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TROUBLESHOOTING

1. Cotter pin union bolt Rear brake master cylinder 1 Clamp ends should face as shown R Rear brake hose n Insert the reservoir tank hose to ITEM N m kgf m Ibf ft O Rear brake reservoir tank the union firmly 23 2 3 16 5 hose 3 White paint faces outside before 27 2 7 19 5 Pin binding the clamp 6 0 6 4 5 Rear brake pedal After the brake hose union has D 18 1 8 13 0 Washer 4 contacted the stopper tighten the SERVICING INFORMATION 10 25 PAIR AIR SUPPLY SYSTEM HOSE ROUTING A a MIN 10 mm 0 4 in PAIR control solenoid valve The clamp end should face downward PAIR reed valve The clamp end should face left side ITEM N m kgf m Ibf ft Air cleaner box The clamp end should face upward 10 1 0 7 0 White mark 10 26 SERVICING INFORMATION FUEL TANK INSTALLATION Fuel tank Vee x Hung on projection part firmly Fuel tank center cover Clean the surface before attaching the cushion Fuel tank cover Fuel tank front cover Keep clearance 2 4 mm 0 08 0 16 in between the fuel tank and fuel tank covers Apply adhesive agent Insert the cushio
2. Front brake hose lever holder with punch mark U Front brake master cylinder 1 ino the lole ol upier Drakel Clutch lever holder 2 punch mark G Handebarholder 3 Align the matching surface of front brake master cylinder with punch mark Guide 4 Align the matching surface of clutch 10 36 SERVICING INFORMATION HEADLIGHT COVER INSTALLATION D Q gt J D Headlight lower cover Headlight side cover RH Headlight upper cover Headlight housing brace Headlight side cover LH Cushion SERVICING INFORMATION 10 37 HEADLIGHT INSTALLATION a F FNI L L Headlight unit Headlight side cover LH Q Combination meter assembly Headlight side cover RH ITEM N m kgf m Ibf ft Headlight upper cover Headlight housing brace 6 0 6 4 5 10 38 SERVICING INFORMATION FRONT TURN SIGNAL LIGHT INSTALLATION Front turn signal light RH Radiator reservoir tank Pass the front turn signal lead wire behind the front turn signal light Front turn signal light LH 1 Coupler position SERVICING INFORMATION 10 39 REAR COMBINATION LIGHT INSTALLATION Brake Tail light Cut the tip of clamp after clamping the lead wires
3. Front brake master cylinder holder bolt SERVICING INFORMATION 10 47 Front brake caliper mounting bolt Front brake caliper sliding pin A Front brake caliper sliding pin B Front brake pad mounting pin Front brake pad pin plug Brake hose union bolt Front brake lever pivot bolt Front brake lever pivot bolt lock nut Air bleeder valve Front and Rear brake caliper Brake disc bolt Front Brake disc bolt Rear Rear brake caliper mounting bolt Rear brake caliper sliding pin Rear brake pad mounting pin Rear brake pad pin plug Rear brake master cylinder mounting bolt Rear brake master cylinder rod lock nut Front footrest bracket mounting bolt Swingarm pivot nut Rear shock absorber mounting nut Upper Rear shock absorber mounting nut Lower Rear axle nut Rear sprocket nut Side stand nut Side stand bolt Frame down tube bolt nut Rear turn signal light mounting nut Front reflector bolt For P 24 Front reflex reflector For P 24 Clutch lever holder bolt Clutch lever pivot nut Bank sensor bolt Center stand nut For P 12 10 48 SERVICING INFORMATION TIGHTENING TORQUE CHART Each fastener should be tightened to the torque specified in TIGHTENING LIST If no description or speci fication is provided refer to the following tightening torque chart
4. Rear fender 1 After clamping the rear turn signal light lead wire and license plate light lead Rear frame center cover wire pass the lead wires inside the hole of the rear fender Do not slacken License plate light When installing the TO sensor do not Rear turn signal light damage the brake tail light bracket a Set the cushion of brake tail light to the ITEM N m kgf m Ibf ft eee 9 rib of the rear frame center cover 7 0 7 5 0 10 40 SERVICING INFORMATION REGULATOR RECTIFIER INSTALLATION Regulator Rectifier Clamp Pass the regulator rectifier lead wire along the frame Do not slacken Bracket ECM Clamp Install the clamp to the bracket Clamp the regulator rectifier lead wire at root of the connector SPECIAL TOOLS 09900 06107 Snap ring pliers 09900 06108 Snap ring pliers Close type 09900 18710 Hexagon socket SERVICING INFORMATION 09900 20101 Vernier calipers 150 mm 10 41 09900 20102 Vernier calipers 200 mm 09900 20202 Micrometer 25 50 mm 09900 20203 Micrometer 50 75 mm 09900 20205 Micrometer 0 25 mm 09900 20530 Cylinder gauge set 09900 20602 Dial gauge 09900 20605 Dial calipers 10 34 mm 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 20803 Thi
5. Drive chain Type DID520VF Links 116 links 20 pitch length Drive chain slack Gearshift lever height 10 54 SERVICING INFORMATION THERMOSTAT RADIATOR FAN COOLANT ITEM STANDARD SPECIFICATION Thermostat valve opening temper ature Approx 88 C 190 F Thermostat valve lift 4 5 mm 0 18 in and over at 100 C 212 F ECT sensor resistance 20 C 68 F Approx 2 45 KQ 50 C 122 F Approx 0 811 KQ 80 C 176 F Approx 0 318 KQ 110 C 230 F Approx 0 142 kQ Radiator cap valve opening pres sure 93 123 kPa 0 93 1 23 kgf cm2 13 2 17 5 psi Cooling fan operating temperature OFF gt ON Approx 105 C 221 F ON OFF Approx 100 C 212 F Engine coolant type Use an antifreeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant INJECTOR FUEL PUMP ITEM Reserve Approx 250 ml tank side 0 3 0 2 US Imp qt Engine Approx 1 100 ml side 1 2 1 0 US Imp qt FUEL PRESSURE REGULATOR STANDARD Injector resistance 11 5 12 5 Q at 20 C 68 F Fuel pump discharge amount 97 2 ml 3 3 3 4 US Imp oz or more 10 sec Fuel pressure regulator operating set pressure Approx 300 kPa 3 0 kgf cm 43 psi FI SENSORS ITEM SERVICING INFORMATION 10
6. CRANK BALANCER ITEM STANDARD Crank balancer journal oil clear ance 0 020 0 044 0 0008 0 0017 Crank balancer journal O D 27 976 28 000 1 0660 1 1024 Balancer spring free length OIL PUMP ITEM STANDARD Oil pressure at 60 C 140 F 200 500 kPa 2 5 kgf cm2 28 71 psi at 3 000 r min CLUTCH ITEM SERVICING INFORMATION STANDARD SPECIFICATION 10 53 Unit mm in Clutch cable play 10 15 0 39 0 59 Clutch release screw 1 turn counterclockwise Drive plate thickness No 1 and 2 2 92 3 08 0 115 0 121 No 3 3 42 3 58 0 135 0 141 Drive plate claw width No 1 and 2 15 9 16 0 0 626 0 630 No 3 15 98 16 05 0 629 0 632 Driven plate distortion No 1 2 and 3 Clutch spring free length TRANSMISSION DRIVE ITEM CHAIN 38 5 1 528 STANDARD Unit m Primary reduction ratio 3 238 68 21 Final reduction ratio 3 286 46 14 Gear ratios Low 2 417 29 12 2nd 1 529 26 17 3rd 4th 1 043 24 23 5th 1 182 26 22 0 909 20 22 Top 0 808 21 26 Shift fork to groove clearance 0 10 0 30 0 004 0 012 Shift fork groove width 0 5 1 0 197 0 201 Shift fork thickness 4 8 4 9 0 189 0 193
7. 0 008 0 013 0 020 0 20 0 32 0 50 0 008 0 013 0 020 Piston ring to groove clearance _ 0 180 0 0071 0 150 0 0059 Piston ring free end gap Piston ring groove width 1 01 1 03 0 0398 0 0406 1 01 1 03 0 0398 0 0406 2 01 2 03 0 0791 0 0799 Piston ring thickness 0 97 0 99 0 0382 0 0390 0 97 0 99 0 0382 0 0390 Piston pin bore 15 002 15 008 0 5906 0 5909 Piston pin O D 14 996 15 000 0 5904 0 5906 10 52 SERVICING INFORMATION CONROD CRANKSHAFT ITEM STANDARD Unit mm in Conrod small end I D 15 006 15 014 0 5908 0 5911 Conrod big end side clearance 0 10 0 20 0 004 0 008 Conrod big end width 19 95 20 00 0 7854 0 7874 Crank pin width 20 10 20 15 0 7913 0 7933 Conrod big end oil clearance 0 032 0 056 0 0013 0 0022 Crank pin O D 30 976 31 000 1 2195 1 2205 Crankshaft journal oil clearance 0 016 0 040 0 0006 0 0016 Crankshaft journal O D 29 976 30 000 1 1802 1 1811 Crankshaft thrust bearing thickness Right side 2 450 2 625 0 0965 0 1033 Left side 2 450 2 475 0 0965 0 0974 Crankshaft thrust clearance 0 050 0 105 0 0020 0 0041 Crankshaft runout
8. Replace the battery Generator over charges Internal short circuit in the battery Damaged or defective regulator rectifier Poorly grounded regulator rectifier Replace the battery Replace Clean and tighten ground connection Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent short circuiting Internally shorted generator Defective regulator rectifier Repair or replace Replace Replace Starter button is not effective Run down battery Defective switch contacts Brushes not seating properly on starter motor commutator Defective starter relay starter interlock switch Defective main fuse Repair or replace Replace Repair or replace Replace Replace BATTERY Complaint Symptom and possible causes SERVICING INFORMATION 10 13 Remedy Sulfation acidic white powdery sub stance or spots on surface of cell plates Cracked battery case Battery has been left in a run down condition for a long time Replace the battery Replace the battery Battery runs down quickly Trouble in the charging system Cell plates have lost much of their active material as a result of overcharging Internal short circuit in the battery Too low battery voltage Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to obtain specifie
9. Defective ECM Defective ECT sensor Clogged water passage Air trapped in the cooling circuit Defective water pump Use incorrect coolant Defective thermostat Damaged ISC valve ISC bad learning Add coolant Clean Repair or replace Repair or replace Replace Replace Clean Bleed air Replace Replace Replace Replace Reset learned value Engine overcools Defective ECT sensor Extremely cold weather Defective thermostat Defective cooling fan relay or open or short circuited Defective ECM Replace Put on the radiator cover Replace Repair or replace Replace 10 10 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering Overtightened steering stem nut Broken bearing in steering stem Distorted steering stem Not enough pressure in tires Adjust Replace Replace Adjust Wobbly handlebars Loss of balance between right and left front forks Distorted front fork Distorted front axle or crooked tire Loose steering stem nut Worn or incorrect tire or wrong tire pressure Worn bearing race in steering stem Adjust Repair or replace Replace Adjust Adjust or replace Replace Wobbly front wheel Distorted wheel rim Worn front wheel bearings Defective or incorrect tire Loose axle or axle pinch bolt Incorrect front fork oil level In
10. Replace Replace Replace Replace Check and repair Adjust Replace Replace Replace Replace Replace Replace Replace Replace Repair or replace 10 4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly Valve clearance out of adjustment Poor seating of valves Defective valve guides Worn down camshaft Too wide spark plug gaps Defective ignition coils Defective CKP sensor Defective ECM Defective TP sensor Defective fuel pump Imbalanced throttle valve Damaged or cracked vacuum hose Damaged or clogged ISC valve ISC bad learning ONOOR WD Adjust Replace or repair Replace Replace Adjust or replace Replace Replace Replace Replace Replace Adjust Replace Replace or repair Reset learned value Engine stalls often Incorrect fuel air mixture 1 Defective IAP sensor or circuit Clogged fuel filter Defective fuel pump Defective fuel pressure regulator Defective ECT sensor Defective thermostat Defective IAT sensor Damaged or cracked vacuum hose 9 Damaged or clogged ISC valve Fuel injector improperly operating 1 Defective fuel injectors 2 No injection signal from ECM 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating Defective ECM Defective fuel pressure regulator Defective TP sensor D
11. SF j ES Ln Ea I OORS 5 xe WF ooN ve i M O S G Ze Q Ss et om INGE VIEW B Pass the IAP sensor hose 1 between the fuel feed hose 2 Clamp end should face left side Washer 1 White mark 3 A U L L a N oll A Cay S j J N V Le YA S INTAKE SYSTEM HOSE ROUTING 10 18 SERVICING INFORMATION K G a okk S o 5 OF a sl D g 2 a S z ololol J2 L o c Cc o o s gt olol 2j 2 Q S lall 2 IS Z l o oe gt Isg 3 fs 1991 E O Iz OINO O SERVICING INFORMATION 10 19 FUEL TANK DRAIN HOSE ROUTING 8 t mp 95 mm 3 74 in 70 mm 2 76 in Fuel tank water drain hose Pass the hoses to the forward of frame Connect the reservoir tank overflow hose to the narrow side of 3 way joint Pass the fuel tank breather hose No 2 to left side of the fuel tank water drain hose Fuel tank breather hose No 3 Align the white making on the hoses with the clamp 3 way joint Match the direction of 3 way joint and hoses Reservoir tank overflow hose White marking Set the fuel tank water drain hose and fuel tank breather hose No 1 with lengthwise To fuel tank back
12. burnt big end bearings 3 Worn and burnt journal bearings 4 Too large thrust clearance Noise seems to come from balancer 1 Worn and burnt journal bearings Noise seems to come from transmission 1 Worn or rubbing gears 2 Worn splines 3 Worn or rubbing primary gears 4 Worn bearings Noise seems to come from water pump 1 Too much play on pump shaft 2 Worn or damaged impeller shaft 3 Worn or damaged mechanical seal 4 Contact between pump case and impeller Adjust Replace Replace Replace Replace Clean Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace thrust bearing Replace Replace Replace Replace Replace Replace Replace Replace Replace 10 6 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 Worn camshaft Replace Valve timing out of adjustment Adjust Too narrow spark plug gaps Adjust Ignition not advanced sufficiently due to poorly Replace ECM working timing advance circuit Defective ignition coils Replace Defective CKP sensor Replace Defective ECM Replace Clogged air cleaner element Clean or replace Clogged fuel hose resulting in inadequate fuel Clean and prime supply to injector 11 Defective fuel pump Replace 12 Defective TP
13. cylinders Replace Worn valve guides Replace Scored or scuffed cylinder walls Replace Worn valves stems Replace Defective stem oil seal Replace Worn oil ring side rails Replace Weakened clutch springs Replace Worn or distorted pressure plate Replace Distorted clutch plates Replace Clutch release screw out of adjustment Adjust Some clutch spring weakened while others Replace are not Distorted pressure plate or clutch plates Replace Clutch release screw out of adjustment Adjust Broken gearshift cam Replace Distorted gearshift forks Replace Worn gearshift pawl Replace Broken return spring on shift shaft Replace Rubbing or stickily shift shaft Repair or replace Distorted or worn gearshift forks Replace Worn shifting gears on driveshaft or Replace Slipping clutch V N N aOR WD Dragging clutch Transmission will not shift Transmission will not shift back N O N KIG N Transmission jumps out of gear countershaft Distorted or worn gearshift forks Replace Weakened stopper spring on gearshift stopper Replace Worn gearshift cam stopper plate Replace RADIATOR COOLING SYSTEM Complaint Symptom and possible causes SERVICING INFORMATION 10 9 Remedy Engine overheats Not enough engine coolant Radiator core clogged with dirt or scale Faulty cooling fan Defective cooling fan relay or open or short circuited
14. switch Face the lock part of clamp backward Cut the tip of clamp after clamping Left and right handlebar switch coupler _ Pass the left handlebar switch lead wire to inside of the throttle cables Set the rear brake light switch lead wire to front side of the motorcycle Pass the generator lead wire the under bridge tube 10 16 SERVICING INFORMATION Route the generator lead wire between the crankcase and starter motor and pass it over 5 10 Nm the crankcase 1 0 kgf m 7 0 Ibf ft Gear position switch lead wire Do not pinch the lead wires Pass the starter motor _ lead wire under the frame J Pass the speed sensor lead wire and side stand switch lead wire under the clutch release camshaft retainer Clutch release camshaft retainer Q 27N m 0 27 kgf m 2 0 Ibf ft a i IR 4 5 N r 5 Nem Starter pa we 0 45 rn RIS Starter L motor N molor 3 25 Ibf ft lead wire Speed sensor Si NS Pa a VIEW B 0 5 5 N m 0 55 kgf m 4 0 Ibf ft 13 0 kgf m 94 0 Ibf ft 5 6 5 N m Gear position switch 0 65 kgf m 4 5 Ibf ft S 13 N m Grommet WVO 1 3 kgf m 9 5 Ibf ft Gear position switch S lead wire CKP sensor L t p e e 3 Do not contact t
15. 0 31 FRAME COVER INSTALLATION Frame upper cover LH Frame head cover RH Frame upper cover RH Rear fender Frame upper cover CENTER Pillion rider handle Frame front cover LH To footrest bracket Frame front cover RH To air cleaner box Frame cover LH To frame Frame cover RH To fuel tank Frame head cover LH To fuel tank cover 10 32 SERVICING INFORMATION FRAME INSTALLATION SIMI 7 Frame down tube RIT ITEM N m kgf m Ibf ft Frame A 60 6 0 43 5 Engine mounting bracket 50 5 0 36 0 SIDE STAND INSTALLATION SERVICING INFORMATION 10 33 CENTER STAND INSTALLATION For P 12 T smu SED il T Center stand Center stand cushion RIT ITEM N m kgf m Ibf ft Center stand spring Ponot apply grease tothe 60 6 0 43 5 flange and thread part 10 34 SERVICING INFORMATION REAR BRAKE PEDAL INSTALLATION 38 48 mm 1 50 1 89 in 25 mm 0 98 in D Rear brake master cylinder Circlip Brake pedal Footrest bracket ITEM N m kgf m Ibf ft Brake pedal spring Washer A 10 1 0 7 0 OO 18 1 8 13 0 Brake switch spring Measuring position Brake switch S O O O HANDLEBARS INSTALLATION Set the boss of handlebar holder SERVICING INFORMATION 10 35
16. 55 STANDARD NOTE CKP sensor resistance 150 230 Q CKP sensor peak voltage 1 5 V or more When cranking IAP sensor input voltage 4 5 5 5 V IAP sensor output voltage Approx 2 6 V at idle speed TP sensor input voltage 4 5 5 5V TP sensor output voltage Closed Approx 1 1 V Opened Approx 4 4 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance Approx 2 45 KQ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor resistance Approx 2 45 KQ at 20 C 68 F TO sensor resistance 25 0 26 0 kQ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4 V When leaning 65 GP switch voltage 0 6 V or more From 1st to Top GP switch resistance Approx 500 Q or more Injector voltage Battery voltage Ignition coil primary peak voltage 80 V or more When cranking HO2 sensor output voltage 0 4 V or less at idle speed 0 6 V or more at 5 000 r min HO2 sensor heater resistance 6 7 9 5 Q at 23 C 73 F PAIR control solenoid valve resistance 18 22 Q at 20 C 68 F EVAP purge control solenoid valve resistance Approx 32 Q at 20 30 C 68 86 F ISC valve resistance THROTTLE BODY Approx 20 Q at 20 C 68 F STANDARD SPECIFICATION Bore size 26 mm 1 02 in LD No 48H1 Idle
17. Generator cover plug Clutch cover bolt Clutch sleeve hub nut Clutch release adjuster lock nut Clutch cable adjuster lock nut Valve timing inspection plug Starter clutch bolt Generator cover bolt Generator rotor bolt Generator stator set bolt Gearshift cam stopper bolt Gearshift cam stopper plate bolt ITEM SERVICING INFORMATION kgf m Ibf ft 10 45 Shift cam bearing retainer screw 1 0 7 0 Oil pressure switch 1 3 9 5 Oil filter 2 0 14 5 Oil pressure switch lead wire bolt 0 15 1 0 Gearshift arm stopper 1 9 13 5 Gearshift fork shaft plug 2 5 18 0 Oil pressure regulator 2 8 20 0 Oil filter union bolt 1 5 11 0 Oil separator plate bolt 1 0 7 0 Engine sprocket cover bolt 1 0 7 0 Ignition coil nut 0 65 4 5 Gearshift lever shaft 4 0 Gearshift link arm bolt 1 0 7 0 Crankshaft journal bolt Initial 1 5 M 8 Final 2 6 Crankcase bolt M 6 1 1 M 8 2 6 Oil gallery plug Cylinder head 1 0 Lower crankcase 2 5 Oil drain plug 2 3 Oil pump mounting bolt 1 0 Conrod cap bolt Initial 1 5 Final 90 1 4 turn Breather cover bolt 1 0 Oil strainer bolt 1 0 Oil pan bolt 1 0 Starter motor mounting bolt 1 0 Starte
18. ICATION Unit mm in LIMIT Front fork stroke 120 4 72 Front fork spring free length 275 9 10 86 270 10 6 Front fork oil level without spring outer tube fully compressed 136 5 4 Front fork oil type SUZUKI FORK OIL G10 or equivalent Front fork oil capacity each leg 338 ml 11 4 11 9 US Imp oz Front fork inner tube O D 37 1 46 Rear shock absorber spring adjuster 3rd position Rear wheel travel 120 4 7 Swingarm pivot shaft runout FUEL OIL SPECIFICATION Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity Including 13 3L reserve 3 5 2 9 US Imp gal Fuel mark indi 9 3L indicator blinking 2 4 2 0 US Imp gal Engine oil type SAE 10W 40 API SG or higher with JASO MA Engine oil capacity 2 1L Change 2 2 1 8 US Imp qt l 2 4L Filter change 2 5 2 1 US Imp qt 2 4L Overhaul 2 5 2 1 US Imp qt
19. TROUBLESHOOTING FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION 4 27 to 29 ENGINE Complaint Symptom and possible causes SERVICING INFORMATION 10 3 Remedy Engine will not start or is hard to start Compression too low Valve clearance out of adjustment Worn valve guides or poor seating of valves Mistiming valves Excessively worn piston rings Worn down cylinder bores Too slowly starter motor cranks Poor seating of spark plugs Plug not sparking 1 Fouled spark plugs Wet spark plugs Defective ignition coils Defective CKP sensor Defective ECM Open circuited wiring connections Open or short in high tension cords No fuel reaching the intake manifold Clogged fuel filter or fuel hose Defective fuel pump Defective fuel pressure regulator Defective fuel injector Defective fuel pump relay Defective ECM Open circuited wiring connections Incorrect fuel air mixture 1 k MONOARAN TP sensor out of adjustment Defective fuel pump Defective fuel pressure regulator Defective TP sensor Defective CKP sensor Defective IAP sensor Defective ECM Defective ECT sensor Defective IAT sensor Clogged ISC valve air passage way Adjust Repair or replace Adjust Replace Replace See electrical section Retighten Clean Clean and dry Replace Replace Replace Repair or replace Replace Clean or replace Replace
20. ark The clamp screw head should face left diagonal backward White mark The clamp screw head should face SSS left side Connect the 3 way joint under the The clamp air cleaner box screw head should face backward The clamp screw head should face forward KS N The clamp screw head water drain hose should face backward Fuel tank Z water drain hose U R gt White mark i Front side When clamping the fuel tank water drain hose clamp the fuel tank water drain hose in this order D gt gt 10 22 SERVICING INFORMATION IGNITION COIL INSTALLATION Ignition coil 1 Pass the high tension cord behind the throt Ignition coil 2 tle cable guide ITEM N m kgf m Ibf ft Spark plug cap Pass the high tension cord under the fuel 6 5 0 65 4 5 High tension cord hose Clamp SERVICING INFORMATION 10 23 FRONT BRAKE HOSE ROUTING VIEW A GA Ce IRS Vc N LA LS H Q Brake hose After the brake hose union has N 1 Pass the brake hose as shown 3 contacted the stopper tighten the ITEM N m kgf m Ibf ft 2 Clamp the brake hose firmly union bolt 23 2 3 16 5 10 24 SERVICING INFORMATION REAR BRAKE HOSE ROUTING
21. auge adapter 09940 40220 09940 52861 09941 54911 Fuel pressure Front fork oil seal 09940 92720 09941 34513 Bearing outer race gauge attachment installer set Spring scale Bearing installer remover 09941 74911 09943 74111 Steering race Front fork oil level 99565 01010 028 installer gauge CD ROM Ver 28 Torx is the registered trademark of Camcar Division of Textron inc U S A NOTE When order the special tool please confirm whether it is available or not 10 44 SERVICING INFORMATION TIGHTENING TORQUE ENGINE Cylinder head cover bolt Initial Final Cylinder head bolt Cylinder head cover cap bolt Cylinder side bolt Primary drive gear nut Exhaust pipe bolt Exhaust connecting bolt Muffler support bolt Muffler chamber support bolt Muffler front cover screw Muffler rear cover stay bolt Muffler rear cover bolt Muffler body cover screw Speed sensor rotor bolt Speed sensor bolt Speed sensor bracket bolt Engine sprocket nut Engine mounting nut Engine mounting bracket nut Crank balancer bolt Valve clearance adjuster lock nut Camshaft sprocket bolt Spark plug Throttle cable nut Camshaft journal holder bolt Cam chain tension adjuster cap bolt Cam chain tension adjuster mounting bolt Cam chain tensioner bolt PAIR reed valve cover bolt
22. ckness gauge 09900 20805 Tire depth gauge 09900 21304 09900 22301 Plastigage 0 025 0 076 mm 09900 22302 Plastigage 0 051 0 152 mm 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set Needle point probe set 09904 41010 SUZUKI Diagnostic system set 09910 60611 Universal clamp wrench 09913 10750 Compression gauge adapter 09913 50121 Oil seal remover 10 42 SERVICING INFORMATION 09915 40620 Oil filter wrench 09915 64512 Compression 09915 72410 Oil pressure gauge attachment 09915 74521 Adapter hose potty 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezer 09917 47011 Vacuum pump gauge set 09920 53740 Clutch sleeve hub holder 09921 20210 Bearing remover 12 mm 09921 20240 Bearing remover 09923 73210 Bearing remover 09923 74511 Bearing remover 09924 84510 Bearing installer set 09925 18011 Bearing installer 09930 10121 Spark plug wrench set 09930 30104 Rotor remover sliding shaft Co 09930 31921 Rotor remover set 09930 40113 Flywheel rotor holder 09930 44521 Rotor holder SERVICING INFORMATION 10 43 09930 82720 09940 14911 09940 34581 09940 40211 Mode selection Steering stem nut 09940 34520 Front fork assembling Fuel pressure switch socket wrench T type handle attachment F g
23. correct front wheel weight balance Replace Replace Replace Retighten Adjust Adjust Front suspension too soft Weakened springs Not enough fork oil Wrong weight fork oil Replace Replenish Replace Front suspension too stiff Too viscous fork oil Too much fork oil Bent front axle Replace Drain excess oil Replace Noisy front suspen sion Not enough fork oil Loose bolts on suspension Replenish Retighten Wobbly rear wheel Distorted wheel rim Worn rear wheel bearings or swingarm bearings Defective or incorrect tire Worn rear suspension bearings Loose nuts or bolts on rear suspension Loose rear axle nut Incorrect rear wheel weight balance Replace Replace Replace Replace Retighten Retighten Adjust Rear suspension too soft Weakened spring of shock absorber Leakage of oil from shock absorber Improperly rear suspension setting Replace Replace Adjust Rear suspension too stiff Bent shock absorber shaft Bent swingarm pivot shaft Worn swingarm and rear suspension bearings Improperly rear suspension setting Replace Replace Replace Adjust Noisy rear suspen sion Loose nuts or bolts on rear suspension Worn swingarm and suspension bearings Retighten Replace BRAKES Complaint Symptom and possible causes SERVICING INFORMATION 10 11 Remedy Insufficient brake
24. d charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Battery sulfation Incorrect charging rate When not in use batteries should be checked at least once a month to avoid sulfation The battery was left unused in a cold climate for too long Replace the battery Replace the battery if badly sulfated 10 14 SERVICING INFORMATION WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Pass the left handlebar switch lead wire to inside of the clutch cable Insert the front brake switch terminal firmly Fix the cover of the front brake switch terminal firmly Pass the left handlebar switch lead wire behind the right handlebar switch lead wire Oil pressure switch p Face the lock part of A e clamp inside Pass the HO2 sensor lead wire to left side of the oil filter ISC valve EA Ry Z S r_ IAP sensor 1 ESP Wiring harness IAP sensor 2 y E Injector 2 HEFL Fixed clamp Fixed clamp Injector 1 Clamp Right handlebar switch Brake hose Cooling fan motor coupler Fixed camp Fuse box ECM Clamp TO sensor Ignition switch d m N S Pass the left handlebar switch lead wire into the cabl
25. e guide Left handlebar switch Clutch cable Turn signal relay Batter terminal PAIR control S y S a Clamp solenoid valve Battery terminal cap SERVICING INFORMATION 10 15 Regulator rectifier Speed sensor Side stand switch Clamp the protector upper of the cable guide Clamp Face the lock part of clamp left side HO2 sensor Wiring harness White tape point Clamp Clamp Regulator rectifier Speed sensor Generator Side stand switch Oil pressure switch BRE GE _HO2 sensor ees Ni a vou M N i r Pass the Oil pressure switch SN ERS lead wire and HO2 sensor lead P sensor R J Starter relay cap wire into the bracket U 5 A o l Clamp 17 EA I Starter relay terminal Oil pressure switch HO2 sensor ae cot gs EIN dr Zs Pass the HO2 sensor lead wire in front of the frame lt A Starter relay Oil pressure switch lead wire Clamp the wiring harness at white tape position Clamp Wiring harness Clamp l Wiring harness Ground lead wire Clamp Gear position switch Ground lead wire Fixed clamp Battery coupler AS ON S L Rear brake light sso lt switch coupler Pass the lead wire outside of frame Clamp Cooling fan motor Regulator rectifier Side stand
26. efective ECM Defective TO sensor Open circuited wiring connections Replace Replace Replace Replace Replace Check and repair Spark plug soon become fouled with carbon Mixture too rich Excessively high idling speed Incorrect gasoline Dirty air cleaner element Too cold spark plugs Inspect Fl system Inspect Fl system Change Replace Replace with hot type plug Spark plug become fouled too soon ON H A E GM i Qn E GM D Worn piston rings Worn piston or cylinders Excessive clearance of valve stems in valve guides Worn stem oil seal Replace Replace Replace Replace Spark plug elec trodes overheat or burn P Too hot spark plugs Overheated the engine Loose spark plugs Too lean mixture Replace with cold type plugs Tune up Retighten Inspect Fl system Generator does not charge Open or short circuited lead wires or loose lead connections Short circuited grounded or open generator coil Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge but charg ing rate is below the specification Lead wires tend to get shorted or open circuited or loosely connected at terminals Grounded or open circuited generator coil Defective regulator rectifier Defective cell plates in the battery Repair or retighten Replace Replace
27. efective IAT sensor Defective CKP sensor Defective ECT sensor Defective fuel pump relay Defective ISC valve ISC bad learning e OL PNM o Engine internal parts improperly operating Fouled spark plugs 2 Defective CKP sensor or ECM 3 Clogged fuel hose 4 Out of adjustment valve clearance Repair or replace Clean or replace Replace Replace Replace Replace Replace Replace Replace or repair Replace Repair or replace Repair or replace Replace or recharge Replace Replace Replace Replace Replace Replace Replace Replace Reset learned value Clean Replace Clean Adjust Complaint Symptom and possible causes SERVICING INFORMATION 10 5 Noisy engine Excessive valve chatter 1 Too large valve clearance 2 Weakened or broken valve springs 3 Worn rocker arm or cam surface 4 Worn and burnt camshaft journal Noise seems to come from piston 1 Worn down pistons or cylinders 2 Carbon combustion chambers fouled with carbon 3 Worn piston pins or piston pin bore 4 Worn piston rings or ring grooves Noise seems to come from timing chain 1 Stretched chain 2 Worn sprockets 3 Tension adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of clutch plates 3 Distorted clutch plates driven and drive 4 Worn clutch release bearing Noise seems to come from crankshaft 1 Rattling bearings due to wear 2 Worn and
28. for the applicable torque for each fastener Thread diameter Nominal diameter mm rene 5 6 8 10 12 14 16 A equivalent of 4T strength fastener without flange 3 0 55 13 29 45 65 105 0 3 1 3 29 4 5 6 5 10 5 2 0 9 5 76 0 A equivalent of 4T strength fastener with flange 3 3 14 116 1 4 S 11 6 A equivalent of 7T strength fastener without flange and small crown shape bolt 1 A equivalent of 7T strength fastener with flange except small crown shape bolt 1 Small crown shape bolt crown shape bolt with flange either A 5 amp 7 or 6 amp 8 SERVICE DATA VALVE GUIDE SERVICING INFORMATION STANDARD 10 49 Unit mm in Valve diam 27 0 1 06 22 5 0 89 Valve clearance when cold 0 05 0 10 0 002 0 004 0 17 0 22 0 007 0 009 Valve guide to valve stem clearance 0 010 0 037 0 0004 0 0015 0 030 0 057 0 0012 0 0022 Valve guide I D 5 000 5 012 0 1969 0 1973 Valve stem O D 4 975 4 990 0 1959 0 1965 4 955 4 970 0 1951 0 1957 Valve stem deflection Valve stem runout Valve head thickness Valve stem end length Valve seat width Valve head radial runout Valve spring free length IN amp EX Valve s
29. he clamp to the crankcase 5 11 N m 1 1 kgf m 8 0 Ibf ft Do not pinch CKP sensor the lead wire Do not slacken Do at this area Q 1 5 Ne m 0 15 kgf m 1 0 Ibf ft i MA Lead wire Generator cover SERVICING INFORMATION 10 17 CABLE ROUTING Throttle cable No 1 Left handlebar switch 7 3 mm 0 12 in Throttle cable No 2 Frame Pass the clutch cable Pass the throttle cables over the water bypass 8 into the clutch cable Clutch cable 1 ioan guie S the throttl les to the right si fh Cable guide 9 Pass e throttle cables to the right side of head pipe Water bypass hose 3 Pass the clutch cable to the left side of head pipe Clutch cable guide 4 7 mm 0 28 in ITEM N m kgf m Ibf ft Bracket 5 Within 1 turn counterclockwise 4 5 0 45 3 5 Right frame head _ Make sure the clutch cable is not contacted to the 6 cover water hose and cylinder head cover cap lL G Srs E x TE WA i TP epp We BN ae o o I I 0 Y 2 Ni a WZ
30. n to the bracket firmly SERVICING INFORMATION 10 27 MUFFLER amp EXHAUST PIPE INSTALLATION 4 6 mm 0 16 0 24 i al S _ AL VIEW A 3 5 mm 0 12 0 20 in VIEW C HO2 sensor The chamfer side of connector face the muffler Muffler side Rear muffler cover 3 Contact the connector to the stopper Connector Install the connector to the exhaust pipe Exhaust pipe and then install the muffler Apply muffler seal SI EIS MI Z 10 28 SERVICING INFORMATION SEAT LOCK CABLE ROUTING Seat lock cable The tip of the cable is cylindrical shaped Clamp The tip of the cable is spherical shaped Flame Set the cable firmly The lock part of clamp over the frame Align the lib of seat lock assembly and groove of each parts SERVICING INFORMATION 10 29 FRONT FENDER INSTALLATION Front fender Washer RH only Front stabilizer 1 The embossed lettering of the front stabilizer must face lower side FRONT LICENSE PLATE INSTALLATION Only for P 12 Frent icense plate 10 30 SERVICING INFORMATION FRONT SIDE REFLEX REFLECTOR INSTALLATION Only for P 24 Reflex reflector Washer RIT ITEM N m kgf m Ibf ft Reflector bolt Front fork A 45 0 45 3 5 1 8 0 18 1 5 SERVICING INFORMATION 1
31. power Leakage of brake fluid from hydraulic system Worn pads Friction surfaces of pad are dirty oil or dust Worn disc Air in hydraulic system Not enough brake fluid in the reservoir Repair or replace Replace Clean disc pads or replace Replace Bleed air Replenish Brake squeaking Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Loosen front wheel axle or rear wheel axle Worn pads Foreign material in brake fluid Clogged return port of master cylinder Repair surface with sandpaper Correct pad fitting or replace Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Excessive brake lever stroke Air in hydraulic system Insufficient brake fluid Improper quality of brake fluid Bleed air Replenish fluid to specified level bleed air Replace with correct fluid Leakage of brake fluid Insufficient tightening of connection joints Cracked hose Worn piston and or cup Tighten to specified torque Replace Replace piston and or cup Brake drags Rusty part Insufficient brake lever or brake pedal pivot lubrication Clean and lubricate Lubricate 10 12 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes No sparking or poor sparking Defective ignition coils Defective spark plugs Defective CKP sensor D
32. pring tension IN amp EX 58 2 71 2 N 6 0 7 3 kgf 13 2 16 1 Ibs at length 28 0 mm 1 10 in 158 7 182 5 N 16 2 18 6 kgf 35 7 41 0 Ibs at length 31 5 mm 1 24 in 10 50 SERVICING INFORMATION CAMSHAFT CYLINDER HEAD STANDARD Unit mm in Cam height 33 34 33 38 1 313 1 314 33 05 33 09 1 301 1 303 Camshaft journal oil clearance 0 032 0 066 0 0013 0 0026 Camshaft journal holder I D 22 012 22 025 0 8666 0 8671 Camshaft journal O D 21 959 21 980 0 8645 0 8654 Camshaft runout Rocker arm I D 12 003 12 018 0 4726 0 4731 Rocker arm shaft O D 11 986 11 994 0 4719 0 4722 Cylinder head distortion SERVICING INFORMATION 10 51 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 300 1 700 kPa 1 000 kPa 13 17 kgf cm2 185 242 psi 10 kgf cm 142 psi Compression pressure difference E 200 kPa 2 kgf cm 28 psi Piston to cylinder clearance 0 04 0 05 0 120 0 001 0 002 0 0047 Cylinder bore 53 500 53 515 53 590 2 1063 2 1069 2 1098 Piston diam 53 455 53 470 2 1045 2 1051 2016 Measure at 10 mm 0 4 in from the skirt end j Cylinder distortion 0 10 0 004 Approx 5 3 0 21 0 17 Approx 4 6 0 18 614 Piston ring end gap 0 20 0 32 0 50
33. r min 1 400 100 r min Throttle cable play 2 0 4 0 mm 0 08 0 16 in 10 56 SERVICING INFORMATION ELECTRICAL STANDARD SPECIFICATION Unit mm in Firing order 1 2 Spark plug NGK CR7E DENSO U22ESR N 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 150 230 Q CKP sensor peak voltage 1 5 V or more Ignition coil resistance Primary 3 4 4 6 Q Terminal Terminal Secondary 11 05 14 95 KQ Plug cap Terminal Ignition coil primary peak voltage 80 V or more Generator coil resistance 0 2 0 9Q Generator no load voltage When engine is cold 60 V AC or more at 5 000 r min Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Regulated voltage 14 0 15 5 V at 5 000 r min Starter relay resistance 3 6 GP switch voltage 0 6 V or more From 1st to Top Battery Type designation YTX9 BS Capacity 12 V 28 8 kC 8 Ah 10 HR Fuse size Headlight 15A Signal 10 A Ignition 10A Fuel 10A Main WATTAGE 30 A SPECIFICATION Unit W Headlight 60 55 Position Brake Tail light Turn signal light License plate light Combination meter light Turn signal indicator light High beam indicator light Neutral indica
34. r motor lead wire bolt 0 27 Headlight mounting screw 0 6 10 46 SERVICING INFORMATION FI SYSTEM AND INTAKE AIR SYSTEM GP switch mounting bolt CKP sensor mounting bolt Fuel delivery pipe mounting screw Fuel pump mounting bolt HO2 sensor EVAP canister bracket mounting bolt EVAP canister holder screw EVAP system purge control solenoid valve mounting nut Air cleaner upper mounting bolt Air cleaner lower mounting bolt COOLING SYSTEM Impeller securing bolt Water pump cover screw Water pump mounting bolt Water pump air bleeder bolt Water jacket plug Cooling fan motor assembly mounting bolt Cooling fan mounting nut ECT sensor Cooling fan motor mounting screw Radiator assembly mounting bolt Reservoir tank mounting bolt Reservoir tank bracket mounting bolt Cylinder head water outlet pipe bolt Water hose clamp screw Thermostat connector cap bolt CHASSIS N m kgf m Ibf ft Steering stem head nut 65 6 5 47 0 Steering stem nut 23 N m 2 3 kgf m 16 5 Ibf ft then turn counterclockwise 0 1 4 Front fork upper clamp bolt 23 2 3 16 5 Front fork lower clamp bolt 33 3 3 24 0 Front fork cap bolt 23 2 3 16 5 Front fork damper rod bolt 30 3 0 21 5 Front axle 65 6 5 47 0 Front axle pinch bolt 23 2 3 16 5 Handlebar clamp bolt 16 1 6 11 5 Handlebar holder bolt 23 2 3 16 5
35. r out of adjustment 9 Defective ISC valve 10 Imbalanced throttle valve synchronization Adjust Replace Adjust Replace Repair Clean or replace Replace Replace Adjust Clean or replace Adjust Repair or replace Drain out excess oil Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Adjust Replace Adjust Engine overheats Defective engine internal parts 1 Heavy carbon deposit on piston crowns Not enough oil in the engine Defective oil pump or clogged oil circuit Sucking air from intake pipes Use incorrect engine oil 6 Defective cooling system Lean fuel air mixture Short circuited IAP sensor lead wire Short circuited IAT sensor lead wire Sucking air from intake pipe joint Defective fuel injectors Defective ECT sensor Other factors 1 Ignition timing is too advanced due to defective timing advance system ECT sensor GP switch CKP sensor and ECM Drive chain is too tight ISC bad learning Clean Add oil Replace or clean Repair or replace Change See radiator section Repair or replace Repair or replace Repair or replace Replace Replace Replace Adjust Reset learned value 10 8 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Dirty or heavy Too much engine oil in the engine Check with inspection exhaust smoke window drain out excess oil Worn piston rings or
36. sensor Replace Defective air flow system 1 Clogged air cleaner element Clean or replace 2 Defective throttle valve Adjust or replace 3 Sucking air from throttle body joint Repair or replace 4 Defective ECM Replace 5 Imbalanced throttle valve synchronization Adjust Defective control circuit or sensor 1 Low fuel pressure Repair or replace Defective TP sensor Replace Defective IAT sensor Replace Defective CKP sensor Replace Defective GP switch Replace Defective IAP sensor Replace Defective ECM Replace TP sensor out of adjustment Replace Defective ISC valve Replace O ONDA KRW ND Complaint Symptom and possible causes SERVICING INFORMATION 10 7 Engine lacks power Defective engine internal electrical parts Loss of valve clearance Weakened valve springs Valve timing out of adjustment Worn piston rings or cylinders Poor seating of valves Fouled spark plugs Incorrect spark plugs Clogged fuel injectors TP sensor out of adjustment 10 Clogged air cleaner element 11 Imbalanced throttle valve synchronization 12 Sucking air from throttle valve or vacuum hose 13 Too much engine oil 14 Defective fuel pump or ECM 15 Defective CKP sensor and ignition coils Defective control circuit or sensor 1 Low fuel pressure Defective TP sensor Defective IAT sensor Defective CKP sensor Defective GP switch Defective IAP sensor Defective ECM TP senso
37. tor light FI indicator light Oil pressure indicator light Engine coolant temp indicator light Engine rpm indicator light BRAKE WHEEL ITEM SERVICING INFORMATION 10 57 STANDARD SPECIFICATION Unit mm in Rear brake pedal height 38 48 1 5 1 9 Brake disc thickness 4 8 5 2 0 189 0 205 4 3 4 7 0 169 0 185 Brake disc runout Brake master cylinder bore amp pis ton diam Front Approx 11 0 0 43 Rear Approx 14 0 0 55 Brake caliper cylinder bore amp piston diam Front Leading Trailing Approx 27 0 1 06 Rear Approx 38 2 1 50 Brake fluid type DOT 4 Wheel rim runout Axial Radial Wheel rim size Front 17 M C x MT 3 00 Rear 17 M C x MT 4 00 Wheel axle runout TIRE ITEM Front Rear STANDARD SPECIFICATION Cold inflation tire pressure Solo riding 250 kPa Front 2 50 kgf cm2 36 psi 250 kPa Rear 2 50 kgf eme 36 psi Cold inflation tire pressure Dual riding 250 kPa Front 2 50 kgf cm2 36 psi 0 kPa 25 Rear 2 50 kgf eme 36 psi Tire size Front 110 80 17 M C 57H Rear 140 70 17 M C 66H Tire type Front IRC RX 01F D Rear IRC RX 01R Tire tread depth Recommended depth Front Rear 10 58 SERVICING INFORMATION SUSPENSION ITEM STANDARD SPECIF
38. ward Fuel tank breather hose No 1 Fuel tank breather hose No 2 10 20 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Frame Q 6 N m Wiin 0 6 kgf m 4 5 Ibf ft Reservoir tank ae N e overflow hose wae The clamp end should face Clamp lt downward Pass the drain hose between the air cleaner upper crankcase and frame bridge _ Yellow mark The clamp end should face upward Q 6 Nm MAX 1 5 mm 0 06 in Fuel tank water drain hose The clamp end should face downward The clamp end should face upward 8 18 Nm x 1 8 kgf m 13 0 Ibf ft N x A N 1 EL A 0 Ate Thermostat White mark The clamp screw head should face right side i a S 5 10N m mamen EE head should face and bracket U 2 ESN forward F q Do not contact i White mark the clamp screw The clamp x screw head The clamp screw head should face should face right side forward 0 6 kgf m 4 5 Ibf ft a 1 0 kgf m 7 0 Ibf ft 2 8mm 0 08 0 31 in isarnes Marking Connect the reservoir tank overflow hose and reservoir tank inlet hose as shown and then tighten the reservoir tank mounting bolt lower The clamp screw head should face right side Reservoir tank _ overflow hose U SERVICING INFORMATION 10 21 8 10N m 1 0 kgf m 7 0 Ibf ft Yellow m

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