Suzuki kingquad 750 мануал

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Summary of Contents for Suzuki kq750

FOREWORD

This manual contains an introductory description on the SUZUKI LT-A750X/P and procedures for its inspection/

service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this

section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure your customers of fast and reliable ser-

vice.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2007

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-

cations have been made since then, differences may exist between the content of this manual and the

actual vehicle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They

may not represent the actual vehicle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for

servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized

SUZUKI motorcycle dealer to help you.

WARNING

!

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to

properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider

and passenger.

99500-47021-03E

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0

1

2

3

4

5

6

9

Precautions…………..…………………………………………. 00-i

Precautions ……………………….……………….…………. 00-1

General Information ……………….……………….…………. 0-i

General Information …..…………….………………..…… 0A-1

Maintenance and Lubrication ….……………….………. 0B-1

Service Data……………..…………….………………..……0C-1

Engine ………………………….………………..…………….…… 1-i

Precautions ……………………….……………….…………… 1-1

Engine General Information and Diagnosis ………..1A-1

Emission Control Devices ……………………….………. 1B-1

Engine Electrical Devices………….………………..……1C-1

Engine Mechanical………….………………..…………….1D-1

Engine Lubrication System ………….………….………. 1E-1

Engine Cooling System…………………..………………. 1F-1

Fuel System …….…………….………………..…………….1G-1

Ignition System…………….………………..…………….…1H-1

Starting System……………………………………..……….. 1I-1

Charging System…………….………………..……………..1J-1

Exhaust System .…………….………………..……………. 1K-1

Suspension…………………..…………….………………..…… 2-i

Precautions ……………………….……………….…………… 2-1

Suspension General Diagnosis…….………….……….2A-1

Front Suspension ……………………………..……………. 2B-1

Rear Suspension…….……………….………………..……2C-1

Wheels and Tires …………………….…………….……….2D-1

Driveline / Axle ……………..………………..…………….…… 3-i

Precautions ……………………….……………….…………… 3-1

Drive Chain / Drive Train / Drive Shaft ………………. 3A-1

Differential ……….…………….………………..……………. 3B-1

Transfer…..…………….……………….…………….……….3C-1

Propeller Shafts..…………….………………..…………….3D-1

Brake …………..…………….……………….……………..……… 4-i

Precautions ……………………….……………….…………… 4-1

Brake Control System and Diagnosis .………………. 4A-1

Front Brakes….…………….………………..…………….…4B-1

Rear Brakes ………..…………….…………….…………….4C-1

Parking Brake..…………….………………..…………….…4D-1

Transmission / Transaxle …………………..………………. 5-i

Precautions ……………………….……………….…………… 5-1

Automatic Transmission..………….………………..…… 5A-1

Steering………………..……………….…………….……………. 6-i

Precautions ……………………….……………….…………… 6-1

Steering General Diagnosis …………………….………. 6A-1

Steering / Handlebar …….…………….………………….. 6B-1

Body and Accessories………………………………..……… 9-i

Precautions …………….………………………………………. 9-1

Wiring Systems ………….…………………………..………9A-1

Lighting Systems………..…………………………..………9B-1

Combination Meter / Fuel Meter / Horn………………9C-1

Exterior Parts ………….…………………………..…………9D-1

Body Structure ………..…………………………..…………9E-1

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LT-A750XK9 (’09 MODEL)

10

LT-A750XPK9 (’09 MODEL)

11

Table of Contents 00- i

00

Section 00

CONTENTS

Precautions

Precautions ………………………………….…….00-1

Precautions….…………….…………….………………..… 00-1

Warning / Caution / Note……..……………….………. 00-1

General Precautions ..……….…………………….…… 00-1

Precautions for Electrical Circuit Service ………… 00-2

00-1 Precautions:

Precauti ons

Precautions

Precautions

Warning / Caution / Note

B831G20000001

Please read this manual and follow its instructions

carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have

special meanings. Pay special attention to the messages

highlighted by these signal words.

WARNING

!

Indicates a potential hazard that could result

in death or injury.

CAUTION

!

Indicates a potential hazard that could result

in vehicle damage.

NOTE

Indicates special information to make

maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions

contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of

servicing, of the vehicle. In addition to the WARNINGS

and CAUTIONS stated, you must use good judgement

and basic mechanical safety principles. If you are unsure

about how to perform a particular service operation, ask

a more experienced mechanic for advice.

General Precautions

B831G20000002

WARNING

!

• Proper service and repair procedures are

important for the safety of the service

mechanic and the safety and reliability of

the vehicle.

• When 2 or more persons work together,

pay attention to the safety of each other.

• When it is necessary to run the engine

indoors, make sure that exhaust gas is

forced outdoors.

• When working with toxic or flammable

materials, make sure that the area you

work in is well ventilated and that you

follow all of the material manufacturer’s

instructions.

• Never use gasoline as a cleaning solvent.

• To avoid getting burned, do not touch the

engine, engine oil, radiator and exhaust

system until they have cooled.

• After servicing the fuel, oil, water, exhaust

or brake systems, check all lines and

fittings related to the system for leaks.

CAUTION

!

• If parts replacement is necessary, replace

the parts with Suzuki Genuine Parts or

their equivalent.

• 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.

• Be sure to use special tools when

instructed.

• Make sure that all parts used in

reassembly are clean. Lubricate them

when specified.

• Use the specified lubricant, bond, or

sealant.

• When removing the battery, disconnect the

negative (–) cable first and then the

positive (+) cable.

• When reconnecting the battery, connect

the positive (+) cable first and then the

negative (–) cable, and replace the terminal

cover on the positive (+) terminal.

• When performing service to electrical

parts, if the service procedures do not

require use of battery power, disconnect

the negative (–) cable the battery.

• When tightening the cylinder head or case

bolts and nuts, tighten the larger sizes

first. Always tighten the bolts and nuts

diagonally from the inside toward outside

and to the specified tightening torque.

• Whenever you remove oil seals, gaskets,

packing, O-rings, locking washers, self-

locking nuts, cotter pins, circlips and

certain other parts as specified, be sure to

replace them with new ones. Also, before

installing these new parts, be sure to

remove any left over material from the

mating surfaces.

Precautions: 00-2

• Never reuse a circlip. When installing a

new circlip, take care not to expand the

end gap larger than required to slip the

circlip over the shaft. After installing a

circlip, always ensure that it is completely

seated in its groove and securely fitted.

• Use a torque wrench to tighten fasteners

to the specified torque. Wipe off grease

and oil if a thread is smeared with them.

• After reassembling, check parts for

tightness and proper operation.

• To protect the environment, do not

unlawfully dispose of used motor oil,

engine coolant and other fluids: batteries,

and tires.

• To protect Earth’s natural resources,

properly dispose of used vehicle and parts.

Precautions for Electrical Circuit Service

B831G20000003

When handling the electrical parts or servicing the FI

systems, observe the following points for the safety of

the systems.

Electrical Parts

Connector / Coupler

• When connecting a connector, be sure to push it in

until a click is felt.

• With a lock type coupler, be sure to release the lock

when disconnecting, and push it in fully to engage the

lock when connecting.

• When disconnecting the coupler, be sure to hold the

coupler body and do not pull the lead wires.

• Inspect each terminal on the connector/coupler for

looseness or bending.

• Push in the coupler straightly. An angled or skewed

insertion may cause the terminal to be deformed,

possibly resulting in poor electrical contact.

• Inspect each terminal for corrosion and

contamination. The terminals must be clean and free

of any foreign material which could impede proper

terminal contact.

• Before refitting the sealed coupler, make sure its seal

rubber is positioned properly. The seal rubber may

possibly come off the position during disconnecting

work and if the coupler is refitted with the seal rubber

improperly positioned, it may result in poor water

sealing.

• Inspect each lead wire circuit for poor connection by

shaking it by hand lightly. If any abnormal condition is

found, repair or replace.

• When taking measurements at electrical connectors

using a tester probe, be sure to insert the probe from

the wire harness side (backside) of the connector/

coupler.

• When connecting meter probe from the terminal side

of the coupler (where connection from harness side

not being possible), 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 terminal. Never push in the

probe where male terminal is supposed to fit.

I310G1000001-01

1. Coupler 2. Probe

I310G1000002-01

I310G1000003-02

2

1

I649G1000013-02

00-3 Precautions:

• Check the male connector for bend and female

connector for excessive opening. Also check the

coupler for locking (looseness), corrosion, dust, etc.

Clamp

• Clamp the wire harness at such positions as indicated

in “Wiring Harness Routing Diagram in Section 9A

(Page 9A-4)”.

• Bend the clamp properly so that the wire harness is

clamped securely.

• In clamping the wire harness, use care not to allow it

to hang down.

• Do not use wire or any other substitute for the band

type clamp.

Fuse

• When a fuse blows, always investigate the cause to

correct it and then replace the fuse.

• Do not use a fuse of different capacity.

• Do not use wire or any other substitute for the fuse.

Switch

Never apply grease material to switch contact points to

prevent damage.

ECM / Various sensors

• Since each component is a high-precision part, great

care should be taken not to apply any severe impacts

during removal and installation.

• Be careful not to touch the electrical terminals of the

electronic parts (ECM, etc.). The static electricity from

your body may damage these.

• When disconnecting and connecting the coupler,

make sure to turn OFF the ignition switch, or

electronic parts may get damaged.

3. Coupler 4. Probe “A”: Where male terminal fits

3

4

4

“A”

I649G1000030-02

CORRECT INCORRECT

I718H1000001-02

I649G1000001-02

I310G1000007-01

I310G1000008-01

I831G1000001-01

Precautions: 00-4

Battery

• Battery connection in reverse polarity is strictly

prohibited. Such a wrong connection will damage the

components of the FI systems instantly when reverse

power is applied.

• Removing any battery terminal of a running engine is

strictly prohibited. The moment such removal is made,

damaging counter electromotive force will be applied

to the ECM which may result in serious damage.

• Before measuring voltage at each terminal, check to

make sure that battery voltage is 11 V or higher.

Terminal voltage check with a low battery voltage will

lead to erroneous diagnosis.

• Never connect any tester (voltmeter, ohmmeter, or

whatever) to the electronic unit when its coupler is

disconnected. Otherwise, damage to electronic unit

may result.

• Never connect an ohmmeter to the ECM with its

coupler connected. If attempted, damage to ECM or

sensors may result.

• Be sure to use a specified voltmeter/ohmmeter.

Otherwise, accurate measurements may not be

obtained and personal injury may result.

Electrical Circuit Inspection Procedure

While there are various methods for electrical circuit

inspection, described here is a general method to check

for open and short circuit using an ohmmeter and a

voltmeter.

Open circuit check

Possible causes for the open circuit are as follows. As

the cause can exist in the connector/coupler or terminal,

they need to be checked carefully.

• Loose connection of connector/coupler

• Poor contact of terminal (due to dirt, corrosion or rust,

poor contact tension, entry of foreign object etc.)

• Wire harness being open.

• Poor terminal-to-wire connection.

When checking system circuits including an electronic

control unit such as ECM, etc., it is important to perform

careful check, starting with items which are easier to

check.

1) Disconnect the negative (–) cable from the battery.

2) Check each connector/coupler at both ends of the

circuit being checked for loose connection. Also

check for condition of the coupler lock if equipped.

I718H1000004-01

I310G1000011-01

I310G1000012-02

1. Sensor “A”: Check for loose connection

ECM

“A”

1

“A”

I718H1000005-02

00-5 Precautions:

3) Using a test male terminal, check the female

terminals of the circuit being checked for contact

tension.

Check each terminal visually for poor contact

(possibly caused by dirt, corrosion, rust, entry of

foreign object, etc.). At the same time, check to

make sure that each terminal is fully inserted in the

coupler and locked.

If contact tension is not enough, rectify the contact to

increase tension or replace. The terminals must be

clean and free of any foreign material which could

impede proper terminal contact.

4) Using continuity inspect or voltage check procedure

as described below, inspect the wire harness

terminals for open circuit and poor connection.

Locate abnormality, if any.

Continuity check

1) Measure resistance across coupler “B” (between “A”

and “C” in figure).

If no continuity is indicated (infinity or over limit), the

circuit is open between terminals “A” and “C”.

2) Disconnect the coupler “B” and measure resistance

between couplers “A” and “B-1”.

If no continuity is indicated, the circuit is open

between couplers “A” and “B-1”. If continuity is

indicated, there is an open circuit between couplers

“B-2” and “C” or an abnormality in coupler “B-2” or

coupler “C”.

Voltage check

If voltage is supplied to the circuit being checked, voltage

check can be used as circuit check.

1) With all connectors/couplers connected and voltage

applied to the circuit being checked, measure

voltage between each terminal and body ground.

2) If measurements were taken as shown in the figure

and results were listed in the following, it means that

the circuit is open between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V

“C” and body ground: 0 V

“B”: Check contact tension by inserting and removing.

“C”: Check each terminal for bend and proper alignment.

“D”: Looseness of crimping

“E”: Open

“F”: Thin wire (A few strands left)

“C”

“B”

I649G1000027-02

“D”

“E”

“F”

I649G1000028-02

ECM

“A”

“B”

“C”

I705H1000006-02

ECM

“A”

“B” “C”

“B-2”

“B-1”

I705H1000010-02

Precautions: 00-6

3) Also, if measured values are as listed following, a

resistance (abnormality) exists which causes the

voltage drop in the circuit between terminals “A” and

“B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V – 2 V voltage

drop

“C” and body ground: 3 V – 2 V voltage drop

Short circuit check (Wire harness to ground)

1) Disconnect the negative (–) cable from the battery.

2) 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. Otherwise, diagnosis

will be misled.

3) Measure resistance between terminal at one end of

circuit (“A” terminal in figure) and body ground. If

continuity is indicated, there is a short circuit to

ground between terminals “A” and “C”.

4) Disconnect the connector/coupler included in circuit

(coupler “B”) and measure resistance between

terminal “A” and body ground. If continuity is

indicated, the circuit is shorted to the ground

between terminals “A” and “B”.

5V

5V

5V

0V

ECM

“A”

“B” “C”

“A” “B” “C”

I705H1000007-01

“D”: To other parts “E”: Other parts

“D”: To other parts

ECM

5V

“A”

“B”

“C”

“D”

“E”

“A” “C”

I705H1000008-01

ECM

“A”

“B” “C”

“D”

I705H1000009-02

00-7 Precautions:

Using The Multi-Circuit Testers

• Use the Suzuki multi-circuit tester set.

• Use well-charged batteries in the tester.

• Be sure to set the tester to the correct testing range.

Special tool

(A): 09900–25008 (Multi-circuit tester set)

Using the testers

• Incorrectly connecting the (+) and (–) probes may

cause the inside of the tester to be burnout.

• If the voltage and current are not known, make

measurements using the highest range.

• When measuring the resistance with the multi-circuit

tester (1), ∞ will be shown as 10.00 MΩ and “1”

flashes in the display.

• Check that no voltage is applied before making the

measurement. If voltage is applied the tester may be

damaged.

• After using the tester, turn the power off.

Special tool

: 09900–25008 (Multi-circuit tester set)

NOTE

• When connecting the multi-circuit tester,

use the needle pointed probe to the back

side of the lead wire coupler and connect

the probes of tester to them.

• Use the needle pointed probe to prevent

the rubber of the water proof coupler from

damage.

• When using the multi-circuit tester, do not

strongly touch the terminal of the ECM

coupler with a needle pointed tester probe

to prevent the terminal damage or terminal

bend.

Special tool

(A): 09900–25009 (Needle pointed probe set)

(A)

I649G1000024-03

I649G1000002-02

(A)

I649G1000025-03

Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ……….…………..…….. 0A-1

General Description ………………….………………..…0A-1

Symbols …….……………….……………..…………….…0A-1

Abbreviations ……………………………..…………….… 0A-1

SAE-to-Former SUZUKI Term ………………………. 0A-2

Vehicle Side View ………..………………..……………. 0A-3

Vehicle Identification Number ………….……………. 0A-3

Fuel and Oil Recommendation ………………………0A-3

Engine Coolant Recommendation ……………….… 0A-4

BREAK-IN Procedures……..……………………..…… 0A-4

Country and Area Codes …….…………………..…… 0A-5

Wire Color Symbols ………………………….…………. 0A-5

Warning, Caution and Information Labels

Location ………………………….…………….…………. 0A-6

Component Location ………..…………….…………….0A-7

Electrical Components Location ……………………. 0A-7

Specifications…….…………….…………….…………….0A-9

Specifications (LT-A750X/ZK8)………..……………. 0A-9

Specifications (LT-A750X/ZK9)………..………….. 0A-11

Special Tools and Equipment …………….………..0A-11

Special Tool ………………..………………..………….. 0A-11

Maintenance and Lubrication…………….. 0B-1

Precautions….…………………..……………….………….0B-1

Precautions for Maintenance ……………..…………. 0B-1

General Description ………………….………………..…0B-1

Recommended Fluids and Lubricants…….………. 0B-1

Scheduled Maintenance ……………………….……….0B-1

Periodic Maintenance Schedule Chart……………. 0B-1

Lubrication Points ………..…………………..…………. 0B-2

Repair Instructions .……………….…………………..…0B-3

Air Cleaner Element Inspection and Cleaning ….0B-3

Exhaust Pipe Bolt and Muffler Bolt Inspection …. 0B-4

Valve Clearance Inspection and Adjustment …… 0B-4

Spark Plug Replacement ……………..………………. 0B-9

Spark Plug Inspection and Cleaning………………. 0B-9

Spark Arrester Cleaning…………………………..….0B-10

Fuel Line Inspection ……………….……………….….0B-10

Engine Oil and Filter Replacement ……………….0B-10

Front Differential Gear Oil Inspection…………….0B-12

Front Differential Gear Oil Replacement ………..0B-13

Final Gear Oil Inspection………………………….….0B-14

Final Gear Oil Replacement………………..……….0B-14

Throttle Cable Play Inspection and

Adjustment ……………………….…………….……….0B-15

Throttle Body Inspection ………………….………….0B-15

Cooling System Inspection……………….………….0B-15

Drive V-belt Inspection and Replacement..…….0B-17

Drive Shaft Boots Inspection…………………….….0B-17

Front Brake System Inspection …………………….0B-17

Rear Brake Pedal / Rear Brake (Parking

Brake) Lever Inspection and Adjustment ……..0B-19

Rear Brake Friction Plate Wear Limit

Inspection…….…………….………………..………….0B-20

Tire Inspection…………………….…………….……….0B-21

Steering System Inspection ………………..……….0B-21

Toe Adjustment ………………..……………….……….0B-22

Suspensions Inspection ……………….……………..0B-22

Chassis Bolt and Nut Inspection …………………..0B-23

Compression Pressure Check ………………….….0B-26

Oil Pressure Check …………..……………….……….0B-26

SDS Check……….……………..…………….………….0B-26

Automatic Clutch Inspection….…………….……….0B-26

Specifications………………..….…………….………….0B-27

Tightening Torque Specifications………………….0B-27

Special Tools and Equipment ……………..……….0B-27

Recommended Service Material ……….………….0B-27

Special Tool ……………………….…………….……….0B-27

Service Data ……………………………………… 0C-1

Specifications………………..….…………….……………0C-1

Service Data………………………….…………………....0C-1

Tightening Torque List ………………………………....0C-7

0A-1 General Information:

General Info rmation

General Information

General Description

Symbols

B831G20101001

Listed in the table below are the symbols indicating instructions and other information necessary for servicing.

The meaning of each symbol is also included in the table.

Abbreviations

B831G20101002

A:

ABDC: After Bottom Dead Center

AC: Alternating Current

ACL: Air Cleaner, Air Cleaner Box

API: American Petroleum Institute

ATDC: After Top Dead Center

A/F: Air Fuel Mixture

B:

BBDC: Before Bottom Dead Center

BTDC: Before Top Dead Center

B+: Battery Positive Voltage

C:

CKP Sensor: Crankshaft Position Sensor (CKPS)

CKT: Circuit

CO: Carbon Monoxide

CPU: Central Processing Unit

D:

DC: Direct Current

DIFF-LOCK Relay: Differential Lock Relay

DMC: Dealer Mode Coupler

DOHC: Double Over Head Camshaft

DRL: Daytime Running Light

DTC: Diagnostic Trouble Code

E:

ECM: Engine Control Module Engine Control Unit

(ECU) (FI Control Unit)

ECT Sensor: Engine Coolant Temperature Sensor

(ECTS)

Water Temp. Sensor (WTS)

F:

FI: Fuel Injection, Fuel Injector

FP: Fuel pump

FPR: Fuel Pressure Regulator

FP Relay: Fuel Pump Relay

Symbol Definition

Torque control required.

Data beside it indicate specified torque.

Apply oil.

Use engine oil unless otherwise specified.

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1).

Apply SUZUKI SUPER GREASE “A” or equivalent.

99000-25010

Apply SUZUKI MOLY PASTE or equivalent.

99000-25140

Apply WATER RESISTANCE GREASE.

99000-25160

Apply SUZUKI SILICONE GREASE or equivalent.

99000-25100

Apply SUZUKI BOND “1215” or equivalent.

99000-31110

Apply SUZUKI BOND “1216B” or equivalent.

99000-31230

Apply THREAD LOCK SUPER “1303” or equivalent.

99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent.

99000-32110

Apply THREAD LOCK SUPER “1360” or equivalent.

99000-32130

Use engine coolant or equivalent.

99000-99032-11X

Apply or use brake fluid.

Use special tool.

Do not reuse.

Note on reassembly.

General Information: 0A-2

G:

GEN: Generator

GND: Ground

GP Switch: Gear Position Switch

H:

HC: Hydrocarbons

I:

IAP Sensor: Intake Air Pressure Sensor (IAPS)

IAT Sensor: Intake Air Temperature Sensor (IATS)

IG: Ignition

ISC Valve: Idle Speed Control Valve (ISCV)

J:

JASO: Japanese Automobile Standards Organization

L:

LCD: Liquid Crystal Display

LED: Light Emitting Diode (Malfunction Indicator Lamp)

LH: Left Hand

M:

MAL-CODE: Malfunction Code (Diagnostic Code)

Max: Maximum

MIL: Malfunction Indicator Lamp (LED)

Min: Minimum

N:

NOx: Nitrogen Oxides

O:

OHC: Over Head Camshaft

P:

PCV: Positive Crankcase Ventilation (Crankcase

Breather)

R:

RH: Right Hand

ROM: Read Only Memory

S:

SAE: Society of Automotive Engineers

SDS: Suzuki Diagnosis System

T:

TO Sensor: Tip-over Sensor (TOS)

TP Sensor: Throttle Position Sensor (TPS)

SAE-to-Former SUZUKI Term

B831G20101003

This list shows 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.

Ex. SAE term (Abbreviation): Former SUZUKI term

A:

Air Cleaner (ACL): Air Cleaner, Air Cleaner Box

B:

Battery Positive Voltage (B+): Battery Voltage, +B

C:

Crankshaft Position Sensor (CKP Sensor):

Crankshaft Position Sensor (CKPS), Crank Angle

D:

Data Link Connector (DLC): Dealer Mode Coupler

Diagnostic Test Mode (DTM): —

Diagnostic Trouble Code (DTC): Diagnostic Code,

Malfunction Code

E:

Electronic Ignition (EI): —

Engine Control Module (ECM): Engine Control

Module (ECM), Fl Control Unit, Engine Control Unit

(ECU)

Engine Coolant Level (ECL): Coolant Level

Engine Coolant Temperature (ECT): Coolant

Temperature, Engine Coolant Temperature, Water

Temperature

Engine Speed (RPM): Engine Speed (RPM)

F:

Fan Control (FC): —

Fuel Level Sensor: Fuel Level Sensor, Fuel Level

Gauge

Fuel Pump (FP): Fuel Pump (FP)

G:

Generator (GEN): Generator

Ground (GND): Ground (GND, GRD)

I:

Ignition Control Module (ICM): —

Intake Air Temperature (IAT): Intake Air Temperature

(IAT), Air Temperature

Idle Speed Control (ISC): —

Ignition Control (IC): Electronic Spark Advance (ESA)

M:

Malfunction Indicator Lamp (MIL): LED Lamp,

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure (MAP): Intake Air

Pressure (IAP), Intake Vacuum

Mass Air Flow (MAF): Air Flow

O:

On-Board Diagnostic (OBD): Self-Diagnosis Function,

Diagnostic

P:

Programmable Read Only Memory (PROM): —

R:

Random Access Memory (RAM): —

Read Only Memory (ROM): ROM

T:

Throttle Body (TB): Throttle Body (TB)

Throttle Body Fuel Injection (TBI): Throttle Body Fuel

Injection (TBI)

Throttle Position Sensor (TP Sensor): TP Sensor

(TPS)

V:

Voltage Regulator (VR): Voltage Regulator

0A-3 General Information:

Vehicle Side View

B831G20101004

NOTE

Difference between illustration and actual

vehicle may exist depending on the markets.

SUZUKI LT-A750X (2008-model)

Right Side

Left Side

Vehicle Identification Number

B831G20101005

The frame serial number or V.I.N. (Vehicle Identification

Number) “A” is stamped on the left side of the front frame

pipe. The engine serial number “B” is located on the right

side of the crankcase. These numbers are required

especially for registering the machine and ordering

spare parts.

Fuel and Oil Recommendation

B831G20101006

Fuel (For USA and Canada)

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 Ether),

less than 10% ethanol, or less than 5% methanol with

appropriate cosolvents and corrosion inhibitor is

permissible.

Fuel (For Other Countries)

Gasoline used should be graded 91 octane (Research

Method) or higher. Unleaded gasoline is recommended.

Engine Oil (For USA)

Oil quality is a major contributor to your engine’s

performance and life. Always select good quality engine

oil.

Suzuki recommends the use of SUZUKI

PERFORMANCE 4 MOTOR OIL or an equivalent

engine oil. Use of SF/SG or SH/SJ in API with MA in

JASO.

Suzuki recommends the use of SAE 10W-40 engine oil.

If SAE 10W-40 engine oil is not available, select and

alternative according to the chart.

I831G1010001-01

I831G1010002-01

“A”

I831G1010003-01

“B”

I831G1010004-01

General Information: 0A-4

Engine Oil (For Other Countries)

Oil quality is a major contributor to your engine’s

performance and life. Always select good quality engine

oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil.

If SAE 10W-40 engine oil is not available, select an

alternative according to the chart.

Front Differential Gear Oil

Use hypoid gear oil that meets the API service

classification GL-5 and is rated SAE #90. Use a hypoid

gear oil with a rating of SAE #80 if the vehicle is

operated where the ambient temperature is below 0 °C

(32 °F).

Rear Drive (Final) Gear Oil

Use mobil fluid 424 or equivalent oil.

Brake Fluid

Specification and classification: DOT 4

WARNING

!

Since the brake system of this vehicle is

filled with a glycol-based brake fluid by the

manufacturer, do not use or mix different

types of fluid such as silicone-based and

petroleum-based fluid for refilling the

system, otherwise serious damage will

result.

Do not use any brake fluid taken from old or

used or unsealed containers.

Never reuse brake fluid left over from a

previous servicing, which has been stored

for a long period.

Engine Coolant Recommendation

B831G20101007

Engine Coolant

Use an anti-freeze/engine coolant compatible with an

aluminum radiator, mixed with distilled water only.

Water for mixing

Use distilled water only. Water other than distilled water

can corrode and clog the aluminum radiator.

Anti-freeze / Engine coolant

The engine coolant perform as a corrosion and rust

inhibitor as well as anti-freeze. Therefore, the engine

coolant should be used at all times even though the

atmospheric temperature in your area does not go down

to freezing point.

Suzuki recommends the use of SUZUKI COOLANT anti-

freeze/engine coolant. If this is not available, use an

equivalent which is compatible with an aluminum

radiator.

Liquid amount of water / Engine coolant

Solution capacity (total)

2 450 ml (2.6/2.2 US/Imp qt)

For engine coolant mixture information, refer to “Engine

Coolant Description in Section 1F (Page 1F-1)”.

CAUTION

!

Mixing of anti-freeze/engine coolant should

be limited to 60%. Mixing beyond it would

reduce its efficiency. If the anti-freeze/engine

coolant mixing ratio is below 50%, rust

inhabiting performance is greatly reduced.

Be sure to mix it above 50% even though the

atmospheric temperature does not go down

to the freezing point.

BREAK-IN Procedures

B831G20101008

During manufacture only the best possible materials are

used and all machined parts are finished to a very high

standard but it is still necessary to allow the moving parts

to “BREAK-IN” before subjecting the engine to maximum

stresses. The future performance and reliability of the

engine depends on the care and restraint exercised

during its early life. The general rules are as follows.

1) Keep to these break-in engine speed limits:

Speed limits

Initial 500 km (300 miles): Less than 1/2 throttle

2) Upon reaching an odometer reading of 500 km (300

miles) you can subject the vehicle to full throttle

operation, for short periods of time.

I831G1010008-01

0A-5 General Information:

Country and Area Codes

B931G20101009

The following codes stand for the applicable country(-ies) and area(-s).

Wire Color Symbols

B931G20101010

Model Code Country or Area Effective Frame No.

LT-A750XK8

P-17 Sweden

5SAAR41A 87100001 –

P-24 Australia

P-28 Canada

P-33 U.S.A.

LT-A750XZK8

P-17 Sweden

P-24 Australia

P-28 Canada

P-33 U.S.A.

LT-A750XK9

P-17 Sweden

5SAAR41A 97100001 –

P-24 Australia

P-28 Canada

P-33 U.S.A.

LT-A750XZK9

P-17 Sweden

P-28 Canada

P-33 U.S.A.

Symbol Wire Color Symbol Wire Color

B Black Br/W Brown with White tracer

Bl Blue G/B Green with Black tracer

Br Brown Gr/R Gray with Red tracer

Dg Dark green Gr/W Gray with White tracer

G Green O/G Orange with Green tracer

Gr Gray O/R Orange with Red tracer

O Orange O/W Orange with White tracer

P Pink O/Y Orange with Yellow tracer

R Red O/B Orange with Black tracer

W White O/Bl Orange with Blue tracer

Y Yellow P/W Pink with White tracer

B/Bl Black with Blue tracer R/B Red with Black tracer

B/Br Black with Brown tracer R/G Red with Green tracer

B/G Black with Green tracer W/B White with Black tracer

B/Lg Black with Light green tracer W/Bl White with Blue tracer

B/R Black with Red tracer W/G White with Green tracer

B/W Black with White tracer W/R White with Red tracer

B/Y Black with Yellow tracer W/Y White with Yellow tracer

Bl/B Blue with Black tracer Y/B Yellow with Black tracer

Bl/G Blue with Green tracer Y/Bl Yellow with Blue tracer

Bl/W Blue with White tracer Y/R Yellow with Red tracer

Bl/R Blue with Red tracer Y/G Yellow with Green tracer

Bl/Y Blue with Yellow tracer

General Information: 0A-6

Warning, Caution and Information Labels Location

B931G20101011

[A]

5

14 17, 18

11

9

6

3

7

8

10

12, 13

15, 16

4

2

1, 21

23, 24 20

19

I831G1010005-06

1. Certification plate For P-24, 33 13. Max AMP caution label For P-17, 28

2. Information label For P-33 14. Fuel caution label For P-24

3. Gearshift label For P-17, 24, 28, 33 15. Front carrier warning label For P-24, 33

4. Gearshift label For P-28 16. Front carrier warning label For P-17, 28

5. Tire air pressure label For P-17, 24, 28, 33 17. Rear carrier warning label For P-24, 33

6. Tire air pressure label and warning no-

passenger label For P-28 18. Rear carrier warning label For P-17, 28

7. General warning & AGE, 16 label For P-17, 24, 28, 33 19. ICES Canada label For P-28

8. General warning label For P-28 20. Compliance label No.2 For P-28

9. Warning no-passenger label For P-17, 24, 28, 33 21. I.D. plate For P-17

10. AGE, 16 label For P-28 22. Cooling fan label For P-17, 24, 28, 33

11. Manual notice label For P-33 23. Compliance label For P-28

12. Max AMP caution label For P-24, 33 [A]: Left side of frame

0A-7 General Information:

Component Location

Electrical Components Location

B931G20103001

15

1

2

3

4

5

68

7

13 14 12

11

17 9

10

16

I831G1010006-02

1. Battery 7. 4WD/Diff-lock relay 13. Ignition switch

2. Starter relay/Main fuse 8. Mode selection switch coupler 14. Power source

3. Fuse box 9. Starter motor 15. Ignition coil

4. Neutral relay 10. ECT sensor 16. Rear brake switch

5. Fuel pump relay 11. 4WD/Diff-lock switch 17. Gear position switch

6. ECM 12. Brake lever switch (R)

General Information: 0A-8

18

19

20

21

22

25

23

24

26

30

28

27

31

29

33

34

32

I831G1010007-03

18. Cooling fan thermo-switch 24. Parking brake switch 30. High position diode

19. Resister 25. Brake lever switch 31. Low position diode

20. 4WD/Diff-lock actuator diode 26. Regulator/Rectifier 32. Speed sensor

21. Neutral relay diode 27. Parking brake relay 33. CKP sensor

22. Cooling fan 28. Diff-lock relay 34. Generator

23. Handlebar switch 29. Actuator

0A-9 General Information:

Specifications

Specifications (LT-A750X/ZK8)

B931G20107001

NOTE

These specifications are subject to change without notice.

Dimensions and dry mass

Engine

Drive train

Item Specification Remark

Overall length 2 115 mm (83.3 in) P-28, 33

2 135 mm (84.1 in) P-17, 24

Overall width 1 210 mm (47.6 in) P-28, 33

1 250 mm (49.2 in) P-17, 24

Overall height 1 245 mm (49.0 in)

Wheelbase 1 280 mm (50.4 in)

Ground clearance 270 mm (10.6 in)

Seat height 880 mm (34.6 in)

Dry mass 273 kg (601 lbs) P-28, 33

275 kg (606 lbs) P-17, 24

Front track 930 mm (36.6 in)

Rear track 940 mm (37.0 in)

Item Specification Remark

Type 4-stroke, liquid-cooled, DOHC

Number of cylinders 1

Bore 104.0 mm (4.094 in)

Stroke 85.0 mm (3.346 in)

Displacement 722 cm3 (44.1 cu.in)

Compression ratio 10.0 : 1

Fuel system Fuel injection

Air cleaner Non-woven fabric element

Starter system Electric and recoil starter

Lubrication system Wet sump

Idle speed 1 300 ± 100 r/min

Item Specification Remark

Clutch Wet shoe, automatic, centrifugal type

Transmission Automatic variable ratio (V-belt)

Transfer 2-speed forward with reverse

Gearshift pattern Transmission Automatic

Transfer L-H-N-R (Hand operated)

Primary reduction ratio (Automatic

drive) Variable change (2.763 – 0.78)

Secondary reduction ratio 2.158 (40/21 x 17/15)

Final reduction ratio (Front & Rear) 3.600 (36/10)

Transfer gear ratio

Low 2.562 (41/16)

High 1.240 (31/25)

Reverse 1.882 (32/17)

Drive system Shaft drive

General Information: 0A-10

Chassis

Electrical

Capacities

Item Specification Remark

Front suspension Independent, double wishbone, coil spring, oil damped

Rear suspension Independent, double wishbone, coil spring, oil damped

Front wheel travel 180 mm (7.1 in)

Rear wheel travel 200 mm (7.9 in)

Caster 1.6°

Trail 3.4 mm (0.13 in)

Toe-out 10 mm (0.39 in)

Camber 0.64°

Steering angle 46° (right & left)

Turning radius 3.1 m (10.2 ft)

Front brake Disc brake, twin

Rear brake Sealed oil-bathed multi-disc

Front tire size AT25 x 8-12, tubeless

Rear tire size AT25 x 10-12, tubeless

Item Specification Remark

Ignition type Electronic ignition (CDI)

Ignition timing 7° B.T.D.C. at 1 300 r/min

Spark plug NGK CR6E or DENSO U20ESR-N

Battery 12 V 64.8 kC (18 Ah)/10 HR

Generator Three-phase A.C. generator

Main fuse 30 A

Fuse 10/10/10/10/15/15 A

Headlight 12 V 35/35 W x 2

Auxiliary light 12 V 35/35 W

Brake light/Taillight 12 V 21/5 W

Revercing light 12 V 21 W P-17

Speedometer light LED

Neutral indicator light LED

High beam indicator light LED P-17

Coolant temperature/FI indicator

light LED

Reverse indicator light LED

Diff-lock indicator light LED

Item Specification Remark

Fuel tank 17.5 L (4.6/3.8 US/lmp gal)

Engine oil

Oil change 2 300 ml (2.4/2.0 US/lmp qt)

With filter change 2 500 ml (2.6/2.2 US/lmp qt)

Overhaul 3 000 ml (3.2/2.6 US/lmp qt)

Differential gear oil 500 ml (0.5/0.4 US/lmp qt)

Final gear oil 770 ml (0.7/0.6 US/lmp qt)

Coolant 2 450 ml (2.6/2.2 US/lmp qt)

0A-11 General Information:

Specifications (LT-A750X/ZK9)

B931G20107002

NOTE

• These specifications are subject to change without notice.

• Any differences between the LT-A750X/ZK8 (’08-model) and LT-A750X/ZK9 (’09-model) in

specifications are indicated with an asterisk mark (*).

Dimensions and curb mass

Special Tools and Equipment

Special Tool

B931G20108001

Item Specification Remark

Overall length 2 115 mm (83.3 in) P-28, 33

2 135 mm (84.1 in) P-17, 24

Overall width 1 210 mm (47.6 in) P-28, 33

1 250 mm (49.2 in) P-17, 24

Overall height 1 245 mm (49.0 in)

Wheelbase 1 280 mm (50.4 in)

Ground clearance 270 mm (10.6 in)

Seat height 880 mm (34.6 in)

* Curb mass 302 kg (666 lbs) P-28, 33

304 kg (670 lbs) P-17, 24

Front track 930 mm (36.6 in)

Rear track 940 mm (37.0 in)

09900–06107

Snap ring pliers

09900–06108

Snap ring pliers

09900–20101

Vernier calipers (1/15

mm, 150 mm)

09900–20102

Vernier calipers (1/20

mm, 200 mm)

09900–20202

Micrometer (1/100

mm, 25 – 50 mm)

09900–20205

Micrometer (0 – 25

mm)

09900–20210

Micrometer (100 – 125

mm)

09900–20530

Cylinder gauge set

09900–20602

Dial gauge (1/1000

mm, 1 mm)

09900–20605

Dial calipers (1/100

mm, 10 – 34 mm)

09900–20607

Dial gauge (1/100 mm,

10 mm)

09900–20701

Magnetic stand

09900–20803

Thickness gauge

09900–20805

Tire depth gauge

09900–21304

V-block (100 mm)

General Information: 0A-12

09900–22301

Plastigauge (0.025 –

0.076 mm)

09900–22302

Plastigauge (0.051 –

0.152 mm)

09900–22403

Small bore gauge (18

– 35 mm)

09900–25008

Multi-circuit tester set

09900–25009

Needle pointed probe

set

09900–26006

Engine tachometer

(solar cell type)

09904–41010

SDS set

09910–32812

Crankshaft installer

09910–32860

Attachment

09912–34510

Cylinder

disassembling tool

09913–50121

Oil seal remover

09913–60910

Bearing remover

09913–61510

Bearing puller

09913–70210

Bearing installer set

09913–75520

Bearing installer

09913–84510

Bearing installer

09915–40610

Oil filter wrench

09915–63311

Compression gauge

attachment

09915–64512

Compression gauge

09915–74511

Oil pressure gauge set

09915–74521

Oil pressure gauge

hose

09915–74533

Oil pressure gauge

attachment

09915–77331

Meter (for high

pressure)

09916–10911

Valve lapper set

09916–14510

Valve lifter

0A-13 General Information:

09916–14521

Valve spring

compressor

attachment

09916–14910

Valve spring

compressor

attachment

09916–34542

Reamer handle

09916–34550

Valve guide reamer

(5.5 mm)

09916–34580

Valve guide reamer

(10.8 mm)

09916–44910

Valve guide remover/

installer

09916–57360

Attachment

09916–84511

Tweezers

09917–23711

Ring nut wrench

09917–47011

Vacuum pump gauge

09919–28610

Sleeve protector

09920–13120

Crankcase separating

tool

09920–31020

Extension handle

09920–33540

Clutch shoe remover

09920–53740

Clutch sleeve hub

holder

09921–20240

Bearing remover set

09921–21910

Bearing holder

09922–21410

Long socket (46 mm)

09922–31430

Clutch spring

compressor

09923–73210

Bearing remover

09923–74511

Bearing remover

09924–41830

Bearing retainer

wrench

09924–52420

Secondary bevel gear

holder

09924–52450

Fixed driven face

holder

09924–52460

Socket (52 mm)

General Information: 0A-14

09924–52470

Fixed final drive gear

holder

09924–74520

Oil seal installer/

remover

09924–74570

Final drive gear

bearing installer/

remover

09924–84521

Bearing installer set

09930–10121

Spark plug wrench set

09930–11950

Torx wrench

09930–30104

Rotor remover sliding

shaft

09930–30721

Rotor remover

09930–31921

Rotor remover

09930–40113

Rotor holder

09930–40131

Balancer drive

sprocket holder

09930–73140

Starter torque limiter

socket

09930–73170

Starter torque limiter

holder

09930–82720

Mode select switch

09940–40211

Fuel pressure gauge

adapter

09940–40220

Fuel pressure gauge

hose attachment

09940–92430

Rear axel wrench A

09941–34513

Steering race installer

09941–51012

Ring locknut wrench

09941–53610

Front fork installer

hammer

09941–64511

Bearing remover

09942–72410

Tie-rod end remover

09943–88211

Bearing remover/

installer

09944–66010

Bearing installer

09951–15810

Bearing installer

0A-15 General Information:

99565–01010–013

CD-ROM Ver.13

Maintenance and Lubrication: 0B-1

General Info rmation

Maintenance and Lubrication

Precautions

Precautions for Maintenance

B931G20200001

The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work

necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in

terms of kilometers, miles and months for your convenience.

NOTE

More frequent servicing may be required on vehicle that are used under severe conditions.

General Description

Recommended Fluids and Lubricants

B931G20201001

Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)” and “Engine Coolant Recommendation in Section

0A (Page 0A-4)”.

Scheduled Maintenance

Periodic Maintenance Schedule Chart

B931G20205001

NOTE

I = Inspect and clean, adjust, replace or lubricate as necessary.

C = Clean.

R = Replace.

T = Tighten.

Item

Interval

km Initial 200 Every 1 000 Every 2 000

miles Initial 100 Every 600 Every 1 200

months Initial 1 Every 3 Every 6

Air cleaner element polyurethane foam element — C C

non-woven fabric element — I I

Exhaust pipe nuts and muffler mounting bolts T T T

Valve clearance I — I

Spark plug —— I

Replace every 6 000 km (4 000 miles).

Spark arrester — — C

Fuel line —I I

Replace every 4 years.

Engine oil and oil filter R — R

Front differential gear oil —— I

Replace every 2 years.

Final gear oil —— I

Replace every year.

Throttle cable play I I I

Throttle body — I I

Engine coolant Replace every 2 years.

Radiator — I I

Radiator hose — — I

Drive belt — I R

Drive shaft boots I I I

Brakes I I I

Rear brake plates Replace every 10 000 km (6 000 miles).

0B-2 Maintenance and Lubrication:

Lubrication Points

B931G20205002

Proper lubrication is important for smooth operation and long life of each working part of the vehicle.

Major lubrication points are indicated as follows.

NOTE

• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the

vehicle has been operated under wet or rainy conditions.

Lubricate exposed parts

Every 1 000 km (600 miles, 3 months)

Brake fluid —I I

Replace every 2 years.

Brake hose —— I

Replace every 4 years.

Tires — I I

Steering III

Suspensions — — I

Chassis nuts and bolts T T T

General lubrications — L L

Item

Interval

km Initial 200 Every 1 000 Every 2 000

miles Initial 100 Every 600 Every 1 200

months Initial 1 Every 3 Every 6

1

4

6

4

4

3

1

2

5

5

I831G1020001-03

1. Steering shaft holder 4. Propeller shaft joint spline : Apply water resistance grease.

2. Brake level holder and throttle lever 5. Drive shaft joint spline

3. Brake pedal 6. Drive belt cover bearing (Inner race)

Maintenance and Lubrication: 0B-3

Repair Instructions

Air Cleaner Element Inspection and Cleaning

B931G20206001

Inspect and clean element

Every 1 000 km (600 miles, 3 months)

Inspection

1) Remove the air cleaner element. Refer to “Air

Cleaner Element Removal and Installation in Section

1D (Page 1D-5)”.

2) Inspect the air cleaner element for clogging. If it is

clogged with dirt, clean or replace it with a new one.

CAUTION

!

If driving under dusty conditions, inspect or

clean the air cleaner element more frequently.

The surest way to accelerate engine wear is

to operate the engine without the element or

to use a torn element. Make sure that the air

cleaner is in good condition at all times. Life

of the engine depends largely on this

component.

3) After finishing the air cleaner element inspection,

reinstall the removed parts.

Cleaning

1) Remove the air cleaner element assembly. Refer to

“Air Cleaner Element Removal and Installation in

Section 1D (Page 1D-5)”.

2) Separate the polyurethane from element.

3) Carefully use compressed air to clean the air cleaner

element.

CAUTION

!

Always apply compressed air to the inside of

the air cleaner element. If compressed air is

applied to the outside, dirt will be forced into

the pores of the air cleaner element,

restricting air flow through the air cleaner

element.

4) After cleaning the air cleaner element, reinstall the

removed parts.

5) Drain water from the air cleaner by removing the

drain plug.

6) Reinstall the drain plug.

I831G1020002-01

I831G1020003-01

I831G1020004-01

0B-4 Maintenance and Lubrication:

Exhaust Pipe Bolt and Muffler Bolt Inspection

B931G20206002

Tighten exhaust pipe bolts, muffler bolt and nut

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Check the exhaust pipe bolts, muffler bolts and nut to the

specified torque. Refer to “Exhaust Pipe / Muffler

Removal and Installation in Section 1K (Page 1K-2)”.

Tightening torque

Exhaust pipe nut (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Muffler mounting bolt (b): 23 N·m (2.3 kgf-m, 16.5

lbf-ft)

Muffler connecting bolt (c): 23 N·m (2.3 kgf-m, 16.5

lbf-ft)

Valve Clearance Inspection and Adjustment

B931G20206003

Inspect valve clearance

Initially at 200 km (100 miles, 1 month) and every 2

000 km (1 200 miles, 6 months) thereafter

Inspection

Valve clearance adjustment must be checked and

adjusted, a) at the time of periodic inspection, b) when

the valve mechanism is serviced, and c) when the

camshafts are removed for servicing.

1) Remove the front inner fender (LH & RH). Refer to

“Front Side Exterior Parts Removal and Installation

in Section 9D (Page 9D-6)”.

2) Remove the inlet V-belt cooling duct. Refer to “V-belt

Cooling Duct Removal and Installation in Section 5A

(Page 5A-5)”.

3) Remove the left side cover (1) and engine side cover

(2).

4) Remove the recoil starter (3).

(b)

(c)

(a)

I831G1020005-02

1

2

I831G1020009-02

3

I831G1020010-01

Maintenance and Lubrication: 0B-5

5) Drain a small amount of engine coolant and

disconnect the radiator upper hose of thermostat

side. Refer to “Cooling System Inspection (Page 0B-

15)”.

6) Remove the spark plug cap (4) and spark plug (5).

Refer to “Spark Plug Cap and Spark Plug Removal

and Installation in Section 1H (Page 1H-3)”.

7) Remove the valve timing inspection plug (6).

Turn the crankshaft to bring the “TDC” line “A” on the

generator rotor to the lug mark “B”.

9) Remove the cylinder head cover. Refer to “Engine

Top Side Disassembly in Section 1D (Page 1D-17)”.

NOTE

• Check the engraved lines “C” on the

camshafts, so it is parallel with the mating

surface “D” on the cylinder head cover.

• The valve clearance should be taken

cylinder is at Top Dead Center (TDC) of

compression stroke.

• The clearance specification is for COLD

state.

• To turn the crankshaft for clearance

checking, be sure to use a wrench, and

rotate in the normal running direction.

I831G1020012-01

5

4

I831G1020085-03

6

I831G1020011-02

“A” “B”

I831G1140086-03

“C”

“C”

“D”

“D”

“C” “C”

EX IN

“D” “D”

I831G1020013-03

0B-6 Maintenance and Lubrication:

10) Insert the thickness gauge between the tappet and

the cam. If the clearance is out of specification,

adjust it to the specified range.

NOTE

The valve clearance specification is different

for both intake and exhaust valves.

Special tool

(A): 09900–20803 (Thickness gauge)

Valve clearance (When cold)

IN.: 0.10 – 0.20 mm (0.004 – 0.008 in)

EX.: 0.20 – 0.30 mm (0.008 – 0.012 in)

Adjustment

The clearance is adjusted by replacing the existing

tappet shim with a thicker or thinner shim.

1) Remove the intake or exhaust camshafts. Refer to

“Engine Top Side Disassembly in Section 1D

(Page 1D-17)”.

2) Remove the tappet (1) and shim (2) by fingers or

magnetic hand.

3) Check the figures printed on the shim. These figures

indicate the thickness of the shim, as illustrated.

4) Select a replacement shim that will provide a

clearance within the specified range. For the

purpose of this adjustment, a total of 25 sizes of

tappet shim are available ranging from 2.50 to 3.50

mm in steps of 0.05 mm.

CAUTION

!

Both the right and left valve clearances

should be as closely as possible.

5) Fit the selected shim (2) to the valve stem end, with

numbers toward tappet. Be sure to check shim size

with micrometer to ensure its size.

NOTE

• Be sure to apply engine oil to tappet shim

top and bottom faces.

• When seating the tappet shim, be sure the

figure printed surface faces the tappet.

(A)

I831G1020015-01

1

2

I831G1020016-01

300

3.00 mm

I831G1020091-01

2

I718H1020002-02

Maintenance and Lubrication: 0B-7

(INTAKE SIDE)

0.00 – 0.04

0.05 – 0.09

0.10 – 0.20

0.21 – 0.25

0.26 – 0.30

0.31 – 0.35

0.36 – 0.40

0.41 – 0.45

0.46 – 0.50

0.51 – 0.55

0.56 – 0.60

0.61 – 0.65

0.66 – 0.70

0.71 – 0.75

0.76 – 0.80

0.81 – 0.85

0.86 – 0.90

0.91 – 0.95

0.96 – 1.00

1.01 – 1.05

1.06 – 1.10

1.11 – 1.15

1.16 – 1.20

1.21 – 1.25

1.26 – 1.30

1.31 – 1.35

1.36 – 1.40

2.40

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.30

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.30

2.35

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.35

2.40

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.40

2.45

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.45

2.50

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.50

2.55

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.55

2.60

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.60

2.65

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.65

2.70

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.70

2.75

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.75

2.80

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.80

2.85

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.85

2.90

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.90

2.95

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.95

3.00

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

3.00

3.05

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

3.05

3.10

3.25

3.30

3.35

3.40

3.45

3.50

3.50

3.10

3.15

3.30

3.35

3.40

3.45

3.50

3.50

3.15

3.20

3.35

3.40

3.45

3.50

3.50

3.20

3.25

3.40

3.45

3.50

3.50

3.25

3.30

3.45

3.50

3.50

3.30

3.35

3.50

3.50

3.35

3.40

3.50

3.40

3.45

230

2.30

235

2.35

240

2.40

245

2.45

250

2.50

255

2.55

260

2.60

265

2.65

270

2.70

275

2.75

280

2.80

285

2.85

290

2.90

295

2.95

300

3.00

305

3.05

310

3.10

315

3.15

320

3.20

325

3.25

330

3.30

335

3.35

340

3.40

345

3.45

350

3.50

MEASURED

VALVE

CLEARANCE

(mm)

Option

SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED

TAPPET SHIM SET (12800-41810)

HOW TO USE THIS CHART:

I. Measure valve clearance. “ENGINE IS COLD”

II. Measure present shim size.

III. Match clearance in vertical column with present shim size in horizontal

column.

EXAMPLE

Valve clearance is 0.23 mm

Present shim size 2.70 mm

Shim size to be used 2.80 mm

TAPPET SHIM SELECTION TABLE [INTAKE]

TAPPET SHIM NO. (12892-41C00-XXX)

SUFFIX

NO.

PRESENT

SHIM SIZE

(mm)

I831G1020017-02

0B-8 Maintenance and Lubrication:

(EXHAUST SIDE)

HOW TO USE THIS CHART:

I. Measure valve clearance. “ENGINE IS COLD”

II. Measure present shim size.

III. Match clearance in vertical column with present shim size in horizontal

column.

EXAMPLE

Valve clearance is 0.38 mm

Present shim size 2.90 mm

Shim size to be used 3.05 mm

0.00 – 0.04

0.05 – 0.09

0.10 – 0.14

0.15 – 0.19

0.20 – 0.30

0.31 – 0.35

0.36 – 0.40

0.41 – 0.45

0.46 – 0.50

0.51 – 0.55

0.56 – 0.60

0.61 – 0.65

0.66 – 0.70

0.71 – 0.75

0.76 – 0.80

0.81 – 0.85

0.86 – 0.90

0.91 – 0.95

0.96 – 1.00

1.01 – 1.05

1.06 – 1.10

1.11 – 1.15

1.16 – 1.20

1.21 – 1.25

1.26 – 1.30

1.31 – 1.35

1.36 – 1.40

1.41 – 1.45

1.46 – 1.50

2.40

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.30

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.30

2.35

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.35

2.40

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.30

2.35

2.40

2.45

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.35

2.40

2.45

2.50

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.40

2.45

2.50

2.55

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.45

2.50

2.55

2.60

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.50

2.55

2.60

2.65

2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.55

2.60

2.65

2.70

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.60

2.65

2.70

2.75

2.90

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.65

2.70

2.75

2.80

2.95

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.70

2.75

2.80

2.85

3.00

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.75

2.80

2.85

2.90

3.05

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.80

2.85

2.90

2.95

3.10

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.85

2.90

2.95

3.00

3.15

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.90

2.95

3.00

3.05

3.20

3.25

3.30

3.35

3.40

3.45

3.50

3.50

2.95

3.00

3.05

3.10

3.25

3.30

3.35

3.40

3.45

3.50

3.50

3.00

3.05

3.10

3.15

3.30

3.35

3.40

3.45

3.50

3.50

3.05

3.10

3.15

3.20

3.35

3.40

3.45

3.50

3.50

3.10

3.15

3.20

3.25

3.40

3.45

3.50

3.50

3.15

3.20

3.25

3.30

3.45

3.50

3.50

3.20

3.25

3.30

3.35

3.50

3.50

3.25

3.30

3.35

3.40

3.50

3.30

3.35

3.40

3.45

230

2.30

235

2.35

240

2.40

245

2.45

250

2.50

255

2.55

260

2.60

265

2.65

270

2.70

275

2.75

280

2.80

285

2.85

290

2.90

295

2.95

300

3.00

305

3.05

310

3.10

315

3.15

320

3.20

325

3.25

330

3.30

335

3.35

340

3.40

345

3.45

350

3.50

MEASURED

VALVE

CLEARANCE

(mm)

Option

SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED

TAPPET SHIM SET (12800-41810)

2.30

TAPPET SHIM SELECTION TABLE [EXHAUST]

TAPPET SHIM NO. (12892-41C00-XXX)

SUFFIX

NO.

PRESENT

SHIM SIZE

(mm)

I831G1020018-02

Maintenance and Lubrication: 0B-9

6) Install the camshafts. Refer to “Engine Top Side

Assembly in Section 1D (Page 1D-21)”.

7) Rotate the engine so that the tappet is depressed

fully. This will squeeze out oil trapped between the

shim and the tappet that could cause an incorrect

measurement, then check the clearance again to

confirm that it is within the specified range.

After finishing the tappet clearance adjustment,

reinstall the removed parts. Refer to “Engine Top

Side Assembly in Section 1D (Page 1D-21)”.

Spark Plug Replacement

B931G20206004

Replace spark plug

Every 6 000 km (4 000 miles)

Refer to “Spark Plug Cap and Spark Plug Removal and

Installation in Section 1H (Page 1H-3)”.

Spark Plug Inspection and Cleaning

B931G20206005

Inspect spark plug

Every 2 000 km (1 200 miles, 6 months)

Heat Range

1) Remove the spark plug. Refer to “Spark Plug Cap

and Spark Plug Removal and Installation in Section

1H (Page 1H-3)”.

2) Check spark plug heat range by observing electrode

color.

If it appears white or glazed, replace the spark plug

with colder type one.

Heat range

3) After finishing the spark plug inspection, reinstall the

removed parts.

Carbon Deposits

1) Remove the spark plug. Refer to “Spark Plug Cap

and Spark Plug Removal and Installation in Section

1H (Page 1H-3)”.

2) Check carbon deposits on the spark plug.

If carbon is deposited, remove it using a spark plug

cleaner machine or carefully use a tool with a

pointed end.

3) After finishing the spark plug inspection, reinstall the

removed parts.

Spark Plug Gap

1) Remove the spark plug. Refer to “Spark Plug Cap

and Spark Plug Removal and Installation in Section

1H (Page 1H-3)”.

2) Measure the spark plug gap using a wire gauge.

Adjust the spark plug gap if necessary.

Spark plug gap

0.7 – 0.8 mm (0.028 – 0.030 in)

3) After finishing the spark plug inspection, reinstall the

removed parts.

Electrodes Condition

1) Remove the spark plug. Refer to “Spark Plug Cap

and Spark Plug Removal and Installation in Section

1H (Page 1H-3)”.

2) Check to see the worn or burnt condition of the

electrodes.

If it is extremely worn or burnt, replace the plug. And

also replace the plug if it has a broken insulator, or

damaged thread.

3) After finishing the spark plug inspection, reinstall the

removed parts.

CAUTION

!

Check the thread size and reach when

replacing the spark plug. If the reach is too

short, carbon will be deposited on the screw

portion of the spark plug hole and engine

damage may result.

Standard Cold type

NGK CR6E CR7E

DENSO U20ESR-N U22ESR-N

I649G1020010-02

I831G1020092-01

0B-10 Maintenance and Lubrication:

Spark Arrester Cleaning

B931G20206006

Spark arrester cleaning

Every 2 000 km (1 200 miles, 6 months)

1) Remove the muffler end cover (1).

2) Remove the spark arrester (2) from the muffler.

3) Clean the spark arrester (2) with a brush.

4) After finishing the spark arrester cleaning, reinstall

the removed parts.

Fuel Line Inspection

B931G20206007

Inspect fuel line

Every 1 000 km (600 miles, 3 months)

Replace fuel line

Every 4 years

Inspect the fuel line in the following procedures:

1) Remove the left side cover. Refer to “Front Side

Exterior Parts Removal and Installation in Section

9D (Page 9D-6)”.

2) Remove the rear fender. Refer to “Rear Side Exterior

Parts Removal and Installation in Section 9D

(Page 9D-9)”.

3) Remove the fuel tank side cover. Refer to “Fuel Tank

Removal and Installation in Section 1G (Page 1G-

8)”.

4) Inspect the fuel feed hose for damage and fuel

leakage. If any defects are found, the fuel feed hose

must be replaced.

5) After finishing the fuel feed hose inspection or

replacement, reinstall the removed parts.

Engine Oil and Filter Replacement

B931G20206008

Replace engine oil

Initially at 200 km (100 miles, 1 month) and every 2

000 km (1 200 miles, 6 months) thereafter

Replace oil filter

Initially at 200 km (100 miles, 1 month) and every 2

000 km (1 200 miles, 6 months) thereafter

Oil should be changed while the engine is warm. Oil filter

replacement at the above intervals, should be done

together with the engine oil change.

1

I831G1020006-02

2

I831G1020007-03

2

I831G1020008-03

I831G1020019-02

Maintenance and Lubrication: 0B-11

Engine Oil Replacement

1) Place the vehicle on a level ground and set the brake

lock.

2) Remove the engine side cover. Refer to “Front Side

Exterior Parts Removal and Installation in Section

9D (Page 9D-6)”.

3) Place an oil pan below the engine, and drain engine

oil by removing the oil drain plug (1) and filler cap

(2).

4) Tighten the oil drain plug (1) to the specified torque.

CAUTION

!

Replace the gasket washer with a new one.

Tightening torque

Oil drain plug (a): 21 N·m (2.1 kgf-m, 15.0 lbf-ft)

5) Pour new oil through the oil filler. When performing

an oil change (without oil filter replacement), the

engine will hold about 2.3 L (2.4/2.0 US/lmp qt) of oil.

Use of SF/SG or SH/SJ in API with MA in JASO.

6) Start up the engine and allow it to run for several

minutes at idling speed after tightening the oil filler

cap.

7) Turn off the engine and wait about three minutes,

and then check the oil level on the dipstick (3). The

oil level should be between the low level line “A” and

full level line “B”. If the oil level is lower than the low

level line “A”, add oil to the full level line “B”.

Oil Level Inspection

1) Place the vehicle on a level ground and set the brake

lock.

2) Start up the engine and allow it to run for several

minutes at idling speed.

3) Turn off the engine and wait about three minutes,

then check the oil level on the dipstick (1). If the level

is below low level line “A”, add oil to full level line “B”.

If the level is above full level line “B”, drain oil to full

level line “B”.

NOTE

When inspecting the oil level, the oil filler cap

threads are not run in but touching the filler

hole upper edge.

1

I831G1020020-01

2

I831G1020022-01

(a)

1

I831G1020021-01

“A”

“B”

3

I831G1020023-01

“A”

“B”

1

I831G1020024-01

0B-12 Maintenance and Lubrication:

Oil Filter Replacement

1) Drain engine oil as described in the engine oil

replacement procedure.

2) Remove left inner cover. Refer to “Front Side

Exterior Parts Removal and Installation in Section

9D (Page 9D-6)”.

3) Remove the oil filter (1) using the special tool.

Special tool

(A): 09915–40610 (Oil filter wrench)

4) Apply engine oil lightly to the O-ring of new oil filter,

before installation.

CAUTION

!

ONLY USE A GENUINE SUZUKI

MOTORCYCLE OIL FILTER.

Other manufacturer’s oil filters may differ in

thread specifications (thread diameter and

pitch), filtering performance and durability

which may lead to engine damage or oil

leaks. Also, do not use a genuine Suzuki

automobile oil filter on this vehicle.

5) Install a new oil filter. Turn it by hand until you feel

that the oil filter O-ring contacts the oil filter mounting

surface. Then, tighten the oil filter two full turns (or to

specified torque) using the special tool.

NOTE

To properly tighten the oil filter, use the

special tool. Never tighten the oil filter by

hand only.

Special tool

(A): 09915–40610 (Oil filter wrench)

Tightening torque

Oil filter (a): 20 N·m (2.0 kgf-m, 14.5 lbf-ft)

6) Add new engine oil and check the oil level is as

described in the engine oil replacement procedure.

Necessary amount of engine oil

Oil change: 2 300 ml (2.4/2.0 US/lmp qt)

Oil and filter change: 2 500 ml (2.6/2.2 US/lmp qt)

Engine overhaul: 3 000 ml (3.2/2.6 US/lmp qt)

Front Differential Gear Oil Inspection

B931G20206009

Inspect front differential gear oil

Every 2 000 km (1 200 miles, 6 months)

1) Place the vehicle on level ground.

2) Remove the oil level plug (1) and oil filler plug (2),

and inspect the oil level. If the oil level is below the

level hole, add fresh oil until oil flows from the level

hole.

(A) 1

I831G1020025-01

(A)

(a)

1

I718H1020026-01

1

2

I831G1020036-01

Maintenance and Lubrication: 0B-13

3) Tighten the oil level plug (1) and oil filler plug (2) to

the specified torque.

CAUTION

!

Replace the gasket washers with new ones.

Tightening torque

Front differential gear oil level plug (a): 8.5 N·m (

0.85 kgf-m, 6.0 lbf-ft)

Tightening torque

Front differential gear oil filler plug (b): 35 N·m (

3.5 kgf-m, 25.5 lbf-ft)

Front Differential Gear Oil Replacement

B931G20206010

Replace front differential gear oil

Every 2 years

1) Place the vehicle on level ground.

2) Remove the front under cover. Refer to “Under

Cover Removal and Installation in Section 9D

(Page 9D-12)”.

3) Drain the front differential gear oil by removing the oil

drain plug (1), oil filler plug and oil level plug.

4) Tighten the oil drain plug (1) to the specified torque.

CAUTION

!

Replace the gasket washers with a new one.

Tightening torque

Front differential gear oil drain plug (a): 32 N·m (

3.2 kgf-m, 23.0 lbf-ft)

5) Pour fresh oil through the oil filler hole until it

overflows from the oil level hole. When performing

an oil change, the front differential will hold about

500 ml (0.53 US qt, 0.44 Imp qt) of oil. Use hypoid

gear oil SAE #90, API grade GL-5.

NOTE

Use hypoid gear oil SAE #80, API grade GL-5,

if the vehicle is ridden where the ambient

temperature is below 0 °C (32 °F).

Front differential gear oil capacity

500 ml (0.53 US qt, 0.44 lmp qt)

6) Tighten the oil level plug (2) and oil filler plug (3) to

the specified torque.

CAUTION

!

Replace the gasket washers with new ones.

Tightening torque

Front differential gear oil level plug (b): 8 N·m (

0.8 kgf-m, 5.7 lbf-ft)

Front differential gear oil filler plug (c): 35 N·m (

3.5 kgf-m, 25.5 lbf-ft)

(b)

2

(a)

1

I831G1020037-01

1

I831G1020038-01

(a)

1

I831G1020081-01

(c)

3

(b)

2

I831G1020039-03

0B-14 Maintenance and Lubrication:

Final Gear Oil Inspection

B931G20206011

Inspect final gear oil

Every 2 000 km (1 200 miles, 6 months)

1) Place the vehicle on a level ground.

2) Remove the filler plug (1), and inspect the oil level. If

the oil level is below, add fresh oil until the oil level

reaches the bottom tip of the thread.

3) Tighten the oil filler plug (1) securely.

Final Gear Oil Replacement

B931G20206012

Replace final gear oil

Every year

1) Place the vehicle on a level ground.

2) Remove the rear under cover. Refer to “Under Cover

Removal and Installation in Section 9D (Page 9D-

12)”.

3) Place an oil pan below the final gear case.

4) Drain oil by removing the oil drain plug (1) and oil

filler plug (2).

5) Tighten the oil drain plug (1) to the specified torque,

and pour fresh oil through the oil filler hole until the

oil level reaches the bottom tip of the thread. Use

Mobil fluid 424 or equivalent oil.

Final gear oil capacity

770 ml (0.81 US qt, 0.68 lmp qt)

CAUTION

!

Replace the gasket with a new one.

Tightening torque

Final gear oil drain plug (a): 23 N·m (2.3 kgf-m,

16.5 lbf-ft)

1

I831G1020040-01

I831G1020041-01

1

2

I831G1020042-02

(a)

1

I831G1020044-02

Maintenance and Lubrication: 0B-15

Throttle Cable Play Inspection and Adjustment

B931G20206013

Inspect throttle cable play

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Inspect and adjust the throttle cable play “a” as follows.

Throttle cable play “a”

3.0 – 5.0 mm (0.12 – 0.20 in)

1) Loosen the lock-nut (1) of the throttle cable.

2) Turn the adjuster (2) in or out until the throttle cable

play “a” (at the throttle lever) is between 3 – 5 mm

(0.12 – 0.20 in).

3) Tighten the lock-nut (1) while holding the adjuster

(2).

WARNING

!

After the adjustment is completed, check that

handlebar movement does not raise the

engine idle speed and that the throttle lever

returns smoothly and automatically.

Throttle Body Inspection

B931G20206014

Inspect throttle body

Every 1 000 km (600 miles, 3 months)

Inspect the throttle body periodically for dart or mud. If

any dirt or mud is found, clean it. Refer to “Throttle Body

Removal and Installation in Section 1D (Page 1D-8)”.

Cooling System Inspection

B931G20206015

Replace engine coolant

Every 2 years

Engine Coolant Level Inspection

1) Place the vehicle on a level ground.

2) Check the engine coolant level by observing the full

and lower lines on the engine coolant reservoir tank.

If the level is below the lower line, add engine

coolant to the full line from the engine coolant

reservoir tank filler.

Engine Coolant Change

Refer to “Engine Coolant Description in Section 1F

(Page 1F-1)”.

WARNING

!

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. If engine coolant gets into

the eyes or in contact with the skin, flush

thoroughly with plenty of water. If swallowed,

induce vomiting and call physician

immediately.

1) Remove the radiator cap lid.

2) Remove the radiator cap (1).

“a”

I831G1020026-01

1

2

I831G1020027-01

“F”

“L”

I831G1020028-01

1

I831G1020029-01

0B-16 Maintenance and Lubrication:

3) Remove the left inner fender. Refer to “Front Side

Exterior Parts Removal and Installation in Section

9D (Page 9D-6)”.

4) Remove the front under cover. Refer to “Under

Cover Removal and Installation in Section 9D

(Page 9D-12)”.

5) Place a pan below the water pump, and then drain

the engine coolant by removing the drain plug (2).

6) Flush the radiator with fresh water if necessary.

7) Tighten the drain plug (4) to the specified torque.

CAUTION

!

Replace the gasket with a new one.

Tightening torque

Engine coolant drain plug (a): 13 N·m (1.3 kgf-

m, 9.5 lbf-ft)

Pour the specified engine coolant up to the radiator

inlet.

Engine coolant capacity (including reservoir)

2 450 ml (2.6/2.2 US/lmp qt)

9) Bleed air from the cooling circuit.

10) After changing engine coolant, reinstall the removed

parts.

Air Bleeding From the Cooling Circuit

1) Place the vehicle on a level ground and set the brake

lock.

2) Pour engine coolant up to the radiator inlet.

3) Slowly swing the vehicle, right and left, to bleed the

air trapped in the cooling circuit.

4) Add engine coolant up to the radiator inlet.

5) Start up the engine and bleed air from the radiator

inlet completely.

6) Add engine coolant up to the radiator inlet.

7) Repeat the 6), 7) procedures until no air bleeds from

the thermostat connector inlet.

Close the radiator cap securely.

9) After warming up and cooling down the engine, add

the specified engine coolant until the level is

between the upper and lower lines on the engine

coolant reservoir tank.

10) Reinstall the removed parts.

Radiator Inspection

Inspect radiator

Every 1 000 km (600 miles, 3 months)

Inspect the radiator for damage and engine coolant

leakage. If any defects are found, replace it with a new

one.

2

I831G1020030-01

(a)

4

I831G1020031-02

I831G1020080-01

I831G1020032-01

I831G1020034-01

Maintenance and Lubrication: 0B-17

Radiator Hoses Inspection

Inspect radiator hoses

Every 2 000 km (1 200 miles, 6 months)

Inspect the radiator hoses for damage and engine

coolant leakage. If any defects are found, replace them

with new ones.

Drive V-belt Inspection and Replacement

B931G20206016

Inspect drive V-belt

Every 1 000 km (600 miles, 3 months)

Replace drive V-belt

Every 2 000 km (1 200 miles, 6 months)

Inspect the drive V-belt in the following procedures:

1) Remove the drive V-belt. Refer to “V-belt Type

Continuously Variable Automatic Transmission

Removal and Installation in Section 5A (Page 5A-5)”.

2) Inspect the drive V-belt for crack or other damage

and measure the width of belt if necessary. If any

abnormal point are found, replace the drive V-belt

with a new one. Refer to “V-belt Type Continuously

Variable Automatic Transmission Removal and

Installation in Section 5A (Page 5A-5)”.

3) Install the removed parts. Refer to “V-belt Type

Continuously Variable Automatic Transmission

Removal and Installation in Section 5A (Page 5A-5)”.

Drive Shaft Boots Inspection

B931G20206017

Inspect drive shaft

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Inspect the boots for wear or damage. If any defects are

found, replace them with new ones.

Front Brake System Inspection

B931G20206018

Inspect brake system

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

WARNING

!

• The brake system of this vehicle is filled

with a glycol-based brake fluid. Do not use

or mix different types of fluid such as

silicone-based and petroleum-based

fluids. 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 a long period of

time.

• Brake fluid, if it leaks, will interfere with

safe running and immediately discolor

painted surfaces. Check the brake hoses

and hose joints for cracks and oil leakage

before riding.

I831G1020033-01

I831G1020043-01

I831G1020045-02

I831G1020046-01

0B-18 Maintenance and Lubrication:

Brake Fluid Level Check

Inspect brake fluid level

Every 1 000 km (600 miles, 3 months)

1) Place the vehicle on a level ground.

2) Check the brake fluid level by observing the lower

limit lines on the brake fluid reservoir. When the

brake fluid level is below the lower limit line,

replenish with brake fluid that meets the following

specification.

BF: Brake fluid (DOT 4)

Brake Fluid Replacement

Replace brake fluid

Every 2 years

Refer to “Brake Fluid Replacement in Section 4A

(Page 4A-6)”.

Air Bleeding from Brake Fluid Circuit

Refer to “Air Bleeding from Front Brake Fluid Circuit in

Section 4A (Page 4A-5)”.

Front Brake Pads Check

The extent of front 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 new ones. Refer to “Front Brake Pad Replacement

in Section 4B (Page 4B-2)”.

CAUTION

!

Replace the brake pad as a set, otherwise

braking performance will be adversely

affected.

Front Brake Hose Inspection

Inspect brake hose

Every 2 000 km (1 200 miles, 6 months)

1) Turn the handlebars to left or right.

2) Inspect the brake hoses and hose joints for crack,

damage or brake oil leakage. If any defects are

found, replace the front brake hose with a new one.

Refer to “Front Brake Hose Removal and Installation

in Section 4A (Page 4A-7)”.

I831G1020047-01

I831G1020048-01

“A”

I831G1020082-01

I831G1020035-01

Maintenance and Lubrication: 0B-19

Front Brake Hose Replacement

Replace brake hose

Every 4 years

Refer to “Front Brake Hose Removal and Installation in

Section 4A (Page 4A-7)”.

Rear Brake Pedal / Rear Brake (Parking Brake)

Lever Inspection and Adjustment

B931G20206019

NOTE

Adjust the rear brake by adjusting the brake

pedal first and then adjust the brake lever.

Brake Pedal Height

1) Inspect the brake pedal height “a” between the pedal

top face and footrest. Adjust the brake pedal height if

necessary.

Brake pedal height “a”

12.5 – 22.5 mm (0.5 – 0.9 in)

2) Loosen the lock-nut (1).

3) Turn the adjuster (2) until the brake pedal becomes

12.5 – 22.5 mm (0.5 – 0.9 in) “a” higher from the top

of the footrest.

4) Tighten the lock-nut (1) securely.

Brake Pedal Free Travel

Inspection

Inspect and adjust the rear brake pedal free travel “a” as

follows.

Rear brake pedal free travel “a”

20 – 30 mm (0.8 – 1.2 in)

Adjustment

• Turn the adjuster nut (1) so the rear brake pedal has

20 – 30 mm (0.8 – 1.2 in) free travel at the rear brake

pedal end before pressure is felt.

• Adjust the rear brake light switch so that the brake

light will come on just before pressure is felt when the

brake pedal is depressed.

“a”

I831G1020051-02

1

2

I831G1020052-02

“a”

I831G1020053-02

1

I831G1020054-01

I831G1020090-01

0B-20 Maintenance and Lubrication:

Rear Brake (Parking Brake) Lever Play Adjustment

1) After adjusting the brake pedal, check the rear brake

lever play “a” The brake lever play “a” as measured

at the lever holder should be between 6 – 8 mm (0.2

– 0.3 in) when the lever is lightly pulled in towards

the grip. If adjustment is necessary, slacken the

cable by loosening the lock-nut (1) and screwing the

cable adjuster (2) on the brake lever holder all the

way in.

Rear brake lever play “a”

6 – 8 mm (0.2 – 0.3 in)

2) Turn the adjust nut (3) so the rear brake lever has 6

– 8 mm (0.2 – 0.3 in) play “a” at the rear brake lever

end before pressure is felt.

3) Minor adjustment can be made with the adjuster (2).

4) Tighten the lock-nut (1).

5) After adjusting the play, check that the rear wheels

roll freely without applying the brake, the

transmission in neutral and the rear wheels off the

ground. Readjust the rear brake lever if the rear

wheels could not roll freely.

Rear Brake Friction Plate Wear Limit Inspection

B931G20206020

Replace rear brake friction plate

Every 10 000 km (6 000 miles)

After adjusted rear brake pedal and rear brake lever,

inspect the rear brake friction plate wear limit.

• While fully applying the rear brake, check to see that

the extension line of the index mark “A” is within the

limit “B”. If the extension line is out of the limit “B”,

replace the friction plates with new ones. Refer to

“Rear Brake Disassembly and Assembly in Section

4C (Page 4C-3)”.

CAUTION

!

Replace the friction plate as a set, otherwise

breaking performance will be adversely

affected.

“a”

21

I831G1020093-01

3

I831G1020057-03

“a”

21

I831G1020093-01

“B”

“A”

I831G1020049-02

Maintenance and Lubrication: 0B-21

Tire Inspection

B931G20206021

Inspect tire

Every 1 000 km (600 miles, 3 months)

Tire Tread Condition

Operating the vehicle with excessively worn tires will

decrease riding stability and consequently invite a

dangerous situation. It is highly recommended to replace

a tire when the remaining depth of tire tread reaches the

following specification.

Special tool

: 09900–20805 (Tire depth gauge)

Tire tread depth “a” (Service limit)

Front: 4.0 mm (0.16 in)

Rear: 4.0 mm (0.16 in)

Tire Pressure

If the tire pressure is too high or too low, steering will be

adversely affected and tire wear increased. Therefore,

maintain the correct tire pressure for good roadability or

longer tire life will result. Cold inflation tire pressure is as

follows.

Cold inflation tire pressure

Vehicle load capacity limit

172 kg (380 lbs)

CAUTION

!

To minimize the possibility of tire damage

from over-inflation, we strongly

recommended that a manual type air pump

be used rather than a high pressure air

compressor as found in service stations.

When filling air into the tires, never exceed 70

kPa (0.7 kgf/cm2, 10 psi)

CAUTION

!

The standard tire fitted on this vehicle is an

AT25 x 8-12 for the front and a AT25 x 10-

12 for the rear. The use of tires other than

those specified may cause instability. It is

highly recommended to use the specified

tires.

Tire type

DUNLOP

• Front: DUNLOP KT411

• Rear: DUNLOP KT415

Steering System Inspection

B931G20206022

Inspect steering system

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Steering should be adjusted properly for smooth turning

of handlebars and safe running.

1) Place the vehicle on level ground.

2) Make sure the tire pressure for right and left tires in

the same and set to the proper specification.

3) Set the front wheels in the straight position.

4) Place a load of 75 kg (165 lbs) on the seat.

5) Measure the distances (“A” and “B”) between the

front wheels. Subtract the measurement of “A” from

that of “B” to find the toe-out. If the toe-out is not

within specification, adjust the tie-rod to the right or

left until the toe-out is within the specified range.

Toe-out (“B” – “A”)

Standard: 10 ± 4 mm (0.39 ± 0.16 in)

kPa kgf/cm2psi

Front 35 0.35 5.1

Rear 30 0.30 4.4

“a”

I831G1020084-01

I831G1020058-01

FWD

“A”

“B”

I831G1020059-04

0B-22 Maintenance and Lubrication:

If the toe-out is out of specification, bring it into the

specified range. Refer to “Toe Adjustment (Page 0B-

22)”.

Toe Adjustment

B931G20206023

Adjust the toe-out as follows:

1) Loosen the lock-nuts (1), (2) on each tie-rod.

CAUTION

!

• The lock-nuts (2) have left-hand threads.

• When loosening and tightening the lock-

nuts, hold the tie-rod end with a open end

wrench.

NOTE

Hold the concave part “a” of tie-rod with a

wrench.

2) Temporarily tighten the four lock-nuts.

3) Check that the distances “C” and “D” are equal, as

shown. If the distances are not equal, adjust the tie-

rod to the right or left until the toe-out is within

specification. Check the toe-out again by measuring

distances “A” and “B”.

4) If the toe-out is not within specification, repeat the

adjustment as above until the proper tor-out is

obtained and distances “C” and “D” become equal.

5) After adjustment has been made, tighten the four

lock-nuts to the specified torque.

Tightening torque

Tie-rod lock-nut (a): 45 N·m (4.5 kgf-m, 32.5 lbf-

ft)

Suspensions Inspection

B931G20206024

Inspect suspension

Every 2 000 km (1 200 miles, 6 months)

1) Support the vehicle with a jack and wooden blocks.

2) Remove the front and rear wheels.

3) Inspect the suspension arm and bearing for

scratches, wear, or damage. If any defects are

found, replace them with new ones. Refer to “Front

Shock Absorber Removal and Installation in Section

2B (Page 2B-3)”.

4) Inspect the front and rear shock absorbers for oil

leakage or damage. If any defects are found, replace

them with new ones. Refer to “Front Shock Absorber

Removal and Installation in Section 2B (Page 2B-3)”

and “Rear Shock Absorber Removal and Installation

in Section 2C (Page 2C-3)”.

2

11

“a”

“a”

FWD

I831G1020087-03

“C”

Right angle

(90

°

)

FWD

“A”

“B”

“D”

I831G1020088-04

(a)

(a)

(a)

I831G1020089-01

Maintenance and Lubrication: 0B-23

Chassis Bolt and Nut Inspection

B931G20206025

Tighten chassis bolt and nut

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Check that all chassis bolts and nuts are tightened to

their specified torque.

1 Handlebar upper clamp bolt 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)

2 Handlebar holder nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

3 Steering shaft holder bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)

4 Steering shaft lower nut 162 N⋅m (16.2 kgf-m, 117.0 lb-ft)

5 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft)

(a)

1(a)

1

I831G1020062-01

(b)

2(b)

2

(c)

3

I831G1020063-01

(d)

4

(e)

5

I831G1020064-01

6 Tie-rod lock-nut 45 N⋅m (4.5 kgf-m, 32.5 lb-ft)

7 Front suspension arm pivot nut (Upper) 60 N⋅m (6.0 kgf-m, 43.5

lb-ft)

8 Front suspension arm pivot nut (Lower) 65 N⋅m (6.5 kgf-m, 47.0

lb-ft)

9 Front hub nut 110 N⋅m (11.0 kgf-m, 79.5 lb-ft)

10 Front wheel set nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

(f)

6

I831G1020065-01

(b)

7

(g)

8

(g)

8

I831G1020060-02

(b)

10

(b)

10

(d)ޓ

9

I831G1020066-03

0B-24 Maintenance and Lubrication:

10 Rear wheel set nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

11 Rear hub nut 121 N⋅m (12.1 kgf-m, 87.5 lb-ft)

12 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft)

13 Steering knuckle end nut (Upper and Lower) 29 N⋅m (2.9 kgf-m,

21.0 lb-ft)

14 Front shock absorber mounting nut (Lower) 60 N⋅m (6.0 kgf-m,

43.5 lb-ft)

15 Front shock absorber mounting bolt (Upper) 55 N⋅m (5.5 kgf-m,

40.0 lb-ft)

(b)

10

(b)

10

(d)

11

I831G1020067-04

(f)

13

(f)

12

(f)

13

I831G1020068-04

(b)

14

(i)

15

I831G1020069-04

16 Front brake air bleeder valve 6 N⋅m (0.6 kgf-m, 4.5 lb-ft)

17 Front brake caliper mounting bolt 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)

18 Footrest bar mounting bolt (M8) 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)

19 Footrest bar mounting bolt (M10) 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)

20 Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)

21 Master cylinder mounting bolt 10 N⋅m (1.0 kgf-m, 7.0 lb-ft)

(j)

16

(a)

17

I831G1020070-03

(k)

18 (j)

19

I831G1020071-03

(c)

20

I831G1020072-03

(l)

21

(l)

21

I831G1020073-04

Maintenance and Lubrication: 0B-25

22 Rear brake pedal pivot bolt 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)

23 Rear brake case bolt 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)

24 Rear brake cam lever nut 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)

25 Rear shock absorber mounting nut (Lower) 60 N⋅m (6.0 kgf-m,

43.5 lb-ft)

26 Rear shock absorber mounting nut (Upper) 60 N⋅m (6.0 kgf-m,

43.5 lb-ft)

27 Rear suspension arm pivot nut (Upper and Lower) 60 N⋅m (6.0

kgf-m, 43.5 lb-ft)

(m)

22

I831G1020074-04

(k)

23 (k)

23

(k)

23

(k)

23

(m)

24

(k)

23

I831G1020075-05

(b)

26

(b)

27

(b)

25

I831G1020076-02

28 Rear knuckle nut 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

29 Rear stabilizer joint nut

[Up to 5SAAR41A497105526: 34 N⋅m (3.4 kgf-m, 24.5 lb-ft)]

[From 5SAAR41A497105527: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)]

30 Trailer towing mounting bolt 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)

(b)

28

I831G1020077-02

(n)

29

I831G1020078-04

(b)

30

I831G1020079-02

0B-26 Maintenance and Lubrication:

Compression Pressure Check

B931G20206026

Refer to “Compression Pressure Check in Section 1D

(Page 1D-2)”.

Oil Pressure Check

B931G20206027

Refer to “Oil Pressure Check in Section 1E (Page 1E-

2)”.

SDS Check

B931G20206028

Refer to “SDS Check in Section 1A (Page 1A-15)”.

Automatic Clutch Inspection

B931G20206029

This vehicle is equipped with a centrifugal type

automatic clutch.

To insure proper performance and longevity of the clutch

assemblies it is essential that the clutches engage

smoothly and gradually. Before checking the initial

engagement and clutch lock-up two inspection checks

must be performed to thoroughly check the operation of

the drive train.

Initial Engagement Inspection

1) Warm up the engine.

2) Connect the tachometer or the multi circuit tester

onto the spark plug high-tension cord (1).

3) Start the engine.

4) Shift the range lever to the “High” position.

5) Slowly open the throttle and note the engine speed

(r/min) when the vehicle begins to move forward.

Special tool

: 09900–26006 (Engine tachometer (solar

cell type))

: 09900–25008 (Multi-circuit tester set)

Engagement speed

1 500 – 2 000 r/min

6) Disconnect the tachometer and install the frame front

cover.

Clutch “Lock-up” Inspection

Perform this inspection to determine if the clutch is

engaging fully and not slipping.

1) Warn up the engine.

2) Connect a tachometer onto the spark plug high-

tension code.

3) Start the engine.

4) Shift the range lever to the “High” position.

5) Apply the front and rear brakes as firm as possible.

6) Fully open the throttle fully and note the maximum

engine speed sustained during the test cycle.

CAUTION

!

Do not apply full power for more than 5

seconds or damage to the clutch or engine

may occur.

Lock-up r/min

3 500 – 4 000 r/min

If the lock-up speed (r/min) does not coincide with

the standard range, inspect the following items for

any abnormalities.

Refer to “V-belt Type Continuously Variable

Automatic Transmission Removal and Installation in

Section 5A (Page 5A-5)”.

• Clutch shoe

• Clutch wheel

• Movable drive and driven face

1

I831G1020086-01

Maintenance and Lubrication: 0B-27

Specifications

Tightening Torque Specifications

B931G20207001

NOTE

The specified tightening torque is also described in the following.

“Chassis Bolt and Nut Inspection (Page 0B-23)”

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C

(Page 0C-7)”.

Special Tools and Equipment

Recommended Service Material

B931G20208001

NOTE

Required service material is also described in the following.

“Lubrication Points (Page 0B-2)”

Special Tool

B931G20208002

Fastening part Tightening torque Note

N⋅mkgf—mlbf—ft

Exhaust pipe nut 23 2.3 16.5 )(Page 0B-4)

Muffler mounting bolt 23 2.3 16.5 )(Page 0B-4)

Muffler connecting bolt 23 2.3 16.5 )(Page 0B-4)

Oil drain plug 21 2.1 15.0 )(Page 0B-11)

Oil filter 20 2.0 14.5 )(Page 0B-12)

Front differential gear oil level plug 8.5 0.85 6.0 )(Page 0B-13)

Front differential gear oil filler plug 35 3.5 25.5

)(Page 0B-13) /

)(Page 0B-13)

Front differential gear oil drain plug 32 3.2 23.0 )(Page 0B-13)

Front differential gear oil level plug 8 0.8 5.7 )(Page 0B-13)

Final gear oil drain plug 23 2.3 16.5 )(Page 0B-14)

Engine coolant drain plug 13 1.3 9.5 )(Page 0B-16)

Tie-rod lock-nut 45 4.5 32.5 )(Page 0B-22)

Material SUZUKI recommended product or Specification Note

Brake fluid DOT 4 — )(Page 0B-18)

09900–20803 09900–20805

Thickness gauge Tire depth gauge

)(Page 0B-6) )(Page 0B-21)

09900–25008 09900–26006

Multi-circuit tester set Engine tachometer (solar

cell type)

)(Page 0B-26) )(Page 0B-26)

0B-28 Maintenance and Lubrication:

09915–40610

Oil filter wrench

)(Page 0B-12) /

)(Page 0B-12)

Service Data: 0C-1

General Info rmation

Service Data

Specifications

Service Data

B931G20307001

Valve + Valve Guide

Unit: mm (in)

Camshaft + Cylinder Head

Unit: mm (in)

Item Standard Limit

Valve diam. IN. 36.0 (1.42) —

EX. 33.0 (1.30) —

Tappet clearance (When cold) IN. 0.10 – 0.20 (0.004 – 0.008) —

EX. 0.20 – 0.30 (0.008 – 0.012) —

Valve guide to valve stem clearance IN. 0.010 – 0.037 (0.0004 – 0.0015) —

EX. 0.030 – 0.057 (0.0012 – 0.0022) —

Valve guide I.D. IN. & EX. 5.500 – 5.512 (0.2165 – 0.2170) —

Valve stem O.D. IN. 5.475 – 5.490 (0.2156 – 0.2161) —

EX. 5.455 – 5.470 (0.2148 – 0.2154) —

Valve stem deflection IN. & EX. — 0.35 (0.014)

Valve stem runout IN. & EX. — 0.05 (0.002)

Valve head thickness IN. & EX. — 0.5 (0.02)

Valve seat width IN. & EX. 0.9 – 1.1 (0.035 – 0.043) —

Valve head radial runout IN. & EX. — 0.03 (0.001)