Copyright for this service manual only ©2011 LIFRASCHAL
Contents
1. F 09900 25008 Multi circuit tester set Tester knob indication Resistance 0 If the resistance is not within the standard range replace the sensor with a new NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor neater is at correct temperature Connect the HO2 sensor coupler securely Installation is in the reverse order of removal CAUTION Tighten the sensor unit to the specified torque v 2 SENSOR 47 5 4 75 kgf m 34 3 Ib ft Houte the HO2 sensor lead wire into the frame Connect the 2 sensor coupler Copyright for this service manual only 2011 LIFRASCHAL HANDLEBAR SWITCH ILLUMINATION i TURN SIGNAL INDICATOR LIGHT 0L WT ENGINE COOLANT TEMP INDICATOR LIGHT GEAR POSITION INDICATOR 1 5 DRIVE MODE INDICATOR POWER MODE INDICATOR HIGH BEAM INDICATOR LIGHT FI PILOT OV OlL PRESSURE INDICATOR LIGHT TR TURN SIGNAL INDICATOR LIGHT 0R BRAKE LOCK INDICATOR LIGHT TL D PM WIRING DIAGRAM E 02 19 13 1 L 14111 4 a H a LII Tj Soe LITT T LI I I H EE glo HH ed TO SENSOR 100 ah is H EE o HE va EL 5 z i7 5 i ma EE2. FOREWORD This manual contains an introductory description on the SUZUKI ANGSO and procedures for its inspec lion service and overhaul of its main components Other information considered as generally known is not Iinciuded Head the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main tenance Lise this section as well as other sections to use as a guide for proper inspection and service This manual will help you know the motorcycle bet ter so that you can assure your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual and the actual motorcycle fllustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motorcy cles If you do not have the proper knowledge and fools ask your authorized SUZUKI motorcycle dealer help you A 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 motorcycle
3. FEEE ESSE uem RR M LLL om HEE TR e HEEE ttt Bi TE EDI LE 8 1 qe Wi jar Hd la ECT li a a I E zi SENSOR SENSOR Peer H at CO HE SENSOR SENSOR SHS ERES AU EEEE HEHH CVT UNIT CONTROLLER SIDE STAND SWITCH 5 oF T TEL dL IGNITION IGNITION 1 COIL 2 2 E i Er 5 5 1 POSEN IDE L D amp LEVEL ENNE a E 1114 H p DE eee E TH Ii 9 eee 4 UIN a LEE om a A Eos i e 8 E ETEPEPEELEPPERELE IL TE H mS T Hn L dM LIII 1 14 d iL IT Tul D va POSITION LIGHT R 4 L FRONTTURN SIGNAL LIGHT FRONT TURN SIGNAL LIGHT ciate HEADLIGHT a HEADLIGH
4. Lower frame cover 19 Center frame cover 10 rider handle 3 Frame cover a Trunk 79 20 Lower frame cover C5 9 15 9 Center frame cover 7779 15 Gi Wind screen cover 9 7 OD Front leg shield cover C5 9 11 a Ignition switch 29 19 93 Floor mat right and left d amp Rear fender Leg sida cover Foot board d Trunk Mainte lid Front box Copyright for this service manual only 2011 LIFRASCHAL 10 4 LOCATION OF ELECTRICAL COMPONENTS 1 Starter motor 2 Engine coolant temp sensor 778 3 IAC valve 557 20 4 Injector 7 6 40 Throttle position sensor 776 31 Intake air temp sensor C7 6 36 7 Intake air pressure sensor 7 6 29 48 CVT motor 776 45 Brake lack switch amp Cooling fan motor relay Gf Side stand relay or Fuel pump relay 17 Fuel pump relay ar Side stand relay 47 Atmospheric pressure sensor 7 6 37 13 d TO sensor 776 39 4 CYT control unit ECM Engine Control Module d amp Solenoid 712 6 d Horn 19 Pulley position sensor 7 6 47 G Center stand switch di 2 sensor 7 5 42 23 CVT secondary pulley revolution sensor 776 51 Copyright for this service manual only 2011 LIFRASCHAL 11 4 WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Clamp CVT control unit harness Headlight L He
5. T LI B aw POSITION LIGHT L ow Copyright for this service manual only 2011 LIFRASCHAL SUZUKI MOTOR CORPORATION Printed in Japan Copyright for this service manual only 62011 LIFRASCHAL
6. adlight R Wiring harness Front turn signal light 11 Front turn signal light Clamp Clamp Wiring harness Front turn signal light iL Handlebar switch iH 4 L TO sensor Clamp Clamp Sat tha front turn signal light coupler ahead the wiring harness the TO sensor as shown sensar CYT control unit Clamp Glamp CYT revolution sensor Center stand switch Center stand switch CVT revalution sensor Fully pasition sensor CVT motor 2 sensor ee Brake lock amp ewitch Brake lock d cable Fuse box LES Clamp AP sensor CVT revolution sensar Center stand switch Pass the each relay lead wire outside the parking brake cable Clamp Copyright for this service manual only 2011 LIFRASCHAL 12 9 HEATED OXGEN SENSOR HO2S INSPECTION Remove the foot board C7 9 18 Disconnect the HO2 sensor lead wire coupler Remove the HO2 sensor unit Do not remove the HO2 sensor while it is hot CAUTION Be careful not to expose it to excessive shock Do not use an impact wrench while removing or installing the HO2 sensor unit Be careful not to twist or damage the sensor lead wire Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 Disconnect the HO sensor coupler Check the resistance between the terminals white white of the sensor Resistance 4 5 at 23 C 73 4
7. om the oil level hole V Drain plug 33 N m 3 3 kgf m 24 0 Ib ft Tighten the oil level plug 3 to the specified torque V oil level plug 33 N m 3 3 kgf m 24 0 Ib ft Oil viscosity and classification Hypoid gear oil SAE 90 API grade GL 5 NECESSARY AMOUNT OF FINAL GEAR OIL Oil change 300 ml 10 1 10 6 US Imp oz Overhaul 430 ml 14 5 15 1 US Imp oz CVT FILTER Inspect every 12 000 km 7 500 miles 12 months Remove the leg side cover L7 8 12 Remove the CVT filter lid 1 xr hooked part Remove the CVT filter cover 2 Remove the CVT filter 3 Copyright for this service manual only 2011 LIFRASCHAL 3 19 DRIVESHAFT Remove the driveshaft assembly 1 and idle shaft 2 Remove the idle gear 3 Remove the circlip 4 and counter drive gear 5 Remove the counter drive gear shaft 65 BALANCER SHAFT Remove the upper balancer shaft 7 Remove the circlip 8 lower balancer shaft 9 oil pump gear id and oil pump drive chain Copyright for this service manual only 2011 LIFRASCHAL 5 2 CVT ASSEMBLY REMOVAL AND INSTALLATION CVT ASSEMBLY REMOVAL Remove the engine assembly ENGINE REMOVAL 3 3 Remove the bracket 1 Remove the bolts 2 and 3 Install the special tool as shown 09920 31050 CVT guide Copyright for this service manual only 2011 LIFRASCHAL 6 11 FISYSTEM PARTS LOCATION Josu
8. s paads iq 10suas uonisod 05uas WOD 90 G 5103 305 Gr 14 2042 d W23 Copyright for this service manual only 2011 LIFRASCHAL 7 21 Apply small quantity of grease to the shaft end and seal lip Ax 99000 25030 SUZUKI SUPER GREASE USA 99000 25010 SUZUKI SUPER GREASE A Others With the TV fully closed install the TP sensor to the original setting position TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft Install the IAC valve CAUTION Replace the O ring with new Apply thin coat of the engine oil to the new O ring Install the injector seal 1 and O ring 2 to each fuel injector Apply thin coat of the engine oil to the new O ring and new seal Install the fuel injectors by pushing them straight to each throt tle body CAUTION Replace the injector seal and O ring with the new ones Never turn the injector while pushing it Install the fuel delivery pipe assembly to the throttle body assembly CAUTION Never turn the fuel injectors while installing fuel deliv ery pipe Tighten the fuel delivery pipe mounting screws 9 Fuel delivery pipe mounting screw 3 5 N m 0 35 kgf m 2 5 Ib f
9. t Copyright for this service manual only 2011 LIFRASCHAL 8 28 OIL FILTER OIL COOLER DIL PRESSURE REGULATOR OIL SUMP FILTER PUMP OL RETURN PUMP ORIFICE JET DRIVESHAFT BEARING 5 WM cwn 8 LUBRICATION OIL RETURNED OIL Copyright for this service manual only 2011 LIFRASCHAL 4 Front box 2 Lid T Cushion 4 Cushion 5 Front inner box 5 Cushion FOOT BOARD ASSEMBLY 1 Foot board i2 Louver 3 Duct Copyright for this service manual only 2011 LIFRASCHAL REMOVAL 9 6 LOCATION OF EXTERIOR COMPONENTS 1 Wind screen 278 7 Handlebar cover 7 5 8 8 3 Front panel 729 8 4 Rear view mirror right and left 3 8 5 Lower leg shield 779 10 6 Leg shield 79 10 7 Leg side cover right and left C7 3 12 amp Maintenance lid 9 13 Seat L5 78 13 d Seat damper 3 14 17 Pilllan rider handle right and left 9 15 2 Trunk box cover 5 9 16 di Frame cover right and left CF 9 15 Foot board 79 18 95 Front box 79 18 Rear fender 2 9 20 ai Wind 5 Lower leg Screen cover shield f Wind screen Gb Front leg shield cover 6 Leg shield 3 Ignition switch 2 Handlebar 3 Front panel 4 Rear view mirror a2 Trunk box cover
10. unsafe for the rider and passenger SUZUKI MOTOR CORPORATION GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE DRIVE TRAIN FISYSTEM CVT SYSTEM FUEL SYSTEM AND THROTTLE BODY COOLING AND LUBHICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMA TION EMISSION CONTROL INFORMA TION WIRING DIAGRAM Copyright for this service manual only 62011 LIFRASCHAL HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 The section titles are listed in the GROUP INDEX 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 The contents are listed on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel Brake disc Coller 3 Dust seal 4 Bearing ibi Front tire Front wheel 7 Spacer Tire valve Disc bolt Front axle Copyright for this service manual only 2011 LIFRASCHAL 2 16 Remove the oil drain plug 2 and oil level plug 3 Tighten the oil drain plug 2 to the specified torque and pour fresh oil through the oil level hole until the oil over flows fr
Download Pdf Manuals
Related Search