- •Generalinformation
- •Informationlabels
- •Periodicmaintenance
- •Valveclearance...................................................................2-8
- •Valveclearance
- •Inspectevery24000km(15000miles,24months).
- •IrWtl09900-20803:Thicknessgauge
- •09913-10750:Adaptor
- •Ventitsshortoropencircuit.
- •Iacautioni
- •09900-22302:Plastigauge
- •09900-22403:Smallboregauge{18-35mm)
- •09916-34542:Reamerhandle
- •09916-43220:Attachment(2)
- •Initialseatcut
- •15Mm(0.6in)fromthepistonskirtend.
- •Installation
- •1Root109913-70210:Bearinginstallerset
- •Inspectionandcleaning
- •09900-20701:Magneticstand
- •09900-21304:V-block(100mm)
- •09900-22401:Smallboregauge(1o-18mm)
- •Inspection
- •Iacautioni
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Becareful!nottodamagethecylinderwallbytheconrod.
- •1L1molybdenumoilsolution
- •Iacautioni
- •Initial:15n·m(1.5kgf·m,11.0lb-ft)Final:90°(1/.Iturn)
- •Inglightly.
- •Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)
- •Usethenewgaskettopreventoilleakage.
- •FlSystemandintakeairsystem
- •Voltagecheck
- •VoltageBetween:
- •VoltageBetween:
- •Injectiontime(injectionvolume)
- •Various
- •ISensors
- •IUltimate
- •Injectionstopcontrol
- •Injectiontiming
- •Intakeairsystem
- •Injection"yes""'yes"
- •Inspection
- •1Root109900-25008:Multicircuittester
- •1Rq109900-25008:Multicircuittester
- •Inspection
- •Irk!09900-25008:Multicircuittester
- •1Rkib09900-25008:Multicircutitester
- •Construction
- •Inspection
- •1Root109930-11960:Torxwrench
- •Inspection
- •Iapsensorinspection
- •Iapsensorremoval/installation
- •28ForTPsensorsettingprocedure.
- •Iatsensorinspection
- •Iatsensorremoval/installation
- •Inspection
- •Installation
- •Inspection
- •..Takespecialcarewhenhandlingthetemperature-sen• sor.Itmaycausedamageifitgetsasharpimpact.
- •Installation
- •Inspection
- •Installation
- •Inspection
- •Usethenew0-ringstopreventenginecoolantleakage.
- •Icamdrivechaini
- •Istarterclutchi
- •Chassis
- •Installation
- •Installation
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Itemn·mkgf·mlb-ft
- •Inspection
- •09940-14960:Steeringstemnutwrenchsocket
- •Inspectionanddisassembly
- •09940-14960:Steeringstemnutwrenchsocket
- •09940-14960:Steeringstemnutwrenchsocket
- •Itemn·mkgf-mlb-ft
- •Inspectionanddisassembly
- •09900-20701:Magneticstand
- •Inspection
- •Inspectionanddisassembly
- •Ingsolventsuchasgasoline,kerosineortheothers.
- •Iw)lllllu.D
- •Inspection
- •Valveinspection
- •Valveinstallation
- •Electricalsystem
- •IIncorrectt
- •Ignitioncoil
- •Ignitionsystem
- •0 Sensor
- •ICorrectIncorrect
- •Inspection
- •Ventanelectricshockwhiletesting.
- •Ignitioncoiuplugcapresistance
- •1Riot109900-25008:Multicircuittesterset
- •Inspection
- •09930-11940:Bitholder
- •Initialcharging
- •Iacautioni
- •Iacautioni
- •Insideofthebodycowling
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Limit
- •Itemstd/spec.Note
- •Itemstd/spec.Note
- •11IiiIu
- •Iatsensor
- •Suzukimotorcorporation
Insideofthebodycowling
Wiringharness
ClampClamp
Handlebarswitch(L·R)Ignitionswitch
Clampthewiringharnesstotheframe.
Wiringharness
-
Wiringharness
Tothefrontturnsignallight(R)
Wiringharness
Waterhose
Clamp
Facetheclampendtodownward.
Wiringharness
Waterhose
Clamp
Clamp
Handlebarswitch
(L·R)
e
Passtheside-standswitchleadwireoverthebatteryleadwire.
ClampClamp
Wiringharness
Battery~
Donotputthetipofclampintothebatterybox.
Clamp
Battery8
Handlebarswitch(L·R)
I
WiringharnessClampthew1nngFanmotorharnesstotheframe.
Clamp
Wirinharness
Wiringharness
Rearturn
Isignallight(L)
Clamp
,~u..'Wiringharness
IRegulator/Rectifier
/Clamp
\
Passthefuelpumpleadwirebetweentheenginecoolantbypasshoseandengine
Wiringharness
Clamp
OilpressureswitchWiringharness
Side-standswitch\BatteryplusleadwireStartermotorPassthebatteryplusleadResistorwirebetweentheECMand
starterrelay.
InstallTosensorsothat
itspawlshouldcomeoutsidetherubberpartsecurely
Clamp
StartermotorleadwirePassthroughthestartermotorleadwirebehindoftheseatlockcable.
Clamp
Wiringharness
Fanmotor-
Setlheiruectorcouplertotheoptimumpositionafterconnectingtheinjectorlead
wirecouplerPasstheneutralswitch
leadwirebehindthebypass
hoseandbreatherhose
InsertTosensoruptotherootofrearfendersecurely.
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PAIR{AIRSUPPLY)SYSTEMHOSEROUTING
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FRAMECOVERSET-UP
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~23N·m
(2.3kgf·m,16.5lb-ft)
Frontseat
HEATSHIELDSET-UP
Leftundercowling
LeftundercowlingheatshieldNo.2
CenterundercowlingheatshieldNo.1
CenterundercowlingheatshieldNo.2
Rightundercowling--.:!~ym.~~
heatshieldNo.3
Centerundercowling
~50N·m
I(5.0kgf·m.36.2lb-ft)
~40N·m
(4.0kgf·m,28.9lb-ft)
GEARSHIFTPEDALSET-UP
-----.------------------=-~I
Footrest
//"\
52-62mm
(2.05-2.44in)
-
SPECIALTOOLS
09900-06104
Snapringpliers
09900-06107
Snapringpliers
09900-06108
Snapringpliers
09900-20101
09900-20102
Verniercalipers
09900-20203 |
09900-20205 |
|
0990Q-20602 |
09900-20605 |
Micrometer |
Micrometer |
09900-20508 |
Dialgauge |
Dialcalipers |
(50-75mm) |
(0-25mm) |
Cylindergaugeset |
(1/1000mm,1mm) |
(1/100mm,10-34mm) |
09900-20607 |
|
09900-20803 |
|
|
Dialgauge |
09900-20701 |
09900-20806 |
09900-20805 |
09900-21304 |
(1/100mm,10mm) |
Magneticstand |
Thicknessgauge |
Tiredepthgauge |
V-block(100mm) |
09900-22301 |
0990Q-22401{10-18 |
mm) |
|
|
09913-10750 |
09900-22302 |
0990Q-22403(18-35 |
mm) |
09900-25008 |
09910-20115 |
Compressiongauge |
Plastigauge |
Smallboregauge |
|
Multicircuittesterset |
Conrodholder |
adapter |
09913-13121 |
09913-50121 |
09913-70210 |
09915-40610 |
09915-64510 |
|
Carburetorbalancerset |
Oilsealremover |
Bearinginstallerset |
Oilfilterwrench |
Compression |
gauge |
-
|
~~ |
|
||
09915-74520 |
09915-74540 |
09915-77330 |
|
09916-14510 |
Oilpressuregauge |
Oilpressuregauge |
Meter |
09916-10911 |
Valvespring |
hose |
adaptor |
(forhighpressure) |
Valvelapperset |
compressor |
"->"-11",.-.._v-.
09916-14521 |
|
09916-20630 |
09916-20650 |
|
Valvespringcompressor |
09916-21111 |
Valveseatcutterhead |
Solidpilot |
09916·34542 |
attachment |
Valveseatcutterset |
(N-126) |
(N-100-4.0) |
Reamerhandle |
09916-33310 |
09916-49030 |
09916-53310 |
|
|
Valveguidereamer |
Valveguidereamer |
Valvequide |
09916-43220 |
09916-84511 |
(4.0mm) |
(9.3mm) |
remover/installer |
Attachment |
Tweezers |
|
|
|
~~ |
|
09920-53740 |
|
09922-22711 |
||
09917-47010 |
09920-34830 |
Clutchsleevehub |
09921-20220 |
Drivechaincutting |
Vacuumpumpgauge |
Starterclutchholder |
holder |
Bearingremoverset |
andjoiningtool |
6~-
09924-84521
Bearinginstallerset
09916-14530
Valvespringcompres•
sorattachment
09925-18011
Steeringbearinginstaller
09930-11920
TorxbitJT40H
09930-11940
Bitholder
-
~
-
09940-14911
09930-11960
09930-34980
09930-44520
09930-82710
Steeringstemnut
Torxwrench
Rotorremover
Rotorholder
Modeselection
switchwrench
09940-14960 Steeringnutwrench |
09940-14970 Swingarmpivotshaft |
09940-14990 Enginemountingthrust |
09940-30221 Frontforkassembling |
09940-40211 Fuelpressuregauge |
socket |
locknutsocketwrench |
adjustersocketwrench |
tool |
adaptor |
~ ~ |
|
|
ti!fil |
|
09940-40220 |
09940-50120 |
|
09940-94922 |
|
Fuelpressuregauge |
Frontforkinnerrod |
09940-92720 |
Frontforkspringstop- |
09940-94930 |
hoseattachment |
holder |
Springscale |
perplate |
Frontforkspacerholder |
~~
.....
......
~
-
09941-34513
09943-74111
09944-60210
Steeringraceinstaller
Forkoillevelgauge
Wheelbearingremover
NOTE:
Whenorderthespecialtool,pleaseconfirmwhetheritisavailableornot.
TIGHTENINGTORQUE
ENGINE
ITEM |
N·m |
kaf·m |
lb-ft |
|
Exhaustoioebolt |
23 |
2.3 |
16.5 |
|
Mufflermountinanut |
23 |
2.3 |
16.5 |
|
Soeedsensorrotorbolt |
20 |
2.0 |
14.4 |
|
Enainesprocketnut |
115 |
11.5 |
83.2 |
|
Enginemountingboltandnut(M:12) |
75 |
7.5 |
54.0 |
|
(M:10) |
55 |
5.5 |
39.8 |
|
Enainemountinathrustadjuster |
23 |
2.3 |
16.5 |
|
Enoinemountinathrustadjusterlocknut |
45 |
4.5 |
32.5 |
|
Enginemountingpinchbolt |
23 |
2.3 |
16.5 |
|
Cylinderheadcoverbolt |
14 |
1.4 |
10.0 |
|
Sparkplug |
11 |
1.1 |
8.0 |
|
Camchainguidebolt |
10 |
1.0 |
7.0 |
|
Camshaftjournalholderbolt |
10 |
1.0 |
7.0 |
|
Camchaintensionadjustercapbolt |
23 |
2.3 |
16.5 |
|
Camchaintensionadjustermountingbolt |
10 |
1.0 |
7.0 |
|
Cylinderheadsidebolt |
14 |
1.4 |
IO.O |
|
Camchaintensionerbolt |
10 |
1.0 |
7.0 |
|
Cylinderheadbolt(M:10) |
46 |
4.6 |
33.3 |
|
(M:6) |
10 |
1.0 |
7.0 |
|
PAIRreedvalvecoverbolt |
10 |
1.0 |
7.0 |
|
Waterjacketplug |
9.5 |
0.95 |
6.9 |
|
Waterinletcoverbolt |
10 |
1.0 |
7.0 |
|
Clutchcoverbolt |
10 |
1.0 |
7.0 |
|
Clutchsleevehubnut |
150 |
15.0 |
108 |
|
Clutchsprinosetbolt |
10 |
1.0 |
7.0 |
|
Starterclutchcoverbolt |
10 |
1.0 |
7.0 |
|
Starteridleaearcoverbolt |
10 |
1.0 |
7.0 |
|
Valvetiminainspectionplua |
11 |
1.1 |
8.0 |
|
Starterclutchbolt |
55 |
5.5 |
40.0 |
|
Generatorcoverbolt |
10 |
1.0 |
7.0 |
|
Generatorrotorbolt |
120 |
12.0 |
88.5 |
|
Generatorstatorsetbolt |
10 |
1.0 |
7.0 |
|
Gearshiftcamstopperbolt |
10 |
1.0 |
7.0 |
|
Gearshiftcamstopperplatebolt |
10 |
1.0 |
7.0 |
|
Oilpressureswitch |
14 |
1.4 |
10.0 |
|
Crankcasebolt(M:6) |
11 |
1.1 |
8.0 |
|
(M:8) |
26 |
2.6 |
19.0 |
|
(M:9) |
32 |
3.2 |
23.0 |
|
Oilgalleryplug(M:6)(M:10) |
11 |
1.1 |
8.0 |
|
(M:16) |
35 |
3.5 |
26.5 |
|
Oildrainplug |
23 |
2.3 |
16.5 |
|
|
|
|
|
- |
ITEMPistoncoolinaoilietbolt |
|
N-m 10 |
|
kgf.m 1.0 |
lb-ft 7.0 |
Oiloumomountinabolt |
|
10 |
|
1.0 |
7.0 |
Conrodbearingcapbolt |
(Initial) |
15 |
|
1.5 |
11.0 |
|
(Final) |
|
90° |
(Vaturn) |
|
Bearinaretainerscrew |
|
10 |
|
1.0 |
7.0 |
Breathercoverbolt |
|
10 |
|
1.0 |
7.0 |
Oilstrainerbolt Oilpanbolt |
|
10 10 |
|
1.0 1.0 |
7.0 7.0 |
Oilcoolerbolt |
|
10 |
|
1.0 |
7.0 |
FlSYSTEMANDINTAKEAIRSYSTEM
Camshaftpositionsensormounting |
bolt |
8 |
0.86.0 |
||
Intakeairtemperaturesensor |
|
18 |
1.8 |
13.0 |
|
Fueldeliverypipemountingscrew |
|
5 |
0.5 |
3.7 |
|
Fuelpumpmountingbolt |
|
10 |
1.0 |
7.0 |
|
Throttlebodyconnectingbolt |
|
5 |
0.5 |
3.5 |
|
STVAmotoryokemountinabolt |
|
3.5 |
0.35 |
2.5 |
|
STVAmotorcovernut |
|
2.0 |
0.2 |
1.5 |
|
ITEMN·mkgf·mlb-ft
COOLINGSYSTEM ITEM |
|
N·m |
kaf·m |
lb-ft |
Impellersecurinabolt |
|
8 |
0.8 |
6.0 |
Waterournocoverbolt |
|
6 |
0.6 |
4.5 |
Waterpumpmountinqbolt |
|
10 |
1.0 |
7.0 |
Coolinafanthermo-switch |
|
17 |
1.7 |
12.5 |
Enainecoolanttemperature |
sensor |
18 |
1.8 |
13.0 |
Thermostatcasebolt |
|
10 |
1.0 |
7.0 |
8·32SERVICINGINFORMATION
CHASSIS
ITEM Steerinostemheadnut |
N·m 90 |
kgf·m 9.0 |
lb-ft 65.0 |
Steerinastemlocknut |
80 |
8.0 |
58.0 |
Steerinadamoerboltandnut |
23 |
2.3 |
16.6 |
Frontforkupperclampbolt |
23 |
2.3 |
16.5 |
Frontforklowerclampbolt |
23 |
2.3 |
16.5 |
Frontforkcapbolt |
35 |
3.5 |
25.5 |
Frontforkinnerrodlocknut |
20 |
2.0 |
14.5 |
Frontforkdamperrodbolt |
35 |
3.5 |
25.5 |
Frontaxle |
100 |
10.0 |
72.5 |
Frontaxlepinchbolt |
23 |
2.3 |
16.5 |
Handlebarclampbolt |
23 |
2.3 |
16.5 |
Handlebarsetbolt |
10 |
1.0 |
7.0 |
Frontbrakemastercylindermountingbolt |
10 |
1.0 |
7.0 |
Frontbrakecalipermountingbolt |
25 |
2.5 |
18.1 |
Frontbrakecaliperhousingbolt |
21 |
2.1 |
15.1 |
Brakehoseunionbolt |
23 |
2.3 |
16.5 |
Clutchholdermountingbolt |
10 |
1.0 |
7.0 |
Airbleedervalve |
8.0 |
0.8 |
6.0 |
Brakediscbolt(Front) |
23 |
2.3 |
16.5 |
Brakediscbolt(Rear) |
35 |
3.5 |
25.5 |
Rearbrakecalipermountingbolt |
25 |
2.5 |
18.1 |
Rearbrakecaliperhousingbolt |
30 |
3.0 |
21.5 |
Rearbrakemastercylindermountingbolt |
10 |
1.0 |
7.0 |
Rearbrakemastercylinderrodlocknut |
18 |
1.8 |
13.0 |
Frontfootrestbracketmountingbolt |
23 |
2.3 |
16.5 |
Swingarmpivotshaft |
15 |
1.5 |
11.0 |
Swingarmpivotnut |
100 |
10.0 |
72.5 |
Swingarmpivotlocknut |
90 |
9.0 |
65.0 |
Torquelinknut(Front) |
28 |
2.8 |
20.5 |
Torquelinknut(Rear) |
34 |
3.4 |
24.6 |
Cushionlevermountingnut |
78 |
7.8 |
56.5 |
Cushionrodmountingnut |
78 |
7.8 |
56.5 |
Rearshockabsorbermountingboltandnut
(UpperandLower)
505.036.0
RearaxlenutIForE-03,28, |
33 |
110 |
11.0 |
79.6 |
IFortheothers |
|
120 |
12.0 |
86.8 |
Rearsprocketnut |
|
60 |
6.0 |
43.5 |
Side-standmountinabracketbolt |
|
50 |
5.0 |
36.0 |
Cowlinabraceboltandnut |
|
23 |
2.3 |
16.5 |
Rearshockabsorberbracketnut |
|
115 |
11.5 |
83.2 |
Seatrailbolt |
|
23 |
2.3 |
16.5 |
TIGHTENINGTORQUECHART
Forotherboltsandnutslistedpreviously,refertothischart:
kgf.m 0.15 |
lb-ft 1.0 |
Nrn 2.3 |
kgf.m 0.23 |
lb-ft 1.5 |
0.3 |
2.0 |
4.5 |
0.45 |
3.0 |
0.55 |
4.0 |
10 |
1.0 |
7.0 |
1.3 |
9.5 |
23 |
2.3 |
16.5 |
2.9 |
21.0 |
50 |
5.0 |
36.0 |
4.5 |
32.5 |
85 |
8.5 |
61.5 |
6.5 |
47.0 |
135 |
13.5 |
97.5 |
10.5 |
76.0 |
210 |
21.0 |
152.0 |
16.0 |
115.5 |
240 |
24.0 |
173.5 |
....BoltDiameterConventionalor"4"markedbolt"7"markedbolt
®(mm)Nrn
41.5
53
65.5
813
1029
1245
1465
16105
18160
Conventionalbolt"4"markedboll"7"markedbolt
8·34SERVICINGINFORMATION-
SERVICEDATA
-
VALVE+GUIDEUnit:mm(in)
Valvediam.
ITEM STD/SPEC.LIMITIN.27.2
(1.07)
EX. 22(0.87)
Valveclearance(whencold)IN.0.10-0.20(0.004-0.008)
EX. 0.20-0.30(0.008-0.012)
Valveguidetovalvestemclearance
Valveguidel.D.ValvestemO.D.
IN. 0.010-0.037(0.0004-0.0015)
(0.0012 |
-0.0022) |
|
4.000 |
-4.012 |
|
(0.1575 |
-0.1580) |
|
3.975- |
3.990 |
|
(0.1565- |
0.1571) |
|
3.955- |
3.970 |
|
EX.0.030-0.057
IN.&EX.
IN.EX.
(0.1557-0.1563)
ValvestemdeflectionIN.&EX.0.35(0.014)
Valvestemrunout
IN.&EX.0.05(0.002)
ValveheadthicknessIN.&EX.0.5(0.02)
Valveseatwidth
Valveheadradialrunout
Valvespringfreelength
IN.&EX.0.9-1.1(0.035-0.043)
IN.&EX.0.03(0.001)
IN.&EX.37.8(1.49)
Valvespringtension173-199N
-
IN.&EX.(17.6-20.3kgf)38.8-44.8lbs
atlength32.85mm(1.29in)
CAMSHAFT+CYLINDERHEADUnit:mm(in)ITEM STD/SPEC.LIMIT
Camheight
IN. 36.58-36.6236.28(1.440-1.442)(1.428)
EX. 35.28-35.3234.98(1.389-1.391)(1.417)
CamshaftjournaloilclearanceIN.&EX.0.032-0.0660.150(0.0013-0.0026)(0.0059)
Camshaftjournalholder1.0.
IN.&EX. 24.012-24.025(0.9454-0.9459)
