Suzuki sv650 manual download

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Terminal voltage check at low battery voltage will lead to erroneous diagnosis. It may cause damage to the throttle valve and throttle body. Overloading your tires can lead to tire failure and loss of motorcycle control. Incorrect spark plugs. Replace the damper if there is anything unusual. If you shift the transmission into gear when the side stand is down, the engine will stop running. This motorcycle also conforms to the U.
 
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Calaméo – Suzuki SV Service Repair Manual DOWNLOAD – Troubleshooting

 

Service Manual Suzuki, a great reference for the repair and maintenance. Periodic maintenance Periodic maintenance schedule Periodic maintenance chart Lubrication points Maintenance and tune-up procedures Air cleaner Spark plug Tappet clearance Engine oil and oil filter Fuel hose Engine idle speed Carburetor synchronization Throttle cable suzuki sv650 manual download Clutch Cooling system Drive chain Brake Tire Steering Front fork Rear suspension Exhaust pipe bolt and nut Chassis bolt and nut Compression pressure check Oil pressure check.

Fuel system and throttle body Fuel System Fuel delivery system Fuel pump Fuel pressure regulator Fuel injector Fuel pump control system Fuel tank lift-up Fuel tank removal Fuel tank installation Fuel pressure inspection Fuel pump inspection Fuel pump relay inspection Fuel pump and fuel filter removal Fuel mesh filter inspection and cleaning Fuel pump case bushing inspection Fuel level switch Fuel suzuki sv650 manual download and fuel mesh filter installation Throttle body and stv actuator Construction Air cleaner and throttle body removal Throttle body disassembly Throttle body cleaning Throttle body inspection Throttle body reassembly STV synchronization Throttle body installation STP sensor adjustment Air cleaner box installation Tp sensor adjustment Fast idle inspection Suzuki sv650 manual download idle adjustment Throttle valve synchronization.

Cooling and lubrication system Engine coolant Cooling circuit Cooling circuit inspection Radiator and water hoses Radiator removal Radiator cap inspection. Servicing information Troubleshooting Engine Radiator Carburetor Chassis Brakes Electrical Battery Wiring diagram Wire harness, ca le and hose routing Wire harness routing Wiring harness routing Speed sensor lead wire routing Cable routing Fuel system hose routing Cooling system hose routing Front rake hose routing Rear rake hose routing Pair air supply system hose routing Fuel tank set-up Special tools Tightening torque Engine Chassis Tightening torque chart Service data.

Emission control information Emission control carburetor components Evaporative emission control читать полностью Canister hose routing Evaporative emission control system inspection Pair air supply system diagram Pair air supply system hose routing Ipair air supply system inspection.

Adventure, cruiser, dualsport, motocross, off road, scooter, sportbike and street Suzuki motorcycles. Share on Facebook Share on Twitter. Service Manual, fix motorcycle yourself with a repair manual. Related Posts. Suzuki V-Strom Suzuki Address. Suzuki RMXZ. Latest Posts. Privacy Policy Site Use. This website uses cookies. By continuing to use this website you are giving consent to cookies being used. Visit suzuki sv650 manual download Privacy and Cookie Policy.

I Suzuki sv650 manual download.

 
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suzuki sv service ( MB) – Repair manuals – English (EN)

 

Park the motorcycle where pedestrians or children are not likely to touch the muffler. You may leave the motorcycle in 1st gear to help prevent it from rolling off the side stand. Shift to neutral before starting engine.

Adjust tire pressures and suspension according to the Tire Pressure and Loading section and the Suspension section of this manual. The passenger should always hold onto your waist or hips, or onto the seat strap or grab bar, as equipped.

Ask your passenger not to make any sudden movements. When you lean going around a corner, the passenger should lean with you. The passenger should always keep his or her feet on the footrests, even when you are stopped at a light. To help prevent burn injuries, warn your passenger not to contact the muffler when mounting or dismounting your motorcycle. There are a great variety of accessories available to Suzuki owners. Suzuki can not have direct control over the quality or suitability of accessories you may wish to purchase.

The addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for Suzuki to test each accessory on the market or combinations of all the available accessories; however, your dealer can assist you in selecting quality accessories and installing them correctly. Use extreme caution when selecting and installing the accessories for your Suzuki.

We have developed some general guidelines which will aid you when deciding whether, and how to equip your motorcycle. Improper accessories or modifications can make your motorcycle unsafe and can lead to an accident. Never modify the motorcycle with improper or poorly installed accessories. The GVWR is the combined weight of the machine, accessories, payload, rider and passenger.

When selecting your accessories, keep in mind the weight of the riders as well as the weight of the accessories. The additional weight of the accessories may not only create an unsafe riding condition but may also affect the steering ease.

Anytime that additional weight or aerodynamic affecting accessories are installed, they should be mounted as low as possible, as close to the motorcycle and as near the center of gravity as is feasible. The mounting brackets and other attachment hardware should be carefully checked to ensure that they provide for a rigid mount. Weak mounts can allow the shifting of the weight and create a hazardous, unstable condition.

Inspect for proper ground clearance and bank angle. An improperly mounted load could critically reduce these two safety factors. Accessories fitted to the handlebars or the front fork area can create serious stability problems. This extra weight will cause the motorcycle to be less responsive to your steering control. The weight may also cause oscillations in the front end and lead to instability problems. Accessories added to the handlebars or front fork of the machine should be as light as possible and kept to a minimum.

Backrests, saddlebags, travel trunks, etc. The motorcycle may be affected by a lifting condition or by an instability in cross winds or when being passed by or passing large vehicles.

Improperly mounted or poorly designed accessories can result in an unsafe riding condition, therefore caution should be used when selecting and installing all accessories. Certain accessories displace the rider from his or her normal riding position. This limits the freedom of movement of the rider and may limit control ability. Additional electrical accessories may overload the existing electrical system. Severe overloads may damage the wiring harness or create a hazardous situation due to the loss of electrical power during the operation of the motorcycle.

When carrying a load on the motorcycle, mount it as low as possible and as close as possible to the machine. An improperly mounted load can create a high center of gravity which is very hazardous and makes the motorcycle difficult to handle. Balance the load between the left and right sides of the motorcycle and fasten it securely.

Obey all applicable equipment regulations in your area. The frame of this motorcycle is made of an aluminum alloy. Therefore, never make any modifications such as drilling or welding to the frame as it weakens the frame significantly.

This could result in an unsafe vehicle operating condition and subsequent accident. Suzuki will not be responsible in any way for personal injury or damage to the motorcycle caused by frame modifications. Bolt-on-accessories that do not modify the frame in any way may be installed, provided that the GVWR is not exceeded. This could result in an unsafe operating condition and may lead to an accident.

Never make any modifications to the frame. Follow the guidelines in the chart. The intervals between periodic services in kilometers, miles and months are shown. At the end of each interval, be sure to perform the maintenance listed.

You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you use your motorcycle under severe conditions, perform maintenance more often than shown in the chart. Use only genuine Suzuki replacement parts or their equivalent.

A tool kit is provided with your motorcycle. Pull the knob 1, open the lid and pull out the tool bag. Lift the front end of the fuel tank and prop it up as shown above. Hold the fuel tank with the prop stand 4. Remove the bolts 1 and covers. Be sure that all lubrication is performed during periodic maintenance on the motorcycle. Increase frequency when you use your motorcycle in severe conditions.

Do not apply grease and oil to the switches. Grease Clutch lever holder Side stand pivot and spring hook Footrest pivot Drive chain Throttle cables and brake lever holder Brake pedal pivot and foot rest pivot. This battery is a sealed type battery and requires no maintenance. The standard charging rate is 1. Never exceed the maximum charging rate. Wash hands after handling. Keep flames and sparks away from the battery. Never smoke when working near the battery. If you use your motorcycle under normal low-stress conditions, you should service the air cleaner at the intervals specified.

If you ride in dusty, wet, or muddy conditions, you will need to inspect the air cleaner element much more frequently. Use the following procedure to remove the element and inspect it. This could cause a fire or severe engine damage. Never run the engine without the air cleaner element properly installed. The air cleaner element will clog under these conditions, and this may cause engine damage, poor performance, and poor fuel economy.

Clean the air cleaner case and element immediately if water gets in the air cleaner box. Air Cleaner Element Removal 1. Loosen the seven screws. Carefully use an air hose to blow the dust from the air cleaner element.

Pull up the air cleaner cover 1. NOTE: Always apply air pressure to the mesh side of the air cleaner element only. If you apply air pressure to the fabric side, dirt will be forced into the pores of the element, restricting the air flow through the element. Carefully examine the air cleaner element for tears during cleaning. Replace it with a new one if it is torn. Remove the plug and drain water and oil at the periodic maintenance interval. The air cleaner drain plug is located beneath the air cleaner box.

Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element. This will cause engine damage. Be sure to properly install the air cleaner element. A light brown color indicates that the plug is correct.

A white or dark insulator indicates that the engine may need adjustment, or another plug type may be needed. Consult your Suzuki dealer or a qualified mechanic if your plug insulator is not a light brown color.

This may cause severe engine damage which will not be covered under warranty. Use only the recommended spark plugs. Use one of the spark plugs listed below or equivalent. Consult your Suzuki dealer or a qualified mechanic if you are not sure which spark plug is correct for your type of usage. Pull off the spark plug caps. Remove the spark plugs with a spark plug wrench.

NOTE: Be careful not to damage the radiator fins. Wait until the radiator and engine are cool enough to touch with bare hands before starting this work. Remove the bolt 2. Move the lower part of the radiator forward. NOTE: Pry up the spark plug cap with a screwdriver or a bar if it is hard to remove by hand.

Do not pull the spark plug cord. Cover the spark plug hole whenever spark plug is removed. Adjust the gap to 0. Use a thickness feeler gauge to check the gap.

NOTE: When installing the spark plug caps, point the arrow marks on the spark plug caps to the exhaust side. Installation To install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench. NOTE: Insert the plug caps to the dead end.

Remount the radiators and tighten the mounting bolts securely. Follow the procedure below to tighten the spark plug properly. Carefully turn the spark plug by hand into the threads until it is finger tight. Daily oil level checks and periodic changes are two of the most important maintenance items to be performed. Engine Oil Level Check Check the engine oil level as follows: 1. Place the motorcycle on level ground on the side stand. Start the engine and allow it to idle for a few minutes.

Stop the engine and wait approximately three minutes. Hold the motorcycle vertically and check the oil level through the oil level inspection window on the right side of the engine. Check the oil level, through the inspection window, with the motorcycle held vertically on level ground before each use of the motorcycle. Engine Oil and Filter Change Change the engine oil and oil filter at the scheduled times. The engine should always be warm when the oil is changed so the oil will drain easily.

The procedure is as follows: 1. Place the motorcycle on the side stand. Remove the drain plug 2 from the bottom of the engine and drain the engine oil into a drain pan. Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil. Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with used oil may irritate skin.

Wipe off the mounting surface on the engine where the new filter will be seated with a clean rag. Smear a little engine oil around the rubber gasket 4 of the new oil filter. Screw on the new filter by hand until the filter gasket contacts the mounting surface a small resistance will be felt.

NOTE: To tighten the oil filter properly, it is important to accurately identify the position at which the filter gasket first contacts the mounting surface. Use an oil filter wrench to tighten the filter 2 turns or to specified torque. Reinstall the drain plug and tighten it securely. Pour about ml 2. NOTE: About ml 2.

Reinstall the oil filler cap. Start the engine while the motorcycle is outside on level ground and allow it to idle for a few minutes. Turn the engine off and wait approximately three minutes. Recheck the oil level in the engine oil inspection window. Inspect the area around the drain plug and oil filter for leaks.

Inspect the engine idle speed. NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle.

This motorcycle has a twin throttle cable system. Cable A is for pulling and cable B is for returning. To adjust the cable play: 1. Loosen the lock nut 1. Turn in the adjuster 2 fully. Loosen the lock nut 3. Turn the adjuster 4 so that the throttle grip has 2. Tighten the lock nut 3.

While holding the throttle grip at the closed position, turn out the adjuster 2 to feel resistance. Tighten the lock nut 1. Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. This can lead to loss of rider control.

Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement. At each maintenance interval, adjust the clutch cable play with the clutch cable adjuster. The cable play should be 10 — 15 mm 0. If you find the play of clutch incorrect, adjust it in the following way: 1.

Turn clutch lever adjuster 2 clockwise as far as it will go. Loosen the lock nut 3 and turn out the adjuster screw 4 two or three rotations. From that position, slowly turn the adjuster screw 4 in until it stops. Loosen cable adjuster lock nuts 5, and turn cable adjuster 6 to obtain approximately 10 — 15 mm 0. Minor adjustment can now be made with the adjuster 2.

Tighten the lock nuts, 1 and 5, after finishing adjustment. NOTE: Any maintenance of the clutch other than the clutch cable play should be performed by your Suzuki dealer. Engine coolant is harmful or fatal if swallowed or inhaled. To add mixed coolant: 1. NOTE: Adding only water will dilute the engine coolant and reduce its effectiveness. Add a mixture of engine coolant and water. We recommend that you take your motorcycle to an authorized Suzuki dealer if the drive chain needs to be replaced.

The condition and adjustment of the drive chain should be checked before each use of the motorcycle. Always follow the guidelines below for inspecting and servicing the chain. If necessary, consult your authorized Suzuki dealer. Damage to the drive chain means that the sprockets may also be damaged. Inspect the sprockets for the following: Good. If you find any of these problems with your sprocket, consult your Suzuki dealer.

NOTE: The two sprockets should be inspected for wear when a new chain is installed and replaced if necessary. Drive Chain Cleaning and Oiling Clean and oil the chain as follows: 1. Wash the chain with kerosene. Kerosene will lubricate and clean the chain. Allow the chain to dry, then lubricate the links with Suzuki chain lube or an equivalent lubricant. Kerosene can be hazardous. Kerosene is flammable. Children or pets may be harmed from contact with kerosene.

Keep flames and smoking materials away from kerosene. Keep children and pets away from kerosene. Call physician immediately. Dispose of used kerosene properly. Clean the drive chain with kerosene only. Inspect the drive chain slack before each use of the motorcycle.

The drive chain should be adjusted for 20 — 30 mm 0. Turn the right and left adjuster nuts 2 until the chain has 20 — 30 mm 0. At the same time that the chain is being adjusted, the rear sprocket must be kept in perfect alignment with the front sprocket.

To assist you in performing this procedure, there are reference marks 3 on the swing arm and each chain adjuster which are to be aligned with each other and to be used as a reference from one side to the other. Tighten the axle nut 1 securely. Recheck the chain slack after tightening and readjust if necessary. NOTE: Operating in mud, water, sand or other extreme conditions can cause accelerated brake wear. If brake fluid gets in eyes, flush eyes with water and seek medical attention.

The brakes may not work correctly without the proper amount and type of brake fluid. This could lead to an accident. Check the brake fluid level in both the front and rear brake fluid reservoirs. If the level in either reservoir is below the lower mark, inspect for brake pad wear and leaks.

Inspect the brake fluid level before each use. Use only DOT4 brake fluid from a sealed container. Never use or mix different types of brake fluid. Inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1. If a front or rear pad is worn to the grooved limit line, both front or both rear pads must be replaced with new ones.

After replacing either the front or rear brake pads, the brake lever or pedal must be pumped several times. This will extend the pads to their proper position. It is difficult to push the pistons back into position. Inspect brake pad wear before each use. Rear Brake Adjustment The rear brake pedal must be adjusted to set the clearance between the pedal and the footrest.

Adjust the brake pedal as follows:. CAUTION An incorrectly adjusted brake pedal may force brake pads to rub against the disk at all times, causing damage to the pads and disk. Follow the steps in this section to adjust the brake pedal properly. Rear Brake Light Switch.

SV 1. Loosen the lock nut 1, and turn the push rod 2 to locate the pedal 50 — 60 mm 2. SVS 1. Loosen the lock nut 1, and turn the push rod 2 to locate the pedal 60 — 70 mm 2. Retighten the lock nut 1 to lock the push rod 2 in the proper position. To adjust the brake light switch, hold the switch body and turn the adjuster so that the brake light will come on just before a pressure rise is felt when the brake pedal is depressed. Failure to follow these warnings may result in an accident due to tire failure.

The tires on your motorcycle form the crucial link between your motorcycle and the road. Perform proper break-in of the tires referring to the BREAK-IN section and avoid hard acceleration, hard cornering, and hard braking for the first km miles.

Tire Pressure and Loading Proper tire pressure and proper tire loading are important factors. Overloading your tires can lead to tire failure and loss of motorcycle control. Check tire pressure each day before you ride, and adjust tire pressure according to the table below. Tire pressure should only be checked and adjusted before riding, since riding will heat up the tires and lead to higher inflation pressure readings. Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear.

Over-inflated tires cause a smaller amount of tire to be in contact with the road, which can contribute to skidding and loss of control. The secondary throttle position sensor is installed at the left side of the No.

The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe. There is no fuel return hose. The fuel in the fuel tank is. Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector the.

The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve. When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impeller. This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it. Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port.

The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped.

Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to – kPa 4. When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction.

This process continuously takes place causing fuel pressure to be built up. The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve. The fuel pressure regulator consists of the spring and valve.

It keeps absolute fuel pressure of kPa 3. When the fuel pressure rises more than kPa 3. The fuel injector consists of the solenoid coil, plunger, needle valve and filter. It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger.

At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion. As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized injection time.

When the ignition switch is turned on, current from the battery flows to the fuel pump motor through the sidestand relay and the fuel pump relay causing the motor to turn. Since the ECM has a timer function, the fuel pump motor stops turning in three seconds after the switch has been turned on. Thereafter, when the crankshaft is turned by the starter motor or the engine has been started, the engine revolving signal is input to the ECM.

Then, current flows to the fuel pump motor from the battery through the side-stand relay and the fuel pump relay so that the pump continues to function. A tip over sensor is provided in the fuel pump control circuit.

By this provision, anytime the motorcycle tips over, the tip over sensor sends a signal to the ECM to turn off power to the fuel pump relay, causing the fuel pump motor to stop. At the same time, current to the fuel injectors as well as the ignition coil is interrupted, which then stops the engine.

Fuel pressure gauge adaptor Fuel pressure gauge hose attachment Oil pressure gauge Oil pressure gauge hose. Turn the ignition switch ON and check the fuel pressure. Fuel pressure : Approx. Keep heat, sparks and flame away. Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip over sensor.

If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel filter is clogged. First, check the insulation between 1O and 02 terminals with pocket tester.

If there is no continuity, replace it with a new one. Keep heat, spark and flame away. If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result. NOTE: If the fuel mesh filter is clogged with many sediment or rust, replace the fuel filter cartridge with a new one. Install the fuel pump and fuel mesh filter in the reverse order of removal, and pay attention to the following points :.

The 0-ring must be replaced with a new one to prevent fuel leakage. It may cause damage to the throttle valve and throttle body. Do not disassemble it other than shown in this manual. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak.

Do not apply carburetor cleaning chemicals to the rubber and plastic materials. Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points :. If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor positioning as follows :. Posision sensor voltage ST valve is fully opened : More than Approx.

When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water temperature and ambient temperature as shown in the following table, the fast idle is cancelled allowing the engine to resume idle speed. If, under the above conditions, the fast idle cannot be cancelled, the cause may possibly be short-circuit in the engine coolant temperature sensor or wiring connections or maladjusted fast idle.

Connect the IAP sensor coupler and vacuum hose. Dirt drawn into the engine will damage the internal engine parts. The balancer gauge is now ready for use in balancing the throttle valves. NOTE: Make sure that the throttle lever should have a gap OO between the throttle lever and throttle lever stopper screw during syn.

This 50 mixture will provide the optimum corrosion protection. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by. Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. In such a case, inspect the entire system and replace the leaking component or part. When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant.

Road dirt or trash stuck to the fins must be removed. Use of compressed air is recommended for this cleaning. Install the cooling fan thermo-switch. Install the radiator in the reverse order of removal. Route the radiator hoses properly. Make sure. Any water hose found in a cracked condition or flattened or water leaked must be replaced. Any leakage from the connecting section should be corrected by proper tightening. Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.

The voltmeter is for making sure that the battery applies 12 volts to the motor. With the motor with electric motor fan running at full speed, the ammeter should be indicating not more than 5 amperes.

If the fan motor does not turn, replace the motor assembly with a new one. NOTE: When making above test, it is not necessary to remove the cooling fan. Remove the radiator.

F Disconnect the cooling fan thermo-switch coupler Remove the cooling fan. Install the radiator. C Pour engine coolant. C–r Install the cowling. Connect the thermo-switch 1O to a circuit tester and place it in the OIL contained in a pan, which is placed on a stove.

It may cause damage if it gets a sharp impact. Connect the temperature sensor O to a circuit tester and place it in the WATER contained in a pan, which is placed on a stove. If the resistance noted to show infinity or too much different resistance value, replace the temperature sensor with a new one.

Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the following manner. Note that the immersed thermostat is in suspension. Heat the water by placing the beaker on a stove 1O and observe the rising temperature on a thermometer This reading, which is the temperature level at which the thermo-.

Thermostat valve opening temperature Standard : Approx. Thermostat valve lift Standard : Over 8. NOTE: The rib of the thermostat case cap 10 should be faced upward.

If engine oil is leaking, visually inspect the oil seal and 0-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal ring.

If there is no abnormal noise, bearing removal is not necessary. NOTE: If there is no abnormal condition, the mechanical seal and the oil seal removal is not necessary. Inspect the play of the bearing by hand while it is in the water pump case.

Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows indications of leakage. Also replace the seal ring if necessary. Replace the oil seal that shows indications of oil leakage. Replace the water pump body if necessary. NOTE: The paint marked side the impeller.

If any defect are found, replace the oil cooler and oil hoses with the new ones. Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver. Seat rail 02 Rear fender No. Remove the frame side covers, right and left. If any damages are found, replace the dust seals with new ones.

An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings.

If bearing replacement fails to reduce the runout, replace the wheel. Wheel runout Service Limit Axial and Radial : 2. Inspect the dust seal for damage or wear.

Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is anything unusual. Reassemble and remount the front wheel in the reverse order of removal and disassembly. Brake disc bolt : 23 N. NOTE: Hold the front fork by hand to prevent it from sliding out of the steering stem.

Invert the fork and drain the fork oil out of the fork by stroking. NOTE: If the damper rod turns together with the damper rod bolt, temporarily install the fork spring, spacer, washer and cap bolt to prevent the damper rod from turning. Be careful not to damage the inner tube. If any defects are found, replace them with the new ones. Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.

Front fork spring free length Service limit : mm Inspect the cylinder and cylinder ring 90 for damage. If any defects are found, replace them with new ones. NOTE: After installing the inner tube into the outer tube, keep the oil lock piece into the inner tube by compressing the front fork fully.

Front fork oil capacity each leg : ml NOTE: Take extreme attention to pump out air completely. NOTE: When adjusting the fork oil level, remove the fork spring and compress the inner tube fully.

Cr NOTE: After install the brake calipers, front brake should be efficient by pumping the front brake lever. After installing the front fork, adjust the spring per-load as follows. Position 0 provides the maximum spring pre-load and position 5 provides the minimum spring pre-load. Reassemble and remount the steering stem in the reverse order of removal and disassembly.

NOTE: This adjustment will vary from motorcycle to motorcycle. NOTE: When installing the washer, align the stopper lug to the groove of the steering stem. NOTE: Before tightening the nut to the specified torque, temporarily install the handlebars in order to align both holders.

Check the steering movement in the following procedure. Do the same on the other grip end. Initial force : – grams : Spring scale. NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose. NOTE: Before removing the rear sprocket mounting drum, slightly loosen the rear sprocket nuts to facilitate later disassembly. If the runout exceeds the limit, replace the rear axle. Axle shaft runout : Service Limit : 0.

Replace the damper if there is anything unusual. If they are worn as shown, replace the engine sprocket, rear sprocket and drive chain as a set. If any damage is found, replace the dust seal with a new one.

Replace the bearing if there is anything unusual. Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Inspect the shock absorber body and bushing for damage and oil leakage. If any defects are found, replace the shock absorber with a new one. It is unserviceable. Mishandling can cause explosion. High gas pressure caused by heat can cause an explosion. Wear eye protection to protect your eyes from released gas and metal chips.

NOTE: When holding the absorber, its bushing must be faced upward. Remount the rear shock absorbers in the reverse order of removal. After installing the rear suspension, adjust the spring pre-load as follows.

Inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with the new ones. If any defect is found, replace the chain buffer with a new one. If excessive play is noted, replace the bearing with a new one.

Reassemble the swingarm in the reverse order of disassembly and removal. NOTE: When installing the bearing, the dust seal that is embedded in the bearing must face outside. Insert the cushion rod mounting bolts and rear shock absorber mounting bolts from the left side.

After installing the rear suspension and wheel, the following adjustments are required before driving. Do not use mix different types of fluid such as silicone-based or petroleum-based. Never reuse brake fluid left over from the last servicing or stored for long periods. Never use cleaning solvent. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent.

Remove the brake pads by removing the pad mounting pin Clean up the caliper especially around the caliper pistons. Fill the reservoir with the new fluid to the upper mark of the reservoir. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. Check the brake hose. If any damage is found, replace the caliper with a new one.

If any damage is found, replace the caliper piston with a new one. If any damage is found, replace it with a new one.

If any damages are found, replace them with the new ones. Reassemble the caliper in the reverse order of removal and disassembly. Particularly wash the dust seal grooves and piston seal grooves.

Never use cleaning solvent or gasoline to wash them. Never use different types of fluid or cleaning solvent such as gasoline, kerosine or others.

Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. Front disc thickness : Service Limit : 4. Measure the runout with a dial gauge. Replace the disc if the runout exceeds the service limit.

Front disc runout : Service Limit : 0. Remove the brake hose union bolt and disconnect the brake hose. The fluid reacts chemically with paint, plastics and rubber materials, etc. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage. Reassemble the master cylinder in the reverse order of removal and disassembly. Brake hose union bolt : 23 N.

Check the brake hose and hose joints for cracks and fluid leakage. If any damage is found, replace the sliding pin with a new one. Inspect the boot and spacer for damage and wear.

If any damages are found, replace boot and spacer with new ones. Inspect the rear brake disc in the same manner as that of the front one.

C Service Limit Rear disc thickness : 4. Remove the union bolt O2 and disconnect the brake hose. The fluid reacts chemically with paint, plastic and rubber materials, etc. Inspect the cup set and each rubber part for damage. Reassemble and remount the master cylinder in the reverse order of removal and disassembly.

The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional. For operating procedures, refer to the instructions supplied by the tire changer manufacturer. NOTE: When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the valve position.

Even though the tire is refitted to the original position after repairing puncture, the tire may have to be balanced again since such a repair can cause imbalance.

Replace the valve with a new one if the seal rubber is peeling or has damage. If the seal 1O has abnormal deformation, replace the valve with a new one. Then install the valve in the rim. NOTE: To properly install the valve into the valve hole, apply a special tire lubricant or neutral soapy liquid to the valve.

This makes the tire bead expand outward to contact the wheel, thereby facilitating air inflation. If inflated beyond this limit, the tire can burst and possibly cause injury. Do not stand directly over the tire while inflating. The line must be equidistant from the wheel rim all around. If the distance between the rim line OA and wheel rim varies, this indicates that the bead is not properly seated.

If this is the case, deflate the tire completely and unseat the bead for both sides. Coat the bead with lubricant and fit the tire again. Neglecting proper procedure may cause damage to this part. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources e.

Do not replace the MF battery with a conventional battery. If voltage is applied, the tester will be damaged. Battery runs down quickly Step1 1 Check accessories which use excessive amounts of electricity. Are accessories being installed? NO Step2 1 Check the battery for current leaks. Step3 1 Measure the charging voltage between the battery terminals.

Step4 1 Measure the continuity of the generator coil. Faulty battery. Poor contact of generator lead wire coupler. If the reading exceeds the specified value, leakage is evident.

When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part. Measure the resistance between the three lead wires. If the resistance is out of the specified value, replace the stator with a new one. Also, check that the generator core is insulated properly.

Using the multi circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the generator with a new one. Measure the voltage between the terminals using the multi circuit tester as indicated in the table below. Starter motor will not run. Is a click sound heard? NO Go to Step3. Step2 1 Check if the starter motor runs when its terminal is connected to the wire because a large amount of current flows.

Does the starter motor run? Is a voltage OK? Go to Step4. Step5 The starter motor runs when the transmission is neutral with the side-stand up or down, but does not run when the transmission is in any position other than neutral with the side-stand down.

If any damage is found, replace the brush assembly with a new one. If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with sand paper and wipe it using a clean dry cloth.

If there is no undercut, scrape out the insulator 1D with a saw blade. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.

If any damage is found, replace the housing end. Reassemble the starter motor in the reverse order of disassembly. Install the washers 02 Remove the front seat. Remove the starter relay cover 1O. Disconnect the starter relay coupler C2.

If the starter relay clicks and continuity is found, the relay is ok. CAUTION Do not apply a battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and get damaged.

Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities.

If any abnormality is found, replace the component with a new one. Measure the voltage between Pink and Black lead wires using the multi circuit tester when shifting the gearshift lever from low to top. Refer to the following table.

Unit : V. NOTE: If the multi circuit tester reads under 1. Make sure the fuse is not blown and the battery is fully-charged before diagnosing. Step1 1 Check ignition system couplers for poor connections. Is there connection in the ignition switch couplers? Go to Step3. NOTE: The ignition coil peak voltage inspection method is applicable only with the multi circuit tester and peak volt adaptor.

Is the peak voltage OK? Step6 1 Measure the CKP sensor peak voltage and its resistance. Is the peak voltage and resistance OK? Faulty CKP sensor. Make sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition. Measure the No. Measure the ignition coil resistance in both the primary and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.

NOTE : Make sure that all of the couplers are connected properly and the battery used is in fully-charged condition. Measure the CKP sensor peak voltage in the following procedures. Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual.

Tester knob indication : Voltage – [. If the peak voltage is lower than the specified values, check the peak voltage at the CKP sensor lead wire coupler. Tester knob indication : Voltage – CKP sensor peak voltage : 3. If the peak voltage on the CKP sensor lead wire coupler is ok but on the ECM coupler is out of specification, the wire harness must be replaced. If both peak voltages are out of specification, the CKP sensor must be replaced and re-checked.

If the resistance is not specified value, the CKP sensor must be replaced. When the tachometer pointer is normal position. If any abnormality is found, replace the combination meter with a new one.

The bulb should come on after several seconds if the switch is in good condition. NOTE: After disconnecting the jump wire, it takes 30 seconds that the fuel level indicator comes off.

Check the oil pressure indicator lights, when grounding the lead wire. If the oil pressure indicator does not come on, check the wiring harness or replace the combination meter with a new one. To adjust the headlight beam, adjust the beam horizontally first, then adjust the vertically. CAUTION If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. NOTE : To adjust the headlight beam, adjust the beam horizontally first, then adjust the vertically.

Front turn signal light bulb 20 :. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. If the turn signal light does not illuminate, inspect the bulb, turn. If the bulb, turn signal switch and circuit connection are OK, the. Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones.

NOTE: When filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. Take precaution not to allow any of the fluid to spill. If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. Wait for about 20 minutes. Otherwise, the battery may be overcharged resulting in shortened service life.

Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery. If the voltage reading is less than the Recharging time : 1. It judges from gear position voltage, engine speed and throttle position by ECM, when the gear position voltage is 0 V. Tappet clearance out of adjustment. Worn valve guides or poor seating of valves. Mistimed valves. Excessively worn piston rings. For problem-free Battery start-up and operation, follow the procedure outlined here.

A few things to keep in mind before you get rolling: 1. The battery is sealed. There is no need to remove the strip of caps or add electrolyte for the life of the battery.

The graph below shows an open circuit voltage characteristic of a sealed VRLA battery just after the elec- trolyte is filled. The sealed VRLA battery, like the conventional one. If you are using an automatic type taper charger, check to make sure using a constant current charger, refer to the standard that the charger current amps is equal to or greater than STD. Because of the charac- battery should be kept to near fully charged for peak teristics of a sealed VRLA battery, too much of a boost performance.

If the ammeter shows equipment and procedures to recharge. Page GLOSSARY Negative Terminal The terminal Polarization Change in voltage at Resistance The opposition of a con- from which current flows through the terminals when a specified current is ductor to the passage of an electrical external circuit to the positive terminal flowing; Page P.

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Quick Links. Table of Contents. Previous Page. Next Page. Other information considered as generally known is not included. Use this section as well as other sections to use as a guide for proper inspection and service. Pay special attention to the messages highlighted by these signal words. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them.

Terminal voltage check with a low battery voltage will lead to erroneous diagnosis. Page 10 Precautions: 1 Disconnect the negative — cable from the battery. Page 14 Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. Suzuki recommends the use of SAE 10W engine oil. If SAE 10W engine oil is not available, select and alternative according to the chart. Page Cylinder Identification 1 ml 2. Noise label For E, 24, 33 For E 2.

Information label For E, 28, 33 — 3. Vacuum hose routing label For E — IAP sensor 1 7. ECT sensor Starter motor 2. IAP sensor 2 8.

Ignition coil 2 Oil pressure switch 3. IAT sensor 9. Ignition coil 1 Cooling fan 4. Fuel injector 1 TO sensor CKP sensor Fuel injector 2 Speed sensor Fuse box GP switch Dimensions and curb mass Item Specification Remark Overall length 2 mm Page 25 General Information: 0A — — — — — Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge 10 — 75 attachment attachment — — — — — Adapter hose Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment kPa — Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

Page Lubrication Points 0B-2 Maintenance and Lubrication: Interval 1 6 12 18 24 Item miles 4 7 11 14 months Rear suspension — — — Chassis bolts and nuts Lubrication Points BH Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated as follows. Page 30 0B-4 Maintenance and Lubrication: Exhaust Pipe Bolts and Muffler Bolts Inspection Valve Clearance Inspection and Adjustment BH BH Tighten exhaust pipe bolts, muffler bolts and nut Inspect valve clearance Initially at 1 km miles, 2 months and every Every 24 km 14 miles, 48 months thereafter 12 km 7 miles, 24 months thereafter Inspection Inspect fuel line 2 Place an oil pan below the engine, and drain engine Every 6 km 4 miles, 12 months oil by removing the oil drain plug 1 and filler cap 2.

Page 37 Also, do not use a genuine Suzuki 3 Turn off the engine and wait about three minutes, automobile oil filter on this motorcycle. Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. Page 40 0B Maintenance and Lubrication: 10 Reinstall the removed parts. Check the radiator hoses for crack, damage or engine Clutch release screw coolant leakage. Page 41 Maintenance and Lubrication: 0B Drive Chain Inspection and Adjustment 4 Count out 21 pins 20 pitches on the chain and BH measure the distance between the two points.

If the distance exceeds the service limit, the chain must be Inspect drive chain replaced. Such oil can damage the O-rings. When the wear exceeds the grooved limit line, replace the pads with new ones. Page 44 0B Maintenance and Lubrication: Brake Fluid Replacement Tire Pressure If the tire pressure is too high or too low, steering will be Replace brake fluid adversely affected and tire wear increased. Page 45 Maintenance and Lubrication: 0B 2 Support the motorcycle so that the front wheel is off the ground, with the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward.

If play is found, readjust the steering. Page 54 Front fork oil level Without spring, 96 3. Front fork upper clamp bolt Page 61 Table of Contents 1-iii Special Tool Page 65 Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time Volume The following different signals are output from the respective sensors for compensation of the fuel injection time volume.

To check the function of the individual FI system devices, the dealer mode is provided. Malfunction means that the ECM does not receive signal from the devices. Repair or replace. Clean or replace. Defective fuel pump.

Defective fuel pressure regulator. Defective engine internal Not enough oil in the engine. Add oil. Replace or clean. Sucking air from intake pipes. Such disconnection may erase the memorized information in ECM memory. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time. Check the manifold absolute pressure.

XXX kPa Check the engine coolant temperature. Check the monifold absolute pressure. Page 84 1A Engine General Information and Diagnosis: Example of Trouble Three data; value 3 current data 3 , value 1 past data 1 and value 2 past data 2 ; can be made in comparison by showing them in the graph.

Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.

The reason for visual inspection is that mechanical failures such as oil leakage cannot be displayed on the screen with the use of mode select switch or SDS.

Go to Step 3. Short circuit in the W wire. Go to Step 2. Short circuit in the R wire. Go to Step 4. Replace the ECM with a If check result is not new one.

Open circuit in the R wire. Refer to 2 Disconnect the IAT sensor coupler. Open circuit in the R and ground. Special tool A : — Multi circuit tester set Tester knob indication Continuity Refer sensor with a new 2 Remove the TO sensor. Refer to the SDS operation manual for further details.

IH 4 Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal. Refer to 2 Connect the ECM coupler. Replace the injector with a new one. Refer to 2 Remove the air cleaner box.

Replace the injector and ground. Replace the FP relay with a new one. Removal and Special tool Installation in Section Replace the cooling fan relay with a new one.