Suzuki de reparatie www.manualedereparatie.info User Manual

GSF650

FOREWORD

This manual contains an introductory description on the SUZUKI GSF650/S and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show the

basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

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.

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 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 Front axle 2 Dust seal 3 Brake disc (RH) 4 Bearing (RH) 5 Spacer 6 Bearing (LH) 7 Brake disc (LH) 8 Collar 9 Front wheel 0 Air bleeder valve A Balancer

A Front axle B Brake disc bolt

ITEM N·m

A 65 6.5 B 23 2.3

kgf-m

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required. Data beside it indicates specified torque.

Apply oil. Use engine oil unless otherwise specified.

Apply molybdenum oil solution (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1).

Apply SUZUKI SUPER GREASE “A”. 99000-25010

Apply SUZUKI MOLY PASTE. 99000-25140

Apply SUZUKI SILICONE GREASE. 99000-25100

Apply THREAD LOCK “1342”. 99000-32050

Apply THREAD LOCK SUPER “1360”. 99000-32130

Use fork oil. 99000-99044-10G

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Apply PBC GREASE. 99000-25110

Apply THERMO-GREASE. 99000-59029

Apply SUZUKI BOND “1207B”. 99000-31140

Apply SUZUKI BOND “1215”. 99000-31110

Apply THREAD LOCK SUPER “1303”. 99000-32030

Apply THREAD LOCK SUPER “1322”. 99000-32110

Measure in current range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

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

GENERAL PRECAUTIONS ...........................................................................1- 2

SUZUKI GSF650 (2005-MODEL) ..................................................................1- 4

SUZUKI GSF650S (2005-MODEL) ................................................................1- 4

SERIAL NUMBER LOCATION ......................................................................1- 4

FUEL AND OIL RECOMMENDATION ..........................................................1- 5

FUEL (For Canada) ...............................................................................1- 5

FUEL (For other countries) ..................................................................1- 5

ENGINE OIL ...........................................................................................1- 5

BRAKE FLUID ........................................................................................1- 5

FRONT FORK OIL .................................................................................1- 5

BREAK-lN PROCEDURES ...........................................................................1- 6

CYLINDER IDENTIFICATION .......................................................................1- 6

INFORMATION LABELS ...............................................................................1- 7

SPECIFICATIONS .........................................................................................1- 8

COUNTRY AND AREA CODES

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

CODE COUNTRY OR AREA

E-02 E-19 E-28

England (UK)

European markets

Canada

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 messages 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 WARNINGS 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, oil cooler and exhaust system

until they have cooled. * After servicing the fuel, oil, 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 working out and to the specified

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 GSF650 (2005-MODEL)

* Difference between photographs and actual motorcycles may exist depending on the markets.

SUZUKI GSF650S (2005-MODEL)

* Difference between photographs and actual motorcycles may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) steering head pipe and frame down tube. The engine serial number crankcase. These numbers are required especially for registering the machine and ordering spare parts.

1 is stamped on the right side of the

2 is located on the right side of the

GENERAL INFORMATION 1-5

MULTIGRADE

TEMP.

FUEL AND OIL RECOMMENDATION

FUEL (For Canada)

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 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. An unleaded gasoline is recommended.

ENGINE OIL

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use SF/SG or SH/SJ with JASO MA in API (American Petroleum Institute) classification. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

BRAKE FLUID

Specification and classification: DOT 4

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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 equivalent fork oil.

1-6 GENERAL INFORMATION

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 : Below 6 000 r/min Up to 1 600 km : Below 9 000 r/min Over 1 600 km : Below 12 000 r/min

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation. However, do not exceed 12 000 r/min at any time.

CYLINDER IDENTIFICATION

The four cylinders of this engine are identified as No. 1, 2, 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat).

INFORMATION LABELS

GENERAL INFORMATION 1-7

No. Label name

1 Information label 2 Fuel caution label 3 Screen label 4 Warning steering label 5 Tire information label 6 General warning label 7 ICES Canada label

8 I.D. plate

9 Safety plate

GSF650 GSF650A GSF650U

E-28

E-02 E-02 E-02 E-02

E-28 E-28

Except

E-28

E-28 E-28

GSF650UA

GSF650S

E-28

Except

E-28

GSF600SA GSF650SU

GSF650SUA

1-8 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length....................................................... 2 110 mm

Overall width ........................................................ 770 mm

Overall height....................................................... 1 085/1 095 mm .........Low/High ..................GSF650

1 225 mm .....................................................GSF650S

Wheelbase ........................................................... 1 440 mm

Ground clearance ................................................ 130 mm

Seat height........................................................... 770/790 mm ...........Low/High

Dry mass .............................................................. 201 kg........................................................GSF650

204 kg........................................................GSF650S

ENGINE

Type ..................................................................... Four-stroke, air-cooled, DOHC

Number of cylinders ............................................. 4

Bore ..................................................................... 65.5 mm

Stroke................................................................... 48.7 mm

Displacement ....................................................... 656 cm

Compression ratio ................................................ 10.5 : 1

Carburetor............................................................ KEIHIN CVR32

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 type

Transmission........................................................ 6-speed constant mesh

Gearshift pattern .................................................. 1-down, 5-up

Primary reduction ratio......................................... 1.744 (75/43)

Gear ratios, Low ................................................ 3.083 (37/12)

2nd................................................. 2.062 (33/16)

3rd ................................................. 1.647 (28/17)

4th.................................................. 1.400 (28/20)

5th.................................................. 1.227 (27/22)

Top ................................................ 1.095 (23/21)

Final reduction ratio ............................................. 3.133 (47/15)

Drive chain ........................................................... RKFS50SMOZ1, 112 links

GENERAL INFORMATION 1-9

CHASSIS

Front suspension................................................. Telescopic, coil spring, oil damped

Rear suspension ................................................. Link type, coil spring, oil damped

Front suspension stroke...................................... 130 mm

Rear wheel travel ................................................ 126 mm

Caster.................................................................. 26°

Trail ..................................................................... 108 mm

Steering angle ..................................................... 35° (right & left)

Turning radius ..................................................... 2.8 m

Front brake.......................................................... Disc brake, twin

Rear brake .......................................................... Disc brake

Front tire size ...................................................... 120/70ZR17M/C (58W), tubeless

Rear tire size ....................................................... 160/60ZR17M/C (69W), tubeless

ELECTRICAL

Ignition type......................................................... Electronic ignition (Transistorized)

Ignition timing ...................................................... 10° B.T.D.C. at 1 200 r/min

Spark plug ........................................................... NGK CR8EK or DENSO U24ETR

Battery ................................................................. 12 V 28.8 kC (8 Ah)/10 HR

Generator ............................................................ Three-phase A.C. generator

Main fuse............................................................. 30 A

Fuse .................................................................... 10/15/15/10/10 A

Headlight ............................................................. 12 V 60/55 W H4 ......................................... GSF650

12 V 55 W H7: Upper and Lower beam....... GSF650S

Parking or city light .............................................. 12 V 5 W...................................................... GSF650

12 V 5 W × 2 ................................................ GSF650S

Turn signal light ................................................... 12 V 21 W

Brake light/Taillight .............................................. 12 V 21/5 W

Speedometer light ............................................... LED

Tachometer light ................................................. LED

Neutral indicator light .......................................... LED

High beam indicator light..................................... LED

Turn signal indicator light .................................... LED

Oil pressure indicator light................................... LED

CAPACITIES

Fuel tank, including reserve............................... 20.0 L

reserve .............................................. 4.5 L

Engine oil, oil change ......................................... 3 300 ml

with filter change............................... 3 500 ml

overhaul ............................................ 4 600 ml

These specifications are subject to change without notice.

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

CONTENTS

PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2

PERIODIC MAINTENANCE CHART .....................................................2- 2

LUBRICATION POINTS .........................................................................2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 4

VALVE CLEARANCE ............................................................................2- 4

SPARK PLUGS ......................................................................................2- 6

EXHAUST PIPE BOLTS AND MUFFLER BOLTS ................................2- 7

AIR CLEANER .......................................................................................2- 8

ENGINE OIL AND OIL FILTER ..............................................................2- 9

FUEL LINE .............................................................................................2-11

ENGINE IDLE SPEED ............................................................................2-11

THROTTLE CABLE PLAY .....................................................................2-11

CARBURETOR SYNCHRONIZATION ..................................................2-12

PAIR (AIR SUPPLY) SYSTEM ...............................................................2-12

FUEL FILTER .........................................................................................2-12

CLUTCH CABLE PLAY .........................................................................2-12

DRIVE CHAIN .........................................................................................2-13

BRAKES .................................................................................................2-15

TIRES .....................................................................................................2-18

STEERING ..............................................................................................2-18

FRONT FORKS ......................................................................................2-19

REAR SUSPENSION .............................................................................2-19

CHASSIS BOLTS AND NUTS ...............................................................2-20

COMPRESSION PRESSURE CHECK ............................................................2-22

COMPRESSION TEST PROCEDURE ...................................................2-22

OIL PRESSURE CHECK .................................................................................2-23

OIL PRESSURE TEST PROCEDURE ...................................................2-23

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. Maintenance intervals are expressed in terms of kilometers and months, and are dependant on whichever comes first.

NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

Interval

Item

Air cleaner element – I I R I Exhaust pipe bolts and muffler bolts Valve clearance I – I – I Spark plugs – I R I R Fuel line –IIII Fuel filter – I R I R Engine oil RRRRR Engine oil filter R – – R – Idle speed IIIII Throttle cable play IIIII Throttle valve synchronization – – I – I PAIR (air supply) system – – I – I Clutch cable play –IIII Drive chain IIIII

Brakes IIIII Brake hoses –IIII

Brake fluid –IIII

Tires –IIII Steering I–I–I Front forks ––I–I Rear suspension ––I–I Chassis bolts and nuts

km 1 000 months2 12243648

TTTTT

6 000 12 000 18 000 24 000

–

Clean and lubricate every 1 000 km.

Replace every 4 years.

Replace every 2 years.

–

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.

1 Brake lever holder and throttle cables 2 Brake pedal pivot and right footrest pivot 3 Clutch lever holder and clutch cable 4 Side-stand pivot and spring hook

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.

5 Gearshift pivot and left footrest pivot 6 Center stand pivot and spring hook 7 Drive chain

2-4 PERIODIC MAINTENANCE

IN. EX.

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item in the Periodic Maintenance Chart.

VALVE CLEARANCE

Inspect initially at 1 000 km (1 month) and every 12 000 km (24 months).

• Remove the fuel tank. (!4-3)

• Remove the frame head covers. (GSF650 !5-5)

• Remove the cowling. (GSF650S !5-5)

• Remove the PAIR valve. (!3-97)

• Remove all the spark plugs.

• Remove the cylinder head cover and signal generator cover.

(!3-12 and -13)

The valve clearance specification is different for both intake and exhaust valves. Valve clearance adjustment 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.

" Valve clearance (when cold):

IN.: 0.10 – 0.15 mm EX.: 0.18 – 0.23 mm

NOTE: * The camshafts must be at positions

or adjust the valve clearance. Clearance readings should not be taken with the camshafts in any other position than the ones shown.

* The valve clearance should only be checked when the engine

is cold.

* Turn the crankshaft clockwise using a 19-mm wrench. Make

sure that all of the spark plugs have been removed.

• Turn the crankshaft clockwise and align the “T” mark on the signal generator rotor with the center of the pickup coil. Also, position the notches shown. Then, measure the following valve clearance

Cylinder #1: Intake and exhaust valve clearance Cylinder #2: Exhaust valve clearance Cylinder #3: Intake valve clearance

1 on the right end of each camshaft as

A or

B, in order to check

• Insert the thickness gauge between the valve stem end and adjusting screw on the rocker arm. If the clearance is out of specification, hold the locknut with a wrench and use the special tool to adjust the clearance.

# 09900-20803: Thickness gauge

09917-14910: Valve adjuster driver

PERIODIC MAINTENANCE 2-5

Both the right and left valve clearances should be as closely as possible.

• Turn the crankshaft clockwise 360° (one full rotation) and align the “T” mark on the signal generator rotor with the center of the pickup coil. Also, position the notches end of each camshaft as shown.

• Measure the valve clearances of the remaining valves adjust them if necessary.

Notch

Camshaft position

C D

• When installing the cylinder head cover, apply the recommended bond to the cylinder head cover groove and camshaft

end caps. (!3-83)

Intake camshaft Exhaust camshaft

1 position

2 on the right

D and

% 99000-31140: SUZUKI BOND “1207B”

• Tighten the cylinder head cover bolts to the specified torque.

(!3-84, 7-33)

• Install the signal generator cover.

2-6 PERIODIC MAINTENANCE

0.6 – 0.7 mm

SPARK PLUGS

Inspect every 6 000 km (6 months) and replace every 12 000 km (24 months).

• Remove all of the spark plugs.

NOTE: If it is difficult to remove any of the spark plug caps, pry them up using a screwdriver.

# 09930-10121: Spark plug wrench set

09900-20803: Thickness gauge

Standard Cold type

NGK CR8EK CR9EK

DENSO U24ETR U27ETR

CARBON DEPOSITS

Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

SPARK PLUG GAP

Measure the spark plug gap using a thickness gauge. If out of specification, regap the spark plug.

" Spark plug gap: 0.6 – 0.7 mm # 09900-20803: Thickness gauge

ELECTRODE’S CONDITION

Check the condition of the electrode. If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged threads, etc.

Check the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the spark plug hole and engine damage may result.

SPARK PLUG INSTALLATION

To avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench.

PERIODIC MAINTENANCE 2-7

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

& Spark plug: 11 N·m (1.1 kgf-m)

EXHAUST PIPE BOLTS AND MUFFLER BOLTS

Tighten initially at 1 000 km (1 month) and every 12 000 km (24 months) thereafter.

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

& Exhaust pipe bolt: 23 N·m (2.3 kgf-m)

& Muffler mounting bolt

Muffler connecting bolt

1: 23 N·m (2.3 kgf-m)

2: 23 N·m (2.3 kgf-m)

2-8 PERIODIC MAINTENANCE

MarMark

Mark

AIR CLEANER

Inspect every 6 000 km (12 months) and replace every 18 000 km (36 months).

• Remove the fuel tank. (!4-3)

• Remove the screws.

• Remove the air cleaner element

• Carefully use compressed air to clean the air cleaner element.

Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the outside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.

• Reinstall the cleaned or new air cleaner element in the reverse order of removal.

• When installing the air cleaner element into the air cleaner box, make sure that the mark points up.

If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component.

• Remove the drain plug from the air cleaner drain hose to allow any water to drain out.

ENGINE OIL AND OIL FILTER

(ENGINE OIL) Replace initially at 1 000 km (2 month) and every 6 000 km (12 months) thereafter.

(OIL FILTER) Replace initially at 1 000 km (2 month) and every 12 000 km (24 months) thereafter.

PERIODIC MAINTENANCE 2-9

The 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.

• Place an oil pan below the engine, and drain engine oil by removing the oil drain plug

• Tighten the oil drain plug new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 3.3 L of oil. Use SF/SG or SH/SJ with JASO MA in API (American Petroleum Institute) classification.

1 and filler cap

1 to the specified torque, and pour

& Oil drain plug: 23 N·m (2.3 kgf-m)

2-10 PERIODIC MAINTENANCE

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

• Turn off the engine and wait about three minutes, then check the oil level through the inspection window below the “L” mark, add oil to the “F” mark. If the level is above the “F” mark, drain the oil until the level reaches the “F” mark.

OIL FILTER REPLACEMENT

• Drain engine oil as described in the engine oil replacement procedure.

• Remove the oil filter

• Apply engine oil lightly to the O-ring of new oil filter, before installation.

# 09915-40610: Oil filter wrench

1 using the special tool.

3. If the level is

• Install the new oil filter. Turn it by hand until you feel that the oil filter O-ring has contacted the oil filter mounting surface. Then, tighten the oil filter two full turns using the special tool.

NOTE: * Before installing the oil filter, apply a light coat of engine oil

onto its O-ring.

* To properly tighten the oil filter, use the special tool. Never

tighten the oil filter by hand only.

• Add new engine oil and check the oil level as described in the engine oil replacement procedure.

" NECESSARY AMOUNT OF ENGINE OIL

Oil change: 3.3 L Oil and filter change: 3.5 L Engine overhaul: 4.6 L

ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering 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.

FUEL LINE

Inspect every 6 000 km (12 months).

• Remove the seat.

• Remove the fuel tank mounting bolts. (!4-3)

• Lift up the fuel tank. Inspect the fuel hoses defects are found, the fuel hoses must be replaced.

1 for damage and fuel leakage. If any

ENGINE IDLE SPEED

Inspect initially at 1 000 km (2 month) and every 6 000 km (12 months) thereafter.

NOTE: Make this adjustment when the engine is hot.

PERIODIC MAINTENANCE 2-11

• Start the engine, turn the throttle stop screw

engine idle speed between 1 100 and 1 300 r/min.

" Engine idle speed: 1 200 ± 100 r/min

1 and set the

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (2 month) and every 6 000 km (12 months) thereafter.

Adjust the throttle cable play

• Loosen the locknut

• Turn the adjuster

the throttle grip)

• Tighten the locknut

" Throttle cable play

1 of the throttle pulling cable

3 in or out until the throttle cable play (at

A is between 2 – 4 mm.

1 while holding the adjuster

A as follows.

A: 2 – 4 mm

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

NOTE: Major adjustment can be made at the carburetor side adjusters.

(!4-24)

2-12 PERIODIC MAINTENANCE

CARBURETOR SYNCHRONIZATION

Inspect initially at 1 000 km (2 month) and every 12 000 km (24 months).

(!4-25)

PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (24 months).

(!3-97)

FUEL FILTER

Inspect every 6 000 km (12 months) and replace every 12 000 km (24 months).

• Lift up the fuel tank. (!2-10)

Check the fuel filter

present, replace the fuel filter with a new one. (!4-6)

1 for evidence of dirt and contamination. If

CLUTCH CABLE PLAY

Inspect every 6 000 km (12 months).

• Loosen the locknut the clutch lever assembly.

• Remove the clutch release cover.

• Loosen the locknut or three rotations.

• Then, slowly turn in the adjusting screw felt.

• Then, turn out the adjusting screw the locknut

• Loosen the locknut 10 – 15 mm of free play

• Tighten the locknut

1 and turn the adjuster

3, and turn out the adjusting screw

4 1/4 of a turn, and tighten

5, and turn the cable adjuster

A at the clutch lever end.

2 all the way into

4 until resistance is

6 to obtain

4 two

" Clutch cable play

A: 10 – 15 mm

DRIVE CHAIN

Inspect initially at 1 000 km (2 month) and every 6 000 km (12 months) thereafter. Lubricate every 1 000 km.

With the transmission in neutral, support the motorcycle using the center-stand and turn the rear wheel slowly by hand. Visually check the drive chain for the possible defects listed below. * Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Dry or rusted links * Missing O-ring seals * Kinked or binding links

A O-ring B Grease

If any defects are found, the drive chain must be replaced.

NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.

PERIODIC MAINTENANCE 2-13

CHECKING

• Remove the cotter pin. (E-28)

• Loosen the axle nut

• Tense the drive chain fully by turning both chain adjuster bolts

• Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

" Drive chain 20-pitch length

Service Limit: 319 mm

123 19 20

2-14 PERIODIC MAINTENANCE

20 – 30 mm

ADJUSTING

• Loosen or tighten both chain adjuster bolts

1 until there is 20

– 30 mm of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.

• Place the motorcycle on its side-stand for accurate adjustment.

• After adjusting the drive chain, tighten the axle nut

3 to the

specified torque.

• Tighten both chain adjuster bolts

1 securely.

& Rear axle nut: 100 N·m (10.0 kgf-m)

• Replace the cotter pin with a new one. (E-28)

CLEANING AND LUBRICATING

• Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

Do not use trichloroethylene, gasoline or any similar solvent. These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain.

• After cleaning and drying the chain, oil it with a heavyweight motor oil.

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

oil”. Such oil can damage the O-rings.

* The standard drive chain is a RKFS50SMOZ1.

SUZUKI recommends to use this standard drive chain as a replacement.

DRIVE CHAIN CUTTING AND RECONNECTING (!5-70)

BRAKES

(BRAKE) Inspect initially at 1 000 km (2 month) and every 6 000 km (12 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (12 months). Replace hoses every 4 years. Replace fluid every 2 years.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebar straight.

• Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoirs.

• When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.

PERIODIC MAINTENANCE 2-15

( Specification and classification: DOT 4 '

* 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 and petroleum-based fluids. 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 of time.

* Brake fluid, if it leaks, will interfere with safe running

and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

2-16 PERIODIC MAINTENANCE

BRAKE PADS

The extent of brake pad wear can be checked by observing the grooved limit line

grooved limit line, replace the pads with new ones. (!5-47)

Replace the brake pads as a set, otherwise braking performance will be adversely affected.

1 on the pad. When the wear exceeds the

BRAKE PEDAL HEIGHT

• Loosen the locknut

• Turn the push rod the top of the footrest.

• Tighten the locknut

" Brake pedal height

Standard: 60 mm

& Master cylinder push rod locknut: 18 N·m (1.8 kgf-m)

BRAKE LIGHT SWITCH

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

2 until the brake pedal is 60 mm

1 securely.

A below

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder 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 restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

Front brake

• Fill the master cylinder reservoir to the top of the inspection window. Place the reservoir cap to prevent dirt from entering.

• Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.

• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder 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.

PERIODIC MAINTENANCE 2-17

NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.

• Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.

& Air bleeder valve: 8 N·m (0.8 kgf-m) $

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

Rear brake

NOTE: Rear brake caliper has two bleeder valves.

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