PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

CONTENTS
PERIODIC MAINTENANCE SCHEDULE 2- 2
PERIODIC MAINTENANCE CHART 2- 2 2
LUBRICATION POINTS 2- 4
MAINTENANCE AND TUNE-UP PROCEDURES 2- 5
AIR CLEANER 2- 5
SPARK PLUG 2- 6
TAPPET CLEARANCE 2- 8
FUEL HOSE 2-14
ENGINE OIL AND OIL FILTER 2-14
ENGINE IDLE SPEED 2-16
THROTTLE CABLE PLAY 2-16
THROTTLE VALVE SYNCHRONIZATION 2-17
EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33 ONLY) ..2-17
PAIR (AIR SUPPLY) SYSTEM 2-17
CLUTCH 2-18
COOLING SYSTEM 2-19

0 DRIVE CHAIN
BRAKE
2-21
2-23
TIRE 2-27
STEERING 2-27
FRONT FORK 2-28
REAR SUSPENSION 2-28
EXHAUST PIPE BOLT 2-28
CHASSIS BOLT AND NUT 2-29
COMPRESSION PRESSURE CHECK 2-31
COMPRESSION TEST PROCEDURE 2-31
OIL PRESSURE CHECK 2-32
OIL PRESSURE TEST PROCEDURE 2-32
2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy . Mileages are expressed in terms of kilome-
ters, miles and time for your convenience .
INPORTANT : The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations . Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure that reliabillity and performance of the motorcycle .
NOTE :
More frequent servicing may be performed on motorcycles that are used under severe conditions .

PERIODIC MAINTENANCE CHART

Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Air cleaner element - I I R I
Exhaust pipe bolts and muffler bolts T - T - T
Tappet clearance - - - - I
Spark plugs - I R I R
Fuel hose - I I I I
Replace every 4 years .
Engine oil R R R R R
Engine oil filter R - - R -
Idle speed I I I I I
Throttle cable play I I I I I
Throttle valve synchronization I
I - I
(E-33 only)
Evaporative emission control system I - I
(E-33 only) Replace vapor hose every 4 years .
PAIR (air supply) system - - I - I
Engine coolant Replace every 2 years .
Radiator hose - I I I I
Clutch hose - I I I I
Replace every 4 years .
Clutch fluid - I I I I
Replace every 2 years .
Drive chain I I I I I
Clean and lublicate every 1 000 km (600 miles) .
Brakes I I I I I
Brake hose - I I I I
Replace every 4 years .
Brake fluid - I I I I
Replace every 2 years .
Tires - I I I I
Steering I - I - I
 PERIODIC MAINTENANCE 2-3

Interval km 1 000 6 000 12 000 18 000 24 000

miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Front fork - I - I
Rear suspension - I - I
Chassis bolts and nuts T T T T T

NOTE : l=Inspect and clean, adjust, replace or lubricate as necessary; R=Replace ; T=Tighten

k )'

0J
2-4 PERIODIC MAINTENANCE

LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle .
Major lubrication points are indicated below .

1is

,
G•

1,0

NOTE : 4.0
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime .
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions .


PERIODIC MAINTENANCE 2 -5

MAINTENANCE AND TUNE-UP PRO-

CEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements .

AIR CLEANER
Inspect every 6 000 km (4 000 miles, 6 months) and
replace every 18 000 km (11 000 miles, 18 months) .

• Remove the seat . (LF6-7)

• Lift and support the feul tank . (C-74-65)
• Remove the air cleaner box cap O.

f 0 • Remove the air cleaner element O.

• Carefully use air hose to blow the dust from the cleaner ele-
ment .

4 r CAUTION

Always use air pressure on the throttle body side of

the air cleaner element . If air pressure is used on the
other side, dirt will be forced into the pores of the air
cleaner element thus restricting air flow through the
I air cleaner element .


2-6 PERIODIC MAINTENANCE

• Reinstall the cleaned or new air cleaner element in the

reverse order of removal .

CAUTION

If driving under dusty condition, clean the air cleaner

element more frequently . The surest way to accelerate
engine wear is to use the engine without the element 1
or to use a ruptured element . Make sure that the air
cleaner is in good condition at all times . Life of the
engine depends largely on this component!

NOTE :
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug .

SPARK PLUG

Inspect every 6 000 km (4 000 miles, 6 months) and

replace every 12 000 km (7 500 miles, 12 months) .

No . 1 (FRONT) SPARK PLUG REMOVAL

• Remove the radiator mounting bolt O.

• Move the radiator forward .

• Remove the spark plug cap O.
NOTE :
Be careful not to damage the radiator fins .

A WARNING 6
The hot radiator and the hot engine can burn you . Wait
until the radiator and the engine are cool enough to
touch .

• Remove the spark plug with a spark plug wrench .



PERIODIC MAINTENANCE 2-7

No . 2 (REAR) SPARK PLUG REMOVAL

• Remove the seat . (r--,-6-7)
• Lift and support the fuel tank . (=4-65)
4-65)
• Disconnect the camshaft position sensor 1O and breather
hose (Z .
• Remove the rubber heat shield ® .
• Remove the spark plug cap .
• Remove the spark plug with a spark plug wrench .

HEAT RANGE
• Check to see the heat range of the plug .

Standard Cold type

NGK CR8EK CR9EK or CR1 OEK
DENSO U24ETR U27ETR or U31 ETR

CARBON DEPOSIT
• Check to see if there are carbon deposits on the plugs . If car-
bon is deposited, remove it with a spark plug cleaner machine
or carefully using a tool with a pointed end .

SPARK PLUG GAP

• Measure the plug gap with a thickness gauge . If out of specifi-
cation, adjust it to the following gap .
09900-20803 : Thickness gauge
Spark plug gap OA
Standard : 0 .6 - 0 .7 mm (0 .024 - 0 .028 in)

I ELECTRODES CONDITION
• Check to see the worn or burnt 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, damaged thread .

It CAUTION

Confirm the thread size and reach when replacing the

plug . If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine dam-
age may result.


2- 8 PERIODIC MAINTENANCE

SPARK PLUG AND PLUG CAP INSTALLATION

• Install the spark plugs to the cylinder heads by finger tight,
and then tighten them to the specified torque .

Spark plug : 11 N .m (1 .1 kgf-m, 8 .0 lb-ft)

CAUTION

When installing a spark plug, carefully turn the spark

4
0
plug wrench by finger into the threads of the cylinder
head to prevent damage the aluminum threads .

NOTE :
When installing the spark plug caps, front and rear, face the tri-
angle mark OA on the water-proof cover to the each cylinder
exhaust side . Insert the spark plaug cap securely to the dead
end.

TAPPET CLEARANCE
Inspect every 24 000 km (15 000 miles, 24 months) .
klb
• Remove the seat . (f" r'6-7)
• Lift and support the fuel tank . (=4-65)
4-65)
• Remove the radiator . (=5-5)
• Remove the spark plugs . ( f"7'2-6)
• Remove the cylinder head covers .

The tappet clearance specification is different for intake and

exhaust valves .
Tappet clearance must be checked and adjusted, 1) at the time
of periodic inspection, 2) when the valve mechanism is serviced,
and 3) when the camshafts are disturbed by removing them for
servicing . I'16
Tappet clearance (when cold)
IN . : 0 .10 - 0 .20 mm (0 .004 - 0 .008 in)
EX . : 0 .20 - 0 .30 mm (0 .008 - 0 .012 in)


PERIODIC MAINTENANCE 2- 9

NOTE:
• The tappet clearance should be taken when each cylinder is at
Top Dead Center (TDC) of compression stroke .
• The cams (IN & EX) on the front cylinder at position ~~ show
the front cylinder at TDC of compression stroke .
• The cams (IN & EX) on the rear cylinder at position © show
the rear cylinder at TDC of compression stroke .
• The clearance specification is for COLD state .
• To turn the crankshaft for clearance checking, be sure to use a
17-mm wrench, and rotate in the normal running direction . All
spark plugs should be removed .
• Remove the generator cover plug 0 and timing inspection
plug OO .

• Turn the crankshaft to set the No . 1 (Front) cylinder at TDC of

compression stroke . (Align the "F I T" line on the generator
rotor to the index mark of valve timing inspection hole and
also bring the camshafts to the position as shown above .)

• To inspect the No . 1 (Front) cylinder tappet clearance, use a

thickness gauge between the tappet and the cam . If the clear-
ance is out of specification, adjust it into the specified range .
.. 09900-20803 : Thickness gauge


2- 1 0 PERIODIC MAINTENANCE

• Turn the crankshaft 270 degrees (3/4 turns) to set the No . 2

(Rear) cylinder at TDC of compression stroke . (Align the
"R I T" line on the generator rotor to the index mark of valve
timing inspection hole and also bring the camshafts to the
position as shown in page 2-9 .)

• Inspect the No . 2 (Rear) cylinder tappet clearance as the

same manner of No . 1 (Front) cylinder and adjust the clear-
ance if necessary .
.. 09900-20803 : Thickness gauge

TAPPET CLEARANCE ADJUSTMENT

The clearance is adjusted by replacing the existing tappet shim
by a thicker or thinner shim .

• Remove the intake or exhaust camshafts . (=3-18)

3-18)
• Remove the tappet and shim by fingers or magnetic hand .
• Check the figures printed on the shim . These figures indicate
the thickness of the shim, as illustrated .
• Select a replacement shim that will provide a clearance within
the specified range . For the purpose of this adjustment, a total
of 25 sizes of tappet shim are available ranging from 2 .30 to
3 .50 mm in steps of 0 .05 mm . Fit the selected shim to the
valve stem end, with numbers toward tappet . Be sure to
check shim size with micrometer to ensure its size .
Refer to the tappet shim selection table (Pages 2-12 and -13)

NOTE:
for details .

* Be sure to apply engine oil to tappet shim top and bottom

I 0
faces .
* When seating the tappet shim, be sure to face figure printed
surface to the tappet .
CAUTION

Reinstall the camshafts as the specified manner .

(CI3-106)


PERIODIC MAINTENANCE 2 -11

• After replacing the tappet shim and camshafts, rotate the

engine so that the tappet is depressed fully . This will squeeze
out oil trapped between the shim and the tappet that could
cause an incorrect measurement, then check the clearance
again to confirm that it is within the specified range .
• After finishing the tappet clearance adjustment, reinstall the
following items .
• When installing the cylinder head cover, do not forget the gas-
ket OA .

Page
* Cylinder head cover 3-112
• Spark plug and plug cap 2-8
• Radiator 5-5
• Seat 6-7


Z
TAPPET SHIM SELECTION TABLE [INTAKE] D
TAPPET SHIM NO . (12892-41000-XXX) M
OPTION TAPPET SHIM SET (12800-41810)
D
M

SUFFIX
230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
NO .
MEASURED
TAPPET
CLEARANCE PRESENT
(mm) SHIM SIZE
(mm) 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2.80 2 .85 290 2 95 3 00 3 05 310 315 3 20 3 25 3 30 3 35 3 40 3 45 350

0,00-0 .04 \ 230 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 310 315 3 20 3 25 3 30 3 35 3 40

0 .05-0 .09 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 7 70 2 75 2 80 2 85 290 2 95 3 00 3 05 310 315 3 20 3 25 3 30 3 35 3 40 3 .45

0.10-0 .20 P`_C A L FR N E/NO ADJUSTMENT FEQUIR -D

0.21-0 .25 240 245 255 260 265 270 275 285 290 295 300 305 310 315 320 325 330 335 340 345 350 350
I
026-030 2 45 2 .50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 .90 2 95 3 .00 3 05 3 10 315 3 20 3 25 3 30 3 35 3 .40 3 45 3 .50 3 .50
0 .31 -0.35 2 50 2 .55 2 60 2 65 2 70 2 75 2 80 2 85 290 2.95 3 00 3 .05 3 0 3 5 3 20 3 25 3 30 3 35 3 40 3 .45 3 50 3.50

036-040 2 55 2 .60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3.00 3 05 3 .10 315 3 20 3 25 3 30 3 35 3 40 3 45 3 .50 3 50

0 .41 -0 .45 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 350
0 .46-0 .50 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 0 3 5 3 20 3 25 3 30 3 35 3 40 3 45 3 50 350

0 .51-0 .55 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 350

0 .56-0 .60 2 75 2 80 2 85 2 90 2 95 300 3 05 3.10 3.15 3 20 3 25 3 30 3 35 3 40 3 45 350 3 .50

0 .61-0 .65 2 80 2 85 290 2 95 3 00 3 05 310 3.15 3.20 3 25 3 30 3 35 3 40 3 45 3 50 350

0.66-0.70 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 .20 325 3 30 3 35 3 40 3 45 3 50 3 50
0 .71-0.75 290 29S 300 3 05 310 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 350
0 .76-0.80 2 95 3 00 3 05 3 10 315 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50
0 .81-0 .85 300 3 .05 3 10 3 20 HOW TO USE THIS CHART:
315 3 25 3 30 3 35 3 40 3 45 350 3.50
0 .86-0 .90 3 05 3 .10 315 3 .20 3 25 3 30 3 35 3 40 3 45 3 50 3.50 1 . Measure tappet clearance . "ENGINE IS COLD"
0 .91 -0 .95 3 10 315 3 20 3 .25 3 30 3 35 3 40 3 45 350 3 50 11 . Measure present shim size .
III . Match clearance in vertical column with present shim size in horizontal
0.96-1 .00 3 5 3 20 3 25 3 .30 3 35 3 40 3 45 3 50 350
column .
1 .01 -1 .05 3 20 3 25 3 30 3.35 3 40 3 45 3 50 3 50
EXAMPLE
~- 1 .06-1 .10 3 .25 330 3 35 3 40 3 45 350 3 .50
Tappet clearance is 0 .23 mm
1 .11-1 .15 3 .30 3 .35 3 40 3 45 3 50 3 .50 Present shim size 2 .70 mm
1 .16-1 .20 3 .35 3 .40 3 45 3 50 3 50 Shim size to be used 2 .80 mm

1 .21 -1 .25 3 40 3 45 3 50 3 50

1 .26-1 .30 3 45 3 50 3 50

1 .31-1 .35 350 350

1 .36-1 .40 3 .50



M
x
x
TAPPET SHIM SELECTION TABLE [EXHAUST] D
TAPPET SHIM NO . (12892-41000-XXX) C
OPTION TAPPET SHIM SET (12800-41810) N
r;)
D
SUFFIX m
230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
NO .
MEASURED
TAPPET
CLEARANCE PRESENT
(mm) SHIM SIZE
(mm) 230 2 .35 2 .40 2 .45 2 .50 2 550 260 265 2 70 2 75 2 80 2.85 2 .90 2 95 3 00 3 05 3 10 3 15 3.20 3 25 3 30 3 35 340 3 45 350

0 .00-0 .04 \ \ 2 .30 2 35 2 40 2 45 2 50 2 55 2 60 265 2 .70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 0 315 3 20 3 25 3.30

~
0 .05-0 .09 230 2 35 2 40 2 45 250 2 55 2 60 2 65 2.70 2 .75 2 80 2 .85 2 90 2 95 300 3 05 3 0 3 5 3 20 3 25 3 30 3 .35

0 .10-0 .14 \ 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 275 2 .80 2 85 290 2 95 300 3 05 310 3 15 3 20 3 25 330 3 35 3 .40

0 .15-0 .19 2 30 2 35 240 2 45 2 50 2 55 2 60 2 65 2 70 2 .75 280 285 2 90 2 .95 3 00 3 05 3 10 3 .15 3 20 3 25 3 30 3 .35 3 .40 3 .45

0 .20-0,30 SPECIFIED CLE/ .RANCE/NO AsJUSTIAENT FEQUIR .D

0 .31 -0.35 2 .40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 290 2 95 300 3 05 3 .10 3 5 3 20 3 25 3 .30 3 35 3 40 3 45 3 .50 3 .50

0 .36-0.40 2.45 2 50 255 2 .60 2 65 2 0 2 75 2 80 285 290 2 .95 300 30.5 3 10 3 .15 3 20 3 25 3 30 3 .35 3 40 3 45 3 50 3 .50

0.41 -0 .45 2 .50 2 55 2 60 2 .65 2 70 2 75 2 80 2 85 290 2 95 3 .00 3 05 3 0 315 3 .20 3 25 3 30 3 35 3.40 34S 3 50 3 50

0.46-0 .50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 300 3 05 3 0 315 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50

0.51-0 .55 260 265 270 275 280 285 290 295 300 305 3 0 315 320 325 330 335 340 345 350 350

056-060
. .2 65 2 70 2 75 2 60 2 85 2 90 2 95 3 00 3 05 3 0 3 5 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50

0 .61-0 .65 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 350

0 .66-0 .70 2 75 2 80 2 85 290 2 95 3 00 3 05 3 10 315 3 20 3 25 3 30 3 35 3 40 3 45 3 50 350

071-075
.2 80 2 85 2 90 2 95 300 3 05 3 10 315 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50

0 .76-0 .80 2 85 2 90 2 95 300 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 350

0 .81 -085 2 90 2 95 3 00 3 05 3 10 315 3 20 3 25 3 .30 3 35 3 40 3 45 3 50 3 .50

0 .86-090 2 95 3 00 3 05 3 0 3 15 3 20 3 25 3 30 3 .35 3 40 3 45 350 3 50

HOW TO USE THIS CHART:
0.91-0.95 300 305 310 3 15 320 325 330 335 340 345 350 350

0.96 1 .00 3 05 3 10 315 3 20 3 25 3 30 3 35 3 40 3 45 3 50 3 50 1 . Measure tappet clearance . "ENGINE IS COLD"

1 .01 -1 .05 3 10 3 15 ' 20 3 25 3 30 3 35 3 40 3 45 350 3 50 11 . Measure present shim size .

III . Match clearance in vertical column with present shim size in horizontal
1 .06-1 .10 3 15 3 20 3 25 330 3 .35 3 40 3 45 3 .50 3.50
column .
1 .11-1 .15 320 325 330 335 340 345 350 3 .50
EXAMPLE
1 .16-1 .20 3 25 3 30 3 35 3 .40 3 .45 3 50 3 50
Tappet clearance is 0 .38 mm
1 .21-1 .25 330 3 35 340 3 45 3 50 3 50 Present shim size 2 .90 mm

1 .26-1 .30 3 35 3 0 3 45 3 50 3 50 Shim size to be used 3 .05 mm

1 .31-1 .35 3 40 3 45 3 50 3 50

1 .36-1 .40 3 45 3 50 3 50

1 .41-1 .45 350 350

I 1 .46-1 .50 3 .50



2- 1 4 PERIODIC MAINTENANCE

FUEL HOSE

Inspect every 6 000 km (4 000 miles, 6 months) .

Replace every 4 years .

Inspect the fuel feed hose OO for damage and fuel leakage . If
any defects are found, the fuel hoses must be replaced .

ENGINE OIL AND OIL FILTER

(ENGINE OIL)
Replace initially at 1 000 km (600 miles, 1 month) and
every 6 000 km (4 000 miles, 6 months) thereafter .

(OIL FILTER)
Replace initially at 1 000 km (600 miles, 1 month) and
every 18 000 km (11 000 miles, 18 months) thereafter .

Oil should be changed while the engine is warm . Oil filter

replacement at the above intervals, should be done together
with the engine oil change . 0
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright .
• Place an oil pan below the engine, and drain oil by removing
the drain plug 10 and filler cap (Z .

• Tighten the drain plug O to the specified torque, and pour

fresh oil through the oil filler . The engine will hold about 2 .7 L
i
0
(2 .9/2 .4 US/Imp qt) of oil . Use an API classification of SF or
SG oil with SAE 1 OW-40 viscosity .

0 Oil drain plug : 23 N .m (2 .3 kgf-m, 16 .5 Ib-ft)



PERIODIC MAINTENANCE 2- 1 5

• Start up the engine and allow it to run for several minutes at

idling speed .
• Turn off the engine and wait about three minutes, then check
the oil level through the inspection window OA . If the level is
below mark "L", add oil to "F" level . If the level is above mark
"F", drain oil to "F" level .

OIL FILTER REPLACEMENT

6 • Remove the under cowling . (r r6-5)
• Drain engine oil in the same manner of engine oil replacement
procedure .
• Remove the oil filter ® by using the oil filter wrench . (Special
tool)
• Apply engine oil lightly to the 0-ring of the new filter before
installation .
• Install the new filter turning it by hand until you feel that the fil-
ter 0-ring contacts the mounting surface . Then tighten it 2
turns using the oil filter wrench .
.. 09915-40610 : Oil filter wrench
NOTE:
To properly tighten the filter, use the special tool . Never tighten
the filter by hand.
• Pour fresh engine oil and check the oil level in the same man-
ner of engine oil replacement procedure .
Engine oil capacity
Oil change : 2 .7 L (2 .9/2 .4 US/Imp qt)
Filter change : 2 .9 L (3 .1/2 .6 US/Imp qt)
Overhaul engine : 3 .3 L (3 .5/2 .9 US/Imp qt)
CAUTION

ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL

FILTER . Other manufacturer's oil filters may differ in
thread specifications (thread diameter and pitch), fil-
tering performance and durability which may lead to
engine damage or oil leaks . Also, do not use a genuine
Suzuki automobile oil filter on this motorcycle .


2- 1 6 PERIODIC MAINTENANCE

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 1 month) and

every 6 000 km (4 000 miles, 6 months) thereafter .

NOTE:
Make this adjustment when the engine is hot .
• Start up the engine and set its idle speed to the specified
i
6
range by turning the throttle stop screw CAC .
Engine idle speed : 1 200 ± 100 r/min
1

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 1 month) and

every 6 000 km (4 000 miles, 6 months) thereafter .

Adjust the throttle cable play W with the following three steps .
MINOR ADJUSTMENT
First step :
• Loosen the lock nut O of the throttle returning cable O and
turn in the adjuster © fully into the threads .
Second step :
• Loosen the lock nut ® of the throttle pulling cable O .
• Turn the adjuster © in or out until the throttle cable play O
0
should be 2 .0 - 4 .0 mm (0 .08 - 0 .16 in) at the throttle grip .
• Tighten the lock nut ® while holding the adjuster © .
Third step :
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster W3 of the throttle returning cable ©
to feel resistance .
• Tighten the lock nut D while holding the adjuster C3 .
Throttle cable play W: 2 .0 - 4 .0 mm (0 .08 - 0 .16 in)
A WARNING

After the adjustment is completed, check that handle-

0
bar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and auto-
matically .

NOTE :
Major adjustment can be made by the throttle body side
adjuster.

PERIODIC MAINTENANCE 2- 1 7

MAJOR ADJUSTMENT
• Lift and support the fuel tank . (L-7- 4-65)
• Remove the air cleaner box . (=4-75)
• Loosen the lock nut 10 of the throttle returning cable .
• Turn the returning cable adjuster 02 to obtain proper cable
play .
S • Loosen the lock nut ® of the throttle pulling cable .
• Turn the pulling cable adjuster ® in or out until the throttle
cable play OA should be 2 .0 - 4 .0 mm (0 .08 - 0 .16 in) at the
throttle grip .
• Tighten the lock nut (2 securely while holding the adjuster 4).
Throttle cable play OA : 2 .0 - 4 .0 mm (0 .08 - 0 .16 in)

• While holding the throttle grip at the fully closed position,

slowly turn the returning cable adjuster (2) to obtain a slack of
1 .0 mm (0 .04 in) .
• Tighten the lock nut O securely .
A WARNING

After the adjustment is completed, check that handle-

bar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and auto-
matically .

THROTTLE VALVE SYNCHRONIZATION

Inspect initially at 1 000 km (600 miles, 1 month) [For
E-33 only] and every 12 000 km (7 500 miles,
12 months) thereafter .

(LY4-88)

EVAPORATIVE EMISSION CONTROL SYS-

TEM (FOR E-33 ONLY)
Inspect every 12 000 km (7 500 miles, 12 months) .
Replace vapor hose every 4 years .

(=9-5)

0)k ~ PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (7 500 miles, 12 months) .

(=9-6)


2- 1 8 PERIODIC MAINTENANCE

CLUTCH
(CLUTCH HOSE AND CLUTCH FLUID)
Inspect every 6 000 km (4 000 miles, 6 months) .
Replace hose every 4 years .
Replace fluid every 2 years .

CLUTCH FLUID LEVEL

is
• Keep the motorcycle upright and place the handlebars
straight .
• Check the clutch fluid level by observing the lower limit line on
the clutch fluid reservoir .
• If the level is found to be lower than the lower mark, replenish
with BRAKE FLUID that meets the following specification .
BF Specification and Classification : DOT 4
A WARNING

The clutch system of this motorcycle is filled with a

glycol-based brake fluid . Do not use or mix different
types of fluid such as silicone-based or petroleum
based . Do not use any brake fluid taken from old, used
or unsealed containers . Never re-use brake fluid left
over from the last servicing or stored for a long peri-
ods . Check the clutch hose and hose joints for cracks
and oil leakage .
0
BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT
The clutch fluid circuit may be purged of air in the following man-
ner .
• Keep the motorcycle upright and place the handlebars
straight .
• Fill up the master cylinder reservoir to the upper end of the
inspection window . Replace the reservoir cap to prevent entry
of dirt .
• Attach a pipe to the bleeder valve and insert the free end of
the pipe into a receptacle .
• Squeeze and release the clutch lever several times in rapid
succession, and squeeze the lever fully without releasing it .
Loosen the bleeder valve by turning it a quarter of a turn so
that the fluid runs into the receptacle ; this will remove the ten-
sion of the clutch lever causing it to touch the handlebar grip .
0
Then, close the valve, pump and squeeze the lever, and open
the valve . Repeat this process until the fluid flowing into the
receptacle no longer contains air bubbles .
• Close the bleeder valve, and disconnect the pipe . Fill the res-
ervoir with brake fluid to the upper end of the inspection win-
0
dow .

0 Air bleeder valve : 5 .4 N .m (0 .54 kgf-m, 4 .0 lb-ft)



PERIODIC MAINTENANCE 2- 1 9

COOLING SYSTEM
Inspect every 6 000 km (4 000 miles, 6 months) .
Replace engine coolant every 2 years .

ENGINE COOLANT LEVEL CHECK

• Keep the motorcycle upright .
• Check the engine coolant level by observing the full and lower
lines on the engine coolant reserve tank .
OO Full line © Lower line
• If the level is below the lower line, add engine coolant to the
full line from the engine coolant reserve tank filler .
NOTE:
To remove the filler cap, lift and support the fuel tank . (C--7-4-65)

ENGINE COOLANT CHANGE

• Remove the front cowling body . (176-5 and -6)
• Remove the radiator cap 90 .
• Drain engine coolant by removing the drain bolt OO .
A WARNING

• Do not open the radiator cap when the engine is hot,

as you may be injured by escaping hot liquid or
vapor .
• Engine coolant may be harmful if swallowed or if it
comes in contact with skin or eyes . If engine coolant
gets into the eyes or in contact with the skin, flush
thoroughly with plenty of water . If swallowed, induce
vomiting and call physician immediately!

0, 'oil
• Flush the radiator with fresh water if necessary .
• Tighten the water drain bolt O to the specified torque .
0 Water drain bolt O : 5 .5 N .m (0 .55 kgf-m, 4 .0 lb-ft)
• Pour the specified engine coolant up to the radiator inlet .
• Bleed the air from the engine coolant circuit as following pro-
cedure .
NOTE:
For engine coolant information, refer to page 5-3.


2 .2 0 PERIODIC MAINTENANCE

AIR BLEEDING FROM THE ENGINE COOLANT CIRCUIT

• Remove the front cowling body . (l"76-5 and -6)
• Bleed air from the air bleeder bolt D .
• Tighten the air bleeder bolt D to the specified torque .

0 Air bleeder bolt : 10 N .m (1 .0 kgf-m, 7 .3 lb-ft)

• Add engine coolant up to the radiator inlet .
• Support the motorcycle upright .

• Lightly tap the thermostat case O2 and slowly swing the motor-
cycle, right and left, to bleed the air trapped in the case O2 .
• Add engine coolant up to the radiator inlet .

• Start up the engine and bleed air from the radiator inlet com-
pletely .
• Add engine coolant up to the radiator inlet .
• Repeat the above procedure until bleed no air from the radia-
tor inlet .

• Close the radiator cap (O securely .

• After warming up and cooling down the engine several times,
add the engine coolant up to the full level of the reserve tank .
CAUTION

Repeat the above procedure several times and make

sure that the radiator is filled with engine coolant up to
the reserve tank full level .

Engine coolant capacity

Reverse tank side : 250 ml (0 .3/0 .2 US/Imp qt)
Engine side : 1 950 ml (2 .1/1 .7 US/Imp qt)
0
0


PERIODIC MAINTENANCE 2- 2 1

RADIATOR HOSES
Check to see the radiator hoses for crack, damage or engine
coolant leakage .
If any defects are found, replace the radiator hoses with new
ones .

DRIVE CHAIN

Inspect initially at 1 000 km (600 miles, 1 month) and

every 6 000 km (4 000 miles, 6 months) thereafter .
Clean and lubricate every 1 000 km (600 miles) .

Visually check the drive chain for the possible defects listed
below . (Support the motorcycle by a jack and a wooden block,
turn the rear wheel slowly by hand with the transmission shifted
to Neutral .)
* Loose pins * Excessive wear
* Damaged rollers * Improper chain adjustment
* Dry or rusted links * Missing 0-ring seals
* Kinked or binding links
If any defects are found, the drive chain must be replaced .
+
44. NOTE:
When replacing the drive chain, replace the drive chain and
sprockets as a set.

Qf CHECKING
410 • Remove the axle cotter pin . (For E-03, 28 and 33 models)
• Loosen the axle nut 90 .
• Loosen the chain adjuster lock nuts C2) .
• Tense the drive chain fully by turning both chain adjusters 03 .


2 .2 2 PERIODIC MAINTENANCE

• Count out 21 pins (20 pitches) on the chain and measure the
distance between the two points . If the distance exceeds the
service limit, the chain must be replaced .
Drive chain 20-pitch length
Service Limit : 319 .4 mm (12 .6 in)

ADJUSTING
• Loosen or tighten both chain adjusters D until the chain has
20 - 30 mm (0 .8 - 1 .2 in) of slack in the middle between
0
engine and rear sprockets . The ends of left and right spacers
must be at the same position on the scales O to ensure that
the front and rear wheels are correctly aligned .
• Place the motorcycle on its side-stand for accurate adjust-
ment .
• After adjusting the drive chain, tighten the axle nut C2C to the
specified torque .
• Recheck the drive chain slack after tightening the axle nut 02 .

• Tighten both chain adjuster lock nuts C1) securely .

Rear axle nut : 100 N .m (10 .0 kgf-m, 72 .5 lb-ft)
[For E-03, 28, 33]
120 N .m (12 .0 kgf-m, 87 .0 lb-ft)
is
[For the others]

PERIODIC MAINTENANCE 2- 23

CLEANING AND LUBRICATING

• Wash the chain with kerosene . If the chain tends to rust
quickly, the intervals must be shortened .

CAUTION

Do not use trichlene, gasoline or any similar fluids :

These fluids have too great a dissolving power for this
k, 40 chain and, what is more important, they can damage
the 0-rings (or seals) confining the grease in the bush
to pin clearance . Remember, high durability comes
from the presence of grease in that clearance .

• After washing and drying the chain, oil it with a heavy-weight

motor oil .

CAUTION

* Do not use any oil sold commercially as "drive chain

oil" . Such oil can damage the 0-rings (or seals) .
* The standard drive chain is RK530SMOZ1 . SUZUKI
recommends that this standard drive chain should
be used for the replacement .

BRAKE
(BRAKE)
Inspect initially at 1 000 km (600 miles, 1 month) and
every 6 000 km (4 000 miles, 6 months) thereafter .

(BRAKE HOSE AND BRAKE FLUID)

Inspect every 6 000 km (4 000 miles, 6 months) .
Replace hoses every 4 years . Replace fluid every 2
years .

rr BRAKE FLUID LEVEL CHECK

• Keep the motorcycle upright and place the handlebars
straight .
• Check the brake fluid level by observing the lower limit lines
on the front and rear brake fluid reservoirs .
• When the level is below the lower limit line, replenish with
brake fluid that meets the following specification .

BF Specification and Classification : DOT 4

IV


2-2 4 PERIODIC MAINTENANCE

A WARNING

* The brake system of this motorcycle is filled with a

t I

glycol-based brake fluid . Do not use or mix different

types of fluid such as silicone-based or petro-
leum-based . Do not use any brake fluid taken from
old, used or unsealed containers . Never re-use brake
11
fluid left over from the last servicing or stored for a
long period .
* 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 . t 1

BRAKE PADS
The extent of brake pad wear can be checked by observing the
grooved limit OO on the pad . When the wear exceeds the
grooved limit, replace the pads with new ones .
(=6-66 and -77)

CAUTION
#1
Replace the brake pad as a set, otherwise braking per-
formance will be adversely affected .

kI
E1
t4


PERIODIC MAINTENANCE 2- 2 5

BRAKE PEDAL HEIGHT

• Loosen the lock nut O and rotate the push rod 02 to locate
brake pedal 55 - 65 mm (2 .17 - 2 .56 in) O below the top face
of the footrest .
• Retighten the lock nut O to secure the push rod 02 in the
proper position .
[', Brake pedal height OO : 55 - 65 mm (2 .17 - 2 .56 in)

0 Rear brake master cylinder rod lock nut 0 :

18 N .m (1 .8 kgf-m, 13 .0 Ib-ft)

40

BRAKE LIGHT SWITCH

Adjust the rear brake light switch so that the brake light will
come on just before pressure is felt when the brake pedal is
I depressed .


2- 26 PERIODIC MAINTENANCE

AIR BLEEDING FROM THE BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a 4' 1
large proportion of the pressure developed by the master cylin-
der and thus interferes with the full braking performance of the
brake caliper . The presence of air is indicated by "sponginess"
of the brake lever and also by lack of braking force . Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake and restor-
ing the brake system to the normal condition, the brake fluid cir-
cuit be purged of air in the following manner :
• Fill up the master cylinder reservoir to the "UPPER" line .
Place the reservoir cap to prevent entry of dirt .
• Attach a pipe to the air bleeder valve, and insert the free end
of the pipe into a receptacle .
© Front air bleeder valve : 7 .5 N .m (0 .75 kgf-m, 5 .5 lb-ft)
Rear air bleeder valve : 6 N-m (0 .6 kgf-m, 4 .4 lb-ft)
• Front brake : Bleed the air from the air bleeder valve .
• Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it .
Loosen the 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 the brake lever causing it to touch the handle-
bar grip . Then, close the valve, pump and squeeze the lever,
and open the valve . Repeat this process until the fluid flowing
into the receptacle no longer contains air bubbles .
NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system . Make sure that there is always some
fluid visible in the reservoir.
• Close the bleeder valve, and disconnect the pipe . Fill the res-
ervoir with brake fluid to the "UPPER" line .
CAUTION

Handle brake fluid with care : the fluid reacts chemi-

cally with paint, plastics, rubber materials and so on .

• The only difference between bleeding the front and rear

brakes is that the rear master cylinder is actuated by a pedal .


PERIODIC MAINTENANCE 2- 2 7

TIRE
1 4

Inspect every 6 000 km (4 000 miles, 6 months) .

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
situation . It is highly recommended to replace a tire when the
remaining depth of tire tread reaches the following specification .
.• 09900-20805 : Tire depth gauge
[ Tire tread depth
Service Limit (FRONT) : 1 .6 mm (0 .06 in)
(REAR) :2 .0 mm (0 .08 in)
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased . Therefore, maintain
the correct tire pressure for good roadability or shorter tire life
will result . Cold inflation tire pressure is as follows .

COLD INFLATION SOLO RIDING DUAL RIDING

TIRE PRESSURE kPa kgf/cm 2 psi kPa kgf/cm 2 psi
FRONT 250 2 .50 36 250 2 .50 36
REAR 250 2 .50 36 290 2 .90 42
CAUTION

The standard tire fitted on this motorcycle is 120/70

ZR1 7M/C (58W) for front and 180/55 ZR17M/C (73W) for
rear . The use of tires other than those specified may
cause instability . It is highly recommended to use a
SUZUKI Genuine Tire .

TIRE TYPE
MICHELIN (FRONT) : PILOT SPORT E
(REAR) : PILOT SPORT L
off
STEERING

Inspect initially at 1 000 km (600 miles, 1 month) and

every 12 000 km (7 500 miles, 12 months) thereafter .

Steering should be adjusted properly for smooth turning of han-

dlebars and safe running . Overtight steering prevents smooth
turning of the handlebars and too loose steering will cause poor
stability . Check that there is no play in the steering stem while
grasping the lower fork tubes by supporting the machine so that
r
the front wheel is off the ground, with the wheel straight ahead,
and pull forward . If play is found, perform steering bearing
adjustment as described in page 6-36 of this manual .


2- 2 8 PERIODIC MAINTENANCE

FRONT FORK

Inspect every 12 000 km (7 500 miles, 12 months) .

Inspect the front forks for oil leakage, scoring or scratches on

the outer surface of the inner tubes . Replace any defective
parts, if necessary . ( f7 6-20)

REAR SUSPENSION

Inspect every 12 000 km (7 500 miles, 12 months) .

Inspect the damper for oil leakage and the spring unit for dam-
age . Check that there is no play in the swingarm assembly .
Replace any defective parts, if necessary . (E T6-51)

EXHAUST PIPE BOLT

Tighten initially at 1 000 km (600 miles, 1 month) and

every 12 000 km (7 500 miles, 12 months) thereafter .

• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque .

0 Muffler mounting bolt and25exhaust pipe bolt OO ©©OO OO : 23 N .m (2 .3 kgf-m, 16 .5 lb-ft)

N .m (2 .5 kgf-m, 18 .0 lb-ft)
Muffler mounting nut O :

99000-32050 : THREAD LOCK "1342"

EXHAUST GAS SEALER : PERMATEX 1372

ITEM N .m kgf-m lb-ft

(&©OOOO® 23 2 .3 16 .5
T) 25 2 .5 18 .0


PERIODIC MAINTENANCE 2-2 9

CHASSIS BOLT AND NUT

40 Tighten initially at 1 000 km (600 miles, 1 month) and
every 6 000 km (4 000 miles, 6 months) thereafter .

Check that all chassis bolts and nuts are tightened to their specified torque . (Refer to page 2-30 for the loca-
tions of the following nuts and bolts on the motorcycle .)

ITEM N .m kgf-m lb-ft

O Steering stem head nut 90 9 .0 65 .0

O Steering stem lock nut 80 8 .0 58 .0

O Front fork upper clamp bolt 23 2 .3 16 .5

® Front fork lower clamp bolt 23 2 .3 16 .5
Front fork cap bolt 23 2 .3 16 .5
© Front axle 100 10 .0 72 .5

O Front axle pinch bolt 23 2 .3 16 .5

® Handlebar clamp bolt 23 2 .3 16 .5

O Front brake master cylinder mounting bolt 10 1 .0 7 .0

1D Front brake caliper mounting bolt 26 2 .6 19 .0
11 Front brake caliper housing bolt 23 2 .3 16 .5
Brake hose union bolt 23 2 .3 16 .5
13 Clutch master cylinder mounting bolt 10 1 .0 7 .0
14 Clutch hose union bolt 23 2 .3 16 .5
15 Air bleeder valve (Clutch) 5 .4 0 .54 4 .0
16 Air bleeder valve (Front) 7 .5 0 .75 5 .5
17 Air bleeder valve (Rear) 6 0 .6 4 .4
18 Brake disc bolt (Front) 23 2 .3 16 .5
19 Brake disc bolt (Rear) 35 3 .5 25 .5
20 Rear brake caliper sliding pin 27 2 .7 20 .0
21 Rear brake caliper mounting bolt 23 2 .3 16 .5
22 Rear brake master cylinder mounting bolt 10 1 .0 7 .0
E3 Rear brake master cylinder rod lock nut 18 1 .8 13 .0
24 Front footrest bracket mounting bolt 23 2 .3 16 .5
25 Front footrest bolt 39 3 .9 28 .0
26 Swingarm pivot nut 100 10 .0 70 .0
27 Swingarm pivot shaft lock nut 90 9 .0 65 .0
28 Swingarm pivot shaft 15 1 .5 11 .0
29 Rear shock absorber mounting nut
5 0 5 .0 36 .0
(Upper & Lower)
I
3D Cushion lever mounting nut 78 7 .8 56 .5
31 Cushion lever rod mounting nut 78 7 .8 56 .5
D Rear axle nut (For E-03, 28, 33) 100 10 .0 72 .5
(For the others) 120 12 .0 87 .0
33 Seat rail bolt 55 5 .5 40 .0
34 Rear sprocket nut 60 6 .0 43 .5
35 Steering damper bolt and nut 23 2 .3 16 .5
2-3 0 PERIODIC MAINTENANCE


PERIODIC MAINTENANCE 2-31

COMPRESSION PRESSURE CHECK

y The compression of a cylinder is a good indicator of its internal condition .
The decision to overhaul the cylinder is often based on the results of a compression test . Periodic mainte-
nance records kept at your dealership should include compression readings for each maintenance service .
COMPRESSION PRESSURE SPECIFICATION (Automatic de-comp . actuated)
Standard Limit Difference
40
1 000 - 1 400 kPa 800 kPa 200 kPa
(10 - 14 kgf/cm 2 , 142 - 199 psi) (8 kgf/cm 2 , 114 psi) (2 kgf/cm 2 , 28 psi)
Low compression pressure can indicate any of the following conditions :
• Worn-down piston or piston rings
,0 * Piston rings stuck in grooves
• Poor seating of valves
• Ruptured or otherwise defective cylinder head gasket
Overhaul the engine in the following cases :
• Compression pressure in one of the cylinders is less than 800 kPa (8 kgf/cm 2 , 114 psi) .
• Difference in compression pressure between two cylinders is more than 200 kPa (2 kgf/cm 2 , 28 psi) .
* All compression pressure are below 1 000 kPa (10 kgf/cm 2 , 142 psi) even when they measure more than
800 kPa (8 kgf/cm 2 , 114 psi) .

COMPRESSION TEST PROCEDURE

NOTE:
• Before testing the engine for compression pressure, make
sure that the cylinder head bolts are tightened to the specified
torque values and valves are properly adjusted .
• Have the engine warmed up by idling before testing.
• Be sure that the battery used is in fully-charged condition.
Remove the parts concerned and test the compression pressure
in the following manner .
• Lift and support the fuel tank . (f74-65)
• Remove the radiator mounting bolts and move the radiator
forward .
• Remove all the spark plugs . ( r-7- 2-6)
• Fit the compression gauge in one of the plug holes, while tak-
ing care of the tight connection .
• Keep the throttle grip in full-open position .
• While cranking the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of
that cylinder .
4 • Repeat this procedure with an other cylinder .
09915-64512 : Compression gauge
09913-10750 : Compression gauge adaptor

40


2- 3 2 PERIODIC MAINTENANCE

OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts . e
OIL PRESSURE SPECIFICATION

Above 350 kPa (3 .5 kgf/cm 2 , 50 psi)

at 3 000 r/min, Oil temp . at 60°C (140°F)
Below 650 kPa (6 .5 kgf/cm 2, 92 psi)

If the oil pressure is lower or higher than the specification, the following causes may be considered .

LOW OIL PRESSURE

• Clogged oil filter
• Oil leakage from the oil passage way I
• Damaged O-ring
• Defective oil pump
• Combination of the above items

HIGH OIL PRESSURE

• Used of high viscosity engine oil
• Clogged oil passage way
• Combination of the above items

OIL PRESSURE TEST PROCEDURE

Start the engine and check if the oil pressure indicator light is
turned on . If it keeps on lighting, check the oil pressure indicator
light circuit . If it is in good condition, check the oil pressure in the
following manner .
• Remove the under cowling . ( r-76-5)
• Remove the main oil gallery plug 90 .
• Install the oil pressure gauge with attachment in the position
shown in the photo .

• Warm up the engine as follows :

Summer 10 min at 2 000 r/min
Winter 20 min at 2 000 r/min
• After warming up, increase the engine speed to 3 000 r/min
(with the engine tachometer), and read the oil pressure
gauge .
l1
.. 09915-72410 : Oil pressure gauge attachment
09915-74521 : Oil pressure gauge hose
09915-74532 : Oil pressure gauge attachment
09915-77331 : Meter (for high pressure)
k 4

Oil gallery plug [M 8] :18 N .m (1 .8 kgf-m, 13 .0 lb-ft)

I t 4