which are not given in this chapter.

  • Page 494: Fuel System

    15-2 VL800TK5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 510 mm (98.8 in) Overall width ………………985 mm (38.8 in) Overall height ………………1 100 mm (43.3 in) Wheelbase ………………1 655 mm (65.2 in) Ground clearance…………….140 mm ( 5.5 in) Seat height ………………

  • Page 495
    VL800TK5 (’05-MODEL) 15-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance (when cold) 0.08 – 0.13 — (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –…
  • Page 496
    15-4 VL800TK5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.52 –…
  • Page 497
    VL800TK5 (’05-MODEL) 15-5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –…
  • Page 498
    15-6 VL800TK5 (’05-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.42 –…
  • Page 499
    VL800TK5 (’05-MODEL) 15-7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — ECT sensor resistance 20 °C Approx.
  • Page 500
    15-8 VL800TK5 (’05-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
  • Page 501: Battery

    VL800TK5 (’05-MODEL) 15-9 THROTTLE BODY ITEM SPECIFICATION Bore size 34 mm I.D. No. 41F1 (For E-33), 41F0 (For the others) Idle r/min 1 100 ± 100 r/min Fast idle r/min 2 100 r/min (When cold engine) Throttle cable play 2.0 – 4.0 mm (0.08 –…

  • Page 502: Position/Parking Light

    15-10 VL800TK5 (’05-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight 60 W ← ← 55 W Position/Parking light ← ← Brake light/Taillight 21/5 W Turn signal light 21/5 W (Front), ← 21 W 21 W (Rear) ←…

  • Page 503
    (21.73) (21.29) Front fork oil level (without spring) — (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 412 ml — (24.0/25.0 US/Imp oz) Front fork inner tube outside diam.
  • Page 504
    15-12 VL800TK5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-…
  • Page 505
    VL800/TK6 (’06-MODEL) 16- 1 VL800/TK6 (’06-MODEL) This chapter describes service specifications, service data and servicing p ocedures which dif- fer from those of the VL800TK5 (’05-MODEL). NOTE:*Any differences between the VL800TK6 (’06-MODEL) and VL800TK5 (’05-MODEL) in specifications and service data are indicated with an asterisk mark (*).
  • Page 506: Specifications

    16- 2 VL800/TK6 (’06-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 510 mm (98.8 in) Overall width………………985 mm (38.8 in) Overall height ………………1 100 mm (43.3 in) Wheelbase ………………1 655 mm (65.2 in) Ground clearance…………….

  • Page 507: Service Data

    VL800/TK6 (’06-MODEL) 16- 3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance (when cold) 0.08 – 0.13 — (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –…

  • Page 508
    16- 4 VL800/TK6 (’06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386)
  • Page 509
    VL800/TK6 (’06-MODEL) 16- 5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –…
  • Page 510
    16- 6 VL800/TK6 (’06-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103)
  • Page 511
    VL800/TK6 (’06-MODEL) 16- 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —…
  • Page 512
    16- 8 VL800/TK6 (’06-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
  • Page 513
    VL800/TK6 (’06-MODEL) 16- 9 THROTTLE BODY ITEM SPECIFICATION Bore size 34 mm I.D. No. 41F1 (For E-33), 41F0 (For the others) Idle r/min 1 100 ± 100 r/min Fast idle r/min 2 100 r/min (When cold engine) Throttle cable play 2.0 –…
  • Page 514
    16-10 VL800/TK6 (’06-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight 60 W ← ← 55 W Position/Parking light ← ← Brake light/Taillight 21/5 W Turn signal light 21/5 W (Front), ← 21 W 21 W (Rear) ←…
  • Page 515
    (21.73) (21.29) Front fork oil level (without spring) — (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 412 ml — (24.0/25.0 US/Imp oz) Front fork inner tube outside diam.
  • Page 516: Special Tools

    16-12 VL800/TK6 (’06-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl…

  • Page 517: Conrod/Crankshaft

    VL800/TK6 (’06-MODEL) 16-13 CONROD/CRANKSHAFT CRANKCASE/CRANKSHAFT BEARING INSPECTION • Inspect the crankshaft and crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. • Measure the crankshaft journal O.D. 1 by using the special tool.

  • Page 518
    16-14 VL800/TK6 (’06-MODEL) Bearing thickness Color code Color (Part No.) Thickness Green 2.006 – 2.009 mm (12229-39G00-0A0) (0.0789 – 0.0790 in) Black 2.009 – 2.012 mm (12229-39G00-0B0) (0.0790 – 0.0792 in) Brown 2.012 – 2.015 mm (12229-39G00-0C0) (0.0792 – 0.0793 in) Bearing must be replaced as a set.
  • Page 519
    VL800/TK6 (’06-MODEL) 16-15 NOTE: Bearing Using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools. » 09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer •…
  • Page 520
    16-16 VL800/TK6 (’06-MODEL) • Set the bearings installed in the special tool to the crankcase half as shown. * Be sure the bearing protruded side B faces the crankcase bore. * Align the special tool mating surface with the line mark C on the crankcase.
  • Page 521
    VL800/TK6 (’06-MODEL) 16-17 NOTE: Using the hand-press is recommended to install the crankshaft journal bearings. However, the crankshaft journal bearings can be installed by using the following special tools. » 09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer…
  • Page 522: Emission Control Systems

    16-18 VL800/TK6 (’06-MODEL) EMISSION CONTROL SYSTEMS EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve.

  • Page 523
    This chapter describes service specifications, service data and servicing p ocedures which differ from those of the VL800TK6 (’06-MODEL). NOTE:*Any differences between the VL800TK6 (’06-MODEL) and VL800/TK7 (’07-MODEL) in specifications and service data are indicated with an asterisk mark (*).
  • Page 524: Fuel System

    17- 2 VL800/TK7 (’07-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ………………2 510 mm (98.8 in) Overall width………………* 970 mm (38.2 in) Overall height ………………* 1 105 mm (43.5 in) Wheelbase ………………1 655 mm (65.2 in) Ground clearance…………….

  • Page 525
    VL800/TK7 (’07-MODEL) 17- 3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance (when cold) 0.08 – 0.13 — (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –…
  • Page 526
    17- 4 VL800/TK7 (’07-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386)
  • Page 527
    VL800/TK7 (’07-MODEL) 17- 5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –…
  • Page 528: Clutch

    17- 6 VL800/TK7 (’07-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103)

  • Page 529
    VL800/TK7 (’07-MODEL) 17- 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —…
  • Page 530
    17- 8 VL800/TK7 (’07-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
  • Page 531: Mm (5.5 In)

    VL800/TK7 (’07-MODEL) 17- 9 THROTTLE BODY ITEM SPECIFICATION Bore size 34 mm I.D. No. 41F1 (For E-33), 41F0 (For the others) Idle r/min 1 100 ± 100 r/min Fast idle r/min 2 100 r/min (When cold engine) Throttle cable play 2.0 –…

  • Page 532: Brake Light/Taillight

    17-10 VL800/TK7 (’07-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight 60 W ← ← 55 W Position/Parking light ← ← Brake light/Taillight 21/5 W Turn signal light 21/5 W (Front), ← 21 W 21 W (Rear) ←…

  • Page 533
    (21.73) (21.29) Front fork oil level (without spring) — (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (each leg) 412 ml — (24.0/25.0 US/Imp oz) Front fork inner tube outside diam.
  • Page 534
    17-12 VL800/TK7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl…
  • Page 535: Fuel Pump And Fuel Level Gauge Removal

    VL800/TK7 (’07-MODEL) 17-13 FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL REMOVAL • Remove the fuel tank. (!VL800K5-93) • Remove the fuel pump assembly 1 mounting bolts diago- nally. » Gasoline is highly flammable and explosive. Keep heat, spark and flame away.

  • Page 536: Fuel Pump And Fuel Level Gauge Installation

    • Install the fuel level gauge 1 into the fuel tank. NOTE: Push the lock portion A fully until the clicking sound heard. • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. $ 99000-25010: SUZUKI SUPER GREASE “A”…

  • Page 537: Fuel Level Gauge Inspection

    VL800/TK7 (’07-MODEL) 17-15 FUEL LEVEL GAUGE INSPECTION • Remove the fuel level gauge assembly. • Measure the resistance at each fuel level gauge float position. 19.5 If the resistance is incorrect, replace the fuel level gauge with (0.77 in) a new one.

  • Page 538: Cable Routing

    17-16 VL800/TK7 (’07-MODEL) CABLE ROUTING Throttle cable No.2 Clamp the white tape of Throttle cable No.1 clutch cable to the center 0 mm of frame dent part. Clutch cable Handle switch RH harness Brake hose Outside High tension 0 mm…

  • Page 539: Front Brake Hose Routing

    VL800/TK7 (’07-MODEL) 17-17 FRONT BRAKE HOSE ROUTING…

  • Page 540
     …
  • Page 541
    VL800/C/ TK9 (’09-MODEL) NOTE: • Any differences between the VL800/C/TK8 (’08-model) and VL800/C/TK9 (’09-model) in specifications and service data are indicated with an asterisk mark (*). CONTENTS © COPYRIGHT SUZUKI MOTOR CORPORATION 2008…
  • Page 542
    18-2 VL800/C/TK9 (’09-MODEL) VL800/C/ TK9 (’09-MODEL) CONTENTS THROTTLE BODY REASSEMBLY …………18-46 THROTTLE BODY INSTALLATION …………18-50 STP SENSOR ADJUSTMENT…………..18-51 TP SENSOR ADJUSTMENT …………..18-52 ISC VALVE REMOVAL …………….18-53 ISC VALVE INSTALLATION …………..18-53 ISC VALVE INSPECTION …………..
  • Page 543
    VL800/C/TK9 (’09-MODEL) 18-3 ABBREVIATIONS USED IN THIS MANUAL NOTE: Please refer to the VL800 (’06-model) service manual and VL800/C/T (’07/’08-models) service informations for other abbreviations which are not given in this manual. EVAP : Evaporative Emission ISC Valve : Idle Speed Control Valve (ISCV)
  • Page 544
    Turning radius ………………3.0 m (9.8 ft) Front brake ………………Disc brake Rear brake ………………Drum brake Front tire………………130/90-16 M/C 67H, tube type..VL800/T/UE 130/90-16 M/C 67H, tubeless ..VL800C/CUE Rear tire …………..
  • Page 545: Periodic Maintenance Schedule

    VL800/C/TK9 (’09-MODEL) 18-5 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and months for your convenience.

  • Page 546
    This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the VL800K6 (’06-MODEL). For details other than the following items, refer to the VL800 Service Manual. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months).
  • Page 547
    VL800/C/TK9 (’09-MODEL) 18-7 • Remove the air cleaner element 6. • Carefully use compressed air to clean the air cleaner element.  Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the…
  • Page 548
    18-8 VL800/C/TK9 (’09-MODEL) SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months) and replace every 12 000 km (7 500 miles, 24 months). No.2 (FRONT) SPARK PLUG REMOVAL (For E-02, 19, 24, 33) • Remove the air cleaner. (Page 18-6) •…
  • Page 549
    VL800/C/TK9 (’09-MODEL) 18-9 • Place a rug on the cylinder head cap 2. • Open the cylinder head cover cap 2 as shown. • Disconnect the spark plug caps 3.  The hot engine can burn you. Wait until the engine are cool enough to touch.
  • Page 550
    18-10 VL800/C/TK9 (’09-MODEL) SPARK PLUG GAP • Measure the plug gap with a thickness gauge. If out of specifi- cation, adjust it to the following gap.  09900-20803: Thickness gauge  Spark plug gap A Standard: 0.6 – 0.7 mm (0.024 – 0.028 in) ….For E-02, 19, 24, 33…
  • Page 551
    VL800/C/TK9 (’09-MODEL) 18-11 VALVE CLEARANCE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. Valve clearance must be checked and adjusted when: (1) the valve mechanism is service, and (2) the camshafts are serviced.
  • Page 552
    18-12 VL800/C/TK9 (’09-MODEL) • Remove the PAIR pipe bolts (Rear cylinder). • Remove the gasket 5.  Do not reuse the removed gasket. • Remove the inspection caps. • Remove the generator cover plug 6. • Remove the cap 7 and timing inspec ion plug 8.
  • Page 553
    VL800/C/TK9 (’09-MODEL) 18-13 • To inspect the No.1 (Rear) cylinder valve clearance, insert the thickness gauge to the clearance between the valve stem end and the adjusting screw on the rocker arms.  09900-20806: Thickness gauge • If the clearance is out of the specification, bring it into the specified range by using the special tool.
  • Page 554
    18-14 VL800/C/TK9 (’09-MODEL) ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
  • Page 555
    3.4 L (3.6/3.0 US/Imp qt) Overhaul engine: 3 7 L (3.9/3.3 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
  • Page 556
    18-16 VL800/C/TK9 (’09-MODEL) THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Adjust the throttle cable play A as follows. • Loosen the lock-nut 2 of the throttle pulling cable 1.
  • Page 557
    VL800/C/TK9 (’09-MODEL) 18-17 COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service.
  • Page 558: Fi System Diagnosis

    18-18 VL800/C/TK9 (’09-MODEL) FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM…

  • Page 559
    VL800/C/TK9 (’09-MODEL) 18-19 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) — IAT sensor signal (IAT) ECT sensor signal (ECT) IAP sensor signal #2 (IAP. F) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Power source for sensors (VCC) IAP sensor signal #1 (IAP.
  • Page 560
    18-20 VL800/C/TK9 (’09-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY…
  • Page 561: Dtc Table And Defective Condition

    VL800/C/TK9 (’09-MODEL) 18-21 DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts signal.

  • Page 562
    18-22 VL800/C/TK9 (’09-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
  • Page 563
    VL800/C/TK9 (’09-MODEL) 18-23 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve The circuit voltage of motor drive is ISC valve circuit open or shorted C40/P0505 unusual. to the ground Power source circuit open Idle speed is lower than the desired Air passage clogged idle speed.
  • Page 564: Dtc Troubleshooting

    18-24 VL800/C/TK9 (’09-MODEL) DTC TROUBLESHOOTING “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.

  • Page 565
    VL800/C/TK9 (’09-MODEL) 18-25 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.
  • Page 566
    18-26 VL800/C/TK9 (’09-MODEL) “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by 4 times or more. • Injector malfunction.
  • Page 567
    VL800/C/TK9 (’09-MODEL) 18-27 6) If OK, then check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
  • Page 568
    18-28 VL800/C/TK9 (’09-MODEL) “C40” (P0505/P0506/P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground unusual. (P0505) Idle speed is lower than the desired idle • Air passage clogged (P0506) speed.
  • Page 569
    VL800/C/TK9 (’09-MODEL) 18-29 4) Disconnect the ISC valve coupler and ECM coupler. 5) Check the continuity between terminals A and g, terminals B and ^, terminals C and i, terminals D and .  When using the multi-circuit tester, do not strongly…
  • Page 570
    18-30 VL800/C/TK9 (’09-MODEL) ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)  09904-41010: SDS set tool 99565-01010-017: CD-ROM Ver.17 2) Check that the engine is running.
  • Page 571
    VL800/C/TK9 (’09-MODEL) 18-31 Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 400 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC…
  • Page 572
    18-32 VL800/C/TK9 (’09-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.
  • Page 573
    VL800/C/TK9 (’09-MODEL) 18-33 “C44” (P0156/P0161) or “C64” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24, 33) DETECTED CONDITION POSSIBLE CAUSE C44/C64 HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0156/ to ECM during engine operation and •…
  • Page 574
    18-34 VL800/C/TK9 (’09-MODEL) 7) Disconnect the ECM coupler. HO2 sensor #1 coupler 8) Check the continuity between W/Bl wire (#1) C and terminal W. (For HO2 sensor #1) Check the continuity between W/G wire (#2) A and terminal 6. (For HO2 sensor #2) 9) Also, check the continuity between B/Br wire B and terminal B.
  • Page 575
    VL800/C/TK9 (’09-MODEL) 18-35 Is the voltage OK? ECM coupler (Harness side) • W/Bl wire or B/Br wire open or shorted to ground, or poor W or B connection. (Rear cylinder side) • W/G wire or B/Br wire open or shorted to ground, or poor 6 or B connection.
  • Page 576
    18-36 VL800/C/TK9 (’09-MODEL) Step 2 (Heater circuit check) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground.
  • Page 577
    VL800/C/TK9 (’09-MODEL) 18-37 “C62” (P0443) EVAP SYSTEM PURGE CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION (E-33 only) DETECTED CONDITION POSSIBLE CAUSE EVAP system purge control solenoid valve voltage is • EVAP system purge control solenoid valve circuit not input to ECM. open or short.
  • Page 578
    18-38 VL800/C/TK9 (’09-MODEL) Step 2 1) Connect the purge control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Measure the voltage at the wire side coupler between O/W wire and ground.  PAIR control solenoid valve voltage: Battery voltage (+ O/W –…
  • Page 579
    VL800/C/TK9 (’09-MODEL) 18-39 THROTTLE BODY CONSTRUCTION E-33 only 1 STP sensor 0 Air screw 2 O-ring A Straight plug  3 TP sensor B IAP sensor 4 ISC valve C 3-way joint (E-33 only) ITEM N·m kgf-m lbf-ft 5 Delivery pipe A STP sensor mounting bolt 0.35…
  • Page 580
    18-40 VL800/C/TK9 (’09-MODEL) THROTTLE BODY REMOVAL • Remove the air cleaner box. (Page 18-8) • Remove the IAP sensors (Front cylinder side 1 and Rear cyl- inder side 2) from the mounting stay. • Remove the PCV hose 3 and loosen the clamp screw 4.
  • Page 581
    VL800/C/TK9 (’09-MODEL) 18-41 • Loosen the throttle body clamp screw at the intake pipe side. • Move the throttle body upward. • Disconnect the vacuum hoses A. • Disconnect the hoses B. (For E-33) • Disconnect the throttle cables from their drum.
  • Page 582
    18-42 VL800/C/TK9 (’09-MODEL) THROTTLE BODY DISASSEMBLY • Remove the fuel feed hose 1. • Remove the clamp 2. • Loosen the screw and remove the plate 3. • Pull on the straight plug 4 straightly outward to remove it so as not to cause scratches on the O-ring seat of the delivery pipe.
  • Page 583
    VL800/C/TK9 (’09-MODEL) 18-43 • When removing the fuel injector 7, pull it straightly so as not to cause scratches on the O-ring seat of delivery pipe.  Never remove the L-joint 8. • Remove the TP sensor 9 and STP sensor 0 with the special tool.
  • Page 584
    18-44 VL800/C/TK9 (’09-MODEL)  Never remove the STVA B from the throttle body.  Never remove the secondary throttle valve C and throttle valve D.  The adjusting screw E is factory-adjusted at the time of delivery and do not turn or remove it.
  • Page 585
    VL800/C/TK9 (’09-MODEL) 18-45 THROTTLE BODY CLEANING  Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.
  • Page 586: Throttle Body Reassembly

    18-46 VL800/C/TK9 (’09-MODEL) THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • Apply thin coat of engine oil to the O-ring.  Replace the O-ring with a new one.

  • Page 587
    VL800/C/TK9 (’09-MODEL) 18-47 • With the STV fully opened, install the STP sensor 2 and tighten the STP sensor mounting screw to the specified torque.  TPS and STPS resemble each other very closely in external appearance. Make sure to check the color of coupler before install- ing.
  • Page 588
    18-48 VL800/C/TK9 (’09-MODEL) • Apply thin coat of engine oil to the new O-rings and cushion seals.  Replace the O-rings and cushion seals with the new ones. • Install the fuel injector 4 by pushing it straight to the delivery pipe 5.
  • Page 589
    VL800/C/TK9 (’09-MODEL) 18-49 • Before installing the straight joint 7, clean its inside and out- side. • Apply thin coat of the engine oil to the O-rings.  Replace the O-rings with the new ones. • Insert both the straight joint 7 and straight plug 8 straightly into the delivery pipe.
  • Page 590: Throttle Body Installation

    18-50 VL800/C/TK9 (’09-MODEL) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the sensor lead wire couplers.  * TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.

  • Page 591: Stp Sensor Adjustment

    VL800/C/TK9 (’09-MODEL) 18-51 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the fuel tank. ( Page 14-93) • Disconnect the STVA coupler 1.

  • Page 592: Tp Sensor Adjustment

    18-52 VL800/C/TK9 (’09-MODEL) TP SENSOR ADJUSTMENT After all adjustments are completed, check or adjust the TPS setting condition. 1. Remove the right frame cover. ( Page 7-2) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. ( Page 14-37) 3.

  • Page 593: Isc Valve Removal

    VL800/C/TK9 (’09-MODEL) 18-53 ISC VALVE REMOVAL • Remove the throttle body. (Page 18-40) • Remove the ISC valve 1. ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal. Pay attention to the following points:  * The ISC valve must be installed with the valve fully contracted (full open position).

  • Page 594: Isc Valve Preset And Opening Initialization

    18-54 VL800/C/TK9 (’09-MODEL) ISC VALVE PRESET AND OPENING INITIALIZATION When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)

  • Page 595: Throttle Valve Synchronization

    VL800/C/TK9 (’09-MODEL) 18-55 THROTTLE VALVE SYNCHRONIZATION USE OF SDS TOOL Check and adjust the throttle valve synchronization between two cylinders. Step 1 • Lift and support the fuel tank. ( Page 14-93) • Disconnect the vacuum hoses 1 from the throttle body.

  • Page 596
    18-56 VL800/C/TK9 (’09-MODEL) • Click “Active control”. • Click “ISC air volume control” 1. • Click “ON” bottom 2 to fix the ISC air volume of two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 90 – 110 °C (194 – 230 °F).
  • Page 597: Ignition System

    VL800/C/TK9 (’09-MODEL) 18-57 IGNITION SYSTEM Engine stop switch sensor 1 sensor 2 Ignition coil Side- stand #1(main) relay Spark plug sensor Fuse #1(sub) Ignition (E-02, 19, 24, 33 only) switch #2(main) Fuse #2(sub) Battery (E-02, 19, 24, 33 only) sensor…

  • Page 598
    18-58 VL800/C/TK9 (’09-MODEL) Measure the ignition coils primary peak voltage in the following Peak volt adaptor procedures: • Connect the multi-circuit tester with peak voltage adaptor as Ignition follows. coil #1 ignition coil (main): + Probe: B/Bl terminal spark — Probe: Ground…
  • Page 599
    VL800/C/TK9 (’09-MODEL) 18-59 IGNITION COIL PRIMARY PEAK VOLTAGE (For E-03, 28) For details other than the following, refer to the VL800 service manual 8-18. • Connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil: + Probe: B/Bl terminal…
  • Page 600: Combination Meter Inspection

    18-60 VL800/C/TK9 (’09-MODEL) COMBINATION METER INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (FI indicator light, Oil pressure indicator light and Engine coolant indicator light) immediately after turning the ignition switch ON. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.

  • Page 601: Wiring Harness Routing

    VL800/C/TK9 (’09-MODEL) 18-61 WIRING HARNESS ROUTING Clamp Wiring harness Guide Speed sensor Clamp 5 – 25 mm (0.20 – 0.98 in) Handlebar switch (L) Clutch cable White tape 200 mm Handlebar switch (R) Clamp Brake hose Wiring harness Handlebar switch 45˚…

  • Page 602: Mm (5.55 In)

    18-62 VL800/C/TK9 (’09-MODEL) Turn down. Speedometer harness Clutch cable 0 – 5 mm Clamp (0.0 – 0.2 in) – 0 High tension cord 0 – 20 mm Wiring harness (0.0 – 0.8 in) High tension cord Clamp Frame Fuel tank 50 –…

  • Page 603
    VL800/C/TK9 (’09-MODEL) 18-63…
  • Page 604
    18-64 VL800/C/TK9 (’09-MODEL) Grommet Clamp Clamp 10 mm (0.4 in) Clamp *1 Set the wire harness between the fender and fender brace. *2 Set the wire harness between the fender and reinforcement. *3 Cut the tip of clamp within 5 mm (0.2 in) from the lock part.
  • Page 605: Cable Routing

    VL800/C/TK9 (’09-MODEL) 18-65 CABLE ROUTING For E-02, 19, 24, 33 300 mm (11.8 in) Throttle cable clip Throttle cable No.2 Throttle cable No.1 Clutch cable Brake hose Guide Wiring harness Outside Cable Protector Fuel tank cushion PAIR control solenoid valve…

  • Page 606
    18-66 VL800/C/TK9 (’09-MODEL) For E-03, 28 300 mm (11.8 in) Throttle cable clip Throttle cable No.2 Throttle cable No.1 Clutch cable Brake hose Guide Wiring harness Outside High tension cord Cable Protector Fuel tank cushion PAIR control solenoid valve lead wire…
  • Page 607: Throttle Body Installation

    VL800/C/TK9 (’09-MODEL) 18-67 THROTTLE BODY INSTALLATION Matching HO2 sensor mark (White) Matching mark 25 N . m (2.5 kgf-m, 18.0 lbf-ft) HO2 sensor Fuel hose 25 N . m (2.5 kgf-m, 18.0 lbf-ft) To purge control A upward. solenoid valve A downward.

  • Page 608: Spacer

    18-68 VL800/C/TK9 (’09-MODEL) IGNITION COIL INSTALLATION For E-02, 19, 24, 33 0 ± 10˚ 0 ± 10˚  1 Ignition coil #1 (main) 2 Ignition coil #1 (sub) ITEM N·m kgf-m lbf-ft 3 Ignition coil #2 (main) 0.45 4 Ignition coil #2 (sub)

  • Page 609
    VL800/C/TK9 (’09-MODEL) 18-69 For E-03, 28  1 Ignition coil #1 2 Ignition coil #2 ITEM N·m kgf-m lbf-ft 3 Protector 0.45 A Ignition coil bolt Pass the spacer to the hole a of protector securely. Do not pinch the…
  • Page 610: Engine Mounting

    18-70 VL800/C/TK9 (’09-MODEL) ENGINE MOUNTING 50 N . m (5.0 kgf-m, 36.0 lbf-ft) 79 N . m (7.9 kgf-m, 57.0 lbf-ft) 23 N . m (2.3 kgf-m, 16.5 lbf-ft) 79 N . m 25 N . m 50 N . m (7.9 kgf-m 57 0 lbf-ft)

  • Page 611: Muffler & Exhaust Pipe Installation

    VL800/C/TK9 (’09-MODEL) 18-71 MUFFLER & EXHAUST PIPE INSTALLATION  HO2 sensor Install the body C with inlaying the claw of ITEM N·m kgf-m lbf-ft (E-02, 19, 24, 33) mouthpiece into the slit of muffler clamp. 16.5 Apply muffler seal [MUFFLER SEAL LOC- 18.0…

  • Page 612: Pair (Air Supply) System Hose Routing

    18-72 VL800/C/TK9 (’09-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Matching mark (Blue) Approx. 45˚ Matching mark (White) Matching mark (Yellow) PAIR pipe PAIR control solenoid valve PAIR control solenoid valve lead wire Fit hose ends onto hose joint all the way until Tighten bolts with PAIR pipe slightly tensioned stopper flange is securely contacted.

  • Page 613: Rear Combination Light Installation

    VL800/C/TK9 (’09-MODEL) 18-73 REAR COMBINATION LIGHT INSTALLATION E-28 E-03, 28, 33 E-02, 19, 24 E-28 E-03, 33 1 Rear turn signal light (LH) 7 Rear combination light Install the cushion to the rear 2 Rear turn signal upper cover 8 Rear fender fender.

  • Page 614: Special Tools

    18-74 VL800/C/TK9 (’09-MODEL) SPECIAL TOOLS 09900-20803 09900-25008 09900-25009 09900-20806 Multi-circuit tester Needle pointed 09904-41010 09915-40620 Thickness gauge probe set SDS set tool Oil filter wrench 09930-10121 09917-10410 Spark plug socket 09930-11950 09930-14530 09930-82720 Valve adjust driver wrench set Torx wrench…

  • Page 615: Tightening Torque

    VL800/C/TK9 (’09-MODEL) 18-75 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lbf-ft Driveshaft bolt 40.0 Ignition coil bolt 0.45 Spark plug Oil drain plug 15.0 Oil pressure switch 10.0 Generator rotor bolt 16.0 115.5 Starter motor mounting bolt Exhaust pipe bolt 16.5 Muffler support bolt 16.5…

  • Page 616: Service Data

    18-76 VL800/C/TK9 (’09-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance (when cold) 0.08 – 0.13 — (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem 0.010 –…

  • Page 617
    VL800/C/TK9 (’09-MODEL) 18-77 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) 36.58 – 36.62 36.28 (1.440 – 1.442) (1.428) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059)
  • Page 618
    18-78 VL800/C/TK9 (’09-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –…
  • Page 619
    VL800/C/TK9 (’09-MODEL) 18-79 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.42 –…
  • Page 620
    18-80 VL800/C/TK9 (’09-MODEL) THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening Approx. 75 °C (167 °F) — temperature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — ECT sensor resistance 20 °C…
  • Page 621: 7° B.t.d.c. At 1 100 R/Min

    VL800/C/TK9 (’09-MODEL) 18-81 FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 1.5 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.

  • Page 622: Spark Plug

    18-82 VL800/C/TK9 (’09-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug * NGK: DR7EA DENSO: X22ESR-U E-02, 19, 24, 33 Type NGK: DPR7EA-9 For E-03, 28 DENSO: X22EPR-U9 * 0.6 – 0.7 (0.024 – 0.028) E-02, 19, 24, 33 0.8 –…

  • Page 623: Position/Parking Light

    VL800/C/TK9 (’09-MODEL) 18-83 WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight ← ← Position/Parking light ← ← Brake light/Taillight Turn signal light 21/5 (Front), ← 21 (Rear) ← ← Licence plate light ← ← Speedometer light ←…

  • Page 624
    18-84 VL800/C/TK9 (’09-MODEL) TIRE ITEM STANDARD LIMIT Cold inflation tire pressure 200 kPa VL800 —- (Solo riding) (2.00 kgf/cm², 29 psi) Front 225 kPa VL800C/T —- (2.25 kgf/cm², 33 psi) 250 kPa Rear —- (2.50 kgf/cm², 36 psi) Cold inflation tire pressure…
  • Page 625
    VL800/C/TK9 (’09-MODEL) 18-85 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl…
  • Page 626: Emission Control System

    18-86 VL800/C/TK9 (’09-MODEL) EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system, HO2 sensor (For E-02, 19, 24, 33), catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control sole- noid valve and PAIR reed valve.

  • Page 627: Evaporative Emission Control System (Only For E-33)

    VL800/C/TK9 (’09-MODEL) 18-87 EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) 1 Fuel-vapor separator 7 Vacuum hose 2 Surge hose 8 IAP sensor 3 Fuel shut-off valve A HC VAPOR 4 EVAP canister B FRESH AIR 5 Purge hose C VACUUM…

  • Page 628: Pair (Air Supply) System Inspection

    18-88 VL800/C/TK9 (’09-MODEL) PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES  Page 14-122 PAIR REED VALVE  Page 14-122 PAIR CONTROL SOLENOID VALVE  Page 14-123 HEATED OXYGEN SENSOR (HO2S) INSPECTION (For E-02, 19, 24, 33) Page 18-33 EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION…

  • Page 629
    VL800/C/TK9 (’09-MODEL) 18-89 • Remove the EVAP system purge control solenoid valve 5 from the purge control solenoid valve bracket. NOTE: EVAP system purge control solenoid valve can be checked with- out removing it. (Page 18-38) INSPECTION • Check that no air flows through both of the air inlet and outlet ports.
  • Page 630: Fuel Shut-Off Valve

    18-90 VL800/C/TK9 (’09-MODEL) FUEL SHUT-OFF VALVE Inspect the fuel shut-off valve body for damage. Inspect the fuel shut-off valve operation in the following proce- dure. • Remove the right frame cover. (Page 7-2) • Remove the purge control solenoid valve bracket.

  • Page 631: Pair (Air Supply) System Diagram

    VL800/C/TK9 (’09-MODEL) 18-91 PAIR (AIR SUPPLY) SYSTEM DIAGRAM 1 PAIR control solenoid valve *1 From air cleaner 2 PAIR reed valve *2 To #1 cylinder A FRESH AIR *3 To #2 cylinder PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Page 18-72…

  • Page 632: Evap Canister Hose Routing (Only For E-33)

    18-92 VL800/C/TK9 (’09-MODEL) EVAP CANISTER HOSE ROUTING (Only for E-33) 2 – 5 mm (0.08 – 0.20 in) 1 Surge hose *2 Matching mark (White) 2 Fuel shut-off valve *3 The end of the clamp should face right side. 3 Surge hose *4 The end of the clamp should face forward.

  • Page 633: Wiring Diagram

    WIRING DIAGRAM VL800K5 (’05-MODEL) E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. TEMP ENGINE COOLANT TEMP. WARNING LIGHT FI LIGHT HANDLEBAR SWITCH (R) SPEEDOMETER FUEL WARNING LIGHT TURN SIGNAL INDICATOR LIGHT FI/TEMP/OIL ENGINE HI-BEAM INDICATOR LIGHT HAZARD STOP STARTER…

  • Page 634
    VL800K5 (’05-MODEL) E-03, 28, 33 TEMP ENGINE COOLANT TEMP. WARNING LIGHT FI LIGHT HANDLEBAR SWITCH (R) SPEEDOMETER FUEL WARNING LIGHT TURN SIGNAL INDICATOR LIGHT ENGINE FI/TEMP/OIL HI-BEAM INDICATOR LIGHT STARTER FRONT BRAKE HAZARD STOP NEUTRAL INDICATOR LIGHT SWITCH SWITCH BUTTON SWITCH OIL INDICATOR LIGHT REAR BRAKE…
  • Page 635
    WIRING DIAGRAM VL800/TK6 FOR E-03, 28, 33 TEMP ENGINE COOLANT TEMP. WARNING LIGHT FI LIGHT HANDLEBAR SWITCH (R) SPEEDOMETER FUEL WARNING LIGHT TURN SIGNAL INDICATOR LIGHT ENGINE FI/TEMP/OIL HI-BEAM INDICATOR LIGHT STARTER FRONT BRAKE HAZARD STOP NEUTRAL INDICATOR LIGHT BUTTON…
  • Page 636
    WIRING DIAGRAM VL800K7 FOR E-02, 19, 24 TEMP WATER TEMP WARNING FUEL INJECTION FUEL WARNING LIGHT SPEEDOMETER HANDLEBAR SWITCH (R) TURN SIGNAL INDICATOR LIGHT HI-BEAM INDICATOR LIGHT FI/TEMP/OIL ENGINE NEUTRAL INDICATOR LIGHT STOP STARTER FRONT BRAKE FUEL OIL INDICATOR LIGHT SWITCH BUTTON SWITCH…
  • Page 637
    FOR E-03, 28, 33 TEMP WATER TEMP WARNING FUEL INJECTION FUEL WARNING LIGHT SPEEDOMETER HANDLEBAR SWITCH (R) TURN SIGNAL INDICATOR LIGHT FI/TEMP/OIL HI-BEAM INDICATOR LIGHT ENGINE FUEL NEUTRAL INDICATOR LIGHT STOP STARTER FRONT BRAKE SWITCH BUTTON SWITCH PUMP OIL INDICATOR LIGHT REAR BRAKE PUSH SWITCH…
  • Page 638
    WIRING DIAGRAM VL800/C/TK9 For E-03, 28 HANDLEBAR SWITCH (R) ENGINE FRONT STOP STARTER BRAKE FUEL PUMP SWITCH BUTTON SWITCH REAR BRAKE SWITCH PUSH RESISTOR SPEED SENSOR FUEL PUMP SENSOR RELAY HEADLIGHT IGNITION IGNITION SENSOR VALVE SPEEDOMETER RELAY COIL (F-I) COIL (F-M)
  • Page 639
    VL800/C/TK9 For E-33 IGNITION IGNITION COIL (R-I) COIL (R-M) EVAP SYSTEM HANDLEBAR SWITCH (R) PURGE CONTROL SOLENOID VALVE ENGINE FRONT STOP STARTER BRAKE RESISTOR FUEL PUMP SWITCH BUTTON SWITCH REAR BRAKE SWITCH PUSH SPEED SENSOR (R) SENSOR (F) SENSOR FUEL PUMP…

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