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Suzuki 2009 LT-A500XP, Service Manual

The Suzuki 2009 LT-A500XP Service Manual is a comprehensive guide that provides detailed instructions for maintaining and repairing your ATV. This manual can be easily downloaded for free from our website, ensuring you have access to the essential information needed to keep your vehicle in top condition.

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Table of Contents 1- i

1

Section 1

CONTENTS

Engine

Precautions .................................................1-1

Precautions............................................................. 1-1

Precautions for Engine.......................................... 1-1

Engine General Information and 
Diagnosis ................................................. 1A-1

General Description .............................................1A-1

Injection Timing Description ................................ 1A-1

Schematic and Routing Diagram........................1A-4

FI System Wiring Diagram .................................. 1A-4
Terminal Alignment of ECM Coupler................... 1A-5

Component Location ...........................................1A-6

FI System Parts Location .................................... 1A-6

Diagnostic Information and Procedures............1A-7

Engine Symptom Diagnosis ................................ 1A-7
Self-Diagnostic Procedures .............................. 1A-10
Use of SDS Diagnosis Reset Procedures......... 1A-12
Show Data When Trouble (Displaying Data at 

the Time of DTC) ............................................ 1A-13

SDS Check ....................................................... 1A-15
DTC Table......................................................... 1A-18
Fail-Safe Function Table ................................... 1A-18
FI System Troubleshooting ............................... 1A-19
Malfunction Code and Defective Condition 

Table ............................................................... 1A-21

DTC “C12” (P0335): CKP Sensor Circuit 

Malfunction...................................................... 1A-23

DTC “C13” (P0105-H/L): IAP Sensor Circuit 

Malfunction...................................................... 1A-26

DTC “C14” (P0120-H/L): TP Sensor Circuit 

Malfunction...................................................... 1A-33

DTC “C15” (P0115-H/L): ECT Sensor Circuit 

Malfunction...................................................... 1A-40

DTC “C20” (P1752): Diff-lock Relay Circuit 

Malfunction...................................................... 1A-45

DTC “C21” (P0110-H/L): IAT Sensor Circuit 

Malfunction...................................................... 1A-47

DTC “C23” (P1651-H/L): TO Sensor Circuit 

Malfunction...................................................... 1A-52

DTC “C24” (P0351): Ignition Coil Circuit 

Malfunction...................................................... 1A-59

DTC “C32” (P0201): Fuel Injector Circuit 

Malfunction...................................................... 1A-59

DTC “C40” (P0505-H/L): ISC Valve Circuit 

Malfunction......................................................1A-62

DTC “C41” (P230-H/L): FP Relay Circuit 

Malfunction......................................................1A-68

Specifications .....................................................1A-70

Service Data......................................................1A-70

Special Tools and Equipment ...........................1A-71

Special Tool ......................................................1A-71

Emission Control Devices ...................... 1B-1

Precautions...........................................................1B-1

Precautions for Emission Control Devices ..........1B-1

Repair Instructions ..............................................1B-1

Crankcase Breather (PCV) Hose Inspection.......1B-1
Crankcase Breather (PCV) Hose Removal 

and Installation ..................................................1B-1

Engine Electrical Devices ....................... 1C-1

Precautions...........................................................1C-1

Precautions for Engine Electrical Device ............1C-1

Component Location ...........................................1C-1

Engine Electrical Components Location .............1C-1

Diagnostic Information and Procedures ............1C-1

Engine Symptom Diagnosis ................................1C-1

Repair Instructions ..............................................1C-1

ECM Removal and Installation............................1C-1
CKP Sensor Inspection .......................................1C-1
CKP Sensor Removal and Installation ................1C-2
IAP / TP / IAT Sensor Inspection ........................1C-2
IAP / TP / IAT Sensor Removal and 

Installation .........................................................1C-2

ECT Sensor Removal and Installation ................1C-2
ECT Sensor Inspection .......................................1C-3
TO Sensor Inspection .........................................1C-3
TO Sensor Removal and Installation ..................1C-3
ISC Valve Inspection...........................................1C-3
ISC Valve Removal and Installation....................1C-4
GP Switch Inspection ..........................................1C-4
GP Switch Removal and Installation ...................1C-4

Specifications .......................................................1C-5

Service Data........................................................1C-5
Tightening Torque Specifications........................1C-5

Special Tools and Equipment .............................1C-5

Special Tool ........................................................1C-5

Summary of Contents for 2009 LT-A500XP

Page 1: ...atest specifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail This manual is written for persons who have enough knowledge skills ...

Page 2: ......

Page 3: ... General Diagnosis 2A 1 Front Suspension 2B 1 Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 i Precautions 3 1 Drive Chain Drive Train Drive Shaft 3A 1 Differential 3B 1 Transfer 3C 1 Propeller Shafts 3D 1 Brake 4 i Precautions 4 1 Brake Control System and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 Transmission Transaxle 5 i Precautions 5 1 Automatic Transmis...

Page 4: ......

Page 5: ...Table of Contents 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 ...

Page 6: ...u follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION If parts replacement is necessary replace the parts with Suzuki...

Page 7: ...o push it in until a click is felt With a lock type coupler be sure to release the lock when disconnecting and push it in fully to engage the lock when connecting When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause...

Page 8: ...A Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band type clamp Fuse When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of different capacity Do not use wire or any other substitute for the fuse Switch Never ...

Page 9: ...rol unit and EPS body assembly cannot be disassembled Replace the whole unit with a new one Battery Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the FI systems instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter electro...

Page 10: ...ct of terminal due to dirt corrosion or rust poor contact tension entry of foreign object etc Wire harness being open Poor terminal to wire connection When checking system circuits including an electronic control unit such as ECM etc it is important to perform careful check starting with items which are easier to check 1 Disconnect the negative cable from the battery 2 Check each connector coupler...

Page 11: ...ked voltage check can be used as circuit check 1 With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground 2 If measurements were taken as shown in the figure and results were listed in the following it means that the circuit is open between terminals A and B Voltage between A and body ground Approx 5 V B and body ...

Page 12: ...tinuity is indicated there is a short circuit to ground between terminals A and C 4 Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is indicated the circuit is shorted to the ground between terminals A and B Using The Multi Circuit Testers Use the Suzuki multi circuit tester set Use well charged batteries in the...

Page 13: ...er may be damaged After using the tester turn the power off Special tool 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to prevent the rubber of the water proof coupler from damage When using the multi circuit tester do not...

Page 14: ...00 9 Precautions ...

Page 15: ...Adjustment 0B 4 Spark Plug Replacement 0B 6 Spark Plug Inspection and Cleaning 0B 6 Spark Arrester Cleaning 0B 7 Fuel Line Inspection 0B 8 Engine Oil and Filter Replacement 0B 8 Front Differential Gear Oil Inspection 0B 10 Front Differential Gear Oil Replacement 0B 11 Final Gear Oil Inspection 0B 12 Final Gear Oil Replacement 0B 12 Throttle Cable Play Inspection and Adjustment 0B 13 Throttle Body ...

Page 16: ... Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS EPS Electronic Power Steering F FI Fuel Injection Fuel Injector FP Fuel pump FPR Fuel Pressure Regulator Symbol Definition Torque control required Data beside it indicate specified torque Apply oil Use engine oil unless otherwise specified Apply molybdenum oil solution Mi...

Page 17: ...tery Voltage B 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 EI Engine Control Module ECM Engine Control Module ECM Fl Control Unit Engine Control Unit ECU Engine Coolant Level ECL Coolant Level Engine Coolan...

Page 18: ...pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Fuel For Other Countries Gasoline used should be graded 91 octane Research Method or higher Unleaded gasoline is recommended Engine Oil For USA Oil quality is a ma...

Page 19: ... radiator Anti freeze Engine coolant The engine coolant perform as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible ...

Page 20: ...R Orange with Red tracer O Orange O W Orange with White tracer P Pink O Y Orange with Yellow tracer R Red O B Orange with Black tracer W White O Bl Orange with Blue tracer Y Yellow P W Pink with White tracer B Bl Black with Blue tracer R B Red with Black tracer B Br Black with Brown tracer R G Red with Green tracer B G Black with Green tracer W B White with Black tracer B Lg Black with Light green...

Page 21: ...glish French For P 28 6 Tire air pressure label and warning no passenger label French For P 28 20 Compliance label English For P 28 7 General warning AGE 16 label English For P 17 24 28 33 21 I D plate English For P 17 8 General warning label French For P 28 22 Cooling fan label English For P 24 33 9 Warning no passenger label English For P 17 24 28 33 23 Cooling fan label English French For P 17 ...

Page 22: ...I931H1010005 03 1 Battery 7 Drive relay 13 Ignition switch 2 Starter relay Main fuse 8 Mode select switch coupler 14 Power source 3 Fuse box 9 Starter motor 15 Ignition coil 4 Neutral relay 10 ECT sensor 16 Rear brake switch 5 Fuel pump relay 11 4WD Diff lock switch 17 Gear position switch 6 ECM 12 Front brake light switch 18 Fuse EPS ...

Page 23: ...33 Speed sensor 20 Resister 27 Regulator Rectifier 34 CKP sensor 21 4WD Diff lock actuator diode 28 Parking brake relay 35 Generator 22 Neutral relay diode 29 Diff lock relay 36 EPS control unit 23 Cooling fan 30 Diff lock actuator 37 EPS body assembly 24 Left handlebar switch 31 High position diode 25 Parking rear brake light switch 32 Low position diode ...

Page 24: ...cification Remark Type 4 stroke liquid cooled OHC Number of cylinders 1 Bore 87 5 mm 3 445 in Stroke 82 0 mm 3 228 in Displacement 493 cm3 30 1 cu in Compression ratio 10 0 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet sump Idle speed 1 500 100 r min Item Specification Remark Clutch Wet shoe automatic centrifugal type Transmission ...

Page 25: ...ion timing 7 B T D C at 1 500 r min Spark plug NGK CR6E or DENSO U20ESR N Battery 12 V 64 8 kC 18 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 15 15 A EPS fuse 40 A Headlight 12 V 35 35 W x 2 Brake light Taillight 12 V 21 5 W Reversing light 12 V 21 W P 17 Speedometer light LED Neutral indicator light LED High beam indicator light LED P 17 Coolant temperature FI ind...

Page 26: ...r gauge set 09900 20602 Dial gauge 09900 20605 Dial calipers 10 34 mm 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V blocks 09900 22301 Plastigauge 09900 22302 Plastigauge 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09900 26006 Engine tachometer 09904 4101...

Page 27: ... 09915 74521 Adapter hose 09915 74533 Oil pressure gauge adapter 09915 77331 Oil pressure gauge 1000 kPa 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 34542 Reamer handle 09916 34570 Valve guide reamer 5 0 mm 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide installer remover 09916 53370 Valve guide installer attachment 09916 84511 Twe...

Page 28: ...2450 Fixed driven face holder 09924 52460 Socket 52 mm 09924 52470 Fixed final drive gear holder 09924 74520 Oil seal installer and remover 09924 74570 Final drive gear bearing installer 09924 84510 Bearing installer set 09924 84521 Bearing installer set 09930 10121 Spark plug wrench set 09930 11950 Torx wrench 5 mm 09930 30104 Rotor remover sliding shaft 09930 30721 Rotor remover 09930 31921 Roto...

Page 29: ... axle nut wrench 36 36 mm 09941 34513 Bearing installer 09941 51012 Ring locknut wrench 09941 53610 Front fork oil seal hammer 09942 72410 Tie rod end remover 09942 83110 Clip remover 09943 88211 Pinion bearing installer 09944 36011 Steering wheel remover 09944 66010 Oil seal installer 09951 15810 Brake disk dust cover installer 99565 01010 019 CD ROM Ver 19 ...

Page 30: ...ction 0A Scheduled Maintenance Periodic Maintenance Schedule Chart B931H20205001 NOTE I Inspect and clean adjust replace or lubricate as necessary C Clean R Replace T Tighten Item Interval km Initial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months Initial 1 Every 3 Every 6 Air cleaner element polyurethane foam element C C non woven fabric element I I Exhaust pipe nuts an...

Page 31: ...vehicle has been operated under wet or rainy conditions Lubricate exposed parts Every 1 000 km 600 miles 3 months Brake fluid I I Replace every 2 years Brake hose I Replace every 4 years Tires I I Steering I I I Suspensions I Chassis nuts and bolts T T T General lubrications L L Item Interval km Initial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months Initial 1 Every 3 Ev...

Page 32: ... is in good condition at all times 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 assembly Refer to Air Cleaner Element Removal and Installation in Section 1D 2 Separate the polyurethane from element 3 Carefully use compressed air to clean the air cleaner element CAUTION...

Page 33: ...clearance Initially at 200 km 100 miles 1 month and every 2 000 km 1 200 miles 6 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 front inner fender left and right Refer to Front Side Exterior Parts Removal and Installation ...

Page 34: ...ligned with the mark 4 on the crankcase 8 Remove the valve timing inspection caps 5 9 Insert the thickness gauge to check the clearance between the valve stem end and the adjusting screw on the rocker arm Special tool A 09900 20803 Thickness gauge Valve clearance When cold IN 0 05 0 10 mm 0 002 0 004 in EX 0 17 0 22 mm 0 007 0 009 in Adjustment 1 If the clearance is out of specification bring it i...

Page 35: ...lug Inspection and Cleaning B931H20206005 Inspect spark plug Every 2 000 km 1 200 miles 6 months Heat Range 1 Remove the spark plug Refer to Spark Plug Cap and Spark Plug Removal and Installation in Section 1H 2 Check spark plug heat range by observing electrode color If it appears white or glazed replace the spark plug with colder type one Heat range 3 After finishing the spark plug inspection re...

Page 36: ... condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator or damaged thread 3 After finishing the spark plug inspection reinstall the removed parts CAUTION Check the thread size and reach when replacing the spark plug If the reach is too short carbon will be deposited on the screw portion of the spark plug hole and engine ...

Page 37: ...stallation in Section 9D 3 Remove the fuel tank side cover Refer to Fuel Tank Removal and Installation in Section 1G 4 Inspect the fuel feed hose for damage and fuel leakage If any defects are found the fuel feed hose must be replaced 5 After finishing the fuel feed hose inspection or replacement reinstall the removed parts Engine Oil and Filter Replacement B931H20206008 Replace engine oil Initial...

Page 38: ...n for several minutes at idling speed after tightening the oil filler cap 7 Turn off the engine and wait about three minutes and then check the oil level on the dipstick 3 The oil level should be between the low level line A and full level line B If the oil level is lower than the low level line A add oil to the full level line B Oil Level Inspection 1 Place the vehicle on a level ground and set t...

Page 39: ...g 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 A 09915 40620 Oil filter wrench Tightening torque Oil filter a 20 N m 2 0 kgf m 14 5 lbf ft 6 Add new engine oil and check the oil level is as described...

Page 40: ...e CAUTION Replace the gasket washers with a new one Tightening torque Front differential gear oil drain plug a 32 N m 3 2 kgf m 23 0 lbf ft 5 Pour fresh oil through the oil filler hole until it overflows from the oil level hole When performing an oil change the front differential will hold about 460 ml 15 6 US oz 16 2 Imp oz of oil Use hypoid gear oil SAE 90 API grade GL 5 NOTE Use hypoid gear oil...

Page 41: ...on a level ground 2 Remove the rear under cover Refer to Under Cover Removal and Installation in Section 9D 3 Place an oil pan below the final gear case 4 Drain oil by removing the oil drain plug 1 and oil filler plug 2 5 Tighten the oil drain plug 1 to the specified torque and pour fresh oil through the oil filler hole until the oil level reaches the bottom tip of the thread Use Mobil fluid 424 o...

Page 42: ... mud If any dirt or mud is found clean it Refer to Throttle Body Removal and Installation in Section 1D Cooling System Inspection B931H20206015 Replace engine coolant Every 2 years Engine Coolant Level Inspection 1 Place the vehicle on a level ground 2 Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir tank If the level is below the lower line add ...

Page 43: ...leed air from the cooling circuit 10 After changing engine coolant reinstall the removed parts Air Bleeding From the Cooling Circuit 1 Place the vehicle on a level ground and set the brake lock 2 Pour engine coolant up to the radiator inlet 3 Slowly swing the vehicle 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 a...

Page 44: ...res 1 Remove the drive V belt Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation in Section 5A 2 Inspect the drive V belt for crack or other damage and measure the width of belt if necessary Refer to Drive V belt Inspection in Section 5A If any abnormal points are found replace the drive V belt with a new one Refer to V belt Type Continuously Variable Automa...

Page 45: ...ke fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding Brake Fluid Level Check Inspect brake fluid level Every 1 000 km 600 miles 3...

Page 46: ...se with a new one Refer to Front Brake Hose Removal and Installation in Section 4A Front Brake Hose Replacement Replace brake hose Every 4 years Refer to Front Brake Hose Removal and Installation in Section 4A Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment B931H20206019 NOTE Adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever Brake Pe...

Page 47: ...After adjusting the brake pedal check the rear brake lever play a The brake lever play a as measured at the lever holder should be between 6 8 mm 0 2 0 3 in when the lever is lightly pulled in towards the grip If adjustment is necessary slacken the cable by loosening the lock nut 1 and screwing the cable adjuster 2 on the brake lever holder all the way in Rear brake lever play a 6 8 mm 0 2 0 3 in ...

Page 48: ...ly invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification Special tool 09900 20805 Tire depth gauge Tire tread depth a Service limit Front 4 0 mm 0 16 in Rear 4 0 mm 0 16 in Tire Pressure If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore mainta...

Page 49: ...out B A Standard 5 4 mm 0 20 0 16 in If the toe out is out of specification bring it into the specified range Refer to Toe Adjustment Page 0B 20 Toe Adjustment B931H20206023 Adjust the toe out as follows 1 Loosen the lock nuts 1 2 on each tie rod CAUTION The lock nuts 2 have left hand threads When loosening and tightening the lock nuts hold the tie rod end with a open end wrench NOTE Hold the conc...

Page 50: ...f any defects are found replace them with new ones Refer to Front Shock Absorber Removal and Installation in Section 2B and Rear Shock Absorber Removal and Installation in Section 2C Chassis Bolt and Nut Inspection B931H20206025 Tighten chassis bolt and nut Initially at 200 km 100 miles 1 month and every 1 000 km 600 miles 3 months thereafter Check that all chassis bolts and nuts are tightened to ...

Page 51: ...f 8 I931H1020082 01 e 9 e 9 I931H1020061 04 10 Front suspension arm pivot nut Upper 60 N m 6 0 kgf m 43 5 lbf ft 11 Front suspension arm pivot nut Lower 65 N m 6 5 kgf m 47 0 lbf ft 12 Front hub nut 110 N m 11 0 kgf m 79 5 lbf ft 13 Front wheel set nut 60 N m 6 0 kgf m 43 5 lbf ft 14 Rear wheel set nut 60 N m 6 0 kgf m 43 5 lbf ft 15 Rear hub nut 121 N m 12 1 kgf m 87 5 lbf ft g 11 b 10 g 11 I931H...

Page 52: ...kgf m 4 5 lbf ft 21 Front brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 lbf ft e 17 e 16 g 17 I931H1020065 04 j 19 b 18 I931H1020066 04 a 21 k 20 I931H1020067 04 22 Footrest mounting bolt M8 26 N m 2 6 kgf m 19 0 lbf ft 23 Footrest mounting bolt M10 55 N m 5 5 kgf m 40 0 lbf ft 24 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lbf ft 25 Master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lbf ft 26...

Page 53: ...pivot nut Upper and Lower 60 N m 6 0 kgf m 43 5 lbf ft 31 Rear knuckle end nut 60 N m 6 0 kgf m 43 5 lbf ft a 27 a 27 a 27 a 27 n 28 a 27 I931H1020072 03 b 29 b 30 b 29 I931H1020073 02 b 31 I931H1020074 02 32 Rear stabilizer joint nut 60 N m 6 0 kgf m 43 5 lbf ft 33 Trailer towing mounting bolt 60 N m 6 0 kgf m 43 5 lbf ft 34 Rear brake pedal screw 4 5 N m 0 45 kgf m 3 0 lbf ft o 32 o 32 I931H1020...

Page 54: ...ottle and note the engine speed r min when the vehicle begins to move forward Engagement speed 1 700 2 200 r min 7 Disconnect the tachometer and install the frame front cover Clutch Lock up Inspection Perform this inspection to determine if the clutch is engaging fully and not slipping 1 Warn up the engine 2 Remove the right side cover Refer to Front Side Exterior Parts Removal and Installation in...

Page 55: ... 3 16 5 Page 0B 4 Muffler connecting bolt 23 2 3 16 5 Page 0B 4 Valve clearance adjuster lock nut 10 1 0 7 0 Page 0B 5 Valve timing inspection cap bolt 10 1 0 7 0 Page 0B 6 TDC plug 23 2 3 16 5 Page 0B 6 Muffler end cover nut 11 1 1 8 0 Page 0B 8 Oil drain plug 21 2 1 15 0 Page 0B 9 Oil filter 20 2 0 14 5 Page 0B 10 Front differential gear oil level plug 8 0 8 5 7 Page 0B 11 Page 0B 11 Front diffe...

Page 56: ...3 09900 20805 Thickness gauge Tire depth gauge Page 0B 5 Page 0B 5 Page 0B 19 09900 25008 09900 26006 Multi circuit tester set Engine tachometer Page 0B 25 Page 0B 25 Page 0B 25 09915 40620 09917 14910 Oil filter wrench Tappet adjust driver Page 0B 10 Page 0B 10 Page 0B 5 ...

Page 57: ...dth IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 38 8 1 53 Valve spring tension IN EX 182 210 N 18 6 21 4 kgf 41 0 47 2 lbs at length 31 5 mm 1 24 in Item Standard Limit Cam height IN 33 45 33 50 1 317 1 319 33 15 1 305 EX 33 47 33 52 1 318 1 320 33 17 1 306 Camshaft journal oil clearance Camshaft end side 0 028 0 059 0 0011 0 0023 0 150 0 0059...

Page 58: ...0 0059 Piston ring groove width 1st 0 78 0 80 0 0307 0 0315 1 30 1 32 0 051 0 052 2nd 1 01 1 03 0 040 0 041 Oil 2 51 2 53 0 099 0 100 Piston ring thickness 1st 0 71 0 76 0 028 0 030 1 08 1 10 0 0425 0 0433 2nd 2R 0 97 0 99 0 038 0 039 Piston pin bore I D 20 002 20 008 0 7875 0 7877 20 030 0 7886 Piston pin O D 19 992 20 000 0 7871 0 7874 19 980 0 7866 Item Standard Limit Conrod small end I D 20 00...

Page 59: ...006 Front drive differential gear backlash 0 05 0 20 0 002 0 008 Final gear backlash 0 08 0 15 0 003 0 006 Front differential gear oil type Hypoid gear oil SAE 90 API grade GL 5 or SAE 75 W 90 Final gear oil type Mobil fluid 424 or equivalent gear oil Front differential gear oil capacity 460 ml 15 6 16 2 US lmp oz Final gear oil capacity 770 ml 26 0 27 1 US lmp oz Item Standard Specification Note ...

Page 60: ...ensor input voltage 4 5 5 5 V TP sensor output voltage Closed 0 93 1 31 V Opened 3 64 4 82 V IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 1 88 3 06 V at 20 C 68 F IAT sensor resistance 20 C 68 F 2 22 3 22 kΩ ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 15 4 85 V ECT sensor resistance 20 C 68 F Approx 2 45 kΩ TO sensor resistance 19 20 kΩ TO sensor voltage Normal 0...

Page 61: ...lated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Starter relay resistance 3 5 Ω Battery Type designation YTX20CH BS Capacity 12 V 64 8 kC 18 Ah 10 HR Fuse size Headlight HI 10 A LO 10 A Power source 10 A Ignition 15 A Fuel 10 A Fan 15 A Main 30 A EPS 40 A Item Standard Specification P 24 28 33 P 17 Headlight HI 35 x 2 LO 35 x 2 Brake light Taillig...

Page 62: ...Standard Limit Cold inflation tire pressure Solo riding Front 35 kPa 0 35 kgf cm2 5 1 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi Tire size Front AT 25 x 8 12 tubeless Rear AT 25 x 10 12 tubeless Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 Item Standard Limit Front shock absorber spring adjuster 2 5 position Rear shock absorber spring adjuster 2 5 position Item Specification Note Fuel type Use only unl...

Page 63: ... 110 11 0 79 5 Movable driven face bolt 110 11 0 79 5 Movable driven face ring nut 110 11 0 79 5 Clutch outer cover bolt 8 0 8 6 0 Clutch inner cover bolt 9 0 9 6 5 Generator rotor nut 140 14 0 101 5 Generator stator set bolt 11 1 1 8 0 Speed sensor bolt 10 1 0 7 0 Starter clutch bolt 26 2 6 19 0 Left crankshaft spacer nut 38 3 8 27 5 Exhaust pipe nut 23 2 3 16 5 Muffler connect bolt 23 2 3 16 5 M...

Page 64: ...l gear case mounting nut 65 6 5 47 0 Final gear case mounting bolt 65 6 5 47 0 Rear propeller shaft boot clamp screw 2 0 2 1 5 Final gear oil drain plug 23 2 3 16 5 Rear propeller shaft coupling nut 100 10 0 72 5 Rear output shaft nut 100 10 0 72 5 Rear output shaft driven gear nut 100 10 0 72 5 Item N m kgf m lbf ft CKP sensor mounting bolt 6 0 6 4 5 Generator lead wire clamp bolt 6 0 6 4 5 Fuel ...

Page 65: ... Lower 60 6 0 43 5 Front hub nut 110 11 0 79 5 Rear hub nut 121 12 1 87 5 Wheel set nut Front and Rear 60 6 0 43 5 Front brake hose union bolt 23 2 3 16 5 Front brake air bleeder valve 6 0 0 6 4 3 Front brake caliper mounting bolt 26 2 6 19 0 Caliper holder pin 18 1 8 13 0 Caliper holder slide pin 23 2 3 16 5 Front brake pad mounting pin 18 1 8 13 0 Brake pipe flare nut 16 1 6 11 5 Front brake dis...

Page 66: ...rked bolt N m kgf m lbf ft N m kgf m lbf ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 04 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt ...

Page 67: ...Coil Circuit Malfunction 1A 59 DTC C32 P0201 Fuel Injector Circuit Malfunction 1A 59 DTC C40 P0505 H L ISC Valve Circuit Malfunction 1A 62 DTC C41 P230 H L FP Relay Circuit Malfunction 1A 68 Specifications 1A 70 Service Data 1A 70 Special Tools and Equipment 1A 71 Special Tool 1A 71 Emission Control Devices 1B 1 Precautions 1B 1 Precautions for Emission Control Devices 1B 1 Repair Instructions 1B ...

Page 68: ...rator Cover Inspection 1D 62 Oil Seal Bearing Crankcase and Generator Cover Removal and Installation 1D 62 Specifications 1D 67 Service Data 1D 67 Tightening Torque Specifications 1D 69 Special Tools and Equipment 1D 70 Recommended Service Material 1D 70 Special Tool 1D 70 Engine Lubrication System 1E 1 Precautions 1E 1 Precautions for Engine Oil 1E 1 Schematic and Routing Diagram 1E 1 Engine Lubr...

Page 69: ...tem Symptom Diagnosis 1H 2 No Spark or Poor Spark 1H 2 Repair Instructions 1H 3 Spark Plug Cap and Spark Plug Removal and Installation 1H 3 Spark Plug Inspection and Cleaning 1H 3 Ignition Coil and Plug Cap Inspection 1H 4 Ignition Coil Removal and Installation 1H 5 CKP Sensor Inspection 1H 5 CKP Sensor Removal and Installation 1H 6 Engine Stop Switch Inspection 1H 6 Ignition Switch Inspection 1H ...

Page 70: ...stallation 1J 4 Regulator Rectifier Inspection 1J 8 Battery Components 1J 9 Battery Charging 1J 9 Battery Removal and Installation 1J 11 Battery Visual Inspection 1J 12 Specifications 1J 12 Service Data 1J 12 Tightening Torque Specifications 1J 13 Special Tools and Equipment 1J 13 Recommended Service Material 1J 13 Special Tool 1J 13 Exhaust System 1K 1 Precautions 1K 1 Precautions for Exhaust Sys...

Page 71: ...Precautions 1 1 Engine Precautions Precautions Precautions for Engine B931H21000001 Refer to General Precautions in Section 00 and Precautions for Electrical Circuit Service in Section 00 ...

Page 72: ...1110080 01 Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR SIGNAL When engine coolant temperature is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low injection time volume is increased BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injecti...

Page 73: ... signal from the ECM is received for 3 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speedometer does not receive any signal form ECM and the panel indicates CHEC If CHEC is indicated the LCD does not indicate the trouble code It is necessary to check the wiring harness between ECM and speedometer couplers The possible cause of this ...

Page 74: ...d devices are indicated in the code form CAUTION Before checking the malfunction code do not disconnect the ECM coupler If the coupler from the ECM is disconnected the malfunction code memory may be erased and the malfunction code can not be checked Special tool A 09930 82720 Mode selection switch Malfunction LCD display indication FI light indication Indication mode NO C00 FI indicator light turn...

Page 75: ...elay Brake switch L Ignition switch Ignition coil Fuel injector Fuel pump relay Fuel pump Engine stop switch START button Starter motor Parking brake relay Diff lock position switch Override switch Gear position switch N L H 30 A 15 A 10 A Speedometer 1 k Ω EPS unit IAP TP IAT sensor B G 23 Bl G B R Y Dg B Bl B Br Br W B Lg P W G W Bl Br G B B W B Y R G 9 6 13 20 19 14 28 11 24 10 17 34 16 33 25 7...

Page 76: ... relay 5 Brake switch BRK 22 Serial data for self diagnosis 6 Power source for sensors VCC 23 Serial data for speedometer 7 ECM ground E1 24 Sensor ground E2 8 Forward sensor signal FOW 25 Override switch OVR 9 CKP sensor signal CKP 26 Neutral switch NT 10 TO sensor signal TO 27 11 ECT sensor signal ECT 28 IAT sensor signal IAT 12 29 Diff lock switch DL 13 IAP sensor signal IAP 30 14 TP sensor sig...

Page 77: ...arts Location B931H21103001 C B G E F A D I931H1110007 05 A ECM C IAP TP IAT sensor E Speed sensor G Diff lock relay B ISC valve D CKP sensor F Combination meter I J M K A L H I931H1110008 02 A ECM I TO sensor K Ignition coil M Fuel pump H ECT sensor J Fuel injector L FP relay ...

Page 78: ... Defective fuel pump relay Replace Defective ECM Replace Open circuited wiring connections Check and repair Engine will not start or is hard to start Incorrect fuel air mixture Defective fuel pump Replace Defective fuel pressure regulator Replace Defective TP sensor Replace Defective CKP sensor Replace Defective IAP sensor Replace Defective ECM Replace Defective ECT sensor Replace Defective IAT se...

Page 79: ... to wear Replace Worn and burnt journal bearings Replace Engine noisy Noise seems to come from balancer Worn and burnt journal bearings Replace Engine noisy Noise seems to come from transmission Worn or rubbing gears Replace Worn splines Replace Worn or rubbing primary gears Replace Worn bearings Replace Engine noisy Noise seems to come from water pump Worn or damaged impeller shaft Replace Worn o...

Page 80: ...Defective ECM Replace Engine overheats Defective engine internal parts Heavy carbon deposit on piston crown Clean Not enough oil in the engine Add oil Defective oil pump or clogged oil circuit Replace or clean Use of incorrect engine oil Change Sucking air from intake pipe Retighten or replace Defective cooling system Refer to Engine Cooling Symptom Diagnosis in Section 1F Engine overheats Lean fu...

Page 81: ...D 2 Connect the special tool to the mode select switch coupler at the wiring harness Special tool A 09930 82720 Mode selection switch 3 Start the engine or crank the engine for more than 4 seconds 4 Turn the special tool s switch ON 5 Check the DTC to determine the malfunction part Refer to DTC Table Page 1A 18 Special tool A 09930 82720 Mode selection switch 6 After repairing the trouble turn OFF...

Page 82: ...CM memory DTC stored in ECM memory can be checked by the SDS Be sure to read Precautions for Electrical Circuit Service in Section 00 before inspection and observe what is written there 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Set up the SDS tools Refer to the SDS operation manual for further details Special tool A 09904 41010 SUZUKI Diagnostic system set B 99565 01...

Page 83: ...DS tool and turn the ignition switch OFF 8 Disconnect the SDS tool and install the right frame cover Use of SDS Diagnosis Reset Procedures B931H21104003 NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS 1 After rep...

Page 84: ...tions e g whether the engine was warm or not where the vehicle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each show data when trouble for two different malfunctions in the order of occurrence as the malfunction is...

Page 85: ...e General Information and Diagnosis 1A 14 1 Click Show data when trouble 1 to display the data 2 Click the drop down button 2 either Failure 1 or Failure 2 can be selected 1 I718H1110269 02 2 I831G1110017 01 ...

Page 86: ...e which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between the same models helps to facilitate the troubleshooting 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Set up the SDS tool Refer to the SDS operation manual for further details...

Page 87: ...on and Diagnosis 1A 16 Data at 3 000 r min under no load Data at the time of racing Approx 3 000 r min Check the manifold absolute pressure XXX kPa I931H1110068 01 Throttle Quick wide open Throttle Slowly open I931H1110069 01 ...

Page 88: ...ion then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring NOTE With DTC not output if the value of intake air pressure is found to be upper than the data saved previously the possible cause may probably lie in a air passage clogged or influence of internal resistance value changes etc No DTC output Unstable idling speed The manif...

Page 89: ... this case it is necessary to bring the vehicle to the workshop for complete repair Code Malfunction Part Remarks C00 None No defective part C12 P0335 Page 1A 23 Crankshaft position sensor CKP sensor Pick up coil signal signal generator C13 P0105 H L Page 1A 26 Intake air pressure sensor IAP sensor C14 P0120 H L Page 1A 33 Throttle position sensor TP sensor 1 C15 P0115 H L Page 1A 40 Engine coolan...

Page 90: ...ack fire After fire No combustion Lack of power Poor starting at Surging cold warm always Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed Throttle valve is opened High Low r min Throttle valve is closed Unstable Load is applied Hunting r min to r min Other Other OTHERS VEHICLE ENVIRONMENTAL CONDITION ...

Page 91: ...el and leakage Refer to Cooling Circuit Inspection in Section 1F Fuel level and leakage Refer to Fuel Line Inspection in Section 0B Clogged air cleaner element Refer to Air Cleaner Element Inspection and Cleaning in Section 0B Battery condition Throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Broken fuse FI light operation Refer to Combination Meter Inspecti...

Page 92: ... voltage should be the following 0 15 V sensor voltage 4 85 V In other than the above range C15 P0115 is indicated ECT sensor lead wire coupler connection P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value ECT sensor circuit shorted to the ground C20 Diff lock relay No voltage is applied to 4WD diff lo...

Page 93: ...er than specified value ISC valve circuit shorted to BATT or ground circuit open P0505 H L ISC valve motor circuit is open ISC valve circuit open or BATT circuit open C41 Fuel pump relay No voltage is applied to the fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay lead wire coupler connection power source to t...

Page 94: ... using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction CKP sensor ECM To regulator rectifier Generator CKP CKP B...

Page 95: ...on switch OFF 3 Check the CKP sensor coupler for loose or poor contacts If OK then measure the CKP sensor resistance 4 Disconnect the CKP sensor coupler and measure the resistance Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω CKP sensor resistance 170 250 Ω Bl W Go to Step 2 Replace the CKP sensor with a new one I931H1110013 01 A I931H1110014 02 ...

Page 96: ... Repeat the above test procedure a few times and measure the highest peak voltage Is the voltage OK Bl G or B wire open or shorted to the ground or poor 9 or 18 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Removal and Ins...

Page 97: ...sor voltage is not within the following range 0 5 V Sensor voltage 4 85 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to the gro...

Page 98: ... 4 Disconnect the IAP sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage at the R wire and ground If OK then measure the voltage at the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R terminal B Br Is the voltage OK ...

Page 99: ...upler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between the R wire and G B wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity Go to Step 3 G B wire shorte...

Page 100: ...r 8 Check the continuity between the G B wire B and terminal 13 If OK then check the continuity between the B Br wire C and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 3 G B wire shorted to VCC or B Br wire open Step Action Yes No B B C 24 A 13 I931H1110022 01 ...

Page 101: ...P sensor coupler 5 Check the continuity between the G B wire and ground Also check the continuity between the G B wire and B Br wire If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 6 Disconnect the ECM coupler Refer to ECM Removal and Installation in Se...

Page 102: ...coupler 2 Turn the ignition switch ON 3 Insert the needle pointed probes to the lead wire coupler 4 Measure the input voltage at the R wire and ground with the needle pointed probes If OK the measure the input voltage at the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAP sensor input voltage 4 5 5 5...

Page 103: ...n Voltage IAP sensor output voltage 1 78 3 35 V at idle speed terminal G Bl terminal B Br Is the voltage OK G B R or B Br wire open or shorted to ground or poor 6 13 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Remo...

Page 104: ...he trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause C14 Output voltage is not within the following range 0 2 V Sensor voltage 4 8 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor circuit is shorted to VCC or gro...

Page 105: ...Turn the ignition switch ON 6 Insert the pointed probes to the lead wire coupler 7 Measure the input voltage at the R wire A and ground If OK then measure the input voltage at the R wire A and B Br wire C Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage TP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R t...

Page 106: ...ontinuity 4 Disconnect the TP sensor coupler 5 Insert the needle pointed probes to the lead wire coupler 6 Check the continuity between R wire A and Y wire B If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity 7 Disconnect the ECM coupler Refer to ECM Removal a...

Page 107: ...lso check the continuity between B Br wire C and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity Is the continuity OK Go to Step 2 R wire shorted to VCC or B Br wire open Step Action Yes No B C A B 14 24 I931H1110032 02 ...

Page 108: ...or coupler 5 Insert the needle pointed probes to the lead wire coupler 6 Check the continuity between Y wire B and ground Also check the continuity between Y wire B and B Br wire C If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test 7 Disconnect the ECM co...

Page 109: ...orted to ground 2 1 Correct the ECM coupler 2 Turn the ignition switch ON 3 Measure the input voltage between the R wire and ground If OK the measure the input voltage between the R wire and B Br wire Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage TP sensor input voltage 4 5 5 5 V terminal R terminal Ground terminal R termi...

Page 110: ...dication Voltage TP sensor output voltage Throttle valve is closed Approx 0 93 1 31 V Throttle valve is opened Approx 3 64 4 82 V Is the voltage OK Y B Br or R wire open or shorted to ground or poor 14 24 or 6 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one ...

Page 111: ...nal bend NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause C15 Output voltage is not within the following range 0 15 V Sensor voltage 4 85 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT sensor circuit is open or...

Page 112: ... side coupler 4 Disconnect the coupler and turn the ignition switch ON 5 Measure the voltage between the B Bl wire terminal and ground If OK then measure the input voltage between B Bl wire terminal and B Br wire terminal Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage ECT sensor voltage 4 5 5 5 V terminal B Bl terminal Ground terminal B Bl terminal B Br Is the v...

Page 113: ...ity 4 Disconnect the ECT sensor coupler 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C 6 Insert the needle pointed probes to lead wire coupler 7 Check the continuity between B Bl wire A and terminal 11 Also check the continuity between B Br wire B and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob...

Page 114: ...ECT sensor lead wire continuity 4 Disconnect the ECT sensor coupler 5 Check the continuity between B Bl wire and ground If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity test 6 Connect the ECT sensor coupler 7 Insert the needle pointed probes to the lead wire coupler 8 Turn the ignition switch ON ...

Page 115: ...ction in Section 1C for details Special tool 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F Terminal Terminal NOTE Refer to ECT Sensor Inspection in Section 1C for details Is the resistance OK B Br or B Bl wire open or shorted to ground or poor 24 or 11 connection If wire and connection are OK intermittent trouble or fault...

Page 116: ...agnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause No voltage is applied to diff lock motor although ignition switch is turned ON or voltage is applied to diff lock motor although ignition switch is turned OFF Diff lock relay circuit open or short Diff lock relay malfunction ECM malfunction ECM Diff lock relay Ignition switch Ignition fuse Main fuse Diff lock relay Transfer sele...

Page 117: ...se or poor contacts If OK then check the diff lock relay insulation and continuity Refer to 2WD 4WD Diff lock System Inspection in Section 3B Is the diff lock relay OK Inspect the 4WD diff lock switch Y B wire open or shorted to ground or poor 21 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection R...

Page 118: ...minal bend NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause C21 Output voltage is not within the following range 0 15 V Sensor voltage 4 85 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ...

Page 119: ...pler and turn the ignition switch ON 5 Measure the voltage between the Dg wire terminal and ground If OK then measure the input voltage between Dg wire terminal and B Br wire terminal Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage IAT sensor input voltage 4 5 5 5 V terminal Dg terminal Ground terminal Dg terminal B Br Is th...

Page 120: ...he IAT sensor coupler 5 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between the Dg wire A and terminal 28 Also check the continuity between the B Br wire B and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indicat...

Page 121: ...the lead wire coupler 5 Check the continuity between the Dg wire and ground If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test 6 Connect the IAT sensor coupler 7 Turn the ignition switch ON 8 Insert the needle pointed probes to the lead wire coupler G...

Page 122: ...he IAT sensor resistance Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω IAT sensor resistance 2 22 3 22 kΩ at 20 C 68 F Terminal Terminal Is the resistance OK Dg or B Br wire open or shorted to the ground or poor 28 or 24 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each terminal and wire harness for open circuit and p...

Page 123: ... repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause C23 The sensor voltage is not within the following range 0 2 V Sensor voltage 4 8 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit open or shorted to VCC or grou...

Page 124: ...acts If OK then measure the TO sensor resistance 4 Remove the TO sensor 5 Disconnect the TO sensor coupler 6 Measure the resistance between terminal A and terminal B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω TO sensor resistance 19 0 20 0 kΩ Terminal A Terminal B Is the resistance OK Go to Step 2 Replace the TO sensor with a new one Refer to TO Sensor ...

Page 125: ...he TO sensor lead wire continuity 4 Remove the TO sensor 5 Disconnect the TO sensor coupler 6 Check the continuity between the R wire A and B Br wire B If the sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity test 7 Disconnect the ECM coupler Refer to ECM Removal and Installation in Section 1C Go to ...

Page 126: ... check the continuity between B Br wire C and terminal 24 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 Br W wire shorted to VCC or B Br wire open Step Action Yes No B A B 10 C 24 I931H1110051 02 ...

Page 127: ...e the TO sensor 5 Disconnect the TO sensor coupler 6 Insert the needle pointed probes to the lead wire coupler 7 Check the continuity between Br W wire B and ground Also check the continuity between Br W wire B and B Br wire C If sound is not heard from the tester the circuit condition is OK Special tool A 09900 25008 Multi circuit tester set 8 Disconnect the ECM coupler Refer to ECM Removal and I...

Page 128: ...inal 6 Also then check the continuity between Br W wire B and terminal 10 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 R or B wire open or Br W wire shorted to the ground A B A B 6 10 I931H1110053 01 ...

Page 129: ...t is learned 65 and more left and right from the horizontal level Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage TO sensor voltage 3 7 4 4 V terminal Br W terminal B Br Is the voltage OK R B Br or Br W wire open or shorted to ground or poor 6 24 or 10 connection If wire and connection are OK intermittent trouble or faulty E...

Page 130: ... repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Injector voltage can be detected only for 3 seconds after ignition switch is turned ON Detected Condition Possible Cause CKP signal is produced but fuel injector signal is interrupted by 4 times or more continuity Injector circuit open or short Injector malfunction ECM malfunction ECM VM F...

Page 131: ... poor contacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Injector resistance Approx 11 13 Ω at 20 C 68 F Terminal Terminal Go to Step 2 Replace the injector with a new one Refer to Throttle Body Disassembly and Assembly in Section 1...

Page 132: ...Turn the ignition switch ON 2 Measure the injector voltage between Y R wire and ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Injector voltage Battery voltage terminal Y R terminal Ground Is the voltage OK Gr W or Y R wire open or shorted to ground or poor 2 or 20 connection If wire and connection are OK intermittent trouble or faulty ECM Recheck each te...

Page 133: ...C valve operation When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend NOTE After repairing the trouble clear the DTC using SDS tool Refer to Use of SDS Diagnosis Reset Procedures Page 1A 12 Detected Condition Possible Cause C40 P0505 H ISC value motor current is higher than the ...

Page 134: ...ISC valve lead wire continuity 4 Disconnect the ISC valve coupler 5 Check the continuity between terminals A and 34 terminals B and 4 terminals C and 17 terminals D and 33 terminals E and 4 and terminals F and 16 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 B Lg R B P W G or W Bl ...

Page 135: ...between terminals A and C terminals B and D Special tool A 09900 25008 Multi circuit tester set ISC valve resistance Approx Terminal A Terminal C Terminal B Terminal D If wire is OK intermittent trouble or faulty ECM Replace the ISC valve with a new one Refer to ISC Valve Removal and Installation in Section 1C Step Action Yes No I931H1110062 01 A A C B D I931H1110063 01 ...

Page 136: ...ol A 09900 25008 Multi circuit tester set ISC valve resistance Approx 31 Ω at 20 C 68 F Terminal A Terminal B Terminal C Terminal D Is the resistance OK If wire is OK intermittent trouble or faulty ECM Replace the ISC valve with a new one Refer to ISC Valve Removal and Installation in Section 1C Step Action Yes No A A B C D I931H1110064 01 ...

Page 137: ...d 3 is within the specified idle rpm Check 2 1 Click the button 4 and decrease the Spec 2 to 1 400 rpm slowly 2 Check that the Desired idle speed 3 is nearly equal to the Spec 2 At the same time check that the number of steps 5 in the ISC valve position decreases 3 Click the button 6 and increase the Spec 2 slowly 4 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that ...

Page 138: ...ton 6 and increase the Spec 2 to 1 800 rpm 2 Check that the Desired idle speed 3 is approx 1 800 rpm 3 Check that the Engine speed 7 is close to 1 800 rpm NOTE Be careful not to increase the Spec to 1 850 rpm or the Engine speed may reach the upper limit If the ISC valve does not function properly replace the ISC valve or inspect the ISC valve Refer to Throttle Body Disassembly and Assembly in Sec...

Page 139: ... applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction P0230 H Voltage is applied to fuel pump although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted to power source Faulty fuel pump relay switch side L No voltage is applied to fuel pump although fuel pump relay is turned ON Fuel pump rel...

Page 140: ... harness for open circuit poor connection Replace the ECM with a known good one and inspect it again Refer to ECM Removal and Installation in Section 1C Replace the FP relay with a new one Step Action Yes No 1 1 Remove the seat Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Turn the ignition switch to OFF 3 Check the FP relay coupler for loose or poor contacts If OK th...

Page 141: ...ECM with a known good one and inspect it again Replace the FP relay with a new one I931H1110065 01 Item Specification Note Injector resistance 11 13 Ω at 20 C 68 F Item Specification Note CKP sensor resistance 170 250 Ω CKP sensor peak voltage 5 0 V and more When cranking IAP sensor input voltage 4 5 5 5 V IAP sensor output voltage 1 78 3 35 V at idle speed TP sensor input voltage 4 5 5 5 V TP sen...

Page 142: ...A 31 Page 1A 32 Page 1A 34 Page 1A 35 Page 1A 36 Page 1A 37 Page 1A 38 Page 1A 38 Page 1A 39 Page 1A 41 Page 1A 42 Page 1A 43 Page 1A 44 Page 1A 44 Page 1A 48 Page 1A 49 Page 1A 50 Page 1A 27 Page 1A 28 Page 1A 29 Page 1A 30 Page 1A 31 Page 1A 31 Page 1A 32 Page 1A 34 Page 1A 35 Page 1A 36 Page 1A 37 Page 1A 38 Page 1A 38 Page 1A 39 Page 1A 42 Page 1A 44 Page 1A 48 Page 1A 49 Page 1A 50 Page 1A 51...

Page 143: ...tallation in Section 9D 3 Inspect the PCV hose 1 for wear or damage If it is worn or damaged replace the PCV hose with a new one Check that the PCV hose 1 is securely connected Crankcase Breather PCV Hose Removal and Installation B931H21206002 Removal 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Remove the right side cover Refer to Front Side Exterior Parts Removal and ...

Page 144: ...formation and Procedures Engine Symptom Diagnosis B931H21304001 Refer to Engine Symptom Diagnosis in Section 1A Repair Instructions ECM Removal and Installation B931H21306001 Removal 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Remove the battery lead wire 3 Disconnect the ECM coupler 1 and remove the ECM 2 Installation NOTE After replacing the ECM turn ON the ignition ...

Page 145: ...embly in Section 1D CAUTION Never remove the IAP TP IAT sensor from the throttle body The IAP TP IAT sensor and throttle body are available only as an assembly ECT Sensor Removal and Installation B931H21306006 Removal 1 Drain engine coolant Refer to Cooling System Inspection in Section 0B 2 Remove the right side cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 3 Disc...

Page 146: ...cation Resistance Ω Temperature sensor specification 4 Install the ECT sensor Refer to ECT Sensor Removal and Installation Page 1C 2 TO Sensor Inspection B931H21306008 Refer to DTC C23 P1651 H L TO Sensor Circuit Malfunction in Section 1A TO Sensor Removal and Installation B931H21306009 Removal 1 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation in Section 1D 2 Disconnec...

Page 147: ...ront Side Exterior Parts Removal and Installation in Section 9D 3 Disconnect the ISC valve coupler 1 and remove the ISC valve 2 Installation NOTE After replacing the ISC valve turn ON the ignition switch and OFF again Install the ISC valve in the reverse order of removal Pay attention to the following points Install the new O ring 1 Install the ISC valve 2 and tighten the ISC valve mounting screws...

Page 148: ...TP sensor output voltage Closed 0 93 1 31 V Opened 3 64 4 82 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 15 4 85 V ECT sensor resistance Approx 2 45 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 1 88 3 06 V at 20 C 68 F IAT sensor resistance 2 22 3 22 kΩ at 20 C 68 F TO sensor resistance 19 20 kΩ TO sensor voltage Normal 0 4 1 4 V Leaning 3 7 4 4...

Page 149: ...agram Throttle Cable Routing Diagram B931H21402001 1 1 2 1 5 5 B 3 6 A 4 I931H1140114 01 1 Throttle cable 5 Throttle cable guide 2 Brake hose 6 Clamp 3 Handlebar A Pass through the throttle cable inside of pin 4 Pin B Pass through the throttle cable front side of brake hose ...

Page 150: ...d Spark Plug Removal and Installation in Section 1H 5 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Special tool A 09915 64512 Compression gauge B 09913 10750 Compression gauge adapter 6 Keep the throttle grip in the fully opened position 7 Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as t...

Page 151: ...K Throttle body Refer to Throttle Body Removal and Installation Page 1D 9 Refer to Throttle Body Inspection and Cleaning Page 1D 13 Refer to Throttle Body Removal and Installation Page 1D 9 Cylinder head Refer to Engine Top Side Disassembly Page 1D 18 Refer to Cylinder Head Cover Related Parts Inspection Page 1D 37 Refer to Engine Top Side Assembly Page 1D 22 Cam chain tension adjuster Refer to En...

Page 152: ...mission Removal and Installation in Section 5A Clutch housing Clutch shoe Refer to Clutch Shoe Removal and Installation in Section 5A Refer to Clutch Related Parts Inspection in Section 5A Refer to Clutch Shoe Removal and Installation in Section 5A Movable driven face assembly Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation in Section 5A Refer to Movable ...

Page 153: ...utch Removal and Installation in Section 1I Starter idle gear Refer to Engine Bottom Side Disassembly Page 1D 46 Refer to Engine Bottom Side Assembly Page 1D 52 Balancer driven gear Refer to Engine Bottom Side Disassembly Page 1D 46 Refer to Engine Bottom Side Assembly Page 1D 52 Oil pump driven gear Refer to Oil Pump Removal and Installation in Section 1E Refer to Oil Pump Removal and Installatio...

Page 154: ...al 1 Remove the seat side covers and air cleaner box cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 3 1 4 a C 2 a B A A 4 4 1 B FWD I931H1140288 01 1 Air cleaner inlet sheet A Insert the air cleaner inlet sheet between the rear fender and frame 2 Air cleaner box B Align the hole of the air cleaner inlet sheet and cushion 3 Frame C Set the air cleaner sheet into t...

Page 155: ... Throttle Body Construction Page 1D 9 Tighten the air cleaner box mounting bolts to the specified torque Tightening torque Air cleaner box mounting bolt a 4 5 N m 0 45 kgf m 3 0 lbf ft Install the removed parts Throttle Cable Removal and Installation B931H21406007 Removal 1 Remove the air cleaner box Refer to Air Cleaner Box Removal and Installation Page 1D 6 2 Remove the right throttle lever case...

Page 156: ...B931H21406008 Check that the throttle lever moves smoothly from full open to full close If it does not move smoothly lubricate the throttle cable Throttle Cable Play Inspection and Adjustment B931H21406009 Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Throttle Body Components B931H21406010 I931H1140012 01 1 2 3 4 5 6 a 8 7 b 9 FWD FWD I931H1140290 03 1 Throttle body assembly...

Page 157: ...tallation Page 1D 6 2 Place a rug under the fuel feed hose 1 and disconnect the fuel feed hose 1 from the fuel delivery pipe WARNING Gasoline is highly flammable and explosive Keep heat spark and flame away 1 1 2 2 3 4 A 2 3 FR LH RH RR LH RH FR RR A 4 I931H1140291 02 1 Air cleaner box 4 Clamp 2 Fuel hose A Pass through the fuel hose between air cleaner guide ribs 3 PCV hose 1 I931H1140013 01 ...

Page 158: ... body clamp screw and remove the throttle body assembly Installation NOTE When replacing the throttle body turn ON the ignition switch and turn OFF again Install the throttle body in the reverse order of removal Pay attention to the following points Install the throttle body NOTE When installing the throttle body fit the concave part A of the intake pipe onto the convex part B of the throttle body...

Page 159: ...d Installation Page 1D 9 Disassembly 1 Remove the fuel delivery pipe assembly 1 by removing its mounting screws 2 Remove the fuel injector 2 3 Remove the ISC valve 3 CAUTION Because the O ring is not available as spare part the ISC valve should not be removed unless necessary CAUTION Never remove the TP IAP IAT sensor 4 CAUTION Never remove the throttle valve 5 1 I931H1140020 01 1 I931H1140021 01 ...

Page 160: ... is found to be damaged replace the ISC valve assembly with new one NOTE After replacing the ISC valve and installing the throttle body turn ON the ignition switch and turn OFF again Tighten the ISC valve mounting screws to the specified torque Special tool 09930 11950 Torx wrench 5 mm Tightening torque ISC valve mounting screw a 2 N m 0 2 kgf m 1 5 lbf ft Apply a thin coat of engine oil to the ne...

Page 161: ...turer s instructions for proper use and cleaning of the throttle body components Do not apply carburetor cleaning chemicals to the rubber and plastic materials Inspection Move the throttle valve by hand to inspect it if operating smoothly ISC Valve Visual Inspection Check the ISC valve for carbon deposits or other damage If carbon is deposited remove it with a brush and clean with a compressed air...

Page 162: ...val and Installation in Section 9D Front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D Rear fender Refer to Rear Side Exterior Parts Removal and Installation in Section 9D 7 Disconnect the spark plug cap 1 8 Disconnect the starter motor lead wire 2 and ground lead wire 3 9 Disconnect the radiator inlet hose 4 and outlet hose 5 10 Remove the air cleaner box Refer ...

Page 163: ...nnect the generator coupler 11 CKP sensor coupler 12 and GP switch coupler 13 16 Remove the inlet cooling duct assembly 14 17 Disconnect the outlet cooling duct connector 15 18 Remove the muffler 16 and exhaust pipe 17 Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K 19 Remove the rear brake cable clamp bolt 18 6 7 I931H1140039 01 8 9 I931H1140040 01 10 I931H1140041 01 13 12 11...

Page 164: ...and rear propeller shaft 25 Refer to Final Gear Assembly Removal and Installation in Section 3B and Rear Propeller Shaft Removal and Installation in Section 3D 26 Remove the engine mounting dumper stopper 26 27 Remove the engine mounting bolts and nuts 28 Remove the engine from the right side WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts a...

Page 165: ... differential assembly Refer to Front Drive Differential Assembly Removal and Installation in Section 3B Install the rear brake pedal Refer to Rear Brake Pedal Removal and Installation in Section 4A Install the right footrest and rear brake cable clamp Refer to Footrest Removal and Installation in Section 9E Install the exhaust pipe and muffler Refer to Exhaust Pipe Muffler Removal and Installatio...

Page 166: ...heir respective groups e g intake exhaust so that they can be reinstalled in their original positions 1 Drain engine coolant Refer to Cooling System Inspection in Section 0B 2 Remove the seat Refer to Seat Removal and Installation in Section 9D 3 Disconnect the battery lead wire 4 Remove the front fender and mud guards Refer to Front Side Exterior Parts Removal and Installation in Section 9D and R...

Page 167: ...Section 1H Recoil Cover Remove the recoil cover 1 Cam Chain Tension Adjuster 1 Remove the TDC plug 1 2 Turn the crankshaft and align the match mark A on the crankshaft with the mark B on the crankcase 3 Remove the cam chain tension adjuster cap bolt 2 and gasket 4 Turn the adjusting screw clockwise with a screwdriver until the push rod locked 1 I931H1140060 01 I931H1140061 01 1 I931H1140062 01 1 I...

Page 168: ...nd cylinder head cover plug 4 Camshaft Crankshaft Sprocket 1 Flatten the tongues of the lock washer 1 2 Remove the camshaft sprocket bolts and lock washer 1 3 Turn the crankshaft and position the camshaft sprocket hole A upward as shown 4 Drop the camshaft sprocket to the camshaft groove B 3 4 I931H1140067 01 1 I931H1140068 02 2 I931H1140069 01 3 4 I931H1140070 01 1 1 I931H1140071 01 A I931H114007...

Page 169: ...5 Cylinder Head 1 Remove the cylinder head base nuts 1 2 Remove the cylinder head bolts M8 2 3 Remove the cylinder head bolts M10 and washers NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally 4 Remove the cylinder head 3 NOTE If the cylinder head does not come off easily lightly tap using a plastic hammer 3 2 4 I931H1140074 01 4 I931H1140075 01 5 I931H1140076...

Page 170: ... over the cylinder base so as not to drop the piston pin circlips into the crankcase 2 Remove the piston pin circlips 1 3 Draw out the piston pin 2 and remove the piston 3 Engine Top Side Assembly B931H21406018 Assemble the engine top side in the reverse order of disassembly Pay attention to the following points Piston When installing the piston pin apply molybdenum oil solution onto piston pin M ...

Page 171: ...ligned with the cutaway in the piston pin bore Position the gaps of the three rings and side rails as shown in the figure Before inserting each piston into the cylinder check that the gaps are properly positioned Cylinder Apply a bond lightly to the mating surfaces at the parting line between the left and right crankcases Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent Fit the dowel pins 1 ...

Page 172: ...and cam drive sprocket Cam Chain Guide Install the cam chain guide 1 CAUTION Be sure that the cam chain guide 1 is installed properly Cylinder Head Fit the dowel pins 1 and cylinder head gasket 2 CAUTION Use the new gasket to prevent gas leakage Place the cylinder head 3 on the cylinder NOTE When installing the cylinder head keep the cam chain taut Apply the engine oil to the both sides of washers...

Page 173: ...ue Tightening torque Cylinder head bolt M8 a 25 N m 2 5 kgf m 18 0 lbf ft Cylinder head nut b 25 N m 2 5 kgf m 18 0 lbf ft Camshaft Camshaft Sprocket Turn the crankshaft and align the match mark A on the crankshaft with the mark B on the crankcase CAUTION Pull the cam chain upward or the chain will be caught between crankcase and cam drive sprocket Engage the cam chain with camshaft sprocket 1 Ins...

Page 174: ...ad lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Camshaft sprocket bolt a 15 N m 1 5 kgf m 11 0 lbf ft Bend up the washer tongue positively to lock the bolts Apply molybdenum oil solution to the cam faces and journals M O Molybdenum oil MOLYBDENUM OIL SOLUTION Cylinder Head Cover Clean the mating surfaces of the cylinder head and head cover before mating Ins...

Page 175: ...e specified torque Tightening torque Cylinder head cover bolt 10 N m 1 0 kgf m 7 0 lbf ft Apply grease to the O rings and install the valve clearance inspection caps CAUTION Use the new O rings to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the valve clearance inspection cap bolts to the specified torque Tightening torque Valve clearance inspection cap bolt a...

Page 176: ...ain tension adjuster cap bolt to the specified torque Tightening torque Cam chain tension adjuster cap bolt b 8 N m 0 8 kgf m 6 0 lbf ft Be sure to check the valve clearance Refer to Valve Clearance Inspection and Adjustment in Section 0B Fit a new gasket 3 CAUTION Use the new gasket to prevent oil leakage Tighten the TDC plug to the specified torque Tightening torque TDC plug c 23 N m 2 3 kgf m 1...

Page 177: ...e found replace the camshaft assembly with a new one CAUTION Do not attempt to disassemble the camshaft automatic decomp assembly It is not serviceable Cam Wear Check the camshaft for wear or damage Measure the cam height a with a micrometer Replace a camshaft if the cams are worn to the service limit Special tool 09900 20202 Micrometer 25 50 mm Cam height a Service limit IN 33 15 mm 1 305 in Serv...

Page 178: ...ylinder head cover bolt 10 N m 1 0 kgf m 7 0 lbf ft 5 Remove the cylinder head cover and measure the width of the compressed plastigauge using the envelope scale 6 This measurement should be taken at the widest part of the compressed plastigauge Camshaft journal oil clearance Service limit 0 150 mm 0 0059 in 7 If the camshaft journal oil clearance exceeds the limit measure the inside diameter of t...

Page 179: ...an automatically adjusted 1 Remove the cam chain tension adjuster Refer to Engine Top Side Disassembly Page 1D 18 2 Insert the screwdriver into the slotted end of cam chain tension adjuster and turn it clockwise to lessen the tension and release the screwdriver Then check the push rod movement If the push rod is stuck or spring mechanism failed replace the cam chain tension adjuster with a new one...

Page 180: ...Cylinder Distortion Check the gasket surface of the cylinder for distortion Use a straightedge and thickness gauge Take clearance readings at several places If any reading exceeds the service limit replace the cylinder Special tool 09900 20803 Thickness gauge Cylinder distortion Service limit 0 05 mm 0 002 in Cylinder Bore Inspect the cylinder wall for any scratches nicks or other damage Measure t...

Page 181: ...ful not to damage the piston Do not expand the piston ring excessively since it is apt to be broken down 1 Install the piston rings in the order of the oil ring second ring and top ring a The first member to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails 2 CAUTION When installing the spacer be careful so that the both edges are not overlapped b Install th...

Page 182: ...r bore diameter If the piston to cylinder clearance exceeds the service limit replace both the cylinder and the piston Piston to cylinder clearance Service limit 0 120 mm 0 0047 in Piston Ring to groove Clearance Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceed the limit replace both the piston and piston rings Special tool A 099...

Page 183: ...limit 1st 4 9 mm 0 19 in Service limit 2nd 9 6 mm 0 38 in Special tool B 09900 20803 Thickness gauge Piston ring end gap Service limit 1st 0 50 mm 0 020 in Service limit 2nd 0 50 mm 0 020 in Piston Pin and Pin Bore Measure the piston pin bore inside diameter using the small bore gauge If measurement is out of specification replace the piston Special tool A 09900 20602 Dial gauge B 09900 22403 Smal...

Page 184: ...be installed in their original positions Disassembly 1 Remove the rocker arm shaft bolts 1 2 Remove the rocker arm shaft 2 using 6 mm bolt A 3 Remove each rocker arm 3 and wave washer 4 Assembly 1 Apply engine oil to the rocker arm shafts 1 2 Install each wave washer 2 rocker arm 3 and rocker arm shaft 1 NOTE Align the rocker arm shaft grooves A with the cylinder head cover holes B 1 I931H1140136 ...

Page 185: ...ol A 09900 20803 Thickness gauge Cylinder head cover distortion Service limit 0 05 mm 0 002 in Rocker Arm Shaft Outside Diameter Measure each rocker arm shaft out side diameter using the micrometer If the diameter exceeds the limit replace the rocker arm shaft with a new one Special tool A 09900 20205 Micrometer 0 25 mm Rocker arm shaft O D IN EX Standard 11 973 11 984 mm 0 4714 0 4718 in Rocker A...

Page 186: ... 1 2 Remove the engine mounting dumper plate 2 thermostat cover 3 and thermostat 4 3 Remove the intake pipe 5 water bypass union 6 and ECT sensor 7 4 Using the special tools compress the valve spring and remove the two cotter halves 8 from the valve stem Special tool A 09916 14510 Valve lifter B 09916 14910 Valve lifter attachment 09916 84511 Tweezer 5 Remove the valve spring retainer 9 and valve ...

Page 187: ...lve take care not to damage the lip of the oil seal M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the valve spring with the small pitch portion A facing cylinder head Put on the valve spring retainer 3 and using the special tools press down the spring fit the cotter halves to the stem end and release the lifter to allow the cotter halves to wedge in between retainer and stem CAUTION Be sure t...

Page 188: ...valent Tightening torque Water bypass union a 12 N m 1 2 kgf m 8 5 lbf ft Apply grease to the O ring of the intake pipe CAUTION Replace the O ring with a new one Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply a small quantity of thread lock to the intake pipe mounting bolts and tighten them to the specified torque NOTE Make sure that the UP mark G faces up Thread lock cement 99000 32...

Page 189: ...readings exceed the service limit replace the cylinder head Special tool 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in Valve Stem Runout Support the valve using V blocks as shown and check its runout using the dial gauge If the runout exceeds the service limit replace the valve Special tool A 09900 20607 Dial gauge B 09900 20701 Dial gauge chuck C 09900 21304 ...

Page 190: ...the valve stem O D using the micrometer If it is out of specification replace the valve with a new one If the valve stem O D is within specification but the valve stem deflection is not replace the valve guide After replacing the valve or valve guide recheck the deflection Special tool A 09900 20205 Micrometer 0 25 mm Valve stem O D Standard IN 4 975 4 990 mm 0 1959 0 1965 in Standard EX 4 955 4 9...

Page 191: ...on IN EX Standard 182 210 N 18 6 21 4 kgf 41 0 47 2 Ibs 31 5 mm 1 24 in Valve Seat Width 1 Visually check for valve seat width on each valve face If the valve face has worn abnormally replace the valve 2 Coat the valve seat with a red lead Prussian Blue and set the valve in place 3 Rotate the valve with light pressure Special tool A 09916 10911 Valve lapper set 4 Check that the transferred red lea...

Page 192: ...alve Guide Replacement B931H21406032 1 Remove the cylinder head Refer to Engine Top Side Disassembly Page 1D 18 2 Remove the valves Refer to Cylinder Head Disassembly and Assembly Page 1D 38 3 Using the valve guide remover drive the valve guide out toward the camshaft side Special tool 09916 44310 Valve guide installer remover NOTE Discard the removed valve guide sub assemblies Only oversized valv...

Page 193: ...16 44310 Valve guide remover installer D 09916 53370 Valve guide installer attachment 8 After installing the valve guides refinish their guiding bores using the reamer Be sure to clean and oil the guides after reaming NOTE Be sure to cool down the cylinder head to ambient air temperature Insert the reamer from the combustion chamber and always turn the reamer handle clockwise Special tool C 09916 ...

Page 194: ...after the cylinder head has been reinstalled Refer to Valve Clearance Inspection and Adjustment in Section 0B Engine Bottom Side Disassembly B931H21406034 1 Remove the engine assembly Refer to Engine Assembly Removal Page 1D 13 2 Remove the front propeller shaft universal joint 1 and rear propeller shaft boot 2 Refer to Front Propeller Shaft Removal and Installation in Section 3D and Rear Propelle...

Page 195: ...l Special tool A 09930 44530 Rotor holder 2 Remove the left crankshaft spacer nut 2 and spacer 1 Generator Remove the generator component parts 1 Refer to Generator Removal and Installation in Section 1J Starter Idle Gear 1 Remove the starter idle gear No 1 1 and shaft 2 2 Remove the starter idle gear No 2 3 and shaft 4 1 A I931H1140174 01 1 I931H1140176 01 1 1 2 A I931H1140177 01 1 I931H1140178 0...

Page 196: ... 4 gearshift cam stopper 5 washer 6 and return spring 7 Transfer Output Drive Gear 1 Remove the snap ring 1 and transfer output drive gear 2 Special tool 09900 06107 Snap ring remover Open type 2 Remove the drive gear spacer 3 3 Remove the output shaft spacer 4 Cam Chain 1 Remove the cam chain 1 1 2 I931H1140182 01 2 1 3 I931H1140183 02 4 5 6 7 I931H1140184 01 1 2 3 I931H1140185 02 4 I931H1140186 ...

Page 197: ...cial tool 09900 06107 Snap ring remover Open type 3 Remove the oil pump driven gear 4 4 Remove the pin 5 and washer 6 5 Remove the oil pump 7 Crank Balancer Drive Gear 1 Unlock the crank balancer drive gear nut with a chisel 2 Remove the crank balancer drive gear nut 1 with the special tools Special tool A 09924 52460 Socket 52 mm B 09920 53740 Clutch sleeve hub holder C 09920 31020 Extension hand...

Page 198: ...Variable Automatic Transmission Removal and Installation in Section 5A and Clutch Shoe Removal and Installation in Section 5A Oil Jet Remove the oil jet 1 from the right crankcase Gear Position Switch 1 Remove the gear position switch 1 2 Remove the gear position switch contacts 2 and springs 3 2 3 I931H1140194 01 4 I931H1140195 02 1 I931H1140196 01 1 I931H1140197 01 1 I931H1140198 01 2 3 I931H114...

Page 199: ...rankshaft remover 3 Remove the spacer 2 4 Remove the dowel pins 3 Oil Sump Filter Remove the oil sump filter 1 Transfer Rear Output Shaft Rear Output Shaft Bevel Gear Remove the transfer component parts 1 rear output shaft 2 and rear output shaft bevel gear component parts 3 Refer to Transfer Removal and Installation in Section 3C and Rear Output Shaft Drive Bevel Gear Removal and Installation in ...

Page 200: ...E Apply engine oil to each running and sliding part before reassembling Crankshaft Install the crankshaft to left crankcase with the special tools CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic mallet Always use the special tool otherwise the accuracy of the crankshaft alignment will be affected Special tool A 09910 32812 Crankshaft installer B 09910 32820 Cranks...

Page 201: ... the oil sump filter in the concave portion of the crankcase Crankcase Wipe the crankcase mating surface both surfaces with a cleaning solvent Install the dowel pins 1 to the left crankcase Apply engine oil to the conrod big end and each gear Apply bond to the mating surface of the right crankcase as follows NOTE Make surfaces free from moisture oil dust and other foreign materials Spread the seal...

Page 202: ...olt M8 26 N m 2 6 kgf m 19 0 lbf ft After the crankcase bolts have been tightened check if the each shaft rotate smoothly Apply grease to the O ring and install the spacer CAUTION Use the new O ring to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the spacer 3 Gear Position Switch Install each gear position switch contact 1 and spring 2 Apply grease to the O ri...

Page 203: ... in Section 5A Crank Balancer Drive Gear Install the pin 1 Install the crank balancer drive gear 2 and washer 3 Hold the crank balancer drive gear with the special tools and tighten the crank balancer drive gear nut to the specified torque with the special tool CAUTION Do not reuse the crank balancer drive gear nut Special tool A 09920 53740 Clutch sleeve hub holder B 09924 52460 Socket 52 mm 0992...

Page 204: ...use a snap ring 4 Special tool 09900 06107 Snap ring remover Open type Install the key 5 and oil pump drive gear 6 Crank Balancer Driven Gear Install the crank balancer driven gear 1 NOTE Align the punch mark A of the crank balancer drive gear with the punch mark B of the crank balancer driven gear 1 Apply thread lock to the crank balancer driven gear bolt Thread lock cement 99000 32030 THREAD LOC...

Page 205: ...ive gear spacer 1 and output shaft spacer 2 Install the transfer output drive gear 3 and snap ring 4 CAUTION Never reuse a snap ring 4 Special tool 09900 06107 Snap ring remover Open type Gearshift System Install the gearshift cam stopper 1 bolt 2 washer 3 and return spring 4 NOTE Hook the return spring end A to the gearshift cam stopper 1 Check the gearshift cam stopper moves smoothly Install the...

Page 206: ...to the starter driven gear bearing Install the starter driven gear 1 and key 2 Starter Idle Gear Install the shaft 1 and starter idle gear No 2 2 Install the shaft 3 and starter idle gear No 1 4 Generator Install the generator component parts 1 Refer to Generator Removal and Installation in Section 1J 6 I931H1140239 02 E D 7 I931H1140240 02 2 1 I931H1140241 01 1 2 I931H1140242 01 3 4 I931H1140243 ...

Page 207: ...A 09930 44530 Rotor holder Tightening torque Left crankshaft spacer nut a 38 N m 3 8 kgf m 27 5 lbf ft Water Pump Apply grease to the O rings CAUTION Replace the O rings with new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the water pump with the slot on the pump shaft end A securely engaged with the flat B on the oil pump shaft Tighten the water pump mounting bolts to the ...

Page 208: ...asure the conrod small end inside diameter with the dial calipers If conrod small end inside diameter exceeds the service limit replace the conrod Special tool A 09900 20605 Dial calipers 10 34 mm Conrod small end I D Service limit 20 040 mm 0 7890 in Conrod Deflection Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check...

Page 209: ...m the tips of the crankshaft Special tool A 09900 20607 Dial gauge 09900 20701 Dial gauge chuck 09900 21304 V blocks Crankshaft runout Service limit 0 08 mm 0 003 in Width Between Crankshaft Webs B931H21406037 Measure the width between crankshaft webs a Width between crankshaft webs a Standard 70 9 71 1 mm 2 79 2 80 in Crankshaft Oil Seal and Driveshaft Spacer Oil Seal Inspection B931H21406038 Ref...

Page 210: ...y from the frame Refer to Engine Assembly Removal Page 1D 13 2 Remove the engine top side Refer to Engine Top Side Disassembly Page 1D 18 3 Disassemble the engine bottom side Refer to Engine Bottom Side Disassembly Page 1D 46 Left crankcase 1 Remove the each bearing retainer 2 Remove the driveshaft bearing 1 with the special tool Special tool A 09921 20240 Bearing remover set 1 Crankshaft bearing ...

Page 211: ... remover 2 Remove the snap ring 2 Special tool 09900 06108 Snap ring remover Close type 3 Remove the crankshaft oil seals 3 and 4 with the special tool Special tool A 09913 50121 Oil seal remover 4 Remove the bearing retainers 5 Remove the each bearing 5 with the special tool Special tool B 09921 20240 Bearing remover set 2 B 2 2 I931H1140259 01 1 A I931H1140260 01 2 I931H1140261 01 3 4 A A I931H1...

Page 212: ...l tool Special tool A 09913 50121 Oil seal remover 2 Remove the generator stator Refer to Generator Removal and Installation in Section 1J 3 Remove the snap ring 2 with the special tool Special tool 09900 06108 Snap ring remover Close type 4 Remove the each bearing 3 with the special tool Special tool B 09921 20240 Bearing remover set 5 Remove the oil seal 4 with the special tool Special tool A 09...

Page 213: ...nap ring remover Close type 5 Install the generator stator Refer to Generator Removal and Installation in Section 1J 6 Install the crankshaft oil seal 4 with the special tool Special tool A 09913 70210 Bearing installer set 10 75 7 Apply grease to the lip of oil seal 4 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Right crankcase 1 Install the each bearing 1 with the special tool NOTE The...

Page 214: ...equivalent 5 Install the crankshaft oil seal No 2 3 with the special tool NOTE The plate side of the crankshaft oil seal No 2 3 faces outside of the crankcase Special tool A 09913 70210 Bearing installer set 10 75 6 Apply grease to the lip of oil seal 3 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 7 Install the snap ring 4 8 Install the driveshaft spacer oil seal 5 with the special tool ...

Page 215: ...lve diam IN 30 6 1 20 EX 27 0 1 06 Valve clearance When cold IN 0 05 0 10 0 002 0 004 EX 0 17 0 22 0 007 0 009 Valve guide to valve stem clearance IN 0 010 0 037 0 0004 0 0015 EX 0 030 0 057 0 0012 0 0022 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 ...

Page 216: ...rance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 87 500 87 515 3 4449 3 4455 Nicks or Scratches Piston diam 87 465 87 480 3 4435 3 4441 Measure at 15 mm 0 6 in from the skirt end 87 380 3 4402 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 6 2 0 24 4 9 0 19 2nd 2R Approx 12 0 0 47 9 6 0 38 Piston ring end gap 1st 0 08 0 20 0 003 0 008 0 50 0 020 2nd 2R 0 10 0 25 0 004...

Page 217: ... 25 Cylinder base head bolt M10 Final 37 3 7 27 0 Page 1D 25 Cylinder head bolt M8 25 2 5 18 0 Page 1D 25 Cylinder head nut 25 2 5 18 0 Page 1D 25 Camshaft sprocket bolt 15 1 5 11 0 Page 1D 26 Cylinder head cover bolt 10 1 0 7 0 Page 1D 27 Page 1D 30 Valve clearance inspection cap bolt 10 1 0 7 0 Page 1D 27 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Page 1D 28 Cam chain tension adjuster c...

Page 218: ...age 1D 24 Page 1D 26 Page 1D 39 Page 1D 39 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 1D 53 SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 1D 23 Page 1D 40 SUZUKI BOND No 1216B or equivalent P No 99000 31230 Page 1D 27 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 1D 26 Page 1D 56 Page 1D 66 Page 1D 67 THREAD LOCK CEMENT SUPER 1...

Page 219: ... 41 Page 1D 41 Page 1D 42 Page 1D 60 Page 1D 61 09900 20701 09900 20803 Dial gauge chuck Thickness gauge Page 1D 29 Page 1D 41 Page 1D 41 Page 1D 42 Page 1D 60 Page 1D 61 Page 1D 32 Page 1D 34 Page 1D 35 Page 1D 37 Page 1D 41 Page 1D 61 09900 21304 09900 22301 V blocks Plastigauge Page 1D 29 Page 1D 41 Page 1D 41 Page 1D 60 Page 1D 61 Page 1D 30 09900 22302 09900 22403 Plastigauge Small bore gauge...

Page 220: ...1D 66 Page 1D 47 09915 64512 09916 10911 Compression gauge Valve lapper set Page 1D 2 Page 1D 43 09916 14510 09916 14910 Valve lifter Valve lifter attachment Page 1D 38 Page 1D 39 Page 1D 38 Page 1D 39 09916 34542 09916 34570 Reamer handle Valve guide reamer 5 0 mm Page 1D 44 Page 1D 45 Page 1D 45 09916 34580 09916 44310 Valve guide reamer 10 8 mm Valve guide installer remover Page 1D 44 Page 1D 4...

Page 221: ...eve hub holder Bearing remover set Page 1D 49 Page 1D 49 Page 1D 55 Page 1D 57 Page 1D 62 Page 1D 63 Page 1D 64 09923 74511 09924 52460 Bearing remover Socket 52 mm Page 1D 64 Page 1D 49 Page 1D 55 09930 11950 09930 30104 Torx wrench 5 mm Rotor remover sliding shaft Page 1D 12 Page 1D 64 09930 44530 09941 53610 Rotor holder Front fork oil seal hammer Page 1D 47 Page 1D 59 Page 1D 52 ...

Page 222: ...rt Diagram B931H21502001 OIL SUMP FILTER OIL PUMP RELIEF VALVE OIL FILTER CRANKCASE RH MAIN GALLERY CYLINDER CYLINDER HEAD CRANKSHAFT BEARING RH CRANKSHAFT RH CAMSHAFT JOURNAL CAMSHAFT CONROD BIG END BEARING CRANKSHAFT LH CYLINDER WALL PISTON CLUTCH SHOE CRANK CASE LH CYLINDER HEAD COVER ROCKER ARM CAM CHAIN CAM FACE OIL PAN OIL JET COUNTER SHAFT GEARS STARTER DRIVEN GEAR BEARING ONE WAY CLUTCH ON...

Page 223: ...Engine Lubrication System 1E 2 Engine Lubrication Circuit Diagram B931H21502002 To cylinder head OIL PUMP I931H1150002 03 ...

Page 224: ...1E 3 Engine Lubrication System EXHAUST SIDE INTAKE SIDE I931H1150003 02 ...

Page 225: ...kPa B 09915 74533 Oil pressure gauge adapter 09900 26006 Engine tachometer 6 Warm up the engine as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min 7 After warm up increase the engine speed to 3 000 r min Observe the tachometer and read the oil pressure gauge If the oil pressure is lower or higher than the specification the following causes may be considered Oil pressure specifica...

Page 226: ...gine Oil Level Inspection B931H21506002 Refer to Engine Oil and Filter Replacement in Section 0B Oil Sump Filter Removal and Installation B931H21506003 Removal 1 Remove the engine assembly from the frame Refer to Engine Assembly Removal in Section 1D 2 Remove the engine top side Refer to Engine Top Side Disassembly in Section 1D 3 Separate the left and right crankcase Refer to Engine Bottom Side D...

Page 227: ... excessively replace the oil sump filter with a new one 3 Install the oil sump filter Refer to Oil Sump Filter Removal and Installation Page 1E 5 Oil Jet Removal and Installation B931H21506005 Removal 1 Remove the clutch cover and gasket Refer to Clutch Shoe Removal and Installation in Section 5A 2 Remove the oil jet 1 Installation Install the oil jet in the reverse order of removal Pay attention ...

Page 228: ... Section 0B 2 Remove the starter idle gear No 1 1 and No 2 2 Refer to Starter Idle Gear Starter Clutch Removal and Installation in Section 1I 3 Remove the generator rotor assembly 3 and starter driven gear 4 Refer to Generator Removal and Installation in Section 1J and Starter Idle Gear Starter Clutch Removal and Installation in Section 1I 1 4 3 a 5 2 I931H1150025 01 1 Oil pump 5 Water pump shaft ...

Page 229: ... and oil pump 10 Installation Install the oil pump in the reverse order of removal Pay attention to the following points Apply thread lock to the oil pump mounting screws Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Install the snap ring 1 and oil pump drive gear 2 CAUTION Use a new snap ring 1 Special tool 09900 06107 Snap ring remover Open type 5 I931H1150014 01 5 I...

Page 230: ... torque Tightening torque Crank balancer driven gear bolt a 50 N m 5 0 kgf m 36 0 lbf ft Oil Pump Inspection B931H21506009 Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Removal and Installation Page 1E 7 2 Rotate the oil pump by hand and check that it moves smoothly If it does not move smoothly replace the oil pump assembly CAUTION Do not attempt to disas...

Page 231: ...onstruction Page 1E 7 Item Standard Limit Oil pressure at 60 C 140 F 80 120 kPa 0 8 1 2 kgf cm2 11 17 psi at 3 000 r min Item Specification Note Engine oil type SAE 10 W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 2 500ml 2 6 2 2 US lmp qt Filter change 2 700 ml 2 9 2 4 US lmp qt Overhaul 3 200 ml 3 4 2 8 US lmp qt Fastening part Tightening torque Note N m kgf m lbf ft Main oil g...

Page 232: ...stem Special Tool B931H21508002 09900 06107 09900 26006 Snap ring remover Open type Engine tachometer Page 1E 8 Page 1E 8 Page 1E 4 09915 74511 09915 74533 Oil pressure gauge 600 kPa Oil pressure gauge adapter Page 1E 4 Page 1E 4 ...

Page 233: ...around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off The engine must be cool before servicing the cooling system Coolant is harmful If it comes in contact with skin or eyes flush with water If swallowed accidentally induce vomiting and call physician immediately Keep it away from children Precautions for Engine Coola...

Page 234: ...ction and excellent heat protection and will protect the cooling system from freezing at temperatures above 31 C 24 F If the vehicle is to be exposed to temperatures below 31 C 24 F this mixing ratio should be increased up to 55 or 60 according to the figure Anti freeze Proportioning Chart Fig 1 Engine coolant density freezing point curve Fig 2 Engine coolant density boiling point curve Schematic ...

Page 235: ...A a b B I931H1160057 01 1 Thermostat 6 Radiator outlet hose D Face the tip of the clip to upper 2 Radiator 7 Water pump 17 N m 1 7 kgf m 12 5 lbf ft 3 Reservoir tank A Yellow mark 12 N m 1 2 kgf m 8 5 lbf ft 4 Radiator inlet hose B White mark 5 Bypass hose C Face the tip of the clip to forward ...

Page 236: ...UTION Do not exceed the radiator cap release pressure or the radiator cap and subsequently the radiator can be damaged 4 After finishing the cooling circuit inspection reinstall the removed parts Condition Possible cause Correction Reference Item Engine overheats Not enough engine coolant Add engine coolant Radiator core clogged with dirt or scale Clean Faulty cooling fan Repair or replace Defecti...

Page 237: ...If any defects are found replace the radiator with a new one If the fins are bent or dented repair them by carefully straightening them with the blade of a small screwdriver Radiator Cleaning Blow out any foreign matter that is stuck in the radiator fins using compressed air CAUTION Make sure not to bend the fins when using compressed air Always apply compressed air from the engine side of engine ...

Page 238: ...m Page 1F 3 Pour engine coolant Refer to Cooling System Inspection in Section 0B Bleed air from the cooling circuit Refer to Cooling System Inspection in Section 0B Water Hose Removal and Installation B931H21606005 Removal 1 Drain engine coolant Refer to Cooling System Inspection in Section 0B 2 Remove the front fender and left side cover Refer to Front Side Exterior Parts Removal and Installation...

Page 239: ...ly the motor with 12 V With the motor running at full speed the ammeter should indicate an amperage not higher than 5 0 A 3 Connect the cooling fan motor coupler Radiator Reservoir Tank Removal and Installation B931H21606007 Removal 1 Remove the radiator cap lid 1 2 Disconnect the hose 2 3 Remove the reservoir tank 3 4 Drain engine coolant Installation Install radiator reservoir tank in the revers...

Page 240: ...he radiator hose with a new one 3 Any leakage from the connecting section should be corrected by proper tightening Refer to Water Hose Routing Diagram Page 1F 3 4 After finishing the water hose inspection reinstall the removed parts ECT Sensor Removal and Installation B931H21606010 Refer to ECT Sensor Removal and Installation in Section 1C ECT Sensor Inspection B931H21606011 Refer to ECT Sensor In...

Page 241: ...ation Page 1F 8 2 Check the thermo switch closing or opening temperatures by testing it at the bench as shown in the figure 3 Connect the thermo switch 1 to a circuit tester and place it in the water A contained in a pan which is placed on the stove 4 Heat the water to raise its temperature slowly and read the column thermometer 2 when the switch closes or opens If any abnormality is found replace...

Page 242: ...allation Install the thermostat in the reverse order of removal Pay attention to the following points Apply engine coolant to the rubber seal on the thermostat Install the thermostat NOTE Align the protrusions on the thermostat with the groove on the cylinder head The jiggle valve of the thermostat faces upside Tighten the thermostat cover bolts 1 Pour engine coolant Refer to Cooling System Inspec...

Page 243: ...on 5 Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer 2 6 Read the thermometer just when opening the thermostat If this reading which is the temperature level at which the thermostat valve begins to open is out of the standard value replace the thermostat with a new one Thermostat valve opening temperature Standard 80 5 83 5 C 177 182 F 7 Keep on ...

Page 244: ...rts Inspection Page 1F 17 1 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Remove the left mud guard Refer to Front Side Exterior Parts Removal and Installation in Section 9D 3 Drain engine oil and coolant Refer to Engine Oil and Filter Replacement in Section 0B and Cooling System Inspection in Section 0B 1 2 3 4 5 2 2 a b c c FWD FWD I931H...

Page 245: ...r pump mounting bolts 4 to the specified torque Tightening torque Water pump mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft Connect the water hoses securely Refer to Water Hose Routing Diagram Page 1F 3 Pour engine oil and coolant Refer to Engine Oil and Filter Replacement in Section 0B and Cooling System Inspection in Section 0B Bleed air from the cooling circuit Refer to Front Differential Gear Oil...

Page 246: ...Remove the mechanical seal with the special tool NOTE If there is no abnormal condition the mechanical seal removal is not necessary Special tool A 09921 20240 Bearing remover set 9 Remove the oil seal 11 NOTE If there is no abnormal condition the oil seal removal is not necessary 3 I931H1160035 01 5 4 I931H1160036 01 6 7 I931H1160037 01 8 I931H1160038 01 10 9 I931H1160039 01 A I931H1160040 01 11 ...

Page 247: ...UZUKI SUPER GREASE A or equivalent 3 Install a new mechanical seal using a suitable size socket wrench CAUTION Replace the mechanical seal with a new one NOTE On the new mechanical seal the sealer A has been applied 4 Install the rubber seal 1 into the impeller 5 After wiping off the oily or greasy matter from the mechanical seal ring 2 install it into the impeller NOTE The paint marked side B of ...

Page 248: ...p body 9 Install the washer 3 and pin 4 to the impeller shaft 10 Install the cap 5 and E ring 6 11 Install a new O ring 7 and apply engine coolant to it CAUTION Use a new O ring to prevent engine coolant leakage 12 Fit the water pump cover and tighten the water pump cover screws 8 to the specified torque Tightening torque Water pump cover screw a 5 5 N m 0 55 kgf m 4 0 lbf ft 2 I931H1160047 01 3 4...

Page 249: ...nical seal that shows indications of leakage Oil Seal Visually inspect the oil seal for damage with particular attention given to the lip Replace the oil seal that shows indications of leakage Impeller Visually inspect the impeller and its shaft for damage Replace the impeller if necessary Impeller Shaft Journal Visually inspect the journal for damage or scratch Replace the water pump body if nece...

Page 250: ... C 68 F Approx 2 45 kΩ 50 C 122 F Approx 0 811 kΩ 80 C 176 F Approx 0 318 kΩ 110 C 230 F Approx 0 142 kΩ Radiator cap valve opening pressure 110 140 kPa 1 1 1 4 kgf cm2 15 6 19 9 psi Cooling fan thermo switch operating temperature OFF ON Approx 93 C 199 F ON OFF Approx 87 C 189 F Engine coolant type Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ...

Page 251: ...l B931H21608002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1F 13 Page 1F 15 SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 1F 16 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 1F 16 09900 25008 09913 70210 Multi circuit tester set Bearing installer set 10 75 Page 1F 9 Page 1F 15 09921 20240 Bearing remover set...

Page 252: ...use care to minimize spillage of gasoline Spilled gasoline should be wiped off immediately Work in a well ventilated area CAUTION To prevent the fuel system fuel tank fuel hose etc from contamination with foreign particles blind all openings After removing the throttle body tape the cylinder intake section to prevent foreign particles from entering ...

Page 253: ... is regulated by the fuel pressure regulator 6 As the fuel pressure applied to the fuel injector 7 the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm2 43 psi the fuel is injected into the throttle body in conic dispersion when the injector 7 opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator ...

Page 254: ... Schematic and Routing Diagram Fuel Hose Routing Diagram B931H21702001 2 2 1 1 3 1 3 FR LH RH RR LH RH FR RR 4 I931H1170028 01 1 Fuel hose 3 PCV hose 2 Air cleaner box 4 Pass the fuel hose between the air cleaner guide ...

Page 255: ...H21702002 1 3 2 7 2 3 5 6 4 1 2 6 8 a A I831G1170003 04 1 Frame 5 Valve Black A Align the fuel pump nipple with the mark 2 Fuel tank breather hose 6 Valve Orange 35 N m 3 5 kgf m 25 5 lbf ft 3 Check valve hose 7 Mark 4 Fuel tank 8 Fuel tank pressure control valve ...

Page 256: ...orrect fuel air mixture Defective IAP sensor or circuit Repair or replace Clogged fuel filter Clean or replace Defective fuel pump Replace Defective fuel pressure regulator Replace Damaged or cracked vacuum hose Replace Defective ECT sensor Replace Defective thermostat Replace Defective IAT sensor Replace Engine stalls often Fuel injector improperly operating Defective fuel injectors Replace No in...

Page 257: ...tor Fuel pump If the fuel pressure is higher than the specification check for the followings Fuel pump Pressure regulator 6 Remove the special tools WARNING Before removing the special tools turn the ignition switch OFF and release the fuel pressure slowly 7 Reinstall the removed parts Fuel Pump Inspection B931H21706002 Turn the ignition switch ON and check that the fuel pump operates for a few se...

Page 258: ... oz and more 10 sec 6 After finishing the fuel discharge inspection reinstall the rear fender Refer to Rear Side Exterior Parts Removal and Installation in Section 9D Fuel Pump Relay Inspection B931H21706004 Refer to Electrical Components Location in Section 0A Inspect the fuel pump relay in the following procedures 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Remove th...

Page 259: ...fer to Fuel Level Indicator Inspection in Section 9C Fuel Tank Removal and Installation B931H21706009 Removal WARNING Keep away from fire or spark Spilled gasoline should be wiped off immediately Work in a well ventilated area 1 Remove the rear fender Refer to Rear Side Exterior Parts Removal and Installation in Section 9D 2 Remove the fuel tank outer cover Refer to Rear Side Exterior Parts Remova...

Page 260: ...ove the fuel pump assembly 2 Installation Install the fuel pump assembly in the reverse order of removal Pay attention to the following points Install the fuel pump gasket 1 CAUTION If there are wear or damage replace the gasket 1 with a new one Align the fuel pump nipple 2 with alignment mark A on the fuel tank Tighten the fuel pump retainer with the special tool to the specified torque Special t...

Page 261: ...p assembly Refer to Fuel Pump Assembly Removal and Installation Page 1G 9 Fuel Injector Inspection and Cleaning B931H21706014 Inspect the fuel injector in the following procedures 1 Remove the fuel injector Refer to Fuel Injector Fuel Delivery Pipe Removal and Installation Page 1G 10 2 Check the fuel injector filter for evidence of dirt and contamination If present clean and check for presence of ...

Page 262: ...ring 2 CAUTION Replace the cushion seal and O ring with the new ones Install the fuel injector 3 by pushing it straight to the delivery pipe 4 CAUTION Never turn the injector while pushing it NOTE Align the coupler A of injector with boss B of the delivery pipe Install the fuel delivery pipe assembly 5 to the throttle body assembly CAUTION Never turn the fuel injector while installing it Tighten t...

Page 263: ...nd Installation in Section 9D 5 Remove the mud guard mounting screws 1 and fasteners 2 6 Remove the fuel tank cap 3 CAUTION To prevent the fuel tank from contamination with foreign particles blind opening 7 Move the rear fender upside 8 Disconnect the check valve hose 4 and fuel tank breather hose 5 9 Remove the FTPC valve 6 Installation Install the FTPC valve in the reverse order of removal pay a...

Page 264: ... Routing Diagram Page 1G 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C A Orange A I705H1170014 02 Item Specification Note Injector resistance 11 13 Ω at 20 C 68 F Fuel pump discharge amount 55 5 ml 1 88 1 95 US lmp oz and more 10 sec Fuel pressure regulator operating set pressure Approx 294 kPa 2 9 kgf cm2 41 psi Item ...

Page 265: ...25008 09915 74521 Multi circuit tester set Adapter hose Page 1G 7 Page 1G 6 09915 77331 09940 40211 Oil pressure gauge 1000 kPa Fuel pressure gauge adapter Page 1G 6 Page 1G 6 09940 40220 09941 51012 Fuel pressure gauge attachment Ring locknut wrench Page 1G 6 Page 1G 9 Page 1G 9 ...

Page 266: ...speed will once again be limited by the speed limiter In forward Differential Lock made the override mode can be used for an indefinite period of time simply by holding the button in continuously Operation 1 Set the diff lock position or R Reverse position 2 Operate the override switch while pushing it Schematic and Routing Diagram Ignition System Diagram B931H21802001 Refer to Wire Color Symbols ...

Page 267: ...t FI system Incorrect gasoline Change Dirty air cleaner element Clean or replace Incorrect spark plug Change to correct spark plug Spark plug quickly becomes fouled with oil or carbon Worn piston rings Replace Worn piston Replace Worn cylinder Rebore or replace Excessive valve stem to valve guide clearance Replace Worn valve stem oil seals Replace Spark plug electrodes overheat or burn Incorrect s...

Page 268: ...inum threads of the cylinder head Special tool 09930 10121 Spark plug wrench set Tightening torque Spark plug 11 N m 1 1 kgf m 8 0 lbf ft Spark Plug Inspection and Cleaning B931H21806002 Refer to Spark Plug Inspection and Cleaning in Section 0B 4 Inspect the spark plug Refer to Spark Plug Inspection and Cleaning in Section 0B Is the spark plug OK Go to Step 5 Faulty spark plug 5 Inspect the igniti...

Page 269: ...instruction manual NOTE Do not disconnect the ignition coil lead wires Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage 5 Measure the ignition coil primary peak voltage in the following procedures a Shift the transfer to the neutral turn the ignition switch ON b Press the starter button and allow the engine to crank for a few seconds and then measure the ignition ...

Page 270: ... Disconnect the spark plug cap 3 Disconnect the lead wire 1 and remove the ignition coil 2 Installation Install the ignition coil in the reverse order of removal CKP Sensor Inspection B931H21806005 Refer to Electrical Components Location in Section 0A CKP Sensor Peak Voltage 1 Remove the left side cover and engine side cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D...

Page 271: ...ween the lead wires and ground If the resistance is not within the standard range replace the CKP sensor with a new one Refer to CKP Sensor Removal and Installation Page 1H 6 Tester knob indication Resistance Ω CKP sensor resistance 170 250 Ω Blue White Ω Blue Ground 4 After measuring the CKP sensor resistance reinstall the removed parts CKP Sensor Removal and Installation B931H21806006 Refer to G...

Page 272: ...llation Install the ignition switch in the reverse order of removal Pay attention to the following point Route the wiring harness properly Refer to Wiring Harness Routing Diagram in Section 9A Override Switch Inspection B931H21806010 1 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Disconnect the override switch read wire coupler 3 Check th...

Page 273: ...01 Electrical Unit mm in Tightening Torque Specifications B931H21807002 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Special Tools and Equipment Special Tool B931H21808001 O G O Color Position SECEDE SET I931H1180012 01 Item Specification Note Spark plug Type NGK CR6E DENSO U20ESR N Gap 0 7 0 8 0 028 0 031 Spark perform...

Page 274: ...arter relay B W Y B R Neutral relay Starter button Engine stop switch Ignition fuse Ignition switch Parking brake relay Parking brake switch Neutral indicator light Neutral relay diode O Y Y G Battery Gear position switch N Bl B B Bl B W O Y B R Bl B B W I831G1190001 01 Condition Possible cause Correction Reference Item Starter button is not effective Run down battery Repair or replace Defective s...

Page 275: ...n wire because a large amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor 3 Measure the starter relay voltage at the starter relay connectors between Y B and B W when the starter button is pushed Is the voltage OK Go to Step 4 Faulty ignition swit...

Page 276: ...ide cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 3 Remove the starter motor lead wire 1 1 2 3 4 d 5 6 5 7 8 c a b FWD FWD I931H1190037 02 1 O ring 6 Starter motor case 10 N m 1 0 kgf m 7 0 lbf ft 2 Housing end Inside 7 Brush holder 3 5 N m 0 35 kgf m 2 5 lbf ft 3 O ring 8 Housing end Outside Apply grease 4 Armature 6 N m 0 6 kgf m 4 5 lbf ft Apply moly paste to s...

Page 277: ...tor Disassembly and Assembly B931H21906003 Refer to Starter Motor Removal and Installation Page 1I 3 Disassembly Disassemble the starter motor as shown in the starter motor components diagram Refer to Starter Motor Components Page 1I 3 Assembly Reassemble the starter motor in the reverse order of removal Pay attention to the following points CAUTION Replace the O rings with new ones to prevent oil...

Page 278: ...ear cracks or smoothness in the brush holder If either carbon brush is defective replace the brush holder set with a new one Measure the length a of the carbon brushes using a vernier calipers If the measurement is less than the service limit replace the housing end assembly with a new one Brush length a Service limit 6 5 mm 0 26 in Special tool 09900 20102 Vernier calipers 200 mm Commutator Inspe...

Page 279: ...end for damage If any damage is found replace the housing end Starter Relay Removal and Installation B931H21906005 Refer to Electrical Components Location in Section 0A Removal 1 Turn the ignition switch OFF position 2 Remove the seat Refer to Seat Removal and Installation in Section 9D 3 Disconnect the battery lead wire from the battery 4 Pull the starter relay 1 5 Disconnect the starter relay co...

Page 280: ...cation Continuity test 3 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 Special tool A 09900 25008 Multi circuit tester set Starter relay resistance 3 5 Ω 4 Install the starter relay Refer to Starter Relay Removal and Installation Page 1I 6 Neutral Relay Removal and ...

Page 281: ...isconnect the neutral relay diode 1 BI B B BI wire 2 Measure the voltage between the A and B terminals using the multi circuit tester Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the multi circuit tester reads 1 4 V and below when the tester probes are not connected replace its battery 3 Connect the neutral relay diode 4 Install the left inner fender ...

Page 282: ... the parking rear brake switch for continuity with a tester If any abnormality is found replace the parking rear brake switch with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the parking brake switch inspection reinstall the removed parts Gear Position Switch Inspection B9...

Page 283: ...fer to Generator Removal and Installation in Section 1J 3 Remove the starter idle gear No 1 2 and starter idle gear No 2 3 4 Remove the generator rotor assembly Refer to Generator Removal and Installation in Section 1J 5 Remove the key 4 and starter driven gear 5 6 Hold the generator rotor with a 36 mm offset wrench and remove the starter clutch bolts 7 Remove the one way clutch 6 from the guide 7...

Page 284: ...read lock to the bolts and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Starter clutch bolt a 26 N m 2 6 kgf m 19 0 lbf ft Apply engine oil to the bearing of the starter driven gear Install the generator rotor assembly onto crankshaft Refer to Generator Removal and Installation in Section 1J Install the starter id...

Page 285: ...ed Parts Inspection B931H21906016 Refer to Starter Idle Gear Starter Clutch Removal and Installation Page 1I 10 Starter Clutch 1 Install the starter driven gear onto the starter clutch 2 Turn the starter driven gear by hand to inspect the starter clutch for smooth movement The gear turns in one direction only If a large resistance is felt for rotation inspect the starter clutch or the starter clut...

Page 286: ...Measure the voltage between Y G and O lead wires Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Specifications Service Data B931H21907001 Unit mm in 1 2 I931H1190035 01 Y G probe O probe ON 0 4 0 6 V OFF 1 4 V and more Tester s battery voltage 1 I931H1190036 01...

Page 287: ...g bolt 10 1 0 7 0 Page 1I 4 Starter motor lead wire mounting nut 6 0 6 4 5 Page 1I 4 Starter motor brush holder mounting nut 7 0 7 5 0 Page 1I 4 Starter motor housing bolt 3 5 0 35 2 5 Page 1I 5 Starter clutch bolt 26 2 6 19 0 Page 1I 11 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1I 4 Page 1I 4 Moly paste SUZUKI Moly p...

Page 288: ...open generator coil Replace Short circuited or punctured regulator rectifier Replace Generator does charge but charging rate is below the specification Lead wires tend to get short or open circuited or loosely connected at terminals Repair or retighten Grounded or open circuited generator coil Replace Defective regulator rectifier Replace Defective cell plates in the battery Replace the battery Ge...

Page 289: ...rence Item Step Action Yes No 1 Check accessories which use excessive amounts of electricity Are accessories being installed Remove accessories Go to Step 2 2 Check the battery for current leakage Refer to Battery Current Leakage Inspection Page 1J 3 Is the battery for current leakage OK Go to Step 3 Short circuit of wire harness Faulty electrical equipment 3 Measure the regulated voltage between ...

Page 290: ...spect the regulated voltage in the following procedures 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Start the engine and keep it running at 5 000 r min with the dimmer switch turned HI position 3 Measure the DC voltage between the and battery terminals using the multi circuit tester If the voltage is not within the specified value inspect the generator and regulator re...

Page 291: ...min 5 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 Special tool 09900 25008 Multi circuit tester set Tester knob indication Voltage Generator no load performance When engine is cold 70 V AC and more at 5 000 r min Generator Removal and Installation B931H21A06004 Removal 1 Disconnect th...

Page 292: ... 09930 44530 Rotor holder 11 Remove the left crankshaft spacer nut 8 and spacer 7 12 Remove the generator cover 9 13 Remove the gasket 10 and dowel pins 14 Hold the generator rotor with a 36 mm offset wrench and remove the generator rotor nut 15 Install the special tool to the crankshaft end Special tool B 09930 31921 Rotor remover set 1 2 3 I931H11A0006 01 5 6 4 I931H11A0007 01 7 A 8 I931H11A0029...

Page 293: ...KP sensor mounting bolts to the specified torque NOTE Be sure the grommet 1 is set to the generator cover Tightening torque Generator stator set bolt a 11 N m 1 1 kgf m 8 0 lbf ft CKP sensor mounting bolt b 6 N m 0 6 kgf m 4 5 lbf ft Lead wire clamp bolt c 6 N m 0 6 kgf m 4 5 lbf ft Degrease the tapered portion A of generator rotor assembly and also the crankshaft B Use nonflammable cleaning solve...

Page 294: ...e finger between the generator cover and the crankcase CAUTION Fit the clamp to the bolt C Apply grease to the O ring 5 and oil seal lip Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replace the O ring 5 with a new one Hold the left crankshaft spacer with the special tool and tighten the left crankshaft spacer nut 6 to the specified torque Special tool A 09930 44530 Rotor holder T...

Page 295: ...circuit tester as indicated in the following table If the voltage is not within the specified value replace the regulator rectifier with a new one NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 5 Connect the regulator rectifier coupler and reinstall the ...

Page 296: ...completely use the removed cap 2 as sealing caps of battery filler holes 3 Insert the nozzles of the electrolyte container 3 into the electrolyte filler holes of the battery 4 Hold the electrolyte container firmly so that it does not fall NOTE Do not allow any of the electrolyte to spill 5 Make sure that air bubbles 4 rise to the top of each electrolyte container and leave in this position for abo...

Page 297: ...ps do not protrude above the upper surface of the battery s top cover CAUTION Once the caps are installed to the battery do not remove the caps Do not tap the caps with a hammer when installing them Charging For initial charging use the charger specially designed for MF battery CAUTION For charging the battery make sure to use the charger specially designed for MF battery Otherwise the battery may...

Page 298: ... the battery voltage using the multi circuit tester If the battery voltage is less than 12 5 V recharge the battery again If the battery voltage is still less than 12 5 V after recharging replace the battery with a new one 4 Install the battery to the vehicle Refer to Battery Removal and Installation Page 1J 11 Battery Removal and Installation B931H21A06008 Removal 1 Remove the seat Refer to Seat ...

Page 299: ... surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance clean the battery terminals with sandpaper 3 Install the seat Specifications Service Data B931H21A07001 Battery CAUTION Never use anything excep...

Page 300: ... 0 6 4 5 Page 1J 6 Lead wire clamp bolt 6 0 6 4 5 Page 1J 6 Generator rotor nut 140 14 0 101 5 Page 1J 7 Left crankshaft spacer nut 38 3 8 27 5 Page 1J 7 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 1J 7 Thread lock cement THREAD LOCK CEMENT SUPER 1322 or equivalent P No 99000 32110 Page 1J 12 09900 25008 09900 26006 Mul...

Page 301: ...should be performed when the system is cool CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting Repair Instructions Exhaust System Construction B931H21B06001 FWD FWD 1 3 a 4 a 6 a 5 2 I931H11B0010 01 1 Exhaust pipe 4 Exhaust pipe nut 23 N m 2 3 kgf m 16 5 lbf ft 2 Muffler 5 Exhaust pipe mounting bolt Do not reuse 3 Conn...

Page 302: ...Rear Side Exterior Parts Removal and Installation in Section 9D 5 Loosen the muffler connecting bolt 1 6 Remove the exhaust pipe 2 NOTE Support the exhaust pipe to prevent it from falling 7 Remove the muffler 3 NOTE Support the muffler to prevent it from falling 8 Remove the muffler cover 4 Installation Install the exhaust pipe muffler in the reverse order of removal Pay attention to the following...

Page 303: ...exhaust pipe bolts muffler connecting bolts and muffler mounting nut are tightened to their specified torque Refer to Exhaust Pipe Bolt and Muffler Bolt Inspection in Section 0B Spark Arrester Inspection B931H21B06004 Refer to Spark Arrester Cleaning in Section 0B Specifications Tightening Torque Specifications B931H21B07001 NOTE The specified tightening torque is described in the following Exhaus...

Page 304: ...1K 4 Exhaust System ...

Page 305: ...erial 2B 15 Special Tool 2B 16 Rear Suspension 2C 1 Repair Instructions 2C 1 Rear Suspension Components 2C 1 Rear Suspension Assembly Construction 2C 2 Rear Shock Absorber Removal and Installation 2C 3 Rear Suspension Inspection 2C 4 Rear Shock Absorber Inspection 2C 4 Spring Pre load Adjustment 2C 4 Rear Wheel Hub Suspension Knuckle Removal and Installation 2C 5 Rear Hub Bearing Inspection 2C 6 R...

Page 306: ... must be tightened to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result NOTE The right and left suspension related parts shock absobers suspension arms and knuckles are installed symmetrically and therefore the removal proc...

Page 307: ...r shaft Replace Bent front upper or lower suspension arm Replace Improperly suspension setting Adjust Front suspension too noisy Loose front suspension fastener Tighten Worn front suspension related bushings Replace Wobbly rear wheel Distorted wheel rim Replace Worn hub bearings Replace Defective or incorrect tire Replace Loose rear wheel nut Tighten Worn rear suspension bushings Replace Loose rea...

Page 308: ...r 11 Suspension arm pivot nut Lower 55 N m 5 5 kgf m 40 0 lbf ft 3 Front shock absorber mounting nut 12 Suspension lower arm set 60 N m 6 0 kgf m 43 5 lbf ft 4 Suspension arm pivot bolt Upper 13 Knuckle end 65 N m 6 5 kgf m 47 0 lbf ft 5 Suspension upper arm 14 Hub bearing 29 N m 2 9 kgf m 21 0 lbf ft 6 Bushing 15 Outer dust seal Apply water resistance grease 7 Inner dust seal 16 Inner dust seal A...

Page 309: ...ck absorber mounting nut a 6 8 7 2 mm 0 27 0 28 in 3 Front suspension arm pivot nut Upper 55 N m 5 5 kgf m 40 0 lbf ft 4 Front suspension arm pivot nut Lower 60 N m 6 0 kgf m 43 5 lbf ft 5 Tie rod end nut 65 N m 6 5 kgf m 47 0 lbf ft 6 Steering knuckle end nut Upper Lower 29 N m 2 9 kgf m 21 0 lbf ft 7 Front wheel hub nut 110 N m 11 0 kgf m 79 5 lbf ft 8 Washer The conical side of washer faces out...

Page 310: ... absorber in the reverse order of removal Pay attention to the following point Tighten the mounting bolt and nut to the specified torque Tightening torque Front shock absorber mounting bolt Upper a 55 N m 5 5 kgf m 40 0 lbf ft Front shock absorber mounting nut Lower b 60 N m 6 0 kgf m 43 5 lbf ft Front Suspension Inspection B931H22206004 Refer to Suspensions Inspection in Section 0B Front Shock Ab...

Page 311: ...Removal and Installation B931H22206007 Removal 1 Remove the cotter pin 1 and loosen the hub nut 2 2 Remove the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D CAUTION Make sure that the vehicle is supported securely 3 Remove the front drive shaft cover 3 4 Remove the brake caliper mounting bolt Refer to Front Brake Caliper Removal and Installation in Section 4...

Page 312: ...kle 11 Installation Install the steering knuckle in the reverse order of removal Pay attention to the following points Clean up the steering knuckle end A and the mating surface B of the steering knuckle NOTE Make surfaces free from moisture oil dust and other foreign materials Apply grease to the lip of inner dust seal Grease 99000 25160 Water resistance grease or equivalent Install the washer 1 ...

Page 313: ...nd nut 7 to the specified torque Tightening torque Tie rod end nut b 29 N m 2 9 kgf m 21 0 lbf ft Install the cotter pin 8 CAUTION The removed cotter pin 8 must be replaced with a new one Apply thread lock to the brake disc cover mounting bolts 9 and tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Apply grease to the wheel hub spline and lip of dust seal Gre...

Page 314: ...ced with a new one Front Hub Bearing Inspection B931H22206008 Inspect the inner race play of the front hub bearing by hand while they are in the steering knuckle Rotate the inner races by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the front hub bearing with a new one Front Hub Bearing Removal and Installation B931H22206009 Refer to Front Wheel Hub S...

Page 315: ...ng 1 using the hydraulic press and special tool CAUTION Never reuse wheel hub bearing 1 Special tool A 09913 70210 Bearing installer set 10 75 Install the snap ring 2 with the special tool CAUTION Never reuse snap ring 2 Special tool 09900 06108 Snap ring remover Close type Install a new inner dust seal 3 using a suitable size socket wrench CAUTION Replace the inner dust seal 3 with a new one Appl...

Page 316: ...Installation in Section 4A 3 Remove the steering knuckle Refer to Front Wheel Hub Steering Knuckle Removal and Installation Page 2B 4 4 Remove the front shock absorber lower mounting nut 1 5 Remove the suspension upper arm 2 by removing the suspension upper arm pivot bolt 3 and pivot nut 4 6 Remove the suspension lower arm 5 by removing suspension lower arm pivot bolts 6 and pivot nuts 7 Installat...

Page 317: ... fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 9 Install the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D 10 Keep a vehicle on a level ground Next loosen each pivot nut and tighten them to the specified torque again Tightening torque Suspension arm pivot nut Lower 65 N m 6 5 kgf m 47 0 lbf ft Suspension arm pivot nut Upper...

Page 318: ...special tool Special tool A 09913 70210 Bearing installer set 10 75 Lower Remove the snap ring 1 with the special tool Special tool 09900 06107 Snap ring remover Open type Remove the front lower knuckle end 2 with the special tools and vise as shown in the figure Special tool A 09913 70210 Bearing installer set 10 75 B 09941 53610 Front fork oil seal hammer Installation Upper Install the knuckle e...

Page 319: ...ension Arm Related Parts Inspection B931H22206013 Refer to Front Suspension Upper Lower Arm Removal and Installation Page 2B 9 Upper arm 1 Inspect the following parts for wear or damage If any defects are found replace defective parts with new ones Upper arm 1 Dust seal 2 Washer 3 Spacer 4 2 Insert the spacer into bushings 3 Check the play by moving the spacer up and down If excessive play is note...

Page 320: ...the front upper arm Dust seal 1 Washer 2 Spacer 3 2 Remove the front upper arm bushings 4 along with inner dust seals 5 Special tool 09923 73210 Bearing remover 09930 30104 Rotor remover slide shaft Installation 1 Install the front upper arm bushings 1 and inner dust seals 2 with the special tool and suitable socket wrench NOTE Position the bushings and dust seals by referring to Front Suspension ...

Page 321: ...tallation B931H22206015 Refer to Front Suspension Upper Lower Arm Removal and Installation Page 2B 9 Removal Remove the front suspension lower arm bushings with the special tool and hydraulic press Special tool A 09913 70210 Bearing installer set 10 75 Installation Install the front suspension lower arm bushings with the special tool and hydraulic press CAUTION The removed bushings must be replace...

Page 322: ...2 Item Standard Limit Front shock absorber spring adjustor 2 5 position Fastening part Tightening torque Note N m kgf m lbf ft Front shock absorber mounting bolt Upper 55 5 5 40 0 Page 2B 3 Front shock absorber mounting nut Lower 60 6 0 43 5 Page 2B 3 Page 2B 10 Steering knuckle end nut 29 2 9 21 0 Page 2B 5 Tie rod end nut 29 2 9 21 0 Page 2B 6 Front hub nut 110 11 0 79 5 Page 2B 7 Suspension arm...

Page 323: ...70210 Oil seal remover Bearing installer set 10 75 Page 2B 7 Page 2B 8 Page 2B 8 Page 2B 8 Page 2B 11 Page 2B 11 Page 2B 11 Page 2B 12 Page 2B 14 Page 2B 14 09923 73210 09930 30104 Bearing remover Rotor remover sliding shaft Page 2B 13 Page 2B 13 09941 34513 09941 53610 Bearing installer Front fork oil seal hammer Page 2B 13 Page 2B 11 09942 72410 09942 83110 Tie rod end remover Clip remover Page ...

Page 324: ...Rear stabilizer joint nut 2 Rear stabilizer bar 10 Rear suspension arm Lower 18 Rear suspension knuckle nut 3 Rear stabilizer bushing 11 Rear suspension knuckle 60 N m 6 0 kgf m 43 5 lbf ft 4 Rear stabilizer bracket 12 Hub bearing Apply water resistance grease 5 Rear stabilizer joint 13 Snap ring Apply thread lock to thread part 6 Rear suspension arm Upper 14 Dust seal Do not reuse 7 Bushing 15 Re...

Page 325: ...ivot nut Upper 8 Rear hub bearing 2 Rear suspension arm pivot nut Lower a 6 8 7 2 mm 0 27 0 28 in 3 Rear wheel hub nut 60 N m 6 0 kgf m 43 5 lbf ft 4 Washer The conical side of washer faces outside 121 N m 12 1 kgf m 87 5 lbf ft 5 Inner dust seal Align the surface of dust seal with the edge of suspension arm Apply water resistance grease 6 Bushing Do not reuse 7 Outer dust seal ...

Page 326: ...a 1 a a 3 a 6 4 a a 3 4 3 a 2 3 4 4 a 7 a 7 I931H1230061 05 1 Suspension knuckle nut Upper 8 Stabilizer bushing 2 Suspension knuckle nut Lower a 6 8 7 2 mm 0 27 0 28 in 3 Inner dust seal Align the surface of dust seal with the edge of suspension arm 60 N m 6 0 kgf m 43 5 lbf ft 4 Outer dust seal Apply water resistance grease 5 Rear shock absorber mounting nut Upper Apply thread lock to the thread ...

Page 327: ... Inspect the rear shock absorber in the following procedures 1 Remove the rear shock absorber Refer to Rear Shock Absorber Removal and Installation Page 2C 3 2 Inspect the rear shock absorber for damage and oil leakage and absorber bushing for wear or damage If any defects are found replace the rear shock absorber with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is u...

Page 328: ...hat the vehicle is supported securely 3 Remove the hub nut 3 washer 4 and rear wheel hub 5 4 Remove the suspension knuckle upper and lower bolts and nuts 5 Remove the rear suspension knuckle 6 Installation Apply grease to the lip of outer dust seal Grease 99000 25160 Water resistance grease or equivalent Install the rear wheel hub 1 to the rear suspension knuckle 2 Apply grease to the lip of outer...

Page 329: ...b nut b 121 N m 12 1 kgf m 87 5 lbf ft Install the cotter pin 6 CAUTION The removed cotter pin 6 must be replaced with a new one Rear Hub Bearing Inspection B931H22306008 Inspect the inner race play of the rear hub bearing by hand while it is in the rear knuckle Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the rear hub bearing...

Page 330: ...cial tool Special tool B 09913 70210 Bearing installer set 10 75 Installation Install the hub bearing in the reverse order of removal Pay attention to the following points Install the hub bearing 1 using the hydraulic press and special tool CAUTION Never reuse wheel hub bearing NOTE The sealed side A of hub bearing 1 faces inside Special tool A 09913 75520 Bearing installing tool 2 I931H1230015 01...

Page 331: ...ce the outer dust seal 4 with a new one Apply grease to the lip of outer dust seal 4 Grease 99000 25160 Water resistance grease or equivalent Rear Suspension Arm Upper Lower Removal and Installation B931H22306010 Removal 1 Remove the rear wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D CAUTION Make sure that the vehicle is supported securely 2 Remove the rear drive ...

Page 332: ...READ LOCK CEMENT SUPER 1303 or equivalent Tighten the shock absorber mounting lower bolt and nut to the specified torque Tightening torque Rear shock absorber mounting nut a 60 N m 6 0 kgf m 43 5 lbf ft Connect the stabilizer joint by tightening the joint nut to the specified torque Tightening torque Rear stabilizer joint nut b 60 N m 6 0 kgf m 43 5 lbf ft Tighten the suspension arm upper pivot nu...

Page 333: ...Spacer 4 2 Insert the spacer into bushings 3 Check the play by moving the spacer up and down If excessive play is noted replace the bushings with a new one Refer to Rear Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation Page 2C 11 Lower Arm 1 Inspect the following parts for wear or damage If any defects are found replace defective parts with new ones Suspension lower arm 1 ...

Page 334: ...ner Dust Seal Removal and Installation Page 2C 11 Rear Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation B931H22306012 Refer to Rear Suspension Arm Upper Lower Removal and Installation Page 2C 8 Removal 1 Remove the following parts from the rear suspension upper arm Dust seal 1 Washer 2 Spacer 3 2 Remove the rear upper suspension arm bushings 4 along with inner dust seals 5...

Page 335: ...ring installer set 2 Apply grease to the lip of inner dust seals spacer 3 and inside of dust seals 4 Grease 99000 25160 Water resistance grease or equivalent 3 Install the washers 5 and dust seals 4 to the rear suspension upper arm Rear Suspension Lower Arm Bushing and Inner Dust Seal Removal and Installation B931H22306013 Refer to Rear Suspension Arm Upper Lower Removal and Installation Page 2C 8...

Page 336: ...ecial tool and suitable socket NOTE Position the bushings and dust seals by referring to Rear Suspension Assembly Construction Page 2C 2 CAUTION The removed bushings and dust seals must be replaced with new ones Special tool A 09941 34513 Bearing installer B 09924 84510 Bearing installer set 2 Apply grease to the lip of inner dust seals spacer 3 and inside of dust seals 4 Grease 99000 25160 Water ...

Page 337: ... Special tool 09923 73210 Bearing remover 09930 30104 Rotor remover slide shaft Installation 1 Install the suspension knuckle bushings 1 and inner dust seals 2 with the special tool and suitable socket wrench NOTE Position the bushings and dust seals by referring to Rear Suspension Assembly Construction Page 2C 2 CAUTION The removed bushings and dust seals must be replaced with new ones Special to...

Page 338: ...e is supported securely 2 Disconnect the stabilizer joints 1 from the rear suspension lower arm and stabilizer bar 3 Remove the stabilizer plates 2 4 Remove the stabilizer bar 3 5 Remove the stabilizer bushings 4 Installation Install the stabilizer in the reverse order of removal Pay attention to the following points Apply thread lock to the stabilizer plate mounting bolts and tighten the bolts se...

Page 339: ...e stabilizer bar with a new one Stabilizer Bushing Plate Inspect the bushing and plate for wear or damage If any defects are found replace the bushing and or plate with a new one Stabilizer Joint Inspect the stabilizer joint for wear or damage If any defects are found replace the stabilizer joint with a new one Inspect the stabilizer joint smooth movement If there are any abnormalities replace the...

Page 340: ...bly Construction Page 2C 2 Item Standard Limit Rear shock absorber spring adjustor 2 5 position Fastening part Tightening torque Note N m kgf m lbf ft Rear shock absorber mounting nut 60 6 0 43 5 Page 2C 4 Page 2C 9 Rear suspension knuckle nut Upper and Lower 60 6 0 43 5 Page 2C 6 Rear wheel hub nut 121 12 1 87 5 Page 2C 6 Rear stabilizer joint nut 60 6 0 43 5 Page 2C 9 Page 2C 16 Suspension arm l...

Page 341: ... Bearing installer set 10 75 Bearing installing tool Page 2C 7 Page 2C 7 09923 73210 09924 84510 Bearing remover Bearing installer set Page 2C 11 Page 2C 13 Page 2C 14 Page 2C 12 Page 2C 13 Page 2C 14 09930 30104 09941 34513 Rotor remover sliding shaft Bearing installer Page 2C 11 Page 2C 13 Page 2C 14 Page 2C 12 Page 2C 13 Page 2C 14 09943 88211 Pinion bearing installer Page 2C 13 ...

Page 342: ...mage such as crack nick or scratch When tire replacement is necessary the original equipment type tire should be used Do not mix different types of tires on the same vehicle because handling may be seriously affected and may result in loss of control Replacement wheel must be equivalent to the original equivalent wheel Repair Instructions Front and Rear Wheel Components B931H22406001 1 7 2 3 a 4 a...

Page 343: ...he directional arrow on the tire should point to the wheel rotation when remounting the wheel Tighten the wheel set nuts to the specified torque NOTE Tighten the wheel set nuts diagonally Tightening torque Wheel set nut Front and Rear a 60 N m 6 0 kgf m 43 5 lbf ft Tire Removal and Installation B931H22406003 1 Remove the wheel from vehicle Refer to Front Rear Wheel Removal and Installation Page 2D...

Page 344: ... tires other than the standard may cause instability It is highly recommended to use the specified tire 3 Mount the tire on the rim by hand as shown in the figure 4 When installing each tire make sure the arrow A on the tire points in the direction of rotation Also make sure the outer side of the wheel rim is facing outward 5 Inflate the tire to seat the tire bead Maximum tire bead seat pressure F...

Page 345: ...size shown on the sidewall The number of on the tire indications the maximum operating pressure Maximum operating pressure 25 kPa 0 25 kgf cm2 3 6 psi 35 kPa 0 35 kgf cm2 5 1 psi 45 kPa 0 45 kgf cm2 6 5 psi Specifications Service Data B931H22407001 Tire Tightening Torque Specifications B931H22407002 NOTE The specified tightening torque is described in the following Front and Rear Wheel Components ...

Page 346: ...2D 5 Wheels and Tires ...

Page 347: ...Gear Shim Inspection and Adjustment 3B 15 2WD 4WD Diff lock System Inspection 3B 18 Rear Drive Breather Hose Routing Diagram 3B 22 Final Gear Components 3B 23 Final Gear Construction 3B 24 Final Gear Oil Level Inspection 3B 25 Final Gear Oil Replacement 3B 25 Final Gear Assembly Removal and Installation 3B 25 Final Gear Assembly Disassembly and Assembly 3B 26 Final Gear Related Parts Inspection 3B...

Page 348: ...sassembly and Assembly 3D 8 Rear Output Shaft Related Parts Inspection 3D 12 Driven Drive Bevel Gear Shim Inspection and Adjustment 3D 12 Front Propeller Shaft Components 3D 15 Front Propeller Shaft Removal and Installation 3D 16 Front Propeller Shaft Related Parts Inspection 3D 17 Rear Propeller Shaft Components 3D 18 Rear Propeller Shaft Removal and Installation 3D 19 Rear Propeller Shaft Relate...

Page 349: ...ine Axle Precautions Precautions Precautions for Driveline Axle B931H23000001 Refer to General Precautions in Section 00 WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train ...

Page 350: ...01 Condition Possible cause Correction Reference Item Noisy Drive Shaft Worn drive shaft joints Replace Worn wheel hub bearings Replace Loose wheel nuts Tighten FWD FWD 1 2 3 7 6 5 4 8 9 10 I931H1310012 03 1 Circlip 6 Inner boot band Small Apply grease 2 Snap ring 7 Drive shaft Apply water resistance grease 3 Stopper ring 8 Outer boot band Small Do not reuse 4 Inner boot band Large 9 Outer boot 5 ...

Page 351: ...spline of the front drive shafts Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply grease to the lip of the oil seal and install the front drive shafts to the front differential gear case Grease 99000 25160 Water resistance grease or equivalent CAUTION Be careful not to damage the front differential gear case oil seals NOTE After installing both drive shafts make sure the stopper rings ...

Page 352: ...t band of the small diameter side Assembly CAUTION Wash all parts before installation clean the inside and outside of the boots with a cloth Do not wash the boots in any commercially available degreaser such as gasoline or kerosene Washing in a degreaser causes deterioration of the boots 1 Fit a boot on the drive shaft end fitting the small diameter side of the boot to the shaft groove fix its end...

Page 353: ...race CAUTION Replace the stopper ring with a new one Position the opening of stopper ring C so that it will not be lined up with a ball 6 After installing the boot on the outer race insert a screw driver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the figure 7 Fi...

Page 354: ...ft in the following procedures 1 Remove the front drive shaft assembly Refer to Front Drive Shaft Assembly Removal and Installation Page 3A 2 2 Check the driveshaft boots for twist and grease leak If any defects are found replace the defective parts with new ones 3 Inspect the boots circlip and boot bands for wear or damage If any damages are found replace them with new ones 4 Install the front dr...

Page 355: ...Refer to Rear Wheel Hub Suspension Knuckle Removal and Installation in Section 2C 4 Hold the in board joint 1 of the rear drive shaft and tug the drive shaft horizontally NOTE If it is difficult to remove the rear drive shaft from the rear differential gear case using the suitable tool FWD FWD 1 4 5 6 8 9 2 7 3 10 I931H1310013 04 1 Circlip 6 Inner boot band Small Apply grease 2 Snap ring 7 Drive s...

Page 356: ... Be careful not to damage the front drive case oil seal NOTE After installing both drive shafts make sure the circlips 1 is seated properly by pulling both inboard joints lightly Rear Drive Shaft Disassembly and Assembly B931H23106007 Refer to Rear Drive Shaft Assembly Removal and Installation Page 3A 6 Rear drive shaft disassembly and assembly are the same manner of front drive shaft disassembly ...

Page 357: ...g Front Drive Shaft Components Page 3A 1 Rear Drive Shaft Components Page 3A 6 Special Tool B931H23108002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 3A 2 Page 3A 7 Water resistance grease or equivalent P No 99000 25160 Page 3A 2 Page 3A 7 09900 06107 Snap ring remover Open type Page 3A 3 Page 3A 4 ...

Page 358: ... or replace Too large rear drive gear thrust clearance Adjust or replace Power will not transmit from the engine to the front wheel Broken drive and driven bevel gear teeth Replace Worn or broken propeller shaft serration Replace Broken or damaged front drive differential gear or pinion Replace Improperly operated front differential shifting motor Repair or replace Worn or damaged shifting sleeve ...

Page 359: ... 34 Oil level plug 5 Front drive differential gear assembly 20 Pinion gear 22 N m 2 2 kgf m 16 0 lbf ft 6 Diff lock sleeve 21 Bearing 10 N m 1 0 kgf m 7 0 lbf ft 7 Bearing 22 Snap ring 32 N m 3 2 kgf m 23 0 lbf ft 8 Shim Left Side 23 Differential sleeve 35 N m 3 5 kgf m 25 5 lbf ft 9 Diff lock fork 24 Snap ring 8 N m 0 8 kgf m 5 7 lbf ft 10 Diff lock shaft 25 Bearing Apply grease 11 Diff lock cam ...

Page 360: ... I931H1320001 03 1 Shim 1 3 N m 0 13 kgf m 0 94 lbf ft Apply thread lock to the thread part 2 Front drive differential case cover bolt 22 N m 2 2 kgf m 16 0 lbf ft Apply bond to matching surface 3 2WD 4WD Diff lock actuator Apply grease A Matching surface Apply water resistance grease ...

Page 361: ...ion 0B 3 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 4 Disconnect the rear brake light switch lead wire coupler 1 5 Remove the lead wire from clamps 6 Remove the clamps and disconnect the 4WD diff lock actuator lead wire coupler 2 7 Remove the drive shaft Refer to Front Drive Shaft Assembly Removal and Installation in Section 3A 8 Remove t...

Page 362: ...t Attach the boot 1 to the input shaft After installing the front drive differential check the wiring harness routing and pour the front differential gear oil Refer to Wiring Harness Routing Diagram in Section 9A and Front Differential Gear Oil Inspection in Section 0B Front Drive Differential Assembly Disassembly and Assembly B931H23206006 Refer to Front Drive Differential Assembly Removal and In...

Page 363: ...ferential gear assembly 4 and shims 6 Remove the diff lock sleeve 5 7 Remove the diff lock fork shaft 6 and diff lock fork 7 8 Remove the snap ring 8 Special tool 09900 06108 Snap ring remover Close type 9 Remove the screw shaft 9 10 Remove the differential fork 10 3 A I931H1320013 01 4 I931H1320014 01 I931H1320015 01 5 6 7 I931H1320016 02 9 8 I931H1320018 02 10 I931H1320019 01 ...

Page 364: ... and oil seal 15 with the special tools Special tool B 09921 20240 Bearing remover set C 09913 70210 Bearing installer set 10 75 14 Remove the dust seal cap 16 and dust seal 17 15 Remove the snap ring 18 and input shaft 19 Special tool 09900 06108 Snap ring remover Close type 16 Remove differential sleeve 20 11 12 I931H1320020 02 13 I931H1320021 01 14 B C 15 I931H1320022 01 16 17 I931H1320023 01 1...

Page 365: ...s no abnormal noise the bearing removal is not necessary Special tool D 09913 60910 Bearing and gear puller 20 Remove the pinion gear pilot bearing 26 with the special tools NOTE If there is no abnormal noise the bearing removal is not necessary Special tool E 09921 20240 Bearing remover set F 09944 66010 Oil seal installer G 09924 84521 Bearing installer set 21 Remove the bearing 27 and oil seal ...

Page 366: ...ial tool A 09913 70210 Bearing installer set 10 75 4 Install the pinion gear 4 into the front drive differential gear case and fix the snap ring 5 Special tool 09900 06108 Snap ring remover Close type 5 Install the input shaft bearing 6 onto the input shaft with the special tool Special tool A 09913 70210 Bearing installer set 10 75 6 Install the snap ring 7 Special tool 09900 06108 Snap ring remo...

Page 367: ...mover C 09924 74570 Final drive gear bearing installer 11 Install the oil seal cap 11 with the special tool Special tool D 09924 52460 Socket 52 mm 12 Install the oil seals 12 into the front drive differential gear case cover with the special tool NOTE Insert the oil seal until the specified value as shown in the figure Special tool A 09913 70210 Bearing installer set 10 75 13 Install the diff loc...

Page 368: ...t D of diff lock cam 13 16 Install the shims 16 17 Install the diff lock fork 17 and diff lock sleeve 18 18 Install the front drive differential gear assembly 19 19 Insert the convex part E of the diff lock fork 17 and groove part F of the diff lock cam 13 20 Install the diff lock fork shaft 20 14 15 A B I931H1320094 02 13 D D C 15 I931H1320041 02 16 16 I931H1320042 01 17 18 I931H1320043 01 19 I93...

Page 369: ...grease to the O ring and lip of oil seal CAUTION Replace the O ring with a new one Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 25 Apply a small quantity of thread lock to the 4WD diff lock actuator mounting bolts 23 and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque 4WD Diff lock actuator mounting bolt b ...

Page 370: ...otation Replace the bearing if there is anything unusual Diff lock Fork Shaft Inspect the diff lock fork shaft for wear or damage If any defects are found replace the diff lock fork shaft with a new ones Differential Fork and Diff lock Fork Inspect the shifting forks for wear or damage If any defects are found replace the shifting forks with new ones Screw Shaft Inspect the rear screw shaft for we...

Page 371: ...ve with a new one Input Shaft Inspect the input shaft for wear or damage Inspect the input shaft bearing for abnormal noise and smooth rotation If any defects are found replace defective parts Pinion Gear Inspect the pinion gear for wear or damage Inspect the pinion gear bearing for abnormal noise and smooth rotation If any defects are found replace defective parts Front Drive Differential Gear In...

Page 372: ...s not necessary to apply a sealant to the mating surface of the gear case Tightening torque Front drive differential case bolt 22 N m 2 2 kgf m 16 0 lbf ft Remove the oil filler cap and measure the backlash of the differential ring gear using the horizontal type dial gauge and drive shaft 3 as shown in the figure Take backlash readings at three places while turning the front drive differential gea...

Page 373: ... right side shim s 1 and front drive differential gear assembly NOTE Do not install the left side shim s at this time Put a few pieces of solder 2 O D 1 2 1 5 mm x L 6 mm on the shim 1 as shown in the figure Install the front drive differential case 3 and tighten the bolts to the special torque diagonally Tightening torque Front drive differential case bolt 22 N m 2 2 kgf m 16 0 lbf ft Backlash Sh...

Page 374: ...ve differential gear as a set Clean and degrease several teeth on the final drive differential gear and pinion gear and the apply a coating of machinist s layout dye or paste to several teeth of the pinion gear Install the left and right side shims and front drive differential assembly Install the front drive differential case and tighten the bolts to the specified torque diagonally Tightening tor...

Page 375: ...2WD 4WD Diff lock System Inspection B931H23206010 Actuator Refer to Front Drive Differential Assembly Removal and Installation Page 3B 4 1 Remove the 2WD 4WD Diff lock actuator assembly 1 2 Connect the 12 V battery to the actuator lead wires Bl wire and Y wire If the motor does not run replace the diff lock transfer actuator assembly with a new one Diff lock Actuator Diode Refer to Electrical Comp...

Page 376: ...y abnormality is found replace the left handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the 4WD diff lock inspection reinstall the removed parts SDS Operation Check 1 Check that the transfer selecting switch diff lock position switch 1 and diff l...

Page 377: ...Turn the transfer selecting switch diff lock position switch and diff lock switch ON position 6 Check that both Differential lock position switch signal and Differential lock switch signal are GND If the transfer selecting switch dose not function properly inspect the 4WD diff lock switch for continuity check 3 I831G1320073 02 I931H1320097 01 I931H1320098 01 ...

Page 378: ...s found replace the 4WD diff lock relay with a new one Special tool 09900 25008 Multi circuit tester set Diff lock Relay 1 Remove the left side cover and engine side cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D and Rear Side Exterior Parts Removal and Installation in Section 9D 2 Remove the diff lock relay 1 3 Check the insulation between A and B terminals with t...

Page 379: ...D 4 I831G1320145 02 1 Breather hose 6 V belt cooling duct 2 Rear drive assembly A Press the breather hose between the fuel tank lower cover and belt cooling duct 3 Clamp B Face the tip of clip to forward 4 Clamp Set the clamp to the concave of belt cooling duct a 20 30 mm 0 79 1 18 in 5 Fuel tank ...

Page 380: ...ng 55 N m 5 5 kgf m 40 0 lbf ft 4 Shim Right side 14 Final drive gear nut 65 N m 6 5 kgf m 47 0 lbf ft 5 Shim Left side 15 Final drive stopper 23 N m 2 3 kgf m 16 5 lbf ft 6 Bearing 16 Final drive gear case cover bolt M8 Apply grease 7 Oil seal 17 Final drive gear case cover bolt M10 Apply water resistance grease 8 Oil seal 18 Final gear case mounting nut Apply thread lock to the thread part 9 Was...

Page 381: ...Lock nut 55 N m 5 5 kgf m 40 0 lbf ft 2 Shim Right side A Matching surface Apply grease 3 Final drive gear shim s 26 N m 2 6 kgf m 19 0 lbf ft Apply water resistance grease 4 Final drive gear nut 100 N m 10 0 kgf m 72 5 lbf ft Apply thread lock to thread part 5 Final drive bearing stopper 2 N m 0 2 kgf m 1 5 lbf ft Apply bond ...

Page 382: ...r to Front Rear Wheel Removal and Installation in Section 2D 5 Remove the rear suspension upper arms Refer to Rear Suspension Arm Upper Lower Removal and Installation in Section 2C 6 Remove the rear drive shaft Refer to Rear Drive Shaft Assembly Removal and Installation in Section 3A 7 Remove the rear stabilizer Refer to Rear Stabilizer Removal and Installation in Section 2C 8 Remove the rear brak...

Page 383: ...lation in Section 3A Install the suspension upper arms Refer to Front Suspension Upper Lower Arm Removal and Installation in Section 2B Install the trailer towing Refer to Trailer Towing Removal and Instruction in Section 9E Adjust the rear brake pedal free travel Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Adjust the parking brake lever play Re...

Page 384: ...ve the final driven gear bearing 7 with the special tool NOTE If there is no abnormal condition the bearing removal is not necessary Special tool B 09913 70210 Bearing installer set 10 75 C 09944 66010 Oil seal installer 8 Remove the shim s 9 Remove the oil seal 8 with the special tool Special tool A 09913 50121 Oil seal remover 2 2 I931H1320092 01 3 4 I831G1320095 01 5 I831G1320096 02 A 6 I831G13...

Page 385: ...he special tool Special tool D 09924 41830 Bearing retainer wrench 50 mm 13 Remove the final drive gear 12 and shim s 13 14 Unlock the final drive gear nut 14 with a chisel 15 Remove the final drive gear nut 14 with the special tool Special tool E 09924 52470 Fixed final drive gear holder F 09940 92430 Rear axle nut wrench 36 36 mm 9 I831G1320101 01 10 I831G1320102 01 D 11 I831G1320103 01 12 13 I8...

Page 386: ...ring and gear puller 19 Remove the final drive gear bearing 18 with the special tool NOTE If there is no abnormal condition the bearing removal is not necessary Special tool I 09921 20240 Bearing remover set Assembly CAUTION The removed oil seals O rings and bearings must be replaced with new ones Install the gear case bearing to the gear case with the special tool Special tool A 09913 70210 Beari...

Page 387: ...emoved final drive gear nut 4 must be replaced with a new one Tighten the final drive gear nut 4 to the specified torque with the special tool Tightening torque Final drive gear nut a 100 N m 10 0 kgf m 72 5 lbf ft Special tool D 09924 52470 Fixed final drive gear holder E 09940 92430 Rear axle nut wrench 36 36 mm Lock the final drive gear nut with a center punch Install the shim s 5 and final dri...

Page 388: ... with a center punch NOTE After the backlash and tooth contact have been checked or adjusted stake the collar of bearing stopper into the notch Install the oil seal to the final gear case with the special tool Special tool G 09951 15810 Brake disk dust cover installer Apply a small quantity of grease to the oil seal lip Grease 99000 25160 Water resistance grease Install the final driven gear beari...

Page 389: ...que diagonally Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Final gear cover bolt M8 c 26 N m 2 6 kgf m 19 0 lbf ft Final gear cover bolt M10 d 55 N m 5 5 kgf m 40 0 lbf ft Check the backlash and tooth contact Refer to Final Gear Shim Inspection and Selection Page 3B 33 Install the rear brake assembly Refer to Rear Brake Assembly Removal and Installa...

Page 390: ...eplace drive and driven gear as a set Final Gear Shim Inspection and Selection B931H23206019 Refer to Final Gear Assembly Removal and Installation Page 3B 25 Backlash Install the shim s final drive gear assembly and new final drive gear bearing stopper Tighten the final drive gear bearing stopper 1 to the specified torque with the special tool NOTE As this time it is not necessary to bend the bear...

Page 391: ...ss of the removed shims as a guide List of shims for right side Check the left side shim selection Left Side Shim Selection Put a few pieces of solder O D 1 2 1 5 mm x L 6 mm on the back side of final driven gear as shown in the figure NOTE Do not install the left side shim s at this time Install the final gear cover and tighten its bolts to the specified torque diagonally Refer to Final Gear Asse...

Page 392: ... contact Tooth Contact Remove the final driven gear assembly 1 Clean and degrease several teeth on the final drive gear and final driven gear and then apply a coating of machinist s layout dye or paste to several teeth of the final drive gear Install the left and right side shim s 2 and final driven gear assembly 1 Part No Shim thickness 27326 31G00 Shim set 5 pcs 27326 31G00 030 0 30 mm 0 0118 in...

Page 393: ... found to be correct example B CAUTION Make sure to check the backlash and shim thickness after the tooth contact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the final drive gear and final driven gear as a set List of shims for final d...

Page 394: ...ront gear backlash Without gear cover specification 0 02 0 06 0 0008 0 0024 Gear cover assembled specification 0 08 0 15 0 0031 0 0059 Fastening part Tightening torque Note N m kgf m lbf ft Front drive differential mounting nut 50 5 0 36 0 Page 3B 5 Front drive differential case cover bolt 22 2 2 16 0 Page 3B 12 4WD Diff lock actuator mounting bolt 10 1 0 7 0 Page 3B 12 Front drive differential ca...

Page 395: ...ge 3B 5 Page 3B 26 Page 3B 31 Page 3B 32 Sealant SUZUKI BOND No 1215 or equivalent P No 99000 31110 Page 3B 12 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 3B 5 Page 3B 12 Page 3B 12 Page 3B 26 Page 3B 32 09900 06107 09900 06108 Snap ring remover Open type Snap ring remover Close type Page 3B 7 Page 3B 8 Page 3B 10 Page 3B 6 Page 3B 7 Page 3B 8 Page 3B 9 Pag...

Page 396: ...set Bearing retainer wrench 50 mm Page 3B 7 Page 3B 8 Page 3B 8 Page 3B 29 Page 3B 28 Page 3B 31 Page 3B 33 09924 52460 09924 52470 Socket 52 mm Fixed final drive gear holder Page 3B 10 Page 3B 28 Page 3B 30 09924 74520 09924 74570 Oil seal installer and remover Final drive gear bearing installer Page 3B 10 Page 3B 10 09924 84521 09940 92430 Bearing installer set Rear axle nut wrench 36 36 mm Page...

Page 397: ...haft Replace shaft Worn bearing Replace Worn splines Replace Transfer will not shift back Broken return spring on shift shaft Replace Distorted or worn gearshift forks Replace Rubbing or sticky gearshift shaft Repair or replace Improperly adjusted shift rod Adjust Transfer jumps out of gear Worn shifting gears on driveshaft or countershaft Replace Distorted or worn gearshift forks Replace Weakened...

Page 398: ...ock washer 32 Transfer output drive gear shaft 5 Driveshaft spacer oil seal 19 Lock washer 33 Spacer 6 Driveshaft spacer 20 High gearshift dog 34 Output shaft bearing Left side 7 O ring 21 Select spacer 35 Oil seal 8 Driveshaft bearing Right side 22 High driven gear Apply grease 9 Driveshaft 23 High driven gear bushing Apply engine oil 10 Driveshaft bearing Left side 24 Wave washer Apply molybdenu...

Page 399: ...1D Special tool A 09920 13120 Crankshaft remover 4 Remove the gearshift fork shaft 1 and gearshift cam shaft 2 5 Remove the gearshift forks 3 6 Remove the countershaft assembly 4 and reverse idle gear 5 7 Remove the driveshaft 6 with a plastic mallet by installing a suitable washer with the driven face bolt 7 8 Remove the rear output shaft 8 Refer to Rear Output Shaft Drive Bevel Gear Removal and ...

Page 400: ...each gear and shaft Install the transfer output shaft assembly 1 with a plastic mallet Install the shim s 2 drive bevel gear 3 and washer 4 Hold the transfer output driven gear with the special tools and tighten the drive bevel gear nut 5 to the specified torque CAUTION The removed drive bevel gear nut must be replaced with a new one Special tool A 09920 53740 Clutch sleeve hub holder B 09920 3102...

Page 401: ... countershaft assembly 7 and reverse idle gear 8 Refer to Transfer Components Page 3C 2 Install the gearshift fork 9 and reverse gearshift fork 10 NOTE Identify the shape of the shift forks and install them properly Install the gearshift cam shaft 11 and gearshift fork shaft 12 Assemble the engine Refer to Engine Bottom Side Assembly in Section 1D and Engine Top Side Assembly in Section 1D Remount...

Page 402: ...roups so that they can be reinstalled in their original position Disassemble the transfer countershaft and reverse idle gear as shown in the transfer construction Refer to Transfer Construction Page 3C 6 Pay attention to the following point Remove the lock washer 1 by aligning the teeth A of the lock washer with the spline grooves B 2 1 3 I931H1330052 01 1 Countershaft 2 Driveshaft 3 Snap ring Ass...

Page 403: ... order of disassembly Pay attention the following points Before installing the high driven gear 1 set the wave washer 2 as shown Install the lock washer 3 onto the countershaft and position it so it fits into the groove A Fit the lock washer 4 onto the lock washer 3 When installing the driven gear bushing onto the countershaft align the shaft oil hole B with the bushing oil hole C as shown Apply m...

Page 404: ...the fork or its dog or both Special tool A 09900 20803 Thickness gauge Gearshift fork to gearshift fork groove clearance Standard 0 10 0 30 mm 0 0040 0 0120 in Service limit 0 50 mm 0 020 in Gearshift Fork Groove Width Measure the gearshift fork groove width using the vernier calipers Special tool A 09900 20102 Vernier calipers 200 mm Gearshift fork groove width Standard Reverse Low High 5 5 5 6 m...

Page 405: ...07 FWD FWD 1 7 10 13 17 2 15 4 18 19 3 5 6 8 9 11 12 14 16 20 I931H1330053 01 1 Gear position switch 9 Gearshift cam stopper plate 17 Gearshift shaft No 2 2 O ring 10 Reverse gearshift fork 18 Snap ring 3 Gearshift shaft No 1 11 High Low gearshift fork 19 Washer 4 Washer 12 Gearshift fork shaft 20 Gearshift arm 5 Spring 13 Gearshift cam stopper Apply grease 6 Gearshift cam 14 Washer Apply water re...

Page 406: ... Identify the position of each removed part Organize the parts in their respective groups so that they can be reinstalled in their original positions 1 Remove the snap ring 1 and gearshift cam 2 Special tool 09900 06107 Snap ring remover Open type 1 2 3 3 I931H1330054 01 1 Gearshift shaft No 1 3 Snap ring Assemble snap ring with sharp edge side out 2 Gearshift cam 1 2 I931H1330028 02 ...

Page 407: ...fitted Install the gearshift cam 1 to the shaft CAUTION Align the punch mark A of the gearshift cam with the punch mark B of the shaft When installing a new snap ring 2 pay attention to its direction Fit it to the side where the thrust is as shown in the figure Special tool 09900 06107 Snap ring remover Open type Gear Position GP Switch Inspection B931H23306010 Refer to Gear Position Switch Inspec...

Page 408: ...Continuously Variable Automatic Transmission Removal and Installation in Section 5A Install the removed parts HI LO Position Diode Inspection B931H23306012 Refer to Electrical Components Location in Section 0A Inspect the HI position diode and LO position diode in the following procedures 1 Remove the left side cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Disco...

Page 409: ...n spring 4 Shift gear 5 Snap ring 6 Special tool 09900 06107 Snap ring remover Open type 5 Remove the gearshift cam stopper plate 7 6 Remove the gearshift cam stopper 8 Installation Install the gearshift shaft No 2 and gearshift cam plate in the reverse order of removal Pay attention to the following points Install the gearshift cam stopper 1 bolt 2 washer 3 and return spring 4 NOTE Hook the retur...

Page 410: ...all the gearshift shaft by aligning the punch mark G of shift gear with the match mark H of gearshift cam stopper plate Install the generator cover Refer to Generator Removal and Installation in Section 1J Pour engine coolant and engine oil Refer to Cooling System Inspection in Section 0B and Engine Oil and Filter Replacement in Section 0B Gearshift Linkage Inspection B931H23306014 Refer to Gearsh...

Page 411: ...r set 10 75 Apply grease to the lip of oil seal 1 Grease 99000 25160 Water resistance grease or equivalent Install the generator cover Refer to Generator Removal and Installation in Section 1J Specifications Service Data B931H23307001 Drive Train Unit mm in Except ratio I931H1330047 01 1 I931H1330048 01 A 1 I931H1330049 02 Item Standard Limit Automatic drive transmission ratio Variable change 2 90...

Page 412: ... m lbf ft Rear output shaft drive bevel gear nut 100 10 0 72 5 Page 3C 4 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 3C 12 Water resistance grease or equivalent P No 99000 25160 Page 3C 15 Molybdenum oil MOLYBDENUM OIL SOLUTION Page 3C 7 09900 06107 09900 20102 Snap ring remover Open type Vernier calipers 200 mm Page 3C...

Page 413: ...e Refer to Engine Top Side Disassembly in Section 1D 3 Separate the crankcase with the special tool Refer to Engine Bottom Side Disassembly in Section 1D Special tool A 09920 13120 Crankcase separating tool 1 2 3 5 6 7 4 FWD FWD I931H1340001 01 1 Front output shaft bearing Rear 7 Front drive collar assembly 2 Front output shaft Apply grease 3 Front output shaft housing Apply water resistance greas...

Page 414: ... right crankcase Tighten the front output shaft bolts Front Output Shaft Disassembly and Assembly B931H23406003 Refer to Front Output Shaft Removal and Installation Page 3D 1 Disassembly 1 Remove the C ring 1 and snap ring 2 Special tool 09900 06107 Snap ring remover Open type 2 Remove the front drive collar assembly 3 front output shaft housing 4 and O ring 5 3 Remove the front drive collar 6 fro...

Page 415: ...mover set 8 Remove the front output shaft bearing rear with the special tools NOTE If there is no abnormal noise the bearing removed is not necessary Special tool D 09923 74511 Bearing remover E 09930 30104 Rotor remover slide shaft Assembly CAUTION The removed bearing snap ring oil seal C ring and O ring must be replaced with new ones 1 Install the front output shaft bearing rear 1 to the right c...

Page 416: ...ll the front drive collar 6 to the output oil seal plate 7 with the special tool Special tool A 09913 70210 Bearing installer set 10 75 7 Install the O ring 8 to the front drive collar 6 8 Apply grease to the O ring 8 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 9 Install the O ring 9 and apply grease to it Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 10 Install the front outpu...

Page 417: ...ct the gear of the front output shaft for wear or damage If any defects are found replace the drive and driven bevel gears as a set Oil Seal Visually inspect the oil seal for damage with particular attention given to the lip Replace the oil seal that shows indications of leakage Front Output Shaft Bearing Inspect the front output shaft bearings for abnormal noise and smooth rotation Replace the be...

Page 418: ... Refer to Engine Bottom Side Disassembly in Section 1D Special tool A 09920 13120 Crankcase separating tool 1 2 3 4 a 11 a 10 a 12 8 9 6 FWD FWD 5 7 8 13 I931H1340023 02 1 Rear output shaft drive bevel gear 7 Shim 13 Yoke 2 Shim s 8 Bearing 100 N m 10 0 kgf m 72 5 lbf ft 3 Rear output shaft driven bevel gear 9 Oil seal Apply water resistance grease 4 Rear output shaft driven gear 10 Drive bevel ge...

Page 419: ... Special tool A 09920 53740 Clutch sleeve hub holder B 09920 31020 Extension handle 4 Remove the washer 2 drive bevel gear 3 and shim s 4 5 Remove the transfer output shaft assembly 5 with a plastic mallet Installation Install the rear output shaft and drive bevel gear in the reverse order of removal Pay attention to the following points Drive bevel gear Install the transfer output shaft assembly ...

Page 420: ...OTE Be sure to fit the C ring 2 and bearing knock pin A on the bearing to the groove of the crankcase After installed rear output shaft check the backlash and tooth contact Refer to Rear Output Shaft Drive Bevel Gear Removal and Installation Page 3D 6 Rear Output Shaft Disassembly and Assembly B931H23406007 Refer to Rear Output Shaft Drive Bevel Gear Removal and Installation Page 3D 6 Disassembly ...

Page 421: ...ing 10 and shim 11 10 Unlock the rear output shaft driven gear nut with a chisel 11 With the rear output shaft held immovable with a vise remove the rear output shaft driven gear nut 12 Remove the washer 12 rear output shaft driven gear 13 bearing 14 and rear output shaft driven bevel gear 15 5 6 3 A I931H1340035 01 I931H1340036 01 I931H1340037 01 7 8 9 10 11 I931H1340038 01 I931H1340039 01 I931H1...

Page 422: ...t driven gear nut must be replaced with a new one Tightening torque Rear output shaft driven gear nut a 100 N m 10 0 kgf m 72 5 lbf ft Lock the rear output shaft driven gear nut 3 with a center punch Install the shim 4 and bearing 5 NOTE The bearing knock pin A should be positioned inside Apply grease to the lip of oil seal 6 Grease 99000 25160 Water resistance grease or equivalent Install the oil...

Page 423: ... 3D 12 Apply grease to the bearings and their lip of dust seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the universal joint 8 and yoke 9 Install the bearings 10 by tapping with the special tool Special tool A 09913 70210 Bearing installer set 10 75 Install the circlips to the universal joint CAUTION The removed circlips must be replaced with new ones After reassembling the un...

Page 424: ...age If any defects are found replace the rear output shaft driven gear with the new one Bearing Inspect the rear output shaft bearing and rear driven bevel gear bearing for abnormal noise and smooth rotation If any defects are found replace the bearing with a new one Universal Joint Refer to Rear Propeller Shaft Related Parts Inspection Page 3D 22 Driven Drive Bevel Gear Shim Inspection and Adjust...

Page 425: ...055 0 550 mm 0 022 in 24945 03G50 058 0 575 mm 0 023 in 24945 03G50 060 0 600 mm 0 024 in 24945 03G50 063 0 625 mm 0 025 in 24945 03G50 065 0 650 mm 0 026 in 24945 03G50 068 0 675 mm 0 027 in 24945 03G50 070 0 700 mm 0 028 in 24945 03G50 073 0 725 mm 0 029 in 24945 03G50 075 0 750 mm 0 030 in 24945 03G50 078 0 775 mm 0 031 in 24945 03G50 080 0 800 mm 0 031 in 24945 03G50 083 0 825 mm 0 032 in 2494...

Page 426: ...t the coated teeth of the rear output shaft drive bevel gear The tooth contact pattern should be as shown in A B and C If tooth contact is found to be incorrect examples A and C the shim thickness between the rear output shaft drive bevel gear and bearing must be changed and the tooth contact re checked until correct examples B List of shims for drive bevel gear 1 I931H1340060 01 Tooth contact Shi...

Page 427: ...8 0 775 mm 0 0305 in 24935 03G50 080 0 800 mm 0 0315 in 24935 03G50 083 0 825 mm 0 0325 in 24935 03G50 085 0 850 mm 0 0335 in 24935 03G50 088 0 875 mm 0 0344 in 24935 03G50 090 0 900 mm 0 0354 in 24935 03G50 093 0 925 mm 0 0364 in 24935 03G50 095 0 950 mm 0 0374 in 24935 03G50 098 0 975 mm 0 0384 in 24935 03G50 100 1 000 mm 0 0394 in 24935 03G50 103 1 025 mm 0 0404 in 24935 03G50 105 1 050 mm 0 04...

Page 428: ...ersal joint and remove the front propeller shaft 4 5 Remove the universal joint 5 from the joint portion at the engine side with special tools Special tool A 09923 74511 Bearing remover B 09930 30104 Rotor remover slide shaft Installation CAUTION The removed circlips must be replaced with new ones 1 Fit the front propeller shaft boot 1 and universal joint boot 2 to the front propeller shaft groove...

Page 429: ... of front propeller shaft and spring Grease 99000 25160 Water resistance grease or equivalent 9 Install the front drive differential assembly Refer to Front Drive Differential Assembly Removal and Installation in Section 3B Front Propeller Shaft Related Parts Inspection B931H23406012 Front Propeller Shaft Inspect the front propeller shaft for wear or damage If any defects are found replace the fro...

Page 430: ...place the defect part with a new one Rear Propeller Shaft Components B931H23406013 I931H1340071 01 I931H1340072 01 6 5 4 3 2 1 7 8 9 10 11 a b I931H1340073 01 1 O ring 9 Universal joint set 2 Rear propeller shaft joint 10 Rear output shaft yoke 3 Rear propeller shaft boot 11 Oil seal 4 Rear propeller shaft spring 100 N m 10 0 kgf m 72 5 lbf ft 5 Rear propeller shaft 2 N m 0 2 kgf m 1 5 lbf ft 6 O ...

Page 431: ...the rear propeller shaft joint 1 3 Remove the O ring 2 4 Remove the rear propeller shaft spring 3 5 Draw out the rear propeller shaft 4 6 Loosen the boot clamp screw and remove the rear propeller shaft boot 5 7 Remove the rear propeller shaft joint boot 6 8 Remove the O ring 7 1 I931H1340074 01 2 I931H1340075 01 3 I931H1340076 01 4 I931H1340077 01 5 I931H1340078 01 6 I931H1340079 01 7 I931H1340080...

Page 432: ...irclips and O ring must be replaced with new ones 1 Apply grease to lip of the oil seal Grease 99000 25160 Water resistance grease or equivalent 2 Shift into the low gear 3 Apply thread lock to the rear output shaft Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent 4 Install the rear output shaft yoke 1 and washer 2 Tighten the rear output shaft nut 3 to the specified torq...

Page 433: ... the rear propeller shaft 11 Fit the rear propeller shaft joint boot 10 to the rear propeller shaft groove 12 Apply resistance grease approx 4 grams to the splines of the rear propeller shaft Grease 99000 25160 Water resistance grease or equivalent 13 Install the rear propeller shaft 11 14 Apply grease approx 4 grams to the spline of rear propeller shaft and propeller shaft spring 12 Grease 99000 ...

Page 434: ...age 3D 19 Rear Propeller Shaft Rear Propeller Shaft Joint Inspect the rear propeller shaft and rear propeller shaft joint for wear or damage If any defects are found replace it with a new one Boots Inspect the rear output joint boot and propeller shaft joint boot for crack or damage If any defects are found replace the boot with a new one Universal Joint Inspect the universal joint in the followin...

Page 435: ...owing Rear Output Shaft Components Page 3D 6 Front Propeller Shaft Components Page 3D 15 Rear Propeller Shaft Components Page 3D 18 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C I831G1340094 01 I931H1340098 01 Item Standard Limit Front Rear output shaft bevel gear backlash 0 03 0 15 0 001 0 006 Fastening part Tightening ...

Page 436: ...ts Page 3D 15 Rear Propeller Shaft Components Page 3D 18 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 3D 2 Page 3D 4 Page 3D 4 Page 3D 11 Water resistance grease or equivalent P No 99000 25160 Page 3D 4 Page 3D 10 Page 3D 16 Page 3D 17 Page 3D 17 Page 3D 20 Page 3D 21 Page 3D 21 Page 3D 22 Thread lock cement THREAD LOCK ...

Page 437: ...aring installer set 10 75 Page 3D 3 Page 3D 2 Page 3D 3 Page 3D 4 Page 3D 4 Page 3D 8 Page 3D 8 Page 3D 11 Page 3D 20 Page 3D 21 09920 13120 09920 31020 Crankshaft remover Extension handle Page 3D 1 Page 3D 6 Page 3D 7 Page 3D 8 09920 53740 09921 20240 Clutch sleeve hub holder Bearing remover set Page 3D 7 Page 3D 8 Page 3D 3 09921 21910 09923 74511 Bearing holder set Bearing remover Page 3D 12 Pa...

Page 438: ...3D 26 Propeller Shafts ...

Page 439: ...15 Tightening Torque Specifications 4A 15 Special Tools and Equipment 4A 16 Recommended Service Material 4A 16 Special Tool 4A 16 Front Brakes 4B 1 Precautions 4B 1 Precautions for Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad Inspection 4B 2 Front Brake Pad Replacement 4B 2 Front Brake Caliper Removal and Installation 4B 3 Front Brake Caliper Disassembly a...

Page 440: ...er Removal and Installation 4D 4 Parking Rear Brake Light Switch Inspection 4D 4 Parking Rear Brake Relay Inspection 4D 4 Specifications 4D 5 Tightening Torque Specifications 4D 5 Special Tools and Equipment 4D 5 Recommended Service Material 4D 5 ...

Page 441: ...rvicing or which has been stored for a long period of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the ...

Page 442: ... B After the brake hose union has contacted the reservoir bottom 5 Front brake caliper C Pass the brake hose behind the throttle cable 6 Frame D Fix the brake hose to the it guide firmly 7 Steering shaft E Pass the brake hose No 2 between the radiator lower hose and frame 8 Union bolt F Pass the brake hose inside of the suspension arm 9 Stopper After the brake hose union has contacted the stopper ...

Page 443: ... 4A 2 Rear Brake Cable Routing Diagram B931H24102002 1 3 2 1 A 1 3 5 6 4 1 FWD FWD I931H1410044 02 1 Rear brake cable 3 Rear brake pedal 5 Washer A Fix the rear brake cable to the footrest bar with clamp 2 Adjust nut 4 Pin 6 Cotter pin ...

Page 444: ...rn pads or friction plate Replace Oil adhesion on friction surface of pads Clean disc and pads Worn disc Replace Air in hydraulic system Bleed air Not enough brake fluid in the reservoir Replenish Defective adjustment of rear brake Adjust Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Damaged hub bearing Replace Worn pads and ...

Page 445: ... the brake pedal Parking Rear Brake Light Switch Inspection B931H24106005 Inspect the parking rear brake light switch in the following procedures 1 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Disconnect the parking rear brake light switch read coupler 1 3 Inspect the parking rear brake light switch for continuity with a tester If any abn...

Page 446: ...ir cap to prevent dirt from entering 2 Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle 3 Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it 4 Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of t...

Page 447: ...uid as much as possible 5 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 6 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle 7 Loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system 8 Close the air bleeder valves 1 and disconnect the clear hose Tightening torque Front brake air b...

Page 448: ...to Front Brake Hose Routing Diagram Page 4A 1 2 Tighten the brake flare nuts 1 to the specified torque Tightening torque Brake pipe flare nut a 16 N m 1 6 kgf m 11 5 lbf ft 3 Bleed air from the front brake system Refer to Air Bleeding from Front Brake Fluid Circuit Page 4A 5 4 Install the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D Rear Brake Cable Remova...

Page 449: ...outing diagram Refer to Rear Brake Cable Routing Diagram Page 4A 2 2 Install the spring as shown in the figure NOTE The large diameter a should face to the adjuster side 3 After installed rear brake cable adjust the adjuster nut Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B 4 Install the removed parts 6 I931H1410020 01 8 7 I931H1410021 01 a I931H1...

Page 450: ...Removal and Installation in Section 6B 3 Disconnect the front brake light switch lead coupler 1 1 2 3 4 5 6 a 7 b c 10 c 9 FWD FWD FWD FWD 8 I931H1410047 01 1 Reservoir tank cap 7 Brake hose union bolt 6 N m 0 6 kgf m 4 5 lbf ft 2 Diaphragm 8 Brake lever Apply silicone grease 3 Plate 9 Brake lever pivot bolt Apply brake fluid 4 Separator 10 Brake lever pivot bolt lock nut Do not reuse 5 Master cyl...

Page 451: ...ction in Section 6B Tightening torque Master cylinder holder bolt Upper and Lower a 10 N m 1 0 kgf m 7 0 lbf ft Set the brake hose union as shown in the front brake hose routing diagram Refer to Front Brake Hose Routing Diagram Page 4A 1 After setting the brake hose union to the stopper tighten the union bolt 3 to the specified torque CAUTION The seal washers should be replaced with the new ones t...

Page 452: ...der Secondary cup 7 Piston 8 Primary cup 9 Spring 10 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of flui...

Page 453: ...ng torque Brake lever pivot bolt a 6 N m 0 6 kgf m 4 5 lbf ft Brake lever pivot bolt lock nut b 6 N m 0 6 kgf m 4 5 lbf ft Front Brake Master Cylinder Parts Inspection B931H24106016 Refer to Front Brake Master Cylinder Brake Lever Disassembly and Assembly Page 4A 11 Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston Inspect the piston surface for any scratche...

Page 454: ... 3 Remove the rear brake light switch spring 1 4 Disconnect the rear brake cable 2 Refer to Rear Brake Cable Removal and Installation Page 4A 7 a A b c B 3 a 5 4 2 4 1 B A b 6 I931H1410048 03 1 Rear brake pedal 6 Rear brake pedal screw B Anchoring point Pedal side 2 Rear brake light switch a 12 5 22 5 mm 0 49 0 89 in 60 N m 6 0 kgf m 43 5 lbf ft 3 Washer b 83 2 mm 3 28 in 4 5 N m 0 45 kgf m 3 0 lb...

Page 455: ... the removed dust seals with new ones Grease 99000 25160 Water resistance grease or equivalent Apply grease to the rear brake pedal shaft 1 Grease 99000 25160 Water resistance grease or equivalent Install the rear brake pedal shaft 1 and tighten the brake pedal nut 2 to the specified torque Tightening torque Rear brake pedal shaft nut a 60 N m 6 0 kgf m 43 5 lbf ft After installed rear brake cable...

Page 456: ...ist in Section 0C Item Standard Limit Rear brake pedal height 12 5 22 5 0 5 0 9 Front master cylinder bore 12 700 12 743 0 5000 0 5017 Front master cylinder piston diam 12 657 12 684 0 4983 0 4994 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lbf ft Front brake air bleeder valve 6 0 6 4 5 Page 4A 5 Page 4A 6 Brake pipe flare nut 16 1 6 11 5 Page 4A ...

Page 457: ...ar Brake Pedal Construction Page 4A 13 Special Tool B931H24108002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4A 6 Page 4A 11 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Page 4A 12 Water resistance grease or equivalent P No 99000 25160 Page 4A 14 Page 4A 14 09900 06108 09900 25008 Snap ring remover Close type Multi circuit tester set Page 4A 11...

Page 458: ...e is the same as that for the other side Repair Instructions Front Brake Components B931H24206001 b b a c c 5 2 4 3 FWD FWD 1 6 d 7 8 I931H1420024 03 1 Front brake caliper 7 Brake caliper mounting bolt Apply silicone grease 2 Piston seal 8 Front brake disk Apply thread lock to the thread part 3 Dust seal 6 N m 0 6 kgf m 4 5 lbf ft Apply thread lock to the thread part 4 Piston 18 N m 1 8 kgf m 13 0...

Page 459: ... Front Rear Wheel Removal and Installation in Section 2D 2 Remove the pad mounting pins 1 NOTE When removing the pads push the piston all the way into the brake caliper CAUTION Do not operate the brake lever while dismounting the pads 3 Remove the front brake caliper by removing the brake caliper mounting bolts 2 Refer to Front Brake Caliper Removal and Installation Page 4B 3 4 Remove the brake pa...

Page 460: ...heel assembly 2 Drain brake fluid Refer to Brake Fluid Replacement in Section 4A 3 Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid 4 Remove the brake caliper by removing the brake caliper mounting bolts 2 Installation Install the brak...

Page 461: ...afe running and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Front Brake Caliper Disassembly and Assembly B931H24206005 Refer to Front Brake Caliper Removal and Installation Page 4B 3 Disassembly 1 Remove the brake caliper Refer to Front Brake Caliper Removal and Installation Page 4B 3 2 Remove the pad spring 1 3 Remove the caliper holder 2 and rubber...

Page 462: ...he brake fluid to piston seal 1 and dust seal 2 CAUTION Replace the piston seal 1 and dust seal 2 with new ones BF Brake fluid DOT 4 Install the piston seal as shown in the figure Apply thread lock to the caliper holder slide pin 3 Thread lock cement 99000 32130 THREAD LOCK CEMENT SUPER 1360 or equivalent Tighten the caliper holder slide pin 4 and caliper holder pin 5 to the specified torque Tight...

Page 463: ...he piston with a new one Boots Inspect the boots for damage or wear If any defects are found replace them with new ones Brake Pad Mounting Pin Inspect the brake pad mounting pin for wear or other damage If any damage is found replace the mounting pin with a new one Brake Pad Spring Inspect the brake pad springs for damage or excessive bend If any defects are found replace them with new ones Brake ...

Page 464: ... Thickness 1 Dismount the front brake caliper Refer to Front Brake Caliper Removal and Installation Page 4B 3 2 Check the brake disc for damage or cracks and measure the thickness using the micrometer 3 Replace the brake disc if the thickness is less than the service limit or if detect is found Special tool A 09900 20205 Micrometer 0 25 mm Brake disc thickness Service limit 3 0 mm 0 12 in 4 Remoun...

Page 465: ...liper cylinder bore 33 960 34 010 1 3370 1 3390 Front brake caliper piston diam 33 878 33 928 1 3338 1 3357 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lbf ft Front brake pad mounting pin 18 1 8 13 0 Page 4B 3 Brake caliper mounting bolt 26 2 6 19 0 Page 4B 3 Front brake hose union bolt 23 2 3 16 5 Page 4B 4 Caliper holder slide pin 23 2 3 16 5 Pa...

Page 466: ...4B 9 Front Brakes Special Tool B931H24208002 09900 20205 09900 20607 Micrometer 0 25 mm Dial gauge Page 4B 7 Page 4B 7 09900 20701 Dial gauge chuck Page 4B 7 ...

Page 467: ... b 18 15 14 FWD FWD 3 6 16 I931H1430023 01 1 Friction plate 9 Ball 17 Rear brake cam lever nut 2 Separator plate 10 Rear brake case 18 Rear brake case mounting bolt 3 Side plate 11 Bearing 11 N m 1 1 kgf m 8 0 lbf ft 4 Side plate pin 12 Snap ring 26 N m 2 6 kgf m 19 0 lbf ft 5 Side plate spring 13 Oil seal Apply water resistance grease 6 Side plate stopper 14 Rear brake cam shaft Apply thread lock...

Page 468: ... cam lever 1 2 Remove the brake lining indicator 2 and rear brake cam lever return spring 3 3 Remove the rear brake case 4 Installation Fit the rear brake case gasket 1 CAUTION Replace the gasket 1 with a new one Install the rear brake case Apply a small quantity thread lock to the rear brake case bolts 2 Tighten the bolts diagonally to the specified torque Tightening torque Rear brake case bolt a...

Page 469: ...ear brake cam lever nut b 11 N m 1 1 kgf m 8 0 lbf ft Install the final gear assembly Refer to Final Gear Assembly Removal and Installation in Section 3B Rear Brake Disassembly and Assembly B931H24306005 Refer to Rear Brake Assembly Removal and Installation Page 4C 2 Disassembly 1 Remove the gasket 1 and dowel pins 2 2 Remove the rear brake plates 3 3 Remove the rear brake pressure plate 4 and bal...

Page 470: ...c mallet 8 Remove the oil seal 9 with the special tool Special tool B 09913 50121 Oil seal remover 9 Remove the oil seal 10 10 Remove the snap ring 11 with the special tool Special tool 09900 06108 Snap ring remover Close type 11 Remove the bearing 12 with the special tool Special tool C 09921 20240 Bearing remover set I831G1430014 01 6 7 A I931H1430009 01 8 I931H1430010 01 10 B 9 I931H1430011 01 ...

Page 471: ...ION Replace the removed side plate stopper 4 with a new one Apply final gear oil to the bearing 5 before installing it Install the bearing with the special tool Special tool A 09913 70210 Bearing installer set 10 75 NOTE The stamped mark of bearing faces outside Install the snap ring 6 Install the oil seals 7 and 8 with the special tool Special tool A 09913 70210 Bearing installer set 10 75 13 14 ...

Page 472: ...the rear propeller shaft coupling 11 Install the washer 12 and rear drive gear shaft nut 13 CAUTION The removed nut 13 must be replaced with a new one Tighten the rear drive gear shaft nut 13 to the specified torque with the special tool Special tool B 09924 52420 Secondary bevel gear holder Tightening torque Rear propeller shaft coupling nut a 100 N m 10 0 kgf m 72 5 lbf ft Bend the collar of the...

Page 473: ... Page 4C 3 Rear Brake Cam Lever Inspect the rear brake cam lever for wear or damage If any wear or damage is found replace it with a new one Inspect the rear brake cam lever return spring for wear or damage If any wear or damage is found replace it with a new one Oil Seal Inspect the oil seals for wear or damage If any wear or damage is found replace it with a new one Bearing Inspect the inner rac...

Page 474: ...tor plates 3 for wear or damage If any defects are found replace them as a set Measure the outer distance a between the side plates as shown in the figure If the distance a is less than the specification reassemble the rear brake plates using the new plate stoppers 4 Outer distance a Standard 26 0 27 0 mm 1 02 1 06 in Brake Side Plate Spring Measure the free length a If the free length a is shorte...

Page 475: ...described in the following Rear Brake Components Page 4C 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C I831G1430042 01 Item Standard Limit Rear brake pedal free travel 20 30 0 8 1 2 Rear brake lever play 6 8 0 2 0 3 Rear brake outer distance 26 0 27 0 1 02 1 06 Brake side plate spring free length 21 3 0 84 20 2 0 80 Fa...

Page 476: ...d product or Specification Note Grease Water resistance grease P No 99000 25160 Page 4C 6 Page 4C 6 Thread lock cement THREAD LOCK CEMENT SUPER 1360 or equivalent P No 99000 32130 Page 4C 2 09900 06108 09913 50121 Snap ring remover Close type Oil seal remover Page 4C 4 Page 4C 4 09913 70210 09921 20240 Bearing installer set 10 75 Bearing remover set Page 4C 5 Page 4C 5 Page 4C 4 09924 52420 Second...

Page 477: ...ing Rear Brake Cable Routing Diagram B931H24402001 1 A 1 3 3 4 1 B 4 2 1 I931H1440001 03 1 Parking brake cable 4 Wiring harness 2 Parking brake cable guide A Pass the parking brake cable under the wiring harness 3 Frame B Pass the parking brake cable over the wiring harness ...

Page 478: ... 1 6 C 3 1 8 7 I931H1440002 02 1 Parking brake cable 6 Clamp 2 Parking brake cable guide 7 Parking brake cable adjust nut 3 Frame 8 Rear brake assembly 4 Wiring harness C Fix the rubber of parking brake cable with clamp 5 Rear fender ...

Page 479: ...brake cable from the cable guide 2 5 Remove the parking brake cable adjuster nut 4 and parking brake cable 5 6 Remove the parking brake cable 5 from the cable guide 6 7 Disconnect the parking brake cable 5 8 Remove the parking brake cable from vehicle Installation 1 Install the parking brake cable as shown in the parking brake cable routing diagram Refer to Parking Rear Brake Cable Routing Diagram...

Page 480: ...n in Section 6B Parking Rear Brake Light Switch Inspection B931H24406005 Refer to Parking Rear Brake Light Switch Inspection in Section 4A Parking Rear Brake Relay Inspection B931H24406006 Refer to Parking Brake Relay Inspection in Section 1I 2 1 3 a 4 a 5 7 6 FWD FWD I831G1440007 01 1 Brake lever lock 4 Brake lever pivot bolt 7 Lock nut 2 Brake lever cover 5 Brake lever pivot nut 6 N m 0 6 kgf m ...

Page 481: ...arking Rear Brake Lever Components Page 4D 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C Special Tools and Equipment Recommended Service Material B931H24408001 NOTE Required service material is also described in the following Parking Rear Brake Lever Components Page 4D 4 ...

Page 482: ...4D 6 Parking Brake ...

Page 483: ...ive Face Disassembly and Assembly 5A 8 Movable Driven Face Disassembly and Assembly 5A 10 Drive V belt Inspection 5A 14 Movable Fixed Drive Face Parts Inspection 5A 14 Movable Fixed Driven Face Parts Inspection 5A 15 Clutch Shoe Removal and Installation 5A 15 Clutch Cover Disassembly and Assembly 5A 18 Clutch Related Parts Inspection 5A 20 Movable Drive Face Cover Disassembly and Assembly 5A 21 Mo...

Page 484: ...5 1 Precautions Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B931H25000001 Refer to General Precautions in Section 00 ...

Page 485: ... 9 3 2 10 1 8 13 12 14 8 11 I931H1510001 03 1 Crankshaft 6 Fixed driven face 11 Low driven gear 2 Movable drive face 7 Transfer input shaft 12 High driven gear 3 Fixed drive face 8 Reverse idle gear 13 Transfer output drive gear 4 V belt 9 Clutch shoe 14 Transfer output driven gear shaft 5 Movable driven face 10 Clutch housing A Drive train route ...

Page 486: ...ssive engine noise Gear worn or abnormal contact Replace Spline worn Replace Bearing worn or burned Replace V belt slipping V belt slipping Replace Pulley face worn Replace Clutch slipping Clutch shoe worn Replace Centrifugal weight operation failure Repair or replace V belt worn Replace Clutch dragging Clutch shoe spring fatigued Replace Movable driven face distorted Replace ...

Page 487: ...pring 2 Movable drive plate 12 Clutch housing 22 Spring plate 3 Damper 13 One way clutch 23 Movable driven face ring nut 4 Spacer 14 Clutch shoe assembly 24 Clutch shoe nut 5 Roller 15 Oil seal 25 Spacer 6 Oil seal 16 Movable driven face 110 N m 11 0 kgf m 79 5 lbf ft 7 Movable drive face 17 Pin 150 N m 15 0 kgf m 108 5 lbf ft 8 Drive V belt 18 Spacer Apply grease 9 Fixed drive face 19 O ring Do n...

Page 488: ... clamp screw and remove the inlet cooling duct assembly 1 3 Remove the rear cover 2 4 Loosen the clamp and remove the outlet belt cooling duct No 2 3 1 2 2 2 3 5 2 4 6 8 7 I931H1510105 02 1 Heat shield 3 Inlet belt cooling duct No 1 5 Inlet belt cooling duct connector 7 Outlet belt cooling duct No 2 2 Clamp 4 Inlet belt cooling duct No 2 6 Outlet belt cooling duct No 1 8 Outlet belt cooling duct c...

Page 489: ...on 9D 2 Remove the right side cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 3 Remove the inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 4 Removal the footrest Refer to Footrest Removal and Installation in Section 9E 5 Remove the brake pedal Refer to Rear Brake Pedal Removal and Installation in Section 4A 6 Remove the V belt ...

Page 490: ...lation Install the automatic transmission component parts in the reverse order of removal Pay attention to the following points V belt inner cover Install the V belt inner cover 1 CAUTION If there are wear or damage replace the gaskets 2 with new ones Install the outlet belt cooling duct connector 3 Fixed drive face Install the fixed drive face 1 CAUTION Degrease the fixed drive face Use nonflamma...

Page 491: ... A or equivalent Install the driven face assembly 2 CAUTION Pull the center area A of upper and lower belt lines to be close to each other to prevent the belt from expanding Tighten the driven face bolt 3 to the specified torque with the special tool Tightening torque Movable driven face bolt a 110 N m 11 0 kgf m 79 5 lbf ft Special tool A 09930 40113 Flywheel rotor holder Movable Drive Face Insta...

Page 492: ... driven faces will move together smoothly without slip Install the movable drive face cover 4 and cap 5 V belt Outer Cover Install the V belt outer cover 1 CAUTION If there are wear or damage replace the gasket 2 with a new one Install the V belt outer cover Movable Drive Face Disassembly and Assembly B931H25106006 Refer to Automatic Transmission Components Page 5A 3 and V belt Type Continuously V...

Page 493: ...il seals must be replaced with new ones 2 Apply grease to the lip of oil seals and inside grease groove A of the movable drive face Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Wipe off any excess grease thoroughly Take care not to apply grease to the contact surface of the drive belt 3 Assemble the rollers 1 to the movable drive face 2 4 Assemble the four dampers 3 to the movabl...

Page 494: ...val and Installation Page 5A 5 Disassembly 1 Hold the driven face assembly 1 with the special tool and vise loosen the movable driven face ring nut 2 with the special tool WARNING Do not remove the movable driven face ring nut before attaching the clutch spring compressor Special tool A 09917 23711 Ring nut socket wrench B 09924 52450 Fixed driven face holder 2 Set the special tool to the driven f...

Page 495: ...and remove the special tool 2 Remove the spring plate 3 and spring 4 3 Remove the spring seat 5 and O rings 6 4 Remove the pins 7 and rollers 8 5 Remove the movable driven face 9 6 Remove the oil seals 10 and 11 from the movable driven face NOTE If there are no abnormal conditions the oil seals removal are not necessary 1 2 C I931H1510032 01 A B I931H1510033 01 3 4 I931H1510034 01 5 6 6 I931H15100...

Page 496: ... new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Wipe off any excess grease thoroughly Take care not to apply grease to the contact surface of the drive belt Install the movable driven face 3 to the fixed driven face 4 Apply grease to the pin grooves of the movable driven face Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION To prevent damaging the oil seal li...

Page 497: ... end A into the slot B of the special tool as shown in the figure Tighten the movable driven face ring nut 10 temporarily Remove the special tool from the movable driven face assembly Tighten the movable driven face ring nut 10 to the specified torque with the special tools Tightening torque Movable driven face ring nut a 110 N m 11 0 kgf m 79 5 lbf ft Special tool C 09917 23711 Ring nut socket wr...

Page 498: ...le Fixed Drive Face Parts Inspection B931H25106009 Movable Fixed Drive Face Inspect the drive faces for any abnormal conditions such as stepped wear or discoloration caused by burning If any damages are found replace the drive faces with new ones Roller Inspect each roller and their sliding surface for wear or damage If any defects are found replace the rollers as a set NOTE The rollers must alway...

Page 499: ...vable driven face spring free length Service limit 204 3 mm 8 04 in O ring and Oil Seal Inspect the O rings and oil seals for wear or damage If any defects are found replace the O rings and oil seals with new ones Clutch Shoe Removal and Installation B931H25106011 Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation Page 5A 5 Removal 1 Drain the engine oil Ref...

Page 500: ...move the washer 10 10 Remove the clutch shoe 11 with the special tools Special tool C 09930 30104 Rotor remover slide shaft D 09920 33540 Clutch shoe remover Installation Install the clutch shoe in the reverse order of removal Pay attention to the following points Install the clutch shoe 1 and washer 2 NOTE Install the washer 2 as shown in the figure 6 6 8 7 I931H1510057 01 A B 9 I931H1510058 01 1...

Page 501: ...lbf ft Special tool A 09930 40113 Flywheel rotor holder B 09930 40120 Rotor holder attachment A Apply molybdenum oil solution to the inside of the one way clutch 4 M O Molybdenum oil MOLYBDENUM OIL SOLUTION Install the one way clutch 4 with facing the OUTSIDE mark A outside Install the dowel pins 5 and gasket 6 CAUTION Use a new gasket 6 to prevent oil leakage Install the clutch cover 7 and inlet ...

Page 502: ... 1 from clutch cover Remove the spacer 2 Remove the oil seal 3 with the special tool Special tool A 09913 50121 Oil seal remover Remove the retainers 4 Remove the bearing 5 with the special tool Special tool B 09921 20240 Bearing remover set NOTE If there is no abnormal noise the bearing removal is not necessary 9 I931H1510070 02 1 I931H1510071 01 2 I931H1510072 01 A 3 I931H1510073 01 4 I931H15100...

Page 503: ...EMENT SUPER 1303 or equivalent Install the oil seal 4 with the special tool CAUTION The removed oil seal 4 must be replaced with a new one Special tool A 09913 70210 Bearing installer set 10 75 Apply grease to the lip of the oil seal 4 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the spacer 5 CAUTION Replace a O ring 6 with a new one Apply grease to the O ring 6 Grease 99000 2501...

Page 504: ...oe thickness Service limit No groove at any part Clutch housing Inspect the clutch housing for any abnormal surface damage Measure the inside diameter of the clutch housing If the measurement exceeds the service limit replace the clutch housing with a new one Clutch housing I D Service limit 140 5 mm 5 53 in Left Clutch Housing Bearing Rotate the inner race by finger to inspect for abnormal play n...

Page 505: ...ovable Drive Face Cover Disassembly and Assembly B931H25106014 Disassembly Remove the oil seal 1 with the special tool Special tool A 09913 50121 Oil seal remover Remove the snap ring 2 Remove the bearing 3 with the special tool NOTE If there is no abnormal noise the bearing removal is not necessary Special tool B 09913 70210 Bearing installer set 10 75 Assembly Press the bearing 1 with the specia...

Page 506: ...d with a new one Apply grease to the lip of oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Movable Driven Face Cover Parts Inspection B931H25106015 Right Clutch Housing Bearing Rotate the inner race by finger to inspect for abnormal play noise and smooth rotation If there is anything unusual replace the bearing with a new one Oil Seal Inspect the oil seal lip for wear or damage If...

Page 507: ...ground 2 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 3 Keep the gearshift link arm 1 in the neutral position 4 Loosen the bolt 2 and remove the gearshift link arm 1 5 Remove the transfer gearshift lever mounting bolts 3 1 Transfer gearshift lever assembly 2 Gearshift knob 3 Rod 4 Gearshift link arm 5 Gate cover mounting bolt 10 N m 1 0 kgf...

Page 508: ...emoval and Installation in Section 9D Shift Lever Disassembly and Assembly B931H25106019 Disassembly 1 Remove the shift lever assembly Refer to Shift Lever Assembly Removal and Installation Page 5A 23 2 Disassemble the shift lever assembly as shown in the shift lever components Refer to Shift Lever Assembly Components Page 5A 23 Assembly 1 Assemble the shift lever as shown in the shift lever compo...

Page 509: ...0 b 33 R L H a b b I931H1510101 01 Item Standard Limit Clutch wheel I D 140 0 140 2 5 512 5 520 140 5 5 53 Clutch shoe No groove at any part Clutch engagement r min 1 700 2 200 r min Clutch lock up r min 3 700 4 300 r min Item Standard Limit Automatic transmission ratio Variable change 2 902 0 779 Secondary reduction ratio 2 603 37 18 x 19 15 Final reduction ratio Front 3 600 36 10 Rear 3 600 36 1...

Page 510: ...Transmission Components Page 5A 3 Shift Lever Assembly Components Page 5A 23 Fastening part Tightening torque Note N m kgf m lbf ft Movable driven face bolt 110 11 0 79 5 Page 5A 7 Movable drive face bolt 110 11 0 79 5 Page 5A 8 Movable driven face ring nut 110 11 0 79 5 Page 5A 13 Clutch shoe nut 150 15 0 108 5 Page 5A 17 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUP...

Page 511: ... 19 Page 5A 21 Page 5A 21 Page 5A 22 Page 5A 10 Page 5A 13 09920 33540 09921 20240 Clutch shoe remover Bearing remover set Page 5A 16 Page 5A 18 09922 31430 09924 52450 Clutch spring compressor Fixed driven face holder Page 5A 10 Page 5A 13 Page 5A 10 Page 5A 13 09930 30104 09930 40113 Rotor remover sliding shaft Flywheel rotor holder Page 5A 16 Page 5A 5 Page 5A 6 Page 5A 7 Page 5A 8 Page 5A 16 P...

Page 512: ...5A 28 Automatic Transmission ...

Page 513: ... 6 EPS Control Unit Diagram 6C 7 EPS System Wiring Harness Routing Diagram 6C 8 Component Location 6C 8 EPS Components Location 6C 8 Diagnostic Information and Procedures 6C 8 EPS Troubleshooting 6C 8 Pre diagnosis Inspection 6C 9 EPS System Check 6C 11 DTC Diagnostic Trouble Code Output 6C 18 DTC Diagnostic Trouble Code Deleting 6C 20 SDS Check 6C 23 DTC Table 6C 24 DTC C1111 Torque Sensor Main C...

Page 514: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B931H26000001 Refer to General Precautions in Section 00 ...

Page 515: ...ciently lubricated Lubricate Not enough pressure in tires Adjust Worn or incorrect tire or wrong tire pressure Adjust or replace Malfunctioning EPS if equipped Inspect EPS system Wobbly Handlebars Distorted front steering shaft Replace Crooked tire Replace Worn or incorrect tire or wrong tire pressure Adjust or replace Worn bearing race in steering stem Replace Worn steering shaft holder bushing R...

Page 516: ...ft switch assembly 2 Handlebar upper clamp 11 Steering arm plate 20 Handle grip 3 Handlebar holder 12 Cotter pin A Apply grip bond 4 Steering shaft plate 13 Tie rod 4 N m 0 4 kgf m 3 0 lbf ft 5 EPS body assembly 14 Tie rod end Apply thread lock to the thread part 6 Steering shaft 15 Cable guide Apply water resistance grease 7 Steering shaft bushing 16 Throttle cable Do not reuse 8 Dust seal 17 Par...

Page 517: ... kgf m 43 5 lbf ft 2 Tie rod end nut 29 N m 2 9 kgf m 21 0 lbf ft 3 Steering shaft lower nut 162 N m 16 2 kgf m 117 0 lbf ft 4 Tie rod nut 120 N m 12 0 kgf m 87 0 lbf ft 5 Washer The conical side of washer faces outside 28 N m 2 8 kgf m 20 0 lbf ft 6 Steering shaft upper nut Apply thread lock to the thread part B Red mark Apply water resistance grease 26 N m 2 6 kgf m 19 0 lbf ft ...

Page 518: ...nt brake master cylinder Front brake lever 2 CAUTION Do not turn the front brake master cylinder upside down c Throttle lever case 3 5 Remove the following parts from left handlebars left side a Left grip 4 b Left switch box 5 c Horn button For P 17 24 d Emergency switch For P 17 6 Disconnect the parking brake cable 6 from left brake lever 7 Remove the clamp 8 Remove the handlebar upper clamps 7 a...

Page 519: ...Handlebars Assembly Construction Page 6B 2 Set the handlebars so that its punch mark B aligns with the mating surface of the left handlebar holder Tighten the handlebar clamp bolts 4 to the specified torque NOTE First tighten the handlebar clamp bolts 4 front ones to the specified torque Tightening torque Handlebar clamp bolt b 26 N m 2 6 kgf m 19 0 lbf ft Apply adhesive agent to the handlebar rig...

Page 520: ...on or damage If any defects are found replace the handlebars with a new one Steering Shaft Removal and Installation B931H26206005 Removal 1 Remove the EPS control unit Refer to EPS Control Unit Removal and Installation in Section 6C 2 Remove the EPS body assembly Refer to EPS Body Assembly Removal and Installation in Section 6C 3 Disconnect the tie rod ends with the special tool Refer to Front Whe...

Page 521: ...21 Rotor remover Installation Install the steering shaft in the reverse order of removal Pay attention to the following points Install the steering shaft bushing 1 along with dust seal 2 with the special tool Special tool A 09924 84521 Bearing installer set Apply grease to the steering shaft bushing 1 and dust seal 2 and install them Grease 99000 25160 Water resistance grease 3 2 1 I931H1620016 01...

Page 522: ...fied torque Tightening torque Steering shaft lower nut a 162 N m 16 2 kgf m 117 0 lbf ft Install the cotter pin 8 CAUTION The removed cotter pin 8 must be replaced with a new one Install EPS body assembly Refer to EPS Body Assembly Removal and Installation in Section 6C Install the EPS control unit Refer to EPS Control Unit Removal and Installation in Section 6C Install the handlebars Refer to Han...

Page 523: ...ve the other tie rod end in the same manner as described previously 5 Separate the tie rod ends 2 nuts 3 4 and tie rods 5 CAUTION The lock nuts 3 have left hand threads Installation Install the tie rod in the reverse order of removal Pay attention to the following points When installing the tie rods make sure the short side a of tie rod come outside Push the tie rod to tie rod lock nut tightening ...

Page 524: ...nd Installation Page 6B 5 and Tie rod Tie rod End Removal and Installation Page 6B 8 Tie rod Inspect the tie rod for distortion or damage If any defects are found replace the tie rod with a new one Tie rod End Inspect the tie rod ends for smooth movement If there are any abnormalities replace the tie rod ends with new ones Inspect the tie rod end boots for wear or damage If any defects are found r...

Page 525: ...ruction Page 6B 2 Item Standard Limit Steering angle 46 right left Turning radius 3 1 m 10 2 ft Toe out with 75 kg 165 lbs 5 4 mm 0 20 0 16 in Camber 1 3 Caster 3 7 Fastening part Tightening torque Note N m kgf m lbf ft Rear brake lever holder clamp bolt 11 1 1 8 0 Page 6B 4 Handlebar clamp bolt 26 2 6 19 0 Page 6B 4 Throttle lever case bolt 4 0 4 3 0 Page 6B 5 Steering shaft lower nut 162 16 2 11...

Page 526: ...B 11 Steering Handlebar Special Tool B931H26208002 09924 84521 09930 30721 Bearing installer set Rotor remover Page 6B 6 Page 6B 6 Page 6B 6 09942 72410 Tie rod end remover Page 6B 5 Page 6B 8 Page 6B 8 ...

Page 527: ... use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts Precautions in Diagnosing Troubles B931H26300003 Take a note of DTC indicated on the SDS tool or EPS indicator light Before inspection be sure to read Precautions for Electrical Circuit Service in Section 00 and understand what is writte...

Page 528: ...hicle speed signal from speed sensor 9 The EPS control unit runs the motor so as to assist the operation of the handlebars 1 Take a note of DTC indicated on the EPS indicator light The EPS diagnoses troubles which may occur in the area including the following components when the ignition switch is ON and the engine is running When the EPS control unit detects any malfunction it stops the motor ope...

Page 529: ... wheel each torque sensor main and sub output is 2 5 V and in this state the EPS control unit determines the steering torque as 0 During operating the handlebars the EPS control unit processes the main torque sensor input signal to determine the steering torque required for the current condition The relation between the steering direction of the EPS control unit and the output voltage is as follow...

Page 530: ...rom the speed sensor This is the fundamental control necessary for the P S system Convergence control This control prevents convergence from deteriorating at a high speed by making current compensating current flow in the direction to keep the steering from turning thereby improving vehicle maneuvering stability Maximum current control If the steering input is sustained at a standstill the motor c...

Page 531: ...f the P S control system This is only to check if the EPS warning light is operated properly If the areas monitored by the EPS control unit is free from any trouble after the engine start while engine is running the EPS warning light turns OFF When the EPS control unit detects a trouble which has occurred in the monitored areas the EPS warning light comes ON while the engine is running to warn the...

Page 532: ... A 15 A 15 A 10 A STARTER MOTOR STARTER RELAY 1 MAIN 30 A BATTERY SPEEDOMETER ECM EPS UNIT EPS MOTOR TORQUE SENSOR O O O Y O Y O R R R O Y O O O Bl B Bl B Bl B Y Y Gr R Gr R W R W R W R W R Gr R Gr R B W B W Bl B Bl B Bl B Gr R W R W R Gr R B W B W B W B W B W B W B W Bl B Bl B Bl B Y Y Gr R Gr R Gr R W R W R W R R B R B R B B W B W O Y O Y O Y B W B W B W R R R R W W W W R B R B R B R R B R B R B...

Page 533: ...e selsct switch Torque sensor 4 5 1 6 3 7 9 10 8 2 12 11 14 13 Y W Bl B R G W B O Y R B B R B W Gr R W R EPS unit I931H1630007 05 10 9 8 7 1 2 3 4 5 6 11 12 13 14 I931H1630092 01 1 Engine speed signal 8 Power source 2 Ignition signal for EPS control unit 9 Motor output 3 Mode select switch 10 Motor output 4 EPS warning light 11 Torque sensor signal Main 5 Vehicle speed signal 12 Power supply for t...

Page 534: ... information from the customer 2 Perform the pre diagnosis inspection Refer to Pre diagnosis Inspection Page 6C 9 3 Inspect the EPS indicator light Refer to EPS System Check Page 6C 11 4 Output the DTCs stored in the EPS control unit Refer to DTC Diagnostic Trouble Code Output Page 6C 18 5 Perform appropriate troubleshooting procedures according to the DTCs output Refer to DTC Table Page 6C 24 If ...

Page 535: ...e steering system should be inspected prior to performing any electrical checks These inspections may find problems that the EPS could not detect thus shortening repair time Tire Tire type Tire type Front DUNLOP KT411 Rear DUNLOP KT415 Tire pressure Refer to Tire Inspection in Section 0B CAUTION The standard tire fitted on this vehicle is AT25 x 8 12 for front and AT25 x 10 12 for rear The use of ...

Page 536: ...uit tester set Tester knob indication Voltage Battery voltage 12 0 V and more 4 Reinstall the seat EPS control unit ground wire inspection 1 Turn the ignition switch OFF 2 Remove the seat Refer to Seat Removal and Installation in Section 9D 3 Disconnect the battery lead wire 4 Remove the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 5 Disconnect the EPS con...

Page 537: ...he EPS warning lamp when turning the ignition switch ON 2 If OK start engine run it idle and check EPS warning lamp remains ON continuously Is EPS warning lamp remains ON continuously Go to Step 3 Go to Step 4 DTC output Refer to DTC Diagnostic Trouble Code Output Page 6C 18 3 The EPS indicator light lights up 1 Start the engine Does the EPS indicator light go off Normal No DTC exists DTC output R...

Page 538: ...isconnected measure the voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B Battery voltage 12 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 5 Inspect the wire harness Faulty ignition or ground wire Step Action Yes No 1 2 I931H1630017...

Page 539: ... the voltage between A and B normal Go to Step 6 Inspect the wire harness Faulty indicator light wire Indicator light is blown 6 1 Turn the ignition switch OFF 2 Check for continuity between terminal A at the coupler and body ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity EPS control unit coupler Vehicle harness end Are there continuity between A and b...

Page 540: ...to Seat Removal and Installation in Section 9D 2 Open the fuse box and inspect the ignition fuse 1 CAUTION If a fuse is blown find the cause of the problem and correct it before replacing the fuse EPS fuse 40 A Is the ignition fuse OK Go to Step 8 Replace the EPS fuse Step Action Yes No 1 I931H1630016 01 ...

Page 541: ...he voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B Battery voltage 12 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 9 Inspect the wire harness Faulty ignition or ground wire Step Action Yes No 1 2 I931H1630017 03 A B A A ޓ I931H16...

Page 542: ...rminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Normal value A B 1 0 V and more EPS control unit coupler Vehicle harness end Is the voltage between A and B normal Go to Step 10 Inspect the wire harness Faulty indicator light wire Step Action Yes No A B A A ޓ I931H1630025 01 ...

Page 543: ...Check for continuity between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity EPS control unit coupler Vehicle harness end Is there continuity between A and B Replace the EPS control unit Inspect the wire harness Faulty mode select switch wire Step Action Yes No A A I931H1630024 01 A B A A ޓ I931H1630110 01 ...

Page 544: ...he ignition switch OFF 2 Remove the seat Refer to Seat Removal and Installation in Section 9D 3 Connect the special tool to the mode select coupler 1 Special tool A 09930 82710 Mode select switch 4 Switch the special tool to ON 5 Turn the ignition switch ON The EPS indicator light starts flashing to indicate the DTC Refer to DTC Table Page 6C 24 NOTE If there is a DTC the EPS indicator light keeps...

Page 545: ...om the engine or main fuse before confirming the malfunction code self diagnostic trouble code stored in memory Such disconnection may erase the memorized information in EPS control unit memory DTC stored in EPS control unit memory can be checked by the SDS 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 Set up the SDS tool Refer to the SDS operation manual for further det...

Page 546: ...e SDS operation manual for further details When DTC is checked DTC C1122 is displayed with ignition switch turned ON However if the engine is started and the display disappears it is not a trouble 4 Close the SDS tool and turn the ignition switch OFF DTC Diagnostic Trouble Code Deleting B931H26304005 Use of Mode Select Switch 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2...

Page 547: ...that the EPS activates correctly 7 Disconnect the mode select switch and reinstall the seat Use of SDS 1 Remove the seat Refer to Seat Removal and Installation in Section 9D 2 After repairing the trouble turn OFF the ignition switch 3 Set up the SDS tool Refer to the SDS operation manual for further details Special tool 09904 41010 SUZUKI Diagnostic system set 99565 01010 019 CD ROM Ver 19 4 Turn ...

Page 548: ...PS control unit also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS 9 Follow the displayed instructions 10 Check that both Current DTC 4 and Past DTC 5 are deleted NIL 11 Close the SDS tool and turn the ignition switch OFF 12 Disconnect the SDS tool and install the ...

Page 549: ... the sample of data check and clear the Past DTC Refer to DTC Diagnostic Trouble Code Deleting Page 6C 20 A number of different data under a fixed condition as shown should be saved or filed as sample Special tool 09904 41010 SUZUKI Diagnostic system set 99565 01010 019 CD ROM Ver 19 DATA sampled from EPS system Handlebars is Handlebars is center position center position Check the torque when turn...

Page 550: ...ensor Sub Circuit Malfunction Page 6C 34 C1121 Vehicle speed signal not input OFF Refer to DTC C1121 Vehicle Speed Signal Circuit Malfunction Page 6C 37 C1122 Engine speed signal circuit failure 1 ON Refer to DTC C1122 Engine Speed Signal Circuit Malfunction Page 6C 40 C1141 EPS motor circuit voltage abnormal ON Refer to DTC C1141 C1142 C1143 C1145 EPS Motor Circuit Malfunction Page 6C 43 C1142 EP...

Page 551: ...accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting Page 6C 20 DTC C1111 and C1113 are indicated at the same time due to the malfunction of the same torque sensor circuit Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 552: ...wire A and ground If OK then measure the voltage at the R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire or ground circuit B wire open If check result is not satisfactory replace the EPS control unit with a new ...

Page 553: ...e set Tester knob indication Voltage Torque sensor main voltage Handlebars is left turn Approx 3 0 V Handlebars is right turn Approx 2 0 V Is voltage OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation Page 6C 48 R wire terminal or G wire terminal circuit open torque sensor side If check result is not satisfactory replace th...

Page 554: ...prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting Page 6C 20 DTC C1113 and C1115 are indicated at the same time due to the malfunction of the same torque sensor circuit Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 555: ...voltage at the R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire open Power source or power supply circuit shorted to torque sensor main or sub circuit Torque sensor main or sub circuit open If check result is not satisfactory...

Page 556: ...ester knob indication Voltage Measuring voltage 0 V Is voltage OK Go to Step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire open Power source or power supply circuit shorted to torque sensor main or sub circuit Torque sensor main or sub circuit open If check result is not satisfactory replace the EPS control unit with a new one Refer to EPS Control Unit Removal and Insta...

Page 557: ...b voltage Handlebars left turn Main Approx 3 0 V Handlebars left turn Sub Approx 2 0 V Handlebars right turn Main Approx 2 0 V Handlebars right turn Sub Approx 3 0 V Is voltage OK G W and B wire open or shorted to ground or poor torque sensor coupler connection If wire and connection are OK intermittent trouble or faulty EPS control unit Replace the EPS control unit with a known good one and inspe...

Page 558: ...hooting CAUTION Never remove the torque sensor to prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting Page 6C 20 Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 559: ...and ground Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK If wire and connection are OK intermittent trouble or faulty EPS body assembly Replace the EPS body assembly with a known good one and inspect it again Refer to EPS Body Assembly Removal and Installation Page 6C 49 Power supply circuit R wire shorted to grou...

Page 560: ...ing CAUTION Never remove the torque sensor to prevent accident and damage NOTE After repairing the trouble clear the DTC using a SDS tool or mode coupler switch Refer to DTC Diagnostic Trouble Code Deleting Page 6C 20 Possible Cause Faulty torque sensor signal circuit Faulty torque sensor Faulty EPS control unit ...

Page 561: ...hen measure the input voltage between R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage Torque sensor input voltage 5 0 V Is voltage OK Go to step 2 Loose or poor contacts on the torque sensor Power supply circuit R wire or ground circuit B wire open If check result is not satisfactory replace the EPS con...

Page 562: ...e set Tester knob indication Voltage Torque sensor Sub voltage Handlebars is left turn Approx 2 0 V Handlebars is right turn Approx 3 0 V Is voltage OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation Page 6C 48 R wire terminal or W wire terminal circuit open torque sensor side If check result is not satisfactory replace the...

Page 563: ...e ignition switch OFF 2 Check the EPS control unit connector for loose or poor contact If OK then check the vehicle speed signal lead wire continuity 3 Disconnect the EPS control unit coupler B speed sensor coupler C and combination meter coupler A Refer to Speed Sensor Removal and Installation in Section 9C and Combination Meter Removal and Installation in Section 9C 4 Turn the ignition switch OF...

Page 564: ...ction 9C 7 Check the continuity between the Bl B wire of EPS control unit coupler B and Bl B wire of speed sensor C Also check the continuity between the Bl B wire of EPS control unit coupler B and Bl B wire of combination meter A Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Continuity Is continuity OK Go to step 2 Bl B wire open...

Page 565: ... voltage OK Go to step 3 Bl B wire shorted to ground 3 1 Remove the engine side cover Refer to Rear Side Exterior Parts Removal and Installation in Section 9D 2 Inspect the speed sensor Refer to Speed Sensor Inspection in Section 9C Is speed sensor OK Replace the EPS control unit Refer to EPS Control Unit Removal and Installation Page 6C 48 Replace the speed sensor Refer to Speed Sensor Removal an...

Page 566: ... Malfunction B931H26304013 Troubleshooting NOTE Start the engine after repairing the DTC and check that the indicator light is turned OFF Refer to Precautions in Diagnosing Troubles Page 6C 1 Possible Cause Faulty engine speed signal circuit Faulty ECM Faulty EPS control unit ...

Page 567: ...t Malfunction in Section 1A 2 1 Turn the ignition switch OFF 2 Check the EPS control unit coupler for loose or poor contact If OK then measure the engine speed signal lead wire continuity 3 Disconnect the EPS control unit coupler and ECM coupler 4 Check the continuity between the W wire A and terminal 31 Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tes...

Page 568: ... Multi circuit tester set Tester knob indication Voltage Engine speed signal voltage It changes between 0 12 V Is voltage OK Replace the EPS control unit with a new one Refer to EPS Control Unit Removal and Installation Page 6C 48 Replace the ECM with a new one Refer to EPS Control Unit Removal and Installation Page 6C 48 Step Action Yes No A A I931H1630053 02 ...

Page 569: ...oose or poor contact If OK measure the EPS motor voltage 3 Insert the needle pointed probes to lead wire coupler 4 Start the engine and turn the handlebars left turn 5 Measure the voltage between R wire A and B wire B Special tool A 09900 25008 Multi circuit tester set B 09900 25009 Needle pointed probe set Tester knob indication Voltage EPS motor voltage Approx 7 0 V Is voltage OK Go to step 2 R ...

Page 570: ...r Refer to EPS Motor Inspection Page 6C 52 Is continuity OK Replace the EPS control unit with a known good one and inspect it again Refer to EPS Control Unit Removal and Installation Page 6C 48 Replace the EPS motor EPS body assembly with a new one Refer to Steering Shaft Removal and Installation in Section 6B Step Action Yes No I931H1630087 02 ...

Page 571: ...uit tester Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Battery voltage 12 0 V and more Is the voltage over 12 V Go to Step 2 Charge or replace the battery 2 1 Start the engine at 5 000 r min with the dimmer switch set to HI 2 Measure the voltage between the and battery terminals Special tool 09900 25008 Multi circuit tester set Tester knob indication Voltage ...

Page 572: ...er 3 Start the engine at 5 000 r min with the dimmer switch set to HI 4 Measure the voltage between terminal A and terminal B at the coupler Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage same as Step 2 Replace the EPS control unit Inspect the wire harness Faulty ignition or ground wire Step Action Yes No A B A A ޓ I931H1630055 02 ...

Page 573: ...ntrol Unit Construction B931H26306001 Possible Cause C1152 Relay welding EPS control unit internal circuit C1154 Relay malfunction EPS control unit internal circuit C1155 EPS control unit malfunction 1 2 3 3 B 4 A a FWD FWD I931H1630056 02 1 EPS control unit 4 Torque sensor coupler 2 EPS control unit plate 12 N m 1 2 kgf m 8 5 lbf ft 3 Cushion B Install the clip of the torque sensor coupler to the...

Page 574: ...A 09942 83110 Clip remover 7 Remove the fastener 4 and bolt 5 8 Remove the EPS control unit 6 along with the EPS control unit plate 7 9 Remove the EPS control unit 6 from the EPS control unit plate 7 as shown in the EPS control unit construction Refer to EPS Control Unit Construction Page 6C 47 Installation Install the EPS control unit in the reverse order of removal Pay attention to the following...

Page 575: ...s in Section 6B Refer to Steering Handlebars Assembly Construction in Section 6B Removal 1 Remove the handlebars Refer to Steering Handlebars Components in Section 6B 2 Remove the combination meter Refer to Combination Meter Removal and Installation in Section 9C 3 Remove the front fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 4 Remove the holder cover 1 by remov...

Page 576: ...ever disassemble the EPS body assembly Installation Refer to Steering Handlebars Assembly Construction in Section 6B Install the EPS body assembly in the reverse order of removal Pay attention to the following points Apply grease to the spline of the EPS body assembly Grease 99000 25160 Water resistance grease or equivalent When installing the EPS body assembly align the marking A of the EPS outpu...

Page 577: ...PER 1303 or equivalent Tightening torque Steering shaft bolt c 26 N m 2 6 kgf m 19 0 lbf ft Install the front brake hose union 5 to the cable guide Apply grease to the spline of the EPS body assembly Grease 99000 25160 Water resistance grease or equivalent Install the steering shaft plate 6 and tighten the steering shaft upper nut to the specified torque CAUTION Never use an impact wrench when tig...

Page 578: ...on with the tester between terminals A and B If continuity does not exist replace the EPS body assembly with a new one Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity 3 Next check for insulation with the tester between terminal A and body ground C and terminal B and body ground C If continuity is found replace the EPS body assembly with a new one Special tool ...

Page 579: ...26308001 Fastening part Tightening torque Note N m kgf m lbf ft EPS control unit mounting nut 12 1 2 8 5 Page 6C 48 EPS body assembly mounting bolt 26 2 6 19 0 Page 6C 51 EPS body assembly mounting nut 28 2 8 20 0 Page 6C 51 Steering shaft bolt 26 2 6 19 0 Page 6C 51 Steering shaft upper nut 120 12 0 87 0 Page 6C 51 Handlebar holder nut 60 6 0 43 5 Page 6C 52 Material SUZUKI recommended product or...

Page 580: ...6C 36 Page 6C 38 Page 6C 39 Page 6C 41 Page 6C 42 Page 6C 43 Page 6C 45 Page 6C 45 Page 6C 46 Page 6C 52 Page 6C 52 Page 6C 27 Page 6C 31 Page 6C 35 Page 6C 36 Page 6C 38 Page 6C 41 Page 6C 43 09904 41010 09930 82710 SUZUKI Diagnostic system set Mode select switch Page 6C 19 Page 6C 21 Page 6C 23 Page 6C 17 Page 6C 18 09930 82720 09942 83110 Mode selection switch Clip remover Page 6C 20 Page 6C 48...

Page 581: ...rature Indicator Light Inspection 9C 3 Engine Coolant Temperature Removal and Installation 9C 4 Fuel Level Indicator Inspection 9C 4 Fuel Level Gauge Inspection 9C 5 Speedometer Inspection 9C 6 Speed Sensor Removal and Installation 9C 6 Speed Sensor Inspection 9C 6 Ignition Switch Inspection 9C 7 Ignition Switch Removal and Installation 9C 7 Horn Inspection For P 17 24 9C 7 Horn Removal and Instal...

Page 582: ...9 ii Table of Contents Specifications 9E 7 Tightening Torque Specifications 9E 7 Special Tools and Equipment 9E 7 ...

Page 583: ...cautions for Electrical System B931H29000001 Refer to General Precautions in Section 00 and Precautions for Electrical Circuit Service in Section 00 Component Location Electrical Components Location B931H29003001 Refer to Electrical Components Location in Section 0A ...

Page 584: ...9A 1 Wiring Systems Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram B931H29102001 Refer to Wire Color Symbols in Section 0A ...

Page 585: ...B W O Bl R Bl R Bl Bl R G R G R O Y O Y R B R B Bl B Bl B W W R W R B Y B Y O Y O Y B W B W W G W G B G B G Y B Y B B W B W O O Y O Y W B B W B R B R B R B R B R B R Bl R Bl R G R R B Bl B W W R B Y B W W G B G Y B O G O G G G B W G G Y Y Y Y G G O Y O O Y O G O O O O Y O Y Y Bl Y Bl W Bl W Bl O Bl O Bl O O W O W Y G Y G B W B W Br Br Br Gr Gr W R W R W Y W Y W G W G B Y B W B W O Y O Y Bl Bl Bl R...

Page 586: ...B W W Y B W W Y B W W Y B W W O Y O Y W B W B B W B W O Bl R Bl R Bl Bl R G R G R O Y O Y R B R B Bl B Bl B W W R W R B Y B Y O Y O Y B W B W W G W G B G B G Y B Y B B W B W W B B W B R B R B R B R B R B R Bl R Bl R G R R B Bl B W W R B Y B W W G B G Y B G G B W G G Y Y Y Y G G O Y O B O B B G O B G O B B G O B G O O G G O O Y O Y Y Bl Y Bl W Bl W Bl O Bl O Bl O W O W Y G Y G B W B W Br Br Br Gr G...

Page 587: ...ooling fan lead wire over the radiator hose 3 Clamp Bind the wiring harness and cooling fan thermo switch with the clamp B To power source 4 Clamp Bind the wiring harness and back up relay For P 17 with the clamp C Pass the wiring harness under of the throttle cable 5 Clamp Bind the EPS motor lead wire and EPS control unit lead wires a 60 80 mm 2 4 3 2 in 6 EPS control unit b 20 30 mm 0 8 1 2 in 7...

Page 588: ...tor lead wire with the clamp 17 TO sensor 6 Clamp Bind the diff lock actuator lead wire and rear brake switch lead wire with the clamp 18 Horn For P 17 24 7 Clamp Bind the rear brake switch lead wire with the clamp B To rear fender top 8 Clamp Bind the wiring harness generator lead wire and gear position switch lead wire C Slack the read wire 9 Speed sensor lead wire D Pass the horn lead wire insi...

Page 589: ...emergency switch lead wire For P 17 with the clamp Cut the tip of clamp after clamping 11 Fuse box 3 Clamp Bind the front brake switch lead wire and 2WD 4WD diff lock switch lead wire with the clamp Cut the tip of clamp after clamping 12 Fuse EPS 4 Clamp Bind the combination meter lead wire 2WD 4WD diff lock lead wire and front brake switch lead wire with the clamp 13 Combination meter lead wire 5...

Page 590: ...gram Page 9A 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C 1 2 3 a 4 5 6 7 7 I931H1910908 01 1 Starter motor 3 Generator stator 5 Starter motor lead wire 7 Clamp 2 Gear position switch 4 Ground wire 6 Grommet a 30 Item Specification Note Fuse size Headlight HI 10 A LO 10 A Fuel 10 A Ignition 15 A Power source 10 A Fan ...

Page 591: ...29206002 Removal 1 Remove the front grill upper cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Disconnect the headlight coupler 1 3 Remove the headlight assembly 2 by removing screw 3 fastener 4 and bolts 5 1 FWD FWD I931H1920011 02 1 Headlight bulb 12 V 35 35 W 1 I831G1920003 01 2 4 5 I931H1920001 01 5 3 I931H1920002 01 ...

Page 592: ...termined wattage Remove the bulb when it gets cool since it may be heated to an extremely high temperature when the headlight is turned ON 1 Remove the headlight housing cover 1 and bulb socket rubber cap 2 2 Disconnect the headlight coupler 3 3 Replace the headlight bulb 4 by unhooking the bulb holder spring 5 4 Reinstall the removed parts NOTE Properly fit the bulb socket rubber cap and headligh...

Page 593: ...ht Bulb Replacement B931H29206007 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 Do not use bulb other than those with predetermined wattage 1 Remove the rear combination light 2 Remove the bulb socket by turning it counterclockwise 3 Push in on the bulb turn it counterclockwise and pull it out ...

Page 594: ...er Switch Inspection B931H29206010 Inspect the dimmer switch in the following procedures 1 Remove the left inner fender Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Disconnect the handlebar switch coupler 1 3 Inspect the dimmer switch for continuity with a tester If any abnormality is found replace the handlebar switch assembly with a new one Refer to Handlebars Remo...

Page 595: ...B931H29207001 Wattage Unit W Special Tools and Equipment Special Tool B931H29208001 Item Specification P 24 28 33 P 17 Headlight HI 35 x 2 LO 35 x 2 Brake light Taillight 21 5 Reversing light 21 09900 25008 Multi circuit tester set Page 9B 4 Page 9B 4 ...

Page 596: ...ght LED is maintenance free LED is less power consuming and more resistant to vibration resistance compared to the bulb 1 3 13 9 16 4 8 15 10 17 11 6 7 14 2 12 5 I931H1930001 02 1 Select button Odo Trip A Trip B 7 LED EPS indicator light 13 LCD Engine coolant temperature indicator 2 LED High beam indicator light For P 17 8 Select button Clock Hour FI DTC 14 LCD FI indicator 3 LED Diff lock indicat...

Page 597: ...UTION When disconnecting and reconnecting the combination meter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Removal 1 Remove the combination meter cover 1 by removing the screws 2 fastener 3 and ignition switch ring nut 4 FWD FWD 1 2 3 I931H1930019 01 1 Upper case 2 Combination meter 3 Lower case 2 1 4 3 I931H1930002 01 ...

Page 598: ...onents Page 9C 2 Combination Meter Inspection B931H29306004 LED Inspection Check that the LEDs Diff lock indicator light Reverse indicator light and FI indicator light Engine coolant temperature indicator light immediately light up for two seconds when the ignition switch is turned to ON Check that other LEDs Neutral indicator light and High beam indicator light for P 17 light up go off by operati...

Page 599: ... sensor coupler 8 Reinstall the removed parts Engine Coolant Temperature Removal and Installation B931H29306006 Refer to ECT Sensor Removal and Installation in Section 1C Fuel Level Indicator Inspection B931H29306007 Inspect the fuel level indicator in the following procedures 1 Move the rear fender upside Refer to Fuel Tank Pressure Control FTPC Valve Removal and Installation in Section 1G 2 Disc...

Page 600: ...31H29306008 Inspect the fuel level gauge in the following procedures 1 Remove the fuel pump Refer to Fuel Pump Assembly Removal and Installation in Section 1G 2 Measure the resistance at each fuel level gauge in float position If the resistance is incorrect replace fuel pump with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω 3 Install the fuel pump...

Page 601: ...tall the speed sensor in the reverse order of removal Pay attention to the following points Apply grease to the speed sensor O ring CAUTION Replace the O ring with a new one Grease 99000 25160 Water resistance grease or equivalent Tighten the speed sensor mounting bolt to the specified torque Tightening torque Speed sensor mounting bolt a 10 N m 1 0 kgf m 7 0 lbf ft Speed Sensor Inspection B931H29...

Page 602: ... Installation B931H29306013 Refer to Ignition Switch Removal and Installation in Section 1H Horn Inspection For P 17 24 B931H29306014 NOTE If the horn sound condition is normal it is not necessary to inspect the horn button continuity Horn Button Inspection 1 Disconnect the horn couplers as shown in the wiring harness routing diagram Refer to Wiring Harness Routing Diagram in Section 9A 2 Inspect ...

Page 603: ...tion refer to Tightening Torque List in Section 0C Special Tools and Equipment Recommended Service Material B931H29308001 Special Tool B931H29308002 Item Specification P 24 28 33 P 17 Speedometer light LED High beam indicator light LED Neutral indicator light LED FI indicator light Engine coolant temp indicator light LED Reverse indicator light LED Differential lock indicator light LED EPS indicat...

Page 604: ...Exterior Parts Repair Instructions Exterior Parts Construction B931H29406001 Front Side 1 2 3 4 7 5 6 I931H1940040 04 1 Front fender 3 Air cleaner box cover 5 Front grill cover 7 Right inner fender 2 Front box 4 Side cover 6 Left inner fender ...

Page 605: ...Exterior Parts 9D 2 Rear Side 1 2 3 4 5 I931H1940041 02 1 Rear fender 2 Right mud guard 3 Left mud guard 4 Engine side cover 5 Rear box ...

Page 606: ...ts Rear Fender Heat Shield Construction B931H29406002 a 2 1 2 a b c d FWD FWD 2 A I931H1940042 01 1 Rear fender a 1 3 mm 0 04 0 12 in c 67 mm 2 64 in A Inside of the rear fender 2 Heat shield b 5 mm 0 2 in d 8 mm 0 3 in ...

Page 607: ...Exterior Parts 9D 4 Fuel Tank Lower Cover Heat Shield Installation B931H29406003 1 2 1 a 3 2 1 1 I931H1940044 01 1 Heat shield 2 Cushion 3 Fuel tank lower cover a Max 5 mm 0 2 in ...

Page 608: ...astener all the way into the installation hole 3 Push in the head of center piece until it becomes flush with the fastener outside face Type B Removal 1 Pry up the head of fastener center piece 1 with a screw driver 2 Pull out the fastener A Installation 1 Insert the fastener into the installation hole NOTE To prevent the pawl 1 from damage insert the fastener all the way into the installation hol...

Page 609: ...ove the seat Refer to Seat Removal and Installation Page 9D 11 2 Remove the air cleaner box cover 1 by removing the fasteners 2 Installation Install the air cleaner box cover in the reverse order of removal Front Box Removal 1 Remove the front box cap 1 2 Disconnect the front box cap wire 2 3 Remove the front box mounting screw 4 Turn the front box 3 counterclockwise and remove it 1 2 I931H1940001...

Page 610: ... cushion to the front box align the cutout C on the front box Inner Fender Removal Remove the inner fenders 1 by removing the fasteners 2 left and right Installation Install the inner fenders in the reverse order of removal Side Cover Removal 1 Remove the seat Refer to Seat Removal and Installation Page 9D 11 2 Remove the side cover 1 left and right 5 4 I931H1940006 01 5 I931H1940007 01 A B I931H1...

Page 611: ...nt box inner fenders and side covers Refer to Front Side Exterior Parts Removal and Installation Page 9D 6 4 Remove the headlight assembly left and right Refer to Headlight Removal and Installation in Section 9B 5 Disconnect the power source socket coupler 1 6 Remove the front fender 2 by removing the screws 3 and fasteners 4 Installation Install the front fender in the reverse order of removal B ...

Page 612: ...ox 1 Installation Install the rear box in the reverse order of removal Mud Guard Removal Remove the mud guards 1 by removing the bolts 2 screws 3 and fasteners 4 left and right Installation Install the mud guard in the reverse order of removal Fuel Tank Outer Cover Removal 1 Remove the fasteners 1 and screws 2 1 I931H1940018 02 1 I931H1940019 01 A Left side B Right side 2 1 A 3 4 3 4 I931H1940020 ...

Page 613: ...nt Side Exterior Parts Removal and Installation Page 9D 6 4 Remove the engine side cover Refer to Rear Side Exterior Parts Removal and Installation Page 9D 9 5 Remove the screws 1 and fasteners 2 6 Remove the battery Refer to Battery Removal and Installation in Section 1J 7 Disconnect the couplers 2 and remove the starter relay 3 along with the battery lead wire Refer to Starter Relay Removal and ...

Page 614: ...install the fuel tank cap after removing the rear fender 11 Remove the rear fender 10 Installation Install the rear fender in the reverse order of removal Seat Removal and Installation B931H29406007 Removal Pull the seat lock lever 1 upward and remove the seat 2 Installation Install the seat in the reverse order of removal 8 I931H1940029 02 10 9 I931H1940030 01 1 2 I931H1940031 01 ...

Page 615: ...r Cover Removal Remove the front under cover 1 by removing the bolts 2 and fasteners 3 Installation 1 Fix the front under cover B to the groove A of engine under cover 1 2 3 FWD FWD I831G1940034 02 1 Front under cover 2 Engine under cover 3 Rear under cover 1 3 2 I931H1940032 01 1 3 2 I931H1940033 01 A B I931H1940034 01 ...

Page 616: ...he engine under cover 1 with the front under cover 2 and rear under cover 3 2 Install the engine under cover Rear Under Cover Removal Remove the rear under cover 1 Installation Install the rear under cover in the reverse order of removal 1 I931H1940035 01 2 1 I931H1940036 01 1 3 I931H1940037 01 1 1 I931H1940038 01 1 I931H1940039 01 ...

Page 617: ...re 9E 1 Body and Accessories Body Structure Repair Instructions Body Frame Construction B931H29506001 FWD FWD 1 2 3 4 4 I931H1950018 02 1 Frame 3 Washer Apply thread lock to the thread part 2 Battery plate 4 Spacer ...

Page 618: ...ntion to the following point Apply thread lock to the footrest mounting bolts and tighten them to the special torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Footrest mounting bolt M8 a 26 N m 2 6 kgf m 19 0 lbf ft Footrest mounting bolt M10 b 55 N m 5 5 kgf m 40 0 lbf ft 3 1 2 b 3 FWD FWD a I831G1950001 04 1 Footrest R 3 Footrest plate 55 N m 5 ...

Page 619: ... 1 Remove the front grill upper cover Refer to Front Side Exterior Parts Removal and Installation in Section 9D 2 Remove the front carrier 1 by removing the bolts 2 FWD FWD 1 2 I931H1950017 02 1 Front carrier 2 Rear carrier Apply thread lock to the thread part 2 I931H1950004 02 2 I931H1950005 01 1 2 I931H1950006 01 ...

Page 620: ...rrier Removal and Installation B931H29506006 Removal 1 Remove the rear carrier 1 by removing the bolts 2 and screw 3 Installation Install the rear carrier in the reverse order of removal Pay attention to the following point Apply thread lock to the rear carrier mounting bolts Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent I931H1950007 02 I931H1950008 01 2 2 2 I931H19500...

Page 621: ...Parts Removal and Installation in Section 9D 3 Remove the front grip bar 1 by removing the bolts 2 Installation Install the front grip bar in the reverse order of removal Pay attention to the following point Apply thread lock to the front grip bar mounting bolts Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent FWD FWD 1 I931H1950013 01 1 Front grip bar Apply thread lock t...

Page 622: ...wing with the trailer towing mounting bolts and then tighten them to the specified torque Tightening torque Trailer towing mounting bolt a 60 N m 6 0 kgf m 43 5 lbf ft FWD FWD a b 1 3 2 FWD a I831G1950020 04 1 Trailer towing warning label P 17 28 60 N m 6 0 kgf m 43 5 lbf ft 2 Trailer towing warning label a 5 mm 0 2 in 3 Trailer towing b 30 mm 1 2 in 1 I831G1950021 01 a I831G1950022 01 ...

Page 623: ... service material is also described in the following Body Frame Construction Page 9E 1 Footrest Construction Page 9E 2 Carrier Construction Page 9E 3 Front Grip Bar Construction Page 9E 5 Fastening part Tightening torque Note N m kgf m lbf ft Footrest mounting bolt M8 26 2 6 19 0 Page 9E 2 Footrest mounting bolt M10 55 5 5 40 0 Page 9E 2 Trailer towing mounting bolt 60 6 0 43 5 Page 9E 6 Material ...

Page 624: ...Prepared by December 2008 Part No 99500 44080 03E Printed in U S A 624 ...

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