(TM) Suzuki Manual de Taller Suzuki Gsx150 2015 en Ingles

IMPORTANT NOTICE
WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.
! WARNING
Indicates a potential hazard that could result in death or serious injury.
! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.
NOTICE
Indicates a potential hazard that could result in motorcycle or equipment damage.
NOTE
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all poten-
tial hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS, CAU-
TIONS and NOTICES stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
FOREWORD
This manual contains an introductory description on the SUZUKI GSX150 and procedures for its inspection/ser-
vice and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
Use this section as well as other sections to use as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable
service.
* This manual has been prepared on the basis of the latest 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 motorcycle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They
may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for
servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
! WARNING
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the
rider and passenger.
SUZUKI MOTORCYCLE INDIA PRIVATE LIMITED

© SUZUKI MOTORCYCLE INDIA PRIVATE LIMITED
Applicable Model / VIN
Applicable model
GSX150 L5 (2015)
Applicable VIN
Applicable Model VIN Number Country or Area
GSX150L5 MB8NG4BA8100001 – India
00
TABLE OF CONTENTS
Precautions............................................................... 00-i Driveline / Axle............................................................ 3-i

Precautions ............................................................ 00-1 Precautions .............................................................. 3-1 1
Drive Chain / Drive Train / Drive Shaft ...................3A-1
General Information ................................................... 0-i
General Information ............................................... 0A-1 Brakes ......................................................................... 4-i
Maintenance and Lubrication ................................. 0B-1 Precautions .............................................................. 4-1
Service Data...........................................................0C-1 Brake Control System and Diagnosis ....................4A-1 2
Front Brakes...........................................................4B-1
Engine ......................................................................... 1-i Rear Brakes ...........................................................4C-1
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1 Transmission / Transaxle .......................................... 5-i
Emission Control Devices ...................................... 1B-1 Precautions .............................................................. 5-1 3
Engine Electrical Devices.......................................1C-1 Manual Transmission .............................................5B-1
Engine Mechanical.................................................1D-1 Clutch .....................................................................5C-1
Engine Lubrication System .................................... 1E-1
Steering ....................................................................... 6-i
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1 Precautions .............................................................. 6-1 4
Starting System....................................................... 1I-1 Steering General Diagnosis ...................................6A-1
Charging System.....................................................1J-1 Steering / Handlebar ..............................................6B-1
Exhaust System ..................................................... 1K-1 Body and Accessories............................................... 9-i
Suspension................................................................. 2-i Precautions .............................................................. 9-1 5
Precautions .............................................................. 2-1 Wiring Systems ......................................................9A-1
Suspension General Diagnosis.............................. 2A-1 Lighting Systems ....................................................9B-1
Front Suspension ................................................... 2B-1 Combination Meter / Fuel Meter / Horn ..................9C-1
Rear Suspension....................................................2C-1 Exterior Parts .........................................................9D-1
Wheels and Tires ...................................................2D-1 Body Structure .......................................................9E-1 6
9
Table of Contents 00- i
Section 00
00
Precautions
CONTENTS
Precautions ...............................................00-1 Precautions for Electrical Circuit Service ............ 00-2

Precautions........................................................... 00-1 Precautions for Circuit Tester.............................. 00-6
General Precautions ........................................... 00-1
00-1 Precautions:
Precautions
Precautions
Precautions
General Precautions • When performing service to electrical
BENF34J10000001 parts, if the service procedures do not
! WARNING require use of battery power, disconnect
the negative (–) cable from the battery.
• Proper service and repair procedures are
• When tightening the cylinder head or case
important for the safety of the service
bolts and nuts, tighten the larger sizes
mechanic and the safety and reliability of
first. Always tighten the bolts and nuts
the motorcycle.
diagonally from the inside toward outside
• When 2 or more persons work together, and to the specified tightening torque.
pay attention to the safety of each other.
• Whenever you remove oil seals, gaskets,
• When it is necessary to run the engine packing, O-rings, locking washers, self-
indoors, make sure that exhaust gas is locking nuts, cotter pins, circlips and
forced outdoors. certain other parts as specified, be sure to
• When working with toxic or flammable replace them with new ones. Also, before
materials, make sure that the area you installing these new parts, be sure to
work in is well ventilated and that you remove any left over material from the
follow all of the material manufacturer’s mating surfaces.
instructions. • Never reuse a circlip. When installing a
• To avoid getting burned, do not touch the new circlip, take care not to expand the
engine, engine oil, radiator and exhaust end gap larger than required to slip the
system until they have cooled. circlip over the shaft. After installing a
circlip, always ensure that it is completely
NOTICE seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners
• Never use gasoline as a cleaning solvent.
to the specified torque. Wipe off grease
• After servicing the fuel, oil, water, exhaust and oil if a thread is smeared with them.
or brake systems, check all lines and
• After reassembling, check parts for
fittings related to the system for leaks.
tightness and proper operation.
• If parts replacement is necessary, replace
• To protect the environment, do not
the parts with Suzuki Genuine Parts or
unlawfully dispose of used motor oil,
their equivalent.
engine coolant and other fluids: batteries,
• When removing parts that are to be reused, and tires.
keep them arranged in an orderly manner
• To protect Earth’s natural resources,
so that they may be reinstalled in the
properly dispose of used motorcycle and
proper order and orientation.
parts.
• Be sure to use special tools when
instructed.
• Make sure that all parts used in
reassembly are clean. Lubricate them
when specified.
• Use the specified lubricant, bond, or
sealant.
• When removing the battery, disconnect the
negative (–) cable first and then the
positive (+) cable.
• When reconnecting the battery, connect
the positive (+) cable first and then the
negative (–) cable, and replace the terminal
cover on the positive (+) terminal.
Precautions: 00-2
Precautions for Electrical Circuit Service • Inspect each lead wire circuit for poor connection by
BENF34J10000002 shaking it by hand lightly. If any abnormal condition is
When handling the electrical parts, observe the following found, repair or replace.
points for the safety of the system.
Electrical Parts
Connector / Coupler
• Faulty electrical system is often related to poor
electrical contact of connector/coupler. Before
servicing individual electronic part, check electrical
contact of the connector/coupler.
• When connecting a connector, be sure to push it in
until a click is felt.
I310G1000003-02
• When taking measurements at electrical connector /

coupler (1) using a tester probe (2), be sure to insert
the probe from the wire harness side (rear) of the
connector / coupler.
I310G1000001-01
• With a lock type coupler, be sure to release the lock

when disconnecting, and push it in fully to engage the
lock when connecting. 1
• When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires.
IF34J1000001-01
• Inspect each terminal on the connector/coupler for
• When connecting meter probe (2) from the terminal
looseness or bending.
side of the coupler (1) because it cannot be connected
• Push in the coupler straightly. An angled or skewed from harness side, use extra care not to bend the
insertion may cause the terminal to be deformed, male terminal of coupler of force its female terminal
possibly resulting in poor electrical contact. open for connection.
• Inspect each terminal for corrosion and In case of such coupler as shown connect probe as
contamination. The terminals must be clean and free shown to avoid opening female terminal.
of any foreign material which could impede proper Never connect probe where male terminal is
terminal contact. supposed to fit.
• Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.
ID26J1000014-01
• Avoid applying grease or other similar material to

connector/coupler terminals to prevent electric
trouble.
I310G1000002-01
00-3 Precautions:
Clamp • Be careful not to touch the electrical terminals of the

• Clamp the wire harness at such positions as indicated electronic parts (CDI unit, etc.). The static electricity
in “Wiring Harness Routing Diagram” in Section 9A from your body may damage them.
(Page 9A-5).
• 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.
[A] [B]
I310G1000008-01
• When disconnecting and connecting the coupler,

make sure to turn OFF the ignition switch (1), or
electronic parts may get damaged.
IE02K1000002-01
[A]: Correct clamping [B]: Incorrect clamping

1
Fuse
• When a fuse is blown, 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.
IF34J1000002-01
Battery
• Select the same type MF battery when replacing the
battery.
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
I649G1000001-02
components of the electrical systems instantly when
reverse power is applied.
Switch
Never apply grease material to switch contact points to
prevent damage.
CDI unit / Various sensors

• Since each component is a high-precision part, great
care should be taken not to apply any severe impacts
during removal and installation.
I718H1000004-01
I310G1000007-01
Precautions: 00-4
• Removing any battery terminal of a running engine is Open circuit check

strictly prohibited. The moment such removal is made, Possible causes for the open circuit are as follows. As
damaging counter electromotive force will be applied the cause can exist in the connector/coupler or terminal,
to the electronic unit which may result in serious they need to be checked carefully.
damage. • Loose connection of connector/coupler
• Poor contact 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 CDI unit, 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 at both ends of the
I310G1000011-01 circuit being checked for loose connection. Also
• Before measuring voltage at each terminal, check to check for condition of the coupler lock if equipped.
make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis. [A]
[A]
2
1
IE02K1000004-01
[A]: Check for loose connection

1. Sensor
I310G1000012-02
2. CDI unit
• Never connect any tester (voltmeter, ohmmeter, or
whatever) to the electronic unit when its coupler is 3) Using a test male terminal, check the female
disconnected. Otherwise, damage to electronic unit terminals of the circuit being checked for contact
may result. tension.
• Never connect an ohmmeter to the CDI unit with its Check each terminal visually for poor contact
coupler connected. If attempted, damage to CDI unit (possibly caused by dirt, corrosion, rust, entry of
or sensors may result. foreign object, etc.). At the same time, check to
• Be sure to use a specified voltmeter/ohmmeter. make sure that each terminal is fully inserted in the
Otherwise, accurate measurements may not be coupler and locked.
obtained and personal injury may result. If contact tension is not enough, rectify the contact to
increase tension or replace. The terminals must be
Electrical Circuit Inspection Procedure clean and free of any foreign material which could
While there are various methods for electrical circuit impede proper terminal contact.
inspection, described here is a general method to check
for open and short circuit using an ohmmeter and a
voltmeter.
[A]
[B]
IE02K1000005-01
[A]: Check contact tension by inserting and removing.

[B]: Check each terminal for bend and proper alignment.
00-5 Precautions:
4) Using continuity inspect or voltage check procedure Voltage check

as described below, inspect the wire harness If voltage is supplied to the circuit being checked, voltage
terminals for open circuit and poor connection. check can be used as circuit check.
Locate abnormality, if any. 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] [C]
[A] and body ground: 0 V
[B] and body ground: Approx. 5 V
[B] [C] and body ground: Approx. 5 V
IE02K1000006-01
[A]: Looseness of crimping 3) Also, if measured values are as listed following, a

[B]: Open resistance (abnormality) exists which causes the
[C]: Thin wire (A few strands left) voltage drop in the circuit between terminals [A] and
[B].
Continuity check
Voltage between
1) Measure resistance across coupler [B] (between [A] [A] and body ground: 3 V – 2 V voltage drop
and [C] in the figure). [B] and body ground: Approx. 5 V
If no continuity is indicated (infinity or over limit), the [C] and body ground: Approx. 5 V
circuit is open between terminals [A] and [C].
[A]
[A]
[B]
1
[B]
[C]
[C]
IE02K1000007-01
1. CDI unit
2) Disconnect the coupler [B] and measure resistance

between couplers [A] and [B-1].
If no continuity is indicated, the circuit is open
between couplers [A] and [B-1]. If continuity is
indicated, there is an open circuit between couplers
[B-2] and [C] or an abnormality in coupler [B-2] or
[A] [B] [C]
coupler [C].
IE02K1000009-01
[A]
[B-2] Short circuit check (Wire harness to ground)

1) Disconnect the negative (–) cable from the battery.
1
2) Disconnect the connectors/couplers at both ends of
the circuit to be checked.
[B] [C] NOTE

[B-1] If the circuit to be checked branches to other
parts as shown, disconnect all connectors/
IE02K1000008-01 couplers of those parts. Otherwise, diagnosis
1. CDI unit will be wrong.
Precautions: 00-6
3) Measure resistance between terminal at one end of Precautions for Circuit Tester
circuit ([A] terminal in the figure) and body ground. If BENF34J10000003
continuity is indicated, there is a short circuit to • Use the Suzuki multi circuit tester set.
ground between terminals [A] and [C]. Special tool
(A): Multi Circuit Tester
[A]
• The following items are included in the special tool.
[D] – Multi circuit tester body
[B]
– Tachometer sensor
– Test leads
– Peak voltage adapter
[C]
– Case
– Instruction Manual
• Read the instruction manual to use the tester
correctly.
[E] • Be sure to set the tester to the correct testing range.
• If the voltage and current are not known, make
measurements using the highest range.
Symbols
Symbol Definition
DC
[A] [C]
AC
Resistance
IE02K1000010-01
Continuity
Diode
[D]: To other parts [E]: Other parts
Functions
4) Disconnect the connector/coupler included in circuit
/ /
(coupler [B]) and measure resistance between Function switch
key switch (6)
terminal [A] and body ground. If continuity is
Voltage
indicated, the circuit is shorted to the ground (1) Select or .
measurement
between terminals [A] and [B].
(2) or (3),
Current
whichever Select or .
[A] measurement
appropriate.
[D] Resistance
(4) —
measurement
Continuity test (5) Select .
Diode test (5) Select .
[B]
[C]
(A)
6
IE02K1000011-01
3
[D]: To other parts
2 4
5
1
ID26J1000011-01
00-7 Precautions:
Using Needle Pointed Prove
NOTICE
• When using the multi circuit tester, do not
strongly touch the terminal of the CDI unit
coupler with a needle pointed tester probe
to prevent the terminal damage or terminal
bend.
• 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.
Section 0
General Information
0
CONTENTS
General Information ................................ 0A-1 Throttle Cable Play Inspection and

General Description .............................................0A-1 Adjustment ........................................................0B-2
Abbreviations ...................................................... 0A-1 Idle Speed Inspection..........................................0B-2
Symbols .............................................................. 0A-2 PAIR System Inspection .....................................0B-2
Wire Color Symbols ............................................ 0A-3 Clutch Cable Play Inspection and Adjustment ....0B-2
Vehicle Side View ............................................... 0A-3 Drive Chain Inspection and Adjustment ..............0B-2
Vehicle Identification Number ............................. 0A-3 Drive Chain Cleaning and Lubricating.................0B-2
Country and Area Codes .................................... 0A-4 Brake System Inspection ....................................0B-2
Warning, Caution and Information Labels Brake Hose Inspection ........................................0B-2
Location ............................................................ 0A-4 Brake Hose Replacement ...................................0B-2
Component Location ...........................................0A-5 Brake Fluid Inspection.........................................0B-3
Electrical Components Location ......................... 0A-5 Brake Fluid Replacement....................................0B-3
Tire Inspection.....................................................0B-3
Maintenance and Lubrication................. 0B-1 Steering System Inspection ................................0B-3
Front Fork Inspection ..........................................0B-3
Precautions...........................................................0B-1
Rear Suspension Inspection ...............................0B-3
Precautions for Maintenance .............................. 0B-1
Chassis Bolts and Nuts Inspection......................0B-3
Scheduled Maintenance ......................................0B-1
Lubrication Points................................................0B-4
Periodic Maintenance Schedule Chart................ 0B-1
Special Tools and Equipment .............................0B-5
Repair Instructions ..............................................0B-2
Recommended Service Material .........................0B-5
Air Cleaner Element Replacement...................... 0B-2
Air Cleaner Element Inspection and Cleaning .... 0B-2 Service Data ............................................. 0C-1
Exhaust Pipe Bolt and Muffler Mounting Bolt
Precautions...........................................................0C-1
Inspection.......................................................... 0B-2
Precautions for Service Data ..............................0C-1
Valve Clearance Inspection and Adjustment ...... 0B-2
Specifications .......................................................0C-1
Spark Plug Replacement .................................... 0B-2
Specifications ......................................................0C-1
Spark Plug Inspection and Cleaning ................... 0B-2
Service Data........................................................0C-3
Fuel Hose Inspection .......................................... 0B-2
Fasteners Information .........................................0C-8
Fuel Filter Replacement ...................................... 0B-2
Fuel Filter Inspection........................................... 0B-2 Special Tools and Equipment ...........................0C-10
Engine Oil Filter Replacement ............................ 0B-2 Fuel / Oil / Fluid Recommendation....................0C-10
Engine Oil Replacement ..................................... 0B-2 Special Tool ......................................................0C-11
0A-1 General Information:
General Information
General Information
General Description
Abbreviations HO2S. Heated Oxygen Sensor
BENF34J10101001
HU. Hydraulic Unit
A. I.
AAT. Ambient Air Temperature IAP. Intake Air Pressure
ABDC. After Bottom Dead Center IAPS. Intake Air Pressure Sensor
ABS. Anti-lock Brake System IAT. Intake Air Temperature
AC. Alternating Current IATS. Intake Air Temperature Sensor
ACL. Air Cleaner I.D.. Inside Diameter
AKI. Anti-knock index IG. Ignition
AP. Atmospheric Pressure IN.. Intake
API. American Petroleum Institute ISC. Idle Speed Control
APS. Atmospheric Pressure Sensor ISCV. Idle Speed Control Valve
ATDC. After Top Dead Center J.
A/F. Air Fuel Mixture JASO. Japanese Automobile Standards Organization
B. L.
BBDC. Before Bottom Dead Center LCD. Liquid Crystal Display
BTDC. Before Top Dead Center LED. Light Emitting Diode
B+. Battery Positive Voltage LH. Left Hand
C. LO. Low
CDI. Capacitive Discharge Ignition M.
CKP. Crankshaft Position Max. Maximum
CKPS. Crankshaft Position Sensor MIL. Malfunction Indicator Lamp
CKT. Circuit Min.. Minimum
CLP. Clutch Lever Position MTBE. Methyl Tertiary Butyl Ether
CMP. Camshaft Position N.
CMPS. Camshaft Position Sensor NOx. Nitrogen Oxides
CO. Carbon Monoxide O.
CPU. Central Processing Unit OHC. Over Head Camshaft
CVT. Continuously Variable Transmission O.D.. Outside Diameter
D. OPS. Oil Pressure Switch
DC. Direct Current P.
DOHC. Double Over Head Camshaft PAIR. Pulsed Secondary Air Injection
DRL. Daytime Running Light PCV. Positive Crankcase Ventilation
DTC. Diagnostic Trouble code PP. Pulley Position
E. R.
ECM. Engine Control Module RH. Right Hand
ECT. Engine Coolant Temperature ROM. Read Only Memory
ECTS. Engine Coolant Temperature Sensor RON. Research Octane Number
EVAP. Evaporative Emission RPM. Engine speed
EX.. Exhaust S.
EXCV. Exhaust control valve SAE. Society of Automotive Engineers
EXCVA. Exhaust control valve actuator SDS. Suzuki Diagnosis System
F. SRAD. Suzuki Ram Air Direct
FI. Fuel Injection, Fuel Injector STCS. Secondary Throttle Control System
FP. Fuel pump STD. Standard
FPR. Fuel Pressure Regulator STP. Secondary Throttle Position
FTPC. Fuel Tank Pressure Control STPS. Secondary Throttle Position Sensor
FWD. Forward STV. Secondary Throttle Valve
G. STVA. Secondary Throttle Valve Actuator
GEN. Generator T.
GND. Ground TC. Traction control
GP. Gear Position TDC. Top Dead Center
H. TO. Tip-over
HC. Hydrocarbons TOS. Tip-over Sensor
HI. High TP. Throttle Position
HO2. Heated Oxygen TPS. Throttle Position Sensor
General Information: 0A-2
Symbols
BENF34J10101002
Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.
Symbol Definition
Torque control required.
Data beside it indicate specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1).
Apply SUZUKI SUPER GREASE A.
99000-25011
Apply SUZUKI MOLYBDENUM GREASE L.
99000-25280
Apply SUZUKI MOLY PASTE.
99000-25140
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply SUZUKI WATER RESISTANT GREASE EP2.
99000-25350
Apply SUZUKI BOND 1207B.
99000-31140
Apply SUZUKI BOND 1215.
99000-31110
Apply THREAD LOCK CEMENT 1322D.
99000-32150
Apply THREAD LOCK CEMENT.
LOCTITE ***
Use SUZUKI SUPER LONG LIFE COOLANT (BLUE).
99000-99032-20X
Use SUZUKI LONG LIFE COOLANT (GREEN).
99000-99032-12X
Use ENDURANCE FORK OIL TYPE 1F or equivalent.
Apply or use brake fluid.
Use special tool.
Do not reuse.
Note on reassembly.
Wire Color Symbols

BENF34J10101003
Symbol Wire Color Symbol Wire Color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dbr Dark brown R Red
Dg Dark green V Violet
G Green W White
Gr Gray Y Yellow
Lbl Light blue
There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored
(striped) wire. The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses two color
symbols (i.e. G/Y). The first symbol represents the base color of the wire and the second symbol represents the color
of the stripe.
ID26J1010224-02
1. G (Base color) 3. G (Base Color)

2. Y (Stripe color)
Vehicle Side View Vehicle Identification Number

BENF34J10101004 BENF34J10101005
SUZUKI GSX150 (2015-model) The frame serial number or V.I.N. (Vehicle Identification
Number) is stamped on the right side of the frame down
tube (1). The engine serial number is located on the left
side of the crankcase (2).
IF34J1010001-02
1
IF34J1010002-01
IF34J1010003-02
Country and Area Codes

BENF34J10101006
The following code stand for the applicable country and area.
Code Country or Area
P74 India
Warning, Caution and Information Labels Location

BENF34J10101007
[A] [B]
1
2
IF34J1010004-01
[A]: Fuel tank cover 1. General warning label

[B]: Swingarm 2. Tire information label
Component Location
Electrical Components Location
BENF34J10103001
1 2
IF34J1010006-02
1. Fuel level gauge 3. Front brake light switch 5. Horn

2. Ignition coil 4. Rear brake light switch 6. Starter motor
1 2
5 11
3 7
4
8
6
9 10
IF34J1010005-02
1. Turn signal relay 4. Generator 7. Regulator/rectifier 10. Main fuse

2. CDI unit 5. Speed sensor 8. TP sensor 11. Battery
3. CKP sensor 6. GP switch 9. Starter relay
0B-1 Maintenance and Lubrication:
Maintenance and Lubrication

General Information
Precautions
Precautions for Maintenance
BENF34J10200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed
in terms of kilometers and months for your convenience.
NOTE
More frequent servicing may be required on motorcycles that are used under severe conditions.
Maintenance Chart
Periodic Maintenance Schedule Chart
Interval: This interval should be judged by odometer reading or days, whichever comes first.
PAIR (air supply) System
NOTE:
I = Inspect
A = Adjust
R = Replace
T = Tighten
C = Clean
G = Repack Grease
L = Lubricate
Maintenance and Lubrication: 0B-2
Repair Instructions
Air Cleaner Element Replacement Idle Speed Inspection
BENF34J10206001 BENF34J10206012
Refer to “Air Cleaner Element Removal and Installation” Refer to “Engine Idle Speed Inspection and Adjustment”
in Section 1D (Page 1D-6). in Section 1G (Page 1G-10).
Air Cleaner Element Inspection and Cleaning PAIR System Inspection

BENF34J10206002 BENF34J10206040
Refer to “Air Cleaner Element Inspection and Cleaning” Refer to “PAIR System Hose Inspection” in Section 1B
in Section 1D (Page 1D-6). (Page 1B-3).
Exhaust Pipe Bolt and Muffler Mounting Bolt Clutch Cable Play Inspection and Adjustment
BENF34J10206041
Inspection Refer to “Clutch Cable Play On-Vehicle Inspection and
BENF34J10206003
Refer to “Exhaust System Inspection” in Section 1K Adjustment” in Section 5C (Page 5C-2).
(Page 1K-3).
Drive Chain Inspection and Adjustment
BENF34J10206024
Valve Clearance Inspection and Adjustment Refer to “Drive Chain Inspection and Adjustment” in
BENF34J10206005
Refer to “Valve Clearance Inspection and Adjustment” in Section 3A (Page 3A-2).
Section 1D (Page 1D-10).
Drive Chain Cleaning and Lubricating
BENF34J10206025
Spark Plug Replacement Refer to “Drive Chain Cleaning and Lubricating” in
BENF34J10206006
Refer to “Spark Plug Removal and Installation” in Section 3A (Page 3A-3).
Section 1H (Page 1H-3).
Brake System Inspection
BENF34J10206026
Spark Plug Inspection and Cleaning Front Brake Pad
BENF34J10206007
Refer to “Spark Plug Inspection and Cleaning” in Section Refer to “Front Brake Pad Inspection” in Section 4B
1H (Page 1H-4). (Page 4B-1).
Fuel Hose Inspection Front Brake Disc

BENF34J10206008 Refer to “Front Brake Disc Inspection” in Section 4B
Refer to “Fuel Hose Inspection” in Section 1G (Page 1G- (Page 4B-7).
3).
Rear Brake Shoe
Fuel Filter Replacement Refer to “Rear Brake Shoe Wear Inspection” in Section
BENF34J10206009 4C (Page 4C-1).
Refer to “Fuel Valve Removal and Installation” in Section
1G (Page 1G-5).
Brake Light Switch
• Front: )(Page 4A-3)
Fuel Filter Inspection
BENF34J10206037 • Rear: )(Page 4A-4)
Refer to “Fuel Filter Inspection and Cleaning” in Section
1G (Page 1G-6). Rear Brake Pedal
Refer to “Brake Pedal Free Travel Inspection and
Engine Oil Filter Replacement Adjustment” in Section 4A (Page 4A-5).
BENF34J10206038
Refer to “Oil Filter Replacement” in Section 1E (Page
1E-5). Brake Hose Inspection
BENF34J10206027
Refer to “Brake Hose Inspection” in Section 4A (Page
Engine Oil Replacement 4A-5).
BENF34J10206010
Refer to “Engine Oil Replacement” in Section 1E (Page
1E-4). Brake Hose Replacement
BENF34J10206028
Refer to “Front Brake Hose Removal and Installation” in
Throttle Cable Play Inspection and Adjustment Section 4A (Page 4A-7).
BENF34J10206039
Refer to “Throttle Cable Play On-Vehicle Inspection and
Adjustment” in Section 1D (Page 1D-8).
Brake Fluid Inspection Steering System Inspection

BENF34J10206029 BENF34J10206032
Refer to “Brake Fluid Level Check” in Section 4A (Page Refer to “Steering On-Vehicle Inspection” in Section 6B
4A-4). (Page 6B-7).
Brake Fluid Replacement Front Fork Inspection

BENF34J10206030 BENF34J10206033
Refer to “Brake Fluid Replacement” in Section 4A (Page Refer to “Front Fork On-Vehicle Inspection” in Section
4A-6). 2B (Page 2B-2).
Tire Inspection Rear Suspension Inspection

BENF34J10206031 BENF34J10206034
Refer to “Tire Inspection and Cleaning” in Section 2D Refer to “Rear Suspension On-vehicle Inspection” in
(Page 2D-9). Section 2C (Page 2C-2).
Chassis Bolts and Nuts Inspection

BENF34J10206035
Check that all chassis bolts and nuts are tightened to their specified torque.
1 (a) 1 (a)
2 (a)
3 (b)
4 (c)
7 (e) 8 (f) 10 (g)
9 (a)
5 (d)
9 (a)
6 (a)
12 (h)
11 (a)
11 (a)
IF34J1020001-03
1. Handlebar clamp bolt 8. Brake caliper mounting bolt (c): 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
2. Front fork upper clamp bolt 9. Brake hose union bolt (d): 44 Nm (4.5 kgf-m, 32.5 lbf-ft)
3. Steering stem head nut 10. Front brake master cylinder mounting bolt (e): 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
4. Front fork lower clamp bolt 11. Front footrest bracket bolt (f): 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
5. Front axle nut 12. Swingarm pivot nut (g): 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
6. Brake disc bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft) (h): 58 Nm (5.9 kgf-m, 43.0 lbf-ft)
7. Brake air bleeder valve (b): 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
Maintenance and Lubrication: 0B-4
4 (c)
3 (a)
1 (a)
2 (b) 5 (d) 6 (d)
IF34J1020002-02
1. Rear shock absorber upper mounting bolt 5. Torque link nut (rear) (c): 7 Nm (0.71 kgf-m, 5.5 lbf-ft)
2. Rear shock absorber lower mounting nut 6. Torque link nut (front) (d): 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
3. Rear axle nut (a): 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
4. Brake cam lever nut (b): 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
Lubrication Points
BENF34J10206036
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated as follows.
NOTE
• 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.
1 2 8 7
3 3
10
6 5 4 9
IF34J1020003-02
1. Clutch lever holder 6. Side-stand pivot and spring hook : Apply oil.
2. Starter cable 7. Brake lever holder : Apply grease.

3. Pillion footrest 8. Throttle cable : Apply silicone grease.
4. Drive chain 9. Brake pedal pivot
5. Gearshift lever pivot 10. Center stand pivot and spring hook
Special Tools and Equipment

Recommended Service Material
BENF34J10208001
NOTE
Required service materials are also described in:
“Lubrication Points” (Page 0B-4)
Service Data: 0C-1
Service Data
General Information
Precautions
Precautions for Service Data
BENF34J10300001
NOTE
Specifications and service data are subject to change without notice.
Specifications
Specifications
BENF34J10307001
Dimensions and curb mass

Item Specification Remark
Overall length 2050 mm (80.71 in) —
Overall width 785 mm (30.91 in) —
Overall height 1030 mm (40.55 in) —
Wheelbase 1330 mm (52.36 in) —
Curb mass 135 kg (297.6 lb) —
Engine
Type Four-stroke, air-cooled, OHC —
Number of cylinders 1 —
Bore 56.0 mm (2.205 in) —
Stroke 62.9 mm (2.476 in) —
Displacement 154.9 cm3 (9.45 cu. in) —
Compression ratio 9.8 : 1 —
Carburetor UCAL UCD29-9, single —
Air cleaner Non-woven fabric element —
Starter system Kick and electric —
Lubrication system Wet sump —
Drive train
Clutch Wet multi-plate type —
Transmission 5-speed constant mesh —
Gearshift pattern 1-down, 4-up —
Primary reduction ratio 3.181 (70/22) —
Low 2.750 (33/12) —
2nd 1.750 (28/16) —
Gear ratios 3rd 1.300 (26/20) —
4th 1.045 (23/22) —
Top 0.875 (21/24) —
Final reduction ratio 3.000 (45/15) —
Drive chain LGB R428NOR, 132 links —
0C-2 Service Data:
Chassis
Front suspension Telescopic, coil spring, oil damped —
Rear suspension Swingarm type, coil spring, oil damped, spring preload —
Front fork stroke 120 mm (4.72 in) —
Rear wheel travel 129 mm (5.08 in) —
Steering angle 43° 30’ (right & left) —
Caster 27° —
Front brake Disc brake —
Rear brake Drum brake —
Front tire size 100/80-17M/C 52P, tubeless —
Rear tire size 140/60R17M/C 63P, tubeless —
Electrical
Item
Specification Remark
Ignition type Electronic ignition (CDI) —
NGK CPR7EA-9
Spark plug DENSO U22EPR9 —
CHAMPION RG8YC
Battery 12 V 10.8 kC (3.0 Ah)/10HR —
Generator Single-phase A.C. generator —
Main fuse 15 A —
Headlight 12 V 35/35 W —
Position light 12 V 5 W —
Brake light/Tail light LED —
Turn signal light 12 V 10 W —
License plate light 12 V 5 W —
Tachometer light LED —
Speedometer light LED —
Turn signal indicator light LED —
Neutral indicator light LED —
High beam indicator light LED —
Engine RPM indicator light LED —
Capacities
Including reserve 12.0 L (3.17 US gal, 2.64 Imp gal) —
Fuel tank
Reserve 2.4 L (2.54 US qt, 2.11 Imp qt) —
Oil change 850 ml (0.90 US qt, 0.75 Imp qt) —
Engine oil With filter change 950 ml (1.00 US qt, 0.84 Imp qt) —
Overhaul 1100 ml (1.16 US qt, 0.97 Imp qt) —
Service Data: 0C-3
Service Data
BENF34J10307002
Engine Electrical Devices
Item Standard / Specification Limit / Note
TP sensor power supply voltage 4.5 – 5.5 V —
0.65 – 0.75 V Closed
TP sensor output voltage
4.5 V Opened
CKP sensor peak voltage 1.2 V or more When cranking
CKP sensor resistance 95 – 150 —
Engine Mechanical
Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) —
900 – 1300 kPa (9.2 – 13.3 kgf/cm2, 130 – 188 500 kPa (5.1 kgf/cm2,
Compression pressure
psi) 72.5 psi)
33.51 – 33.61 mm
Cam height IN.&EX. 33.21 mm (1.307 in)
(1.319 – 1.323 in)
9.003 – 9.018 mm
Rocker arm I.D. IN.&EX. —
(0.3544 – 0.3550 in)
8.981 – 8.990 mm
Rocker arm shaft O.D. IN.&EX. —
(0.3536 – 0.3539 in)
0.04 – 0.08 mm (0.0016
Intake
– 0.0031 in)
Valve clearance (When engine is cold) —
0.12 – 0.16 mm (0.0047
Exhaust
– 0.0063 in)
Intake 29 mm (1.14 in) —
Valve diam.
Exhaust 23 mm (0.91 in) —
Valve stem runout IN.&EX. — 0.05 mm (0.002 in)
Valve head radial runout IN.&EX. — 0.03 mm (0.001 in)
Valve head thickness IN.&EX. — 0.5 mm (0.02 in)
Valve stem deflection IN.&EX. — 0.35 mm (0.014 in)
4.975 – 4.990 mm
Intake —
(0.1959 – 0.1965 in)
Valve stem O.D.
4.955 – 4.970 mm
Exhaust —
(0.1951 – 0.1957 in)
Valve stem end length IN.&EX. — 2.5 mm (0.099 in)
0.9 – 1.1 mm (0.035 –
Valve seat width IN.&EX. —
0.043 in)
5.000 – 5.012 mm
Valve guide I.D. IN.&EX. —
(0.1969 – 0.1973 in)
0.010 – 0.037 mm
Intake —
(0.0004 – 0.0015 in)
Valve guide to valve stem clearance
0.030 – 0.057 mm
Exhaust —
(0.0012 – 0.0022 in)
Valve spring free length IN.&EX. — 39.0 mm (1.535 in)
Valve spring pre-load when compressed to 114 – 131 N (11.6 – 13.4
IN.&EX. —
35.8 mm (1.41 in) kgf, 25.6 – 29.4 lbf)
Cylinder head distortion — 0.05 mm (0.002 in)
Cylinder distortion — 0.05 mm (0.002 in)
56.095 mm (2.2085
Cylinder bore 56.000 – 56.015 mm (2.2047 – 2.2053 in)
in)
55.960 – 55.975 (2.2031 – 2.2037 in) 55.880 mm (2.2000
Piston diam.
Measure at 10 mm (0.39 in) from the skirt end in)
Piston to cylinder clearance 0.035 – 0.045 mm (0.0014 – 0.0018 in) 0.120 mm (0.0047 in)
1st — 0.180 mm (0.0071 in)
Piston ring to groove clearance
2nd — 0.150 mm (0.0059 in)
0C-4 Service Data:

0.81 – 0.83 mm (0.0319
1st —
– 0.0327 in)
0.81 – 0.83 mm (0.0319
Piston ring groove width 2nd —
– 0.0327 in)
1.51 – 1.53 mm (0.0594
Oil —
– 0.0602 in)
0.77 – 0.79 mm (0.0303
1st —
– 0.0311 in)
Piston ring thickness
0.77 – 0.79 mm (0.0303
2nd —
– 0.0311 in)
Approx. 8.3 mm (0.33
1st 6.6 mm (0.26 in)
in)
Piston ring free end gap
Approx. 7.8 mm (0.31
2nd 6.2 mm (0.24 in)
in)
0.08 – 0.20 mm (0.003 –
1st 0.50 mm (0.020 in)
0.008 in)
Piston ring end gap
0.18 – 0.30 mm (0.007 –
2nd 0.70 mm (0.028 in)
0.012 in)
14.030 mm (0.5524
Piston pin bore I.D. 14.002 – 14.008 mm (0.5513 – 0.5515 in)
in)
13.980 mm (0.5504
Piston pin O.D. 13.996 – 14.000 mm (0.5510 – 0.5512 in)
in)
14.040 mm (0.5528
Conrod small end I.D. 14.006 – 14.024 mm (0.5514 – 0.5521 in)
in)
Conrod deflection — 3.0 mm (0.12 in)
Conrod big end side clearance 0.10 – 0.45 mm (0.004 – 0.018 in) 1.0 mm (0.04 in)
Conrod big end width 13.95 – 14.00 mm (0.549 – 0.551 in) —
Crank web to web width 49.9 – 50.1 mm (1.965 – 1.972 in) —
Crankshaft thrust clearance –0.02 – 0.07 mm (–0.0008 – 0.0028 in) —
Crankshaft runout — 0.080 mm (0.0031 in)
Balancer spring free length — 10.1 mm (0.40 in)
Engine Lubrication System

30 – 45 kPa (0.31 – 0.46 kgf/cm2, 4.35 – 6.52 psi)
Oil pressure (at 60°C, 140°F) —
at 3000 r/min
850 ml (0.90 US qt, 0.75
Oil change —
Imp qt)
950 ml (1.00 US qt, 0.84
Necessary amount of engine oil Oil and filter change —
Imp qt)
1100 ml (1.16 US qt,
Engine overhaul —
0.97 Imp qt)
Service Data: 0C-5
Fuel System
Carburetor type UCAL / UCD29-9 —
Bore size 29 mm (1.14 in) —
I.D. No 34J0 —
Idle speed 1600 ± 100 r/min —
Fuel level (From center of venturi tube) 32.0 ± 0.5 mm (1.26 ± 0.02 in) —
Float height 7.1 ± 1.0 mm (0.28 ± 0.04 in) —
Main jet (M.J.) #135 —
Main air jet (M.A.J.) 0.9 mm (0.035 in) —
Jet needle (J.N.) V1 —
Needle jet (N.J.) 0–3 —
Throttle valve (Th.V.) #110 —
Pilot jet (P.J.) #12.5 —
Pilot screw (P.S.) PRE-SET 2.0 turn counterclockwise —
Fuel tank capacity 12.0 L (3.17 US gal, 2.64 Imp gal) —
Ignition System
NGK: CPR7EA-9
Type DENSO: U22EPR9 —
Spark plug CHAMPION: RG8YC
0.8 – 0.9 mm (0.031 –
Gap —
0.035 in)
Spark performance Over 8 mm (0.3 in) at 1 atm —
Ignition coil primary peak voltage 150 V or more —
0.315 – 0.385 at 25
Primary Terminal - Ground
°C (77 °F)
Ignition coil resistance
8.0 – 12.0 k at 25 °C
Secondary Plug cap - Terminal
(77 °F)
Starting System
Starter motor brush length 9.0 mm (0.35 in) 4.5 mm (0.18 in)
Starter relay resistance 3–6 —
Charging System
Battery leakage current 3 mA or less —
Regulated voltage 14.0 – 15.0 V 5000 r/min
Generator coil resistance 0.6 – 1.5 —
Generator no-load voltage (When cold) More than 80 V (AC) 5000 r/min
0.3 A for 5 to 10 hours Standard charging
Recharging time
3 A for 0.5 hours Fast charging
Generator Max. output Approx. 125 W 5000 r/min
Type designation ETZ-4 or ATZ 4L —
Battery 12 V 10.8 kC (3.0 Ah)/
Capacity —
10 HR
Front Suspension
Front fork stroke 120 mm (4.7 in) —
Front fork inner tube O.D. 41 mm (1.6 in) —
Front fork oil level (Without spring, inner
130 mm (5.1 in) —
tube fully compressed)
Front fork spring free length 315 mm (12.4 in) 308 mm (12.1 in)
Front fork oil capacity (Each leg) 400 ml (13.5 US oz, 14.1 Imp oz) —
0C-6 Service Data:
Rear Suspension
Rear shock absorber spring adjuster 3rd position from softest end —
Swingarm pivot shaft runout — 0.3 mm (0.01 in)
Wheels and Tires

Axial — 2.0 mm (0.08 in)
Front wheel rim runout
Radial — 2.0 mm (0.08 in)
Axial — 2.0 mm (0.08 in)
Rear wheel rim runout
Radial — 2.0 mm (0.08 in)
Front — 0.25 mm (0.010 in)
Wheel axle runout
Rear — 0.25 mm (0.010 in)
100/80-17M/C 52P,
Front —
tubeless
Tire size
140/60R17M/C 63P,
Rear —
tubeless
MRF: NYLOGRIP
Front —
Tire type ZAPPER-FX
Rear MRF: REVZ-M —
Front — 1.6 mm (0.06 in)
Tire tread depth (Recommend depth)
Rear — 2.0 mm (0.08 in)
200 kPa (2.00 kgf/cm2,
Front —
29 psi)
Cold inflation tire pressure (Solo riding)
225 kPa (2.25 kgf/cm2,
Rear —
33 psi)
200 kPa (2.00 kgf/cm2,
Front —
29 psi)
Cold inflation tire pressure (Dual riding)
225 kPa (2.25 kgf/cm2,
Rear —
33 psi)
Front 17 M/C x MT 2.50 —
Wheel rim size
Rear 17 M/C x MT 3.50 —
Drive Chain / Drive Train / Drive Shaft

Type LGB R428NOR —
Drive chain Links 132 links —
20-pitch length — 255.5 mm (10.06 in)
Drive chain slack (on side-stand/center
20 – 30 mm (0.8 – 1.2 in) —
stand)
Brake Control System and Diagnosis

Rear brake pedal height 32 – 42 mm (1.26 – 1.65 in) —
Approx. 12.0 mm (0.47
Master cylinder bore / piston diameter Front —
in)
Rear brake pedal free travel 10 – 20 mm (0.4 – 0.8 in) —
Front Brakes
Front brake disc thickness 3.8 – 4.2 mm (0.15 – 0.17 in) 3.5 mm (0.14 in)
Front brake disc runout — 0.30 mm (0.012 in)
Front brake caliper cylinder bore / piston
Approx. 28 mm (1.10 in) —
diameter
Rear Brakes
Rear Brake drum I.D. — 130.7 mm (5.15 in)
Service Data: 0C-7
Manual Transmission
Primary reduction ratio 3.181 (70/22) —
Final reduction ratio 3.000 (45/15) —
Low 2.750 (33/12) —
2nd 1.750 (28/16) —
Gear ratios 3rd 1.300 (26/20) —
4th 1.045 (23/22) —
Top 0.875 (21/24) —
0.1 – 0.3 mm (0.004 –
No.1 0.5 mm (0.020 in)
0.012 in)
Shift fork to groove clearance
0.1 – 0.3 mm (0.004 –
No.2 0.5 mm (0.020 in)
0.012 in)
5.0 – 5.1 mm (0.197 –
No.1 —
0.201 in)
Shift fork groove width
5.0 – 5.1 mm (0.197 –
No.2 —
0.201 in)
4.8 – 4.9 mm (0.189 –
No.1 —
0.193 in)
Shift fork thickness
4.8 – 4.9 mm (0.189 –
No.2 —
0.193 in)
Gearshift lever height 23 – 37 mm (0.91 – 1.46 in) —
Clutch
Clutch cable play 10 – 15 mm (0.4 – 0.6 in) —
2.9 – 3.1 mm (0.11 –
No.1 2.6 mm (0.10 in)
0.12 in)
Drive plate thickness
2.9 – 3.1 mm (0.11 –
No.2 2.6 mm (0.10 in)
0.12 in)
11.9 – 12.0 mm (0.469 –
No.1 11.1 mm (0.437 in)
0.472 in)
Drive plate claw width
11.9 – 12.0 mm (0.469 –
No.2 11.1 mm (0.437 in)
0.472 in)
Driven plate distortion — 0.10 mm (0.004 in)
Clutch spring free length 32.5 mm (1.28 in) 30.9 mm (1.22 in)
Steering / Handlebar
Steering tension initial force 2 – 5 N (0.20 – 0.51 kgf, 0.45 – 1.12 lbf) —
Wiring Systems
Fuse size Main 15 A —
Lighting Systems
Hi 12 V 35 W —
Headlight
Lo 12 V 35 W —
Position light 12 V 5 W —
Brake light / Taillight LED —
Turn signal light 12 V 10 W —
License light 12 V 5 W —
0C-8 Service Data:
Combination Meter / Others

Tachometer light LED —
Speedometer light LED —
Turn signal indicator light LED —
High beam indicator light LED —
Neutral indicator light LED —
RPM indicator light LED —
Fasteners Information Fastener Strength Identification

BENF34J10307003 Most commonly used strength classes of metric
Metric Fasteners
fasteners are 4T, 6.8, 7T and 8.8. Strength class is
Most of the fasteners used for this vehicle are JIS-
indicated by a number or radial line(s) embossed on the
defined and ISO-defined metric fasteners. When
head of each bolt. Some metric nuts have a punched
replacing any fasteners, it is most important that
number, 6 or 8 on their end surfaces. Figure shows
replacement fasteners are of the correct diameter,
different strength markings.
thread pitch and strength.
When replacing metric fasteners, use bolts and nuts of
NOTICE the same strength class as or higher class than the
original bolts and nuts. It is also important to select
Combining male and female fasteners with replacement fasteners of the correct diameter and
different thread pitches will damage both thread pitch. Correct replacement bolts and nuts are
fasteners. available as SUZUKI spare parts.
It is important to note that, even when the Metric bolts and nuts: Strength class numbers or marks
nominal diameter (1) of the threads is the (The larger the number, the greater the strength).
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the
mating fastener.
JIS-TO-ISO main fasteners comparison table

Nominal diameter
M6 M8 M10 M12 M14
Thread pitch 1.0 1.25 1.25 1.25 1.5
JIS
Width across flats 10 12 14 17 19
Thread pitch 1.0 1.25 1.5 1.5 1.5
ISO
Width across flats 10 13 16 18 21
IE31J1030002-01
1. Nut strength identification
IE31J1030001-01
Service Data: 0C-9
Standard Tightening Torques

Each fastener should be tightened to the torque specified in each section. If no torque description or specification is
provided in the relevant section, refer to the following tightening torque chart for the applicable torque for each
fastener. When a fastener of greater strength than the original one is used, use the torque specified for the original
fastener.
NOTE
• For flanged bolts, flanged nuts and self-locking nuts of the 4T and 7T strength classes, add 10% to
the applicable tightening torques given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel or light alloy.
Tightening torque chart

Thread diameter (Nominal diameter) (mm)
Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to Nm 1.5 3.0 5.5 13 29 45 65 105 160
4T kgf-m 0.15 0.31 0.56 1.3 3.0 4.6 6.6 10.7 16.3
lbf-ft 1.5 2.5 4.0 9.5 21.5 33.5 48.0 77.5 118.0
IE31J1030003-01
Fastener of strength class equivalent to Nm 2.4 4.7 8.4 20 42 80 125 193 280
6.8 kgf-m 0.24 0.48 0.86 2.0 4.3 8.2 12.7 19.7 28.6
lbf-ft 2.0 3.5 6.5 15.0 31.0 59.0 92.5 142.5 206.5
IE31J1030004-01
Flanged fastener of strength class Nm 2.4 4.9 8.8 21 44 84 133 203 298
equivalent to 6.8 kgf-m 0.24 0.50 0.90 2.1 4.5 8.6 13.6 20.7 30.4
*: Self-locking nut (6 strength) lbf-ft 2.0 4.0 6.5 15.5 32.5 62.0 98.5 150.0 220.0
IE31J1030005-01
Fastener of strength class equivalent to Nm 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.46 1.0 2.3 5.1 8.7 13.8 21.4 24.5
lbf-ft 2.0 3.5 7.5 17.0 37.0 63.0 99.5 155.0 177.0
IE31J1030006-01
Fastener of strength class equivalent to Nm 3.1 6.3 11 27 56 105 168 258 373
8.8 (bolt) or 8 (nut) kgf-m 0.32 0.64 1.1 2.8 5.7 10.7 17.1 26.3 38
lbf-ft 2.5 5.0 8.5 20.0 41.5 77.5 124.0 190.5 275.5
IE31J1030007-01
Flanged fastener of strength class Nm 3.2 6.5 12 29 59 113 175 270 395
equivalent to 8.8 (bolt) or 8 (nut) kgf-m 0.33 0.66 1.2 3.0 6.0 11.5 17.8 27.5 40.3
lbf-ft 2.5 5.0 9.0 21.5 43.5 83.5 129.0 199.5 291.5
IE31J1030008-01
0C-10 Service Data:
Width across flats Thread diameter Unit

Small crown shape bolt
“b” [mm] “a” [mm] Nm kgf-m lbf-ft
7 5 4.5 0.46 3.5
8 6 10 1.0 7.5
ID26J1030004-01
*: Self-locking nut

Fuel / Oil / Fluid Recommendation Brake Fluid
BENF34J10308001 Specification and classification: DOT 3 or DOT 4
Fuel
NOTICE
! WARNING
Do not use leaded gasoline. If it is used, the Since the brake system of this motorcycle is
engine and the emission control system will filled with a glycol-based brake fluid by the
be damaged. manufacturer, do not use or mix different
types of fluid such as silicone-based and
Use unleaded gasoline with an octane rating of 91 RON petroleum-based fluid for refilling the
or higher. system, otherwise serious damage will
result.
Engine Oil Do not use any brake fluid taken from old or
Use engine oils which meet the following requirements. used or unsealed containers.
• API service classification: SG or higher Never reuse brake fluid left over from a
previous servicing, which has been stored
• JASO T903 standard: MA
for a long period.
• Viscosity: SAE 10W-40
If SAE 10W-40 engine oils are not available, select oils
of an appropriate viscosity grade according to the Front Fork Oil
following chart. Use ENDURANCE FORK OIL TYPE 1F or equivalent.
Fork oil (ENDURANCE FORK OIL TYPE 1F or
equivalent)
ENGINE OIL
IF34J1030001-01
Suzuki does not recommend the use of engine oils

which have an “ENERGY CONSERVING” or
“RESOURCE CONSERVING” indication in the API
service symbol for any of its motorcycles / ATVs.
They can affect the engine life and the clutch
performance.
ID26J1030005-01
Service Data: 0C-11
SPECIAL TOOLS
99000F10035C000
99000F10033C000 99000F10034C000
Wheel bearing remover set
Steering race installer Clutch sleeve hub holder
99000F10036C000 99000F10037C000 99000F10040C000

Steering stem nut socket wrench Con rod holder Oil seal remover
99000F10041C000 99000F10281C000 99000F10047C000

Oil pressure gauge T- Handle (20 mm) Steering race installer lower
99000F10048C000 99000F10049C000 99000F10050C000

Crankcase separator Engine sprocket holder N.R.B. remover
99000F10051C000 99000F10053C000 99000F10054C000

Cylinder head bearing remover Engine bearing installer Valve spring compressor
0C-12 Service Data:
99000F10057C000 99000F10056C000 99000F10042C000

Oil Seal Installer (Handle with 5 Pilots) Thickness gauge Valve adjusting wrench ( tappet & socket )
99000F10060C000 99000F10061C000 99000F10098C000

Scraper Steering race remover Rotor holder
99000F10124C000 99000F10125C000 99000F10261C000

Engine bearing installer 15 mm Allen key 6 mm Spacer Crankshaft Bearing Installer
99000F10127C000 99000F10038C000 99000F10242C000

Screwdriver 903 Crankshaft installer Crankshaft bearing puller
99000F10243C000 99000F10272C000 99000F10245C000

Shocker adjuster C spanner Bearing Puller (Camshaft) Engine bearing puller with plate
Service Data: 0C-13
99000F10262C000 99000F10240C000 99000F10248C000

Piston pin replacer Adapter pressure gauge Engine mounting bracket
99000F10280C000 9900F10043C000 99000F10251C000

TFF Oil Seal Installer (41 mm) Rotor Remover Crankshaft bearing installer
99000F10254C000
Steering nut tightening tool - 28 mm
NOTE:
When ordering a special tool, please confirm whether it is available or not.
0C-14 Service Data:
Section 1
Engine
CONTENTS
Precautions .................................................1-1 Speed Sensor Removal and Installation .............1C-4

Precautions............................................................. 1-1 Speed Sensor Inspection ....................................1C-5
Precautions for Engine.......................................... 1-1 Specifications .......................................................1C-6
Tightening Torque Specifications........................1C-6
Engine General Information and Special Tools and Equipment .............................1C-6
Diagnosis ................................................. 1A-1 Recommended Service Material .........................1C-6
Diagnostic Information and Procedures............1A-1 Special Tool ........................................................1C-6
Engine Symptom Diagnosis ................................ 1A-1
Engine Mechanical .................................. 1D-1
Emission Control Devices ...................... 1B-1 Precautions...........................................................1D-1
Precautions...........................................................1B-1 Precautions for Engine Mechanical.....................1D-1
Precautions for Emission Control Devices .......... 1B-1 Diagnostic Information and Procedures ............1D-1
General Description .............................................1B-1 Compression Pressure Check ............................1D-1
Crankcase Emission Control System Schematic and Routing Diagram ........................1D-2
Description ........................................................ 1B-1 Throttle Cable Routing Diagram..........................1D-2
Schematic and Routing Diagram........................1B-2 Repair Instructions ..............................................1D-5
PAIR System Hose Routing Diagram ................. 1B-2 Intake System Components ................................1D-5
Repair Instructions ..............................................1B-3 Air Cleaner Element Removal and Installation ....1D-6
PCV Hose Inspection .......................................... 1B-3 Air Cleaner Element Inspection and Cleaning ....1D-6
PCV Hose Removal and Installation ................... 1B-3 Air Cleaner Box Removal and Installation...........1D-7
PAIR System Hose Inspection ............................ 1B-3 Throttle Cable Play On-Vehicle Inspection
PAIR System Hose / Pipe Removal and and Adjustment .................................................1D-8
Installation ......................................................... 1B-3 Throttle Cable Removal and Installation .............1D-8
PAIR Control Valve Assembly Removal and Throttle Cable Inspection ....................................1D-8
Installation ......................................................... 1B-4 Intake Pipe Removal and Installation..................1D-9
PAIR Control Valve Assembly Inspection ........... 1B-4 Cylinder Head Cover Removal and
Specifications.......................................................1B-5 Installation .........................................................1D-9
Tightening Torque Specifications........................ 1B-5 Valve Clearance Inspection and Adjustment ....1D-10
Cam Chain Tension Adjuster / Camshaft
Special Tools and Equipment .............................1B-5
Housing / Camshaft Removal .........................1D-11
Special Tool ........................................................ 1B-5
Cam Chain Tension Adjuster / Camshaft
Engine Electrical Devices ....................... 1C-1 Housing / Camshaft Installation ......................1D-12
Cam Chain Tension Adjuster Inspection...........1D-15
Precautions...........................................................1C-1
Camshaft Sprocket Inspection ..........................1D-15
Precautions for Engine Electrical Device ............1C-1
Camshaft Housing Disassembly and
Component Location ...........................................1C-1 Reassembly ....................................................1D-15
Engine Electrical Components Location .............1C-1 Rocker Arm Shaft / Rocker Arm Inspection ......1D-16
Diagnostic Information and Procedures............1C-1 Camshaft Inspection .........................................1D-17
Engine Symptom Diagnosis ................................1C-1 Camshaft Bearing Removal and Installation .....1D-17
Repair Instructions ..............................................1C-1 Cylinder Head Assembly / Cam Chain Guide
CDI Unit Removal and Installation ......................1C-1 / Cylinder Removal and Installation.................1D-18
TP Sensor Inspection and Adjustment................1C-1 Cylinder Head Disassembly and Reassembly ..1D-20
TP Sensor Removal and Installation...................1C-2 Cylinder Head Inspection ..................................1D-21
CKP Sensor Inspection .......................................1C-3 Cam Chain Tensioner Inspection......................1D-21
CKP Sensor Removal and Installation ................1C-4 Cam Chain Guide Inspection ............................1D-21
1-ii Table of Contents
Valve / Valve Spring Removal and Installation ..1D-21 Diagnostic Information and Procedures ........... 1G-3
Valve Inspection................................................1D-23 Fuel System Symptom Diagnosis ...................... 1G-3
Valve Spring Inspection ....................................1D-25 Repair Instructions ............................................. 1G-3
Valve Guide Replacement ................................1D-25 Fuel Hose Inspection ......................................... 1G-3
Valve Seat Repair .............................................1D-27 Fuel Tank Construction ...................................... 1G-4
Cylinder Inspection............................................1D-27 Fuel Tank Removal and Installation ................... 1G-5
Piston Removal and Installation........................1D-27 Fuel Valve Removal and Installation .................. 1G-5
Piston Ring Removal and Installation ...............1D-28 Fuel Filter Inspection and Cleaning.................... 1G-6
Piston and Piston Ring Inspection ....................1D-29 Fuel Level Gauge Removal and Installation ...... 1G-6
Cam Chain Removal and Installation................1D-31 Fuel Level Gauge Inspection ............................. 1G-7
Balancer Shaft Drive / Driven Gear Removal Starter Cable Removal and Installation.............. 1G-7
and Installation ................................................1D-31 Starter Cable On-Vehicle Inspection .................. 1G-8
Balancer Shaft Driven Gear Disassembly and Carburetor Components..................................... 1G-9
Reassembly ....................................................1D-32 Engine Idle Speed Inspection and Adjustment . 1G-10
Balancer Shaft Drive / Driven Gear Inspection ..1D-33 Carburetor Assembly Removal and
Engine Assembly Removal ...............................1D-33 Installation ...................................................... 1G-10
Engine Assembly Installation ............................1D-35 Carburetor Disassembly and Reassembly ....... 1G-11
Crankcase Assembly Disassembly ...................1D-36 Float Height Inspection and Adjustment .......... 1G-16
Crankcase Assembly Reassembly....................1D-37 Carburetor Inspection and Cleaning ................ 1G-16
Conrod / Crankshaft Inspection.........................1D-39 Specifications .................................................... 1G-18
Balancer Shaft Inspection .................................1D-40 Tightening Torque Specifications..................... 1G-18
Crankcase Bearing / Oil Seal Inspection...........1D-41 Special Tools and Equipment .......................... 1G-18
Crankcase Bearing Removal and Installation ...1D-41 Recommended Service Material ...................... 1G-18
Crankshaft Thrust Clearance Inspection and Special Tool ..................................................... 1G-18
Shim Selection ................................................1D-42
Specifications.....................................................1D-44 Ignition System........................................ 1H-1
Tightening Torque Specifications......................1D-44 Schematic and Routing Diagram ........................1H-1
Special Tools and Equipment ...........................1D-45 Ignition System Diagram .....................................1H-1
Recommended Service Material .......................1D-45 Ignition System Components Location................1H-1
Special Tool ......................................................1D-45 Diagnostic Information and Procedures ............1H-1
Ignition System Symptom Diagnosis...................1H-1
Engine Lubrication System .....................1E-1 No Spark or Poor Spark ......................................1H-2
Precautions........................................................... 1E-1 Repair Instructions ..............................................1H-3
Precautions for Engine Oil .................................. 1E-1 Ignition Coil Construction ....................................1H-3
Schematic and Routing Diagram........................ 1E-2 Spark Plug Removal and Installation ..................1H-3
Engine Lubrication System Chart Diagram ......... 1E-2 Spark Plug Inspection and Cleaning ...................1H-4
Diagnostic Information and Procedures............ 1E-3 Ignition Coil Removal and Installation .................1H-4
Engine Lubrication Symptom Diagnosis ............. 1E-3 Ignition Coil Inspection ........................................1H-5
Oil Pressure Check ............................................. 1E-3 Engine Stop Switch Inspection............................1H-6
Repair Instructions .............................................. 1E-4 Ignition Switch Inspection....................................1H-6
Engine Oil Inspection .......................................... 1E-4 Ignition Switch Removal and Installation.............1H-6
Engine Oil Replacement ..................................... 1E-4 Specifications .......................................................1H-7
Oil Filter Replacement......................................... 1E-5 Tightening Torque Specifications........................1H-7
Oil Sump Filter Removal and Installation ............ 1E-6 Special Tools and Equipment .............................1H-7
Oil Sump Filter Inspection and Cleaning............. 1E-6 Special Tool ........................................................1H-7
Oil Pump Removal and Installation ..................... 1E-6
Oil Pump Inspection ............................................ 1E-8 Starting System .........................................1I-1
Specifications....................................................... 1E-9 Schematic and Routing Diagram ......................... 1I-1
Tightening Torque Specifications........................ 1E-9 Starting System Diagram ..................................... 1I-1
Special Tools and Equipment ............................. 1E-9 Component Location ............................................ 1I-1
Special Tool ........................................................ 1E-9 Starting System Components Location ................ 1I-1
Diagnostic Information and Procedures ............. 1I-1
Fuel System ............................................. 1G-1 Starting System Symptom Diagnosis ................... 1I-1
Precautions.......................................................... 1G-1 Starter Motor Will Not Run ................................... 1I-2
Precautions for Fuel System .............................. 1G-1 Starter Motor Runs But Does Not Crank the
General Description ............................................ 1G-1 Engine ................................................................ 1I-2
I.D. No. Location ................................................ 1G-1 Repair Instructions ............................................... 1I-3
Schematic and Routing Diagram....................... 1G-2 Starter Motor Components................................... 1I-3
Fuel Hose Routing Diagram............................... 1G-2
Table of Contents 1-iii
Starter Motor Assembly Removal and Repair Instructions .............................................. 1J-4

Installation .......................................................... 1I-3 Battery Current Leakage Inspection.................... 1J-4
Starter Motor Disassembly and Reassembly ....... 1I-4 Regulated Voltage Inspection ............................. 1J-4
Starter Motor Inspection....................................... 1I-5 Generator Inspection........................................... 1J-4
Starter Relay Removal and Installation................ 1I-6 Generator Removal............................................. 1J-5
Starter Relay Inspection....................................... 1I-7 Generator Installation.......................................... 1J-6
Starter Clutch Removal and Installation............... 1I-7 Regulator / Rectifier Construction ....................... 1J-8
Starter Clutch Inspection...................................... 1I-9 Regulator / Rectifier Inspection ........................... 1J-8
Starter Switch Inspection ................................... 1I-10 Regulator / Rectifier Removal and Installation .... 1J-8
Kick Starter Components ................................... 1I-11 Battery Charging ................................................. 1J-9
Kick Starter Lever Removal and Installation ...... 1I-12 Battery Removal and Installation ...................... 1J-10
Kick Starter Shaft Removal and Installation....... 1I-12 Battery Visual Inspection................................... 1J-10
Kick Starter Parts Inspection.............................. 1I-14 Specifications ..................................................... 1J-11
Specifications...................................................... 1I-15 Tightening Torque Specifications...................... 1J-11
Tightening Torque Specifications....................... 1I-15 Special Tools and Equipment ........................... 1J-11
Special Tools and Equipment ............................ 1I-15 Recommended Service Material ....................... 1J-11
Recommended Service Material ........................ 1I-15 Special Tool ...................................................... 1J-11
Special Tool ....................................................... 1I-15
Exhaust System ....................................... 1K-1
Charging System ......................................1J-1 Precautions...........................................................1K-1
Schematic and Routing Diagram........................ 1J-1 Precautions for Exhaust System .........................1K-1
Charging System Diagram ...................................1J-1 Repair Instructions ..............................................1K-1
Component Location ........................................... 1J-1 Exhaust System Components.............................1K-1
Charging System Components Location..............1J-1 Muffler Removal and Installation.........................1K-2
Diagnostic Information and Procedures............ 1J-2 Exhaust System Inspection.................................1K-3
Charging System Symptom Diagnosis.................1J-2 Specifications .......................................................1K-4
Battery Runs Down Quickly .................................1J-3 Tightening Torque Specifications........................1K-4
1-1 Precautions:
Precautions
Engine
Precautions
Precautions for Engine
BENF34J11000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2) and “Precautions for Circuit Tester” in Section 00 (Page 00-6).
Engine General Information and Diagnosis: 1A-1
Engine General Information and Diagnosis

Engine
Diagnostic Information and Procedures

Engine Symptom Diagnosis
BENF34J11104001
Condition Possible cause Correction / Reference Item

Engine will not start or is Valve clearance out of adjustment. Adjust. )(Page 1D-10)
hard to start Worn valve guide or poor seating of Repair or replace. )(Page 1D-25)
(Compression too low) valve.
Mistimed valve. Adjust. )(Page 1D-10)
Excessively worn piston rings. Replace. )(Page 1D-28)
Worn-down cylinder bore. Replace. )(Page 1D-18)
Too slow starter motor cranking. Refer to “Starting System Diagram” in Section
1I (Page 1I-1).
Poor seating of spark plug. Retighten. )(Page 1H-3)
Engine will not start or is Defective spark plug. Replace. )(Page 1H-3)
hard to start (Plug not Too wide spark plug gap. Adjust or replace. )(Page 1H-4)
sparking) Fouled spark plug. Clean. )(Page 1H-4)
Wet spark plug. Clean and dry. )(Page 1H-4)
Defective ignition coil. Replace. )(Page 1H-4)
Defective stator coil. Replace. )(Page 1J-5)
)(Page 1J-6)
Defective CKP sensor. Replace. )(Page 1J-5)
)(Page 1J-6)
Defective CDI unit. Replace. )(Page 1C-1)
Open-circuited wiring connection. Repair or replace. )(Page 9A-4)
Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. )(Page 1G-6)
hard to start (No fuel Defective carburetor needle valve. Replace. )(Page 1G-11)
reaching the carburetor)
Engine idles poorly Valve clearance out of adjustment. Adjust. )(Page 1D-10)
Poor seating of valves. Replace or repair. )(Page 1D-27)
Defective valve guides. Replace. )(Page 1D-25)
Worn rocker arms and/or cam surfaces. Replace. )(Page 1D-11)
)(Page 1D-12)
Too wide spark plug gap. Adjust or replace. )(Page 1H-4)
Defective stator coil. Replace. )(Page 1J-5)
)(Page 1J-6)
)(Page 1J-6)
Defective TP sensor. Replace. )(Page 1C-2)
Clogged carburetor jets. Clean or replace. )(Page 1G-16)
Throttle stop screw out of adjustment. Adjust. )(Page 1G-10)
Pilot screw out of adjustment. Adjust. )(Page 1G-11)
Damaged or cracked vacuum hose. Replace.
Clogged air cleaner element. Clean or replace. )(Page 1D-6)
Incorrect float chamber fuel level. Adjust float height. )(Page 1G-16)
1A-2 Engine General Information and Diagnosis:

Engine stalls often Fouled spark plug. Clean. )(Page 1H-4)
Defective CKP sensor or CDI unit. Replace. )(Page 1J-5)
)(Page 1J-6)
)(Page 1C-1)
Clogged fuel hose. Clean.
Clogged carburetor jets. Clean. )(Page 1G-16)
Valve clearance out of adjustment. Adjust. )(Page 1D-10)
Air leaking from carburetor. Tighten or replace.
Clogged exhaust pipe. Replace. )(Page 1K-2)
Open or short circuited wiring Repair or replace. )(Page 9A-4)
connection.
Noisy engine (Excessive Too large valve clearance. Adjust. )(Page 1D-10)
valve chatter) Weakened or broken valve springs. Replace. )(Page 1D-21)
Worn rocker arms and/or cam surfaces. Replace. )(Page 1D-11)
)(Page 1D-12)
Worn or burnt camshaft bearings. Replace. )(Page 1D-11)
)(Page 1D-12)
Noisy engine (Noise Worn down piston or cylinder. Replace. )(Page 1D-27)
seems to come from )(Page 1D-18)
piston) Combustion chamber fouled with Clean. )(Page 1D-21)
carbon.
Worn piston pin or piston pin bore. Replace. )(Page 1D-27)
Worn piston rings or ring grooves. Replace. )(Page 1D-28)
Noisy engine (Noise Stretched cam chain. Replace. )(Page 1D-31)
seems to come from cam Worn sprockets. Replace. )(Page 1D-36)
chain) )(Page 1D-37)
)(Page 1D-11)
)(Page 1D-12)
Cam chain tension adjuster not working. Repair or replace. )(Page 1D-11)
)(Page 1D-12)
Noisy engine (Noise Worn splines of countershaft or clutch Replace. )(Page 5B-4)
seems to come from sleeve hub. )(Page 5C-6)
clutch) )(Page 5C-7)
Worn teeth of clutch plates. Replace. )(Page 5C-6)
)(Page 5C-7)
Distorted clutch plates, driven and drive. Replace. )(Page 5C-6)
)(Page 5C-7)
Worn clutch release bearing. Replace. )(Page 5C-6)
)(Page 5C-7)
Weakened clutch dampers. Replace the primary driven gear. )(Page 5C-
6)
)(Page 5C-7)
Weakened clutch springs. Replace. )(Page 5C-6)
)(Page 5C-7)
Worn or rubbing primary gears. Replace. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-12)
Noisy engine (Noise Rattling bearing due to wear. Replace. )(Page 1D-41)
seems to come from Worn or burnt big-end bearing. Replace. )(Page 1D-36)
crankshaft) )(Page 1D-37)
Worn or burnt crankcase bearings. Replace. )(Page 1D-41)
Too large crankshaft thrust clearance Adjust. )(Page 1D-42)
Noisy engine (Noise Worn or rubbing gears. Replace. )(Page 5B-4)
seems to come from Worn countershaft and/or driveshaft Replace. )(Page 5B-4)
transmission) splines.
)(Page 5C-7)
)(Page 5C-12)
Worn transmission bearings. Replace. )(Page 5B-7)
Engine General Information and Diagnosis: 1A-3

Engine runs poorly in Weakened valve spring. Replace. )(Page 1D-21)
high speed range Worn camshaft and/or rocker arms. Replace. )(Page 1D-11)
)(Page 1D-12)
Valve timing out of adjustment. Adjust. )(Page 1D-10)
Too narrow spark plug gap. Adjust. )(Page 1H-4)
Ignition not advanced sufficiently due to Replace CDI unit. )(Page 1C-1)
poorly working timing advance circuit.
)(Page 1J-6)
Clogged air cleaner element. Replace. )(Page 1D-6)
Clogged fuel hose, resulting in Clean and prime.
inadequate fuel supply to carburetor.
Low float chamber fuel level. Adjust float height. )(Page 1G-16)
Defective TP sensor. Replace. )(Page 1C-2)
Engine lacks power Loss of valve clearance. Adjust. )(Page 1D-10)
Weakened valve springs. Replace. )(Page 1D-21)
Valve timing out of adjustment. Adjust. )(Page 1D-10)
Worn piston rings or cylinder. Replace. )(Page 1D-28)
)(Page 1D-18)
Poor seating of valves. Repair. )(Page 1D-27)
Fouled spark plug. Clean or replace. )(Page 1H-3)
Incorrect spark plug. Adjust or replace. )(Page 1H-4)
Clogged carburetor jets. Clean. )(Page 1G-16)
TP sensor out of adjustment. Adjust. )(Page 1C-1)
Clogged air cleaner element. Clean or replace. )(Page 1D-6)
Sucking air from intake pipe. Retighten or replace. )(Page 1D-5)
Too much engine oil. Drain out excess oil. )(Page 1E-4)
Defective CKP sensor and ignition coil. Replace. )(Page 1J-5)
)(Page 1J-6)
)(Page 1H-4)
Engine overheats Heavy carbon deposit on piston crown. Clean.
Not enough oil in the engine. Add oil. )(Page 1E-4)
Defective oil pump or clogged oil circuit. Replace or clean. )(Page 1E-6)
Low float chamber fuel level. Adjust float height. )(Page 1G-16)
Sucking air from intake pipe. Retighten or replace. )(Page 1D-5)
Use of incorrect engine oil. Change. )(Page 1E-4)
Clogged air intake with dust. Clean.
Dirty or heavy exhaust Too much engine oil. Drain out excess oil. )(Page 1E-4)
smoke Worn piston rings or cylinder. Replace. )(Page 1D-28)
)(Page 1D-18)
Worn valve guides. Replace. )(Page 1D-25)
Scored or scuffed cylinder wall. Replace. )(Page 1D-18)
Worn valve stems. Replace. )(Page 1D-21)
Defective valve stem seal. Replace. )(Page 1D-21)
Worn oil ring side rails. Replace. )(Page 1D-28)
1B-1 Emission Control Devices:
Emission Control Devices

Engine
Precautions
Precautions for Emission Control Devices
BENF34J11200001
Refer to “General Precautions” in Section 00 (Page 00-1).
General Description
Crankcase Emission Control System Description
BENF34J11201002
The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is
returned to the combustion chamber through the PCV (breather) hose (1), air cleaner box (2) and carburetor (3).
[A]
[B]
[C]
IF34J1120001-02
[A]: Fresh air [B]: Fuel/Air mixture [C]: Blow-by gas

Emission Control Devices: 1B-2
Schematic and Routing Diagram

PAIR System Hose Routing Diagram
BENF34J11202001
[D]
[C]
[A]
7
[C]
(a) 1
2 (a)
(a)
[A]
[B]
4 (a)
IF34J1120002-03
[A]: Face the tip of the clamp forward. 2. PAIR valve bracket 7. PAIR vacuum hose
[B]: Face the tip of the clamp downward. 3. PAIR pipe gasket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Face the sealant side to the PAIR pipe.
[C]: Face the tip of the clamp upward. 4. PAIR pipe : Do not reuse.
[D]: Face the match mark upward. 5. PAIR valve hose
1. PAIR valve assembly 6. PAIR cleaner hose
Repair Instructions
PCV Hose Inspection 4) Install the removed parts.
BENF34J11206001
1) Remove the right frame side cover. )(Page 9D-12) PAIR System Hose / Pipe Removal and
2) Inspect the PCV hose (1) for wear and damage. Installation
If it is worn or damaged, replace the PCV hose with BENF34J11206004
a new one. Refer to “PAIR System Hose Routing Diagram” (Page
1B-2).
3) Check that the PCV hose (1) is securely connected.
Removal
1) Remove the following parts.
• Frame side cover, right and left: )(Page 9D-12)
• Left frame front cover: )(Page 9D-13)
2) Remove the PAIR valve hose (1), PAIR cleaner hose
(2) and PAIR vacuum hose (3).
3) Remove the PAIR pipe (4).
3
1
IF34J1120003-01
4) Install the removed parts.
PCV Hose Removal and Installation

BENF34J11206002
Refer to “Intake System Components” in Section 1D 4
(Page 1D-5).
Removal 1 2
1) Remove the right frame side cover. )(Page 9D-12) IF34J1120005-01
2) Remove the PCV hose. Installation

1) Install the PAIR pipe new gasket to the cylinder head
Installation
facing its sealant side (1) outward.
1) Install the PCV hose.
2) Install the PAIR pipe (2) and tighten its bolts (3) to
2) Install the removed parts. the specified torque.
Tightening torque
PAIR System Hose Inspection
BENF34J11206003 PAIR pipe bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
1) Remove the frame side cover, right and left. )(Page
9D-12)
1 2
2) Inspect the PAIR valve hose (1), PAIR cleaner hose
(2) and PAIR vacuum hose (3) for wear and damage.
If any defect is found, replace the hose with a new
one.
3) Check that the PAIR valve hose, PAIR cleaner hose
and PAIR vacuum hoses are securely connected.
3, (a)
3 IF34J1120006-02
3) Install the PAIR valve hose, PAIR cleaner hose and

PAIR vacuum hose.
1
2
IF34J1120004-01
Emission Control Devices: 1B-4
PAIR Control Valve Assembly Removal and PAIR Control Valve Assembly Inspection
BENF34J11206006
Installation Refer to “PAIR Control Valve Assembly Removal and
BENF34J11206005
Removal Installation” (Page 1B-4).
1) Remove the following parts. 1) Remove the PAIR reed valve cover (1) and PAIR
• Left frame side cover: )(Page 9D-12) reed valve (2).
2) Disconnect the PAIR valve hose (1) and PAIR
vacuum hose (2). 1 2
3) Remove the PAIR control valve assembly (3).
4) Disconnect the PAIR cleaner hose (4).
IF34J1120009-01
2) Inspect the reed valve (1) for the carbon deposit. If

the carbon deposit is found in the reed valve, replace
3 the PAIR reed valve with a new one.
4
1
IF34J1120007-01 1
Installation
1) Install the PAIR control valve assembly and tighten
the bolts to the specified torque.
Tightening torque
PAIR control valve assembly bolt (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)
IF34J1120010-01
3) Install the PAIR reed valve and PAIR reed valve

cover.
4) Inspect the air flow through the PAIR control valve air
inlet port to the air outlet port. If air does not flow out,
replace the PAIR control valve with a new one.
(a)
IF34J1120008-01
IF34J1120011-01
5) Connect the special tool to the vacuum port of the

PAIR control valve as shown in the figure.
Special tool
(A): Vacuum Pump Gauge Set
6) Apply negative pressure slowly to the PAIR control
valve and inspect the air flow. If air does not flow out,
the PAIR control valve is in normal condition. If the
PAIR control valve does not function, replace the
PAIR control valve with a new one.
(A )
Negative pressure range
Standard: –48.7 kPa (395 mmHg) IF34J1120012-01
Specifications
Tightening Torque Specifications
BENF34J11207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
PAIR pipe bolt 10 1.0 7.5 )(Page 1B-3)
PAIR control valve assembly bolt 10 1.0 7.5 )(Page 1B-4)
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“PAIR System Hose Routing Diagram” (Page 1B-2)
“Fasteners Information” in Section 0C (Page 0C-8)

Special Tool
BENF34J11208001
Vacuum pump gauge set

)(Page 1B-5)
Engine Electrical Devices: 1C-1
Engine Electrical Devices

Engine
Precautions
Precautions for Engine Electrical Device
BENF34J11300001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2) and “Precautions for Circuit Tester” in Section 00 (Page 00-6).
Component Location
Engine Electrical Components Location
BENF34J11303001
Refer to “Electrical Components Location” in Section 0A (Page 0A-5).

Engine Symptom Diagnosis
BENF34J11304001
Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-1).
Repair Instructions
CDI Unit Removal and Installation TP Sensor Inspection and Adjustment
BENF34J11306001 BENF34J11306002
Removal Inspection
1) Remove the seat. )(Page 9D-11) TP sensor power supply voltage
2) Unhook the band and remove the CDI unit (1). 1) Disconnect the TP sensor coupler. Refer to “TP
Sensor Removal and Installation” (Page 1C-2).
2) Turn the ignition switch ON.
3) Measure the voltage between the Bl wire and B/W
1
wire. If the voltage is not within the specified value,
check the wire harness. If wire harness is good
condition, replace the CDI unit.
TP sensor power supply voltage
(+) Bl – (–) B/W: 4.5 – 5.5 V
IF34J1130001-02
3) Disconnect the CDI unit couplers (1).
IF34J1130003-01
IF34J1130002-02
Installation
Install the CDI unit in the reverse order of removal.
1C-2 Engine Electrical Devices:
TP sensor output voltage 6) Loosen the TP sensor mounting screw (1) using the
1) Check that the throttle cable play is within the special tool and adjust the TP sensor output voltage
specification. )(Page 1D-8) to the specification.
2) Check the engine idle speed is within the Special tool
specification. )(Page 1G-10) Torx Wrench
3) Disconnect the TP sensor coupler. Refer to “TP TP sensor output voltage
Sensor Removal and Installation” (Page 1C-2). Throttle valve is closed: 0.65 – 0.75 V
4) Connect the special tool to the TP sensor. ((+) terminal: B/G – (–) terminal: B/W)
Special tool
(A): TP Sensor Test Lead
6) Measure the TP sensor output voltage between each
terminal with turning the throttle grip open and close.
If the output voltage is not within the specified value, 1
adjust or replace the TP sensor.
TP sensor output voltage
Throttle valve is closed: 0.65 – 0.75 V
Throttle valve is opened: 4.5 V
IF34J1130005-01
((+) terminal: B/G – (–) terminal: B/W)
7) Tighten the TP sensor mounting screw to the
(A) specified torque. Refer to “TP Sensor Removal and
Installation” (Page 1C-2).
Bl
8) After adjusting the TP sensor, reinstall the removed
parts.
TPS B/W CDI
B/G TP Sensor Removal and Installation
BENF34J11306003
Removal
1) Remove the left frame side cover. )(Page 9D-12)
IF34J1130004-03
2) Disconnect the TP sensor coupler (1).
3) Prior to disassembly, mark the sensor’s original
Adjustment position with a paint or scribe for accurate
1) Check that the throttle cable play is within the reinstallation.
specification. )(Page 1D-8) 4) Remove the TP sensor (2) using the special tool.
2) Check the engine idle speed is within the Special tool
specification. )(Page 1G-10)
Torx Wrench
3) Disconnect the TP sensor coupler. Refer to “TP
Sensor Removal and Installation” (Page 1C-2).
4) Connect the special tool to the TP sensor.
Special tool 1
TP Sensor Test Lead
IF34J1130006-03
Installation CKP Sensor Inspection

Install the TP sensor in the reverse order of removal. BENF34J11306004
CKP Sensor Peak Voltage
Pay attention to the following points:
1) Remove the seat. )(Page 9D-11)
• Apply a thin coat of engine oil to the O-ring (1).
2) Disconnect the CDI unit couplers. Refer to “CDI Unit
• Apply grease to the throttle shaft end (2), if necessary.
Removal and Installation” (Page 1C-1).
‘‘A” : (SUZUKI SUPER GREASE A) 3) Connect the multi circuit tester with the peak voltage
adapter (1) as follows.
• With the throttle valve fully closed, install the TP
sensor (3) aligning the throttle shaft end with the CDI unit coupler – circuit tester connection
groove (4) of the TP sensor. (+) Probe (–) Probe
Bl/Y wire B/W wire
• Tighten the TP sensor mounting screw to the CDI unit coupler (2)
terminal terminal
specified torque.
Special tool CKP sensor peak voltage
Torx Wrench (+) Bl/Y – (–) B/W: 1.2 V or more
Tightening torque
TP sensor mounting screw (a): 3 N·m (0.31 kgf- V
m, 2.5 lbf-ft)
2
3 1
2, “ A ” G Bl/Y
B B/W
3
IF34J1130008-01
3. CKP sensor
4
1 (a) 4) Measure the CKP sensor peak voltage in the
following procedures:
IF34J1130007-01 a) Shift the transmission to the neutral and turn the
• Check the throttle valve operating smoothly. ignition switch ON.
• Adjust the position of TP sensor. )(Page 1C-1) b) Grasp the clutch lever.
c) Press the starter switch and allow the engine to
crank for a few seconds, and then measure the
CKP sensor peak voltage.
5) Repeat the c) procedure several times and measure
the highest CKP sensor peak voltage. If the peak
voltage measured on the CDI unit coupler is lower
than standard range, measure the peak voltage on
the CKP sensor coupler as follows.
6) Turn the ignition switch OFF.
8) Disconnect the CKP sensor coupler (1).
IF34J1130009-02
9) Connect the multi circuit tester with the peak voltage

adapter (1) as follows.
CKP sensor coupler – circuit tester connection

(+) Probe (–) Probe
G wire B wire
CKP sensor coupler (2)
terminal terminal
CKP sensor peak voltage

(+) G – (–) B: 1.2 V or more
V IF34J1130011-02
4) After measuring the CKP sensor resistance, reinstall

the removed parts.
2
1
CKP Sensor Removal and Installation
G BENF34J11306005
B Refer to “Generator Removal” in Section 1J (Page 1J-5)
and “Generator Installation” in Section 1J (Page 1J-6).
3
IF34J1130010-01
3. CKP sensor Speed Sensor Removal and Installation

BENF34J11306006
Removal
10) Measure the CKP sensor peak voltage in the same
manner as on the CDI unit coupler. If the peak
voltage on the CKP sensor coupler is within 2) Disconnect the speed sensor lead wire coupler (1).
specification, but on the CDI unit coupler is not within
specification, replace the wire harness with a new
one. If both peak voltages are out of specification,
replace the CKP sensor with a new one. Refer to 1
“Generator Removal” in Section 1J (Page 1J-5) and
“Generator Installation” in Section 1J (Page 1J-6).
11) After measuring the CKP sensor peak voltage,
reinstall the removed parts.
CKP Sensor Resistance

IF34J1130012-02
2) Disconnect the CKP sensor coupler (1).
3) Remove the clamp (1).
4) Remove the speed sensor (2).
2
IF34J1130009-02
3) Measure the resistance between the terminals of

IF34J1130013-02
CKP sensor coupler. If the resistance is not within
the standard range, replace the CKP sensor with a
new one. Refer to “Generator Removal” in Section
1J (Page 1J-5) and “Generator Installation” in
Section 1J (Page 1J-6).
CKP sensor resistance at 20 °C (68 °F)
G – B: Approx. 95 – 150 ȍ
Installation Speed Sensor Inspection

Install the speed sensor in the reverse order of removal. BENF34J11306007
Refer to “Speed Sensor Removal and Installation” (Page
1C-4).
• Tighten the speed sensor bolt to the specified torque.
1) Connect a 12 V battery, 10 k resistor and multi
Tightening torque circuit tester to the speed sensor (1) as shown in the
Speed sensor bolt (a): 4.5 N·m (0.46 kgf-m, 3.5 figure.
lbf-ft)
12 V
10 kΩ
B/W
B B/R
(a)
1
IF34J1130015-01
IF34J1130014-02
• Route the speed sensor lead wire. Refer to “Wiring 2) Move a screwdriver back and forth across the pickup
Harness Routing Diagram” in Section 9A (Page 9A-5). surface of the speed sensor. The voltage readings
should cycle as follows (0 V 12 V or 12 V 0 V).
If the voltage reading does not change, replace the
speed sensor with a new one.
NOTE
While testing, the highest voltage reading
should be the same as the battery voltage (12
V).
ID26J1110254-01
Specifications
BENF34J11307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
TP sensor mounting screw 3 0.31 2.5 )(Page 1C-3)
Speed sensor bolt 4.5 0.46 3.5 )(Page 1C-5)
Reference:

BENF34J11308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A )(Page 1C-3)
Special Tool
BENF34J11308002
TP Sensor test lead Torx® wrench (T25H)

)(Page 1C-2) / )(Page 1C-2) /
)(Page 1C-2) )(Page 1C-2) /
)(Page 1C-3)
Torx® is the registered trademark of Camcar Division of Textron inc. U.S.A.

Engine Mechanical: 1D-1
Engine Mechanical
Engine
Precautions
Precautions for Engine Mechanical
BENF34J11400001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).
NOTE
Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake,
exhaust) so that they can be reinstalled in their original positions.

Compression Pressure Check 4) Keep the throttle grip in the fully-opened position.
BENF34J11404001
The compression pressure reading 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 maintenance
records kept at your dealership should include
compression readings for each maintenance service.
NOTE
• Before checking the engine for
compression pressure, make sure that the
cylinder head bolts are tightened to the
IF34J1140002-01
specified torque values and the valves are
properly adjusted. 5) Press the starter switch and crank the engine for a
few seconds. Record the maximum gauge reading
• Make sure that the battery is in fully-
as the cylinder compression.
charged condition.
Compression pressure
1) Warm up the engine. Standard: 900 – 1300 kPa (9.2 – 13.3 kgf/cm2, 130
2) Remove the spark plug. )(Page 1H-3) – 188 psi)
3) Install the compression gauge and adaptor in the Service limit: 500 kPa (5.1 kgf/cm2, 72.5 psi)
spark plug hole. Make sure that the connection is If compression pressure is less than the service
tight. limit, it is considered any of the following
Special tool reasons:
(A): Compression Gauge • Excessively worn cylinder walls
(B): Adaptor • Worn piston or piston rings
• Piston rings stuck in grooves
• Poor valve seating
(A)
• Ruptured or otherwise defective cylinder head
gasket
(B) 6) After checking the compression pressure, install the
removed parts.
IF34J1140001-01
1D-2 Engine Mechanical:

Throttle Cable Routing Diagram
BENF34J11402002
2
3
(a)
[B]
“a”
(a) (c)
6 [A]
1
8 “b”
5
5
2
7
(b)
IF34J1140003-03
[A]: Upper side 4. Throttle cable clamp “a”: 0 mm (0 in)

[B]: Position the throttle cable putting the throttle 5. Clamp “b”: 0 – 5 mm (0 – 0.20 in)
cable upper nut to the end of the throttle : Cut off the excess tip of the clamp.
cable adjusting thread.
1. Throttle cable 6. Frame : 4.5 Nm (0.46 kgf-m, 3.5 lbf-ft)
2. Clutch cable 7. Clutch cable stopper : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Starter cable 8. Wiring harness : 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
3 2
1 6
2
4 1
5
7 4
2
8
2 10
11
1
[A]
2
9
1
10
2
9
12
12
IF34J1140004-05
[A]: Pass the starter cable behind the engine 5. Clutch lever holder 10. Wiring harness
mounting upper plate.
1. Clutch cable 6. Clutch cable end 11. PAIR valve hose
: Insert the clutch cable end into the lever hole
correctly. Make sure that the cable end moves
smoothly without catch on edge of the lever
hole.
2. Starter cable 7. Bushing 12. Engine mounting upper plate
3. Throttle cable 8. Starter cable clamp
4. Clutch lever 9. Clutch cable clamp
: Insert the clutch cable clamp into the hole
fully and check that it is fixed.
Repair Instructions
Intake System Components
BENF34J11406001
[M]
15
7, 11 (b) [H]
14
RH LH 5 (a) [J]
[L]
[K]
[C]
(a)
[F]
[G]
11
[J] FWD
[L]
[K] 8
9
[I] 13
(a) 10
[M] 12
14
13
(a) 1
15
1
2
7
3
[D]
4
[A]
6 [E] FWD
[B]
IF34J1140005-04
[A]: Align lower end of the carburetor overflow hose [L]: Wrap the air cleaner inlet sheet at the tab 10. Joint tube
with the fuel tank water drain hose end. around the frame from the inside and fix it with
the clip.
[B]: Pass the hoses inside of the right frame lower [M]: Pass the slit of the air cleaner inlet sheet 11. Joint tube clamp
cover. through the frame bracket.
[C]: Face the tip of the clamp backward. 1. Carburetor overflow hose 12. Carburetor assembly
: Check that the hose is not folded or crushed.
[D]: Align protrusion on the intake pipe with 2. Fuel tank water drain hose 13. Carburetor air vent hose
cutaway in the joint tube. : Check that the hose is not folded
or crushed.
[E]: Align protrusion on the carburetor with cutaway 3. Fuel tank water drain hose clamp 14. Air cleaner inlet sheet
in the joint tube. : Clamp the carburetor overflow hose and fuel
tank water drain hose together.
[F]: Face the intake pipe nipple diagonally to the 4. Right frame lower cover 15. Air cleaner inlet sheet clip
upper left.
[G]: Face the embossed mark on the joint tube to 5. PCV hose : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
the carburetor.
[H]: Upper side 6. Air cleaner box : 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft)
[I]: Insert the end of the carburetor air vent hose in 7. Air cleaner outlet tube clamp : Do not reuse.
the gap of the air cleaner box directing
downward.
[J]: Inside 8. Intake pipe O-ring
[K]: Outside 9. Intake pipe
Air Cleaner Element Removal and Installation Air Cleaner Element Inspection and Cleaning
BENF34J11406002 BENF34J11406003
Removal Refer to “Air Cleaner Element Removal and Installation”
1) Remove the seat. )(Page 9D-11) (Page 1D-6).
2) Remove the air cleaner cover (1).
Inspection
Inspect the air cleaner element for clogging. If it is
1 clogged with dirt, clean or replace it.
NOTICE
If driving under dusty conditions, clean the
air cleaner element more frequently. Make
sure that the air cleaner is in good condition
at all times. Life of the engine depends
largely on this component.
IF34J1140006-01
3) Remove the air cleaner element (1).
IF34J1140008-01
IF34J1140007-01
Installation
Install the air cleaner element in the reverse order of
removal.
Cleaning 2) Loosen the air cleaner outlet tube clamp screw (1).
1) Carefully use compressed air to blow the dust from 3) Disconnect the PCV hose (2) and PAIR cleaner hose
the air cleaner element. (3).
NOTICE
1
Always apply compressed air to the inside of
the air cleaner element. If compressed air is
applied to the outside, dirt will be forced into
the pores of the air cleaner element,
restricting air flow through the air cleaner
element.
2 3
IF34J1140011-02
4) Remove the air cleaner box (1) to the right side.
IF34J1140009-01
2) Remove the drain plug (1) and drain water from the
air cleaner box.
IF34J1140012-01
Installation
Install the air cleaner box in the reverse order of
removal. Pay attention to the following points:
• Connect the PCV hose. Refer to “Intake System
Components” (Page 1D-5).
1 • Connect the PAIR cleaner hose. Refer to “PAIR
System Hose Routing Diagram” in Section 1B (Page
1B-2).
IF34J1140010-01
• Position the air cleaner outlet tube clamp and tighten
3) Install the drain plug.
the air cleaner outlet tube clamp screw (1) to the
specified torque. )(Page 1D-5)
Air Cleaner Box Removal and Installation
BENF34J11406004 Tightening torque
Removal Air cleaner outlet tube clamp screw (a): 1.5 N·m (
1) Remove the following parts. 0.15 kgf-m, 1.5 lbf-ft)
• Frame upper covers: )(Page 9D-14)
• Fuel tank side covers: )(Page 9D-16)
• Air cleaner element: )(Page 1D-6)
1, (a)
IF34J1140013-02
Throttle Cable Play On-Vehicle Inspection and Throttle Cable Removal and Installation
BENF34J11406042
Adjustment Removal
BENF34J11406041
Inspection 1) Disconnect the throttle cable from right handle
Turn the throttle grip slowly and inspect the throttle cable switch. Refer to “Handlebar Removal and
play “a” at the periphery of the grip. Installation” in Section 6B (Page 6B-3).
Throttle cable play “a” 2) Remove the clamps (1).
2.0 – 4.0 mm (0.08 – 0.16 in)
“a”
IF34J1140016-02
IF34J1140014-01 3) Loosen the lock-nut (1) and disconnect the throttle

cable from carburetor.
Adjustment
1) Move the rubber boot (1).
2) Loosen the lock-nut (2) of the throttle cable.
3) Turn the adjuster (3) in or out until the throttle cable 1
play (at the throttle grip) is within the specification.
Throttle cable play
2.0 – 4.0 mm (0.08 – 0.16 in)
4) Tighten the lock-nut while holding the adjuster.
! WARNING
IF34J1140017-02
After the adjustment is completed, check that
handlebar movement does not raise the Installation
engine idle speed and the throttle grip Install the throttle cable in the reverse order of removal.
returns smoothly and automatically. Pay attention to the following points:
• Install the throttle cable as shown in the throttle cable
routing diagram. Refer to “Throttle Cable Routing
Diagram” (Page 1D-2).
• After installing, check the throttle cable play and
proper operation. )(Page 1D-8)
Throttle Cable Inspection

BENF34J11406043
Check that the throttle cable moves smoothly from full
1 close to full open, and in the reverse direction. If it does
2 3
not move smoothly, lubricate the throttle cable.
IF34J1140015-01
5) Install the rubber boot.

Intake Pipe Removal and Installation • Align protrusion (1) on the intake pipe with cutaway in
BENF34J11406044 the joint tube.
Refer to “Carburetor Assembly Removal and Installation”
in Section 1G (Page 1G-10) • Tighten the joint tube clamp screw to the specified
torque.
Removal Tightening torque
1) Loosen the joint tube clamp screw (1) and remove Joint tube clamp screw (a): 1.5 N·m (0.15 kgf-m,
the joint tube (2). 1.5 lbf-ft)
2) Disconnect the PAIR vacuum hose (3).
(a)
3 1
2 IF34J1140021-01
IF34J1140018-01
3) Remove the intake pipe (1). Cylinder Head Cover Removal and Installation
BENF34J11406005
Removal
1 1) Remove the following parts.
• Frame side covers: )(Page 9D-12)
• Frame front covers: )(Page 9D-13)
2) Disconnect the spark plug cap (1).
3) Remove the cylinder head cover (2) and its gasket.
IF34J1140019-01
2
Installation
Install the intake pipe in the reverse order of removal.
• Install the new O-ring (1).
• Tighten the intake pipe mounting bolts to the specified 1
torque. IF34J1140023-02
Tightening torque
Intake pipe mounting bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1
(a)
IF34J1140020-01
Installation Valve Clearance Inspection and Adjustment

Install the cylinder head cover in the reverse order of BENF34J11406045
Refer to “Cylinder Head Cover Removal and Installation”
(Page 1D-9) and “Spark Plug Removal and Installation”
• Install the new gasket (1) to the cylinder head cover. in Section 1H (Page 1H-3).
• Apply sealant to the “A” of the gasket as shown.
Inspection
‘‘A” : (SUZUKI BOND 1207B)
The valve clearance specification is different between
the intake and exhaust valves. Valve clearance
1 adjustment must be checked and adjusted, a) at the time
of periodic inspection, b) when the valve mechanism is
serviced, and c) when the camshaft is removed for
“A” servicing.
NOTE
• The piston must be at “TDC” in the
compression stroke in order to check the
valve clearance or to adjust valve
clearance.
IF34J1140024-01
• The clearance specification is in COLD
• Set the new gasket (1) to the cylinder head cover bolt
state.
and coat the both sides of the gasket with engine oil.
• For checking the valve clearance, rotate
the crankshaft in the normal running
direction.
1 1) Remove the valve timing inspection plug (1) and

generator cover plug (2).
IF34J1140025-01
• Tighten the cylinder head cover bolts (1) to the

specified torque in order of “1” “2”.
Tightening torque
Cylinder head cover bolt (a): 14 N·m (1.4 kgf-m, 2
10.5 lbf-ft) IF34J1140027-01
1, (a), “1”
1, (a), “2”
IF34J1140026-02
2) Turn the crankshaft to bring the “TDC” line (1) on the

generator rotor to the index mark (2) on the
generator cover.
(a)
IF34J1140031-01
5) Install the new O-rings to valve timing inspection

plug (1) and generator cover plug (2), and then
IF34J1140028-01 tighten each plug to the specified torque.
Tightening torque
Valve timing inspection plug (a): 2.3 N·m (0.23
kgf-m, 2.0 lbf-ft)
2
Generator cover plug (b): 11 N·m (1.1 kgf-m, 8.5
lbf-ft)
1
1 , (a )
IF34J1140029-01
3) Measure the valve clearance inserting a thickness

gauge between the valve stem end and adjusting
screw (1). If the clearance is out of specification,
2 , (b )
loosen the lock-nut (2) and adjust the adjusting
screw to the specified range. IF34J1140032-01
Special tool
(A): Thickness Gauge Cam Chain Tension Adjuster / Camshaft
(B): Valve adjusting wrench ( tappet & socket ) Housing / Camshaft Removal
BENF34J11406046
Valve clearance (cold) (IN.) 1) Remove the cylinder head cover. )(Page 1D-9)
Standard: 0.04 – 0.08 mm (0.0016 – 0.0031 in)
2) Remove the spark plug. )(Page 1H-3)
Valve clearance (cold) (EX.) 3) Remove the valve timing inspection plug (1) and
Standard: 0.12 – 0.16 mm (0.0047 – 0.0063 in) generator cover plug (2).
1
1
(B)
(A)
2
IF34J1140030-01
IF34J1140027-01
4) After finishing the valve clearance adjustment,
tighten the lock-nut to the specified torque.
Tightening torque
Valve clearance adjusting screw lock-nut (a): 10
N·m (1.0 kgf-m, 7.5 lbf-ft)
4) Turn the crankshaft to bring the “TDC” line (1) on the 9) Remove the camshaft housing (1).
generator rotor to the index mark (2) on the
generator cover.
IF34J1140037-01
10) Remove the camshaft (1), dowel pins (2) and C-ring
IF34J1140033-01 (3).
5) Remove the cam chain tension adjuster (1) and
gasket.
1
2
2
3
1
IF34J1140038-01
IF34J1140034-01 Cam Chain Tension Adjuster / Camshaft

6) Hold the crankshaft and remove the bolts (1). Housing / Camshaft Installation
BENF34J11406047
7) Remove the washer (2), decompression cam (3) and
1) Turn the crankshaft to align the “TDC” line (1) on the
camshaft sprocket (4).
generator rotor with the index mark (2) on the
generator cover while keeping the cam chain pulled
upward.
4
2
2
3
1 1
IF34J1140035-01
8) Remove the dowel pin (1) and locating pin (2).

IF34J1140033-01
2
1
IF34J1140036-01
2) Install the C-ring (1) and dowel pins (2). 5) Install the dowel pin (1) and locating pin (2).
2 2
2
1
1
IF34J1140039-02 IF34J1140036-01
3) Apply molybdenum oil solution to the cam faces and 6) Align the engraved lines (1) on the camshaft
install the camshaft (1). sprocket with the cylinder head top surface and
engage the cam chain (2) with the camshaft
“A”: Assembly lubrication (Molybdenum oil
sprocket.
solution)
7) Make sure that the locating pin (3) on the camshaft
aligns with the locating pin hole on the camshaft
“A” sprocket.
IF34J1140155-01
4) Install the camshaft housing (1) and tighten the bolts 3

(2) to the specified torque in order of “1” “4”.
IF34J1140041-02
Tightening torque 8) Install the decompression cam (1).
Camshaft housing bolt (a): 10 N·m (1.0 kgf-m,
9) Turn the decompression arm (2) 140° clockwise and
7.5 lbf-ft)
align the decompression arm pin (3) with the
decompression cam cutaway (4).
2, ( a) , “4”
2, ( a) , “1”
NOTE
Make sure that the decompression spring (5)
2 , ( a ) , “2” is hooked on the decompression arm
1
cutaway.
2 , ( a ) , “3”
2
IF34J1140040-01
3
5
IF34J1140042-01
10) Install the washer (1) and tighten the camshaft 15) Install the rubber cap (1).
sprocket bolts to the specified torque.
Tightening torque
Camshaft sprocket bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1
1
IF34J1140046-02
16) Turn the crankshaft 720 degrees (2 turns) and align

the “TDC” line (1) on the generator rotor with the
(a)
index mark (2) on the generator cover.
IF34J1140043-01
11) Turn the adjusting screw clockwise with a flat-bladed

screwdriver.
2
IF34J1140033-01
17) Recheck the positions of the engraved lines (1) on

the camshaft sprocket with the cylinder head top
IF34J1140044-03
surface.
12) Fit a new gasket (1).
13) Holding the push rod with the flat-bladed screwdriver
(2), install the cam chain tension adjuster with “UP”
mark (3) faced to the top of cylinder head.
14) Tighten the bolts (4) to the specified torque.
Tightening torque
Cam chain tension adjuster mounting bolt (a):
10 N·m (1.0 kgf-m, 7.5 lbf-ft)
1
4, (a) IF34J1140047-01
18) Inspect the valve clearance. )(Page 1D-10)

3
2
1
4, (a)
IF34J1140045-02
19) Install the new O-rings to valve timing inspection Camshaft Sprocket Inspection
plug (1) and generator cover plug (2), and then BENF34J11406049
Refer to “Cam Chain Tension Adjuster / Camshaft
tighten each plug to the specified torque.
Housing / Camshaft Removal” (Page 1D-11) and “Cam
Tightening torque Chain Tension Adjuster / Camshaft Housing / Camshaft
Valve timing inspection plug (a): 2.3 N·m (0.23 Installation” (Page 1D-12).
kgf-m, 2.0 lbf-ft) Check the camshaft sprocket teeth for wear or damage.
Generator cover plug (b): 11 N·m (1.1 kgf-m, 8.5 If any defects are found, replace the camshaft sprocket
lbf-ft) and cam chain as a set. )(Page 1D-31)
1, ( a)
2, ( b)
IF34J1140032-01 IF34J1140048-01
20) Install the spark plug. )(Page 1H-3)

21) Install the cylinder head cover. )(Page 1D-9) Camshaft Housing Disassembly and
Reassembly
BENF34J11406050
Cam Chain Tension Adjuster Inspection Refer to “Cam Chain Tension Adjuster / Camshaft
BENF34J11406048
Refer to “Cam Chain Tension Adjuster / Camshaft Housing / Camshaft Removal” (Page 1D-11) and “Cam
Housing / Camshaft Removal” (Page 1D-11) and “Cam Chain Tension Adjuster / Camshaft Housing / Camshaft
Chain Tension Adjuster / Camshaft Housing / Camshaft Installation” (Page 1D-12).
Installation” (Page 1D-12).
Insert a (–) screwdriver into the slotted end of cam chain Disassembly
tension adjuster and turn it clockwise to lessen the 1) Remove the rocker arm shaft bolts (1).
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.
IF34J1140049-01
2) Pull out the rocker arm shafts (1) using an

appropriate length of M6 bolt (2).
IF34J1140044-03
IF34J1140050-01
3) Remove the exhaust valve rocker arm (1), intake • Tighten the rocker arm shaft bolts to the specified
valve rocker arm (2) and wave washers (3). torque.
Tightening torque
3
Rocker arm shaft bolt (a): 4 N·m (0.41 kgf-m, 3.0
lbf-ft)
2
3
IF34J1140051-01
(a)
Reassembly
Reassemble the camshaft housing in the reverse order
IF34J1140158-01
of disassembly. Pay attention to the following points:
• Apply engine oil to the rocker arm shafts (1)
Rocker Arm Shaft / Rocker Arm Inspection
sufficiently. BENF34J11406051
• Install the rocker arms (2), wave washers (3) and Refer to “Camshaft Housing Disassembly and
rocker arm shafts, and then align the rocker arm shaft Reassembly” (Page 1D-15).
bolt holes (4) with the camshaft housing holes (5).
Rocker Arm Shaft
3
On the sliding surface, take two measurements at right
angle to each other. If the outside diameter is less than
5 the standard value, replace the shaft.
2
Special tool
(A): Micrometer
2 4 Rocker arm shaft O.D. (IN. & EX.)
Standard: 8.981 – 8.990 mm (0.3536 – 0.3539 in)
3 4 1
IF34J1140156-01
(A)
1
3
2 2
IF34J1140053-02
3
4, 5
4, 5
[A]
IF34J1140157-01
[A]: Camshaft sprocket side

Rocker Arm
Measure the rocker arm inside diameter in two directions
at right angle to each other. If the inside diameter
measured exceeds the standard value, replace the
rocker arm. “a”
Special tool
(A): Dial Gauge
(B): Small Bore Gauge attachment
IF34J1140161-01
Rocker arm I.D. (IN. & EX.)
Standard: 9.003 – 9.018 mm (0.3544 – 0.3550 in)
Camshaft Bearing Removal and Installation
BENF34J11406053
Chain Tension Adjuster / Camshaft Housing / Camshaft
Removal
(A) (B)
Remove the camshaft bearings (1) with the special tool.
Special tool
(A): Bearing / Gear Puller
IF34J1140159-02
Camshaft Inspection
BENF34J11406052 (A )
Chain Tension Adjuster / Camshaft Housing / Camshaft
Installation” (Page 1D-12). 1
Camshaft Bearing
Rotate the camshaft bearing outer races (1) by finger to
inspect for abnormal play, noise and smooth rotation.
Replace the bearing if there is anything unusual. IF34J1140055-01
Installation
Install the new camshaft bearings (1) with the special
tool.
Special tool
(A): Bearing Installer Set
[A] [B]
1
(A)
IF34J1140054-02
1
Camshaft (A) 1
Check for abnormal surface damage or wear on the cam
face.
Measure the cam height “a” with a micrometer. Replace
the camshaft if found worn down to the service limit. IF34J1140056-02
Special tool [A]: Left side [B]: Right side

Micrometer
Cam height (IN. & EX.)
Service limit: 33.21 mm (1.307 in)
Cylinder Head Assembly / Cam Chain Guide / 5) Remove the cylinder head assembly.
Cylinder Removal and Installation
BENF34J11406054
Chain Tension Adjuster / Camshaft Housing / Camshaft 1 1
Removal
• Muffler: )(Page 1K-2)
• Intake pipe: )(Page 1D-9)
• PAIR pipe: )(Page 1B-3) IF34J1140059-02
• PAIR control valve assembly: )(Page 1B-4) 6) Remove the cylinder head gasket (1) and dowel pins
(2).
2) Remove the engine mounting upper plate (1).
1 1
2
IF34J1140060-01
IF34J1140057-01
7) Remove the cam chain guide (1) and cylinder (2).
3) Remove the cylinder head bolts (M6) (1).
2
1
IF34J1140061-01
IF34J1140058-02
8) Remove the cylinder gasket (1) and dowel pins (2).
4) Remove the cylinder head bolts (M8) (1) and
washers.
NOTE
Be sure to loosen the cylinder head bolts 2
(M8) evenly and in a crisscross pattern.
IF34J1140062-01
Installation 5) Apply molybdenum oil to the sliding surface of the

1) Thoroughly wipe off oil from the fitting surface of the piston (1), piston rings (2) and cylinder wall.
crankcase. “A”: Assembly lubrication (Molybdenum oil
2) Coat sealant lightly to the mating surfaces at the solution)
parting line between the right and left crankcases as
shown. 2, “A”
“A”: (SUZUKI BOND 1207B)
1, “A”
“A”
IF34J1140064-03
6) Hold the piston rings in proper positions, and insert

the piston into the cylinder (1). )(Page 1D-28)
“A”
NOTE
IF34J1140063-01
3) Install the dowel pins (1) and new cylinder gasket • When inserting the piston into the cylinder,
(2). take care not to bend the piston rings.
• When installing the cylinder, keep the cam
chain (2) taut.
IF34J1140160-01 1
4) Position the gaps of the three rings and side rails as
shown.
IF34J1140065-01
7) Install the cam chain guide (1).

EX.
NOTE
1 2
There is a guide holder at the bottom of cam
chain guide cast in the crankcase. Be sure
that the cam chain guide is inserted to the
holder properly.
IN.
3
ID26J1140121-04
1. 2nd ring and lower side rail

2. Upper side rail
3. 1st ring and spacer
IF34J1140066-01
8) Install the dowel pins (1) and new cylinder head 12) Tighten the cylinder head bolts (M6) (1) to the
gasket (2). specified torque.
Tightening torque
1 Cylinder head bolt (M6) (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
2
1
IF34J1140067-01
9) Place the cylinder head assembly on the cylinder. 1, (a)
NOTE
IF34J1140069-02
When installing the cylinder head, keep the
13) Install the engine mounting upper plate (1) and
cam chain taut.
tighten the bolts to the specified torque.
10) Apply engine oil to the washers (1) and thread Tightening torque
portion “A” of the cylinder head bolts before installing Engine mounting upper plate bolt (a): 23 N·m (
them. 2.3 kgf-m, 17.0 lbf-ft)
Engine mounting upper bolt (b): 23 N·m (2.3 kgf-
NOTE
m, 17.0 lbf-ft)
The rounded side of the washer should be
positioned upside. (a)
“A”
1
IE12J1140074-01
1
11) Tighten the cylinder head bolts (M8) (1) to the
specified torque in order of in order of “1” “4”.
Tightening torque (b)
Cylinder head bolt (M8) (a): 25 N·m (2.5 kgf-m, IF34J1140070-01
18.5 lbf-ft) 14) Install the removed parts.
1, (a), “4” Cylinder Head Disassembly and Reassembly

1, (a), “1”
BENF34J11406055
Refer to “Cylinder Head Assembly / Cam Chain Guide /
Cylinder Removal and Installation” (Page 1D-18).
Disassembly
1) Remove the cam chain tensioner (1).
1, (a), “2” 1, (a), “3”

IF34J1140068-02
IF34J1140071-02
2) Remove the valves and valve springs. )(Page 1D- Cam Chain Tensioner Inspection
21) BENF34J11406057
Refer to “Cylinder Head Disassembly and Reassembly”
Reassembly (Page 1D-20).
Check the contacting surface of the cam chain tensioner.
1) Install the valves and valve springs. )(Page 1D-21) If it is worn or damaged, replace it with a new one.
2) Install the cam chain tensioner (1).
3) Install the new washer (2) to the bolt (3), and then
tighten the bolt to the specified torque.
Tightening torque
Cam chain tensioner bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
3, ( a) 2
IF34J1140074-02
Cam Chain Guide Inspection

BENF34J11406058
1 Cylinder Removal and Installation” (Page 1D-18).
Check the contacting surface of the cam chain guide. If it
IF34J1140072-01 is worn or damaged, replace it with a new one.
Cylinder Head Inspection

BENF34J11406056
1) Decarbonize the combustion chamber.
2) Check the gasket surface of the cylinder head for
distortion with a straightedge and thickness gauge,
taking a clearance reading at several places as
indicated. If the largest reading at any position of the
straightedge exceeds the limit, replace the cylinder
head. IF34J1140075-01
Special tool
Thickness Gauge Valve / Valve Spring Removal and Installation
BENF34J11406017
Cylinder head distortion Refer to “Cylinder Head Assembly / Cam Chain Guide /
Service limit: 0.05 mm (0.002 in) Cylinder Removal and Installation” (Page 1D-18).
NOTICE
Identify the position of each removed part.
Organize the parts so that they can be
reinstalled in their original positions.
IF34J1140073-01
Removal Installation
1) Using the special tools, compress the valve spring 1) Install the valve spring seat (1).
and remove the two cotter halves (1) from the valve 2) Apply molybdenum oil solution to the new oil seal
stem. (2), and press-fit it into position.
Special tool “A”: Assembly lubrication (Molybdenum oil
(A): Valve spring compressor solution)
2 , “A ”
1 1
IF34J1140079-01
(A)
3) Insert the valve, with its stem coated with
IF34J1140076-01
molybdenum oil solution all around and along the full
2) Remove the valve spring retainer (1) and valve stem length without any break.
spring (2).
3) Pull out the valve (3) from the combustion chamber NOTICE
side. When inserting the valve, take care not to
damage the lip of the oil seal.
2
solution)
1 3
IF34J1140077-01
“A”
4) Remove the oil seal (1) and spring seat (2). ID26J1140087-01
4) Install the valve spring with the small-pitch portion

(1) facing cylinder head.
1
4
3 2
1
2
IF34J1140078-01 ID26J1140274-03
5) Remove the other valve in the same manner as 2. Large-pitch portion 4. Paint
described previously. 3. UPWARD
5) Put on the valve spring retainer (1), and using the Valve Inspection
special tools, press down the spring, fit the cotter BENF34J11406018
Refer to “Valve / Valve Spring Removal and Installation”
halves (2) to the stem end, and release the lifter to
(Page 1D-21).
allow the cotter halves to wedge in between retainer
and stem.
Valve Stem Runout
NOTICE Support the valve using V-blocks, and check its runout
using the dial gauge as shown in the figure. If the runout
• Be sure to restore each spring and valve to exceeds the service limit, replace the valve.
their original positions.
• Be careful not to damage the valve and Special tool
valve stem when handling it. (A): Dial Gauge
(B): Dial Gauge Check
• Compressing of the valve spring must be (C): V Block
restricted to the extent only necessary to
prevent the spring from fatigue. Valve stem runout (IN. & EX.)
Special tool
(A): Valve spring compressor (A)
(B)
2 (C)
ID26J1140091-01
(A) Valve Head Radial Runout

IF34J1140080-01 Place the dial gauge at a right angle to the valve head
6) Be sure that the rounded lip (1) of the cotter (3) fits face and measure the valve head radial runout. If it
snugly into the groove (2) in the stem end. measures more than the service limit, replace the valve.
Special tool
2 (A): Dial Gauge
1
(C): V Block
Valve head radial runout (IN. & EX.)
3 Service limit: 0.03 mm (0.001 in)
(A)
IE12J1140082-01
(B)
(C)
ID26J1140092-01
Valve Face Wear Valve stem O.D. (EX.)

Visually inspect each valve face for wear. Replace any Standard: 4.955 – 4.970 mm (0.1951 – 0.1957 in)
valve with an abnormally worn face. The thickness of the
valve face decreases as the face wears. Measure the
valve head “a”. If it is out of specification replace the
valve with a new one.
Special tool
Vernier Caliper
Valve head thickness “a” (IN. & EX.)
(A)
ID26J1140094-01
Valve Stem End Condition

Inspect the valve stem end face for pitting and wear. If
pitting or wear is present, resurface the valve stem end.
“a” Make sure that the length “a” is not less than service
IF34J1140162-01
limit. If this length becomes less than service limit,
replace the valve.
Valve Stem Deflection Valve stem end length (IN. & EX.)
Lift the valve about 10 mm (0.39 in) from the valve seat. Service limit: 2.5 mm (0.099 in)
Measure the valve stem deflection in two directions, (1)
and (2), perpendicular to each other, positioning the dial
gauge as shown in the figure. If the deflection measured
exceeds the service limit, then determine whether the “a”
valve or the guide should be replaced with a new one.
Special tool
(A): Dial Gauge
Valve stem deflection (IN. & EX.)
IE12J1140084-01
(A)
Valve Seat Width
1) Visually check for valve seat width on each valve
face. If the valve face has worn abnormally, replace
1 the valve.
2
2) Coat the valve seat with a red lead (Prussian Blue)
and set the valve in place.
(B)
3) Rotate the valve with light pressure.
Special tool
IF34J1140081-01 (A): Valve Lapper Set
Valve Stem Wear

Measure the valve stem O.D. using the micrometer. (A )
If the valve stem is worn down to the limit, as measured
with a micrometer, replace the valve.
If the stem is within the limit, then replace the guide.
After replacing valve or guide, be sure to recheck the
deflection.
Special tool
(A): Micrometer
Valve stem O.D. (IN.)
IF34J1140082-01
Standard: 4.975 – 4.990 mm (0.1959 – 0.1965 in)
4) Check that the transferred red lead (Blue) on the Special tool
valve face is uniform all around and in center of the (A): Vernier Caliper
valve face.
Valve spring free length (IN. & EX.)
If the seat width “a” measured exceeds the standard
value, or seat width is not uniform reface the seat
using the seat cutter. )(Page 1D-27) Valve spring preload when compressed to 35.8 mm
(1.41 in) (IN. & EX.)
Valve seat width (IN. & EX.)
Standard: 114 – 131 N (11.6 – 13.4 kgf, 25.6 – 29.4 lbf)
Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)
(A)
“a”
ID26J1140098-01
IF34J1140163-01
Valve Seat Sealing Condition

1) Clean and assemble the cylinder head and valve
components.
2) Fill the intake and exhaust ports with gasoline to
check for leaks. If any leaks occur, inspect the valve
seat and face for burrs or other things that could
prevent the valve from sealing. )(Page 1D-27)
ID26J1140263-01
Valve Guide Replacement

BENF34J11406023
(Page 1D-21)
1) Using the special tool, drive the valve guide out
toward the camshaft side.
Special tool
(A): Valve Guide Installer / Remover
IF34J1140083-01
NOTE
Valve Spring Inspection • Discard the removed valve guide sub
BENF34J11406020
Refer to “Valve / Valve Spring Removal and Installation” assemblies.
(Page 1D-21). • Only oversized valve guides are available
The force of the coil spring keeps the valve seat tight. as replacement parts. (Part No. 11115-
Weakened spring results in reduced engine power 34J70)
output and often accounts for the chattering noise
coming from the valve mechanism.
Check the valve springs for proper strength by
(A )
measuring its free length and also by the force required
to compress it. If the spring length is less than the
service limit or if the force required to compress the
spring does not fall within the range specified, replace
spring as a set.
IF34J1140084-01
2) Refinish the valve guide holes in the cylinder head

using the special tools.
(A)
3) Remove the special tools by turning clockwise and
raising them at the same time.
NOTICE (B)
Never turn the special tools
“a”
counterclockwise, as this will dull the blades.
Special tool
1 2
(A): Valve Guide Reamer
ID26J1140106-01
(B): Reamer Handle
1. Cylinder head “a”: 17.0 mm (0.67 in)
2. Valve guide
(B)
(A )
(A)
(B )
IF34J1140085-01
4) Cool down the new valve guides in a freezer for

about one hour and heat the cylinder head to 100 –
IF34J1140086-01
150 °C (212 – 302 °F).
7) After installing the valve guides, refinish their guiding
NOTICE bores using the reamer. Be sure to clean and oil the
Do not use a burner to heat the valve guide guides after reaming.
hole to prevent cylinder head distortion. NOTE
5) Apply engine oil to each valve guide and valve guide • Cool down the cylinder head to ambient air
hole. temperature.
NOTICE • Insert the reamer from the combustion
chamber and always turn the reamer
Failure to oil the valve guide hole before handle clockwise.
driving the new guide into place may result in
a damaged guide or head. Special tool
(A): Reamer Handle
6) Drive the guide into the guide hole using the valve (B): Valve Guide Reamer
guide installer and attachment.
NOTE
Install the valve guide until the attachment
(A )
contacts the cylinder head.
Special tool (B )
(A): Valve Guide Installer / Remover
IF34J1140087-01
Valve Seat Repair

BENF34J11406019
(Page 1D-21).
The valve seats (1) for intake and exhaust valves are
machined to two or three different angles. The seat
contact surface is cut at 45°.
NOTICE
• The valve seat contact area must be
inspected after each cut.
• Do not use lapping compound after the IF34J1140089-01
final cut is made. The finished valve seat
should have a velvety smooth finish but Cylinder Bore
not a highly polished or shiny finish. This Check the cylinder wall for any scratches, nicks or other
will provide a soft surface for the final damage. Measure the cylinder bore diameter at six
seating of the valve which will occur places.
during the first few seconds of engine
operation. Special tool
Cylinder Gauge Set
NOTE Cylinder bore
After servicing the valve seats, be sure to Standard: 56.000 – 56.015 mm (2.2047 – 2.2053 in)
check the valve clearance after the cylinder
head has been installed. )(Page 1D-10)
60° 45° 15° 45° 5°
1 1
IN. EX. IF34J1140090-01

IF34J1140088-01
Intake Exhaust Piston Removal and Installation

Seat angle 15°/45°/60° 5°/45° BENF34J11406025
0.9 – 1.1 mm Refer to “Cylinder Head Assembly / Cam Chain Guide /
Seat width
(0.035 – 0.043 in) Cylinder Removal and Installation” (Page 1D-18).
Valve 29 mm 23 mm
diameter (1.14 in) (0.91 in) Removal
Valve guide 5.000 – 5.012 mm 1) Place a clean rag over the cylinder base so as not to

I.D. (0.1969 – 0.1973 in) drop the piston pin circlip (1) into the crankcase.
2) Remove the piston pin circlip.
Cylinder Inspection
BENF34J11406024 3) Draw out the piston pin (2) and remove the piston
Refer to “Cylinder Head Assembly / Cam Chain Guide / (3).
Cylinder Distortion 3
Check the gasket surface of the cylinder for distortion
with a straightedge and thickness gauge, taking a
clearance reading at several places as indicated. If the
1
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder.
Special tool
Thickness Gauge 2
Cylinder distortion IF34J1140091-01
Installation Piston Ring Removal and Installation

BENF34J11406026
1) When installing the piston pin, apply molybdenum oil Refer to “Piston Removal and Installation” (Page 1D-27).
solution onto the piston pin.
NOTE Removal
1) Carefully spread the ring opening with your thumbs
When installing the piston, the indent (1) on
and then push up the opposite side of the 1st ring to
the piston head must be faced to exhaust
remove it.
side.
NOTE
solution) Do not expand the piston ring excessively
since it is apt to be broken down.
“A” 1
IF34J1140092-01
I831G1140178-01
2) Place a clean rag over the cylinder base so as not to
drop the piston pin circlip (1) into the crankcase. 2) Remove the 2nd ring and oil ring in the same
procedure.
3) Install the new piston pin circlip.
NOTE Installation
End gap of the circlip should not be aligned NOTE
with the cutaway (2) in the piston pin bore.
• When installing the piston ring, be careful
not to damage the piston.
• Do not expand the piston ring excessively
since it is apt to be broken down.
2
1) Install the piston rings in the order of the oil ring, 2nd
ring and 1st ring.
1
a) The first member to go into the of the oil ring
groove is a spacer (1).
After placing the spacer, fit the two side rails (2).
IF34J1140093-01
IE39J1140163-01
NOTICE 2) Position the gaps of the three rings and side rails as
When installing the spacer, be careful not to shown. Before inserting piston into the cylinder,
allow its two ends to overlap in the groove. check that the gaps are so located.
EX.
[A]
1 2
IN.
3
ID26J1140121-04
1. 2nd ring and lower side rail

[B]
IF34J1140094-02
2. Upper side rail
3. 1st ring and spacer
[A]: Incorrect [B]: Correct
b) Install the 2nd ring (1) and 1st ring (2) to piston. Piston and Piston Ring Inspection
BENF34J11406027
Refer to “Piston Ring Removal and Installation” (Page
NOTE
1D-28).
1st ring (2) and 2nd ring (1) differ in shape.
Piston Diameter
Measure the piston diameter using the micrometer at 10
1 mm (0.4 in) “a” from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
Special tool
(A): Micrometer
2
Piston diameter
IF34J1140095-01
NOTE
Face the side with the stamped mark upward
when assembling.
“a”
2
IE12J1140101-01
1 (A)
IE12J1140102-01
IF34J1140096-01
Piston to Cylinder Clearance

Subtract the piston diameter from the cylinder bore
diameter. If the piston to cylinder clearance exceeds the
service limit, replace both the cylinder and the piston.
Piston to cylinder clearance
Piston Ring to Groove Clearance Special tool

Measure the side clearances of the 1st and 2nd piston (A): Vernier Caliper
rings using the thickness gauge. If any of the clearances (B): Thickness Gauge
exceed the limit, replace both the piston and piston
Piston ring free end gap
rings.
Service limit: (1st): 6.6 mm (0.26 in)
Special tool Service limit: (2nd): 6.2 mm (0.24 in)
(A): Thickness Gauge
Piston ring end gap
(B): Micrometer
Piston ring to groove clearance Service limit: (2nd): 0.70 mm (0.028 in)
Service limit: (2nd): 0.150 mm (0.0059 in)
Piston ring groove width
Standard: (1st): 0.81 – 0.83 mm (0.0319 – 0.0327 in)
Standard: (2nd): 0.81 – 0.83 mm (0.0319 – 0.0327 in)
Standard: (Oil): 1.51 – 1.53 mm (0.0594 – 0.0602 in)
(A)
Piston ring thickness
Standard: (1st): 0.77 – 0.79 mm (0.0303 – 0.0311 in)
Standard: (2nd): 0.77 – 0.79 mm (0.0303 – 0.0311 in)
ID26J1140126-02
(B )
(A)
ID26J1140124-01
IF34J1140097-01
Piston Pin Bore

(A)
(A)
(B)
Measure the piston pin bore inside diameter using the
small bore gauge. If measurement is out of specification,
replace the piston.
Special tool
(A): Dial Gauge
ID26J1140125-01 (B): Small Bore Gauge
Piston Ring Free End Gap and Piston Ring End Gap Piston pin bore I.D.
Measure the piston ring free end gap using vernier Service limit: 14.030 mm (0.5524 in)
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
(A)
thickness gauge. If any of the measurements exceed the
(B)
service limit, replace the piston ring with a new one.
ID26J1140128-01
Piston Pin Balancer Shaft Drive / Driven Gear Removal and

Measure the piston pin outside diameter at three Installation
positions using the micrometer. If any of the BENF34J11406060
measurements are out of specification, replace the Removal

piston pin. 1) Remove the following parts.
Special tool • Clutch component parts: )(Page 5C-6)
(A): Micrometer • Oil pump component parts: )(Page 1E-6)
Piston pin O.D. 2) Hold the crank balancer shaft at the width across
Service limit: 13.980 mm (0.5504 in) flats (1) and remove the crank balancer shaft nut (2).
3) Remove the crank balancer driven gear (3).
(A)
2
3
ID26J1140129-01
1
IF34J1140099-02
Cam Chain Removal and Installation
BENF34J11406059 4) Remove the key (1) and spacer (2).
Removal
1) Remove the cylinder. )(Page 1D-18)
2) Remove the starter clutch gear. )(Page 1I-7)
3) Remove the cam chain (1). 1
2
IF34J1140100-02
5) Remove the crank balancer drive gear (1) and key

(2).
IF34J1140098-01
Installation
Install the cam chain in the reverse order of removal.
2
1
IF34J1140101-02
Installation
Install the balancer shaft drive gear and driven gear in 1
the reverse order of removal. Pay attention to the 7
following points: 2
6
• Align the punch marks (1) on the balancer shaft drive
gear (2) and balancer shaft driven gear (3).
5 3
1 4
4 5
3 2
IF34J1140104-01
Reassembly
1) Apply engine oil to the sliding surfaces of the
2 balancer shaft driven gear (1) and inner race (2).
IF34J1140102-02
1
• Hold the crank balancer shaft at the width across flats 2
(1) and tighten the balancer shaft driven gear nut (2)
to the specified torque.
Tightening torque
Balancer shaft driven gear nut (a): 50 N·m (5.1
kgf-m, 37.0 lbf-ft)
IF34J1140105-01
2, (a) 2) Facing the sharp edge side of the snap ring (1)
outward, fit it to the balancer shaft driven gear inner
race (2). Position the opening (3) of the snap ring in
the center of the rib portion as shown in the figure.
3) Install the washer (4) and wave washer (5).
1
5
IF34J1140103-02 2
Balancer Shaft Driven Gear Disassembly and

Reassembly
BENF34J11406061
Refer to “Balancer Shaft Drive / Driven Gear Removal
and Installation” (Page 1D-31).
1
Disassembly 4
3
1) Remove the following parts from the balancer shaft IF34J1140106-01
driven gear inner race (1).
• Snap rings (2)
• Balancer shaft driven gear (3)
• Dampers (4)
• Springs (5)
• Wave washer (6)
• Washer (7)
Special tool
Snapring Pliers
4) Aligning the protrusion (1) with the punch mark (2), Balancer Shaft Drive / Driven Gear Inspection
combine the balancer shaft driven gear inner race BENF34J11406062
Refer to “Balancer Shaft Drive / Driven Gear Removal
with the balancer shaft driven gear.
and Installation” (Page 1D-31).
Inspect the balancer shaft drive gear (1) and driven gear
2 (2) for wear or damage. If any defects are found, replace
them with new ones.
1 2
IF34J1140107-02
5) Align the cutaway (1) of the balancer shaft driven

gear inner race with the punch mark (2) of the
balancer shaft driven gear as shown in the figure and
IF34J1140110-01
install springs (3) and dampers (4).
Engine Assembly Removal
3 BENF34J11406063
1 2
1) Drain engine oil. )(Page 1E-4)
• Frame front covers: )(Page 9D-13)
• Right frame lower cover: )(Page 9D-12)
4 4
3) Disconnect the battery (–) lead wire. )(Page 1J-10)
4) Remove the muffler. )(Page 1K-2)
3 5) Remove the carburetor assembly. )(Page 1G-10)
IF34J1140108-02
6) Facing the sharp edge side of the snap ring (1) 6) Disconnect the spark plug cap (1), PAIR vacuum
outward, fit it to the balancer shaft driven gear inner hose (2) and remove the PAIR pipe (3).
race. Position the opening (2) of the snap ring in the
center of the rib portion as shown in the figure.
1 2
1
3
IF34J1140111-01
2
7) Disconnect the starter motor lead wire (1).
IF34J1140109-02
IF34J1140112-01
8) Disconnect the GP switch lead wire coupler (1), CKP 12) Remove the clutch cable stopper (1) and disconnect
sensor lead wire coupler (2) and generator lead wire the engine ground wire (2).
coupler (3). 13) Disconnect the clutch cable end from the clutch
9) Release the clamp (4). release arm (3). Refer to “Clutch Cable Removal and
Installation” in Section 5C (Page 5C-2).
14) Disconnect the PCV hose (4) from the left
2
crankcase.
1 2
4
1
IF34J1140113-02
10) Remove the engine sprocket (1). )(Page 3A-4)

3
IF34J1140116-02
15) Support the engine using a jack.

1
IF34J1140114-01
11) Disconnect the gearshift link arm (1) from gearshift

shaft (2).
IF34J1140117-01
16) Remove the engine mounting upper plate (1).

2
1
1
IF34J1140115-01
IF34J1140118-01
17) Remove the engine mounting lower bracket (1). Engine Assembly Installation
BENF34J11406064
Install the engine assembly in the reverse order of
• Install the engine assembly using a jack.
NOTICE
Be careful not to catch the wiring harness
1 and hoses between the frame and the engine.
• Insert the engine mounting bolts (1) and (2) from left
side, and install their new nuts (4).
• Install the engine mounting upper plate and engine
IF34J1140119-01
mounting lower bracket.
18) Remove the engine mounting nuts (1) and bolts.
• Tighten the each bolts and nuts to the specified
19) Gradually lower the engine. Then, remove the torque, referring to the following illustration.
engine assembly from the frame.
IF34J1140120-01
LH RH
6 (b)
3
3 (b)
“c”
4 (a) 7 (a)
(a)
2
5
“b”
4 (a)
1
“a”
IF34J1140122-03
1. Engine mounting rear bolt “a”: 140 mm (5.51 in)

2. Engine mounting lower bolt “b”: 85 mm (3.35 in)
3. Engine mounting upper bolt “c”: 20 mm (0.79 in)
4. Engine mounting nut : 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
5. Engine mounting lower bracket bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
6. Engine mounting upper plate bolt : Do not reuse.
7. Engine mounting lower bracket nut
• Check the wiring harness routing. )(Page 9A-5) 10) Remove the GP switch (1). )(Page 5B-9)
• After finishing the engine installation, check the
following items.
– Drive chain slack. )(Page 3A-2)
– Gearshift lever height. )(Page 5B-11)
– Throttle cable play: )(Page 1D-8)
– Clutch cable play: )(Page 5C-2)
1
– Engine oil leakage: )(Page 1E-4)
Crankcase Assembly Disassembly

BENF34J11406030
1) Remove the engine assembly. )(Page 1D-33) IF34J1140124-01
2) Remove the piston. )(Page 1D-27) 11) Remove the generator rotor (1). )(Page 1J-5)
3) Remove the starter motor assembly. )(Page 1I-3) 12) Remove the starter clutch gear (2) and starter idle
4) Remove the oil pump component parts (1). )(Page gear (3). )(Page 1I-7)
1E-6) 13) Remove the cam chain (4). )(Page 1D-31)
5) Remove the oil sump filter (2). )(Page 1E-6)
6) Remove the clutch component parts (3). )(Page 2
5C-6) 4
1 1
3
IF34J1140125-01
14) Remove the crankcase bolts (1).

2 NOTE
IF34J1140121-01
Loosen the crankcase bolts diagonally.
7) Remove the kick starter component parts (1).
)(Page 1I-12)
8) Remove the gearshift component parts (2). )(Page
5B-12)
9) Remove the crank balancer drive gear (3) and crank 1
balancer driven gear (4). )(Page 1D-31)
3
1
IF34J1140126-01
4 1
2
IF34J1140123-02
IF34J1140127-01
15) Remove the right crankcase (1) with the special tool. 18) Remove the transmission component parts. )(Page
5B-3)
NOTE
19) Remove the crankshaft assembly (1) with the special
• Fit the crankcase separating tool, so that tool.
the tool arms are in parallel with the side of
Special tool
crankcase.
(A): Crankcase Separator
• The crankshaft and transmission
components should remain in the left
(A )
crankcase half.
Special tool
(A): Crankcase Separator
1
(A)
1 IF34J1140131-01
20) Remove the crankcase bearings. )(Page 1D-41)
Crankcase Assembly Reassembly

BENF34J11406031
1) Install the crankcase bearings: )(Page 1D-41)
IF34J1140128-01
16) Remove the dowel pins (1). 2) Install the crankshaft assembly into the left
crankcase using the special tools.
1 NOTICE
• Do not hit the crankshaft with a plastic
mallet or the like to install it into the
crankcase.
• Make sure that the direction of conrod is
turned toward the cylinder hole.
IF34J1140129-01
17) Remove the crank balancer shaft (1) and shim (2).
IF34J1140130-01
NOTE 6) Install the dowel pins (1) into the left crankcase.
When installing the crankshaft into the

1
crankcase, insert the (b) Crankshaft Installer
Spacer between (a) Crankshaft Installer and
crankcase from LHS.
Special tool
(A): Crankshaft Installer
(B): Crankshaft Installer Spacer
1
(A )
IF34J1140129-01
7) Apply engine oil to each running and sliding part.

(B)
8) Apply sealant to the mating surface of the right
crankcase.
NOTE
• Make surfaces free from moisture, oil, dust
and other foreign materials.
• Spread on surfaces thinly to form an even
IF34J1140133-01
layer, and assemble the crankcases within
few minutes.
• Take extreme care not to apply any sealant
to the oil hole, oil groove and bearing.
(A)
• Apply to distorted surfaces as it forms a
comparatively thick film.
“A”: (SUZUKI BOND 1215)
(B)
IF34J1140132-01
3) Install the transmission component parts. )(Page

5B-3)
4) Install the crank balancer shaft (1) and shim (2).
“A”
IF34J1140134-02
1
9) Assemble the right and left crankcase halves.
IF34J1140130-01
5) Clean the mating surfaces of the left and right

crankcase halves.
10) Tighten the crankcase bolts (L60) (1) and (L50) (2) a Conrod / Crankshaft Inspection
little at a time to equalize the pressure. BENF34J11406065
Refer to “Crankcase Assembly Disassembly” (Page 1D-
Tightening torque 36) and “Crankcase Assembly Reassembly” (Page 1D-
Crankcase bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 37).
1, ( a) Conrod Small End I.D.

1, ( a) Measure the conrod small end inside diameter with a
pair of dial calipers.
If the conrod small end inside diameter exceeds the
service limit, replace the crankshaft assembly.
Special tool
(A): Dial Caliper
Conrod small end I.D.
1, ( a)
IF34J1140135-01
1, ( a)
2, ( a)
(A)
2, (a)
IF34J1140164-01
1 , (a) 1, ( a)
2, ( a) Conrod Big End Side Clearance
IF34J1140136-01 Push the big end of the conrod to one side and measure
11) After the crankcase bolts have been tightened, the side clearance using a thickness gauge. If the
check if the crankshaft, driveshaft and countershaft clearance exceeds the service limit, replace crankshaft
rotate smoothly. assembly.
Special tool
Conrod big end side clearance
(A )
IF34J1140137-01
IF34J1140139-01
IF34J1140138-01

Conrod Deflection Special tool

Wear on the big end of the conrod can be estimated by (A): Dial Gauge
checking the movement of the small end. This method Dial Gauge Check
can also check the extent of wear on the parts of the V Block
conrod big end.
If the deflection exceeds the service limit, replace the
crankshaft assembly.
(A) (A)
• Move the small end sideways while holding the big
end immovable in thrust direction.
• Measure the amount of deflection.
• Turn the conrod and see if it moves smoothly without
play and noise.
Conrod deflection
Service limit: 3.0 mm (0.12 in) IF34J1140140-01
Special tool
Width Between Crankshaft Webs
(A): Dial Gauge
Measure the width “a” between crankshaft webs. If the
width is out of specification, replace the crankshaft
(C): V Block
assembly.
(A) Width between crankshaft webs “a”
Standard: 49.9 – 50.1 mm (1.965 – 1.972 in)
(B)
(C) “a”
IF34J1140165-01
IF34J1140141-01
Crankshaft Runout
Balancer Shaft Inspection
With the right and left crank journals supported with V- BENF34J11406066
blocks, turn the crankshaft slowly. At this time, measure Refer to “Crankcase Assembly Disassembly” (Page 1D-
the crankshaft end runout using a dial gauge. If the 36) and “Crankcase Assembly Reassembly” (Page 1D-
runout exceeds the service limit, replace the crankshaft 37).
assembly. Inspect the balancer shaft for wear or damage. If any
wear or damage is found, replace the balancer shaft with
NOTE a new one.
Set the V-blocks so that the crankshaft
becomes horizontal.
Crankshaft runout
IF34J1140142-01
Crankcase Bearing / Oil Seal Inspection 2) Inspect oil seal lip (1) for wear or damage. If any
BENF34J11406067 defects are found, replace the oil seal with a new
one. )(Page 5B-7)
36) and “Crankcase Assembly Reassembly” (Page 1D-
37).
1) Inspect the play “a” of the bearings by hand while it
is in the crankcase or installed in the crankshaft.
1
Rotate the inner race or outer race by hand to
inspect for abnormal noise and smooth rotation.
Replace the bearings if there is anything unusual.
)(Page 1D-41)
“a”
“a”
IF34J1140146-01
Crankcase Bearing Removal and Installation

BENF34J11406068
ID26J1140287-02
37).
Removal
Left crankcase
1) Remove the crankshaft bearing (1) and balancer
shaft bearing (2) with the special tools.
Special tool
(B): Bearing Remover
(A)
IF34J1140143-02
(B)
1
2
IF34J1140147-02
2) Remove the driveshaft bearing and countershaft

bearing. )(Page 5B-7)
IF34J1140144-01
Right crankcase Right crankcase

1) Remove the crankshaft bearing (1) and balancer 1) Install the new crankshaft bearing (1) and balancer
shaft bearing (2) with the special tool. shaft bearing (2) using the special tool.
Special tool Special tool
(A): Engine Bearing Puller With Plate (A): Engine Bearing Puller With Plate
(B): Bearing Installer Set (B): Bearing Installer Set
(B)
(A ) (B) (A)
2 2
1 1
IF34J1140149-01 IF34J1140151-01
2) Remove the driveshaft bearing, countershaft bearing 2) Install the driveshaft bearing, countershaft bearing
and gearshift cam bearing. )(Page 5B-7) and gearshift cam bearing. )(Page 5B-7)
Installation Crankshaft Thrust Clearance Inspection and

Left crankcase Shim Selection
BENF34J11406069
1) Install the new crankshaft bearing (1) and balancer
shaft bearing (2) using the special tool.
Special tool 37).
Inspection
( A) 1) Install the crankshaft into the left crankcase.
(A)
2) Clean and degrease the contact surfaces of the
crankshaft, shim and inner race of the right
crankshaft bearing.
3) Install the removed shim (1) onto the crankshaft (2).
1
1
2
IF34J1140150-01
2) Install the driveshaft bearing and countershaft

bearing. )(Page 5B-7) 2
IF34J1140152-01
4) Put the plastigage (special tool) of about 10 mm

(0.39 in) on the shim as shown. 1 , (a )
2 , (a )
Special tool
(A): Plastigage
2 , (a )
(A) 1, (a)
1 , (a ) 2 , (a )
IF34J1140136-01
(A )
6) Separate the crankcase into 2 parts, left and right.
7) Measure the width of compressed plastigage with
the envelope scale.
IF34J1140153-01
Crankshaft thrust clearance
5) Install the right crankcase and tighten the bolts (L60) Standard: –0.02 – 0.07 mm (–0.0008 – 0.0028 in)
(1) and (L50) (2) to the specified torque.
NOTE
Do not apply sealant to the mating surfaces
in this stage.
Tightening torque
Crankcase bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
1, ( a)
1, ( a)
IF34J1140154-01
8) If the thrust clearance is out of standard value, select

an appropriate shim.
1, ( a)
IF34J1140135-01
Selection
1) Remove the thrust shim and measure its thickness using the micrometer.
Special tool
(A): Micrometer
(A)
ID26J1140236-01
2) Select a suitable shim from the following table.

Crankshaft thrust clearance (measured value) +
Part No. Thrust shim thickness
shim thickness (measured value)
0.60 – 0.65 mm (0.024 – 0.026 in) 09181-28187 0.58 – 0.62 mm (0.023 – 0.024 in)
0.65 – 0.70 mm (0.026 – 0.028 in) 09181-28021 0.63 – 0.67 mm (0.025 – 0.026 in)
0.70 – 0.75 mm (0.028 – 0.030 in) 09181-28188 0.68 – 0.72 mm (0.027 – 0.028 in)
0.75 – 0.80 mm (0.030 – 0.031 in) 09181-28189 0.73 – 0.77 mm (0.029 – 0.030 in)
0.80 – 0.85 mm (0.031 – 0.033 in) 09181-28190 0.78 – 0.82 mm (0.031 – 0.032 in)
0.85 – 0.90 mm (0.033 – 0.035 in) 09181-28191 0.83 – 0.87 mm (0.033 – 0.034 in)
0.90 – 0.95 mm (0.035 – 0.037 in) 09181-28192 0.88 – 0.92 mm (0.035 – 0.036 in)
0.95 – 1.00 mm (0.037 – 0.039 in) 09181-28193 0.93 – 0.97 mm (0.037 – 0.038 in)
1.00 – 1.05 mm (0.039 – 0.041 in) 09181-28194 0.98 – 1.02 mm (0.039 – 0.040 in)
1.05 – 1.10 mm (0.041 – 0.043 in) 09181-28197 1.03 – 1.07 mm (0.041 – 0.042 in)
1.10 – 1.15 mm (0.043 – 0.045 in) 09181-28200 1.08 – 1.12 mm (0.043 – 0.044 in)
1.15 – 1.20 mm (0.045 – 0.047 in) 09181-28202 1.13 – 1.17 mm (0.044 – 0.046 in)
1.20 – 1.25 mm (0.047 – 0.049 in) 09181-28204 1.18 – 1.22 mm (0.046 – 0.048 in)
1.25 – 1.30 mm (0.049 – 0.051 in) 09181-28207 1.23 – 1.27 mm (0.048 – 0.050 in)
1.30 – 1.34 mm (0.051 – 0.053 in) 09181-28209 1.28 – 1.32 mm (0.050 – 0.052 in)
Specifications
BENF34J11407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Air cleaner outlet tube clamp screw 1.5 0.15 1.5 )(Page 1D-7)
Intake pipe mounting bolt 10 1.0 7.5 )(Page 1D-9)
Joint tube clamp screw 1.5 0.15 1.5 )(Page 1D-9)
Cylinder head cover bolt 14 1.4 10.5 )(Page 1D-10)
Valve clearance adjusting screw lock-nut 10 1.0 7.5 )(Page 1D-11)
Valve timing inspection plug )(Page 1D-11) /
2.3 0.23 2.0
)(Page 1D-15)
Generator cover plug )(Page 1D-11) /
11 1.1 8.5
)(Page 1D-15)
Camshaft housing bolt 10 1.0 7.5 )(Page 1D-13)
Camshaft sprocket bolt 10 1.0 7.5 )(Page 1D-14)
Cam chain tension adjuster mounting bolt 10 1.0 7.5 )(Page 1D-14)
Rocker arm shaft bolt 4 0.41 3.0 )(Page 1D-16)
Cylinder head bolt (M8) 25 2.5 18.5 )(Page 1D-20)
Cylinder head bolt (M6) 10 1.0 7.5 )(Page 1D-20)
Engine mounting upper plate bolt 23 2.3 17.0 )(Page 1D-20)
Engine mounting upper bolt 23 2.3 17.0 )(Page 1D-20)
Cam chain tensioner bolt 10 1.0 7.5 )(Page 1D-21)
Balancer shaft driven gear nut 50 5.1 37.0 )(Page 1D-32)
Crankcase bolt )(Page 1D-39) /
10 1.0 7.5
)(Page 1D-43)
Reference:
“Throttle Cable Routing Diagram” (Page 1D-2)
“Intake System Components” (Page 1D-5)
“Engine Assembly Installation” (Page 1D-35)

BENF34J11408001
Assembly lubrication Molybdenum oil solution — )(Page 1D-13) / )(Page
1D-19) / )(Page 1D-22) /
)(Page 1D-22) / )(Page
1D-28)
Sealant SUZUKI BOND 1215 )(Page 1D-38)
SUZUKI BOND 1207B )(Page 1D-10) / )(Page
1D-19)
Special Tool
BENF34J11408002
Snap ring pliers (External) Vernier calipers (200 mm)

)(Page 1D-32) )(Page 1D-24) /
)(Page 1D-25) /
)(Page 1D-30)
Micrometer (25 - 50 mm) Micrometer (50 - 75 mm)

)(Page 1D-17) )(Page 1D-29)
Cylinder gauge set Dial gauge (1 x 0.001 mm)

)(Page 1D-27) )(Page 1D-17) /
)(Page 1D-30)
Dial calipers (10 - 34 mm) Dial gauge (10 x 0.01 mm)

)(Page 1D-39) )(Page 1D-23) /
)(Page 1D-23) /
)(Page 1D-24) /
)(Page 1D-40) /
)(Page 1D-40)
Dial gauge chuck Bearing remover set

)(Page 1D-23) / F(Page 1D-41)
)(Page 1D-23) /
)(Page 1D-24) /
)(Page 1D-40) /
)(Page 1D-40)
Thickness gauge V blocks

)(Page 1D-11) / )(Page 1D-23) /
)(Page 1D-21) / )(Page 1D-23) /
)(Page 1D-27) / )(Page 1D-40) /
)(Page 1D-30) / )(Page 1D-40)
)(Page 1D-30) /
)(Page 1D-39)
Plastigage (0.025 - 0.076 Small bore gauge (10 - 18

mm) mm)
)(Page 1D-43) )(Page 1D-30)
Small bore gauge Crankshaft installer

attachment (6-10mm)
)(Page 1D-17) 1. Main unit 2. Attachment
)(Page 1D-38)
Spacer Crankshaft Installer Micrometer (0 - 25 mm)
)(Page 1D-38)
)(Page 1D-16) /
)(Page 1D-24) /
)(Page 1D-30) /
)(Page 1D-31) /
)(Page 1D-43)
Bearing / gear puller Bearing installer set

)(Page 1D-17) )(Page 1D-17) /
)(Page 1D-38) /
)(Page 1D-41) /
)(Page 1D-42) /
)(Page 1D-42) /
)(Page 1D-42)
Compression gauge adapter Compression gauge set

(2500 kpa)
)(Page 1D-1) 1. Gauge 2. Hose (Adapter)
)(Page 1D-1)
Valve lapper set Valve Spring Compressor

)(Page 1D-24)
)(Page 1D-22) /
)(Page 1D-23)
Reamer handle
)(Page 1D-26) /
)(Page 1D-26)
Valve guide reamer (ø5.0) Valve guide reamer (ø10.8)

)(Page 1D-26) )(Page 1D-26)
Valve guide installer / Valve Guide Installer

remover
)(Page 1D-25) / )(Page 1D-26)
)(Page 1D-26)
Tweezers Valve adjusting wrench (tappet & socket)

)(Page 1D-22) / )(Page 1D-11)
)(Page 1D-23)
Crankcase separator
Attachment
)(Page 1D-37) /
)(Page 1D-37)
1E-1 Engine Lubrication System:
Engine Lubrication System

Engine
Precautions
Precautions for Engine Oil
BENF34J11500001
Refer to “Fuel / Oil / Fluid Recommendation” in Section 0C (Page 0C-10).
Engine Lubrication System: 1E-2

Engine Lubrication System Chart Diagram
BENF34J11502001
ROCKER ARM ROCKER ARM

SHAFT (IN.) SHAFT (EX.)
ROCKER ARM ROCKER ARM
CAM FACES AND

CAMSHAFT BEARINGS
CYLINDER WALL CONROD SMALL END
CAM CHAIN
CYLINDER HEAD CONROD BIG END BEARING
CYLINDER
CRANKSHAFT
CYLINDER WALL PISTON
JET
COUNTERSHAFT
LEFT SIDE BEARING
OIL FILTER
DRIVESHAFT LEFT
SIDE BEARING
COUNTERSHAFT BY-PASS
AND GEARS
OIL PUMP
DRIVESHAFT
AND GEARS CLUTCH PLATES
OIL SUMP
FILTER
IF34J1150001-02

Engine Lubrication Symptom Diagnosis
BENF34J11504001

Engine overheats Insufficient amount of engine oil. Check level and add. )(Page 1E-4)
Defective oil pump. Replace. )(Page 1E-6)
Clogged oil circuit. Clean.
Incorrect engine oil. Change. )(Page 1E-4)
Exhaust smoke is dirty or Excessive amount of engine oil. Check level and drain. )(Page 1E-4)
thick
Engine lacks power Excessive amount of engine oil. Check level and drain. )(Page 1E-4)
Oil Pressure Check 3) Warm up the engine as follows:

BENF34J11504002 Summer: 10 min. at 2000 r/min
Check the engine oil pressure periodically. This will give
Winter: 20 min. at 2000 r/min
a good indication of the condition of the moving parts.
4) After warm up, increase the engine speed to 3000 r/
NOTE min and read the oil pressure gauge.
Before checking the oil pressure, check the If the oil pressure is lower or higher than the
following: specification, the following causes may be
considered.
• Oil level: )(Page 1E-4)
• Oil leaks (If leak is found, repair it.) Oil pressure specification when oil temp. is 60 °C
(140 °F)
• Oil quality (If oil is discolored or
30 – 45 kPa (0.31 – 0.46 kgf/cm2, 4.35 – 6.52 psi)
deteriorated, replace it.)
at 3000 r/min
1) Remove the oil gallery plug (M8) (1). High oil pressure Low oil pressure
• Engine oil viscosity is • Clogged oil filter
too high • Oil leakage from the oil
• Clogged oil passage passage
• Combination of the • Damaged O-ring
1
above items • Defective oil pump
• Combination of the
above items
5) Stop the engine and remove the oil pressure gauge

and attachment.
IF34J1150002-01 ! WARNING
2) Install the oil pressure gauge and attachment into
To avoid the risk of being burned, remove the
the oil gallery.
oil pressure gauge when the oil has cooled.
Special tool
(A): Oil Pressure Gauge Set
(B): Oil Pressure Gauge Hose
(B)
( A)
IF34J1150003-01
6) Install the new gasket to the oil gallery plug (M8) (1).
7) Install the oil gallery plug (M8) and tighten it to the
specified torque.
1 , (a )
Tightening torque
Oil gallery plug (M8) (a): 12 N·m (1.2 kgf-m, 9.0
lbf-ft)
IF34J1150004-01
8) Check the engine oil level. )(Page 1E-4)
Repair Instructions
Engine Oil Inspection 2) Place an oil pan below the engine and remove the oil
BENF34J11506001 filler cap (1).
Engine Oil Leakage Inspection
Visually check the cylinder, crankcase, etc. for oil 3) Drain engine oil by removing the oil drain plug (2).
leakage. NOTE
Engine Oil Level Inspection Warming up of the engine will facilitate

draining of the engine oil due to reduction of
1) Keep the motorcycle upright.
the oil viscosity.
2) Start the engine and allow it to run for three minutes
at idling speed.
3) Turn off the engine and wait about three minutes,
then check the oil level through the inspection
window. If the level is below mark “L”, add oil to “F”
level. If the level is above mark “F”, drain oil to “F” 1
level.
F
IF34J1150006-01
4) Install the new gasket washer to the oil drain plug

L
(1).
5) Tighten the oil drain plug to the specified torque.
Tightening torque
IF34J1150005-01
Oil drain plug (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
Engine Oil Replacement

BENF34J11506002
1) Keep the motorcycle upright with the center stand.
1 , (a )
IF34J1150007-01
6) Pour new oil through the oil filler hole. 4) Fix the spring (1) to the oil filter cap firmly.
Necessary amount of engine oil 5) Replace the oil filter cap O-ring (2) with a new one
Oil change: 850 ml (0.90 US qt, 0.75 Imp qt) and apply engine oil to it.
Oil and filter change: 950 ml (1.00 US qt, 0.84 Imp
qt)
1
Engine overhaul: 1100 ml (1.16 US qt, 0.97 Imp
qt)
2
IF34J1150011-01
6) Position the oil filter (1) so that the valve (2) comes
outside.
IF34J1150008-01
7) Install the oil filler cap.

Oil Filter Replacement

BENF34J11506003
2) Remove the oil filter cap (1) and oil filter (2). 2
1
IF34J1150012-01
7) Install the oil filter cap (1) and tighten the bolts (2) to
1 2 the specified torque.
Tightening torque
Oil filter cap bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft)
2 , (a )
IF34J1150009-01
3) Replace the oil filter O-ring (1) with a new one and
apply engine oil to it.
1
1
IF34J1150013-01
8) Add new engine oil. )(Page 1E-4)

IF34J1150010-01
Oil Sump Filter Removal and Installation Oil Sump Filter Inspection and Cleaning
BENF34J11506004 BENF34J11506005
Removal Refer to “Oil Sump Filter Removal and Installation”
1) Remove the clutch cover and gasket. )(Page 5C-6) (Page 1E-6).
If the oil sump filter is clogged with sediment or rust,
2) Remove the oil sump filter (1).
clean the oil sump filter using compressed air.
NOTE
When the oil sump filter is dirtied
excessively, replace it with a new one.
1
IF34J1150014-01
Installation
1) Install the oil sump filter (1).
NOTICE
IF34J1150015-01
• The lip (2) of the oil sump filter should be
positioned downward. Oil Pump Removal and Installation
BENF34J11506011
• The shorter side of the oil sump filter
Removal
should be positioned inside.
NOTICE
Do not attempt to disassemble the oil pump
assembly. The oil pump is available only as
an assembly.
1) Remove the clutch cover and gasket. Refer to

“Clutch Removal” in Section 5C (Page 5C-6).
2) Remove the dowel pin (1), O-ring (2), E-ring (3) and
oil pump driven gear (4).
2
1
IF34J1150014-01
1
3
“a”
2
[a]
4
IF34J1150016-01
IF34J1150026-02
“a”: Shorter side [a]: Down side
2) Install the clutch cover. )(Page 5C-7)

3) Remove the pin (1), oil pump (2) and dowel pins (3). Installation
Install the oil pump in the reverse order of removal. Pay
attention to the following points:
• Install the oil pump drive gear (1), washer (2), conical
spring washer (3) and oil pump drive gear nut (4).
2
NOTE
• The conical curve side of spring washer
faces outside.
• The primary drive gear nut has left-hand
3 threads.
1
IF34J1150017-01
4) Remove the generator cover. Refer to “Generator

Removal” in Section 1J (Page 1J-5).
5) Hold the generator rotor (1) with the special tool and
remove the oil pump drive gear nut (2).
NOTE
1
This oil pump drive gear nut has left-hand
threads. 2
3
Special tool 4 1 2 3 4
(A): Rotor Holder IF34J1150020-01
• Hold the generator rotor (1) with the special tool and
tighten the oil pump drive gear nut (2) to the specified
torque.
2 Special tool
1 (A): Rotor Holder
Tightening torque
Oil pump drive gear nut (a): 50 N·m (5.1 kgf-m,
(A) 37.0 lbf-ft)
IF34J1150018-01
6) Remove the conical spring washer (1), washer (2)

and oil pump drive gear (3).
1
(A)
2, (a)
3
IF34J1150021-02
IF34J1150019-01
• Tighten the oil pump mounting bolts to the specified Oil Pump Inspection
torque. BENF34J11506012
Refer to “Oil Pump Removal and Installation” (Page 1E-
Tightening torque 6).
Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m, Rotate the oil pump by hand and check that it moves
7.5 lbf-ft) smoothly. If it does not move smoothly, replace the oil
pump assembly.
( a)
(a)
IF34J1150022-01
• When installing a new E-ring (1), pay attention to its IF34J1150025-01
direction. Fit it to the side where the thrust (2) is as

shown in the illustration.
3 1
IF34J1150023-01
3. Oil pump driven gear 4. Sharp edge
• Apply engine oil to the new O-ring (1) and install it.
IF34J1150024-01
Specifications
BENF34J11507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil gallery plug (M8) 12 1.2 9.0 )(Page 1E-4)
Oil drain plug 18 1.8 13.5 )(Page 1E-4)
Oil filter cap bolt 10 1.0 7.5 )(Page 1E-5)
Oil pump drive gear nut 50 5.1 37.0 )(Page 1E-7)
Oil pump mounting bolt 10 1.0 7.5 )(Page 1E-8)
Reference:

Special Tool
BENF34J11508001
Oil pressure gauge set (600 Adapter Pressure Gauge

kpa)
)(Page 1E-3)
1. Gauge 2. Hose
)(Page 1E-3)
Rotor holder
)(Page 1E-7) /
)(Page 1E-7)
Fuel System: 1G-1
Fuel System
Engine
Precautions
Precautions for Fuel System
BENF34J11700001
! WARNING
• Keep away from fire or spark.

• During disassembling, 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 carburetor, tape the cylinder intake section to prevent foreign particles from
entering.
General Description
I.D. No. Location
BENF34J11701001
The carburetor has an I.D. number (1) printed on its body.
IF34J1170001-02
1G-2 Fuel System:

Fuel Hose Routing Diagram
BENF34J11702001
[A]
FWD
7 [A] (a) 5
7
2
1
6 7
[D]
3
[C]
3
[B] 4
8
FWD
IF34J1170002-03
[A]: Insert the hose to the nipple up to the end of the 2. PAIR cleaner hose 7. Clamp
strait part of the nipple. : Face the tip of the clamp front side.
[B]: Pass the fuel tank water drain hose behind the 3. Fuel tank water drain hose 8. carburetor overflow hose
PCV hose.
[C]: Clamp the fuel tank water drain hose at the white 4. PCV hose : 4.4 Nm (0.45 kgf-m, 3.5 lbf-ft)
mark together with the carburetor overflow hose
and push them inside until they touch the clutch
cover.
[D]: PAIR cleaner hose protector end 5. Fuel valve
1. Fuel hose 6. Clamp
: Position the long straight side of the hose toward : Clamp the fuel tank water drain hose
the carburetor. and PAIR cleaner hose at out of the
PAIR cleaner hose protector front end
positioning its tab upward and the
protrusion inward.
Fuel System: 1G-3

Fuel System Symptom Diagnosis
BENF34J11704001

Starting difficulty Clogged starter jet. Clean. )(Page 1G-16)
Clogged starter jet passage. Clean. )(Page 1G-16)
Air leaking from joint between starter Tighten, adjust or replace gasket. )(Page 1D-
body and carburetor. 5)
Improperly working starter plunger. Check. )(Page 1G-10)
Clean. )(Page 1G-16)
Idling or low-speed Clogged or loose slow jet. Clean or tighten. )(Page 1G-16)
trouble Clogged slow jet passage. Clean. )(Page 1G-16)
Clogged pilot outlet port. Clean. )(Page 1G-16)
Clogged bypass port. Clean. )(Page 1G-16)
Starter plunger not fully closed. Check. )(Page 1G-10)
Improperly set pilot screw. Adjust. )(Page 1G-11)
Incorrect float height. Adjust. )(Page 1G-16)
Medium-or high speed Clogged main jet. Clean. )(Page 1G-16)
trouble Clogged main air jet. Clean. )(Page 1G-16)
Clogged needle jet. Clean. )(Page 1G-16)
Improperly working throttle valve. Check. )(Page 1G-16)
Clogged fuel filter. Clean or replace. )(Page 1G-6)
Incorrect float height. Adjust. )(Page 1G-16)
Starter plunger not fully closed. Check. )(Page 1G-10)
Overflow and fuel level Worn or damaged needle valve. Replace. )(Page 1G-11)
fluctuations Broken needle valve. Replace. )(Page 1G-11)
Improperly working float. Adjust or replace. )(Page 1G-16)
Foreign matter on the needle valve. Clean or replace with needle valve seat.
)(Page 1G-16)
Repair Instructions
Fuel Hose Inspection
BENF34J11706039
2) Inspect the fuel hose (1) for damage and fuel
leakage. If any defects are found, replace the fuel
hose with a new one.
IF34J1170003-01
3) After finishing the fuel hose inspection, reinstall the

removed parts.
1G-4 Fuel System:
Fuel Tank Construction

BENF34J11706001
(a) 2
3 4
1
(a)
4
4
(a)
4 4
“a”
5
IF34J1170004-01
1. Fuel tank 5. Clamp

: Cut off the tip of the clamp leaving 10 mm (0.39 in) at the
maximum.
: Position the clamp end within the range as shown in the figure.
2. Fuel cap assembly “a”: 45°
3. Fuel tank brace : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
4. Cushion
Fuel System: 1G-5
Fuel Tank Removal and Installation Installation

BENF34J11706002 Install the fuel tank in the reverse order of removal. Pay
attention to the following point:
Removal
• Tighten the fuel tank brace mounting bolts and fuel
1) Remove the fuel tank covers. )(Page 9D-16)
tank mounting bolts to the specified torque.
2) Turn the fuel valve (1) to OFF position.
Tightening torque
3) Disconnect the fuel hose (2), fuel tank water drain
Fuel tank brace mounting bolt (a): 10 N·m (1.0
hose (3) and fuel level gauge lead wire coupler (4).
kgf-m, 7.5 lbf-ft)
Fuel tank mounting bolt (b): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1
3
4
IF34J1170005-01
(a)
4) Remove the fuel tank (1).
IF34J1170008-01
(b)
IF34J1170006-01
5) Remove the fuel tank brace (1). IF34J1170009-01
Fuel Valve Removal and Installation

BENF34J11706003
Removal
1) Remove the fuel tank. )(Page 1G-5)
2) Remove the fuel valve (1).
IF34J1170007-01
6) Drain fuel completely.
1
IF34J1170010-01
1G-6 Fuel System:
Installation Fuel Level Gauge Removal and Installation

Install the fuel valve in the reverse order of removal. Pay BENF34J11706005
Removal
1) Remove the fuel tank. )(Page 1G-5)
• Install the new gasket (1) and gasket washers (2).
2) Remove the fuel level gauge (1).
1
1
IF34J1170011-01
IF34J1170014-01
• Tighten the fuel valve bolts (1) to the specified torque.
Tightening torque Installation
Fuel valve bolt (a): 4.4 N·m (0.45 kgf-m, 3.5 lbf-ft) Install the fuel level gauge in the reverse order of
• Install the new O-ring (1).
1, ( a) • Tighten the fuel gauge mounting nuts to the specified
torque.
Tightening torque
Fuel gauge mounting nut (a): 5 N·m (0.51 kgf-m,
4.0 lbf-ft)
(a)
1
IF34J1170012-01
Fuel Filter Inspection and Cleaning

BENF34J11706004
Refer to “Fuel Valve Removal and Installation” (Page
1G-5).
Inspect and cleaning the fuel filter.
If the fuel filter is clogged excessively, replace the fuel (a)
valve with a new one.
IF34J1170015-01
IF34J1170013-02
Fuel System: 1G-7
Fuel Level Gauge Inspection 3) Disconnect the starter cable end (1) from starter
BENF34J11706006 lever (2).
Refer to “Fuel Level Gauge Removal and Installation”
(Page 1G-6).
2
1) Inspect the float (1) of the fuel gauge assembly
moves smoothly.
2) Using the multi circuit tester, measure the resistance
between the terminals at full position (1) and empty
position (2) of the fuel level gauge float. If the
resistance is incorrect, replace the fuel level gauge
with a new one.
Fuel level gauge resistance
1
Full: 8 – 17
Empty: 209 – 219 IF34J1170018-01
4) Release the starter cable from the clamp (1).
“a” 1
Ω
2
IF34J1170019-01

“b”
IF34J1170016-01
“a”: 126.3 – 132.3 mm (4.97 – 5.21 “b”: 12.7 – 18.7 mm (0.50 – 0.74
in) in)
1
Starter Cable Removal and Installation
BENF34J11706010
Removal
1) Remove the frame side covers. Refer to “Frame Side
Cover Removal and Installation” in Section 9D (Page
9D-12).
2) Remove the left handle switch (1).
IF34J1170056-01
6) Remove the starter cable (1) from carburetor

assembly.
1
1
IF34J1170017-01
IF34J1170020-02
1G-8 Fuel System:
Installation
Install the starter cable in the reverse order of removal.
• Install the starter cable as shown in the throttle cable
routing diagram. Refer to “Throttle Cable Routing
Diagram” in Section 1D (Page 1D-2).
• Install the new O-ring (1) and tighten the starter cable
guide holder (2) to the specified torque.
Tightening torque
Starter cable guide holder (a): 2.5 N·m (0.25 kgf-
m, 2.0 lbf-ft)
1 2, ( a)
IF34J1170021-02
• After installing, check the proper operation.
Starter Cable On-Vehicle Inspection

BENF34J11706011
Refer to “Frame Side Cover Removal and Installation” in
Check that the starter knob moves smoothly from full
open to full close. If it does not smoothly, lubricate the
starter cable.
Fuel System: 1G-9
Carburetor Components
BENF34J11706013
1
4
(d)
5
19
2
6
9 (f)
10 (a)
12 (b) (e)
11 (a) 16
8
(c)
13
14
15
18 (c)
20
17
(c)
IF34J1170022-01
1. Carburetor top cap 11. Main jet : 1.8 Nm (0.18 kgf-m, 1.5 lbf-ft)
2. Spring 12. Pilot jet : 0.8 Nm (0.08 kgf-m, 0.5 lbf-ft)
3. Holder 13. Needle valve : 2.0 Nm (0.20 kgf-m, 1.5 lbf-ft)
4. Jet needle 14. Float : 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)
5. Diaphragm 15. Pilot screw : 3.0 Nm (0.31 kgf-m, 2.5 lbf-ft)
6. Piston valve 16. Throttle stop screw : 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
7. Starter plunger 17. Float chamber body : Apply grease.
8. TP sensor 18. Fuel drain screw : Apply engine oil.
9. Needle jet 19. Carburetor air vent hose : Do not reuse.

10. Needle jet holder 20. Carburetor overflow hose
1G-10 Fuel System:
Engine Idle Speed Inspection and Adjustment Carburetor Assembly Removal and Installation
BENF34J11706040 BENF34J11706014
1) Remove the following parts. Removal
• Right frame front cover: )(Page 9D-13) 1) Remove the following parts.
• Right frame side cover: )(Page 9D-12) • Frame side covers: )(Page 9D-12)
2) Before inspection the engine idle speed, check the • Frame upper covers: )(Page 9D-14)
throttle cable play. )(Page 1D-8) 2) Turn the fuel valve (1) to OFF position and
3) Warm up the engine. disconnect the fuel hose (2).
5) Connect the special tool to the high-tension cord.
1
Special tool
(A): Techometer
2
IF34J1170025-01
3) Disconnect the starter cable (1) and TP sensor

coupler (2).
(A)
IF34J1170023-01
6) Start the engine and set the engine idle speed within
the specified range by turning the throttle stop screw
2
(1).
Engine idle speed
1600 ± 100 r/min
1
IF34J1170026-02
4) Loosen the fuel drain screw (1) and drain gasoline.

5) Tighten the fuel drain screw.
Tightening torque
Fuel drain screw (a): 2 N·m (0.20 kgf-m, 1.5 lbf-
ft)
1
IF34J1170024-02

8) Remove the special tool and install the removed
parts.
1, (a)
IF34J1170027-02
Fuel System: 1G-11
6) Disconnect the throttle cable (1) and loosen the • Perform the following adjustments.
clamp screws (2). – Engine idle speed. Refer to “Engine Idle Speed
Inspection and Adjustment” (Page 1G-10).
1
– Throttle cable play. Refer to “Throttle Cable Play
2 On-Vehicle Inspection and Adjustment” in Section
2 1D (Page 1D-8).
Carburetor Disassembly and Reassembly

BENF34J11706015
Refer to “Carburetor Assembly Removal and Installation”
(Page 1G-10)
NOTICE
IF34J1170028-02 • Never remove the throttle valve (1).
7) Slightly move the air cleaner box (1) backward and • Never remove the jets (2) and (3). They are
remove the carburetor assembly. press fitted at the factory and attempting
to remove them will cause damage.
• Do not use compressed air on the
carburetor body before removing the
diaphragm; this may damage the
diaphragm.
1 1 3
IF34J1170029-02
Installation
Install the carburetor assembly in the reverse order of
• Align protrusion (1) on the carburetor with cutaway in 1
the joint tube. IF34J1170039-01
1) Remove the fuel hose (1), air vent hose (2) and
overflow hose (3).
1
2
1
IF34J1170030-02
3
• Route the fuel hoses properly. Refer to “Intake System
Components” in Section 1D (Page 1D-5) and “Fuel IF34J1170031-02
Hose Routing Diagram” (Page 1G-2).
• Install the new O-ring and tighten the starter cable
guide holder to the specified torque. Refer to “Starter
Cable Removal and Installation” (Page 1G-7).
• Tighten the throttle cable lock-nut to the specified
torque. Refer to “Throttle Cable Routing Diagram” in
• Tighten the air cleaner box bolts and clamp screws to
the specified torque. Refer to “Intake System
Components” in Section 1D (Page 1D-5).
1G-12 Fuel System:
2) Remove the carburetor top cap (1). 5) Remove the following parts.
• Spring (1)
• Washer (2)
• E-ring (3)
• Ring (4)
• Jet needle (5)
5
1 4
IF34J1170032-01
3) Remove the spring (1) and diaphragm (2).
2
3 2 1
IF34J1170035-01
6) Remove the float chamber body (1).

1
1
IF34J1170033-01
4) Remove the holder (1) from diaphragm by turning it

counterclockwise with a screwdriver.
IF34J1170036-01
7) Remove the float pin (1), float (2) and needle valve
(3).
1
2
IF34J1170034-01
3
1
IF34J1170037-01
Fuel System: 1G-13
8) Remove the following parts. 10) Remove the pilot screw (1), spring (2), washer (3)
• Main jet (1) and O-rings (4).
• Needle jet holder (2) NOTE
• Needle jet (3) Before removing the pilot screw, determine
• Pilot jet (4) the setting by slowly turning it clockwise and
count the number of turns required to lightly
1 seat the screw. This counted number is
important when reassembling pilot screw to
4 original position.
3
4
IF34J1170038-01
9) Remove the throttle position sensor (1) using the 3

special tool.
2
NOTE 1
4
Prior to disassembly, mark (2) on the throttle IF34J1170041-03
position sensor original position with paint or 11) Remove the throttle stop screw (1) and spring (2).
scribe for accurate reinstallation.
Special tool
Torx Wrench
2 1
IF34J1170051-01
2 Reassembly
1 Reassemble the carburetor in the reverse order of
IF34J1170040-02 disassembly. Pay attention to the following points:
• Install the new pilot screw O-rings (1).
1
IF34J1170042-01
1G-14 Fuel System:
• Install the pilot screw to the original setting by turning • Install a new O-ring (1) to the float chamber body
the screw (1) in until it lightly seats, and then backing properly.
it out the same number of turns counted during
disassembly.
IF34J1170044-01
• Install the float chamber body (1), and tighten the

IF34J1170043-02 screws to the specified torque.
• Install the needle jet (1) with the shorter flange “a”
Tightening torque
facing the main jet side.
Float chamber body screw (a): 2.0 N·m (0.20 kgf-
• Install the needle jet holder (2), main jet (3) and pilot m, 1.5 lbf-ft)
jet (4), and tighten them to the specified torque.
Tightening torque
(a)
Needle jet holder (a): 1.8 N·m (0.18 kgf-m, 1.5 lbf-
ft)
Main jet (b): 1.8 N·m (0.18 kgf-m, 1.5 lbf-ft)
Pilot jet (c): 0.8 N·m (0.08 kgf-m, 0.5 lbf-ft)
3, (b) 1
1 4, (c)
IF34J1170054-01
2, (a)
“a”
IF34J1170052-01
• Install the float (1), needle valve (2) and float pin (3)
as a set, and tighten the float pin screw to the
specified torque.
Tightening torque
Float pin screw (a): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)
(a)
1
2
3
IF34J1170053-01
• Check the float height. )(Page 1G-16)

Fuel System: 1G-15
• Install the diaphragm (1) and spring (2). • Apply a thin coat of engine oil to the new O-ring (1).
• Apply grease to the throttle shaft end (2), if necessary.
NOTE
When installing the diaphragm, make sure “A”: (SUZUKI SUPER GREASE A)
the tab (3) of the diaphragm is aligned with
the concave section of the carburetor body’s • With the throttle valve fully closed, install the TP
rim. sensor (3) aligning the throttle shaft end with the
groove (4) of the TP sensor.
• Tighten the TP sensor mounting screw to the
specified torque.
1
Tightening torque
TP sensor mounting screw: 3.0 N·m (0.31 kgf-m,
2.5 lbf-ft)
3
3 4
IF34J1170045-02
2, “A”
1
IF34J1170046-02
• After installing the TP sensor, make sure the throttle

2
valve (1) opens or closes smoothly, and adjust the TP
sensor position. )(Page 1C-1)
1
IF34J1170057-01
• Tighten the carburetor top cap screws (1) to the

specified torque.
Tightening torque
Carburetor top cap screw (a): 3.5 N·m (0.36 kgf-
m, 2.5 lbf-ft)
1, (a)
IF34J1170047-01
• After installing the carburetor to the engine, adjust the

engine idle speed. )(Page 1G-10)
1, (a)
IF34J1170055-01
1G-16 Fuel System:
Float Height Inspection and Adjustment Carburetor Inspection and Cleaning

BENF34J11706017 BENF34J11706018
Refer to “Carburetor Assembly Removal and Installation” Refer to “Carburetor Disassembly and Reassembly”
(Page 1G-10). (Page 1G-11).
1) Remove the float chamber body. Refer to
“Carburetor Disassembly and Reassembly” (Page Inspection
1G-11). Carburetor parts
2) To check the float height, tilt the carburetor as Check the following items for any damage or clogging.
shown. If they are clogged, clean the fuel passage.
3) Measure the float height “a” while the float arm is just • Main jet
contacting the needle valve using vernier calipers. • Pilot jet
Bend the tongue (1) as necessary to bring the float • Main air jet
height “a” to the specified level. • Pilot air jet
Special tool • Needle jet holder air bleeding holes
09900–20102 • Float
Float height “a” • Jet needle
7.1 ± 1.0 mm (0.28 ± 0.04 in) • Piston valve
• Starter plunger
• O-rings
• Diaphragm
• Pilot outlet and bypass ports
Needle Valve
Check the needle valve for damage or worn.
If foreign matter is caught between the valve seat and
the needle valve, the gasoline will continue flowing and
“a” overflow. If the valve seat and needle valve are worn
IF34J1170048-02 beyond the permissible limits, similar trouble will occur.
Conversely, if the needle valve sticks, the gasoline will
not flow into the float chamber. Clean the float chamber
and float parts with gasoline. If the needle valve is worn,
as shown in the illustration, replace it along with a new
valve seat.
IF34J1170049-01
4) Install the float chamber body. Refer to “Carburetor

Disassembly and Reassembly” (Page 1G-11).
[A] [B]
IF34J1170050-01
[A]: Correct [B]: Incorrect

Fuel System: 1G-17
Throttle Valve
Check the throttle valve (1) moves smoothly from full
open to full close. If it does not smoothly, clean the
carburetor.
IF34J1170047-01
Cleaning
! WARNING
Some carburetor cleaning chemicals,
especially dip-type soaking solutions, are
very corrosive and must be handled carefully.
Always follow the chemical manufacturer’s
instructions on proper use, handling and
storage.
1) Clean all jets with a spray-type carburetor cleaner

and dry them using compressed air.
I649G1170063-02
2) Clean all circuits of the carburetor thoroughly – not

just the perceived problem area.
3) Clean the circuits in the carburetor body with a
spray-type cleaner and allow each circuit to soak, if
necessary, to loosen dirt and varnish.
4) Blow the body dry using compressed air.
NOTICE
Do not use a wire to clean the jets or
passageways. A wire can damage the jets
and passageways. If the components cannot
be cleaned with a spray cleaner it may be
necessary to use a dip-type cleaning solution
and allow them to soak.
1G-18 Fuel System:
Specifications
BENF34J11707001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel tank brace mounting bolt 10 1.0 7.5 )(Page 1G-5)
Fuel tank mounting bolt 10 1.0 7.5 )(Page 1G-5)
Fuel valve bolt 4.4 0.45 3.5 )(Page 1G-6)
Fuel gauge mounting nut 5 0.51 4.0 )(Page 1G-6)
Starter cable guide holder 2.5 0.25 2.0 )(Page 1G-8)
Fuel drain screw 2 0.20 1.5 )(Page 1G-10)
Needle jet holder 1.8 0.18 1.5 )(Page 1G-14)
Main jet 1.8 0.18 1.5 )(Page 1G-14)
Pilot jet 0.8 0.08 0.5 )(Page 1G-14)
Float pin screw 2.0 0.20 1.5 )(Page 1G-14)
Float chamber body screw 2.0 0.20 1.5 )(Page 1G-14)
Carburetor top cap screw 3.5 0.36 2.5 )(Page 1G-15)
TP sensor mounting screw 3.0 0.31 2.5 )(Page 1G-15)
Reference:
“Fuel Hose Routing Diagram” (Page 1G-2)
“Fuel Tank Construction” (Page 1G-4)
“Carburetor Components” (Page 1G-9)

BENF34J11708001
Grease SUZUKI SUPER GREASE A )(Page 1G-15)
NOTE
“Carburetor Components” (Page 1G-9)
Special Tool
BENF34J11708002
Vernier calipers (200 mm) Engine tachometer

)(Page 1G-16) )(Page 1G-10)
Torx® wrench (T25H)

)(Page 1G-13)

Ignition System: 1H-1
Ignition System
Engine

Ignition System Diagram
BENF34J11802001
2 6 7
3 O/W
Y Y 8 9
10
4
B/W
IF34J1180001-01
1. Battery 5. CKP sensor 9. Ignition coil

2. Fuse 6. Ignition switch 10. Spark plug
3. Regulator/rectifier 7. Engine stop switch
4. Generator 8. CDI unit
Ignition System Components Location

BENF34J11802002

Ignition System Symptom Diagnosis
BENF34J11804001

Spark plug not sparking Damaged spark plug. Replace. )(Page 1H-3)
Fouled spark plug. Replace. )(Page 1H-3)
Wet spark plug. Dry or replace. )(Page 1H-4)
Defective ignition coil or spark plug cap. Replace. )(Page 1H-4)
)(Page 1J-6)
Open-circuited wiring connections. Repair or replace. )(Page 9A-4)
Open or short in high-tension cord. Replace. )(Page 1H-4)
Engine stalls easily (No Fouled spark plug. Replace. )(Page 1H-3)
spark) Defective CKP sensor. Replace. )(Page 1J-5)
)(Page 1J-6)
Spark plug is wet or Excessively rich air/fuel mixture. Adjust carburetor.
quickly becomes fouled Excessively idling speed. Adjust carburetor. )(Page 1G-10)
with carbon Incorrect gasoline. Change.
Dirty air cleaner element. Replace. )(Page 1D-6)
Incorrect spark plug (Cold type). Change to standard spark plug. )(Page 1H-3)
1H-2 Ignition System:

Spark plug quickly Worn piston rings. Replace. )(Page 1D-27)
becomes fouled with oil Worn piston. Replace. )(Page 1D-27)
or carbon Worn cylinder. Replace. )(Page 1D-18)
Excessive valve-stem to valve-guide Replace. )(Page 1D-21)
clearance.
Worn valve stem oil seals. Replace. )(Page 1D-21)
Spark plug electrodes Incorrect spark plug (Hot type). Change to standard spark plug. )(Page 1H-3)
overheat or burn Overheated engine. Tune-up.
Loose spark plug. Tighten. )(Page 1H-3)
Excessively lean air/fuel mixture. Adjust carburetor.
No Spark or Poor Spark Step 4

BENF34J11804002
Troubleshooting Inspect the spark plug. )(Page 1H-4)
Is the spark plug OK?
Step 1
1) Check that the transmission is in neutral and the Yes Go to Step 5.
engine stop switch is in the “RUN” position.
No Faulty spark plug.
2) Check that the fuse is not blown and the battery is
fully-charged before diagnosing. Step 5
3) Check the ignition system couplers for poor Inspect the ignition coil. )(Page 1H-5)
connections. Is the ignition coil OK?
Are check result OK?
Yes Go to Step 6.
Yes Go to Step 2.
No Faulty ignition coil.
No Repair or replace defective part.
Step 6
Step 2 Measure the CKP sensor peak voltage and its
1) Turn the ignition switch ON. resistance. Refer to “CKP Sensor Inspection” in
Section 1C (Page 1C-3).
2) Measure the battery voltage between O/W wire
(+) and B/W wire (–) of CDI unit. Refer to “Ignition Are the peak voltage and resistance OK?
System Diagram” (Page 1H-1).
Yes • Faulty CDI unit.
Is the voltage OK? • Open or short circuit in wire harness.
Yes Go to Step 3. • Poor connection of ignition couplers.
No • Faulty ignition switch. No • Faulty CKP sensor.
• Faulty engine stop switch. • Metal particles or foreign material being
• Broken wire harness or poor connection stuck on the CKP sensor and rotor tip.
of related circuit couplers.
Step 3
Measure the ignition coil primary peak voltage. Refer
to “Ignition Coil Inspection” (Page 1H-5).
Is the peak voltage OK?
Yes Go to Step 4.
No Go to Step 5.
Repair Instructions
Ignition Coil Construction
BENF34J11806001
(a)
IF34J1180002-01
1. Ignition coil 3. Spark plug cap

2. Ignition coil bracket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
Spark Plug Removal and Installation Installation

BENF34J11806002 Install the spark plug in the reverse order of removal.
Removal
Pay attention to the following point:
! WARNING • Screw the spark plug into the cylinder head with
fingers, and then tighten it to the specified torque.
The hot engine can burn you.
Wait until the engine is cool enough to touch. NOTICE
Do not cross thread or over tighten the spark
1) Turn the ignition switch OFF. plug, or such an operation will damage the
2) Disconnect the spark plug cap (1). aluminum threads of the cylinder head.
3) Remove the spark plug (2) using the special tool.
Special tool
Special tool (A): Spark Plug Socket Set
(A): Spark Plug Socket Set
Tightening torque
Spark plug (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)
1 (A)
(A ), (a )
2
IF34J1180003-01
IF34J1180004-01
Spark Plug Inspection and Cleaning NOTICE

BENF34J11806003
Refer to “Spark Plug Removal and Installation” (Page Confirm the thread size and reach when
1H-3). replacing the spark plug. If the reach is too
short, carbon will be deposited on the screw
Heat Range portion of the spark plug hole and engine
Check spark plug heat range by observing electrode damage may result.
color.
If the electrode of the spark plug is wet appearing or dark Ignition Coil Removal and Installation
color, replace the spark plug with hotter type one. BENF34J11806004
If it is white or glazed appearing, replace the spark plug Refer to “Ignition Coil Construction” (Page 1H-3).
with colder type one.
Removal
Heat range
Hot type Standard Cold type
NGK CPR6EA-9 CPR7EA-9 CPR8EA-9 2) Remove the right frame side cover. )(Page 9D-12)
DENSO U20EPR9 U22EPR9 U24EPR9 3) Disconnect the spark plug cap. Refer to “Spark Plug
CHAMPION RG6YC RG8YC RG10YC Removal and Installation” (Page 1H-3).
4) Disconnect the ignition coil primary lead wire (1).
Carbon Deposits
5) Remove the ignition coil (2).
Check carbon deposits on the spark plug.
If carbon is deposited, remove it using a spark plug
cleaner machine or carefully use a tool with a pointed 2
end.
IF34J1180005-03
I649G1020010-02
Installation
Spark Plug Gap Install the ignition coil in the reverse order of removal.
Measure the spark plug gap “a” using a thickness gauge. Pay attention to the following point:
Adjust the spark plug gap if necessary. • Tighten the ignition coil mounting bolts to the specified
torque.
Spark plug gap
Standard: 0.8 – 0.9 mm (0.031 – 0.035 in) Tightening torque
Ignition coil mounting bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
(a)
“a”
ID26J1180010-02
Electrodes Condition
Check the worn or burnt condition of the electrodes. IF34J1180006-02
If it is extremely worn or burnt, replace the spark plug.

And also replace the spark plug if it has a broken
insulator, or damaged thread.
Ignition Coil Inspection 4) Measure the ignition coil primary peak voltage in the
BENF34J11806005 following procedures:
Refer to “Frame Side Cover Removal and Installation” in
Section 9D (Page 9D-12). ! WARNING
Ignition Coil Primary Peak Voltage Do not touch the tester probes and spark
1) Disconnect the spark plug cap. Refer to “Spark Plug plug to prevent an electric shock while
Removal and Installation” (Page 1H-3). testing.
2) Connect a new spark plug to the spark plug cap and
a) Shift the transmission to the neutral and turn the
ground it to the cylinder head.
ignition switch ON.
NOTE b) Grasp the clutch lever.
Be sure that the spark plug is connected c) Press the starter switch and allow the engine to
properly and the battery used is in fully- crank for a few seconds, and then measure the
charged condition. ignition coil primary peak voltage.
5) Repeat the c) procedure several times and measure
the highest peak voltage.
If the voltage is lower than standard range, replace
the ignition coil. )(Page 1H-4)
Ignition coil primary peak voltage
150 V or more
6) After measuring the ignition coil primary peak
voltage, install the removed parts.
Ignition Coil Resistance

1) Disconnect the spark plug cap. Refer to “Spark Plug
IF34J1180007-01 Removal and Installation” (Page 1H-3).
3) Connect the multi circuit tester with the peak voltage 2) Disconnect the ignition coil lead wires (1).
adaptor (1) as follows:
NOTE
Do not disconnect the ignition coil primary
lead wire.
Ignition coil – circuit tester connection

(–) Probe (+) Probe
W/Bl wire
Ignition coil (2) Ground 1
terminal
IF34J1180009-02
V
1
4 2 3
IF34J1180008-02
3. New spark plug 4. CDI unit

3) Measure the ignition coil for resistance in both

primary and secondary coils. If the resistance is not Color
Br/W B/R
within the standard range, replace the ignition coil Position
with a new one. OFF ( )
Ignition coil resistance at 25 °C (77 °F) RUN ( )

IF34J1180013-02
Primary: 0.315 – 0.385 ((+) terminal – Ground
(1)) 5) After finishing the engine stop switch inspection,
Secondary: 8.0 – 12.0 k ((+) terminal – Plug cap) install the removed parts.
Ignition Switch Inspection

BENF34J11806007
1
2) Remove the headlight assembly. )(Page 9B-3)
3) Disconnect the ignition switch coupler (1).
( +)
IF34J1180010-02
IF34J1180014-01
4) Inspect the ignition switch for continuity with a circuit

tester. If any defect is found, replace the ignition
switch with a new one.
(+) Color
R O
IF34J1180011-01 Position
4) After measuring the ignition coil resistance, install ON
the removed parts. OFF
LOCK
Engine Stop Switch Inspection IF34J1180015-01
BENF34J11806006
1) Turn the ignition switch OFF. Ignition Switch Removal and Installation
2) Remove the headlight assembly. )(Page 9B-3) BENF34J11806008
Removal
3) Disconnect the right handle switch coupler (1).
3) Disconnect the ignition switch coupler (1).
1
1
IF34J1180012-01
4) Inspect the engine stop switch for continuity with a

circuit tester.
If any defect is found, replace the right handle switch IF34J1180014-01
assembly with a new one. )(Page 6B-3)

4) Remove the ignition switch (1) using the special

tools.
Special tool 1
Torx Bit
Torx Bit Holder
IF34J1180016-01
Installation
Install the ignition switch in the reverse order of removal.
Specifications
BENF34J11807001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 11 1.1 8.5 )(Page 1H-3)
Ignition coil mounting bolt 10 1.0 7.5 )(Page 1H-4)
Reference:
“Ignition Coil Construction” (Page 1H-3)

Special Tool
BENF34J11808001
Spark plug socket set Torx® bit (JT30H)

)(Page 1H-3) / )(Page 1H-7)
)(Page 1H-3)
Torx® bit holder (3/8 sq.)

)(Page 1H-7)

1I-1 Starting System:
Starting System
Engine

Starting System Diagram
BENF34J11902001
3 5
4 6
2
Y/R Y/R
1 B/W B
IF34J1190001-01
1. Battery 3. Ignition switch 5. Starter switch 7. Starter relay

2. Main fuse 4. Engine stop switch 6. Clutch lever position switch 8. Starter motor
Component Location
Starting System Components Location
BENF34J11903001

Starting System Symptom Diagnosis
BENF34J11904001

Engine does not turn Faulty starter clutch. Replace. )(Page 1I-7)
though the starter motor
runs
Starter switch is not Run down battery. Repair or replace. )(Page 1J-9)
effective Defective switch contacts. Replace. )(Page 6B-3)
Brushes not seating properly on starter Repair or replace. )(Page 1I-5)
motor commutator.
Defective starter relay or starter interlock Replace. )(Page 1I-6)
switch.
Defective main fuse. Replace.
Starting System: 1I-2
Starter Motor Will Not Run Step 3

BENF34J11904002
NOTE Measure the voltage between Y/R wire (+) and B/W
wire (–) at the starter relay coupler when the starter
Check the main fuse and charge the battery
switch is pushed.
fully before diagnosing.
Is the voltage OK?
Troubleshooting
Yes Go to Step 4.
Step 1
No • Faulty ignition switch.
1) Shift the transmission into neutral.
• Faulty engine stop switch.
2) Grasp the clutch lever, turn on the ignition switch
with the engine stop switch in the “RUN” position • Faulty starter switch.
and listen for a click from the starter relay when • Faulty clutch lever position switch.
the starter switch is pushed. • Poor contact of connector.
Does the starter relay click? • Open circuit in wire harness.
Yes Go to Step 2.
Step 4
No Go to Step 3. Check the starter relay. )(Page 1I-7)
Is the starter relay OK?
Step 2
Check if the starter motor runs when its terminal is Yes Poor contact of the starter relay.
connected to the battery (+) terminal.
No Faulty starter relay.
NOTICE
Do not use thin “wire” because a large
amount of current flows. Starter Motor Runs But Does Not Crank the
Engine
BENF34J11904003
Does the starter motor run?
Yes • Faulty starter relay. Step 1

Check the starter clutch. )(Page 1I-9)
• Loose or disconnected starter motor
lead wire. Is the starter clutch OK?
• Loose or disconnected between starter Yes Faulty starter motor.
relay and battery (+) terminal.
No Faulty starter clutch.
No Faulty starter motor.
Repair Instructions
Starter Motor Components
BENF34J11906001
(c)
(b)
4
2
(a)
IF34J1190002-03
1. Rear bracket 5. Oil seal : 3.4 Nm (0.35 kgf-m, 2.5 lbf-ft) : Apply engine oil.
2. Brush 6. Front bracket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Do not reuse.
3. Armature 7. O-ring : Apply grease.
4. O-ring : 2.7 Nm (0.28 kgf-m, 2.0 lbf-ft) : Apply moly past.
Starter Motor Assembly Removal and 2) Disconnect the starter motor read wire (1) and
Installation remove the starter motor mounting bolts (2).
BENF34J11906002
Removal
1) Turn the ignition switch OFF and disconnect the
battery (–) lead wire. )(Page 1J-10)
IF34J1190003-01
3) Remove the starter motor (1). Starter Motor Disassembly and Reassembly
BENF34J11906003
Disassembly
Disassemble the starter motor. )(Page 1I-3)
Reassembly
Reassemble the starter motor in the reverse order of
disassembly. Pay attention to the following points:
• Replace the O-rings with new ones.
• Apply grease to the lip of the oil seal and bearing.
1
“A”: (SUZUKI SUPER GREASE A)
IF34J1190004-01
Installation
Install the starter motor in the reverse order of removal. “A ”
• Apply grease to the new O-ring (1).
‘‘A” : (SUZUKI SUPER GREASE A)
• Apply engine oil to the armature shaft (2).
IF34J1190007-02
1, “A”
• Apply a small quantity of moly paste to the armature
shaft.
“A”: (SUZUKI MOLY PASTE)
2
IF34J1190005-01
• Tighten the starter motor mounting bolts (1) to the “A ”

specified torque.
• Set the starter motor read wire in the specified
position and tighten the mounting nut (2) to the
specified torque. )(Page 9A-5)
Tightening torque
Starter motor mounting bolt (a): 10 N·m (1.0 kgf- IF34J1190008-01
m, 7.5 lbf-ft) • Align the groove (1) on the rear bracket with the
Starter motor lead wire mounting nut (b): 3.4 N·m punch mark (2) on the starter motor case.
(0.35 kgf-m, 2.5 lbf-ft)
2, ( b) 1
2
1, (a)
IF34J1190009-01
IF34J1190006-01
• Align the projection (1) on the front bracket with the Commutator
punch mark (2) on the starter motor case. Inspect the commutator for discoloration, abnormal wear
or undercut “a”.
If the commutator is abnormally worn, replace the
armature.
2
If the commutator surface is discolored, polish it with
#400 sandpaper and wipe it using a clean, dry cloth.
1 If there is no undercut, scrape out the insulator (1) with a
saw blade.
IF34J1190010-01
• Apply grease to the new O-ring (1) and then tighten

the housing bolt (2) to the specified torque. IE31J1190009-01
‘‘A” : (SUZUKI SUPER GREASE A) 2. Segment
Armature Coil
Tightening torque Measure for continuity between each segment. Measure
Housing bolt (a): 2.7 N·m (0.28 kgf-m, 2.0 lbf-ft) for continuity between each segment and the armature
shaft.
If there is no continuity between the segments or there is
1, “ A ” continuity between the segments and shaft, replace the
2, ( a) armature with a new one.
2, ( a)
IF34J1190011-02
Starter Motor Inspection

BENF34J11906004
Refer to “Starter Motor Disassembly and Reassembly”
IF34J1190012-01
(Page 1I-4).
Bearing
Carbon Brush
Inspect the armature shaft bearing (1) for abnormal
Inspect the carbon brushes for abnormal wear, cracks or
noise and smooth rotation. If there is anything unusual,
smoothness in the brush holder.
replace the front bracket with a new one.
If any damages are found, replace the brush holder or
brush terminal set with a new one.
Make sure that the length “a” is not less than the service 1
limit. If this length becomes less than the service limit,
replace the brush with a new one.
Brush length “a”
Special tool
Vernier Caliper
IF34J1190013-01
“a”
IF34J1190054-01
Oil Seal 4) Disconnect the starter motor lead wire (1) and
Check the seal lip (1) for damage. battery (+) lead wire (2).
If any damage is found, replace the oil seal with a new
one. NOTE
Be sure to disconnect the starter motor lead
wire (1) first, then disconnect the battery (+)
1 lead wire (2).
5) Remove the starter relay (3).
IF34J1190014-01
2
Bushing 1
Inspect the bushing (1) for wear and damage. If any
defects are found, replace the rear bracket with a new
one. IF34J1190017-02
Installation
Install the starter relay in the reverse order of removal.
1 Pay attention to the following point:
• Tighten the starter relay terminal nuts (1) to the
specified torque.
Tightening torque
Starter relay terminal nut (a): 4.4 N·m (0.45 kgf-
m, 3.5 lbf-ft)
IF34J1190015-01
Starter Relay Removal and Installation

BENF34J11906005
Removal
2) Disconnect the battery (–) lead wire from the battery.
)(Page 1J-10) 1
1 , (a )
3) Disconnect the starter relay coupler (1).
IF34J1190052-03
IF34J1190016-01
Starter Relay Inspection Starter Clutch Removal and Installation

BENF34J11906006 BENF34J11906009
Refer to “Starter Relay Removal and Installation” (Page Removal
1I-6). 1) Drain the engine oil. )(Page 1E-4)
1) Apply 12 V to (1) and (2) terminals and check for 2) Remove the speed sensor from the engine sprocket
continuity between the positive and negative cover. )(Page 1C-4)
terminals using the multi circuit tester. If the starter
3) Remove the engine sprocket cover (1) and dowel
relay clicks and continuity is found, the relay is OK.
pins (2).
NOTICE
1 2
Do not apply battery voltage to the starter
relay for five seconds or more, otherwise the
relay coil may overheat and get damaged.
2
IF34J1190053-01
1 2 4) Remove the generator cover (1).
IF34J1190018-01
1
2) Measure the relay coil resistance between the
terminals using the circuit tester. If the resistance is
not within the specified value, replace the starter
relay with a new one.
Starter relay resistance
3–6
IF34J1190020-01
5) Remove the shaft (1), spacer (2) and starter idle

gear (3).
3 2
Ω
IF34J1190019-01
1
IF34J1190021-01
6) Remove the generator rotor (1). ) (Page 1J-5) Installation

Install the starter clutch in the reverse order of removal.
• Apply engine oil to the one way clutch (1).
• Install the one way clutch pointing the plate side (2)
toward the generator rotor.
1
IF34J1190022-01
7) Remove the key (1) and starter clutch gear (2).
IF34J1190026-01
• Apply thread lock to the bolts (1), and then tighten

1 them to the specified torque with the special tool.
“A”: (THREAD LOCK CEMENT 1322D)
Special tool
2
(A): Rotor Holder
IF34J1190023-01
Tightening torque
8) Remove the starter clutch gear bearing (1).
Starter clutch bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft)
1 1, “A”, (a)
(A)
IF34J1190024-01
9) Hold the generator rotor with the special tool and IF34J1190027-01
remove the starter clutch (1).
• Apply engine oil to the starter clutch gear bearing (1)
Special tool and install it to the crankshaft.
(A): Rotor Holder
(A)
1
IF34J1190024-01
IF34J1190025-01
• Fit the key (1) in the key slot on the crankshaft. Starter Clutch Inspection
BENF34J11906011
Starter Clutch
1) Install the starter clutch gear onto the starter clutch.
1
2) Turn the starter clutch gear by hand to inspect the
starter clutch for a smooth movement. The gear
turns in one direction only. If a large resistance is felt
for rotation, inspect the starter clutch or the starter
clutch contacting surface on the starter clutch gear
for wear or damage.
If they are found to be damaged, replace them with
IF34J1190028-01
new ones.
• Install the generator rotor onto crankshaft. )(Page
1J-6)
• Apply engine oil to the starter idle gear shaft holes (1),
starter idle gear (2) and shaft (3).
1 1
IF34J1190031-01
Starter Idle Gear

Inspect the starter idle gear for wear or damage. If any
defects are found, replace it with a new one.
IF34J1190029-01
2 3
IF34J1190032-01
IF34J1190030-01
Starter Clutch Gear Bearing
Inspect the starter clutch gear bearing for any
abnormality, especially cracks. If any defects are found,
replace the starter clutch gear bearing with a new one.
IF34J1190033-01
Starter Switch Inspection

BENF34J11906012
3) Disconnect the right handle switch lead wire coupler
(1).
1
IF34J1190034-01
4) Inspect the starter switch for continuity with a tester.

If any defect is found, replace the right handle switch
with a new one. Refer to “Handlebar Removal and
Installation” in Section 6B (Page 6B-3).
Color
Y/G B/R
Position
PUSH
IF34J1190035-02
5) After finishing the starter switch inspection, install the

removed parts.
Kick Starter Components

BENF34J11906013
3
4
(a)
7 8
12
9
(b)
10
11
IF34J1190036-02
1. Kick starter lever 7. Snap ring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Kick starter shaft oil seal 8. Kick starter : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Spring guide 9. Spring : Apply grease.
4. Return spring 10. Kick starter guide : Apply engine oil.
5. Kick starter shaft 11. Kick starter stopper : Apply thread lock to the thread part.
6. Kick starter drive gear 12. Kick starter idle gear : Do not reuse.
Kick Starter Lever Removal and Installation Kick Starter Shaft Removal and Installation
BENF34J11906014 BENF34J11906015
Removal
1) Remove the kick starter lever (1). Removal
1) Remove the clutch cover and gasket. )(Page 5C-6)
2) Unhook the return spring end (1) from crank case
and remove washer (2), spring guide (3) and return
1
spring (4) from the kick starter shaft.
2
IF34J1190037-02
Installation
1
1) Install the kick starter lever (1) as shown in the
illustration. IF34J1190039-01
NOTE 3) Remove the kick starter shaft assembly (1).
Install the kick starter lever positioning it at

the closest to but not in contact with the
clutch cover.
2) Tighten the kick starter lever bolt (2) to the specified

torque.
Tightening torque
Kick starter lever bolt (a): 23 N·m (2.3 kgf-m,
1
17.0 lbf-ft)
IF34J1190040-01
4) Remove the following parts from the kick starter

shaft.
1
• Washers (1)
• Spring (2)
• Kick starter (3)
“b”
• Snap ring (4)
• Kick starter drive gear (5)
“a”
5
3
2, (a) 2 1
IF34J1190038-01
1 4
“a”: Approx. 40.5° “b”: 38.5 – 51.0 mm (15.2 – 20.1 in)
IF34J1190041-01
5) Remove the kick starter guide (1) and kick starter • Apply thread lock to the kick starter guide bolts (1) and
stopper (2). tighten them to the specified torque.
2 Tightening torque
Kick starter guide bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
IF34J1190042-01
6) Remove the clutch component parts. Refer to

“Clutch Removal” in Section 5C (Page 5C-6).
7) Remove the following parts from the drive shaft.
• Snap ring (1) 1, “A”, (a)
• Washer (2) IF34J1190044-01
• Kick starter idle gear (3) • Aligning the punch mark (1) on the kick starter with
• Busing (4) the punch mark (2) on the kick starter shaft, install the
kick starter to the kick starter shaft.
• Washer (5)
1 5 1
4
2
2
IF34J1190045-01
IF34J1190043-01
• Install the kick starter shaft assembly into the
Installation crankcase and engage the kick starter (1) with the
Install the kick starter shaft in the reverse order of kick starter guide (2).
• When installing a new snap ring (1), pay attention to
its direction. Fit it to the side where the thrust (2) is as
shown in the illustration.
1
2
IF34J1190046-01
IE31J1520022-01
3. Sharp edge
• Insert the return spring end into the hole (1) of the kick Return Spring
starter shaft. Inspect the return spring for damage or fatigue. If any
• Fit the cutout (2) of the spring guide with the return defects are found, replace the return spring with a new
spring. one.
IF34J1190047-01 IF34J1190050-01
• Turn the return spring (1) clockwise using pliers and

Kick Starter / Kick Starter Drive Gear / Kick Starter
hook the spring end into the hole (2) of the crankcase.
Idle Gear
Inspect the kick starter (1), kick starter drive gear (2) and
kick starter idle gear (3) for wear and damage. If any
defects are found, replace the defective part with a new
one.
2
IF34J1190048-01
Kick Starter Parts Inspection 1

BENF34J11906016 3 2
Refer to “Kick Starter Shaft Removal and Installation”
(Page 1I-12). IF34J1190051-01
Kick Starter Shaft

Inspect the kick starter shaft for wear or bend. If any
defects are found, replace the kick starter shaft with a
new one.
IF34J1190049-01
Specifications
BENF34J11907001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starter motor mounting bolt 10 1.0 7.5 )(Page 1I-4)
Starter motor lead wire mounting nut 3.4 0.35 2.5 )(Page 1I-4)
Housing bolt 2.7 0.28 2.0 )(Page 1I-5)
Starter relay terminal nut 4.4 0.45 3.5 )(Page 1I-6)
Starter clutch bolt 10 1.0 7.5 )(Page 1I-8)
Kick starter lever bolt 23 2.3 17.0 )(Page 1I-12)
Kick starter guide bolt 10 1.0 7.5 )(Page 1I-13)
Reference:
“Starter Motor Components” (Page 1I-3)
“Kick Starter Components” (Page 1I-11)

BENF34J11908001
Assembly lubrication SUZUKI MOLY PASTE )(Page 1I-4)
Grease )(Page 1I-4) / )(Page 1I-4)
SUZUKI SUPER GREASE A
/ )(Page 1I-5)
Thread lock cement )(Page 1I-8) / )(Page 1I-
THREAD LOCK CEMENT 1322D
13)
NOTE
“Starter Motor Components” (Page 1I-3)
“Kick Starter Components” (Page 1I-11)
Special Tool
BENF34J11908002
Vernier calipers (200 mm) Rotor holder

)(Page 1I-5) )(Page 1I-8) /
)(Page 1I-8)
Charging System: 1J-1
Charging System
Engine

Charging System Diagram
BENF34J11A02001
2
3
6
1
7
5
4
IF34J11A0001-03
1. Generator 4. Battery 7. IC
2. Regulator/rectifier 5. Load
3. Ignition switch 6. Main fuse
Component Location
Charging System Components Location
BENF34J11A03001
1J-2 Charging System:

Charging System Symptom Diagnosis
BENF34J11A04001

Generator does not Open- or short-circuited lead wires, or Repair, replace or connect properly.
charge loose lead connections.
Short-circuited, grounded or open Replace. )(Page 1J-5)
generator coil. )(Page 1J-6)
Short-circuited or punctured regulator/ Replace. )(Page 1J-8)
rectifier.
Generator does charge, Lead wires tend to get short- or open- Repair or retighten.
but charging rate is below circuited or loosely connected at
the specification terminals.
Grounded or open-circuited generator Replace. )(Page 1J-5)
coil. )(Page 1J-6)
Defective regulator/rectifier. Replace. )(Page 1J-8)
Defective cell plates in the battery. Replace the battery. )(Page 1J-10)
Generator overcharges Internal short-circuit in the battery. Replace the battery. )(Page 1J-10)
Damaged or defective regulator/rectifier. Replace. )(Page 1J-8)
Poorly grounded regulator/rectifier. Clean and tighten ground connection.
Unstable charging Lead wire insulation frayed due to Repair or replace.
vibration, resulting in intermittent short-
circuiting.
Internally short-circuited generator. Replace. )(Page 1J-5)
)(Page 1J-6)
Defective regulator/rectifier. Replace. )(Page 1J-8)
Battery overcharges Faulty regulator/rectifier. Replace. )(Page 1J-8)
Faulty battery. Replace. )(Page 1J-10)
Poor contact of generator lead wire Repair.
coupler.
Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and
circuit connections and make necessary
adjustments to obtain specified charging
operation. )(Page 1J-4)
Cell plates have lost much of their active Replace the battery and correct the charging
materials a result of overcharging. system. )(Page 1J-10)
Internal short-circuit in the battery. Replace the battery. )(Page 1J-10)
Too low battery voltage. Recharge the battery fully. )(Page 1J-9)
Too old battery. Replace the battery. )(Page 1J-10)
Battery “sulfation” Incorrect charging rate. (When not in Replace the battery. )(Page 1J-10)
use battery should be checked at least
once a month to avoid sulfation.)
The battery was left unused in a cold Replace the battery if badly sulfated. )(Page
climate for too long. 1J-10)
“Sulfation”, acidic white Cracked battery case. Replace the battery. )(Page 1J-10)
powdery substance or Battery has been left in a run-down Replace the battery. )(Page 1J-10)
spots on surface of cell condition for a long time.
plates
Battery Runs Down Quickly Step 5

BENF34J11A04002
Troubleshooting Measure the generator no-load performance. )(Page
1J-4)
Step 1
Is the generator no-load performance OK?
Check accessories which use excessive amounts of
electricity. Yes Go to Step 6.
Are accessories installed? No Faulty generator.
Yes Remove accessories.
Step 6
No Go to Step 2. Inspect the regulator/rectifier. )(Page 1J-8)
Is the regulator/rectifier OK?
Step 2
Check the battery for current leakage. )(Page 1J-4) Yes Go to Step 7.
Is the battery for current leakage OK? No Faulty regulator/rectifier.
Yes Go to Step 3.
Step 7
No • Short circuit of wire harness. Inspect wirings.
• Faulty electrical equipment. Is the wirings OK?
Step 3 Yes Faulty battery.

Measure the regulated voltage between the battery
No • Short circuit of wire harness.
terminals. )(Page 1J-4)
• Poor contact of couplers.
Is the regulated voltage OK?
Yes • Faulty battery.

• Abnormal driving condition.
No Go to Step 4.
Step 4
Measure the resistance of the generator coil. )(Page
1J-4)
Is the resistance of generator coil OK?
Yes Go to Step 5.
No • Faulty generator coil.

• Poor contact of couplers.
Repair Instructions
Battery Current Leakage Inspection
BENF34J11A06001
2) Remove the left frame side cover and disconnect the
battery (–) lead wire. )(Page 1J-10)
3) Measure the current between battery (–) terminal
and the battery (–) lead wire using the multi circuit
tester. If the reading exceeds the specified value,
leakage is evident.
NOTICE V
• In case of a large current leak, turn the IF34J11A0002-02
tester to high range first to avoid tester

damage. Generator Inspection
BENF34J11A06003
• Do not turn the ignition switch to ON Generator Coil Resistance
position when measuring current.
Battery leakage current 2) Disconnect the generator lead wire coupler (1).
3 mA or less
IF34J11A0003-03
I649G11A0002-02 3) Measure the resistance of the generator coil.

4) Connect the battery (–) terminal and install the left If the resistance is out of specified value, replace the
frame side cover. )(Page 1J-10) generator stator with a new one. Also, check that the
generator core is insulated properly.
Regulated Voltage Inspection Generator coil resistance
BENF34J11A06002
0.6 – 1.5 (Y – Y)
1) Remove the left frame side cover. )(Page 9D-12) (Y – Ground)
2) Start the engine and keep it running at 5000 r/min
with the dimmer switch turned HI position.
3) Measure the DC voltage between the battery (+) and
(–) terminals using the multi circuit tester. If the
voltage is not within the specified value, inspect the Y
generator and regulator/rectifier.
• Generator: )(Page 1J-4) Y
• Regulator/rectifier: )(Page 1J-8)
NOTE
When making this test, be sure that the IF34J11A0004-02
battery is in fully charged condition.
Regulated voltage (Charging output)

Standard: 14.0 – 15.0 V at 5000 r/min
No-load Performance 5) Disconnect the CKP sensor lead wire coupler (1)
1) Remove the left frame side cover. )(Page 9D-12) and generator lead wire coupler (2).
2) Disconnect the generator lead wire coupler (1).
1
IF34J11A0006-03
IF34J11A0003-03
3) Start the engine and keep it running at 5000 r/min.
4) Using the multi circuit tester, measure the voltage of
the generator coil.
If the tester reads under the specified value, replace
the generator stator with a new one. 1
Generator no-load voltage (When engine is cold)
80 V (AC) or more at 5000 r/min
IF34J11A0007-02
Y 7) Remove the generator cover (1).
IF34J11A0005-02 1
Generator Removal
BENF34J11A06004
1) Disconnect the battery (–) lead wire. )(Page 1J-10)
3) Remove the speed sensor from the engine sprocket
cover. )(Page 1C-4)
IF34J11A0008-01
8) Remove the gasket (1) and dowel pins (2).
pins (2).
2 1
1 2
2
2
IF34J11A0009-01
IF34J11A0028-01
9) Hold the generator rotor with the special tool and Generator Installation
remove the generator rotor nut. BENF34J11A06005
1) Install the generator stator (1), lead wire clamp (2)
Special tool and CKP sensor (3), and tighten the bolts to the
(A): Rotor Holder specified torque.
NOTE
Pass the generator lead wire (4) between the
generator cover ribs (5) and lead wire clamp.
Be careful not to pinch the wire.
(A)
Tightening torque
Generator stator bolt (a): 5 N·m (0.51 kgf-m, 4.0
lbf-ft)
CKP sensor bolt (b): 5 N·m (0.51 kgf-m, 4.0 lbf-ft)
IF34J11A0010-01 2 (b)
10) Remove the generator rotor (1) with the special
tools. (a)
3
Special tool
(A): Rotor Remover
1 (b)
1
IF34J11A0013-03
2
(A)
5
5
IF34J11A0011-01
11) Remove the generator stator (1), CKP sensor (2),

lead wire clamp and grommet (3). 4
1 IF34J11A0014-01
2) Apply sealant to the grommet (1) as shown and

3 install it to the generator cover.
“A”: (SUZUKI BOND 1207B)
IF34J11A0012-01
1
“A”
“A”
IF34J11A0015-01
3) Degrease the tapered portion (1) of crankshaft and 8) Install the generator cover (1) and tighten the bolts to
also the generator rotor (2). Use nonflammable the specified torque.
cleaning solvent to wipe off oily or greasy matter and
make these surfaces completely dry. ! CAUTION
4) Align the key (3) and key slot on the generator rotor. Be careful not to pinch the finger between the
generator cover and the crankcase.
3
Tightening torque
Generator cover bolt (a): 10 N·m (1.0 kgf-m, 7.5
2 lbf-ft)
1 (a)
IF34J11A0016-01
5) Install the generator rotor (1) on the crankshaft.

6) Hold the generator rotor with the special tool and
tighten its nut to the specified torque.
Special tool IF34J11A0019-01
(A): Rotor Holder 9) Route the GP switch lead wire. Refer to “Wiring
Tightening torque Harness Routing Diagram” in Section 9A (Page 9A-
Generator rotor nut (a): 120 N·m (12.2 kgf-m, 5).
88.5 lbf-ft) 10) Install the dowel pins (1) and engine sprocket cover
(2).
(A)
2
(a) 1
(1 )
IF34J11A0017-01 1
7) Install the dowel pins (1) and new gasket (2). IF34J11A0029-01
11) Install the speed sensor. )(Page 1C-4)

1 2 12) Connect the generator lead wire coupler (1) and
CKP sensor lead wire coupler (2).
1
IF34J11A0018-01
IF34J11A0006-03
13) Clamp the generator lead wire and CKP sensor lead
wire. )(Page 9A-5) 2 1
14) Connect the battery (–) lead wire. )(Page 1J-10)
15) Pour engine oil. )(Page 1E-4)
Regulator / Rectifier Construction

BENF34J11A06011
4 3
IF34J11A0021-01
4 (+) probe of tester to:

(1) (2) (3) (4)
(–) probe of (1) – * * *
3 tester to: (2) – – * *
(3) 0.3 – –
* *
0.8 V
2 (4) 0.3 – –
* *
0.8 V
* Tester’s battery voltage: 1.4 V or more
1
(a) Regulator / Rectifier Removal and Installation
BENF34J11A06007
IF34J11A0020-01
1. Regulator/rectifier 4. Washer Removal

2. Battery No.1 holder : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Spacer
2) Disconnect the regulator/rectifier coupler (1).
Regulator / Rectifier Inspection 3) Remove the regulator/rectifier (2).
BENF34J11A06006
Refer to “Regulator / Rectifier Removal and Installation”
(Page 1J-8).
1) Set the “Diode test” of the multi circuit tester. Refer to 2
“Precautions for Circuit Tester” in Section 00 (Page
00-6).
2) Check that the tester reads 1.4 V or more.
NOTE
If the tester reads less than 1.4 V when the
tester probes are not connected, replace its 1
battery. IF34J11A0022-02
3) Measure the voltage between the terminals using the

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.
Installation 2) Measure the battery voltage using the multi circuit

Install the regulator/rectifier in the reverse order of tester.
removal. Pay attention to the following point: If the voltage reading is less than the 12 V (DC),
• Tighten the regulator/rectifier nuts (1) to the specified recharge the battery with a battery charger.
torque. Recharging time
Tightening torque 0.3 A for 5 to 10 hours or 3 A for 0.5 hour
Regulator/rectifier nut (a): 10 N·m (1.0 kgf-m, 7.5
NOTICE
lbf-ft)
Be careful not to permit the charging current
to exceed 5 A at any time.
1, ( a)
3) After recharging, wait at least 30 minutes and then
measure 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.
1
1
IF34J11A0023-02
2
Battery Charging
BENF34J11A06008
Initial Charging
For initial charging, use the charger specially designed
for MF battery.
NOTICE
• For charging the battery, make sure to use
the charger specially designed for MF ID26J11A0039-02
battery. Otherwise, the battery may be 1. Charging period 2. Stop charging

overcharged resulting in shortened service
life. 4) Install the battery to the motorcycle. )(Page 1J-10)
• Do not remove the cap during charging.
• Position the battery with the cap facing
upward during charging.
Battery Recharging
NOTICE
Do not remove the caps on the battery top
while recharging.
NOTE
IF34J11A0032-01
When the motorcycle is not used for a long
[A]: Battery charged condition
period, check the battery every 1 month to
prevent the battery discharge.
1) Remove the battery from the motorcycle. )(Page

1J-10)
Battery Removal and Installation Battery Visual Inspection

BENF34J11A06009 BENF34J11A06010
Removal 1) Remove the left frame side cover. )(Page 9D-12)
1) Remove the left frame side cover. )(Page 9D-12) 2) Visually inspect the surface of the battery container.
2) Disconnect the battery (–) lead wire (1). If any signs of cracking or electrolyte leakage from
3) Disconnect the battery (+) lead wire (2). the sides of the battery have occurred, replace the
battery with a new one. )(Page 1J-10)
NOTE If the battery terminals are found to be coated with
Disconnect the battery (–) lead wire (1) first, rust or an acidic white powdery substance, clean the
then disconnect the battery (+) lead wire (2). battery terminals with sandpaper.
3) Install the left frame side cover. )(Page 9D-12)
4) Remove the battery band (3) and battery (4) from the
motorcycle.
2
1
3 4
IF34J11A0026-02
Installation
Install the battery in the reverse order of removal. Pay
NOTICE
Never use anything except the specified
battery.
• Connect the battery (+) lead wire (1) first, then

connect battery (–) lead wire (2).
• Tighten the battery lead wire mounting bolts securely.
1
2
IF34J11A0027-02
Specifications
BENF34J11A07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Generator stator bolt 5 0.51 4.0 )(Page 1J-6)
CKP sensor bolt 5 0.51 4.0 )(Page 1J-6)
Generator rotor nut 120 12.2 88.5 )(Page 1J-7)
Generator cover bolt 10 1.0 7.5 )(Page 1J-7)
Regulator/rectifier nut 10 1.0 7.5 )(Page 1J-9)
Reference:
“Regulator / Rectifier Construction” (Page 1J-8)

BENF34J11A08001
Sealant SUZUKI BOND 1207B )(Page 1J-6)
Special Tool
BENF34J11A08002
Rotor remover Rotor holder

)(Page 1J-6) )(Page 1J-6) /
)(Page 1J-7)
1K-1 Exhaust System:
Exhaust System
Engine
Precautions
Precautions for Exhaust System
BENF34J11B00001
! WARNING
To avoid the risk of being burned, do not touch the exhaust system when the system is hot.
NOTICE
After installation of the muffler, make sure that there is no leakage of exhaust gas.
Repair Instructions
Exhaust System Components
BENF34J11B06002
(b)
(a)
2
1
5
5
4
(a)
(a)
(a)
3
(b)
IF34J11B0001-02
1. Muffler 4. Muffler rear cover : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

2. Gasket 5. Frame : Do not reuse.
3. Muffler cover : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
Exhaust System: 1K-2
Muffler Removal and Installation 5) Remove the muffler cover (1) and muffler rear cover
BENF34J11B06008 (2).
Removal
1) Support the motorcycle with the center stand. 1
2) Remove the exhaust pipe bolts (1).
IF34J11B0007-01
IF34J11B0002-01
3) Remove the muffler mounting bolts (1) and muffler

(2).
IF34J11B0008-02
Installation
1 1) Install the muffler cover (1) and rear muffler cover
(2), and tighten the bolts to the specified torque.
Tightening torque
IF34J11B0004-02
Muffler cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft)
1 Muffler rear cover bolt (b): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
2
1
IF34J11B0005-01
4) Remove the exhaust pipe gasket (1).

(a) (b)
IF34J11B0009-02
IF34J11B0006-01
2) Install the new exhaust pipe gasket (1). Exhaust System Inspection
BENF34J11B06010
Inspect the muffler connection for exhaust gas leakage
and mounting condition. If any defect is found, replace
the muffler with a new one.
Check the exhaust pipe bolts and muffler mounting bolt
are tightened to their specified torque.
Tightening torque
Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
Muffler mounting bolt (b): 23 N·m (2.3 kgf-m, 17.0
1 lbf-ft)
IF34J11B0006-01
3) Install the muffler.

a
4) Tighten the exhaust pipe bolts (1) first, and then
tighten the muffler mounting bolts (2) to the specified
torque.
Tightening torque
Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft) (b)
Muffler mounting bolt (b): 23 N·m (2.3 kgf-m,
17.0 lbf-ft) IF34J11B0012-01
(b)
1, (a) (b)
2, (b)
IF34J11B0010-01
IF34J11B0013-02
2, (b)
2, (b)
IF34J11B0011-02
Exhaust System: 1K-4
Specifications
BENF34J11B07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Muffler cover bolt 10 1.0 7.5 )(Page 1K-2)
Muffler rear cover bolt 10 1.0 7.5 )(Page 1K-2)
Exhaust pipe bolt )(Page 1K-3) /
23 2.3 17.0
)(Page 1K-3)
Muffler mounting bolt )(Page 1K-3) /
23 2.3 17.0
)(Page 1K-3)
Reference:
“Exhaust System Components” (Page 1K-1)
Section 2
Suspension
CONTENTS
Precautions .................................................2-1 Specifications .......................................................2C-8

2
Precautions............................................................. 2-1 Tightening Torque Specifications........................2C-8
Precautions for Suspension .................................. 2-1 Special Tools and Equipment .............................2C-8
Recommended Service Material .........................2C-8
Suspension General Diagnosis.............. 2A-1 Special Tool ........................................................2C-8
Diagnostic Information and Procedures............2A-1
Suspension and Wheel Symptom Diagnosis ...... 2A-1 Wheels and Tires ..................................... 2D-1
Precautions...........................................................2D-1
Front Suspension .................................... 2B-1 Precautions for Wheel and Tire...........................2D-1
Repair Instructions ..............................................2B-1 Repair Instructions ..............................................2D-1
Front Fork Components ...................................... 2B-1 Front Wheel Components ...................................2D-1
Front Fork On-Vehicle Inspection ....................... 2B-2 Front Wheel Assembly Removal and
Front Fork Assembly Removal and Installation .........................................................2D-2
Installation ......................................................... 2B-2 Front Wheel Dust Seal / Front Wheel Bearing
Front Fork Disassembly and Reassembly .......... 2B-3 Removal and Installation...................................2D-2
Front Fork Inspection .......................................... 2B-8 Rear Wheel Components....................................2D-4
Specifications.......................................................2B-9 Rear Wheel Assembly Removal and
Tightening Torque Specifications........................ 2B-9 Installation .........................................................2D-5
Special Tools and Equipment .............................2B-9 Rear Wheel Bearing Removal and Installation ....2D-6
Recommended Service Material ......................... 2B-9 Wheel / Wheel Axle Inspection ...........................2D-7
Special Tool ........................................................ 2B-9 Rear Wheel Damper Removal and Installation ....2D-8
Rear Wheel Damper Inspection ..........................2D-9
Rear Suspension ..................................... 2C-1 Tire Inspection and Cleaning ..............................2D-9
Repair Instructions ..............................................2C-1 Tire Removal and Installation............................2D-10
Rear Suspension Components ...........................2C-1 Wheel Rim / Air Valve Inspection and
Rear Suspension On-vehicle Inspection .............2C-2 Cleaning ..........................................................2D-11
Rear Shock Absorber Adjustment.......................2C-2 Air Valve Removal and Installation ...................2D-11
Rear Shock Absorber Removal and Specifications .....................................................2D-12
Installation .........................................................2C-2 Tightening Torque Specifications......................2D-12
Rear Shock Absorber Inspection ........................2C-3 Special Tools and Equipment ...........................2D-13
Swingarm Removal and Installation....................2C-3 Recommended Service Material .......................2D-13
Swingarm Inspection...........................................2C-5 Special Tool ......................................................2D-13
Swingarm Bearing Removal and Installation ......2C-7
2-1 Precautions:
Precautions
Suspension
Precautions
Precautions for Suspension
BENF34J12000001
! WARNING
• Never attempt to heat, quench or straighten any suspension part. If any damage or deformation is
found, replace the part with a new one without correct it.
• When removing or installing the suspension or wheel, place the motorcycle on a level surface and
support it securely with a hoist or jack etc.
• Do not support the motorcycle with the muffler.
Suspension General Diagnosis: 2A-1
Suspension General Diagnosis

Suspension

Suspension and Wheel Symptom Diagnosis
BENF34J12104001

Wobbly front wheel Distorted wheel rim. Replace. )(Page 2D-10)
Worn front wheel bearings. Replace. )(Page 2D-2)
Defective or incorrect tire. Replace. )(Page 2D-10)
Loose front axle nut. Tighten. )(Page 2D-2)
Incorrect fork oil level. Adjust. )(Page 2B-3)
Front suspension too soft Insufficiently viscous fork oil. Replace. )(Page 2B-3)
Insufficient fork oil. Check level and add. )(Page 2B-3)
Weak spring. Replace. )(Page 2B-3)
Front suspension too stiff Excessively viscous fork oil. Replace. )(Page 2B-3)
Excessive fork oil. Check level and drain. )(Page 2B-3)
Front suspension too Insufficient fork oil. Check level and add. )(Page 2B-3)
noisy Loose front suspension fastener. Tighten. )(Page 2B-2)
Wobbly rear wheel Distorted wheel rim. Replace. )(Page 2D-10)
Worn rear wheel bearings. Replace. )(Page 2D-6)
Defective or incorrect tire. Replace. )(Page 2D-10)
Worn swingarm bearings. Replace. )(Page 2C-7)
Loose rear suspension fastener. Tighten. )(Page 2C-2)
Loose rear axle nut. Tighten. )(Page 2D-5)
Rear suspension too soft Weak rear shock absorber spring. Replace. )(Page 2C-2)
Rear shock absorber leaks oil. Replace. )(Page 2C-2)
Improper suspension setting. Adjust. )(Page 2C-2)
Rear suspension too stiff Bent rear shock absorber shaft. Replace. )(Page 2C-2)
Worn swingarm bearings. Replace. )(Page 2C-7)
Bent swingarm pivot shaft. Replace. )(Page 2C-3)
Improper suspension setting. Adjust. )(Page 2C-2)
Rear suspension too Loose rear suspension fastener. Tighten. )(Page 2C-2)
noisy Worn swingarm bearings. Replace. )(Page 2C-7)
2B-1 Front Suspension:
Front Suspension
Suspension
Repair Instructions
Front Fork Components
BENF34J12206001
6
1 (a)
2
10
7
11
3
12
8
13
4
14
15
5
16
17
18
19 (b)
IF34J1220001-03
1. Front fork cap bolt 7. Damper rod 13. Oil seal retainer 19. Damper rod bolt
2. O-ring 8. Rebound spring 14. Outer tube slide metal : 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
3. Spacer 9. Inner tube 15. Inner tube slide metal : 24 Nm (2.4 kgf-m, 18.0 lbf-ft)
4. Washer 10. Dust seal 16. Oil lock piece : Apply fork oil.
5. Spring 11. Oil seal stopper ring 17. Outer tube : Apply thread lock to the thread part.
6. Damper rod ring 12. Oil seal 18. Damper rod bolt gasket : Do not reuse.
Front Suspension: 2B-2
Front Fork On-Vehicle Inspection 3) Loosen the front fork upper clamp bolt (1).
BENF34J12206002
Inspect the front forks for oil leakage, scoring or NOTE
scratches on the outer surface of the inner tubes (1).
Slightly loosen the front fork cap bolt (2) to
Replace any defective parts, if necessary. Refer to
facilitate later disassembly.
“Front Fork Disassembly and Reassembly” (Page 2B-3).
1 2
IF34J1220002-01
IF34J1220004-01
4) Loosen the front fork lower clamp bolt (1), and then
Front Fork Assembly Removal and Installation remove the front fork (2) by supporting it.
BENF34J12206004
Refer to “Front Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-2).
NOTE
The right and left front forks are installed
symmetrically (except front brake caliper)
and therefore the removal procedure for one 1
side is the same as that for the other side.
Removal 2
1) Remove the brake hose clamp (1) and front brake
caliper (2). (Right side only) IF34J1220005-01
2) Remove the front fender by removing the left and

right bolts (3). Installation
1) Set the front fork (1) to the steering stem lower
bracket temporarily by tightening the lower clamp
bolt (2).
3
3 1
2
2
IF34J1220003-01
1
IF34J1220006-01
2) Tighten the front fork cap bolt (1) to the specified 7) Install the front fender and tighten the front fender
torque. mounting bolts.
Tightening torque Tightening torque
Front fork cap bolt (a): 27 N·m (2.8 kgf-m, 20.0 Front fender mounting bolt (a): 10 N·m (1.0 kgf-
lbf-ft) m, 7.5 lbf-ft)
3) Loosen the lower clamp bolts. 8) Install the front brake caliper (1) and brake hose
4) Set the front fork with the upper surface (2) of the clamp (2).
inner tube positioned “a” from the upper surface of • Front brake caliper: )(Page 4B-3)
the steering stem upper bracket. • Brake hose clamp: )(Page 4A-2)
1, (a)
2 (a)
“a” (a) 2
1
IF34J1220007-01 IF34J1220010-01
“a”: 2.0 mm (0.16 in)
Front Fork Disassembly and Reassembly
5) Tighten the front fork lower clamp bolt to the BENF34J12206005
specified torque. Refer to “Front Fork Assembly Removal and Installation”

(Page 2B-2).
Tightening torque
Front fork lower clamp bolt (a): 29 N·m (3.0 kgf- NOTE
m, 21.5 lbf-ft) The right and left front forks are installed
symmetrically and therefore the disassembly
procedure for one side is the same as that for
the other side.
Disassembly
1) Remove the front fork cap bolt (1).
(a)
NOTICE
Hold the front fork cap bolt by hand when
removing the bolt. The cap bolt may pop up
pushed by the spring.
IF34J1220008-01
6) Tighten the front fork upper clamp bolt.

Tightening torque
1
Front fork upper clamp bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
(a)
IF34J1220011-01
IF34J1220009-01
2) Remove the spacer (1), washer (2) and spring (3). 6) Remove the damper rod (1), rebound spring (2) and
damper rod ring (3).
2
3
3
2 1
IF34J1220012-01
3) Invent the fork and stroke it several times to drain out IF34J1220014-01
fork oil. 7) Remove the dust seal (1).

4) Hold the fork inverted for a few minutes to drain oil. 8) Remove the oil seal stopper ring (2).
1
2
I649G1220012-02 IF34J1220015-01
5) Remove the damper rod bolt using the special tools. 9) Remove the oil seal by pulling out the inner tube.
Special tool
(A): T-Handle
(B): Front Fork Assembling Attachment
IF34J1220016-01
(A)
(B)
IF34J1220013-01
10) Remove the following parts. 3) Install the following parts onto the inner tube.
• Oil lock piece (1) • New outer tube slide metal (1)
• Oil seal (2) • Oil seal retainer (2)
• Oil seal retainer (3) • New oil seal (3)
• Outer tube slide metal (4)
NOTICE
• Inner tube slide metal (5)
When installing the oil seal to the inner tube,
be careful not to damage the oil seal lip.
4) Apply fork oil to the outer slide metal and oil seal lip.
4
2 “A”: Fork oil (ENDURANCE FORK OIL TYPE 1F
or equivalent)
1
“A”
5
3
IF34J1220017-01
Reassembly
NOTICE 3
1 2
• Thoroughly wash all the component parts
being assembled. IF34J1220018-01
Insufficient washing can result in oil 5) When installing the oil lock piece (1), insert the
leakage or premature wear of the parts. tapered end (2) of the oil lock piece into the inner
• When reassembling the front fork, use new tube (3).
fork oil.
• Use the specified fork oil for the front fork.
• Use care not to cause damage to the slide 3
1
metal surfaces since the surfaces are
teflon coated.
1) Hold the inner tube vertically, clean the metal groove

and install the inner tube slide metal by hand.
NOTICE
Do not damage the Teflon coated surface of 2
IF34J1220019-01
the inner tube’s slide metal when mounting it.
6) Install the inner tube into the outer tube with care not
2) Apply fork oil to the new inner tube slide metal (1). to drop the oil lock piece out.
“A”: Fork oil (ENDURANCE FORK OIL TYPE 1F NOTE
or equivalent)
After installing the inner tube into the outer
tube, keep the oil lock piece into the inner
tube by compressing the front fork fully.
1, “A”
ID26J1220021-01
7) Install the new oil seal (1) into the outer tube using 11) Install the rebound spring (1) to the damper rod (2).
the special tool. 12) Apply fork oil to the damper rod ring (3) and insert
Special tool the damper rod into the inner tube.
(A): Front Fork Oil Seal Installer Set “A”: Fork oil (ENDURANCE FORK OIL TYPE 1F
or equivalent)
1
3 , “A ”
ID26J1220024-02
8) When installing the oil seal stopper ring (1), make IF34J1220022-01
sure that the oil seal stopper ring is fitted securely 13) Install the new damper rod bolt gasket (1).
into the groove. 14) Apply thread lock to the damper rod bolt (2), and
9) Install the new dust seal (2). tighten it to the specified torque using a 8 mm
hexagon wrench and special tools.
2
NOTE
Check the front fork for smoothness by
stroking it after installing the damper rod.
1
Special tool
(A): T-Handle
(B): Front Fork Assembling Attachment
“A”: Thread lock cement (LOCTITE® ***)
IF34J1220020-01
Tightening torque
10) Install the damper rod ring (1) to the damper rod. Front fork damper rod bolt (a): 24 N·m (2.4 kgf-
m, 18.0 lbf-ft)
1
2 , (a )
“A”
IF34J1220021-01 1
IF34J1220023-01
(A)
(B )
IF34J1220013-01
15) Place the front fork vertically without spring.

16) Compress it fully. (A)
17) Pour specified front fork oil to the inner tube.
“A”: Fork oil (ENDURANCE FORK OIL TYPE 1F
or equivalent)
Front fork oil capacity (each leg)
“a”
400 ml (13.5 US oz, 14.1 Imp oz)
IF34J1220030-01
21) Install the fork spring (1) into the inner tube with its
smaller pitch “a” facing the bottom side.
“A” 22) Install the washer (2) and spacer (3).
ID26J1220030-01
18) Move the inner tube up and down several strokes

until bubbles do not come out from the oil.
19) Keep the front fork vertically and wait 5 – 6 minutes.
“a”
IF34J1220024-01
2
I717H1220029-01
1
20) Hold the front fork vertically and adjust fork oil level
“a” with the special tool.
IF34J1220025-01
NOTE 23) Apply fork oil lightly to the new front fork cap bolt O-
When adjusting the fork oil level, remove the ring (1).
fork spring and compress the inner tube fully.
“A”: Fork oil (ENDURANCE FORK OIL TYPE 1F
Special tool or equivalent)
(A): Front Fork Oil Level Gauge
Fork oil level
130 mm (5.1 in) 1 , “A ”
IF34J1220026-01
24) Temporarily tighten the front fork cap bolt (1) pushing Damper Rod / Damper Rod Ring
it down. Inspect the damper rod (1) and damper rod ring (2) for
wear or damage. If any defects are found, replace the
damper rod or damper rod ring with a new one.
1
IF34J1220011-01
Front Fork Inspection IF34J1220029-01

BENF34J12206006
Refer to “Front Fork Disassembly and Reassembly” Outer Tube Slide Metal / Inner Tube Slide Metal
(Page 2B-3).
• Inspect the outer tube slide metal and inner tube slide
metal for wear or damage. If any defect is found,
Inner Tube / Outer Tube
replace the part with a new one.
Inspect the inner tube sliding surface and outer tube
sliding surface for scuffing. If any defect is found, replace • Check the Teflon coated surface for dirt. If any dirt is
the part with a new one. found, clean the surface with fork oil and nylon blush.
ID26J1220043-02
IF34J1220027-01
Fork Spring
Measure the fork spring free length “a”. If it is shorter
than the service limit, replace it with a new one.
Front fork spring free length
Service limit: 308 mm (12.1 in)
“a”
IF34J1220028-01
Specifications
BENF34J12207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front fork cap bolt 27 2.8 20.0 )(Page 2B-3)
Front fork lower clamp bolt 29 3.0 21.5 )(Page 2B-3)
Front fork upper clamp bolt 23 2.3 17.0 )(Page 2B-3)
Front fender mounting bolt 10 1.0 7.5 )(Page 2B-3)
Front fork damper rod bolt 24 2.4 18.0 )(Page 2B-6)
Reference:
“Front Fork Components” (Page 2B-1)

BENF34J12208001
Fork oil ENDURANCE FORK OIL TYPE 1F — )(Page 2B-5) / )(Page 2B-
or equivalent 5) / )(Page 2B-6) / )(Page
2B-7) / )(Page 2B-7)
Thread lock cement LOCTITE® *** — )(Page 2B-6)
NOTE
“Front Fork Components” (Page 2B-1)
Special Tool
BENF34J12208002
T-handle (20 mm)

Front fork oil level gauge
)(Page 2B-4) /
)(Page 2B-6) )(Page 2B-7)
Front fork oil seal installer

set
)(Page 2B-6)
Rear Suspension: 2C-1
Rear Suspension
Suspension
Repair Instructions
Rear Suspension Components
BENF34J12306001
2 (a)
1
12
3 (b)
10 (c)
13
16 14
4
(d) 11
5 6
7
7 15
8 6 4
9
5
IF34J1230001-01
1. Rear shock absorber 9. Swingarm pivot shaft : 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
2. Rear shock absorber upper mounting bolt 10. Swingarm pivot nut : 78 Nm (8.0 kgf-m, 57.5 lbf-ft)
3. Rear shock absorber lower mounting nut 11. Swingarm : 58 Nm (5.9 kgf-m, 43.0 lbf-ft)
4. Dust cover 12. Chain case : 16 Nm (1.6 kgf-m, 12.0 lbf-ft)
5. Thrust washer 13. Chain adjuster guide plate : Apply grease.
6. Spacer 14. Chain adjuster : Do not reuse.
7. Pivot bearing 15. Chain buffer
8. Center spacer 16. Torque link
2C-2 Rear Suspension:
Rear Suspension On-vehicle Inspection 2) Turn the adjuster (1) clockwise or counterclockwise
BENF34J12306002 to the appropriate position.
Inspect the rear shock absorber (1) for oil leakage and
check that there is no play in the swingarm (2). NOTE
Replace any defective parts, if necessary.
Position 1 provides the softest spring pre-
• Rear shock absorber replacement: )(Page 2C-2) load and 7 provides the stiffest spring pre-
• Swingarm pivot shaft and bearing inspection: )(Page load.
2C-5)
• Swingarm inspection: )(Page 2C-5) Rear shock absorber spring adjuster
Standard: 3rd position from softest end
1
IF34J1230002-01
IF34J1230004-01
Rear Shock Absorber Removal and Installation

BENF34J12306004
Removal
1) Support the motorcycle with the center stand to
relieve load on the rear shock absorber.
2 2) Remove the chain case (1).
IF34J1230003-01
1
Rear Shock Absorber Adjustment
BENF34J12306003
1) Set the center stand upright position and hold the
vehicle vertically.
IF34J1230005-01
3) Remove the rear shock absorber lower mounting nut

(1) and bolt (2).
1
IF34J1230006-01
4) Remove the rear shock absorber upper mounting Rear Shock Absorber Inspection
bolt (1). BENF34J12306005
Refer to “Rear Shock Absorber Removal and
5) Remove the rear shock absorber. Installation” (Page 2C-2).
Inspect the rear shock absorber for damage and oil
1 leakage, and absorber bushing for wear and damage. If
any defect is found, replace the rear shock absorber with
a new one.
NOTICE
Do not attempt to disassemble the rear shock
absorber. It is unserviceable.
IF34J1230007-02
Installation
1) Install the rear shock absorber.
2) Insert the rear shock absorber upper mounting bolt
(1) from the left side and lower mounting bolt (2)
from the right side.
3) Tighten the upper mounting bolt and lower mounting
nut to the specified torque.
IF34J1230010-01
Tightening torque
Rear shock absorber upper mounting bolt (a): Swingarm Removal and Installation
65 N·m (6.6 kgf-m, 48.0 lbf-ft) BENF34J12306013
Rear shock absorber lower mounting nut (b): 78
N·m (8.0 kgf-m, 57.5 lbf-ft) Removal
1) Remove the rear wheel assembly. )(Page 2D-5)
1 , ( a) 2) Remove the rear side guard. )(Page 9D-18)
3) Remove the chain case (1).
IF34J1230008-02
IF34J1230011-01
4) Remove the rear shock absorber lower mounting nut

(1) and bolt (2).
(b)
IF34J1230009-01
1
IF34J1230012-02
5) Remove the left and right frame lower covers. 10) Remove the dust covers (1) and thrust washers (2).
)(Page 9D-12) 11) Remove the chain buffer (3) by removing the bolt.
6) Remove the swingarm pivot nut (1) and draw out the 12) Remove the spacers (4).
pivot shaft (2).
7) Remove the swingarm assembly.
1 2 2 1
1 2
4 4 3
IF34J1230016-01
IF34J1230013-01 Installation
8) Remove the chain adjusters (1). 1) Apply a small quantity of grease to the spacer outer
surfaces and install the spacers (1).
2) Install the chain buffer (2).

3) Apply a small quantity of grease to the seal lip of
dust covers (3).
1
4) Install the thrust washers (4) and dust covers.
IF34J1230014-01
9) Remove the torque link (1).
4 4
3 , “A” 3, “A”
1 1 , “A” 1 , “A” 2
IF34J1230017-01
IF34J1230015-01
5) Install the torque link (1) and tighten the torque link 8) Insert the swingarm pivot shaft (1) from left side and
nut (front) to the specified torque. tighten the swingarm pivot nut (2) to the specified
torque.
Tightening torque
Torque link nut (front) (a): 16 N·m (1.6 kgf-m, Tightening torque
12.0 lbf-ft) Swingarm pivot nut (a): 58 N·m (5.9 kgf-m, 43.0
lbf-ft)
(a)
1 2, (a)
IF34J1230018-01
6) Install the chain adjusters (1). IF34J1230020-01
9) Install the left and right frame lower covers. )(Page

9D-12)
10) Tighten the rear shock absorber lower mounting nut
to the specified torque and install the chain case.
Refer to “Rear Shock Absorber Removal and
11) Install the rear side guard. )(Page 9D-18)
12) Install the rear wheel assembly. )(Page 2D-5)
1 Swingarm Inspection
BENF34J12306014
IF34J1230014-01 Refer to “Swingarm Removal and Installation” (Page 2C-
7) Pass the drive chain (1) to the swingarm and then 3).
install the swingarm assembly (2).
Spacers
Inspect the spacers for wear and damage. If any defects
are found, replace the spacers with new ones.
1
IF34J1230019-02
IF34J1230021-01
Chain Buffer Swingarm

Inspect the chain buffer for wear and damage. If any Inspect the swingarm for damage. If any defect is found,
defect is found, replace the chain buffer with a new one. replace the swingarm with a new one.
IF34J1230022-02 IF34J1230025-01
Torque Link Swingarm Pivot Shaft

Inspect the torque link for damage. If any defect is found, Using a dial gauge, check the swingarm pivot shaft for
replace the torque link with a new one. runout. If the runout exceeds the service limit, replace
the pivot shaft.
Special tool
(A): Dial Gauge
(C): V Blocks
Swingarm pivot shaft runout
(A )
IF34J1230023-01
(B )
Swingarm Bearing
1) Insert the spacers into bearings.
2) Check the play by moving the spacers up and down.
If excessive play is noted, replace the bearings with
new ones. )(Page 2C-7) (C)
IF34J1230026-01
IF34J1230024-01
Swingarm Bearing Removal and Installation Installation

BENF34J12306015
Refer to “Swingarm Removal and Installation” (Page 2C- 1) Install the center spacer.
3). 2) Press the new pivot bearings (1) into the swingarm
Refer to “Rear Suspension Components” (Page 2C-1). using the special tool.
NOTE
Removal
1) Remove the swingarm pivot bearings (1) on both The stamped mark side of the pivot bearing
sides using the special tools. faces outside.
Special tool Special tool

(A): Bearing remover (A): Bearing installer set
(A )
1
(A) 1
IF34J1230029-01
IF34J1230027-01 3) Apply grease to the bearings.
2) Remove the center spacer (1).
“A”
IF34J1230028-01
“A”
IF34J1230030-01
Specifications
BENF34J12307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber upper mounting bolt 65 6.6 48.0 )(Page 2C-3)
Rear shock absorber lower mounting nut 78 8.0 57.5 )(Page 2C-3)
Torque link nut (front) 16 1.6 12.0 )(Page 2C-5)
Swingarm pivot nut 58 5.9 43.0 )(Page 2C-5)
Reference:
“Rear Suspension Components” (Page 2C-1)

BENF34J12308001
Grease SUZUKI SUPER GREASE A )(Page 2C-4) / )(Page 2C-
4) / )(Page 2C-7)
NOTE
“Rear Suspension Components” (Page 2C-1)
Special Tool
BENF34J12308002
Dial gauge (10 x 0.01 mm) Dial gauge chuck

)(Page 2C-6) )(Page 2C-6)
V blocks Bearing remover (ø17)

)(Page 2C-6) )(Page 2C-7)
Bearing installer set

)(Page 2C-7)
Wheels and Tires: 2D-1
Wheels and Tires

Suspension
Precautions
Precautions for Wheel and Tire
BENF34J12400001
! WARNING
• Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion,
crack, nick or scratch.
• When tire replacement is necessary, the original equipment type tire should be used.
Repair Instructions
Front Wheel Components
BENF34J12406001
10 (a)
4
5
2 (b)
9
5
3
7 1
IF34J1240012-01
1. Front axle 5. Spacer 9. Front tire : Apply grease.

2. Brake disc bolt 6. Dust seal 10. Front axle nut : Do not reuse.
3. Brake disc 7. Front wheel : 44 Nm (4.5 kgf-m, 32.5 lbf-ft)
4. Bearing 8. Air valve : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2D-2 Wheels and Tires:
Front Wheel Assembly Removal and Installation Installation

BENF34J12406002
1) Install the spacers (1) into the both sides of the
Removal wheel.
1) Remove the front axle nut (1).
1
1
1
IF34J1240003-01
2) Install the front wheel with the front axle and tighten
IF34J1240001-01
the front axle nut temporarily.
2) Raise the front wheel off the ground and support the
motorcycle with a jack or a wooden block. 3) Remove the jack or the wooden block.
3) Draw out the front axle (1) and remove the front 4) Tighten the front axle nut to the specified torque.
wheel. Tightening torque
Front axle nut (a): 44 N·m (4.5 kgf-m, 32.5 lbf-ft)
(a)
1
IF34J1240002-01
4) Remove the spacers (1). IF34J1240004-01
Front Wheel Dust Seal / Front Wheel Bearing

Removal and Installation
BENF34J12406003
1 Installation” (Page 2D-2).
1
Removal
1) Remove the dust seals (1) on both sides using the
special tool.
Special tool
IF34J1240003-01 (A): Oil seal remover
(A )
IF34J1240005-01
2) Remove the bearings (1) on both sides using the 2) First install the right wheel bearing (1), then install
special tool. the spacer (2) and left wheel bearing (3) using the
special tool.
Special tool
(A): Wheel Bearing Removal Set NOTICE
The sealed cover of the bearing must face
(A ) outside.
Special tool
(A): Bearing installer set
(A)
1
IF34J1240006-01
3) Remove the spacer (1).
1
1
IF34J1240008-01
LH RH
(A)
(B)
(B)
IF34J1240007-02
Installation
1) Apply grease to the new wheel bearings.
(SUZUKI SUPER GREASE A)
1
LH RH
2 (B)
(B)
3
“a”
I649G1240019-02 IF34J1240009-01
“a”: Clearance
3) Install the new dust seals on both sides using the 4) Apply grease to the lip of the dust seals.
special tool.
Special tool
(A) “A”
“A”
IF34J1240011-01
IF34J1240010-01
Rear Wheel Components

BENF34J12406004
13 (a)
10
11
7
9
5 8
6
2
4 1
12 (b)
IF34J1240013-01
1. Rear axle 7. Rear sprocket mounting drum 13. Rear axle nut
2. Spacer 8. Rear sprocket : 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
3. Dust seal 9. Rear wheel : 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
4. Bearing 10. Rear tire : Apply grease.
5. Rear wheel damper 11. Air valve : Do not reuse.
6. Retainer 12. Rear sprocket nut
Rear Wheel Assembly Removal and Installation Installation

BENF34J12406005
1) Install the left spacer (1).
Removal
2) Remove the rear brake adjuster nut (1), spring (2),
washer (3) and pin (4).
3) Remove the torque link nut and bolt (5).
3
2
1
IF34J1240016-01
2) Install the rear wheel assembly.
! WARNING
5
4
The directional arrow on the tire should point
to the wheel rotation, when installing the
IF34J1240014-01
wheel.
4) Remove the rear axle nut (1) and washer (2).
5) Loosen the drive chain adjuster nuts (3).
6) Disengage the drive chain (4) from the rear sprocket.
7) Draw out the rear axle (5) and washer (6), and then
remove the right spacer (7).
8) Remove the rear wheel assembly.
7 IF34J1240017-01
1
3) Engage the drive chain to the rear sprocket.

2 4) Install the rear axle (1) and right spacer (2).
5
3 4 5) Tighten the rear axle nut (3) temporarily.
3
IF34J1240015-01
9) Remove the left spacer (1).
1 2
3
IF34J1240018-01
6) Adjust the drive chain slack. Refer to “Drive Chain

Inspection and Adjustment” in Section 3A (Page 3A-
IF34J1240016-01 2).
7) Install the torque link (1) and tighten the torque link 3) Remove the spacer (1).
nut (rear) to the specified torque.
Tightening torque
Torque link nut (rear) (a): 16 N·m (1.6 kgf-m, 12.0 1
lbf-ft)
8) Tighten the rear axle nut to the specified torque.
Tightening torque
Rear axle nut (b): 65 N·m (6.6 kgf-m, 48.0 lbf-ft)
9) Install the pin (2), washer (3), spring (4) and rear
brake adjuster nut (5).
IF34J1240021-01
(b)
Installation
1) Apply grease to the new wheel bearings.
3 SUZUKI SUPER GREASE A
5
2 4 (a)
IF34J1240019-01
10) Adjust the brake pedal free travel. )(Page 4A-5)
Rear Wheel Bearing Removal and Installation

BENF34J12406006
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” in Section 3A (Page 3A-5) and I649G1240019-02
“Rear Brake Panel Removal and Installation” in Section
4C (Page 4C-2).
Removal
1) Remove the rear wheel dampers. )(Page 2D-8)
2) Remove the bearings (1) on both sides using the
special tool.
Special tool
(A): Wheel Bearing Removal Set
(A )
1
IF34J1240020-01
2) First install the right wheel bearing (1), then install

the spacer (2) and left wheel bearing (3) using the LH RH
special tools. (A) (A)
NOTICE
The sealed cover of the bearing must face
outside.
Special tool
1
(A)
LH RH
(B) (C) (B)
2
1 3
“a” 1
IF34J1240022-01 IF34J1240024-01
“a”: Clearance
(A)
3) Install the rear wheel dampers. )(Page 2D-8)
Wheel / Wheel Axle Inspection

BENF34J12406007
Refer to “Rear Wheel Assembly Removal and
3
Wheel
IF34J1240023-01
1) Remove the brake pads. )(Page 4B-2)
2) Make sure that the wheel runout checked as shown
does not exceed the service limit. An excessive
runout is usually due to worn or loosened wheel
bearings and can be reduced by replacing the
bearings.
• Front: )(Page 2D-2)
• Rear: )(Page 2D-6)
If bearing replacement fails to reduce the runout,
replace the wheel.
Wheel rim runout
Service limit (Axial and Radial): 2.0 mm (0.08 in)
Special tool Wheel Bearing

(A): Dial gauge 1) Remove the rear sprocket mounting drum assembly
and rear brake panel (Rear wheel only).
• Rear sprocket mounting drum: )(Page 3A-5)
(A) • Rear brake panel: )(Page 4C-2)
2) Inspect the play of the wheel bearings by hand while
they are in the wheel. Rotate the inner race by hand
to inspect for abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual.
• Front: )(Page 2D-2)
• Rear: )(Page 2D-6)
ID26J1240033-01
3) Install the brake pads. )(Page 4B-2)
Wheel Axle
Using a dial gauge, check the wheel axle for runout. If
the runout exceeds the limit, replace the wheel axle.
Wheel axle runout I649G1240015-02
Service limit: 0.25 mm (0.010 in) 3) Install the rear sprocket mounting drum assembly
and rear brake panel (Rear wheel only).
Special tool
(A): Dial gauge • Rear sprocket mounting drum: )(Page 3A-5)
(B): Dial gauge chuck • Rear brake panel: )(Page 4C-2)
(C): V blocks
Brake Disc
Refer to “Front Brake Disc Inspection” in Section 4B
(Page 4B-7).
(A)
(B) Rear Brake Drum
Refer to “Rear Brake Parts Inspection” in Section 4C
(Page 4C-3).
Rear Sprocket
Refer to “Rear Sprocket Mounting Drum / Sprocket
(C) Inspection” in Section 3A (Page 3A-6).
IF34J1240025-01
Tire
Dust Seal Refer to “Tire Inspection and Cleaning” (Page 2D-9).
Inspect the dust seals lip (1) for wear or damage. If any
defect is found, replace the dust seals with new ones.
Rear Wheel Damper Removal and Installation
)(Page 2D-2) BENF34J12406008
Removal and Installation” in Section 3A (Page 3A-5).
1 Removal
1
Remove the rear wheel dampers (1).
1
1
IF34J1240026-01
IF34J1240027-01
Installation
Install the rear wheel dampers in the reverse order of
removal. Pay attention to the following point:
• Install the rear wheel damper aligning its groove (1)
with the rib (2) of the rear wheel.
1
I649G1240042-02
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
2 a tire when the remaining depth of tire tread reaches the
following specification.
IF34J1240028-01 Front tire tread depth (Service limit)
Rear Wheel Damper Inspection
BENF34J12406009 Rear tire tread depth (Service limit)
Inspect the rear wheel damper for wear and damage. Service limit: 2.0 mm (0.08 in)
Replace the damper if there is anything unusual.
Special tool
Tire Depth Gauge
IF34J1240029-01
I310G1020068-02
Tire Inspection and Cleaning Tire pressure

BENF34J12406010
If the tire pressure is too high or too low, steering will be
Tire
adversely affected and tire wear increased. Therefore,
Wipe the tire clean and check for the following points:
maintain the correct tire pressure for good roadability or
• Nick and rupture on side wall shorter tire life will result. Cold inflation tire pressure is as
• Tread separation follows.
• Abnormal, uneven wear on tread Cold inflation tire pressure
• Surface damage on bead Front Rear
• Localized tread wear due to skidding (Flat spot) Solo 200 kPa 225 kPa
• Abnormal condition of inner liner riding (2.00 kgf/cm2, 29 psi) (2.25 kgf/cm2, 33 psi)
Dual 200 kPa 225 kPa
Front tire size riding (2.00 kgf/cm2, 29 psi) (2.25 kgf/cm2, 33 psi)
100/80-17M/C 52P, tubeless
Rear tire size
140/60R17M/C 63P, tubeless
Front tire type
MRF: NYLOGRIP ZAPPER-FX
Rear tire type
MRF: REVZ-M
Installation
NOTICE
• Do not use oil, grease or gasoline on the
tire bead in place of tire lubricant.
• Do not reuse the air valve which has been
once removed.
1) Apply tire lubricant to the tire bead.

I310G1020069-02
Tire Removal and Installation

BENF34J12406011
Removal and Installation” in Section 3A (Page 3A-5).
NOTICE
For removal and installation procedure of tire I649G1240038-02
onto the wheel, follow the instructions given 2) Install the tire aligning the arrow (1) on the side wall
by the tire changer manufacturer. with the direction of the wheel rotation.
Removal NOTE
The most critical factor of a tubeless tire is the seal Align the chalk mark put on the tire at the
between the wheel rim and the tire bead. For this time of removal with the valve position.
reason, it is recommended to use a tire changer that can
satisfy this sealing requirement and can make the
operation efficient as well as functional.
NOTE
When replacing the tire with a new one, the
tire mark (1) should be aligned with the valve
position. However, when removing the tire in
case of repair or inspection, mark the tire
with a chalk to indicate the tire position 1
ID26J1240047-02
relative to the valve position. Even though
the tire is refitted to the original position after 3) Bounce the tire several times while rotating. This
repairing puncture, the tire may have to be makes the tire bead expand outward to contact the
balanced again since such a repair can cause wheel, thereby facilitating air inflation.
imbalance. 4) Inflate the tire.
! WARNING
• Do not inflate the tire to more than 400 kPa

(4.0 kgf/cm2, 57 psi). If inflated beyond this
limit, the tire can burst and possibly cause
injury. Do not stand directly over the tire
while inflating.
• In the case of preset pressure air inflator,
pay special care for the set pressure
IE31J1240036-01 adjustment.
5) In this condition, check the “rim line” (1) cast on the Air Valve
tire side walls. The line must be equidistant from the • Inspect the air valve (1) for peeling and damage. If
wheel rim all around. any defect is found, replace the air valve with a new
6) If the distance between the “rim line” and wheel rim one.
varies, this indicates that the bead is not properly
seated. If this is the case, deflate the tire completely
and unseat the bead for both sides. Coat the bead
with lubricant and fit the tire again.
IE31J1240038-01
• Inspect the valve core seal (1) for wear and damage.
IE31J1240037-01
If any defect is found, replace the valve core with a
new one.
7) When the bead has been fitted properly, install the
valve core and adjust the pressure to the
specification. )(Page 2D-9)
Wheel Rim / Air Valve Inspection and Cleaning

BENF34J12406012
Refer to “Tire Removal and Installation” (Page 2D-10).
Refer to “Air Valve Removal and Installation” (Page 2D- IE31J1240039-01
11).
Air Valve Removal and Installation
Wheel Rim BENF34J12406013
Wipe the wheel clean and check for the following points: Refer to “Tire Removal and Installation” (Page 2D-10).
• Distortion and crack.
Removal
• Any flaws and scratches at the bead seating area.
1) Remove the air valve (1) from the wheel.
• Wheel rim runout. Refer to “Wheel / Wheel Axle
Inspection” (Page 2D-7).
IE31J1240040-01
I649G1240041-02 Installation
1) Any dust or rust around the valve hole (1) must be
cleaned off.
IE31J1240041-01
2) Install the new air valve (1) into the air valve hole NOTICE
with a special tire lubricant or neutral soapy liquid Be careful not to damage the valve lip of the
applied at the valve lip (2). air valve.
2 1
IF34J1240030-01
3. Wheel
Specifications
BENF34J12407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front axle nut 44 4.5 32.5 )(Page 2D-2)
Torque link nut (rear) 16 1.6 12.0 )(Page 2D-6)
Rear axle nut 65 6.6 48.0 )(Page 2D-6)
Reference:
“Front Wheel Components” (Page 2D-1)
“Rear Wheel Components” (Page 2D-4)

BENF34J12408001
Grease SUZUKI SUPER GREASE A )(Page 2D-3) / )(Page 2D-
4) / )(Page 2D-6)
NOTE
“Front Wheel Components” (Page 2D-1)
“Rear Wheel Components” (Page 2D-4)
Special Tool
BENF34J12408002
Dial gauge (10 x 0.01 mm) Dial gauge chuck

)(Page 2D-8) / )(Page 2D-8)
)(Page 2D-8)
Tire depth gauge V blocks

)(Page 2D-9) )(Page 2D-8)
Oil seal remover Bearing installer set

)(Page 2D-2) )(Page 2D-4) /
)(Page 2D-7)
Wheel Bearing Remover Set

)(Page 2D-3) /
)(Page 2D-6)
Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1 Rear Sprocket Removal and Installation.............3A-5

Precautions............................................................. 3-1 Rear Sprocket Mounting Drum Assembly
Precautions for Driveline / Axle ............................. 3-1 Removal and Installation...................................3A-5
Rear Sprocket Mounting Drum / Sprocket
Drive Chain / Drive Train / Drive Shaft... 3A-1 Inspection..........................................................3A-6
Diagnostic Information and Procedures............3A-1 Rear Sprocket Mounting Drum Dust Seal / 3
Drive Chain and Sprocket Symptom Bearing Removal and Installation .....................3A-7
Diagnosis .......................................................... 3A-1 Drive Chain Replacement ...................................3A-8
Repair Instructions ..............................................3A-1 Specifications .......................................................3A-9
Drive Chain Related Components....................... 3A-1 Tightening Torque Specifications........................3A-9
Drive Chain Inspection and Adjustment .............. 3A-2 Special Tools and Equipment .............................3A-9
Drive Chain Cleaning and Lubricating................. 3A-3 Recommended Service Material .........................3A-9
Engine Sprocket Removal and Installation ......... 3A-4 Special Tool ........................................................3A-9
3-1 Precautions:
Precautions
Driveline / Axle
Precautions
Precautions for Driveline / Axle
BENF34J13000001
! WARNING
Never inspect or adjust the drive chain while the engine is running.
NOTICE
• Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings
of the drive chain.
• Clean the drive chain with a spray-type chain cleaner and blow dry with compressed air. If the drive
chain cannot be cleaned with a spray cleaner, it may be necessary to use a kerosine. Always follow
the chemical manufacturer’s instructions on proper use, handling and storage.
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant.
Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.
Drive Chain / Drive Train / Drive Shaft: 3A-1
Drive Chain / Drive Train / Drive Shaft

Driveline / Axle

Drive Chain and Sprocket Symptom Diagnosis
BENF34J13104001

Noisy Drive Chain Worn sprocket. Replace. )(Page 3A-4)
)(Page 3A-5)
Worn drive chain. Replace. )(Page 3A-8)
Stretched drive chain. Replace. )(Page 3A-8)
Too large drive chain slack. Adjust. )(Page 3A-2)
Drive chain out of adjustment. Adjust. )(Page 3A-2)
Repair Instructions
Drive Chain Related Components
BENF34J13106001
7
9
4
10
1
3 (a)
5
2 6 (b)
IF34J1310001-02
1. Engine sprocket 6. Rear sprocket nut : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. Drive chain 7. Rear sprocket : 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
3. Engine sprocket bolt 8. Rear sprocket mounting drum : Apply grease.
4. Dust seal 9. Wheel damper : Apply thread lock to the thread part.
5. Bearing 10. Retainer : Do not reuse.
3A-2 Drive Chain / Drive Train / Drive Shaft:
Drive Chain Inspection and Adjustment 5) Count out 21 pins (20 pitches) on the chain and
BENF34J13106002 measure the distance between the two points. If the
Drive Chain Visual Check
distance exceeds the service limit, the chain must be
1) With the transmission in neutral, support the replaced. )(Page 3A-8)
motorcycle with the center stand and turn the rear
wheel slowly by hand. Drive chain 20-pitch length
2) Visually check the drive chain for the possible
defects listed as follows. If any defects are found, the 1 2 3 19 20 21
drive chain must be replaced. )(Page 3A-8)
• Loose pins
• Damaged rollers
• Dry or rusted links
• Kinked or binding links
• Excessive wear IF34J1310030-01
• Improper chain adjustment 6) After finishing the drive chain length inspection,
• Missing O-rings (1) adjust the drive chain slack. )(Page 3A-2)
NOTE Drive Chain Slack Adjustment

When replacing the drive chain, replace the 1) Support the motorcycle with the center stand.
drive chain and sprockets as a set. 2) Loosen the torque link nut (rear) (1).
3) Loosen the rear axle nut (2).
2
1
2
IF34J1310002-01
2. Grease
Drive Chain Length Inspection 1

IF34J1310028-01
1) Support the motorcycle with the center stand.
2) Loosen the torque link nut (rear) (1).
4) Give tension to the drive chain fully by turning both
chain adjuster nuts (3).
3
3
1
IF34J1310003-01
4) Loosen or tighten both chain adjuster nuts (1) until Drive Chain Cleaning and Lubricating
the slack “a” at the middle of the chain between the BENF34J13106003
engine and rear sprockets becomes within the 1) Remove dirt and dust from the drive chain (1). Be
standard range. careful not to damage the O-rings.
2) Clean the drive chain (1) with a sealed drive chain
NOTICE cleaner, or water and neutral detergent.
The reference marks (2) on both sides of the
chain adjuster and the edge of each NOTICE
swingarm hole (rear side or front side) must Cleaning the drive chain improperly can
be aligned to ensure that the front and rear damage O-rings and ruin the drive chain.
wheels are correctly aligned. • Do not use a volatile solvent such as paint
thinner, kerosene and gasoline.
Drive chain slack “a”
Standard: 20 – 30 mm (0.8 – 1.2 in) • Do not use high pressure cleaner to clean
the drive chain.
• Do not use wire brush to clean the drive
chain.
2 2
1 1 3) Use a soft brush to clean the drive chain (1). Be
careful not to damage the O-rings even through
using a soft brush.
4) Wipe off water and neutral detergent.
5) Lubricate with a motorcycle sealed drive chain
lubricant or high viscosity oil.
NOTICE
IF34J1310004-02
Some drive chain lubricant contains solvents
2 and additives which could damage the O-
rings in the drive chain.
Use sealed drive chain lubricant which is
specifically intended for use with sealed
drive chains.
6) Lubricate both front and back plates of the drive

chain (1).
1 7) Wipe off excess lubricant after lubricating all around
of the drive chain (1).
IF34J1310029-01 NOTE
The standard drive chain is a LGB R428NOR,
132 Links. SUZUKI recommends to use this
standard drive chain as a replacement.
“a”
IF34J1310031-02
5) After adjusting the drive chain, tighten the rear axle

nut and torque link nut (rear) to the specified torque.
Tightening torque
Rear axle nut: 65 N·m (6.6 kgf-m, 48.0 lbf-ft)
Torque link nut (rear): 16 N·m (1.6 kgf-m, 12.0
1
lbf-ft)
6) Recheck the drive chain slack after tightening the IF34J1310005-02
axle nut.
7) Tighten both chain adjuster nuts securely.
8) Check the brake pedal free travel. )(Page 4A-5)
Engine Sprocket Removal and Installation 8) Loosen the torque link nut (rear) (1).
BENF34J13106004
Removal 10) Loosen the adjuster nuts (3) to provide additional
1) Remove the speed sensor from the engine sprocket chain slack.
cover. )(Page 1C-4)
pins (2). 2
1 2
3
3
1
IF34J1310003-01
11) Remove the engine sprocket (1).

2
IF34J1310006-02
3) Remove the speed sensor rotor bolt (1) while

depressing the rear brake pedal.
1
4) Remove the speed sensor rotor (2).
1
IF34J1310009-01
Installation
1) Install the engine sprocket (1) and lock washer (2).
2 2) Apply thread lock to the engine sprocket bolts.
IF34J1310007-01 “A”: THREAD LOCK CEMENT 1322D)
5) Remove the engine sprocket bolts (1) while
depressing the rear brake pedal. 3) Tighten the engine sprocket bolts to the specified
6) Remove the lock washer (2). torque.
NOTE
2
The stamped mark (3) on the engine sprocket
should face outside.
Tightening torque
Engine sprocket bolts (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
3
1 2
IF34J1310008-01
7) Support the motorcycle with the center stand.

1
“A ”, (a )
IF34J1310010-02
4) Install the speed sensor rotor (1) and tighten its bolt • Tighten the rear sprocket nuts to the specified torque.
to the specified torque.
NOTE
Tightening torque
The stamped mark (1) on the sprocket should
Speed sensor rotor bolt (a): 23 N·m (2.3 kgf-m,
face outside.
17.0 lbf-ft)
Tightening torque
Rear sprocket nut (a): 29 N·m (3.0 kgf-m, 21.5 lbf-
ft)
(a) (a)
1
IF34J1310011-01
5) Install the dowel pins (1) and engine sprocket cover

(2). (a)
IF34J1310014-01
2
1
Rear Sprocket Mounting Drum Assembly
Removal and Installation
BENF34J13106006
Removal
1) Remove the rear sprocket mounting drum assembly
1 (1).
IF34J1310012-02
6) Install the speed sensor. )(Page 1C-4)

7) Adjust the drive chain slack. Refer to “Drive Chain
Inspection and Adjustment” (Page 3A-2).
1
Rear Sprocket Removal and Installation

BENF34J13106005
Removal
1) Remove the rear sprocket (1). IF34J1310015-01
2) Remove the retainer (1).
IF34J1310013-01
IF34J1310016-01
Installation
Install the rear sprocket in the reverse order of removal.
Installation Dust Seal

1) Apply grease to the retainer (1). Inspect the sprocket mounting drum dust seal (1) for
wear or damage. If any defect is found, replace the dust
“A”: (SUZUKI SUPER GREASE A) seal with a new one. )(Page 3A-7)
1
1, “A”
IF34J1310019-01
IF34J1310017-01
2) Apply grease to the contacting surface between the Bearing

rear wheel hub and the rear sprocket mounting Inspect the play of the sprocket mounting drum bearings
drum. by hand while they are in the wheel and drum. Rotate
the inner race by hand to inspect for abnormal noise and
smooth rotation. Replace the bearing if there is anything
unusual. )(Page 3A-7)
“A”
I649G1310015-02
Sprocket
IF34J1310018-01 1) Remove the engine sprocket cover. (Engine
3) Install the rear sprocket mounting drum assembly to sprocket only) Refer to “Engine Sprocket Removal
the rear wheel assembly. and Installation” (Page 3A-4).
2) Inspect the sprocket teeth for wear. If they are worn
Rear Sprocket Mounting Drum / Sprocket as shown, replace the engine sprocket, rear
Inspection sprocket and drive chain as a set.
BENF34J13106007 • Engine: )(Page 3A-4)
• Rear: )(Page 3A-5)
IE31J1310022-01
1. Normal wear 2. Excessive wear
3) Install the engine sprocket cover (Engine sprocket

only). Refer to “Engine Sprocket Removal and
Installation” (Page 3A-4).
Wheel Damper Installation

Refer to “Rear Wheel Damper Inspection” in Section 2D 1) Apply grease to the new bearing.
(Page 2D-9).
(SUZUKI SUPER GREASE A)
Drive Chain
Refer to “Drive Chain Inspection and Adjustment” (Page
3A-2).
Rear Sprocket Mounting Drum Dust Seal /

Bearing Removal and Installation
BENF34J13106008
Removal and Installation” (Page 3A-5).
Removal
1) Remove the dust seal (1) using the special tool.
I649G1310020-02
Special tool 2) Install the bearing (1) using the special tool.
(A): Oil seal remover
NOTICE
(A) The sealed cover of the bearing must face
inside.
Special tool
(A): Bearing installer
1
(A)
IF34J1310020-01
2) Remove the bearing (1) using the special tool.

Special tool
(A): Bearing removal set
(A) 1
IF34J1310022-01
3) Install a new dust seal using the special tool.

Special tool
1 (A): Bearing installer
(A )
IF34J1310021-01
IF34J1310023-01
4) Apply grease to the dust seal lip. 6) Install the new drive chain joint clip (1). It should be
attached in the way that the slit end faces opposite to
the direction of the chain travel [a].
[a]
“A”
1
IF34J1310027-01
7) Adjust the drive chain slack, after connecting the

chain. Refer to “Drive Chain Inspection and
Adjustment” (Page 3A-2).
IF34J1310024-01
Drive Chain Replacement

BENF34J13106009
1) Remove the dive chain clip (1) from the joint pins (2)
using pliers, and disengage the drive chain from the
rear sprocket.
1
IF34J1310025-01
2) Remove the drive chain from the motorcycle.

3) Engage the new drive chain onto the sprockets.
4) Apply grease to the new joint pins (1), new O-rings
(2) and new plate (3).
5) Connect both ends of the drive chain with the joint

pins (1) inserted from the wheel side [a].
IF34J1310026-02
Specifications
BENF34J13107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear axle nut 65 6.6 48.0 )(Page 3A-3)
Torque link nut (rear) 16 1.6 12.0 )(Page 3A-3)
Engine sprocket bolts 10 1.0 7.5 )(Page 3A-4)
Speed sensor rotor bolt 23 2.3 17.0 )(Page 3A-5)
Rear sprocket nut 29 3.0 21.5 )(Page 3A-5)
Reference:
“Drive Chain Related Components” (Page 3A-1)

BENF34J13108001
Grease SUZUKI SUPER GREASE A )(Page 3A-6) / )(Page 3A-
6) / )(Page 3A-7) / )(Page
3A-8) / )(Page 3A-8)
Thread lock cement THREAD LOCK CEMENT 1322D )(Page 3A-4)
NOTE
“Drive Chain Related Components” (Page 3A-1)
Special Tool
BENF34J13108002
Oil seal remover Bearing installer set

)(Page 3A-7) )(Page 3A-7)
Section 4
Brakes
CONTENTS
Precautions .................................................4-1 Recommended Service Material .......................4A-14

Precautions............................................................. 4-1 Special Tool ......................................................4A-14
Precautions for Brake System .............................. 4-1
Brake Fluid Information ......................................... 4-1
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Brake Control System and Diagnosis ... 4A-1 Front Brake Components ....................................4B-1
Diagnostic Information and Procedures............4A-1 Front Brake Pad Inspection.................................4B-1
Brake Symptom Diagnosis.................................. 4A-1 Front Brake Pad Replacement............................4B-2
Repair Instructions ..............................................4A-2 Front Brake Caliper Removal and Installation.....4B-3
Front Brake Hose Routing Diagram .................... 4A-2 Front Brake Caliper Disassembly and 4
Rear Brake Pedal Construction .......................... 4A-3 Reassembly ......................................................4B-4
Front Brake Light Switch Inspection ................... 4A-3 Front Brake Caliper Parts Inspection ..................4B-6
Rear Brake Light Switch Inspection .................... 4A-4 Front Brake Disc Removal and Installation .........4B-7
Rear Brake Light Switch Inspection and Front Brake Disc Inspection ................................4B-7
Adjustment ........................................................ 4A-4 Specifications .......................................................4B-8
Brake Fluid Level Check ..................................... 4A-4 Tightening Torque Specifications........................4B-8
Brake Hose Inspection ........................................ 4A-5 Special Tools and Equipment .............................4B-9
Brake Pedal Free Travel Inspection and Recommended Service Material .........................4B-9
Adjustment ........................................................ 4A-5 Special Tool ........................................................4B-9
Air Bleeding from Brake Line .............................. 4A-5
Brake Fluid Replacement.................................... 4A-6 Rear Brakes.............................................. 4C-1
Front Brake Hose Removal and Installation........ 4A-7 Repair Instructions ..............................................4C-1
Front Brake Master Cylinder Assembly / Rear Brake Components.....................................4C-1
Brake Lever Components ................................. 4A-8 Rear Brake Shoe Wear Inspection......................4C-1
Front Brake Master Cylinder Assembly Rear Brake Shoe Replacement ..........................4C-1
Removal and Installation................................... 4A-8 Rear Brake Panel Removal and Installation .......4C-2
Front Brake Master Cylinder Assembly / Rear Brake Panel Disassembly and
Brake Lever Disassembly and Reassembly ..... 4A-9 Reassembly ......................................................4C-2
Front Brake Master Cylinder Parts Inspection .. 4A-11 Rear Brake Parts Inspection ...............................4C-3
Rear Brake Pedal Components ........................ 4A-12 Specifications .......................................................4C-4
Rear Brake Pedal Removal and Installation ..... 4A-12 Tightening Torque Specifications........................4C-4
Rear Brake Pedal Inspection ............................ 4A-13 Special Tools and Equipment .............................4C-4
Specifications.....................................................4A-14 Recommended Service Material .........................4C-4
Tightening Torque Specifications...................... 4A-14 Special Tool ........................................................4C-4
Special Tools and Equipment ...........................4A-14
4-1 Precautions:
Precautions
Brakes
Precautions
Precautions for Brake System
BENF34J14000001
(Page 00-2).
Brake Fluid Information

BENF34J14000002
! WARNING
• This brake system is filled with an ethylene glycol-based DOT 3 or DOT 4 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 reuse brake fluid left
over from the last servicing 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 disc with high quality brake cleaner or neutral detergent.
NOTICE
The brake fluid is damaging to painted surfaces, plastics and rubber materials, and do not allow the
fluid to spill on the surrounding parts.
If the fluid is spilled, flush it with water immediately.
Brake Control System and Diagnosis: 4A-1
Brake Control System and Diagnosis

Brakes

Brake Symptom Diagnosis
BENF34J14104001

Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. )(Page 4A-5)
system.
Worn brake pads and/or disc. Replace. )(Page 4B-2)
)(Page 4B-7)
Oil adhesion on friction surface of pads. Clean disc and pads.
Worn brake shoes and/or drum. Replace. )(Page 4C-1)
)(Page 2D-5)
Air in hydraulic system. Bleed air. )(Page 4A-5)
Not enough brake fluid in the reservoir. Replenish. )(Page 4A-4)
Oil on brake shoe surfaces. Clean.
Excessive brake pedal play. Adjust. )(Page 4A-5)
Brake squeaking Carbon adhesion on brake pad and/or Repair surface with sandpaper.
brake shoe surfaces.
Tilted brake pads and/or brake shoes. Correct brake pads and/or shoes fitting or
replace. )(Page 4B-2)
)(Page 4C-1)
Damaged wheel bearings. Replace. )(Page 2D-2)
)(Page 2D-6)
Loose front wheel axle or rear wheel Tighten to specified torque.
axle.
Worn brake pads and/or disc. Replace. )(Page 4B-2)
)(Page 4B-7)
Foreign material in brake fluid. Replace brake fluid. )(Page 4A-6)
Clogged return port of master cylinder. Disassemble and clean master cylinder.
Worn brake shoes and/or drum. Replace. )(Page 4C-1)
)(Page 2D-5)
Excessive brake lever or Air in hydraulic system. Bleed air. )(Page 4A-5)
brake pedal stroke Insufficient brake fluid. Replenish fluid to specified level. )(Page 4A-
4)
Improper quality of brake fluid. Replace with correct fluid. )(Page 4A-6)
Worn brake cam. Replace. )(Page 4C-2)
Excessively worn brake shoes and/or Replace. )(Page 4C-1)
drum. )(Page 2D-5)
Leakage of brake fluid Insufficient tightening of connection Tighten to specified torque.
joints.
Cracked hose. Replace. )(Page 4A-7)
Worn piston and/or cup. Replace piston and/or cup. )(Page 4A-9)
Worn piston seal and dust seal. Replace piston seal and dust seal. )(Page
4B-4)
Brake drags Rusty part. Clean and lubricate. )(Page 0B-4)
Insufficient brake lever or brake pedal Lubricate. )(Page 0B-4)
pivot lubrication.
4A-2 Brake Control System and Diagnosis:
Repair Instructions
Front Brake Hose Routing Diagram
BENF34J14106001
“a”
3
6
5
(b)
(a)
2 (b)
“b”
“c”
IF34J1410001-02
1. Stopper 5. Headlight housing brace “c”: 21°

: After the brake hose union has contacted the stopper,
tighten the union bolt to the specified torque.
2. Clamp 6. Seal washer : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Fix the hose sleeve to the clamp firmly.
3. Clamp “a”: 49° : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Cut off the excess tip of the clamp.
4. Front brake hose “b”: 28° : Do not reuse.
Rear Brake Pedal Construction

BENF34J14106002
IF34J1410002-02
[A]: Outside 2. Spring 9. Front washer

[B]: Inside 3. Rear washer 10. Front pin
[C]: Brake pedal free travel adjusting area 4. Rear pin “a”: 38.5 mm (1.52 in)
[D]: Brake pedal initial position 5. Rear brake adjuster nut “b”: 88 mm (3.46 in)
: Approx. 42 mm (1.7 in) between the brake pedal top
face and footrest.
[E]: 10 mm (0.4 in) from the brake pedal initial position. 6. Brake rod : Do not reuse.
: Face the marking of the brake rod joint outside.
[F]: 20 mm (0.8 in) from the brake pedal initial position. 7. Brake pedal
1. Brake cam lever 8. Cotter pin
Front Brake Light Switch Inspection

BENF34J14106003
1) Disconnect the front brake light switch lead wire
couplers (1).
1
IF34J1410003-01
2) Inspect the switch for continuity with a circuit tester. Rear Brake Light Switch Inspection and
If any defect is found, replace the front brake light Adjustment
switch with a new one. )(Page 4A-9) BENF34J14106005
Check the rear brake light switch so that the brake light
will come on just before pressure is felt when the brake
Color
Terminal (B) Terminal (B) pedal is depressed. If the brake light switch adjustment
Position
OFF
is necessary, turn the adjuster nut (1) in or out while
holding the brake pedal.
ON
IF34J1410004-01
3) Connect the front brake light switch lead wire

couplers.
Rear Brake Light Switch Inspection

BENF34J14106004
1) Remove the left frame side cover. )(Page 9D-12) 1
2) Disconnect the rear brake light switch lead wire
coupler (1).
IF34J1410007-02
Brake Fluid Level Check

BENF34J14106006
1) Keep the motorcycle upright and place the
1 handlebars straight.
2) Check the brake fluid level by observing the lower
limit line (1) on the front brake fluid reservoir. When
the brake fluid level is below the lower limit line,
inspect for brake pad wear and leaks and replenish
IF34J1410005-03
with brake fluid that meets the following
3) Inspect the switch for continuity with a circuit tester. specification.
If any defect is found, replace the rear brake light
switch with a new one. Brake fluid (DOT 3)
Brake fluid (DOT 4)
Color
Terminal (W) Terminal (W/B)
Position
OFF
ON
IF34J1410006-02
4) Connect the rear brake light switch lead wire coupler.

5) Install the left frame side cover. )(Page 9D-12)
1
IF34J1410008-01
Brake Hose Inspection Air Bleeding from Brake Line

BENF34J14106007 BENF34J14106009
Inspect the brake hose and hose joints for crack, Trapped air in the brake line acts like a cushion to
damage or brake fluid leakage. If any defects are found, absorb a large proportion of the pressure developed by
replace the brake hose with a new one. )(Page 4A-7) the master cylinder and thus greatly reduces the braking
force. The presence of air bubbles is indicated by a
“spongy” feel in the brake lever and low braking force.
This condition is extremely dangerous, and therefore the
air must be bled every time after replacing any parts in
the brake line in the following manner.
1) Place the motorcycle on a level surface and keep the
handlebars straight.
2) Remove the reservoir cap (1), plate and diaphragm.
3) Fill the master cylinder reservoir with new brake fluid
to the top of the inspection window (2).
IF34J1410009-01 Brake fluid (DOT 3)

Brake fluid (DOT 4)
IF34J1410010-01
IF34J1410012-01
Brake Pedal Free Travel Inspection and 4) Attach a clear hose to the air bleeder valve, and
Adjustment insert the free end of the hose into a receptacle.
BENF34J14106008
1) Inspect the brake pedal free travel “a” at the brake
pedal top face depressing the brake pedal until
pressure is felt. If the brake pedal free travel is out of
the specification, adjust the brake pedal free travel.
Brake pedal free travel “a”
Standard: 10 – 20 mm (0.4 – 0.8 in)
2) Turn the adjuster nut (1) to obtain the specification of
brake pedal free travel.
“a”
IF34J1410011-02
3) After finishing the brake pedal free travel inspection

and adjustment, check the rear brake light switch.
)(Page 4A-4)
4) Check that the rear brake shoe wear limit indicator is
within the specified range. )(Page 4C-1)
5) Operate the brake lever several times and, while Brake Fluid Replacement
holding the lever gripped, loosen the air bleeder BENF34J14106010
valve (1) and drain the brake fluid into a receptacle. 1) Place the motorcycle on a level surface and keep the
handlebars straight.
2) Remove the brake fluid reservoir cap, plate and
diaphragm.
3) Suck up the old brake fluid as much as possible.
IF34J1410013-01
1 IF34J1410016-01
4) Fill the reservoir with new brake fluid.

Brake fluid (DOT 3)
Brake fluid (DOT 4)
5) Attach a clear hose to the air bleeder valve (1) and
insert the free end of the hose into a receptacle.
IF34J1410014-01
6) Tighten the air bleeder valve and release the brake

lever slowly.
7) Repeat the steps 5) and 6) until the fluid is flowing
out without bubbles.
NOTE
While bleeding the brake system, replenish
the reservoir with the brake fluid as
necessary to keep the fluid above the lower
level.
8) Tighten the air bleeder valve to the specified torque.

Tightening torque
Brake air bleeder valve: 7.5 N·m (0.76 kgf-m, 5.5
lbf-ft)
9) Fill the reservoir with brake fluid to the upper line (1)
of the reservoir.
IF34J1410015-01
10) Install the diaphragm, plate and reservoir cap.

6) Loosen the air bleeder valve, squeeze and release Front Brake Hose Removal and Installation
the brake lever and drain the old brake fluid out of BENF34J14106011
Refer to “Front Brake Hose Routing Diagram” (Page 4A-
the brake system.
2).
NOTE
Removal
While bleeding the brake system, replenish
the reservoir with the brake fluid as 1) Drain brake fluid. )(Page 4A-6)
necessary to keep the fluid above the lower 2) Remove the front brake hose.
level.
Installation
1) Install the front brake hose.
2) Bleed air from the front brake system. )(Page 4A-5)
IF34J1410013-01
IF34J1410017-01
7) Bleed air from the front brake system. )(Page 4A-5)

Front Brake Master Cylinder Assembly / Brake Lever Components

BENF34J14106013
(e)
10
11
(d)
1
(b)
2
7 3 (a)
5
6
9 (c)
IF34J1410018-02
1. Reservoir cap 6. Return spring 11. Brake light switch : 1 Nm (0.10 kgf-m, 1.0 lbf-ft)
2. Plate 7. Push rod : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Apply silicone grease.
3. Diaphragm 8. Dust boot : 1.2 Nm (0.12 kgf-m, 1.0 lbf-ft) : Apply brake fluid.
4. Master cylinder 9. Brake hose union bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft) : Do not reuse.
5. Piston/cup set 10. Brake lever : 6 Nm (0.61 kgf-m, 4.5 lbf-ft)
Front Brake Master Cylinder Assembly Removal 6) Remove the master cylinder assembly (4) by
and Installation removing the bolts.
BENF34J14106014
4 1
Removal
1) Drain brake fluid. )(Page 4A-6)
2) Remove the right rear view mirror (1). 3
3) Disconnect the front brake light switch lead wire

couplers (2).
4) Place a rag underneath the brake hose union bolt (3)
on the master cylinder to catch any spilt brake fluid.
5) Remove the brake hose union bolt and disconnect 2
the brake hose.
IF34J1410019-02
Installation
1) Install the master cylinder assembly (1) onto the
handlebars (2) aligning the edge of master cylinder
holder (3) with the punch mark (4) on the handlebars
and tighten the front mounting bolt (5) first.
NOTE 1 , (a )
Face the front mark (6) forward.
Tightening torque
Front brake master cylinder mounting bolt (a):
10 N·m (1.0 kgf-m, 7.5 lbf-ft) IF34J1410023-01
4) Connect the front brake light switch lead wire

5, ( a) couplers.
5) Install the right rear view mirror.
(a)
6) Bleed air from the brake system. )(Page 4A-5)
Front Brake Master Cylinder Assembly / Brake

4 Lever Disassembly and Reassembly
BENF34J14106015
Refer to “Front Brake Master Cylinder Assembly
Removal and Installation” (Page 4A-8).
3
IF34J1410020-02
Disassembly
1) Remove the reservoir cap (1), plate (2) and
(a) diaphragm (3).
3
5, ( a)
1
2
IF34J1410021-02
5, (a) (a) IF34J1410024-01
1 2) Remove the brake lever (1) and brake light switch

(2).
“a”
2
3
4 1
2
IF34J1410022-02
“a”: Clearance
2) Install the brake hose union bolt and new seal

washers to brake hose.
3) After setting the brake hose union to the stopper, IF34J1410025-01
tighten the union bolt (1) to the specified torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
3) Pull out the dust boot (1) with the push rod (2). NOTICE
4) Remove the snap ring (3) using the special tool. • Wash the master cylinder components with
Special tool new brake fluid before reassembly.
Snapring Pliers • 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 fluid or cleaning solvents such as
gasoline, kerosine, etc.
1
• Apply brake fluid to the master cylinder
bore and all of the master cylinder
component to be inserted into the bore.
2 3 Brake fluid (DOT 3)

Brake fluid (DOT 4)
IF34J1410026-01
5) Remove the following parts from the master cylinder.

• Piston/cup set (1)
• Return spring (2)
I649G1410036-02
1 2) Install the return spring (1) and new piston/cup set
(2) to the master cylinder.
IF34J1410027-01
Reassembly
1) Install the new piston/cup set (1) to the return spring
(2). 2
1
2 1
IF34J1410029-01
3) Install the new snap ring (1) using the special tool.
Special tool
Snapring Pliers
IF34J1410028-01
IF34J1410030-01
4) Apply grease to the push rod (1). 10) Tighten the pivot bolt (1) and new lock-nut (2) to the
specified torque.
“A”: (SUZUKI SILICONE GREASE)
Tightening torque
Brake lever pivot bolt (a): 1 N·m (0.10 kgf-m, 1.0
5) Set the push rod with the dust boot (2) to the master
lbf-ft)
cylinder securely.
Brake lever pivot bolt lock-nut (b): 6 N·m (0.61
kgf-m, 4.5 lbf-ft)
1 , (a )
1, “ A ”
2 2 , (b )
IF34J1410031-01
6) Install the brake light switch aligning the projection IF34J1410034-01

(1) on the switch with the hole (2) in the master
11) Install the diaphragm, plate and reservoir cap to the
cylinder.
master cylinder.
7) Tighten the brake light switch mounting screw to the
specified torque.
Front Brake Master Cylinder Parts Inspection
BENF34J14106016
Tightening torque
Refer to “Front Brake Master Cylinder Assembly / Brake
Brake light switch screw: 1.2 N·m (0.12 kgf-m,
Lever Disassembly and Reassembly” (Page 4A-9).
1.0 lbf-ft)
Master Cylinder
Inspect the master cylinder bore (1) for any scratches or
other damage. If any defect is found, replace the master
cylinder with a new one.
IF34J1410032-01
1
8) Apply grease to the brake lever pivot bolt.
9) Apply grease to the contact point between push rod
and brake lever.
“A”: (SUZUKI SILICONE GREASE) IF34J1410035-01
“A”
IF34J1410033-01
Piston / Cup Set Rear Brake Pedal Removal and Installation

Inspect the piston/cup set for any scratches or other BENF34J14106018
Removal
damage. If any defect is found, replace it with a new one.
1) Remove the left and right frame side covers.
)(Page 9D-12)
2) Disconnect the rear brake light switch coupler (1).
IF34J1410036-01
Dust Boot
Inspect the dust boot for wear or damage. If any defect is IF34J1410005-03
found, replace it with a new one. 3) Remove the rear brake adjuster nut (1), spring (2),
washer (3) and pin (4).
IF34J1410037-01 4
IF34J1410039-01
Rear Brake Pedal Components 4) Remove the front footrest bracket (1) with the rear
BENF34J14106017
brake pedal (2).
4 3
2
IF34J1410038-01
1. Rear brake pedal 4. Cotter pin IF34J1410040-02

2. Rear brake pedal return spring : Do not reuse.
3. Washer
5) Remove the cotter pin (1), washer (2) and rear brake • Tighten the front footrest bracket bolts to the specified
pedal (3). torque.
6) Remove the rear brake pedal return spring (4) and Tightening torque
rear brake light switch spring (5). Front footrest bracket bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
(a)
3 4
1 2
IF34J1410041-02
IF34J1410044-02
Installation
Install the rear brake pedal in the reverse order of
Rear Brake Pedal Inspection
removal. Pay attention to the following points: BENF34J14106019
• Apply grease to the rear brake pedal shaft of the front Refer to “Rear Brake Pedal Removal and Installation”
footrest bracket. (Page 4A-12).
‘‘A” : (SUZUKI SUPER GREASE A) Inspect the brake pedal and rod for damage and
excessive bend. If any defect is found, replace them with
new ones.
“A”
IF34J1410042-02
IF34J1410045-02
• Install the rear brake pedal return spring (1) and rear
brake light switch spring (2) in correct direction as
shown.
• Install the washer (3) and new cotter pin (4).
1
4
3
IF34J1410043-02
Specifications
BENF34J14107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake air bleeder valve 7.5 0.76 5.5 )(Page 4A-6)
Front brake master cylinder mounting bolt 10 1.0 7.5 )(Page 4A-9)
Brake hose union bolt 23 2.3 17.0 )(Page 4A-9)
Brake light switch screw 1.2 0.12 1.0 )(Page 4A-11)
Brake lever pivot bolt 1 0.10 1.0 )(Page 4A-11)
Brake lever pivot bolt lock-nut 6 0.61 4.5 )(Page 4A-11)
Front footrest bracket bolt 23 2.3 17.0 )(Page 4A-13)
Reference:
“Front Brake Hose Routing Diagram” (Page 4A-2)
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-8)

BENF34J14108001
Brake fluid DOT 3 — )(Page 4A-4) / )(Page 4A-
5) / )(Page 4A-6) / )(Page
4A-10)
DOT 4 — )(Page 4A-4) / )(Page 4A-
5) / )(Page 4A-6) / )(Page
4A-10)
Grease SUZUKI SUPER GREASE A )(Page 4A-13)
SUZUKI SILICONE GREASE )(Page 4A-11) / )(Page
4A-11)
NOTE
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-8)
“Rear Brake Pedal Components” (Page 4A-12)
Special Tool
BENF34J14108002
Snap ring pliers (Internal)

)(Page 4A-10) /
)(Page 4A-10)
Front Brakes: 4B-1
Front Brakes
Brakes
Repair Instructions
Front Brake Components
BENF34J14206001
(b)
(a)
13
6 9
11
14
7 8
9
1
2 11 (c)
(d)
12
3
10
4
5
IF34J1420001-03
1. Piston seal 9. Rubber boot : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
2. Dust seal 10. Brake caliper bracket : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Piston 11. Brake caliper bracket pin : Apply grease.
4. Brake pad spring 12. Spacer : Apply thread lock to the thread part.
5. Brake pad 13. Brake pad mounting pin : Apply brake fluid.
6. Front brake caliper 14. Clip : Do not reuse.

7. Front brake disc : 7.5 Nm (0.76 kgf-m, 5.5 lbf-ft)
8. Snap ring : 26 Nm (2.7 kgf-m, 19.5 lbf-ft)
Front Brake Pad Inspection

BENF34J14206002
The extent of brake pads (1) wear can be checked by “a”
observing the grooved limit line “a” on the pads. When
the wear exceeds the grooved limit line, replace the
pads with new ones. )(Page 4B-2) 1
“a”
IF34J1420002-01
4B-2 Front Brakes:
Front Brake Pad Replacement 4) Remove the pad mounting pin (1) and brake pads
BENF34J14206003 (2).
NOTE NOTE
After replacing the brake pads, pump the Do not operate the brake lever while
brake lever several times to check for proper removing the brake pads.
brake operation and then check the brake
fluid level.
1) Remove the brake caliper (1).
1 IF34J1420006-01
5) Clean up the caliper especially around the caliper

pistons.
IF34J1420005-02
2) Remove the clip (1). 6) Install the new brake pads (1) and temporarily new
pad mounting pin (2).
NOTE
• Replace the brake pads as a set.
• Pushing back the caliper pistons into the
caliper will facilitate installation of the
brake pads. At the time, observe the
reservoir level not to exceed the upper
1 level.
IF34J1420003-02
3) Push out the pad mounting pin (1) gradually tapping

it with a suitable bar (2) and release fitting of the pad
mounting pin ring (3).
1
IF34J1420007-01
2
3 1
IF34J1420004-02
Front Brakes: 4B-3
7) Insert the pad mounting pin gradually tapping it with 4) Remove the caliper (2) by removing the caliper
the suitable bar (1) and fit the pad mounting pin ring mounting bolts.
(2).
2
1
2 IF34J1420010-01
IF34J1420009-02
8) Install the new clip (1). Installation

1) Install the brake caliper (1).
2) Tighten caliper mounting bolts (2) to the specified
torque.
Tightening torque
Caliper mounting bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)
3) Install the brake hose union bolt (3) and new seal
1 washers to brake hose.
4) After setting the brake hose union to the stopper,
tighten the union bolt to the specified torque.
IF34J1420003-02
Tightening torque
9) Tighten the brake caliper mounting bolts to the
Brake hose union bolt (b): 23 N·m (2.3 kgf-m,
specified torque.
17.0 lbf-ft)
Tightening torque
Caliper mounting bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft)
2, (a)
3 , (b )
(a)
IF34J1420011-01
5) Bleed air from the brake system after installing the

caliper. )(Page 4A-5)
IF34J1420008-02
6) Check the brake fluid leakage referring to “Brake
Hose Inspection” in Section 4A (Page 4A-5) and
Front Brake Caliper Removal and Installation brake operation.
BENF34J14206004
Removal
1) Drain brake fluid. )(Page 4A-6)
2) Place a rag underneath the union bolt on the brake
caliper to catch any spilt brake fluid.
3) Remove the brake hose from the caliper by
removing the union bolt (1) and catch the brake fluid
in a suitable receptacle.
4B-4 Front Brakes:
Front Brake Caliper Disassembly and 4) Remove the dust seals (1) and piston seals (2).
Reassembly
BENF34J14206005
Refer to “Front Brake Caliper Removal and Installation”
(Page 4B-3).
NOTICE
Take care not to damage piston and caliper
2 2
cylinder of front brake caliper.
Disassembly 1 1
1) Remove the brake pads. )(Page 4B-2)
2) Remove the pad spring (1) and caliper bracket (2). IF34J1420014-01
5) Remove the brake air bleeder valve (1).
IF34J1420012-01
3) Remove the caliper pistons applying compressed air IF34J1420015-01

gradually from the hole for the brake hose.
6) Remove the rubber boots (1).
! WARNING
Do not apply highly compressed air to the 1
piston as it is. Place a cloth to prevent brake
piston from jumping-out. Gradually apply
compressed air. Do not place your fingers in
front of brake piston while applying
compressed air.
1
IF34J1420030-01
7) Remove the caliper bracket pin (1) and spacer (2).
IF34J1420013-01
IF34J1420031-01
Front Brakes: 4B-5
8) Remove the snap ring (1) using the special tool. 3) Install the piston seals and dust seals.
Special tool
Snap Ring Pliers
IE31J1420012-02
4) Install the caliper pistons to the brake caliper.

5) Install the new snap ring (1) using the special tool.
IF34J1420034-01
Special tool
Reassembly Snap Ring Pliers
1) Wash the caliper bores and pistons with specified
brake fluid. Particularly wash the dust seal grooves
and piston seal grooves.
1
NOTICE
• Wash the caliper components with fresh
brake fluid before reassembly. Never use
cleaning solvent or gasoline to wash them.
• Do not wipe the brake fluid off after
washing the components.
• When washing the components, use the IF34J1420032-01
specified brake fluid. Never use different
6) Apply thread lock to the thread portion of the caliper
types of fluid or cleaning solvent such as
bracket pin (1).
gasoline, kerosine or the others.
“A”: Thread lock cement (LOCTITE® ***)
Brake fluid (DOT 3)
Brake fluid (DOT 4) 7) Install the spacer (2) and caliper bracket pin, and
tighten the caliper bracket pin to the specified torque.
Tightening torque
Caliper bracket pin (a): 8.5 N·m (0.87 kgf-m, 6.5
lbf-ft)
1 , “A ”, ( a )
I649G1420012-02 2
2) Apply the brake fluid to new piston seals (1) and new
dust seals (2).
IF34J1420033-01
Brake fluid (DOT 3)
Brake fluid (DOT 4)
4B-6 Front Brakes:
8) Install the rubber boots (1). Front Brake Caliper Parts Inspection
BENF34J14206006
Refer to “Front Brake Caliper Disassembly and
Reassembly” (Page 4B-4).
1
Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any defect is found,
replace the brake caliper with a new one.
1
IF34J1420016-01
9) Install the brake air bleeder valve and tighten it to the

specified torque.
Tightening torque
Brake air bleeder valve (a): 7.5 N·m (0.76 kgf-m,
5.5 lbf-ft)
IF34J1420022-01
Brake Caliper Piston

Inspect the brake caliper pistons surface for any
(a) scratches or other damage. If any defect is found,
replace them with new ones.
IF34J1420020-01
10) Apply grease to the sliding surface of the caliper

bracket pins and install the caliper bracket (1).
“A”: (SUZUKI SILICONE GREASE)
11) Install the pad spring pointing the triangle mark (2)
IF34J1420023-01
toward the brake disc rotation.
Brake Pad Spring
Inspect the brake pad spring for damage and excessive
bend. If any defects are found, replace it with a new one.
“A” 1
IF34J1420021-01
12) Install the brake pads. )(Page 4B-2)
IF34J1420025-01
Front Brakes: 4B-7
Brake Caliper Bracket / Brake Caliper Bracket Pin Installation

Inspect the brake caliper bracket and caliper bracket 1) Make sure that the brake disc is clean and free of
pins for wear and other damage. If any defect is found, any grease.
replace them with new ones.
2) Install the front brake disc and tighten the new brake
disc bolts to the specified torque.
NOTE
The stamped mark (1) on the brake disc
should face to the outside.
Tightening torque
Brake disc bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
(a ) 1
IF34J1420026-02
Rubber Boot
Inspect the rubber boots for damage and cracks. If any
defect is found, replace them with new ones.
(a)
IF34J1420029-01
Front Brake Disc Inspection

BENF34J14206008
Brake Disc Thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
If the thickness is less than the service limit or if defect is
IF34J1420027-01
found, replace the brake disc.
Front brake disc thickness
Front Brake Disc Removal and Installation Service limit: 3.5 mm (0.14 in)
BENF34J14206007
Refer to “Front Wheel Assembly Removal and Special tool
Installation” in Section 2D (Page 2D-2). (A): Micrometer
Removal
Remove the front brake disc (1).
(A)
ID26J1420029-01
IF34J1420028-01
4B-8 Front Brakes:
Brake Disc Runout

1) Dismount the front brake pads.
Refer to “Front Brake Pad Replacement” (Page 4B-
2). (A)
2) Measure the runout using the dial gauge.
Replace the disc if the runout exceeds the service
limit.
Brake disc runout
Special tool ID26J1420030-04
(A): Dial gauge 3) Remount the front brake pads.

(B): Dial gauge chuck Refer to “Front Brake Pad Replacement” (Page 4B-
2).
Specifications
BENF34J14207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Caliper mounting bolt )(Page 4B-3) /
26 2.7 19.5
)(Page 4B-3)
Brake hose union bolt 23 2.3 17.0 )(Page 4B-3)
Caliper bracket pin 8.5 0.87 6.5 )(Page 4B-5)
Brake air bleeder valve 7.5 0.76 5.5 )(Page 4B-6)
Brake disc bolt 23 2.3 17.0 )(Page 4B-7)
Reference:
“Front Brake Components” (Page 4B-1)
Front Brakes: 4B-9

BENF34J14208001
Brake fluid DOT 3 — )(Page 4B-5) / )(Page 4B-
5)
DOT 4 — )(Page 4B-5) / )(Page 4B-
5)
Grease SUZUKI SILICONE GREASE )(Page 4B-6)
Thread lock cement LOCTITE® *** — )(Page 4B-5)
NOTE
“Front Brake Components” (Page 4B-1)
Special Tool
BENF34J14208002
Snap ring pliers (External) Dial gauge (10 x 0.01 mm)

)(Page 4B-5) / )(Page 4B-8)
)(Page 4B-5)
Dial gauge chuck Micrometer (0 - 25 mm)

4C-1 Rear Brakes:
Rear Brakes
Brakes
Repair Instructions
Rear Brake Components
BENF34J14306001
2
(a)
IF34J1430001-02
1. Rear brake cam lever 4. Rear brake panel : Apply grease.

2. Rear brake cam 5. O-ring : Do not reuse.
3. Rear brake shoe : 7 Nm (0.71 kgf-m, 5.5 lbf-ft)
Rear Brake Shoe Wear Inspection Rear Brake Shoe Replacement

BENF34J14306002 BENF34J14306003
This motorcycle is equipped with the brake shoe wear Refer to “Rear Brake Panel Removal and Installation”
limit indicator on the brake panel. (Page 4C-2).
1) Check that the rear brake system is properly 1) Remove the brake shoes (1) with springs (2) from
adjusted. Refer to “Brake Pedal Free Travel the brake panel.
Inspection and Adjustment” in Section 4A (Page 4A-
5).
1
2) While operating the rear brake, check that the slit (1)
is within the range (2) embossed on the brake panel. 1
If the slit goes beyond the range, the brake shoe
assembly should be replaced with a new set of
2
shoes. )(Page 4C-1)
IF34J1430003-01
IF34J1430002-01
Rear Brakes: 4C-2
2) Clean up the contacting surfaces of the brake shoes Rear Brake Panel Disassembly and Reassembly
and brake panel. BENF34J14306005
Refer to “Rear Brake Shoe Replacement” (Page 4C-1).
3) Apply grease to the brake cam (1) and anchor pin (2)
sliding surfaces slightly. Disassembly
“A”: (SUZUKI SUPER GREASE A) 1) Remove the brake cam lever bolt and nut.
2) Remove the brake cam lever (1).
4) Install the new brake shoes with spring hooks (3)
facing inside.
NOTE
Do not use tool.
2, “A”
3
1
IF34J1430006-01
3) Remove the washer (1), O-ring (2) and brake cam

(3).
1, “ A ”
IF34J1430004-01
1
Rear Brake Panel Removal and Installation 3

BENF34J14306004
Removal
1) Remove the rear wheel assembly. )(Page 2D-5)
2) Remove the brake panel (1). 2
IF34J1430007-01
1
Reassembly
1) Apply grease lightly to the brake cam, cam face and
anchor pin.
2) Install the brake cam.
IF34J1430005-01
Installation
Install the brake panel in the reverse order of removal.
• Make sure that the brake drum is clean and free of “A” “A”
any grease.
• Adjust the brake pedal free travel. )(Page 4A-5)
IF34J1430008-01
4C-3 Rear Brakes:
3) Apply grease to the new O-ring (1).

“A”: (SUZUKI SUPER GREASE A) “a”
4) Install the O-ring and washer (2).
IF34J1430011-01
2 Brake Shoe
Inspect the brake shoes for crack or damage. If any
1, “ A ”
defect is found, replace the brake shoes as a set.
IF34J1430009-01
5) Install the brake cam lever by aligning its punch mark

(1) with slit (2) of the brake cam.
6) Tighten the brake cam lever nut to the specified
torque.
Tightening torque
Rear brake cam lever nut (a): 7 N·m (0.71 kgf-m,
5.5 lbf-ft)
(a) IF34J1430012-01
Brake Cam
Inspect the brake cam for abnormal wear.
Place the brake cam into the brake panel and check for
smooth rotation.
Check that the rotating parts (1) are coated with
2
1 sufficient grease.
IF34J1430010-01
Rear Brake Parts Inspection

BENF34J14306006
Installation” in Section 2D (Page 2D-5), “Rear Brake
Shoe Replacement” (Page 4C-1) and “Rear Brake Panel
Disassembly and Reassembly” (Page 4C-2).
Brake Drum 1
Inspect the brake drum and measure the brake drum I.D.
IF34J1430013-01
to determine the extent of the wear. If the measurement
exceeds the service limit, replace the rear wheel with a
new one.
Special tool
Vernier Caliper
Rear brake drum I.D. “a”
Rear Brakes: 4C-4
Specifications
BENF34J14307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear brake cam lever nut 7 0.71 5.5 )(Page 4C-3)
Reference:
“Rear Brake Components” (Page 4C-1)

BENF34J14308001
Grease SUZUKI SUPER GREASE A )(Page 4C-2) / )(Page 4C-
2) / )(Page 4C-3)
NOTE
“Rear Brake Components” (Page 4C-1)
Special Tool
BENF34J14308002
Vernier calipers (200 mm)

)(Page 4C-3)
4C-5 Rear Brakes:
Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1 Special Tools and Equipment ...........................5B-16

Precautions............................................................. 5-1 Recommended Service Material .......................5B-16
Precautions for Transmission / Transaxle............. 5-1 Special Tool ......................................................5B-16
Manual Transmission.............................. 5B-1 Clutch ....................................................... 5C-1

Diagnostic Information and Procedures............5B-1 Precautions...........................................................5C-1
Manual Transmission Symptom Diagnosis ......... 5B-1 Precautions for Clutch System............................5C-1
Repair Instructions ..............................................5B-2 Diagnostic Information and Procedures ............5C-1
Transmission Components ................................. 5B-2 Clutch System Symptom Diagnosis ....................5C-1
Transmission Removal and Installation .............. 5B-3 Repair Instructions ..............................................5C-2
Transmission Construction.................................. 5B-4 Clutch Lever Position Switch Inspection .............5C-2
Countershaft Assembly / Driveshaft Clutch Cable Inspection ......................................5C-2
Assembly Disassembly and Reassembly ......... 5B-4 Clutch Cable Play On-Vehicle Inspection and
Gearshift Fork / Gearshift Cam Inspection.......... 5B-6 Adjustment ........................................................5C-2 5
Transmission Bearing / Oil Seal Removal and Clutch Cable Removal and Installation ...............5C-2
Installation ......................................................... 5B-7 Clutch Lever Removal and Installation................5C-3
Transmission Bearing / Oil Seal Inspection ........ 5B-9 Clutch Components.............................................5C-5
GP Switch Inspection .......................................... 5B-9 Clutch Removal...................................................5C-6
GP Switch Removal and Installation ................... 5B-9 Clutch Installation................................................5C-7
Gearshift Lever Removal and Installation ......... 5B-10 Clutch Cover Disassembly and Reassembly ....5C-10
Gearshift Lever Height Inspection..................... 5B-11 Clutch Parts Inspection .....................................5C-11
Gearshift Lever Construction ............................ 5B-11 Primary Drive Gear Removal and Installation ...5C-12
Gearshift Shaft / Gearshift Cam Plate Primary Drive Gear Inspection ..........................5C-12
Components.................................................... 5B-12 Primary Drive Gear Disassembly and
Gearshift Shaft / Gearshift Cam Plate Reassembly ....................................................5C-12
Removal and Installation................................. 5B-12 Specifications .....................................................5C-13
Gearshift Linkage Inspection ............................ 5B-14 Tightening Torque Specifications......................5C-13
Gearshift Shaft Oil Seal Removal and Special Tools and Equipment ...........................5C-14
Installation ....................................................... 5B-14 Recommended Service Material .......................5C-14
Specifications.....................................................5B-15 Special Tool ......................................................5C-14
Tightening Torque Specifications...................... 5B-15
5-1 Precautions:
Precautions
Precautions
Precautions for Transmission / Transaxle
BENF34J15000001
Manual Transmission: 5B-1
Manual Transmission

Manual Transmission Symptom Diagnosis
BENF34J15204001

Noisy engine (Noise Worn or rubbing gear. Replace. )(Page 5B-4)
seems to come from the Worn countershaft spline. Replace countershaft. )(Page 5B-4)
transmission) Worn driveshaft spline. Replace driveshaft. )(Page 5B-4)
Worn bearing. Replace. )(Page 5B-7)
Transmission will not Broken gearshift cam. Replace. )(Page 5B-3)
shift Distorted gearshift fork. Replace. )(Page 5B-3)
Worn gearshift pawl. Replace. )(Page 5B-12)
Transmission will not Broken gearshift shaft return spring. Replace. )(Page 5B-12)
shift back Rubbing or stuck gearshift shaft. Repair or replace. )(Page 5B-12)
Worn or distorted gearshift fork. Replace. )(Page 5B-3)
Transmission jumps out Worn shifting gears on driveshaft or Replace. )(Page 5B-4)
of gear countershaft.
Worn or distorted gearshift fork. Replace. )(Page 5B-3)
Weakened gearshift cam stopper spring. Replace. )(Page 5B-12)
Worn gearshift cam plate. Replace. )(Page 5B-12)
5B-2 Manual Transmission:
Repair Instructions
Transmission Components
BENF34J15206001
2 3
13 14
7
(a)
15
(b) 8
13
17
10 (b)
16
11
12
(c)
IF34J1520001-02
1. 1st driven gear 9. 4th drive gear 17. GP switch

2. 4th driven gear 10. 3rd drive gear : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. 3rd driven gear 11. 5th drive gear : 8.5 Nm (0.87 kgf-m, 6.5 lbf-ft)
4. 5th driven gear 12. 2nd drive gear : 4 Nm (0.41 kgf-m, 3.0 lbf-ft)
5. Driveshaft 13. Gearshift fork shaft : Apply grease.
6. 2nd driven gear 14. Gearshift fork No.1 : Apply engine oil.
7. Oil seal retainer 15. Gearshift fork No.2 : Apply thread lock to the thread part.
8. Countershaft 16. Gearshift cam : Do not reuse.
Transmission Removal and Installation 2) Install the gearshift forks No. 1 (1) and No. 2 (2).
BENF34J15206002
Refer to “Crankcase Assembly Disassembly” in Section NOTE
1D (Page 1D-36) and “Crankcase Assembly
The gearshift forks No. 1 (1) are same parts.
Reassembly” in Section 1D (Page 1D-37).
Removal
1) Remove the gearshift fork shafts (1), gearshift forks
(2) and gearshift cam (3).
2
1
2
IF34J1520031-01
3
1
IF34J1520029-02
2) Remove the driveshaft assembly (1) with the

countershaft assembly (2). 2
2 1
1
IF34J1520032-02
3) Install the gearshift cam (1) so that the projection (2)

face upward.
4) Install the gearshift fork shafts (3).
NOTE
IF34J1520030-02
• After the gearshift fork shafts and gearshift
Installation forks have been fitted, make sure that the
gears engage normally.
1) Install the driveshaft assembly (1) with the
countershaft assembly (2). • Set the transmission gears to the neutral
position.
IF34J1520030-02
1
IF34J1520033-02
Transmission Construction
BENF34J15206003
1
2
IF34J1520002-02
1. Countershaft 2. Driveshaft 3. Snap ring

: Face the sharp edge outside.
Countershaft Assembly / Driveshaft Assembly

Disassembly and Reassembly 3
BENF34J15206004
Refer to “Transmission Removal and Installation” (Page
5B-3). 1
Disassembly
NOTE
Identify the position of each removed part.
Organize the parts in their respective groups
(i.e., drive or driven) so that they can be 2
IF34J1520034-01
reinstalled in their original positions.
Countershaft
1) Remove the snap ring (1), washer (2) and 2nd drive
gear (3).
Special tool
Spring Ring Pliers
2) Remove the 5th drive gear (1) and 3rd drive gear (2). 2) Remove the 2nd driven gear bushing (1), washer (2)
and 5th driven gear (3).
2
1 3
IF34J1520035-01
3) Remove the snap ring (1). IF34J1520039-01
3) Remove the washer (1) and 1st driven gear (2).

Special tool
Snap Ring Pliers
2
IF34J1520040-01
IF34J1520036-01
4) Remove the 1st driven gear bushing (1), washer (2)
and 4th driven gear (3).
4) Remove the washer (1) and 4th drive gear (2).
2 2
1
1
3
IF34J1520041-01
IF34J1520037-01
5) Remove the snap ring (1).
Driveshaft Special tool
1) Remove the washer (1) and 2nd driven gear (2). Snap Ring Pliers
2
1
1
IF34J1520038-01 IF34J1520042-01
6) Remove the washer (1) and 3rd driven gear (2). Gearshift Fork / Gearshift Cam Inspection
BENF34J15206005
Refer to “Countershaft Assembly / Driveshaft Assembly
Disassembly and Reassembly” (Page 5B-4).
1
Gearshift Fork to Groove Clearance
NOTE
The clearance for each gearshift fork plays
an important role in the smoothness and
positiveness of the shifting action.
2
Using a thickness gauge, check the gearshift fork
IF34J1520043-01 clearance in the groove of its gear.
If the clearance checked is noted to exceed the limit
Reassembly specified, replace the fork or its gear, or both.
Reassemble the countershaft and driveshaft in the
reverse order of disassembly. Pay attention to the Special tool
following point: (A): Thickness Gauge
Gearshift fork to groove clearance
NOTE
Standard: 0.1 – 0.3 mm (0.004 – 0.012 in)
• When reassembling the transmission Service limit: 0.5 mm (0.020 in)
gears, attention must be given to the
locations and positions of washers and
snap rings. The cross sectional view
shows the correct position of the gears,
bushings, washers and snap rings. Refer
to “Transmission Construction” (Page 5B-
4).
• When installing a new snap rings, do not
expand the end gap larger than required to
slip the snap rings over the shaft. IE31J1520026-01
• After installing a snap rings, make sure

that it is completely seated in its groove Gearshift Fork Groove Width
and securely fitted. Measure the gearshift fork groove width using the
vernier calipers.
• Before installing the gears, apply engine
oil to each rotating and sliding part. Special tool
(A): Vernier Caliper
• When installing a new snap ring (1), pay attention to
its direction. Fit it to the side where the thrust (2) is as Gearshift fork groove width
shown in the illustration. Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)
IE31J1520022-01 IE31J1520027-01
3. Sharp edge
Gearshift Fork Thickness 2) Remove the driveshaft oil seal (1) using the special
Measure the gearshift fork thickness using the vernier tool.
calipers.
Special tool
Special tool (A): Oil seal remover
(A): Vernier Caliper
Gearshift fork thickness ( A)
Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)
1
IF34J1520046-01
3) Remove the countershaft bearing (1) and driveshaft

IE31J1520028-01 bearing (2) using the special tools.
Gearshift Cam Special tool

(A): Bearing Remover Set
Inspect the gearshift cam groove for abnormal wear and
damage. If any defects are found, replace the gearshift (B): Bearing Installer Set
cam with a new one. (A)
(B)
1
IF34J1520047-01
IF34J1520044-01
Right crankcase
Transmission Bearing / Oil Seal Removal and 1) Remove the bearing retainers (1).
Installation
BENF34J15206006
Refer to “Crankcase Assembly Disassembly” in Section
1D (Page 1D-36) and “Crankcase Assembly
Reassembly” in Section 1D (Page 1D-37).
Removal 1
Left crankcase
1) Remove the oil seal retainer (1).
1
IF34J1520048-02
1
IF34J1520045-01
2) Remove the countershaft bearing (1), driveshaft 2) Install the new driveshaft oil seal (1) using the
bearing (2) and gearshift cam bearing (3) using the special tool.
special tool.
Special tool
Special tool (A): Bearing installer set
( A)
(A )
1
2
2 1
3
“a”
1
IF34J1520052-01
IF34J1520049-01 2. Left crankcase “a”: 0 - 1 mm (0 - 0.04 in)
Installation 3) Apply grease to the oil seal lip.

Left crankcase
1) Install the new driveshaft bearing (1) and new
countershaft bearing (2) using the special tool.
NOTE
The sealed side (3) of the bearings faces
outside. “A”
Special tool
3 3
IF34J1520053-01
4) Apply thread lock to the oil seal retainer bolts (1).

2 5) Install the oil seal retainer (2) and tighten its bolts to
1 the specified torque.
IF34J1520050-01 Tightening torque
Driveshaft oil seal retainer bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)
(A) (A)
1, “A”, (a)
1 2
IF34J1520051-01
2
IF34J1520054-01
Right crankcase GP Switch Inspection

BENF34J15206009
1) Install the new countershaft bearing (1), new
driveshaft bearing (2) and new gearshift cam bearing
(3) using the special tool. 2) Disconnect the GP switch lead wire coupler (1).
Special tool NOTICE

(A): When disconnecting and connecting the
neutral switch coupler, make sure to turn
“OFF” the ignition switch, or electronic parts
(A)
may get damaged.
1
2
1
3
IF34J1520055-01
2) Apply thread lock to the bearing retainer screws (1).

IF34J1520003-03
3) Install the bearing retainers (2) and tighten its screws 3) Check the continuity between the Bl wire and ground
to the specified torque. with the transmission in “NEUTRAL”. If any defect is
Tightening torque found, replace the GP switch with a new one.
Countershaft bearing retainer screw (a): 8.5 N·m
(0.87 kgf-m, 6.5 lbf-ft) Color
Bl Ground
Gearshift bearing retainer screw (b): 8.5 N·m ( Position
0.87 kgf-m, 6.5 lbf-ft) Neutral
Except neutral
IF34J1520004-02
1, “A”, (b)
1, “A”, (a)
GP Switch Removal and Installation
BENF34J15206010
Removal
2) Remove the left frame side cover: )(Page 9D-12)
2 3) Remove the speed sensor from the engine sprocket
cover. )(Page 1C-4)
2
IF34J1520056-01 pins (2).
Transmission Bearing / Oil Seal Inspection 1 2

BENF34J15206008
Refer to “Crankcase Bearing / Oil Seal Inspection” in
2
IF34J1520057-01
5) Disconnect the GP switch lead wire coupler (1). • Tighten the GP switch mounting bolts (1) to the
specified torque.
Tightening torque
GP switch mounting bolt (a): 4 N·m (0.41 kgf-m,
3.0 lbf-ft)
IF34J1520003-03

1, (a)
IF34J1520008-02
• Route the GP switch lead wire. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-5).
1
Gearshift Lever Removal and Installation

BENF34J15206011
Removal
1) Remove the gearshift link arm (1).
IF34J1520005-02
NOTE
7) Remove the GP switch (1). Mark the position of the gearshift link arm on
the gearshift shaft (2) before removing the
link arm.
1
1
IF34J1520006-02
Installation
Install the GP switch in the reverse order of removal. Pay IF34J1520009-02
attention to the following points: 2) Remove the gearshift lever. Refer to “Gearshift Lever
• Install the new O-ring (1) to the GP switch. Construction” (Page 5B-11).
IF34J1520007-01
Installation Gearshift Lever Construction

Install the gearshift lever in the reverse order of removal. BENF34J15206013

7
• Install the gearshift link arm so that the gearshift lever
height becomes the specified range. )(Page 5B-11) (b)
• Tighten the gearshift link arm bolt (1) to the specified

torque.
Tightening torque 7
Gearshift link arm bolt (a): 10 N·m (1.0 kgf-m, 7.5 [A]
lbf-ft) 7
[B]
5
(a)
“b”
4
“a”
1
6 2 3 6
1, (a) IF34J1520012-05
[A]: Gear shift lever height 7. Washer

measuring point
IF34J1520010-02 [B]: Footrest upper “a”: 1 – 11 mm (0.04 – 0.43 in)
surface
1. Gearshift link arm “b”: 23 – 37 mm (0.91 – 1.46 in)
Gearshift Lever Height Inspection
BENF34J15206012 2. Gearshift link rod : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
Inspect the gearshift lever height “a” between the pedal 3. Gearshift lever : 40 Nm (4.1 kgf-m, 29.5 lbf-ft)
top face and footrest. 4. Footrest : Apply thread lock to thread
part.
Gearshift lever height “a” 5. Snap ring : Apply grease.
: Face the sharp edge
Standard: 23 – 37 mm (0.91 – 1.46 in) outside.
6. Cotter pin : Do not reuse.
“a”
IF34J1520011-02
Gearshift Shaft / Gearshift Cam Plate • Gearshift cam drive plate (5)
Components • Gearshift shaft return spring (6)
BENF34J15206014
Special tool
(a) Snap Ring Plier
1
2 2 3
6
(b) 3 1
5
(b)
5
2 3 4
IF34J1520015-01
4
4) Remove the gearshift cam plate bolt (1) and
6 gearshift cam plate (2).
IF34J1520013-03 5) Remove the gearshift cam stopper (3).
1. Gearshift cam drive plate 6) Remove the gearshift arm stopper (4).
2. Gearshift shaft
3. Gearshift shaft return spring
2
4. Gearshift shaft oil seal
5. Gearshift cam plate
6. Gearshift cam stopper 1
4
: 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
: 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Apply grease.
: Apply thread lock to the thread part.
: Do not reuse.
3
Gearshift Shaft / Gearshift Cam Plate Removal

and Installation IF34J1520016-02
BENF34J15206015
Installation
Removal 1) Apply a small quantity of thread lock to the gearshift
1) Remove the following parts. arm stopper (1) and tighten it to the specified torque.
• Gearshift lever: )(Page 5B-10)
• Kick starter shaft assembly: )(Page 1I-12)
2) Remove the gearshift shaft assembly (1).
Tightening torque
Gearshift arm stopper (a): 19 N·m (1.9 kgf-m,
14.0 lbf-ft)
1, (a)
“A”
1
IF34J1520014-02
3) Remove the following parts from the gearshift shaft

(1). IF34J1520017-02
• Snap ring (2) 2) Install the gearshift cam stopper (1), bolt (2), washer
• Washer (3) (3) and spring (4).
• Spring (4)
3) Tighten the gearshift cam stopper bolt (2) to the 7) Apply a small quantity of thread lock to the gearshift
specified torque. cam plate bolt (1) and tighten it to the specified
torque.
NOTE
Hook the return spring end (5) to the
gearshift cam stopper (1).
Tightening torque
Tightening torque Gearshift cam plate bolt (a): 10 N·m (1.0 kgf-m,
Gearshift cam stopper bolt (a): 10 N·m (1.0 kgf- 7.5 lbf-ft)
m, 7.5 lbf-ft)
1, (a)
“A”
4
2
IF34J1520021-02
IF34J1520018-01
8) Install the gearshift shaft return spring (1).
NOTE
Position the stopper (2) of gearshift arm
1 between the shaft return spring ends (3).
5
3
2, (a)
2
IF34J1520019-02
4) Check the gearshift cam stopper moves smoothly.

5) Locate the gearshift cam in the neutral position. 1
6) Install the gearshift cam plate (1).
IF34J1520022-02
NOTE
9) Install the following parts.
Align the gearshift cam projection (2) with the
gearshift cam plate hole (3). • New snap ring (1)
• Washer (2)
• Gearshift cam drive plate (3)
• Spring (4)
2
3
2 1 1
1
IF34J1520020-02
3 4 2
IF34J1520028-01
10) Install the gearshift shaft assembly (1). Gearshift Shaft Oil Seal Removal and
Installation
NOTE BENF34J15206017
Pinch the gearshift arm stopper (2) with Refer to “Gearshift Shaft / Gearshift Cam Plate Removal
return spring ends (3). and Installation” (Page 5B-12).
Removal
1) Remove the speed sensor from the engine sprocket
cover. )(Page 1C-4)
3
pins (2).
1 2
2
1
IF34J1520023-02
Gearshift Linkage Inspection

BENF34J15206016 2
Refer to “Gearshift Shaft / Gearshift Cam Plate Removal IF34J1520057-01
and Installation” (Page 5B-12).
3) Remove the gearshift shaft oil seal (1).
Gearshift Shaft
Check the gearshift shaft (1) for bend or wear.
Check the return spring (2) for damage or fatigue.
If any defects are found, replace the defective part(-s).
IF34J1520026-02
2
Installation
1
1) Install the new oil seal (1) with the special tool.
IF34J1520024-01
NOTE
Gearshift Shaft Oil Seal Install the gearshift shaft oil seal to the
Inspect the gearshift shaft oil seal lip (1) for damage or specified depth from the left crankcase end.
wear. If any defect is found, replace the oil seal with a
new one. Special tool
IF34J1520025-02
2) Apply grease to the oil seal lip.

1 2
1, “A”
“a”
(A )
IF34J1520027-03
2. Left crankcase “a”: 2 – 3 mm (0.08 – 0.12 in)
Specifications
BENF34J15207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Driveshaft oil seal retainer bolt 10 1.0 7.5 )(Page 5B-8)
Countershaft bearing retainer screw 8.5 0.87 6.5 )(Page 5B-9)
Gearshift bearing retainer screw 8.5 0.87 6.5 )(Page 5B-9)
GP switch mounting bolt 4 0.41 3.0 )(Page 5B-10)
Gearshift link arm bolt 10 1.0 7.5 )(Page 5B-11)
Gearshift arm stopper 19 1.9 14.0 )(Page 5B-12)
Gearshift cam stopper bolt 10 1.0 7.5 )(Page 5B-13)
Gearshift cam plate bolt 10 1.0 7.5 )(Page 5B-13)
Reference:
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-11)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-12)

BENF34J15208001
Grease SUZUKI SUPER GREASE A )(Page 5B-8) / )(Page 5B-
15)
Thread lock cement THREAD LOCK CEMENT 1322D )(Page 5B-8) / )(Page 5B-
9) / )(Page 5B-12) /
)(Page 5B-13)
NOTE
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-11)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-12)
Special Tool
BENF34J15208002
Snap ring pliers (External) Vernier calipers (200 mm)

)(Page 5B-4) / )(Page 5B-6) /
)(Page 5B-5) / )(Page 5B-7)
)(Page 5B-5) /
)(Page 5B-12)
Thickness gauge Oil seal remover

Bearing installer set Bearing remover set

)(Page 5B-7) / )(Page 5B-7)
)(Page 5B-8) /
)(Page 5B-8) /
)(Page 5B-8) /
)(Page 5B-9) /
)(Page 5B-14)
Clutch: 5C-1
Clutch
Precautions
Precautions for Clutch System
BENF34J15300001

Clutch System Symptom Diagnosis
BENF34J15304001

Noisy engine (Noise Worn countershaft spline. Replace countershaft. )(Page 5B-4)
seems to come from the Worn clutch sleeve hub spline. Replace clutch sleeve hub. )(Page 5C-6)
clutch) )(Page 5C-7)
Worn clutch plate teeth. Replace clutch plate. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-7)
Worn clutch release bearing. Replace. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-7)
Weakened clutch dampers. Replace primary driven gear. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-7)
)(Page 5C-12)
Clutch slips Clutch cable out of adjustment. Adjust. )(Page 5C-2)
)(Page 5C-7)
Worn or distorted clutch pressure plate. Replace. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-7)
Clutch drags Clutch cable out of adjustment. Adjust. )(Page 5C-2)
Some clutch springs are weak, while Replace. )(Page 5C-6)
others are not. )(Page 5C-7)
Worn or distorted clutch pressure plate. Replace. )(Page 5C-6)
)(Page 5C-7)
)(Page 5C-7)
5C-2 Clutch:
Repair Instructions
Clutch Lever Position Switch Inspection Adjustment
BENF34J15306001
1) Loosen the lock-nut (1), and adjust the clutch cable
1) Disconnect the clutch lever position switch lead wire by turning the adjuster (2) to obtain free play at the
connectors (1). clutch lever end.
Clutch cable play “a”
10 – 15 mm (0.4 – 0.6 in)
1
IF34J1530001-02
2) Inspect the clutch lever position switch for continuity

with the tester.
If any defect is found, replace the switch with a new IF34J1530004-02
one.
Color
Terminal (Y/R) Terminal (Y/G)
Position
OFF
ON “a”
IF34J1530002-01
3) Connect the clutch lever position switch lead wire.
Clutch Cable Inspection

BENF34J15306022
Check that clutch lever moves smoothly. If it does not IF34J1530003-01
move smoothly, lubricate the clutch cable.
Clutch Cable Removal and Installation
Clutch Cable Play On-Vehicle Inspection and BENF34J15306024
Adjustment
BENF34J15306023 Removal
Inspection 1) Remove the following parts.
Inspect the clutch cable play at the clutch lever end.
Adjust the clutch cable play if necessary.
• Left frame side cover: )(Page 9D-12)
Clutch cable play “a”
2) Full loosen the lock-nut (1) and adjuster (2).
10 – 15 mm (0.4 – 0.6 in)
2
“a”
IF34J1530004-02
IF34J1530003-01
Clutch: 5C-3
3) Disconnect the clutch cable end (1) from the clutch • Tighten the clutch cable stopper bolt (1) to the
lever (2). specified torque.
Tightening torque
2 Clutch cable stopper bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1, (a)
1
IF34J1530005-02
4) Remove the clutch cable clamps (1).
IF34J1530008-02
• Adjust the clutch cable play. )(Page 5C-2)
Clutch Lever Removal and Installation

BENF34J15306025
Removal
1 1) Disconnect the clutch cable end from clutch lever.
Refer to “Clutch Cable Removal and Installation”
1 (Page 5C-2).
IF34J1530006-03
2) Remove the clutch lever pivot nut (1) and bolt (2),
5) Remove the clutch cable stopper (1) and disconnect and then remove the clutch lever (3).
the clutch cable end from the clutch release arm (2).
1
1 3
2 IF34J1530009-01
IF34J1530007-02
3) Remove the clutch lever holder. Refer to “Handlebar
Removal and Installation” in Section 6B (Page 6B-3).
Installation
Install the clutch cable in the reverse order of removal.
• Route the clutch cable properly. Refer to “Throttle
Cable Routing Diagram” in Section 1D (Page 1D-2).
5C-4 Clutch:
Installation
Install the clutch lever in the reverse order of removal.
• Install the clutch lever holder securely. Refer to
“Handlebar Removal and Installation” in Section 6B
(Page 6B-3).
• Tighten the clutch lever pivot bolt (1) and new clutch
lever pivot nut (2) to the specified torque.
Tightening torque
Clutch lever pivot bolt (a): 1.5 N·m (0.15 kgf-m,
1.5 lbf-ft)
Clutch lever pivot nut (b): 3 N·m (0.30 kgf-m, 2.5
lbf-ft)
1, (a)
2, (b)
IF34J1530010-01
• Adjust the clutch cable play. )(Page 5C-2)

Clutch: 5C-5
Clutch Components
BENF34J15306015
(c)
10
11
(a)
3 12
4
5 2
4
5
4
5
4
3
(b)
9
7
8
IF34J1530011-02
1. Clutch pressure plate 7. Clutch sleeve hub : 5 Nm (0.51 kgf-m, 4.0 lbf-ft)
2. Clutch release rack 8. Primary driven gear assembly : 70 Nm (7.1 kgf-m, 52.0 lbf-ft)
3. Clutch drive plate No.1 9. Spacer : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
4. Clutch driven plate 10. Clutch release arm : Apply grease.
5. Clutch drive plate No.2 11. Clutch release camshaft oil seal : Apply engine oil.
6. Conical spring washer 12. Clutch release camshaft : Do not reuse.

5C-6 Clutch:
Clutch Removal 7) Remove the clutch spring set bolts (1), clutch springs
BENF34J15306016 and clutch pressure plate (2).
2) Remove the following parts. NOTE
• Right frame lower cover: )(Page 9D-12) Loosen the clutch spring set bolts little by
little and diagonally.
• Oil filter: )(Page 1E-5)
• Kick starter lever: )(Page 1I-12)
3) Full loosen the lock-nut (1) and adjuster (2). 1
4) Remove the clutch cable stopper (3) and clutch
release arm (4).
1 2
IF34J1530015-01
3 8) Remove the clutch release rack (1) and bearing (2)

4 from the clutch pressure plate.
IF34J1530012-03
1
5) Remove the clutch cover (1).
2
1
IF34J1530016-01
9) Remove the clutch drive plates (1) and driven plates

(2).
IF34J1530013-02
6) Remove the gasket (1) and dowel pins (2). 1
2
IF34J1530017-01
2
IF34J1530014-01
Clutch: 5C-7
10) Hold the clutch sleeve hub with the special tool and Clutch Installation
remove the clutch sleeve hub nut (1). BENF34J15306017
1) Install the thrust washer (1).
Special tool
2) Apply engine oil to the spacer (2) and install it.
(A): Clutch Sleeve Hub Holder
1
1
2
( A)
IF34J1530022-01
IF34J1530018-01
3) Install the primary driven gear assembly (1) and
11) Remove the conical spring washer (1), washer (2)
thrust washer (2) onto the countershaft.
and clutch sleeve hub (3).
NOTE
2 • When engaging the primary drive and
driven gears, turn the primary drive
scissors gear (3) clockwise.
• Engage the kick starter idle gear (4) and
kick starter driven gear (5).
3 1
1
IF34J1530019-01
12) Remove the thrust washer (1) and primary driven

gear assembly (2). 3
2
IF34J1530023-01
2
IF34J1530020-01
13) Remove the spacer (1) and thrust washer (2). 4
2
5
IF34J1530024-01
4) Install the clutch sleeve hub (1), washer (2) and

conical spring washer (3).
NOTE
The conical curve side of spring washer (3)
1
faces outside.
IF34J1530021-01
5C-8 Clutch:
5) Install the clutch sleeve hub nut (4). 8) Insert the clutch drive plates and driven plates one
by one into the clutch sleeve hub (1) in the
prescribed order.
2
1
3
IF34J1530025-01
1
1 2 3 IF34J1530028-01
4
2 3 2
IF34J1530026-01 4
IF34J1530029-01
6) Hold the clutch sleeve hub with the special tool and
2. Clutch drive plate No. 1 4. Clutch drive plate
tighten the clutch sleeve hub nut (1) to the specified
3. Clutch drive plate No. 2
torque.
Special tool NOTE
(A): Clutch Sleeve Hub Holder
The clutch system is equipped with two kinds
Tightening torque of the drive plate (No. 1 and No. 2). They can
Clutch sleeve hub nut (a): 70 N·m (7.1 kgf-m, be distinguished by the facing width “a”.
52.0 lbf-ft)
1, ( a)
“a”
IF34J1530030-01
Drive plate Facing width “a”

(A)
5.05 – 5.75 mm
No. 1
IF34J1530027-01 (1.99 – 2.26 in)
7) Apply engine oil to the clutch drive plates and driven 4.35 – 5.05 mm
No. 2
plates. (1.71 – 1.99 in)
9) Apply engine oil to the bearing (1).

Clutch: 5C-9
10) Install the bearing and clutch release rack (2) into the 14) Apply engine oil to the clutch release rack gear (1)
clutch pressure plate (3). and face the gear backward.
2 1
3
IF34J1530031-01 IF34J1530034-01
11) Install the clutch pressure plate (1), clutch springs 15) Install the clutch cover and tighten the bolts to the
and clutch spring set bolts (2). specified torque.
12) Tighten the clutch spring set bolts to the specified Tightening torque
torque. Clutch cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
NOTE ft)
Tighten the clutch spring set bolts little by NOTE

little and diagonally. Fit the clamp (1) to the clutch cover bolt.
Tightening torque
Clutch spring set bolt (a): 5 N·m (0.51 kgf-m, 4.0
lbf-ft) (a)
2, ( a)
IF34J1530035-02
1 16) Install the clutch release arm (1).

IF34J1530032-01 NOTE
13) Install the dowel pins (1) and the new gasket (2). Remove play of the clutch release camshaft
turning it clockwise and install the clutch
release arm to the release camshaft in the
2 angle as shown.
1
1
IF34J1530033-01
5C-10 Clutch:
17) Tighten the clutch release arm bolt to the specified Reassembly
torque. Reassemble the clutch cover component part in the
reverse order of disassembly. Pay attention to the
Tightening torque
following points:
Clutch release arm bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft) • Apply grease to the lip of the new oil seals.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
(a)
• Install the oil seal until it seats in the clutch cover hole.
1
“A”
“A”
“a”
IF34J1530036-03
“a”: 7.5° – 22.5 °

IF34J1530039-01
19) Inspect the clutch cable play. )(Page 5C-2)
Clutch Cover Disassembly and Reassembly

BENF34J15306026
Refer to “Clutch Removal” (Page 5C-6) and “Clutch
Disassembly
1) Remove the kick starter shaft oil seal (1) and
crankshaft oil seal (2).
“A”
IF34J1530040-01
1 • After installing the clutch release camshaft (1), check
2
the clutch release camshaft operation.
IF34J1530037-01
2) Pull out the clutch release camshaft oil seal (1) and
washer with the clutch release camshaft (2).
IF34J1530041-01
IF34J1530038-01
Clutch: 5C-11
Clutch Parts Inspection

BENF34J15306018
Refer to “Clutch Removal” (Page 5C-6), “Clutch
Installation” (Page 5C-7) and “Clutch Cover Disassembly (A)
and Reassembly” (Page 5C-10).
Clutch Drive / Driven Plate
NOTE
Wipe off the engine oil from the drive and IE31J1530088-01
driven plates with a clean rag.
Clutch Spring
Measure the thickness of drive plates with a vernier Measure the free length of each coil spring with a vernier
calipers. If the drive plate thickness is found to have calipers, and compare the length with the specified limit.
reached the limit, replace it with a new one. Replace all the springs if any spring is not within the
Special tool limit.
(A): Vernier Caliper Special tool
Clutch drive plate thickness (A): Vernier Caliper
Service limit (No.1 and No.2): 2.6 mm (0.10 in) Clutch spring free length
(A) (A)
IE31J1530086-01
Measure the claw width of drive plates with a vernier

IE31J1530089-01
calipers. Replace the drive plates found to have worn
down to the limit. Clutch Release Bearing
Special tool Inspect the play “a” of the clutch release bearing by
(A): Vernier Caliper hand. Rotate the inner race by hand to inspect for
abnormal noise and smooth rotation. Replace the
Clutch drive plate claw width bearing if there is anything unusual.
Service limit (No.1 and No.2): 11.1 mm (0.437 in) Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
(A)
IE31J1530087-01
Measure each driven plate for distortion with a thickness IE31J1140298-01
gauge and surface plate.

Replace driven plates which exceed the limit.
Special tool
Clutch driven plate distortion
5C-12 Clutch:
Clutch Sleeve Hub / Primary Driven Gear Assembly Installation

Inspect the slot of the clutch sleeve hub (1) and primary Install the primary drive gear in the reverse order of
driven gear assembly (2) for damage or wear caused by removal.
the clutch plates. If necessary, replace it with a new one.
Inspect the springs of primary driven gear assembly for Primary Drive Gear Inspection
any damages. If necessary, replace primary driven gear BENF34J15306020
assembly with a new one. Refer to “Primary Drive Gear Removal and Installation”
(Page 5C-12).
Visually inspect the gear teeth for wear and damage. If
they are worn, replace the gear with a new one.
1 2
IF34J1530042-01
Clutch Release Camshaft

Inspect the clutch release camshaft for wear or bend. If IF34J1530045-01
necessary, replace it with a new one.

Primary Drive Gear Disassembly and
Reassembly
BENF34J15306021
Refer to “Primary Drive Gear Removal and Installation”
(Page 5C-12).
Disassembly
Remove the springs (1) and scissors gear (2).
IF34J1530043-01
1
Primary Drive Gear Removal and Installation
BENF34J15306019
Refer to “Clutch Removal” (Page 5C-6) and “Clutch 1
2
Removal
IF34J1530046-02
1) Remove the oil pump drive gear. Refer to “Oil Pump
Removal and Installation” in Section 1E (Page 1E-6).
2) Remove the primary drive gear (1).
IF34J1530044-01
Clutch: 5C-13
Reassembly
Reassemble the scissors gear in the reverse order of 1
disassembly. Pay attention to the following point:
• Install the scissors gear facing the mark (1) outward.
IF34J1530047-01
Specifications
BENF34J15307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Clutch cable stopper bolt 10 1.0 7.5 )(Page 5C-3)
Clutch lever pivot bolt 1.5 0.15 1.5 )(Page 5C-4)
Clutch lever pivot nut 3 0.30 2.5 )(Page 5C-4)
Clutch sleeve hub nut 70 7.1 52.0 )(Page 5C-8)
Clutch spring set bolt 5 0.51 4.0 )(Page 5C-9)
Clutch cover bolt 10 1.0 7.5 )(Page 5C-9)
Clutch release arm bolt 10 1.0 7.5 )(Page 5C-10)
Reference:
“Clutch Components” (Page 5C-5)
5C-14 Clutch:

BENF34J15308001
Grease SUZUKI SUPER GREASE A )(Page 5C-10)
NOTE
“Clutch Components” (Page 5C-5)
Special Tool
BENF34J15308002
Vernier calipers (200 mm) Thickness gauge

)(Page 5C-11) / )(Page 5C-11)
)(Page 5C-11) /
)(Page 5C-11)
Clutch sleeve hub holder

)(Page 5C-7) /
)(Page 5C-8)
Section 6
Steering
CONTENTS
Precautions .................................................6-1 Steering On-Vehicle Inspection...........................6B-7

Precautions............................................................. 6-1 Steering Tension Adjustment ..............................6B-7
Precautions for Steering ....................................... 6-1 Steering Stem Upper Bracket Removal and
Installation .........................................................6B-8
Steering General Diagnosis.................... 6A-1 Steering Stem Upper Bracket Inspection ............6B-9
Diagnostic Information and Procedures............6A-1 Steering Stem Removal and Installation .............6B-9
Steering Symptom Diagnosis.............................. 6A-1 Steering Stem Inspection ..................................6B-12
Steering Stem Bearing Removal and
Steering / Handlebar................................ 6B-1 Installation .......................................................6B-13
Repair Instructions ..............................................6B-1 Specifications .....................................................6B-14
Handlebar Components ...................................... 6B-1 Tightening Torque Specifications......................6B-14
Handlebar Construction ...................................... 6B-2 Special Tools and Equipment ...........................6B-15
Handlebar Removal and Installation ................... 6B-3 Recommended Service Material .......................6B-15
Handlebar Inspection .......................................... 6B-6 Special Tool ......................................................6B-15
Steering Stem Components ................................ 6B-6
6
6-1 Precautions:
Precautions
Steering
Precautions
Precautions for Steering
BENF34J16000001
Steering General Diagnosis: 6A-1
Steering General Diagnosis

Steering

Steering Symptom Diagnosis
BENF34J16104001

Heavy steering Over tightened steering stem nut. Adjust. )(Page 6B-7)
Broken steering stem steel ball/race. Replace. )(Page 6B-13)
Distorted steering stem. Replace. )(Page 6B-9)
Not enough pressure in tires. Adjust. )(Page 2D-9)
Wobbly handlebar Loss of balance between right and left Replace fork, adjust fork oil level or replace
front forks. fork spring. )(Page 2B-2)
)(Page 2B-3)
Distorted front fork. Repair or replace. )(Page 2B-2)
Distorted front axle or crooked tire. Replace. )(Page 2D-2)
)(Page 2D-10)
Loose steering stem nut. Adjust. )(Page 6B-7)
Worn or incorrect tire. Replace. )(Page 2D-10)
Incorrect tire pressure. Adjust. )(Page 2D-9)
Worn steering stem steel ball/race. Replace. )(Page 6B-13)
6B-1 Steering / Handlebar:
Steering / Handlebar
Steering
Repair Instructions
Handlebar Components
BENF34J16206001
5 (a)
[A] 8
IF34J1620001-04
[A]: Apply handle grip glue. 3. Left handle switch 6. Handlebar holder : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
1. Throttle grip 4. Left handlebar grip 7. Handlebars
2. Right handle switch 5. Handlebar clamp bolt 8. Grip end cap
Steering / Handlebar: 6B-2
Handlebar Construction
BENF34J16206002
1 [A]
RH, “a”
LH, “b”
(e)
(e)
(b)
(c)
(d)
[D]
(a) (a)
[C]
3
(h)
(f)
(g)
[B]
IF34J1620002-02
[A]: Align the mating surface of the steering stem upper “a”: 1.1 – 3.1 mm (0.04 – 0.12 in) : 1.2 Nm (0.12 kgf-m, 1.0 lbf-ft)
bracket with the punch mark of handlebars.
[B]: Align the punch mark of the handlebars with the edge “b”: 0 – 2 mm (0 – 0.08 in) : 6 Nm (0.60 kgf-m, 4.5 lbf-ft)
of front brake master cylinder holder.
[C]: Align the mating surface of the clutch lever holder with : 23 Nm (2.3 kgf-m, 17.0 lbf-ft) : 3 Nm (0.30 kgf-m, 2.5 lbf-ft)
the punch mark of handlebars.
[D]: Align the groove of grip end cap with the seam line of : 1 Nm (0.10 kgf-m, 1.0 lbf-ft) : Apply grease to sliding surface.
handlebars.
1. Grip end cap : 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft) : Apply silicone grease to sliding
surface.
2. Handlebars : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
3. Front brake light switch : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
Handlebar Removal and Installation 4) Remove the clamps (1).

BENF34J16206003
5) Remove the handlebar holders (2) and clutch lever
NOTE assembly (3).
Do not turn the front brake master cylinder
upside down. 3
1
Removal 1
1) Remove the following parts from the left side of the
handlebar.
a) Rear view mirror (1)
2
b) Left handle switch (2)
c) Grip end cap (3)
2
d) Left handlebar grip (4)
2) Loosen the clutch lever holder bolt (5). IF34J1620005-01
Installation
1) Install the clutch lever assembly to the handlebars
1 temporarily.
2) Position the handlebars.
3) Install the handlebar holders positioning the punch
mark (1) frontward.
3 4
5
2
IF34J1620003-01
3) Remove the following parts from the right side of the

handlebar.
a) Rear view mirror (1)
b) Front brake master cylinder assembly (2)
c) Right handle switch (3)
d) Grip end cap (4)
e) Throttle grip (5)
2 1
5 4
3
IF34J1620004-01
4) Install the handlebar clamp bolts (2). 6) Align the mating surface (1) of the clutch lever holder
with the punch mark (2) on the handlebars and
1 tighten the holder bolt to the specified torque.
Tightening torque
Clutch lever holder bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
IF34J1620006-01 2
2
1
(a)
IF34J1620009-03
2 2 7) Apply grease to the end of the starter cable.

8) Insert the projection (1) of the left handle switch into

the hole of the handlebars.
IF34J1620007-01
5) Set the handlebars so that its punch mark (1) aligns

with the mating surface (2) of the steering stem 1
upper bracket and tighten the front side of the
handlebar clamp bolts (3) first.
Tightening torque
Handlebar clamp bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
“A”
3, ( a)
IF34J1620010-01
9) Clean, decrease and dry both the left handlebar

(a) outer surface (1) on which the grip is being fitted and
internal surface of the left handlebar grip (2).
10) Apply handle grip glue to both the left handlebar
outer surface on which the grip is being fitted and
1
internal surface of the left handlebar grip evenly.
2
“A”: Adhesive (Handle grip glue)
IF34J1620008-02
IE31J1620007-01 IE31J1620012-01
“a”: Clearance
11) Aligning the groove (1) on the left handlebar grip end 16) Aligning the groove (1) on the right handlebar grip
cap (2) with the seam line (3) in the handlebars, end cap (2) with the seam line (3) in the handlebars,
install the end cap to the handlebars as shown. install the end cap to the handlebars as shown.
Left handlebar grip end cap installing position Right handlebar grip end cap installing position
“a”: “a”:
0 – 2 mm (0 – 0.08 in) 1.1 – 3.1 mm (0.04 – 0.12 in)
3 3
1 1
IF34J1620011-01 IF34J1620014-01
2 2
“a” “a”
IF34J1620012-01 IF34J1620015-01
12) Install the left rear view mirror. 17) Install the right rear view mirror.
13) Install the front brake master cylinder assembly. 18) Check to make sure that the wire harnesses, cables
)(Page 4A-8) and hoses are properly routed.
14) Apply grease to the end of the throttle cable. • Wire harness: )(Page 9A-5)
“A”: (SUZUKI SUPER GREASE A) • Cable: )(Page 1D-2)
• Hose: )(Page 4A-2)
15) Insert the projection (1) of the right handle switch 19) Check the throttle cable for the play and smooth
into the hole of the handlebars. operation. )(Page 1D-8)
20) Check the clutch cable for the play and smooth
operation. )(Page 5C-2)
1 “A”
IF34J1620013-02
Handlebar Inspection
BENF34J16206004
Refer to “Handlebar Removal and Installation” (Page 6B-
3).
Inspect the handlebars for distortion and damage.
If any defect is found, replace the handlebars with a new
one.
IF34J1620016-01
Steering Stem Components

BENF34J16206005
2 (b)
4 (d)
5 (a)
6
7
8
9
10
11
12
(c)
IF34J1620017-02
1. Handlebar holder 6. Steering stem upper steel ball 11. Steering stem lower steel ball : 20 Nm (2.0 kgf-m, 15.0 lbf-ft)
outer race outer race turn counterclockwise 0 – 1/4
2. Steering stem head nut 7. Steering stem upper steel ball 12. Steering stem lower bracket : Apply grease.
3. Steering stem upper bracket 8. Steering stem upper steel ball : 23 Nm (2.3 kgf-m, 17.0 lbf-ft) : Do not reuse.
inner race
4. Steering stem nut 9. Steering stem lower steel ball : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
inner race
5. Dust cover 10. Steering stem lower steel ball : 29 Nm (3.0 kgf-m, 21.5 lbf-ft)
Steering On-Vehicle Inspection 5) If the initial force reading on the scale when the
BENF34J16206006 handlebars start turning is either too heavy or too
Steering should be adjusted properly for smooth turning
light, adjust the tension until it satisfies the
of handlebars and safe running. Overtighten steering
specification as follows.
prevents smooth turning of the handlebars and too loose
steering will cause poor stability. a) First, loosen the front fork upper clamp bolts and
steering stem head nut, and then adjust the
1) Check that there is no play in the front fork.
steering stem nut by loosening or tightening it.
2) Check that there is no play in the steering stem
bearings holding the handlebar, moving the
motorcycle back-and-forth with the front brake
applied. Or, support the motorcycle so that the front
wheel is off the ground, grasp the front fork outer
tubes near the axle and move the tubes back-and-
forth and up-and-down.
If play is found, readjust the steering. )(Page 6B-7)
(A )
IF34J1620019-01
b) Tighten the steering stem head nut, front fork

upper clamp bolts to the specified torque, and
recheck the initial force with the spring scale
according to the previously described procedure.
IF34J1620018-01
Tightening torque
Steering stem head nut: 90 N·m (9.2 kgf-m,
Steering Tension Adjustment 66.5 lbf-ft)
BENF34J16206007
Front fork upper clamp bolt: 23 N·m (2.3 kgf-
1) By supporting the motorcycle with a jack, lift the front
m, 17.0 lbf-ft)
wheel until it is off the ground 20 – 30 mm (0.8 – 1.2
in). c) Make sure that the initial force is within the
2) Check to make sure that the cables and wire specified range and the steering is not loose.
harnesses are properly routed.
3) With the front wheel in the straight ahead state, hitch
the spring scale (special tool) on one handlebar grip
end as shown in the figure and read the graduation
when the handlebars start moving.
Steering tension initial force
2 – 5 N (0.20 – 0.51 kgf, 0.45 – 1.12 lbf)
Special tool
(A): Spring Scale
IF34J1620020-01
(A)
ID26J1620028-01
4) Do the same on the other grip end.

Steering Stem Upper Bracket Removal and 11) Remove the steering stem head nut (2), washer (3)
Installation and steering stem upper bracket assembly (4).
BENF34J16206008
Removal
1
2) Disconnect the clutch cable from the clutch lever.
Refer to “Clutch Cable Removal and Installation” in
Section 5C (Page 5C-2).
3) Remove the front brake master cylinder assembly
from the right handlebar. )(Page 4A-8)
4) Remove the left and right handle switches.
3 2 4
IF34J1620023-01
12) Remove the following parts from the steering stem

upper bracket.
• Cushions (1)
• Ignition switch (2): )(Page 1H-6)
IF34J1620021-01

6) Disconnect the ignition switch coupler. Refer to
“Ignition Switch Inspection” in Section 1H (Page 1H- 1 1
6).
7) Disconnect the clutch lever position switch lead wire 2
connectors. Refer to “Clutch Lever Position Switch IF34J1620024-01
Inspection” in Section 5C (Page 5C-2)

Installation
8) Remove the clamps (1).
1) Install the following parts to the steering stem upper
9) Remove the handlebar holders (2) and handlebars.
bracket.
• Cushions (1)
1
• Ignition switch (2): )(Page 1H-6)
1 1
IF34J1620022-01
10) Loosen the front fork upper clamp bolts (1).

2
IF34J1620024-01
2) Install the steering stem upper bracket assembly (1),

washer (2) and steering stem head nut (3).
3) Tighten the steering stem head nut and front fork Steering Stem Upper Bracket Inspection
upper clamp bolts (4) to the specified torque. BENF34J16206009
Refer to “Steering Stem Upper Bracket Removal and
Tightening torque Installation” (Page 6B-8).
Steering stem head nut (a): 90 N·m (9.2 kgf-m, Inspect the steering stem upper bracket for damage.
66.5 lbf-ft) If any damage is found, replace the steering stem upper
Front fork upper clamp bolt (b): 23 N·m (2.3 kgf- bracket with a new one.
m, 17.0 lbf-ft)
4, (b)
4, ( b)
1
2 3, ( a) IF34J1620027-01
IF34J1620025-01
4) Install the handlebars. )(Page 6B-3) Steering Stem Removal and Installation
BENF34J16206010
5) Install the clamps (1).
Removal
1
1) Remove the front forks. )(Page 2B-2)
2) Remove the handlebars. Refer to “Steering Stem
1 Upper Bracket Removal and Installation” (Page 6B-
8).
3) Remove the clamps (1).
4) Disconnect the combination meter (2), ignition switch
(3), left handle switch (4) and right handle switch (5)
couplers.
IF34J1620026-01 2
1
6) Connect the clutch lever position switch lead wire 1
connectors. Refer to “Clutch Lever Position Switch 4
Inspection” in Section 5C (Page 5C-2).
7) Connect the ignition switch coupler. Refer to “Ignition 5
Switch Inspection” in Section 1H (Page 1H-6).
8) Install the headlight assembly. )(Page 9B-3) 3
1
9) Install the left and right handle switches. Refer to
“Handlebar Removal and Installation” (Page 6B-3).
10) Install the front brake master cylinder assembly to IF34J1620028-01
the right handlebar. )(Page 4A-8) 5) Remove the front brake hose clamps.
11) Connect the clutch cable to the clutch lever. Refer to
“Clutch Cable Removal and Installation” in Section
5C (Page 5C-2).
12) Adjust the clutch cable play. )(Page 5C-2)
IF34J1620029-01
6) Remove the headlight housing brace (1) with the 10) Remove the dust cover (1) and steering stem upper
combination meter assembly (2). steel ball outer race (2).
2
1
2
IF34J1620030-01 IF34J1620033-01
7) Remove the steering stem head nut (1) and washer 11) Remove the steering stem upper (1) and lower (2)
(2), and then remove the steering stem upper steel balls.
bracket assembly (3).
Number of steel ball
Upper 22 pieces
3 Lower 18 pieces
IF34J1620031-01
8) While holding the steering stem lower bracket,

remove the steering stem nut (1) using the special
tool.
IF34J1620034-01
Special tool
(A): Steering Stem Nut Socket Installation
9) Remove the steering stem lower bracket. 1) Apply grease to the steering stem upper and lower
inner races.
“A”
(A)
IF34J1620032-01
“A”
IE29J1620043-01
2) Install the new steering stem upper (1) and lower (2)
steel balls.
Number of steel ball 1

Upper 22 pieces
Lower 18 pieces
(A )
2
1
1 , (a )
2
IF34J1620036-01
“a”
IF34J1620034-01
3) Install the new steering stem upper steel ball outer

race (1) and dust cover (2).
1
2 IF34J1620042-01
8) In this condition, check that the steering stem lower

bracket can turn smoothly without rattle and
stiffness. If there is a rattle or heavy movement,
readjust the tightness by the steering stem nut.
9) Install the steering stem upper bracket (1), washer
(2) and steering stem head nut (3) temporarily.
10) Install the front forks (4) temporarily.
IF34J1620035-01 11) Tighten the steering stem head nut to the specified
4) Set the steering stem lower bracket to the frame. torque.
5) Install the steering stem nut (1) with the flange side Tightening torque
(2) face down and tighten it to the specified torque Steering stem head nut (a): 90 N·m (9.2 kgf-m,
(20 Nm (2.0 kgf-m, 15.0 lbf-ft)) using the special 66.5 lbf-ft)
tool.
Special tool 3 , (a ) 1
(A): Steering Stem Nut Socket
6) Turn the steering stem lower bracket to the left and
right about five or six times so that the steering stem
steel balls seat properly.
7) Loosen the steering stem nut 0 – 1/4 turn “a”.
4 4
Tightening torque 2
Steering stem nut (a): 20 Nm (2.0 kgf-m, 15.0
lbf-ft) turn counterclockwise 0 – 1/4
IF34J1620037-01
12) Install the front forks in proper position. )(Page 2B-

2)
13) Pass the cables correctly and install the headlight Steering Stem Inspection
housing brace (1) with the combination meter BENF34J16206011
Refer to “Steering Stem Removal and Installation” (Page
assembly (2). )(Page 1D-2)
6B-9).
Tightening torque Inspect the removed parts for the following
Headlight housing brace bolt (a): 10 N·m (1.0 abnormalities:
kgf-m, 7.5 lbf-ft) • Distortion of the steering stem
• Steering stem steel ball wear or damage
• Abnormal bearing noise
2 • Steering stem steel ball race wear or damage
If any abnormal points are found, replace defective parts
with new ones.
(a) 1
IF34J1620038-01
14) Pass the front brake hose correctly and install the
brake hose clamps. )(Page 4A-2)
IF34J1620039-01
IF34J1620029-01
15) Pass the wire harness and install the clamps (1).
)(Page 9A-5)
16) Connect the combination meter (2), ignition switch
IF34J1620040-01
(3), left handle switch (4) and right handle switch (5)
couplers.
2
1
1
4
3
1
IF34J1620028-01
17) Install the handlebars. Refer to “Steering Stem

Upper Bracket Removal and Installation” (Page 6B-
8).
18) Check the steering tension. )(Page 6B-7)
Steering Stem Bearing Removal and Installation Installation

BENF34J16206012
1) Press in the new steering stem upper and lower
Removal steel ball inner races using the special tool.
1) Remove the dust cover, steering stem upper steel Special tool
ball outer race and steering stem upper/lower steel (A): Steering Race Installer
balls. Refer to “Steering Stem Removal and
Installation” (Page 6B-9). (A)
2) Remove the steering stem lower steel ball outer race
using a chisel.
IF34J1620041-01
2) Press in the new steering stem lower steel ball outer

race using the special tool.
I649G1620033-02
Special tool
3) Drive out the steering stem upper and lower steel (A): Steering Race Installer Lower
ball inner races using a suitable bar.
(A)
IF34J1620043-01
IE29J1620050-01
3) Apply grease to the steering stem upper/lower steel
ball races, install the new steering stem upper/lower
steel balls and the steering stem lower bracket to the
frame. Refer to “Steering Stem Removal and
Installation” (Page 6B-9).
Specifications
BENF34J16207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Handlebar clamp bolt 23 2.3 17.0 )(Page 6B-4)
Clutch lever holder bolt 10 1.0 7.5 )(Page 6B-4)
Steering stem head nut )(Page 6B-7) /
90 9.2 66.5 )(Page 6B-9) /
)(Page 6B-11)
Front fork upper clamp bolt )(Page 6B-7) /
23 2.3 17.0
)(Page 6B-9)
Steering stem nut 20 Nm (2.0 kgf-m, 15.0 lbf-ft) turn )(Page 6B-11)
counterclockwise 0 – 1/4
Headlight housing brace bolt 10 1.0 7.5 )(Page 6B-12)
Reference:
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Stem Components” (Page 6B-6)

BENF34J16208001
Adhesive Handle grip glue )(Page 6B-4)
Grease )(Page 6B-4) / )(Page 6B-
SUZUKI SUPER GREASE A
5) / )(Page 6B-10)
NOTE
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Stem Components” (Page 6B-6)
Special Tool
BENF34J16208002
Adjustable hook wrench Steering stem nut socket

)(Page 6B-7) )(Page 6B-10) /
)(Page 6B-11)
Spring scale (400 - 1000 g) Bearing installer set

)(Page 6B-7) )(Page 6B-13)
Steering race installer lower

)(Page 6B-13)
Section 9
Body and Accessories

CONTENTS
Precautions .................................................9-1 Front Turn Signal Light / Rear Turn Signal

Precautions............................................................. 9-1 Light Construction .............................................9B-9
Precautions for Electrical System ......................... 9-1 Front Turn Signal Light / Rear Turn Signal
Component Location ............................................. 9-1 Light Components ...........................................9B-10
Electrical Components Location ........................... 9-1 Front Turn Signal Light Removal and
Installation .......................................................9B-10
Wiring Systems........................................ 9A-1 Rear Turn Signal Light Removal and
Installation .......................................................9B-11
General Description .............................................9A-1
Turn Signal Light Bulb Replacement.................9B-11
Abbreviations ...................................................... 9A-1
Reflex Reflector Construction ...........................9B-12
Wire / Connector Color Symbols......................... 9A-1
Turn Signal Relay Inspection ............................9B-12
How to Read Terminal Nos. ................................ 9A-1
Turn Signal Relay Removal and Installation .....9B-12
Glossary .............................................................. 9A-2
Turn Signal Switch Inspection...........................9B-13
Schematic and Routing Diagram........................9A-4
Lighting Switch Inspection.................................9B-13
Wiring Diagram ................................................... 9A-4
Passing Light Switch Inspection........................9B-13
Wiring Harness Routing Diagram........................ 9A-5
Dimmer Switch Inspection.................................9B-14
Component Location ...........................................9A-8
Specifications .....................................................9B-14
Electrical Components Location ......................... 9A-8
Tightening Torque Specifications......................9B-14
Lighting Systems..................................... 9B-1 Combination Meter / Fuel Meter / Horn.. 9C-1
Precautions...........................................................9B-1 General Description .............................................9C-1
Precautions for Lighting Systems ....................... 9B-1 Combination Meter System Description..............9C-1
Diagnostic Information and Procedures............9B-1 Diagnostic Information and Procedures ............9C-2
Headlight Symptom Diagnosis ............................ 9B-1 Combination Meter Symptom Diagnosis.............9C-2
Turn Signal Light Symptom Diagnosis ................ 9B-1 Horn Symptom Diagnosis ...................................9C-2
Rear Combination Light Symptom Diagnosis ..... 9B-1
Repair Instructions ..............................................9C-2
Repair Instructions ..............................................9B-2 Combination Meter Construction.........................9C-2
Headlight Construction........................................ 9B-2 Combination Meter Components ........................9C-3
Headlight Housing Cushion Construction ........... 9B-3 Combination Meter On-Vehicle Inspection..........9C-3
Headlight / Position Light Components ............... 9B-3 Engine RPM Indicator Light Preset .....................9C-3
Headlight Removal and Installation .................... 9B-3 Combination Meter Removal and Installation .....9C-4
Position Light Removal and Installation .............. 9B-4 9
Combination Meter Disassembly and
Headlight Bulb / Position Light Bulb Reassembly ......................................................9C-4
Replacement ..................................................... 9B-4 Speedometer On-Vehicle Inspection ..................9C-4
Headlight Beam Adjustment ............................... 9B-5 Fuel Level Indicator Inspection ...........................9C-4
Rear Combination Light / License Plate Light Fuel Level Gauge Inspection ..............................9C-5
Construction ...................................................... 9B-6 Horn Inspection ...................................................9C-5
Rear Combination Light / License Plate Light Horn Removal and Installation ............................9C-6
Components...................................................... 9B-7
Specifications .......................................................9C-6
Rear Combination Light Removal and
Tightening Torque Specifications........................9C-6
Installation ......................................................... 9B-7
Rear Combination Light Bulb Replacement ........ 9B-7 Exterior Parts ........................................... 9D-1
License Plate Light Removal and Installation ..... 9B-7
Schematic and Routing Diagram ........................9D-1
License Plate Light Bulb Replacement ............... 9B-8
Seat Lock Cable Routing Diagram......................9D-1
Repair Instructions ..............................................9D-2
9-ii Table of Contents
Frame Cover Construction ..................................9D-2 Meter Cover Removal and Installation ..............9D-17
Front Fender Construction ..................................9D-4 Battery Holder Removal and Installation ...........9D-17
Rear Fender Construction...................................9D-5 Rear Side Guard Removal and Installation .......9D-18
Fuel Tank Cover Construction ............................9D-6 Specifications .....................................................9D-18
Meter Cover Construction ...................................9D-7 Tightening Torque Specifications......................9D-18
Fuel Tank Cover Protector Construction.............9D-8
Rear Fender Cushion Construction.....................9D-9 Body Structure......................................... 9E-1
Battery Holder Protector Construction ..............9D-10 Repair Instructions ..............................................9E-1
Fastener Removal and Installation....................9D-10 Frame Construction.............................................9E-1
Seat Removal and Installation ..........................9D-11 Front Footrest Construction ................................9E-2
Seat Lock Cable / Seat Lock Assembly Front Footrest Removal and Installation .............9E-2
Removal and Installation.................................9D-11 Pillion Footrest Construction ...............................9E-3
Frame Side Cover Removal and Installation.....9D-12 Pillion Footrest Removal and Installation ............9E-3
Frame Lower Cover Removal and Installation ..9D-12 Side-stand Construction......................................9E-3
Frame Front Cover Removal and Installation ...9D-13 Side-stand Removal and Installation...................9E-4
Pillion Rider Handle Removal and Installation ..9D-13 Center Stand Construction..................................9E-4
Frame Upper Cover / Frame Center Cover / Center Stand Removal and Installation...............9E-4
Frame Center Lower Cover Removal and Specifications .......................................................9E-4
Installation .......................................................9D-14 Tightening Torque Specifications........................9E-4
Rear Fender Extension / Rear Fender
Special Tools and Equipment .............................9E-5
Removal and Installation.................................9D-15
Recommended Service Material .........................9E-5
Fuel Tank Cover Removal and Installation .......9D-16
Precautions: 9-1
Precautions
Precautions
Precautions for Electrical System
BENF34J19000001
(Page 00-2).
Component Location
BENF34J19003001
9A-1 Wiring Systems:
Wiring Systems
General Description
Abbreviations
BENF34J19101001
Refer to the “Abbreviations” in Section 0A (Page 0A-1) for the general abbreviations.
Wire / Connector Color Symbols

BENF34J19101002
Refer to “Wire Color Symbols” in Section 0A (Page 0A-3).
How to Read Terminal Nos.

BENF34J19101003
The connector shape and terminal layout shown in this manual are those when viewed from “Z” in the illustration.
NOTE
• Molded terminal numbers that are different from the above can be found on some connectors in rare
cases.
• These molded numbers are not applied in this manual.
View Z
Male terminal A40

4 3 2 1
Z
8 7 6 5
(View Z)
Female terminal D18
1 2 3 4 View Z’
5 6 7 8
(View Z’)
Terminal No. Z’
IE31J1910901-02
Wiring Systems: 9A-2
Glossary
BENF34J19101004
English
ABS CONTROL UNIT
ABS MOTOR
ABS VALVE
AMBIENT AIR TEMP SENSOR
BATTERY
CDI UNIT
CKP SENSOR
CLUTCH LEVER POSITION SWITCH
COOLING FAN MOTOR
DIMMER SWITCH
ECM
ECT SENSOR
ENGINE STOP SWITCH
EVAP SYSTEM PURGE CONTROL SOLENOID VALVE
EXCV ACTUATOR
FAN
FAN RELAY
FRONT BRAKE LIGHT SWITCH
FRONT TURN SIGNAL LIGHT
FRONT WHEEL SPEED SENSOR
FUEL
FUEL INJECTOR
FUEL LEVEL GAUGE
FUEL PUMP
FUEL PUMP RELAY
FUSE BOX
GENERATOR
GP SWITCH
HANDLE SWITCH
HAZARD SWITCH
HEADLIGHT
HIBEAM INDICATOR LIGHT
HO2 SENSOR
HORN
HORN SWITCH
IAP SENSOR
IAT SENSOR
IF EQUIPPED
IGNITION
IGNITION COIL
IGNITION SWITCH
IMMOBILIZER ANTENNA
LICENSE PLATE LIGHT
LIGHTING SWITCH
MAIN FUSE
MODE SWITCH
OIL PRESSURE SWITCH
PASSING LIGHT SWITCH
POSITION LIGHT
POWER SOURCE
REAR BRAKE LIGHT SWITCH
REAR COMBINATION LIGHT
REAR TURN SIGNAL LIGHT
REAR WHEEL SPEED SENSOR
REGULATOR RECTIFIER
SELECT SWITCH
SIDE-STAND DIODE
English
SIDE-STAND RELAY
SIDE-STAND SWITCH
SIGNAL
SPEED SENSOR
SPEEDOMETER
STARTER SWITCH
STARTER MOTOR
STARTER RELAY
STV ACTUATOR
TO SENSOR
TP SENSOR
TURN SIGNAL RELAY
TURN SIGNAL SWITCH
HANDLE SWITCH (RH)
ENGINE LIGHTING
STARTER STOP SWITCH FRONT BRAKE
SWI TCH SWITCH LIGHT SWITCH FUEL
OFF
TURN LEVEL
OFF OFF
PUSH RUN ON SIGNAL GAUGE
IGNITION RELAY
SWITCH IGNITION REAR BRAKE
B
B
COIL LIGHT SWITCH
ON
OFF ON
LOCK OFF
SPEEDMETER CDI UNIT
R
O
O
W
Bl
O
Gr
Y/B
B/W
W/B
B/W
Y/G
B/R
W/Bl
Y/W
Br/W
Wiring Diagram
P
Y
V
B
R
O
O
O
O
O
W
Bl
Bl
Br
Br
Gr
Gr
Gr
Lg
B/R
B/R
Y/G
B/G
R/B
W/Y
Bl/Y
B/W
W/B
B/W
B/W
O/W
Y/Bl
W/B
O/W
G/Bl
G/Bl
Br/R
W/Bl
FRONT TURN SIGN AL LIGHT (RH) REAR TURN SIGNAL LIGHT (RH)
Lg Lg Lg Lg
B/W B/W B/W B/W
POSITION LIGHT
Br Gr
B/W B/W
HEADLIGHT REAR COMBINATION LIGHT

Y Gr Gr
B/W B/W B/W
W W/B W/B
LICENSE PLATE LIGHT

FRONT TURN SIGN AL LIGHT (LH) Gr Gr
B V B/W B/W
B/W B/W
V B
B/W B/W
REAR TURN SIGNAL LIGHT (LH)

P
W
Y/R
Y/G
B/W
B
Y/R
Y/G
B/R
B/W
Y/R
B/W
OFF
ON
CLUTCH
LEVER
B
B
O
O
Bl
Y
Y
W
R
B
R
B
B
B
R
R
B
R
R
Bl
Y
Y
Gr
B
Lg
Bl
POSITION
B/G
B/W
Y/R
B/W
R/B
W/Y
B/W
Bl/Y
Y/Bl
B/W
G/Bl
SPEED SENSOR
B/W
Br/R
SWITCH
Y
Y
B
G
G
Bl
Gr
Lg
Lbl
R/B
HORN
V/W
W/Y
B/W
W/R
Y/Bl
G/Bl
Br/R
REGULATOR/ FUSE BOX

RECTIFIER BATTERY
N
1 STARTER STARTER
RELAY TP
2 MOTOR SENSOR
3
4 CKP
5 SENSOR GENERATOR
L HI GP SWITCH
PUSH PUSH PUSH LO
HORN R PASSING DIMMER
Wiring Systems:
SWITCH TURN SIGNAL LIGHT SWITCH

SWITCH SWITCH
HANDLE SWITCH (LH)
IF34J1910904-05
9A-4
BENF34J19102001
Wiring Harness Routing Diagram

BENF34J19102002
[G] 26 16 17
15
25
18
24
19
19
27
23 20
30
1 29
[F] [D] 40
36
21
[E]
22
1
1
[C]
2 [A] 28
1 4
[S]
3 5 6
14
7
[Q]
[B] 11
9 41
13
8
10
[R]
12 [U]
37
31
10
39 38
[I]
[N] [O]
33
“a”
[H] [J]
[T]
[P]
[K] 35
32 34
[L]
[M]
IF34J1910901-05
[A]: Pass the wiring harness on the right side of 1. Clamp 22. Front brake hose
the engine mounting upper plate. : Clamp the wiring harness and insert the
clamp end into the hole.
[B]: Pass the starter motor lead wire to the inside 2. Turn signal relay coupler 23. Clutch switch lead wire connector
of the frame front cover center bracket. : Pass the clutch switch lead wire in front
of the combination meter lead wire.
[C]: Pass the wiring harness on the right side of 3. Fuel level gauge lead wire coupler 24. Throttle cable
the PAIR valve hose, and lower side of the
center frame.
[D]: Pass the ignition switch lead wire behind the 4. Clamp 25. Right handle switch lead wire
front brake hose. : Clamp the wiring harness.
[E]: Pass the left and right handle switch lead 5. Battery (–) lead wire 26. Clamp
wires behind the front brake hose. : Clamp the right handle switch lead wire
positioning the clamp head downward.
[F]: Cover the ignition switch lead wire coupler, 6. Battery (+) lead wire 27. CDI unit coupler
left and right handle switch lead wire
couplers, position light lead wire coupler and
right front turn signal light lead wire
connectors with the boot.
[G]: Pass both of the front brake switch lead 7. Main fuse 28. Clamp
wires in the same place. : Clamp the left and right rear turn signal
light lead wire connectors and license
plate light lead wire connectors, and
insert the clamp end into the hole.
[H]: Pass the battery lead wire, starter relay lead 8. Battery (+) lead wire (Red cap) 29. Rear combination light lead wire coupler
wire and speed sensor lead wire on the left
side of the PAIR cleaner hose.
[I]: Cover the CKP sensor lead wire coupler, 9. Starter motor lead wire (Gray cap) 30. Clamp
generator lead wire coupler, rear brake light : Clamp the rear combination light lead
switch lead wire coupler and GP switch lead wire.
wire coupler with the boot.
[J]: To regulator/rectifier 10. Clamp 31. TP sensor coupler
: Clamp the CKP sensor lead wire /
generator lead wire, speed sensor lead
wire and GP switch lead wire, and insert
the clamp end into the hole.
[K]: Tighten the engine ground lead wire with the 11. Regulator/rectifier coupler 32. Rear brake light switch lead wire
clutch cable stopper.
[L]: Pass the regulator/rectifier wire harness 12. Starter motor lead wire 33. Ignition coil ground lead wire terminal
outside of the other wire harnesses. : Tighten the ignition coil ground lead
wire with the ignition coil.
[M]: Pass the engine ground lead wire on the 13. Clamp 34. Clamp
front side of the PCV hose. : Clamp the starter motor lead wire aligning : Clamp the wiring harness and starter
the clamp with the upper end of the engine cable at the blue tape on the wiring
mounting lower bracket. harness positioning the clamp head
: Position the clamp head to the left and the downward, and insert the clamp into the
excess tip of the clamp to the rear. hole.
[N]: Details: Rear brake light switch 14. Horn 35. Clamp
: Clamp the wiring harness and throttle
cable.
[O]: Details: Ignition coil 15. Combination meter coupler 36. Right front turn signal light lead wire
: Fit the coupler boot to the combination connector
meter until it reaches bottom of the meter : Pass the right front turn signal light lead
case. wire in front of the headlight housing
brace.
[P]: Connect the ignition coil lead wire connector 16. Clamp 37. CKP sensor lead wire / generator lead
to the ignition coil primary terminal : Clamp the left handle switch lead wire and wire
positioning the wire inward. clutch switch lead wire positioning the : Pass the CKP sensor lead wire /
clamp head downward. generator lead wire above the GP switch
: Cut off the excess tip of the clamp. lead wire.
[Q]: Connect the horn lead wire connectors to 17. Left handle switch lead wire 38. GP switch lead wire
the horn terminals positioning the wire
upward.
[R]: Fix the horn holding the horn bracket in the 18. Clutch switch lead wire 39. Speed sensor lead wire
position by the stopper.
[S]: Pass the wiring harness above the battery 19. Clamp 40. Rear combination light lead wire
box. : Clamp the wiring harness, left handle : Pass the rear combination light lead
switch lead wire and clutch switch lead wire wire under the seat bracket.
at the blue tape on the wiring harness.
[T]: Fix the engine ground lead wire holding the 20. Headlight coupler 41. Clamp
terminal in the position by the clutch cable : Clamp the battery lead wire.
stopper.
[U]: Pass the CKP sensor lead wire / generator 21. Left front turn signal light lead wire “a”: 80 – 100°
lead wire and GP switch lead wire above the connector
engine mounting rear bolt without slack. : Pass the left front turn signal light lead
wire in front of the headlight housing brace.
[F]
2
“a” [B]
[A]
[E]
[C]
[D]
4
IF34J1910902-02
[A]: Pass the speed sensor lead wire under [E]: Hook the GP switch lead wire on the lug 3. Starter motor terminal cover
the hook of the engine sprocket cover. of the generator cover.
[B]: Do not pinch the lead wires between the [F]: Pass the generator lead wire between 4. Speed sensor
crankcase and engine sprocket cover. the ribs of the generator cover.
[C]: Pass the CKP sensor lead wire, 1. Starter motor 5. Lead wire clamp
generator lead wire and GP switch lead
wire behind the oil seal retainer.
[D]: Set the GP switch lead wire along the 2. Starter motor lead wire “a”: 75 – 105°
groove of the generator cover.
1
[A]
2 3
IF34J1910903-02
[A]: Set the left and right rear turn signal light 2. Right rear turn signal light lead wire 4. License plate light lead wire
lead wires and license plate light lead
wire without slack.
1. Rear fender 3. Left rear turn signal light lead wire
Component Location
BENF34J19103001
9B-1 Lighting Systems:
Lighting Systems
Precautions
Precautions for Lighting Systems
BENF34J19200001
NOTICE
• When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol
or soap water to prevent premature bulb failure.
• Do not use the bulb of a wattage other than specification.

Headlight Symptom Diagnosis
BENF34J19204004

Low beam does not light Circuit fuse blown. Replace fuse and check short circuit.
up Bulb blown. Replace bulb. )(Page 9B-4)
Wiring or ground faulty. Repair wiring. )(Page 9A-4)
Lighting switch faulty. Check lighting switch. )(Page 9B-13)
Dimmer switch faulty. Check dimmer switch. )(Page 9B-14)
High beam does not light Circuit fuse blown. Replace fuse and check short circuit.
up Bulb blown. Replace bulb. )(Page 9B-4)
Wiring or ground faulty. Repair wiring. )(Page 9A-4)
Lighting switch faulty. Check lighting switch. )(Page 9B-13)
Dimmer switch faulty. Check dimmer switch. )(Page 9B-14)
Passing switch faulty. Check passing switch. )(Page 9B-13)
Turn Signal Light Symptom Diagnosis

BENF34J19204002

Flash rate high or one Bulb blown. Replace bulb. )(Page 9B-11)
side only flashes Incorrect bulb. Replace bulb. )(Page 9B-11)
Turn signal relay faulty. Check turn signal relay. )(Page 9B-12)
Open circuit or high resistance between Repair wiring. )(Page 9A-4)
turn signal switch and non lighting bulb.
Flash rate low Supply voltage low or high resistance. Check charging system. )(Page 1J-4)
Repair wiring. )(Page 9A-4)
Turn signal relay faulty. Check turn signal relay. )(Page 9B-12)
Rear Combination Light Symptom Diagnosis

BENF34J19204003

All lights do not light up Wiring or grounding faulty. Repair wiring. )(Page 9A-4)
Some lights do not light Bulbs (LED) blown. Replace rear combination light assembly and
up check short circuit.
Wiring or grounding faulty. Repair wiring. )(Page 9A-4)
Brake light do not light up Front brake light switch faulty. Check front brake light switch. )(Page 4A-3)
Rear brake light switch faulty. Check rear brake light switch. )(Page 4A-4)
Wiring or grounding faulty. Repair wiring. )(Page 9A-4)
Rear combination light bulbs (LED) Replace rear combination light assembly.
faulty.
Brake light stay on Front brake light switch faulty. Check front brake light switch. )(Page 4A-3)
Rear brake light switch faulty. Check rear brake light switch. )(Page 4A-4)
Rear combination light bulb (LED) faulty. Replace rear combination light assembly.
Lighting Systems: 9B-2
Repair Instructions
Headlight Construction
BENF34J19206001
(b)
(a)
(a)
3
1
[A] [B]
1
1 6
(c)
6 6
IF34J1920001-03
[A]: Correct 3. Right headlight housing : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
[B]: Incorrect 4. Upper headlight housing : 2 Nm (0.20 kgf-m, 1.5 lbf-ft)
1. Headlight 5. Headlight housing brace : 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
: Install the headlight to the headlight cushions correctly.
2. Left headlight housing 6. Headlight cushion
Headlight Housing Cushion Construction

BENF34J19206025
[B]
2
[A] 3
[A]
IF34J1920002-01
[A]: Stick the cushion aligning the end of the 2. Upper headlight housing
cushion with the rib corner of the headlight
housing.
[B]: Stick the cushion not to protrude from the rib 3. Headlight housing (LH and RH)
of the headlight housing.
1. Headlight housing cushion
Headlight / Position Light Components Headlight Removal and Installation

BENF34J19206002 BENF34J19206003
Removal
1 2
1) Remove the headlight housing, right and left.
)(Page 9B-10)
2) Remove the headlight bolt (1), move the headlight
assembly (2) frontward and detach it from the
headlight cushion (3).
1
(a) IF34J1920004-01
IF34J1920003-02
1. Headlight
2. Headlight bulb (12 V 35/35 W, HS1)
3. Position light bulb (12 V, 5 W)
: 2.5 Nm (0.25 kgf-m, 2.0 lbf-ft)
3) Disconnect the headlight coupler (1) and position

light coupler (2).
1
IF34J1920008-01
1
IF34J1920005-01 Installation
4) Remove the upper headlight housing (1). Install the position light in the reverse order of removal.
Headlight Bulb / Position Light Bulb

Replacement
BENF34J19206005
1
! CAUTION
As the headlight bulb operates at a high
temperature, handle the bulb after
sufficiently cooled.
Headlight Bulb
IF34J1920006-01
2) Remove the bulb socket rubber cap (1).
Installation 3) Unhook the bulb holder spring (2) and remove the
Install the headlight in the reverse order of removal. Pay headlight bulb (3).
• Install the headlight assembly to the headlight
cushions securely. )(Page 9B-2)
1
• After installing, be sure to inspect the headlight beam.
)(Page 9B-5) 2
Position Light Removal and Installation

BENF34J19206004
Removal
1) Disconnect the position light coupler (1). 3
IF34J1920009-01
4) After finishing the headlight bulb replacing, install the

removed parts.
5) After installing the removed parts, be sure to inspect
the headlight beam. )(Page 9B-5)
IF34J1920007-01
2) Pull out the position light (1).

Position Light Bulb Headlight Beam Adjustment

BENF34J19206006
1) Pull out the position light socket (1).
1) Loosen the headlight bolt (1).
2) Adjust the headlight beam vertically moving the
headlight assembly.
1
IF34J1920008-01
2) Replace the position light bulb (1).

1
IF34J1920011-02
3) Tighten the headlight bolt.
IF34J1920010-01
3) Install the position light socket.

Rear Combination Light / License Plate Light Construction

BENF34J19206007
[A] (a) “1”

1
[A] (a) “2” 1 3

2
(b)
1
3
4
2
2
4
(c)
IF34J1920012-03
[A]: Tighten the screws in order of “1” “2”. 4. Frame cover bracket : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
1. Rear combination light 5. License plate light : 3 Nm (0.31 kgf-m, 2.5 lbf-ft)
2. Frame center lower cover 6. Rear fender
3. Frame center cover : 2 Nm (0.20 kgf-m, 1.5 lbf-ft)
Rear Combination Light / License Plate Light Components

BENF34J19206008
(a)
(b)
4
6
IF34J1920013-03
1. Rear combination light (LED) 4. Gasket : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
2. Mounting rubber 5. License plate light lens : 3 Nm (0.31 kgf-m, 2.5 lbf-ft)
3. License plate light bulb (12 V, 5 W) 6. Cover
Rear Combination Light Removal and

Installation
BENF34J19206009
Refer to “Frame Upper Cover / Frame Center Cover / 1
Frame Center Lower Cover Removal and Installation” in
2
Rear Combination Light Bulb Replacement
BENF34J19206010
NOTE
If LED operation is abnormal, replace the rear
combination light with a new one.
IF34J1920014-02
License Plate Light Removal and Installation

BENF34J19206011
Removal
• Seat: )(Page 9D-11)
• Rear fender bracket: )(Page 9D-15)
2) Remove the clamp (1) and disconnect the license
plate light lead wire connectors (Black-Black/white
and Black-Black) (2).
3) Remove the screws (1) and license plate light License Plate Light Bulb Replacement
assembly (2). BENF34J19206012
1) Remove the screws (1) and lens (2).
1 2
IF34J1920015-01 1
IF34J1920017-01
Installation 2) Replace the license plate light bulb (1).

Install the license plate light in the reverse order of
• Tighten the license plate light mounting screws (1) to
the specified torque.
Tightening torque
License plate light mounting screw (a): 3 N·m (
0.31 kgf-m, 2.5 lbf-ft)
1
IF34J1920018-01
1, ( a)
IF34J1920016-01
• Check the wiring harness routing. )(Page 9A-5)

Front Turn Signal Light / Rear Turn Signal Light Construction

BENF34J19206013
1
[A]
1
1
2 3
[B]
1
3
3
2 2
[B]
2
5
5
[D]
4
6
4
5 [D]
4
[C]
4
6 5
IF34J1920019-02
[A]: Install the front turn signal light to the headlight housing fitting its 2. Headlight housing
groove with the hole of the headlight housing.
[B]: Insert the front turn signal light plate to the headlight housing fully until 3. Front turn signal light plate
it stops.
[C]: Install the rear turn signal light to the rear fender fitting its groove with 4. Rear turn signal light
the hole of the rear fender.
[D]: Insert the rear turn signal light plate to the rear fender fully until it stops. 5. Rear fender
1. Front turn signal light 6. Rear turn signal light plate
Front Turn Signal Light / Rear Turn Signal Light 2) Disconnect the front turn signal light lead wire
Components connectors (1).
BENF34J19206014
IF34J1920022-02
3 3) Pull out the plate (1) and front turn signal light (2).
3
1
IF34J1920020-02
1. Front turn signal lens

2. Front turn signal light bulb (12 V, 10 W)
1
3. Plate
4. Rear turn signal lens IF34J1920023-01
5. Rear turn signal light bulb (12 V, 10 W)

Installation
Front Turn Signal Light Removal and Install the front turn signal light in the reverse order of
removal.
Installation
BENF34J19206015
NOTE
The same procedures is applicable to both
the right and left lights.
Removal
1) Remove the headlight housing (1) with the turn
signal light.
1
IF34J1920021-01
Rear Turn Signal Light Removal and Installation Turn Signal Light Bulb Replacement
BENF34J19206016 BENF34J19206017
NOTE NOTE
The same procedures is applicable to both The same procedures is applicable to both
the right and left lights. right and left, and front and rear lights.
Removal 1) Remove the screw (1) and lens (2).

• Rear fender bracket: )(Page 9D-15)
2
2) Remove the clamp (1) and disconnect the rear turn
signal light lead wire connectors (2).
• Right side: Light green-Light green and Black/
White-Black/White
• Left side: Violet-Violet and Black/White-Black/ 1
White
IF34J1920026-01
2) Remove the screws (1) and replace the bulb (2) with
1 a new one.
IF34J1920024-02
3) Pull out the plate (1) and remove the rear turn signal
light (2). 1
IF34J1920027-01
3) Reinstall the removed parts.
IF34J1920025-01
Installation
Install the rear turn signal light in the reverse order of
• Check the wiring harness routing. )(Page 9A-5)
Reflex Reflector Construction

BENF34J19206018
1
1
[A] 2
(a)
2
IF34J1920028-02
[A]: Fit the projection on the rear reflex reflector into the hole in the rear fender and tighten the nut. 2. Rear fender
1. Rear reflex reflector : 1.8 Nm (0.18 kgf-m, 1.5 lbf-ft)
Turn Signal Relay Inspection Turn Signal Relay Removal and Installation
BENF34J19206019 BENF34J19206020
Refer to “Electrical Components Location” in Section 0A Removal
(Page 0A-5). 1) Turn the ignition switch OFF.
NOTE 2) Remove the left frame side cover. )(Page 9D-12)
Make sure that the battery is fully charged. 3) Disconnect the coupler (1) and remove the turn
signal relay (2).
Before removing the turn signal relay, check the
operation of the turn signal light.
If the turn signal light does not illuminate, inspect the
bulb, turn signal switch and circuit connection. 2
If the bulb, turn signal switch and circuit connection are
OK, the turn signal relay may be faulty; therefore,
replace the turn signal relay with a new one. )(Page 9B-
12)
1
IF34J1920029-01
Installation
Install the turn signal relay in the reverse order of
removal.
Turn Signal Switch Inspection 4) Inspect the lighting switch for continuity with a circuit
BENF34J19206022 tester.
1) Turn the ignition switch OFF. If any defect is found, replace the right handle switch
2) Remove the headlight assembly. )(Page 9B-3) with a new one. Refer to “Handlebar Removal and
3) Disconnect the left handle switch lead wire coupler Installation” in Section 6B (Page 6B-3).
(1).
Color
Position Gr Y/W Br
OFF
ON
IF34J1920033-02
5) After finishing the lighting switch inspection, reinstall

the removed parts.
Passing Light Switch Inspection

1 BENF34J19206023
IF34J1920030-01 1) Turn the ignition switch OFF.

4) Inspect the turn signal switch for continuity with a 2) Remove the headlight assembly. )(Page 9B-3)
circuit tester. 3) Disconnect the left handle switch lead wire coupler
If any defect is found, replace the left handle switch (1).
with a new one. Refer to “Handlebar Removal and
Installation” in Section 6B (Page 6B-3).
Color
Lg Lbl V
Position
L
PUSH
R
IF34J1920031-01
5) After finishing the turn signal switch inspection,

1
IF34J1920030-01
Lighting Switch Inspection 4) Inspect the passing light switch for continuity with a
BENF34J19206026 circuit tester.
1) Turn the ignition switch OFF. If any defect is found, replace the left handle switch
3) Disconnect the right handle switch lead wire coupler Installation” in Section 6B (Page 6B-3).
(1).
Color
Y/W Y
Position
PUSH
IF34J1920034-01
5) After finishing the passing light switch inspection,

1
IF34J1920032-01
Dimmer Switch Inspection 4) Inspect the dimmer switch for continuity with a circuit
BENF34J19206024 tester.
1) Turn the ignition switch OFF. If any defect is found, replace the left handle switch
3) Disconnect the left handle switch lead wire coupler Installation” in Section 6B (Page 6B-3).
(1).
Color
Position Gr W/R Y
HI
LO
IF34J1920035-01
5) After finishing the dimmer switch inspection, reinstall

the removed parts.
IF34J1920030-01
Specifications
BENF34J19207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
License plate light mounting screw 3 0.31 2.5 )(Page 9B-8)
Reference:
“Headlight Construction” (Page 9B-2)
“Headlight / Position Light Components” (Page 9B-3)
“Rear Combination Light / License Plate Light Construction” (Page 9B-6)
“Rear Combination Light / License Plate Light Components” (Page 9B-7)
“Reflex Reflector Construction” (Page 9B-12)
9C-1 Combination Meter / Fuel Meter / Horn:
Combination Meter / Fuel Meter / Horn

General Description
Combination Meter System Description
BENF34J19301001
This combination meter mainly consists of the LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
The LCDs indicate, Fuel level indicator (4), Clock (5), Odo / Trip A / Trip B (6), Speed (7), Engine rpm indicator (8) and
Gear position indicator (9) respectively.
LED (Light Emitting Diode)

LED is used for the illumination light and each indicator light.
LED is maintenance free. LED is less power consuming and more resistant to vibration resistance compared to the
bulb.
Engine RPM Indicator Light

When the engine speed reaches the specified value, the Engine rpm indicator light (11) lights up or blinks in the light
mode or blink mode. At this time, the Engine rpm indicator (8) in LCD comes on. And if Engine rpm indicator light is set
in the no light mode, the Engine rpm indicator in LCD does not come on.
Lighting up or blinking timing of the Engine rpm indicator light can be set in steps of 500 r/min between 4000 – 9500 r/
min. The Engine rpm indicator light is initially set at 7000 r/min.
5 2 9
13 13
11
12 10
3 7 6 8 4 1
IF34J1930001-01
1. Adjust switch 10. LED (Neutral indicator light)

2. Tachometer 12. LED (Hi beam indicator light)
3. Select switch 13. LED (Turn signal indicator light)
Combination Meter / Fuel Meter / Horn: 9C-2

Combination Meter Symptom Diagnosis
BENF34J19304001
1) Check the combination meter power and ground circuit.

Speedometer does not Speed sensor Check speed sensor. )(Page 1C-5)
operate Speedometer Check speedometer. )(Page 9C-4)
Speed sensor circuit Repair circuit. )(Page 9A-4)
Fuel level indicator does Fuel level gauge Check fuel level gauge. )(Page 9C-5)
not operate Fuel level indicator Check fuel level indicator. )(Page 9C-4)
Fuel level gauge circuit Repair circuit. )(Page 9A-4)
Horn Symptom Diagnosis

BENF34J19304002

Horn does not operate Horn switch faulty Check horn switch. )(Page 9C-5)
Wiring or ground faulty Repair circuit. )(Page 9A-4)
Horn faulty Check horn. )(Page 9C-5)
Repair Instructions
Combination Meter Construction
BENF34J19306001
[A]
3
(a)
3
IF34J1930002-02
[A]: Fit the coupler boot to the speedometer until it reaches 2. Headlight housing brace : 2 Nm (0.20 kgf-m, 1.5 lbf-ft)
bottom of the meter case.
1. Combination meter 3. Combination meter cushion
Combination Meter Components

BENF34J19306002
IF34J1930003-02
1. Upper case 2. Speedometer 3. Lower case
Combination Meter On-Vehicle Inspection 3) Push the adjust switch (2) to change the light mode,
BENF34J19306003 blink mode or no light mode. The engine rpm
Check that the LED (Engine rpm indicator light (1))
indicator light (3) comes on steady in the light mode
immediately lights up when the ignition switch is turned
and blinks in the blink mode. The engine rpm
to ON.
indicator (4) in LCD comes on when the light mode
Check that other LEDs (Neutral indicator light (2), High-
or blink mode is selected.
beam indicator light (3) and Turn signal indicator lights
Engine rpm indicator light
(4)) light up/go off by operating the gearshift lever, Engine rpm indicator (4)
(3) lighting mode
dimmer and turn signal switches.
Light mode Lighting
If abnormal condition is found, replace the combination
Blink mode Lighting
meter unit with a new one after checking its wire
No light mode No lighting
harness/coupler. )(Page 9C-4)
4) Push the select switch to fix the selected mode.
4 4
NOTE
1 While in the mode selection, if the motorcycle
reaches speed of more than 10 km/h or the
ignition switch is turned to OFF, the mode
selection is cancelled.
3 2
IF34J1930004-01
3
Engine RPM Indicator Light Preset
BENF34J19306019
Light / Blink / No Light Mode Selection
2) Press and hold the select switch (1) for more than 2
seconds to change the mode. 1 4 2
IF34J1930005-02
Preset Engine RPM Selection

1) Select the light mode or blink mode. (a)
2) Push the select switch (1) to select a preset engine
rpm mode. Push the adjust switch (2) to change the
preset engine rpm from 4000 r/min to 9500 r/min in
steps of 500 r/min.
3) Push the select switch to fix the selected setting. The
engine rpm indicator system holds the selected
settings when the ignition switch is turned OFF. The 1
system settings have remained when the ignition
switch is turned ON again.
IF34J1930008-01
Combination Meter Disassembly and

Reassembly
BENF34J19306005
Disassemble/reassemble the combination meter
referring to the combination meter components. )(Page
9C-3)
1 2 Speedometer On-Vehicle Inspection

IF34J1930006-02 BENF34J19306006
If the speedometer, odometer or tripmeter does not
Combination Meter Removal and Installation function properly, inspect the speed sensor and coupler
BENF34J19306004 connections. If the speed sensor and coupler
connections are OK, replace the combination meter unit
Removal with a new one. )(Page 9C-4)
1) Remove the meter cover. )(Page 9D-17)
2) Remove the headlight assembly.)(Page 9B-3) Fuel Level Indicator Inspection
BENF34J19306010
3) Removal the coupler boot (1) and disconnect the
combination meter coupler (2).
2) Disconnect the fuel level gauge coupler (1).
4) Remove the combination meter (3).
2 1
IF34J1930009-02
IF34J1930007-01
3) Connect a variable resistor (1) between the Br and
Installation B/W lead wires from the wire harness side.
Install the combination meter in the reverse order of
• Tighten the screw to the specified torque.
Tightening torque
Combination meter mounting screw (a): 2 N·m (
0.20 kgf-m, 1.5 lbf-ft)
1
• Install the coupler boot (1) securely.
IF34J1930010-02

5) Check the display of fuel level indicator (LCD) Horn Inspection

referring to the following table. BENF34J19306017
If any defect is found, replace the combination meter Horn Switch Inspection
with a new one. )(Page 9C-4) 1) Remove the headlight assembly. )(Page 9B-3)
2) Disconnect the left handle switch lead wire coupler
NOTE (1).
It takes approx. 40 seconds that the fuel level
indicator indicates the detected fuel level.
Resistance Fuel level indicator
178.9 – 201.1 Ω
1
Flicker Flicker
IF34J1930012-01
3) Inspect the horn switch for continuity with a circuit

138.1 – 154.9 Ω tester.
If any defect is found, replace the left handle switch
with a new one.
ON Flicker
Color
B/O B/W
Position
114.2 – 128.4 Ω
PUSH
ON ON IF34J1930013-02
4) After finishing the horn switch inspection, reinstall

the removed parts.
90.5 – 102.3 Ω
Horn Inspection
1) Disconnect the horn couplers. Refer to “Horn
ON ON
Removal and Installation” (Page 9C-6).
2) Connect a 12 V battery to terminal (1) and terminal
(2). If the sound is not heard from the horn, replace
69.2 – 78.8 Ω
the horn with a new one.
ON ON
1
2
17.7 – 22.9 Ω
ON ON
IF34J1930011-02
Fuel Level Gauge Inspection

BENF34J19306011
Refer to “Fuel Level Gauge Inspection” in Section 1G IF34J1930014-01
(Page 1G-7).
Horn Removal and Installation

BENF34J19306018
Removal 1
1) Disconnect the horn couplers (1).
2) Remove the horn (2).
IF34J1930015-02
Installation
Install the horn in the reverse order of removal.
Specifications
BENF34J19307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Combination meter mounting screw 2 0.20 1.5 )(Page 9C-4)
Reference:
“Combination Meter Construction” (Page 9C-2)
9D-1 Exterior Parts:
Exterior Parts

Seat Lock Cable Routing Diagram
BENF34J19402001
[D]
FWD
1 [B]
[B]
(a)
2
3
4
FWD
[A]
[C]
[B]
[E]
IF34J1940001-01
[A]: Install the seat lock assembly plate behind of the seat lock [E]: After connecting the seat lock cable 4. Seat lock cable guide
cable guide. end, bend one side of the lever.
[B]: Set the seat lock cable firmly. 1. Seat lock cable : 4.5 Nm (0.46 kgf-m, 3.5 lbf-ft)
[C]: Align the rib of seat lock assembly and groove of each part. 2. Seat lock assembly
[D]: Spherical cable end 3. Seat lock assembly plate
Exterior Parts: 9D-2
Repair Instructions
Frame Cover Construction
BENF34J19406002
1 7
[A]
[B] [A] [A] [A]
3
[A] [A]
2
[C]
[B]
[B] 5
8
[A]
[A]
[B]
[A]
4
9 [A]
6
IF34J1940002-01
[A]: To frame 2. Frame front cover (RH) 6. Frame lower cover (LH)
[B]: To fuel tank cover 3. Frame lower cover (RH) 7. Frame upper cover/frame center cover/frame center lower cover
[C]: To pillion rider handle 4. Frame side cover (LH) 8. Rear fender extension/rear fender
1. Frame side cover (RH) 5. Frame front cover (LH) 9. Frame front cover center bracket
6
5
IF34J1940003-01
1. Frame center cover 3. Frame cover bracket 5. Frame upper cover (LH)
2. Rear combination light 4. Frame center lower cover 6. Frame upper cover (RH)
Front Fender Construction

BENF34J19406026
1 4
(b)
[A]
4
(b) 2
3
[A] (a)
[A] 4
[A]
2 3
3 2
3
2
4
(a)
IF34J1940004-02
[A]: To front fork 3. Cushion : 8.4 Nm (0.86 kgf-m, 6.5 lbf-ft)
1. Front fender 4. Washer
2. Spacer : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
Rear Fender Construction

BENF34J19406003
IF34J1940005-01
1. Rear fender 2. Rear fender bracket 3. Rear fender extension

Fuel Tank Cover Construction

BENF34J19406004
4
[G]
1
5
[e] (b) [G]
(a) [d]
2 [b]
6
3 [c]
[G]
10
7
[f] (c)
[a] 11
(a)
8
(a)
[D] [E]
(a)
[C]
1
[F]
[A]
[B]
“a”
“b”
5
9 12
“c”
4 “d”
(a)
13
“e”
“f”
5
12 “b”
“a”
13
IF34J1940006-01
[A]: To [a] 4. Fuel tank cap cover “a”: 0 – 1.0 mm (0 – 0.04 in)
: Face the arrow mark forward.
[B]: To [b] 5. Fuel tank center cover “b”: 0 – 0.8 mm (0 – 0.03 in)
[C]: To [c] 6. Fuel tank cover center cushion “c”: –0.5 – 0 mm (–0.02 – 0 in)
[D]: To [d] 7. Fuel tank cover rubber “d”: 1.4 – 2.6 mm (0.06 – 0.10 in)
[E]: To [e] 8. Fuel tank assembly “e”: 1.2 – 2.7 mm (0.05 – 0.11 in)
[F]: To [f] 9. Fuel tank front brace “f”: 0.2 – 0.8 mm (0.01 – 0.03 in)
[G]: Stick the cushion aligning with the emboss line. 10. Fuel tank rear lower cushion : 3 Nm (0.31 kgf-m, 2.5 lbf-ft)
1. Fuel tank side cover (RH) 11. Seat front bracket : 5.5 Nm (0.56 kgf-m, 4.0 lbf-ft)
2. Fuel tank cover cushion 12. Fuel tank side cover (LH) : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Fuel tank side cushion 13. Fuel tank cap
: Stick the cushion aligning with the emboss line.
Meter Cover Construction

BENF34J19406005
(a) 1
(a)
4
IF34J1940007-02
1. Front license plate 3. Combination meter : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. Meter cover 4. Headlight housing brace
Fuel Tank Cover Protector Construction

BENF34J19406007
3 1 2
4 [B]
6 “a” “a” 5 6 4 5 [A]

“a” “a” 7, 8
[B] [B]
[A]
[B] [B]
8 7
6 6
[B]
IF34J1940008-01
[A]: Stick the protector aligning the curved surface 3. Fuel tank side cover (LH) 7. Fuel tank side cover No.2 protector (RH)
end with the protector end.
[B]: Curved surface end 4. Fuel tank center cover protector 8. Fuel tank side cover No.2 protector (LH)
1. Fuel tank center cover 5. Fuel tank side cover No.1 protector (RH) “a”: 1.0 mm (0.04 in)
2. Fuel tank side cover (RH) 6. Fuel tank side cover No.1 protector (LH)
Rear Fender Cushion Construction

BENF34J19406008
[A] [A]
1
IF34J1940009-01
[A]: Stick the cushion aligning with the emboss line. 1. Rear fender cushion
Battery Holder Protector Construction

BENF34J19406009
[A]
“a”
[A] 2
2
“a”
“a” “b”
[B]
1
“a” “c”
2
2 “a”
“d”
[C]
IF34J1940010-01
[A]: Align the edge of the protector with the edge of the battery holder. 1. Battery holder “b”: –5 – 5 mm (–0.2 – 0.2 in)
[B]: Stick the protector not to protrude beyond the hole of the battery holder. 2. Battery holder protector “c”: 15 – 25 mm (0.6 – 1.0 in)
[C]: Stick the protector parallel to the battery holder. “a”: 0 – 5 mm (0 – 0.2 in) “d”: 5 – 15 mm (0.2 – 0.6 in)
Fastener Removal and Installation Installation

BENF34J19406011
Removal 1) Let the center piece stick out toward the head so that
the claws (1) closes.
1) Depress the head of fastener center piece (1).
2) Pull out the fastener (2).
ID26J1940192-01
2) Insert the fastener into the installation hole.
NOTE
To prevent the pawl (1) from damage, insert
the fastener all the way into the installation
hole.
IF34J1940012-01
Seat Lock Cable / Seat Lock Assembly Removal

and Installation
BENF34J19406013
ID26J1940160-01 Removal
3) Push in the head of center piece until it becomes 1) Remove the seat. )(Page 9D-11)
flush with the fastener outside face. 2) Remove the right and left pillion rider handles.
)(Page 9D-13)
3) Disconnect the seat lock cable (1).
I649G1940007-02
1
Seat Removal and Installation IF34J1940013-01

BENF34J19406012
Removal 4) Remove the left frame upper cover. Refer to “Frame
Upper Cover / Frame Center Cover / Frame Center
1) Unlock the seat with the ignition key (1).
Lower Cover Removal and Installation” (Page 9D-
2) Remove the seat. 14).
5) Open the lever (1) of the seat lock assembly and
disconnect the seat lock cable (2).
6) Remove the seat lock assembly plate (3), seat lock
cable guide (4) and seat lock assembly (5).
2 4
5
IF34J1940011-01
Installation
Slide the seat hooks into the seat hook retainers and 3
1
push down firmly until the seat snaps into the locked
position. IF34J1940014-01
Installation Installation
Install the seat lock cable and seat lock assembly in the Install the frame side cover in the reverse order of
reverse order of removal. Pay attention to the following removal. Pay attention to the following point:
point: • Tighten the frame cover No. 2 screw to the specified
• After connecting the seat lock cable end, bend one torque.
side of the lever (1).
Tightening torque
Frame cover No. 2 screw (a): 2 N·m (0.20 kgf-m,
1.5 lbf-ft)
(a)
IF34J1940015-01
Frame Side Cover Removal and Installation IF34J1940018-01

BENF34J19406014
NOTE Frame Lower Cover Removal and Installation

BENF34J19406015
The same procedures are applicable to both
the right and left covers. NOTE
Removal The same procedures are applicable to both

the right and left covers.
2) Remove the frame side cover (1). Removal
2 2) Remove the frame side cover. )(Page 9D-12)
3) Remove the frame lower cover (1).
1
IF34J1940016-01
2. Hooked point
3) Remove the frame cover No. 2 (1) from the frame

IF34J1940019-02
side cover (2).
Installation
1 Install the frame lower cover in the reverse order of
removal.
IF34J1940017-02
Frame Front Cover Removal and Installation Pillion Rider Handle Removal and Installation
BENF34J19406016 BENF34J19406017
Removal
NOTE
The same procedures are applicable to both
2) Remove the right and left pillion rider handles (1).
the right and left covers.
Removal 1
1) Remove the frame front cover (1).
1
IF34J1940023-01
1 Installation
Install the pillion rider handles in the reverse order of
IF34J1940020-01 removal. Pay attention to the following point:
2) Remove the frame front inner cover (1) from the • Tighten the pillion rider handle mounting bolts to the
frame front cover (2). specified torque.
Tightening torque
Pillion Rider handle mounting bolt (a): 21 N·m (
2.1 kgf-m, 15.5 lbf-ft)
(a)
IF34J1940021-01
Installation (a )
Install the frame front cover in the reverse order of
removal. Pay attention to the following point: IF34J1940024-02
• Tighten the frame front inner cover screws to the

specified torque.
Tightening torque
Frame front inner cover screw (a): 2 N·m (0.20
kgf-m, 1.5 lbf-ft)
(a)
(a)
IF34J1940022-01
Frame Upper Cover / Frame Center Cover / 8) Remove the right and left frame upper covers (1).
Frame Center Lower Cover Removal and
Installation
BENF34J19406018
1 1
Removal
2) Remove the right and left frame side covers.
)(Page 9D-12)
3) Remove the right and left pillion rider handles.
)(Page 9D-13)
4) Disconnect the seat lock cable (1) and rear
IF34J1940029-02
combination light lead wire coupler (2).
5) Remove the bolts (3). 9) Remove the seat lock assembly from the left frame
upper cover. )(Page 9D-11)
3 10) Remove the clamp (1) and frame cover bracket (2).
1 1
3
IF34J1940025-02
2
6) Remove the screws (1).
IF34J1940030-02
11) Remove the screws (1).
1 1
1
1
IF34J1940026-01
7) Remove the frame upper cover/frame center cover/

IF34J1940031-01
frame center lower cover (1) to backward.
12) Release the hook (1) and remove the frame center
cover (2).
2
2
1
1
IF34J1940027-01
2. Hooked point
IF34J1940032-01
13) Remove the rear combination light (1) from the 2) Remove the right and left frame side covers.
frame center lower cover (2). )(Page 9D-12)
3) Remove the right and left pillion rider handles.
2 )(Page 9D-13)
4) Remove the frame upper cover/frame center cover/
frame center lower cover. )(Page 9D-14)
5) Unhook the CDI unit band (1).
6) Remove the clamp (2) and disconnect the rear turn
signal light/license plate light connectors (3).
1
3
IF34J1940033-01
1
2
Installation
Install the frame upper cover/frame center cover/frame
center lower cover in the reverse order of removal. Pay
• Insert the rib (1) of the rear combination light to the
socket (2) of the frame center lower cover securely.
IF34J1940036-02
7) Remove the rear fender extension (1).

2
1
1
IF34J1940034-01
• Tighten the rear combination light mounting screws to

the specified torque in order of “1” “2”. IF34J1940037-01
8) Remove the rear fender bracket (1) and rear fender

Tightening torque
(2).
Rear combination light mounting screw (a): 2
N·m (0.20 kgf-m, 1.5 lbf-ft)
2
(a), “1”
( a ) , “2” IF34J1940038-01
9) Remove the following parts from the rear fender.

IF34J1940035-01
• Rear turn signal lights: )(Page 9B-11)
Rear Fender Extension / Rear Fender Removal • License plate light: )(Page 9B-7)
and Installation • Rear reflex reflector: )(Page 9B-12)
BENF34J19406019
Installation
Removal
Install the rear fender in the reverse order of removal.
Fuel Tank Cover Removal and Installation Installation

BENF34J19406020 Install the fuel tank cover in the reverse order of removal.
Removal
• Tighten each of the bolt and screws to the specified
torque.
Tightening torque
Fuel tank center cover bolt (a): 3 N·m (0.31 kgf-
• Frame front covers: )(Page 9D-13) m, 2.5 lbf-ft)
2) Remove the seat front bracket (1), right and left fuel Fuel tank center cover screw (b): 5.5 N·m (0.56
tank side covers (2). kgf-m, 4.0 lbf-ft)
Fuel tank side cover bolt (c): 3 N·m (0.31 kgf-m,
3 3 2.5 lbf-ft)
Seat front bracket bolt (d): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
2
2
(b)
3
3
(a)
1
IF34J1940039-02
IF34J1940042-01
(c) (c)
3
3
IF34J1940040-02
3. Hooked point
3) Remove the fuel tank center cover (1). (c) (c)

IF34J1940043-01
(c) (c)
IF34J1940041-01 (d) (d)

IF34J1940044-01
Meter Cover Removal and Installation 4) Remove the regulator/rectifier (1).

BENF34J19406021
5) Remove the starter relay (2).
Removal
1) Remove the front license plate (1).
1
1
IF34J1940048-02
6) Remove the battery holder (1).

IF34J1940045-01
2) Remove the meter cover (1).
1
1
IF34J1940049-02
Installation
IF34J1940046-01
Install the battery holder in the reverse order of removal.
Installation
Install the meter cover in the reverse order of removal. • Tighten the battery holder mounting bolts to the
Pay attention to the following point: specified torque.
• Tighten the front license plate bolts to the specified Tightening torque
torque. Battery holder mounting bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
Tightening torque
Front license plate bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
(a)
(a)
(a)
IF34J1940050-02
• Tighten the regulator/rectifier mounting nuts to the

specified torque. Refer to “Regulator / Rectifier
IF34J1940047-02
Removal and Installation” in Section 1J (Page 1J-8).
Battery Holder Removal and Installation
BENF34J19406025
Removal
3) Remove the battery. )(Page 1J-10)
Rear Side Guard Removal and Installation • Tighten the rear side guard mounting bolts to the
BENF34J19406027 specified torque.
Removal
Remove the rear side guard (1). Tightening torque
Rear side guard mounting bolt (a): 23 N·m (2.3
kgf-m, 17.0 lbf-ft)
1
(a)
(a)
IF34J1940051-01
(a)
Installation IF34J1940052-01
Install the rear side guard in the reverse order of
Specifications
BENF34J19407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Frame cover No. 2 screw 2 0.20 1.5 )(Page 9D-12)
Frame front inner cover screw 2 0.20 1.5 )(Page 9D-13)
Pillion Rider handle mounting bolt 21 2.1 15.5 )(Page 9D-13)
Rear combination light mounting screw 2 0.20 1.5 )(Page 9D-15)
Fuel tank center cover bolt 3 0.31 2.5 )(Page 9D-16)
Fuel tank center cover screw 5.5 0.56 4.0 )(Page 9D-16)
Fuel tank side cover bolt 3 0.31 2.5 )(Page 9D-16)
Seat front bracket bolt 10 1.0 7.5 )(Page 9D-16)
Front license plate bolt 10 1.0 7.5 )(Page 9D-17)
Battery holder mounting bolt 10 1.0 7.5 )(Page 9D-17)
Rear side guard mounting bolt 23 2.3 17.0 )(Page 9D-18)
Reference:
“Seat Lock Cable Routing Diagram” (Page 9D-1)
“Front Fender Construction” (Page 9D-4)
“Fuel Tank Cover Construction” (Page 9D-6)
“Meter Cover Construction” (Page 9D-7)
9E-1 Body Structure:
Body Structure
Repair Instructions
Frame Construction
BENF34J19506001
(a)
(b)
IF34J1950001-01
1. Frame 3. Engine mounting lower bracket : 65 Nm (6.6 kgf-m, 48.0 lbf-ft)
2. Engine mounting upper plate : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
Body Structure: 9E-2
Front Footrest Construction

BENF34J19506003
3 3
2
4
“a”
6
6
4 “b”
5 5
IF34J1950002-02
1. Front footrest bar 4. Rear brake light switch spring 7. Brake pedal washer “b”: 32 – 42 mm (1.3 – 1.7 in)
2. Front footrest bracket 5. Brake pedal 8. Brake pedal cotter pin : Apply grease to sliding surface.
3. Rear brake light switch 6. Brake pedal spring “a”: 25 mm (1.0 in) : Do not reuse.
Front Footrest Removal and Installation

BENF34J19506004
Refer to “Front Footrest Construction” (Page 9E-2).
Pillion Footrest Construction

BENF34J19506005
5
4
2
3 6
(a)
IF34J1950003-02
1. Rear side guard 4. Pillion footrest spring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Pillion footrest pin 5. Pillion footrest bar : Apply grease to sliding surface.
3. Pillion footrest cotter pin 6. Pillion footrest ball : Do not reuse.
Pillion Footrest Removal and Installation

BENF34J19506006
Refer to “Pillion Footrest Construction” (Page 9E-3).
Side-stand Construction
BENF34J19506007
(a)
[A]
(b)
IF34J1950004-02
[A]: Outside : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

: 40 Nm (4.1 kgf-m, 29.5 lbf-ft) : Apply grease to sliding surface.
Body Structure: 9E-4
Side-stand Removal and Installation

BENF34J19506008
Refer to “Side-stand Construction” (Page 9E-3).
Center Stand Construction

BENF34J19506009
(b)
(a)
[A] (b)
IF34J1950005-01
[A]: To muffler : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

1. Center stand stopper : Apply grease to sliding surface.
: 40 Nm (4.1 kgf-m, 29.5 lbf-ft)
Center Stand Removal and Installation

BENF34J19506010
Refer to “Center Stand Construction” (Page 9E-4).
NOTE
Support the motorcycle securely with a jack.
Specifications
BENF34J19507001
Reference:
“Frame Construction” (Page 9E-1)
“Front Footrest Construction” (Page 9E-2)
“Pillion Footrest Construction” (Page 9E-3)
“Side-stand Construction” (Page 9E-3)
“Center Stand Construction” (Page 9E-4)

BENF34J19508001
NOTE
“Front Footrest Construction” (Page 9E-2)
“Pillion Footrest Construction” (Page 9E-3)
“Side-stand Construction” (Page 9E-3)
“Center Stand Construction” (Page 9E-4)

(TM) Suzuki Manual de Taller Suzuki Gsx150 2015 en Ingles

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IMPORTANT NOTICE

WARNING / CAUTION / NOTICE / NOTE

SUZUKI MOTORCYCLE INDIA PRIVATE LIMITED

Precautions............................................................... 00-i Driveline / Axle............................................................ 3-i

Precautions ...............................................00-1 Precautions for Electrical Circuit Service ............ 00-2

• When taking measurements at electrical connector /

• With a lock type coupler, be sure to release the lock

• Avoid applying grease or other similar material to

Clamp • Be careful not to touch the electrical terminals of the

• When disconnecting and connecting the coupler,

[A]: Correct clamping [B]: Incorrect clamping

CDI unit / Various sensors

• Removing any battery terminal of a running engine is Open circuit check

[A]: Check for loose connection

[A]: Check contact tension by inserting and removing.

4) Using continuity inspect or voltage check procedure Voltage check

[A]: Looseness of crimping 3) Also, if measured values are as listed following, a

2) Disconnect the coupler [B] and measure resistance

[B-2] Short circuit check (Wire harness to ground)

[B] [C] NOTE

Using Needle Pointed Prove

General Information ................................ 0A-1 Throttle Cable Play Inspection and

Wire Color Symbols

1. G (Base color) 3. G (Base Color)

Vehicle Side View Vehicle Identification Number

Country and Area Codes

Warning, Caution and Information Labels Location

[A]: Fuel tank cover 1. General warning label

1. Fuel level gauge 3. Front brake light switch 5. Horn

1. Turn signal relay 4. Generator 7. Regulator/rectifier 10. Main fuse

Maintenance and Lubrication

PAIR (air supply) System

Air Cleaner Element Inspection and Cleaning PAIR System Inspection

Fuel Hose Inspection Front Brake Disc

Brake Fluid Inspection Steering System Inspection

Brake Fluid Replacement Front Fork Inspection

Tire Inspection Rear Suspension Inspection

Chassis Bolts and Nuts Inspection

7 (e) 8 (f) 10 (g)

2 (b) 5 (d) 6 (d)

2. Starter cable 7. Brake lever holder : Apply grease.

Special Tools and Equipment

Dimensions and curb mass

Item Standard / Specification Limit / Note

Engine Lubrication System

Wheels and Tires

Drive Chain / Drive Train / Drive Shaft

Brake Control System and Diagnosis

Combination Meter / Others

Fasteners Information Fastener Strength Identification

JIS-TO-ISO main fasteners comparison table

1. Nut strength identification

Standard Tightening Torques

Tightening torque chart

Width across flats Thread diameter Unit

Special Tools and Equipment

Suzuki does not recommend the use of engine oils

99000F10036C000 99000F10037C000 99000F10040C000

99000F10041C000 99000F10281C000 99000F10047C000