FOREWORD GROUP INDEX

This manual contains an introductory description on

the SUZUKI AN650/A and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
GENERAL INFORMATION 1
not included.
Read the GENERAL INFORMATION section to
PERIODIC MAINTENANCE 2
3
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
ENGINE
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet- DRIVE TRAIN 4
ter so that you can assure your customers of fast
and reliable service. CVT 5
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
FI SYSTEM/ CVT SYSTEM 6
cation. If modifications have been made since
then, differences may exist between the con- FUEL SYSTEM AND THROTTLE BODY 7
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show COOLING AND LUBRICATION SYSTEM 8
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
CHASSIS 9
* This manual is written for persons who have
enough knowledge, skills and tools, including
ELECTRICAL SYSTEM 10
11
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
SERVICING INFORMATION
and tools, ask your authorized SUZUKI
motorcycle dealer to help you. EMISSION CONTROL INFORMATION 12

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.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2003

 SUPPLEMENTS
AN650K4 (’04-MODEL) 13
AN650/AK5 (’05-MODEL) 14
AN650/AK6 (’06-MODEL) 15
AN650/AK7 (’07 -MODEL) 16
AN650/AK8 (’08-MODEL) 17
AN650/AK9 (’09-MODEL) 18
WIRING DIAGRAM 19
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel

1 Brake disc
2 Coller
3 Dust seal
4 Bearing
5 Front tire
6 Front wheel
7 Spacer
8 Tire valve
A Disc bolt
B Front axle

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5 FW
D

B 65 6.5 47.0
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.
Data beside it indicates specified Use engine coolant.
torque.

Apply oil. Use engine oil unless other- Use fork oil.
wise specified. 99000-99044-10G

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKl Apply or use brake fluid.
MOLY PASTE in a ratio of 1 : 1)

Apply SUZUKI SUPER GREASE “A”.

Measure in voltage range.
99000-25030

Apply SUZUKI MOLY PASTE. Measure in current range.

99000-25140

Apply SUZUKI BOND “1207B” Measure in resistance range.

99104-31140 (USA)

Apply SUZUKI BOND “1215”. Measure in diode test range.

99000-31110 (Except USA)

Apply SUZUKI BOND “1216B”.

1216B Measure in continuity test range.
99000-31230

Apply THREAD LOCK SUPER “1303”.

Use special tool.
99000-32030

Apply THREAD LOCK “1342”.

99000-32050 Indication of service data.

Apply THREAD LOCK SUPER “1360”.

99000-32130
ABBREVIATIONS USED IN THIS
MANUAL
A E
ABDC : After Bottom Dead Center ECM : Engine Control Module
AC : Alternating Current Engine Control Unit (ECU)
ACL : Air Cleaner, Air Cleaner Box (FI Control Unit)
API : American Petroleum Institute ECT Sensor : Engine Coolant Temperature
ATDC : After Top Dead Center Sensor (ECTS), Water Temp.
ATM Pressure: Atmospheric Pressure Sensor (WTS)
Atmospheric Pressure Sensor EVAP : Evaporative Emission
(APS) EVAP Canister : Evaporative Emission
A/F : Air Fuel Mixture Canister (Canister)

B F
BBDC : Before Bottom Dead Center FI : Fuel Injection, Fuel Injector
BTDC : Before Top Dead Center FP : Fuel Pump
B+ : Battery Positive Voltage FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
C FTPC Valve : Fuel Tank Pressure Control Valve
(TPC Valve)
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit G
CLP Switch : Clutch Lever Position Switch GEN : Generator
(Clutch Switch) GND : Ground
CMP Sensor : Camshaft Position Sensor GP Switch : Gear Position Switch
(CMPS)
CO : Carbon Monoxide H
CPU : Central Processing Unit HC : Hydrocarbons
CVT Control HO2S : Heated Oxygen Sensor
Unit : Continuously Variable
Transmission Control Unit
I
(TCU)
IAC Valve : Idle Air Control Valve
IAP Sensor : Intake Air Pressure Sensor (IAPS)
D IAT Sensor : Intake Air Temperature Sensor
DC : Direct Current (IATS)
DMC : Dealer Mode Coupler IG : Ignition
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
L
DTC : Diagnostic Trouble Code
Malfunction Code LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum

N
NOx : Nitrogen Oxides

O
OHC : Over Head Camshaft
OLS : Oil Level Switch
OPS : Oil Pressure Switch

P
PCV : Positive Crankcase
Ventilation (Crankcase Breather)

R
RH : Right Hand
ROM : Read Only Memory

S
SAE : Society of Automotive Engineers

T
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DLC Dealer Mode Coupler
Diagnostic Test Mode DTM ––––
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition El ––––
Engine Control Module ECM Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Coolant Level ECL Coolant Level
Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-
perature
Water Temperature
Engine Speed RPM Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister –––– (Canister)
Exhaust Control System EXCS EXC System (EXCS)
Exhaust Control Valve EXCV EXC Valve (EXCV)
Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA)
Purge Valve Purge Valve Purge Valve (SP Valve)
F
Fan Control FC ––––
Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)
 SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
I
Idle Air Control Valve IAC Valve IAC Valve (IACV)
Idle Speed Control ISC ––––
Ignition Control IC Electronic Spark Advance (ESA)
Ignition Control Module ICM ––––
Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera-
ture
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum
Mass Air Flow MAF Air Flow
O
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL ––––
P
Programmable Read Only Memory PROM ––––
Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR)
R
Random Access Memory RAM ––––
Read Only Memory ROM ROM
S
Secondary Air Injection AIR ––––
Secondary Throttle Control Sys- STCS STC System (STCS)
tem
Secondary Throttle Valve STV ST Valve (STV)
Secondary Throttle Valve Actuator STVA STV Actuator (STVA)
T
Tank Pressure Control Valve TPC Valve TPC Valve (TPCV)
Throttle Body TB Throttle Body (TB)
Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)
Throttle Position Sensor TP Sensor TP Sensor (TPS)
Transmission Control Module TCM CVT Control Unit (TCU)
 SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
V
Voltage Regulator VR Voltage Regulator
Volume Air Flow VAF Air Flow

WIRE COLOR
B : Black G : Green P : Pink
Bl : Blue Gr : Gray R : Red
Br : Brown Lbl : Light blue V : Violet
Dg : Dark green Lg : Light green W : White
Dgr : Dark gray O : Orange Y : Yellow

B/Bl : Black with Blue tracer B/Br : Black with Brown tracer
B/G : Black with Green tracer B/O : Black with Orange tracer
B/R : Black with Red tracer B/W : Black with White tracer
B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer
Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer
Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer
Br/B : Brown with Black tracer Br/W : Brown with White tracer
G/B : Green with Black tracer G/Bl : Green with Blue tracer
G/R : Green with Red tracer G/W : Green with White tracer
G/Y : Green with Yellow tracer Gr/B : Gray with Black tracer
Gr/R : Gray with Red tracer Gr/W : Gray with White tracer
Gr/Y : Gray with Yellow tracer Lg/B : Light green with Black tracer
Lg/Y : Light green with Yellow tracer O/B : Orange with Black tracer
O/Bl : Orange with Blue tracer O/G : Orange with Green tracer
O/R : Orange with Red tracer O/W : Orange with White tracer
O/Y : Orange with Yellow tracer P/B : Pink with Black tracer
P/W : Pink with White tracer R/B : Red with Black tracer
R/Bl : Red with Blue tracer R/G : Red with Green tracer
R/W : Red with White tracer R/Y : Red with Yellow tracer
W/B : White with Black tracer W/Bl : White with Blue tracer
W/G : White with Green tracer W/R : White with Red tracer
W/Y : White with Yellow tracer Y/B : Yellow with Black tracer
Y/Bl : Yellow with Blue tracer Y/G : Yellow with Green tracer
Y/R : Yellow with Red tracer Y/W : Yellow with White tracer
 GENERAL INFORMATION 1-1

GENERAL INFORMATION

1
CONTENTS

WARNING/ CAUTION/ NOTE .............................................................1- 2

GENERAL PRECAUTIONS ................................................................1- 2
SUZUKI AN650K3 (’03-MODEL) ........................................................1- 4
SERIAL NUMBER LOCATION ...........................................................1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .............1- 4
FUEL (FOR USA AND CANADA) ...............................................1- 4
FUEL (FOR OTHER COUNTRIES) ..............................................1- 4
ENGINE OIL AND TRANSMISSION OIL (FOR USA) .................1- 5
ENGINE OIL AND TRANSMISSION OIL
(FOR OTHER COUNTRIES) ........................................................1- 5
FINAL GEAR OIL .........................................................................1- 5
BRAKE FLUID .............................................................................1- 5
FRONT FORK OIL .......................................................................1- 5
ENGINE COOLANT .....................................................................1- 5
WATER FOR MIXING ..................................................................1- 5
ANTI-FREEZE/ENGINE COOLANT ............................................1- 5
LIQUID AMOUNT OF WATER/ENGINE COOLANT ...................1- 6
BREAK-lN PROCEDURES .................................................................1- 7
CYLINDER IDENTIFICATION ............................................................1- 7
INFORMATION LABELS ....................................................................1- 8
SPECIFICATIONS ..............................................................................1- 9
COUNTRY AND AREA CODES .........................................................1-11
1-2 GENERAL INFORMATION

WARNING/ CAUTION/ NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.

!
Indicates a potential hazard that could result in death or injury.

"
Indicates a potential hazard that could result in motorcycle 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
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS 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.

GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
 GENERAL INFORMATION 1-3

"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* 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.
* When performing service to electrical parts, if the service procedures not require use of bat-
tery power, disconnect the negative cable the battery.
* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries, and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION

SUZUKI AN650K3 (’03-MODEL)

RIGHT SIDE LEFT SIDE

* Difference between photographs and actual motorcycles depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the
frame down tube. The engine serial number 2 is located on the left side of the crankcase. These numbers
are required especially for registering the machine and ordering spare parts.

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane ( R + M ) or 91 octane or higher rated by the research
2
method.
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible.

FUEL (FOR OTHER COUNTRIES)

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
 GENERAL INFORMATION 1-5

ENGINE OIL AND TRANSMISSION OIL (FOR USA)

SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG
under the API (American Pertoleum Institute) service classification. The recommended viscosity is SAE
10W-40. If an SAE 10W-40 oil is not available, select and alternative according to the following chart.

ENGINE OIL AND TRANSMISSION OIL (FOR

OTHER COUNTRIES)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification. The recommended vis-
cosity is SAE 10W-40. If an SAE 10W-40 motor oil is not avail-
able, select an alternative according to the right chart.

FINAL GEAR OIL

Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear
oil with a rating of SAE #80 if the motorcycle is operated where the ambient temperature is below 0 °C (32
°F).

BRAKE FLUID
Specification and classification: DOT 4
!
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-
facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

FRONT FORK OIL

Use fork oil #10 or an equivalent fork oil.

ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.

WATER FOR MIXING

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT
The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use
an equivalent which is compatible with an aluminum radiator.
1-6 GENERAL INFORMATION

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): 1 300 ml (1.4/1.1 US/Imp qt)
For engine coolant mixture information, refer to cooling system section, page 8-3.
"
Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce
its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting perfor-
mance is greatly reduced. Be sure to mix it above 50% even though the atmospheric tempera-
ture does not go down to the freezing point.
 GENERAL INFORMATION 1-7

BREAK-lN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Initial 800 km ( 500 miles): Below 4 000 r/min
Up to 1 600 km (1 000 miles): Below 6 000 r/min
Over 1 600 km (1 000 miles): Below 8 500 r/min
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt-
tle operation. However, do not exceed 8 500 r/min at any time.

CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No.1 and No.2 cylinder, as counted from left to right (as
viewed by the rider on the seat).

#2

#1
1-8 GENERAL INFORMATION

INFORMATION LABELS
1 Warning safety label
2 Engine starting label
3 Screen warning label
4 Tire pressure label
5 Fuel information label
6 Front box loading capacity label
7 Trunk box loading capacity label
8 ID label
9 Noise label
0 Manual notice label
A Safety plate
B Information label
C Oil information label
D EVAP canister hose routing label

Trunk box

Forward

Front panel
A

VIEW A

Stick the label behind

the fuel lid.
 GENERAL INFORMATION 1-9

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................... 2 260 mm (89.0 in)
Overall width ....................................................... 810 mm (31.9 in)
Overall height ...................................................... 1 430 mm (56.3 in)
Wheelbase .......................................................... 1 595 mm (62.8 in)
Ground clearance................................................ 125 mm ( 4.9 in)
Seat height .......................................................... 750 mm (29.5 in)
Dry mass ............................................................. 238 kg (394 lbs)

ENGINE
Type .................................................................... Four-stroke, Liquid-cooled, DOHC
Number of cylinders ............................................ 2
Bore..................................................................... 75.5 mm (2.972 in)
Stroke .................................................................. 71.3 mm (2.807 in)
Piston displacement ............................................ 638 cm³ (38.9 cu. in)
Compression ratio ............................................... 11.2 : 1
Fuel system ......................................................... Fuel injection system
Air cleaner ........................................................... Non-woven fabric element
Starter system ..................................................... Electric starter
Lubrication system .............................................. Wet sump

DRIVE TRAIN
Clutch .................................................................. Wet multi-plate automatic, centrifugal type
Gearshift pattern ................................................. Automatic & Manual shift
Automatic transmission ratio ............................... Variable change (1.800 – 0.465)
Final reduction ratio............................................. 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system ....................................................... Gear drive

CHASSIS
Front suspension................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................. Swingarm type, coil spring, oil damped
Steering angle ..................................................... 41° (right & left)
Caster.................................................................. 26°
Trail ..................................................................... 102 mm (4.0 in)
Turning radius ..................................................... 2.7 m (8.9 ft)
Front brake .......................................................... Disc brake, twin
Rear brake .......................................................... Disc brake
Front tire size ...................................................... 120/70 R15M/C 56H, tubeless
Rear tire size ....................................................... 160/60 R14M/C 65H, tubeless
Front fork stroke .................................................. 105 mm (4.1 in)
Rear wheel travel ................................................ 100 mm (3.9 in)
1-10 GENERAL INFORMATION

ELECTRICAL
lgnition type..........................................................Electronic ignition (ECM, Transistorized)
lgnition timing .......................................................10° B. T. D. C at 1 200 r/min
Spark plug............................................................NGK: CR8E or DENSO: U24ESR-N
Battery..................................................................12 V 43.2 kC (12 Ah)/10 HR
Generator.............................................................Three-phase A.C. Generator
Main fuse .............................................................40 A
CVT fuse ..............................................................40 A
Fuse .....................................................................15/15/15/15/10/10/10 A
Headlight..............................................................12 V 60/55 W + 55 W (H4 + H7) ....... E-02, 19
12 V 60/55W × 2 (H4) .......E-03, 24, 28, 33
Position light.........................................................12 V 5 W × 2 ........ E-02, 19
Turn signal light....................................................12 V 21 W
License light .........................................................12 V 5 W
Brake light/Taillight...............................................12 V 21/5 W × 2
Speedometer light................................................12 V 1.4 W × 2
Power mode indicator light...................................12 V 1.4 W
Drive indicator light ..............................................12 V 1.4 W
High beam indicator light .....................................12 V 1.4 W
Turn signal indicator light .....................................12 V 1.4 W
Brake-lock indicator light......................................12 V 1.4 W
Fuel injector indicator light ...................................12 V 1.4 W
Engine coolant temperature indicator light...........12 V 1.4 W
Oil pressure indicator light ...................................12 V 1.4 W
Gear position indicator light .................................12 V 1.4 W × 5

CAPACITIES
Fuel tank, including reserve .................................15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ..........................................2 600 ml (2.7/2.3 US/Imp qt)
with filter change ...............................2 900 ml (3.1/2.6 US/Imp qt)
overhaul.............................................3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ................................ 360 ml (12.2/12.7 US/Imp oz)
overhaul ................................... 400 ml (13.5/14.1 US/Imp oz)
Final gear oil, oil change ...................................... 300 ml (10.1/10.6 US/Imp oz)
overhaul......................................... 430 ml (14.5/15.1 US/Imp oz)
Engine coolant, including reserve ........................1 300 ml (1.4/1.1 US/Imp qt)
Front fork oil (each leg) ........................................ 482 ml (16.3/17.0 US/Imp oz)

These specifications are subject to change without notice.

 GENERAL INFORMATION 1-11

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA

E-02 U. K.
E-03 U. S. A. (Except for California)
E-19 EU
E-24 Australia
E-28 Canada
E-33 California (U. S. A.)
White Page
 PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

CONTENTS
PERIODIC MAINTENANCE SCHEDULE ............................................2- 2
2
PERIODIC MAINTENANCE CHART ...........................................2- 2
LUBRICATION POINTS ...............................................................2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ...............................2- 4
AIR CLEANER .............................................................................2- 4
SPARK PLUG ..............................................................................2- 6
TAPPET CLEARANCE ................................................................2- 7
FUEL HOSE .................................................................................2-13
ENGINE OIL AND OIL FILTER ....................................................2-13
TRANSMISSION OIL ...................................................................2-15
FINAL GEAR OIL .........................................................................2-15
CVT FILTER .................................................................................2-16
ENGINE IDLE SPEED ..................................................................2-18
THROTTLE CABLE PLAY ...........................................................2-18
THROTTLE VALVE SYNCHRONIZATION ..................................2-19
PAIR (AIR SUPPLY) SYSTEM ....................................................2-19
EVAPORATIVE EMISSION CONTROL SYSTEM .......................2-19
COOLING SYSTEM .....................................................................2-20
BRAKE .........................................................................................2-22
TIRE .............................................................................................2-25
STEERING ...................................................................................2-26
FRONT FORK ..............................................................................2-26
REAR SUSPENSION ...................................................................2-27
EXHAUST PIPE BOLT AND MUFFLER MOUNTING BOLT ......2-27
CHASSIS BOLT AND NUT ..........................................................2-28
COMPRESSION PRESSURE CHECK .................................................2-30
COMPRESSION TEST PROCEDURE .........................................2-30
OIL PRESSURE CHECK ......................................................................2-31
OIL PRESSURE TEST PROCEDURE .........................................2-31
AUTOMATIC CLUTCH INSPECTION ..................................................2-32
1. INITIAL ENGAGEMENT INSPECTION ...................................2-32
2. CLUTCH “LOCK-UP” INSPECTION .......................................2-32
BRAKE-LOCK INSPECTION ...............................................................2-33
2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome-
ters, miles and time for your convenience.
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
Item months 1 6 12 18 24
Air cleaner — I I R I
Exhaust pipe bolts and muffler bolts T — T — T
Tappet clearance — — — — I
Spark plugs — I R I R
— I I I I
Fuel hose
Replace every 4 years.
Engine oil R R R R R
Engine oil filter R — — R —
Transmission oil R I R I R
Final gear oil R — R — R
CVT filter — — I — I
Idle speed I I I I I
Throttle cable play I I I I I
I
Throttle valve synchronization — I — I
E-33 only
Evaporative emission control system — — I — I
E-33 (California) model only Replace vapor hose every 4 years.
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Brakes I I I I I
— I I I I
Brake hose
Replace every 4 years.
— I I I I
Brake fluid
Replace every 2 years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
NOTE:
I=Inspect and clean, adjust, replace or lubricate as necessary;
R=Replace; T=Tighten
 PERIODIC MAINTENANCE 2-3

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

v Rear brake lever holder

v Side stand pivot and spring hook

v Center stand pivot and spring hook

v Front brake lever holder

o Throttle cable

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.
2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP

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

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

• Open the front box 1.

• Remove the air cleaner box lid 2.
• Remove the air cleaner element lid 3.

• Remove the air cleaner element 4.

• Inspect the air cleaner element and O-ring for damage. If any
defects are found, the air cleaner element and O-ring must be
replaced.
 PERIODIC MAINTENANCE 2-5

• Carefully use air hose to blow the dust from the cleaner ele-
ment.
!
Always use air pressure on the throttle body side of
the air cleaner element. If air pressure is used on the
other side, dirt will be forced into the pores of the air
cleaner element thus restricting air flow through the
air cleaner element.

• Install the O-ring 5 properly.

• Reinstall the cleaned or new air cleaner element in the
reverse order of removal.
!
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component!

NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug.
2-6 PERIODIC MAINTENANCE

SPARK PLUG
Inspect every 6 000 km (4 000 miles, 6 months) and
replace every 12 000 km (7 500 miles, 12 months).

SPARK PLUG REMOVAL

• Remove the lower leg shield. ("9-10)
• Remove the bolt.
• Move the radiator 1 forward.
NOTE:
Be careful not to damage the radiator fins.
#
The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.

• Remove the ignition coil/plug caps 2.

• Remove the spark plugs with the spark plug wrench.

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

Standard Cold type Hot type

NGK CR8E CR9E CR7E
DENSO U24ESR-N U27ESR-N U22ESR-N
 PERIODIC MAINTENANCE 2-7

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

SPARK PLUG GAP

• Measure the plug gap with a thickness gauge. If out of specifi-
cation, adjust it to the following gap.
$ 09900-20803: Thickness gauge
% Spark plug gap
Standard: 0.7 – 0.8 mm (0.028 – 0.031 in)

ELECTRODES CONDITION
• Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.
!
Confirm the thread size and reach when replacing the 0.7 – 0.8 mm
(0.028 – 0.031 in)
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine dam-
age may result.

SPARK PLUG INSTALLATION

!
Before tightening the spark plug to the specified
torque, carefully turn the spark plug by finger into the
threads of the cylinder head to prevent damage the
aluminum threads.

• Install the spark plugs to the cylinder heads by finger tight,

and then tighten them to the specified torque.
& Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

TAPPET CLEARANCE
Inspect every 24 000 km (14 500 miles, 24 months).

• Remove the front box. ("9-18)

• Remove the foot board. ("9-18)
• Remove the radiator. ("8-6)
• Remove the spark plugs. ("2-6)
• Remove the cylinder head cover 1.
2-8 PERIODIC MAINTENANCE

The tappet clearance specification is different for intake and

exhaust valves. Tappet clearance must be checked and
adjusted, 1) at the time of periodic inspection, 2) when the valve
mechanism is serviced, and 3) when the camshafts are removed
for servicing.
% Tappet clearance (when cold):
Standard: IN. : 0.10 – 0.20 mm (0.004 – 0.008 in)
EX.: 0.20 – 0.30 mm (0.008 – 0.012 in)
NOTE:
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, be sure to use a
wrench, and rotate in the normal running direction. All spark
plugs should be removed.

• Remove the valve timing inspection cap 2.

• Turn the crankshaft to bring the “Top” line on the starter clutch
to the index mark and also to align the notches A on the both
ends of each camshaft with “1” mark B on the exhaust
sprocket to the positions as shown.
 PERIODIC MAINTENANCE 2-9

• In this condition, read the tappet clearance at the valves (In

and Ex of No.2).
• If the clearance is out of specification, adjust the clearance as
shown below.
$ 09900-20803: Thickness gauge

• Turn the crankshaft 360 degrees (one rotation) to bring the

“TOP” line on the starter clutch to the index mark of valve tim-
ing inspection hole and also to bring notches A to the position
as shown.
• Read the clearance at the remaining valves (In and Ex of
No.1) and adjust the clearance if necessary as shown below.

TAPPET CLEARANCE ADJUSTMENT

The clearance is adjusted by replacing the existing tappet shim
by a thicker or thinner shim.
• Remove the intake or exhaust camshafts. ("3-12)
• Remove the tappet 1 and shim 2 by fingers or magnetic
hand.
• Check the figures printed on the shim. These figures indicate
the thickness of the shim, as illustrated.
• Select a replacement shim that will provide a clearance within
the specified range. For the purpose of this adjustment, a total
of 25 sizes of tappet shim are available ranging from 1.20 to
2.20 mm in steps of 0.05 mm. Fit the selected shim to the
valve stem end, with numbers toward tappet. Be sure to
check shim size with micrometer to ensure its size.
Refer to the tappet shim selection table (Pages 2-11 and
2-12) for details.
2-10 PERIODIC MAINTENANCE

NOTE:
* Be sure to apply engine oil to tappet shim top and bottom
faces.
* When seating the tappet shim, be sure to face figure printed
surface to the tappet. 170
! 1.70 mm

Reinstall the camshafts as the specified manner.

("3-72)

• After replacing the tappet shim and camshafts, rotate the

engine so that the tappet is depressed fully. This will squeeze
out oil trapped between the shim and the tappet that could
cause an incorrect measurement, then check the clearance
again to confirm that it is within the specified range.
• After finishing the valve clearance adjustment, reinstall the fol-
lowing items.

Page
* Cylinder head cover .........................................3-74
* Spark plug and plug cap ..................................2-6
* Valve timing inspection plug ............................2-8
 TAPPET SHIM SELECTION TABLE [INTAKE]
TAPPET SHIM NO. (12892-05C00-XXX)

(INTAKE SIDE)
TAPPET SHIM SET (12800-05820)

SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
NO.
MEASURED
TAPPET PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

0.00-0.04 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.10-0.20 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.21-0.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.26-0.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.31-0.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.36-0.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.61-0.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.76-0.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 HOW TO USE THIS CHART:
0.81-0.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 I. Measure tappet clearance. “ENGINE IS COLD”
0.86-0.90 1.95 2.00 2.05 2.10 2.15 2.20 II. Measure present shim size.
0.91-0.95 2.00 2.05 2.10 2.15 2.20 III. Match clearance in vertical column with present shim size
0.96-1.00 2.05 2.10 2.15 2.20 in horizontal column.
1.01-1.05 2.10 2.15 2.20
1.06-1.10 2.15 2.20
EXAMPLE
Tappet clearance is 0.23 mm
1.11-1.15 2.20
Present shim size 1.70 mm
Shim size to be used 1.80 mm
PERIODIC MAINTENANCE
2-11
 2-12
TAPPET SHIM SELECTION TABLE [EXHAUST]
TAPPET SHIM NO. (12892-05C00-XXX)

TAPPET SHIM SET (12800-05820)

(EXHAUST SIDE)
SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
PERIODIC MAINTENANCE
NO.
MEASURED
TAPPET PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
0.10-0.14 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.15-0.19 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.20-0.30 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.31-0.35 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.36-0.40 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.61-0.65 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.76-0.80 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.81-0.85 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.86-0.90 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 HOW TO USE THIS CHART:
0.91-0.95 1.90 1.95 2.00 2.05 2.10 2.15 2.20 I. Measure tappet clearance. “ENGINE IS COLD”
0.96-1.00 1.95 2.00 2.05 2.10 2.15 2.20 II. Measure present shim size.
1.01-1.05 2.00 2.05 2.10 2.15 2.20
III. Match clearance in vertical column with present shim size
in horizontal column.
1.06-1.10 2.05 2.10 2.15 2.20
1.11-1.15 2.10 2.15 2.20
EXAMPLE
1.16-1.20 2.15 2.20
Tappet clearance is 0.33 mm
1.21-1.25 2.20 Present shim size 1.70 mm
Shim size to be used 1.80 mm
 PERIODIC MAINTENANCE 2-13

FUEL HOSE
Inspect every 6 000 km (4 000 miles, 6 months).
Replace every 4 years.

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

ENGINE OIL AND OIL FILTER

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

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

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

replacement at the above intervals, should be done together
with the engine oil change.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright with the center stand.
• Remove the maintenance lid. ("9-13)
• Place an oil pan below the engine, and drain oil by removing
the drain plug 1 and filler cap 2.

• Tighten the drain plug 1 to the specified torque, and pour

fresh oil through the oil filler. The engine will hold about 2.6 L
(2.7/2.3 US/Imp qt) of oil. Use an API classification of SF or
SG oil with SAE 10W-40 viscosity.
& Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
2-14 PERIODIC MAINTENANCE

• Start the engine and allow it to run for three minutes at idling
speed.
• Turn off the engine and wait about three minutes, then check
the oil level through the inspection window A. If the level is
below mark “L”, add oil to “F” level. If the level is above mark
“F”, drain oil to “F” level.

OIL FILTER REPLACEMENT

• Drain engine oil in the same manner of engine oil replacement
procedure.
• Remove the oil filter 1 by using the oil filter wrench. (Special
tool)
• Apply engine oil lightly to the gasket of the new filter before
installation.
• Install the new filter turning it by hand until you feel that the fil-
ter gasket contacts the mounting surface. Then tighten it 2
turns using the oil filter wrench.
$ 09915-40610: Oil filter wrench
NOTE:
To properly tighten the filter, use the special tool. Never tighten
the filter by hand.
• Pour fresh engine oil and check the oil level in the same man-
ner of engine oil replacement procedure.
% Engine oil capacity After contcting the gasket,
Oil change: 2.6 L (2.7/2.3 US/Imp qt) tighten 2 turns.
Filter change: 2.9 L (3.1/2.6 US/Imp qt)
Overhaul engine: 3.4 L (3.6/3.0 US/Imp qt)
!
ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL
FILTER. Other manufacturer’s oil filters may differ in
thread specifications (thread diameter and pitch), fil-
tering performance and durability which may lead to
engine damage or oil leaks. Also, do not use a genuine
Suzuki automobile oil filter on this motorcycle.
 PERIODIC MAINTENANCE 2-15

TRANSMISSION OIL
Replace initially at 1 000 km (600 miles, 1 month) and
every 12 000 km (7 500 miles, 12 months) thereafter.
Inspect every 6 000 km (4 000 miles, 6 months) there-
after.

TRANSMISSION OIL REPLACEMENT

• Keep the motorcycle upright with the center stand.
• Place an oil pan below the mission case.
• Remove the oil drain plug 1 and filler plug 2.

• Tighten the drain plug 1 to the specified torque, and pour

fresh oil through the oil filler.
• Remove the oil level plug 3 and inspect the oil level. If the
level is below the level hole, add oil until oil flows from the
level hole.
! Oil viscosity and classification
: SAE 10W-40 with API SF or SG
• Tighten the oil level plug 3 and filler plug 2 to the specified
torque.

" Transmission oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
Transmission oil filler plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Transmission oil level plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
# NECESSARY AMOUNT OF TRANSMISSION OIL
Oil change: 360 ml (12.2/12.7 US/lmp oz)
Overhaul: 400 ml (13.5/14.1 US/lmp oz)

FINAL GEAR OIL

Replace initially at 1 000 km (600 miles, 1 month) and
every 12 000 km (7 500 miles, 12 months) thereafter.

FINAL GEAR OIL REPLACEMENT

• Keep the motorcycle upright with the center stand.
• Remove the final gear case cover 1.
• Place an oil pan below the final gear case.
2-16 PERIODIC MAINTENANCE

• Remove the oil drain plug 2 and oil level plug 3.

• Tighten the oil drain plug 2 to the specified torque, and pour
fresh oil through the oil level hole until the oil over flows from
the oil level hole.
& Drain plug: 33 N·m (3.3 kgf-m, 24.0 lb-ft)
• Tighten the oil level plug 3 to the specified torque.
& Oil level plug: 33 N·m (3.3 kgf-m, 24.0 lb-ft)

' Oil viscosity and classification

: Hypoid gear oil SAE #90 API grade GL-5
% NECESSARY AMOUNT OF FINAL GEAR OIL
Oil change: 300 ml (10.1/10.6 US/lmp oz)
Overhaul: 430 ml (14.5/15.1 US/lmp oz)

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

• Remove the leg side cover. ("9-12)

• Remove the CVT filter lid 1.

✩: hooked part

• Remove the CVT filter cover 2.

• Remove the CVT filter 3.

 PERIODIC MAINTENANCE 2-17

• Inspect the CVT filter for damage and dirt. If any defects are
found, the CVT filter must be replaced.
2-18 PERIODIC MAINTENANCE

ENGINE IDLE SPEED

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

NOTE:
Make this adjustment when the engine is hot.
• Remove the maintenance lid. ("9-13)
• Start the engine and set its idle speed to the specified range
by turning the throttle stop screw A.
% Engine idle speed: 1 200 ± 100 r/min

THROTTLE CABLE PLAY

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

Adjust the throttle cable play A with the following three steps.
MINOR ADJUSTMENT
First step:
• Loosen the locknut 3 of the throttle returning cable 1 and
turn in the adjuster 4 fully into the threads.
Second step:
• Loosen the locknut 5 of the throttle pulling cable 2.
• Turn the adjuster 6 in or out until the throttle cable play A
should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.
• Tighten the locknut 5 while holding the adjuster 6.
Third step:
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster 4 of the throttle returning cable 1
to feel resistance.
• Tighten the locknut 3 while holding the adjuster 4.
% Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
#
After the adjustment is completed, check that handle-
bar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and auto-
matically.

NOTE:
Major adjustment can be made by the throttle body side
adjuster.
 PERIODIC MAINTENANCE 2-19

MAJOR ADJUSTMENT
• Remove the front box. ("9-18)
• Loosen the locknut 1 of the throttle returning cable 2.
• Turn the returning cable adjuster 3 to obtain proper cable
play.
• Loosen the locknut 4 of the throttle pulling cable 5.
• Turn the pulling cable adjuster 6 in or out until the throttle
cable play A should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the
throttle grip.
• Tighten the locknut 4 securely while holding the adjuster 6.
%(Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in)
• While holding the throttle grip at the fully closed position,
slowly turn the returning cable adjuster 3 to obtain a slack B
of 1.0 mm (0.04 in).
• Tighten the locknut 1 securely.
#
After the adjustment is completed, check that handle-
bar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and auto-
matically.

THROTTLE VALVE SYNCHRONIZATION

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

Inspect the throttle valve synchronization periodically.

("7-24)

PAIR (AIR SUPPLY) SYSTEM

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

Inspect the PAIR (air supply) system periodically.

("12-6)

EVAPORATIVE EMISSION CONTROL SYSTEM

Inspect every 12 000 km (7 500 miles, 12 months).
Replace vapor hose every 4 years.

Inspect the EVAP system periodically.

("12-9)
2-20 PERIODIC MAINTENANCE

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

ENGINE COOLANT LEVEL CHECK

• Keep the motorcycle upright with the center stand.
• Check the engine coolant level by observing the full and lower
lines on the engine coolant reserve tank.
A Full line B Lower line
• If the level is below the lower line, add engine coolant to the
full line from the engine coolant reserve tank filler. To remove
the filler cap, remove the maintenance lid. ("9-13)

ENGINE COOLANT CHANGE

• Remove the lower leg shield. ("9-10)
• Remove the radiator cap 1.
• Drain engine coolant by removing the drain bolt A.
#
* Do not open the radiator cap when the engine is hot,
as you may be injured by escaping hot liquid or
vapor.
* Engine coolant may be harmful if swallowed or if it
comes in contact with skin or eyes. If engine coolant
gets into the eyes or in contact with the skin, flush
thoroughly with plenty of water. If swallowed, induce
vomiting and call physician immediately!
 PERIODIC MAINTENANCE 2-21

• Remove the front box. ("9-18)

• Remove the foot board. ("9-18)
• Drain engine coolant by disconnecting the radiator hose 2.
• Flush the radiator with fresh water if necessary.
• Tighten the water drain bolt A to the specified torque.
& Water drain bolt A: 6 N·m (0.6 kgf-m, 4.3 lb-ft)
• Pour the specified engine coolant up to the radiator inlet.
• Bleed the air from the engine coolant circuit as following pro-
cedure.
NOTE:
For engine coolant information, refer to page 8-3.

AIR BLEEDING THE ENGINE COOLANT CIRCUIT

• Add engine coolant up to the radiator inlet.
• Support the motorcycle upright with the center stand.
• Slowly swing the motorcycle, right and left, to bleed the air
trapped.
• Add engine coolant up to the radiator inlet.

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

• Close the radiator cap 1 securely.

• After warming up and cooling down the engine several times,
add the engine coolant up to the full level of the reserve tank.
!
Repeat the above procedure several times and make
sure that the radiator is filled with engine coolant up to
the reserve tank full level.

) Engine coolant capacity

Reverse tank side: 250 ml (0.3/0.2 US/lmp qt)
Engine side: 1 050 ml (1.1/0.9 US/lmp qt)
2-22 PERIODIC MAINTENANCE

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

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

(BRAKE HOSE AND BRAKE FLUID)

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

BRAKE FLUID LEVEL CHECK

• Keep the motorcycle upright and place the handlebars
straight.
• Check the brake fluid level by observing the lower limit lines
on the front and rear brake fluid reservoirs.
• When the level is below the lower limit line, replenish with
brake fluid that meets the following specification.
* Specification and Classification: DOT 4
 PERIODIC MAINTENANCE 2-23

#
The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or petro-
leum-based. Do not use any brake fluid taken from
old, used or unsealed containers. Never re-use brake
fluid left over from the last servicing or stored for a
long period.

#
Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check the
brake hoses and hose joints for cracks and fluid leak-
age before riding.

BRAKE PADS
The extent of brake pad wear can be checked by observing the
grooved limit A on the pad. When the wear exceeds the
grooved limit, replace the pads with new ones. ("9-64, 9-74)

!
Replace the brake pad as a set, otherwise braking per-
formance will be adversely affected.
2-24 PERIODIC MAINTENANCE

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master cylin-
der and thus interferes with the full braking performance of the
brake caliper. The presence of air is indicated by “sponginess”
of the brake lever and also by lack of braking force. Considering
the danger to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake and restor-
ing the brake system to the normal condition, the brake fluid cir-
cuit be purged of air in the following manner:
• Fill up the master cylinder reservoir to the “UPPER” line.
Place the reservoir cap to prevent entry of dirt.
• Attach a pipe to the air bleeder valve, and insert the free end
of the pipe into a receptacle.
& Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
• Front brake: Bleed the air from the air bleeder valve.
• Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this will remove
the tension of the brake lever causing it to touch the handle-
bar grip. Then, close the valve, pump and squeeze the lever,
and open the valve. Repeat this process until the fluid flowing
into the receptacle no longer contains air bubbles.
NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is always some
fluid visible in the reservoir.
• Close the bleeder valve, and disconnect the pipe. Fill the res-
ervoir with brake fluid to the “UPPER” line.
!
Handle brake fluid with care: the fluid reacts chemi-
cally with paint, plastics, rubber materials and so on.
 PERIODIC MAINTENANCE 2-25

• The procedure to bleed the rear brake is indentical to that of

the front.

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

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
situation. It is highly recommended to replace a tire when the
remaining depth of tire tread reaches the following specification.
$ 09900-20805: Tire depth gauge
% Tire tread depth
Service Limit (FRONT): 1.6 mm (0.06 in)
(REAR): 2.0 mm (0.08 in)
2-26 PERIODIC MAINTENANCE

TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased. Therefore, maintain
the correct tire pressure for good roadability or shorter tire life
will result. Cold inflation tire pressure is as follows.

COLD INFLATION SOLO RINDING DUAL RIDING

TIRE PRESSURE kPa kgf/cm² psi kPa kgf/cm² psi
FRONT 225 2.25 33 225 2.25 33
REAR 250 2.50 36 280 2.80 41
!
The standard tire fitted on this motorcycle is 120/70
R15M/C 56H for front and 160/60 R14M/C 65H for rear.
The use of tires other than those specified may cause
instability. It is highly recommended to use a SUZUKI
Genuine Tire.

TIRE TYPE
BRIDGESTONE (Front: TH01F Rear: TH01R)

STEERING
Inspect initially at 1 000 km (600 miles, 1 month) and
every 12 000 km (7 500 miles, 12 months) thereafter.

Steering should be adjusted properly for smooth turning of han-

dlebars and safe running. Overtight steering prevents smooth
turning of the handlebars and too loose steering will cause poor
stability. Check that there is no play in the steering stem while
grasping the lower fork tubes by supporting the machine so that
the front wheel is off the ground, with the wheel straight ahead,
and pull forward. If play is found, perform steering bearing
adjustment as described in page 9-46 of this manual.

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

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

the outer surface of the inner tubes. Replace any defective
parts, if necessary. ("9-32)
 PERIODIC MAINTENANCE 2-27

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

Inspect the rear shock absorbers for oil leakage and mounting
rubbers for wear and damage. Replace any defective parts, if
necessary. ("9-57)

EXHAUST PIPE BOLT AND MUFFLER

MOUNTING BOLT
Tighten initially at 1 000 km (600 miles, 1 month) and
every 12 000 km (7 500 miles, 12 months) thereafter.

• Tighten the exhaust pipe bolts, muffler mounting bolts and nut
to the specified torque.
& Muffler mounting bolt /nut A: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Exhaust pipe bolt B: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
2-28 PERIODIC MAINTENANCE

CHASSIS BOLT AND NUT

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

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-28 for the loca-
tions of the following nuts and bolts on the motorcycle.)

ITEM N·m kgf-m lb-ft

1 Steering stem head nut 65 6.5 47.0
2 Front fork upper clamp bolt 23 2.3 16.5
3 Front fork lower clamp bolt 23 2.3 16.5
4 Front axle 65 6.5 47.0
5 Front axle pinch bolt 23 2.3 16.5
6 Handlebar clamp bolt 23 2.3 16.5
7 Front brake master cylinder mounting bolt 10 1.0 7.0
8 Front brake caliper mounting bolt 26 2.6 19.0
9 Brake hose union bolt 23 2.3 16.5
0 Air bleeder valve 7.5 0.75 5.5
A Brake disc bolt (Front & Rear) 23 2.3 16.5
B Rear brake caliper mounting bolt 26 2.6 19.0
C Rear brake master cylinder mounting bolt 10 1.0 7.0
D Front footrest bracket mounting bolt (M8) 26 2.6 19.0
(M6) 11 1.1 8.0
E Swingarm pivot nut 100 10.0 72.5
F Rear shock absorber mounting nut
29 2.9 21.0
(Upper & Lower)
G Rear axle nut 100 10.0 72.5
PERIODIC MAINTENANCE 2-29
2-30 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

The compression of a cylinder is a good indicator of its internal condition.
The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte-
nance records kept at your dealership should include compression readings for each maintenance service.
COMPRESSION PRESSURE SPECIFICATION
Standard Limit Difference
1 500 – 1 900 kPa 1 200 kPa 200 kPa
15 – 19 kgf/cm2 12 kgf/cm2 2 kgf/cm2
(
213 – 270 psi ) ( 171 psi ) ( 28 psi )
Low compression pressure can indicate any of the following conditions:
* Excessively worn cylinder walls
* Worn-down piston or piston rings
* Piston rings stuck in grooves
* Poor seating of valves
* Ruptured or otherwise defective cylinder head gasket

Overhaul the engine in the following cases:

* Compression pressure in one of the cylinders is less than 1 200 kPa (12 kgf/cm², 171 psi).
* Difference in compression pressure between two cylinders is more than 200 kPa (2 kgf/cm², 28 psi).
* All compression pressure are below 1 500 kPa (15 kgf/cm², 213 psi) even when they measure more than
1 200 kPa (12 kgf/cm², 171 psi).
COMPRESSION TEST PROCEDURE
NOTE:
* Before testing the engine for compression pressure, make
sure that the cylinder head bolts are tightened to the specified
torque values and valves are properly adjusted.
* Have the engine warmed up by idling before testing.
* Be sure that the battery used is in fully-charged condition.
Remove the parts concerned and test the compression pressure
in the following manner.
• Support the motorcycle with the center stand.
• Move the radiator. ("2-6)
• Remove all the spark plugs. ("2-6)
• Fit the compression gauge in one of the plug holes, while tak-
ing care of the tight connection.
• Keep the throttle grip in full-open position.
• While cranking the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of
that cylinder.
• Repeat this procedure with an other cylinder.
$ 09915-64512: Compression gauge
09915-63311: Compression gauge attachment
09915-74521: Gauge hose
 PERIODIC MAINTENANCE 2-31

OIL PRESSURE CHECK

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

Above 350 kPa (3.5 kgf/cm², 50 psi)

at 3 000 r/min., Oil temp. at 60°C (140°F)
Below 550 kPa (5.5 kgf/cm², 78 psi)

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

LOW OIL PRESSURE

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

HIGH OIL PRESSURE

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

OIL PRESSURE TEST PROCEDURE

Start the engine and check if the oil pressure indicator light is
turned on. If it keeps on lighting, check the oil pressure indicator
light circuit. If it is in good condition, check the oil pressure in the
following manner.
• Remove the main oil gallery plug 1.
• Install the oil pressure gauge with attachment in the position
shown in the figure.

• Warm up the engine as follows:

Summer 10 min. at 2 000 r/min.
Winter 20 min. at 2 000 r/min.
• After warming up, increase the engine speed to 3 000 r/min.
(with the engine tachometer), and read the oil pressure
gauge.
$ 09915-74521: Gauge hose
09915-74532: Oil pressure gauge attachment
09915-74511: Oil pressure gauge
& Oil gallery plug [M8]: 10 N·m (1.0 kgf-m, 7.3 lb-ft)
2-32 PERIODIC MAINTENANCE

AUTOMATIC CLUTCH INSPECTION

This motorcycle is equipped with an automatic clutch and vari-
able ratio belt drive transmission. The engagement of the clutch
is governed by engine RPMs and centrifugal mechanism located
in the clutch.
To insure proper performance and longer lifetime of the clutch
assembly it is essential that the clutch engages smoothly and
gradually. The following inspections must be performed:

1. INITIAL ENGAGEMENT INSPECTION

• Warm up the engine to normal operating temperature.
• Start the engine.
• Seated on the motorcycle with the motorcycle on level
ground, increase the engine RPMs slowly and note the RPM
at which the motorcycle begins to move forward.
$ 09900-26006: Tachometer
% Engagement r/min: 1 500 – 2 100 r/min

2. CLUTCH “LOCK-UP” INSPECTION

Perform this inspection to determine if the clutch is engaging
fully and not slipping.
• Start the engine.
• Apply the front and rear brakes as firm as possible.
• Briefly open the throttle fully and note the maximum engine
RPMs sustained during the test cycle.
!
Do not apply full power for more than 3 seconds or
damage to the clutch or engine may occur.

% Lock-up r/min: 3 200 – 3 800 r/min

 PERIODIC MAINTENANCE 2-33

BRAKE-LOCK INSPECTION
Inspect that the rear wheel is locked up when pulling the
brake-lock lever 4 to 6 notches and moving the motorcycle for-
ward to make sure that the brake-lock acts enough.
Adjust the brake-lock, if necessary. ("9-85)
White Page
 ENGINE 3-1

ENGINE

CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE
IN PLACE .............................................................................................3- 2 3
ENGINE REMOVAL AND REMOUNTING ...........................................3- 3
ENGINE REMOVAL .....................................................................3- 3
ENGINE REMOUNTING ..............................................................3-10
ENGINE DISASSEMBLY .....................................................................3-12
ENGINE COMPONENT INSPECTION AND SERVICE .......................3-22
CYLINDER HEAD COVER ..........................................................3-22
CAMSHAFT ..................................................................................3-23
CAM CHAIN TENSION ADJUSTER ............................................3-25
CAM CHAIN TENSIONER ...........................................................3-25
CAM CHAIN GUIDE .....................................................................3-25
CYLINDER HEAD ........................................................................3-26
CYLINDER ...................................................................................3-34
PISTON AND PISTON RING .......................................................3-36
CLUTCH .......................................................................................3-38
STARTER CLUTCH .....................................................................3-43
STARTER TORQUE LIMITER .....................................................3-44
OIL PUMP ....................................................................................3-44
OIL PRESSURE REGULATOR/OIL SUMP FILTER ....................3-44
CRANK BALANCER ....................................................................3-45
DRIVE SHAFT ..............................................................................3-45
CONROD/CRANKSHAFT ............................................................3-47
OIL JET ........................................................................................3-55
CRANKCASE ...............................................................................3-56
ENGINE REASSEMBLY ......................................................................3-59
3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

Engine components which can be removed while the engine is installed on the chassis are listed below. For
the installing and removing procedures, refer to respective paragraphs describing each component.

ITEM REMOVAL INSPECTION INSTALLATION

CENTER OF ENGINE
Muffler !3-7 — !3-11
Cylinder head cover !3-12 !3-22 !3-74
Camshaft !3-12 !3-23 !3-72
Starter motor !3-12 !10-13 !3-75
Cam chain tensioner adjuster !3-13 !3-25 !3-71
Cylinder head !3-13 !3-26 !3-71
Cylinder !3-13 !3-34 !3-70
Oil level switch !3-12 !10-29 !3-75
Piston !3-14 !3-36 !3-70
Oil filter/Oil cooler !3-17 — !3-63
Cam position sensor !3-22 !6-27 !3-23
Engine coolant temperature switch !8-12 !8-13 !8-13
RIGHT OF ENGINE
Starter clutch !3-16 !3-43 !3-64
Starter torque limiter !3-16 !3-44 !3-64
Thermostat !3-34 !8-14 !3-35
LEFT SIDE OF ENGINE
Oil sump filter !3-15 !3-44 !3-67
Generator !3-15 !10-9 !3-67
CKP sensor !3-15 !6-28
Clutch !3-16 !3-40 !3-66
Oil pressure switch !3-56 !10-36 !3-56
 ENGINE 3-3

ENGINE REMOVAL AND REMOUNTING

ENGINE REMOVAL
• Drain the engine oil and transmission oil. (!2-10, 2-13)
• Drain the engine coolant. (!2-20)
NOTE:
If the engine is stained, clean with steam cleaner before
removal.
• Cover the parts, A and B, to prevent water from entering the
CVT unit.
EXTERNAL PARTS
• Remove the following parts: (!9-6)
• Lower leg shield. Front leg shield cover. Leg shield. Front box.
Maintenance lid. Lower frame cover. Center frame cover. Pil-
ion rider handle. Trunk box cover. Frame cover. Foot board.
Trunk box. Rear fender. Leg side cover.
• Remove the final gear case cover. (!10-48)
• Disconnect the battery terminals. (!10-3)
"
Remove the battery terminals from the - side first.

• Disconnect the joint hose 1 and breather hose 2.

• Remove the air cleaner box 3.

3-4 ENGINE

• Remove the IAP sensor lead wire coupler 1, IAT sensor 2,

and PAIR solenoid valve lead wire coupler 3.
• Disconnect the vacuum hose 4.

• Loosen the throttle body clamp screws.

• Remove the PAIR solenoid valve 5.
• Remove the air chamber 6.

• Disconnect the throttle cables 7.

• Disconnect the injector couplers 8.
• Disconnect the TP sensor coupler 9 and IAC valve coupler
0.
• Loosen the throttle body clamp screws.
• Disconnect the fuel delivery hose.
• Remove the throttle body ass’y.
 ENGINE 3-5

• Disconnect the PAIR hose 1 and crankcase breather hose

2.

• Disconnect the engine coolant breather hose 3 and radiator

hose 4.
• Disconnect the radiator inlet hose.

• Disconnect the cooling fan switch coupler 5.

• Remove the radiator.

3-6 ENGINE

• Disconnect the engine ground lead wire.

• Disconnect the center stand switch lead wire coupler 1, CVT

pulley position sensor lead wire coupler 2, CVT motor lead
wire coupler 3, CVT scondary pulley revolution sensor lead
wire coupler 4 and HO2 sensor lead wire coupler 5.

• Disconnect the starter motor lead wire.

• Disconnect the ECT sensor coupler 6.

• Disconnect the side-stand switch lead wire coupler 7, oil

pressure switch lead wire coupler 8, oil level switch lead wire
9, CKP sensor coupler 0 and trunk light seat switch lead
coupler A.

• Disconnect the CMP sensor coupler B.

• Remove the ignition coil/spark plug cap.
 ENGINE 3-7

• Disconnect the generator coupler 1.

• Disconnect the HO2 sensor coupler 2.

• Remove the muffler.

• Remove the brake-lock cable clamp.

• Remove the rear brake hose clamp.
• Remove the rear brake caliper bolts and remove the rear
brake caliper 3.
• Remove the both sides of the rear shock absorber lower bolts
4.
3-8 ENGINE

• Remove the clamps.

• Move the fuel feed hose not to interfere with the work.

• Support the engine using an engine jack.

• Remove the engine mounting bolts and nuts.

• Remove the foot board bracket.

• Remove the engine from the frame.

 ENGINE 3-9

• Remove the CVT assembly. (!5-2)

• Remove the swingarm. (!9-59)

• Remove the final gear case assembly. (!4-3)

"
Be careful not to allow the engine main body to fall
down.

• Remove the center stand.

3-10 ENGINE

ENGINE REMOUNTING
• Reinstall the engine assembly following the procedure below:
Assembling of center stand (!11-26)
Installation of final gear case (!4-7)
Installation of rear wheel (!9-56)
Installation of CVT unit (!5-4)
Installation of rear brake caliper (!9-81)
• Pass through the engine mounting bolts from the right side of
the frame.
• Tighten the engine mounting nuts to the specified torque.
"
The engine mounting nut is the self-lock type and can-
not be used repeatedly. If the self-lock effect is lost,
replace it with new one.

Left Right
55 N·m
(5.5 kgf-m)
Front lower side

55 N·m
(5.5 kgf-m)
Front upper side

55 N·m
(5.5 kgf-m)
Rear side
 ENGINE 3-11

MUFFLER

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5

After mounting the engine, connect the wiring, cables and hoses
securely. (!11-14, 11-18)
• Supply a specified amount of engine oil and transmission oil.
(!2-13)
• Supply a specified amount of cooling water. (!2-29)
Adjust or inspect the following items:
• Play of throttle cable (!2-18, 2-19)
• Idling rpm (!2-18)
• Check the leakage of oil, cooling water, etc.
3-12 ENGINE

ENGINE DISASSEMBLY
STARTER MOTOR
• Remove the starter motor 1.
• Disconnect the water bypass hose 2.

OIL PRESSURE SWITCH

• Remove the oil pressure switch.

OIL LEVEL SWITCH

• Remove the oil level switch 3.

CYLINDER HEAD COVER

• Remove the cylinder head cover 4.
NOTE:
Do not remove the dowel pin at the back side of the cylinder
head cover since it is embedded.

CAMSHAFT
• Remove the valve timing inspection cap and bring the piston
to the top dead center by turning the crankshaft. (!2-8)
NOTE:
Take note of the tappet clearance. (!2-9)
 ENGINE 3-13

• Push the cam chain tension adjuster rod and insert the spe-
cial tool.
#09918-53810: Chain tensioner lock tool

• Remove the two camshaft journal holders 1 by removing the

bolts.
"
Be sure to loosen the camshaft journal holder bolts
evenly by shifting the wrench diagonally.

• Remove the camshafts 2.

CYLINDER HEAD AND CYLINER

• Remove the cylinder head side bolt 1.
• Remove the cam chain tension adjuster bolts 2.

• Loosen the cylinder head bolts 3.

• Remove the cylinder head bolts diagonally.
• Remove the cylinder head assembly.
3-14 ENGINE

• Remove the cylinder head gasket 1, dowel pins 2 and cam

chain guide 3.
• Remove the cylinder 4.

• Remove the cylinder base gasket 5 and dowel pins 6.

PISTON
• Place a clean rag over the cylinder base so as not to drop the
piston pin circlip into the crankcase.
• Remove the piston pin circlip.
• Remove the piston by driving out the piston pin.
NOTE:
* Scribe the piston number on the head of the piston.

OIL HOSE
• Remove the oil hose 7 and oil return hose 8.

GENERATOR COVER
• Remove the generator cover 9.
 ENGINE 3-15

• Remove the oil sump filter 1.

GENERATOR
• Remove the generator rotor nut with the special tool.
# 09930-40113: Rotor holder

• Remove the generator rotor 2 with the special tools.

# 09930-40113: Rotor holder
09930-30450: Rotor remover

• Remove the generator stator 3, CKP sensor 4 and lead wire

grommet 5.
• Remove the key.
3-16 ENGINE

CLUTCH
• Remove the clutch cover 1.

• Remove the clutch housing nut and washer.

• Remove the clutch assembly.
# 09930-40113: Rotor holder

• Remove the clutch shaft 3.

• Remove the driveshaft oil seal retainer 4.

STARTER CLUTCH
• Remove the starter clutch cover 5.

• Remove the starter torque limiter shaft 6, starter torque lim-

iter 7 and washer.
• Remove the starter idle gear shaft 8 and starter idle gear 9.
 ENGINE 3-17

• Remove the starter clutch bolt with the special tool.

# 09920-34830: Starter clutch rotor holder

CAM CHAIN
• Remove the cam chain tensioner 1 and cam chain 2.

• Remove the cam chain sprocket 3.

WATER PUMP
• Remove the water pump assembly.

OIL FILTER
• Remove the oil filter 4 with the special tool.
# 09915-40610: Oil filter wrench
3-18 ENGINE

OIL COOLER
• Untighten the union bolt and remove the oil cooler.

SEPARATION OF CRANKCASE
• Untighten the crankcase tightening bolts diagonally.

• Separate the crankcase into 2 parts, right and left, with the
crankcase separating tool.
# 09920-13120: Crankcase/crankshft separator
NOTE:
* Pay attention when separating the crankcase so that it is kept
horizontal with the mating surface.
 ENGINE 3-19

DRIVESHAFT
• Remove the driveshaft assembly 1 and idle shaft 2.

• Remove the idle gear 3.

• Remove the circlip 4 and counter drive gear 5.

• Remove the counter drive gear shaft 6.

BALANCER SHAFT
• Remove the upper balancer shaft 7.

• Remove the circlip 8, lower balancer shaft 9, oil pump gear

0 and oil pump drive chain.
3-20 ENGINE

OIL PUMP
• Remove the pin 1, washer 2 and oil pump assembly 3.

• Remove the oil sump filter 4.

OIL PRESSURE REGULATOR

• Remove the oil pressure regulator 5.

PISTON COOLING NOZZLE

• Remove the piston cooling nozzle.

• Remove the O-ring.

 ENGINE 3-21

• Remove the oil separator.

CRANKSHAFT
• Remove the crankshaft assembly 1.

PRIMARY DRIVEN GEAR

• Remove the primary drive gear 2.

RETURN OIL PUMP

• Remove the circlip 3 and return oil pump gear 4.

• Remove the pin 5 and return oil pump assembly 6.

3-22 ENGINE

ENGINE COMPONENT INSPECTION

AND SERVICE
"
Identify the position of each removed part. Organize
the parts in their respective groups (i.e., intake,
exhaust, No.1 or No.2) so that they can be installed in
their original locations.

CYLINDER HEAD COVER

• Remove the PAIR reed valve cover 1, cam position sensor
2 and breather cover 3.

INSPECTION
• Inspect the reed valve for the carbon deposit.
• If the carbon deposit is found in the reed valve, replace the
reed valve with a new one.

REASSEMBLY
• Apply THREAD LOCK “1342” to the thread and install the
PAIR reed valve cover.
$ 99000-32050: THREAD LOCK “1342”

• Check for stain and clogging in the breather and clean as

required.
• Assemble a new gasket and breather cover and tighten the
part A together with the clamp.
% Tightning torque: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
 ENGINE 3-23

CAM POSITION SENSOR

• Apply SUZUKI SUPER GREASE “A” to the O-ring and install
it.
• Install the CMP sensor.
% Cam position sensor bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
&'99000-25030: SUZUKI SUPER GREASE “A” (USA)
'99000-25010: SUZUKI SUPER GREASE “A” (Others)

CAMSHAFT
• Exhaust camshaft and intake camshaft are distinguished by
the punched mark.
Exhaust camshaft: Punched mark “B”
Intake camshaft: Punched mark “A”

Punched mark

CAM FACE
• Check the sliding surface for extraordinary scratches or wear.
• Measure the cam height H with a micrometer.
• If the service limit has been exceeded, replace the camshaft.
( Cam height H:
Service Limit: (IN.): 35.1 mm (1.378 in)
(EX.): 33.7 mm (1.339 in)

CAMSHAFT RUNOUT
• Measure the runout using the dial gauge.
• Replace the camshaft if the runout exceeds the limit.
# 09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
( Camshaft runout:
Service Limit (IN & EX): 0.10 mm (0.004 in)
3-24 ENGINE

CAMSHAFT JOURNAL WEAR

• Determine whether or not each journal is worn down to the limit by
measuring the oil clearance with the camshaft installed in place.
• Use the plastigauge to read the clearance at the widest por-
tion, which is specified as follows:
( Camshaft journal oil clearance:
Standard: (IN & EX): 0.032 – 0.066 mm
(0.0013 – 0.0026 in)
Service Limit: (IN & EX): 0.150 mm (0.0059 in)

# 09900-22301: Plastigauge
09900-22302: Plastigauge
• Tighten the camshaft journal holder bolts evenly and diago-
nally to the specified torque.
% Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.4 lb-ft)
NOTE:
Do not rotate the camshaft with the plastigauge in place.

• Remove the camshaft holders, and read the width of the com-
pressed plastigauge with envelope scale.
• This measurement should be taken at the widest part.

• If the camshaft journal oil clearance measured exceeds the

limit, measure the inside diameter of the camshaft journal
holder and outside diameter of the camshaft journal.
• Replace the camshaft or the cylinder head depending upon
which one exceeds the specification.

( Journal holder I.D.:

Standard: (IN & EX): 24.012 – 24.025 mm
(0.9454 – 0.9459 in)
# 09900-20602: Dial gauge (1/1000, 1 mm)
09900-22403: Small bore gauge (18 – 35 mm)
( Camshaft journal O.D.:
Standard (IN & EX): 23.959 – 23.980 mm
(0.9433 – 0.9441 in)
# 09900-20205: Micrometer (0 – 25 mm)
 ENGINE 3-25

CAM CHAIN TENSION ADJUSTER

INSPECTION
• Remove the cam chain tension adjuster cap bolt.
• Check that the push rod slides smoothly when releasing stop-
per.
• If it does not slide smoothly, replace the cam chain tension
adjuster with a new one.

CAM CHAIN TENSIONER

INSPECTION
• Check the contacting surface of the cam chain tensioner.
• If it is worn or damaged, replace it with a new one.

CAM CHAIN GUIDE

INSPECTION
• Check the contacting surfaces of the cam chain guides.
• If they are worn or damaged, replace them with the new ones.
3-26 ENGINE

CYLINDER HEAD
VALVE AND VALVE SPRING DIASSEMBLY
• Remove the tappets and shims by fingers or magnetic hand.
"
Identify the position of each removed part.

• Using special tools, compress the valve spring and remove

the two cotter halves 1 from valve stem.
# 09916-14510: Valve lifter
09916-14521: Valve lifter attachment (24 mm)
09916-84511: Tweezers
"
Be careful not to damage the tappet sliding surface
with the special tool.

• Remove the valve spring retainer 2 and valve spring 3.

• Pull out the valve 4 from the other side.

• Remove the oil seal 5.

"
Do not reuse the removed oil seal.

• Remove the spring seat 6.

CYLINDER HEAD DISTORTION

• Decarbonize the combustion chambers.
• Check the gasket surface of the cylinder head for distortion
with a straightedge and thickness gauge, taking a clearance
reading at several places indicated.
• If the largest reading at any position of the straightedge
exceeds the limit, replace the cylinder head.
( Cylinder head distortion:
Service Limit: 0.10 mm (0.004 in)
 ENGINE 3-27

VALVE STEM DEFLECTION

• Lift the valve about 10 mm (0.39 in) from the valve seat.
• Measure the valve stem deflection in two directions, perpen-
dicular to each other, by positioning the dial gauge as shown.
• If the deflection measured exceeds the limit, then determine
whether the valve or the guide should be replaced with a new
one.
# 09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
( Valve stem deflection (IN & EX):
Service Limit: 0.35 mm (0.014 in)

VALVE STEM WEAR

• 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 deflec-
tion.
# 09900-20205: Micrometer (0 – 25 mm)
( Valve stem O.D.:
Standard (IN): 4.475 – 4.490 mm (0.1762 – 0.1768 in)
(EX): 4.455 – 4.470 mm (0.1754 – 0.1760 in)
NOTE:
If valve guides have to be removed for replacement after
inspecting related parts, carry out the steps shown in valve
guide servicing.

VALVE STEM RUNOUT

• Support the valve using V-blocks and check its runout using
the dial gauge as shown.
• If the runout exceeds the service limit, replace the valve.
# 09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
( Valve stem runout: Service Limit: 0.05 mm (0.002 in)

VALVE HEAD RADIAL RUNOUT

• Place the dial gauge at a right angle to the valve head face
and measure the valve head radial runout.
• If it measures more than the service limit, replace the valve.
( Valve head radial runout:
Service Limit: 0.03 mm (0.001 in)
3-28 ENGINE

VALVE FACE WEAR

• Visually inspect each valve face for wear. Replace any valve
with an abnormally worn face. The thickness of the valve face
decreases as the face wears. Measure the valve face T. If it
is out of specification, replace the valve with a new one.
( Valve head thickness T:
Service Limit: 0.5 mm (0.02 in)

VALVE SPRING
The force of the coil spring keeps the valve seat tight. Weak-
ened spring result in reduced engine power output, and often
account for the chattering noise coming from the valve mecha-
nism.
• Check the valve spring for proper strength by 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 the spring.

# 09900-20102: Vernier calipers

( Valve spring free length (IN & EX): Service limit:
40.6 mm (1.60 in)
( Valve spring tension (IN & EX): Standard:
136 – 156 N, 13.6 – 15.6 kgf/33.4 mm
(30.0 – 33.4 lbs/1.31 in)
 ENGINE 3-29

VALVE GUIDE SERVICING

• Using the valve guide remover, drive the valve guide out
toward the intake or exhaust camshaft side.
# 09916-53310: Valve guide remover/installer
NOTE:
* Discard the removed valve guide subassemblies.
* Only oversized valve guides are available as replacement
parts. (Part No. 11115-33D71)

• Refinish the valve guide holes in cylinder head with the

reamer and handle.
# 09916-34561: Valve guide reamer
09916-34542: Reamer handle
"
When refinishing or removing the reamer from the
valve guide hole, always turn it clockwise.

• Apply engine oil to the valve guide hole.

• Drive the valve guide into the hole using the special tool.
# 09916-43210: Valve guide installer/remover
NOTE:
Valve guide
Install the valve guide until the attachment contacts with the cyl-
inder head. Cylinder head

# 09916-43210: Valve guide remover/installer

09916-44930: Valve guide installer attachment
"
Failure to oil the valve guide hole before driving the
new guide into place may result in a damaged guide or
head.

• After installing the valve guides, refinish their guiding bores

using the reamer.
• Clean and oil the guides after reaming.
# 09916-33310: Valve guide reamer
09916-34542: Valve guide reamer handle
NOTE:
Insert the reamer from the combustion chamber and always turn
the reamer handle clockwise.
3-30 ENGINE

VALVE SEAT WIDTH INSPECTION

• Visually check for valve seat width on each valve face.
• If the valve face has worn abnormally, replace the valve.
• Coat the valve seat with Prussian Blue and set the valve in
place. Rotate the valve with light pressure.
• Check that the transferred blue on the valve face is uniform all
around and in center of the valve face.
# 09916-10911: Valve rapper set

• If the seat width W measured exceeds the standard value, or

seat width is not uniform reface the seat using the seat cutter.
( Valve seat width W:
Standard: 0.9 – 1.1 mm (0.035 – 0.043 in)
If the valve seat is out of specification, recut the seat.

VALVE SEAT SERVICING

• The valve seats for both the intake and exhaust valves are 60˚ 45˚ 15˚
machined to four different angles. The seat contact surface is
cut at 45°.

INTAKE EXHAUST
15° N-121
30° N-126 Exhaust
45° N-122 N-122
60° N-111 N-111

# 09916-21111: Valve seat cutter set

09916-20630: Valve seat cutter (N-126) 60˚ 45˚ 30˚
09916-20640: Solid pilot (N-100-4.5)
NOTE:
The valve seat cutters (N-121), (N-122) and (N-111) are
included in the valve seat cutter set (09916-21111).

Intake

"
The valve seat contact area must be inspected after
each cut.

• When installing the solid pilot 1, rotate it slightly.

 ENGINE 3-31

INITIAL SEAT CUT

• Install the 45° cutter 1, attachment 2 and T-handle 3.

• Using the 45° cutter, descale and clean up the seat. Rotate
the cutter one or two turns.
• Measure the valve seat width W after every cut.

45˚

• If the valve seat is pitted or burned, use the 45° cutter to con-
dition the seat some more.
NOTE:
Cut only the minimum amount necessary from the seat to pre-
vent the possibility of the valve stem becoming too close to the
camshaft.

TOP NARROWING CUT Too high or too wide

contact surface on valve
• If the contact area W is too high on the valve, or if it is too
wide, use the 15° (for the exhaust side) and the 30° (for the
intake side) to lower and narrow the contact area.

15˚ (EX)
30˚ (IN)
3-32 ENGINE

BOTTOM NARROWING CUT

• If the contact area W is too wide or too low, use the 60° cutter
to narrow and raise the contact area.

60˚

FINAL SEAT CUT Too low or too narrow

contact surface on valve
• If the contact area W is too low or too narrow, use the 45° cut-
ter to raise and widen the contact area.

NOTE:
After cutting the 15°, 30° and 60° angles, it is possible that the
valve seat (45°) is too narrow. If so, recut the valve seat to the
correct width.
• After the desired seat position and width is achieved, use the
45° cutter very lightly to clean up any burrs caused by the pre-
vious cutting operations.
" 45˚

Do not use lapping compound after the final cut is

made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny fin-
ish. This will provide a soft surface for the final seat-
ing of the valve which will occur during the first few
seconds of engine operation.

NOTE:
After servicing the valve seats, be sure to check the tappet
clearance after the cylinder head has been reinstalled. (!2-9)

• Clean and assemble the head and valve components. 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.
)
Always use extreme caution when handling gasoline.
 ENGINE 3-33

VALVE AND VALVE SPRING REASSEMBLY

• Apply molybdenum oil solution to each oil seal, and press-fit
them into position with the valve guide installer.
# 09916-43210: Valve guide remover/installer
* MOLYBDENUM OIL SOLUTION
"
Do not reuse the removed oil seals.

• Insert the valves, with their stems coated with molybdenum oil
solution all around and along the full stem length without any
break.
"
When inserting each valve, take care not to damage
the lip of the oil seal.

* MOLYBDENUM OIL SOLUTION

• Install the valve springs with the small-pitch portion facing cyl-
inder head.
A: Small-pitch portion
B: Large-pitch portion

• Put on the valve spring retainer, and using the valve lifter,
press down the springs, fit the cotter halves to the stem end,
and release the lifter to allow the cotter 1 to wedge in
between retainer and stem. Be sure that the rounded lip A of
the cotter fits snugly into the groove B in the stem end.
# 09916-14510: Valve lifter
09916-14521: Valve lifter attachment
09916-84511: Tweezers
"
Be sure to restore each spring and valve to their origi-
nal positions.

• Install the tappet shims and the tappets to their original posi-
tion.
3-34 ENGINE

NOTE:
* Apply engine oil to the shim and tappet before fitting them.
* When seating the tappet shim, be sure the figure printed sur-
face faces the tappet. (!2-9)

INTAKE PIPE
• Coat the O-ring with grease and install the intake pipe
together with the O-ring.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

CYLINDER
• Disconnect the water pipe 1 and remove the O-ring.

• Untighten the thermostat case bolt.

• Remove the thermostat 2.

CYLINDER DISTORTION
• Check the gasket surface of the cylinder for distortion with a
straightedge and thickess 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.
# 09900-20803: Thickness gauge
( Cylinder distortion:
Service Limit: 0.10 mm (0.004 in)
 ENGINE 3-35

CYLINDER BORE
• Check the cylinder bore for stepped wear or scars.
• Measure the 6 positions as shown in the right figure with a cyl-
inder gauge.
# 09900-20508: Cylinder gauge set
( Cylinder bore:
Standard: 75.500 – 75.515 mm (2.9724 – 2.9730 in)
Service Limit: 75.585 mm (2.9758 in)

• Fit the O-ring 1 to the water pipe and install the water pipe to
the cylinder.
• Coat the water pipe bolt with screw lock agent and tighten the
water pipe with the bolt.
$ 99000-32050: THREAD LOCK “1342”
"
Use new O-rings.

• Install the thermostat to the cylinder.

• Tighten the thermostat case bolt.
NOTE:
Position the thermostat jiggle valve as shown in the photo.
3-36 ENGINE

PISTON AND PISTON RING

PISTON DIAMETER
• Using a micrometer, measure the piston outside diameter at
15 mm (0.6 in) from the piston skirt end.
• If the measurement is less than the limit, replace the piston.
( Piston diameter:
Standard: 75.450 – 75.465 mm (2.9704 – 2.9710 in) 15 mm (0.6 in)
Service Limit: 75.380 mm (2.9677 in)
at 15 mm (0.6 in) from the skirt end

# 09900-20204: Micrometer (75 – 100 mm)

PISTON TO CYLINDER CLEARANCE

• Subtract the piston diameter from the cylinder bore diameter.
• If the piston to cylinder clearance exceeds the service limit,
replace the cylinder and the piston.
( Piston to cylinder clearance:
Standard: 0.045 – 0.055 mm (0.00177 – 0.00216 in)
Service Limit: 0.120 mm (0.0047 in)

PISTON PINS AND PIN BORE

• Measure the piston pin bore inside diameter using the small
bore gauge.
• If the measurement is out of specification, replace the piston.
# 09900-20602: Dial gauge (1/1000 mm)
09900-22401: Small bore gauge (10 – 18 mm)
( Piston pin bore I.D.:
Service Limit: 16.030 mm (0.6311 in)

• Measure the piston pin outside diameter at three positions

using the micrometer.
• If any of the measurements are out of specification, replace
the piston pin.
# 09900-20205: Micrometer (0 – 25 mm)
( Piston pin O.D.:
Service Limit: 15.980 mm (0.6291 in)
 ENGINE 3-37

PISTON RING TO GROOVE CLEARANCE

• Measure the side clearances of the 1st and 2nd piston rings
using the thickness gauge.
• If any of the clearances exceed the limit, replace both the pis-
ton and piston rings.
# 09900-20803: Thickness gauge
09900-20205: Micrometer (0 – 25 mm)

( Piston ring to groove clearance:

Service Limit (1st): 0.18 mm (0.0071 in)
(2nd): 0.15 mm (0.0059 in)
( Piston ring groove width:
Standard (1st): 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(2nd): 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(Oil): 2.01 – 2.03 mm (0.0791 – 0.0799 in)
( Piston ring thickness:
Standard (1st): 0.970 – 0.990 mm (0.03819 – 0.03898 in)
(2nd): 0.970 – 0.990 mm (0.03819 – 0.03898 in)

PISTON RING FREE END GAP AND PISTON RING END GAP
• Measure the piston ring free end gap using vernier calipers.
• Next, fit the piston ring squarely into the cylinder and measure
the piston ring end gap using the thickness gauge.
• If any of the measurements exceed the service limit, replace
the piston ring with a new one.
# 09900-20102: Vernier calipers
( Piston ring free end gap:
Service Limit (1st): 9.3 mm (0.36 in)
(2nd): 6.9 mm (0.27 in)

# 09900-20803: Thickness gauge

( Piston ring end gap:
Service Limit (1st): 0.50 mm (0.020 in)
(2nd): 0.50 mm (0.020 in)
3-38 ENGINE

CLUTCH

1 Circlip
2 Spring seat
3 Concaved washer
4 Outer plate
5 Driven plate No.2
6 Clutch plate concaved washer
7 Drive plate
5.5 N·m
8 Driven plate No.1
0.55 kgf-m
9 Clutch hub
4.0 lb-ft
0 Spring
A Inner plate
B Roller
C Clutch housing

DISASSEMBLY
• Remove the circlip 1 with the special tools.
# 09920-33530: Clutch spring compressor
09924-84510: Bearing installer set

• Remove the clutch hub 1 and spacer.

 ENGINE 3-39

• Remove the spring seat and concaved washer.

• Remove the outer plate, driven plate No.1, clutch plate con-
caved washer, drive plate and driven plate No.2.

• Remove the clutch spring bolts 2, springs 3 and clutch inner

plate 4.

• Remove the rollers.

CLUTCH DRIVE PLATES/CLUTCH DRIVEN PLATES NO.2

INSPECTION
NOTE:
Wipe off engine oil from the clutch drive plates with a clean rag.
• Measure the thickness of drive plates with a vernier calipers.
• If each drive plate thickness is less than the limit, replace it
with a new one.
( Drive plate thickness:
Service Limit: 2.62 mm (0.095 in)
Driven plate No.2 thickness:
Service Limit: 2.27 mm (0.0894 in)
# 09900-20102: Vernier calipers
3-40 ENGINE

• Measure the claw width of drive plates with a vernier calipers.

• Replace the drive plates found to have worn down to the limit.
( Drive plate claw width:
Service Limit: 13.05 mm (0.5138 in)
# 09900-20102: Vernier calipers

CLUTCH DRIVEN PLATE NO.2 INSPECTION

• Check for discoloration due to burning.
• Measure the distortion of the plate on the level block with a
thickness gauge.
• If the service limit has been exceeded, replace with new one.
( Distortion of driven plate:
Service Limit: 0.1 mm (0.004 in)
# 09900-20803: Thickness gauge

CLUTCH SPRING FREE HEIGHT

• Measure the free length of the clutch spring with vernier cali-
pers.
• If the length is below the service limit, replace the spring.
( Clutch spring free length:
Service Limit: 13.2 mm (0.5197 in)
# 09900-20102: Vernier calipers

CLUTCH PLATE CONCAVED WASHER INSPECTION

• Measure the clutch plate concaved washer height A when
applying the weight 9.8 N (1 kgf, 2.2 lb) as shown. 9.8 N (1 kgf, 2.2 lb)
• If clutch plate concaved washer height is less than the limit,
replace it with the new one.
( Clutch plate concaved washer height:
Service Limit: 3.1 mm (0.12 in)
# 09900-20102: Vernier calipers

ROLLER
• Check that there is no abnormal wear or damage on the roller,
if any defects are found, replace the rollers as a set.
 ENGINE 3-41

REASSEMBLY
NOTE:
Reassemble the clutch in the reverse order of removal and dis-
assembly. Pay attention to the following points:
• Install the rollers.
• Tighten the clutch spring bolts to the specified torque.
% Clutch spring bolt: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)

• Install the spacer 1 and clutch sleeve hub.

3-42 ENGINE

1 Driven plate No.2

2 Driven plate No.1
3 Drive plate

Expanded view

Clutch plate
concaved
washer

Concaved washer

Engine side Outside

• Install the driven plate No.1, driven plate No.2, drive plate,
clutch plate concaved washer outer plate, concaved washer
and spring seat.

• Install the circlip with the special tools.

# 09920-33530: Clutch spring compressor
09924-84510: Bearing installer set
 ENGINE 3-43

STARTER CLUTCH

1 Washer
2 Starter torque limiter
3 Idle gear
4 Wahser
5 Starter clutch

55 N.m
5.5 kgf-m
40.0 lb-ft

INSPECTION
• Install the starter driven gear onto the starter clutch.
• Turn the starter driven gear by hand.
• Inspect the starter clutch for a smooth movement.
• Inspect that the gear turns one direction only.

• If a large resistance is felt for rotation, inspect the starter

clutch bearing or the starter clutch contacting surface on the
starter driven gear for wear and damage.
• If they are found to be damaged, replace them with new ones.
3-44 ENGINE

STARTER TORQUE LIMITER

INSPECTION
• Measure the torque when slipping by means of the special
tool and torque wrench.
• If the measurement result is out of standard value, replace the
starter torque limiter with a new one.
( Slip torque
standard: 22 – 41 N·m (2.2 – 4.1 kgf-m, 16 – 29.5 lb-ft)
# 09930-73170: Starter torque limiter holder
09930-73120: Starter torque limiter socket

OIL PUMP
INSPECTION
• Rotate the oil pump by hand and check that it moves
smoothly.
• If it does not move smoothly, replace the oil pump assembly.
"
* Do not attempt to disassemble the oil pump assem-
bly.
* The oil pump is available only as an assembly.

OIL PRESSURE REGULATOR/OIL SUMP

FILTER
• Inspect the operation of the oil pressure regulator by pushing
on the piston with a proper bar.
• If the piston dose not operate, replace the oil pressure regula-
tor with a new one.

• Check the oil sump filter for clogging and damage.

• If any fault is detected, clean or replace with new one.
 ENGINE 3-45

CRANK BALANCER
DISASSEMBLY
• Remove the circlip 1, washer 2, spring 3 and scissors gear
4.

REASSEMBLY
• Carry out the assembly procedure in the reverse order of dis-
assembly while observing the following instructions.
• Assemble the scissors gear with its punch mark side the out-
side.
• When assembling, align the balancer driven gear hole A with
the scissors gear hole B.

• Install the springs 5.

• Install the washer 6 and circlip 7.

DRIVESHAFT
DISASSEMBLY
• Remove the driveshaft nut.

• Remove the washer 8, spring stopper 9, dumper cam spring

0, cam dog A, final driven gear B, and driveshaft oil seal C.
3-46 ENGINE

INSPECTION
• Check the disassembled components for any damage.
• Damaged cam dog
• Abnormal wear or damage of gear and spline

ASSEMBLING
NOTE:
Reassemble the components in the reverse order to disassem-
bly taking care particularly about the following items:
• Coat the spline area of the cam dog 2 with grease.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the bushing 1, final drive gear 2, cam dog 3, dumper
spring 4, spring stopper 5, washer 6 and nut 7 to the drive-
shaft.

• Fix the driveshaft assembly to the vise and tighten the nut.
% Driveshaft nut: 105 N·m (10.5 kgf-m, 76.0 lb-ft)
 ENGINE 3-47

CONROD/CRANKSHAFT
CONROD SMALL END I.D.
• Using a small bore gauge, measure the inside diameter of the
conrod small end.
# 09900-20602: Dial gauge (1/1000 mm, 1 mm)
09900-22401: Small bore gauge (10 – 18 mm)
( Conrod small end I.D.:
Service Limit: 16.040 mm (0.6315 in)
• If the inside diameter of the conrod small end exceeds the
limit, replace the conrod.

CONROD BIG END SIDE CLEARANCE

• Inspect the conrod side clearance by using a thickness
gauge.
• If the clearance exceeds the limit, remove the conrod and
inspect the conrod big end width and the crank pin width.
• If the width exceed the limit, replace conrod or crankshaft.
( Conrod big end side clearance:
Service Limit: 0.30 mm (0.012 in)

# 09900-20803: Thickness gauge

( Conrod big end width:
Standard: 19.95 – 20.00 mm (0.7854 – 0.7874 in)
# 09900-20205: Micrometer (0 – 25 mm)
( Crank pin width:
Standard: 20.10 – 20.15 mm (0.7913 – 0.7933 in)
# 09900-20205: Micrometer (0 – 25 mm)
09900-20605: Dial caliper (10 – 34 mm)
09900-20803: Thickness gauge

CONROD-CRANK PIN BEARING INSPECTION

• Inspect the bearing surfaces for any sign of fusion, pitting,
burn, or flaws. If any, replace them with a specified set of
bearings.
3-48 ENGINE

CONROD-CRANK PIN BEARING SELECTION

• Place the plastigauge axially along the crank pin, avoiding the
oil hole, as shown.
# 09900-22301: Plastigauge
• Tighten the conrod cap bolts to the specified torque, in two
stages. (! 3-50)

"
* Apply engine oil to the bearing cap bolt.
* Never rotate the crankshaft or conrod when a piece
of plastigauge is installed.

• Remove the bearing caps and measure the width of the com-
pressed plastigauge using the envelope scale. This measure-
ment should be taken at the widest part of the compressed
plastigauge.
( Conrod big end oil clearance:
Standard: 0.032 – 0.056 mm (0.0013 – 0.0022 in)
Service Limit: 0.080 mm (0.0031 in)
• If the oil clearance exceeds the service limit, select the speci-
fied bearings from the bearing selection table.

• Check the corresponding conrod I.D. code number (“1” or “2”)

A.

• Check the corresponding crank pin O.D. code number (“1”,

“2” or “3”) B.
( Bearing selection table

Crank pin O.D. B

Code 1 2 3
Conrod 1 Green Black Brown
I.D. A 2 Black Brown Yellow
 ENGINE 3-49

('Conrod I.D.
Code A I.D. specification
48.000 – 48.008 mm
1
(1.8898 – 1.8901 in)
48.008 – 48.016 mm
2
(1.8901 – 1.8904 in)

('Crank pin O.D.

Code B O.D. specification
44.992 – 45.000 mm
1
(1.7713 – 1.7717 in)
44.984 – 44.992 mm
2
(1.7710 – 1.7713 in)
44.976 – 47.984 mm
3
(1.7707 – 1.7710 in)
#09900-20202: Micrometer (25 – 50 mm)

('Bearing thickness
Color code
Color Thickness
1.480 – 1.484 mm
Green
(0.0583 – 0.0584 in)
1.484 – 1.488 mm
Black
(0.0584 – 0.0586 in)
1.488 – 1.492 mm
Brown
(0.0586 – 0.0587 in)
1.492 – 1.496 mm
Yellow
(0.0587 – 0.0589 in)
"
The bearing must be replaced as a set.

BEARING ASSEMBLY
• When fitting the bearing to the bearing cap and conrod, be
sure to fix the stopper part A first, and press in the other end.

• Apply molybdenum oil solution to the crank pin and bearing

surface.
* MOLYBDNUM OIL SOLUTION
3-50 ENGINE

• When fitting the conrods on the crankshaft, make sure that 21 N·m
I.D. A of the conrods face each cylinder intake valve sides. (2.1 kgf-m
)
90˚ 15 lb-ft
• Apply engine oil to the bearing cap bolts.
• Tighten the bearing cap bolts as following two steps.
% Conrod bearing cap bolt
(Initial) : 21 N·m (2.1 kgf-m, 15 lb-ft)
(Final) : After tightening the bolts to the above torque,
tighten them + of a turn (90°).
90˚
• Check the conrod movement for smooth turning.

CRANKCASE-CRANKSHAFT BEARING INSPECTION

• Inspect the crankshaft journal bearings for any damage. If
any, replace them with a specified set of bearings.

• Inspect the crankshaft journal for any damage.

• Measure the crankshaft journal O.D. with the special tool.
( Crankshaft journal O.D.
Standard: 47.985 – 48.000 mm (1.8892 – 1.8898 in)
# 09900-20202: Micrometer (25 – 50 mm)

CRANKCASE-CRANKSHAFT BEARING SELECTION

Select the specified bearings from the crankcase bore I.D. code.
The crankcase bore I.D. code A “A”, “B” or “C”, is stamped on
the inside of each crankcase half.

I.D. code A Color Thickness

A Green 1.988 – 1.991 mm (0.0783 – 0.0784 in)
B Black 1.991 – 1.994 mm (0.0784 – 0.085 in)
C Brown 1.994 – 1.997 mm (0.085 – 0.0786 in)
 ENGINE 3-51

CRANKSHAFT JOURNAL BEARING REPLACEMENT

• Use the special tool to replace the crankshaft journal bear- Hand press
ings. The replacement procedure is as follows.
# 09913-60230: Journal bearing remover/installer
Bearing
• Set the special tool as shown to remove the crankshaft journal Crankcase
bearings.
NOTE:
Remove the crankshaft journal bearings in only one direction,
from inside to outside of each crankcase half.

• Gradually press out the bearing with the special tool by using
the hand-press.
"
The removed bearings must be replaced with new
ones.

NOTE: Bearing
Using the hand-press is recommended to remove the crankshaft
journal bearings. However, the crankshaft journal bearings can
be removed by using with the following special tools.
# 09913-60230: 1 Jornal bearing remover/installer
09924-84510: 2 Bearing installer set
09924-74570: 3 Final drive gear bearing
remover/installer
3-52 ENGINE

• Set the specified crankshaft journal bearings to the special

tool.
# 09913-60241: Jornal bearing installer holder
"
* Before setting the bearing, apply enough engine oil
to the special tool and bearings.
* When setting the bearing, align the bearing side with
the engraved line A and also the bearing edge with
the mating surface of the special tool.

• Tighten the special tool bolt to the specified torque.

% Special tool bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

"
Before installing the bearings, lightly shave off the
sharp edge part of the crankcase chamfer by using an
oilstone and wash the crankcase bore with enough
engine oil. Sharp edge
 ENGINE 3-53

• Set the bearings installed in the special tool to the crankcase

half as shown.
"
* Be sure the bearing protruded side A faces the
crankcase bore.
* Align the special tool mating surface with the line
mark B on the crankcase.

• Apply enough engine oil to the special tool and the bearings
and then set the special tool carefully.
• Gradually press in the bearing into the main journal bore by
using the hand-press until the special tool 1 or 2 stops the
special tool 3.
# 1 09913-60210: Journal bearing remover/installer
(Left crankcase)
2 09913-60230: Journal bearing remover/installer
(Right crankcase)
3 09913-60241: Journal bearing installer holder

1 Left crankcase
Hand press 2 Right crankcase
or
Bearing
or

Bearing

"
Since the journal bearing press-fitting position is dif-
ferent between the right and left crankcases, use the
correct installer respectively.
3-54 ENGINE

NOTE:
Using the hand-press is recommended to install the crankshaft
journal bearings. However, the crankshaft journal bearings can
be installed by using the following special tools.
"
Match the hole center of the special tool correctly.

# 09924-84510: Bearing installer

CRANKSHAFT THRUST CLEARANCE

• Face the oil groove A of the crankshaft shim 1 toward the
crank web.
• Install the crankshaft to the crankcase. (!3-62)
• Install the starter clutch. (!3-64)

• Measure the gap between the thrust washer and crankcase.

( Crankshaft thrust clearance

Standard: 0.10 – 0.15 mm (0.004 – 0.006 in)
• If the thrust clearance is out of the standard range, replace
the shim so that the standard value is obtained.

• To replace the shim, remove the thrust shim and measure the
thickness. Select shims from the table below so that the stan-
dard value can be obtained.
• Inspect the crankshaft thrust clearance again.
Unit: mm (in)
Part number Thrust shim thickness
09160-48005 2.025 – 2.050 (0.0797 – 0.0807)
09160-48006 2.050 – 2.075 (0.0807 – 0.0817)
09160-48007 2.075 – 2.100 (0.0817 – 0.0827)
09160-48008 2.100 – 2.125 (0.0827 – 0.0837)
09160-48009 2.125 – 2.150 (0.0837 – 0.0846)
09160-48010 2.150 – 2.175 (0.0846 – 0.0856)
 ENGINE 3-55

OIL JET
• Check the oil jets for clogging.
NOTE:
Before fitting, coat the O-ring with engine oil. Use a new O-ring.
Note the carved mark not to mistake the size.

NOTE:
The crankcase side of the oil jet is identified by letter 8.

NOTE:
The cylinder head side of the oil jet is identified by letter 14.

PISTON COOLING NOZZLE

• Check the piston cooling nozzle for clogging or deformation.
NOTE:
Before installing, coat the O-ring with engine oil. Use a new
O-ring.
3-56 ENGINE

CRANKCASE
OIL PRESSURE SWITCH
• Remove the oil pressure switch.

• When installing the switch, apply SUZUKI BOND “1207B”.

% Oil pressure switch: 13 N·m (1.3 kgf-m, 10.0 lb-ft)
, 99104-31140: SUZUKI BOND “1207B” (USA)
99000-31140: SUZUKI BOND “1207B” (Others)

• Remove the right crankcase cover 1.

• Remove the primary shaft cap 2.
• Install the right crankcase cover 1 and primary shaft cap 2.
% Right crankcase cover bolt: 11 N·m (1.1 kgf-m, 8 lb-ft)
Primary shaft cap bolt: 11 N·m (1.1 kgf-m, 8 lb-ft)

BEARING DISASSEMBLY
• Remove the bearings with the special tool.
# 09921-20240: Bearing remover set . . . . . . . . . . . . . . . 1
09941-54911: Bearing outer race remover . . . . . . . . . 2
 ENGINE 3-57

BEARING INSPECTION
Play
Rotate the bearing inner race by finger to inspect for abnormal
play, noise and smooth rotation while the bearings are in the
crankcase. Play
Replace the bearing in the following procedure if there is any-
thing unusual.

BEARING REASSEMBLY
• Install the bearing into the crankcase with the special tool.
# 09913-70210: Bearing installer set

OIL SEAL DISASSEMBLY

• Remove the oil seal with the special tools.
# 1 09913-70210: Bearing remover set
2 09913-85210: Bearing remover

# 09913-50121: Oil seal remover

3-58 ENGINE

OIL SEAL REASSEMBLY

• Apply grease to the oil seal lip.
& 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the oil seal with the special tool.
# 09913-70210: Bearing installer set
"
Use a new Oil seal.

BUSHING INSTALLATION
• Replace the bushing with a new one if necessary.
• Assemble the engine mount bushing as shown in the illustra-
tion. Crankcase
Bushing

0.5 mm (0.0197 in)

 ENGINE 3-59

ENGINE REASSEMBLY
• Reassemble the engine in the reverse order of disassembly.
• The following steps require special attention or precautionary
measures should be taken.
NOTE:
Apply engine oil to each running and sliding part before reas-
sembling.

RETURN OIL PUMP

• Install the return oil pump and insert the pin 1 into the shaft.
• Install the pin aligning to the groove of the return oil pump
gear and fit a circlip.

PRIMARY DRIVEN GEAR/ CRANKSHAFT

• Install the primary driven gear 2 and crankshaft assembly 3.
3-60 ENGINE

• Install the crankcase oil separator.

OIL SUMP FILTER

• Install the oil sump filter by aligning the projection of the oil
sump filter to the concave of the crankcase.

PISTON COOLING NOZZLE

• Coat the O-ring with a small amount of grease and install the
piston cooling nozzle 1.

OIL PUMP/ OIL PRESSURE REGULATOR

• Install the oil pump 2, washer 3 and pin 4.

• Coat the O-ring with grease and install the oil pressure regula-
tor 5 to the crankcase.
"
Use a new O-ring.
 ENGINE 3-61

CRANK BALANCER SHAFT

• Install the upper crank balancer shaft 1.
• Install the lower crank balancer 2, oil pump drive gear 3 and
oil pump drive chain 4.
• Engage the drive chain to the oil pump gear and install the oil
pump gear by aligning the groove and pin.
• Install the circlip 5.

"
Align the punched marks in line.

DRIVESHAFT
• Install the counter drive gear shaft 6 from the outside, install
the counter drive gear 7 and fit the circlip.
"
Check that the circlip is positively fitted.

• Install the idle gear 8, idle shaft 9 and driveshaft assembly

0.
3-62 ENGINE

CRANKCASE
• Install the dowel pins.
• Coat each gear and bearing with engine oil, before mating the
crankcase halves.

• Coat the O-ring 1 with grease and fit the O-ring to the crank-
case.
& 99000-25030: SUZUKI SUPER GREASE “A”
• Install the spacer 2.
"
Use a new O-ring.

• Clean the mating surfaces of the left and right crankcase halves.
• Apply SUZUKI BOND to the mating surface of the right crank-
case.
, 99104-31140: SUZUKI BOND “1207B” (USA)
- 99000-31110: SUZUKI BOND “1215” (Others)
"
* Coat the sealing agent quickly in uniform thickness
without interruption.
* Be careful when coating the sealing agent not to
allow it to enter the oil hole, bearing, etc.

• Assemble the crankcases with in few minutes and tighten the

crankcase bolts diagonally and uniformly.
% Right crankcase bolt (M6): 11 N·m (1.1 kgf-m, 8 lb-ft)
% Left crankcase bolt (M8): 26 N·m (2.6 kgf-m, 19 lb-ft)

NOTE:
After tightening the crankcase bolts, check that the crankshaft
rotates smoothly.
 ENGINE 3-63

OIL COOLER
• Coat the O-ring with engine oil and install the oil cooler.
• Install the washer 1 and tighten the union bolt 2 to the spec-
ified torque.
% Oil cooler union bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)
NOTE:
Use a new O-ring.

WATER PUMP
• Install the water pump assembly.

CAM CHAIN
• Install the cam chain sprocket.
NOTE:
Align the punched mark on the crankshaft and that of the cam
chain sprocket.

• Install the washer 3.

• Coat the cam chain tensioner bolt with thread lock and tighten
it.
$ 99000-32050: THREAD LOCK “1342”
• Install the cam chain 4.
3-64 ENGINE

STARTER CLUTCH
• Install the washer 1.

• Coat the internal surface of the starter clutch gear and crank-
shaft with engine oil.
• Install the starter clutch assembly to the crankshaft.
NOTE:
Align the engraved line A of the starter clutch and punched
mark B of the crankshaft.

• Install the starter clutch bolt together with the washer 2.

• Using the special tool, tighten the bolt to the specified torque.
# 09920-34830: Starter clutch rotor holder
% Starter clutch bolt: 55 N·m (5.5 kgf-m, 40.0 lb-ft)

• Install the starter torque limiter shaft 3 and washer 4.

• Install the starter torque limiter 5, starter idle gear shaft 6
and starter idle gear.
* MOLYBDENUM OIL
"
Coat each shaft bearing with a sufficient amount of
molybdenum oil.
 ENGINE 3-65

• Install the new gasket 1 and dowel pin.

• Coat the starter clutch cover bearings with molybdenum oil.

* MOLYBDENUM OIL SOLUTION

• Install the starter clutch cover.

NOTE:
Tighten the starter clutch cover bolt A together with the clamp.
3-66 ENGINE

• Coat the O-ring of the driveshaft oil seal retainer with grease
and install it.
• Install the driveshaft oil seal retainer to the crankcase.
% Driveshaft oil seal retainer bolt:
22 N·m (2.2 kgf-m, 16.0 lb-ft)
NOTE:
Use a new O-ring.

CLUTCH
• Install the clutch shaft to the clutch assembly.
• Coat the part A of the clutch shaft with SUZUKI MOLY
PASTE.
. 99000-25140: SUZUKI MOLY PASTE

• Install the clutch assembly, washer 1 and clutch housing nut

2 to the left crankcase.
• Using the special tool, tighten the clutch housing nut to the
specified torque.
# 09930-40113: Rotor holder
% Clutch housing nut: 70 N·m (7.0 kgf-m, 5 lb-ft)

• Install the new gasket 3 and dowel pins.

• Install the clutch cover.

 ENGINE 3-67

GENERATOR
• Wipe off the oily from the tapered part of the crankshaft.
• Install the key.

• Install the stator coil 1 and CKP sensor 2.

• Fit the grommet firmly.

• Using the special tool, tighten the generator rotor nut to the
specified torque.
# 09930-40113: Rotor holder
% Generator rotor bolt: 160 N·m (16.0 kgf-m, 115.5 lb-ft)

• Install the oil sump filter.

NOTE:
Set the projection of the oil sump filter to concave of the crank-
case.

• Install the new gasket.

3-68 ENGINE

• Install the generator cover.

NOTE:
Tighten the generator cover bolt A together with the clamp.

• Fit the gasket washers 3 and union bolts to the oil hose 1
and oil return hose 2.
NOTE:
Use a new gasket washer.

• Connect the oil hose and oil return hose to the crankcase.
% Oil hose union bolt: 20 N·m (2.0 kgf-m, 14.5 lb-ft)
Oil return hose union bolt: 28 N·m (2.8 kgf-m, 20.0 lb-ft)
 ENGINE 3-69

PISTON RING
• Install the piston rings in the order of the oil ring, second ring
and top ring.
• Install the spacer 1 of the oil ring first and then the side rail
2.

"
* When installing the spacer, be careful so that the
both edges are not overlapped.
* 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.

• Be careful not to mistake the second ring 3 and the top ring
4, the sectional form is different.

• Face the side with the stamped mark upward when assem- 1st ring
Mark
bling.

2nd ring
Mark

• After installing all the piston rings, check that each ring rotates EX
smoothly.
• To prevent poor compression or oil leaking up to the cylinder
inside, position each ring end gap as shown in the right figure.
A Second ring / side rail (lower side)
B Side rail (upper side)
C Top ring / spacer

IN
3-70 ENGINE

PISTON
• Coat the piston pin and conrod small end with molybdenum
oil.
* MOLYBDENUM OIL SOLUTION
• Face the indent mark on the piston head to the exhaust side
of the cylinder, install the pistons 1.

• Place a clean cloth under the piston and fit the circlip 2.
"
Use a new circlip.

CYLINDER
• Coat the conrod big end with oil.
• Install the dowel pins 1 and new cylinder base gasket 2.
"
Use a new gasket.

• Coat the cylinder inside surface and piston rings with engine
oil and install the cylinder.
"
Keep the cam chain pulled out not to be caught
between the sprocket and crankshaft.
 ENGINE 3-71

CYLINDER HEAD
• Install the dowel pins 1, cylinder head gasket 2 and cam
chain guide 3 to the cylinder.
"
Use a new gasket.

• Coat the thread of the cylinder head bolts with engine oil.
• Tighten the cylinder head bolts 1 and 2 in ascending order
of the numbers as illustrated.
• Tighten the bolts to the specified torque in 2 steps; lightly first
and then firmly.

% Cylinder head bolt (M10) 1, 2

Initial tightening:25 N·m (2.5 kgf-m, 18.0 lb-ft)
Final tightening: 53 N·m (5.3 kgf-m, 38.5 lb-ft)
NOTE:
Bolt 1: 150 mm
Bolt 2: 155 mm
• Tighten the cylinder head bolts 3.
% Cylinder head bolt (M8) 3: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

• Unlock the ratchet of the cam chain tension adjuster and push
and compress the adjuster rod.
• Insert the special tool into the gap between the tension
adjuster body and ratchet.
• Install the cam chain tention adjuster bolts 4 and copper
washers 5.
# 09918-53810: Tensioner locking tool
% Cam chain tensioner adjust bolt:
10 N·m (1.0 kgf-m, 7.3 lb-ft)
NOTE:
Use a new copper washer.

• Coat the both sides of the gasket washer 6 with engine oil.
• Tighten the cylinder head side bolt.
% Cylinder head side bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
NOTE:
Face the metal side of the gasket washer outward.
Pass the cylinder head side bolt through the cam chain.
3-72 ENGINE

CAMSHAFT
• Turn the crankshaft clockwise and bring the piston to the top
dead center. (!2-8)

• Before installing the camshafts to the cylinder head, coat the

journals, cam surfaces and camshaft journal holders with
molybdenum oil.
" MOLYBDENUM OIL
NOTE:
Before installing the camshafts, check that the tappet is properly
installed.

• The exhaust camshaft and intake camshaft are distinguished

by the punched mark.
Exhaust camshaft: “B”
Intake camshaft: “A”

Punched mark

• Match the arrow marked (→) on the exhaust cam sprocket “1”
to the cylinder head gasket surface.

IN. EX.

• Match the arrow marked on the intake cam sprocket “3” to the
15 roller pins counted from the exhaust cam sprocket “2”.
NOTE:
Do not move the crankshaft until the camshaft journal holders
and cam chain tension adjuster are fixed.
IN. EX.
 ENGINE 3-73

POSITION OF CAMSHAFTS AND SPROCKETS

15
32 1
3-74 ENGINE

• Install the dowel pins.

• Install the camshaft holders and cam chain guide.

• Arrange the camshaft holder by hand so that it is positioned at
1 – 2 mm from the cylinder head mating surface.
• Tighten the camshaft holder bolts in ascending order of num-
bers as shown in the illustration.
% Cam shaft holder bolt 1: 10 N·m (1.0 kgf-m, 0.7 lb-ft)
Cam shaft holder bolt 2: 10 N·m (1.0 kgf-m, 0.7 lb-ft)
NOTE:
Install the camshaft holder to the correct positions according to
the identification marks.
Intake camshaft: IN
Exhaust camshaft: EX
• Unlock the cam chain tension adjuster.

CYLINDER HEAD COVER

• Assemble the new gasket to the cylinder head cover.
• Coat the semicircular part of the gasket with sealing agent. 1216

1216 '99000-31230: SUZUKI BOND “1216B”

NOTE:
Do not remove the dowel pin at the backside of the cylinder
head cover since it is embedded.

• Install the cylinder head cover.

• Coat the both sides of the gasket washers 3 with engine oil
and tighten the head cover bolts.
% Cylinder head cover bolt
Light tightening: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Final tightening: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
 ENGINE 3-75

OIL LEVEL SWITCH

• Install the oil level switch.
% Oil level switch bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

STARTER MOTOR
• Install the starter motor 1.
• Install the water bypass hose 2.
% Starter motor bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft)
White Page
 DRIVE TRAIN 4-1

DRIVE TRAIN

CONTENTS
DRIVE TRAIN .......................................................................................4- 2
CONSTRUCTION .........................................................................4- 2
REMOVAL AND DISASSEMBLY ................................................4- 3
4
INSPECTION AND REPLACEMENT ...........................................4- 4
REASSEMBLY AND REMOUNTING ..........................................4- 7
4-2 DRIVE TRAIN

DRIVE TRAIN
CONSTRUCTION

10 N.m
1 Final drive gear
(1.0 kgf-m, 7.0 lb-ft)
2 No.1 gear
3 No.2 gear
4 No.3 gear
5 Final driven gear
6 Final gear case cover
7 Final gear case
8 Plate
9 Final driven gear hub
0 Right oil seal
A Left oil seal
B Oil seal
C Circlip

1 mm
(0.04 in)

2 mm (0.08 in)

1 mm
(0.04 in)

1 mm (0.04 in)
 DRIVE TRAIN 4-3

REMOVAL AND DISASSEMBLY

• Remove the right/left side leg shield cover. (!9-12)
• Drain the final gear oil. (!2-15)
• Remove the rear wheel. (!9-48)
• Remove the swingarm. (!9-59)
• Remove the speedometer sensor 1 and harness guide 2.

• Remove the final gear case.

• Remove the bearing from the engine.

• Remove the dowel pins.

• Remove the final gear case bolts in a crisscross pattern.

4-4 DRIVE TRAIN

• Remove the gascket 3 and dowel pins.

• Remove the following gears.
A Final drive gear
B No.1 gear
C No.2 gear
D No.3 gear
E Final driven gear

• Remove the final drive gear hub 4.

INSPECTION AND REPLACEMENT

GEARS
Inspect the gears for wear and damage.
If any defects are found, replace the gear with a new one.

OIL SEALS
Inspect the oil seals for wear and damage.
If any defects are found, replace the seal with a new one.
 DRIVE TRAIN 4-5

• Remove the oil seal with the special tool.

" 09913-50121: Oil seal remover
#
Replace the removed oil seal with a new one.

• Install the new oil seal to the final gear case.

• Apply SUZUKI SUPER GREASE “A” to the oil seals.
$ 99000-25030: SUZUKI SUPER GREASE “A”
NOTE:
Direction of the oil seal is shown in the illustration at page 4-2.

BEARINGS
Inspect the inner race play of the bearing by hand while it is in
the final gear case.
Rotate the inner race by hand to inspect for abnormal noise and
smooth rotation.
If there is anything unusual, replace the bearing with a new one.

• Remove the bearing with the special tool.

" 09921-20240: Bearing remover set

• To facilitate setting the special tool, knock down the plate 1

that is at the No.2 gear bearing.
• Remove the bearing with the special tool.
" 09921-20240: Bearing remover set
#
Replace the removed plate 1 with a new one.
4-6 DRIVE TRAIN

• Remove the final driven gear bearing by using the appropriate

bar.

• Remove the final drive gear bearing with the special tools.
" 09941-64511: Bearing remover
09930-30104: Sliding shaft

• Install the bearings to the final gear case with the special tool.
" 09913-70210: Bearing installer set
#
Replace the removed bearing with a new one.

• Install the plate 2 into the final gear case cover at the No.2
gear, and then install the bearing.
#
Install the plate 2 with the convexity A showed up.

FINAL DRIVEN GEAR HUB

Inspect the final driven gear hub for wear and damage. If any
defects are found, replace the final driven gear hub with a new
one.
 DRIVE TRAIN 4-7

REASSEMBLY AND REMOUNTING

• Install the gears and final driven gear hub onto the final gear
case cover.
• Install the dowel pins 1 and the new gasket.
• Apply SUZUKI SUPER GREASE “A” to spline of the final
drive gear.
$ 99000-25030: SUZUKI SUPER GREASE “A”

• Assemble the final gear case.

• Tighten the final gear case bolts to the specified torque.
% Final gear case bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Apply SUZUKI SUPER GREASE “A” to the bearing.

• Install the bearing to the drive shaft.
$ 99000-25030: SUZUKI SUPER GREASE “A”

• Install the final gear case assembly.

• Tighten the rear shock absorber mounting bolt.
% Rear shock absorber mounting bolt:
29 N·m (2.9 kgf-m, 21.0 lb-ft)

• Install the speedometer sensor 2 and harness guide 3.

• Tighten the speedometer sensor bolt to the specified torque.
% Speedometer sensor bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
NOTE:
Apply grease to the O-ring of speedometer sensor before install-
ing the sensor to the final gear case.
4-8 DRIVE TRAIN

• Clamp the breather hose 4 and speedometer sensor harness

5.

• Install the swingarm. (!9-61)

• Install the exhaust muffler. (!3-11)
• Install the rear wheel. (!9-56)
• Install the right/left side leg shield covers.
• Pour the final gear oil. (!2-16)
 CVT 5-1

CVT

CONTENTS
CVT ASSEMBLY REMOVAL AND INSTALLATION ...........................5- 2
CVT ASSEMBLY REMOVAL .......................................................5- 2
CVT ASSEMBLY INSTALLATION ..............................................5- 4
CVT DISASSEMBLY AND REASSEMBLY .........................................5- 5
CVT DISASSEMBLY ....................................................................5- 6 5
CVT INSPECTION ........................................................................5-11
CVT PRIMARY PULLEY SHIMS ADJUSTMENT ........................5-16
CVT REASSEMBLY .....................................................................5-19
5-2 CVT

CVT ASSEMBLY REMOVAL AND INSTALLATION

CVT ASSEMBLY REMOVAL
• Remove the engine assembly.
ENGINE REMOVAL !3-3

• Remove the bracket 1.

• Remove the bolts, 2 and 3.

• Install the special tool as shown.

" 09920-31050: CVT guide
 CVT 5-3

• Remove the CVT mounting bolts.

• Remove the CVT assembly.

5-4 CVT

CVT ASSEMBLY INSTALLATION

• Remove the valve timing inspection cap 1.

• Install the special tool to the engine assembly as shown.

• Apply SUZUKI MOLY PASTE to the primary driven gear shaft
and clutch shaft.
" 09920-31050: CVT guide
#99000-25140: SUZUKI MOLY PASTE

• Engage the spline and install the CVT assembly by turning

the crankshaft slowly.

• Install the bracket 2.

• Tighten the CVT mounting bolt to the specified torque.
$ CVT mounting bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft)

• Install the valve timing inspection cap 3.

ENGINE INSTALLATION !3-10
 CVT 5-5

CVT DISASSEMBLY AND REASSEMBLY

D Oil seal
1 Secondary pulley shaft nut E Washer
2 Secondary pulley shaft adaptor F Secondary pulley assembly
3 O-ring G Secondary pulley fan
4 Primary pulley shaft bolt H Bearing
5 Primary pulley shaft adaptor I Snap ring
6 CVT casing J Primary slide pulley idle gear
7 Bearing K Secondary pulley revolution
8 O-ring sensor
9 CVT belt L CVT motor
0 Primary pulley assembly M CVT cover
A Shim N CVT filter
B O-ring O Primary pulley stopper bolt
C Bearing P Pulley position sensor
Q Dust seal
5-6 CVT

CVT DISASSEMBLY
CVT CASING/COVER
• Remove the pulley position sensor 1.

• Remove the secondary pulley revolution sensor 2.

• Remove the CVT motor.

• Remove the CVT filter cover.

• Remove the CVT filter

 CVT 5-7

• Remove the secondary pulley shaft nut by holding the shaft

with the special tools.
" 09920-31020: Extension handle
09920-31030: CVT secondary pulley shaft holder

• Remove the secondary shaft adaptor with a bearing puller.

• Remove the primary pulley shaft bolt by holding the primary

pulley shaft with the special tools.
" 09920-31010: CVT primary pulley shaft holder
09920-31020: Extension handle

• Screw in the special tool and remove the primary pulley shaft
adaptor.
" 09920-31040: CVT primary pulley shaft adaptor
remover
5-8 CVT

• Separate the CVT assembly by using 6 mm screws.

NOTE:
When separating the CVT assembly, position the right side fac-
ing downward.

• After separating the CVT assembly, remove the CVT casing

with the special tool.
" 09920-13120: Crankcase separater
%
The crankcase separator plate is parallel with the end
face of the CVT crankcase.

%
When servicing the inside of the CVT assembly, make
sure to wear clean protective gloves.

• Remove the dowel pins.

 CVT 5-9

SECONDARY PULLEY ASSEMBLY

• Remove the washer 1 on the secondary pulley shaft.

• Turn the primary slide pulley idle gear clockwise and open the
primary pulley fully.

• Remove the primary slide pulley idle gear 2 and 3.

• Place a piece of clean rag on the primary pulley faces to pre-

vent them from scratches.

• Remove the secondary pulley assembly.

%
Use caution not to cause scratches on the pulley sur-
faces dne to their contact.
5-10 CVT

CVT BELT
• Place a piece of clean rag on the CVT cover mating face to
prevent the CVT belt from scratches.

• Remove the CVT belt.

• Mark the direction mark on the CVT belt.

PRIMARY PULLEY
• Remove the primary pulley stopper bolt A.
NOTE:
In the case of replacing the CVT belt only, removing of the primary
pulley is not necessary. (CVT BELT INSTALLATION !5-20)

• Remove the primary pulley assembly.

 CVT 5-11

• Remove the shim 1 and O-ring 2.

CVT INSPECTION
PRIMARY PULLEY INSPECTION
• Check that the primary pulley faces are free from any greasy
substance.
• Inspect the primary pulley faces for any abnormal conditions
such as scratches or stepped wear.
%
If the surface is found greasy, make sure to degrease
it thoroughly.
• If any damages are found, replace the primary pulley assem-
bly with a new one.
• Replace the O-ring with a new one.

SECONDARY PULLEY INSPECTION

• Inspect the secondary pulley faces for any abnormal condi-
tions such as scratches or stepped wear.
• If any damages are found, replace the primary pulley assem-
bly with a new one.
• Check that the secondary pulley faces are free from any
greasy substance.
%
If the surface is found greasy, make sure to degrease
it thoroughly.
5-12 CVT

• Rotate the bearing outer race by finger to inspect for abnor-

mal play, noise and smooth rotation.
• Inspect the secondary pulley fan for cracks or damage.
• Replace the bearing or secondary pulley fan if there is any-
thing unusual.

SECONDARY PULLEY DISASSEMBLY

• Remove the secondary pulley fan 1.

• Remove the snap ring 2.

" 09900-06107: Snap ring pliers

• Remove the bearing with a bearing puller.

CVT MOTOR
• When replacing the CVT motor gear, align the hole A with the
hole of motor shaft to install the pin.
 CVT 5-13

SECONDARY PULLEY REASSEMBLY

• Fit the special tool and install a new bearing by a hydraulic
press.
Bearing
" 09913-75810: Bearing installer
%
Replace the removed bearing with a new one.

• Install the snap ring.

" 09900-06107: Snap ring pliers

• Apply THREAD LOCK “1342” to the secondary pulley fan

bolts and tighten them.
& 99000-32050: THREAD LOCK “1342”

CVT BELT INSPECTION

• Check that the drive belt is free from any greasy substance.
• Inspect the CVT belt for cracks or uneven wear.
• If any damages are found, replace the CVT belt with a new
one.
%
* If the CVT belt is found greasy, replace it with a new
one.
* Do not spray a cleaning solvent directly on the CVT
belt.
5-14 CVT

CVT CASING/COVER INSPECTION

• Replace the oil seal 1 with a new one.
%
Replace the oil seal every time the CVT assembly is
separated.

• Rotate the bearing by finger to inspect for abnormal play,

noise and smooth rotation.
• Replace the bearing if there is anything unusual.

• Replace the O-ring with a new one.

• Apply SUZUKI SUPER GREASE “A” to the new O-ring and
install it.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• Thoroughly clean the case free from dirt and sealant.

CVT CASING/COVER DISASSEMBLY

• Remove the bearing retainer 1.
 CVT 5-15

• Remove the bearing with the special tool.

" 09921-20240: Bearing remover set

• Remove the bearing together with the oil seal by using the
special tool.
" 09913-70210: Bearing installer set

CVT CASING/COVER REASSEMBLY

• Install the bearing with the special tool.
" 09913-70210: Bearing installer set

• Install the bearing retainer 1.

• Install the oil seal and bearing with the special tool.
" 09913-70210: Bearing installer set
5-16 CVT

PRIMARY SLIDE PULLEY IDLE GEAR INSPECTION

• Inspect the pulley gears for wear or damage.
• Rotate the bearing by finger to inspect for abnormal play,
noise and smooth rotation.
• If any wear or damage is found, replace the idle gear assem-
bly with a new one.

CVT PRIMARY PULLEY SHIMS ADJUSTMENT

%
If any of the primary pulley, CVT casing or CVT cover
has been replaced, install the shim whose thickness
has been adjusted in the shim adjustment procedure.

CVT COVER DEPTH MEASUREMENT

• Fix the CVT cover securely with its mating face positioned
horizontally.
• With the straightedge placed on the cover mating face, mea-
sure the depth D to the face A of the cover which the primary
pulley assembly contacts using the vernier calipers.
• Measure the depth D at three points and note the measured
value D1, D2 and D3.
" 09900-20102: Vernier calipers

PRIMARY PULLEY HEIGHT MEASUREMENT

• Install the primary pulley assembly onto the CVT casing.

• Install the primary pulley shaft adaptor with the special tool.
" 09913-60910: Bearing puller or
09913-61110: Bearing puller or
09913-61510: Bearing puller
 CVT 5-17

• Tighten the primary pulley shaft bolt to the specified torque

with the special tools.
$ Primary pulley shaft bolt: 64 N·m (6.4 kgf-m, 46.5 lb-ft)
" 09920-31010: CVT primary pulley shaft holder
09920-31020: Extension handle

• Fix the CVT casing securely with its mating face positioned
horizontally.
• With the straightedge placed on the casing mating face, mea-
sure the height H to the face B of the primary pulley assem-
bly using the vernier calipers.
• Measure the height H at three points and note the measured
value H1, H2 and H3.
" 09900-20102: Vernier calipers

D H
5-18 CVT

SHIM SELECTION
• Get the average depth Da by averaging D1, D2 and D3.
• Get the average height Ha by averaging H1, H2 and H3.
• Obtain the valve X by subtracting Da from Ha.
• Using the chart below, select the appropriate shim with reference to the value X.

SHIM SELECTION TABLE

SHIM THICKNESS VALUE X
0.12 mm (0.005 in) 3.12 – 3.31 mm (0.123 – 0.130 in)
0.32 mm (0.013 in) 3.32 – 3.51 mm (0.131 – 0.138 in)
0.52 mm (0.020 in) 3.52 – 3.71 mm (0.139 – 0.146 in)
0.72 mm (0.028 in) 3.72 – 3.91 mm (0.147 – 0.154 in)
0.92 mm (0.036 in) 3.92 – 4.11 mm (0.155 – 0.162 in)
1.12 mm (0.044 in) 4.12 – 4.31 mm (0.163 – 0.170 in)
1.32 mm (0.052 in) 4.32 – 4.51 mm (0.171 – 0.178 in)

NOTE:
The shims are available as a set (21746-10G00).

EXAMPLE:

CVT cover depth D D1 = 125.35 mm (4.935 in)

D2 = 125.15 mm (4.927 in)
D3 = 125.25 mm (4.931 in)
Average depth Da = (125.35 + 125.15 + 125.25) ÷ 3
= 125.25 mm (4.931 in)

Primary pulley height H H1 = 121.45 mm (4.781 in)

H2 = 121.60 mm (4.787 in)
H3 = 121.45 mm (4.781 in)
Average height Ha = (121.45 + 121.60 + 121.45) ÷ 3
= 121.50 mm (4.783 in)

Value X = Da – Ha
= 125.25 mm (4.931 in) – 121.50 mm (4.783 in)
= 3.75 mm (0.148 in)

* Slelect the 0.72 mm (0.028 in) shim.

 CVT 5-19

CVT REASSEMBLY
PRIMARY PULLEY ASSEMBLY
%
Wear clean protective gloves.

• Degrease the inside of the CVT cover and CVT casing com-
pletely with a cleaning solvent by using a clean rag.

• Install the O-ring 1 and shim 2.

%
If any of the primary pulley, CVT casing or CVT cover
has been replaced, install the shim whose thickness
has been adjusted in the shim adjustment procedure.

• Turn the slide pulley gear and close the primary pulley.

• Align the cutaway B of the screw shaft with the protrusion A.

%
Degrease the primary pulley faces completely.
5-20 CVT

NOTE:
Primary pulley cover has the protrusion A and C.

• Turn the primary pulley cover 180 degrees along the groove
on the screw shaft and align the cutaway B with D or E posi-
tion of the primary pulley cover.

• With the cutaway B aligned with the stopper bolt hole F of

the CVT cover, position the primary pulley assembly onto the
CVT cover.

• Make sure that the screw shaft is in proper position by check-

ing the location of cutaway B when viewed from the stopper
bolt hole F.
• Tighten the stopper bolt to the specified torque.
$ Primary pulley stopper bolt: 36 N·m (3.6 kgf-m, 26.0 lb-ft)

CVT BELT INSTALLATION

• Install the primary slide pulley idle gear temporarily.
• Turn the idle gear clockwise and open the primary pulley fully.
 CVT 5-21

• Place a piece of clean rag on the CVT casing mating face to

prevent the CVT belt from scratches.

• Install the CVT belt so that the direction mark on the CVT belt
points in the normal turning direction.
%
Never touch the side walls of the CVT belt.

• Place a piece of clean rag on the primary pulley faces to pre-

vent them from scratches.

SECONDARY PULLEY ASSEMBLY

• Install the secondary pulley assembly.
• Remove the rags.
%
* Degrease the secondary pulley faces completely.
* Use caution not to cause scratches on the pulley
surfaces due to their contact.

• Check that the secondary pulley is located inwardly relative to

the primary pulley.
5-22 CVT

• Check that the CVT belt is in parallel with the CVT cover mat-
ing face.

• Install the primary slide pulley idle gear 1 and 2.

• Turn the idle gear until the primary pulley faces just touch the
CVT belt.

• Check the CVT belt movement for smooth rotation by turning

the both pulleys.

• Install the secondary pulley washer 3.

 CVT 5-23

CVT CASING/COVER
• Wipe the CVT casing/cover mating surface with a cleaning
solvent.
• Fit the dowel pins.

• Apply a small quantity of SUZUKI SUPER GREASE to the

grease groove A of the primary pulley shaft.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
%
Do not apply grease under the groove A.

• Cover the secondary pulley shaft with a vinyl film to prevent

oil seal damage.

• Apply a small quantity of engine oil to the main lip B of the oil
seal.
(ENGINE OIL

• Apply SUZUKI BOND “1215” to the mating surface of the CVT

casing.
) 99000-31110: SUZUKI BOND “1215”
NOTE:
* Make surfaces free from moisture, oil, dust and other foreign
materials.
* Spread on surfaces thinly to form an even layer, and assemble
the CVT casing and cover within few minutes.
5-24 CVT

• Tighten the CVT cover bolts diagonally to the specified

torque.
$ CVT cover bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft)
NOTE:
Fit the clamp to the bolt A.

• Apply SUZUKI SUPER GREASE “A” to the primary pulley

shaft adaptor.
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• Install the primary pulley shaft adaptor with the special tool.
" 09913-60910: Bearing puller or
09913-61110: Bearing puller or
09913-61510: Bearing puller

• Apply THREAD LOCK SUPER “1360” to the primary pulley

shaft bolt.
* 99000-32130: THREAD LOCK SUPER “1360”

• Tighten the primary pulley shaft bolt to the specified torque

with the special tools.
$ Primary pulley shaft bolt: 64 N·m (6.4 kgf-m, 46.5 lb-ft)
" 09920-31010: CVT primary pulley shaft holder
09920-31020: Extension handle
 CVT 5-25

• Apply a small quantity of engine oil to the secondary pulley

bearing.
• Apply grease to the secondary pulley shaft adaptor.
(ENGINE OIL
' 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• Install the special tool onto the secondary pulley shaft.

" 09910-32850: Crankshaft installer attachment

• Press in the secondary pulley shaft adaptor with the special

tool.
" 09910-32812: Crankshaft installer

• Apply THREAD LOCK SUPER “1360” to the secondary pulley

shaft nut.
* 99000-32130: THREAD LOCK SUPER “1360”

• Tighten the secondary pulley shaft nut to the specified torque

with the special tools.
$ Secondary pulley shaft nut:
226 N·m (22.6 kgf-m, 163.5 lb-ft)
" 09920-31020: Extension handle
09920-31030: CVT secondary pulley shaft holder
5-26 CVT

• Clean the CVT filter by using compressed air.

• Install the CVT filter.

• Install the CVT filter cover.

• Fit the clamp to the bolts A.

• Install the CVT motor.

NOTE:
Pay attention to the direction of the CVT motor.

• Install the secondary pulley revolution sensor.

 CVT 5-27

• Install the pulley position sensor 1 with the sensor pushed

toward the primary pulley shaft side.

CVT BELT BRAKE-IN PROCEDURES

• It is necessary to allow the CVT belt to “BRAKE-IN” before
subjecting the CVT to maximum stresses.
Brake -in engine speed
Initial 800 km (500 miles): Below 4 000 rpm.
NOTE:
When the CVT belt is new, the engine rpm may jump briefly
under hard acceleration due to the smoothness of the belt.

CLAMP LOCATION

30˚

35˚

30˚
White Page
 FI SYSTEM/ CVT SYSTEM 6-1

FI SYSTEM/ CVT SYSTEM

CONTENTS
PRECAUTIONS IN SERVICING ............................................................. 6- 2
ELECTRICAL PARTS ...................................................................... 6- 2
ELECTRICAL CIRCUIT INSPECTION PROCEDURE ..................... 6- 5
USING TESTERS ............................................................................. 6- 8
FI SYSTEM TECHNICAL FEATURES .................................................... 6- 9
INJECTION TIME (INJECTION VOLUME) ...................................... 6- 9
COMPENSATION OF INJECTION TIME (VOLUME) ...................... 6-10
INJECTION STOP CONTROL ......................................................... 6-10
FI SYSTEM PARTS LOCATION ...................................................... 6-11
FI SYSTEM WIRING DIAGRAM ...................................................... 6-13
CVT SYSTEM TECHNICAL FEATURES ................................................ 6-14 6
CVT SYSTEM PARTS LOCATION .................................................. 6-15
SELF-DIAGNOSIS FUNCTION ............................................................... 6-18
USER MODE .................................................................................... 6-18
DEALER MODE ............................................................................... 6-19
TPS ADJUSTMENT ......................................................................... 6-20
FAIL-SAFE FUNCTION ........................................................................... 6-21
FI SYSTEM/ CVT SYSTEM TROUBLESHOOTING ............................... 6-22
CUSTOMER COMPLAINT ANALYSIS ............................................ 6-22
SELF-DIAGNOSTIC PROCEDURES ............................................... 6-24
SELF-DIAGNOSIS RESET PROCEDURE ...................................... 6-24
MALFUNCTION CODE AND DEFECTIVE CONDITION ................. 6-25
“C11” CMP SENSOR CIRCUIT MALFUNCTION ............................ 6-27
“C12” CKP SENSOR CIRCUIT MALFUNCTION ............................ 6-28
“C13” IAP SENSOR CIRCUIT MALFUNCTION .............................. 6-29
“C14” TP SENSOR CIRCUIT MALFUNCTION ............................... 6-31
“C15” ECT SENSOR CIRCUIT MALFUNCTION ............................ 6-33
“C16” SPEED SENSOR CIRCUIT MALFUNCTION ....................... 6-34
“C21” IAT SENSOR CIRCUIT MALFUNCTION .............................. 6-36
“C22” AP SENSOR CIRCUIT MALFUNCTION ............................... 6-37
“C23” TO SENSOR CIRCUIT MALFUNCTION ............................... 6-39
“C24” or “C25” IGNITION SYSTEM MALFUNCTION .................... 6-40
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION ....... 6-40
“C40” IAC VALVE CIRCUIT MALFUNCTION ................................. 6-41
“C41” FP RELAY CIRCUIT MALFUNCTION .................................. 6-41
“C42” IG SWITCH CIRCUIT MALFUNCTION ................................. 6-41
“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION
(E-02, 19) .......................................................................................... 6-42
“C50” CVT SERIAL COMMUNICATION CIRCUIT
MALFUNCTION ................................................................................ 6-44
“C51” CVT MOTOR CIRCUIT MALFUNCTION .............................. 6-45
“C52” CVT PULLEY POSITION SENSOR (PPS) CIRCUIT
MALFUNCTION ................................................................................ 6-47
“C53” CVT SPEED SENSOR CIRCUIT MALFUNCTION ............... 6-49
“C54” CVT SECONDARY PULLEY REVOLUTION SENSOR
CIRCUIT MALFUNCTION ................................................................ 6-51
“C55” CVT ENGINE REVOLUTION SIGNAL CIRCUIT
MALFUNCTION ................................................................................ 6-53
“C56” CVT THROTTLE POSITION SIGNAL CIRCUIT
MALFUNCTION ................................................................................ 6-54
“C58” CVT REDUCTION RATIO DISAGREEMENT ....................... 6-55
SENSORS ........................................................................................ 6-56
6-2 FI SYSTEM/ CVT SYSTEM

PRECAUTIONS IN SERVICING
When handling the FI/CVT component parts or servicing the FI
system/CVT system, observe the following points for the safety
of the system.

ELECTRICAL PARTS
CONNECTOR/COUPLER
• When connecting a connector, be sure to push it in until a
Click
click is felt.
• With a lock type coupler, be sure to release the lock when dis-
connecting, and push it in fully till the lock works when con-
necting it.
• When disconnecting the coupler, be sure to hold the coupler
body and do not pull the lead wires.
• Inspect each terminal on the connector/coupler for looseness
or bending.
• Inspect each terminal for corrosion and contamination.
Click
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.

• Inspect each lead wire circuit for poor connection by shaking it

by hand lightly. If any abnormal condition is found, repair or
replace.

• When taking measurements at electrical connectors using a

tester probe, be sure to insert the probe from the wire harness
side (backside) of the connector/coupler.

Coupler
Probe
 FI SYSTEM/ CVT SYSTEM 6-3

• When connecting meter probe from the terminal side of the

coupler (connection from harness side not being possible),
use extra care not to force and cause the male terminal to
bend or the female terminal to open.
Connect the probe as shown to avoid opening of female ter-
minal.
Coupler
Never push in the probe where male terminal is supposed to Probe
fit. Where male
• Check the male connector for bend and female connector for terminal fits

excessive opening. Also check the coupler for locking (loose-

ness), corrosion, dust, etc.

FUSE
• When a fuse blows, always investigate the cause, correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.

ECM/ CVT CONTROL UNIT/ VARIOUS SENSORS

• Since each component is a high-precision part, great care INCORRECT
should be taken not to apply any sharp impacts during
removal and installation.

• Be careful not to touch the electrical terminals of the

ECM/CVT control unit. The static electricity from your body
may damage this part.
6-4 FI SYSTEM/ CVT SYSTEM

• When disconnecting and connecting the ECM/CVT control Ignition S/W

unit couplers, make sure to turn OFF the ignition switch, or

electronic parts may get damaged.

• Battery connection in reverse polarity is strictly prohibited. INCORRECT

Such a wrong connection will damage the components of the

FI system/CVT control unit instantly when reverse power is
applied.

• Removing any battery terminal of a running engine is strictly

prohibited.
The moment such removal is made, damaging counter elec-
tromotive force will be applied to the ECM/CVT control unit
which may result in serious damage.

• Before measuring voltage at each terminal, check to make

sure that battery voltage is 11 V or higher. Terminal voltage
check at low battery voltage will lead to erroneous diagnosis.

• Never connect any tester (voltmeter, ohmmeter, or whatever)

to the ECM/CVT control unit when its coupler is disconnected.
Otherwise, damage to ECM/CVT control unit may result.
• Never connect an ohmmeter to the ECM/CVT control unit with
its coupler connected. If attempted, damage to ECM/CVT
control unit or sensors may result.
• Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained and personal
injury may result.
 FI SYSTEM/ CVT SYSTEM 6-5

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE
While there are various methods for electrical circuit inspection,
described here is a general method to check for open and short
circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause
can exist in the connector/coupler or terminal, they need to be
checked carefully.
• 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
• Disconnect the negative cable from the battery.
• Check each connector/coupler at both ends of the circuit
being checked for loose connection. Also check for condition
of the coupler lock if equipped.
Sensor
ECM

Check for loose connection

• Using a test male terminal, check the female terminals of the

circuit being checked for contact tension. Check contact
Check each terminal visually for poor contact (possibly tension by inserting
and removing.
caused by dirt, corrosion, rust, entry of foreign object, etc.). At
the same time, check to make sure that each terminal is fully
inserted in the coupler and locked.
If contact tension is not enough, rectify the contact to increase Check each terminal
for bend and proper
tension or replace. alignment.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
• Using continuity inspect or voltage check procedure as
described below, inspect the wire harness terminals for open
circuit and poor connection. Locate abnormality, if any.

Looseness of crimping
Open
Thin wire (a few strands left)
6-6 FI SYSTEM/ CVT SYSTEM

Continuity check
• Measure resistance across coupler B (between A and C in
the figure).
If no continuity is indicated (infinity or over limit), the circuit is ECM
open between terminals A and C.

• Disconnect the coupler B and measure resistance between ’

couplers A and B.
If no continuity is indicated, the circuit is open between cou-
plers A and B. If continuity is indicated, there is an open cir- ECM
cuit between couplers B’ and C or an abnormality in coupler
B’ or coupler C.

VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
• With all connectors/couplers connected and voltage applied
to the circuit being checked, measure voltage between each
terminal and body ground.

If measurements were taken as shown in the figure at the right

and results are as listed below, it means that the circuit is open
between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 0V

5V
Also, if measured values are as listed below, a resistance
5V
(abnormality) exists which causes the voltage drop in the circuit
0V
between terminals A and B. 5V

Voltage Between:
C and body ground: Approx. 5V
B and body ground: Approx. 5V 2 V voltage drop
A and body ground: 3V
 FI SYSTEM/ CVT SYSTEM 6-7

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.
To other
• Disconnect the connectors/couplers at both ends of the circuit parts
to be checked.
NOTE:
If the circuit to be checked branches to other parts as shown,
disconnect all connectors/couplers of those parts. Otherwise,
diagnosis will be misled.
• Measure resistance between terminal at one end of circuit (A
terminal in figure) and body ground. If continuity is indicated,
there is a short circuit to ground between terminals A and C. Other parts

5V

• Disconnect the connector/coupler included in circuit (coupler

B) and measure resistance between terminal A and body To other
parts
ground.
ECM
If continuity is indicated, the circuit is shorted to the ground
between terminals A and B.
6-8 FI SYSTEM/ CVT SYSTEM

USING TESTERS
• Use the Suzuki multi-circuit tester (09900-25008).
• Use well-charged batteries in the tester.
• Be sure to set the tester to the correct testing range.

USING THE TESTER MULTI-CIRCUIT TESTER

• Incorrectly connecting the + and - probes may cause the
inside of the tester to burnout.
• If the voltage and current are not known, make measure-
ments using the highest range.
• When measuring the resistance with the multi-circuit tester, ∞
will be shown as 10.00 MΩ and “1” flashes in the display.
• Check that no voltage is applied before making the measure-
ment. If voltage is applied, the tester may be damaged.
• After using the tester, turn the power off.
! 09900-25008: Multi-circuit tester
NOTE:
* When connecting the multi-circuit tester, use a fine needle
pointed probe or install fine copper wires (O.D is below
0.5 mm) to the back side of the lead wire coupler and connect
the probes of tester to them.
* Use a fine copper wire, the outer diameter being below
0.5 mm, to prevent the rubber of the water proof coupler from
damage.
 FI SYSTEM/ CVT SYSTEM 6-9

FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time which is calculated on the
basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine
and driving conditions.

ECM

Intake Air Pressure Intake air pressure

Sensor (IAP Sensor) signal
Basic
Crankshaft Position Engine speed fuel
Sensor (CKP Sensor) signal injection
time
Throttle Position Throttle opening
Sensor (TP Sensor) signal

Various Various signals

Compensation
Sensors

Ultimate
Injectors Injection signal fuel
injection
time
6-10 FI SYSTEM/ CVT SYSTEM

COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection
time (volume).

SIGNAL DESCRIPTION
ATMOSPHERIC PRESSURE SENSOR When atmospheric pressure is low, the sensor sends the
SIGNAL signal to the ECM and reduce the injection time (volume).
ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol-
SOR SIGNAL ume) is increased.
INTAKE AIR TEMPERATURE SENSOR When intake air temperature is low, injection time (volume)
SIGNAL is increased.
HEATED OXYGEN SENSOR SIGNAL Air/fuel ratio is compensated to the theoretical ratio from
(E-02, 19) density of oxygen in exhaust gasses. The compensation
occurs in such a way that more fuel is supplied if detected
air/fuel ratio is lean and less fuel is supplied if it is rich.
BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at the same time,
it monitors the voltage signal for compensation of the fuel
injection time (volume). A longer injection time is needed to
adjust injection volume in the case of low voltage.
ENGINE RPM SIGNAL At high speed, the injection time (volume) is increased.
STARTING SIGNAL When starting engine, additional fuel is injected during
cranking engine.
ACCELERATION SIGNAL/ During acceleration, the fuel injection time (volume) is
DECELERATION SIGNAL increased, in accordance with the throttle opening speed
and engine rpm. During deceleration, the fuel injection time
(volume) is decreased.

INJECTION STOP CONTROL

SIGNAL DESCRIPTION
TIP OVER SENSOR SIGNAL When the motorcycle tips over, the tip over sensor sends a
(FUEL SHUT-OFF) signal to the ECM. Then, this signal cuts OFF current sup-
plied to the fuel pump, fuel injectors and ignition coils.
OVER-REV. LIMITER SIGNAL The fuel injectors stop operation when engine rpm reaches
rev. limit rpm.
 FI SYSTEM PARTS LOCATION

A Combination meter F Ignition coil (IG COIL)

B ECM G Camshaft position sensor (CMPS)
C PAIR control solenoid valve H Crankshaft position sensor (CKPS)
D Fuel injector (FI) I Speed sensor
E Engine coolant temperature sensor (ECTS)
FI SYSTEM/ CVT SYSTEM 6-11
 6-12
FI SYSTEM/ CVT SYSTEM

B ECM O Intake air temperature sensor (IATS)

J Tip over sensor (TOS) P Throttle position sensor (TPS)
K CVT control unit Q IAC valve
L Fuel pump relay (FP RELAY) R Fuel pump (FP)
M Atomospheric pressure sensor (APS) S Heated oxygen sensor (HO2S) [E-02, 19]
N Intake air pressure sensor (IAPS)
Camshaft position sensor (CMPS) Combination meter Fuel pump (FP)

Fuel injector (FI)

Crankshaft position sensor

(CKPS) Fuel pump relay
(FP RELAY)
10A
Ignition
Throttle position sensor switch
(TPS)
10A 30A
FI SYSTEM WIRING DIAGRAM

Ignition coil Engine 15A

(IG COIL) stop
Intake air pressure switch
sensor (IAPS) Brake switch

Starter
ECM switch
Atomospheric pressure
sensor (APS)

Starter
Side relay
stand
Engine coolant temperature relay
sensor (ECTS)
Starter motor

Side
Intake air temperature stand
sensor (IATS) switch

Tip over sensor (TOS)

Heated oxygen sensor

(HO2S) [E-02, 19]
FI SYSTEM/ CVT SYSTEM 6-13
6-14 FI SYSTEM/ CVT SYSTEM

CVT SYSTEM TECHNICAL FEATURES

The CVT reduction ratio is controlled in relation to Actual CVT ratio and Target CVT ratio.
The reduction ratio as detected by the CVT pulley position sensor is compensated for more accurate valve
as Actual CVT ratio by comparing with the signals from the crankshaft position sensor and CVT secondary
pully revolution sensor.
Target CVT ratio is calculated on the basis of the target engine speed as determined by the speed sensor
and the throttle position sensor.

CVT Control Unit

Speed Sensor Vehicle speed

Target engine rpm

Throttle Position Throttle position
Sensor (TP Sensor)

Target CVT ratio

Crankshaft Position Engine rpm

Sensor (CKP Sensor)

CVT Pulley Position CVT primary pulley

Actual CVT ratio
Sensor position

CVT Secondary Pulley CVT secondary pulley

Revolution Sensor revolution

CVT motor
operating voltage

CVT motor
A CVT secondary pulley revolution signal D Center stand voltage
(CVT secondary pulley revolution sensor) (Center stand switch)
B CVT motor operating voltage E Serial communication
(CVT motor) F Throttle position voltage
C CVT pulley position voltage (Throttle position sensor)
(CVT pulley position sensor)
CVT SYSTEM PARTS LOCATION
FI SYSTEM/ CVT SYSTEM 6-15
 6-16
FI SYSTEM/ CVT SYSTEM

E Serial communication
G Speed signal
(Speed sensor)
H Engine rpm
(Crankshaft position sensor)
 FI SYSTEM/ CVT SYSTEM 6-17

The CVT control unit adjusts the CVT reduction ratio by making the pulley wider or narrower. The slide pul-
ley movement is controlled by the CVT motor revolution.
The secondary pulley squeezes the CVT belt with the spring force and the width of pulley adjusts itself in
accordance with that of the primary pulley.

CVT motor

CVT pulley position sensor

Primary pulley assembly

Slide pulley

Secondary pulley assembly

Clutch

CVT belt
6-18 FI SYSTEM/ CVT SYSTEM

SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and
“Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and FI light. To check the func-
tion of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is neces-
sary to read the code of the malfunction items.

USER MODE
LCD (DISPLAY) FI LIGHT
MALFUNCTION INDICATIONﾅ@MODE
INDICATION INDICATION
“NO” Odometer ––– –––
“YES” Odometer and FI light turns ON. Each 2 sec. Odometer
“FI” letters or “FI” is indicated.
Engine can start *1
Engine can not start “FI” letters FI light turns ON “FI” is indicated
*2 and blinks. continuously.

*1
When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In
this case, “FI” and odometer are indicated in the LCD panel and motorcycle can run.
*2
The injection signal is stopped, when the crankshaft position sensor signal, tip over sensor signal, #1/#2
ignition signals, #1/#2 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In
this case, “FI” is indicated in the LCD panel. Motorcycle does not run.

“CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for
3 seconds.
For Example
: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speed-
ometer does not receive any signal from the ECM, and the panel indicates “CHEC”.
If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wir-
ing harness between ECM and speedometer couplers.
The possible cause of this indication is as follows;
Engine stop switch is in OFF position. Ignition fuse is burnt.
 FI SYSTEM/ CVT SYSTEM 6-19

DEALER MODE
The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer
mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means
that the ECM does not receive signal from the devices. These affected devices are indicated in the code
form.
! 09930-82720: Mode select switch

"
Before checking the malfunction code, do not disconnect the ECM lead wire couplers.
If the couplers from the ECM are disconnected, the malfunction code memory is erased and the
malfunction code can not be checked.

LCD (DISPLAY)
MALFUNCTION FI LIGHT INDICATION INDICATION MODE
INDICATION
“NO” C00 –––
C** code is indicated
FI light turns OFF. For each 2 sec., code is
“YES” from small numeral to
indicated.
large one.
6-20 FI SYSTEM/ CVT SYSTEM

CODE MALFUNCTION PART REMARKS

C00 None No defective part
C11 Camshaft position sensor (CMPS)
C12 Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator
C13 Intake air pressure sensor (IAPS)
C14 Throttle position sensor (TPS)
C15 Engine coolant temp. sensor (ECTS)
C16 Speed sensor Speed sensor signal for FI system
C21 Intake air temperature sensor (IATS)
C22 Atmospheric pressure sensor (APS)
C23 Tip over sensor (TOS)
C24 Ignition signal #1 (IG coil #1) For #1 cylinder
C25 Ignition signal #2 (IG coil #2) For #2 cylinder
C32 Fuel injector signal #1 For #1 cylinder
C33 Fuel injector signal #2 For #2 cylinder
C40 Idle air control valve (IAC valve)
C41 Fuel pump control system (FP control system) Fuel pump, Fuel pump relay
C42 Ignition switch signal (IG switch signal) Anti-theft
C44 Heated oxygen sensor (HO2S) E-02, 19
C50 CVT serial communication
C51 CVT motor
C52 CVT pulley position sensor
C53 CVT speed sensor Speed sensor signal for CVT system
C54 CVT secondary pulley revolution sensor
C55 CVT engine revolution signal
C56 CVT throttle position signal
C58 CVT reduction ratio disagreement
In the LCD (DISPLAY) panel, the malfunction code is indicated from small code to large code.

TPS ADJUSTMENT
1. Warm up the engine and adjust the engine idle speed to 1 200
± 100 rpm. (#2-18)
2. Stop the engine.
3. Connect the special tool (Mode select switch) and select the
dealer mode.
4. If the throttle position sensor adjustment is necessary, loosen
the screw and turn the throttle position sensor and bring the
line to middle.
5. Then, tighten the screw to fix the throttle position sensor.

Incorrect

Correct position

Incorrect
 FI SYSTEM/ CVT SYSTEM 6-21

FAIL-SAFE FUNCTION
FI system/CVT system is provided with fail-safe function to allow the engine to start and the motorcycle to
run in a minimum performance necessary even under malfunction condition.

STARTING RUNNING
ITEM FAIL-SAFE MODE
ABILITY ABILITY
Camshaft position sensor When camshaft position signal has “NO” “YES”
failed during running, the ECM
Motorcycle can run, but once engine
determines cylinder as # before
stops, engine can not start.
occurrence of such a failure.
Crankshaft position sensor The motorcycle stops. “NO” “NO”
Intake air pressure sensor Intake air pressure is fixed to
“YES” “YES”
760 mmHg.
Throttle position sensor The throttle opening is fixed to full
open position. “YES” “YES”
Ignition timing is also fixed.
Engine coolant temp. Engine coolant temperature value is
“YES” “YES”
sensor fixed to 80 °C.
Intake air temperature Intake air temperature value is fixed
“YES” “YES”
sensor to 40 °C.
Atmospheric pressure Atmospheric pressure is fixed to
“YES” “YES”
sensor 760 mmHg.
Ignition signal #1 (IG coil #1) #1 Ignition-off “YES” “YES”
#2 cylinder can run.
Ignition signal #2 (IG coil #2) #2 Ignition-off “YES” “YES”
#1 cylinder can run.
Injection signal #1 #1 Fuel-cut “YES” “YES”
#2 cylinder can run.
Injection signal #2 #2 Fuel-cut “YES” “YES”
#1 cylinder can run.
HO2 sensor (E-02, 19) Feedback compensation is inhibited.
“YES” “YES”
(Air/fuel ratio is fixed to normal.)
CVT motor Current supply to motor is inter-
“YES” “YES”
rupted.
CVT pulley position sensor Automatic mode: Shifting to manual “YES” “YES”
CVT speed sensor mode is inhibited. Reduction ratio is “YES” “YES”
CVT secondary pulley fixed to an equivalent to 2nd range.
Manual mode: During running on “YES” “YES”
revolution sensor
CVT engine revolution signal 2nd or higher range, the reduction
ratio is fixed to an equivalent to 2nd
range. If running on 1st range, it is “YES” “YES”
fixed to 1st range.
All shifting is inhibited.
CVT throttle position signal Throttle position signal is fixed to
“YES” “YES”
30% open.

The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is nec-
essary to bring the motorcycle to the workshop for complete repair.
6-22 FI SYSTEM/ CVT SYSTEM

FI SYSTEM/ CVT SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper
analysis and diagnosis.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN: CVT No.:
Date of issue: Date Reg. Date of problem: Mileage:

Shift mode Automatic (Normal·Power) Manual (1st·2nd·3rd·4th·5th)

Malfunction indicator
Always ON Sometimes ON Always OFF Good condition
lamp condition (LED)
Malfunction display/code User mode: No display Malfunction display ( )
(LCD) Dealer mode: No code Malfunction code ( )

PROBLEM SYMPTOMS
Difficult Starting Poor Driveability
No cranking Hesitation on acceleration
No initial combustion Back fire/ After fire
No combustion Lack of power
Poor starting at Surging
( cold warm always) Abnormal knocking
Other CVT will not shift
Engine rpm jumps briefly
Other
Poor Idling Engine Stall when
Poor fast Idle Immediately after start
Abnormal idling speed Throttle valve is opened
( High Low) ( r/min) Throttle valve is closed
Unstable Load is applied
Hunting ( r/min. to r/min) Other
Other
OTHERS:
 FI SYSTEM/ CVT SYSTEM 6-23

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather Fair Cloudy Rain Snow Always Other
Temperature Hot Warm Cool Cold ( °F/ °C) Always
Frequency Always Sometimes ( times/ day, month) Only once
Under certain condition
Road Urban Suburb Highway Mountainous ( Uphill Downhill)
Tarmacadam Gravel Other
Motorcycle condition
Engine condition Cold Warming up phase Warmed up Always Other at starting
Immediately after start Racing without load Engine speed ( r/min)
Motorcycle con- During driving: Constant speed Accelerating Decelerating
dition Right hand corner Left hand corner When shifting (Gear position )
At stop Motorcycle speed when problem occurs ( km/h, Mile/h)
Other

NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.
6-24 FI SYSTEM/ CVT SYSTEM

SELF-DIAGNOSTIC PROCEDURES
• Don’t disconnect couplers from ECM/CVT control unit, battery
cable from battery, ECM ground wire harness from engine or
main fuse before confirming malfunction code (self-diagnostic
trouble code) stored in memory. Such disconnection will
erase memorized information in ECM memory.
• Malfunction code stored in ECM memory can be checked by
the special tool.
• Before checking malfunction code, read SELF-DIAGNOSIS
FUNCTION “USER MODE and DEALER MODE” (#6-18)
carefully to have good understanding as to what functions are
available and how to use it.
• Be sure to read “PRECAUTIONS for Electrical Circuit Ser-
vice” (#6-2) before inspection and observe what is written
there.
• Lift the seat.
• Connect the special tool to the dealer mode coupler A at the
wiring harness, and start the engine or crank the engine for
more than 4 seconds.
• Turn the special tool’s switch ON and check the malfunction
code to determine the malfunction part.
! 09930-82720: Mode select switch

SELF-DIAGNOSIS RESET PROCEDURE

• After repairing the trouble, turn OFF the ignition switch and
turn ON again.
• If the malfunction code indicates (C00), the malfunction is
cleared.
• Disconnect the special tool from the dealer mode coupler.
 FI SYSTEM/ CVT SYSTEM 6-25

MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
C00 NO FAULT –––––––––––
Camshaft position The signal does not reach ECM for more than 2 sec. after
sensor receiving the starter signal.
C11 The camshaft position sensor wiring and mechanical parts.
(Camshaft position sensor, intake cam pin, wiring/coupler con-
nection)
Crankshaft position The signal does not reach ECM for more than 2 sec. after
sensor receiving the starter signal.
C12
The crankshaft position sensor wiring and mechanical parts.
(Crankshaft position sensor, wiring/coupler connection)
Intake air pressure The sensor should produce following voltage.
sensor (0.50 V sensor voltage < 4.85 V)
C13
Without the above range, C13 is indicated.
Intake air pressure sensor, wiring/coupler connection.
Throttle position The sensor should produce following voltage.
sensor (0.20 V sensor voltage < 4.80 V)
C14
Without the above range, C14 is indicated.
Throttle position sensor, wiring/coupler connection.
Engine coolant The sensor voltage should be the following.
temperature sensor (0.15 V sensor voltage < 4.85 V)
C15
Without the above range, C15 is indicated.
Engine coolant temperature sensor, wiring/coupler connection.
Speed sensor The speed sensor signal is not input for more than 3 sec. during
C16 vehicle deceleration.
Speed sensor, wiring/coupler connection.
Intake air temperature The sensor voltage should be the following.
sensor (0.15 V sensor voltage < 4.85 V)
C21
Without the above range, C21 is indicated.
Intake air temperature sensor, wiring/coupler connection.
Atmospheric pressure The sensor voltage should be the following.
sensor (0.50 V sensor voltage < 4.85 V)
C22
Without the above range, C22 is indicated.
Atm. pressure sensor, wiring/coupler connection.
Tip over sensor The sensor voltage should be the following for more than 2 sec.
after ignition switch turns ON.
C23 (0.20 V sensor voltage < 4.80 V)
Without the above value, C23 is indicated.
Tip over sensor, wiring/coupler connection.
Ignition signal Crankshaft position sensor (pick-up coil) signal is produced but
signal from ignition coil is interrupted continuous by 4 times or
C24 or C25 more. In this case, the code C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery.
6-26 FI SYSTEM/ CVT SYSTEM

Fuel injector Crankshaft position sensor (pick-up coil) signal is produced but
fuel injector signal is interrupted continuous by 4 times or more.
C32 or C33
In this case, the code C32 or C33 is indicated.
Injector, wiring/coupler connection, power supply to the injector.
Intake air control (IAC) No IAC valve voltage is supplied after starting the engine.
C40
valve IAC valve, wiring/coupler connection.
Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is
turned ON, or voltage is applied to fuel pump although fuel
C41 pump relay is turned OFF.
Fuel pump relay, connecting lead, power source to fuel pump
relay.
Ignition switch Ignition switch signal is not input in the ECM.
C42
Ignition switch, lead wire/coupler.
Heated oxygen sensor During O2 feedback control, O2 sensor voltage is higher or
(HO2S) [E-02, 19] lower than the specification.
No signal is detected during engine operation or no electrical
C44
power is supplied from battery.
HO2S lead wire/coupler connection.
Battery voltage supply to the HO2S.
CVT serial No signal is supplied from CVT control unit to ECM for more
C50 communication than 5 sec. after starting the engine.
Wiring/coupler connection.
CVT motor The CVT motor operating voltage is not supplied from CVT
C51 control unit.
CVT motor, wiring/coupler connection.
CVT pulley position The sensor should produce following voltage.
sensor (0.06 sensor voltage 5.04)
C52
Without the above range, C52 is indicated.
CVT pulley position sensor, wiring/coupler connection.
CVT speed sensor The CVT speed sensor signal is not input to CVT control unit
C53 for more than 3 sec. during vehicle rurning.
Speed sensor, wiring/coupler connection.
CVT secondary pulley The CVT secondary pulley revolution signal is not input to CVT
revolution sensor control unit at speed of 20 km or higher.
C54
CVT secondary pulley revolution sensor, wiring/coupler con-
nection.
CVT engine revolution The CVT engine revolution signal is not input to CVT control
C55 signal unit from ECM at speed of 20 km or higher.
Wiring/coupler connection.
CVT throttle position The CVT throttle position signal does not reach for more than 5
C56 signal sec. from ECM to CVT control unit after ignition switch turns ON.
Wiring/coupler connection.
CVT reduction ratio The CVT pulley position signal disagrees with actual revolution
C58 disagreement ratio for more than 4 sec.
PPS, CVT belt, CVT primary pulley/secondary pulley.
 FI SYSTEM/ CVT SYSTEM 6-27

“C11” CMP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
No CMP sensor signal for more than 2 seconds • Metal particles or foreign material being attached
after receiving the starter signal. on the CMP sensor and rotor tip.
• CMP sensor circuit open or short.
• CMP sensor malfunction.
• ECM malfunction.
INSPECTION
• Remove the maintenace lid. (:9-13) 1
1Turn the ignition switch OFF.
Check the CMP sensor coupler for loose or poor contacts.
If OK, then measure the CMP sensor resistance.
Disconnect the CMP sensor coupler 1
and measure the
resistance.
; CMP sensor resistance: 0.9 – 1.7 kΩ
(B/Y – Brown)
If OK, then check the continuity between each terminal
and ground.
; CKP sensor continuity: ∞ Ω (Infinity) 1
B/Y – Ground
(
Br – Ground )
z 09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω)
Ω Ω
No Replace the CMP sensor
Yes with a new one.
2 Disconnect the CMP sensor coupler.
Crank the engine a few seconds with the starter motor,
and measure the CMP sensor peak voltage at the sensor.
2
; CMP sensor peak voltage: More than 0.5 V
+
( B/Y – Br) -
Repeat the above test procedure a few times and
measure the highest peak voltage.
If OK, then measure the CMP sensor peak voltage at the V
ECM terminals. ( / )[d Peak volt
adaptor
z 09900-25008: Multi circuit tester


u Tester knob indication: Voltage (-)

No Loose or poor contacts on the CMP

sensor coupler or ECM coupler.
Replace the CMP sensor with a
Yes new one.
B/Y or Br wire open or shorted to ground, or poor [ d or
connection.
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for open circuit and
poor connection. ECM couplers

Replace the ECM with a new one,

and inspect it again.
6-28 FI SYSTEM/ CVT SYSTEM

“C12” CKP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
No CKP sensor signal for more than 2 seconds • Metal particles or foreign material being attached
after receiving the starter signal. on the CKP sensor and rotor tip.
• CKP sensor circuit open or short.
• CKP sensor malfunction.
• ECM malfunction.
INSPECTION
• Remove the maintenance lid. ( :9-13) 1
1 Turn the ignition switch OFF.
Check the CKP sensor coupler for loose or poor contacts.
If OK, then measure the CKP sensor resistance.
Disconnect the CKP sensor coupler 1
and measure the

;
resistance.
CKP sensor resistance: 150 – 300 Ω
(Blue – Green)
If OK, then check the continuity between each terminal
and ground.
; CKP sensor continuity: ∞ Ω (Infinity) 1
Blue – Ground
( )
z
Green – Ground
09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω)
No Replace the CKP sensor
Yes with a new one.
2 Disconnect the CKP sensor coupler.
Crank the engine a few seconds with the starter motor,
and measure the CKP sensor peak voltage at the coupler.
; CKP sensor peak voltage: More than 2.0 V 2
(Blue – Green)
Repeat the above test procedure a few times and Peak
volt
measure the highest peak voltage. adaptor
If OK, then measure the CKP sensor peak voltage at the
Zc
ECM terminals. ( / )
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
No Loose or poor contacts on the CKP
sensor coupler or ECM coupler.
Replace the CKP sensor with a
Yes new one.
Bl or G wire open or shorted to ground, or poor Z cor
Z
connection. c
If wire and connection are OK, intermittent trouble or faulty ECM.
Recheck each terminal and wire harness for open circuit and
poor connection. ECM couplers
Replace the ECM with a new one,
and inspect it again.
 FI SYSTEM/ CVT SYSTEM 6-29

“C13” IAP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
IAP sensor voltage low or high. • Clogged vacuum passage between throttle body
Sensor voltage < 4.85 V and IAP sensor.
( 0.50 V
without the above range. ) • Air being drawn from vacuum passage between
NOTE: throttle body and IAP sensor.
Note that atmospheric pressure varies depending • IAP sensor circuit open or shorted to ground.
on weather conditions as well as altitude. • IAP sensor malfunction.
Take that into consideration when inspecting voltage. • ECM malfunction.

:9-18)
INSPECTION
• Remove the front box. (
1 Turn the ignition switch OFF.
Check the IAP sensor coupler for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
Disconnect the IAP sensor coupler.
Turn the ignition switch ON.
Measure the voltage at the Red wire and ground.
If OK, then measure the voltage at the Red wire and B/Br
wire.
; IAP sensor input voltage: 4.5 – 5.5 V
+
(+ -
Red – Ground
-
Red – B/Br
) 1

z 09900-25008: Multi circuit tester V

u Tester knob indication: Voltage (-)

No Loose or poor contacts on Red
the ECM coupler.
Open or short circuit in
the Red wire or B/Br wire.

Yes 1
B/Br
2 Connect the IAP sensor coupler.
Insert the copper wires to the lead wire coupler. V
Start the engine at idle speed.
Measure the IAP sensor output voltage at the wire
side coupler (between Lg/B and B/Br wires).

; IAP sensor output voltage: Approx. 2.6 V at idle Red

speed (+Lg/B – -B/Br)

z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-) 2
Lg/B
No Check the vacuum hose for
crack or damage. V
Open or short circuit in the
Lg/B wire.
Replace the IAP sensor with
a new one.
B/Br
Yes
6-30 FI SYSTEM/ CVT SYSTEM

3 3 Ground
Remove the IAP sensor.
Connect the vacuum pump gauge to the vacuum port of Vout
the IAP sensor.
Arrange 3 new 1.5 V batteries in series (check that total
voltage is 4.5 – 5.0 V) and connect -terminal to the
ground terminal and +
terminal to the Vcc terminal. Vcc V
Check the voltage between Vout and ground. Also, check
if voltage reduces when vacuum is applied up to 40 cmHg 1.5 V battery
by using vacuum pump gauge. (See table below.) (4.5 V in total)

z 09917-47010: Vacuum pump gauge

09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)

No
If check result is not satis-
factory, replace IAP sensor h
with a new one. n r
Yes
ECM couplers
Red, Lg/B or B/Br wire open or shorted to ground, or poor h,
n or r connection.
If wire and connection are OK, intermittent trouble or faulty
ECM.
Recheck each terminal and wire harness for open circuit and
poor connection.

Replace the ECM with a new

one, and inspect it again.

Output voltage (Vcc voltage 4.5 – 5.0 V, ambient temp. 20 –

30 °C, 68 – 86 °F)
ALTITUDE ATMOSPHERIC OUTPUT
(Reference) PRESSURE VOLTAGE
(ft) (m) (mmHg) kPa (V)
0 0 760 100
    3.1 – 3.6
2 000 610 707 94
2 001 611 707 94
    2.8 – 3.4
5 000 1 524 634 85
5 001 1 525 634 85
    2.6 – 3.1
8 000 2 438 567 76
8 001 2 439 567 76
    2.4 – 2.9
10 000 3 048 526 70
 FI SYSTEM/ CVT SYSTEM 6-31

“C14” TP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage low or high. • TP sensor maladjusted.
Sensor voltage < 4.80 V • TP sensor circuit open or short.
( 0.20 V
without the above range. ) • TP sensor malfunction.
• ECM malfunction.

INSPECTION
• Remove the maintenance lid. ( :9-13) 1
1 Turn the ignition switch OFF.
Check the TP sensor coupler for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
Disconnect the TP sensor coupler .1
Turn the ignition switch ON.
Measure the voltage at the Red wire and ground.
If OK, then measure the voltage at the Red wire and B/Br
wire.
; TP sensor input voltage: 4.5 – 5.5 V
+
(+ -
Red – Ground
-
Red – B/Br ) 1

z 09900-25008: Multi circuit tester V

u Tester knob indication: Voltage (-)
Loose or poor contacts on Red
No the ECM coupler.
Open or short circuit in the Ground
Red wire or B/Br wire.
Yes
2 Turn the ignition switch OFF.
1
Disconnect the TP sensor coupler.
Check the continuity between Yellow wire and ground.
; TP sensor continuity: ∞ Ω (Infinity)
V B/Br

(Yellow wire – Ground)

If OK, then measure the TP sensor resistance at the
coupler (between Yellow and Gr or R wires).
Red
;
Turn the throttle grip and measure the resistance.
TP sensor resistance
Throttle valve is closed : Approx. 1.1 kΩ
Throttle valve is opened : Approx. 4.2 kΩ
z 09900-25008: Multi circuit tester 2
t Tester knob indication: Resistance (Ω) Ω Ω
No Reset the TP sensor
position correctly.
Replace the TP sensor
with a new one.
Yes
6-32 FI SYSTEM/ CVT SYSTEM

3 Connect the TP sensor coupler. 3

Insert the copper wires to the lead wire coupler.
Turn the ignition switch ON. V
Measure the TP sensor output voltage at the coupler (be-
tween Yellow and Gr or R wires) by turning the throttle grip.
; TP sensor output voltage Yellow
Throttle valve is closed : Approx. 1.1 V Gr or R
Throttle valve is opened : Approx. 4.3 V
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
No If check result is not satisfactory,
replace TP sensor with a new one.
Yes hi
n
Red, P/B or B/Br wire open or shorted to ground, or poor , h
i n or connection.
ECM couplers

If wire and connection are OK, intermittent trouble or faulty

ECM.
Recheck each terminal and wire harness for open circuit
and poor connection.

Replace the ECM with a new one,

and inspect it again.
 FI SYSTEM/ CVT SYSTEM 6-33

“C15” ECT SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage low or high. • ECT sensor circuit open or short.
Sensor voltage < 4.85 V • ECT sensor malfunction.
( 0.15 V
without the above range. ) • ECM malfunction.

INSPECTION
• Remove the maintenance lid. ( :9-13) 1
1 Turn the ignition switch OFF.
Check the ECT sensor coupler for loose or poor contacts.
If OK, then measure the ECT sensor voltage at the wire
side coupler.
Disconnect the coupler and turn the ignition switch ON.
Measure the voltage between B/Bl wire terminal and
ground.
If OK, then measure the voltage between B/Bl wire termi-
nal and B/Br wire terminal.
; ECT sensor voltage: 4.5 – 5.5 V
+B/Bl – -Ground )
(+ 1
B/Bl – -B/Br
B/Br

z 09900-25008: Multi circuit tester

u Tester knob indication: Voltage (-) V

No Loose or poor contacts on

B/Bl
the ECM coupler.
Open or short circuit in the
Yes B/Bl wire or B/Br wire.
2 Turn the ignition switch OFF.
Measure the ECT sensor resistance. 2
; ECT sensor resistance:

z
Approx. 2.45 kΩ at 20 ˚C (68 ˚F) (Terminal – Terminal)
09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω)
Refer to page 8-13 for details. Ω
No Replace the ECT sensor
Yes with a new one.
k
n
B/Bl or B/Br wire open or shorted to ground, or poor or
connection. Engine Coolant
If wire and connection are OK, intermittent trouble or faulty Resistance
Temp.
ECM.
Recheck each terminal and wire harness for open circuit 20 ˚C ( 68 ˚F) Approx. 2.45 kΩ
and poor connection. 50 ˚C (112 ˚F) Approx. 0.811 kΩ
Replace the ECM with a new 80 ˚C (176 ˚F) Approx. 0.318 kΩ
one, and inspect it again. 110 ˚C (230 ˚F) Approx. 0.142 kΩ

k
n
ECM coupler
6-34 FI SYSTEM/ CVT SYSTEM

“C16” SPEED SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The speed sensor signal is not input to ECM for • Speed sensor circuit open or short.
more than 3 sec. during vehicle deceleration. • Metal particles or foreign material being attached
on the speed sensor.
• Speed sensor malfunction.
• ECM malfunction.

INSPECTION
• Remove the foot board. ( :9-18) 1
1 Turn the ignition switch OFF.
Check the speed sensor lead wire coupler 1 for loose or
poor contacts.
If OK, then measure the speed sensor input voltage.
Insert the copper wires to the lead wire coupler.
Turn the ignition switch ON.
Measure the speed sensor input voltage at the coupler
+ -
between O/R and B/W wire.
; Speed sensor input voltage: More than 7 V
(+O/R – -B/W)
1
V
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
NG Loose or poor contacts on
the ECM couplers.
Open or short circuit in the
O/R wire or B/W wire.
OK
2 Remove the speed sensor.
Clean away metal particles or foreign material. 2

Next page
 FI SYSTEM/ CVT SYSTEM 6-35

3 Check the speed sensor output voltage. 3

V
Insert the copper wires to the lead wire caupler. (White –
Black/White)
Turn the ignition switch ON.
Check that the voltage varies when a screwdriver is
brought close to the pick-up face of the speed sensor.
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
NG
Short circuit in the lead 3
wire.
Replace the speed sensor
with a new one.
OK
Recheck ECM coupler for loose or
poor contacts.
Replace ECM with a new one and
inspect it again.
6-36 FI SYSTEM/ CVT SYSTEM

“C21” IAT SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage low or high. • IAT sensor circuit open or short.
Sensor voltage < 4.85 V • IAT sensor malfunction.
( 0.15 V
without the above range. ) • ECM malfunction.

INSPECTION
• Remove the front box. ( :9-18)
1 Turn the ignition switch OFF.
Check the IAT sensor coupler for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire
side coupler.
Disconnect the coupler and turn the ignition switch ON.
Measure the voltage between Dg wire terminal and
ground.
If OK, then measure the voltage between Dg wire termi-

;
nal and B/Br wire terminal.
IAT sensor voltage: 4.5 – 5.5 V
+
(+ -
Dg – Ground 1
-
Dg – B/Br ) B/Br

z 09900-25008: Multi circuit tester

u Tester knob indication: Voltage (-) V

No Loose or poor contacts on Dg

the ECM coupler.
Open or short circuit in the
Yes Dg wire or B/Br wire.
2 Turn the ignition switch OFF.
Measure the IAT sensor resistance. 2
; IAT sensor resistance:

z
Approx. 2.45 kΩ at 20 ˚C (68 ˚F) (Terminal – Terminal)
09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω)
Ω
No Replace the IAT sensor
with a new one.
Yes
Dg or B/Br wire open or shorted to ground, or poor j
or
n connection.
Intake Air Temp. Resistance
If wire and connection are OK, intermittent trouble or faulty
ECM. 20 ˚C ( 68 ˚F) Approx. 2.45 kΩ
Recheck each terminal and wire harness for open circuit
and poor connection. 50 ˚C (112 ˚F) Approx. 0.808 kΩ
80 ˚C (176 ˚F) Approx. 0.322 kΩ
Replace the ECM with a new
one, and inspect it again. 110 ˚C (230 ˚F) Approx. 0.148 kΩ

NOTE:
j IAT sensor resistance measurement
n method is the same way as that of the
ECM couplers ECT sensor. Refer to page 8-13 for
details.
 FI SYSTEM/ CVT SYSTEM 6-37

“C22” AP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage low or high. • Clogged air passage with dust.
Sensor voltage < 4.85 V • AP sensor circuit open or short.
( 0.50 V
without the above range. ) • AP sensor malfunction.
NOTE: • ECM malfunction.
Note that atmospheric pressure caries depending on
weather conditions as well as altitude.
Take that into consideration when inspecting voltage.
INSPECTION
• Remove the front box. ( :9-18)
1 Turn the ignition switch OFF.
Check the AP sensor coupler for loose or poor contacts.
If OK, then measure the AP sensor input voltage.
Turn the ignition switch ON.
Disconnect the AP sensor coupler.
Measure the voltage between Red wire and ground.
If OK, then measure the voltage between Red wire and

;
B/Br wire.
AP sensor input voltage: 4.5 – 5.5 V
+
(+ -
Red – Ground
-
Red – B/Br ) 1

z 09900-25008: Multi circuit tester

V

u Tester knob indication: Voltage (-)

Loose or poor contacts on Red
No
the ECM coupler.
Open or short circuit in the
Red wire or B/Br wire.
Yes
2 Connect the AP sensor coupler.
Insert the copper wires to the lead wire coupler. 1 B/Br
Turn the ignition switch ON. V
Measure the AP sensor output voltage at the wire side
coupler between G/Y and B/Br wires.
; AP sensor output voltage: Approx. 3.6 V
at 760 mmHg (100 kPa)
+ -
z
( G/Y – B/Br) Red
09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
2
Check the air passage
No
for clogging.
Open or short circuit in the V
G/Y wire.
Replace the AP sensor
with a new one.
Yes
6-38 FI SYSTEM/ CVT SYSTEM

3 Remove the AP sensor. 3

Connect the vacuum pump gauge to the air passage port PA Ground
of the AP sensor.
Arrange 3 new 1.5 V batteries in series (check that total
voltage is 4.5 – 5.0 V) and connect -
terminal to the
ground terminal and +
terminal to the Vcc terminal. Vcc V
Check the voltage between PA and ground. Also, check
if voltage reduces when vacuum is applied up to 40 cmHg 1.5 V battery
by using vacuum pump gauge. (See table below.) (4.5 V in total)

z 09917-47010: Vacuum pump gauge

09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)

No
If check result is not satisfactory,
replace AP sensor with a new one. h l
n
Yes
ECM couplers
Red, G/Y or B/Br wire open or shorted to ground, or poor h,
l or n connection.
If wire and connection are OK, intermittent trouble or faulty
ECM.
Recheck each terminal and wire harness for open circuit and
poor connection.

Replace the ECM with a new

one, and inspect it again.

Output voltage (Vcc voltage 4.5 – 5.0 V, ambient temp. 20 –

30 °C, 68 – 86 °F)
ALTITUDE ATMOSPHERIC OUTPUT
(Reference) PRESSURE VOLTAGE
(ft) (m) (mmHg) kPa (V)
0 0 760 100
    3.1 – 3.6
2 000 610 707 94
2 001 611 707 94
    2.8 – 3.4
5 000 1 524 634 85
5 001 1 525 634 85
    2.6 – 3.1
8 000 2 438 567 76
8 001 2 439 567 76
    2.4 – 2.9
10 000 3 048 526 70
 FI SYSTEM/ CVT SYSTEM 6-39

“C23” TO SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
Output voltage low or high. • TO sensor circuit open or short.
V Sensor voltage < 4.80 V • TO sensor malfunction.
( 0.20
without the above range. ) • ECM malfunction.

INSPECTION
• Remove the front panel. (:9-8)
1Turn the ignition switch OFF.
Check the TO sensor coupler for loose or poor contacts.
If OK, then measure the TO sensor resistance.
Disconnect the TO sensor coupler.
Measure the resistance between Red and B/Br wire
terminals.
; TO sensor resistance: 19.1 – 19.7 kΩ (Red – B/Br)
z 09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω)
1
No Replace the TO sensor Ω
Yes with a new one.

2 Connect the TO sensor coupler.

Insert the copper wires to the lead wire coupler.
Turn the ignition switch ON.
Measure the voltage at the wire side coupler between
B and B/Br wires.
; TO sensor voltage: Less than 1.4 V (B – B/Br)
Also, measure the voltage when leaning of the motorcycle.
Dismount the TO sensor from its bracket and measure the 2
voltage when it is leaned more than 65˚, left and right, from
the horizontal level.
; TO sensor voltage: More than 3.7 V (B – B/Br)
z 09900-25008: Multi circuit tester

V
u Tester knob indication: Voltage (-)

No Loose or poor contacts on the ECM

coupler.
Open or short circuit.
Replace the TO sensor with a new
one.
Yes
Red, B or B/Br wire open or shorted to ground, or poor , h
n s or connection. h
If wire and connection are OK, intermittent trouble or faulty ECM. n s
Recheck each terminal and wire harness for open circuit and
ECM couplers
poor connection.

Replace the ECM with a new one,

and inspect it again.
6-40 FI SYSTEM/ CVT SYSTEM

“C24” or “C25” IGNITION SYSTEM MALFUNCTION

*Refer to the IGNITION SYSTEM for details. (#10-18)
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBLE CAUSE
CKP signal is produced but fuel injector signal is • Injector circuit open or short.
interrupted continuous by 4 times or more. • Injector malfunction.
• ECM malfunction.
INSPECTION
• Remove the front box. ( :9-18)
1 Turn the ignition switch OFF.
Check the injector coupler for loose or poor contacts.
If OK, then measure the injector resistance.
Disconnect the coupler and measure the resistance
between terminals.
; Injector resistance: 11 – 13 Ω at 20 ˚C (68 ˚F)
(Terminal – Terminal)
If OK, then check the continuity between each terminal
and ground.
; Injector continuity: ∞ Ω (Infinity) 1
(Terminal – Ground)
z 09900-25008: Multi circuit tester Ω
t Tester knob indication: Resistance (Ω) Ω

:
No Replace the injector with
a new one. ( 7-17, 21)
Yes
2 Turn the ignition switch ON.
Ground
Measure the injector voltage between Y/R wire and
ground.
; Injector voltage: Battery voltage 2
(Y/R – Ground)
Ground
NOTE:
Injector voltage can be detected only 3 seconds after
ignition switch is turned ON.
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
No Open circuit in the Yellow/
Yes Red wire.

Gr/W, Gr/B or Y/R wire open or shorted to ground, or poor , 4

5 b or connection.
If wire and connection are OK, intermittent trouble or faulty
ECM. 45
Recheck each terminal and wire harness for open circuit and b
poor connection.
ECM couplers
Replace the ECM with a new one,
and inspect it again.
 FI SYSTEM/ CVT SYSTEM 6-41

“C40” IAC VALVE CIRCUIT MALFUNCTION

*Refer to the IAC VALVE INSPECTION for details. (#7-20)

“C41” FP RELAY CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
No voltage is applied to fuel pump although fuel • Fuel pump relay circuit open or short.
pump relay is turned ON, or voltage is applied to • Fuel pump relay malfunction.
fuel pump although fuel pump relay is turned OFF. • ECM malfunction.

INSPECTION
• Remove the front box. (
1
: 9-18) 1
Turn the ignition switch OFF.
Check the FP relay coupler for loose or poor contacts.
If OK, then check the insulation and continuity. Refer to
page 10-28 for details.

No
Replace the FP relay with
a new one.
Yes
Y/G or O/W wire open or shorted to ground, or poor or 9 b
connection.
If wire and connection are OK, intermittent trouble or faulty
ECM. 9
Recheck each terminal and wire harness for open circuit and b
poor connection.

ECM couplers
Replace the ECM with a new one,
and inspect it again.

“C42” IG SWITCH CIRCUIT MALFUNCTION

* Refer to the IGNITION SWITCH INSPECTION for details.
• Remove the leg shield. (#10-35)
6-42 FI SYSTEM/ CVT SYSTEM

“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (E-02, 19)

DETECTED CONDITION POSSIBLE CAUSE
During O2 feedback control, O2 sensor voltage is • HO2 sensor or its circuit open or short.
higher or lower than the specification. • Fuel system malfunction.
No signal is detected during engine operation, or no • ECM malfunction.
electrical power is supplied from battery.

INSPECTION
• Remove the foot board. (#9-18)
1 Turn the ignition switch OFF.
Check the HO2 sensor coupler for loose or poor contacts.
Insert the copper wires to the HO2 sensor lead wire coupler.
Warm up the engine enough.
Measure the HO2 sensor output voltage at the coupler
(between Black and Gray wires) when idling condition.
Also, measure the HO2 sensor output voltage while

;
holding the engine speed at 3 000 r/min.
HO2 sensor output voltage at idle speed:
Less than 0.4 V ( B – + -
Gr)
HO2 sensor output voltage at 3 000 r/min:
+ -
1
More than 0.6 V ( B – Gr)
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-) V

No
Replace the HO2 sensor with
a new one.

Yes
 FI SYSTEM/ CVT SYSTEM 6-43

2 Turn the ignition switch OFF. 2

Turn the ignition switch ON and measure the heater
voltage between Orange/White wire (ECM side) and
ground.
If the tester voltage indicates the battery voltage for few
seconds, it is good condition.
; Heater voltage: Battery voltage
(O/W – Ground) Ground
NOTE:
Battery voltage can be detected only during few seconds
after ignition switch is turned ON.
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
No
Replace the HO2 sensor with
a new one.
Yes
3 Turn the ignition switch OFF.
Disconnect the HO2 sensor coupler.
Check the resistance between the terminals (White – 3
White) of the HO2 sensor.
; HO2 heater resistance: 4 – 5 Ω (at 23 ˚C/73.4 ˚F) Ω
(White – White)
NOTE:
* Temperature of the sensor affects resistance value
largely.
* Make sure that the sensor heater is at correct tempera-
ture.
z 09900-25008: Multi circuit tester set
t Tester knob indication: Resistance (Ω)
No
Replace the HO2 sensor with
Yes a new one.

Black, Gray or White wire open or shorted to ground, or poor

G\e n
, , or connection.
G
\
e
If wire and connection are OK, intermittent trouble or faulty
ECM. n
Recheck each terminal and wire harness for open circuit ECM couplers
and poor connection.

Check the fuel supply system,

if the system is OK, replace
the ECM with a new one, and
inspect it again.
6-44 FI SYSTEM/ CVT SYSTEM

“C50” CVT SERIAL COMMUNICATION CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
No signal is supplied from CVT control unit to ECM • “C58” circuit open or short.
for more than 5 sec. after starting the engine. • CVT control unit malfunction.
• ECM malfunction.

INSPECTION
• Remove the front panel. ( :9-8) 1
1 Turn the ignition switch OFF.
Check the ECM coupler and CVT control unit coupler for
loose or poor contacts.
If OK, check for existance of CVT serial communication
signal.
Insert the copper wire to the lead wire coupler at the CVT CVT control unit coupler
control unit side. Measure the communication signal at
the Dark brown wire and Ground.
NOTE:
Do not need to disconnect any CVT control unit couplers. 1
; CVT serial communication signal:
More than 7 V
+ -
( Dbr – Ground)
z 09900-25008: Multi circuit tester
V

u Tester knob indication: Voltage (-)

NG Loose or poor contacts on
the CVT contol unit coupler.
Replace the CVT control
unit with a new one. 1 CVT control unit coupler
OK
Replace the ECM with a new one, and inspect it
again.

Dark brown

f
ECM coupler
 FI SYSTEM/ CVT SYSTEM 6-45

“C51” CVT MOTOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
CVT motor operating voltage is not supplied from • CVT motor circuit open or short.
CVT control unit. • CVT motor malfunction.
• CVT control unit malfunction.

INSPECTION
• Remove the foot board. (: 9-18) 1
• Place the motorcycle on the center stand and put the side
stand in.

1 Turn the ignition switch OFF.

Check the CVT motor coupler 1 for loose or poor
contacts.
If OK, then measure the CVT motor operating voltage.
1
Insert the copper wires to the coupler .
Remove the center stand switch . 2
Start the engine and shift to Automatic mode. 1
Check that there is a change of motor operating voltage
as the engine speed is raised.

z 09900-25008: Multi circuit tester

u Tester knob indication: Voltage (-)
NG Loose or poor contacts on
the CVT contol unit coupler.
Replace the CVT control
OK unit with a new one.
1
2 Disconnect the CVT motor coupler.
Check the continuity between Red wire – ground and
B wire – ground.

; CVT motor continuity: ∞ Ω (Infinity)

( Red wire – Ground
Brack wire – Ground )
If OK, then measure the CVT motor resistance at the
coupler.
; CVT motor resistance: Less than 0.8 Ω
z 09900-25008: Multi circuit tester 2

t Tester knob indication: Resistance (Ω)

NG
Replace the CVT motor.
Ω
OK
Next page
6-46 FI SYSTEM/ CVT SYSTEM

3 Remove the CVT motor. 3

Apply 12 volts to the terminals of the CVT motor lead wire
coupler.
Check the CVT motor movement.
Then, swap the wires supplied 12 volts and check the
movement.
Check the CVT motor both way movements.

NG
Replace the CVT motor.

3
OK
Replace the ECM with a new one, and inspect it
again. 12V
 FI SYSTEM/ CVT SYSTEM 6-47

“C52” CVT PULLEY POSITION SENSOR (PPS) CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
PPS voltage low or high. • PPS circuit open or short.
0.06 V Sensor voltage 5.04 V • PPS malfunction.
without the above range. • CVT control unit malfunction.

INSPECTION
• Remove the foot board. (:9-18) 1
• Place the motorcycle on the center stand and put the side
stand in.
1 Turn the ignition switch OFF.
Check the PPS coupler 1 for loose or poor contacts.
If OK, then measure the PPS input voltage.
Insert the copper wires to the coupler.
Turn the ignition switch ON and measure the PPS input
voltage.

; PPS input voltage: 4.5 – 5.5 V ( + Lbl/O or R – - B) 1

z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
NG Loose or poor contacts on
the CVT contol unit coupler.
Open or short in the
OK Lbl/O or R wire or B wire.
2 Turn the ignition switch OFF.
Measure the PPS output voltage.
Insert the copper wires to the PPS coupler. 2
Remove the center stand switch . 2
Start the engine and shift to Manual mode.
Check for PPS output voltage at revolution each for 1st,
3rd and 5th as shown below.

+
; PPS output voltage: ( Lbl/Y or Bl – - B)
1st-Idle rpm: Approx. 3.3 V
3rd-3000 rpm: Approx. 1.3 V

5th-3000 rpm: Approx. 0.5 V
z 09900-25008: Multi circuit tester 2
u Tester knob indication: Voltage (-)

NG
Replace the CVT control
unit.

OK
Next page
6-48 FI SYSTEM/ CVT SYSTEM

3 Turn the ignition switch OFF. 3

Remove the PPS.
Measure the resistance each when the sensor is

;
compressed and extended to the maximum between
Lbl/Y or Bl wire and B wire terminals. Ω
PPS resistance : (Lbl/Y or Bl – B)

zt
Compressed : 1.9 – 2.3 kΩ
Extended : 0.2 – 1.0 kΩ
09900-25008: Multi circuit tester
Tester knob indication: Resistance (Ω)
3
Check the PPS smooth movement.
NG Replace the PPS with a
new one.
Ω
OK
8D J
, or wire open or shorted to ground, or poor
connection.
If wire and connection are OK, intermittent trouble or faulty
ECM.
Recheck each terminal and wire harness for open circuit and
poor connection.

CVT control unit coupler

Replace the ECM with a new one, and inspect it again.
 FI SYSTEM/ CVT SYSTEM 6-49

“C53” CVT SPEED SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The speed sensor signal is not input to CVT control • Speed sensor circuit open or short.
unit for more than 3 sec. during vehicle running. • Metal particles or foreign material being attached
on the speed sensor.
• Speed sensor malfunction.
• CVT control unit malfunction.

INSPECTION
• Remove the foot board. (:9-18) 1
1 Turn the ignition switch OFF.
Check the speed sensor lead wire coupler 1 for loose or
poor contacts.
If OK, then measure the speed sensor input voltage.
Insert the copper wires to the lead wire coupler.
Turn the ignition switch ON.
Measure the speed sensor input voltage at the coupler
+ -
between O/R and B/W wire.
; Speed sensor input voltage: More than 7 V
(+O/R – -B/W)
1
V
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
NG Loose or poor contacts on
the CVT control unit
couplers.
Open or short circuit in the
OK O/R wire or B/W wire.
2 Remove the speed sensor.
Clean away metal particles or foreign material. 2

Next page
6-50 FI SYSTEM/ CVT SYSTEM

3 Check the speed sensor output voltage. 3

V
Insert the copper wires to the lead wire caupler. (White –
Black/White)
Turn the ignition switch ON.
Check that the voltage varies when a screwdriver is
brought close to the pick-up face of the speed sensor.

z 09900-25008: Multi circuit tester

u Tester knob indication: Voltage (-)
NG
Short circuit in the lead 3
wire.
Replace the speed sensor
with a new one.
OK
Recheck the CVT control unit coupler for loose or
poor contacts.
Replace the CVT control unit with a new one and
inspect it again.
 FI SYSTEM/ CVT SYSTEM 6-51

“C54” CVT SECONDARY PULLEY REVOLUTION SENSOR CIRCUIT MAL-

FUNCTION
DETECTED CONDITION POSSIBLE CAUSE
The CVT secondary pulley revolution signal is not • Sensor circuit open or short.
input to CVT control unit at speed of 20 km or • Metal particles or foreign material being attached
higher. on the speed sensor.
• Revolution sensor malfunction.
• CVT control unit malfunction.

INSPECTION
• Remove the foot board. (: 9-18) 1
• Place the motorcycle on the center stand and put the side
stand in.
1 Turn the ignition switch OFF.
Check the CVT secondary pulley revolution sensor
coupler1 for loose or poor contacts.
If OK, then measure the revolution sensor resistance.
Disconnect the revolution sensor coupler and measure
the resistance between Yellow and White wire terminals.
; CVT secondary pulley revolution sensor 1
resistance: 400 – 600 Ω
(Yellow – White) Ω
z 09900-25008: Multi circuit tester
t Tester knob indication: Resistance (Ω) Ω
NG Replace the revolution
sensor with a new one.

OK
2 Remove the revolution sensor lead wire coupler.
Start the engine and measure the revolution sensor peak 2
voltage at idle speed.
; Revolution sensor peak voltage V Peak volt
: More than 5.0 V (at idle speed)
+ -
( Yellow – White)
adaptor

Repeat the above procedure a few times and measure

the highest peak voltage.

z 09900-25008: Multi circuit tester

u Tester knob indication: Voltage (-)
OK Loose or poor contacts on
the CVT control unit coupler.
CVT control unit
malfunction.
NG
Next page
6-52 FI SYSTEM/ CVT SYSTEM

3 Remove the CVT assembly. ( : 5-2)

Remove the CVT secondary pulley revolution sensor 2.
3

Clean away metal particles or foreign material.

It “C54” code is indicated, replace the CVT control unit.

3
 FI SYSTEM/ CVT SYSTEM 6-53

“C55” CVT ENGINE REVOLUTION SIGNAL CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The CVT engine revolution signal is not input to • Lead wire open or short.
CVT control unit from ECM at speed of 20 km or • ECM malfunction.
higher. • CVT control unit malfunction.

INSPECTION
• Remove the front panel. (: 9-8) 1
• Place the motorcycle on the center stand and put the side
stand in.
1 Check the ECM and CVT control unit couplers for loose 3
or poor contacts.
If OK, check the CVT engine revolution signal.
Insert the copper wire to the 3
(Br/W) wire of the CVT
CVT control unit coupler
control unit coupler.
Start the engine and measure the signal voltage between
+ 3 -
Br/W ( ) wire and Ground.
NOTE: 1
Do not need to disconnect any couplers.
; CVT engine revolution signal: Approx. 2.5 V
(+Br/W – -Ground) V
z 09900-25008: Multi circuit tester
u Tester knob indication: Voltage (-)
NG Short circuit in the Br/W
lead wire.
Loose or poor contacts.
ECM malfunction. 1 CVT control unit coupler

OK
3
Loose or poor contacts on the CVT control unit
couplers.
Br/W
CVT control unit malfunction.

O
ECM couplers
6-54 FI SYSTEM/ CVT SYSTEM

“C56” CVT THROTTLE POSITION SIGNAL CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
The CVT throttle position signal is not input to CVT • Lead wire open or short.
control unit from ECM for more than 5 sec. after • ECM malfunction.
ignition switch turns ON. • CVT control unit malfunction.

INSPECTION
• Remove the front panel. ( :9-8) 1
1 Check the ECM and CVT control unit couplers for loose
or poor contacts.
If OK, check the CVT throttle signal.
+ E
Insert the copper wire to the Brack/Red ( ) wire of the
CVT control unit coupler.
Turn the ignition switch ON and measure the signal CVT control unit
voltage by turning the throttle grip.
NOTE:
Do not need to disconnect any couplers.

; CVT throttle signal

1

Throttle valve is closed: Approx. 3.6 V

Throttle valve is opend: Approx. 1.7 V
z 09900-25008: Multi circuit tester V
u Tester knob indication: Voltage (-)
NG Short circuit in the B/R
lead wire.
Loose or poor contacts.
ECM malfunction. 1 CVT control unit coupler
OK
Loose or poor contacts on the CVT control unit
couplers.
CVT control unit malfunction. B/R

ECM couplers
 FI SYSTEM/ CVT SYSTEM 6-55

“C58” CVT REDUCTION RATIO DISAGREEMENT

DETECTED CONDITION POSSIBLE CAUSE
The revolution ratio detected by CVT pulley position PPS is stuck immovable.
sensor (PPS) disagrees with actual revolution ratio Foreign substance such as water, oil or metal parti-
for more than 4 sec. cle has entered CVT assembly.

INSPECTION
1 Turn the ignition switch OFF so that the malfunction code 1
is reset.
Warm up the engine sufficiently and test drive to see if
“C58” code appears.
If “C58” appears during test running, proceed to stage 2 .
OK Transitory slipping due to
entry of water, oil, metal
particle, etc.
It problem does not persist,
complete the inspection.
2

:
“C58” is indcated.
2 Inspect the PPS .1
Remove the foot board. ( 9-18)
Remove the PPS 1 and check the PPS for smooth
movement.
NG Replace the PPS with a
new one.

OK
2

:
3 Inspect the CVT assembly.
Check for existance of water, oil or metal particle, etc.
( 5-5)
If anything is wrong, replace the defective parts.
OK
Complete the inspection.

NG
Replace the CVT control unit (CVT control
module) with a new one and inspect it again.
6-56 FI SYSTEM/ CVT SYSTEM

SENSORS
THROTTLE POSITION SENSOR (TPS) SETTING
• After all adjustments are completed, check or adjust the TPS
setting condition.
TPS SETTING PROCEDURE (#6-20)

CMP SENSOR
The signal rotor is installed on the exhaust camshaft, and the
camshaft position sensor (Pick-up coil) is installed on the cylin-
der head cover. (#6-27)

CKP SENSOR
The signal rotor is mounted on the generator rotor, and the
crankshaft position sensor (Pick-up coil) is installed above the
rotor. (#6-28)

IAP SENSOR
The intake air pressure sensor is located at the right side of the
air chamber. (#6-29)
 FI SYSTEM/ CVT SYSTEM 6-57

TP SENSOR
• The throttle position sensor is installed on the No.2 throttle
body. (#6-31)

ECT SENSOR
• The engine coolant temperature sensor is installed on the cyl-
inder head. (#6-33)
$ ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

SPEED SENSOR
• The speed sensor is installed on the final gear case. (#6-
34)

IAT SENSOR
• The intake air temperature sensor is installed on the right side
of the air chamber. (#6-36)

AP SENSOR
• The atmospheric pressure sensor is located at the right side
of the leg shield brace. (#6-37)
6-58 FI SYSTEM/ CVT SYSTEM

TO SENSOR
• The tip over sensor is located under the combination meter.
(#6-39)
NOTE:
When installing the TO sensor, bring the “UPPER” letter to the
top.

HO2 SENSOR (E-02, 19)

• The heated oxygen sensor is installed on the exhaust pipe.
(#6-42)
%
Do not remove the HO2 sensor while it is hot.

"
Be careful not to expose it to excessive shock.
Do not use an impact wrench while removing or
installing the HO2 sensor unit.
Be careful not to twist or damage the sensor lead wire.

"
Do not apply oil or other materials to the sensor air
hole.

$ HO2 SENSOR: 47.5 N·m (4.75 kgf-m, 34.3 lb-ft)

CVT PULLEY POSITION SENSOR

• The CVT pulley position sensor is mounted on the CVT cover.
(#6-47)

CVT SECONDARY PULLEY REVOLUTION SENSOR

• The secondary pulley revolution sensor is located underneath
the CVT assembly. (#6-51)
 FUEL SYSTEM AND THROTTLE BODY 7-1

FUEL SYSTEM AND THROTTLE BODY

CONTENTS
FUEL SYSTEM .....................................................................................7- 2
FUEL TANK COMPONENTS .......................................................7- 2
FUEL TANK REMOVAL ..............................................................7- 3
FUEL TANK INSTALLATION ......................................................7- 4
TANK PRESSURE CONTROL (TPC) VALVE INSPECTION ......7- 4
FUEL PRESSURE INSPECTION .................................................7- 5
FUEL PUMP INSPECTION ..........................................................7- 6
FUEL PUMP RELAY INSPECTION .............................................7- 6
FUEL PUMP COMPONENTS ......................................................7- 7 7
FUEL PUMP/FUEL LEVEL GAUGE REMOVAL AND
DISASSEMBLY ............................................................................7- 7
FUEL MESH FILTER INSPECTION AND CLEANING ................7-10
FUEL LEVEL GAUGE INSPECTION ...........................................7-10
FUEL PUMP/FUEL LEVEL GAUGE REASSEMBLY AND
INSTALLATION ...........................................................................7-11
THROTTLE BODY ................................................................................7-14
THROTTLE BODY COMPONENTS ............................................7-14
THROTTLE BODY REMOVAL ....................................................7-15
THROTTLE BODY DISASSEMBLY ............................................7-17
THROTTLE BODY CLEANING AND INSPECTION ....................7-19
IAC VALVE INSPECTION ............................................................7-20
THROTTLE BODY REASSEMBLY .............................................7-20
THROTTLE BODY INSTALLATION ............................................7-22
THROTTLE CABLE ADJUSTMENT ............................................7-23
TP SENSOR ADJUSTMENT .......................................................7-23
FUEL INJECTOR REMOVAL ......................................................7-23
FUEL INJECTOR INSPECTION ..................................................7-23
FUEL INJECTOR INSTALLATION ..............................................7-23
THROTTLE VALVE SYNCHRONIZATION ..................................7-24

!
Gasoline must be handled carefully in an area well ventilated and away from
fire or sparks.
7-2 FUEL SYSTEM AND THROTTLE BODY

FUEL SYSTEM
FUEL TANK COMPONENTS

33 N·m (3.3 kgf-m, 24 lb-ft)

1 Fuel tank
2 Seal ring
3 Ring locknut
4 Tank pressure control valve (Orange/Black)
5 Tank pressure control valve (Gray/Black)
6 Fuel tank inlet pipe
7 Fuel tank inlet hose
8 Fuel filler
9 Fuel filler cap
 FUEL SYSTEM AND THROTTLE BODY 7-3

FUEL TANK REMOVAL

The fuel tank is located under the seat.
• Remove the following parts. (!9-6)
* Seat * Pillion rider handles
* Battery cover * Lower frame cover
* Center frame cover * Helmet box cover
* Frame covers * Helmet box

• Loosen the fuel tank inlet hose clamp.

• Disconnect the fuel tank breather hose 1.
• Remove the fuel tank inlet hose 2 along with the fuel tank
inlet pipe 3.

• Disconnect the fuel pump/fuel level gauge coupler 4.

• Disconnect the fuel feed hose 5.
• Disconnect the fuel cut valve hose 6.

• Remove the fuel tank mounting bolts.

7-4 FUEL SYSTEM AND THROTTLE BODY

• Remove the fuel tank sideward.

"
Gasoline is highly flammable and explosive. Keep
heat, spark and flame away.

FUEL TANK INSTALLATION

Installation is in the reverse order of removal.

TANK PRESSURE CONTROL (TPC) VALVE

INSPECTION
Two kinds of the TPC valve are equipped in the fuel tank, they
can be distinguished by the color.
Fuel inlet side: 1 Gray/Black
Fuel tank side: 2 Orange/Black

Check TPC valve if air can pass through smoothly when blown
from the orange color side or gray color side and not from the
other side.
Should any abnormal condition be found, replace the valve with
a new one.

Orange or Gray
 FUEL SYSTEM AND THROTTLE BODY 7-5

FUEL PRESSURE INSPECTION

• Remove the front box. (!9-18)
• Place a rag under the fuel feed hose.
• Disconnect the fuel feed hose at the fuel delivery pipe, and
install the special tools between the fuel feed hose and fuel
delivery pipe.
# 09940-40211: Fuel pressure gauge adaptor
09940-40220: Fuel pressure gauge hose attachment
09915-77330: Oil pressure gauge
09915-74520: Oil pressure gauge hose

Turn the ignition switch ON and check the fuel pressure.

$ Fuel pressure: Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
If the fuel pressure is lower than the specification, inspect the
following items:
* Fuel hose leakage
* Clogged fuel filter
* Pressure regulator
* Fuel pump

If the fuel pressure is higher than the specification, inspect the

following items:
* Fuel pump check valve
* Pressure regulator
"
* Before removing the special tools, turn the ignition
switch to OFF position and release the fuel pressure
slowly. To fuel delivery pipe
* Gasoline is highly flammable and explosive. Keep
heat, spark and flame away.

To fuel feed hose

7-6 FUEL SYSTEM AND THROTTLE BODY

FUEL PUMP INSPECTION

Turn the ignition switch ON and check that the fuel pump oper-
ates for few seconds.
If the fuel pump motor does not make operating sound, replace
the fuel pump assembly or inspect the fuel pump relay and tip
over sensor.

FUEL DISCHARGE AMOUNT INSPECTION

"
Gasoline is highly flammable and explosive. Keep
heat, spark and flame away.

• Remove the front box. (!9-18)

• Disconnect the fuel feed hose from the fuel delivery pipe.
• Place the measuring cylinder and insert the fuel feed hose
end into the measuring cylinder.
• Disconnect the ECM lead wire coupler.
• With the lead wire’s fastener A unlocked, pull out the power
source lead wire (Yellow with red tracer) 1. Battery
• Apply 12 volts to the fuel pump for 30 seconds and measure
the amount of fuel discharged.
If the pump does not discharge the amount specified, it means
that the fuel pump is defective or that the fuel filter is clogged.
$ Fuel discharge amount: More than 900 ml/30 sec.
(30.4/31.7 US/Imp oz)/30 sec.
NOTE:
The battery must be in fully charged condition.

FUEL PUMP RELAY INSPECTION

Fuel pump relay is located behind the front panel.
• Remove the front panel.
• Remove the fuel pump relay.
First, check the insulation between 1 and 2 terminals with
pocket tester. Then apply 12 volts to 3 and 4 terminals, + to
3 and - to 4, and check the continuity between 1 and 2.
If there is no continuity, replace it with a new one.
 FUEL SYSTEM AND THROTTLE BODY 7-7

FUEL PUMP COMPONENTS

33 N·m
3.3 kgf-m
24 lb-ft

Align the marks

in line.

1 Fuel pump assembly

2 O-ring
3 Fuel filter cartridge assembly
4 Fuel pressure regulator
5 O-ring
6 Fuel level gauge
7 Fuel pump upper cover
8 Fuel pump lower cover
9 Fuel feed hose

FUEL PUMP/FUEL LEVEL GAUGE

REMOVAL AND DISASSEMBLY
• Remove the seat and battery cover.
• Disconnect the fuel pump/fuel level gauge coupler 1.
• Disconnect the fuel feed hose 2.
NOTE:
The fuel pump can be removed without removing the fuel tank.
7-8 FUEL SYSTEM AND THROTTLE BODY

• Remove the fuel pump ring locknut by using the special tool.
# 09941-51010: Ring locknut wrench

"
Gasoline is highly flammable and explosive. Keep
heat, spark and flame away.

• Remove the fuel pump assembly.

• Disconnect the fuel level gauge lead wire coupler.

• Remove the fuel level gauge.

• Disconnect the ground wire.

• Remove the fuel pressure regulator.
 FUEL SYSTEM AND THROTTLE BODY 7-9

• Disconnect the fuel pump lead wire coupler and ground wire.

• Remove the fuel pump lower case 1.

• Disconnect the fuel feed hose 2.

• Disconnect the fuel pump lead wire coupler.

• Remove the fuel pump from its holder.

7-10 FUEL SYSTEM AND THROTTLE BODY

FUEL MESH FILTER INSPECTION AND

CLEANING
If the fuel mesh filter is clogged with sediment or rust, fuel will
not flow smoothly and loss in engine power may result.
Blow the fuel mesh filter with compressed air.
NOTE:
If the fuel mesh filter is clogged with many sediment or rust,
replace the fuel filter cartridge with a new one.

FUEL LEVEL GAUGE INSPECTION

Measure resistance between the terminals when the float is at
the position listed below.
# 09900-25008: Multi-circuit tester

Fuel level position Resistance between terminals

130 mm (F) 11 – 13 Ω
82 mm (½) Approx. 71.5 Ω
23 mm (E) 130 – 150 Ω
If the resistance measured is out of the specification, replace the
gauge with a new one.
Fuel meter inspection (!10-27)

130 mm

82 mm

23 mm

E
 FUEL SYSTEM AND THROTTLE BODY 7-11

FUEL PUMP/FUEL LEVEL GAUGE

REASSEMBLY AND INSTALLATION
Install the fuel pump/fuel level gauge in the reverse order of
removal and disassembly, and pay attention to the following
points:
• Install the new O-rings to the fuel pump, fuel pressure regula-
tor and fuel feed hose.
• Apply thin coat of the engine oil to the O-rings.

%
Use the new O-rings to prevent fuel leakage.

• Install the fuel pump to its holder and connect the lead wire
coupler.

• Connect the fuel feed hose securely.

7-12 FUEL SYSTEM AND THROTTLE BODY

• Install the fuel pressure regulator and ground wire.

• Install the fuel level gauge.

• Connect the fuel pump lead wire coupler, ground wire and fuel
level gauge lead wire coupler.

• Install the new seal ring 1 to the fuel tank.

• Install the fuel pump assembly.
 FUEL SYSTEM AND THROTTLE BODY 7-13

• Align the alignment marks A and B in line.

• Using the special tool, tighten the fuel pump ring locknut to
the specified torque.
# 09941-51010: Ring locknut wrench
& Ring locknut: 33 N·m (3.3 kgf-m, 24 lb-ft)
7-14 FUEL SYSTEM AND THROTTLE BODY

THROTTLE BODY
THROTTLE BODY COMPONENTS

1 TP sensor
2 O-ring
3 Fuel injector
4 Fuel injector seal
5 O-ring
6 Fuel delivery pipe
7 Fuel delivery pipe joint
8 O-ring
9 IAC hose connector
0 O-ring
3.5 N·m
A IAC valve
0.35 kgf-m
B O-ring
2.5 lb-ft
C Throttle stop screw
D Throttle lever stopper
E Throttle cable bracket
screw

F Throttle body
G Synchronizing screw
H O-ring
I Vacuum hose

3.5 N·m
0.35 kgf-m
2.5 lb-ft

3.5 N·m
0.35 kgf-m
2.5 lb-ft

3.5 N·m
0.35 kgf-m
2.5 lb-ft
 FUEL SYSTEM AND THROTTLE BODY 7-15

THROTTLE BODY REMOVAL

• Remove the front box. (!9-18)
• Disconnect the PCV hose from the bottom side of the air
cleaner box.
• Remove the air cleaner box 1.

• Remove the IAP sensor 2.

• Disconnect the IAT sensor coupler 3.

• Remove the PAIR solenoid valve 4.

• Loosen the respective throttle body clamp screws (air cham-

ber side).
7-16 FUEL SYSTEM AND THROTTLE BODY

• Disconnect the IAC hose 5.

• Remove the air chamber 6.

• Disconnect the various lead wire couplers.

7 TPS 8 IAC valve
9 FI

• Disconnect the fuel feed hose 0.

• Disconnect the throttle cables.

%
After disconnecting the throttle cables, do not snap
the throttle valve from full open to full close. It may
cause damage to the throttle valve and throttle body.

• Loosen the respective throttle body clamp screws (intake pipe

side).
• Remove the throttle body assembly.
 FUEL SYSTEM AND THROTTLE BODY 7-17

THROTTLE BODY DISASSEMBLY

• Remove the IAC hose.
• Remove the vacuum hoses.

• Remove the fuel delivery pipe.

• Remove the fuel injectors.

• Remove the IAC valve.

• Remove the TPS.

NOTE:
Prior to disassembly, mark sensor’s original position with a paint
or scribe for accurate reinstallation.
7-18 FUEL SYSTEM AND THROTTLE BODY

%
Never remove the throttle valve.

%
Avoid removing the throttle lever stopper screw A.

• Remove the IAC hose connector.

• Remove the throttle cable bracket.

• Remove the synchronizing screws.

NOTE:
Before removing the synchronizing screw, determine the setting
by slowly turning it clockwise and count the number of turns
required to lightly seat the screw. This counted number is impor-
tant when reassembling synchronizing screw to original position.
 FUEL SYSTEM AND THROTTLE BODY 7-19

THROTTLE BODY CLEANING AND

INSPECTION
"
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.

• Clean all passageways with a spray-type carburetor cleaner

and blow dry with compressed air.
%
Do not use wire to clean passageways. Wire can dam-
age 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. Always follow the chemical manufacturer’s
instructions for proper use and cleaning of the throttle
body components. Do not apply carburetor cleaning
chemicals to the rubber and plastic materials.

• Check following items for any damage or clogging.

* O-ring * Fuel injector filter
* Throttle shaft bushing and seal * Injector seal
* Throttle valve * Vacuum hose
* Synchronizing screw * IAC hose
* Fuel injector
7-20 FUEL SYSTEM AND THROTTLE BODY

IAC VALVE INSPECTION

The IAC valve can be checked without removing it from the Ω
throttle body.
• Remove the front box. (!9-18)
• Disconnect the IAC valve lead wire coupler.
• Check the resistance between the terminals of the IAC valve.
$ Resistance: Approx. 4 Ω (at 20 – 24 °C/68 – 75 °F)
# 09900-25008: Multi circuit tester set
' Tester knob indication: Resistance (Ω
Ω)

If the resistance is not within the standard range, replace the

IAC valve with a new one.
%
Do not attempt to disassemble the IAC valve. IAC
valve is available only as an assembly.

• Remove the IAC valve cover 1.

• Disconnect the IAC valve lead wire coupler.
• Connect the 12 V battery to the IAC valve terminals for more Battery
than 3 minutes and check for change of the IAC valve temper-
ature from the cold condition.
• If the IAC valve is not warmed up, replace the IAC valve with
a new one.

THROTTLE BODY REASSEMBLY

Reassemble the throttle body in the reverse order of disassem-
bly.
Pay attention to the following points:

• Apply thread lock “1342” to the screws and tighten them.

( 99000-32050: THREAD LOCK “1342”
& Throttle cable bracket screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
 FUEL SYSTEM AND THROTTLE BODY 7-21

• Apply a small quantity of grease to the shaft end and seal lip.
) 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• With the TV fully closed, install the TP sensor to the original

setting position.
& TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

• Install the IAC valve.

%
Replace the O-ring with a new one.

• Apply thin coat of the engine oil to the new O-ring.

• Install the injector seal 1 and O-ring 2 to each fuel injector.

• Apply thin coat of the engine oil to the new O-ring and new seal.
• Install the fuel injectors by pushing them straight to each throt-
tle body.
%
Replace the injector seal and O-ring with the new
ones. Never turn the injector while pushing it.

• Install the fuel delivery pipe assembly to the throttle body

assembly.
%
Never turn the fuel injectors while installing fuel deliv-
ery pipe.

• Tighten the fuel delivery pipe mounting screws.

& Fuel delivery pipe mounting screw:
3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
7-22 FUEL SYSTEM AND THROTTLE BODY

• Install the IAC hose connector.

%
Replace the O-ring with a new one.

• Apply thin coat of the engine oil to the new O-ring.

• Install the synchronizing screw to the original setting by turn-

ing the screw in until it lightly seats, and then backing it out
the same number of turns counted during disassembly.
%
Replace the O-ring with a new one.

• Apply thin coat of the engine oil to the new O-ring.

THROTTLE BODY INSTALLATION

Installation is in the reverse order of removal. Pay attention to
the following points:
• Connect the throttle pulling cable and throttle returning cable
to the throttle cable drum.
• Adjust the throttle cable play with the cable adjusters.
Refer to page 2-19 for details.

THROTTLE BODY CLAMP POSITION

Air cleaner side Forward

#1 #2

10˚

LH IAC hose Top mark RH

#1 #2

VIEW OF TOP Intake pipe side Backward

 FUEL SYSTEM AND THROTTLE BODY 7-23

THROTTLE CABLE ADJUSTMENT

NOTE:
Minor adjustment can be made by the throttle grip side adjuster.
(!2-18)

TP SENSOR ADJUSTMENT
• After checking or adjusting the throttle valve synchronization,
adjust the TP sensor positioning as follows:
• After warming up engine, adjust the idling speed to 1 200 ±
100 rpm.
• Stop the warmed-up engine and connect the special tool to
the dealer mode coupler. (!6-24)
# 09930-82710: Mode select switch
• Turn the special tool’s switch ON.

• If the TP sensor adjustment is necessary, loosen the TP sen-

sor mounting screw.
• Turn the TP sensor and bring the line to middle. Incorrect
• Tighten the TP sensor mounting screw.
Correct position
& TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)
Incorrect

FUEL INJECTOR REMOVAL

• Remove the front box. (!9-18)
• Disconnect the injector couplers.
• Remove the fuel delivery pipe assembly. (!7-17)
• Remove the fuel injectors No.1 and No.2. (!7-17)

FUEL INJECTOR INSPECTION

The fuel injector can be checked without removing it from the
throttle body.
Refer to page 6-40 for details.
• Check the fuel injector filter for evidence of dirt and contami-
nation. If present, clean and check for presence of dirt in the
fuel lines and fuel tank.

FUEL INJECTOR INSTALLATION

• Apply thin coat of the engine oil to new injector seals and
O-rings.
• Install the injector by pushing it straight to the throttle body.
Never turn the injector while pushing it. (!7-21)
7-24 FUEL SYSTEM AND THROTTLE BODY

THROTTLE VALVE SYNCHRONIZATION

Check and adjust the throttle valve synchronization between two
cylinders. To synchronize throttle valves, disconnect the IAP
sensor’s vacuum hoses from the vacuum nipples on the respec-
tive throttle bodies and connect the vacuum balancer gauge
hoses to each vacuum nipple.
NOTE:
Before balancing the throttle valves, calibrate each vacuum bal-
ancer gauge.
• Remove the front box. (!9-18)

• Start up the engine and run it in idling condition for warming

up.
• Stop the warmed-up engine.
• Connect a tachometer and start up the engine.
• Bring the engine rpm to 1 200 rpm by the throttle stop screw.
• Check the vacuum of the two cylinders and balance the two
throttle valves with the synchronizing screw A.

NOTE:
* During balancing the throttle valves, always set the engine
rpm at 1 200 rpm, using throttle stop screw.
* After balancing the two valves, set the idle rpm to 1 200 rpm.

For vacuum balancer gauge (09913-13121)

The vacuum gauge is positioned approx. 30° from the horizontal
level, and in this position the two balls should be within one ball
dia. If the difference is larger than one ball, turn the synchroniz-
ing screw on the throttle body and bring the ball to the same
level.
A correctly adjusted throttle valve synchronization has the balls
in the No.1 and No.2 at the same level.
 COOLING AND LUBRICATION SYSTEM 8-1

COOLING AND LUBRICATION SYSTEM

CONTENTS
COOLING SYSTEM ..............................................................................8- 2
DESCRIPTION .............................................................................8- 2
COOLING CIRCUIT .....................................................................8- 2
OIL COOLER ...............................................................................8- 2
ENGINE COOLANT ..............................................................................8- 3
RADIATOR AND HOSES .....................................................................8- 4
COOLING CIRCUIT INSPECTION ..............................................8- 4
RADIATOR CAP INSPECTION ...................................................8- 4
RADIATOR INSPECTION ............................................................8- 4
RADIATOR HOSE INSPECTION .................................................8- 5
RADIATOR REMOVAL ................................................................8- 6
RADIATOR REMOUNTING .........................................................8- 7
RADIATOR RESERVOIR TANK ..................................................8- 7
COOLING FAN .....................................................................................8- 8
INSPECTION ................................................................................8- 8
8
REMOVAL ....................................................................................8- 8
REMOUNTING .............................................................................8- 9
COOLING FAN THERMO-SWITCH .....................................................8-10
REMOVAL ....................................................................................8-10
INSPECTION ................................................................................8-11
INSTALLATION ...........................................................................8-11
ENGINE COOLANT TEMPERATURE SENSOR .................................8-12
REMOVAL ....................................................................................8-12
INSPECTION ................................................................................8-13
INSTALATION ..............................................................................8-13
THERMOSTAT .....................................................................................8-14
REMOVAL ....................................................................................8-14
INSPECTION ................................................................................8-14
INSTALLATION ...........................................................................8-15
WATER PUMP ......................................................................................8-16
CONSTRUCTION .........................................................................8-16
REMOVAL AND DISASSEMBLY ................................................8-17
INSPECTION ................................................................................8-19
REASSEMBLY AND INSTALLATION .........................................8-21
LUBRICATION SYSTEM ......................................................................8-25
OIL PRESSURE ...........................................................................8-25
OIL FILTER ..................................................................................8-25
OIL COOLER ...............................................................................8-25
OIL PRESSURE REGULATOR ...................................................8-25
OIL SUMP FILTER .......................................................................8-25
OIL LEVEL SWITCH ....................................................................8-25
OIL PRESSURE SWITCH ............................................................8-25
OIL PUMP ....................................................................................8-25
OIL RETURN PUMP ....................................................................8-25
ENGINE LUBRICATION SYSTEM CHART .................................8-26
ENGINE LUBRICATION SYSTEM ..............................................8-27
8-2 COOLING AND LUBRICATION SYSTEM

COOLING SYSTEM
DESCRIPTION
The engine is cooled by the forced circulation of engine coolant, using a high-capacity, centrifugal water
pump, through water jackets formed in the cylinder and cylinder head, and through the radiator. The tube-
and-fin type radiator is made of aluminum, which is characterized by lightness in weight and good heat dissi-
pation.
A wax-pellet type thermostat is used to regulate the flow of engine coolant through the radiator. As the cool-
ant temperature rises to about 88°C (190°F) the thermostat valve unseats and a normal coolant flow is
established. At about 100°C (212°F) the thermostat becomes completely open and, as a result, heat is
released to the atmosphere through the radiator core.

COOLING CIRCUIT
RESERVOIR
TANK
BREATHER

BY-PASS THERMOSTAT

RADIATOR
COOLANT COOLING
TEMPERATURE FAN THERMO
SENSOR SWITCH

RH CYLINDER
CYLINDER
CRANKCASE HEAD

OIL COOLER

WATER PUMP

OIL COOLER
Oil cooler is setting on the place of oil filter.
The engine oil is cooled by engine coolant, which is circulated
through inside core of oil cooler.
Oil cooler

Oil filter

: Engine oil flow

: Engine coolant flow
 COOLING AND LUBRICATION SYSTEM 8-3

ENGINE COOLANT
At the time of manufacture, the cooling system is filled with a
50:50 mixture of distilled water and ethylene glycol anti-freeze. Anti-freeze
Freezing point
This 50:50 mixture will provide the optimum corrosion protection density
and excellent heat protection, and will protect the cooling system 50% –31˚C (–24˚F)
from freezing at temperatures above –31°C (–24°F). 55% –40˚C (–40˚F)
If the vehicle is to be exposed to temperatures below –31°C 60% –55˚C (–67˚F)
(–24°F), this mixing ratio should be increased up to 55% or
60% according to the figure.
! (˚F) (˚C)
32 0
* Use a high quality ethylene glycol base anti-freeze,
14 –10
mixed with distilled water. Do not mix an alcohol
base anti-freeze and different brands of anti-freeze. –4 –20

Freezing point
* Do not put in more than 60% anti-freeze or less than –22 –30
50%. (Refer to Right figure.) –40 –40
* Do not use a radiator anti-leak additive.
–58 –50
50% Engine coolant including reserve tank capacity –76 –60

Anti-freeze 650 ml (1.4/1.1 US/lmp. pt) –94 –70

Water 650 ml (1.4/1.1 US/lmp. pt)
20 40 60 80 100
Density (%)
Fig.1 Engine coolant density-freezing
point curve.

(˚F) (˚C) (kgf/cm²)

302 150

284 140 1.5

Gauge pressure
Boiling point

266 130 0.9

248 120 0.5

230 110 0

212 100

0 10 20 30 40 50 60
Density (%)
Fig.2 Engine coolant density-boiling
point curve.

"
* You can be injured by scalding fluid or steam if you open the radiator cap when the engine is
hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
* The engine must be cool before servicing the cooling system.
* Coolant is harmful;
• If it comes in contact with skin or eyes, flush with water.
• If swallowed accidentally, induce vomiting and call physician immediately.
• Keep it away from children.
8-4 COOLING AND LUBRICATION SYSTEM

RADIATOR AND HOSES

COOLING CIRCUIT INSPECTION
Before removing the radiator and draining the engine coolant,
check the following.
Check the cooling system for leaks with a radiator tester 1.
Remove the radiator cap and connect the radiator tester to the
filler. Pressurize the cooling system with 120 kPa (1.2 kgf/cm²,
17 psi) of pressure, and then check if it holds the pressure for 10
seconds. If the cooling system does not hold the pressure for at
least 10 seconds, check the entire cooling system for leaks. If a
leak is found, replace the damaged part.
"
* Do not open the radiator cap when the engine is hot,
as you may be injured by escaping hot liquid or
vapor.
* When removing the radiator cap tester, put a rag on
the filler to prevent the engine coolant from spraying
out.

!
Do not exceed the radiator cap release pressure, or
the radiator cap and subsequently the radiator, can be
damaged.

RADIATOR CAP INSPECTION

Check the radiator cap 2 using a radiator tester 1.
Attach the radiator cap to the radiator tester as shown. Slowly
apply pressure to the radiator cap; do not exceed 95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi). If the radiator cap does
not hold the pressure for at least 10 seconds, replace it with a
new one.
# Radiator cap release pressure: 95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)

RADIATOR INSPECTION
Check the radiator for dirt and other foreign materials. If any are
found, clean the radiator using compressed air. Also, repair any
bent or dented fins using a small screwdriver.
 COOLING AND LUBRICATION SYSTEM 8-5

RADIATOR HOSE INSPECTION

• Remove the leg shield and footboard. ($9-10, 9-18)
Any radiator hose found in a cracked condition or flattened must
be replaced.
Any leakage from the connecting section should be corrected by
proper tightening.
8-6 COOLING AND LUBRICATION SYSTEM

RADIATOR REMOVAL
• Remove the leg shield and footboard. ($9-10, 9-18)
• Drain engine coolant by removing the drain plug.

• Disconnect the fan motor lead wire coupler 1.

• Disconnect the upper and lower radiator hoses.

• Remove the three mounting bolts and radiator assembly.

• Remove the radiator guard.

 COOLING AND LUBRICATION SYSTEM 8-7

• Remove the four fixing places and the heat shield.

RADIATOR REMOUNTING
Install the radiator and the radiator hoses in the reverse order of removal.
Pay attention to the following points:
• Connect the fan motor lead wire coupler.
• Tighten the drain plug to the specified torque.
% Drain plug: 6 N·m (0.6 kgf-m, 4.3 lb-ft)
• Pour engine coolant. ($2-21)
• Bleed air from the cooling circuit. ($2-21)

RADIATOR RESERVOIR TANK

REMOVAL/REMOUNTING
• Remove the reservoir tank mounting bolt.
• Disconnect the siphon hose from the reservoir tank and drain
engine coolant.
• Install the reservoir tank in the reverse order of removal.
• Fill the reservoir tank to the upper level line.
8-8 COOLING AND LUBRICATION SYSTEM

COOLING FAN
INSPECTION
• Remove the leg side cover and footboard. ($9-12, 9-18)
• Disconnect the cooling fan motor lead wire coupler 1 and fan
switch coupler 2.
Test the cooling fan motor for load current with an ammeter con-
nected as shown in the illustration.

The voltmeter is for making sure that the battery applies 12 volts
to the motor. With the motor with electric motor fan running at
full speed, the ammeter should be indicating not more than 5
Fan motor Ammeter
amperes.
If the fan motor does not turn, replace the motor assembly with a Battery
new one.
NOTE:
When making above test, it is not necessary to remove the cool-
ing fan.

Connection: + → Fan motor lead wire coupler BLUE

- → Fan switch coupler BLACK (fan motor side)

Bl B B

Fan motor

Fan switch

REMOVAL
• Remove the radiator. ($8-6)
• Disconnect the cooling fan switch coupler 1.
• Remove the three mounting bolts and the cooling fan unit.
 COOLING AND LUBRICATION SYSTEM 8-9

• Remove the cooling fan.

REMOUNTING
Remount the cooling fan in the reverse order of removal.
Pay attention to the following point:
• Tighten the cooling fan mounting bolts to the specified torque.
% Cooling fan mounting bolt: 6.5 N·m (0.65 kgf-m, 4.7 lb-ft)
8-10 COOLING AND LUBRICATION SYSTEM

COOLING FAN THERMO-SWITCH

The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo-
switch. The thermo-switch remains open when the temperature of the engine coolant is low, but closes
when the temperature reaches approximately 98°C (208°F) setting the cooling fan in motion.

Ignition
switch Fuse
O O/G CVT
controller
R
Fuse
Gr/Y
B/O
M B B

Main Cooling Cooling fan

fuse fan motor thermoswitch

Battery B/W
WIRE COLOR
B : Black
O : Orange
Fan relay
R : Red
B/O : Black with Orange tracer
B/W : Black with White tracer
Gr/Y: Gray with Yellow tracer
O/G : Orange with Green tracer

REMOVAL
• Remove the leg shield and footboard. ($9-10, 9-18)
• Drain engine coolant. ($2-20)
• Disconnect the cooling fan thermo-switch lead wire coupler
1.
• Remove the cooling fan thermo-switch 2.
 COOLING AND LUBRICATION SYSTEM 8-11

INSPECTION
• Check the thermo-switch closing or opening temperatures by
testing it at the bench as shown in the figure. Connect the
thermo-switch 1 to a circuit tester and place it in the oil con-
tained in a pan, which is placed on a stove.
• Heat the oil to raise its temperature slowly and read the col-
umn thermometer 2 when the switch closes or opens.
& 09900-25008: Multi circuit tester set Oil
' Tester knob indication: Continuity test (()
# Cooling fan thermo-switch operating temperature
Standard (OFF→ →ON): Approx. 98°C (208°F)
(ON→→OFF): Approx. 92°C (198°F)

!
* Take special care when handling the cooling fan
thermo-switch. Do not subject it to strong blows or
allow it to be dropped.
* Do not contact the cooling fan thermo-switch 1 and
the column thermometer 2 with a pan.

INSTALLATION
Install the cooling fan thermo-switch in the reverse order of
removal. Pay attention to the following points:
• Apply engine coolant to the O-ring.
• Tighten the cooling fan thermo-switch to the specified torque.
% Cooling fan thermo-switch: 17 N·m (1.7 kgf-m, 12.3 lb-ft)
!
Replace the removed O-ring with a new one.
• Pour engine coolant. ($2-21)
• Bleed air from the cooling circuit. ($2-21)
8-12 COOLING AND LUBRICATION SYSTEM

ENGINE COOLANT TEMPERATURE SENSOR

The following circuit diagram shows the electrical wiring for the thermometer. The major components are
temperature sensor in contact with coolant; and temperature indicator (engine coolant temperature meter).

Water temp
warning
Speedometer ECU

Ignition O/W B/Br

B/Br B/Bl P/W
switch O/G
Fuse
O

Handle
Main switch
fuse Fuse
O/Y

RR

WIRE COLOR
O : Orange B/W
B/W
Battery R : Red
B/Br : Black with Brown tracer
B/Bl : Black with Blue tracer
B/W : Black with White tracer Water temp
O/G : Orange with Green tracer sensor
O/Y : Orange with Yellow tracer
O/W : Orange with White tracer
P/W : Pink with White tracer

REMOVAL
• Remove the footboard. ($9-18)
• Disconnect the engine coolant temperature sensor lead wire
coupler 1.
• Remove the engine coolant temperature sensor 2.
 COOLING AND LUBRICATION SYSTEM 8-13

INSPECTION
• Check the engine coolant temperature by testing it at the
bench as shown in the figure. Connect the temperature sen-
sor 1 to a circuit tester and place it in the oil contained in a Ω
pan, which is placed on a stove.
• Heat the water to raise its temperature slowly and read the
column thermometer 2 and the ohmmeter.
• If the temperature sensor ohmic valve does not change in the Oil
proportion indicated, replace it with a new one.
# Temperature sensor specification

Temperature Standard resistance

20°C (68°F) Approx. 2.45 kΩ
50°C (122°F) Approx. 0.811 kΩ
80°C (176°F) Approx. 0.318 kΩ
110°C (230°F) Approx. 0.142 kΩ

If the resistance noted to show infinty or too much different resis-

tance value, replace the temperature sensor with a new one.
!
* Take special care when handling the temperature
sensor. It may cause damage if it gets a sharp
impact.
* Do not contact the engine coolant temperature sen-
sor 1 and the column thermometer 2 with a pan.

INSTALATION
• Tighten the engine coolant temperature sensor to the speci-
fied torque.
% Engine coolant temperature sensor:
18 N·m (1.8 kgf-m, 13.0 lb-ft)
!
Replace the removed sealing washer 1 with a new
one.
8-14 COOLING AND LUBRICATION SYSTEM

THERMOSTAT
REMOVAL
• Remove the leg shield and footboard. ($9-10, 9-18)
• Drain a small amount of engine coolant. ($2-20)
• Place a rag under the thermostat case.
• Remove the thermostat case.

• Remove the thermostat 1.

INSPECTION
Inspect the thermostat pellet for signs of cracking.
Test the thermostat at the bench for control action, in the follow-
ing manner.
• Immerse the thermostat 1 in the water contained in a beaker,
as shown in the illustration. Note that the immersed thermo-
stat is in suspension. Heat the water by placing the beaker on
a stove and observe the rising temperature on a thermometer
2.
• Read the thermometer just when opening the thermostat. This
String
reading, which is the temperature level at which the thermo-
stat valve begins to open, should satisfy the standard value.
# Thermostat valve opening temperature
Standard: Approx. 88°C (190 °F) Water

!
* Do not contact the thermostat 1 and the column
thermometer 2 with a pan.
* As the thermostat operating response to water tem-
perature change is gradual, do not raise water tem-
perature too quickly.
* The thermostat with its valve open even slightly
under normal temperature must be replaced.
 COOLING AND LUBRICATION SYSTEM 8-15

• Keep on heating the water to raise its temperature.

• Just when the water temperature reaches specified value, the
Valve lift
thermostat valve should have lifted by at least 8.0 mm (0.31 in).
# Thermostat valve lift
Standard: Over 8.0 mm at 100°C
(Over 0.31 in at 212°F)
• A thermostat failing to satisfy either of the two requirements
(start-to-open temperature and valve lift) must be replaced
with a new one.

INSTALLATION
Install the thermostat in the reverse order of removal.
• Apply engine coolant to the rubber seal on the thermostat.

• Install the thermostat.

NOTE:
The jiggle valve A of the thermostat faces upside.

• Install the thermostat case.

• Pour engine coolant. ($2-21)
• Bleed air from the cooling circuit. ($2-21)
8-16 COOLING AND LUBRICATION SYSTEM

WATER PUMP
CONSTRUCTION
1 Water pump cover
2 O-ring
3 Impeller
4 Mechanical seal
5 Oil seal
6 O-ring
7 Inner bearing
8 Outer bearing
9 E-ring
0 Circlip
A O-ring

Oil pump drive chain

Inner bearing

Outer bearing
Impeller Oil pump

Impeller shaft Shaft

Oil pump driven sprocket

Mechanical seal
 COOLING AND LUBRICATION SYSTEM 8-17

REMOVAL AND DISASSEMBLY

• Remove the leg shield and footboard. ($9-10, 9-18)
• Drain engine coolant. ($2-20)
• Hold the chassis by side stand.
"
* Do not open the radiator cap when the engine is hot,
as you may be injured by escaping hot liquid or vapor.
* The engine must be cool before servicing the cooling
system.
* Engine coolant may be harmful if swallowed or if it
comes in contact with the skin or eyes. If engine cool-
ant gets into the eyes or contacts the skin, flush the
eyes or wash the skin thoroughly, with plenty of
water. If engine coolant is swallowed, induce vomiting
and call a physician immediately.

• Disconnect the radiator hose.

• Remove the water pump cover.

• Remove the cable clip.

• Remove the water pump body 1 with impeller 2.
8-18 COOLING AND LUBRICATION SYSTEM

• Remove the E-ring 1 and impeller 2.

• Remove the mechanical seal using the special tool.

& 09921-20240: Bearing remover set
NOTE:
If there is no abnormal condition, the mechanical seal removal is
not necessary.
!)
The removed mechanical seal must be replaced with a
new one.

• Remove the outer bearing using the special tool.

& 09921-20240: Bearing remover set
NOTE:
If there is no abnormal noise, bearing removal is not necessary.
!
The removed bearing must be replaced with a new
one.

• Remove the circlip 1.

• Remove the inner bearing using the special tool.

& 09921-20240: Bearing remover set
NOTE:
If there is no abnormal noise, bearing removal is not necessary.
!
The removed bearing must be replaced with a new
one.
 COOLING AND LUBRICATION SYSTEM 8-19

• Place a rag over the water pump body.

• Remove the oil seal using a suitable bar.
NOTE:
If there is no abnormal condition, the oil seal removal is not nec-
essary.
!
The removed oil seal must be replaced with a new one.

• Remove the mechanical seal ring 1 and the rubber seal 2

from the impeller.

INSPECTION
BEARING
• Inspect the play of the outer bearing and inner bearing by
hand while it is in the water pump case.
• Rotate the inner race by hand to inspect for abnormal noise
and smooth rotation.
• Replace the bearing if there is anything unusual.

MECHANICAL SEAL
• Visually inspect the mechanical seal for damage, with particu-
lar attention given to the sealing face.
• Replace the mechanical seal that shows indications of leak-
age.
8-20 COOLING AND LUBRICATION SYSTEM

OIL SEAL
• Visually inspect the oil seal for damage, with particular atten-
tion given to the lip.
• Replace the oil seal that shows indications of leakage.

BEARING CASE/MECHANICAL CASE

• Visually inspect the bearing case and mechanical case for
damage.
• Replace the water pump body if necessary.

IMPELLER
• Visually inspect the impeller and its shaft for damage.
 COOLING AND LUBRICATION SYSTEM 8-21

REASSEMBLY AND INSTALLATION

• Install the new inner bearing using the special tool.
& 09913-70210: Bearing installer set

• Install the circlip 1.

• Install the new outer bearing using the special tool.

& 09913-70210: Bearing installer set

• Install the new oil seal using the special tool.

& 09913-70210: Bearing installer set
NOTE:
The stamped mark on the oil seal faces outside.

• Apply a small quantity of the SUZUKI SUPER GREASE “A” to

the oil seal lip.
* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
8-22 COOLING AND LUBRICATION SYSTEM

• Install the new mechanical seal using a suitable size socket

wrench.
NOTE:
On the new mechanical seal, the seealer A has been applied.

• Install the rubber seal 1 into the impeller.

• After wiping off the oily or greasy matter from the mechanical
seal ring, install it into the impeller.
NOTE:
The paint marked side A of the mechanical seal ring faces the
impeller.
Make sure the mechanical seal ring is fit into the impeller.

• Apply grease to the impeller shaft.

* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
• Install the impeller shaft to the water pump body.

• Install the E-ring 1 to the impeller shaft.

 COOLING AND LUBRICATION SYSTEM 8-23

• Install the new O-rings 1 and 2.

• Apply grease to the O-rings.
* 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• Install the water pump body 1 with impeller 2 to the crank-

case.
• Fit the cable clip.

NOTE:
Set the water pump shaft end A to the oil pump shaft B as
shown in the figures.

• Install the O-ring to the water pump cover.

!
Use the new O-rings to prevent engine coolant leak-
age.

• Apply engine coolant to the O-ring.

• Install the water pump cover.

8-24 COOLING AND LUBRICATION SYSTEM

• Connect the radiator hose.

• Pour engine coolant. ($2-21)
• Bleed air from the cooling circuit. ($2-21)
• Install the leg shield and footboard.
 COOLING AND LUBRICATION SYSTEM 8-25

LUBRICATION SYSTEM
OIL PRESSURE
$2-31

OIL FILTER
$2-14

OIL COOLER
$3-17, 3-63

OIL PRESSURE REGULATOR

$3-44

OIL SUMP FILTER

$3-44

OIL LEVEL SWITCH

$10-29

OIL PRESSURE SWITCH

$10-36

OIL PUMP
$3-20, 3-60

OIL RETURN PUMP

$3-21, 3-59
 8-26

IN. CAMFACE & CAMSHAFT JOURNALS EX. CAMFACE & CAMSHAFT JOURNALS

IN. CAMSHAFT EX. CAMSHAFT

TAPPETS & TAPPETS &
VALVES VALVES

IN. CAMSHAFT JOURNAL RH EX. CAMSHAFT JOURNAL RH

CAMSHAFT CAM SPROCKET AND CAM CHAIN CAMSHAFT

FLANGE FLANGE

TO OIL PAN ORIFICE JET ORIFICE JET TO OIL PAN

COOLING AND LUBRICATION SYSTEM

CYLINDER HEAD

#1 #2
CYLINDER WALL CYLINDER WALL

#1 #2
PISTON & PIN PISTON & PIN

CLUTCH CASE CRANKSHAFT PIN CRANKSHAFT PIN WATER PUMP

ENGINE LUBRICATION SYSTEM CHART

BEARING LH BEARING RH BEARING

CLUTCH PLATE DRIVESHAFT BEARING

CRANK JOURNAL CRANK JOURNAL
BEARING LH PISTON COOLING NOZZLE BEARING RH
CLUTCH COVER

STARTER IDLE
ORIFICE JET GEAR

OIL FILTER
OIL PIPE OIL PRESSURE
SWITCH STATER
CLUTCH
OIL SUMP FILTER OIL COOLER
OIL RETURN OIL RETURN OIL PRESSURE
HOSE PUMP REGULATOR
OIL PUMP

TRANSMISSION CASE
OIL SUMP
DRIVESHAFT & GEAR FILTER
IDLE SHAFT & GEAR
COUNTER SHAFT & GEAR
 COOLING AND LUBRICATION SYSTEM 8-27

ENGINE LUBRICATION SYSTEM

EXHAUST SIDE

INTAKE SIDE

To oil pump

OIL SUMP FILTER LUBRICATION OIL

RETURNED OIL

MAIN GALLERY
8-28 COOLING AND LUBRICATION SYSTEM

OIL FILTER

OIL COOLER

To A From A
OIL PRESSURE
REGULATOR

OIL SUMP FILTER

OIL PUMP

OIL RETURN PUMP

ORIFICE JET

OIL SUMP FILTER

DRIVESHAFT
BEARING

LUBRICATION OIL
RETURNED OIL
White Page
 CHASSIS

CONTENTS
EXTERIOR PARTS .............................................................................. 9- 2
CONSTRUCTION ........................................................................ 9- 2
REMOVAL ................................................................................... 9- 6
REMOUNTING ............................................................................ 9-23
FRONT WHEEL ................................................................................... 9-25
CONSTRUCTION ........................................................................ 9-25
REMOVAL ................................................................................... 9-26
INSPECTION AND DISASSEMBLY ........................................... 9-27
REASSEMBLY AND REMOUNTING .......................................... 9-29
FRONT FORK ...................................................................................... 9-32
CONSTRUCTION ........................................................................ 9-32
REMOVAL AND DISASSEMBLY ............................................... 9-33
INSPECTION ............................................................................... 9-35
REASSEMBLY AND REMOUNTING .......................................... 9-36
STEERING AND HANDLEBARS ........................................................ 9-40
CONSTRUCTION ........................................................................ 9-40
REMOVAL ................................................................................... 9-41
INSPECTION AND DISASSEMBLY ........................................... 9-43
REASSEMBLY AND REMOUNTING .......................................... 9-43
STEERING TENSION ADJUSTMENT ........................................ 9-46
REAR WHEEL ..................................................................................... 9-47
CONSTRUCTION ........................................................................ 9-47
REMOVAL ................................................................................... 9-48
INSPECTION AND DISASSEMBLY ........................................... 9-50
REASSEMBLY AND REMOUNTING .......................................... 9-52
REAR SHOCK ABSORBER ................................................................ 9-57
CONSTRUCTION ........................................................................ 9-57
REMOVAL ................................................................................... 9-57
INSPECTION ............................................................................... 9-58
REMOUNTING ............................................................................ 9-58
SUSPENSION SETTING ............................................................. 9-58
 CHASSIS 9-1

REAR SWINGARM .............................................................................. 9-59

CONSTRUCTION ........................................................................ 9-59
REMOVAL ................................................................................... 9-59
INSPECTION ............................................................................... 9-60
REMOUNTING ............................................................................ 9-61
FRONT BRAKE ................................................................................... 9-63
CONSTRUCTION ........................................................................ 9-63
BRAKE PAD REPLACEMENT ................................................... 9-64
BRAKE FLUID REPLACEMENT ................................................ 9-65
CALIPER REMOVAL AND DISASSEMBLY .............................. 9-66
CALIPER INSPECTION .............................................................. 9-67
CALIPER REASSEMBLY AND REMOUNTING ......................... 9-68
BRAKE DISC INSPECTION ........................................................ 9-70
MASTER CYLINDER REMOVAL AND DISASSEMBLY ............ 9-70 9
MASTER CYLINDER INSPECTION ........................................... 9-71
MASTER CYLINDER REASSEMBLY AND REMOUNTING ...... 9-71
REAR BRAKE ..................................................................................... 9-73
CONSTRUCTION ........................................................................ 9-73
BRAKE PAD REPLACEMENT ................................................... 9-74
BRAKE FLUID REPLACEMENT ................................................ 9-76
CALIPER REMOVAL AND DISASSEMBLY .............................. 9-76
CALIPER INSPECTION .............................................................. 9-78
CALIPER REASSEMBLY AND REMOUNTING ......................... 9-79
BRAKE DISC INSPECTION ........................................................ 9-83
MASTER CYLINDER REMOVAL AND DISASSEMBLY ............ 9-83
MASTER CYLINDER INSPECTION ........................................... 9-83
MASTER CYLINDER REASSEMBLY AND REMOUNTING ...... 9-83
BRAKE-LOCK ADJUSTMENT ................................................... 9-84
BRAKE-LOCK CABLE REPLACEMENT ................................... 9-85
BRAKE-LOCK SYSTEM ............................................................. 9-87
TIRE AND WHEEL .............................................................................. 9-91
TIRE REMOVAL .......................................................................... 9-91
INSPECTION ............................................................................... 9-91
VALVE INSTALLATION .............................................................. 9-92
TIRE INSTALLATION ................................................................. 9-92
BALANCER WEIGHT INSTALLATION ...................................... 9-93
9-2 CHASSIS

EXTERIOR PARTS
CONSTRUCTION

1 Front meter panel

2 Leg shield brace
3 Meter cover
4 Front panel
5 Leg shield
6 Lower leg shield
7 Floor mat
8 Front box
 CHASSIS 9-3

1 Maintenance lid
2 Foot board
3 Frame cover
4 Leg side cover
5 Center frame cover
6 Lower frame cover
7 Rear fender
8 Floor mat
9 Tray
0 Packing
9-4 CHASSIS

Weather strip Outside

Frame

Upper trunk box

A: Max 1mm (0.04 in)

Both ends of weather strip should be
butted at the front of the trunk box.

Lower trunk box

Battery cover

Trunk box cover

Fuel tank

Frame cover

Frame Foot board

 CHASSIS 9-5

FRONT BOX

1 Front box
2 Lid
3 Cushion
4 Cushion
5 Front inner box
6 Cushion

FOOT BOARD ASSEMBLY

1 Foot board
2 Louver
3 Duct
9-6 CHASSIS

REMOVAL
LOCATION OF EXTERIOR COMPONENTS

::
1 Wind screen ( 9-7) : :
9 Seat ( 9-13) : :
G Trunk box ( 9-20)
:
2 Handlebar cover ( 9-8)
3 Front panel ( 9-8)
0 Seat damper ( 9-14)
: :
A Pillion rider handle (right and left)
:::
H Lower frame cover ( 9-15)
I Center frame cover ( 9-15)
: :
4 Rear view mirror (right and left)
B Trunk box cover ( 9-16)
( 9-15) J Wind screen cover ( 9-7)
:
K Front leg shield cover ( 9-11)
:
5 Lower leg shield ( 9-10)
: :
C Frame cover (right and left) L Ignition switch ( 9-19)
( 9-9)

6 Leg shield ( 9-10) M Floor mat (right and left)

: :
7 Leg side cover (right and left)
::
D Foot board ( 9-18)
( 9-16)

E Front box ( 9-18)

8 Maintenance lid ( 9-13) F Rear fender ( 9-20)
( 9-12)

REMOVAL PROCEDURE FLOW CHART

H Lower
frame cover

I Center
B Trunk
frame cover
F Rear fender
box cover
J Wind 5 Lower leg 2 Handlebar A Pillion rider
screen cover shield cover handle

1 Wind screen 3 Front panel C Frame cover 7 Leg side

cover

K Front leg
4 Rear view mirror D Foot board
shield cover

6 Leg shield G Trunk box

L Ignition
8 Mainte-
switch

nance lid

E Front box
 CHASSIS 9-7

WIND SCREEN
• Remove the screws.

• Remove the wind screen cover 1.

✩: hooked part

• Remove the wind screen.

• Remove the wind screen brace 2.

9-8 CHASSIS

HANDLEBAR COVER
• Remove the handlebar rear cover 1.

• Remove the handlebar front cover 2.

FRONT PANEL
• Remove the handlebar cover. (!above)
• Remove the screws.
• Remove the front panel.
 CHASSIS 9-9

REAR VIEW MIRROR

• Remove the handlebar covers. (!9-8)
• Remove the front panel. (!9-8)
• Remove the bolts.
• Disconnect the turn signal coupler which is located under the
combination meter.

• Remove the screws.

• Insert the screw driver into the hole A.

• Pry the turn signal light out. (!10-32)

• Disconnect the turn signal coupler.

9-10 CHASSIS

LOWER LEG SHIELD

• Disconnect the fasteners 1 by pulling the tab of fastener.
• Remove the screws.
• Remove the lower leg shield 2.

LEG SHIELD
• Remove the handlebar covers. (!9-8)
• Remove the front panel. (!9-8)
• Remove the lower leg shield. (!above)
• Remove the screws.

• Remove the right/left floor mat.

• Remove the screws.

• Detach the insertings of the leg side covers.

 CHASSIS 9-11

• Remove the front leg shield cover 1.

✩: hooked part

• Remove the screws.

• Disconnect the headlight couplers, ECM couplers and posi-

tion light couplers (only E02, E19).
• Remove the leg shield.
9-12 CHASSIS

RIGHT LEG SIDE COVER

• Remove the floor mats.
• Remove the screws and fasteners.
• Remove the right leg side cover by detaching the insertings.
Foot board

Leg side
cover

LEFT LEG SIDE COVER

• Remove the floor mats.
• Remove the screws and fasteners.
• Remove the left side cover by detaching the insertings.
Foot board

Leg side
cover
 CHASSIS 9-13

MAINTENANCE LID
• Remove the screw.
• Detach the inserting A of maintenance lid.
• Remove the maintenance lid.
NOTE:
Cover the hatched areas in order to prevent the front box from
getting damage.

Foot board

Maintenance lid

SEAT
• Lift the seat up.
• Remove the tool set.
• Remove the battery cover 1.
• Remove the battery. (!10-3)

• Disconnect the trunk light coupler 2.

• Disconnect the seat damper. (!9-14)

• Remove the seat by removing the nuts at the seat hinge.

9-14 CHASSIS

SEAT DAMPER
• Remove the right frame cover. (!9-16)
• Remove the clip 1, washer 2 and mounting bolt 3.
• Remove the seat damper 4.

Upward
Seat

Right

Frame
 CHASSIS 9-15

PILLION RIDER HANDLE

• Lift the seat up.
• Remove the lower frame cover 1 by removing the fasteners.

• Remove the center frame cover 2.

• Remove the pillion rider handles 3.

9-16 CHASSIS

TRUNK BOX COVER

• Remove the battery cover 1.
• Remove the starter relay 2 and coupler 3 from the battery
cover.
• Remove the battery. (!10-3)

• Remove the trunk box cover 4.

FRAME COVER
• Remove the lower frame cover, center frame cover and pillion
rider handles 1. (!9-15)
• Remove the trunk box cover. (!above)
• Remove the bolt and the fasteners.
 CHASSIS 9-17

• Remove the fuel tank cap.

• Remove the fuel inlet mounting screws and tray 2.
NOTE:
When applying a tool to the mounting screw, turn the lower part
of cushion 3 over.

• Remove the screws.

• Remove the turn signal light socket and combination light
socket.

• Remove the frame covers.

• Unclamp the harness in the back of the frame cover.
9-18 CHASSIS

FOOT BOARD
• Remove the following parts.
Pillion rider handles (!9-15)
Trunk box cover (!9-16)
Frame covers (!9-16)
Right/left leg side covers (!9-12)
Front box (!9-18)

• Remove the screws on the cooling duct.

• Remove the foot board.

FRONT BOX
• Remove the following parts.
Maintenance lid (!9-13)
Handlebar covers (!9-8)
Front panel (!9-8)
Leg shield (!9-10)
Screws in the box
• Disconnect the power source coupler.
 CHASSIS 9-19

• Pull the brake-lock knob.

• Remove the brake-lock knob 1.

• Remove the inner box 2.

• Remove the ignition switch 3 by using the special tools.

" 09930-11930: Torx bit JT30H
09930-11940: Bit holder

• Remove the screws.

• Remove the front box.
9-20 CHASSIS

REAR FENDER
• Remove the lower frame cover 1.

• Remove the fasteners and bolts.

• Remove the rear fender 2.
• Disconnect the license light coupler.

TRUNK BOX
• Remove the following parts.
Seat (!9-13)
Pillion rider handles (!9-15)
Right/left frame covers (!9-16)
Rear fender (!above)
Foot board (!9-18)
• Remove the rear frame brace 1.

• Remove the trunk light seat switch 2.

 CHASSIS 9-21

• Remove the seat lock 3.

• Remove the trunk box screws.

• Remove the muffler bracket 4.

• Remove the seat rail 5.

• Remove the trunk box 6.

9-22 CHASSIS

LEG SHIELD BRACE

• Remove the wind screen and wind screen brace. (!9-7)
• Remove the leg shield. (!9-10)
• Remove the front meter panel 1 and the combination meter
assembly.

• Remove the electrical parts from the leg shield brace.

• Remove the mounting bolts.
NOTE:
It is possible to remove the leg shield brace without removing
the front box.
 CHASSIS 9-23

REMOUNTING
Remounting the exterior parts in the reverse order of removal.
Pay attention to the following points:

SEAT RAIL
• Apply THREAD LOCK SUPER “1360” to the seat rail mount-
ing bolts (only M10).
# 99000-32130: THREAD LOCK SUPER “1360”
• Tighten the seat rail mounting bolts to the specified torque.

$ Seat rail mounting bolt

(M8): 23 N·m (2.3 kgf-m, 16.5 lb-ft)
(M10): 50 N·m (5.0 kgf-m, 36.0 lb-ft)
9-24 CHASSIS

HANDLEBAR COVER
After installing the handlebar covers, inspect clearances A
between the handlebar cover 1 and front panel 2/meter panel Handlebars
3. If the clearance A is less than 5 mm (0.2 in), adjust the han-
dlebar’s position.
Clearance Clearance

Forward

Steering stem
upper bracket

• Remove the handlebar covers. (!9-8)

• Loosen the handlebar clamp bolts 4.
• Turn the handlebars until the clearances A should be more
than 5 mm (0.2 in) at all around the handlebar cover.

NOTE:
When turning the handlebars by 0.5 mm (0.02 in) at the punched Punch mark
mark, the clearances would be varied as follows.
C 4.7 mm (0.19 in) at front end of handlebar cover
B 7.3 mm (0.29 in) at rear end of handlebar cover Handlebar
cover
Meter
panel

Forward
Front panel

• Tighten the handlebar clamp bolts to the specified torque.

$ Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Install the handlebar covers.
• Inspect the clearance.
NOTE:
* First tighten the bolts 5, and then tighten the bolts 6.
* Because of above adjustment, it is possible that the punched
mark on the handlebars is out of alignment with the mating
surface of handlebar holder.
 CHASSIS 9-25

FRONT WHEEL
CONSTRUCTION

1 Brake disc
2 Coller
3 Dust seal
4 Bearing
5 Front tire
6 Front wheel
7 Spacer
8 Tire valve
A Disc bolt
B Front axle

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5
B 65 6.5 47.0
9-26 CHASSIS

REMOVAL
• Remove the right and left brake hose clamp bolts.

• Remove the right and left brake calipers.

NOTE:
* Cover the front fender, especially hatched area A, from dam-
age.
* Do not operate the brake lever while removing the caliper.

• Loosen the axle pinch bolt.

• Loosen the front axle with special tool.
" 09900-18710: Hexagon socket (12 mm)

• Rise the front wheel off the ground and support the motorcy-
cle with a jack or wooden block.
%
Make sure that the motorcycle is supported securely.

• Remove the front axle and the front wheel.

• Remove the collar 1.
NOTE:
After removing the front wheel, fit the calipers temporarily to the
original positions.
 CHASSIS 9-27

INSPECTION AND DISASSEMBLY

• Remove the discs.

DUST SEAL
Inspect the dust seal’s lip for wear or damage.
If any damages are found, replace the dust seals with new ones.

• Remove the dust seals by using the special tool.

" 09913-50121: Oil seal remover
%
Do not reuse the removed dust seals.

FRONT AXLE
Using a dial gauge, check the front axle for runout and replace it
if the runout exceeds the limit.
" 09900-20607: Dial gauge (1/100)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
& Axle shaft runout
Service Limit: 0.25 mm (0.010 in)

WHEEL
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 replac-
ing the bearings. If bearing replacement fails to reduce the
runout, replace the wheel.
(Wheel inspection: !9-91)
& Wheel runout
Service Limit (Axial and Radial): 2.0 mm (0.08 in)
9-28 CHASSIS

WHEEL BEARING
Inspect the play of the wheel bearings by finger while they are in
the wheel. Rotate the inner race by finger to inspect for abnor-
mal noise and smooth rotation.
Replace the bearing in the following procedure if there is any-
thing unusual.

• Remove the wheel bearings by using the special tool.

" 09921-20240: Bearing remover set
%
Do not reuse the removed bearings.
 CHASSIS 9-29

REASSEMBLY AND REMOUNTING

Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to
the following points:

Left Right

65 N.m

(
6.5 kgf-m
)
47.0 lb-ft

23 N.m 23 N.m
( 2.3 kgf-m
)
16.5 lb-ft ( 2.3 kgf-m
)
16.5 lb-ft
9-30 CHASSIS

WHEEL BEARING
• Apply grease to the wheel bearings.
' 99000-25030: SUZUKI SUPER GREASE “A”

• First install the right wheel bearing, then install the left wheel
bearing and spacer by using the special tools.
" 09941-34513: Bearing/Steering race installer set
09913-70210: Bearing installer set
%
The sealed cover of the bearing must face outside.

Left Right Left Right

Spacer

Clearance

BRAKE DISC
Make sure that the brake disc is clean and free of any greasy
matter.
• Apply THREAD LOCK SUPER “1360” to the disc mounting
bolts and tighten them to the specified torque.
$ Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
# 99000-32130: THREAD LOCK SUPER “1360”
 CHASSIS 9-31

DUST SEAL
• Apply SUZUKI SUPER GREASE “A” to the dust seals.
' 99000-25030: SUZUKI SUPER GREASE “A”
• Install the dust seals to the wheel.
NOTE: Inside
The spring A of dust seal must face to the bearing.

FRONT AXLE
• Install the front wheel and front axle.
• Tighten the front axle to the specified torque with special tool.
" 09900-18710: Hexagon socket 12 mm
$ Front axle: 65 N·m (6.5 kgf-m, 47.0 lb-ft)
NOTE:
* Before tightening the two axle pinch bolt on the left front fork
leg, move the front fork up and down 4 or 5 times without
applying front brake.
* Make sure that the arrow on the tire side wall points to the
wheel rotation. (!9-93)
• Tighten axle pinch bolt on the left front fork leg to the specified
torque.
$ Front axle pinch bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

BRAKE CALIPER
• Tighten the brake caliper mounting bolts to the specified
torque.
$ Front brake caliper mounting bolt:
26 N·m (2.6 kgf-m, 19.0 lb-ft)
NOTE:
* Push the pistons all the way into the caliper and remount the
calipers.
* After installing the wheel, pump the brake lever several times
in order to operate the brake correctly.
9-32 CHASSIS

FRONT FORK
CONSTRUCTION

1 O-ring
2 Spacer
3 Washer
4 Spring
5 Piston ring A Fork cap bolt
6 Cylinder B Axle pinch bolt
7 Rebound spring C Cylinder bolt
8 Inner tube
9 Dust seal
0 Stopper ring
A Oil seal
B Retainer
C Guide metal
D Slide metal
E Oil lock piece
F Fork cover
G Outer tube
H Gasket

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5
B 23 2.3 16.5
C 30 3.0 21.5
 CHASSIS 9-33

REMOVAL AND DISASSEMBLY

• Remove the handlebar cover. (!9-8)
• Remove the front panel. (!9-8)
• Remove the front wheel. (!9-26)
• Remove the front fender.

• Loosen the front fork upper clamp bolt 1.

NOTE:
Slightly loosen the front fork cap bolt 2 before loosening the
lower clamp bolts to facilitate later disassembly.

• Loosen the front fork lower clamp bolts.

NOTE:
Hold the front fork by the hand to prevent sliding out of the steer-
ing stem.

• Remove the front fork cap bolt 3 with the special tool.
" 09940-30230: Socket hexagon (17 mm)
9-34 CHASSIS

• Remove the spacer 4, washer 5 and spring 6.

• Invert the fork and drain the fork oil out of the fork by stroking.
• Hold the fork inverted for a few minutes to drain oil.

• Remove the cylinder bolt 7.

NOTE:
If the cylinder turns together with the cylinder bolt, temporarily
install the fork spring, spacer, washer and cap bolt to prevent the
cylinder from turning.

• Remove the cylinder 8 and rebound spring 9.

• Remove the dust seal.

• Remove the oil seal stopper ring.
 CHASSIS 9-35

• Pull the inner tube out of the outer tube.

NOTE:
Be careful not to damage the inner tube.
%
The slide metal, guide metal, oil seal and dust seal
must be replaced with the new ones when reassem-
bling the front fork.

• Remove the following parts.

0 Oil seal
A Oil seal retainer
B Guide metal
C Slide metal
D Oil lock piece

INSPECTION
INNER AND OUTER TUBES
Inspect the inner tube outer surface and the outer tube inner sur-
face for scratches. If any defects are found, replace them with
the new ones.

FORK SPRING
Measure the fork spring free length. If it is shorter than the ser-
vice limit, replace it with a new one.
& Front fork spring free length
Service limit: 341 mm (13.42 in)
9-36 CHASSIS

CYLINDER
Inspect the cylinder and piston ring 1 for damage. If any defects
are found, replace them with new ones.

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of
removal and disassembly. Pay attention to the following points:
METALS AND SEALS
• Hold the inner tube vertically and clean the metal groove and
install the guide metal by hand as shown.
%
* Use special care to prevent damage to the “Teflon”
coated surface of the guide metal when mounting it.
* When installing the oil seal to inner tube, be careful
not to damage the oil seal lip.
* Replace the removed metals and seals with new
ones.
* Apply fork oil to the Anti-triction metals and lip of the
oil seal.

• Apply fork oil to the oil seal lip lightly before installing it.
• Assemble the following parts as shown.
1 Oil seal
2 Oil seal retainer
3 Guide metal
4 Slide metal
NOTE:
Stamped mark on the oil seal must face upward.

• Install the spring 5 into the oil lock piece 6 securely.

 CHASSIS 9-37

• Install the oil lock piece into the inner tube.

• Install the inner tube into the outer tube with care not to drop
the oil lock piece out.
NOTE:
After installing the inner tube into the outer tube, keep the oil
lock piece into the inner tube by compressing the front fork fully.

• Install the guide metal, the retainer and the oil seal into the
outer rube with special tool.
" 09940-52861: Front fork oil seal installer

• Install the oil seal stopper ring 7 and the dust seal 8.

A Dust seal
B Oil seal stopper ring
C Oil seal
D Oil seal retainer
E Guide metal

CYLINDER BOLT
• Install the rebound spring to the cylinder.
• Install the cylinder into the front fork.
9-38 CHASSIS

• Apply THREAD LOCK “1342” to the cylinder bolt and tighten it

to the specified torque.
( 99000-32050: THREAD LOCK “1342”
$ Cylinder bolt: 30 N·m (3.0 kgf-m, 21.5 lb-ft)
%
Use a new gasket 7 to prevent oil leakage.

NOTE:
* If the cylinder turns together with the cylinder bolt, temporarily
install the fork spring, spacer, washer and cap bolt to prevent
the cylinder from turning.
* Check the front fork for smoothness by stroking it after install-
ing the cylinder.

FORK OIL
• Place the front fork vertically without spring.
• Compress the front fork fully.
• Pour the specified front fork oil into the front fork.
) 99000-99044-10G: SUZUKI FORK OIL #10
& Front fork oil capacity (each leg):
482 ml (16.29/16.97 US/Imp oz)

• Move the inner tube up and down several strokes until no

more bubbles come out from the oil.
• Keep the front fork vertically and leave it during 5 – 6 minutes.
NOTE:
Take extreme attention to pump out air completely.

• Hold the front fork vertically and adjust the fork oil level with
the special tool.
NOTE:
When adjusting the fork oil level, remove the fork spring and
compress the inner tube fully.
" 09943-74111: Front fork oil level gauge
& Fork oil level: 129 mm (5.08 in)
) 99000-99044-10G: SUZUKI FORK OIL #10
 CHASSIS 9-39

FORK SPRING
• Install the fork spring into the front fork.
• Install the washer 1 and the spacer 2.
NOTE:
The smaller spring pitch end must face upward.

FRONT FORK CAP BOLT

• Apply fork oil lightly to the O-ring.
%
Use a new O-ring to prevent oil leakage.

• Tighten the front fork cap bolt temporarily.

• Set the front fork to the front fork lower bracket temporarily by
tightening the lower clamp bolts.
• Tighten the front fork cap bolt 1 to the specified torque with
the special tool.
$ Front fork cap bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
" 09940-30230: Socket hexagon (17 mm)
• Align the top of the inner tube with the upper surface of the
steering stem upper bracket.
• Tighten the front fork upper and lower clamp bolts.
$ Front fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Front fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Install the front fender.

• Install the front wheel and brake calipers. (!9-31)
NOTE:
After install the brake calipers, front brake should be efficient by
pumping the front brake lever.
9-40 CHASSIS

STEERING AND HANDLEBARS

CONSTRUCTION

1 Handlebar clamp
2 Steering stem upper bracket
3 Dust seal
4 Upper bearing
5 Lower bearing
6 Steering stem lower bracket
7 Dust seal
A Handlebar clamp bolt
B Upper clamp bolt
C Lower clamp bolt
D Steering stem head nut

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5
B 23 2.3 16.5
C 23 2.3 16.5
D 65 6.5 47.0
 CHASSIS 9-41

REMOVAL
HANDLEBARS
• Remove the handlebar covers. (!9-8)
• Remove the right switch box 1.
• Disconnect the brake switch coupler.
• Remove the front brake master cylinder 2.

• Remove the left switch box 3.

• Disconnect the brake switch coupler.
• Remove the rear brake master cylinder 4.

• Remove the handlebars.

STEERING STEM
• Remove the front panel. (!9-8)
• Remove the front fork. (!9-33)
• Remove the cable/harness guide 1.
• Remove the brake hose clamp 2.
NOTE:
Before removing the handlebars, loosen the steering stem head
nut to facilitate later disassembly.

• Remove the steering stem lower cover.

9-42 CHASSIS

• Remove the brake hose clamp 3.

• Remove the front brake assembly.
%
Take care not to make air come in the front brake sys-
tem.

• Remove the steering stem upper bracket.

• Remove the steering stem nut with the special tool.

" 09940-14911: Steering socket wrench
• Remove the steering stem lower bracket.
NOTE:
When loosing the stem nut, hold the steering stem lower bracket
to prevent it from falling.

• Remove the dust cover 4 and bearing 5.

 CHASSIS 9-43

INSPECTION AND DISASSEMBLY

Inspect the removed parts for the following abnormalities.
* Handlebars distriction
* Race wear and brinelling
* Bearing wear or damage
* Abnormal bearing noise
* Distortion of the steering stem
If any abnormal points are found, replace defective parts with
the new ones.

• Remove the steering stem lower bearing and dust seal using
a chisel.
%
The removed bearing inner race and dust seal must be
replaced with the new ones.

• Drive out the steering stem upper and lower bearing races
using the special tools.
" 09941-54911: Bearing outer race remover
09941-74911: Steering bearing installer

REASSEMBLY AND REMOUNTING

Reassemble and remount the steering stem in the reverse order
of removal and disassembly. Pay attention to the following
points:
BEARING RACES
• Press in the upper and lower outer races using the special
tool.
" 09941-34513: Steering outer race installer

BEARINGS
• Press in the lower bearing and dust seal using the special
tool.
" 09941-18011: Steering bearing installer
9-44 CHASSIS

• Apply grease to the bearings, dust cover and dust seal.

• Install the upper bearing and the dust cover onto the frame.
' 99000-25010: SUZUKI SUPER GREASE “A”

STEERING STEM
• Tighten the steering stem nut to the specified torque with the
special tools.
" 09940-14911: Steering stem nut wrench
$ Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Turn the steering stem about five or six times to the left and
right so that the angular ball bearing will be seated properly.
• Loosen the steering stem nut by ¼ – ½ turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle.

• Install the front fork to the steering stem lower bracket tempo-
rarily.
• Install the steering stem upper bracket 1.
• Tighten the steering stem head nut 2.
$ Steering stem head nut: 65 N·m (6.5 kgf-m, 47.0 lb-ft)
• Remount the front fork. (!9-39)

HANDLEBARS
• Install the handlebars with the punch mark A on the handle-
bars aligned with the mating surface B of the handlebar
clamp.
NOTE:
Make sure that the dent C on the handlebar clamp faces for-
ward.
 CHASSIS 9-45

• Tighten the handlebar clamp bolt to the specified torque.

$ Handlebar clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
NOTE:
When tightening the handlebar clamp bolts, first tighten the bolts
1 and then tighten the bolts 2.

• Install the left switch box 3 to the handlebars by engaging the

stopper D with the hole E on the handlebars.
• Install the rear brake master cylinder. (!9-84)

• Install the right switch box 4 to the handlebars by engaging

the stopper F with the hole G on the handlebars.
• Install the front brake master cylinder. (!9-72)

• Install the handlebar covers and inspect the handlebar cover

clearance. (!9-24)
9-46 CHASSIS

STEERING TENSION ADJUSTMENT

Check the steering movement in the following procedure.
• By supporting the motorcycle with a jack, lift the front wheel
until it is off the floor by 20 – 30 mm (0.8 – 1.2 in).
• Check to make sure that the cables and wire harnesses are
properly routed.
• 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 handle-
bar starts moving. Do the same on the other grip end.
& Initial force: 200 – 500 grams
" 09940-92720: Spring scale
• If the initial force read on the scale when the handlebar starts
turning is either too heavy or too light, adjust it till it satisfies
the specification.
1)First, loosen the front fork upper clamp bolts, steering stem
head nut and steering stem nut, and then adjust the steering
stem nut by loosening or tightening it.
2)Tighten the steering stem nut, stem head nut and front fork
upper and lower clamp bolts to the specified torque and re-
check the initial force with the spring scale according to the
previously described procedure.
3)If the initial force is found within the specified range, adjust-
ment has been completed.
NOTE:
Hold the front fork legs, move them back and forth and make
sure that the steering is not loose.
 CHASSIS 9-47

REAR WHEEL
CONSTRUCTION

1 Washer
2 Spacer
3 Collar
4 Dust seal
5 Bearing
6 Brake disc
7 Rear tire
8 Spacer
9 Hub damper
0 Washer
A Lock washer
B O-ring
C Rear hub driven joint
D Spacer
E Rear axle
F Rear wheel

A Disc bolt
B Rear axle nut

@
ITEM N·m kgf-m lb-ft
A 23 2.3 16.5
B 100 10.0 72.5
9-48 CHASSIS

REMOVAL
• Place the motorcycle on the center stand.
• Remove the final gear case cover 1.

• Disconnect the brake-lock cable 2. (!9-85)

• Remove the cotter pin. (For E-03, 28, 33)

• Loosen the rear axle nut.
• Remove the caliper.
• Remove the axle nut and draw out the rear axle.
%
Do not operate the brake lever while removing the rear
wheel.

• Remove the spacer 3.

• Remove the rear wheel.

• Remove the collars 4.

 CHASSIS 9-49

• Flatten the lock washers 5.

• Remove the bolts and washers 6.

• Remove the rear hub driven joint 7.

• Remove the O-ring 8.

%
Replace the removed O-ring with a new one.

• Remove the brake disc.

9-50 CHASSIS

INSPECTION AND DISASSEMBLY

TIRE: (!9-91)
WHEEL: (!9-27 and 9-91)

REAR AXLE
Using a dial gauge, check the rear axle for runout.
If the runout exceeds the limit, replace the rear axle.
& Axle shaft runout: Service Limit: 0.25 mm (0.010 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)

REAR HUB DAMPER

Inspect the dampers for wear and damage.
Replace the damper if there is anything unusual.

• Remove the dampers with the appropriate bar.

REAR HUB DRIVEN JOINT

Inspect the rear hub driven joint for wear and damage. If any
defects are found, replace it with a new one.
 CHASSIS 9-51

DUST SEAL
Inspect the wheel dust seal lip for wear or damage. If any dam-
ages are found, replace the dust seal with a new one.

• Remove the dust seal with the special tool.

" 09913-50121: Oil seal remover
%
Do not reuse the removed dust seal.

BEARING
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 any-
thing unusual.

• Remove the wheel bearings by using the special tool.

" 09921-20240: Bearing remover set
%
The removed bearings must be replaced with the new
ones.
9-52 CHASSIS

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear wheel in the reverse order of removal and disassembly. Pay attention to
the following points:

Left Right

100 N.m

( 10.0 kgf-m
72.5 lb-ft)

For E-03, 28, 33

23 N.m

(2.3 kgf-m
16.5 lb-ft )
 CHASSIS 9-53

BEARING
• Apply grease to the bearings before installing.
' 99000-25030: SUZUKI SUPER GREASE “A”

• First install the right wheel bearing, then install the left wheel
bearing and spacer using the special tool.
" 09941-34513: Bearing/Steering race installer set
%
The sealed cover of the bearing must face outside.

Left Right Left Right

Spacer

Bearing

Clearance Spacer

Wheel hub

Clearance
9-54 CHASSIS

DUST SEAL
• Install the new dust seal using the special tool.
" 09913-70210: Bearing installer set
• Apply SUZUKI SUPER GREASE “A” to the dust seal lips
before assembling rear wheel.
' 99000-25030: SUZUKI SUPER GREASE “A”
NOTE:
When installing the dust seals, the stamped mark of dust seal
must face the special tool.
REAR HUB DAMPER
• Install the rear hub damper into the rear wheel at a depth of Rear wheel
5.5 mm (0.22 in).
NOTE:
Apply soap water to the hub damper before installing the hub
damper in order to facilitate press fit.

5.5 mm (0.22 in)

Hub damper

BRAKE DISC
Make sure that the brake disc is clean and free of any greasy
matter.
• Apply THREAD LOCK SUPER “1360” to the disc bolts and
tighten them to the specified torque.
# 99000-32130: THREAD LOCK SUPER “1360”
$ Brake disc bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

REAR HUB DRIVEN JOINT

• Apply SUZUKI SUPER GREASE “A” to the O-ring and wheel.
' 99000-25030: SUZUKI SUPER GREASE “A”
• Install the O-ring to the rear wheel.
%
Replace the removed O-ring with a new one.

• Apply SUZUKI SUPER GREASE “A” to the rear hub driven

gear joint.
' 99000-25030: SUZUKI SUPER GREASE “A”
 CHASSIS 9-55

• Install the rear hub driven gear joint.

• Install the washers 1, lock washers 2.

• Apply THREAD LOCK SUPER “1303” to the bolts and tighten
them.
* 99000-32030: THREAD LOCK SUPER “1303”
• Bend the lock washers securely.

• Install the collar.

9-56 CHASSIS

REAR AXLE
• Install the left spacer 1 into the final gear case 2.

• Remount the rear wheel, coller, spacer and rear axle.

• Install the washer and rear axle nut.
• Tighten the rear axle nut 3 to the specified torque.
$ Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Install the new cotter pin. (For E-03, 28, 33)
• Install the final gear case cover.

• Install the caliper. (!9-81)

• Install the brake-lock cable and brake-lock arm. (!9-82)
• Adjust the brake-lock. (!9-84)
NOTE:
If the caliper pistons come out by operating the rear brake lever
while removing the rear caliper, it is impossible to push back the
pistons into the caliper because of the brake-lock system.
Therefore remove the pads and turn the piston clockwise so that
the piston will come in. Refer to REAR BRAKE PAD REPLACE-
MENT page 9-74.
 CHASSIS 9-57

REAR SHOCK ABSORBER

CONSTRUCTION

Left Right

1 Rear shock absorber

2 Frame
3 Swingarm
4 Final gear case
5 Washer
A Rear shock absorber nut
B Rear shock absorber bolt
@
ITEM N·m kgf-m lb-ft
A 29 2.9 21.0
B 29 2.9 21.0

REMOVAL
• Place the motorcycle on the center stand.
• Remove the rear shock absorber mounting nut 1.

• Remove the rear shock absorber mounting bolt 2.

• Remove the rear shock absorber.
9-58 CHASSIS

INSPECTION
Inspect the shock absorber body and bushing for damage and
oil leakage.
If any defects are found, replace the shock absorber with a new
one.
%
Do not attempt to disassemble the rear shock
absorber unit. It is unserviceable.

REMOUNTING
• Install the rear shock absorber and tighten the rear shock
absorber mounting nut 1/bolt 2.
$ Rear shock absorber mounting nut:
29 N·m (2.9 kgf-m, 21.0 lb-ft)
Rear shock absorber mounting bolt:
29 N·m (2.9 kgf-m, 21.0 lb-ft)

SUSPENSION SETTING
After installing the rear suspension, adjust the spring pre-load as
follows.
SPRING PRE-LOAD ADJUSTMENT
The pre-load is adjusted by turning the pre-load adjuster.
Set the indicator a in the center of absorber lower bracket 1.
Position “1” provides the softest spring pre-load.
Position “5” provides the stiffest spring pre-load.
STD position: “2”
%
Adjust the right and left absorbers to the same set-
tings.
 CHASSIS 9-59

REAR SWINGARM
CONSTRUCTION

1 Rear shock absorber

2 Swingarm
3 Bushing
4 Bearing
5 Dowel pin
A Rear shock absorber
B Rear shock absorber
mounting nut

C Pivot bolt
mounting bolt

D Locknut

@
ITEM N·m kgf-m lb-ft
A 29 2.9 21.0
B 29 2.9 21.0
C 9.5 0.95 7.0
D 100 10.0 72.5

REMOVAL
• Place the motorcycle on the center stand.
• Remove the exhaust muffler. (!3-7)
• Remove the rear wheel. (!9-48)
• Remove the rear brake hose guide 1, 2.

• Remove the rear shock absorber bolt 3.

9-60 CHASSIS

• Remove the swingarm bolts.

• Remove the swingarm 4.

• Remove the swingarm pivot bearing.

• Remove the swingarm pivot locknut 5, washer and the swin-

garm pivot bolt 6.

INSPECTION
SWINGARM BEARING
Insert the bearing and check smoothness of rotation.
If there is anything unusual, replace the bearing with a new one.

Inspect the dust seal on the bearing for wear and damage.
If any defects are found, replace the bearing with a new one.
 CHASSIS 9-61

• Remove the swingarm pivot bearing with the special tools.

" 09921-20240: Bearing remover set
%
Do not reuse the removed bearings.

• Install the bearing with the special tool.

"09913-70210: Bearing installer set

BUSHING
Inspect the bushing for damage. If any defects are found,
replace it with a new one.

REMOUNTING
Remount the swingarm in the reverse order of disassembly and
removal, and pay attention to the following points:
• Apply SUZUKI SUPER GREASE “A” to the bearing, and then
install the bearing.
' 99000-25030: SUZUKI SUPER GREASE “A”
• Install the dowel pins 1.

• Install the swingarm.

• Apply THREAD LOCK “1342” to the swingarm bolts.
• Tighten the swingarm bolt.
( 99000-32050: THREAD LOCK “1342”
9-62 CHASSIS

• Tighten the swingarm pivot bolt to the specified torque.

$ Swingarm pivot bolt: 9.5 N·m (0.95 kgf-m, 7.0 lb-ft)

• Tighten the swingarm pivot locknut 2 to the specified torque.

$ Swingarm pivot locknut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)
• Install the rear wheel. (!9-56)
• Install the exhaust muffler. (!3-11)

Engine
100 N.m
Washer (10.0 kgf-m, 72.5 lb-ft)

9.5 N.m

(0.95 kgf-m
7.0 lb-ft )

Swingarm
 CHASSIS 9-63

FRONT BRAKE
CONSTRUCTION
1 Diaphragm
2 Dust boot
3 Piston/cup set
4 Brake hose
5 Boot
6 Caliper
7 Brake pad spring
8 Brake pad
9 Piston seal
0 Dust seal
A Piston
B Caliper holder
C Insulator
D Shim
A Front brake master cylinder mounting bolt
B Brake hose union bolt
C Air bleeder valve
D Brake caliper mounting bolt
E Pad mounting pin
F Plug
G Cliper holder pin

@
ITEM N·m kgf-m lb-ft
A 10 1.0 7.0
B 23 2.3 16.5
C 7.5 0.75 5.5
D 26 2.6 19.0
E 18 1.8 13.0
F 2.5 0.25 1.8
G 13 1.3 9.5

+
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use 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 stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh 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.

%
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials
etc. and will damage then severly.
9-64 CHASSIS

BRAKE PAD REPLACEMENT

• Remove the plug 1.

• Remove the pad mounting pin 2.

• Remove the pads 3.

• Inspect the pad mounting pin for wear. If excessive wear is
found, replace the mounting pin with a new one.

• Assemble the new brake pad 4, insulator 5 and shim 6.

%
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
NOTE:
The pad fitted shim and insulator must be installed at piston
side.

• Install the brake pads.

 CHASSIS 9-65

• Tighten the pad mounting pin 7 to the specified torque.

$ Front brake pad mounting pin:
18 N·m (1.8 kgf-m, 13.0 lb-ft)
• Install the brake hose clamp bolt.

• Install the plug 8 and tighten it to the specified torque.

$ Pad pin plug: 2.5 N·m (0.25 kgf-m, 1.8 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever several
times in order to operate the brake correctly and then check the
brake fluid level.

BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-
bars straight.
• Remove the brake fluid reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with the new brake fluid.
, Specification and Classification: DOT 4
9-66 CHASSIS

• Connect a clear hose to the caliper air bleeder valve and

insert the other end of hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until
old brake fluid flows out of the bleeder system.
• Close the caliper air bleeder valve and disconnect a clear
hose. Fill the reservoir with the new fluid to the upper mark of
the reservoir.
$ Brake air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

%
* Never reuse the brake fluid left over from previous
servicing and which has been stored for long peri-
ods of time.
* Bleed air from the brake system.
(!2-24)

CALIPER REMOVAL AND DISASSEMBLY

• Drain the brake fluid. (!9-65)
• Disconnect the brake hoses by removing the brake hose
union bolts.
%
Place a rag underneath the union bolt on the brake
caliper to catch any spilt brake fluid.

• Remove the brake calipers by removing the caliper mounting

bolts.
• Remove the brake pads. (!9-64)
• Remove the caliper holder 1.
• Remove the pad spring 2.
 CHASSIS 9-67

• Place a rag over the pistons to prevent them from popping out
and then force out the pistons using compressed air.
%
Do not use high pressure air to prevent piston dam-
age.

• Remove the dust seals and piston seals.

%

Do not reuse the removed dust seals and piston seals

to prevent fluid leakage.

CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches and
other damage. If any damage is found, replace the caliper with a
new one.

BRAKE CALIPER PISTON

Inspect the brake caliper piston surface for any scratches and
other damage. If any damage is found, replace the caliper piston
with a new one.

CALIPER HOLDER
• Inspect the caliper holder for damage. If any damage is found,
replace it with a new one.
9-68 CHASSIS

RUBBER PARTS
Inspect the rubber parts for damage. If any damage is found,
replace them with the new ones.

CALIPER REASSEMBLY AND REMOUNTING

Reassemble the caliper in the reverse order of removal and dis-
assembly. Pay attention to the following points:
• Wash the caliper bores and pistons with specified brake fluid.
Particularly wash the dust seal groove and piston seal groove.
, Specification and Classification: DOT 4
%
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or gaso-
line to wash them.
* Do not wipe the brake fluid off after washing the compo-
nents with a rag.
* When washing the components, use the specified brake
fluid. Never use different types of fluid or cleaning sol-
vent such as gasoline, kerosine or the others.
* Replace the piston seals and dust seals with the new
ones when reassembly.
* Apply the brake fluid to both seals when installing them.

PISTON SEAL
• Install the piston seal and dust seal as shown in the illustra-
tion.
• Install the piston to the caliper.
 CHASSIS 9-69

CALIPER HOLDER
• Apply THREAD LOCK SUPER “1303” to the pin 2.
* 99000-32030: THREAD LOCK SUPER “1303”
• Tighten the pin 2 to the caliper holder 1 to the specified
torque.
$ Caliper holder pin: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
• Apply SUZUKI SILICONE GREASE to the brake caliper
holder pin 2.
- 99000-25100: SUZUKI SILICONE GREASE

• Be sure to check that the boot is fitted on the slide pin.

• Install the pad spring 3.

• Install the brake pads. (!9-64)
NOTE:
Before remounting the caliper, push the piston all the way into
the caliper.

• Remount the brake caliper to the front fork.

• Tighten each bolt to the specified torque.
$ Front brake caliper mounting bolt 4:
26 N·m (2.6 kgf-m, 19.0 lb-ft)
Front brake hose union bolt 5:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
%
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the cal-
iper. (!2-24)
* Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.
9-70 CHASSIS

BRAKE DISC INSPECTION

Visually check the brake disc for damage or cracks.
Measure the thickness with a micrometer.
Replace the disc if the thickness is less than the service limit or if
damage is found.
& Front disc thickness
Service Limit: 4.0 mm (0.16 in)
" 09900-20205: Micrometer (0 – 25 mm)

Measure the runout with a dial gauge.

Replace the disc if the runout exceeds the service limit.
& Front disc runout
Service Limit: 0.30 mm (0.012 in)
" 09900-20607: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
* Brake disc removal (!9-27)
* Brake disc installation (!9-30)

MASTER CYLINDER REMOVAL AND DISAS-

SEMBLY
• Remove the handlebar cover. (!9-8)
• Drain the brake fluid. (!9-65)
• Disconnect the front brake light switch coupler 1.
• Place a rag underneath the union bolt on the master cylinder
to catch any spilt brake fluid. Remove the brake hose union
bolt and disconnect the brake hose.
• Remove the master cylinder.
%
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics and rubber materials,
etc. and will damage them severely.

• Remove the brake lever 2 and brake switch 3.

 CHASSIS 9-71

• Pull out the dust boot 4 and remove the snap ring 5.

• Remove the piston and return spring.

6 Piston
7 Secondary cup
8 Primary cup
9 Return spring

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other dam-
age.
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust boot for wear
or damage.
If any defects are found, replace them with new ones.

MASTER CYLINDER REASSEMBLY AND

REMOUNTING
Reassemble the master cylinder in the reverse order of removal
and disassembly. Pay attention to the following points:
%
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning
solvent or gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the
component to be inserted into the bore.

, Specification and Classification: DOT 4

9-72 CHASSIS

• Apply brake fluid to the piston and cups.

• Install the following parts to the master cylinder.
1 Dust boot
2 Snap ring
3 Secondary cup
4 Piston
5 Primary cup
6 Return spring

• When remounting the brake master cylinder onto the handle-

bars, align the master cylinder holder’s mating surface A with
punch mark B on the handlebars and tighten the upper bolt
7 first.
$ Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)

• After touching the brake hose union to the stopper, tighten the
brake hose union bolt to the specified torque.
$ Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
%
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the
master cylinder. (!2-24)
 CHASSIS 9-73

REAR BRAKE
CONSTRUCTION

1 Diaphragm A Master cylinder bolt

2 Piston/cup set B Brake hose union bolt
3 Master cylinder C Brake pipe nut
4 Brake hose No. 1 D Caliper holder sliding pin
5 Brake pipe E Caliper holder sliding pin
6 Brake hose No. 2 F Air bleeder valve
7 Caliper holder G Brake-lock housing bolt
8 Caliper H Locknut
9 Gasket I Pad mounting pin
0 Brake-lock housing
A O-ring
B Brake-lock shaft
C Brake-lock adjuster
D Brake-lock arm
E Pad
F Piston
G Dust seal
H Piston seal

@
ITEM N·m kgf-m lb-ft
A 10 1.0 7.0
B 23 2.3 16.5
C 16 1.6 11.5
D 23 2.3 16.5
E 13 1.3 9.5
F 7.5 0.75 5.5
G 23 2.3 16.5
H 9.5 0.95 7.0
I 18 1.8 13.0

+
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix dif-
ferent 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 stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh 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.

%
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.
and will damage them severly.
9-74 CHASSIS

BRAKE PAD REPLACEMENT

• Remove the brake-lock arm 1 and spring 2.
• Disconnect the brake-lock cable 3. (!9-85)

• Remove the caliper.

%
Do not operate the brake lever while dismounting the
pads.

• Remove the pad mounting pins 4, and then remove the

brake pads.
• Clean up the caliper especially around the pistons.

• Inspect the pad mounting pins for wear. If excessive wear is

found, replace the mounting pins with new ones.

• Assemble the new pads 5, insulators 6 and shims 7.

%
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
 CHASSIS 9-75

• Turn the piston 8 clockwise until it stops.

• Align the groove with line A by turning the piston out.
• Install the pad with the projection B fitted in the groove on the
piston.

• Install the pad to the caliper with the pad seated at the
hatched area C of pad spring.

• Tighten the pad mounting pins to the specified torque.

$ Pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

• Install the caliper.

• Tighten the caliper mounting bolt to the specified torque.
$ Caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever several
times to check for proper brake operation and then check the
brake fluid level.

• Install the brake-lock cable. (!9-86)

• Install the brake-lock arm with the punch mark D aligned with
punch mark E on the brake-lock shaft.
NOTE:
Make sure that the spring end faces to right side of the vehicle.
• Adjust the brake-lock. (!9-84)
9-76 CHASSIS

BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-
bars straight.
• Remove the brake fluid reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with the new brake fluid.
, Specification and Classification: DOT 4

• Connect a clear hose to the caliper air bleeder valve and

insert the other end of hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until
old brake fluid flows out of the bleeder system.
• Close the caliper air bleeder valve and disconnect a clear
hose. Fill the reservoir with the new fluid to the upper mark of
the reservoir.
$ Brake air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft)

%
* Never reuse the brake fluid left over from previous
servicing and which has been stored for long peri-
ods of time.
* Bleed air from the brake system.
(!2-25)

CALIPER REMOVAL AND DISASSEMBLY

• Drain the brake fluid. (!above)
• Disconnect the brake-lock cable. (!9-85)

• Disconnect the brake hose.

• Remove the caliper.
• Remove the brake pads. (!9-74)
%
Place a rag underneath the union bolt on the brake
caliper to catch any spilt brake fluid.
 CHASSIS 9-77

• Remove the pad spring 1 and caliper holder 2.

• Remove the parking brake housing 3.

• Disassemble the parking brake.

%
Replace the removed O-ring with a new one.

• Turn the piston counterclockwise fully.

• Place a rag over the piston to prevent it from popping out and
then force out the piston using compressed air.
%
Do not use high pressure air to prevent piston dam-
age.
9-78 CHASSIS

• Remove the dust seals 4 and piston seals 5.

%
Do not reuse the dust seal and piston seal to prevent
fluid leakage.

CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder walls for nicks, scratches and
other damage. If any damage is found, replace the caliper with a
new one.
%
Do not attempt to disassemble the brake-lock bolt that
is built in the caliper. It is unserviceable.

Inspect the brake fluid leakage from O-ring 1 and cup 2.

If any abnormal condition found, replace the rear brake caliper.

Brake-lock bolt

BRAKE CALIPER PISTON

Inspect the brake caliper pistons surface for any scratches and
other damage. Inspect the grooved piston for spring tension by
pushing the retainer 1. If any damage is found, replace the cali-
per piston with a new one.
%
Do not attempt to disassemble the piston. It is unser-
viceable.
 CHASSIS 9-79

CALIPER HOLDER
Inspect the brake holder sliding pins for wear and other damage.
If any damage is found, replace the sliding pin with a new one.

BOOT
Inspect the boots for damage and wear. If any damage is found,
replace boots with new ones.

CALIPER REASSEMBLY AND REMOUNTING

Reassemble and remount the caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
%
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or
gasoline to wash them.
* Apply brake fluid to the caliper bore and piston to be
inserted into the bore.

, Specification and Classification: DOT 4

PISTON SEAL
• Install the piston seals as shown in the right illustration.
• Install the pistons to the caliper.
9-80 CHASSIS

• Turn the piston clockwise fully.

• Install the pad spring 1.

CALIPER HOLDER
• Apply THREAD LOCK SUPER “1303” to the sliding pins.
* 99000-32030: THREAD LOCK SUPER “1303”
• Tighten the sliding pins 1, 2 to the specified torque.
$ Caliper sliding pin 1: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Caliper sliding pin 2: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
• Apply SUZUKI SILICONE GREASE to the sliding pin.
- 99000-25100: SUZUKI SILICONE GREASE

• Install the caliper holder to the caliper.

• Set the boot onto the sliding pin securely.
• Install the brake pad. (!9-75)
 CHASSIS 9-81

CALIPER
• Install the caliper.
• Tighten the caliper mounting bolts 1 to the specified torque.
$ Rear caliper mounting bolt: 26 N·m (2.6 kgf-m, 19.0 lb-ft)

• Connect the brake hose 2 to the caliper with the brake hose
union pipe seated in the cutaway on the caliper.
• Tighten the brake hose union bolt to the specified torque.
$ Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
%
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the cal-
iper. (!2-25)
* Brake fluid, if it leaks, will interfere with safe running
and discolor painted surfaces. Check the brake hose
and hose joints for cracks and fluid leakage.

BRAKE-LOCK
• Apply SUZUKI SILICONE GREASE to the brake-lock bolt end
A.
- 99000-25100: SUZUKI SILICONE GREASE

• Install the new gasket and the brake-lock housing to the cali-
per.
• Apply THREAD LOCK SUPER “1360” to the brake-lock bolts.
# 99000-32130: THREAD LOCK SUPER “1360”
• Tighten the brake-lock housing bolts to the specified torque.
$ Brake-lock housing bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
• Apply SUZUKI SILICONE GREASE to the O-ring.
- 99000-25100: SUZUKI SILICONE GREASE
• Install the O-ring into the brake-lock housing.
%
Replace the gasket and O-ring with new ones.
9-82 CHASSIS

• Apply SUZUKI SILICONE GREASE to the brake-lock shaft.

- 99000-25100: SUZUKI SILICONE GREASE

• Install the brake-lock shaft so that the punch mark B can be

positioned in C when the brake-lock shaft is turned clockwise
until it stops.

• Install the brake-lock cable and E-ring.

• Install the brake-lock adjust bolt 1 to the brake-lock shaft.

• Turn the brake-lock shaft about 90 degree counterclockwise
so that the punch mark D will face upward.

• Install the brake-lock arm 2 with the punch mark E aligned

with the punch mark F on the brake-lock arm 2.
• Hook the spring and connect the brake arm 2 with the brake-
lock cable.
NOTE:
Make sure that the spring end faces to right side of the vehicle.
• Adjust the brake-lock. (!9-85)
 CHASSIS 9-83

BRAKE DISC INSPECTION

Inspect the rear brake disc in the same manner as the front
brake disc. (!9-70)
& Service Limit
Rear disc thickness: 5.0 mm (0.20 in)
Rear disc runout: 0.30 mm (0.012 in)
* Brake disc removal (!9-49)
* Brake disc installation (!9-54)

MASTER CYLINDER REMOVAL AND DISASSEMBLY

Remove and disassemble the rear master cylinder in the same
manner as the front brake master cylinder. (!9-70)

MASTER CYLINDER INSPECTION (!9-71)

MASTER CYLINDER REASSEMBLY AND

REMOUNTING
Reassemble and remount the master cylinder in the reverse
order of removal and disassembly. Pay attention to the following
points:
%
* Wash the master cylinder components with fresh
brake fluid before reassembly. Never use cleaning
solvent or gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the
component to be inserted into the bore.

, Specification and Classification: DOT 4

• Apply brake fluid to the piston/cup set.

• Install the following parts to the master cylinder.
1 Dust boot
2 Snap ring
3 Secondary cup
4 Piston
5 Primary cup
6 Return spring
9-84 CHASSIS

When remounting the brake master cylinder onto the handle-

bars, align the master cylinder holder’s mating surface A with
the punch mark B on the handlebars and tighten the upper bolt
7 first.
$ Master cylinder mounting bolt:
10 N·m (1.0 kgf-m, 7.0 lb-ft)

• After touching the brake hose union pipe to the stopper,

tighten the brake hose union bolt to the specified torque.
$ Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
%
* The seal washers should be replaced with the new
ones to prevent fluid leakage.
* Bleed air from the system after reassembling the
master cylinder. (!2-25)

BRAKE-LOCK ADJUSTMENT
Before adjusting the brake-lock, perform to bleed the air from
the rear brake system.
• Pull the brake-lock lever by one step (one notch).
NOTE:
* The brake-lock lever has eight steps (eight notches) when pull-
ing in full.
* When pulling the brake-lock lever, first the brake-lock switch
makes sound, then notch makes a sound. Make a count of
notch by sound except the brake-lock switch’s sound.

• Loosen the locknut 1 and the adjust bolt 2.

 CHASSIS 9-85

• Turn the adjuster bolt 2 clockwise until it stops.

• Tighten the locknut 1 to the specified torque with the adjust
bolt 2 held in that position.
$ Brake-lock adjust locknut: 9.5 N·m (0.95 kgf-m, 7.0 lb-ft)
NOTE:
Do not turn the adjust bolt more than the given position, or the
adjust bolt may be damaged.
• Inspect the brake-lock. (!2-33)

BRAKE-LOCK CABLE REPLACEMENT

• Remove the right side leg shield. (!9-12)
• Remove the front box. (!9-18)
• Loosen the locknut 1.
• Disconnect the brake-lock cable 2.

• Remove the brake hose clamp on the swingarm.

• Remove the locknut 3.

• Remove the brake-lock arm 4 from the caliper.

• Disconnect the brake-lock cable 5 by removing the E-ring 6.

9-86 CHASSIS

• Install the brake-lock cable.

(CABLE ROUTING: 11-18)
• Turn the nut 7 until the clearance is 0 mm (0 in).

Clearance

• Connect the brake-lock cable to the brake-lock lever assem-

bly.
• Fit the nut 8 into the concavity on the brake-lock lever
assembly.
• Tighten the locknut 9 securely.
• Be sure to fit the boot 0 on the brake-lock cable.

• Connect the brake-lock cable and install the E-ring B.

• Be sure to the dust boots C on the brake-lock cable.

• Install the brake-lock arm D. (!9-82)

NOTE:
The open end of spring E must face to the right side of vehicle.

• Install the brake hose clamp.

• Adjust the brake-lock. (!9-84)
• Install the front box and right leg side shield.
 CHASSIS 9-87

BRAKE-LOCK SYSTEM
BRAKE-LOCK OPERATION
The brake-lock arm turns through the brake-lock cable as soon as pulling the brake-lock lever. The turning
movement is converted to axial movement by the brake-lock adjuster connected to the body with the thread A.
The axial movement transmits automatically from sleeve piston to adjust-bolt. The adjust-bolt presses brake
pad to brake disk through the adjust-nut/caliper piston. In this bout, the adjust-bolt and adjust-nut move
together with the relation as shown in the illustration.
When releasing the brake-lock lever, each parts return to home position, the caliper piston will be returned
by an elasticity transform of piston seal, the adjust-bolt will be returned by the adjust-bolt spring, the brake-
lock adjuster will be returned by the return-spring.

Brake-lock lever

Brake
caliper Brake-lock arm Brake-lock cable

Brake-lock adjuster

Brake-lock arm

Caliper piston

Adjust-bolt
spring

Adjust-bolt
Adjuster-bolt

Brake-lock adjuster
Sleeve piston
Adjust-nut
Adjuster-bolt
Brake pad

Adjust-bolt presses adjust-nut

9-88 CHASSIS

AUTOMATIC BRAKE-LOCK ADJUSTER SYSTEM

The automatic brake-lock adjuster system is equipped on the brake-lock. If the brake pad worn, the adjust-
bolt/nut adjust the position of caliper piston so as to keep the certain clearance between brake pad and
brake disk.
OPERATION (Normal condition➔ ➔ Braking)
The hydraulic pressure by brake lever operation acts on the adjust-nut/caliper piston. The adjust-bolt
threads and adjust-nut threads have a clearance. The piston stroke when braking is shorter than clearance,
thus, the braking operation will finish without automatic brake-lock adjuster system operation.

Adjust-bolt

Hydraulic pressure

Clearance
Adjust-nut

Caliper piston
stroke
 CHASSIS 9-89

OPERATION (Brake pads are worn➔ ➔ Braking➔➔ Automatic adjuster operate)

If braking when the brake pad being worn, the caliper piston/adjust-nut move [1] untill the clearance
depended on abrasion is done away.
The axial movement [2] is converted to rotary movement and acts on the adjust-bolt and adjust-nut. Only
the adjust-bolt turns [3] because the caliper piston/adjust-nut is fixed to the brake pad with caliper piston
groove and pad boss at A. Thus, the adjust-bolt keeps original position with rotating as well as the caliper
piston/adjust-nut moves outside.
The adjust-bolt stops rotating once the brake pad-to-disc clearance become zero, so the automatic adjuster
operation is completed.
9-90 CHASSIS

OVER-ADJUST PREVENTION MECHANISM

When rapid braking [1], the automatic brake-lock adjuster operation works too fast [2].
The caliper piston/adjust-nut is forced to stop [3] as soon as the brake pad contacts with brake disk, but the
adjust-bolt turns by inertia force [4] after that. The adjust-bolt stops after the adjust-bolt/nut clearance
becomes zero. On this account, the caliper piston/adjust-nut can not return back [5] using the elasticity
transform of piston seal when releasing the brake lever. It is the over-adjust condition.

Caliper piston

Piston seal

Hydraulic pressure

Rapid rotation
Adjust-bolt Turn by inertia

Rapid braking Sudden stop Impossible to return

Adjust-nut

The spring is equipped between the caliper piston and the adjust-nut for preventing the over-adjust, serves
damper interm of rapid caliper piston movement.
The spring compress [2] as soon as the caliper piston moves exponentially [1], the adjust-nut moves [3],
[4] behind time. Here with, it is possible to make correct clearance of the adjust-bolt/nut because the inertia
force with rapid movement does not work the adjust-bolt.

Spring

Rotate

Spring tensions/
Spring compresses Rapid braking Adjuster-nut moves
 CHASSIS 9-91

TIRE AND WHEEL

TIRE REMOVAL
The most critical factor of a tubeless tire is the seal between the
wheel rim and the tire bead. For this reason, it is recommended
to use a tire changer that can satisfy this sealing requirement
and can make the operation efficient as well as functional.
For operating procedures, refer to the instructions supplied by
the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection, mark
the tire with a chalk to indicate the tire position relative to the
valve position.
Even though the tire is refitted to the original position after
repairing puncture, the tire may have to be balanced again since
such a repair can cause imbalance.

INSPECTION
WHEEL
Wipe the wheel clean and check for the following:
* Distortion and crack
* Any flaws and scratches at the bead seating area.
* Wheel rim runout (!9-27)

TIRE
Tire must be checked for the following points:
* Nick and rupture on side wall
* Tire tread depth (!2-25)
* Tread separation
* Abnormal, uneven wear on tread
* Surface damage on bead
* Localized tread wear due to skidding (Flat spot)
* Abnormal condition of inner liner
9-92 CHASSIS

VALVE
• Inspect the valve after the tire is removed from the rim.
Replace the valve with a new one if the seal rubber is peeling
or has damage.
• Inspect the valve core. If the seal has abnormal deformation,
replace the valve with a new one.

Seal

VALVE INSTALLATION
• Any dust or rust around the valve hole must be cleaned off.
Then install the valve in the rim.
Valve hole
NOTE:
To properly install the valve into the valve hole, apply a special
tire lubricant or neutral soapy liquid to the valve.
%
Be careful not to damage the lip of valve.

Wheel

Valve lip Valve

TIRE INSTALLATION
• Apply tire lubricant to the tire bead.
• When installing the tire onto the wheel, observe the following
points.
%
* Do not reuse the valve which has been once
removed.
* Do not use oil, grease or gasoline on the tire bead in
place of tire lubricant.
 CHASSIS 9-93

• When installing the tire, the arrow 1 on the side wall should
point to the direction of wheel rotation.
• Align the chalk mark put on the tire at the time of removal with
the valve position.

• For installation procedure of tire onto the wheel, follow the

instructions given by the tire changer manufacturer.
• Bounce the tire several times while rotating. This makes the
tire bead expand outward to contact the wheel, thereby facili-
tating air inflation.
• Inflate the tire.
+
* Do not inflate the tire to more than 400 kPa (4.0kgf/
cm2). 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 adjustment.

• In this condition, check the “rim line” cast on the tire side
walls. The line must be equidistant from the wheel rim all
around. If the distance between the rim line and wheel rim Rim line
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.
• When the bead has been fitted properly, adjust the pressure
to specification. (!2-26)
• As necessary, adjust the tire balance.
%
Do not run with a repaired tire at a high speed.

BALANCER WEIGHT INSTALLATION

• When installing the balancer weights to the wheel, set the two
balancer weights on both sides of wheel rim.
%
Weight difference between the two balancer weights
must be less than 10 g.
Balancer weight

Wheel
White Page
 ELECTRICAL SYSTEM 10-1

ELECTRICAL SYSTEM

CONTENTS
CAUTIONS IN SERVICING ......................................................................... 10- 2
CONNECTORS .................................................................................... 10- 2
COUPLERS ......................................................................................... 10- 2
CLAMPS .............................................................................................. 10- 2
FUSES ................................................................................................. 10- 2
SEMI-CONDUCTOR EQUIPPED PARTS ........................................... 10- 2
BATTERY ............................................................................................ 10- 3
CONNECTING THE BATTERY ........................................................... 10- 3
WIRING PROCEDURE ........................................................................ 10- 3
USING THE MULTI CIRCUIT TESTER ............................................... 10- 3
LOCATION OF ELECTRICAL COMPONENTS ......................................... 10- 4
CHARGING SYSTEM ................................................................................. 10- 6
TROUBLESHOOTING ......................................................................... 10- 6
INSPECTION ....................................................................................... 10- 8
STARTER SYSTEM .................................................................................... 10-11
TROUBLESHOOTING ......................................................................... 10-11
STARTER MOTOR REMOVAL AND DISASSEMBLY ....................... 10-12
STARTER MOTOR INSPECTION ....................................................... 10-13
STARTER MOTOR REASSEMBLY .................................................... 10-14
STARTER RELAY INSPECTION ........................................................ 10-15 10
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ....................................................................................... 10-16
IGNITION SYSTEM ..................................................................................... 10-18
TROUBLESHOOTING ......................................................................... 10-18
INSPECTION ....................................................................................... 10-20
COMBINATION METER ............................................................................. 10-23
PARTS NAMES ................................................................................... 10-23
REMOVAL AND DISASSEMBLY ........................................................ 10-23
OPERATING PROCEDURE ................................................................ 10-24
INSPECTION ....................................................................................... 10-26
LAMP ........................................................................................................... 10-31
HEADLIGHT ........................................................................................ 10-31
BRAKE LIGHT/ TAILLIGHT, TURN SIGNAL LIGHT AND
LICENSE LIGHT .................................................................................. 10-32
RELAYS ...................................................................................................... 10-34
TURN SIGNAL RELAY ........................................................................ 10-34
COOLING FAN MOTOR RELAY ......................................................... 10-34
FUEL PUMP RELAY ........................................................................... 10-34
SIDE-STAND RELAY .......................................................................... 10-34
STARTER RELAY ............................................................................... 10-34
SWITCHES .................................................................................................. 10-34
IGNITION SWITCH REMOVAL ........................................................... 10-34
BATTERY .................................................................................................... 10-37
SPECIFICATIONS ............................................................................... 10-37
INITIAL CHARGING ............................................................................ 10-37
SERVICING .......................................................................................... 10-39
RECHARGING OPERATION .............................................................. 10-39
10-2 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING
CONNECTORS
• When disconnecting a connector, be sure to hold the termi-
nals; do not pull the lead wires. Click
• When connecting a connector, push it in so it is firmly
attached.
• Inspect the connector for corrosion, contamination and any
breakage in the cover.

COUPLERS
• With a lock-type coupler, be sure to release the lock before
disconnecting it. When connecting a coupler, push it in until
the lock clicks shut.
• When disconnecting a coupler, be sure to hold the coupler; do
not pull the lead wires.
• Inspect each terminal on the coupler for looseness or bends.
• Inspect each terminal for corrosion and contamination.

CLAMPS
• Refer to the “WIRING HARNESS ROUTING” section for
proper clamping procedures. (!11-14 to 11-17)
• Bend the clamp properly, as shown in the illustration.
• When clamping the wire harness, do not allow it to hang
down.
• Do not use wire or any substitutes for the band-type clamp.

FUSES
• When a fuse blows, always investigate the cause, correct the
problem, and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use any substitutes for the fuse (e.g., wire).

SEMI-CONDUCTOR EQUIPPED PARTS

• Do not drop any part that contains a semi-conductor (e.g., INCORRECT
ECM, CVT control unit, regulator/rectifier).
• When inspecting the part, follow the inspection instructions
carefully. Neglecting proper procedures may cause this part
to be damaged.
 ELECTRICAL SYSTEM 10-3

BATTERY
• The MF battery used in this motorcycle does not require main-
tenance (e.g., electrolyte level inspection, distilled water
replenishment).
• During normal charging, no hydrogen gas is produced. How-
ever, if the battery is overcharged, hydrogen gas may be pro-
duced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open
area.
• Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.

CONNECTING THE BATTERY

• When disconnecting terminals from the battery for disassem-
bly or servicing, be sure to disconnect the - battery lead
wire, first.
• When connecting the battery lead wires, be sure to connect
the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the
battery terminals.
• Install the cover over the + battery terminal.

WIRING PROCEDURE
• Properly route the wiring harness according to the “WIRING
HARNESS ROUTING” section. (!11-14 to 11-17)

USING THE MULTI CIRCUIT TESTER

• Properly use the multi circuit tester + and - probes.
Improper use can cause damage to the motorcycle and
tester.
• If the voltage and current values are not known, begin mea-
suring in the highest range.
• When measuring the resistance, make sure no voltage is
applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF
position.
"
Before using the multi circuit tester, read its instruc-
tion manual.
10-4 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

1 Starter motor
: : :
B Atmospheric pressure sensor ( 6-37)
::
2 Engine coolant temp. sensor ( 8-13) C TO sensor ( 6-39)
3 IAC valve ( 7-20) D CVT control unit
4 Injector ( 6-40)
:::
5 Throttle position sensor ( 6-31) :
E ECM (Engine Control Module)
F Solenoid ( 12-6)
6 Intake air temp. sensor ( 6-36)
7 Intake air pressure sensor ( 6-29)
8 Brake lock switch
G Horn
: :
H CVT motor ( 6-45)
I Pulley position sensor ( 6-47)
9 Cooling fan motor relay
0 Side-stand relay or Fuel pump relay
A Fuel pump relay or Side-stand relay
:
J Center stand switch
:
K HO2 sensor ( 6-42)
L CVT secondary pulley revolution sensor ( 6-51)
 ELECTRICAL SYSTEM 10-5

1 Fuel pump/fuel gauge C Speedometer sensor

2 Starter relay diode D Ignition coil/plug cap (#1)
3 Main fuse E Ignition coil/plug cap (#2)
4 CTV fuse F Generator
5 Battery G Oil pressure switch
: ::
6 Trunk light seat switch H Side-stand switch
7 Starter relay I Cam position sensor ( 6-27)
8 Trunk light J Fan motor ( 8-8)
9 Trunk light switch
0 Fuse box
A Turn signal relay
:
K Cooling fan thermo-switch ( 8-16)
L CKP sensor ( 6-28)
M Oil level switch
B Regulator/rectifier
10-6 ELECTRICAL SYSTEM

CHARGING SYSTEM

Ignition switch

Main fuse

Battery

Load
Generator

Regulator/rectifier

TROUBLESHOOTING

Battery runs down quickly.

Check accessories which use excessive Accessories

amounts of electricity. are installed • Remove accessories

No accessories

:
Check the battery for current leaks.
( 10-8)
Current leaks • Short circuit of wire harness
• Faulty electrical equipment

No current leaks

the battery terminals. (:

Measure the charging voltage between
10-9) Correct • Faulty battery
• Abnormal driving condition

Incorrect

Continued on next page

 ELECTRICAL SYSTEM 10-7

(:
Measure the continuity of the generator coil.
10-9)
No continuity • Faulty generator coil or
disconnected lead wires

Continuity

(:
Measure the generator no-load voltage.
10-10)
Incorrect • Faulty generator

Correct

(:
Inspect the regulator/rectifier.
10-10) Incorrect • Faulty regulator/rectifier

Correct

Inspect the wires. Incorrect • Short circuit of wire

harness
• Poor contact of coupler
Correct

• Faulty battery

Others

Battery overcharges • Faulty regulator/rectifier

• Faulty battery
• Poor contact of generator lead wire coupler
10-8 ELECTRICAL SYSTEM

INSPECTION
BATTERY CURRENT LEAKAGE
• Open the seat.
• Remove the tool bag.
• Remove the battery cover 1 with starter relay.
• Turn the ignition switch to the “OFF” position.
• Disconnect the - battery lead wire 2.
Measure the current between - battery terminal and the - bat-
tery lead wire using the multi circuit tester. If the reading
exceeds the specified value, leakage is evident.
# 09900-25008: Multi circuit tester set
$ Tester knob indication: Current (%, 20 mA)
& Battery current (leak): Under 3.0 mA
"
* Because the current leak might be large, turn the
tester to the high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position
when measuring current.

When checking to find the excessive current leakage, remove

the couplers and connectors, one by one, checking each part.
 ELECTRICAL SYSTEM 10-9

REGULATED VOLTAGE
• Open the seat. DCV

• Remove the battery cover. (!10-8)

• Start the engine, turn the ignition switch to LIGHT (') (for
Italy) and the dimmer switch to HI and run the engine at 5 000
r/min.
Measure the DC voltage between the + and - battery termi-
nals using the multi circuit tester. If the voltage is not within the
specified value, inspect the generator and regulator/rectifier.
(!10-9 and 10-10)
NOTE:
When making this test, be sure that the battery is in fully-
charged condition.
# 09900-25008: Multi circuit tester set
( Tester knob indication: Voltage (%)
& Regulated voltage: 14.0 – 15.5 V at 5 000 r/min

GENERATOR COIL RESISTANCE

• Remove the left frame cover. (!9-16)
• Disconnect the generator coupler.
Measure the resistance between the three lead wires.
If the resistance is not specified value, replace the stator coil
with a new one.
Also, check that the generator core is insulated.
# 09900-25008: Multi circuit tester set
) Tester knob indication: Resistance (Ω
Ω)
& Generator coil resistance: 0.1 – 1.0 Ω (Yellow – Yellow)
∞ Ω (Yellow – Ground)
10-10 ELECTRICAL SYSTEM

GENERATOR NO-LOAD PERFORMANCE

• Remove the left frame cover. (!9-16)
• Disconnect the generator lead wire coupler.
• Start the engine and run it at 5 000 r/min.
Measure the AC voltage between the lead wires of the generator
using the multi circuit tester.
If the voltage is under the specified value, replace the AC gener-
ator with a new one.
# 09900-25008: Multi circuit tester set
( Tester knob indication: Voltage (~)
& Generator no-load performance (when engine is cold):
More than 50 V (AC) at 5 000 r/min

REGULATOR/RECTIFIER
• Remove the left frame cover. (!9-16)
• Disconnect the regulator/rectifier couplers 1.
Measure the voltage between the terminals using the multi cir-
cuit tester, as indicated in the table below.
If the voltage is not within the specified value, replace the regu-
lator/rectifier with a new one.
# 09900-25008: Multi circuit tester set
* Tester knob indication: Diode test (+)
Unit: V
+ Tester probe
B/R B/W B1 B2 B3
- Tester probe

B/R 0.5 – 1.2 0.4 – 0.7 0.4 – 0.7 0.4 – 0.7

B/W ✽ ✽ ✽ ✽
B1 ✽ 0.4 – 0.7 ✽ ✽
B2 ✽ 0.4 – 0.7 ✽ ✽ B/R B/W B1 B2 B3
B3 ✽ 0.4 – 0.7 ✽ ✽
WIRE COLOR
✽ More than 1.4 V (tester’s battery voltage) B: Black, B/R: Black with Red tracer,
B/W: Black with White tracer

NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace the battery of multi circuit tester.
 ELECTRICAL SYSTEM 10-11

STARTER SYSTEM

Starter button Front brake switch

Stater
relay
Rear brake switch
To ignition
coil/plug cap Engine Fuse Fuse
stop Ignition
switch switch
Side-stand relay
Starter
motor

Battery

Side-stand
switch

TROUBLESHOOTING
Make sure the fuses are not blown
Starter motor will not run. and the battery is fully-charged
before diagnosing.
Grasp the front or rear brake lever, turn on the Check if the starter motor runs
when its terminal is connected
+
ignition switch with the engine stop switch in
the “RUN” position and side-stand switch in the Clicks to the battery terminal (Do
“ON” position. Listen for a click from the starter not use a thin wire because a
relay when the starter button is pushed. large amount of current flows.)

Does not run

Runs
No click • Faulty starter motor
• Faulty starter relay
• Loose or disconnected starter
motor lead wire
Measure the starter relay voltage at the starter
relay connectors (between Y/G + and Y/B ) - No voltage • Faulty ignition switch
when the starter button is pushed. • Faulty engine stop switch
• Faulty side-stand relay
• Faulty front brake switch
Voltage • Faulty rear brake switch
• Faulty starter button
• Improper connector contact
Continued on next page • Open circuit in wire harness
10-12 ELECTRICAL SYSTEM

(:
Check the starter relay.
10-15)
Incorrect • Faulty starter relay

Correct
• Improper starter relay contact

Others

Engine does not turn though the starter motor runs. • Faulty starter clutch

STARTER MOTOR REMOVAL AND

DISASSEMBLY
• Remove the foot board. (!9-18)
• Disconnect the starter motor lead wire 1 and remove the
starter motor bolts 2.

• Remove the starter motor A from the crankcase.

• Turn the starter motor B 180° to forward.
• Remove the starter motor.
 ELECTRICAL SYSTEM 10-13

• Disassembly the starter motor, as shown.

1 Housing end (outside)

2 Brush holder
3 Brush spring
4 O-ring
5 Brush terminal set
6 Starter motor case
7 Armature
8 Housing end (inside)
@ 9 O-ring
ITEM N·m kgf-m lb-ft A Starter motor bolt
A, B 6 0.6 4.5 B Lead wire nut

STARTER MOTOR INSPECTION

CARBON BRUSHES
Inspect the carbon brushes for abnormal wear, cracks, or
smoothness in the brush holder.
If any damages are found, replace the brush assembly with a
new one.

COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or
undercut A.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand-
paper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw
blade.

ARMATURE COIL INSPECTION

Check for continuity between each segment and between each
segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is conti-
nuity between the segments and shaft, replace the armature
with a new one.
# 09900-25008: Multi circuit tester set
, Tester knob indication: Continuity test (-)
10-14 ELECTRICAL SYSTEM

OIL SEAL INSPECTION

Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.

STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of disassem-
bly. Pay attention to the following points:
• Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal.
. 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)

• Align the marks as shown.

• Apply a small quantity of THREAD LOCK “1342” to the starter

motor housing bolts.
/ 99000-32050: THREAD LOCK “1342”
• Apply SUZUKI SUPER GREASE “A” to the O-ring.
. 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 ELECTRICAL SYSTEM 10-15

STARTER RELAY INSPECTION

• Open the seat.
• Remove the battery cover. (!10-8)
• Disconnect the battery - lead wire from the battery.

• Disconnect the battery lead wire 1 and starter motor lead

wire 2.

• Disconnect the starter realy lead wire coupler 3.

• Remove the starter relay with battery cover.

Apply 12 V to A and B lead wires and check for continuity

between the positive and negative terminals using the multi cir-
cuit tester. If the starter relay clicks and continuity is found, the
relay is ok.
# 09900-25008: Multi circuit tester set
, Tester knob indication: Continuity test (-
-)
"
Do not apply a battery voltage to the starter relay for
more than five seconds, since the relay coil may over-
heat and damaged.
10-16 ELECTRICAL SYSTEM

Measure the relay coil resistance between the terminals using

the multi circuit tester. If the resistance is not within the specified
value, replace the starter relay with a new one.
# 09900-25008: Multi circuit tester set
& Starter relay resistance: 3 – 6 Ω

SIDE-STAND/IGNITION INTERLOCK
SYSTEM PARTS INSPECTION
Check the interlock system for proper operation. If the interlock
system does not operate properly, check each component for
damage or abnormalities. If any abnormality is found, replace
the component with a new one.

SIDE-STAND SWITCH
• Remove the maintenance lid. (!9-13)
• Remove the left leg shield cover. (!9-12)
• Disconnect the side-stand switch coupler and measure the
voltage between Green and Black/White lead wires.
# 09900-25008: Multi circuit tester set
* Tester knob indication: Diode test (+
+)

+ Probe) -
Green Black/White
( ( Probe)
ON 0.4 – 0.6 V
(Side-stand up)
OFF More than 1.4 V
(Side-stand down) (Tester’s battery voltage)

NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace its battery.

SIDE-STAND RELAY
• Remove the leg shield. (!9-10)
• Remove the side-stand relay. (!10-4)
NOTE:
Wire color of the side-stand relay lead wire are G, O/W, B/W and
Y/B.
 ELECTRICAL SYSTEM 10-17

First check the insulation between A and B terminals with the

tester. Then apply 12 V to terminals as shown and check the
continuity between A and B. If there is no continuity, replace
the side-stand relay with a new one.

STARTER RELAY DIODE INSPECTION

• Remove left frame cover. (!9-16)
• Remove the diode.

Measure the voltage between the terminals using the multi cir-
cuit tester.
Unit: V
+ Probe of tester to:
A B
- Probe
of tester

A
to:

0.3 – 0.6
B ✽
✽ More than 1.4 V (tester’s battery voltage)
# 09900-25008: Multi circuit tester set
* Tester knob indication: Diode test (+)
NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace the batter of multi circuit tester.
10-18 ELECTRICAL SYSTEM

IGNITION SYSTEM
Engine stop switch

ECM
Ignition
fuse
Power source
circuit
CKP
sensor Ignition
Wave form switch
arrangement #1
circuit
Main
fuse
CPU

Wave form Battery

arrangement #2
circuit
Cam position
sensor

Throttle Engine
CVT control
position coolant
unit
sensor temp. sensor

NOTE:
The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine. If engine rpm
reaches 8 000 r/min., this circuit cuts off ignition primary current for all spark plugs.
"
Under no load, the engine can run over 8 000 r/min, even if the ignition cut-off circuit is effec-
tive, and it may cause engine damage. Do not run the engine without load over 8 000 r/min at
anytime.

TROUBLESHOOTING
Make sure the engine stop switch is in the “RUN” position
No spark or poor spark and side-stand is in up-right position. Grasp the front
or rear brake lever. Make sure the fuse is not blown
and the battery is fully-charged before diagnosing.
Check the ignition system couplers for Loose • Improper coupler connection
poor connections.

Correct

Continued on next page

 ELECTRICAL SYSTEM 10-19

Measure the battery voltage between

input lead wires (O/W and B/W) at the Incorrect • Faulty ignition switch
ECM with the ignition switch in the • Faulty engine stop switch
“ON” position. • Broken wire harness or poor
connection of related circuit
Correct couplers

:
Measure the ignition coil primary peak

:
voltage. ( 10-20)
NOTE: The ignition coil peak voltage Correct Inspect the spark plug (-s).
inspection methotd is applicable only ( 2-7)
with the multi circuit tester and the peak
volt adaptor.
Correct Incorrect

Incorrect
• Faulty spark
plug (-s)

• Improper ignition coil/plug

:
cap (-s) connection
Inspect the ignition coil/plug cap (-s).
Incorrect • Faulty ignition coil/plug cap (-s)
( 10-21)

Correct

:
Measure the CKP sensor peak voltage
and its resistance. ( 10-21 to 10-22)
NOTE: The CKP sensor peak voltage Incorrect • Faulty CKP sensor
inspection is applicable only with the
multi circuit tester and peak volt adaptor.

Correct
• Faulty ECM
• Faulty wire harness
• Improper ignition
coupler connection
10-20 ELECTRICAL SYSTEM

INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Remove the lower leg shield. (!9-10)
• Remove the radiator mounting bolt.
• Disconnect the two ignition coil/plug caps.
• Connect the new spark plugs to the each ignition coil/plug cap
and ground them on the cylinder head.
NOTE:
Make sure that the each ignition coil/plug cap and spark plug are
connected properly.

Measure the ignition coil primary peak voltage using the multi
circuit tester in the following procedure.
• Connect the multi circuit tester with the peak volt adaptor as
follows.
No.1 ignition coil/plug cap: + Probe: White/Blue lead wire connector
- Probe: Ground
No.2 ignition coil/plug cap: + Probe: Black/Yellow lead wire connector
- Probe: Ground
NOTE:
Do not disconnect the ignition coil/plug cap lead wire couplers.
# 09900-25008: Multi circuit tester set
"
Before using the multi circuit tester and peak volt adaptor,
be sure to refer to the appropriate instruction manual.

• Set the side-stand upright position, and then turn the ignition
switch to the “ON” position.
• Pull the front or rear brake lever.
• Press the starter button and allow the engine to crank for a few
seconds, and then measure the ignition coil primary peak voltage.

• Repeat the above procedure a few times and measure the Peak volt
highest ignition coil primary peak voltage. adaptor

( Tester knob indication: Voltage (%)

& Ignition coil primary peak voltage: More than 80 V
0 To engine
ECM stop switch
While testing, do not touch the tester probes and IG coil
spark plugs to prevent receiving an electric shock.

If the peak voltage is lower than the specified values, inspect the
ignition coil/plug cap. (!10-21)
 ELECTRICAL SYSTEM 10-21

IGNITION COIL/PLUG CAP RESISTANCE

• Remove the radiator mounting bolt. (!10-20)
• Remove the ignition coil/plug cap and disconnect its coupler.
Measure the ignition coil/plug cap resistance in both the primary
and secondary windings. If the resistance is not within the stan-
dard range, replace the ignition coil/plug cap with a new one.
# 09900-25008: Multi circuit tester set
) Tester knob indication: Resistance (Ω
Ω)
& Ignition coil/plug cap resistance
Primary : 0.8 – 2.5 Ω (Terminal – Terminal)
Ω (Plug cap – Terminal)
Secondary: 8 – 18 kΩ
• Install the ignition coil/plug cap.

CKP SENSOR PEAK VOLTAGE

• Remove the front panel. (!9-8)
• Disconnect the wire harness coupler 1 at the ECM.
Measure the CKP sensor peak voltage in the following proce-
dure.
• Connect the multi circuit tester with the peak volt adaptor as
follows.

+ Probe: White lead wire

- Probe: White/Green lead wire
# 09900-25008: Multi circuit tester set
"
Before using the multi circuit tester and peak volt
adaptor, be sure to refer to the appropriate instruction
manual.
10-22 ELECTRICAL SYSTEM

• Turn the ignition switch to the “ON” position.

• Pull the front or rear brake. ECM
CKP sensor coupler
• Press the starter button and allow the engine to crank for a coupler
few seconds, and then measure the CKP sensor peak volt- W/G
G/W
age. W
CKP sensor
• Repeat the above procedure a few times and measure the Peak
highest peak voltage. volt
adaptor
( Tester knob indication: Voltage (%)
& CKP sensor peak voltage: More than 2.0 V
If the peak voltage is lower than the specified values, check the
peak voltage at the CKP sensor lead wire coupler.

• Remove the maintenance lid. (!9-13)

• Dicsonnect the CKP sensor lead wire coupler and connect the
multi circuit tester with the peak volt adaptor.
+ Probe: Blue lead wire
- Probe: Green lead wire
Measure the CKP sensor peak voltage at the CKP sensor lead
wire coupler, in the same manner as on the ECM coupler.
( Tester knob indication: Voltage (%)
& CKP sensor peak voltage: More than 2.0 V
If the peak voltage on the CKP sensor lead wire coupler is ok but
on the ECM coupler is out of specification, the wire harness
CKP sensor
must be replaced. If both peak voltages are out of specification, coupler
the generator must be replaced and re-checked. G
BI
CKP sensor
Peak
volt
adaptor

CKP SENSOR RESISTANCE

Measure the resistance between the lead wires and ground. If
the resistance is not specified value, the CKP sensor must be CKP sensor
coupler
replaced.
# 09900-25008: Multi circuit tester set
CKP sensor
) Tester knob indication: Resistance (Ω
Ω)
& CKP sensor resistance: 150 – 300 Ω (Green – Blue)
: ∞ Ω (Green – Ground)
• Connect the CKP sensor coupler and install the maintenance
lid.
 ELECTRICAL SYSTEM 10-23

COMBINATION METER
PARTS NAMES

1 Engine coolant temp. indicator light A FI indicator light

2 Engine coolant temp. meter B Engine oil pressure indicator light
3 Fuel meter C High beam indicator light
4 Turn signal indicator light (L) D Clock hour adjust button
5 Engine oil change indicator E Clock minute adjust button
6 Engine oil level indicator F Clock
7 Tachometer G Riding mode indicator light
8 Speedometer H Odometer/tripmeter (A, B)
9 Turn signal indicator light (R) I Select button
0 Brake lock indicator light J Reset button
REMOVAL AND DISASSEMBLY
• Remove the combination meter. (!9-22)
• Disassembly the combination meter, as shown.
10-24 ELECTRICAL SYSTEM

OPERATING PROCEDURE
INITIAL DISPLAY
When the ignition switch is set to ON, all LCD (Liquid Crystal
Display) and engine coolant temp. Indicator, FI indicator and
shift indicator lights light up for two seconds.
The tachometer light up for 0.5 second and then it operates 0 ↔
10 000 r/min two times.
NOTE:
If the power supply is cut (e.g., when the battery is replaced);
Since the clock resets to “AM1:00”, it will need to be readjusted.

CHANGE THE DISPLAY MODE

With each press of the SELECT button, the display changes
between odometer, tripmeter A and tripmeter B as shown.

Odometer Tripmeter A Tripmeter B

0
To aboid riding with only one hand, do not operate the
button while riding.

ODOMETER
Displays the total distance travelled.

TRIPMETER
Displays the distance travelled since the tripmeter was last
reset.
NOTE:
The tripmeters A and B can be used independently.
Hold down the RESET button over two seconds to reset the trip-
meter.

CLOCK
Displays the time (hour and minutes) on a 12-hour clock.

Setting the time (Ignition switch is “ON” position)

Press the “H” button to adjust the hour display.
Press the “M” button to adjust the minute display.
 ELECTRICAL SYSTEM 10-25

OIL CHANGE INDICATOR

The oil change indicator warns the driver of engine oil replacement timing. The indicator comes on at initial
600 mile (1 000 km) and the preset intervals thereafter. The preset interval can be varied in the range
between 300 mile (500 km) to 3 600 mile (6 000 km) with a step of 300 mile (500 km). Reset the indicator
after changing engine oil to turn off the display.

To reset the oil change indicator:

1. Turn off the ignition switch.
2. Hold down the “SELECT” and “RESET” buttons together and turn the ignition switch to the ON position.
Continue pushing on the “SELECT” and “RESET” buttons for two seconds.
3. Oil change counter will be reset to initial and the indicator blinks for three seconds.

To vary the preset interval of oil change indicator:

1. Push the SELECT and RESET buttons together for two seconds until INTERVAL display comes on.
2. Push the SELECT button to decrease the interval from the maximum of 3 600 mile (6 000 km) to the
desired interval with a step of 300 mile (500 km). The minimum possible interval is 300 mile (500 km).
3. Push the RESET button to increase the interval from the minimum of 300 mile (500 km) to the desired
interval with a step of 300 mile (500 km). The maximum possible interval is 3 600 mile (6 000 km).
4. Push the SELECT and RESET buttons together for more than two seconds.
NOTE:
* The preset interval can be adjusted after the odometer reading has exceeded 600 mile (1 000 km).
* Reset the indicator after engine oil replacement has been performed.

Example of oil change indicator setting

With the odometer reading past 600 mile, the oil change interval setting can be adjusted
manually. If the setting is left unattended (as shown in the left column), the display
600 mile: OIL CHANGE Indicator displayed. “OIL CHANGE” will appear automatically as a default setting at every 3 600 mile thereafter.
If the setting is varied manually to a desired interval (as shown in the middle column),
Oil changed the display will thereafter appear at the end of the varied interval.
From then on, the same interval will be succeeded automatically. The interval once
610 mile: RESET Indicator goes out. adjusted can be readjusted later as desired (as shown in the right column).

Default interval (3 600 mile) Interval set to 2 400 mile

4 210 mile: OIL CHANGE Indicator displayed. 3 010 mile: OIL CHANGE Indicator displayed.

Oil changed Oil changed

4 220 mile: RESET Indicator goes out. 3 020 mile: RESET Indicator goes out.

Default interval (3 600 mile) Set interval succeeded (2 400 mile) Interval set again to 3 000 mile

7 820 mile: OIL CHANGE Indication displayed. 5 420 mile: OIL CHANGE Indicator displayed. 6 020 mile: OIL CHANGE Indicator
displayed.
10-26 ELECTRICAL SYSTEM

INSPECTION
ENGINE COOLANT TEMPERATURE METER AND INDICA-
TOR LIGHT
• Disconnect the engine coolant temperature sensor coupler.
"
When connecting and disconnecting the engine cool-
ant temp. sensor lead wire coupler, make sure to turn
OFF the ignition switch, or electronic parts may get
damaged.

• Connect the variable resistor A between the terminals.

• Turn the ignition switch “ON”.
• Check the display of engine coolant temperature meter as
shown below. If any abnormality is found, replace the combi-
Engine
nation meter with a new one. coolant
temp.
sensor
Variable resister

! 8-13)
Engine coolant temperature sensor. (!

Engine coolant
Under 39 ˚C 40 – 59 ˚C 60 – 99 ˚C 100 – 111 ˚C
temperature

More than
Resistance 1.148 – 0.587 kΩ 0.587 – 0.188 kΩ 0.188 – 0.140 kΩ
1.148 kΩ

Engine coolant ON ON ON ON
C H C H C H C H
temperature meter

Engine coolant
temperature indicator OFF OFF OFF OFF
light

Engine coolant
112 – 119 ˚C Over 120 ˚C
temperature

Less than
Resistance 0.140 – 0.116 kΩ
0.116 kΩ

Engine coolant ON Flicker

C H C H
temperature meter

Engine coolant
temperature indicator OFF ON
light
 ELECTRICAL SYSTEM 10-27

FUEL METER
• Remove the trunk box. (!9-16)
• Connect each resistor between the Red/Black and Black/
White lead wires at the wire harness.
• Turn the ignition switch “ON” position and wait for approx. 13
seconds.
Check the display of fuel meter as shown below, If any abnor-
mality is found, replace the combination meter with a new one.

More than Less than

Resistance 96 – 112 Ω 82 – 96 Ω 71 – 82 Ω 51 – 62 Ω
112 Ω 50 Ω

– ON – ON – ON – ON
Fuel level
E F E F E F E F E F E F
meter

FUEL GAUGE
• Remove the fuel pump. (!7-7)
Measure the resistance at each fuel level gauge float position. If
the resistance is incorrect, replace the fuel level gauge with a
new one.

Float position Resistance

A “F” (Full) Approx. 13 Ω
B “E” (Empty) Approx. 130 Ω

# 09900-25008: Multi circuit tester set

F
) Tester knob indication: Resistance (Ω
Ω)

130 mm

E
22 mm
10-28 ELECTRICAL SYSTEM

• Remove the fuel gauge 1 from the fuel pump.

• Install the fuel gauge.
• Install the fuel pump. (!7-11)

FUEL PUMP RELAY

• Remove the fuel pump relay. (!10-4)
Same as side-stand relay. (!10-17)

OIL PRESSURE INDICATOR

NOTE:
Before inspecting the oil pressure switch, check the engine oil
level.
• Remove the leg side cover. (!9-12)
• Disconnect the oil pressure switch lead wire from the oil pres-
sure switch.
• Turn the ignition switch “ON” position.

Check if the oil pressure indicator comes on, when grounding

the lead wire. If the oil pressure indicator does not come on,
check the circuit connection or replace the bulb.

To oil pressure
switch
 ELECTRICAL SYSTEM 10-29

ENGINE OIL LEVEL INDICATOR

• Remove the maintenance lid. (!9-13)
• Disconnect the oil level switch lead wire 1.
• Turn the ignition switch to the ON position.
Check if the oil level indicator comes on. If the oil level indicator
does not come on, check the combination meter coupler or
replace the combination meter.

ENGINE OIL LEVEL SWITCH

• Remove the engine oil level switch. (!3-12)
Check the continuity between the lead wine and switch body.
The relation between the position of the oil level gauge float in
the oil level gauge and the continuity as shown below.

Switch position Continuity

A ON
B OFF

• Install the oil level switch. (!3-74)

SPEEDOMETER
If the speedometer, odometer or trip meter does not function
properly, inspect the speedometer sensor and connection of
coupler. If the speedometer sensor and connection are all right,
replace the meter with a new one.
10-30 ELECTRICAL SYSTEM

SPEEDOMETER SENSOR
• Remove the final gear case cover. (!2-15)
• Remove the left frame cover. (!9-16)
• Disconnect speedometer sensor coupler 1.
• Remove the speedometer sensor 2 by removing its mounting
bolt and lead wire set bolts.

Connect 12 V battery, 10 kΩ resistor and the multi circuit tester

as shown in the right illustration.
10 kΩ 12 V
O/R: Orange with Red tracer
B/W: Black with White tracer
W: White
# 09900-25008: Multi circuit tester set Speedometer sensor

( Tester knob indication: Voltage (%

%)

Under above condition, if a suitable screwdriver touching the

pick-up surface of the speedometer sensor is moved, the tester
reading voltage changes (0 V → 12 V or 12 V → 0 V). If the
tester reading voltage does not change, replace the speedome-
ter sensor with a new one.
NOTE:
The highest voltage reading in this test will be the same as that
of battery voltage (12 V).
(Battery voltage)

• Apply SUZUKI SUPER GREASE “A” to the speed sensor O-

ring before installing it.
. 99000-25030: SUZUKI SUPER GREASE “A” (USA)
99000-25010: SUZUKI SUPER GREASE “A” (Others)
 ELECTRICAL SYSTEM 10-31

LAMP
HEADLIGHT

E-02

! E-19

If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with
alcohol or soapy water to prevent premature bulb failure.

HEADLIGHT BULB REPLACEMENT

• Disconnect the lead wire couplers.
• Remove the headlight socket cover.
• Remove the headlight bulb 1 by releasing the bulb spring 2.
• Remove the position light 3.
• Install the bulbs.

HEADLIGHT BEAM ADJUSUMENT

• Remove the front panel. (!9-8)
• Adjust the headlight beam, both vertical and horizontal.
A Vertical adjuster (using a screw driver +)
B Horizontal adjuster (using a screw driver +)
10-32 ELECTRICAL SYSTEM

BRAKE LIGHT/ TAILLIGHT, TURN SIGNAL LIGHT AND LICENSE LIGHT

! If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with
alcohol or soapy water to prevent premature bulb failure.

BULB REPLACEMENT
Front turn signal light
• Remove the cap 1 and screw 2.
• Insert the suitable screwdriver into the screw hole.
• Remove the front turn signal light as shown.

• Remove the socket 3.

• Remove the bulb 4.
• Install the turn signal light in the reverse order of removal.
 ELECTRICAL SYSTEM 10-33

Rear turn signal light

• Remove the center frame cover. (!9-15)
• Remove the socket 1.
• Remove the bulb 2.
• Install the turn signal light in the reverse order of removal.

Brake light/taillight
• Remove the center frame cover. (!9-15)
• Remove the socket holder plate 1 and socket 2.
• Remove the bulb 3.
• Install the brake light/taillight in the reverse order of removal.

License light
• Remove the lower frame cover. (!9-15)
• Remove the lens 1.
• Remove the bulb 2.
• Install the license light in the reverse order of removal.
10-34 ELECTRICAL SYSTEM

RELAYS
TURN SIGNAL RELAY
INSPECTION
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.
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.
NOTE:
Make sure that the battery is fully charged.

COOLING FAN MOTOR RELAY

• Remove the cooling fan motor relay. (!10-4)
First check the insulation between A and B terminals with the
tester. Then apply 12 V to terminals as shown and check the
continuity between A and B. If there is no continuity, replace
the side-stand relay with a new one.

FUEL PUMP RELAY

!10-28

SIDE-STAND RELAY
!10-16, 10-17

STARTER RELAY
!10-15

SWITCHES
IGNITION SWITCH REMOVAL
!9-19
 ELECTRICAL SYSTEM 10-35

INSPECTION HAZARD SWITCH

Inspect each switch for continuity with a tester. Except for E-24 and AN650L
Color
If any abnormality is found, replace the respective B Lbl Lg
Position
switch assemblies with new ones. OFF
IGNITION SWITCH ON
For E-24
Color ENGINE STOP SWITCH
R O O/B B/W O/G Br Color
Position O/B O/W
À
ON Position
OFF ( )
OFF
LOCK ¾
RUN ( )

STARTER BUTTON
For Others
Color
Color B/BI Y/G
R O O/B B/W O/G Br Position
Position
ON
PUSH
OFF
LOCK
HORN BUTTON
P
Color
B/BI B/W
Position
LIGHTING SWITCH
For AN650L PUSH
Color
Position
O/BI Gr O/R Y/W
FRONT BRAKE SWITCH
OFF
Color
S B/R B/BI
Position
ON OFF
ON
DIMMER SWITCH
Color REAR BRAKE SWITCH
W Y Y/W
Position
Color
HI B/G B/R
Position
LO OFF
ON
PASSING LIGHT SWITCH
Color BRAKE LOCK SWITCH
Y O/R
Position Color
Y O/G
Position
PUSH OFF
ON
TURN SIGNAL SWITCH
Color CVT UP/DOWN SWITCH
Lg Lbl B
Position Color
Y/G Br/W G
L Position
PUSH UP
R FREE
DOWN
10-36 ELECTRICAL SYSTEM

CVT POWER SWITCH

Color WIRE COLOR
Br/W R/W
Position B : Black Lbl : Light blue Y : Yellow
FREE Br : Brown Lg : Light green W : White
G : Green O : Orange
PUSH Gr : Gray R : Red
B/Bl : Black with Blue tracer
CVT “D” ↔ “M” SWITCH B/G : Black with Green tracer
B/W : Black with White tracer
Color B/R : Black with Red tracer
Br/W BI/Y
Position BI/Y : Blue with Yellow tracer
FREE Br/W : Brown with White tracer
G/Y : Green with Yellow tracer
PUSH O/B : Orange with Black tracer
O/Bl : Orange with Blue tracer
TRUNK LIGHT SWITCH O/G : Orange with Green tracer
O/R : Orange with Red tracer
Color O/W : Orange with White tracer
R B/W
Position R/W : Red with White tracer
OFF Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
ON
OFF

TRUNK LIGHT SEAT SWITCH

Color
B B/W
Position

PUSH

:
OIL LEVEL SWITCH
10-29

OIL PRESSURE SWITCH

Color
G/Y Ground
Position
ON (engine
is stopped)
OFF (engine
is running)

:
NOTE:
Before inspecting the oil pressure switch
check if engine oil level is enough. ( 2-14)

:
COOLING FAN THERMO SWITCH
8-16
 ELECTRICAL SYSTEM 10-37

BATTERY
SPECIFICATIONS
Type designation FTX14-BS
Capacity 12V, 43.2 kC (12 Ah)/10HR

a Anode plates e Stopper

b Separator (fiberglass plate) f Filter
c Cathode plates g Terminal
d Upper cover breather h Safty valve

INITIAL CHARGING
FILLING ELECTROLYTE
• Remove the aluminum tape 1 which seals the battery filler
holes 2.

• Remove the caps 3 from the electrolyte container.

NOTE:
* Do not remove or pierce the sealed areas 4 of the electrolyte
container.
* After completely filling the battery with electrolyte, use the caps
3 from the electrolyte container to seal the battery filler holes.

• Insert the nozzles of the electrolyte container 5 into the elec-

trolyte filler holes of the battery. Hold the electrolyte container
firmly so that it does not fall. Do not allow any of the electro-
lyte to spill.

• Make sure the air bubbles 1 rise to the top of each electrolyte
container and leave the electrolyte container in this position
for more than 20 minutes.
10-38 ELECTRICAL SYSTEM

NOTE:
If air bubbles do not rise from any one of the filler ports, tap the
bottom of the electrolyte container two or three times.
Never remove the electrolyte container from the battery while
there is still electrolyte in the container.
• After the electrolyte container is completely empty, remove it
from the battery and wait about 20 minutes.
• Insert the caps 2 firmly into the filler holes, so that the top of
the caps do not protrude above the upper surface of the top
cover of the battery.
"
* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove
the caps.
* Do not tap the caps with a hammer when installing
them.

CORRECT INCORRECT

• For initial charging, use the charger specially designed for MF

battery.
"
* For charging the battery, make sure to use the
charger specially designed for MF battery. Other-
wise, the battery may be overcharged resulting in
shortned service life.
* Do not remove the caps on the battery top while
charging.
* Position the battery with the cap facing upward dur-
ing charging.
 ELECTRICAL SYSTEM 10-39

SERVICING
Visually inspect the surface of the battery container. If any signs
of cracking or electrolyte leakage from the sides of the battery
have occurred, replace the battery with a new one. If the battery
terminals are found to be coated with rust or an acidic white
powdery substance, clean the battery terminals with sandpaper.

Charging period
RECHARGING OPERATION (V)
Stop charging
Measure the battery voltage using the multi circuit tester. If the 18
voltage reading is less than the 12 V (DC), recharge the battery 17
with a battery charger. 16
15
" 14
13
When recharging the battery, remove the battery from 12
the motorcycle.
0 10 20 30 40 50 60
Time (Minutes)
NOTE:
While recharging, do not remove the caps on the top of the bat-
tery.
Recharging time: 1.4 A for 5 to 10 hours or 6 A for 1 hour. (V) (at 0˚C – 40˚C)
14
"
13
Be careful not to permit the charging current to
12
exceed 6 A at any time.
11
After recharging, wait at least 30 minutes and then measure the 10
battery voltage using the multi circuit tester. If the battery voltage
is less than 12.5 V, recharge the battery again. If the battery 100 75 50 25 0 (%)
Battery charged condition
voltage is still less than 12.5 V after recharging, replace the bat-
tery with a new one.
When a battery is left unused for a long time, its voltage needs
to be regularly measured. When the motorcycle is not used for
more than one month (especially during the winter season),
measure the battery voltage at least once a month.
White Page
 SERVICING INFORMATION 11-1

SERVICING INFORMATION

CONTENTS
TROUBLESHOOTING ........................................................................11- 2
FI SYSTEM/ CVT SYSTEM MALFUNCTION CODE AND
DEFECTIVE CONDITION ..........................................................11- 2
ENGINE ......................................................................................11- 4
CVT ............................................................................................11- 9
RADIATOR (COOLING SYSTEM) .............................................11- 9
CHASSIS ....................................................................................11-10
BRAKES .....................................................................................11-11
ELECTRICAL .............................................................................11-12
BATTERY ...................................................................................11-13
WIRING HARNESS, CABLE AND HOSE ROUTING ........................11-14
WIRING HARNESS ROUTING ..................................................11-14
CABLE ROUTING ......................................................................11-18
THROTTLE BODY INSTALLATION/HOSE ROUTING .............11-20 11
FUEL TANK MOUNTING ...........................................................11-21
FUEL TANK HOSE ROUTING ...................................................11-23
RADIATOR HOSE ROUTING ....................................................11-25
FRONT BRAKE HOSE ROUTING .............................................11-26
REAR BRAKE HOSE ROUTING ...............................................11-27
SIDE-STAND SET-UP ........................................................................11-28
CENTER STAND SET-UP ..................................................................11-28
SPECIAL TOOLS ...............................................................................11-29
TIGHTENING TORQUE ......................................................................11-33
ENGINE ......................................................................................11-33
CVT ............................................................................................11-34
CHASSIS ....................................................................................11-34
TIGHTENING TORQUE CHART ................................................11-35
SERVICE DATA .................................................................................11-36
11-2 SERVICING INFORMATION

TROUBLESHOOTING
FI SYSTEM/ CVT SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
C00 NO FAULT –––––––––––
Camshaft position The signal does not reach ECM for more than 2 sec. after
sensor receiving the starter signal.
C11 The camshaft position sensor wiring and mechanical parts.
(Camshaft position sensor, intake cam pin, wiring/coupler con-
nection)
Crankshaft position The signal does not reach ECM for more than 2 sec. after
sensor receiving the starter signal.
C12
The crankshaft position sensor wiring and mechanical parts.
(Crankshaft position sensor, wiring/coupler connection)
Intake air pressure The sensor should produce following voltage.
sensor (0.50 V sensor voltage < 4.85 V)
C13
Without the above range, C13 is indicated.
Intake air pressure sensor, wiring/coupler connection.
Throttle position The sensor should produce following voltage.
sensor (0.20 V sensor voltage < 4.80 V)
C14
Without the above range, C14 is indicated.
Throttle position sensor, wiring/coupler connection.
Engine coolant The sensor voltage should be the following.
temperature sensor (0.15 V sensor voltage < 4.85 V)
C15
Without the above range, C15 is indicated.
Engine coolant temperature sensor, wiring/coupler connection.
Speed sensor The speed sensor signal is not input for more than 3 sec. during
C16 vehicle deceleration.
Speed sensor, wiring/coupler connection.
Intake air temperature The sensor voltage should be the following.
sensor (0.15 V sensor voltage < 4.85 V)
C21
Without the above range, C21 is indicated.
Intake air temperature sensor, wiring/coupler connection.
Atmospheric pressure The sensor voltage should be the following.
sensor (0.50 V sensor voltage < 4.85 V)
C22
Without the above range, C22 is indicated.
Atm. pressure sensor, wiring/coupler connection.
Tip over sensor The sensor voltage should be the following for more than 2 sec.
after ignition switch turns ON.
C23 (0.20 V sensor voltage < 4.80 V)
Without the above value, C23 is indicated.
Tip over sensor, wiring/coupler connection.
Ignition signal Crankshaft position sensor (pick-up coil) signal is produced but
signal from ignition coil is interrupted continuous by 4 times or
C24 or C25 more. In this case, the code C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery.
 SERVICING INFORMATION 11-3

Fuel injector Crankshaft position sensor (pick-up coil) signal is produced but
fuel injector signal is interrupted continuous by 4 times or more.
C32 or C33
In this case, the code C32 or C33 is indicated.
Injector, wiring/coupler connection, power supply to the injector.
Intake air control (IAC) No IAC valve voltage is supplied after starting the engine.
C40
valve IAC valve, wiring/coupler connection.
Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is
turned ON, or voltage is applied to fuel pump although fuel
C41 pump relay is turned OFF.
Fuel pump relay, connecting lead, power source to fuel pump
relay.
Ignition switch Ignition switch signal is not input in the ECM.
C42
Ignition switch, lead wire/coupler.
Heated oxygen sensor During O2 feedback control, O2 sensor voltage is higher or
(HO2S) [E-02, 19] lower than the specification.
No signal is detected during engine operation or no electrical
C44
power is supplied from battery.
HO2S lead wire/coupler connection.
Battery voltage supply to the HO2S.
CVT serial No signal is supplied from CVT control unit to ECM for more
C50 communication than 5 sec. after starting the engine.
Wiring/coupler connection.
CVT motor The CVT motor operating voltage is not supplied from CVT
C51 control unit.
CVT motor, wiring/coupler connection.
CVT pulley position The sensor should produce following voltage.
sensor (0.06 sensor voltage 5.04)
C52
Without the above range, C52 is indicated.
CVT pulley position sensor, wiring/coupler connection.
CVT speed sensor The CVT speed sensor signal is not input to CVT control unit
C53 for more than 3 sec. during vehicle rurning.
Speed sensor, wiring/coupler connection.
CVT secondary pulley The CVT secondary pulley revolution signal is not input to CVT
revolution sensor control unit at speed of 20 km or higher.
C54
CVT secondary pulley revolution sensor, wiring/coupler con-
nection.
CVT engine revolution The CVT engine revolution signal is not input to CVT control
C55 signal unit from ECM at speed of 20 km or higher.
Wiring/coupler connection.
CVT throttle position The CVT throttle position signal does not reach for more than 5
C56 signal sec. from ECM to CVT control unit after ignition switch turns ON.
Wiring/coupler connection.
CVT reduction ratio The CVT pulley position signal disagrees with actual revolution
C58 disagreement ratio for more than 4 sec.
PPS, CVT belt, CVT primary pulley/secondary pulley.
11-4 SERVICING INFORMATION

ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low
or is hard to start. 1. Tappet clearance out of adjustment. Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3. Mistimed valves. Adjust.
4. Excessively worn piston rings. Replace.
5. Worn-down cylinder bores. Replace.
6. Starter motor cranks too slowly. See electrical section.
7. Poor seating of spark plugs. Retighten.
Plugs not sparking
1. Fouled spark plugs. Clean.
2. Wet spark plugs. Clean and dry.
3. Defective ignition coil or camshaft position sensor. Replace.
4. Open or short in high-tension cords. Replace.
5. Defective crankshaft position sensor. Replace.
6. Defective ECM. Replace.
7. Open-circuited wiring connections. Repair or replace.
No fuel reaching the intake manifold
1. Clogged fuel filter or fuel hose. Clean or replace.
2. Defective fuel pump. Replace.
3. Defective fuel pressure regulator. Replace.
4. Defective fuel injector. Replace.
5. Defective fuel pump relay. Replace.
6. Defective ECM. Replace.
7. Open-circuited wiring connections. Check and repair.
Incorrect fuel/air mixture
1. Throttle position sensor out of adjustment. Adjust.
2. Defective fuel pump. Replace.
3. Defective fuel pressure regulator. Replace.
4. Defective throttle position sensor. Replace.
5. Defective crankshaft position sensor. Replace.
6. Defective intake air pressure sensor. Replace.
7. Defective atmospheric pressure sensor. Replace.
8. Defective ECM. Replace.
9. Defective engine coolant temp. sensor. Replace.
10. Defective intake air temp. sensor. Replace.
Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust.
2. Poor seating of valves. Replace or repair.
3. Defective valve guides. Replace.
4. Worn down camshaft. Replace.
5. Too wide spark plug gaps. Adjust or replace.
6. Defective ignition coil. Replace.
7. Defective crankshaft position sensor. Replace.
8. Defective ECM. Replace.
9. Defective throttle position sensor. Replace.
10. Defective fuel pump. Replace.
11. Imbalanced throttle valve. Adjust.
12. Damaged or cracked vacuum hose. Replace.
13. Defective IAC valve. Replace.
 SERVICING INFORMATION 11-5

Complaint Symptom and possible causes Remedy

Engine stalls often Incorrect fuel/air mixture
1. Defective intake air pressure sensor or circuit. Repair or replace.
2. Clogged fuel filter. Clean or replace.
3. Defective fuel pump. Replace.
4. Defective fuel pressure regulator. Replace.
5. Damaged or cracked vacuum hose. Replace.
6. Defective engine coolant temp. sensor. Replace.
7. Defective thermostat. Replace.
8. Defective intake air temp. sensor. Replace.
Fuel injector improperly operating
1. Defective fuel injector. Replace.
2. No injection signal from ECM. Repair or replace.
3. Open or short circuited wiring connection. Repair or replace.
4. Defective battery or low battery voltage. Replace or recharge.
Control circuit or sensor improperly operating
1. Defective ECM. Replace.
2. Defective fuel pressure regulator. Replace.
3. Defective throttle position sensor. Replace.
4. Defective intake air temp. sensor. Replace.
5. Defective camshaft position sensor. Replace.
6. Defective crankshaft position sensor. Replace.
7. Defective engine coolant temp. sensor. Replace.
8. Defective fuel pump relay. Replace.
Engine parts improperly operating
1. Fouled spark plugs. Clean.
2. Defective crankshaft position sensor or ECM. Replace.
3. Clogged fuel hose. Clean.
4. Tappet clearance out of adjustment. Adjust.
11-6 SERVICING INFORMATION

Complaint Symptom and possible causes Remedy

Noisy engine. Excessive valve chatter
1. Too large tappet clearance. Adjust.
2. Weakened or broken valve springs. Replace.
3. Worn tappet or cam surface. Replace.
4. Worn and burnt camshaft journal. Replace.
Noise seems to come from piston
1. Worn down pistons or cylinders. Replace.
2. Combustion chambers fouled with carbon. Clean.
3. Worn piston pins or piston pin bore. Replace.
4. Worn piston rings or ring grooves. Replace.
Noise seems to come from timing chain
1. Stretched chain. Replace.
2. Worn sprockets. Replace.
3. Tension adjuster not working. Repair or replace.
Noise seems to come from clutch
1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
4. Worn clutch release bearing. Replace.
5. Weakened clutch dampers. Replace the primary driven
gear.
Noise seems to come from crankshaft
1. Rattling bearings due to wear. Replace.
2. Worn and burnt big-end bearings. Replace.
3. Worn and burnt journal bearings. Replace.
4. Too large thrust clearance. Replace thrust bearing.
Noise seems to come from transmission
1. Worn or rubbing gears. Replace.
2. Worn splines. Replace.
3. Worn or rubbing primary gears. Replace.
4. Worn bearings. Replace.
Noise seems to come from water pump
1. Too much play on pump shaft bearing. Replace.
2. Worn or damaged impeller shaft. Replace.
3. Worn or damaged mechanical seal. Replace.
4. Contact between pump case and impeller. Replace.
Engine runs poorly in Defective engine internal/electrical parts
high speed range. 1. Weakened valve springs. Replace.
2. Worn camshafts. Replace.
3. Valve timing out of adjustment. Adjust.
4. Too narrow spark plug gaps. Adjust.
5. Ignition not advanced sufficiently due to poorly working Replace ECM.
timing advance circuit.
6. Defective ignition coil. Replace.
7. Defective crankshaft position sensor. Replace.
8. Defective ECM. Replace.
9. Clogged air cleaner element. Clean.
10. Clogged fuel hose, resulting in inadequate fuel supply Clean and prime.
to injector.
11. Defective fuel pump. Replace.
12. Defective throttle position sensor. Replace.
 SERVICING INFORMATION 11-7

Complaint Symptom and possible causes Remedy

Engine runs poorly in Defective air flow system
high speed range. 1. Clogged air cleaner element. Clean or replace.
2. Defective throttle valve. Adjust or replace.
3. Defective IAC valve. Replace.
4. Sucking air from throttle body joint. Repair or replace.
5. Imbalanced throttle valve synchronization. Adjust.
Defective control circuit or sensor
1. Low fuel pressure. Repair or replace.
2. Defective throttle position sensor. Replace.
3. Defective intake air temp. sensor. Replace.
4. Defective camshaft position sensor. Replace.
5. Defective crankshaft position sensor. Replace.
6. Defective gear position switch. Replace.
7. Defective intake air pressure sensor. Replace.
8. Defective atmospheric pressure sensor. Replace.
9. Defective ECM. Replace.
10. Throttle position sensor out of adjustment. Adjust.
11. Defective fuel tank pressure control valve. Replace.
Engine lacks power. Defective engine internal/electrical parts
1. Loss of tappet clearance. Adjust.
2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston rings or cylinders. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plug. Clean or replace.
7. Incorrect spark plug. Adjust or replace.
8. Clogged injector. Clean.
9. Throttle position sensor out of adjustment. Adjust.
10. Clogged air cleaner element. Clean.
11. Imbalanced throttle valve synchronization. Adjust.
12. Sucking air from throttle valve or vacuum hose. Retighten or replace.
13. Too much engine oil. Drain out excess oil.
14. Defective fuel pump or ECM. Replace.
15. Defective crankshaft position sensor and ignition coil. Replace.
Defective control circuit or sensor
1. Low fuel pressure. Repair or replace.
2. Defective throttle position sensor. Replace.
3. Defective intake air temp. sensor. Replace.
4. Defective camshaft position sensor. Replace.
5. Defective crankshaft position sensor. Replace.
6. Defective gear position switch. Replace.
7. Defective intake air pressure sensor. Replace.
8. Defective atmospheric pressure sensor. Replace.
9. Defective ECM. Replace.
10. Imbalanced throttle valve synchronization. Adjust.
11. Throttle position sensor out of adjustment. Adjust.
12. Defective fuel tank pressure control valve. Replace.
11-8 SERVICING INFORMATION

Complaint Symptom and possible causes Remedy

Engine overheats. Defective engine internal parts
1. Heavy carbon deposit on piston crowns. Clean.
2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Replace or clean.
4. Sucking air from intake pipes. Retighten or replace.
5. Use of incorrect engine oil. Change.
6. Defective cooling system. See radiator section.
Lean fuel/air mixture
1. Short-circuited intake air pressure sensor/lead wire. Repair or replace.
2. Short-circuited intake air temp. sensor/lead wire. Repair or replace.
3. Sucking air from intake pipe joint. Repair or replace.
4. Defective fuel injector. Replace.
5. Defective engine coolant temp. sensor. Replace.
The other factors
1. Ignition timing too advanced due to defective timing Replace.
advance system (engine coolant temp. sensor, gear
position switch, crankshaft position sensor and ECM.)
Dirty or heavy 1. Too much engine oil in the engine. Check with inspection window.
exhaust smoke. Drain excess oil.
2. Worn piston rings or cylinders. Replace.
3. Worn valve guides. Replace.
4. Scored or scuffed cylinder walls. Replace.
5. Worn valves stems. Replace.
6. Defective stem seal. Replace.
7. Worn oil ring side rails. Replace.
Slipping clutch. 1. Weakened clutch springs. Replace.
2. Worn or distorted pressure plate. Replace.
3. Distorted clutch plates. Replace.
Dragging clutch. 1. Some clutch spring weakened while others are not. Replace.
2. Distorted pressure plate or clutch plate. Replace.
 SERVICING INFORMATION 11-9

CVT
Complaint Symptom and possible causes Remedy
CVT is noisy. 1. Worn or burnt bearing. Replace.
2. Primary pulley shim maladjusted. Adjust.
3. Broken CVT motor gear. Replace.
4. Broken or damaged secondary pulley fan. Replace.
Slipping CVT belt. 1. Worn CVT belt. Replace.
2. Worn pulley face. Replace.
3. Entrance of foreign substance. Clean or adjust.
CVT will not shift. 1. Defective handle switches. Replace.
2. Defective sensors. Replace.
3. CVT motor locking. Replace.

RADIATOR (COOLING SYSTEM)

Complaint Symptom and possible causes Remedy
Engine overheats. 1. Not enough engine coolant. Add engine coolant.
2. Radiator core clogged with dirt or scale. Clean.
3. Faulty cooling fan. Repair or replace.
4. Defective cooling fan thermo-switch. Replace.
5. Clogged water passage. Clean.
6. Air trapped in the cooling circuit. Bleed air.
7. Defective water pump. Replace.
8. Use of incorrect engine coolant. Replace.
9. Defective thermostat. Replace.
Engine overcools. 1. Defective cooling fan thermo-switch. Replace.
2. Extremely cold weather. Put on radiator cover.
3. Defective thermostat. Replace.
11-10 SERVICING INFORMATION

CHASSIS
Complaint Symptom and possible causes Remedy
Heavy steering. 1. Overtightened steering stem nut. Adjust.
2. Broken bearing in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Wobbly handlebars. 1. Loss of balance between right and left front forks. Replace.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
4. Loose steering stem nut. Adjust.
5. Worn or incorrect tire or wrong tire pressure. Adjust or replace.
6. Worn bearing/race in steering stem. Replace.
Wobbly front wheel. 1. Distorted wheel rim. Replace.
2. Worn front wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose axle or axle pinch bolt. Retighten.
5. Incorrect front fork oil level. Adjust.
Front suspension too 1. Weakened springs. Replace.
soft. 2. Not enough fork oil. Replenish.
3. Wrong viscous fork oil. Replace.
Front suspension too 1. Too viscous fork oil. Replace.
stiff. 2. Too much fork oil. Drain excess oil.
3. Bent front axle. Replace.
Noisy front suspen- 1. Not enough fork oil. Replenish.
sion. 2. Loose bolts on suspension. Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Replace.
2. Worn rear wheel bearing or swingarm bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nuts or bolts on rear suspension and rear swing- Retighten.
arm.
Rear suspension too 1. Weakened spring of shock absorber. Replace.
soft. 2. Leakage of oil from shock absorber. Replace.
3. Improperly set rear spring unit adjuster. Adjust.
Rear suspension too 1. Bent shock absorber shaft. Replace.
stiff. 2. Over tightened swingarm pivot bolt. Retighten.
3. Worn swingarm and suspension bearings. Replace.
4. Improperly set rear suspension adjuster. Adjust.
Noisy rear suspen- 1. Loose nuts or bolts on rear suspension. Retighten.
sion. 2. Worn swingarm bearings. Replace.
 SERVICING INFORMATION 11-11

BRAKES
Complaint Symptom and possible causes Remedy
Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace.
power. 2. Worn pads. Replace.
3. Oil adhesion on friction surface of pads/shoe. Clean disc and pads.
4. Worn disc. Replace.
5. Air in hydraulic system. Bleed air.
6. Not enough brake fluid in the reservoir. Replenish.
Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with sandpaper.
2. Tilted pad. Correct pad fitting or replace.
3. Damaged wheel bearing. Replace.
4. Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5. Worn pads or disc. Replace.
6. Foreign material in brake fluid. Replace brake fluid.
7. Clogged return port of master cylinder. Disassemble and clean master
cylinder.
Excessive brake lever 1. Air in hydraulic system. Bleed air.
stroke. 2. Insufficient brake fluid. Replenish fluid to specified
level; bleed air.
3. Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified torque.
fluid. 2. Cracked hose. Replace.
3. Worn piston and/or cup. Replace piston and/or cup.
Brake drags. 1. Rusty part. Clean and lubricate.
2. Insufficient brake lever or brake pedal pivot lubrication. Lubricate.
3. Malfunction of brake-lock. Adjust or replace.
11-12 SERVICING INFORMATION

ELECTRICAL
Complaint Symptom and possible causes Remedy
No sparking or poor 1. Defective ignition coil/plug cap or camshaft position Replace.
sparking. sensor.
2. Defective spark plugs. Replace.
3. Defective generator. Replace.
4. Defective ECM. Replace.
5. Defective tip over sensor. Replace.
6. Open-circuited wiring connections. Check and repair.
Spark plugs soon 1. Mixture too rich. Consult FI system.
become fouled with 2. Idling speed set too high. Adjust fast idle or throttle stop
carbon. screw.
3. Incorrect gasoline. Change.
4. Dirty air cleaner element. Clean or replace.
5. Too cold spark plugs. Replace with hot type plugs.
Spark plugs become 1. Worn piston rings. Replace.
fouled too soon. 2. Worn piston or cylinders. Replace.
3. Excessive clearance of valve stems in valve guides. Replace.
4. Worn stem oil seal. Replace.
Spark plug electrodes 1. Too hot spark plugs. Replace with cold type plugs.
overheat or burn. 2. Overheated the engine. Tune up.
3. Loose spark plugs. Retighten.
4. Too lean mixture. Consult FI system.
Generator does not 1. Open- or short-circuited lead wires, or loose lead con- Repair or replace or retighten.
charge. nections.
2. Short-circuited, grounded or open generator coils. Replace.
3. Short-circuited or panctured regulator/rectifiers. Replace.
Generator does 1. Lead wires tend to get short- or open-circuited or Repair or retighten.
charge, but charging loosely connected at terminals.
rate is below the 2. Grounded or open-circuited stator coils or generator. Replace.
specification. 3. Defective regulator/rectifier. Replace.
4. Defective cell plates in the battery. Replace the battery.
Generator over- 1. Internal short-circuit in the battery. Replace the battery.
charges. 2. Damaged or defective resistor element in the regulator/ Replace.
rectifier.
3. Poorly grounded regulator/rectifier. Clean and tighten ground con-
nection.
Unstable charging. 1. Lead wire insulation frayed due to vibration, resulting in Repair or replace.
intermittent short-circuiting.
2. Internally short-circuited generator. Replace.
3. Defective regulator/rectifier. Replace.
Starter button is not 1. Run down battery. Repair or replace.
effective. 2. Defective switch contacts. Replace.
3. Brushes not seating properly on starter motor commu- Repair or replace.
tator.
4. Defective starter relay or starter interlock switch. Replace.
5. Defective main fuse. Replace.
 SERVICING INFORMATION 11-13

BATTERY
Complaint Symptom and possible causes Remedy
“Sulfation”, acidic 1. Cracked battery case. Replace the battery.
white powdery sub- 2. Battery has been left in a run-down condition for a long Replace the battery.
stance or spots on time.
surfaces of cell
plates.
Battery runs down 1. Trouble in charging system. Check the generator, regulator/
quickly. rectifier and circuit connections
and make necessary adjust-
ments to obtain specified
charging operation.
2. Cell plates have lost much of their active material as a Replace the battery, and cor-
result of overcharging. rect the charging system.
3. Internal short-circuit in the battery. Replace the battery.
4. Too low battery voltage. Recharge the battery fully.
5. Too old battery. Replace the battery.
Battery “sulfation”. 1. Incorrect charging rate. Replace the battery.
(When not in use battery should be checked at least
once a month to avoid sulfation.)
2. The battery was left unused in a cold climate for too Replace the battery if badly
long. sulfated.
11-14 SERVICING INFORMATION

WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING

Throttle cable
Clamp
CVT control unit Wiring harness
Position light (R)
Position light (L)

Headlight (L)
ECM ECM
Headlight (R)
Wiring harness
Front turn signal light (L)
Front turn signal light (R) Clamp
Clamp Wiring harness
Front turn signal light (L)
Handlebar switch (R & L) TO sensor
Clamp
Clamp
Set the front turn signal light (L) coupler
ahead the wiring harness.

Set the TO sensor as shown.

TO sensor

CVT control unit

Clamp
Clamp
CVT revolution sensor Center stand switch
Center stand switch CVT revolution sensor
HO2 sensor Pully position sensor
CVT motor
Clamp Power source fuse
HO2 sensor Brake lock
HO2 sensor switch
Brake lock
Fuse box cable

Clamp AP sensor
CVT revolution sensor
Center stand switch Pass the each relay lead wire
outside the parking brake cable.
Clamp
 SERVICING INFORMATION 11-15

- lead wire coupler

Battery
Battery
Set the lead wires
under the fuel hose.
Wiring harness

Battery + terminal Battery - terminal Fuel hose

Set the battery +

lead wire coupler
under the wiring harness.

Starter relay

Fix the starter relay lead wire coupler

to hole of the battery cover.
Set the lead wires to the
front of the battery box. Trunk light Clamp
seat switch
Brake light/taillight

Trunk light switch

Trunk light seat switch

Clamp

Pass the brake light/taillight

lead wire under the frame.

Main fuse

Pass the brake light/taillight CVT fuse

lead wire under the frame.
11-16 SERVICING INFORMATION

Engine coolant temp. sensor Clamp

Injector #2 Starter motor Wiring harness

Center stand switch
Clamp
CVT revolution sensor
Wiring harness
PP sensor
Solenoide
CVT motor
HO2 sensor

Injector #1 IAC valve

TPS sensor
Wiring harness
Clamp
Clamp
Set the regulator/
Clamp rectifier lead wire coupler
Clamp
Wiring harness Fix the clamp to the under the fuel hose.
hole of the rear frame. Wiring harness
Generator
Generator
Starter motor
Clamp Clamp Speedometer sensor
Trunk light switch
Wiring harness Wiring harness
Generator
Starter motor
Clamp
Wiring
harness

Regulator/rectifier

Oil level switch Speedometer sensor

Oil pressure switch Clamp
Clamp

Side-stand switch
Oil level switch Trunk light seat switch
Oil pressure switch
Ignition coil/ Fuel hose Clamp
To the trunk light switch
Ignition coil/ plug cap #1
plug cap #2 Clamp
Wiring harness

Clamp

Generator lead
wire coupler
 C
Battery ground wire

VIEW C

Oil pressure switch

Starter motor lead wire
Starter motor
lead wire Battery ground Oil level switch
wire lead wire
E Wirng harness
clamp
VIEW B
VIEW E VIEW D
D

Oil pressure switch 45˚

Forward
Oil level switch

Clamp
Oil level switch
SERVICING INFORMATION

VIEW A
A
Oil pressure switch
11-17
 11-18

Throttle cable
(pulling)
Throttle cable Handlebar
(returning) switch (RH)
Pass the throttle Throttle cable
cables under the (pulling)
CABLE ROUTING

harness. Front brake hose Pass the throttle cables

Throttle cable between steering upper
SERVICING INFORMATION

(returning) bracket and rear brake hose.

Rear brake hose
A
Handlebar Pass the throttle cables
switch (LH) behind the brake hoses.
Wiring harness A
Guide
Rear brake hose Throttle cable
VIEW B SECT A – A (returning)
Throttle cable
(pulling)
B
Wiring harness

Clamp
Rear brake hose

Clamp Rear brake-

lock cable

Clamp Clamp

Fix the clamp as shown.

Pass the rear brake-lock cable

between the frame and engine.
 Seat lock cable
Seat lock cable To the ignition switch

Clamp

VIEW A

Clamp Seat lock cable

Clamp

A
SERVICING INFORMATION
11-19
 11-20

AP sensor
IAT sensor AP sensor
IAT sensor
PAIR control 18 N·m
solenoid valve (1.8 kgf-m, 13.0 lb-ft)
IAC
hose
A backward. TP sensor
A downward.
B top side.
PCV (breather)
SERVICING INFORMATION

hose A top side. Vacuum hose

VIEW OF “B”
Throttle cables
PAIR hose

IAC hose
Fuel feed
B top side. hose Forward

VIEW OF “A” Vacuum hose

Pass through the PCV (breather) Air cleaner side
hose above the throttle cables.
IAC hose
10˚
Fuel feed hose

A LH IAC hose Top mark RH

Fixed with
PAIR clamp
B
THROTTLE BODY INSTALLATION/HOSE ROUTING

hose Intake pipe side

Fuel pump

Backward
Clamp VIEW OF TOP

A: The end of the clamp should face....

B: The clamp screw head should face....
 SERVICING INFORMATION 11-21

FUEL TANK MOUNTING

11-22 SERVICING INFORMATION

FUEL TANK HOSE ROUTING

TPC valve

Orange Black

Clamp

TPC valve

5 – 8 mm
5 – 8 mm

Gray Black

5 mm
 SERVICING INFORMATION 11-23

EVAP CANISTER HOSE ROUTING (Only for E-33)

 11-24

Radiator

Yellow mark

Reservoir
Bypass hose
SERVICING INFORMATION

Reservoir inlet
hose
Air vent hose
RADIATOR HOSE ROUTING

Reservoir overflow hose

Air vent hose

0 – 20˚ White mark Reservoir

inlet hose

B
Radiator inlet
hose
Yellow mark
White mark Oil cooler
inlet hose
14˚
VIEW B Oil cooler
10˚ outlet hose

Yellow mark
A
White mark Yellow mark
White mark
White mark Radiator outlet
Radiator outlet hose
hose
VIEW A
A : Face the tip of clamp to the right. D : Face the head of screw to the right.
B : Face the tip of clamp to the top. E : Face the head of screw to the back.
C : Face the tip of clamp to the bottom.
 Washer
Throttle cable

Front brake B Stopper

hose A Front brake hose After touching
21˚ 14˚ the brake hose
Front brake Brake hose
Brake hose master cylinder union to the
guide
guide VIEW A VIEW B stopper, tighten
the union bolt to
the specified
Brake hose torque.
clamp
Rear brake hose
Fix the brake
hose grommet
to its hose
FRONT BRAKE HOSE ROUTING

clamp. Rear brake pipe

After touching the clamp
to the stopper, tighten the Brake hose
clamp bolt. clamp

Stopper After touching the clamp

to the stopper, tighten the Fix the brake
clamp bolt. hose grommet to
its hose clamp.
14˚ Brake hose
14˚

Washer

Front brake caliper (R) Front brake caliper (L)

SERVICING INFORMATION
11-25
 11-26

After touching the brake

hose union to the stopper,
Rear brake master tighten the union bolt to
cylinder the specified torque. Washer

A Rear brake hose

Stopper 14˚ 21˚

VIEW B VIEW A
B
SERVICING INFORMATION

Brake hose
Clamp Rear brake hose
guide
Brake hose guide

C
Rear brake hose
REAR BRAKE HOSE ROUTING

Brake hose Rear brake pipe

Rear brake
Fix a non-cover portion of Fix the white mark pipe
14˚ brake pipe with the clamp. on the brake pipe
with the clamp.
Rear brake
D pipe

VIEW G Rear brake hose D VIEW C

28˚ E
F
E
F

Stopper Rear brake lock cable

Rear brake caliper Clamp
Clamp Clamp
After touching the brake hose
union to the stopper, tighten the Rear brake pipe
union bolt to the specified torque.
SECT DD
Rear brake hose Rear brake hose
SECT FF SECT EE
 SERVICING INFORMATION 11-27

SIDE-STAND SET-UP

40 N·m 50 N·m
4.0 kgf-m 5.0 kgf-m
29.0 lb-ft 36.0 lb-ft

Outside

CENTER STAND SET-UP

23 N·m
(2.3 kgf-m, 16.5 lb-ft)

29 N·m
2.9 kgf-m
Spring position 21.0 lb-ft

VIEW A

A
11-28 SERVICING INFORMATION

SPECIAL TOOLS

09900-18710
09900-06107 09900-06108 09900-09004 Hexagon socket 09900-20102
Snap ring pliers Snap ring pliers Impact driver set 12 mm Vernier calipers

09900-20202 09900-20204 09900-20205 09900-20602

Micrometer Micrometer Micrometer 09900-20508 Dial gauge
(25 – 50 mm) (75 – 100 mm) (0 – 25 mm) Cylinder gauge set (1/1000 mm, 1 mm)

09900-20607 09900-20803
09900-20605 Dial gauge 09900-20701 09900-20806 09900-20805
Dial gauge (1/100 mm, 10 mm) Magnetic stand Thickness gauge Tire depth gauge

09900-22301 09900-22401 09900-25008

09900-21304 09900-22302 Small bore gauge Multi circuit tester 09910-32812
V-block (100 mm) Plastigauge (10 – 18 mm) set Crankshaft installer

09913-60210 09913-60912 or
09910-32850 09913-60230 09913-60241 09913-61110 or
Crankshaft installer 09913-50121 Journal bearing Journal bearing 09913-61510
attachment Oil seal remover remover/installer holder Bearing puller
 SERVICING INFORMATION 11-29

09915-63311
09913-70210 09913-75810 09915-40610 Compression gauge 09915-74511
Bearing installer set Bearing installer Oil filter wrench attachment Compression gauge

09915-74521 09915-74532 09915-77331 09916-14510

Oil pressure gauge Oil pressure gauge Meter (for high pres- 09916-10911 Valve spring
hose adaptor sure) Valve lapper set compressor

09916-14521 09916-20630 09916-20640 09916-33210

Valve spring com- Valve seat cutter Solid pilot 09916-21111 Valve guide reamer
pressor attachment head (N-126) (N-100-4.5) Valve seat cutter set (4.5 mm)

09916-34561 09916-43210
09916-34542 Valve guide reamer Valve guide 09916-44930 09916-84511
Reamer handle (11.3 mm) remover/installer Attachment Tweezers

09918-53810 09920-13120 09920-31010

09917-23711 Chain tensioner lock Crankcase separat- CVT primary 09920-31020
Ring nut wrench tool ing tool pulley shaft holder Extension handle
11-30 SERVICING INFORMATION

09920-31040
09920-31030 CVT primary pulley 09920-33530
CVT secondary shaft adaptor 09920-31050 Clutch spring 09920-34830
pulley shaft holder remover CVT guide compressor Starter clutch holder

09924-74570
09920-53740 Final drive gear 09925-18011
Clutch sleeve hub 09921-20240 bearing installer/ 09924-84510 Steering bearing
holder Bearing remover set remover Bearing installer set installer

09930-73170
09930-11930 09930-11940 09930-30450 09930-40113 Starter torque limiter
Torx bit JT30H Bit holder Rotor remover Rotor holder holder

09930-73120 09930-82720 09940-14911 09940-30230 09940-40211

Starter torque limiter Mode selection Steering stem nut Socket hexagon Fuel pressure gauge
socket switch wrench 17 mm adapter
 SERVICING INFORMATION 11-31

09940-40220 09940-52861 09941-34513

Fuel pressure gauge Front fork oil seal 09940-92720 Steering race 09941-51010
hose attachment installer Spring scale installer Ring locknut wrench

09941-54911 09941-74911
Bearing outer race 09943-74111 Steering bearing
remover Fork oil level gauge installer

NOTE:
When ordering a special tool, please confirm whether it is available or not.
11-32 SERVICING INFORMATION

TIGHTENING TORQUE
ENGINE
ITEM N·m kgf-m lb-ft
Cylinder head cover bolt Tighten lightly. 10 1.0 7.3
Tighten firmly. 14 1.4 10.0
Cylinder head bolt (M8) 25 2.5 1.8
(M10) Tighten lightly. 25 2.5 1.8
Tighten firmly. 53 5.3 38.5
Cam chain tension adjuster bolt 10 1.0 7.3
Clutch spring set bolt 5.5 0.55 4.0
Clutch housing nut 70 7.0 50.5
Generator rotor bolt 160 16.0 115.5
Starter clutch bolt 55 5.5 40.0
Crankcase bolt (M6) 11 1.1 8.0
(M8) 26 2.6 19.0
Oil pressure switch 13 1.3 9.5
Engine oil drain plug 23 2.3 16.5
Transmission oil drain plug 21 2.1 15.0
Transmission breather plug 35 3.5 25.5
Transmission oil filler plug 23 2.3 16.5
Transmission oil level plug 21 2.1 15.0
Right crankcase cover bolt 11 1.1 8.0
Primary shaft cap bolt 11 1.1 8.0
Breather cover bolt 10 1.0 7.3
Spark plug 11 1.1 8.0
Cam shaft holder bolt 10 1.0 7.3
Cylinder head side bolt 14 1.4 10.0
Cam position sensor bolt 10 1.0 7.3
Oil level switch bolt 10 1.0 7.3
Oil cooler union bolt 70 7.0 5.0
Engine mount bolt 55 5.5 40.0
Final gear oil drain plug 33 3.3 24.0
Final gear oil level plug 33 3.3 24.0
Exhaust pipe clamp bolt 23 2.3 16.5
Muffler mounting bolt 23 2.3 16.5
Oil hose union bolt (M10) 20 2.0 14.5
Oil return hose union bolt (M14) 28 2.8 20.5
Timing cap 15 1.5 11.0
Drive shaft nut 105 10.5 76.0
Connecting rod bolt Tighten lightly. 21 2.1 15.0
Tighten firmly. 90°
Starter motor mounting bolt 6 0.6 4.5
Starter motor lead wire nut 6 0.6 4.5
 SERVICING INFORMATION 11-33

CVT
ITEM N·m kgf-m lb-ft
CVT mounting bolt 50 5.0 36.0
Primary pulley stopper bolt 36 3.6 26.0
CVT cover bolt 22 2.2 16.0
Primary pulley shaft bolt 64 6.4 46.5
Secondary pulley shaft nut 226 22.6 163.5

CHASSIS
ITEM N·m kgf-m lb-ft
Handlebar clamp bolt 23 2.3 16.5
Steering stem head nut 65 6.5 47.0
Steering stem nut 45 4.5 32.5
Front fork upper clamp bolt 23 2.3 16.5
Front fork lower clamp bolt 23 2.3 16.5
Front fork cap bolt 23 2.3 16.5
Front fork cylinder bolt 30 3.0 21.5
Front axle 65 6.5 47.0
Front axle pinch bolt 23 2.3 16.5
Brake hose union bolt 23 2.3 16.5
Brake disc bolt (Front and Rear) 23 2.3 16.5
Brake air bleeder valve (Front and Rear) 7.5 0.75 5.5
Brake caliper mounting bolt (Front and Rear) 26 2.6 19.0
Brake master cylinder mounting bolt (Front and Rear) 10 1.0 7.0
Front brake caliper holder pin 13 1.3 9.5
Front brake pad mounting pin plug 2.5 0.25 1.8
Brake pad mounting pin (Front and Rear) 18 1.8 13.0
Rear brake caliper holder sliding pin 13 1.3 9.5
23 2.3 16.5
Brake-lock housing bolt 23 2.3 16.5
Brake-lock adjuster locknut 9.5 0.95 7.0
Brake pipe nut 16 1.6 11.5
Swingarm pivot bolt 9.5 0.95 7.0
Swingarm pivot bolt locknut 100 10.0 72.5
Rear shock absorber mounting nut (Upper) 29 2.9 21.0
Rear shock absorber mounting bolt (Lower) 29 2.9 21.0
Rear axle nut 100 10.0 72.5
Seat rail mounting bolt (M8) 23 2.3 16.5
(M10) 50 5.0 36.0
Side-stand bolt 50 5.0 36.0
Side-stand nut 40 4.0 29.0
Center stand bracket bolt 23 2.3 16.5
Center stand nut 29 2.9 21.0
11-34 SERVICING INFORMATION

TIGHTENING TORQUE CHART

For other nuts and bolts not listed in the preceding page, refer to this chart:

Bolt Diameter Conventional or “4” marked bolt “7” marked bolt

A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 1.5
5 3 0.3 2.0 4.5 0.45 3.0
6 5.5 0.55 4.0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115.5 240 24.0 173.5

Conventional bolt “4” marked bolt “7” marked bolt

 SERVICING INFORMATION 11-35

SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
11-36 SERVICING INFORMATION

ITEM STANDARD LIMIT

Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2 ,
171 psi)
Compression pressure difference 200 kPa
— (2.0 kgf/cm2,
28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 75.585
(2.9724 – 2.9730) (2.9758)
Piston diam. 75.450 – 75.465 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.20 – 0.30 0.50
(0.008 – 0.012) (0.020)
2nd 0.20 – 0.30 0.50
(0.008 – 0.012) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)
 SERVICING INFORMATION 11-37

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 –16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60°C, 140°F) Above 350 kPa (3.5 kgf/cm2)
Below 550 kPa (5.5 kgf/cm 2) —
at 3 000 r/min.

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No.2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate No.1 distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer — 3.1
height (0.12)
Clutch engagement 1 500 – 2 100 r/min. —
Clutch lock-up 3 200 – 3 800 r/min. —
11-38 SERVICING INFORMATION

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec, at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 760 mmHg (100 kPa)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal Less than 1.4 V
Leaning Less than 3.7 V
Injector voltage Battery voltage
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/min. More than 0.6 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 : Idle speed
st
Approx. 3.3 V
output voltage 3 : 3 000 r/min.
rd
Approx. 1.3 V
5 : 3 000 r/min.
th
Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage
 SERVICING INFORMATION 11-39

THROTTLE BODY
ITEM SPECIFICATION
ID No. 10GO
Bore size 32 mm
Fast idle r/min. 1 300 – 1600 r/min.
Idle r/min. 1 200 ± 100 r/min.
Synchronizing screw opening 1! turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper-
Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100°C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C —
ing temperature OFF 87 – 97 °C —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse tank
Approx. 250 ml —
side
Engine side Approx. 1 050 ml —

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 mm (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
11-40 SERVICING INFORMATION

ITEM STD/SPEC. NOTE

Generator no-load voltage
More than 50 V at 5 000 r/min.
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min.
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3–6Ω
Battery Type
FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuze size Head- HI 15 A
light LO 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 10 A
Main 40 A
CVT 40 A

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
Trunk light 5 ←
 SERVICING INFORMATION 11-41

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT4 —
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 105 —
(4.1)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10)
—
or an equivalent fork oil
Front fork oil capacity (each leg) 482 ml (16.29/16.97 US/Imp oz) —
Front fork oil level 129 —
(5.09)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring
2nd —
adjuster
11-42 SERVICING INFORMATION

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane ( R +2 M ) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10 % ethanol, or less than 5 %
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L
reserve (4.0/3.3 US/lmp gal)
Fuel meter
Approx. 3.0 L
mark
(0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L
LCD (0.40/0.33 US/lmp gal)
flickering
Engine oil and transmission oil type SAE 10W-40, API, SF or SG
Engine oil capacity Oil change 2.6 L (2.7/2.3 US/lmp qt)
Filter change 2.9 L (3.1/2.6 US/lmp qt)
Overhaul 3.4 L (3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml (12.2/12.7 US/lmp oz)
Overhaul 400 ml (13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml (10.1/10.6 US/lmp oz)
Overhaul 430 ml (14.5/15.1 US/lmp oz)
 EMISSION CONTROL INFORMATION 12-1

EMISSION CONTROL INFORMATION

CONTENTS
EMISSION CONTROL SYSTEMS ....................................................12- 2
FUEL INJECTION SYSTEM ......................................................12- 2
CRANKCASE EMISSION CONTROL SYSTEM ........................12- 3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ..12- 4
NOISE EMISSION CONTROL SYSTEM ...................................12- 5
EVAPORATIVE EMISSION CONTROL SYSTEM (For E-33) ...12- 5
PAIR (AIR SUPPLY) SYSTEM INSPECTION ..................................12- 6
HOSE .........................................................................................12- 6
PAIR REED VALVE ...................................................................12- 6
PAIR CONTROL SOLENOID VALVE ........................................12- 6
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................12- 8
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33) ..................................................................................12- 9
HOSES .......................................................................................12- 9
EVAP CANISTER .......................................................................12- 9
EVAP CANISTER HOSE ROUTING (Only for E-33)........................12-10
12
12-2 EMISSION CONTROL INFORMATION

EMISSION CONTROL SYSTEMS

FUEL INJECTION SYSTEM
AN650 motorcycles are equipped with a fuel injection system for emission level control.
This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable
emission limits.

BEFORE-PRESSURIZED
Fuel pressure

PRESSURIZED FUEL
regulator

RELIEVED FUEL
Fuel mesh filter (For low pressure)

FUEL
Fuel delivery pipe

Throttle body
Fuel feed hose
Fuel pump
(For high pressure)

Fuel injector
Fuel filter
 EMISSION CONTROL INFORMATION 12-3

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank-
case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle
body.

FUEL/AIR MIXTURE

BLOW-BY GAS
FRESH AIR
PCV hose
PAIR hose
12-4 EMISSION CONTROL INFORMATION

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)

The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys-
tem (Except for USA). The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR
reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to
the TPS, ECTS, IATS, IAPS and CKPS.

Three-way catalyst
(Except for USA)
ECM

(Except for USA)

HO2 sensor
solenoid valve

FUEL/AIR MIXTURE
FRESH AIR
EXHAUST GAS
PAIR control

PAIR reed
valve
 EMISSION CONTROL INFORMATION 12-5

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following
acts or the causing thereof:
1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2. The use of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any
other component which conducts exhaust gases.
• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which
conducts intake air.
• Replacing the exhaust system or muffler with a system or muffler not marked with the same model spe-
cific code as the code listed on the Motorcycle Noise Emission Control Information label.

EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)

Throttle body

IAP sensor

TPC valve

Fuel shut-off valve

Fuel feed hose

Fuel pump EVAP canister

Purge hose FRESH AIR

HC VAPOR

VACUUM

FUEL
Surge hose TPC valve
12-6 EMISSION CONTROL INFORMATION

PAIR (AIR SUPPLY) SYSTEM INSPECTION

HOSE
• Remove the front box. (!9-18)
• Inspect the hose for wear or damage.
• Inspect that the hose is securely connected.

PAIR REED VALVE

• Remove the air chamber. (!7-16)
• Remove the PAIR reed valve cover.

• Inspect the reed valve for the carbon deposit.

• If the carbon deposit is found in the reed valve, replace the
PAIR reed valve with a new one.
• Installation is in the reverse order of removal.

PAIR CONTROL SOLENOID VALVE

• Disconnect the PAIR control solenoid valve lead wire coupler.
• Disconnect the PAIR hose.
• Remove the PAIR control solenoid valve.

• Check that air flows through the air inlet port to the air outlet
port.
• If air does not flow out, replace the PAIR control solenoid
valve with a new one.
 EMISSION CONTROL INFORMATION 12-7

• Connect the 12 V battery to the PAIR control solenoid valve

terminals and check the air flow.
• If air does not flow out, the solenoid valve is in normal condi-
Battery
tion.

• Check the resistance between the terminals of the PAIR con-

trol solenoid valve.
" Resistance: 20 – 24 Ω (at 20 °C/68 °F)
# 09900-25008: Multi circuit tester set
Ω
$ Tester knob indication: Resistance (Ω
Ω)
If the resistance is not within the standard range, replace the
PAIR control solenoid valve with a new one.

• Installation is in the reverse order of removal.

• Connect the PAIR control solenoid valve lead wire coupler
securely.
12-8 EMISSION CONTROL INFORMATION

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING

10 N.m (1.0 kgf-m, 7.3 lb-ft)

PAIR control
solenoid valve

3 – 5 mm (0.1 – 0.2 in)

PAIR
reed valve

PAIR control
solenoid valve
 EMISSION CONTROL INFORMATION 12-9

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION

(Only for E-33)
• Remove the following parts. (! 9-6)
* Seat
* Battery cover
* Center frame cover
* Frame cover
* Pillion rider handles
* Lower frame cover
* Helmet box cover
* Helmet box

HOSES
• Inspect the hoses for wear or damage.
• Make sure that the hoses are securely connected.

EVAP CANISTER
• Inspect the canister for damage to the body.

• Install the evaporative emission control device in the reverse order of removal.
12-10 EMISSION CONTROL INFORMATION

EVAP CANISTER HOSE ROUTING (Only for E-33)

TPC valve

Orange
Black

To throttle body

EVAP canister Clamp

A
TPC valve
Purge hose

Surge hose

Purge hose

Surge hose

Cap

VIEW A
 AN650K4 (’04-MODEL) 13-1

AN650K4 (’04-MODEL)
13
This chapter describes service data, service specifications and servicing procedures which dif-
fer from those of the AN650K3 (’03-MODEL).

NOTE:
Please refer to the chapter 1 through 12 for details which are not given in this chapter.

CONTENTS
SPECIFICATIONS .........................................................................................13- 2
SERVICE DATA ............................................................................................13- 4
PERIODIC MAINTENANCE CHART .............................................................13-13
CAMCHAIN SPROCKET/STARTER CLUTCH INSTALLATION ..................13-14
THROTTLE CABLE/BRAKE-LOCK CABLE ROUTING ...............................13-15
SEAT LOCK CABLE ROUTING ...................................................................13-16
LEFT LEG SIDE COVER/UNDER COVER INSTALLATION ........................13-18
PILLION SEAT BACKREST INSTALLATION ..............................................13-19
13-2 AN650K4 (’04-MODEL)

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 260 mm (89.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ......................................................................................* 1 435 mm (56.5 in)
Wheelbase .......................................................................................... 1 595 mm (62.8 in)
Ground clearance................................................................................* 130 mm ( 5.1 in)
Seat height .......................................................................................... 750 mm (29.5 in)
Dry mass............................................................................................. 238 kg (524 lbs)
ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 2
Bore .................................................................................................... 75.5 mm (2.972 in)
Stroke.................................................................................................. 71.3 mm (2.807 in)
Displacement ...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio ............................................................................... 11.2 : 1
Carburetion ......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate, automatic, centrifugal type
Primary reduction ratio........................................................................ 1.333 (88/66)
Gearshift pattern ................................................................................. Automatic & Manual shift
Automatic transmission ratio ............................................................... Variable change (1.8 – 0.465)
Final reduction ratio............................................................................. 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system ....................................................................................... Gear drive
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front fork stroke ..................................................................................* 110 mm (4.3 in)
Rear wheel travel ................................................................................ 100 mm (3.9 in)
Caster .................................................................................................* 26° 10’
Trail......................................................................................................* 106 mm (4.17 in)
Steering angle ..................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ....................................................................................... 160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery.................................................................................................12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................. 40 A
Fuse ....................................................................................................
15/15/15/15/10/10/10 A .......................... E-02, 19
15/15/15/15/15/10/10 A ....... .................. E-03, 24, 28, 33
Headlight ............................................................................................. 12 V 60 + 55/55 + 55 (H4 + H7) ............. E-02, 19
12 V 60/55 × (H4 × 2) .......... .................. E-03, 24, 28, 33
Position/parking light ........................................................................... 12 V 5 W × 2........................................... E-02, 19
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
Lisense plate light ............................................................................... 12 V 5 W
Trunk light............................................................................................ 12 V 5 W
Turn signal light ................................................................................... 12 V 21 W × 4
Instrument panel light.......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ...................................................... 12 V 1.4 W
Fuel injection warning light.................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake-lock warning light ...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light .................................................................... 12 V 1.4 W × 2
Power mode indicator light .................................................................. 12 V 1.4 W
Drive indicator light.............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
 AN650K4 (’04-MODEL) 13-3

CAPACITIES
Fuel tank, including reserve .............................................................. 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ........................................................................ 2 600 ml (2.7/2.3 US/Imp qt)
with filter change.............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change .............................................................. 360 ml (12.2/12.7US/Imp oz)
overhaul ................................................................. 400 ml (13.5/14.1US/Imp oz)
Final gear oil, oil change .................................................................... 300 ml (10.1/10.6US/Imp oz)
overhaul....................................................................... 430 ml (14.5/15.1US/Imp oz)
Coolant ............................................................................................... 1.3 L (1.4/1.1 US/Imp qt)
13-4 AN650K4 (’04-MODEL)

SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)
 AN650K4 (’04-MODEL) 13-5

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 24.000 —
(0.9433 – 0.9449)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2,
171 psi)
Compression pressure difference 200 kPa
— (2.0 kgf/cm2,
28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 75.585
(2.9724 – 2.9730) (2.9758)
Piston diam. 75.450 – 75.465 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.20 – 0.30 0.50
(0.008 – 0.012) (0.020)
2nd 0.20 – 0.30 0.50
(0.008 – 0.012) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
13-6 AN650K4 (’04-MODEL)

ITEM STANDARD LIMIT

Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 –16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60°C, 140°F) Above 350 kPa (3.5 kgf/cm 2)
Below 550 kPa (5.5 kgf/cm 2) —
at 3 000 r/min
 AN650K4 (’04-MODEL) 13-7

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer — 3.1
height (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec, at 300 kPa (3.0 kgf/cm2 , 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure
13-8 AN650K4 (’04-MODEL)

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 760 mmHg (100 kPa)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal Less than 1.4 V
Leaning Less than 3.7 V
Injector voltage Battery voltage
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/min More than 0.6 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 : Idle speed
st
Approx. 3.3 V
output voltage 3rd : 3 000 r/min Approx. 1.3 V
5th: 3 000 r/min Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5V at idle speed +: Y, -: W
sensor peak voltage
 AN650K4 (’04-MODEL) 13-9

THROTTLE BODY
ITEM SPECIFICATION
ID No. 10GO
Bore size 32 mm
Fast idle r/min 1 300 – 1600 r/min
Idle r/min 1 200 ± 100 r/min
Synchronizing screw opening 1 and 1/2 turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper-
Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100°C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C —
ing temperature OFF 87 – 97 °C —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse tank
Approx. 250 ml —
side
Engine side Approx. 1 050 ml —

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 mm (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
13-10 AN650K4 (’04-MODEL)

ITEM STD/SPEC. NOTE

Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type
FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size 15 A.......... E-03, 24, 28, 33
Head- LO
10A........... E-02, 19
light
HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
Trunk light 5 ←
 AN650K4 (’04-MODEL) 13-11

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke * 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) * 458 ml —
Front fork oil level * 151 —
(5.9)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster
13-12 AN650K4 (’04-MODEL)

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L
reserve (4.0/3.3 US/lmp gal)
Fuel meter Approx. 3.0 L
mark (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L
LCD (0.40/0.33 US/lmp gal)
flickering
Engine oil and transmission oil type SAE 10W-40, API, SF or SG
Engine oil capacity Oil change 2.6 L (2.7/2.3 US/lmp qt)
Filter change 2.9 L (3.1/2.6 US/lmp qt)
Overhaul 3.4 L (3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml (12.2/12.7 US/lmp oz)
Overhaul 400 ml (13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml (10.1/10.6 US/lmp oz)
Overhaul 430 ml (14.5/15.1 US/lmp oz)
 AN650K4 (’04-MODEL) 13-13

PERIODIC MAINTENANCE CHART

Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 2 12 24 36 48
Air cleaner — I I R I
Exhaust pipe bolts and muffler bolts T — T — T
Tappet clearance — — — — I
Spark plugs — I R I R
— I I I I
Fuel hose
Replace every 4 years.
Engine oil R R R R R
Engine oil filter R — — R —
Transmission oil R I R I R
Final gear oil R — R — R
CVT filter — — I — I
Idle speed I I I I I
Throttle cable play I I I I I
I
Throttle valve synchronization — I — I
(E-33 only)
Evaporative emission control system — — I — I
E-33 (California) model only Replace vapor hose every 4 years.
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Brakes I I I I I
— I I I I
Brake hoses
Replace every 4 years.
— I I I I
Brake fluid
Replace every 2 years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
I = Inspect and adjust, clean, lubricate or replace lubricate as necessary
R = Replace
T = Tighten
13-14 AN650K4 (’04-MODEL)

CAMCHAIN SPROCKET/STARTER CLUTCH INSTALLATION

NOTE: Crankshaft
Each wide spline tooth in line.

Cam chain sprocket

Starter clutch
 AN650K4 (’04-MODEL) 13-15

THROTTLE CABLE/BRAKE-LOCK CABLE ROUTING

Handlebar
switch (RH)

Throttle cable (Pulling)

Front brake
hose Throttle cable (Returning)

Rear brake
hose
Handlebar
switch (LH)
Throttle cable
Throttle cable
(Returning)
Cable guide (Pulling)

Brake hose Throttle cable

(Returning)

Throttle cable
(Pulling)

Wiring harness
Wiring harness

Cover Brake-lock knob

0 mm
Rear brake hose
Clamp

Clamp
Clamp

Clamp
Pass the rear brake-lock cable
between the frame and engine. Clamp
13-16 AN650K4 (’04-MODEL)

SEAT LOCK CABLE ROUTING

Clamp

Clamp
Clamp

Clamp
 Only for E-33

Clamp

Purge hose
Clamp Clamp

Clamp

TPC valve

Surge hose
AN650K4 (’04-MODEL)
13-17
13-18 AN650K4 (’04-MODEL)

LEFT LEG SIDE COVER/UNDER COVER INSTALLATION

Left leg side cover

Forward

Forward
Under cover
 13-19
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4-MO D
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A N 650

I NS TA L LATION
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PILLION S

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Seat

cs)
n (2 p
Cusio

pcs)
Nut (4

Screw)
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(4 pc

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(3 pc

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Clip (

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White Page
 AN650/AK5 (’05-MODEL) 14-1

AN650/AK5 (’05-MODEL)

This chapter describes service data, service specifications, ABS and servicing procedures 14
which differ from those of the AN650K3 (’03-model) and AN650AK4 (’04-model).

NOTE:
Any differences between the AN650K3 (’03-model) and AN650K5 (’05-model),
AN650AK4 (’04-model) and AN650AK5 (’05-model) in specifications and service data
are indicated with an asterisk mark (*).
Please refer to the chapters 1 through 13 for details which are not given in this chapter.

CONTENTS
SPECIFICATION (AN650K5) ........................................................................ 14- 3
SPECIFICATION (AN650AK5)...................................................................... 14- 4
SERVICE DATA (AN650K5) ......................................................................... 14- 5
SERVICE DATA (AN650AK5)....................................................................... 14-14
IMMOBILIZER (E-02, 19, 000) ...................................................................... 14-23
OPERATION......................................................................................... 14-23
COMBINATION METER................................................................................ 14-25
TERMINAL ALIGNMENT ..................................................................... 14-25
POWER WIND SCREEN (AN650AK5 E-02, 19, 000)................................... 14-26
INSPECTION ........................................................................................ 14-26
REMOVAL ............................................................................................ 14-26
INSTALLATION.................................................................................... 14-27
AMBIENT AIR TEMPERATURE SENSOR ................................................... 14-28
INSPECTION ........................................................................................ 14-28
FI SYSTEM WIRING DIAGRAM.................................................................... 14-29
E-02, 19, 000 ........................................................................................ 14-29
E-03, 28, 33 .......................................................................................... 14-30
ECM COUPLERS .......................................................................................... 14-31
K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS ................ 14-31
K5 MODEL ECM COUPLERS ............................................................. 14-31
MALFUNCTION CODE ........................................................................ 14-33
ABS TROUBLESHOOTING (AN650AK5) .................................................... 14-34
MALFUNCTION CODE TROUBLESHOOTING................................... 14-34
WIND SCREEN CABLE ROUTING............................................................... 14-40
RADIATOR HOSE ROUTING ....................................................................... 14-41
EXTERIOR PARTS CONSTRUCTION.......................................................... 14-42
CVT CONSTRUCTION .................................................................................. 14-45
AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION ..... 14-46
SPECIAL TOOLS .......................................................................................... 14-47
TIGHTENING TORQUE CHART ................................................................... 14-47
14-2 AN650/AK5 (’05-MODEL)

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

E-03 U.S.A.
E-28 Canada JS1CP51A52 100001 –
E-33 California (U.S.A.)
AN650K5 E-02 U.K. JS1BU111200100468 –
E-19 E.U. JS1BU111100113619 –
E-24 Australia JS1BU121300100200 –
000 JAPAN !""!""!""!""!
E-02 U.K. JS1BU132200100080 –
AN650AK5 E-19 E.U. JS1BU132100105119 –
000 JAPAN !""!""!""!""!
 AN650/AK5 (’05-MODEL) 14-3

SPECIFICATION (AN650K5)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 260 mm (89.0 in)
Overall width....................................................................................... 810 mm (31.9 in)
Overall height ..................................................................................... 1 435 mm (56.5 in)
Wheelbase ......................................................................................... 1 595 mm (62.8 in)
Ground clearance ............................................................................... 130 mm (5.1 in)
Seat height ......................................................................................... 750 mm (29.5 in)
Dry mass ............................................................................................ * 235 kg (518 lbs)

ENGINE
Type .................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ........................................................................... 2
Bore.................................................................................................... 75.5 mm (2.972 in)
Stroke ................................................................................................. 71.3 mm (2.807 in)
Displacement...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio .............................................................................. 11.2 : 1
Carburetion......................................................................................... Fuel injection
Air cleaner .......................................................................................... Non-woven fabric element
Starter system .................................................................................... Electric
Lubrication system ............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min

DRIVE TRAIN
Clutch ................................................................................................. Wet multi-plate, automatic, centrifugal type
Primary reduction ratio ....................................................................... 1.333 (88/66)
Gearshift pattern................................................................................. Automatic & Manual shift
Automatic transmission ratio .............................................................. Variable change (1.800 – 0.465)
Final reduction ratio ............................................................................ 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system....................................................................................... Gear drive

CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................ Swingarm type, coil spring, oil damped
Front fork stroke.................................................................................. 110 mm (4.3 in)
Rear wheel travel................................................................................ 100 mm (3.9 in)
Caster................................................................................................. 26° 10’
Trail ..................................................................................................... 106 mm (4.17 in)
Steering angle .................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake ......................................................................................... Disc brake, twin
Rear brake.......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ...................................................................................... 160/60R14M/C 65H, tubeless

ELECTRICAL
Ignition type ........................................................................................ Electronic ignition (Transistorized)
Ignition timing ..................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug .......................................................................................... NGK CR8E or DENSO U24ESR-N
Battery ................................................................................................12 V 43.2 kC (12 Ah)/10 HR
Generator ........................................................................................... Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................ 40 A
Fuse ...................................................................................................15/15/15/15/10/10/10 A ................................. E-02, 19
15/15/15/15/15/10/10 A ................................. E-03, 24, 28, 33
Headlight ............................................................................................ 12 V 60 + 55/55 + 55 (H4 + H7)..................... E-02, 19
12 V 60/55 W × 2 (H4 × 2) ............................. E-03, 24, 28, 33
Position/parking light .......................................................................... 12 V 5 W ........................................................ E-02, 19
Brake light/Taillight.............................................................................. 12 V 21/5 W × 2
License plate light............................................................................... 12 V 5 W
Trunk light ........................................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Instrument panel light ......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ..................................................... 12 V 1.4 W
Fuel injection warning light ................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake-lock warning light ..................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light.................................................................... 12 V 1.4 W × 2
Power mode indicator light ................................................................. 12 V 1.4 W
Drive indicator light ............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
Immobilizer indicator light ................................................................... * LED ................................................................ E-02, 19
Over drive indicator light..................................................................... * 12 V 1.4 W ..................................................... E-02, 19

CAPACITIES
Fuel tank, including reserve .............................................................. 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ........................................................................ 2 600 ml (2.7/2.3 US/Imp qt)
with filter change ............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change .............................................................. 360 ml (12.2/12.7 US/Imp oz)
overhaul ................................................................. 400 ml (13.5/14.1 US/Imp oz)
Final gear oil, oil change .................................................................... 300 ml (10.1/10.6 US/Imp oz)
overhaul....................................................................... 430 ml (14.5/15.1 US/Imp oz)
Coolant ............................................................................................... 1.6 L (1.7/1.4 US/Imp qt)
14-4 AN650/AK5 (’05-MODEL)

SPECIFICATION (AN650AK5)
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 260 mm (89.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ...................................................................................... 1 435 mm (56.5 in)
Wheelbase .......................................................................................... 1 595 mm (62.8 in)
Ground clearance................................................................................ 130 mm (5.1 in)
Seat height .......................................................................................... 750 mm (29.5 in)
Dry mass.............................................................................................* 243 kg (535 lbs)

ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 2
Bore .................................................................................................... 75.5 mm (2.972 in)
Stroke.................................................................................................. 71.3 mm (2.807 in)
Displacement ...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio ............................................................................... 11.2 : 1
Carburetion ......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min

DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate, automatic, centrifugal type
Primary reduction ratio........................................................................ 1.333 (88/66)
Gearshift pattern ................................................................................. Automatic & Manual shift
Automatic transmission ratio ............................................................... Variable change (1.800 – 0.465)
Final reduction ratio............................................................................. 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system ....................................................................................... Gear drive

CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front fork stroke .................................................................................. 110 mm (4.3 in)
Rear wheel travel ................................................................................ 100 mm (3.9 in)
Caster ................................................................................................. 26° 10’
Trail...................................................................................................... 106 mm (4.17 in)
Steering angle ..................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ....................................................................................... 160/60R14M/C 65H, tubeless

ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................. 40 A
Fuse .................................................................................................... 15/15/15/15/15/10/10/15/15 A
Headlight ............................................................................................. 12 V 60 + 55/55 + 55 (H4 + H7)
Position/parking light ........................................................................... 12 V 5 W × 2
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
License plate light ............................................................................... 12 V 5 W
Trunk light............................................................................................ 12 V 5 W
Turn signal light ................................................................................... 12 V 21 W
Instrument panel light.......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ...................................................... 12 V 1.4 W
Fuel injection warning light.................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake-lock warning light ...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light .................................................................... 12 V 1.4 W × 2
Power mode indicator light .................................................................. 12 V 1.4 W
Drive indicator light.............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
ABS warning light................................................................................ 12 V 1.4 W
Immobilizer indicator light....................................................................* LED
Over drive indicator light .....................................................................* 12 V 1.4 W

CAPACITIES
Fuel tank, including reserve ................................................................ 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change......................................................................... 2 600 ml (2.7/2.3 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ............................................................... 360 ml (12.2/12.7 US/Imp oz)
overhaul .................................................................. 400 ml (13.5/14.1 US/Imp oz)
Final gear oil, oil change..................................................................... 300 ml (10.1/10.6 US/Imp oz)
overhaul ....................................................................... 430 ml (14.5/15.1 US/Imp oz)
Coolant................................................................................................ 1.6 L (1.7/1.4 US/Imp qt)
 AN650/AK5 (’05-MODEL) 14-5

SERVICE DATA (AN650K5)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)
14-6 AN650/AK5 (’05-MODEL)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. * 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st * 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd * 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
 AN650/AK5 (’05-MODEL) 14-7

ITEM STANDARD LIMIT

Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2 , 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min
14-8 AN650/AK5 (’05-MODEL)

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: B, -: B/Br
Leaning 3.7 – 4.4 V +: B, -: B/Br
Injector voltage Battery voltage
 AN650/AK5 (’05-MODEL) 14-9

ITEM SPECIFICATION NOTE

Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/min More than 0.6 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1st: Idle speed Approx. 3.3 V
output voltage 3rd : 3 000 r/min Approx. 1.3 V
5 : 3 000 r/min
th
Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. 10G0
Bore size 32 mm (1.26 in)
Fast idle r/min 1 300 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
Synchronizing screw opening 1 and 1/2 turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
14-10 AN650/AK5 (’05-MODEL)

ITEM STANDARD/SPECIFICATION LIMIT

Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine side Approx. 1 350 ml —
(1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size 15 A .......... E-03, 24, 28, 33
Head- LO 10 A .......... E-02, 19
light
HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source
 AN650/AK5 (’05-MODEL) 14-11

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
Trunk light 5 ←
* Immobilizer indicator light LED
* Over drive indicator light 1.4 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
14-12 AN650/AK5 (’05-MODEL)

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41 —
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
 AN650/AK5 (’05-MODEL) 14-13

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SJ/SH with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
14-14 AN650/AK5 (’05-MODEL)

SERVICE DATA (AN650AK5)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)
 AN650/AK5 (’05-MODEL) 14-15

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. * 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st * 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd * 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
14-16 AN650/AK5 (’05-MODEL)

ITEM STANDARD LIMIT

Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min
 AN650/AK5 (’05-MODEL) 14-17

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2 , 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: B, -: B/Br
Leaning 3.7 – 4.4 V +: B, -: B/Br
Injector voltage Battery voltage
14-18 AN650/AK5 (’05-MODEL)

ITEM SPECIFICATION NOTE

Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/min More than 0.6 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 : Idle speed
st
Approx. 3.3 V
output voltage 3 : 3 000 r/min
rd
Approx. 1.3 V
5 th
: 3 000 r/min Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. 10G0
Bore size 32 mm (1.26 in)
Fast idle r/min 1 300 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
Synchronizing screw opening 1 and 1/2 turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C Approx. 2.45 kΩ —
resistance (68 °F)
50 °C Approx. 0.811 kΩ —
(122 °F)
80 °C Approx. 0.318 kΩ —
(176 °F)
110 °C Approx. 0.142 kΩ —
(230 °F)
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
 AN650/AK5 (’05-MODEL) 14-19

ITEM STANDARD/SPECIFICATION LIMIT

Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine Approx. 1 350 ml —
side (1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size Head- LO 10 A 000: 15 A
light HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source
ABS 15 A × 2
14-20 AN650/AK5 (’05-MODEL)

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
ABS warning indicator light 1.4
Trunk light 5 ←
* Immobilizer indicator light LED
* Over drive indicator light 1.4 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
 AN650/AK5 (’05-MODEL) 14-21

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41 —
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
14-22 AN650/AK5 (’05-MODEL)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type * SAE 10W-40, API, SF/SG or SH/SJ with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
 AN650/AK5 (’05-MODEL) 14-23

IMMOBILIZER (E-02, 19, 000)

• The immobilizer, an anti-theft system, is installed as a Immobi-antenna
standard equipment.
• The immobilizer verifies that the key ID agrees with ECM ID
by means of radio communication through the immobilizer
antenna. When the ID agreement is verified, the system
makes the engine ready to start.
• This system is same as the AN250/400K5.

Immobilizer Indicator light

Transponder antenna

ID ECM

OPERATION
When the ignition switch is turned ON with the engine stop switch in ON and the side stand in up position,
the immobi-antenna and ECM are powered ON.
The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison
between the key ID and ECM ID.
With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make com-
parison with its own ID, and if it matches, the engine is made ready to start.

Transponder
Immobi-antenna

Ignition switch

ECM
14-24 AN650/AK5 (’05-MODEL)

Also, when the ignition switch is turned ON, the indicator light
Flashing Lighting
flashes as many as the number of IDs registered in ECM.
Thereafter, if the IDs are in agreement, the indicator light turns 2 registered Normal
on for two seconds to notify of completion in successful 3 registered Normal
communication. 4 registered Normal
If the indicator light flashes fast, it notifies of communication Abnormal
error or disagreement of ID. Fast flashing
Approx. 1.6 sec. Approx. 2.0 sec.

NOTE:
If the indicator light flashes fast, turn the ignition switch OFF
then ON to make judgment again as there is possible misjudg-
ment due to environmental radio interference.
!
When the battery performance is lowered in winter
(low temperature), the system may make a re-
judgment at the time of beginning of the starter motor
operation. In this case, the indicator light operation
starts immediately after the starter motor operation.
 AN650/AK5 (’05-MODEL) 14-25

COMBINATION METER

1 AN650A only
2 E-02, 19, 000 only

TERMINAL ALIGNMENT
1 Oil pressure switch (G/Y) A Turn signal L (B)
2 — B Turn signal R (Lg)
3 Speed sensor (O/R) C Illumination + (O/G)
4 Ignition (O/G) D ABS (Br) [AN650A]
5 Battery (R/Bl) E Brake lock switch (V)
6 Speed sensor signal (W) F High beam (Y)
7 Tachometer signal (Br/W) G Immobilizer (E-02, 19, 000)
8 Oil level switch (Bl) H Ambient air temperature sensor (Bl)
9 FI (P/W) I Fuel pump (R/B)
0 Signal ground (B/W) J Power ground (B/W)
14-26 AN650/AK5 (’05-MODEL)

POWER WIND SCREEN (AN650AK5 E-02, 19, 000)

INSPECTION
• Remove the lower leg shield. ("9-10)
• Disconnect the wind screen regulator coupler 1.

• Apply 12 V voltage to the terminals of the regulator coupler

and check that the wind screen moves in the correct direction.
G R
Terminal – Terminal Window screen
R+–-G UP
G+–-R DOWN
• Repeat above inspection several times and replace the
window screen regulator assembly if necessary.

REMOVAL
• Remove the wind screen. ("14-42)
• Remove the leg shield. ("9-10)
• Remove the meter front lower panel 1.
NOTE:
Remove the bolts/screws behind the regulator by moving the
regulator up or down.

• Remove the meter front upper panel 2.

 AN650/AK5 (’05-MODEL) 14-27

• Remove the regulator mounting bolts.

• Disconnect the couplers.

• Disconnect the regulator coupler 4.

• Remove the regulator motor mounting bolt and nuts.
• Remove the wind screen regulator assembly.

INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following point:
• Rout the cables properly. ("14-40)
• Apply grease to the wires, pulleys and guide rails.
14-28 AN650/AK5 (’05-MODEL)

AMBIENT AIR TEMPERATURE SENSOR

INSPECTION
• Turn the ignition switch to OFF.
• Remove the AAT (Ambient Air Temperature) sensor by
pushing off the clamp.

• Check the AAT sensor coupler for loose or poor contacts.

If OK, measure the AAT sensor resistance.
# AAT sensor resistance:
Approx. 2.12 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
$ 09900-25008: Multi-circuit tester set
% Tester knob indication: Resistance (Ω) AAT sensor
Intake Air Temp Resistance
20 °C (68 °F) Approx. 2.1 kΩ
25 °C (77 °F) Approx. 1.7 kΩ
30 °C (86 °F) Approx. 1.4 kΩ
40 °C (104 °F) Approx. 0.9 kΩ
NOTE:
AAT sensor resistance measurement method is the same way
as that of the ECT sensor. Refer to 8-13 for details.
• If neccesary, replace the AAT sensor with a new one.
 Combination meter

Fuel pump (PU)

Camshaft position sensor (CMPS)
R/B
BATT
W (+B1)
+N Gr/W
#1
E-02, 19, 000

-N
W/G Fuel injector (FI)
#2 Gr/B

Crankshaft position sensor

(CKPS)
B/Y +G
FP Y/Bl 10 A
-G
Br
FRL Gr/Y Fan motor relay
40 A
VB R/B
Throttle position sensor (TPS)
+B O/W
P/B VTA
SOL G/Bl Solenoid valve
E2
B Y/W O2 heater Engine stop sw. 10 A Main sw. 30 A
OXH (Ignition coil)
Y/W
Intake air pressure sensor (IAPS) Br/B PTC heater
R VCC PTC
PM Ignition coil 15 A Brake sw. Starter sw.
Lg/B B (IG coil)
GND Battery
FI SYSTEM WIRING DIAGRAM

#2 #1 Brake lamp
Atomospheric pressure sensor (APS)
IG1 W/Bl
G/Y IG2 B/Y
PA
VM Y/R

SPD P
Engine coolant temp. sensor (ECTS)
Speed sensor
B/Bl THW

STA Y/G
Intake air temp. sensor (IATS) SS G
Starter relay
Side
Dg
THA Mode select stand
MS B/Br
relay
TS W/R Test select
Tip over sensor (TOS) B/Br EXS sw.
EXS Starter motor
E1 B/W Side
Br/R stand
DON B/G sw.
OX
B/O
RXCK
Y/Bl Immobilizer
TXCK

Shift up sw. Y MO+ R/W

UP
Shift down sw. Pulley
G/W DOWN CVT motor position Heated oxygen sensor
Power sw. R/W MO- B/R sensor (HO2S)
POWER
Center stand sw. Lg/Y Bl
MODE PPS
Mode sw. Lg
CSTD G/R
SPR+ Secondary
Brake sw. W/B pulley
BRK G/B
SPR- sensor
SDL Gr/R
AN650/AK5 (’05-MODEL)

R CVT unit
B/Br
14-29
 Combination meter

Fuel pump (PU)

Camshaft position sensor (CMPS)
R/B
E-03, 28, 33

BATT
W (+B1)
+N Gr/W
-N #1
W/G Fuel injector (FI)
#2 Gr/B

Crankshaft position sensor

14-30 AN650/AK5 (’05-MODEL)

(CKPS)
B/Y
+G Y/Bl
-G FP 10 A
Br Fan motor relay
FRL Gr/Y
40 A
R/B
VB
B/Lg
Throttle position sensor (TPS) AT
+B O/W 100 Ω
P/B VTA Solenoid valve
G/Bl
SOL
E2 Engine stop sw. 10 A Main sw. 30 A
B
(Ignition coil)

Intake air pressure sensor (IAPS) Br/B PTC heater

R PTC
VCC
Ignition coil 15 A Brake sw. Starter sw.
PM
Lg/B (IG coil)
GND Battery
#2 #1 Brake lamp
Atomospheric pressure sensor (APS)
IG1 W/Bl
G/Y IG2 B/Y
PA Y/R
VM

SPD
Engine coolant temp. sensor (ECTS) Speed sensor
B/Bl
THW
Y/G
STA
G Starter relay
Intake air temp. sensor (IATS) SS Side
Dg stand
THA B/Br Mode select
MS relay
W/R Test select
TS
Tip over sensor (TOS) Starter motor
B/W
E1
Side-stand sw.
Br/R
DON

Shift up sw. Y MO+ R/W

UP
Shift down sw. G/W CVT motor Pulley position sensor
DOWN
Power sw. R/W B/R
POWER MO-
Center stand sw. Lg/Y
MODE PPS
Mode sw. Lg
CSTD G/R
SPR+
Brake sw. W/B
BRK G/B Secondary pulley sensor
SPR-
Gr/R
SDL
CVT unit
R
 AN650/AK5 (’05-MODEL) 14-31

ECM COUPLERS
K4 MODEL ECM AND CVT CONTROL UNIT COUPLERS
ECM couplers CVT control unit couplers

K5 MODEL ECM COUPLERS

ECM couplers

9 8 7 6 5 4 3 2 1 35 36 37 38 39 40 41 62 61
17 16 15 14 13 12 11 10 47 46 45 44 43 42

25 24 23 22 21 20 19 18 53 52 51 50 49 48
64 63
34 33 32 31 30 29 28 27 26 60 59 58 57 56 55 54

ECM ECM
TERMINAL CIRCUIT TERMINAL CIRCUIT
NO. NO.
1 Ignition coil (IG1) G Battery (+B)
2 Fuel injector (#1) H Center stand switch (CSTD)
3 Fuel injector (#2) I Side stand switch (SS)
4 Shift up switch (UP) J Brake switch (BRK)
5 Pulley position sensor (PPS) K Mode select switch (MS)
6 PTC heater (PTC) L Test switch (TS)
Speedometer (SPD) CO and injection pulse width adjust box
7 M
(COV1)
Solenoid valve (SOL) CO and injection pulse width adjust box
8 N
(COV2)
Fuel pump relay (FP) CO and injection pulse width adjust box
9 O
(COV3)
0 Ignition coil (IG2) P Ground (E03)
A Fan motor relay (FRL) Q Ground (E01)
B Power switch (POWER) R Starter relay (STA)
C Mode switch (MODE) S Writing tool (RXD1)
D Shift down switch (DOWN) T Writing tool (TXD1)
CO and injection pulse width adjust box SDL-KWP (SDL)
E U
(COS1)
CO and injection pulse width adjust box
F V Writing tool (FWE)
(COS2)
14-32 AN650/AK5 (’05-MODEL)

ECM ECM
TERMINAL CIRCUIT TERMINAL CIRCUIT
NO. NO.
W Battery (BATT) i TP sensor (VTA)
X Writing tool (RST) j IAT sensor (THA)
Y Ground (E1) k ECT sensor (THW)
Z CKP sensor (N-) l AP sensor (PA)
[ CMP sensor (G+) m O2 sensor control selector (EXS)
\ OX heater (OXH) n Ground (E2)
] Immobilizer (TXCK) o Tachometer (TACO)
^ Immobilizer (RXCK) p Meter (TECH)
a Immobilizer LED (LED) q Writing tool (SCK)
b Injector power voltage (VM) r IAP sensor (PM)
c CKP sensor (N+) s TO sensor (DON)
d CMP sensor (G-) t Blank
e O2 sensor (OX) u Battery (VB)
f Secondary pulley sensor (SPR-) v Motor (MO+)
g Secondary pulley sensor (SPR+) w Ground
h Sensor power (VCC) x Motor (MO-)
 AN650/AK5 (’05-MODEL) 14-33

MALFUNCTION CODE
MALFUNCTION ECM COUPLER TERMINALS TO CHECK
DETECTED ITEM
CODE K4 K5
C00 NO FAULT ––––––––––– –––––––––––
Camshaft position [, d
C11 ←
sensor ("6-27)
Crankshaft position Z, c
C12 ←
sensor ("6-28)
Intake air pressure h, n, r
C13 ←
sensor ("6-30)
Throttle position h, i, n
C14 ←
sensor ("6-32)
Engine coolant k, n
C15 ←
temperature sensor ("6-33)
C16 Speed sensor ––––––––––– –––––––––––
Intake air temperature j, n
C21 ←
sensor ("6-36)
Atmospheric pressure h, l, n
C22 ←
sensor ("6-38)
Tip over sensor h, n, s
C23 ←
("6-39)
Ignition signal 4, 5, b
C24 or C25 ←
("6-40)
Fuel injector 4, 5, b
C32 or C33 2, 3, b
("6-40)
Intake air control (IAC)
C40 ––––––––––– –––––––––––
valve
Fuel pump relay 9, b
C41 ←
("6-41)
C42 Ignition switch ––––––––––– –––––––––––
Heated oxygen sensor G, \, e, n
C44 ←
(HO2S) [E-02, 19] ("6-43)
C51 CVT motor ––––––––––– –––––––––––
CVT pulley position 8, D, J
C52 sensor (CVT control unit coupler) 5, Q, h
("6-48)
C53 CVT speed sensor ––––––––––– –––––––––––
CVT secondary pulley
C54 ––––––––––– –––––––––––
revolution sensor
CVT engine revolution 3 (CVT control unit coupler)
C55 signal o (ECM coupler) o
("6-53)
CVT reduction ratio
C58 ––––––––––– –––––––––––
disagreement
14-34 AN650/AK5 (’05-MODEL)

ABS TROUBLESHOOTING (AN650AK5)

MALFUNCTION CODE TROUBLESHOOTING
“41” Wheel speed sensor signal malfunction (F)
POSSIBLE CAUSE
• Poor contact on the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.

1) Inspect the clearance between the front wheel speed sensor

and sensor rotor using the thickness gauge.
# Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm
$ 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Is the clearance OK?

YES Go to step 2.
NO Adjust the clearance.

2) Inspect the front wheel speed sensor rotor for damage and
check that no foreign objects are caught in the rotor
openings.
Is the sensor rotor OK?

YES Go to step 3.
NO Clean or replace the sensor rotor.

3) Check that the front wheel speed sensor is mounted steadily.

Is the sensor mounted steadily?

YES Go to malfunction code “42”. ("14-35)

Tighten the mounting bolts or replace the bracket
NO
if necessary.
 AN650/AK5 (’05-MODEL) 14-35

“42” Wheel speed sensor circuit open (F)

POSSIBLE CAUSE
• Poor contact on the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.

• Turn the ignition switch to OFF.

• Remove the leg shield. ("9-10)
• Remove the meter front lower panel. ("14-26)
• Check the ABS control unit coupler and front wheel speed
sensor coupler for looseness. If OK, disconnect the ABS
control unit coupler.

1) Measure the resistance between B (B/R) and ground at the

ABS control unit coupler.
# Normal value: ∞
$ 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
% Tester knob indication: Resistance (Ω)
Is the resistance between B and ground OK?

YES Go to step 3.
NO Go to step 2.

• Disconnect the front wheel speed sensor coupler.

2) Measure the resistance between A (B) and ground at the
front wheel speed sensor coupler.
# Normal value: ∞
% Tester knob indication: Resistance (Ω)
Is the resistance between A and ground OK?

YES Inspect the wire harness. (Faulty B/R wire)

NO Faulty front wheel speed sensor

3) Measure the resistance between 3 (W/R) and ground at the

ABS control unit coupler.
# Normal value: ∞
% Tester knob indication: Resistance (Ω)
Is the resistance between 3 and ground OK?

YES Go to step 5.
NO Go to step 4.
14-36 AN650/AK5 (’05-MODEL)

4) Measure the resistance between B (W) and ground at the

front wheel speed sensor coupler.
# Normal value: ∞
% Tester knob indication: Resistance (Ω)
Is the resistance between B and ground OK?

YES Inspect the wire harness. (Faulty W/R wire)

NO Faulty front wheel speed sensor

5) Check for continuity between B (B/R) on the ABS control unit

coupler and C (B/R) on the front wheel speed sensor
coupler.
& Tester knob indication: Continuity (')
Is there continuity between B and C?

YES Go to step 6.
NO Inspect the wire harness. (Faulty B/R wire)

6) Check for continuity between 3 (W/R) on the ABS control

unit coupler and D (W/R) on the front wheel speed sensor
coupler.
& Tester knob indication: Continuity (')
Is there continuity between 3 and D?

YES Go to step 7.
NO Inspect the wire harness. (Faulty W/R wire)

• Connect the front wheel speed sensor coupler.

7) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + dry cell terminal and B (B/
R) on the ABS control unit coupler.
# Normal value: 3 – 14 mA DCmA

( Tester knob indication: Current (), 20 mA)

Is the current OK?

YES Replace the ABS control unit/HU.

NO Faulty front wheel speed sensor.
 AN650/AK5 (’05-MODEL) 14-37

“44” Wheel speed sensor signal malfunction (R)

POSSIBLE CAUSE
• Poor contact on the rear wheel speed sensor coupler
• Faulty rear wheel speed sensor, etc.

1) Inspect the clearance between the rear wheel speed sensor

and sensor rotor using the thickness gauge.
# Wheel speed sensor – sensor rotor clearance:
0.3 – 1.5 mm
$ 09900-20803: Thickness gauge
09900-20806: Thickness gauge
Is the clearance OK?

YES Go to step 2.
NO Adjust the clearance.

2) Inspect the rear wheel speed sensor rotor for damage and
check that no foreign objects are caught in the rotor
openings.
Is the sensor rotor OK?

YES Go to step 3.
NO Clean or replace the sensor rotor.

3) Check that the rear wheel speed sensor is mounted steadily.

Is the sensor mounted steadily?

YES Go to malfunction code “45”. ("14-38)

Tighten the mounting bolts or replace the bracket
NO
if necessary.
14-38 AN650/AK5 (’05-MODEL)

“45” Wheel speed sensor circuit open (R)

POSSIBLE CAUSE
• Poor contact on the rear wheel speed sensor coupler
• Faulty rear wheel speed sensor, etc.

• Turn the ignition switch to OFF.

• Remove the front box. ("9-18)
• Remove the trunk box cover. ("9-16)
• Check the ABS control unit/HU coupler and rear wheel speed
sensor coupler for loose or poor contacts. If OK, then
disconnect the ABS control unit/HU coupler

1) Check the resistance between terminal 2 (B/Y) on the ABS

control unit coupler and ground.
# Normal value: ∞ Ω (Infinity)
$ 09900-25008: Multi circuit tester set
09900-25009: Needle pointed probe set
% Tester knob indication: Resistance (Ω)
Is the resistance OK?

YES Go to step 3.
NO Go to step 2.

2) Check the resistance between A (B) and ground.

# Normal value: ∞ Ω (Infinity)
% Tester knob indication: Resistance (Ω)
Is the resistance OK?

YES Inspect the wire harness. (Faulty B/Y wire)

NO Replace the rear wheel speed sensor.

3) Check the resistance between terminal H (W/Y) and ground.

# Normal value: ∞ Ω (Infinity)
% Tester knob indication: Resistance (Ω)
Is the resistance OK?

YES Go to step 5.
NO Go to step 4.
 AN650/AK5 (’05-MODEL) 14-39

• Disconnect the rear wheel speed sensor coupler.

4) Check the resistance between B (W) and ground.
# Normal value: ∞ Ω (Infinity)
Is the resistance OK?

YES Inspect the wire harness. (Faulty W/Y wire)

NO Replace the rear wheel speed sensor.

5) Check the continuity between C (B/Y) and terminal 2.

# Normal value: Continuity (')
]
& Tester knob indication: Continuity test (')
Is the continuity OK?

YES Go to step 6.
NO Inspect the wire harness. (Faulty B/Y wire)

6) Check the continuity between D (W/Y) and terminal H.

]
# Normal value: Continuity (')
& Tester knob indication: Continuity test (')
Is the continuity OK?

YES Go to step 7.
NO Inspect the wire harness. (Faulty W/Y wire)

• Connect the rear wheel speed sensor coupler.

7) Connect three 1.5 V dry cells A in series as shown and make
sure that their total voltage is more than 4.5 V.
Measure the current between + dry cell terminal and 2 (B/
Y) on the ABS control unit coupler.
# Normal value: 3 – 14 mA DCmA

$ 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set
( Tester knob indication: Current (), 20 mA)
Is the current OK?

YES Replace the ABS control unit/HU.

NO Replace the rear wheel speed sensor.
14-40 AN650/AK5 (’05-MODEL)

WIND SCREEN CABLE ROUTING

Cushion

Speedometer

Do not drop the

cushion.

Screen relay

Wind screen
Clamp
regulator

Air pressure
Clamp sensor
Fun motor
Screen relay
Cushion
relay Tip over
sensor
Pass through Side stand relay
ECM the cable Fuel pump relay
back side
of relay.

Cushion

Attach

ECM
 AN650/AK5 (’05-MODEL) 14-41

RADIATOR HOSE ROUTING

Face the tip of clamp to the bottom.

Reservoir
inlet hose

White mark Oil cooler

inlet hose
14˚
Oil cooler
outlet hose

10˚

Yellow mark
White mark

Radiator outlet Face the tip of clamp to the forward.

hose
Face the tip of clamps to the bottom.
14-42 AN650/AK5 (’05-MODEL)

EXTERIOR PARTS CONSTRUCTION

1 Meter front upper panel 6 Lower leg shield A Wind screen regulator
2 Leg shield brace 7 Floor mat B Meter front lower panel
3 Meter cover 8 Front box C Front leg shield cover
4 Front panel 9 Wind screen D Lower bracket cover
5 Leg shield 0 Wind screen cover
 AN650/AK5 (’05-MODEL) 14-43

1 Maintenance lid 5 Center frame cover 9 Fuel tank inlet tray

2 Foot board 6 Lower frame cover 0 Fuel tank inlet packing
3 Frame cover 7 Rear fender
4 Leg side cover 8 Floor mat
14-44 AN650/AK5 (’05-MODEL)
 AN650/AK5 (’05-MODEL) 14-45

CVT CONSTRUCTION
K4
93 N·m
(9.3 kgf-m, 67.5 lb-ft)

K5
D
FW

1 Secondary pulley shaft nut 9 CVT belt G Secondary pulley fan

2 Secondary pulley shaft adapter 0 Primary pulley assembly H Bearing
3 O-ring A Shim I Snap ring
4 Primary pulley shaft bolt B O-ring J Primary slide pulley idle gear
5 Primary pulley shaft adapter C Bearing K Secondary pulley revolution sensor
6 CVT casing D Oil seal L CVT motor
7 Bearing E Washer M CVT cover
8 O-ring F Secondary pulley assembly N CVT filter

• Use new special tool for 4.

$ 09924-51010: Primary pulley shaft bolt holder
* Primary pulley shaft bolt: 93 N·m (9.3 kgf-m, 67.5 lb-ft)
NOTE:
Do not reuse the removed primary pulley shaft bolt.
14-46 AN650/AK5 (’05-MODEL)

AMBIENT AIR TEMPERATURE SENSOR BRACKET INSTALLATION

Wind screen
regulator motor

Leg shield brace

Ambient air
temperature
sensor
Mirror drive relay
(Electric mirror only)

FWD
 AN650/AK5 (’05-MODEL) 14-47

SPECIAL TOOLS

09900-20803 09900-25008 09900-25009 09924-51010

09900-20806 Multi circuit tester Needle pointed Primary pulley shaft 09930-82710
Thickness gauge set probe set bolt holder Mode select switch

TIGHTENING TORQUE CHART

For other nuts and bolts not listed in the preceding page, refer to this chart:

Bolt Diameter A Conventional or “4” marked bolt “7” marked bolt

(mm) N·m kgf-m N·m kgf-m
4 1.5 0.15 2.3 0.23
5 3 0.3 4.5 0.45
6 5.5 0.55 10 1.0
8 13 1.3 23 2.3
10 29 2.9 50 5.0
12 45 4.5 85 8.5
14 65 6.5 135 13.5
16 105 10.5 210 21.0
18 160 16.0 240 24.0

Conventional bolt “4” marked bolt “7” marked bolt

White Page
 AN650/AK6 (’06-MODEL) 15-1

AN650/K6 (’06-MODEL)

This chapter describes service data, service specifications and servicing procedures which dif-
fer from those of the AN650/AK5 (’05-MODEL).

NOTE:
15
Please refer to the chapter 1 through 14 for details which are not given in this chapter.

CONTENTS
SPECIFICATIONS (AN650K6) ..................................................................... 15- 2
SPECIFICATIONS (AN650AK6) .................................................................. 15- 4
SERVICE DATA (AN650K6) ........................................................................ 15- 6
SERVICE DATA (AN650AK6) ...................................................................... 15-14
SEAT LOCK CABLE ROUTING .................................................................. 15-22
FUEL HOSE ROUTING (For E-33/K5, K6) .................................................. 15-23
VACCUM HOSE ROUTING (For E-33/K5, K6) ............................................ 15-25
15-2 AN650/AK6 (’06-MODEL)

SPECIFICATIONS (AN650K6)
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 260 mm (89.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ...................................................................................... 1 435 mm (56.5 in)
Wheelbase .......................................................................................... 1 595 mm (62.8 in)
Ground clearance................................................................................ 130 mm ( 5.1 in)
Seat height .......................................................................................... 750 mm (29.5 in)
Dry mass............................................................................................. 235 kg (518 lbs)
ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 2
Bore .................................................................................................... 75.5 mm (2.972 in)
Stroke.................................................................................................. 71.3 mm (2.807 in)
Displacement ...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio ............................................................................... 11.2 : 1
Fuel system......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate,automatic,centrifugal type
Primary reduction ratio........................................................................ 1.333 (88/66)
Gearshift pattern ................................................................................. Automatic & Manual shift
Automatic transmission ratio ............................................................... Variable change (1.800-0.465)
Secondary reduction ratio ................................................................... 3.934 (39/31 × 43/25 × 40/22)
Final reduction ratio............................................................................. 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system ....................................................................................... Gear drive
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front fork stroke .................................................................................. 110 mm (4.3 in)
Rear wheel travel ................................................................................ 100 mm (3.9 in)
Caster ................................................................................................. 26° 10’
Trail...................................................................................................... 106 mm (4.17 in)
Steering angle ..................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake .......................................................................................... Disc brake,twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ....................................................................................... 160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................. 40 A
Fuse .................................................................................................... 15/15/15/15/10/10/10 A .......................... E-02, 19
15/15/15/15/15/10/10 A .......................... E-03, 24, 28, 33
Headlight ............................................................................................. 12 V 60 + 55/55 + 55 (H4 + H7) ............. E-02, 19
12 V 60/55 × 2 (H4 × 2) .......................... E-03, 24, 28, 33
Position/Parking light........................................................................... 12 V 5 W × 2
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
Lisense plate light ............................................................................... 12 V 5 W
Trunk light............................................................................................ 12 V 5 W
Turn signal light ................................................................................... 12 V 21 W
Instrument panel light.......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ...................................................... 12 V 1.4 W
Fuel injection warning light.................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake lock warning light ...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light .................................................................... 12 V 1.4 W × 2
Power mode indicator light .................................................................. 12 V 1.4 W
Drive indicator light.............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
Immobilizer indicator light.................................................................... LED .......E-02, 19, 24
Over drive indicator light ..................................................................... 12 V 1.4 W
 AN650/AK6 (’06-MODEL) 15-3

CAPACITIES
Fuel tank, including reserve .............................................................. 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ........................................................................ 2 600 ml (2.7/2.3 US/Imp qt)
with filter change.............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ................................................................ 360 ml (12.2/12.7US/Imp oz)
overhaul................................................................... 400 ml (13.5/14.1US/Imp oz)
Final gear oil, oil change .................................................................... 300 ml (10.1/10.6US/Imp oz)
overhaul....................................................................... 430 ml (14.5/15.1US/Imp oz)
Coolant ............................................................................................... 1.6 L (1.7/1.4 US/Imp qt)
15-4 AN650/AK6 (’06-MODEL)

SPECIFICATIONS (AN650AK6)
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 260 mm (89.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ...................................................................................... 1 435 mm (56.5 in)
Wheelbase .......................................................................................... 1 595 mm (62.8 in)
Ground clearance................................................................................ 130 mm ( 5.1 in)
Seat height .......................................................................................... 750 mm (29.5 in)
Dry mass............................................................................................. 243 kg (535 lbs)
ENGINE
Type..................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ............................................................................ 2
Bore .................................................................................................... 75.5 mm (2.972 in)
Stroke.................................................................................................. 71.3 mm (2.807 in)
Displacement ...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio ............................................................................... 11.2 : 1
Fuel system......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate,automatic,centrifugal type
Primary reduction ratio........................................................................ 1.333 (88/66)
Gearshift pattern ................................................................................. Automatic & Manual shift
Automatic transmission ratio ............................................................... Variable change (1.800-0.465)
Secondary reduction ratio ................................................................... 3.934 (39/31 × 43/25 × 40/22)
Final reduction ratio............................................................................. 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system ....................................................................................... Gear drive
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front fork stroke .................................................................................. 110 mm (4.3 in)
Rear wheel travel ................................................................................ 100 mm (3.9 in)
Caster ................................................................................................. 26° 10’
Trail...................................................................................................... 106 mm (4.17 in)
Steering angle ..................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake .......................................................................................... Disc brake,twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ....................................................................................... 160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8E or DENSO U24ESR-N
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................. 40 A
Fuse .................................................................................................... 15/15/15/15/15/10/10/15/15 A
Headlight ............................................................................................. 12 V 60 + 55/55 + 55 (H4 + H7)
Position/Parking light........................................................................... 12 V 5 W × 2
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
Lisense plate light ............................................................................... 12 V 5 W
Trunk light............................................................................................ 12 V 5 W
Turn signal light ................................................................................... 12 V 21 W
Instrument panel light.......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ...................................................... 12 V 1.4 W
Fuel injection warning light.................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake lock warning light ...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light .................................................................... 12 V 1.4 W × 2
Power mode indicator light .................................................................. 12 V 1.4 W
Drive indicator light.............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
ABS indicator light............................................................................... 12 V 1.4 W
Immobilizer indicator light.................................................................... LED .......E-02, 19, 24
Over drive indicator light ..................................................................... 12 V 1.4 W
 AN650/AK6 (’06-MODEL) 15-5

CAPACITIES
Fuel tank, including reserve .............................................................. 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ........................................................................ 2 600 ml (2.7/2.3 US/Imp qt)
with filter change.............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ................................................................ 360 ml (12.2/12.7US/Imp oz)
overhaul................................................................... 400 ml (13.5/14.1US/Imp oz)
Final gear oil, oil change .................................................................... 300 ml (10.1/10.6US/Imp oz)
overhaul....................................................................... 430 ml (14.5/15.1US/Imp oz)
Coolant ............................................................................................... 1.6 L (1.7/1.4 US/Imp qt)
15-6 AN650/AK6 (’06-MODEL)

SERVICE DATA (AN650K6)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)
 AN650/AK6 (’06-MODEL) 15-7

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
15-8 AN650/AK6 (’06-MODEL)

ITEM STANDARD LIMIT

Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure
 AN650/AK6 (’06-MODEL) 15-9

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: B, -: B/Br
Leaning 3.7 – 4.4 V +: B, -: B/Br
Injector voltage Battery voltage
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/ More than 0.6 V
min
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Com- 1.9 – 2.3 kΩ
pressed
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 : Idle
st
Approx. 3.3 V
output voltage speed
3rd: 3 000 Approx. 1.3 V
r/min
5th : 3 000 Approx. 0.5 V
r/min
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage
15-10 AN650/AK6 (’06-MODEL)

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. 10G0
Bore size 32 mm (1.26 in)
Fast idle r/min 1 300 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
Synchronizing screw opening 1 and 1/2 turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine side Approx. 1 350 ml —
(1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
 AN650/AK6 (’06-MODEL) 15-11

ITEM STD/SPEC. NOTE

Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size 15 A ..........E-03, 24, 28, 33
Head- LO 10 A ..........E-02, 19
light
HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
Trunk light 5 ←
Immobilizer indicator light LED
Over drive indicator light 1.4 ←
15-12 AN650/AK6 (’06-MODEL)

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster
 AN650/AK6 (’06-MODEL) 15-13

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or The others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
15-14 AN650/AK6 (’06-MODEL)

SERVICE DATA (AN650AK6)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)
 AN650/AK6 (’06-MODEL) 15-15

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
15-16 AN650/AK6 (’06-MODEL)

ITEM STANDARD LIMIT

Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure
 AN650/AK6 (’06-MODEL) 15-17

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.2 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: B, -: B/Br
Leaning 3.7 – 4.4 V +: B, -: B/Br
Injector voltage Battery voltage
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V (When cranking) -: Ground
#2 +: B/Y,
-: Ground
HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)
HO2 sensor output voltage Idle speed Less than 0.4 V
3 000 r/min More than 0.6 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 : Idle speed
st
Approx. 3.3 V
output voltage 3rd : 3 000 r/min Approx. 1.3 V
5th: 3 000 r/min Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage
15-18 AN650/AK6 (’06-MODEL)

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. 10G0
Bore size 32 mm (1.26 in)
Fast idle r/min 1 300 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
Synchronizing screw opening 1 and 1/2 turns out
IAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C Approx. 2.45 kΩ —
resistance (68 °F)
50 °C Approx. 0.811 kΩ —
(122 °F)
80 °C Approx. 0.318 kΩ —
(176 °F)
110 °C Approx. 0.142 kΩ —
(230 °F)
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine Approx. 1 350 ml —
side (1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl,
More than 80 V -: Ground
#2 +: B/Y,
-: Ground
 AN650/AK6 (’06-MODEL) 15-19

ITEM STD/SPEC. NOTE

Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size Head- LO 15 A
light HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source
ABS 15 A × 2

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Brake-lock indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
ABS warning indicator light 1.4
Trunk light 5 ←
Immobilizer indicator light LED
Over drive indicator light 1.4 ←
15-20 AN650/AK6 (’06-MODEL)

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster
 AN650/AK6 (’06-MODEL) 15-21

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
15-22 AN650/AK6 (’06-MODEL)

SEAT LOCK CABLE ROUTING

AN650

AN650A

1 Clamp add.
 AN650/AK6 (’06-MODEL) 15-23

FUEL HOSE ROUTING (For E-33/K5, K6)

*1

To inlet

Gray Black

33 N.m
(3.3 kgf.m, 24 lb-ft)

To canister To fuel tank (Fuel cut valve)

Orange Black

5 – 8 mm 5 – 8 mm

*2

0 – 15 mm
*3
80 mm
*4
White marking 35 N.m (3.5 kgf.m, 25.5 lb-ft)

*1 Set fuel pump with match mark not to be out of position. 5 Fuel pump retainer
*2 Bend the base of clamp (90°) after tightning. 6 Fuel pump packing
*3 Take care of direction. 7 Fuel tank comp.
*4 Insert hose firmly. 8 Check valve hose
1 Clip 9 Fuel drain hose
2 Check valve 0 Fuel tank filler hose
3 Canister A Fuel tank inlet comp.
4 Fuel pump assy. B Clamp face downward
15-24 AN650/AK6 (’06-MODEL)

*1

*1 Set the frame cover. 2 Double sided tape

1 Cushion
 AN650/AK6 (’06-MODEL) 15-25

VACCUM HOSE ROUTING (For E-33/K5, K6)

Black Gray

Black Orange

White marking

1 Tank pressure control valve (Black/Gray) 7 Surge hose (Red stripe & White marking)
2 Tank pressure control valve (Brack/Orange) 8 Map sensor
3 Surge hose (Red stripe) 9 3 way connector
4 Canister 0 Purge hose
5 Fuel tank A Union
6 Fuel-vapor separator/Fuel shut-off valve
White Page
 AN650/AK7 (’07-MODEL) 16-1

AN650/AK7 (’07-MODEL)

This manual describes service data, service specifications, FI and servicing procedures which
differ from those of the AN650/AK6 (’06-model).

NOTE:
• Any differences between the AN650/AK6 (’06-model) and AN650/AK7 (’07-model) in
specifications and service data are indicated with an asterisk mark (*).
• Please refer to the AN650K5 (’05-model) service manual and AN650/AK6 (’06-model)
16
service information for details which are not given in this manual.

CONTENTS
SPECIFICATIONS (AN650K7) ........................................................................... 3
SPECIFICATIONS (AN650AK7) ........................................................................ 5
SDS CHECK ....................................................................................................... 7
FI SYSTEM WIRING DIAGRAM......................................................................... 11
ECM/PCM TERMINAL........................................................................................ 12
FAIL-SAFE FUNCTION............................................................................. 14
MALFUNCTION CODE AND DEFECTIVE CONDITION .......................... 15
“C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT
MALFUNCTION......................................................................................... 16
“C41” (P2505) ECM/PCM POWER INPUT CIRCUIT
MALFUNCTION......................................................................................... 21
“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT
MALFUNCTION......................................................................................... 23
“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT
MALFUNCTION......................................................................................... 27
“C62” (P0443) EVAP SYSTEM PURGE CONTROL SOLENOID
VALVE CIRCUIT MALFUNCTION (E-33 ONLY) ...................................... 29
ISC VALVE REMOVAL ............................................................................. 31
ISC VALVE INSPECTION ......................................................................... 31
ISC VALVE INSTALLATION..................................................................... 31
ISC VALVE PRE-SET ............................................................................... 32
THROTTLE VALVE SYNCHRONIZATION ............................................... 33
HO2 SENSOR INSPECTION .................................................................... 35
HO2 SENSOR REMOVAL AND INSTALLATION .................................... 35
NOISE EMISSION CONTROL SYSTEM................................................... 36
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33) .......... 36
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33) ................................................................................................... 37
HOSES ...................................................................................................... 37
EVAP CANISTER ...................................................................................... 37
EVAP SYSTEM PURGE CONTROL SOLENOID VALVE ........................ 37
16-2 AN650/AK7 (’07-MODEL)

AN650/AK7 (’07-MODEL)

CONTENTS
WIRING HARNESS AND HOSE ROUTING ...................................................... 39
WIRING HARNESS ROUTING................................................................. 39
THROTTLE BODY INSTALLATION AND HOSE ROUTING ................... 40
SPECIAL TOOLS............................................................................................... 41
TIGHTENING TORQUE CHART .............................................................. 41
SERVICE DATA (AN650K7).............................................................................. 42
SERVICE DATA (AN650AK7) ........................................................................... 51
WIRING DIAGRAM ............................................................................................ 61

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO.

E-02 U.K. JS1BU111200100524 –
E-03 U.S.A. (Except for california) JS1BU111200 100001 –
E-19 E.U. JS1BU111100114140 –
AN650
E-24 Australia JS1BU121300100404 –
E-28 Canada JS1BU111200 100001 –
E-33 California (U.S.A.) JS1BU111200 100001 –
E-02 U.K. JS1BU132200100227 –
E-03 U.S.A. (Except for california) JS1CP51B 72100001 –
E-19 E.U. JS1BU132100117025 –
AN650A E-24 Australia JS1BU142300100012 –
E-28 Canada JS1CP51B 72100001 –
E-33 California (U.S.A.) JS1CP51B 72100001 –
E-51 Korea JS1BU132470100001 –
 AN650/AK7 (’07-MODEL) 16-3

SPECIFICATIONS (AN650K7)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 260 mm (89.0 in)
Overall width....................................................................................... 810 mm (31.9 in)
Overall height ..................................................................................... 1 435 mm (56.5 in)
Wheelbase ......................................................................................... 1 595 mm (62.8 in)
Ground clearance ............................................................................... 130 mm ( 5.1 in)
Seat height ......................................................................................... 750 mm (29.5 in)
Dry mass ............................................................................................ 235 kg (518 lbs)
ENGINE
Type .................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ........................................................................... 2
Bore.................................................................................................... 75.5 mm (2.972 in)
Stroke ................................................................................................. 71.3 mm (2.807 in)
Displacement...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio .............................................................................. 11.2 : 1
Fuel system ........................................................................................ Fuel injection
Air cleaner .......................................................................................... Non-woven fabric element
Starter system .................................................................................... Electric
Lubrication system ............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min
DRIVE TRAIN
Clutch ................................................................................................. Wet multi-plate,automatic,centrifugal type
Primary reduction ratio ....................................................................... 1.333 (88/66)
Gearshift pattern................................................................................. Automatic & Manual shift
Automatic transmission ratio .............................................................. Variable change (1.800-0.465)
Secondary reduction ratio .................................................................. 3.934 (39/31 × 43/25 × 40/22)
Final reduction ratio ............................................................................ 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system....................................................................................... Gear drive
CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................ Swingarm type, coil spring, oil damped
Front fork stroke.................................................................................. 110 mm (4.3 in)
Rear wheel travel................................................................................ 100 mm (3.9 in)
Caster................................................................................................. 26° 10’
Trail ..................................................................................................... 106 mm (4.17 in)
Steering angle .................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake ......................................................................................... Disc brake,twin
Rear brake.......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ...................................................................................... 160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type ........................................................................................ Electronic ignition (Transistorized)
Ignition timing ..................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug .......................................................................................... NGK CR8E or DENSO U24ESR-N
Battery ................................................................................................ 12 V 43.2 kC (12 Ah)/10 HR
Generator ........................................................................................... Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................ 40 A
Fuse ................................................................................................... 15/15/15/15/10/10/10 A ..........................E-02, 19
15/15/15/15/15/10/10 A ..........................E-03, 24, 28, 33
Headlight ............................................................................................ 12 V 60 + 55/55 + 55 (H4 + H7)..............E-02, 19
12 V 60/55 × 2 (H4 × 2) ..........................E-03, 24, 28, 33
Position/Parking light .......................................................................... 12 V 5 W × 2 ....... E-02, 19
Brake light/Taillight.............................................................................. 12 V 21/5 W × 2
License plate light............................................................................... 12 V 5 W
Trunk light ........................................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Instrument panel light ......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ..................................................... 12 V 1.4 W
Fuel injection warning light ................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake lock warning light...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light.................................................................... 12 V 1.4 W × 2
Power mode indicator light ................................................................. 12 V 1.4 W
Drive indicator light ............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
Immobilizer indicator light ................................................................... LED....... E-02, 19, 24
Over drive indicator light..................................................................... 12 V 1.4 W
16-4 AN650/AK7 (’07-MODEL)

CAPACITIES
Fuel tank, including reserve ............................................................... 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ......................................................................... 2 600 ml (2.7/2.3 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul............................................................................ 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ................................................................ 360 ml (12.2/12.7US/Imp oz)
overhaul ................................................................... 400 ml (13.5/14.1US/Imp oz)
Final gear oil, oil change..................................................................... 300 ml (10.1/10.6US/Imp oz)
overhaul ....................................................................... 430 ml (14.5/15.1US/Imp oz)
Coolant................................................................................................ 1.6 L (1.7/1.4 US/Imp qt)
 AN650/AK7 (’07-MODEL) 16-5

SPECIFICATIONS (AN650AK7)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 260 mm (89.0 in)
Overall width....................................................................................... 810 mm (31.9 in)
Overall height ..................................................................................... 1 435 mm (56.5 in)
Wheelbase ......................................................................................... 1 595 mm (62.8 in)
Ground clearance ............................................................................... 130 mm ( 5.1 in)
Seat height ......................................................................................... 750 mm (29.5 in)
Dry mass ............................................................................................ 243 kg (535 lbs)
ENGINE
Type .................................................................................................... 4-stroke, liquid-cooled, DOHC
Number of cylinders ........................................................................... 2
Bore.................................................................................................... 75.5 mm (2.972 in)
Stroke ................................................................................................. 71.3 mm (2.807 in)
Displacement...................................................................................... 638 cm3 (38.9 cu. in)
Compression ratio .............................................................................. 11.2 : 1
Fuel system ........................................................................................ Fuel injection
Air cleaner .......................................................................................... Non-woven fabric element
Starter system .................................................................................... Electric
Lubrication system ............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min
DRIVE TRAIN
Clutch ................................................................................................. Wet multi-plate,automatic,centrifugal type
Primary reduction ratio ....................................................................... 1.333 (88/66)
Gearshift pattern................................................................................. Automatic & Manual shift
Automatic transmission ratio .............................................................. Variable change (1.800-0.465)
Secondary reduction ratio .................................................................. 3.934 (39/31 × 43/25 × 40/22)
Final reduction ratio ............................................................................ 1.580 (32/31 × 31/32 × 34/31 × 49/34)
Drive system....................................................................................... Gear drive
CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................ Swingarm type, coil spring, oil damped
Front fork stroke.................................................................................. 110 mm (4.3 in)
Rear wheel travel................................................................................ 100 mm (3.9 in)
Caster................................................................................................. 26° 10’
Trail ..................................................................................................... 106 mm (4.17 in)
Steering angle .................................................................................... 41° (right and left)
Turning radius ..................................................................................... 2.7 m (8.9 ft)
Front brake ......................................................................................... Disc brake,twin
Rear brake.......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70R15M/C 56H, tubeless
Rear tire size ...................................................................................... 160/60R14M/C 65H, tubeless
ELECTRICAL
Ignition type ........................................................................................ Electronic ignition (Transistorized)
Ignition timing ..................................................................................... 10° B.T.D.C. at 1 200 r/min
Spark plug .......................................................................................... NGK CR8E or DENSO U24ESR-N
Battery ................................................................................................ 12 V 43.2 kC (12 Ah)/10 HR
Generator ........................................................................................... Three-phase A.C. generator
Main fuse ............................................................................................ 40 A
CVT fuse ............................................................................................ 40 A
Fuse ................................................................................................... 15/15/15/15/15/10/10/15/15 A
Headlight ............................................................................................ 12 V 60 + 55/55 + 55 (H4 + H7)..............E-02, 19, 51
12 V 60/55 × 2 (H4 × 2) ..........................E-03, 24, 28, 33
Position/Parking light .......................................................................... 12 V 5 W × 2 ....... E-02, 19, 51
Brake light/Taillight.............................................................................. 12 V 21/5 W × 2
License plate light............................................................................... 12 V 5 W
Trunk light ........................................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Instrument panel light ......................................................................... 12 V 1.4 W × 2
Coolant temperature warning light ..................................................... 12 V 1.4 W
Fuel injection warning light ................................................................. 12 V 1.4 W
Oil pressure warning light ................................................................... 12 V 1.4 W
Brake lock warning light...................................................................... 12 V 1.4 W
High beam indicator light .................................................................... 12 V 1.4 W
Turn signal indicator light.................................................................... 12 V 1.4 W × 2
Power mode indicator light ................................................................. 12 V 1.4 W
Drive indicator light ............................................................................. 12 V 1.4 W
Gear position indicator light ................................................................ 12 V 1.4 W × 5
ABS indicator light .............................................................................. 12 V 1.4 W
Immobilizer indicator light ................................................................... LED....... E-02, 19, 24, 51
Over drive indicator light..................................................................... 12 V 1.4 W
16-6 AN650/AK7 (’07-MODEL)

CAPACITIES
Fuel tank, including reserve ............................................................... 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change ......................................................................... 2 600 ml (2.7/2.3 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul............................................................................ 3 400 ml (3.6/3.0 US/Imp qt)
Transmission oil, oil change ................................................................ 360 ml (12.2/12.7US/Imp oz)
overhaul ................................................................... 400 ml (13.5/14.1US/Imp oz)
Final gear oil, oil change..................................................................... 300 ml (10.1/10.6US/Imp oz)
overhaul ....................................................................... 430 ml (14.5/15.1US/Imp oz)
Coolant................................................................................................ 1.6 L (1.7/1.4 US/Imp qt)
 AN650/AK7 (’07-MODEL) 16-7

SDS CHECK
Using SDS, sample the data at the time of new and periodic vehicle inspections.

After saving the sampled data in the computer, file them by model and by user.
The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition
of vehicle functions that has changed with time.
For example, when a vehicle is brought in for service but the troubleshooting of a failure is not easy, compar-
ing the current data value to the past filed data value at time of normal condition can allow the specific
engine failure to be determined.
Also, in the case of a customer vehicle which is not periodically brought in for service with no past data value
having been saved, if the data value of a good vehicle condition have been already saved as a master
(STD), comparison between the same models helps facilitate the troubleshooting.
• Set up the SDS tools. (Refer to the SDS operation manual for further details.)
! 09904-41010: SDS set tool
99565-01010-010: CD-ROM Ver.10

NOTE:
* Before taking the sample of data, check and clear the Past DTC. (Refer to the SDS operation manual for
further details.)
* A number of different data under a fixed condition as shown below should be saved or filed as sample.

SAMPLE:
Data sampled from cold starting through warm-up

Check the engine r/min.

XXXX r/min

Check the engine coolant temperature.

XX ˚C

Check the manifold absolute pressure.

XX kPa
16-8 AN650/AK7 (’07-MODEL)

Data at 3 000 r/min under no load

Approx. 3 000 r/min

Check the manifold absolute pressure.

XX kPa

Check the engine coolant temperature.

XX ˚C

Data of manifold absolute pressure operation at the time of cold starting

Check the engine r/min.

XXXX r/min

Check the manifold absolute pressure.

XX kPa

Check the engine coolant temperature.

XX ˚C
 AN650/AK7 (’07-MODEL) 16-9

Data of intake negative pressure during idling (100 °C)

Check the manifold absolute pressure.

XX kPa

Check the engine coolant temperature.

Approx. 100 ˚C

Data of manifold absolute pressure operation at the time of hot starting

Check the engine r/min.

XXXX r/min

Check the manifold absolute pressure.

XX kPa

Check the engine coolant temperature.

XX ˚C
16-10 AN650/AK7 (’07-MODEL)

Example of trouble
Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar-
ison by showing them in the graph. Read the change of value by comparing the current data to the past data
that have been saved under the same condition, then you may determine how changes have occurred with
the pass of time and identify what problem is currently occurring.

With DTC not output, if the value of engine coolant temperature is found to be lower than the data saved
previously, the possible cause may probably lie in a sensor circuit open or ground circuit opened or influence
of internal resistance value changes, etc.

Unstable idling speed (Too high)

Abnormal curve of graph

Abnormal value of engine coolant temperature

No DTC output
 AN650/AK7 (’07-MODEL) 16-11

FI SYSTEM WIRING DIAGRAM

Fuel injector #1 Fuel injector #2

Combination
P/W Br/W O/Bl
meter
Fuel pump
W Gr/W
W/G *1 Gr/B
Ignition coil #1 Ignition coil #2
Crankshaft position sensor(CKPS)
B/W
Camshaft position sensor (CMPS)
B/W
B/Y
Br W/Bl
B/Y
Y/Bl
Intake air pressure sensor (IAPS) G/Bl PAIR Fuel pump relay
R control
solenoid
valve
Lg/B

Y/W
Ambient pressure sensor 40 A
(APS) R/B HO2 sensor heater
R/Bl
G/Y To Engine Ignition
Combi- stop switch
nation switch
10 A 30 A
O/W meter

Throttle position sensor O/Y

*2
(TPS) 15 A
Brake light Starter
Gr/Y switch switch
P/B
Cooling Brake
B fan relay
Engine coolant temperature light
sensor (ECTS) ECM/PCM Y/G Starter
B/Bl G relay M
Dbr
*3
Intake air temperature EVAP system
purge control Side-stand switch
sensor (IATS) solenoid
Dg valve
B/W Side-stand relay

CVT unit
R/W
HO2 sensor (HO2S)
B/G
CVT motor M Pulley position sensor
Br
Bl
Tip-over sensor (TOS)
G/R
G/B Secondary pulley
revolution sensor
Br/R

B/Lg
Y/R
P/W
Speed sensor G
P W/B

Shift up
B/Br Y switch
Shift down
G/W switch ISC valve
Immobilizer Power
R/W switch
Mode
Lg/Y switch
B/O Center stand
*1 Lg switch
Brake light
Y/Bl W/B switch
*1 *1: For E-02, 19, 24
*2: For E-03, 28, 33
*3: For E-33 only
16-12 AN650/AK7 (’07-MODEL)

ECM/PCM TERMINAL

ECM TERMINAL CIRCUIT

NO. K6 K7
1 Ignition coil (IG2) ←
2 Fuel injector (#1) ←
3 Fuel injector (#2) ←
4 Shift up switch (UP) ←
5 Pulley position sensor (PPS) ←
PTVC heater (PTC) EVAP system purge control solenoid valve
6
(E-33 only)
7 Speed sensor (SPD) ←
8 PAIR control solenoid valve (PAIR) ←
9 Fuel pump relay (FP) ←
0 Ignition coil (IG1) ←
A Cooling fan relay (FRL) ←
B Power switch (POWER) ←
C Mode switch (MODE) ←
D Shift down switch (DOWN) ←
E — —
F — —
G Battery (+B) ←
H Center stand switch (CSTD) ←
I Side-stand switch (SS) ←
J Brake switch (BRK) ←
K — —
L — —
M — —
N — —
O — —
P Ground (E03) ←
Q Ground (E01) ←
R Starter relay (STA) ←
S — TO sensor (DON)
T — IAP sensor (PM)
U — —
 AN650/AK7 (’07-MODEL) 16-13

ECM TERMINAL CIRCUIT

NO. K6 K7
V — —
W Battery (BATT) ←
X — —
Y Ground (E1) ←
Z CKP sensor (N-) ←
[ CMP sensor (G+) ←
\ HO2 sensor heater (OXH) ←
] Immobilizer (TXCK) (For E-02, 19, 24) ←
^ Immobilizer (RXCK) (For E-02, 19, 24) ←
Immobilizer LED (Meter) (For E-02, 19, 24)
a ←
Anti-thief switch (AT) (For E-03, 28, 33)
b Injector power voltage (VM) ←
c CKP sensor (N+) ←
d CMP sensor (G-) ←
e HO2 sensor (OX) ←
f Secondary pulley revolution sensor (SPR-) ←
g Secondary pulley revolution sensor (SPR+) ←
h Sensor power (Vcc) ←
i TP sensor (VTA) ←
j IAT sensor (THA) ←
k ECT sensor (THW) ←
l AP sensor (PA) ←
m — ISC valve 1A (IS1A)
n Ground (E2) ←
o Tachometer (TACO) ←
p Meter communication (ETCH) ←
q — —
r IAP sensor (PM) ISC valve 2B (IS2B)
s TO sensor (DON) ISC valve 2A (IS2A)
t IG switch (AT) ISC valve 1B (IS1B)
u Battery (VB) ←
v CVT motor (MO+) ←
w Ground ←
x CVT motor (MO-) ←
16-14 AN650/AK7 (’07-MODEL)

FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini-
mum performance necessary even under malfunction condition.

STARTING RUNNING
ITEM FAIL-SAFE MODE
ABILITY ABILITY
HO2 sensor Feedback compensation is inhibited.
“YES” “YES”
(Air/fuel ratio is fixed to normal.)
PAIR control solenoid valve ECM stops controlling PAIR control
solenoid valve.
HO2 sensor feedback compensation “YES” “YES”
is inhibited.
Power for HO2 sensor is shut off.
ISC valve When motor disconnection or lock
“YES” “YES”
occurs, power from ECM is shut off.
EVAP system purge control ECM stops controlling EVAP sys-
“YES” “YES”
solenoid valve (For E-33) tem purge control solenoid valve.

The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is nec-
essary to bring the motorcycle to the workshop for complete repair.
 AN650/AK7 (’07-MODEL) 16-15

MALFUNCTION CODE AND DEFECTIVE CONDITION

DETECTED
DTC No. DETECTED FAILURE CONDITION CHECK FOR
ITEM
C00 NO FAULT ––––––––––– –––––––––––
ISC valve Although current is flowing though the ISC valve circuit open or shorted
C40 (P0505) ISC valve motor, the current detection to ground
is not possible.
Idle speed is lower than the desired Air passage clogged
idle speed. ISC valve is fixed
C40 (P0506)
ISC valve pre-set position is
incorrect
Idle speed is higher than the desired ISC valve is fixed
C40 (P0507) idle speed. ISC valve pre-set position is
incorrect
ECM/PCM No voltage is applied to the ECM, Lead wire/coupler connection of
power input although the ignition switch is turned ECM terminal to fuel fuse, fuel
C41 (P2505) signal ON. fuse, battery voltage to ECM
(BATT) shorted to ground or
open
HO2 sensor HO2 sensor output voltage is not input HO2 sensor circuit open
C44 to ECM during engine operation and
running condition.
(Sensor voltage < 1.0 V)
P0130 In other than the above value, C44
(P0130) is indicated.
The Heater can not operate so that HO2 sensor lead wire/coupler
C44
heater operation voltage is not supply connection
to the oxygen heater circuit, C44 Battery voltage supply to the
P0135
(P0135) is indicated. HO2 sensor
C49 PAIR control PAIR control solenoid valve voltage is PAIR control solenoid valve, lead
solenoid not input to ECM. wire/coupler
P1656
valve
EVAP system EVAP system purge control solenoid EVAP system purge control
C62
purge con- valve voltage is not input to ECM. solenoid valve, lead wire/coupler
trol solenoid
P0443 valve
(For E-33)
16-16 AN650/AK7 (’07-MODEL)

“C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
C40 Although current is flowing though the • ISC valve circuit open or shorted to ground
(P0505) ISC valve motor, the current detection is • Power source circuit open
not possible.
C40 Idle speed is lower than the desired idle • Air passage clogged
(P0506) speed. • ISC valve is fixed
• ISC valve pre-set position is incorrect
C40 Idle speed is higher than the desired • ISC valve is fixed
(P0507) idle speed. • ISC valve pre-set position is incorrect

ISC valve ECM

B/Lg ISC. 1A

P/W ISC. 1B

G ISC. 2A

W/B ISC. 2B

"
* Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is
turned OFF.
If the ECM coupler or ISC valve coupler is disconnected within 5 seconds after ignition switch
is turned OFF, there is a possibility of an unusual valve position being written in ECM and
causing an error of ISC valve operation.
* When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler
with a needle pointed tester probe to prevent the terminal damage or terminal bend.

INSPECTION 1
Step 1
1) Turn the ignition switch OFF.
2) Remove the maintenance lid. (#AN650K3 9-13)
3) Check the ISC valve coupler 1 for loose or poor contacts.
If OK, then check the ISC valve lead wire continuity.
 AN650/AK7 (’07-MODEL) 16-17

4) Remove the front panel. (#AN650K3 9-8) 1

5) Disconnect the ISC valve coupler and ECM couplers.
6) Check the continuity between terminals A (B/Lg) and m, ter-
minals B (P/W) and t, terminals C (G) and s, terminals D
(W/B) and r.

$ ISC valve lead wire continuity: Continuity (%) 1

! 09900-25008: Multi-circuit tester set ECM coupler (Harness side)

09900-25009: Needle pointed probe set

& Tester knob indication: Continuity test (%)
Is the continuity OK?

YES Go to Step 2.
NO Y, B/Lg, P/W, G or W/B wire open.
7) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)

Step 2 2
1) Remove the front box. (#AN650K3 9-18)
2) Measure the resistance between terminals A and B, termi-
nals C and D.
$ ISC valve resistance: Approx. 80 Ω at 25 °C (77 °F)
(Terminal A – Terminal B)
(Terminal C – Terminal D)
Is the resistance OK?

YES If wire is OK, intermittent trouble or faulty ECM.

NO Replace the ISC valve with a new one.
3) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
16-18 AN650/AK7 (’07-MODEL)

ACTIVE CONTROL INSPECTION (ISC RPM CONTROL)

Check 1
1) Place the motorcycle on the center stand.
2) Pull the parking brake lever and make sure that the rear
wheel is locked.
3) Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
4) Check that the engine is running.
5) Click the “Engine and Transmission” 1.

6) Click the “ISC rpm control” 2.

7) Check that the “Spec” 3 is idle speed 1 200 ± 100 rpm.

8) Check that the “Desired idle speed” 4 is within the specified
idle rpm.
 AN650/AK7 (’07-MODEL) 16-19

Check 2
1) Click the button 1 and decrease the “Spec” 2 to 1 050 rpm
slowly.
2) Check that the “Desired idle speed” 3 is nearly equal to the
“Spec” 2. At the same time, check that the number of steps
4 in the ISC valve position decreases.
NOTE:
It takes a few seconds for “Desired idle speed” to catch up with
the changed value of “Spec”.
3) Click the button 5 and increase the “Spec” 2 slowly.
4) Check that the “Desired idle speed” 3 is nearly equal to the
“Spec” 2. Also, check that the number of steps 4 in the ISC
valve position increases.

Check 3
1) Click the button 1 and increase the “Spec” 2 to 1 400 rpm
slowly.
2) Check that the “Desired idle speed” 3 is nearly equal to the
“Spec” 2. Also, check that the number of steps 4 in the ISC
valve position increases.
16-20 AN650/AK7 (’07-MODEL)

Check 4
1) Increase the “Spec” 1 to 1 500 rpm.
2) Check that the “Desired idle speed” 2 is approx. 1 500 rpm.
3) Check that the “Engine speed” 3 is close to 1 500 rpm.
NOTE:
Be careful not to increase the “Spec” to more than 1 600 rpm, or
the “Engine speed” may reach the upper limit.

If the ISC valve does not function properly, inspect the ISC valve (#Page 29) or replace if necessary.
 AN650/AK7 (’07-MODEL) 16-21

“C41” (P2505) ECM/PCM POWER INPUT CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
C41 No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to
(P2505) although the ignition switch is turned fuel fuse
ON. • Fuel fuse
• Battery voltage to ECM (BATT) shorted to ground
or open

To Speedometer
ECM

BATT R/Bl Engine stop

switch

To side-stand Ignition
VM Y/R Y/G R/BI switch switch
Side-stand
FP Relay Y/Bl O/W relay
FP relay

"
When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with
a needle pointed tester probe to prevent the terminal damage or terminal bend.

INSPECTION 1
Step 1 (When indicating C41:)
1) Turn the ignition switch OFF.
2) Remove the front panel. (#AN650K3 9-8)
3) Check the ECM couplers 1 for loose or poor contacts.
If OK, then measure the ECM input voltage.

4) Disconnect the ECM couplers. 1

5) Measure the voltage between terminal W and ground. ECM coupler (Harness side)

$ ECM input voltage: Battery voltage

! 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage (()
16-22 AN650/AK7 (’07-MODEL)

Is the voltage OK?

• Fuel pump related circuit malfunction.

• R/Bl wire open or shorted or poor terminal W
connection.
• Battery voltage to ECM (BATT) shorted to
ground or open.
YES • If the wire and connection are OK, intermittent
trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO • Open or short in the R/Bl wire.
6) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
 AN650/AK7 (’07-MODEL) 16-23

“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
C44 HO2 sensor output voltage is not input • HO2 sensor circuit open
(P0130) to ECM during engine operation and
running condition.
(Sensor voltage < 1.0 V)
In other than the above value, C44
(P0130) is indicated.
C44 The heater can not operate so that • HO2 sensor lead wire/coupler connection
(P0135) heater operation voltage is not supplied • Battery voltage supply to the HO2 sensor.
to the oxygen heater circuit.

ECM

E2 B/Br Engine stop Side-stand Ignition

switch relay switch
OX B/G
O/W
OXH Y/W To side-stand
switch
W
Bl
B

HO2 sensor

"
When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with
a needle pointed tester probe to prevent the terminal damage or terminal bend.

INSPECTION 1
Step 1 (When indicating C44/P0130:)
1) Turn the ignition switch OFF.
2) Remove the footboard. (#AN650K3 9-18)
3) Check the HO2 sensor coupler 1 for loose or poor contacts.
If OK, then check the HO2 sensor lead wire continuity.

4) Disconnect the HO2 sensor coupler.

5) Check the continuity between B/G wire A and ground.
1
]
6) Also, check the continuity between B/G wire A and B/Br wire
B. If the sound is not heard from the tester, the circuit condi-
tion is OK.
! 09900-25008: Multi-circuit tester set
& Tester knob indication: Continuity test (%)
16-24 AN650/AK7 (’07-MODEL)

7) Remove the front panel. (#AN650K3 9-8)

8) Disconnect the ECM coupler.
1 ]
9) Check the continuity between B/G wire A and terminal e.
10)Also, check the continuity between B/Br wire B and terminal
n.
$ HO2S lead wire continuity: Continuity (%)
! 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
ECM coupler (Harness side)
& Tester knob indication: Continuity test (%)

Is the continuity OK?

YES Go to Step 2. (When indicating C44/P0130:)

B/G wire shorted to ground, or B/G or B/Br wire
NO
open.
11)After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)

Step 2 (When indicating C44/P0130:) 2

1) Connect the ECM couplers and HO2 sensor coupler. V
2) Warm up the engine enough.
3) Measure the HO2 sensor output voltage between B/G wire
and B/Br wire, when idling condition.
$ HO2 sensor output voltage at idle speed:
0 – 1.0 V (+ B/G – - B/Br)

4) If OK, then remove the lower leg shield (#AN650K3 9-10) 2

and pinch the PAIR hose 1 with proper hose clamp.
5) Measure the HO2 sensor output voltage while holding the
engine speed at 5 000 r/min.
$ HO2 sensor output voltage at 5 000 r/min:
0 – 1.0 V (+ B/G – - B/Br)
! 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage (()
 AN650/AK7 (’07-MODEL) 16-25

Is the voltage OK? 2

• B/G wire or B/Br wire open or shorted to ECM coupler (Harness side)

ground, or poor e or n connection.

• If wire and connection are OK, intermittent trou-
ble or faulty ECM.
YES
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Replace the HO2 sensor with a new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)

Step 1 (When indicating C44/P0135:) 1

1) Turn the ignition switch OFF.
2) Remove the footboard. (#AN650K3 9-18)
3) Check the HO2 sensor coupler 1 for loose or poor contacts.
If OK, then measure the HO2 sensor resistance.

4) Disconnect the HO2 sensor coupler and measure the resis- 1

tance between terminals.
$ HO2 heater resistance: Approx. 13 Ω at 20 °C (68 °F)
(B – B)
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at atmospheric tempera-
ture.
! 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)

Is the voltage OK?

YES Go to Step 2.
NO Replace the HO2 sensor with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
16-26 AN650/AK7 (’07-MODEL)

Step 2 (When indicating C44/P0135:) 2

1) Connect the HO2 sensor coupler.
2) Insert the needle pointed probe to the HO2 sensor coupler. V
3) Turn the ignition switch ON and measure the heater voltage
between B (O/W) wire and ground.
4) If the tester voltage indicates the battery voltage, it is good
condition.
$ Heater voltage: Battery voltage
(+ B – - Ground)
NOTE:
Battery voltage can be detected only before starting the engine.
! 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
' Tester knob indication: Voltage (()

Is the voltage OK? 2

• O/W or B wire open or shorted to ground, or ECM coupler (Harness side)

poor \ connection.
• Recheck each terminal and wire harness for
open circuit and poor connection.
YES
• If wire and connection are OK, intermittent trou-
ble or faulty ECM.
• Replace the ECM with a known good one, and
inspect it again.
• Open or short circuit in the Y/W wire or O/W
wire.
NO
• Loose or poor contacts on the ECM coupler
(Terminal \) or HO2 sensor coupler.
5) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
 AN650/AK7 (’07-MODEL) 16-27

“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION

DETECTED CONDITION POSSIBLE CAUSE
PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short
ECM. • PAIR control solenoid valve malfunction
• ECM malfunction

ECM
Engine stop Side-stand Ignition
switch relay switch
PAIR G/Bl O/W
To side-stand
switch
R B

PAIR control
solenoid valve

INSPECTION 1
Step 1
1) Turn the ignition switch OFF.
2) Remove the lower leg shield. (#AN650K3 9-10)
3) Check the PAIR control solenoid valve coupler 1 for loose or
poor contacts.
If OK, then measure the PAIR control solenoid valve resis-
tance.

4) Remove the PAIR control solenoid valve coupler.

5) Measure the resistance between terminals (valve side).
$ PAIR control solenoid valve resistance:
20 – 24 Ω at 20 °C (68 °F)
(Terminal – Terminal)
! 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES Go to Step 2.
Replace the PAIR control solenoid valve with a
NO
new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
16-28 AN650/AK7 (’07-MODEL)

Step 2 2
1) Turn the ignition switch ON.
V
2) Measure the voltage between O/W wire and ground.
$ PAIR control solenoid valve voltage: Battery voltage
(+ O/W – - Ground)
! 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage (()

Is the voltage OK? 2

ECM coupler (Harness side)
• G/Bl wire open or shorted to ground, or poor 8
connection failure.
• If wire and connection are OK, intermittent trou-
ble or faulty ECM.
YES
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Open or short circuit in the O/W wire.
3) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
2) Turn the ignition switch ON.
3) Click “PAIR Sol operating control” 1.

4) Click each button 2.

At this time, if an operation sound is heard from the PAIR
control solenoid valve, the function is normal.
 AN650/AK7 (’07-MODEL) 16-29

“C62” (P0443) EVAP SYSTEM PURGE CONTROL SOLENOID VALVE

CIRCUIT MALFUNCTION (E-33 ONLY)
DETECTED CONDITION POSSIBLE CAUSE
EVAP system purge control solenoid valve voltage is • EVAP system purge control solenoid valve circuit
not input to ECM. open or short
• EVAP system purge control solenoid valve
malfunction
• ECM malfunction

ECM
Engine stop Side-stand Ignition
switch relay switch
EVAP Dbr O/W
To side-stand
switch

EVAP system
purge control
solenoid valve

INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Remove the maintenance lid. (#AN650K3 9-13)
3) Check the EVAP system purge control solenoid valve coupler
1 for loose or poor contacts.
If OK, then measure the EVAP system purge control solenoid
valve resistance.

4) Remove the footboard. (#AN650K3 9-18) 1

5) Remove the EVAP system purge control solenoid valve.
(#Page 37)
6) Measure the resistance between the terminals.
$ EVAP system purge control solenoid valve resistance:
Approx. 32 Ω at 20 °C (68 °F)
! 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES Go to Step 2.
Replace the EVAP system purge control solenoid
NO
valve with a new one.
7) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)
16-30 AN650/AK7 (’07-MODEL)

Step 2 2
1) Turn the ignition switch ON.
V
2) Measure the voltage between O/W wire and ground.
$ EVAP system purge control solenoid valve voltage:
Battery voltage (+ O/W – - Ground)
! 09900-25008: Multi-circuit tester set
' Tester knob indication: Voltage (()

Is the voltage OK? 2

ECM coupler (Harness side)
• Dbr wire open or shorted to ground, or poor 6
connection failure.
• If wire and connection are OK, intermittent trou-
ble or faulty ECM.
YES
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
NO Open or short circuit in the O/W wire.
3) After repairing the trouble, clear the DTC using SDS tool.
(Refer to the SDS operation manual for further details.)

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
2) Turn the ignition switch ON.
3) Click “EVAP purge valve operating control” 1.

4) Click each button 2.

At this time, if an operation sound is heard from the EVAP
system purge control solenoid valve, the function is normal.
 AN650/AK7 (’07-MODEL) 16-31

ISC VALVE REMOVAL

• Remove the front box. (#AN650K3 9-18)
• Disconnect the ISC valve coupler 1.
"
Be careful not to disconnect the ISC valve coupler at
least 5 seconds after ignition switch is turned OFF.
If the ECM coupler or ISC valve coupler is discon-
nected within 5 seconds after ignition switch is turned
OFF, there is a possibility of an unusual valve position
being written in ECM and causing an error of ISC valve
operation.

• Remove the ISC valve 2.

ISC VALVE INSPECTION

• Inspect the ISC valve for carbon deposition or damage.
• Clean or replace the ISC valve if necessary.
NOTE:
The ISC valve can be checked without removing it.
(#Page 16)

ISC VALVE INSTALLATION

Install the ISC valve in the reverse order of removal.
"
When removing or replacing, the ISC valve must be
set to the PRE-SET position. (#Page 32)
16-32 AN650/AK7 (’07-MODEL)

ISC VALVE PRE-SET

When removing or replacing the ISC valve, set the ISC valve in
the following procedures:
1) Turn the ignition switch ON.
2) Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
3) Click “Active control”.
4) Click “ISC learned value reset” 1.

5) Click “Reset” button 2 to clear the ISC learned value.

NOTE:
The learned value of the ISC valve is set at PRE-SET position.

6) Close the SDS tool.

7) Turn the ignition switch OFF.
NOTE:
The ISC valve opening initialization is automatically started after
the ignition switch is turned OFF.
 AN650/AK7 (’07-MODEL) 16-33

THROTTLE VALVE SYNCHRONIZATION

Check and adjust the throttle valve synchronization between two
cylinders.
Step 1
• Remove the front box. (#AN650K3 9-18)
• Disconnect the respective vacuum hoses 1 from vacuum nip-
ples.

• Disconnect the IAP sensor coupler 2.

• Connect the respective vacuum tester hoses to the nipples on

the throttle body.

Step 2
• Set up the SDS tool. (Refer to the SDS operation manual for
further details.)
• Start the engine.
• Click “Data monitor”.
• Warm up the engine (Water temp. more than 80 °C (176 °F).
16-34 AN650/AK7 (’07-MODEL)

• Click “Active control”.

• Click “ISC air volume control” 1.
• Click “ON” 2 to fix the ISC air volume of two cylinders.
NOTE:
When making this synchronization, be sure that the water tem-
perature is within 80 – 100 °C (176 – 212 °F).
A Engine speed: Approx. 1 200 rpm
B ISC valve position: Approx. 75 step

• Check for the synchronization of vacuum of #1 and #2 cylin-

ders.

• Equalize the vacuum of the cylinders by turning each air

screw 3 and keep it running at idling speed.
NOTE:
Always set the engine rpm at idle rpm.
• If the adjustment is not yet correct, remove each air screw
and clean them with a spray-type carburetor cleaner and blow
dry with a compressed air. Also, clean the air screw passage-
ways.
NOTE:
* Slowly turn the air screw clockwise and count the number of
turns until the screw is lightly seated.
* Make a note of how many turns were made so the screw can
be reset correctly after cleaning.
• Repeat the procedures of Step 2.
• Disconnect the vacuum tester and install the removed parts.
• After completing the throttle valve synchronization, clear the
DTC and reset the ISC learned value using SDS tool.
(#Page 32)
 AN650/AK7 (’07-MODEL) 16-35

HO2 SENSOR INSPECTION

(#Page 23)

HO2 SENSOR REMOVAL AND

INSTALLATION
• Remove the footboard. (#AN650K3 9-18)
• Disconnect the HO2 sensor coupler 1.
• Remove the clamps 2.
• Remove the HO2 sensor 3.
*
Do not remove the HO2 sensor while it is hot.

"
* Be careful not to expose it to excessive shock.
* Do not use an impact wrench while removing or
installing the HO2 sensor.
* Be careful not to twist or damage the sensor lead
wire.

Installation is in the reverse order of removal. Pay attention to

the following points:
"
Do not apply oil or other materials to the sensor air
hole.

• Tighten the HO2 sensor to the specified torque.

+ HO2 sensor: 47.5 N·m (4.75 kgf-m, 34.3 lb-ft)
• Rout the HO2 sensor lead wire properly. (#Page 39)
16-36 AN650/AK7 (’07-MODEL)

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the
following acts or the causing thereof:
1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2. The use of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any
other component which conducts exhaust gases.
• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which
conducts intake air.
• Replacing the exhaust system or muffler with a system or muffler not marked with the same model spe-
cific code as the code listed on the Motorcycle Noise Emission Control Information label.

EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)

1 Fuel shut-off valve
2 Surge hose
3 TPC valve
4 EVAP canister
5 Vacuum hose
6 IAP sensor
7 Purge hose
EVAP system purge
8
control solenoid valve
9 Throttle body assembly
A FUEL
B HC VAPOR
C FRESH AIR
D VACUUM
 AN650/AK7 (’07-MODEL) 16-37

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION

(Only for E-33)
• Remove the footboard. (#AN650K3 9-18)

HOSES
Inspect the hoses for wear and damage.
Make sure that the hoses are securely connected.

EVAP CANISTER
Inspect the canister body for damage.

EVAP SYSTEM PURGE CONTROL SOLENOID

VALVE
REMOVAL
• Disconnect the EVAP system purge control solenoid valve
lead wire coupler 1 and hoses 2.
• Remove the clamps 3.
• Remove the EVAP system purge control solenoid valve 4.
NOTE:
EVAP system purge control solenoid valve can be checked with-
out removing it. (#Page 29)

INSPECTION
• Check that no air flows through both of the air inlet and outlet
ports.
• If air flows out, replace the EVAP system purge control sole-
noid valve with a new one.

• Connect 12 V battery to the terminals of the EVAP system

purge control solenoid valve and check the air flow.
• If air flows out, the solenoid valve is in normal condition.
16-38 AN650/AK7 (’07-MODEL)

• Check the resistance between the terminals of the EVAP sys-

tem purge control solenoid valve.
$ EVAP system purge control solenoid valve resistance:
Approx. 32 Ω at 20 °C (68 °F)
! 09900-25008: Multi-circuit tester set
) Tester knob indication: Resistance (Ω)
• If the resistance is not within the standard range, replace the
EVAP system purge control solenoid valve with a new one.

INSTALLATION
Installation is in the reverse order of removal.
• Connect the EVAP system purge control solenoid valve lead
wire coupler and PAIR hoses securely. (#Page 40)
 AN650/AK7 (’07-MODEL) 16-39

WIRING HARNESS AND HOSE ROUTING

WIRING HARNESS ROUTING
Clamp
CVT control unit Wiring harness
Position light (LH)

Throttle cable

Position light (RH)

Headlight (LH)
To ECM/PCM Wiring harness

Pass the headlight

harness inside the
wiring harness.
Headlight (RH)
To headlights
Front turn signal light (LH)
Front turn signal light (RH) Clamp
Clamp Wiring harness
Front turn signal light (LH)
Handlebar switch (RH & LH) TO sensor
Clamp
Clamp
Set the front turn signal light (LH) coupler
ahead the wiring harness.
Set the TO sensor as shown.
TO sensor

ECM/PCM

Clamp Clamp
CVT revolution sensor Center stand switch
Center stand switch CVT revolution sensor
HO2 sensor Pully position sensor
Clamp CVT motor
Power source fuse
HO2 sensor Parking brake
HO2 sensor switch
Fuse box Parking brake
cable

Clamp
AP sensor
CVT revolution sensor
Pass the each relay lead wire
Center stand switch outside the parking brake cable.
Clamp
 IAT sensor AP sensor AP sensor
16-40

PAIR control IAT sensor

solenoid valve 18 N·m
(1.8 kgf-m, 13.0 lb-ft)
A backward.
A downward. TP sensor
B top side.
PCV (breather)
hose A left side.
AN650/AK7 (’07-MODEL)

Vacuum hose
Throttle cables
PAIR hose

VIEW OF “B” IAC hose

ISC
A upward.
B top side.
E-33 only To canister
VIEW OF “A”
Set the nail of bracket Forward
Pass through the PCV (breather)
hose above the throttle cables. into the hole on frame.

ISC hose Air cleaner side

Fuel feed hose

A 10˚

Fixed with ISC hose Top mark

LH RH
clamp
PAIR
B hose Fuel pump
THROTTLE BODY INSTALLATION AND HOSE ROUTING

Intake pipe side

Clamp

Backward
VIEW OF TOP

A: The end of the clamp should face....

B: The clamp screw head should face....
 AN650/AK7 (’07-MODEL) 16-41

SPECIAL TOOLS

09900-25008 09900-25009 09930-82720

Multi-circuit tester Needle pointed 09904-41010 Mode select 99565-01010-010
set probe set SDS set tool switch CD-ROM Ver.10
NOTE:
When order the special tool, please confirm whether it is available or not.

TIGHTENING TORQUE CHART

For other nuts and bolts not listed in the preceding page, refer to this chart:

Bolt Diameter Conventional or “4” marked bolt “7” marked bolt

A (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 1.5
5 3 0.3 2.0 4.5 0.45 3.0
6 5.5 0.55 4.0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115.5 240 24.0 173.5

Conventional bolt “4” marked bolt “7” marked bolt

16-42 AN650/AK7 (’07-MODEL)

SERVICE DATA (AN650K7)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)
 AN650/AK7 (’07-MODEL) 16-43

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
16-44 AN650/AK7 (’07-MODEL)

ITEM STANDARD LIMIT

Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min
 AN650/AK7 (’07-MODEL) 16-45

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2 , 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
Injector voltage Battery voltage
16-46 AN650/AK7 (’07-MODEL)

ITEM SPECIFICATION NOTE

TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: Gr/R
-: B/Br
Leaning 3.7 – 4.4 V +: Gr/R
-: B/Br
Ignition coil primary peak voltage #1 +: W/Bl
More than 80 V (When cranking) -: Ground
#2 +: B/Y
-: Ground
* HO2 sensor heater resistance Approx. 13 Ω at 20 °C (68 °F)
* HO2 sensor output voltage Idle speed 0 – 1.0 V
5 000 r/min 0 – 1.0 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 st
: Idle speed Approx. 3.3 V
output voltage 3 : 3 000 r/min
rd
Approx. 1.3 V
5 : 3 000 r/min
th
Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage
* EVAP system purge control Approx. 32 Ω at 20 °C (68 °F) E-33 only
solenoid valve resistance

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. * 10G3 (E-33), 10G2 (Others)
Bore size 32 mm (1.26 in)
Fast idle r/min * 1 200 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
* ISC valve resistance Approx. 80 Ω at 25 °C (77 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
 AN650/AK7 (’07-MODEL) 16-47

ITEM STANDARD/SPECIFICATION LIMIT

Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine side Approx. 1 350 ml —
(1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl
More than 80 V -: Ground
#2 +: B/Y
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size 15 A ..........E-03, 24, 28, 33
Head- LO 10 A ..........E-02, 19
light
HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source
16-48 AN650/AK7 (’07-MODEL)

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Parking brake indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
Trunk light 5 ←
Immobilizer indicator light LED ← (E-24 only)
Over drive indicator light 1.4 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
 AN650/AK7 (’07-MODEL) 16-49

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
16-50 AN650/AK7 (’07-MODEL)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type SAE 10W-40, API, SF/SG or SJ/SH with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
 AN650/AK7 (’07-MODEL) 16-51

SERVICE DATA (AN650AK7)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 29.5 —
(1.16)
EX. 25.0 —
(0.98)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.0039 – 0.0079)
EX. 0.20 – 0.30 —
(0.0079 – 0.0118)
Valve guide to valve stem IN. 0.010 – 0.040 —
clearance (0.0004 – 0.0016)
EX. 0.030 – 0.060 —
(0.0012 – 0.0024)
Valve guide I.D. IN. & EX. 4.500 – 4.515 —
(0.1772 – 0.1778)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length (IN. & EX.) IN. & EX. — 40.6
(1.60)
Valve spring tension (IN. & EX.) 136 – 156 N
IN. & EX. (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
at length 33.4 mm (1.31 in)
16-52 AN650/AK7 (’07-MODEL)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 35.38 – 35.43 35.10
(1.393 – 1.395) (1.382)
EX. 33.98 – 34.03 33.70
(1.338 – 1.340) (1.327)
Camshaft journal oil clearance IN. & EX. 0.032– 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 15th pin —
Cylinder head distortion — 0.10
(0.004)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 500 – 1 900 kPa 1 200 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi) (12 kgf/cm2, 171 psi)
Compression pressure difference — 200 kPa
(2.0 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.045 – 0.055 0.120
(0.0018 – 0.0022) (0.0047)
Cylinder bore 75.500 – 75.515 Nicks or
(2.9724 – 2.9730) scratches
Piston diam. 75.470 – 75.485 75.380
(2.9705 – 2.9711) (2.9677)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.10
(0.004)
Piston ring free end gap 1st R Approx. 11.6 (0.46) 9.3
(0.37)
2nd RN Approx. 8.6 (0.34) 6.9
(0.27)
Piston ring end gap 1st 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
2nd 0.06 – 0.18 0.50
(0.002 – 0.005) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
 AN650/AK7 (’07-MODEL) 16-53

ITEM STANDARD LIMIT

Piston ring thickness 1st 0.97 – 0.99 —
(0.038 – 0.039)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore 16.002 – 16.008 16.030
(0.6300 – 0.6302) (0.6311)
Piston pin O.D. 15.995 – 16.000 15.980
(0.6297 – 0.6299) (0.6291)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.010 – 16.018 16.040
(0.6303 – 0.6306) (0.6315)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 19.950 – 20.000 —
(0.7854 – 0.7874)
Crank pin width 20.100 – 20.150 —
(0.7913 – 0.7933)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.018 – 0.045 0.080
(0.0007 – 0.0018) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft thrust bearing thickness 2.025 – 2.175 —
(0.0797 – 0.0856)
Crankshaft thrust clearance 0.10 – 0.15 —
(0.0039 – 0.0059)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2 , 49.8 psi)
Below 550 kPa (5.5 kgf/cm2, 78.2 psi) —
at 3 000 r/min
16-54 AN650/AK7 (’07-MODEL)

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Drive plate claw width 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
Driven plate No. 2 thickness 2.42 – 2.58 2.27
(0.095 – 0.102) (0.089)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 13.9 13.2
(0.547) (0.520)
Clutch plate concaved washer 3.2 3.1
height (0.126) (0.12)
Clutch engagement 1 500 – 2 100 r/min —
Clutch lock-up 3 200 – 3 800 r/min —

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F) —
Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt) —
For 30 sec. at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —
set pressure

FI/CVT-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor resistance 0.9 – 1.7 kΩ
CMP sensor peak voltage More than 0.5 V (When cranking) +: B/Y, -: Br
CKP sensor resistance 150 – 300 Ω
CKP sensor peak voltage More than 2.0 V (When cranking) +: Bl, -: G
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.6 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)
Injector voltage Battery voltage
 AN650/AK7 (’07-MODEL) 16-55

ITEM SPECIFICATION NOTE

TO sensor resistance 19.1 – 19.7 kΩ
TO sensor output voltage Normal 0.4 – 1.4 V +: Gr/R
-: B/Br
Leaning 3.7 – 4.4 V +: Gr/R
-: B/Br
Ignition coil primary peak voltage #1 +: W/Bl
More than 80 V (When cranking) -: Ground
#2 +: B/Y
-: Ground
* HO2 sensor heater resistance Approx. 13 Ω at 20 °C (68 °F)
* HO2 sensor output voltage Idle speed 0 – 1.0 V
5 000 r/min 0 – 1.0 V
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ
Extended 0.2 – 1.0 kΩ
CVT primary pulley position sensor 1 st
: Idle speed Approx. 3.3 V
output voltage 3 : 3 000 r/min
rd
Approx. 1.3 V
5 : 3 000 r/min
th
Approx. 0.5 V
CVT secondary pulley revolution 400 – 600 Ω
sensor resistance
CVT secondary pulley revolution More than 5 V at idle speed +: Y, -: W
sensor peak voltage
* EVAP system purge control Approx. 32 Ω at 20 °C (68 °F) E-33 only
solenoid valve resistance

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. * 10G3 (E-33), 10G2 (Others)
Bore size 32 mm (1.26 in)
Fast idle r/min * 1 200 – 1 600 r/min
Idle r/min 1 200 ± 100 r/min
* ISC valve resistance Approx. 80 Ω at 25 °C (77 °F)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD/SPECIFICATION LIMIT
Thermostat valve opening temper- Approx. 88 °C (190 °F) —
ature
Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —
Engine coolant temperature sensor 20 °C (68 °F) Approx. 2.45 kΩ —
resistance 50 °C (122 °F) Approx. 0.811 kΩ —
80 °C (176 °F) Approx. 0.318 kΩ —
110 °C (230 °F) Approx. 0.142 kΩ —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm²) —
sure
Eclectic fan thermo-switch operat- ON 93 – 103 °C (199 – 217 °F) —
ing temperature OFF 87 – 97 °C (188 – 206 °F) —
16-56 AN650/AK7 (’07-MODEL)

ITEM STANDARD/SPECIFICATION LIMIT

Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the —
ratio of 50:50.
Engine coolant including reserve Reverse Approx. 250 ml —
tank side (0.264/0.220 US/Imp qt)
Engine side Approx. 1 350 ml —
(1.427/1.188 US/Imp qt)

ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1·2
Spark plug Type NGK: CR8E
DENSO: U24ESR-N
Gap 0.7 – 0.8
(0.028 – 0.031)
Spark performance Over 8.0 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.0 V +: Bl, -:G
Ignition coil resistance Primary 0.8 – 2.5 Ω
Secondary 8 – 18 kΩ
Ignition coil primary peak voltage #1 +: W/Bl
More than 80 V -: Ground
#2 +: B/Y
-: Ground
Generator coil resistance CKP sensor 150 – 300 Ω G – BI
Charging 0.1 – 1.0 Ω Y–Y
Generator no-load voltage More than 50 V at 5 000 r/min
(When cold)
Generator Max. output Approx. 500 W at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size Head- LO 15 A
light HI 15 A
Fuel pump 10 A
Ignition 15 A
Turn signal 15 A
Fan motor 15 A
Main 40 A
CVT 40 A
Power 10 A
source
ABS 15 A × 2
Wind 20 A
screen
Mirror 3A
 AN650/AK7 (’07-MODEL) 16-57

WATTAGE Unit: W
STD/SPEC.
ITEM
E-02, 19, 51 E-03, 24, 28, 33
Headlight HI 60 + 55 60 × 2
LO 55 55 × 2
Parking or position light 5×2
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
License plate light 5 ←
Instrument panel light 1.4 × 2 ←
Engine coolant temp. indicator light 1.4 ←
FI indicator light 1.4 ←
Engine oil pressure indicator light 1.4 ←
Parking brake indicator light 1.4 ←
High beam indicator light 1.4 ←
Turn signal indicator light 1.4 × 2 ←
Power mode indicator light 1.4 ←
Drive indicator light 1.4 ←
Gear position indicator light 1.4 × 5 ←
ABS warning indicator light 1.4 ←
Trunk light 5 ←
Immobilizer indicator light LED ← (E-24 only)
Over drive indicator light 1.4 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.5 ± 0.2 5.0
(0.217 ± 0.008) (0.20)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 12.700 – 12.743 —
(0.5000 – 0.5017)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 12.657 – 12.684 —
(0.4983 – 0.4994)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Front 25.400 – 25.450 —
(1.0000 – 1.0020)
Rear 27.000 – 27.050 —
(1.0630 – 1.0650)
Brake caliper piston diameter Front 25.318 – 25.368 —
(0.9968 – 0.9987)
Rear 26.918 – 26.968 —
(1.0598 – 1.0617)
Brake fluid type DOT 4 —
16-58 AN650/AK7 (’07-MODEL)

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 15 M/C × MT3.50 —
Rear 14 M/C × MT4.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 110 —
(4.3)
Front fork spring free length — 341
(13.4)
Front fork oil type SUZUKI FORK OIL G-10 (#10) or —
an equivalent fork oil
Front fork oil capacity (each leg) 458 ml —
Front fork oil level 151 —
(5.9)
Front fork inner tube diam. 41
(1.61)
Rear wheel travel 100 —
(3.9)
Rear shock absorber spring 2nd —
adjuster

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 225 kPa —
Solo (2.25 kgf/cm2, 33 psi)
riding 250 kPa
Rear (2.50 kgf/cm2, 36 psi) —

Front 225 kPa —

Dual (2.25 kgf/cm2, 33 psi)
riding 280 kPa
Rear (2.80 kgf/cm2, 41 psi) —
Tire size Front 120/70R15M/C 56H —
Rear 160/60R14M/C 65H —
Tire type Front BRIDGESTONE TH01F —
Rear BRIDGESTONE TH01R —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
 AN650/AK7 (’07-MODEL) 16-59

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including 15.0 L (4.0/3.3 US/lmp gal)
reserve
Fuel meter
mark Approx. 3.0 L (0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and Approx. 1.5 L (0.40/0.33 US/lmp gal)
LCD
flickering
Engine oil and transmission oil type SAE 10W-40, API, SF/SG or SJ/SH with JASO MA
Engine oil capacity Oil change 2.6 L
(2.7/2.3 US/lmp qt)
Filter change 2.9 L
(3.1/2.6 US/lmp qt)
Overhaul 3.4 L
(3.6/3.0 US/lmp qt)
Transmission oil capacity Oil change 360 ml
(12.2/12.7 US/lmp oz)
Overhaul 400 ml
(13.5/14.1 US/lmp oz)
Final gear oil type Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity Oil change 300 ml
(10.1/10.6 US/lmp oz)
Overhaul 430 ml
(14.5/15.1 US/lmp oz)
03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
 AN650/AK8 (’08-MODEL) 17-1

AN650/AK8 (’08-MODEL)

CONTENTS

WIRING HARNESS ROUTING ..................................................................... 17- 217-2

WIRING HARNESS ROUTING (For ABS model) ....................................... 17- 5 17-5

17
17- 2 AN650/AK8 (’08-MODEL)
WIRING HARNESS ROUTING
AN650AZ only
Cut excess tip of clamp.
Clamp
CVT control unit Wiring harness

Position light (L)

Throttle cable
Cut excess tip
of clamp.
Position light (R)

Headlight (L)

Wiring
harness

ECM
Headlight (R)
Front turn signal light (L)
Front turn signal light (R) Clamp
Grip heater lead
Clamp
TO sensor
Handlebar switch (R & L) AN650AZ only
Set the TO
Clamp sensor
as shown.
TO sensor
Clamp Wiring harness
CVT revolution sensor Front turn signal light (L)
Center stand switch
HO2 sensor Clamp

Clamp Set the front turn signal light (L) coupler

ahead the wiring harness.
Center stand switch
K7 – CVT revolution sensor CVT control unit
Pully position sensor
CVT motor
Clamp Power source fuse
HO2 sensor Brake lock
switch
HO2 sensor
Brake lock
Fuse box cable

Clamp
Be careful not touch the exhaust pipe. AP sensor
CVT
revolution Pass the relay lead wire
sensor outside the parking brake cable.
Center stand
switch

Clamp
K7 – K7 –
 AN650/AK8 (’08-M ODEL) 17- 3
Engine coolant temp. sensor Clamp
Injector #2 Starter motor Wiring harness
Clamp
Center stand switch
Wiring harness
CVT revolution sensor
Solenoid
PP sensor
CVT motor
HO2 sensor

Pass through the license plate light coupler

Injector #1 IAC valve from the hole after connect coupler.
TPS sensor
Wiring harness
Clamp
Clamp

Fix the clamp

to the hole of
the rear frame. Set the regulator/
Clamp rectifier lead wire
20 mm 30 mm 30 mm 20 mm coupler
Clamp Wiring harness
under the fuel
Wiring harness Generator hose.
Clamp Clamp
Generator Speedometer
Wiring harness Wiring harness
sensor
Starter motor Generator
Trunk light switch Starter motor

Clamp
Wiring
harness

Regulator/rectifier
Oil level switch
Speedometer sensor
Side-stand switch Oil pressure switch
Oil level switch Clamp
Oil pressure switch Clamp
Fuel hose
Trunk light seat switch
Clamp Set to bracket end

Clamp
Ignition coil/ Ignition coil/plug cap #1 Seat heater
plug cap #2 AN650AZ only To the trunk
Wiring harness 0 – 5 mm
light switch
AP Clamp
sensor
Fuse
Set harness clamp inside.

Generator lead
wire coupler

Clamp bottom side of

the harness clamp.

Pass the harness Vent clamp inside, not to outside

inside parking cable. the actuator set plate.
17- 4 AN650/AK8 (’08-MODEL)

Battery
Battery - lead wire coupler
Set the lead wires
under the fuel hose.
Wiring harness

Battery + terminal Battery - terminal Fuel hose

Set the battery + lead wire coupler

under the wiring harness.

Starter relay

Fix the starter relay lead wire coupler

Set the lead wires to the to hole of the battery cover.
front of the battery box.
Trunk light Clamp
seat switch
Brake light/taillight

Trunk light switch

Trunk light seat switch
Clamp

Pass the brake light/taillight

lead wire under the frame.

Main fuse

Pass the brake light/taillight CVT fuse

lead wire under the frame.
 AN650/AK8 (’08-MODEL) 17- 5

WIRING HARNESS ROUTING (For ABS model)

Pass meter lead to backside of brace.

Left front turn signal

Left mirror

Clamp

Screen relay Wiring harness

 AN650/AK9 (’09-MODEL) 18-1

AN650/A K9 ('09-MODEL)

#/.4%.43
0!'%
30%#)&)#!4)/.3 
2%!2"2!+%
7)2).'(!2.%33#!",%!.$(/3%2/54).'
3%26)#%$!4!

18

NOTE:
• Differences between K9-MODEL and K8-MODEL specifications are indicated with an
asterisk mark (*).
• Different tables between K9-MODEL and K8-MODEL in service data are attached.
18- 2 AN650/AK9 (’09-MODEL)

30%#)&)#!4)/.3
!.+
$)-%.3)/.3!.$#52"-!33
/VERALLLENGTH  MMIN
/VERALLWIDTH MMIN
/VERALLHEIGHT  MMIN
7HEELBASE  MMIN
'ROUNDCLEARANCE MMIN
3EATHEIGHT  MMIN

#URBMASS  KGLBS % 
KGLBS % 

%.').%
4YPE  STROKELIQUID COOLED$/(#
.UMBEROFCYLINDERS  
"ORE MMIN
3TROKE  MMIN
$ISPLACEMENT  CMCUIN
#OMPRESSIONRATIO  
&UELSYSTEM  &UELINJECTION
!IRCLEANER  .ON WOVENFABRICELEMENT
3TARTERSYSTEM  %LECTRIC
,UBRICATIONSYSTEM  7ETSUMP
)DLESPEED ÕRMIN

$2)6%42!).
#LUTCH  7ETMULTI PLATEAUTOMATICCENTRIFUGALTYPE
4RANSMISSION  3%#64
'EARSHIFTPATTERN  !UTOMATIC-ANUALSHIFT
0RIMARYREDUCTIONRATIO  
!UTOMATICTRANSMISSIONRATIO   6ARIABLE
3ECONDARYREDUCTIONRATIO  ¾¾
&INALREDUCTIONRATIO ¾¾¾
$RIVESYSTEM 'EARDRIVE

#(!33)3
&RONTSUSPENSION 4ELESCOPICCOILSPRINGOILDAMPED
2EARSUSPENSION  3WINGARMTYPECOILSPRINGOILDAMPED
&RONTFORKSTROKE  MMIN
2EARWHEELTRAVEL  MMIN
#ASTER —
4RAIL MMIN
3TEERINGANGLE  —RIGHTLEFT
4URNINGRADIUS MFT
&RONTBRAKE  $ISCBRAKETWIN
2EARBRAKE $ISKBRAKE
&RONTTIRE  :2-#(TUBELESS
2EARTIRE  :2-#(TUBELESS

%,%#42)#!,
)GNITIONTYPE  %LECTRONICIGNITION4RANSISTORIZED
)GNITIONTIMING  —"4$#ATRMIN
3PARKPLUG  .'+#2%OR$%.3/)5%32 .
"ATTERY 6K#!H (2
'ENERATOR  4HREE PHASE!#GENERATOR
-AINFUSE !
#64FUSE  !
&USE !% 
(EADLIGHT67( ¾% 
"RAKELIGHT4AILLIGHT  67¾
4URNSIGNALLIGHT  67
,ICENSEPLATELIGHT  67
4RUNKLIGHT 67
)NSTRUMENTPANELLIGHT ¾7¾
4URNSIGNALINDICATORLIGHT 67¾
#OOLANTTEMPERATUREINDICATORLIGHT  67
&UELINJECTIONINDICATORLIGHT  67
/ILPRESSUREINDICATORLIGHT 67
(IGHBEAMINDICATORLIGHT 67
0OWERMODEINDICATORLIGHT  67
$RIVEINDICATORLIGHT 67
'EARPOSITIONINDICATORLIGHT 67¾
/VERDRIVEINDICATORLIGHT 67
"RAKELOCKINDICATORLIGHT  67

#!0!#)4)%3
&UELTANK  ,53)MPGAL
%NGINEOILOILCHANGE  ML53)MPQT
WITHFILTERCHANGE  ML53)MPQT
OVERHAUL  ML53)MPQT
4RANSMISSIONOILOILCHANGE  ML53LMPOZ
OVERHAUL  ML53LMPOZ
&INALGEAROILOILCHANGE  ML53LMPOZ
OVERHAUL  ML53LMPOZ
#OOLANT  ,53)MPQT
 AN650/AK9 (’09-MODEL) 18- 3

!.!+
$)-%.3)/.3!.$#52"-!33
/VERALLLENGTH  MMIN
/VERALLWIDTH MMIN
/VERALLHEIGHT  MMIN
7HEELBASE  MMIN
'ROUNDCLEARANCE MMIN
3EATHEIGHT  MMIN

#URBMASS  KGLBS % 

KGLBS % 

%.').%
4YPE  STROKELIQUID COOLED$/(#
.UMBEROFCYLINDERS  
"ORE MMIN
3TROKE  MMIN
$ISPLACEMENT  CMCUIN
#OMPRESSIONRATIO  
&UELSYSTEM  &UELINJECTION
!IRCLEANER  .ON WOVENFABRICELEMENT
3TARTERSYSTEM  %LECTRIC
,UBRICATIONSYSTEM  7ETSUMP
)DLESPEED ÕRMIN

$2)6%42!).
#LUTCH  7ETMULTI PLATEAUTOMATICCENTRIFUGALTYPE
4RANSMISSION  3%#64
'EARSHIFTPATTERN  !UTOMATIC-ANUALSHIFT
0RIMARYREDUCTIONRATIO  
!UTOMATICTRANSMISSIONRATIO   6ARIABLE
3ECONDARYREDUCTIONRATIO  ¾¾
&INALREDUCTIONRATIO ¾¾¾
$RIVESYSTEM 'EARDRIVE

#(!33)3
&RONTSUSPENSION 4ELESCOPICCOILSPRINGOILDAMPED
2EARSUSPENSION  3WINGARMTYPECOILSPRINGOILDAMPED
&RONTFORKSTROKE  MMIN
2EARWHEELTRAVEL  MMIN
#ASTER —
4RAIL MMIN
3TEERINGANGLE  —RIGHTLEFT
4URNINGRADIUS MFT
&RONTBRAKE  $ISCBRAKETWIN
2EARBRAKE $ISKBRAKE
&RONTTIRE  :2-#(TUBELESS
2EARTIRE  :2-#(TUBELESS

%,%#42)#!,
)GNITIONTYPE  %LECTRONICIGNITION4RANSISTORIZED
)GNITIONTIMING  —"4$#ATRMIN
3PARKPLUG  .'+#2%OR$%.3/)5%32 .
"ATTERY 6K#!H (2
'ENERATOR  4HREE PHASE!#GENERATOR
-AINFUSE !
#64FUSE  !
&USE
!% 
+HDGOLJKW9:+î(
"RAKELIGHT4AILLIGHT  67¾
4URNSIGNALLIGHT  67
,ICENSEPLATELIGHT  67
4RUNKLIGHT 67
)NSTRUMENTPANELLIGHT ¾7¾
4URNSIGNALINDICATORLIGHT 67¾
#OOLANTTEMPERATUREINDICATORLIGHT  67
&UELINJECTIONINDICATORLIGHT  67
/ILPRESSUREINDICATORLIGHT 67
(IGHBEAMINDICATORLIGHT 67
0OWERMODEINDICATORLIGHT  67
$RIVEINDICATORLIGHT 67
'EARPOSITIONINDICATORLIGHT 67¾
/VERDRIVEINDICATORLIGHT 67
"RAKELOCKINDICATORLIGHT  67
!"3INDICATORLIGHT  67

#!0!#)4)%3
&UELTANK  ,53)MPGAL
%NGINEOILOILCHANGE  ML53)MPQT
WITHFILTERCHANGE  ML53)MPQT
OVERHAUL  ML53)MPQT
4RANSMISSIONOILOILCHANGE  ML53LMPOZ
OVERHAUL  ML53LMPOZ
&INALGEAROILOILCHANGE  ML53LMPOZ
OVERHAUL  ML53LMPOZ
#OOLANT  ,53)MPQT
18- 4 AN650/AK9 (’09-MODEL)

2%!2"2!+%
#/.3425#4)/.

1$IAPHRAGM A/ RING

20ISTONCUPSET B"RAKELOCKSHAFT
3-ASTERCYLINDER C"RAKELOCKADJUSTER
4"RAKEHOSE.O D"RAKELOCKARM
5"RAKEPIPE E0AD
6"RAKEHOSE.O F0ISTON
7#ALIPERHOLDER G$USTSEAL
8#ALIPER H0ISTONSEAL
9'ASKET
0"RAKELOCKHOUSING

"
)4%- .qM KGF M LBF FT
A-ASTERCYLINDERBOLT 17
A   18
B"RAKEHOSEUNIONBOLT
B   C"RAKEPIPENUT
C   D#ALIPERHOLDERSLIDINGPIN 17
E#ALIPERHOLDERSLIDINGPIN 18
D  
F!IRBLEEDERVALVE
E   G"RAKELOCKHOUSINGBOLT
F   H"RAKELOCKADJUSTBOLTLOCK NUT
I0ADMOUNTINGPIN
G  
J#ALIPERMOUNTINGBOLT
H  
I  
J  

#

4HISBRAKESYSTEMISFILLEDWITHANETHYLENEGLYCOL BASED$/4BRAKEFLUID$ONOTUSEOFMIX
DIFFERENTTYPESOFFLUIDSUCHASSILICONE BASEDORPETROLEUM BASED

$ONOTUSEANYBRAKEFLUIDTAKENFROMOLDUSEDORUNSEALEDCONTAINERS.EVERREUSEBRAKE
FLUIDLEFTOVERFROMTHELASTSERVICINGORSTOREDFORLONGPERIODS

7HENSTORINGTHEBRAKEFLUIDSEALTHECONTAINERCOMPLETELYANDKEEPAWAYFROMCHILDREN

7HENREPLENISHINGBRAKEFLUIDTAKECARENOTTOGETDUSTINTOFLUID

7HENWASHINGBRAKECOMPONENTSUSEFRESHBRAKEFLUID.EVERUSECLEANINGSOLVENT

!CONTAMINATEDBRAKEDISCORBRAKEPADREDUCESBRAKINGPERFORMANCE$ISCARDCONTAMINATED
PADSANDCLEANTHEDISCWITHHIGHQUALITYBRAKECLEANERORNEUTRALDETERGENT


(ANDLEBRAKEFLUIDWITHCARETHEFLUIDREACTSCHEMICALLYWITHPAINTPLASTICSRUBBERMATERIALS
ETCANDWILLDAMAGETHEMSEVERELY
 AN650/AK9 (’09-MODEL) 18- 5

"2!+%0!$).30%#4)/.
4HEEXTENTOFBRAKEPADWEARCANBECHECKEDBYOBSERVINGTHE
GROOVEDLIMIT AONTHEPADS7HENTHEWEAREXCEEDSTHE
GROOVEDLIMITREPLACETHEPADSWITHNEWONES

"2!+%0!$2%0,!#%-%.4
s ,OOSENTHEPADMOUNTINGPINS1

s 2EMOVETHEBRAKELOCKCABLEGUIDE2

s 2EMOVETHELOCK NUT 3BRAKELOCKARM 4ANDRETURNSPRING

5
s 2EMOVETHE% RING6ANDDISCONNECTTHEBRAKELOCKCABLE7
18-6 AN650/AK9 (’09-MODEL)

s 2EMOVETHECALIPER8

$ONOTOPERATETHEBRAKELEVERWHILETHECALIPERIS
REMOVED

s 2EMOVETHEBRAKEPADS 9BYREMOVINGTHEPADMOUNTING
PINS1
s #LEANUPTHECALIPERESPECIALLYAROUNDTHEPISTONS

s !SSEMBLETHENEWPADSINSULATORS0ANDSHIMSA

2EPLACETHEBRAKEPADSASASETOTHERWISEBRAKING
PERFORMANCEWILLBEADVERSELYAFFECTED

s 7ITHTHEPISTONREARSIDE BPUSHEDBACKINTOTHECALIPER
FORCETHEOTHERPISTONFRONTSIDE C ALSOINTOTHECALIPERBY
TURNINGITCLOCKWISE
s !LIGNONEOFTHEGROOVEWITHTHEPUNCHMARKABYTURNINGTHE
PISTONFRONTSIDE CCOUNTERCLOCKWISE
s )NSTALLTHEPADWITHTHEPROJECTIONBFITTEDINTHEGROOVEONTHE
PISTON
s 4EMPORARILYTIGHTENTHEPADMOUNTINGPINS

s )NSTALLTHECALIPERTOTHESWINGARM
s 4IGHTENTHECALIPERMOUNTINGBOLTSTOTHESPECIFIEDTORQUE
" #ALIPERMOUNTINGBOLT.qMKGF MLBF FT
 AN650/AK9 (’09-MODEL) 18-7

s 4IGHTENTHEPADMOUNTINGPINSTOTHESPECIFIEDTORQUE
" 0ADMOUNTINGPIN.qMKGF MLBF FT
NOTE:
After replacing the brake pads, pump the brake lever several
times to check for proper brake operation.

s )NSTALLTHEBRAKELOCKCABLE7AND% RING6

s (OOKTHEBRAKELOCKCABLEANDRETURNSPRINGTOTHEBRAKELOCK
ARM4
NOTE:
Make sure that the spring ends face to right side of the vehicle.
s )NSTALLTHEBRAKELOCKARM 4TOTHECALIPERWITHALIGNINGTHE
PUNCHMARKSCANDD
s !DJUSTTHEBRAKELOCK0AGE

#!,)0%22%-/6!,
s $ISCONNECTTHEBRAKELOCKCABLEFROMTHECALIPER
0AGE
s $ISCONNECTTHEBRAKEHOSE1

0LACEARAGUNDERNEATHTHEUNIONBOLTONTHEBRAKE
CALIPERTOCATCHANYSPILTBRAKEFLUID

s ,OOSENTHEPADMOUNTINGPINS0AGE
s 2EMOVETHECALIPER0AGE
s 2EMOVETHEBRAKEPADS0AGE
2EFERTO!.!!:+SERVICEMANUALFORTHECALIPERDISAS
SEMBLYANDASSEMBLY
18-8 AN650/AK9 (’09-MODEL)

#!,)0%2).34!,,!4)/.
)NSTALLTHECALIPERINTHEREVERSEORDEROFREMOVAL0AYATTENTION
TOTHEFOLLOWINGPOINTS

#!,)0%2
s 4IGHTENTHECALIPERMOUNTINGBOLTSTOTHESPECIFIEDTORQUE
" 2EARCALIPERMOUNTINGBOLT.qMKGF MLBF FT
s #ONNECTTHEBRAKEHOSETOTHECALIPERWITHTHEBRAKEHOSE
UNIONSEATEDTOTHESTOPPERA
s 4IGHTENTHEBRAKEHOSEUNIONBOLTTOTHESPECIFIEDTORQUE
" "RAKEHOSEUNIONBOLT.qMKGF MLBF FT



4HESEALWASHERSSHOULDBEREPLACEDWITHTHENEW
ONESTOPREVENTFLUIDLEAKAGE

"LEEDAIRFROMTHESYSTEMAFTERREASSEMBLINGTHECAL
IPER!.!!:+ 

"RAKEFLUIDIFITLEAKSWILLINTERFEREWITHSAFERUNNING
ANDDISCOLORPAINTEDSURFACES#HECKTHEBRAKEHOSE
ANDHOSEJOINTSFORCRACKSANDFLUIDLEAKAGE

"2!+%,/#+
s !PPLY35:5+)3),)#/.%'2%!3%TOTHEBRAKELOCKBOLT
END
[  35:5+)3),)#/.%'2%!3%
OREQUIVALENT

s )NSTALLNEWGASKET1ANDTHEBRAKELOCKHOUSING2TOTHECAL
IPER
s !PPLY4(2%!$,/#+350%2hvTOTHEBRAKELOCKBOLTS
K  4(2%!$,/#+350%2hv
OREQUIVALENT
s 4IGHTENTHEBRAKELOCKHOUSINGBOLTSTOTHESPECIFIEDTORQUE
" "RAKELOCKHOUSINGBOLT.qMKGF MLBF FT
s !PPLY35:5+)3),)#/.%'2%!3%TOTHE/ RING
[  35:5+)3),)#/.%'2%!3%
OREQUIVALENT
s )NSTALLTHE/ RINGINTOTHEBRAKELOCKHOUSING

2EPLACETHEGASKETAND/ RINGWITHNEWONES
 AN650/AK9 (’09-MODEL) 18-9

s !PPLY35:5+)3),)#/.%'2%!3%TOTHEBRAKELOCKSHAFT
[  35:5+)3),)#/.%'2%!3%
OREQUIVALENT

s )NSTALLTHEBRAKELOCKSHAFTSOTHATTHEPUNCHMARK ACANBE
POSITIONEDINBWHENTHEBRAKELOCKSHAFTISTURNEDCLOCKWISE
UNTILITSTOPS

s )NSTALLTHEBRAKELOCKCABLEAND% RING0AGE
s )NSTALLTHEBRAKELOCKADJUSTBOLT2TOTHEBRAKELOCKSHAFT
s 4URNTHEBRAKELOCKSHAFTABOUT —COUNTERCLOCKWISESOTHAT
THEPUNCHMARKCWILLFACEUPWARD

s (OOKTHEBRAKELOCKCABLEANDRETURNSPRINGTOTHEBRAKELOCK
ARM3
NOTE:
Make sure that the spring ends face to right side of the vehicle.
s )NSTALLTHEBRAKELOCKARM 3TOTHECALIPERWITHALIGNINGTHE
PUNCHMARKSDANDE
s !DJUSTTHEBRAKELOCK0AGE
18-10 AN650/AK9 (’09-MODEL)

"2!+%,/#+!$*534-%.4
"EFOREADJUSTINGTHEBRAKELOCKPERFORMTOBLEEDTHEAIRFROMTHE
REARBRAKESYSTEM
s 0ULLTHEBRAKELOCKLEVER1BYONESTEPONENOTCH 
NOTE:
* The brake lock lever has eight steps (eight notches) when pull-
ing in full.
* When pulling the brake lock lever, first the brake lock switch
makes sound, then notch makes a sound. Make a count of
notch by sound except the brake lock switch’s sound.
s ,OOSENTHELOCK NUT2ANDADJUSTERBOLT3

s 4URNTHEADJUSTERBOLT3CLOCKWISEUNTILITSTOPS
s 4IGHTENTHELOCK NUT 2TOTHESPECIFIEDTORQUEWITHTHE
ADJUSTERBOLT3HELDINTHATPOSITION
" "RAKELOCKADJUSTLOCK NUT.qMKGF MLBF FT
NOTE:
Do not turn the adjust bolt more than the given position, or the
adjust bolt may be damaged.
s )NSPECTTHEBRAKELOCK!.!!:+ 
 AN650/AK9 (’09-MODEL) 18-11

7)2).'(!2.%33#!",%!.$(/3%2/54).'
7)2).'(!2.%332/54).'

AN650A (E-02, 19, 28)

Cut excess tip of clamp.

Throttle cable
Cut excess tip
of clamp.
AN650A (E-02, 19, 28)

Clamp
CVT revolution sensor AN650:
Center stand switch Pass the fuse branch
lead wire over the
HO2 sensor inlet pipe. Power
Fuse box source
Clamp fuse
Center stand switch
CVT revolution sensor
Pulley position sensor
Clamp CVT motor
HO2 sensor HO2 sensor

AN650A:
Pass the fuse branch
lead wire under the
inlet pipe.

Clamp
CVT
revolution
sensor
Center stand
switch
Be careful not touch the exhaust pipe.
Clamp
18-12 AN650/AK9 (’09-MODEL)

Engine coolant temp. sensor

Clamp Injector #2 Clamp
Starter motor
Wiring harness
Wiring harness
Center stand switch
PAIR Solenoid
CVT revolution sensor
PP sensor
CVT motor
HO2 sensor

Injector #1 ISC valve Pass the license plate light coupler

Wiring harness TPS sensor from the hole.
0 – 5 mm 0 – 5 mm
(0 – 0.2 in) (0 – 0.2 in) Clamp Clamp

Bend to
the other 0 – 5 mm 0 – 5 mm
side
side. (0 – 0.2 in) (0 – 0.2 in) Fix the clamp
to the hole of
the rear frame. Set the regulator/
rectifier lead wire
Clamp coupler
ECM cushion ECM cushion Wiring harness under the fuel
Generator hose.
Clamp Clamp
Wiring harness Speedometer
Wiring harness Clamp sensor
Generator
Wiring harness
Starter motor
Generator
Trunk light switch
Starter motor
Clamp
Wiring
harness

Noise label
(E-28 only)

Regulator/rectifier
Oil level switch
Speedometer sensor
Side-stand switch Oil pressure switch
Oil level switch Clamp
Oil pressure switch Clamp
Fuel hose
0 – 15q Trunk light seat switch
Clamp Set to bracket end.

Clamp
Ignition coil/ Ignition coil/plug cap #1 Seat heater
plug cap #2 AN650A (E-02, 19, 28) To the trunk
Wiring harness 0 – 5 mm
(0 – 0.2 in) light switch
AP Clamp
sensor
Fuse
Set harness clamp inside.

Generator lead
wire coupler

Clamp bottom side of

the harness clamp.

Pass the wiring

harness above Pass the wiring harness Bend the clamp to inside, not to outside
the relay. inside the brake lock cable. the actuator set plate.
 AN650/AK9 (’09-MODEL) 18-13

#LAMP
(ANDLEBARSWITCH,2
!"3SENSOR!.!
'RIPHEATER!.!% 
'RIPHEATERSWITCH!.!% 
#LAMP
#LAMP
&RONTTURNSIGNALLIGHT2
&RONTTURNSIGNALLIGHT,
-IRRORMOTOR2
-IRRORMOTOR,

#OUPLERCONNECTING
AREA
0ASSTHESPEEDOMETER
#LAMP LEADWIREBEHINDTHE
3TARTERRELAY BRACE

'RIPHEATER
LEADWIRE
#OUPLER
#ONNECTING
AREA

#LAMP
7IRINGHARNESS

3ETTHEBOOTON %#-
THEIGNITIONSWITCH
COUPLER
4OPOSITIONLIGHT,
4OPOSITIONLIGHT2

!"3SENSOR
&RONTBRAKEHOSE
LEADWIRE
!.!
18-14 AN650/AK9 (’09-MODEL)

Battery
Battery - lead wire coupler
Set the lead wires
under the fuel hose.
Wiring harness

Battery + terminal Battery - terminal Fuel hose

Set the battery + lead wire coupler

under the wiring harness.

Starter relay

Fix the starter relay lead wire coupler

to hole of the battery cover.
Set the lead wires to the
front of the battery box. Trunk light Clamp
seat switch
Brake light/taillight
Tape

Tape

Trunk light switch

Trunk light seat switch

Clamp

Pass the brake light/taillight

lead wire under the frame.

Main fuse

Pass the brake light/taillight CVT fuse

lead wire under the frame.
 AN650/AK9 (’09-MODEL) 18-15

2%!27(%%,30%%$3%.3/2
).34!,,!4)/.!.!
Clamp
Wheel speed sensor lead wire
Speedometer sensor lead wire

Wheel speed sensor

Speedometer
sensor

Basic position tape

Harness guide

Wheel speed sensor lead

wire (Right side)

Speedometer sensor lead

wire (Left side)
 18-16

Pass the throttle Pass the throttle cables

cables under the between steering upper
bracket and rear brake hose.
harness. Throttle cable Handlebar
(pulling) switch (RH) Throttle cable A
(pulling)
Throttle cable Front brake hose
(returning) Throttle cable
A
(returning)
AN650/AK9 (’09-MODEL)

Rear brake hose Throttle cable

#!",%2/54).'

Rear brake hose

(returning)
Handlebar Pass the throttle cables Throttle cable
switch (LH) behind the brake hoses. (pulling)
B
Wiring harness Wiring harness

VIEW B

Guide
Rear brake hose
C

Clamp C
Brake lock cable

Clamp
Clamp

Brake lock cable Fix the clamp as shown.

Pass the brake lock cable

SECT C C between the frame and engine.
 AN650/AK9 (’09-MODEL) 18-17

Seat lock cable To ignition switch

Clamp
Clamp

Clamp

Pass the seat

lock cable Pass the
inside of seat lock cable
the guide rib. outside of
the guide rib.

AN650

Ignition switch

Pass through the seat lock

cable inside of brake hose.

Pass through the seat lock

cable inside of frame pipe.
Clamp

ABS control unit/HU

Pass the seat

lock cable Pass the
inside of seat lock cable
the guide rib. outside of
the guide rib.
Seat lock cable

AN650A
 18-18
After touching the brake hose union
to the stopper, tighten the union bolt.
Rear brake 23 N¦m (2.3 kgf-m, 16.5 lbf-ft)
23Nm(2.3kgf¦m,16.5lbf-ft)
master cylinder
Washer

A Rear brake hose

Stopper
AN650/AK9 (’09-MODEL)

B
B VIEW B VIEW A
Brake hose guide
Clamp Rear brake hose
Brake hose guide

Rear brake hose

C
Brake hose Rear brake pipe
Fix a non-cover portion of Rear brake
brake pipe with the clamp. Fix the white mark pipe
on the brake pipe
with the clamp. Rear brake
pipe

VIEW C
2%!2"2!+%(/3%2/54).'!.

D
Rear brake hose
D

E
E

Brake lock cable

Clamp

Rear brake pipe

After touching the brake hose Guide SECT DD
union to the caliper, tighten the
union bolt.
23 N¦m (2.3 kgf-m, 16.5 lbf-ft)
23Nm(2.3kgf¦m,16.5lbf-ft)

Rear brake hose

SECT EE
 AN650/AK9 (’09-MODEL) 18-19

2%!2"2!+%(/3%2/54).'!.!

Guide Pass through the brake hoses inside the guide.

Front brake hose No. 1

Rear brake hose No. 1

Clamp ABS control unit/HU

Clamp the sleeve of

the brake hose firmly.

Front brake hose No. 2

Clamp the sleeve of the brake hose firmly.

Position the clamp with the bracket stopper
before tightening the bolt.
Guide

Clamp

Front brake
hose No. 2

Fix the white painted section

of the brake pipe with the clamp.
Rear brake pipe
Rear brake hose

E 14˚

Parking brake cable

After touching the brake

hose to the caliper,
tighten the union bolt. Clamp the
23 N.m
23N m (2.3kgf-m)
(2.3 kgf-m 16.5 lbf-ft) Guide brake hose
14˚ firmly.

Rear brake hose

SECT E-E
E
18-20 AN650/AK9 (’09-MODEL)

7)2).'(!2.%3302/4%#4/2#/.3425#4)/.
FWD

30 mm (1.18 in)

LH RH

Stick the wiring

harness protector
from the engine
mounting bushing
edge side.
Crankcase front upper part

'2)0(%!4%2#/.3425#4)/.!.!% 

Clamp the lead wire so it is not pulled tightly Clamp the lead wire so it is not too tight or slack.
when the throttle is operated.
Throttle grip
Left handle grip

Cut surplus of clamp. Cut surplus of clamp.

UP
Clamp the lead wire between the handle switch and master cylinder holder.
Take care not to pinch the lead wire with the handlebar covers.

FWD

Left handle grip adhering position

 AN650/AK9 (’09-MODEL) 18-21

3%26)#%$!4!
%,%#42)#!,!.!
)4%- 34!.$!2$ ./4%
&USESIZE ,/ !  % 
(EAD !  % 
LIGHT
() !
&UELPUMP !
)GNITION !  % 
!  % 
4URNSIGNAL !
&ANMOTOR !
-AIN !
#64 !
0OWERSOURCE !  % 
!  % 
!"3 !¾
7INDSCREEN !
-IRROR !
3EATHEATER !  % 

4)2%
)4%- 34!.$!2$ ,)-)4
#OLDINFLATIONTIREPRESSURE &RONT K0A
3OLO KGFCMPSI
RIDING
K0A
2EAR KGFCMPSI
&RONT K0A
$UAL KGFCMPSI
RIDENG K0A
2EAR KGFCMPSI
4IRESIZE &RONT 2-#(
2EAR 2-#(
4IRETYPE &RONT "2)$'%34/.%4(&
2EAR
"2)$'%34/.%4(2-
4IRETREADDEPTH &RONT
2ECOMMENDEDDEPTH
2EAR
WIRING DIAGRAM
AN650K3 (’03-MODEL)

HI : HIGH BEAM INDICATOR LIGHT

OI : OIL PRESSURE INDICATOR LIGHT
FI : FI PILOT
BRK : BRAKE-LOCK INDICATOR LIGHT
TR : TURN SIGNAL INDICATOR LIGHT (R)
IL : ILLUMINATION
TL : TURN SIGNAL INDICATOR LIGHT (L)
WT : ENGINE COOLANT TEMP. INDICATOR LIGHT
GP : GEAR POSITION INDICATOR
D : DRIVE MODE INDICATOR
PM : POWER MODE INDICATOR
HANDLEBAR SWITCH (R)
HAZARD SWITCH STARTER
BUTTON IAC
OFF VALVE CVT UNIT CONTROLLER ECM
ON ENGINE
PUSH SIDE STAND
PM D WT BRK FI OI HI STOP FRONT BRAKE SWITCH
TL IL IL TR SWITCH CVT
SWITCH
OFF OFF PUSH MOTOR
SPEEDOMETER
RUN ON FREE CENTER M
STAND
IGNITION IGNITION SOLENOID
SPEED SENSOR IGNITION
COIL #1 COIL #2
SWITCH

19

Gr/W
Br/W

Br/W
W/Bl

Bl/W

Lg/B

Bl/W
Lg/Y

Gr/R

Gr/B

Gr/R

Gr/R
Gr/Y

Br/B

B/Br

B/Br
B/Br

B/Br
G/Bl

Bl/G

Bl/G
PUSH

O/W

G/W

Bl/R

O/W

Bl/B

R/Bl

W/G

B/Bl

Bl/B

Bl/R

O/W
R/W

W/B

R/W

Y/Bl

Bl/Y

B/W

W/R

B/W
B/W

B/W

Bl/Y

W/R

B/W
W/Y

Y/W

W/Y

P/W
G/R

O/R

G/B

B/O

R/G

R/G

B/G

O/B
Y/G
R/B

B/R

Dgr

R/B

B/R

B/R
R/B

Y/G

Dgr

G/Y
R/Y

B/Y

R/Y

B/Y

Y/R

P/B
Dg
Lg

Br
Bl

W
G
B

R
SWITCH

P
FREE
BRAKE- ON

O/W

B/Bl
O/B

B/R

Y/G
Lbl
Lg
B/W
O/G

B
O/R

LOCK OFF
W

SWITCH

B/W

B/W
LOCK

R
B
R
B
B
Y
Y
P
ON
OFF
Br/W

W/Bl
R/Bl

O?G
B/W

B/W

B/W

Br/B
P/W

G/Bl
O/G

O/G

O/W

O/W

O/W

O/W

O/W
O/R

O/R

W/B

B/W

B/W

B/W

R/W
P/G

R/B

G/Y

O/G

O/G
O/B
O/Y

Y/G

B/R
B/Y
Lbl
Lg

Lg

Lg
Bl
W

Br
B

Y
V

G
B

R
O/G
V

LICENSE PLATE LIGHT

B/W
Gr
FRONT TURN SIGNAL LIGHT (R) B/W
Lg Lg Lg Lg
B/W B/W Br Gr
B/W B/W
HEADLIGHT (R) W/B W/B
Y
B/W
REAR TURN SIGNAL LIGHT (R)
W BRAKE LIGHT/TAILLIGHT (R)

Y
B/W
W
HEADLIGHT (L) BRAKE LIGHT/TAILLIGHT (L)
Br Gr
B/W B/W
W/B W/B
Lg B B B
B/W B/W B/W
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

Gr/W

Lg/B
Gr/B
Gr/Y

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br
O/BI

O/Bl

O/Bl

R/Bl

R/Bl
O/W

O/W

R/Bl

R/BI
R/Bl

B/Bl

W/G

B/W
B/W

B/W

B/W

B/W

B/W

B/W

R/W

B/W

R/W

R/W

B/W

R/W

B/W
Y/W
W/Y
O/G

O/G

O/G
B/O

B/O

G/R
G/B

O/R

B/O
G/Y

Y/G

O/Y

R/B

G/Y

R/B

Y/G

Y/G
Y/B

Y/R

Y/R

Y/R

Y/R

P/B

B/Y

Y/B

Y/B
Lbl

Dg

Br
Bl

Bl
W

B
B
B
G

O
B

R
B

B
B

Y
Lg/Y
B/Bl

B/Bl

G/W
B/W

W/B

R/W

B/W
W/Y
Y/W
O/G

O/G
Lbl
Lg
O

O
B

B/W
B/R
Br/W

FAN MOTOR

B/W
B/Bl
B/W

Bl/Y
R/W

Bl
Y/W

O/R

B/G
B/R

Y/G

B
Lbl
Lg

B
W

G
B

R
Y

BI

B/W

B/W
Bl

B
Y
R

B
HORN

Bl
4 5 6

B
B
RELAY

G
Y
Y
Y
M

R
POWER PUSH DIODE
SOURCE SIDE- FP (40A) (10A) CMP TO MAIN
FUSE

B/W
STAND RELAY CTV POWER
W

SENSOR
B

SENSOR
W

TRUNK
Y

#2 CVT TP

R
RELAY 1 2 3 #1 FUEL FUSE SOURCE (40A)
REGULATOR/ STARTER LIGHT SEAT
FAN INJECTOR PULLEY PUMP SENSOR FUSE RECTIFIER
POSITION RELAY SWITCH
OFF FREE MOTOR ON BATTERY
PUSH PUSH ON PUSH OFF SENSOR OFF
FUSE BOX 1.HEAD HI 15A CVT GENERATOR ON
PASSING HORN REAR POWER FAN 2.HEAD LO 10A REVOLUTION TRUNK
LIGHT BUTTON BRAKE SWITCH MOTOR
ON ON
3.FUEL 10A SENSOR TRUNK LIGHT
OFF OFF IAP AP ECT IAT STARTER LIGHT
SWITCH HI SWITCH FREE SWITCH 4.IGNITION 15A
MOTOR
L UP
5.SIGNAL 15A SENSOR SENSOR SENSOR SENSOR SWITCH
LO PUSH PUSH FREE
R DOWN OIL OIL LEVEL 6.FAN 10A
DIMMER D M
TURN SIGNAL PRESSURE SWITCH
SWITCH SWITCH UP/DOWN
LIGHT SWITCH SWITCH SWITCH

HANDLEBAR SWITCH (L)

AN650K4 (’04-MODEL)

HI : HIGH BEAM INDICATOR LIGHT

OI : OIL PRESSURE INDICATOR LIGHT
FI : FI PILOT
BRK : BRAKE-LOCK INDICATOR LIGHT
TR : TURN SIGNAL INDICATOR LIGHT (R)
IL : ILLUMINATION
TL : TURN SIGNAL INDICATOR LIGHT (L)
WT : ENGINE COOLANT TEMP. INDICATOR LIGHT
GP : GEAR POSITION INDICATOR –
D : DRIVE MODE INDICATOR IAC
PM : POWER MODE INDICATOR SIDE-STAND VALVE
SWITCH
HANDLEBAR SWITCH (R) CVT
MOTOR
PM D – WT BRK FI OI HI ENGINE PUSH M
TL IL IL TR STARTER FRONT BRAKE FREE CENTER
HAZARD STOP SOLENOID CVT UNIT CONTROLLER ECM
STAND
SPEEDOMETER SWITCH SWITCH BUTTON SWITCH SWITCH
OFF OFF OFF
ON RUN PUSH ON
IGNITION IGNITION PUSH
COIL #1 COIL #2 FREE
SPEED SENSOR

B/W

B/W

B/W

B/W
B/Lg

Y/W
BRAKE-

O/W
O/B

B/R

Y/G
IGNITION

Lbl
Lg

B
B
B

Gr/W

W/Bl

Bl/W

Bl/W
Br/W
Gr/B

Gr/R

Gr/R
Br/B

B/Br

B/Br
Lg/B

B/Lg
G/Bl

Bl/G
B/W

Bl/G
Bl/R

O/W

Bl/B

R/Bl

W/G

Bl/B

Bl/R

O/W
B/Br
Bl/Y

B/W

W/R

B/W
B/W

B/W
O/G

Bl/Y

W/R

B/W
B/Bl
R/G

W/Y

P/W
Y/G

B/R
R/B

Y/G
B/Y

R/Y

B/Y
LOCK

G/B
Dgr

G/Y
Y/R

P/B
SWITCH

Br/W

Dg
Lg/Y

Gr/R
Gr/Y

Br
O/W

G/W

R/W

W/B

R/W
W/Y

W
G
P

R
G/R

O/R

G/B

B/O

R/G

P
R/B

B/R

Dgr

R/B

B/R
R/Y

B
Lg

Bl

B
Y

P
SWITCH ON
ON OFF
OFF LOCK
P
Br/W
R/Bl
B/W

B/W

P/W

W/Bl
O/G

O/G

O/W
O/R
B/W

W/B
R/B

G/Y

O/G

O/W

O/W
O/R

O/G

O/B
O/Y

Y/G
Lbl

B/Y
Lg

Lg
Bl
W
W

Y
V

B
V

Br/B

G/Bl
B/W

O/W

O/W
R/W
B/W

B/R
Lg
G
B/Lg

B/Br
B/W
O/G
B/R
B
LICENSE PLATE LIGHT
B/W
Gr
FRONT TURN B/W
SIGNAL Lg Lg Lg Lg
LIGHT (R) B/W B/W Br Gr
B/W B/W
HEADLIGHT W/B W/B
(R) Y
B/W REAR TURN SIGNAL LIGHT (R)
W BRAKE LIGHT/TAILLIGHT (R)
HEADLIGHT
(L) Y
B/W
W
BRAKE LIGHT/TAILLIGHT (L)
Br Gr
B/W B/W
W/B W/B
B B B B
B/W B/W B/W
FRONT TURN
SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)
B/O

G/Y

Bl
B
Gr/Y

B/W
O/G
B

Gr/W

Gr/B

Lg/B
B/Bl

B/Br

B/Br
Lg/Y

B/Br
B/Br

B/Br
O/Bl

R/W

R/W
B/Br
O/Bl

B/Bl
O/Bl
O/G

B/Bl

R/W
R/Bl

B/W
B/W

G/W

O/W

W/G
B/W

W/B

B/W

B/W
B/W

G/R
G/B
R/W

B/W

B/W

O/W

R/Bl
W/Y
Y/W

Y/W
W/Y

Y/G
O/G

Y/G
O/G

O/R

B/O
O/G

Y/B
Y/B
R/B

R/Bl
B/W

R/W

R/Bl
B/O

G/Y

G/B
Y/R

R/B

P/B

B/Y

B/W

B/W
B/R
O/Y

Y/R
Y/B

Y/G

Y/R
Y/R

Lbl
Lbl

Dg
Lg

Br
Bl
W

R
O

R
G

R
B

R
R

B
B
B

R
B
Y
Y

B
Br/W

Bl
Bl/Y
R/W

B
B/Bl

Y/G
B/W
Y/W

B/G
B/R

B/R
Lbl

HORN
Lg

FAN MOTOR
W

B
Y

Bl

B/W

B/W

G
B/W

B/W

R
Bl

B/R
B

Bl
POWER
W

Y
R

B
B
G
Y

Y
Y
Y
4 5 6 M

B
R
RELAY SOURCE

B/W
B IAP AP DIODE

R
(40A) (10A)
G/Y

SIDE- FP CMP TO MAIN PUSH

SENSOR SENSOR POWER SENSOR FUSE
STAND RELAY 1 2 3 CVT FUEL TP SENSOR
#1 #2 PULLEY PUMP CTV SOURCE ECT
RELAY SENSOR
FUSE FUSE
IAT STARTER (40A)
FAN
CVT INJECTOR POSITION SENSOR SENSOR RELAY
HI L UP MOTOR REGULATOR/ GENERATOR OFF
OFF FREE FREE
REVOLUTION SENSOR RECTIFIER
PUSH LO PUSH PUSH ON PUSH PUSH FREE
ON FUSE BOX 1.HEAD HI 15A BATTERY ON TRUNK
R DOWN 2.HEAD LO 15A SENSOR TRUNK LIGHT
PASSING DIMMER HORN REAR POWER OFF
SWITCH BUTTON SWITCH UP/DOWN 3.FUEL 10A LIGHT
LIGHT BRAKE FAN
SWITCH SWITCH D↔M SWITCH ON ON 4.IGNITION 15A STARTER SWITCH
TURN SIGNAL MOTOR OFF OFF 5.SIGNAL 15A MOTOR TRUNK
LIGHT SWITCH SWITCH SWITCH 6.FAN 15A LIGHT SEAT
OIL SWITCH
HANDLEBAR SWITCH (L)
PRESSURE OIL LEVEL
SWITCH SWITCH
AN650K5 (’05-MODEL)

HI : HIGH BEAM INDICATOR LIGHT

OI : OIL PRESSURE INDICATOR LIGHT
FI : FI PILOT
BRK : BRAKE-LOCK INDICATOR LIGHT
TR : TURN SIGNAL INDICATOR LIGHT (R)
TL : TURN SIGNAL INDICATOR LIGHT (L)
WT : ENGINE COOLANT TEMP. INDICATOR LIGHT
D : DRIVE MODE INDICATOR
PM : POWER MODE INDICATOR
OD : OVER DRIVE INDICATOR LIGHT

TL TR
HANDLEBAR SWITCH (R) SIDE-STAND
SWITCH ECM
BRK PM IAC
BRK FI OI HI IGNITION IGNITION
ABS
PM
WT ENGINE FRONT VALVE
COIL #1 COIL #2
SP/TA HAZARD STOP STARTER BRAKE PUSH
SWITCH SWITCH BUTTON SWITCH FREE CENTER CVT
OFF OFF OFF STAND MOTOR
FI OI HI
2 5 ON RUN PUSH ON SWITCH
D 1 3 4 OD M
SOLENOID

Gr/W

W/Bl

Bl/W
PUSH

Gr/B

Lg/Y

Br/W
Br/B

Gr/Y

B/Br
G/Bl

Bl/G

Gr/R

Lg/B

B/Lg
G/W
Bl/R

O/W

Bl/B
R/W

Bl/Y

W/B

W/R

B/W
B/W

B/Br

Br/R
B/W

R/Bl

O/Bl
W/G

B/Bl
B/W

R/W
Y/G

Y/G

P/W
B/Y

G/B
G/R

G/Y

R/B

B/R
B/Y

Y/R

P/B
Lg

Dg
Bl
Bl

Br
G

W
Y

B
FREE

SPEED IGNITION

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
SWITCH

Lbl
Gr
Lg
SENSOR

P
B

B/W

B/W

B/W

B/W
Y/W
BRAKE-

B
B
ON
LOCK
B/W
O/G

OFF
P

Bl/W

Gr/R
B/Br

Bl/G
Bl/B

Bl/R

O/W
Bl/Y

W/R

B/W
SWITCH LOCK

R
ON P
OFF
B/W

Br/W

B/W
O/R

O/W

W/B
O/G
O/Bl

W/Bl

Br/B
O/W
R/Bl

O/Y

Y/G

G/Bl
B/W

B/W

O/W

O/W
P/W

R/W
O/G

O/G

O/W
O/R

R/B

G/Y

B/Y

B/W

B/R
Lbl
O/G
W

Lg
Lg

G
O
Bl
Bl
W

Lg
B
B

Y
V

B/Lg

B/Br
B/W
B/G
B/R
B

LICENSE PLATE LIGHT

B/W
Gr
FRONT TURN B/W REAR TURN
SIGNAL Lg Lg SIGNAL LIGHT
Lg Lg
LIGHT (R) B/W
(R)
B/W Br
B/W
W/B Gr
Y B/W
B/W W/B
HEAD
LIGHT(R) W
BRAKE LIGHT/TAILLIGHT (R)
Y
HEAD B/W
LIGHT(L) W
BRAKE LIGHT/TAILLIGHT (L)
Br Gr
B/W B/W
W/B W/B
B B B B
B/W B/W B/W
FRONT TURN REAR TURN SIGNAL LIGHT (L)
SIGNAL LIGHT (L)
Gr/Y

B/W
O/G

B/O

B/Br
B

Gr/W

Gr/B

Lg/B
B/Bl

B/Br

B/Br
Lg/Y

B/Br
B/Br
B/Br
O/Bl

R/W

R/W
O/Bl

B/Bl
O/Bl
O/G

BBr
O/W

R/Bl

R/Bl

R/W
G/W
B/W

O/W

B/W
B/W

G/R
G/B

B/W
Lbl
R/W

B/W

G/Y

B/W

Y/W
W/Y

Y/G
Y/G
O/G

Y/B
Y/B
B/O

R/B

R/Bl

R/Bl
B/W

R/W
Y/G

Dg
B/R
O/Y

G/Y
Y/R

R/B

P/B

B/W

B/W
B

Y/R

Y/R
Y/B

Y/R
B/Bl
B/W

W/B

Br
Y/W

O/G

Bl

/R
Bl
Lbl

Bl
W

R
Lg

O
G

R
R
R
Y
Y

B
W

B
O
B
Y

Br/R
B/Br
B/W

W/G
B/Y
Br

R
W
R
Bl
B
Br/W
B/Bl

Bl/Y
R/W
B/W
Y/W

O/R

B/G

Y/G
B/R

HORN FAN MOTOR

Lbl
Lg
W

Bl

B/W
G

G
R

B/W

B/W

R
B

Bl
Y

Bl
POWER
W

Y
R

B
B
G
Y

Y
Y
Y
4 5 6 M

B
R
RELAY
SOURCE

B/W
B IAP AP DIODE

R
(40 A) (10 A)
G/Y

SIDE- FP CMP TO MAIN PUSH

SENSOR SENSOR POWER SENSOR FUSE
STAND RELAY 4 2 3 CVT FUEL TP SENSOR
#1 #2 CTV SOURCE
RELAY PULLEY PUMP SENSOR
FUSE FUSE ECT IAT STARTER (40 A)
FAN CVT INJECTOR POSITION SENSOR SENSOR RELAY
HI L OFF FREE UP MOTOR REGULATOR/ GENERATOR OFF
FREE
REVOLUTION SENSOR RECTIFIER
PUSH LO PUSH PUSH ON PUSH PUSH FREE
ON FUSE BOX BATTERY ON TRUNK
R DOWN SENSOR TRUNK LIGHT
PASSING DIMMER HORN REAR POWER OFF
SWITCH UP/DOWN 1. HEAD HI 15 A LIGHT
LIGHT SWITCH BUTTON BRAKE FAN 2. HEAD LO 15 A
SWITCH SWITCH D↔M SWITCH ON ON STARTER SWITCH
TURN SIGNAL MOTOR OFF OFF 3. FUEL 10 A MOTOR TRUNK
LIGHT SWITCH SWITCH SWITCH 4. IGNITION 15 A LIGHT SEAT
OIL 5. SIGNAL 15 A SWITCH
HANDLEBAR SWITCH (L) PRESSURE OIL LEVEL 6. FAN 15 A
SWITCH SWITCH
AN650K6 (’06-MODEL)

HI : HIGH BEAM INDICATOR LIGHT

OI : OIL PRESSURE INDICATOR LIGHT
FI : FI PILOT
BRK : BRAKE LOCK INDICATOR LIGHT
TR : TURN SIGNAL INDICATOR LIGHT (R)
IL : ILLUMINATION
TL : TURN SIGNAL INDICATOR LIGHT (L)
WT : ENGINE COOLANT TEMP. INDICATOR LIGHT
GP : GEAR POSITION INDICATOR –
D : DRIVE MODE INDICATOR
PM : POWER MODE INDICATOR

TL TR

BRK ABS PM
ABS
PM
WT BRK FI OI HI HANDLEBAR SWITCH (R) ECU
AT
SP/TA SENSOR
ENGINE PTC
FI OI HI IMO HAZARD STOP STARTER FRONT BRAKE SIDE-STAND
D 1 2 3 4 5 OD SWITCH SWITCH BUTTON SWITCH SWITCH
ON OFF OFF
CVT
OFF RUN PUSH ON PUSH MOTOR
IGNITION IGNITION

Br/W

Lg/B

B/Lg
Gr/R
Gr/W

B/Br

Br/R
O/Bl
R/Bl

W/G
W/Bl

Bl/W

B/Bl
B/W
Gr/B

Lg/Y

R/W
Br/B

Gr/Y

B/Br

P/W
G/Bl

Bl/G
FREE

G/W
Bl/R

O/W

Bl/B

G/B
G/R
R/W

Bl/Y

W/B

W/R

B/W
B/W

G/Y

R/B

B/R
B/Y

Y/R

P/B
Y/G

Y/G
B/Y
CENTER M

Dg
COIL #1 COIL #2

Br
Lg

W
SPEED

Bl

B
G
Y

P
SENSOR BRAKE STAND
LOCK SWITCH SOLENOID

B/W
Bl
SWITCH
PUSH
OFF

O/W

B/Bl
Y/W
B/W

O/B

O/R
Y/G

B/R
O/G

Lbl

Bl/W

Gr/R
B/Br

Bl/G
Lg

Bl/B

Bl/R

O/W
Gr

Bl/Y

W/R

B/W
FREE

P
P

ON

R
B/W

B/W
Y/W
B/W

B/W

B
B
G

G
O/W

W/B
O/G
IGNITION

O/Y

Y/G
O/G

Lbl
Lg

O
B

Y
V
SWITCH
Br/W

O/Bl
R/Bl
B/W

B/W

B/W

P/W
O/G

O/G
O/R

O/R

R/B

G/Y

W/Bl
Lg

O/W

O/W
Bl

Bl
W

B/Y

Br/B
B

G/Bl
Y
V

O/W

O/W
ON

B/W

B/W

R/W
B/R
Lg
G
OFF
LOCK

B/Br
B/G
B/R
B
LICENSE PLATE LIGHT
B/W
Gr
FRONT TURN SIGNAL LIGHT (R) B/W
Lg Lg Lg Lg
B/W B/W Br Gr
B/W B/W
HEADLIGHT (R)
W/B W/B
Y
B/W REAR TURN SIGNAL LIGHT (R)
W BRAKE LIGHT/TAILLIGHT (R)
Y
B/W
W
HEADLIGHT (L) BRAKE LIGHT/TAILLIGHT (L)
Br Gr
B/W B/W
W/B W/B
B B B B
B/W B/W B/W
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)
G/Y

Bl
Gr/Y

B/W

B/O
O/G

B
B

Gr/W

Lg/B

Br/R
B/Br
Gr/B

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br

B/W

W/G
O/Bl

O/Bl

B/W

R/W
O/W

O/W

R/Bl

R/Bl

R/Bl
B/W

B/W

B/Bl

R/W

R/W

R/Bl
B/W

B/W

B/W

B/W
R/W
Y/W
W/Y
Lg/Y
B/Bl

O/G

G/R
G/B
B/Bl
O/BI

B/Y
B/O
B/W

R/B

Y/G
Y/G

B/R
O/Y
W/Y
Y/W

Y/G
G/W

G/Y
Y/R

P/B

R/B
B/W

Y/B
O/G

Y/B

Y/R

Y/R

Y/R

Y/B
W/B

R/W

B/W

Lbl
O/G
Lbl

Dg

Br
Br

B/Br
Bl
Lg

W
W

B
G

O
R

R
R

B
R

B
Y
O
B
Y

G/Y

ON
OFF
OPTION
ON
Br/W

Bl
B/Bl
B/W
Y/W

Bl/Y
R/W

B
O/R

OFF
B/G
B/R

Y/G

HORN
Lbl

FAN MOTOR
Lg
W

G
Y

B/W
RELAY OIL

G
R
BI
B

B/W

B/W
B
Y
R

B
B
4 5 6

Bl

Bl
PRESSURE

G
M

R
Y
Y
Y
POWER SIDE- FP
W
Y

SWITCH SOURCE STAND RELAY PUSH DIODE

(40A) (10A) CMP TO MAIN

B/W
RELAY CTV POWER FUSE

R
CVT SENSOR SENSOR TRUNK SECOM
FAN ON OIL LEVEL 1 2 3 #1 #2 FUEL TP FUSE SOURCE (40A)
REGULATOR/ STARTER LIGHT SEAT (OPTION)
MOTOR OFF SWITCH CVT INJECTOR PULLEY PUMP SENSOR FUSE
OFF FREE POSITION RECTIFIER RELAY SWITCH
PUSH PUSH ON PUSH
FAN MOTOR REVOLUTION BATTERY
SWITCH SENSOR OFF
FUSE BOX 1.HEAD HI 15A SENSOR GENERATOR
PASSING HORN REAR POWER ON TRUNK
LIGHT BUTTON BRAKE SWITCH 2.HEAD LO 15A
3.FUEL 10A TRUNK LIGHT
SWITCH HI L SWITCH FREE UP M.P A.P W.T M.T STARTER LIGHT
4.IGNITION 15A
LO PUSH PUSH FREE SENSOR SENSOR SENSOR SENSOR MOTOR SWITCH
5.SIGNAL 15A
R DOWN
DIMMER D M 6.FAN 15A
SWITCH TURN SIGNAL SWITCH UP/DOWN
SWITCH SWITCH

HANDLEBAR SWITCH (L)

AN650/AK6 (’06-MODEL)

HI : HIGH BEAM INDICATOR LIGHT

OI : OIL PRESSURE INDICATOR LIGHT
FI : FI PILOT HANDLEBAR SWITCH (R)
BRK : BRAKE LOCK INDICATOR LIGHT
TR : TURN SIGNAL INDICATOR LIGHT (R)
IL : ILLUMINATION WINDSCREEN ENGINE
TL : TURN SIGNAL INDICATOR LIGHT (L) SWITCH HAZARD STOP STARTER FRONT BRAKE
WT : ENGINE COOLANT TEMP. INDICATOR LIGHT UP SWITCH SWITCH BUTTON SWITCH
GP : GEAR POSITION INDICATOR – FREE ON OFF OFF
D : DRIVE MODE INDICATOR DOWN OFF RUN PUSH ON
PM : POWER MODE INDICATOR

TL TR

O/W

B/Bl
B/W

Y/W
O/B

O/R
Y/G

B/R
Lbl
Lg
Bl

G
B
BRK ABS PM SCREEN AT SCREEN
ABS
PM
WT BRK FI OI HI IGNITION IGNITION MOTER SENSOR FUSE
COIL #1 COIL #2 PTC ECU ABS CONT
SP/TA S-RELAY

M
O/W
B/W

W/B
O/G
G/B

O/Y

Y/G
SIDE-STAND

Lbl
Lg
Bl

O
B

Y
IGNITION
SWITCH SWITCH
FI OI HI IMO CVT

G
R
D 2 5 ON MOTOR
1 3 4 OD PUSH
OFF FREE
LOCK
CENTER M
STAND
SWITCH SOLENOID

Gr/W

W/Bl

Bl/W
Gr/B

Lg/Y

Br/W
Br/B

Gr/Y

B/Br

Gr/R
G/Bl

Bl/G

Lg/B

B/Lg
G/W
Bl/R

O/W

Bl/B
B/W

B/W

Gr/R
R/W

Bl/Y

W/B

W/R

B/W
B/W

B/Br

Br/R
R/Bl

W/G
B/W
G/B

B/Bl

R/W

W/R
W/B

B/W
B/W
Y/G

Y/G

P/W

W/Y
B/Y

G/B
G/R
B/Y

G/Y

R/B

B/R

B/R

O/Y
Y/R

P/B

B/Y
Lg

Dg
Bl

Bl

Bl

Br

Br
SPEED SENSOR

O
O

G
R

W
Y

O
R

R
R
PUSH
BRAKE- FREE
LOCK

B/Lg

W/Bl
B/Br
B/W

O/W

O/W
B/G
B/R

B/Y
B/W
O/G

B
SWITCH
P

B/W

B/W
Y/W
B/W

B/W

B
B
ON

G
OFF

Bl/W

Gr/R
B/Br

Bl/G
Bl/B

Bl/R

O/W
Bl/Y

W/R

B/W
R
Br/B

G/Bl
O/W

O/W
B/W

B/W

R/W
B/R
Lg
G
Br/W
O/G

R/Bl
B/W

B/W

B/W

P/W
O/G

O/G
O/R

O/R

R/B

G/Y
Lg

Br
Bl

Bl
W

W
V

Y
V

MIRROR MOTOR (R)

B B
M Bl Bl

LICENSE PLATE LIGHT

B/W
Gr
FRONT TURN SIGNAL LIGHT (R) B/W
Lg Lg Lg Lg
B/W B/W Br Gr
B/W B/W
HEADLIGHT (R) W/B W/B
Y
B/W REAR TURN SIGNAL LIGHT (R)
W BRAKE LIGHT/TAILLIGHT (R)
Y
B/W
W
HEADLIGHT (L) BRAKE LIGHT/TAILLIGHT (L)
Br Gr
B/W B/W
W/B W/B
B B
B B B/W
B/W B/W REAR TURN SIGNAL LIGHT (L)
FRONT TURN SIGNAL LIGHT (L)

B B
M Bl Bl
MIRROR MOTOR (L)

Gr/W

Lg/B

Br/R
B/Br
Gr/Y

B/Br
Gr/B

B/Br

B/Br

B/Br

B/Br

B/Br

B/W

W/G
O/Bl

O/Bl

B/W

R/W

B/W
B/W

W/R
R/Bl
O/W

O/W

R/Bl

R/Bl

B/Bl
B/W

B/W

R/W

R/W

R/Bl

W/Y
B/W

B/W
B/W

B/W

R/W
O/G

Y/W
W/Y
B/O

O/G

G/R
G/B

B/Y

R/B

R/B

B/R
B/O

R/B

Y/G

B/Y
Y/G

Y/G
B/R
O/Y

G/Y

R/B
Y/R

P/B

Y/B
Y/B

Y/R

Y/B
Y/R

Y/R
Lbl
G/Y

Dg

Br
Br

Bl

W
W

O
B

R
B

O
R

B
R

B
Y
O/BI

B/Bl
B/W

B/W

O/G
B/O

G/R

B/O

G/B
Bl
O

B/Y/
B/W
B/Y
B/R

B/W
OPTION SHORT C

W
G
R

B
BI
Bl
FAN MOTOR

B/W

B/W
B
Y
R

B
B
4 5 6

Bl
G
M

R
Y
Y
Y
Bl

SIDE- FP
B

RELAY
W

HORN
Y

STAND RELAY PUSH DIODE

(40A) (10A)
Lg/Y

MAIN ABS ABSMOT

B/Bl

G/W
B/W

W/B

R/W

B/W
W/Y
Y/W

O/G

G/R

G/B

F-CUT
Lbl

MIRROR B CAM
Lg

B/W
O

O
B
Y

RELAY FUSE FUSE FUSE

G

CTV POWER

R
FUSE M-RELAY POWER SENSOR SENSOR TRUNK SECOM FVW RVW
1 2 3 #1 #2 CVT FUEL TP FUSE SOURCE (40A)
SOURCE PULLEY PUMP SENSOR REGULATOR/ STARTER LIGHT SEAT (OPTION)
CVT INJECTOR FUSE RECTIFIER
POSITION RELAY SWITCH
BATTERY
Br/W

ON REVOLUTION
B/Bl
B/W

Bl/Y
R/W
Y/W

O/R

B/G

G/R
B/O
G/B

FAN
B/R

Y/G
Lbl
Lg

SENSOR
W

OFF
B
Y

MOTOR OFF FUSE BOX 1.HEAD HI 15A SENSOR GENERATOR ON

FAN MOTOR 2.HEAD LO 15A TRUNK
Bl

SWITCH 3.FUEL 10A TRUNK LIGHT

M.P A.P W.T M.T STARTER LIGHT
ON 4.IGNITION 15A
SENSOR SENSOR SENSOR SENSOR MOTOR SWITCH
OFF 5.SIGNAL 15A
6.FAN 15A
OFF FREE
PUSH PUSH ON PUSH OPEN OIL
G/Y

CLOSE PRESSURE
PASSING HORN REAR POWER
SWITCH
LIGHT BUTTON BRAKE SWITCH MIRROR
SWITCH HI SWITCH FREE SWITCH ON
L UP
LO PUSH PUSH FREE OFF
R DOWN
DIMMER D M
SWITCH TURN SIGNAL SWITCH UP/DOWN
SWITCH SWITCH
OIL LEVEL
HANDLEBAR SWITCH (L) SWITCH
WIRING DIAGRAM
AN650K7 (E-03, 28, 33)

–
AN650/AK7 (E-03, 28, 33)