Suzuki GSR 600 service manual

GSR600

99500-36160-01E

FOREWORD

This manual contains an introductory description on the SUZUKI GSR600 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.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

* 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.



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.

FI SYSTEM DIAGNOSIS

FUEL SYSTEM AND THROTTLE BODY

EXHAUST SYSTEM

COOLING AND LUBRICATION SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL INFORMATION

WIRING DIAGRAM

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 Front axle 2 Brake disc 3 Dust seal 4 Bearing 5 Front wheel 6 Spacer 7 Collar

A Brake disc bolt



ITEM N·m

1 100 10.0

A 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” or equivalent grease. 99000-25010

Apply SUZUKI MOLY PASTE. 99000-25140

Apply SUZUKI SILICONE GREASE. 99000-25100

Apply THREAD LOCK SUPER “1360”. 99000-32130

Use engine coolant. 99000-99032-11X

Use fork oil. 99000-99044-10G

Apply or use brake fluid.

Measure in voltage range.

Measure in current range.

Apply SUZUKI BOND “1215” or equivalent bond. 99000-31110

Apply SUZUKI BOND “1207B” 99000-31140

Apply THREAD LOCK SUPER “1303”. 99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent thread lock. 99000-32110

Apply THREAD LOCK “1342”. 99000-32050

Measure in resistance range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

ABBREVIATIONS USED IN THIS MANUAL

ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center ATM Pressure

A/F : Air Fuel Mixture

: Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor)

BBDC : Before Bottom Dead Center BTDC : Before Top Dead Center B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch

(Clutch Switch) CMP Sensor : Camshaft Position Sensor

(CMPS) CO : Carbon Monoxide CPU : Central Processing Unit

DC : Direct Current DMC : Dealer Mode Coupler DOHC : Double Over Head Camshaft DRL : Daytime Running Light DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU) (FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp. Sensor (WTS)

FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay

GEN : Generator GND : Ground GP Switch : Gear Position Switch

HC : Hydrocarbons HO2 Sensor : Heated Oxygen Sensor

IAP Sensor : Intake Air Pressure Sensor (IAPS) IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

LCD : Liquid Crystal Display LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp

(LED) Min : Minimum

NOX : Nitrogen Oxides

OHC : Over Head Camshaft OPS : Oil Pressure Switch

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

RH : Right Hand ROM : Read Only Memory

SAE : Society of Automotive Engineers SDS : Suzuki Diagnosis System STC System : Secondary Throttle Control System

(STCS) STP Sensor : Secondary Throttle Position Sensor

(STPS) ST Valve : Secondary Throttle Valve (STV) STV Actuator : Secondary Throttle Valve Actuator

(STVA)

TO Sensor : Tip Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

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

B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/G : Black with Green tracer B/Lg : Black with Light green 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/Y : Brown with Yellow 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/BI : Light green with Blue tracer Lg/G : Light green with Green tracer Lg/W : Light green with White tracer O/B : Orange with Black tracer O/BI : 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/Y : Red with Yellow tracer R/W : Red with White 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

CONTENTS

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

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

SUZUKI GSR600K6 (’06-MODEL) ................................................................1- 4

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

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .......................1- 5

FUEL .......................................................................................................1- 5

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

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

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

ENGINE COOLANT ...............................................................................1- 6

WATER FOR MIXING ............................................................................1- 6

ANTI-FREEZE/ENGINE COOLANT .......................................................1- 6

LIQUID AMOUNT OF WATER/ENGINE COOLANT .............................1- 6

BREAK-IN PROCEDURES ...........................................................................1- 7

CYLINDER IDENTIFICATION .......................................................................1- 7

INFORMATION LABELS ...............................................................................1- 8

SPECIFICATIONS .........................................................................................1- 9

COUNTRY AND AREA CODES

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

MODEL CODE COUNTRY or AREA EFECTIVE FRAME NO.

E-02

GSR600

GSR600UE E-19 EU JS1B9121100 100001 –

E-19 E-24

U.K.

Australia

JS1B9111100 100001 – JS1B9111100 100001 – JS1B9111300 100001 –

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 in 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 GSR600K6 (’06-MODEL)

RIGHT SIDE

LEFT SIDE

• Difference between illustration and actual motorcycle may exist depending 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 steering head pipe. The engine serial number 2 is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. 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 of API SF/SG or SH/SJ with JASO MA. 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 right 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 G-10 or an equivalent fork oil.

1-6 GENERAL INFORMATION

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.

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): Approx. 2 800ml

For engine coolant mixture information, refer to cooling system section, page 7-2



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 performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point.

GENERAL INFORMATION 1-7

BREAK-IN 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 7 000 r/min Up to 1 600 km: Below 10 500 r/min Over to 1 600 km: Below 14 000 r/min

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation. However, do not exceed 14 000 r/min at any time.

CYLINDER IDENTIFICATION

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

1-8 GENERAL INFORMATION

INFORMATION LABELS

GSR600 GSR600U

E-02 E-19 E-24 E-19

1 Noise label A 2 Fuel caution label A A 3 Tire information label A A A A 4 General information label A A 5 General warning label A A 6 ID plate A A A A

A: Attached

Chain cover

GENERAL INFORMATION 1-9

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length .......................................................................... 2 090 mm

Overall width ........................................................................... 795 mm

Overall height .......................................................................... 1 075 mm

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

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

Seat height .............................................................................. 785 mm

Dry mass ................................................................................. 183 kg

ENGINE

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

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

Bore......................................................................................... 67.0 mm

Stroke ...................................................................................... 42.5 mm

Displacement .......................................................................... 599 cm³

Compression ratio ................................................................... 12.5:1

Fuel system............................................................................. Fuel injection

Air cleaner ............................................................................... Paper element

Starter system ......................................................................... Electric

Lubrication system .................................................................. Wet sump

Idle speed................................................................................ 1 300 ± 100 r/min

DRIVE TRAIN

Clutch ...................................................................................... Wet multi-plate type

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

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

Primary reduction ratio ............................................................ 1.926 (79/41)

Gear ratios, Low ...................................................................... 2.785 (39/14)

2nd....................................................................... 2.000 (32/16)

3rd........................................................................ 1.600 (32/20)

4th........................................................................ 1.363 (30/22)

5th........................................................................ 1.208 (29/24)

Top....................................................................... 1.086 (25/23)

Final reduction ratio................................................................. 3.000 (48/16)

Drive chain .............................................................................. RK525SMOZ7Y, 114 links

1-10 GENERAL INFORMATION

CHASSIS

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

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

Front fork stroke...................................................................... 130 mm

Rear wheel travel .................................................................... 134 mm

Steering angle......................................................................... 33° (Right and left)

Caster ..................................................................................... 25°15’

Trail ......................................................................................... 104 mm

Turning radius ......................................................................... 2.9 m

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

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

Front tire size .......................................................................... 120/70 ZR 17 M/C (58 W), tubeless

Rear tire size........................................................................... 180/55 ZR 17 M/C (73 W), tubeless

ELECTRICAL

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

Ignition timing.......................................................................... 6° B.T.D.C. at 1 300 r/min

Spark plug............................................................................... NGK CR9E or DENSO U27ESR-N

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

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

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

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

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

Turn signal light....................................................................... 12 V 10 W

Brake light/Taillight.................................................................. LED

Position light............................................................................ 12 V 5 W × 2

License plate light ................................................................... 12 V 5 W

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

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

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

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

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

Oil pressure/Engine coolant temp. warning indicator light

Fl warning indicator light ......................................................... LED

Immobilizer indicator light ....................................................... LED

.......... LED

CAPACITIES

Fuel tank ................................................................................. 16.5 L

Engine oil,oil change............................................................... 3 200 ml

with filter change .................................................... 3 600 ml

overhaul ................................................................. 3 900 ml

Coolant.................................................................................... 2.8 L

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

AIR CLEANER....................................................................................... 2- 4

SPARK PLUG........................................................................................ 2- 5

VALVE CLEARANCE............................................................................ 2- 7

ENGINE OIL AND OIL FILTER............................................................. 2-13

FUEL LINE............................................................................................. 2-14

ENGINE IDLE SPEED ........................................................................... 2-15

PAIR (AIR SUPPLY) SYSTEM .............................................................. 2-15

THROTTLE CABLE PLAY .................................................................... 2-15

CLUTCH ................................................................................................ 2-16

COOLING SYSTEM............................................................................... 2-17

DRIVE CHAIN........................................................................................ 2-19

BRAKE .................................................................................................. 2-22

TIRES..................................................................................................... 2-26

STEERING............................................................................................. 2-26

FRONT FORK........................................................................................ 2-27

REAR SUSPENSION ............................................................................ 2-27

EXHAUST PIPE BOLT AND NUT......................................................... 2-28

CHASSIS BOLTS AND NUTS .............................................................. 2-29

COMPRESSION PRESSURE CHECK ........................................................ 2-31

COMPRESSION TEST PROCEDURE .................................................. 2-31

OIL PRESSURE CHECK ............................................................................. 2-32

SDS CHECK................................................................................................. 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 kilometers, miles and time for your convenience.

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

PERIODIC MAINTENANCE CHART

Interval Item Air cleaner element ---- I I R I Spark plugs ---- I R I R Va lve c le a ra nc e ---- ---- ---- ---- I Engine oil R R R R R E n gin e oi l fi lt er R ---- ---- R ---Fuel line ----IIII Idle speed IIIII Th rot tle va lv e sy nc hr o niz at io n ---- ---- I ---- I PAIR (air supply) system ---- ---- I ---- I Throttle cable play I I I I I Clutch cable play ---- I I I I Radiator hoses ---- I I I I Engine coolant Replace every 2 years.

Drive chain

Brakes I I I I I

Brake hoses

Brake fluid

Tires ----IIII S te er in g I ---- I ---- I Fro nt for ks ---- ---- I ---- I R e ar s usp ens ion ---- ---- I ---- I E x hau st p ipe bol ts an d muf fle r bo lt an d nu t T ---- T ---- T Chassis bolts and nuts T T T T T

km months

1 000 6 000 12 000 18 000 24 000

212243648

IIIII

Clean and lubricate every 1 000 km.

----IIII Replace every 4 years.

----IIII 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 2 Brake pedal pivot

and footrest pivot

3 Clutch lever holder 4 Side-stand pivot

and spring hook

5 Footrest pivot and

gearshift lever pivot

6 Drive chain

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 (12 months). Replace every 18 000 km (36 months).

• Lift and support the fuel tank. (5-3)

• Remove the air cleaner box cover 1 by removing the screws

and IAP sensor.

• Remove the air cleaner element.

• Inspect the air cleaner element for clogging. If the air cleaner element is clogged with dust, replace the air cleaner element with a new one.



Do not blow the air cleaner element with compressed air.

NOTE: If driving under dusty conditions, replace the air cleaner element more frequently. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.

• Install a new air cleaner element in the reverse order of removal.

• Remove the drain plug 2 from the air cleaner box to allow any water to drain out.

SPARK PLUG

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

SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL

• Lift and support the fuel tank. (5-3)

• Remove the air cleaner box. (5-13)

• Disconnect all lead wire couplers 1 from ignition coil/plug

caps.



Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler damage.

• Remove the ignition coil/plug caps.

PERIODIC MAINTENANCE 2-5



* Do not pry up the ignition coil/plug cap with a screw

driver or a bar to avoid its damage.

* Be careful not to drop the ignition coil/plug cap to

prevent short/open circuit.

• Remove the spark plugs.

 09930-10121: Spark plug wrench set

HEAT RANGE

• Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.

Hot type Standard Cold type

NGK CR8E CR9E CR10E

ND U24ESR-N U27ESR-N U31ESR-N

NOTE: “R” type spark plug has a resistor built into at the center electrode to prevent radio noise.

CARBON DEPOSITS

• Check carbon deposits on the spark plug.

• If carbon is deposited, remove it using a spark plug cleaner machine.

2-6 PERIODIC MAINTENANCE

SPARK PLUG GAP

• Measure the spark plug gap with a thickness gauge.

• Adjust the spark plug gap if necessary.

 Spark plug gap:

Standard: 0.7 – 0.8 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 thread, etc.



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

SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION

• Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque.

 Spark plug: 11 N·m (1.1 kgf-m) 

Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.

• Install the ignition coil/plug caps and connect their lead wire couplers.



CONTACT

* Do not hit the ignition coil/plug cap with a plastic

hammer when installing it.

* Place the ignition coil/spark plug cap so that the cou-

pler does not touch the cylinder head cover.

INCORRECT

VALVE CLEARANCE

Inspect every 24 000 km (48 months).

• Lift and support the fuel tank. (5-3)

• Remove the air cleaner box. (5-13)

• Disconnect the CMP sensor coupler 1.

• Remove the PAIR control solenoid valve 2.

• Remove the spark plugs. (2-5)

PERIODIC MAINTENANCE 2-7

• Loosen the throttle body clamp screws at the intake pipe side.

(5-14)

• Move the throttle body assembly.

• Remove the frame bridge bar 3.

• Remove the cylinder head cover. (3-14)

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

 Valve clearance (when cold):

Standard: IN. : 0.10 – 0.20 mm

EX. : 0.20 – 0.30 mm

NOTE: * The cam must be at positions,

or B, when checking or adjusting the valve clearance. Clearance readings should not be taken with the cam in any other position than these two positions.

* 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.

EX. IN.

2-8 PERIODIC MAINTENANCE

• Remove the valve timing inspection plug 1.

• Turn the crankshaft to bring the “Top” line on the starter clutch

to the index mark and also to bring the notches A on the left ends of both camshafts (Ex. and In.) to the positions as shown.

• In this condition, read the valve clearance at the valves B (In.

and Ex. of No.4 cylinder, Ex. of No.3 and In. of No.2).

• If the clearance is out of specification, adjust the clearance.

(2-9)

 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 timing inspection hole and also to bring the notches A to the position as shown.

• Read the clearance at the rest of the valves C and adjust the clearance if necessary. (below)

PERIODIC MAINTENANCE 2-9

Cam position

B ← Front ← Front

C ← Front ← Front

VALVE CLEARANCE ADJUSTMENT

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

• Remove the intake or exhaust camshafts. (3-15)

• Remove the tappet and shim by fingers or magnetic hand.

Exhaust Camshaft Intake Camshaft

Notch A position

• 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 (2-11 and -12) for details.

170

1.70 mm

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 the figure printed sur-

face faces the tappet.

NOTE: Reinstall the camshafts in the specified manner. (

• 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 following items.

* Cylinder head cover (3-101) * Spark plugs and plug caps (2-6) * Throttle body assembly (5-19)



3-97)

 Valve timing inspection plug: 11 N·m (1.1 kgf-m)

(INTAKE SIDE)

PERIODIC MAINTENANCE 2-11

TAPPET SHIM SET (12800-05830)

TAPPET SHIM SELECTION TABLE [INTAKE]

TAPPET SHIM NO. (12892-05C00-XXX)

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

120 125 130 135

NO.

SUFFIX

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

1.20 1.25 1.30 1.35

(mm)

PRESENT

SHIM SIZE

EXAMPLE

column.

HOW TO USE THIS CHART:

I. Measure valve clearance. “ENGINE IS COLD”

II. Measure present shim size.

III. Match clearance in vertical column with present shim size in horizontal

Valve clearance is 0.23 mm

Present shim size 1.70 mm

Shim size to be used 1.80 mm

MEASURED

VALVE

CLEARANCE

(mm)

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

0.81 – 0.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

0.86 – 0.90 1.95 2.00 2.05 2.10 2.15 2.20

0.91 – 0.95 2.00 2.05 2.10 2.15 2.20

0.96 – 1.00 2.05 2.10 2.15 2.20

1.01 – 1.05 2.10 2.15 2.20

1.06 – 1.10 2.15 2.20

1.11 – 1.15 2.20

2-12 PERIODIC MAINTENANCE

(EXHAUST SIDE)

TAPPET SHIM SET (12800-05830)

TAPPET SHIM SELECTION TABLE [EXHAUST]

TAPPET SHIM NO. (12892-05C00-XXX)

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

120 125 130 135

NO.

SUFFIX

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

1.20 1.25 1.30 1.35

(mm)

PRESENT

SHIM SIZE

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

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 2.100.10 – 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 2.15

SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED

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

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

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

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

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

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

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

1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.90 1.95 2.00 2.05 2.10 2.15 2.20

HOW TO USE THIS CHART:

I. Measure valve clearance. “ENGINE IS COLD”

II. Measure present shim size.

III. Match clearance in vertical column with present shim size in horizontal

1.95 2.00 2.05 2.10 2.15 2.20

2.00 2.05 2.10 2.15 2.20

2.05 2.10 2.15 2.20

2.10 2.15 2.20

2.15 2.20

EXAMPLE

column.

Valve clearance is 0.33 mm

Present shim size 1.70 mm

Shim size to be used 1.80 mm

MEASURED

VALV E

CLEARANCE

(mm)

0.05 – 0.09

0.15 – 0.19

0.20 – 0.30

0.31 – 0.35

0.36 – 0.40

0.41 – 0.45

0.46 – 0.50

0.51 – 0.55

0.56 – 0.60

0.61 – 0.65

0.66 – 0.70

0.71 – 0.75

0.76 – 0.80

0.81 – 0.85

0.86 – 0.90

0.91 – 0.95

0.96 – 1.00

1.01 – 1.05

1.06 – 1.10

1.11 – 1.15

1.16 – 1.20

1.21 – 1.25 2.20

ENGINE OIL AND OIL FILTER

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

(OIL FILTER) Replace initially at 1 000 km (2 months) and every 18 000 km (36 months) thereafter.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

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

the oil 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 3.2 L of oil. Use of API SF/SG or SH/SJ with JASO MA.

PERIODIC MAINTENANCE 2-13

 Oil drain plug: 23 N·m (2.3 kgf-m)

• 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. If the level is below lower line B, add oil to full line A. If the level is above full line, drain oil to full line.

A: Full line B: Lower line

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