TABLE OF CONTENTS Precautions. Precautions General Information General Information Maintenance and Lubrication .. Service Data... Engine . Precautions .. Engine General Information and Diagnosis Emission Control Devices .... Engine Electrical Devices... Engine Mechanical Engine Lubrication System .. Engine Cooling System. Fuel System uss Ignition System Starting System.. Charging System. Exhaust System Suspension....non Precautions... Suspension General Diagnosis Front SUspeNBiON ...nsunnnnnnr Rear Suspension. Wheels and Tires... Driveline / Axi Precautions Drive Chain / Drive Train / Drive Brak OS soesonsee Precautions . 7 Brake Control System and Diagnosis Front Brakes... 6 i Rear Brakes ABS Transmission / Transaxle sn... Precautions Manval Transmission Clutch... Steering Precautions Steering General Diagnosi Steering / Handlebar Body and Accessories... Precautions. Wiring Systems Lighting Systems Combination Meter / Fuel Meter / Horn Exterior Parts . Body StructureAbbreviations .. ‘SAE-to-Former Wehicle Side View ....... ‘Vehicle Identification Number Fuel and Oil Recommendation ‘Engine Coolant Recommendation . ‘SREAK-IN Procedures. ‘Cylinder Identification. ‘Country and Area Codes .. Wire Color Symbols .. ‘Warning, Caution and Information Labels ‘Specification: ‘Specifications. Recommended Fluids and Lubricants. juled Maintenance ‘Penodic Maintenance Schedule Chat Lubrication Points .. ir Instructions. Air Cleaner Element Replacement. Air Cleaner Element Inspection and Cleaning .. Section 0 Table of Contents _0-i General Information CONTENTS Exhaust Pipe Bolts and Muffler Bolts Inspection... ry Valve Clearance Inspection and Adjustment .0B-4 Spark Plug Replacement... 08-9 Spark Plug Inspection and Cleaning Fuel Line Inspection Evaporative Emissior Inspection (E-33 Only) Engine Oil and Filter Replacement Throttle Cable Play Inspection and Adjustment : Throttle Valve Synchronization .. Cooling System Inspection.. Clutch System Inspection. Drive Chain Inspection and Adjustment Drive Chain Cleaning and Lubricating... Brake System Inspection i Tire Inspection Steering System Inspectio Front Fork Inspection . Rear Suspension Inspection Chassis Bolt and Nut Inspe Compression Pressure Check Oil Pressure Check .. SDS Check. Specifications Tightening Torque Specifications Special Tools and Equipment. Recommended Service Material Special Toot .. Service Data.. susseneese OCH1 Specifications. OCA Service Data.. .0C-1 Tightening Torque List 0C-70A-1_General Information: General Information General Description ‘Symbols aencrstororoot 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. ‘Symbol Definition Torque control required. Data beside it indicates specified torque. ‘Apply oil Use engine oil uniess otherwise specified. Apply molybdenum oil solution. oil and SUZUKI MOLY PASTE in a ratio of 1:1). AD JPER GREASE * 99000-25280 ‘Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 _ ‘Apply SUZUKI SILICONE GREASE or equivalent. |99000-25100 ‘Apply SUZUKI BOND "12078" or equivalent. 99000 ‘Apply SU; 99000-31110 ‘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 SUZUKI SUPER LONG LIFE COOLANT (BLUE), 99000-99032-20x |Use SUZUKI LONG LIFE COOLANT (GREEN) or equivalent '99000-99032-12x _ ‘Use SUZUKI FORK OIL $S-8 or equivalent |99000-99001-SS8 ; _ _ ‘Apply MUFFLER SEAL LOCTITE "8920" (commercially available) or equivalent. Apply or use brake fluid. Use special tool. Do not reuse. 1 ‘Note on reassembly. bags coPeAd a ae alalAdrisis T BOND "1215" or equivalent.Abbreviations z ABDC: After Bottom Dead Center ABS. Anti-lock Brake System AC: Aliernating Current BCL: Air Cleaner, Air Cleaner Box Pt American Petroleum Institute TDC: After Top Dead Center AI: Air Fuel Mixture = SEDC: Before Bottom Dead Center STDC: Before Top Dead Center Sr Battery Positive Voltage c FENOMI10101002 ‘CAP Sensor: Crankshaft Position Sensor (CKPS) XT: Circuit ‘CLE Switch: Clutch Lever Position Switch (Clutch Switch) ©0: Carbon Monoxide ‘SPU: Central Processing Unit a Be: Direct Current ‘DMC: Dealer Mode Coupler DOHC: Double Over Head Camshaft ‘DRL: Daytime Running Light DTC: Diagnostic Trouble code = OM: Engine Control Module Engine Control Unit (ECU) (FI Controt Unit) ECT Sensor: Engine Coolant Temperature Sensor (cts) Water Temp. Sensor (WTS) = FE Fuel Injection, Fuel Injector FP: Fuel pump FPR: Fuel Pressure Regulator FP Relay: Fuel Pump Relay = ‘GEN: Generator GND: Ground ‘SP Switch: Gear Position Switch = C= Hydrocarbons 802 sensor: Heated Oxygen Sensor (HO2S) t WAP Sensor: Intake Air Pressure Sensor (IAPS) SAT Sensor: Intake Air Temperature Sensor (IATS) NG: Ignition SSC Valve: Idle Speed Control Valve (ISCV) = JASO: Japanese Automobile Standards Organization 3 LED: Liquid Crystal Display LED: Light Emitting Diode (Malfunction Indicator Lamp) LH: Left Hand = MAL-CODE: Malfunction Code (Diagnostic Code) Max: Maximum Malfunction Indicator Lamp (LED) General Information: _0A-2 Min: Minimum Ni NOx: Nitrogen Oxides oO: OHC: Over Head Camshaft OPS: Oil Pressure Switch P: PCV: Positive Crankcase Ventilation (Crankcase Breather) R: RH: Right Hand ROM: Read Only Memory Ss: SAE: Society of Automotive Engineers SDS: Suzuki Diagnosis System STC System: Secondary Throttle Control System (sTcs) STP Sensor: Secondary Throttle Position Sensor (STPS) ST Valve: Secondary Throttle Valve (STV) STV Actuator: Secondary Throttle Valve Actuator (STVA) t TO Sensor: Tip-over Sensor (TOS) Sensor (TPS)0A-3_ General Information: SAE-to-Former SUZUKI Term BENCHII10101000 This list shows SAE (Society of Automotive Engineers) 4J1930 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, +8 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 (El): — Engine Control Module (ECM): Engine Control ‘Module (ECM), FI 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) Evaporative Emission (EVAP): Evaporative Emission Evaporative Emission Canister (EVAP Canister): — (Canister) Evaporative Emission (EVAP): Evaporative Emission Evaporative Emission Canister (EVAP Canister): — (Canister) Fr Fan Control (FC): — Fuel Level Sensor: Fuel Level Sensor, Fuel Level Gauge Fuel Pump (FP): Fuel Pump (FP) Generator (GEN): Generator Ground (GND): Ground (GND, GRD) H: Hydrocarbons (HC): Hydrocarbons Heated Oxygen Sensor (HO2S): Healed Oxygen Sensor (HO2S), 02 sensor I: Ignition Control Module (/CM): — Intake Air Temperature (IAT): Intake Air Temperature (IAT), Air Temperature Idle Speed Control (ISC): — Ignition Control (IC): Electronic Spark Advance (ESA) Ignition Control Module (ICM): — M Malfunction Indicator Lamp (MIL): LEO Lamp, Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure (MAP): Intake Air Pressure (|AP), Intake Vacuum Mass Air Flow (MAF): Air Flow oO: On-Board Diagnostic (OBD): Self-Diagnosis Function, Diagnostic Open Loop (OL): — P: Programmable Read Only Memory (PROM): — Purge Valve (Purge Valve); Purge Valve (SP Valve) R Random Access Memory (RAM): — Read Only Memory (ROM): ROM Ss: Secondary Air Injection (AIR): Secondary Throttle Control System (STCS): STC System (STCS) Secondary Throttle Valve (STV): ST Valve (STV) Secondary Throttle Valve Actuator (STVA): STV Actuator (STVA) t Throttle Body (TB): Throttle Body (TB) Throttle Body Fuel Injection (TBI): Throttle Body Fuel Injection (TB!) Throttle Position Sensor (TP Sensor): TP Sensor (TPS) Vv: Voltage Regulator (VR): Voltage Regulator Volume Air Flow (VAF): Air FlowVehicle Side View NOTE Difference between illustration and actual motorcycles may exist depending on the markets. BENCI1J10101004 ‘SUZUKI DL650 A/AUE (2012-model) Right Side Left Side TErvor0082.01 General Information: _0A-4 Vehicle Identification Number BENCII510101005 The frame serial number or V.LLN. (Vehicle Identification Number) “A” is stamped on the right side of the steering head pipe. The engine serial number “B"is located on the lef side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. a Te110100030" reno1oeorotFuel and Oil Recommendation Fuel (For USA and Canada) Use unleaded gasoline with a minimum pump octane rating of 87 ((R¢M)/2 method). Gasoline containing MTBE (Methyl Tertiary Butyl Ether). less than 10% ethanol, or less than §% methanol with appropriate cosolvents and corrosion inhibitor is permissible BENCs10101006, Fuel (For Other Countries) Use unleaded gasoline with an octane rating of 91 or higher (Research method) Engine Oil (For USA) il quality is a major contributor to your engine's performance and life. Always select good quality engine ll. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil Use oil with an API (American Petroleum institute) classification of SF/SG or SH/SJ, or with a JASO classification of MA (sae “|__SF or SG SHorSJ_ [MA If SAE 10W-40 engine oil is not available, select an altemative according to the chart MULTIGRADE Suzuki does not recommend the use of "ENERGY CONSERVING" oils. ww Engine Oil (For Other Countries) Oil quality is @ major contributor to your engine's performance and life. Always select good quailty engine oil Suzuki recommends the use of engine oll as follows. [SAE APIL__| _ JASO_ | —Tow-40_-| SF or SG 4OW-40 SH or SJ if SAE 10W-40 engine ol is not available, select an alternative according to the chart utrionant ‘Suzuki does not recommend the use of ‘ENERGY CONSERVING’ oils. ta) (8) (Ca arcoaene Te Recameend Brake Fluid Specification and classification: DOT 4 ZT Since the brake system of this motorcycle 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. i Front Fork Oil Use SUZUKI FORK OIL SS-8 or equivalent.General Information: 0A-6 Engine Coolant Recommendation Recommended Engine Coolant The factory filled engine coolant of this vehicle is SUZUKI super long life coolant (Coolant color: Blue). Itis recommended to use this SUZUKI super long life coolant when replenishing or changing the engine coolant. SUZUKI super long life coolant (Coolant color: Blue) as supply part is already diluted to the 50 percentage with Geionized water. Use it as it is without diluting. SUZUKI recommends to use following coolants in that order. 1) SUZUKI super long life coolant (Coolant color: Blue) 2) SUZUKI long life coolant (Coolant color: Green) or equivalent BENCH1U10101007 Engine Coolant + Use an anti-freeze/engine coolant compatible with an aluminum radiator. ~ There are two types of engine coolant: one used after diluting with distilled water and the other used as it is (without diluting). SUZUKI super long life coolant is the latter type and SUZUKI long life coolant is the former type. Anti-freeze | Engine coolant The engine coolant performs as a corrosion and rust ehibitor as well as anti-freeze. Therefore, the engine slant should be used at all times even though the ospheric temperature in your area does not go down 2 freezing point. Water for mixing (for coolant requiring water ilution) Use cistilled water only. Water other than distilled water rode and clog the aluminum radiator. Liquid amount of water / Engine coolant mixture (for coolant requiring water dilution) Solution capacity (total + 950 ml (2.0/1.7 USiimp qt) 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 BENCH 10101008 During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it's 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 800 km (500 miles): Below 5 000 r/min Up to 1 600 km (1 000 miles): Below 7 500 r/min Over 1 600 km (1 000 miles): Below 10 000 r/min 2) Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 10 000 r/ min at any time. Cylinder Identification BENCHJ10101009, The two cylinders of this engine are identified as #1 and #2 cylinder, as counted from front to rear (as viewed by the rider on the seat).Country and Area Codes The following codes stand for the applicable country(-ies) and area(-s). BENCHHWI0101010 Code Country or Area Effective Frame No. DLES0A 2 (E-03) jS1VP56A C2100001 — DLESOA L2 (E-21) USA er for California) U, JSIC7111100100001 = DL6S50A L2 (E-24) Australia JS1C7141200100004 — [DL6S0A L2 (E-28) Canada JSIVP56A C2100001 — DL6SOA L2 (E-33) California (USA) JSIVPS56A C2100001 — [BLES0AUE L2 (E-21) EU. JS1C7211100100001 — Wire Color Symbols BENCHs1010108 ‘Symbol Wire Color ‘Symbol Wire Color Black BiB ‘Brown with Black tracer El Blue Briw Brown with White tracer Br Brown GB (Green with Black tracer Dbr Dark brown GR Green with Red tracer 0g Dark green GY Green with Yeliow tracer cS {Green Gri8|Gray with Black tracer —6r Gray GR Gray with Red tracer toi Light blue Gr. (Gray with White tracer tg Light green OB (Orange with Black tracer 0 ‘Orange OBI ‘Orange with Blue tracer P Pink ‘OIG ‘Orange with Green tracer R Red OR ‘Orange with Red tracer W. White OW. ‘Orange with White tracer y. ‘Yellow ‘Ov Orange with Yellow tracer BiB Biack with Blue tracer PW. Pink with White tracer Ber Black with Brown tracer RB Red with Black tracer BIG Biack with Green tracer RW Red with White tracer Bh Black with Light green tracer we ‘White with Black tracer 870. ‘Black with Orange tracer Wisi White with Biue tracer BR ‘Black with Red tracer Wi ‘White with Green tracer BW ‘Black with White tracer wR ‘White with Red tracer BY Black with Yellow tracer Ye Yellow with Biack tracer vB ‘Blue with Black tracer Yisi Yellow with Blue tracer BIG Biue with Green tracer YiG ‘Yeliow with Green tracer BW. Biue with White tracer YIR Yellow with Red tracer BIY Biue with Yellow tracer YW. Yellow with White tracerGeneral information: _0A-8 Warning, Caution and Information Labels Location ro) Y ESS 26 (For E-28) 25, 26 (For E-21), 27, 28, 29, 30 BENCHI10101012 42, 13, 14, 15, 16, 17, 18, 19 {c) DD restar0r008.01 ‘Woe abel (AOR (Engi For E24) ‘Seering waring label Engian) (For 6-09.99) Nese abel (EPA (Engh (Fo €-03, 33) ‘Steering warnng label Engish/FenehGornan) (For E21. 2428) [_eormation abe (EPAI (Engin) (Fer €-03), 24,_ Stowing warning label Russian) For OLBSOA 6-21) “oration abe [EPA] (Eng French) (For £26) 25,__Screon abel Engish) For E03, 24,24 28.39) rormation lobe [EPA 8 CARB) (Engish) (For E39) 26. Scivon label French (For DLBBOA E21, 28) ICES Canada abel Englshvrench) (For E28) 27._ Seren iol Gorman) (For DLESOA E21) 7 Veewum howe routing label (Engish) (For E33) 28._Scrven tabel alia) (For DLOSOA E21) Manval notice abel English) (For £03.29) 729,_Sewen label Sweilish) (For DLBSOA E-21) Tre formation abel Englah) (For £03.39) 30._Scren abel Spanish (For OLEOA E-21) 3E_Teenlematoninbel(EnglahvFrendvGerman) (For E21, 2428) 31._ Seren inbel Russian) (For DLBSOA E-21) Tae iniormation abel (Russian) (For DLBSOA E21) 3210 label ForE-21) TE_Genoral waring abel (English) (For 03, 21,24. 3). '33._10 plato For E-28) 75_Gaaal warning abel (French) (For DLGSOA E-21) 4, Safely plat ngish) (For 603,39) 7 General waring abel (German) (Fer OLSSOA E-21) '36,_Saety plate (English ih Canada mark) For 6-28) 3E__Genoral warring label (alan) (For OLOSOA E21) 36.__Brave Mud inrmation mark (For DLBSOA E21) 3E_Genoral waring abel (Swedish (For OLESOA E-21) '37._Brewe approval mark For DLBSON E21) 77 General warning abel (Spanish) (Fer OLOSOAE-21) '38._Radiator cap abel Russian (For E21) SE_ General warning abel (Russian) (Fer OLOGOA E-21) Ai Rear font fender 35 Sena warning label English rench) (For €-28) {18} Mer panel Z_ Rear carrer waming label Engksh) For €-03, 21,24, 9) {6} Frame (RH) Rear carrer waming label Engiahrench) (For E28) [D}- Radiator capEr Component Location Electrical Components Location BENCHtJI010300 [EA ee onaar [gon nt je contol solenod valve (Ex Immobilizer antenna (E21, €24 onh)General Information: 0A-10 Hom 7. Genweator KP sensor ‘Speed sensor 0. GPSpecifications Specifications BENCIHJT0107001 NOTE These specifications are subject to change without notice. Specification Remark 2.290 mm (90.2 in) (Overall width ‘835 mm (32.9 in) ‘Overall height 7405 mm (55.3 in) Wheelbase 1560 mm (61.4 in) (Ground clearance “475 mm (6.9 in) ‘Seat height 835 mm (32.9 in) Curb mass 214 kg (472 Ibs) Engine Item Specification - Remark Type ‘a-stroke, liquid-cooled, DOHC, 90° V-twin ‘Number of cylinders 2 Bore ‘81.0 mm (3.189 in} Stroke 62.6 mm (2.465 in} Displacement _ 645 cm (39.4 cu, Compression ratio 12: — Fuel system Fuel inje — 1 Air cleaner Non-woven fabric Starter system Electric Lubrication system Wet sump Idle speed 7300 # 100 rimin Drive train 7 item Specification Remark [Clutch Wet multi-plate type Transmission 6-speed constant mesh Gearshift pattern 1-down, 5-up Primary reduction ratio 2.088 (71/34) tow 2.464 (32/13) nd nr are 4.380 (29721) aeration! ath 1.125 (27/24) 3th 0.964 (25/26) Top 0.854 (23/27) 133 (47/15) RK 525SMOZ8, 178 links Wem Specification Remark Front suspension Telescopic, coil spring, oll damped Rear suspension Link type, coil spring, oil damped Front suspension stroke ‘150 mm (5.9 in) Rear wheel travel 19 mm (6.3 in) Caster Trail Steering angle 2.7 m (8.9 ft) Diss) rake, twin [Front tire size Rear tire size 150/70R17MIC 69H, tubelGeneral Information: _0A-12 Electrical [ Tem Remark ignition type Electronic ignition (Transistorized) 8° B.T.0.C, at 1 300 r/min NGK CR8EIA-9 or DENSO 1U24D Battery 42 V36.0 KC (10 Ah)/10 HR Generator Three-phase A.C. generator Main fuse 30 Fuse AS/SHOMO/IEIIS A Headlight 12 V 60/55 W (HA) x 2 Pe ion light A2VSWx2 Brake ght ailight 42.V 24/5 W Turn signal light License plate light Speedometer light ‘Tachometer light Neutral indicator light | ‘High beam indicator light Turn signal indicator light ‘Oil pressure/Coolant temperature indicator light Fl indicator light Freeze indicator light ABS indicator light immobilizer indicator light _ (E21, 24 Capacities item Spetification Remark Fuel tank 20.0 (5.3/4.4 USiImp gal) Oil change 2400 Engine oil | With filter change 2750 mi (2. L ‘Overhaul ‘3000 mi (3.2/2.6 US/imp qt) Coolant 4950 ml (2.0/7.7 US/imp gt)Special Too! Special Tools and Equipment eNCIs10108002 09900-06107 type) “A Snap ring pliers (Open \ 09900-06108 ‘Snap ring pliers (Close type) (09900-18710 |Hexagon socket (12 mm) 09900-20101 Vernier calipers (150 |) 09900-20102 Vernier calipers (200 mm) 09900-20202 mm) 09900-20204 Micrometer (75 ~ 100 09900-20205 Micrometer (0 ~ 26 mm) 09900-20530 Cylinder gauge set (09900-20602 Dial gauge @ |09900-20804 09900-20607 09900-20701 09900-20805 09900-20806 Dial gauge DDial gauge chuck __Thickness gauge __|Tire depth gauge __| Thickness gauge “ & Ss AY S 09900-21304 09900-22301 09900-22302 09900-22403 09900-25008 V blocks Plastigage (0.025 - |Plastigage (0.051- | Small bore gauge (18 /Multicircuit tester set | 0.076 mm) 0.152 mm) 35 mm) 09900-25009 |Needie-point probe |set (09900-28630 TP Sensor test lead 09904-41010 ‘SUZUKI Diagnostic isystem set 09910-60611 ‘Universal clamp wrench (09913-50121 il seal removerGeneral Information: _0A-14 Y 09913-60221 09913-70210 09915-40620 09915-63311 09915-64512 Journal bearing Bearing installing set [Oil filter wrench [Compression gauge Compression gauge installer & holder (10-75 @) jattachment | | ~ Se Na eororo% 0 | 02915-70610 09915-74521 09915-77331 09916-10911 09916-14510 Ol pressure gauge | Adapter hose il pressure gauge | Valve lapper set Valve lifter attachment (1000 kPa) 99916-14522 09916-33210 09916-34542 09916-34580 09916-43211 valve lifter attachment | Valve guide reamer Reamer handle ‘Valve guide reamer Valve guide installer & (4.5mm) (10.8 mm) remover CO He 99916-53330 09916-84511 09917-47011 09919-28620 09920-13120 valve guide installer |Tweezer Vacuum pump gauge |Sleeve protector Crankshaft remover attachment set Q aw 93920-53740 09921-20240 09922-22711 09925-18011 (09930-10121 sieeve hub | Bearing remover set Drive chain cutting _| Bearing installer Spark plug wrench set and joint tool setAL) @ (09930-11920 09930-11940 (09930-11950 Torx® bit (JT40H) —_|Torx® bit holder (3/8 | Torx® wrench (T25H) 09930-30450 Rotor remover bolt Gf 09930-40113 Flywheel rotor holder sq.) 09930-44530 09930-82710 09930-82720 09940-14911 09940-14940 Rotor holder Mode select switch Mode selection switch | Steering stem nut Swingarm pivot thrust socket wrench {adjuster wrench 09940-14960 09940-14990 09940-34520 09940-34531 09940-40211 ‘Steering stem nut —_|Engine mounting T type handle Front fork assembling |Fuel pressure gauge |socket wrench adjust wrench 7 attachment (A) adapter _ el (® ob "@ | s | 09940-40220 09940-52861 09940-92720 09941-34513 09943-74111 Fuel pressure gauge |Front fork ollseal_ Spring scale Bearing installer Front fork oil level attachment installer set gauge | (09944-28320 (99565-01010-024 Hexagon socket (19 (CD-ROM Ver.24 mm) _| _| Torx® is the registered trademark of Camcar Division of Textron inc. U. SA,Maintenance and Lubrication: _0B-1 Maintenance and Lubrication Precautions Precautions for Maintenance ‘BENC11410200001 "= ‘Periodic Maintenance Schedule Chart’ lists the recommended intervals for all the required periodic service work essary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed 27s of kilometers, miles and months for your convenience. |MPORTANT: The periodic maintenance intervals and service requirements have been established in ‘2ccordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed ‘emission standards and it will also ensure the reliability and performance of the motorcycle. ing may be required on motorcycles that are used under severe conditions. General Description Recommended Fluids and Lubricants BENCH1J10201001 Refer to “Fuel and Oil Recommendation” in Section 0A (Page OA-5) and “Engine Coolant Recommendation” in Section 0A (Page 0A-6). Scheduled Maintenance Periodic Maintenance Schedule Chart NOTE [= Inspect and clean, adjust, replace or lubricate as necessary. [BENCt1020500% km 7000] Een miles 600 months 2 Se cleaner element =I R ‘aust pipe bolts and muffler bolts — Ti . a weve clearance = - = = Spark plugs = T R I Tine = r i I porative emission conirol system (E-33 only) = = T = ne oil R R R R ine oil fiter ~ R = = R | Throttle cable play t T tT 7 i Throttle valve synchronization ess only), _ ' - 1 SUZUKI SUPER LONG LIFE = —_ R COOLANT (BLUE) — — Kasoaany ‘SUZUKI LONG LIFE COOLANT a (GREEN) or an engine coolant i _ A = FR ‘other than SUZUKI SUPER LONG LIFE COOLANT (BLUE) hose = i 7 i i cable play (= 1 1 1 i = TT es 1 satel Giean and lubricate every 1 000 km (600 miles).Maintenance and Lubrication Interval Item km [4000 6000 | 12000 | 18000 | 24000 miles 600 4000 7 500 41000 14 500 months | 2 12 24 36 48 Brakes i T 1 1 1 ~ T T i i Brake fud i Replace every 2 years. = TT T T 1 Brake hoes Replace every 4 years, Tras ST 1 i Steering [1 = T 7 7 Front forks == 1 = 1 Rear suspension | = 1 = T ‘Chassis bolts and nuts T Tt TF T T_ Lubrication Points NOTE BENG HHUI0205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. * 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 motorcycle has been operated under wet or rainy conditions. terro20001.09| 7. Chtchiever hoor 5,_Orive chan Aix Fosiy goose, 2. Gearshift lever pivot 6. Brake lover Raider ‘Apply sicone grease, '3._Siessinndpivct and spring hook 7_Brako peda iva and foctrest phat “© Footrest prot ‘pp olMaintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement Replace air cleane Every 18 000 km ( fer to “Air Cleaner Element Removal and Installation” © Section 1D (Page 1D-6). BENCIU10200001 0 miles, 36 months) Alr Cleaner Element Inspection and Cleaning BeNCTtsT02oE002 Sespect air cleaner element Every 6 000 km (4000 miles, 12 months) tespection 1) Remove the air cleaner element. Refer to “Air leaner Element Removal and installation’ in Section 1D (Page 1-6). Inspect the air cleaner element for clogging. Ifit is clogged with dirt, replace it with a new one. NOTICE Do not blow the air cleaner compressed air. x ment with NOTE if driving under dusty conditions, replace the air cleaner element more frequently. Make ‘sure that the air cleaner is in good condition at all times. The 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. Refer to “Air Gleaner Element Removal and Installation” in Section 1D (Page 10-6), 2) Carefully use compressed air to clean the air cleaner element. ACAUTION 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. rewinaoon.ot 3) After cleaning the air cleaner element, reinstall the removed parts. 4) Drain water from the air cleaner by removing the drain plug (1). sersseenetor 5) Reinstall the drain plug.06-4 ter id Lubric: Exhaust Pipe Bolts and Muffler Bolts Inspection BEN T0200003 Tighten exhaust pipe bolts, muffler bolts and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Check the exhaust pipe bolts, muffler bolts and nut tothe specified torque, Tightening torque Exhaust pipe bolt (a): 23 N-m (2.3 kgf-m, 16.5 Ibf-ft) Muffler mounting bolt (b): 23 Nem (2.3 kgf-m, 16.5 If-ft) Exhaust pipe connecting bolt (c): 18 Nem (1.8 kgf« m, 13.0 Ibf-ft) Muffler mounting nut (d): 23 Nem (2.3 kgf-m, 16.8 Ibf-ft) rerrcaon0g. Valve Clearance Inspection and Adjustment BENGT/10200004 Inspect valve clearance Every 24 000 km (14 500 miles, 48 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 fuel tank. Refer to “Fue! Tank Removal and Installation” in Section 1G (Page 16-6). 2) Remove the radiator reservoir tank. Refer to “Radiator Reservor Tank Removal and Installation” in Section 1F (Page 1-9). 3) Remove the spark plug caps (1). Refer to “Spark Plug Cap and Spark Plug Removal and Installation” in Section 1H (Page 1H-6). 4) Remove the cylinder head covers (2) by removing the bolts (3). TeManca000001 Rear NOTE The valve clearance specification is different for both intake and exhaust valves. Valve cleara n cold) IN.: 0. .20 mm (0.004 ~ 0.008 in) EX.: 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) nce (WhetNOTE + The valve clearance should be taken when each cylinder is at Top Dead Center (TOC) of compression stroke, ~ The cams (IN. & EX.) on the front cylinder at position “A” show the front cylinder at ‘TDC of compression strok: * The cams (IN. & EX.) on the rear cylinder at position “B” show the rear cylinder at TOC 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. All spark plugs should be removed. oua20067 01 5) Remove the generator cover plug (4) and timing ‘spection plug (5), tert eae. © Tum the crankshaft to set the #1 (Front) cylinder at TDC of compression stroke. (Align the *| F” ine on the generator rotor to the center of timing inspection hale and also bring the camshafts to the position “A” 2s shown in the figure.) Maintenance and Lubrication: _0B-5 iezarron0ors01 7) To inspect the #1 (Front) cylinder valve clearance, use a thickness gauge between the tappat and the cam. If the clearance is out of specification, adjust it into the specified range. Special toot (2D (A): 09900-20804 (Thickness gauge) Wr eits1e20010010B-6 Maintenance and Lubrication: 8) Turn the crankshaft 270 degrees (3/4 turns) to set Adjustment the #2 (Rear) cylinder at TDC of compression stroke. | The clearance is adjusted by replacing the existing (Align the “| R” line on the generator rotor to the tappet shim by a thicker or thinner shim. center of timing inspection hole and also bring the 1) Remove the intake or exhaust camshafts, Refer to camshafts to the position “B” as shown in the figure.) “Engine Top Side Disassembly” in Section 1D (Page 40-27). 2) Remove the tappet (1) and shim (2) by fingers or magnetic hand. anro2tor6c 3) Check the figures printed on the shim. These figure: indicate the thickness of the shim, as illustrated. inzanra0e20 9) Inspect the #2 (Rear) cylinder valve clearance as the => ae ‘same manner of #1 (Front) cylinder and adjust the oe. clearance if necessary. 4.65 mm : Special tool 4) Select a replacement shim that will provide a (ap (A): 09900-20804 (Thickness gauge) clearance within the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. ACAUTION Both the right and left valve clearances should be as closely as possible. 5) Fit the selected shim (2) to the valve stem end, witt numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. TeM0200120 10) After finishing the valve clearance inspection, NOTE: reinstall the removed parts. Refer to “Engine Top + Be sure to apply engine oil to tappet shim Side Reassembiy” in Section 1D (Page 10-32), top and bottom faces, “Spark Plug Cap and Spark Plug Removal and Wha asauina the taopat hires ba wurethe Installation” in Section 1H (Page 1H-6), “Radiator Reservoir Tank Removal and Installation’ in Section 1F (Page 1F-9) and "Fuel Tank Removal and Installation” in Section 1G (Page 16-6). figure printed sur \ce faces the tappet. rncarroz0%0.$s 8 2 5 3 3 z € & 2 3 € 5 € 2 & 3 = (INTAKE SIDE) ww gz" pasn 9qo} azis wus [ozeso-o0821) 135 wikis 13¢av (XXX-000S0-26871) ON WIHS Ladd WL [3VINII 318VL NOLLOATSS WIHS Ladd VL ww gor — ez uMys uesarg ww zo st eouereajs yedde, a1SIWWX3 <2 we] sre ‘wuunjoo yewozu04 Ut siz [ore 9215 ius 1uasesd YI UWUN}OD (eONIEA UI eoUEIEEID YOTEWY ore | 502 Seo160 ‘01s wiys wwasoid ainseayy soz [ove 50980 0109 $1 3NION. “souRVeaI9 1adder ainseoyy sao180 31YVHO SIHL3SN OL MOH or oH09C0 we ser Sc01z0 wea or ec0990 Gz se] ore sa S190 we ore | 30% oa COO sez | ove | soz | oe sot S50150 we oe oz) set or C509" wae [sve soe 351 | OFF oi Sow ee | siz | ove [ooz [ost [see [sex] Ot Oroseo sre [ore | soe oot oot | om ae oF SEOWEO ore [soz or ont [ect Sor ore oc0820 Te] oe 3072 | 002 oa seo wr oD SEO oz0-060 Stz | ov | 90 | oz ost | see fore oe srt sz | 02k 00500 ore [soz | coz [oot seu fort [sc en on oH 00000 | | set ees | or | se oes | exe se | oe | se | oe | ses | ont | ser | ns | ses | xs | sau | oe | st | os ax | sa roxanoz001901ww gz't pasn 9g 0} ezis wus, uw sot azs uNYsiussald aE www gos! eourse9; ieddey, rls S1gvWx3 we] iz | ore aa kee wel srelore| soe 23715 ways 1wsaid yy UULOD FeINIOR Uy SOUEIED!D YOIeY Ih STE AE et Oe sean See nis wise oieesre Hy Wz | sz fore | soz oot-as0 {QOD SANNA somasiodde onsen | We | sre | ore | soe [ooe 350160 SLUVHO SIHL3SN OLMOH ee Rel excare Be] sz [ove se ‘S010 wee | Se et [ere SOO WEE | siz | ove | soz | we | sou | oF at wow Bz] 512 | oz | 02 | oor S50100 a Wee | sve | ove | s0z | ove | sot wom 3 BF] siz ore [ost [oer] 30150 z Tz [az pare] oe ont fer coca g TF] siz | ove | soe | ove [estos sore g TEE] siz | ore | soz | woz [sor om [scr OKO z Teele sz] vz | soz | one | oer | oot Sit [ort seoreo w 060-020 She | oe | $02 | 002 [S64] 061 | seu fore | sce ee srt s10s10 ore [S02 [002 | sox [on [ome [oat [ozs [are se re wr ook. S02 | 002 [S61 obs [584 | ov [ses | ore [sou aE srt ore [see st e000 ] ozz | siz] ovz | ez | vz | sox on 591 | cov os | ort | ov | se 21 | 021 Jom cuwat J ixsssve onSaaa| exe | siz | ore | s0e | 002 | ses | oot | sos sextet se es na (028S0-008Z+) 13S WIHS L3ddvi (XXX-000S0-26821) ON WIHS Ladd WL UsnvHx3] 37@VL NOILO373S WIHS Ladd VL 08-8 Maintenance and LubriMaintenance and Lubrication: _0B-9 © Install the intake or exhaust camshafts and cam chain tension adjuster. Refer to “Engine Top Side Reassembly” in Section 1D (Page 1-32). Rotate the engine so that the tappet is depressed Sully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to conifrm that itis within the specified range. After finishing the valve clearance adjustment, reinstall the removed parts, Refer to “Engine Top Side Reassembly’ in Section 1D (Page 1D-32). Spark Plug Replacement faeNC1s10206008 Seplace spark plug Every 12.000 km (7 500 miles, 24 months) Stefer to “Spark Plug Cap and Spark Plug Removal and testelation” in Section 1H (Page 1H-6). ‘Spark Plug Inspection and Cleaning BENC11J10206006 Sespect spark plus Every 6 000 km (4000 miles, 12 months) ‘Seat Range *) Remove the spark plugs. Refer to “Spark Plug Cap and Spark Plug Removal and Installation” in Section ‘TH (Page 1H-6). 2) Check spark plug heat range by observing electrode colo. If the electrode of the spark plug is wet appearing or dark color, replace the spark piug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one. Heat range | Standard | Coldtype | Hot type NGK | CR8EIA-9 | CROEIA- CRTEIA-9 DENSO | iU24D_— 10270 = 3) After finishing the spark plug inspection, reinstall the removed parts, Spark Plug Gap 1) Remove the spark plugs. Refer to “Spark Plug Cap and Spark Plug Removal and Installation” in Section 4H (Page 1H-6). 2) Measure the spark plug gap using a wire gauge. Ifit is notwithin the specification, replace the spark plug. NOTICE + To prevent the damage of iridium center electrode, use a wire gauge to check the gap. + Never adjust the spark plug gap. rk plu 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) rovetoooeeor 3) After finishing the spark plug inspection, reinstall the removed parts. Electrodes Condition 1) Remove the spark plugs. Refer to “Spark Plug Cap and Spark Plug Removal and Installation” in Section 1H (Page 1H-6). 2) Check to see the worn or burnt condition of the electrodes. Ifitis extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, or damaged thread replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage 3) After finishing the spark plug inspection, reinstall the removed parts.Maintenance and Lubricatior Fuel Line Inspection Bencr1s 10206007 Inspect fu Every 6 000 km (4.000 miles, 12 months) Inspect the fuel line in the following procedures: 1) Lift and support the fuel tank. Refer to “Fuel Tank Removal and installation” in Section 1G (Page 1G- 6). 2) Inspect the fuel feed hoses for damage and fuel leakage. If any defects are found, the fuel feed hoses must be replaced. 3) Alter finishing the Fuel feed hoses Inspection, reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation” in Section 1G (Page 16-6). Evaporative Emission Control System Inspection (E-33 Only) ENC, 10206008 ion control s) "4 months) Inspect evapor mi Every 12 000 km (7 500 mi Inspect the evaporative emission control system periodically (E-33 only). Engine Oil and Filter Rep! ement aENC11110206009 Replace engine oil Initially at 1000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Replace oil filter Initially at 1000 km (600 miles, 2 months) and every 18.000 km (11 000 miles, 36 months) thereafter Oil should be changed while the engine is warm. Oil fiter replacement at the above intervals, should be done together with the engine oil change. Engine Oil Replacement 1) Keep the motorcycle upright 2) Place an oil pan below the engine, and drain engine il by removing the oil drain plug (1) and filer cap (2). renaye200140 rev 2001501 3) Install the new gasket washer and tighten the oil drain plug (1) to the specified torque. Tightening torque Oil drain plug (a): 21 Nm (2.1 kgf-m, 15.0 Ibf-ft) BV.) 4) Pour new oil through the oil filler. When performing, an oil change (without oil filter replacement), the engine will hold about 2.4 L (2.6/2.1 US/Imp qt) of ol. Use of SF/SG or SH/SJ in API with MA in JASO.©) Tum off the engine and wait about three minutes, shen check the oil level through the inspection window (3). If the oll level is below the "L" mark, add ‘to the “F” mark. If the level is above the “F” mark, ain the oil until the level reaches the “F” mark. renasoa001r-0+ ‘Qe Level Inspection +) Keep the motorcycle upright. 2) Stert up the engine and allow it to run for few minutes at idle speed, ‘S) Tam off the engine and wait about three minutes, ten check the oil level through the inspection ‘window (1). if the level is below mark “L", add oil to °& mark. If the level is above mark °F", drain oil to 7 mark. HeMt020018.01 De Fiiter Replacement ) Drain engine oil as described in the engine oil seplacement procedure. 2) Remove the oil filter (1) using the special tool. Special tool aA): 09945~40620 (Oil filter wrench) roro200%901 __ 3) Apply engine ol lightly o the O-ring of new ol fiter, before installation. NOTICE 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 motorcy 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 (2a (A): 09915-40620 (Oil filter wrench) Tightening torque Oil filter (a): 20 N-m (2.0 kgf-m, 14.5 Ibf-f) irs 5) Add new engine oil and check the oil level is as described in the engine oil replacement procedure. Necessar gine oil Oil change: 2 400 ml (2.5/2.1 US/Imp qt) Oil and filter change: 2 750 ml (2.9/2.4 US/Imp qt) Engine overhaul: 3 000 ml (3.2/2.6 US/Imp qt)0B-12_ Maintenance and Lubrication: oe eeeeneoee—me0wq| TTT Throttle Cable Play Inspection and Adjustment BENCTIJI0206010 Inspect throttle cable play Initially at 1 000 km (6 000 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Inspect and adjust the throttle cable play “a” as follows. Throttle cable play “a” 2.0 = 4.0 mm (0.08 = 0.16 in) 1) Remove the rubber boot (1). 2) Loosen the lock-nut (2) of the throttle pulling cable (3). 3) Turn the adjuster (4) in or out unti the throttle cable play ‘a’ (at the throttle grip) is between 2.0 - 4.0 mm (0.08 - 0.16 in). 4) Tighten the lock-nut (2) while holding the adjuster (4). renstc2002.04 5) Install the rubber boot (4) firmly. After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically. nt Throttle Valve Synchronization ENC141020601 Inspect thr Ive synchroni Initially 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 months) Inspect the throttle vaive synchronization periodically Refer to "Throttle Valve Synchronization” in Section 1D (Page 1D-15), Cooling System Inspection ENC H1020601 Inspect cooling system Every 6 000 km (4 000 miles, 12 months) Replace engine coolant (Coolant color: Blue] Every 24 000 km (14 500 miles, 48 months) Replace engine coolant (Coolant color: Green) Every 12 000 km (75 000 miles, 24 months) Engine Coolant Level inspection 1) Keep the motorcycle upright. 2) Remove the right frame side cover. Refer to “Exterior Parts Removal and installation” in Section 9D (Page 90-5). 3) Check the engine coolant level by observing the *F” and “L" lines on the engine coolant reservoir tank. If the level is below the *L" line, add engine coolant to the ‘F” line from the engine coolant reservoir tank filer, afer lift up the fuel tank. Refer to "Fuel Tank Removal and Installation” in Section 1G (Page 1G- 6). wee ier8Jt02002201 4) After finishing the engine coolant level inspection, reinstall the removed parts.Maintenance and Lubrication: _0B-13 Engine Coolant Change Sefer to “Engine Coolant Descriotion” in Section 1F (Pace 1F-1) Do not open the radiator cap when the engine 's hot, as you may be injured by escaping hot Squid 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. ) Remove the body cowling assembly. Refer to “Exterior Parts Removal and Installation” in Section (Page 90-5). BRemove the radiator cap (1), erso200.01 ) Drain engine coolant by removing the drain bolt (2). =) Flush the radiator with fresh water if necessary. ‘S)irstall the new gasket and tighten the drain plug (2) te the specified torque. Tightening torque Engine coolant drain plug (a) m, 9.5 Ibf-ft) 13. Nem (1.3 kgf 6) Pour the specified engine coolant up to the radiator inlet, Engine coolant capacity (excluding reservoir) 1700 mi (1.8/4. silts Coe 7) Bleed air from the cooling circuit 8) After changing engine coolant, reinstall the removed parts, Air Bleeding From the Cooling Circuit 1) Support the motorcycle upright. 2) Remove the radiator cap and pour engine coolant up to the radiator inlet. Refer to "Engine Coolant Change” (Page 0B-13) 3) Slowly swing the motorcycle, 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 4), 5) procedures until no air bleeds from the thermostat connector inlet. 8) Close the radiator cap securely.9) After warming up and cooling down the engine several times, add the engine coolant up to the full level of the reservoir tank. Refer to “Engine Coolant Change" (Page 0B-13). NOTICE Make sure that the radiators filled with engine coolant up to the reservoir tank full level. 10) Reinstall the removed parts. Radiator Hose Inspection ‘Check the radiator hoses for crack, damage or engine coolant leakage. Refer to “Water Hose Inspection” Section 1F (Page 1F-7), Clutch System Inspection BENCH1410206013 Inspect clutch cable play Every 6 000 km (4 000 miles, 12 months) Inspect and adjust the clutch cable play “a” as follows, Clutch cable play 10-15 mm (0.4 ~ 0.6 in) renste200260+ 1) Turn the adjuster (1) all the way into the clutch lever assembly. veratoaenes.0¢ 2) Remove the clutch cover. Refer to “Clutch Removal” in Section 5C (Page 5C-7). 3) Loosen the lock-nut (2) and turn in the release screw (3) to feel resistance. 4) From that position, turn out the release screw (3) 1 tum and tighten the lock-nut (2) to the specified torque by holding the release screw (3). Clutch release screw 1 turn back Tightening torque Release screw lock-nut (a): 5N:m (0.5 kgf-m, 3. serarea0000: 5) Install the clutch cover. Refer to “Clutch Removal!” i Section SC (Page 5C-7). 6) Loosen the lock-nut (4). NOTE The adjustment of clutch cable play should be made on the adjuster on which the clutch cable cap is installed with 3 - 5 mm (0.12 — 0.20 in) of threads left on the clutch lever adjuster. 7) Turn the adjuster (5) in or out until the clutch cable play “a” is between 10 ~ 15 mm (0.4 - 0.6 in). 8) Tighten the lock-nut (4) while holding the adjuster (5),®) Tighten the adjuster lock-nut (6). ®) Pour engine oll and coolant, Refer to “Engine Oil and ter Replacement” (Page 0B-10) and “Cooling System Inspection” (Page 0B-12). Maintenance and Lubrication: _0B-15 Drive Chain Inspection and Adjustment BENC 1 10208018 Inspect drive chain Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter Drive Chain Visual Check 1) With the transmission in neutral, support the motorcycle a jack and turn the rear wheel slowly by hand, A.CAUTION Make sure that the motorcycle is supported securely. NOTICE Do not support the motorcycle with the exhaust pipes. 2) Visually check the drive chain for the possible defects listed as follows. If any defects are found, the drive chain must be replaced. Refer to “Drive Chain Replacement” in Section 3A (Page 3A-7). Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear Improper chain adjustment Missing O-ring seals NOTE When replacing the drive chain, replace the drive chain and sprockets as aDrive Chain Length Inspection 1) Loosen the rear axle nut (1) 2) Give tension to the drive chain fully by tuming both chain adjuster bolts (2). 3) Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Drive chain 20-pitch length jervice limit: 319.4 mm (12.57 in) 4) After finishing the drive chain length inspection, adjust the drive chain slack Drive Chain Stack Adjustment 1) Support the motorcycle with a jack. ACAUTION Make sure that the motorcycle is supported securely. NOTICE Do not support the motorcycle with the ‘exhaust pipes. 2) Loosen the rear axle nut (1). 3) Loosen or tighten both chain adjuster bolts (2) unt there is 20 - 30 mm (0.8 - 1.2 in) ‘a” of slack at the middle of the chain between the engine and rear sprockets as shown in the figure. NOTICE The reference marks “A” on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned. Drive chain slack “a” Standard 20-30 mm (0.8 - 1.2 in) ve maniaoon 4) After adjusting the drive chain, tighten the rear axle nut to the specified torque Tightening torque Rear axle nut: 100 Nem (10.0 kgf-m, 72.5 Ibf-ft) 5) Recheck the drive chain slack after tightening the axle nut.ion: _0B-17 ‘Delve Chain Cleaning and Lubricating BENCTIUIO205015 ‘Sean and lubricate dri Every 1000 km (600 miles) ‘Dems and lubricate the drive chain in the following grocedures: *) Clean the drive chain with kerosine. Ifthe drive chain Sends to rust quickyy, the intervals must be shortened. NOTICE ‘Do not use trichloroethyle similar solvent. These fluids have too great a dissolving power for this chain and they can damage the ‘O-rings. Use only kerosine to clean the drive chain. in gasoline or any Aer cleaning and drying the chain, oil it with a heavyweight motor oll “drive chain oil”. Such oil can damage the O- rings. Brake System Inspection BENCH 10206016 Inspect | rystem Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4.000 miles, 12 months) thereafter Inspect brake hose and brake fluid Every 6 000 km (4 000 miles, 12 months) CNIS The brake system of this motorcycle 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 ret brake fluid left over from the last servicing or stored for a long period of tim NOTICE Brake fluid, leaks, wi re with safe. running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. NOTE ‘The standard drive chain is a RK 525SMOZ8. ‘SUZUKI recommends to use this standard rive chain as a replacement. Her1s102000401 Brake Fluid Level Check 1) Keep the motorcycle upright and place the handlebars straight. 2) Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs 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) penatc2003601Brake Pads Check The extent of brake pad wear can be checked by ‘observing the grooved limit ine “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 48 (Page 48-2) and “Rear Brake Pad Replacement" in Section 4C (Page 4C-2). NOTICE Replace the brake pad as a set, otherwise braking performance will be adversely affected. Front and Rear Brake Hose Inspection Inspect the brake hoses and hose joints for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Refer to “Front Brake Hose Removal and installation’ in Section 4A (Page 4A-16) and “Rear Brake Hose Removal and Installation’ in Section 4A (Page 4A-17).Maintenani rake Pedal Height Inspection and Adjustment * lespect the brake pedal height ‘a between the pedal fop face and footrest. Asjust the brake pedal height if necessary. Brake pedal height “'a” Standard; 23 - 33 mm (0.9 - 1.3 in) @Leesen the lock-nut (1) = Tem the push rod (2) unti the brake pedal becomes 23 — 33 mm (0.9 ~ 1.3 in) “a” below the top of the fcotrest Tighten the lock-nut (1) securely. Tightening torque Rear brake master cylinder rod lock-nut (a): 18 fem (1.8 kgf-m, 13.0 Ibf-ft) sevstoa00424 © Ater finishing the brake pedal height inspection and ‘saustment, check the rear brake light switch. Refer SS “Rear Brake Light Switch Inspection and Aczustment’ in Section 4A (Page 4A-5). ‘Sree Fluid Replacement Peclece brake fluid Every 2 years Fe to “Brake Fluid Replacement’ in Section 4A (Page =r He Bleeding from Brake Fluid Circuit Bee © “Air Bleeding from Brake Fluid Circuit” in Becton 4A (Page 4A-5). Fee Brake Light Switch Adjustment et to "Rear Brake Light Switch Inspection and eesmment” in Section 4A (Page 4-5), Brake Hose Replacement Replace brake Every 4 years Refer to “Front Brake Hose Removal and Installation” in ‘Section 4A (Page 4A-16) and “Rear Brake Hose Removal and Installation” in Section 4A (Page 44-17) Tire inspection BeNcts10206017 Inspect tire Every 6 000 km (4 000 miles, 12 months) Tire Tread Condition Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation, Itis highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. Special tool (2D: 09900-20805 (Tire depth gauge) Tire tread depth (Service limit Front: 1.6 mm (0.06 in) Rear: 2.0 mm (0.08 in) saracsoz006.02 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 shorter tire life wil resuit. Cold inflation tire pressure is as follows. Cold inflatio ng | *| psi_| KP [kPa | kgffem? Front | 225 | 33_| 225 Rear | 250 2.50 | 36 | 260 | & Soli [ks0B-20 Maintenance and Lubric: ———er—ssssc:'_——||_ hw NOTICE The standard tire fitted on this motorcycle is 110/80 R19 M/C 59H for front and 150/70 R17 MIC 69H for rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires. type RIDGESTONE + Front: TW101 RADIAL J + Rear: TW152 RADIAL F Steering System Inspection BENCturoz06018 Inspect steering system Initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter Steering should be adjusted property for smooth turning of handlebars and safe running. Overtighten steering prevents smooth turning of the handlebars and too loose steering wil cause poor stability, 1) Check that there is no play in the front fork. 2) Support the motorcycle so that the front wheel is off the ground, with the wheel facing straight ahoad grasp the lower fork tubes near the axie and pull forward. If play is found, readjust the steering. Refer to "Steering Tension Adjustment” in Section 6B (Page 6B-10). ACAUTION Make sure that the motorcycle is supported securely. NOTICE Do not support the motorcycle with the exhaust pipes. Front Fork Inspection BENCH J107060 Inspect front fork Every 12 000 km (7 500 miles, 24 months) Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. Refer to “Front Fork Disassembly and Assembly’ in Section 2B (Page 28-4). Rear Suspension Inspection BENCH 102060 Inspect rear suspension Every 12 000 km (7 $00 miles, 24 months) Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective parts, if necessary, Refer to "Rea Shock Absorber Removal and Installation’ in Section 2¢ (Page 2C-3), “Cushion Lever / Cushion Rod Removal and Installation” in Section 2C (Page 2C-6) and “Swingarm Removal and Installation” in Section 2C (Page 2C-8). rernna2o%er0TEI) _ Front rato hove ion bot 23 Nm Tam 10S Fron bre capri ‘Shessis Bolt and Nut Inspection BENCtWr0z06021 ‘Tighten chassis bolt and nut “Selly at 1 000 km (600 miles, 2 months) and every = 80 km (4 000 miles, 12 months) thereafter ‘ck that all chassis bolts and nuts are tightened to Pee specified torque. perruzon2c2 Tara TS 7 TERE Steering stom hood nit 90 Nim (0.0 Kg SEES Hircnnar hover bot 23 Nim @.3 kgm, a) (Frente clamp BOR TS Nem (2 GFN 16s [14 HE) Rear brake tose union Bat 23 Nm (2.3 kam, 165 [sew ILD _Rear brake dec bot 23 New (2 3kgh-n, 16.5 ON) [FR cnc na tobe pga (ee ear brake caliper mooring bol 23 Nn (23 Fgh Rear brake air beodor valve 6 Nev (06 kot, 4.3 ER) geen, 43.5 1BER) — [74 (EI Rearbrake hose unon bak Nez Toten). re02005 rm, 185 1) [18 CHIE” Rearbrake master ojinder mounting bat 10Nim [1.0 holm vemos. feet Tare nat 16 Nm (16 Kam, 11S ERY BH WIEN Rear take manor cyinderrodioccnut @Nen (V8 Kgl 13D” He Manze.<, Icftrox080 21 Fear shock absafber mounting nul (Upper) 60 Wen (5.0 Kam, vestssecoosz or DS ew tock abcorser moaning nak Lowen SON GOKGm, | be NATE Gut 78 renat020060-0¢ SO Nm (GO KGFm, BOOHER, Seat a Compression Pressure Check BENCH 0208022 Refer to “Compression Pressure Check’ in Section 1D (Page 10-3). Oil Pressure Check sencr1s10208009 Refer to “Oil Pressure Check" in Section 1 (Page 1E- 5). ‘SDS Check ENC ss10206004 Refer to “SDS Check” in Section 1A (Page 1A-18).0B-24 Maintenance and Lubrication: Specifications Tightening Torque Specifications wastia aati " Tightening torque . Fastening part Nm ight TEE Note [Exhaust pipe bolt 23 23 16.5 ® (Page 0B-4) 7 ‘Muffler mounting bot 23 23 16.5 |= (Page 08-4) [Exhaust pipe connecting bolt 18 48 43.0 |= (Page 0B-4) Muffler mounting nut 23 23 16.5 ___|=(Page 08-4) (Oil drain plug 24 15.0___|™(Page 08-10) Oil filter 2.0 14.5 i) Engine coolant drain plug 13 95 ) [Release screw lock-nut 05 3.7___|=(Page 08-14) Rear axle nul “400 40.0 72.5 |=(Page 0B-16) [Rear brake master cylinder rod lock-nut L 18 18 43.0 ___| =(Page 08-19) NOTE The tightening torque(s) also specified in: “Chassis Bolt and Nut Inspection” (Page 0B-21) Reference: For the tightening torques of fasteners not specified in this section, refer to “Tightening Torque List” in Section OC (Page 0C-7). Special Tools and Equipment Recommended Service Material a _ BeNCtrst020800 Cc ‘Material ‘SUZUKI recommended product or Specification i Note - [Brake fluid DoT 4 = = (Page 08-17) NOTE Required service material(s) also described in: “Lubrication Points” (Page 0B-2) Special Too! _ BeNCI1510z080 (09900-20804 (09900-20805 ‘Thickness gauge Tire depth gauge © (Page 0B-5)/ >, | (Page 08-19) » (Page 08-6) 3 (09915-40620 Oil filter wrench (Page 0B-11)/ » (Page 0B-11)(when cold) to valve stem clearance! 1D. 0.0. jection runout thickness ‘width radial runout length tension + Cylinder Head (n) item ial ol clearance imal holder 1.D. .D. runout, pin (at arrow ™ head distortion Specifications in 31.0(7.22) 7 10 = 0.20 (0.004 = 0.008) 0.20 — 0.30 (0.008 - 0.012) 1.010 = 0.037 ( .0015 0.030 - 0.057 002: 4.500 4.512 (0.1772 = 0.177 4.475 ~ 4.490 (0.1762 - 0.1 4.455 — 4.470 (0.1754 — 0.1760) 19 = 1.1 (0.035 — 0.043) = 147 NZ: 28.5 — at length 33.4 mm (1.31 in) ni 35.48 ~ 36.55 (1.397 - 4. 48 — 1.318 — 1.321 0.027 — 0.069 (0.0011 - 0. ) .007 = 22. = 0.8672) 21.959 = 21.980 (0.8645 - 0. 6th pin Service Data: _0C-1 BENC11310907001 10105 (0.002 37.1 (1.46) Limit 18 (1.385) 33.18 (1.306) 40C-2_ Service Data: =~. eee Cylinder + Piston + Piston Ring Unit: mm (in) [ Item ‘Standard Limit 1300-1700 KPa 7700 KPa Compression pressure (13 = 17 kgficm?, 185 - 242 psi) (11 kgt/em?, 156 psi) . Pi ‘Compression pressure difference 7 oe tae pal Piston-to-cylinder clearance 0.025 — 0.035 (0.0010 - 0.0014) 0.120 (0.0047) Cylinder bore 1,000 81.015 (3.1890 - 3.1896) No nicks or Scratches ae 80.970 — 80.985 (3.1678 - 3. 1884) psion aem. Measure 20 mm (0.8 in) from the skirt end. 0.800,(8:1842) Cylinder distortion = 0:05 (0.003) a List | — Approx. 6.5 (0.26) 5.2 (0.20) Ebene tee ent gen 2nd | 2T ‘Approx. 9.0 (0:35) 72 (0.28) : ist | — 0.06 = 0.18 (0.002 - 0.007) 05 (0.020) Psion ing ondoee 2nd | -2T 10.06 0.18 (0.002 - 0.007) 10.5 (0.020) ist = 1.180 (0.0077 Piston ring-to-groove clearance ay = 2180 (oussy 4st 0.83 - 0.85 (0.0327 - 0.0335) = i 1.30 — 1.32 (0.0512 — 0.0520) Paton fig orcas Mack 2nd 1.01 ~ 1.03 (0.0398 = 0.0406) = Ol 2.01 - 2.03 (0.0791 — 0.0799) = a 0.76 - 0.81 (0.0299 - 0.0319) Piston ring thickness 1.08 - 1.10 (0.0425 — 0.0433) == | 2nd 0.97 = 0.99 (0.0382 — 0.0390) = Piston pin bore LD. | 20.002 = 20.008 (0.7875 - 0.7877) 70.030 (0.7886) Piston pin O.D. i 9.992 = 20.000 (0.7871 — 0° 7A74) 0.080 (0.7866) Conrod + Crankshaft Unit: mm (in) [ Item’ Standard Limit ‘Conrod small end 1. 2010 = 20.016 (0.7878 - 0.7881) 20.040 (0.7890) (Conrod big end side clearance 0.170 — 0.320 (0.0067 - 0.0126) 0.5 (0.020) [Conrod big end wiath 20.95 - 21.00 (0.825 - 0.827) = ‘Crank pin width [42.17 = 42.22 (1.660 — 1.662) | = [Conrod big end oil clearance 10.032 = 01056 (0.0013 - 0.0022) 0.080 (0.0037) (Crank pin 0.0. 37.976 — 38.000 (1.4951 — 1.4961) =_ Crankshaft journal 0.D- 41.985 — 42.000 (1.6529 - 1.6535) — ‘Crankshaft runout = 0:05 (0.002) oll Pump Item Standard Limit Ol ure (at 60 °C, 140 °F) 200-600 kPa ee pene 28 — 85 psi) - Clutch Unit: mm (in) tem Standard Limit Clutch cable play 10-15 (04-06) | = Clutch release screw 1 turn counterclockwise ss Clutch drive plate thickness No.1, 2] 2.92 - 3.08 (0.115 - 0.121) 2.62 (0.103) ‘Clutch crive plate claw width [No.i,2 | 13.7= 138 (0.539 - 0.543) 12.9 (0.508) Clutch riven plate distortion _ 0.10 (0.004) (Clutch spring free length i 06 (2.39) [876 227)