Suzuki GSX-R600 2006 User Manual [ru]

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Page 1

GSX-R600

99500-35100-01E

Page 2

FOREWORD

This manual contains an introductory description on the SUZUKI GSX-R600 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

FI SYSTEM DIAGNOSIS

FUEL SYSTEM AND THROTTLE BODY

EXHAUST SYSTEM

COOLING AND LUBRICATION SYSTEM

CHASSIS



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.

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL INFORMATION

WIRING DIAGRAM

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

A Front axle bolt B Brake disc bolt



ITEM N·m

A 100 10.0 72.5 B 23 2.3 16.5

kgf-m

lb-ft

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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 BOND “1215” or equivalent bond. 99000-31110

Apply THREAD LOCK SUPER “1360”. 99000-32130

Use engine coolant. 99000-99032-11X (Except USA)

Use fork oil. 99000-99001-SS5

Apply or use brake fluid.

Measure in voltage range.

Measure in current range.

Apply SUZUKI BOND “1207B”. 99104-31140 (USA)

Apply SUZUKI BOND “1207B”. 99000-31140 (Except USA)

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.

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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) EVAP : Evaporative Emission EVAP Canister : Evaporative Emission

Canister (Canister) EXC System : Exhaust Control System (EXCS) EXC Valve : Exhaust Control Valve (EXCV) EXCV Actuator

: Exhaust Control Valve Actuator

(EXCVA)

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

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor) IAT Sensor : Intake Air Temperature Sensor

(IATS) IG : Ignition

LCD : Liquid Crystal Display LED : Light Emitting Diode

(Malfunction Indicator Lamp) LH : Left Hand

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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)

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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

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GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

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

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

SUZUKI GSX-R600K6 (’06-MODEL)............................................................ 1- 4

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

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

FUEL (FOR USA AND CANADA).......................................................... 1- 5

FUEL (FOR OTHER COUNTRIES) ........................................................ 1- 5

ENGINE OIL (FOR USA)........................................................................ 1- 5

ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5

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

FRONT FORK OIL.................................................................................. 1- 6

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

DIMENSIONS AND DRY MASS............................................................. 1- 9

ENGINE .................................................................................................. 1- 9

DRIVE TRAIN ......................................................................................... 1- 9

CHASSIS ................................................................................................ 1-10

ELECTRICAL ......................................................................................... 1-10

CAPACITIES .......................................................................................... 1-10

COUNTRY AND AREA CODES

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

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

E-02

E-19 (GSX-R600) E-19 (GSX-R600U2) E-19 (GSX-R600U3)

E-24 E-03 E-28 E-33

U.K. E.U. E.U. E.U.

Australia

U.S.A. (Except for California)

Canada

California (U.S.A.)

JS1CE111100100001 – JS1CE111100100001 – JS1CE211100100001 – JS1CE311100100001 –

JS1CE121300100001 – JS1GN7DA 62100001 – JS1GN7DA 62100001 – JS1GN7DA 62100001 –

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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, 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.

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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 do not require use of

battery power, disconnect the negative cable from the battery. * When tightening the cylinder head or 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.

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1-4 GENERAL INFORMATION

SUZUKI GSX-R600K6 (’06-MODEL)

RIGHT SIDE

LEFT SIDE

• Difference between illustrations 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 right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

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GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL (FOR USA AND 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. Unleaded gasoline is recommended.

ENGINE OIL (FOR USA)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. 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.

ENGINE OIL (FOR OTHER COUNTRIES)

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. 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.

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1-6 GENERAL INFORMATION

FRONT FORK OIL

Use fork oil SS-05 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 performs 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. 2 700 ml (2.9/2.4 US/Imp qt)

For engine coolant mixture information, refer to cooling system section in 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.

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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 ( 500 miles): Below 8 000 r/min Up to 1 600 km (1 000 miles): Below 12 000 r/min Over to 1 600 km (1 000 miles): Below 16 000 r/min

• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 16 000 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.)

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1-8 GENERAL INFORMATION

INFORMATION LABELS

GSX-R600 GSX-R600UE GSX-R600UF

1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Manual notice label A (For E-03, 33) 6 Screen label A (Except E-19 ) 7 Screen label A (For E-28) A 8 Screen label A (For E-19) A 9 Warning steering label A (For E-03, 33) 0 Warning steering label A (Except E-03, 33) A A A Tire information label A (For E-03, 33) B Tire information label A (Except E-03, 33) A A C General warning label A (Except E-19, 28) D General warning label A E General warning label A (For E-28) F General warning label A (For E-19) A G ICES Canada label A (For E-28) H I.D. plate A (For E-02, 19, 24) A A I E-19 I.D. label A J Safety plate A (For E-03, 28, 33)

A: Attached *1: Rear fender (front) *2: Chain case

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GENERAL INFORMATION 1-9

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length .......................................................................... 2 040 mm (80.3 in)

Overall width ........................................................................... 715 mm (28.1 in)

Overall height .......................................................................... 1 125 mm (44.3 in)

Wheelbase .............................................................................. 1 400 mm (55.1 in)

Ground clearance.................................................................... 130 mm (5.1 in)

Seat height .............................................................................. 810 mm (31.9 in)

Dry mass ................................................................................. 162 kg (357 lbs) ...........E-33

161 kg (354 lbs) ...........Others

ENGINE

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

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

Bore......................................................................................... 67.0 mm (2.638 in)

Stroke ...................................................................................... 42.5 mm (1.673 in)

Displacement .......................................................................... 599 cm³ (36.5 cu. in)

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 ............................................................ 1.974 (77/39)

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

2nd....................................................................... 2.052 (39/19)

3rd........................................................................ 1.714 (36/21)

4th........................................................................ 1.500 (36/24)

5th........................................................................ 1.347 (31/23)

Top....................................................................... 1.208 (29/24)

Final reduction ratio................................................................. 2.687 (43/16)

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

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1-10 GENERAL INFORMATION

CHASSIS

Front suspension .................................................................... Inverted telescopic, coil spring, oil damped

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

Front fork stroke...................................................................... 120 mm (4.7 in)

Rear wheel travel .................................................................... 130 mm (5.1 in)

Steering angle......................................................................... 27°

Caster ..................................................................................... 23° 45’

Trail ......................................................................................... 97 mm (3.8 in)

Turning radius ......................................................................... 3.4 m (11.2 ft)

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 55 W (H7) + 12 V 65 W (H9)

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

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

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

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

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

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

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

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

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

Fuel level indicator light .......................................................... LED

Oil pressure/Coolant temperature/FI warning light

Engine RPM indicator light...................................................... LED

Immobilizer indicator light ....................................................... LED .........E-02, 19, 24

..................... LED

CAPACITIES

Fuel tank, including reserve .................................................... 15.5 L (4.1/3.4 US/lmp gal) ......E-33

16.5 L (4.4/3.6 US/lmp gal) ......Others

Engine oil, oil change ............................................................. 2 200 ml (2.3/1.9 US/Imp qt)

with filter change .................................................. 2 500 ml (2.6/2.2 US/lmp qt)

overhaul................................................................ 2 900 ml (3.1/2.6 US/lmp qt)

Coolant.................................................................................... 2.7 L (2.9/2.4 US/lmp qt)

These specifications are subject to change without notice.

Page 18

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............................................................. 2-12

EXHAUST CONTROL VALVE .............................................................. 2-13

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

ENGINE IDLE SPEED ........................................................................... 2-14

THROTTLE VALVE SYNCHRONIZATION ........................................... 2-15

EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY) .......... 2-15

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

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

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

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

DRIVE CHAIN........................................................................................ 2-20

BRAKE .................................................................................................. 2-23

TIRES..................................................................................................... 2-27

STEERING............................................................................................. 2-27

FRONT FORK........................................................................................ 2-28

REAR SUSPENSION ............................................................................ 2-28

EXHAUST PIPE BOLT AND NUT......................................................... 2-29

CHASSIS BOLTS AND NUTS .............................................................. 2-30

COMPRESSION PRESSURE CHECK ........................................................ 2-32

COMPRESSION TEST PROCEDURE .................................................. 2-32

OIL PRESSURE CHECK ............................................................................. 2-33

SDS CHECK................................................................................................. 2-34

Page 19

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. IMPORTANT (For E-28): 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 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 l v e c le ar a n c e ---- ---- ---- ---- I E x h a u s t c o n t r o l va l ve I ---- I ---- I Engine oil R R R R R E n g i n e o il fi lt e r R ---- ---- R ---Fuel line ----IIII Idle speed IIIII

Throttle valve synchronization

Evaporative emission control system (E-33 only) 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 III II

Brakes I I I I I

Brake hoses

Brake fluid

Tires ----IIII S te er in g I ---- I ---- I Fro nt fo r k s ---- ---- I ---- I R e a r s u s p e ns i o n ---- ---- I ---- I E x h a u s t pi pe b o l t s a n d m uf fl e r b o l t a nd n u t T ---- T ---- T Chassis bolts and nuts T T T T T

miles km months

600 4 000 7 500 11 000 14 500

1 000 6 000 12 000 18 000 24 000

212243648

(E-33 only)

---- ---- I ---- I

Clean and lubricate every 1 000 km (600 miles).

----IIII

---- I ---- I

Replace every 4 years.

Replace every 2 years.

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

Page 20

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.

Brake lever holder

Brake pedal pivot and footrest pivot

Clutch lever holder

Footrest pivot and gearshift lever pivot

Side-stand pivot and spring hook

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.

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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, 12 months). Replace every 18 000 km (11 000 miles, 36 months).

• Remove the front seat. (8-7)

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

• Remove the air cleaner element by removing the screws.

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

Page 22

SPARK PLUG

Inspect every 6 000 km (4 000 miles, 12 months). Replace every 12 000 km (7 500 miles, 24 months).

SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL

• Remove the front seat. (8-7)

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

• Remove the air cleaner box. (5-14)

• Disconnect all lead wire couplers 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 coils/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 with a spark plug wrench.

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 or carefully use a tool with a pointed end.

Page 23

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 (0.028 – 0.031 in)

 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, 8.0 Ib-ft) 

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 coils/plug caps and connect their lead wire couplers.



* 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

CONTACT

INCORRECT

Page 24

VALVE CLEARANCE

Inspect every 24 000 km (14 500 miles, 48 months).

• Remove the right under cowling. (8-5)

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

• Remove the air cleaner box. (5-14)

• Disconnect the CMP sensor coupler 1.

• Remove the PAIR control solenoid valve 2.

• Remove the spark plugs. (2-5)

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

• Move the throttle body assembly.

• Move the radiator forward. (6-10)

• Remove the regulator/rectifier and horn. (3-6)

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

PERIODIC MAINTENANCE 2-7

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. : 0.08 – 0.18 mm (0.003 – 0.007 in)

EX. : 0.18 – 0.28 mm (0.007 – 0.011 in)

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.

• Remove the valve timing inspection cap 1.

EX. IN.

Page 25

2-8 PERIODIC MAINTENANCE

• Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover 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 line on the CKP sensor rotor 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. (2-9)

Cam position

Exhaust Camshaft Intake Camshaft

Notch A position

B ← Front ← Front

← Front ← Front

Front

Page 26

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. (3-14)

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

• Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.

• Select a replacement shim that will provide a clearance within the specified range. For the purpose of this adjustment, a total of 21 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 (2-10 and -11) for details.

170

PERIODIC MAINTENANCE 2-9

1.70 mm

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 (3-97) * Spark plug and plug cap (2-6) * Throttle body assembly (5-21) * Valve timing inspection plug (3-97) * PAIR control solenoid valve (11-7)



3-92)

Page 27

2-10 PERIODIC MAINTENANCE

(INTAKE SIDE)

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

Page 28

(EXHAUST SIDE)

TAPPET SHIM SET (12800-05830)

PERIODIC MAINTENANCE 2-11

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

Page 29

2-12 PERIODIC MAINTENANCE

ENGINE OIL AND OIL FILTER

(ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

(OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.

ENGINE OIL REPLACEMENT

• Remove the under cowlings. (8-5)

• 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 2.2 L (2.3/1.9 US/Imp qt) of oil. Use of SF/SG or SH/SJ in API with MA in JASO.

 Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• 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 mark “L”, add oil to “F” level. If the level is above mark “F”, drain oil to “F” level.

F L

Page 30

OIL FILTER REPLACEMENT

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

• Remove the oil filter 1 with the special tool.

 09915-40610: Oil filter wrench

• Apply engine oil lightly to the gasket of the new oil filter before installation.

• Install the new oil filter. Turn it by hand until you feel that the oil filter gasket contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) with the special tool.

NOTE: To properly tighten the oil filter, use the special tool. Never tighten the oil filter by hand.

 Oil filter: 20 N·m (2.0 kgf-m, 14.5 lb-ft)

PERIODIC MAINTENANCE 2-13

After contacting the gasket, tighten 2 turns. (20 N·m, 2.0 kgf-m, 14.5 lb-ft)

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

 NECESSARY AMOUNT OF ENGINE OIL:

Oil change : 2.2 L (2.3/1.9 US/Imp qt) Oil and filter change : 2.5 L (2.6/2.2 US/Imp qt) Engine overhaul : 2.9 L (3.1/2.6 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), 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.

EXHAUST CONTROL VALVE

Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter.

Exhaust control valve actuator is installed in the right-hand side in tail cowl. Check the exhaust control valve actuator 1 for its movement when the ignition switch is turned ON. If the exhaust valve actuator does not move, check exhaust valve actuator electrical circuit and exhaust valve carbon sticking. Check the exhaust

control cable play. (6-14)

Page 31

2-14 PERIODIC MAINTENANCE

• Remove the under cowlings. (8-5)

• Check the lock-nuts tightness. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts.

FUEL LINE

Inspect initially 6 000 km (4 000 miles, 12 months).

• Inspect the fuel feed hose 1 for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

NOTE: Warm up the engine before adjusting the engine idle speed.

• Start the engine, turn the throttle stop screw and set the engine idle speed as follows.

 Engine idle speed: 1 300 ± 100 r/min

Page 32

THROTTLE VALVE SYNCHRONIZATION

Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths).

• Inspect the throttle valve synchronization periodically.

(5-26)

EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY)

Inspect every 12 000 km (7 500 miles, 24 months). Replace vapor hose every 4 years.

• Inspect the evaporative emission control system periodically.

PAIR (AIR SUPPLY) SYSTEM

PERIODIC MAINTENANCE 2-15

Inspect every 12 000 km (7 500 miles, 24 months).

• Inspect the PAIR (air supply) system periodically. (11-6)

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

• Adjust the throttle cable play A as follows.

• Loosen the lock-nut 2 of the throttle pulling cable 1.

• Turn the adjuster 3 in or out until the throttle cable play (at the throttle grip) A is between 2.0 – 4.0 mm (0.08 – 0.16 in).

• Tighten the lock-nut 2 while holding the adjuster 3.

 Throttle cable play A: 2.0 – 4.0 mm (0.08 – 0.16 in) 

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.

Page 33

2-16 PERIODIC MAINTENANCE

CLUTCH

Inspect every 6 000 km (4 000 miles, 12 months).

• Lift and support the fuel tank with its prop stay. (5-3)

• Turn in the adjuster 1 all the way into the clutch lever assem-

bly.

• Loosen the lock-nut 2 and turn the clutch cable adjuster 3

to obtain proper cable play.

• Remove the clutch release adjuster cap.

• Loosen the lock-nut 4 and turn out the adjusting screw 5

two or three rotations.

• From that position, slowly turn in the adjusting screw 5 until

resistance is felt.

• From this position, turn out the adjusting screw 5 1/2 rotation, and tighten the lock-nut 4 while holding the screw 5.

• Turn the cable adjuster 3 to obtain 10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch lever end.

• Tighten the lock-nut 2.

 Clutch lever play A: 10 – 15 mm (0.4 – 0.6 in)

Clutch release screw: 1/2 turn out

 Clutch release adjuster cap: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

Page 34

COOLING SYSTEM

Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years.

ENGINE COOLANT LEVEL CHECK

• Keep the motorcycle upright.

• Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A Full line B Lower line

• If the level is below the lower line, remove the right under

cowling (8-5), and add engine coolant to the full line from

the engine coolant reservoir filler.

PERIODIC MAINTENANCE 2-17

ENGINE COOLANT CHANGE

• Remove the under cowlings. (8-5)

• Remove the radiator cap 1.

• Drain engine coolant by disconnecting the radiator hose 2 from the pump.



* 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!

• Flush the radiator with fresh water if necessary.

• Connect the radiator hose 2 securely.

• Pour the specified engine coolant up to the radiator inlet.

 Engine coolant capacity (excluding reservoir):

2 400 ml (2.5/2.1 US/lmp qt)

• Bleed the air from the engine coolant circuit in the following

procedure. (2-18)

ENGINE COOLANT INFORMATION (7-2)

Page 35

2-18 PERIODIC MAINTENANCE

AIR BLEEDING THE COOLING CIRCUIT

• Add engine coolant up to the radiator inlet.

• Support the motorcycle upright.

• Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit.

• Add engine coolant up to the radiator inlet.

• Start up the engine and bleed air from the radiator inlet completely.

• Add engine coolant up to the radiator inlet.

• Repeat the above procedure until no air bleeds from the radiator inlet.

• Loosen the air bleeding bolt 1 and check that the engine coolant flows out.

• Close the air bleeding bolt securely.

• Close the radiator cap securely.

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



Repeat the above procedure several times and make sure that the radiator is filled with engine coolant up to the reservoir full level.

 Engine coolant capacity:

Engine side : 2 400 ml (2.5/2.1 US/Imp qt) Reservoir tank side : 250 ml (0.3/0.2 US/lmp qt)

Page 36

RADIATOR HOSES

• Remove the under cowlings. (8-5)

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

• Check the radiator hoses for crack, damage or engine coolant leakage.

• If any defect is found, replace the radiator hose with new one.

PERIODIC MAINTENANCE 2-19

Page 37

2-20 PERIODIC MAINTENANCE

DRIVE CHAIN

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Clean and lubricate every 1 000 km (600 miles).

Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.)

* Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Dry or rusted links * Missing O-ring seals * Kinked or binding links

If any defect is found, the drive chain must be replaced.

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

Grease

O-ring

CHECKING

• Remove the axle cotter pin. (For E-03, 28, 33)

• Loosen the axle nut 1.

• Loosen the chain adjuster lock-nuts 2.

• Give tension to the drive chain fully by turning both chain

adjuster bolts 3.

Page 38

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

 Drive chain 20-pitch length:

Service limit: 319.4 mm (12.57 in)

ADJUSTING

• Loosen or tighten both chain adjuster bolts 1 until there is 20 – 30 mm (0.8 – 1.2 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The chain adjuster position relative to the reference marks A on both sides of the swingarm must be equal to ensure that the front and rear wheels are correctly aligned.

 Drive chain slack:

Standard: 20 – 30 mm (0.8 – 1.2 in)

PERIODIC MAINTENANCE 2-21

1 2 3 19 20 21

20 – 30 mm (0.8 – 1.2 in)

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

• After adjusting the drive chain, tighten the axle nut 2 to the specified torque.

• Tighten both chain adjuster lock-nuts 3 securely.

 Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

• Install a new cotter pin. (For E-03, 28, 33)

• Recheck the drive chain slack after tightening the axle nut.

NOTE: Do not adjust the drive chain beyond the adjustable range

Replace the drive chain before drive chain exceeds the limit.

Page 39

2-22 PERIODIC MAINTENANCE

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 will damage the O-rings. Use only kerosine to clean the drive chain.

• After washing 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 RK525SMOZ7Y. Suzuki

recommends to use this standard drive chain as a replacement.

Page 40

BRAKE

PERIODIC MAINTENANCE 2-23

(BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 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 relative to 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 

* 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 fluid leakage before riding.

Page 41

2-24 PERIODIC MAINTENANCE

BRAKE PADS Front brake

The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones.

(8-65)



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

Rear brake

The extent of brake pad wear can be checked by observing the grooved limit line B on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones.

(8-76)



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

BRAKE PEDAL HEIGHT

• Loosen the lock-nut 1.

• Turn the push rod 2 until the brake pedal height becomes 65 – 75 mm (2.6 – 3.0 in) A below the top of the footrest.

• Tighten the lock-nut 1 securely.

 Rear brake master cylinder rod lock-nut:

18 N·m (1.8 kgf-m, 13.0 Ib-ft)

 Brake pedal height A:

Standard: 65 – 75 mm (2.6 – 3.0 in)

Page 42

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.

AIR BLEEDING FROM 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:

PERIODIC MAINTENANCE 2-25

FRONT BRAKE (Caliper side)

• Fill the master cylinder reservoir to the top of the inspection window. Replace 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 fluid flowing into the receptacle no longer contains air bubbles.

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: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft) 

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

Page 43

2-26 PERIODIC MAINTENANCE

FRONT BRAKE (Master cylinder side)

• Bleed air from the master cylinder in the same manner as front brake (caliper side).

 Air bleeder valve: 6.0 N·m (0.6 kgf-m, 4.3 Ib-ft)

NOTE: If air is trapped in the master cylinder, bleed air from the master cylinder first.

REAR BRAKE

• Bleed air from the rear brake system in the same manner as front brake.

 Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft)

NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal.

Page 44

TIRES

Inspect every 6 000 km (4 000 miles, 12 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

 09900-20805: Tire depth gauge  Tire tread depth:

Service Limit: FRONT : 1.6 mm (0.06 in)

REAR : 2.0 mm (0.08 in)

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.

PERIODIC MAINTENANCE 2-27

 Cold inflation tire pressure

Solo riding: Front: 250 kPa (2.50 kgf/cm

Rear: 250 kPa (2.50 kgf/cm

Dual riding: Front: 250 kPa (2.50 kgf/cm

Rear: 290 kPa (2.90 kgf/cm

, 36 psi)

, 42 psi)



The standard tire fitted on this motorcycle is 120/70 ZR17 M/C (58 W) for the front and 180/55 ZR17 M/C (73 W) for the rear. The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.

 TIRE TYPE

BRIDGESTONE (Front: BT014FJ, Rear: BT014R N)

STEERING

Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter.

The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtighten steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, read-

just the steering. (8-33)

Page 45

2-28 PERIODIC MAINTENANCE

FRONT FORK

Inspect every 12 000 km (7 500 miles, 24 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. (8-18)

REAR SUSPENSION

Inspect every 12 000 km (7 500 miles, 24 months).

• Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. Replace any defective

parts if necessary. (8-49)

Page 46

EXHAUST PIPE BOLT AND NUT

Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter.

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

PERIODIC MAINTENANCE 2-29

1 Gasket 2 Exhaust pipe connecter 



Replace the gaskets and exhaust pipe connector with the new ones.

ITEM N·m

AB CD

23 2.3 16.5

kgf-m

lb-ft

Page 47

2-30 PERIODIC MAINTENANCE

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-31 for the locations of the following nuts and bolts on the motorcycle.)

Item N·m kgf-m Ib-ft

1 Steering stem head nut 90 9.0 65.0 2 Steering stem lock-nut 80 8.0 58.0 3 Front fork upper clamp bolt 23 2.3 16.5 4 Front fork lower clamp bolt 23 2.3 16.5 5 Front fork cap bolt 23 2.3 16.5 6 Front axle bolt 100 10.0 72.5 7 Front axle pinch bolt 23 2.3 16.5 8 Handlebar clamp bolt 23 2.3 16.5 9 Front brake master cylinder mounting bolt 10 1.0 7.0 0 Front brake caliper mounting bolt 39 3.9 28.0 A Front brake caliper housing bolt 22 2.2 16.0 B Brake hose union bolt (Front & Rear) 23 2.3 16.5 C Air bleeder valve

(Front brake caliper & Rear brake caliper)

D Air bleeder valve (Master cylinder) 6.0 0.6 4.5 E Brake disc bolt (Front) 23 2.3 16.5 F Brake disc bolt (Rear) 35 3.5 25.5 G Rear brake caliper mounting bolt 17 1.7 12.5 H Rear brake master cylinder mounting bolt 10 1.0 7.0 I Rear brake master cylinder rod lock-nut 18 1.8 13.0 J Front footrest bracket mounting bolt 23 2.3 16.5 K Swingarm pivot nut 100 10.0 72.5 L Swingarm pivot lock-nut 90 9.0 65.0 M Rear suspension bracket nut 115 11.5 83.0

Rear shock absorber mounting bolt/nut (Upper & Lower)

N O Cushion rod nut 78 7.8 56.5 P Cushion lever mounting nut 98 9.8 71.0 Q Rear axle nut 100 10.0 72.5 R Rear sprocket nut 93 9.3 67.5 S Steering damper bolt/nut 23 2.3 16.5 T Rear brake caliper pin bolt 32 3.2 23.0

7.5 0.75 5.5

50 5.0 36.0

Page 48

PERIODIC MAINTENANCE 2-31

Page 49

2-32 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Standard Limit Difference

1 200 – 1 600 kPa

(12 – 16 kgf/cm

, 171 – 228 psi)

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder walls * Worn piston or piston rings * Piston rings stuck in grooves * Poor valve seating * Ruptured or otherwise defective cylinder head gasket

900 kPa

(9 kgf/cm2, 128 psi)

200 kPa

(2 kgf/cm2, 28 psi)

Overhaul the engine in the following cases:

* Compression pressure in one of the cylinders is 900 kPa (9 kgf/cm

, 128 psi) and less.

* The difference in compression pressure between any two cylinders is 200 kPa (2 kgf/cm

more.

* All compression pressure readings are below 1 200 kPa (12 kgf/cm

900 kPa (9 kgf/cm

, 128 psi) and more.

, 171 psi) even when they measure

COMPRESSION TEST PROCEDURE

NOTE: * Before testing the engine for compression pressure, make

sure that the cylinder head nuts are tightened to the specified

torque values and the valves are properly adjusted. * Have the engine warmed up before testing. * Make sure that the battery is fully-charged.

Remove the related parts and test the compression pressure in the following manner.

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

• Remove all the spark plugs. (2-5)

• Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

• Keep the throttle grip in the fully opened position.

• Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression.

• Repeat this procedure with the other cylinders.

, 28 psi) and

 09915-64512: Compression gauge set

09913-10750: Adaptor

Page 50

PERIODIC MAINTENANCE 2-33

OIL PRESSURE CHECK

Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.

OIL PRESSURE SPECIFICATION

100 – 400 kPa (1.0 – 4.0 kgf/cm

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 * Damaged O-ring * Defective oil pump * Combination of the above items

HIGH OIL PRESSURE

* Engine oil viscosity is too high * Clogged oil passage * Combination of the above items

OIL PRESSURE TEST PROCEDURE

Start the engine and check if the oil pressure indicator light is turned on. If the light stays on, check the oil pressure indicator light circuit. If the circuit is OK, check the oil pressure in the following manner.

• Remove the main oil gallery plug 1.

• Install the oil pressure gauge and adaptor into the main oil gallery.

• 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 (observe the tachometer), and read the oil pressure gauge.

, 14 – 57 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F)

 09915-74521: Oil pressure gauge hose

09915-74540: Oil pressure gauge attachment 09915-77331: Meter (for high pressure)

 Oil gallery plug (M16): 35 N·m (3.5 kgf-m, 25.5 lb-ft)

Page 51

2-34 PERIODIC MAINTENANCE

SDS CHECK

Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle. For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with the normal data that have been saved or filed can allow the specific engine failure to be determined.

• Remove the front seat. (8-7)

• Set up the SDS tool. (4-26)

 09904-41010: SDS set tool

99565-01010-007: CD-ROM Ver. 7

NOTE: * Before taking the sample of data, check and clear the Past DTC. ( * A number of different data under a fixed condition as shown below should be saved or filed as sample.



4- )

SAMPLE: Data sampled from cold starting through warm-up

Check the fast idle time. Approx. XX sec.

Fast idle section

Check the engine r/min. XXXX r/min

Check the manifold absolute pressure. XXXX mmHg

Check the engine r/min. XXXX r/min

Check the secondary throttle valve operation in according with the engine r/min.

Page 52

Data at 3 000 r/min under no load

3 000 r/min

PERIODIC MAINTENANCE 2-35

Data at the time of racing

Throttle: Quick wide open

Check the manifold absolute pressure. XXX mmHg

Throttle: Slowly open

Secondary throttle valve opens closes in according with the engine r/min.

Page 53

2-36 PERIODIC MAINTENANCE

Data of intake negative pressure during idling (100 °C)

Check the manifold absolute pressure. Approx. XXX mmHg

Data of secondary throttle valve operation at the time of starting

Closes fully in approx. XX sec.

Page 54

ENGINE

CONTENTS

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE .......... 3- 2

ENGINE REMOVAL AND INSTALLATION................................................. 3- 3

ENGINE REMOVAL .............................................................................. 3- 3

ENGINE INSTALLATION ...................................................................... 3-10

ENGINE DISASSEMBLY............................................................................. 3-14

ENGINE COMPONENTS INSPECTION AND SERVICE............................. 3-26

CYLINDER HEAD COVER .................................................................... 3-26

CMP SENSOR ....................................................................................... 3-26

PAIR REED VALVE............................................................................... 3-26

CRANKCASE BREATHER REED VALVE ........................................... 3-27

PCV HOSE............................................................................................. 3-27

CAMSHAFT ........................................................................................... 3-28

CAM CHAIN TENSION ADJUSTER ..................................................... 3-30

CAM CHAIN TENSIONER..................................................................... 3-30

CAM CHAIN GUIDE .............................................................................. 3-30

CYLINDER HEAD AND VALVE............................................................ 3-30

CLUTCH ................................................................................................ 3-38

CLUTCH LIFTER................................................................................... 3-39

OIL PUMP.............................................................................................. 3-41

STARTER CLUTCH .............................................................................. 3-41

GENERATOR ........................................................................................ 3-43

WATER PUMP....................................................................................... 3-43

GEARSHIFT SYSTEM........................................................................... 3-43

OIL PRESSURE REGULATOR............................................................. 3-44

OIL STRAINER...................................................................................... 3-44

TRANSMISSION.................................................................................... 3-45

CYLINDER............................................................................................. 3-48

PISTON AND PISTON RING................................................................. 3-49

CRANKCASE ........................................................................................ 3-51

CRANKSHAFT AND CONROD ............................................................ 3-61

CRANKSHAFT JOURNAL BEARING .................................................. 3-65

CRANKSHAFT THRUST BEARING ..................................................... 3-68

ENGINE REASSEMBLY.............................................................................. 3-70

ENGINE 3-1

Page 55

3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions.

ENGINE CENTER

ITEM REMOVAL INSPECTION INSTALLATION

PAIR control solenoid valve 11-7 11-7 11-7 Starter motor 3-14 9-14 3-98 Breather cover 3-22 — 3-79 Thermostat 7-9 7-9 7-10 Cylinder head cover 3-14 — 3-97 Camshaft 3-14 3-28 3-91 Intake pipe 3-37 — 3-38 Oil filter 3-22 — 3-79 Oil cooler 3-23 7-17 3-78 Oil pan 3-23 — 3-78 Oil pump 3-23 3-41 3-77

ENGINE RIGHT SIDE

ITEM REMOVAL INSPECTION INSTALLATION

Exhaust pipe and muffler 3-5 — 3-12 Cam chain tension adjuster 3-15 3-30 3-94 Clutch cover 3-16 — 3-89 Clutch (plates) 3-17 3-38 3-87 Clutch lifter 3-18 3-39 3-85 Primary driven gear 3-18 3-39 3-85 Oil pump drive sprocket 3-19 — 3-84 Gearshift shaft 3-19 3-43 3-83 CKP sensor 3-16 4-35 3-89 Oil pump driven gear 3-41 — — Cam chain tensioner 3-20 3-30  3-81 Cam chain guide 3-20 3-30 3-81

ENGINE LEFT SIDE

ITEM REMOVAL INSPECTION INSTALLATION

Engine sprocket 3-7, 8 — 3-12 Gear position switch 3-22 4-75 3-79 Starter idle gear cover 3-19 — 3-83 Starter idle gear 3-19, 20 — 3-82, 83 Generator cover 3-20 — 3-82 Starter clutch 3-21 3-41 3-81 Generator rotor 3-21 — 3-81 Water pump 3-21 7-13 3-80

Page 56

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure.

• Remove the under cowlings. (8-5)

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

• Drain engine oil. (2-12)

• Drain engine coolant. (2-17)

• Disconnect the battery - lead wire 1.

ENGINE 3-3

• Remove the air cleaner box. (5-14)

• Remove the throttle body assembly. (5-15)

Page 57

3-4 ENGINE

RADIATOR

• Disconnect the by-pass hose 1 and radiator inlet hose 2.

• Disconnect the oil cooler outlet hose 3.

• Disconnect the cooling fan coupler 4.

• Remove the radiator mounting bolts.

• Remove the radiator 5.



Be careful not to bent the radiator fins.

Page 58

EXHAUST PIPE AND MUFFLER

• Remove the EXCV cables along with the bracket 1.

• Loosen the muffler connecting bolt.

• Remove the HO2 sensor 2 (For E-02, 19). (6-10)

• Remove the exhaust pipe bolts.

• Remove the exhaust pipe.

• Remove the exhaust pipe gaskets.

ENGINE 3-5

• Remove the radiator mounting bracket 2.

• Remove the muffler body. (6-11)

ELECTRIC PARTS AND PAIR HOSE

• Disconnect the oil pressure switch lead wire 1.

• Remove the under cowling lower bracket 2.

Page 59

3-6 ENGINE

• Disconnect the following couplers.

3 GP switch lead wire 4 CKP sensor lead wire 5 Ground lead wire 6 Starter motor lead wire 7 Speed sensor lead wire 8 ECT sensor lead wire

• Disconnect the ignition coil/plug cap lead wire couplers.



Do not remove the ignition coil/plug cap before disconnecting its coupler.

• Disconnect the CMP sensor lead wire coupler 9 and regulator/rectifier couplers 0.

• Remove the ignition coils/plug caps.



* 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 its short or open circuit.

• Disconnect the PAIR hoses A.

• Disconnect the horn coupler B.

• Remove the horn and regulator/rectifier along with their bracket.

• Remove the front engine cover C.

Page 60

ENGINE SPROCKET AND GEARSHIFT LEVER

• Disengage the gearshift lever 1.

• Remove the engine sprocket cover 2.

• Remove the clutch push rod 3.

ENGINE 3-7

• Remove the speed sensor rotor 4.

• Remove the engine sprocket nut 5 and the washer 6.

• Remove the cotter pin. (For E-03, 28, 33)

• Loosen the rear axle nut 7.

• Loosen the chain adjuster lock-nuts 8.

• Loosen the chain adjusters 9.

• Push the rear wheel forward and make sure that the drive chain has enough slack.

• Disengage the drive chain from the rear sprocket.

Page 61

3-8 ENGINE

• Remove the engine sprocket 0.

ENGINE MOUNTING

• Support the engine using an engine jack.

• Remove the engine mounting bolt A.

• Loosen the engine mounting pinch bolt 1.

• Remove the engine mounting bolt B.

Page 62

• Remove the engine mounting nut 2.

• Remove the engine mounting thrust adjuster lock-nut 3 with the special tool.

• Loosen the engine mounting thrust adjuster 4 fully.

 09940-14980: Engine mounting thrust adjuster

socket wrench

ENGINE 3-9

• Remove the engine mounting nut 5.

• Loosen the engine mounting thrust adjuster lock-nut 6 with the special tool.

• Loosen the engine mounting thrust adjuster 7 fully.

 09940-14980: Engine mounting thrust adjuster

socket wrench

NOTE: Do not remove the engine mounting bolts at this stage.

• Remove the engine mounting bolts and gradually lower the front side of the engine. Then, take off the drive chain from the driveshaft.

• Remove the engine assembly.

Page 63

3-10 ENGINE

ENGINE INSTALLATION

Install the engine in the reverse order of engine removal. Pay attention to the following points:

NOTE: Be careful not to damage the frame and engine when installing the engine.

• Before installing the engine, install the engine mounting thrust

adjusters 1 and 2.

• Gradually raise the rear side of the engine assembly, and then put the drive chain on the driveshaft.

• Install all engine mounting bolts and tighten them temporarily.

(3-11)



Be careful not to catch the wiring harness between the frame and the engine.

• Tighten the engine mounting thrust adjusters to the specified torque.

 09940-14980: Engine mounting thrust adjuster

socket wrench

 Engine mounting thrust adjuster:

23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the engine mounting thrust adjuster lock-nuts to the specified torque with the special tool.

 09940-14980: Engine mounting thrust adjuster

socket wrench

 Engine mounting thrust adjuster lock-nut:

45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Tighten all engine mounting bolts and nuts to the specified

torque. (3-11)

NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.

• Tighten the engine mounting pinch bolts to the specified

torque. (3-11)

Page 64

ENGINE 3-11

 LENGTH

ITEM N·m

AB 55 5.5 40.0

1 23 2.3 16.5 B 55 2.17

34 23 2.3 16.5 C 215 8.46

kgf-m

lb-ft ITEM mm in

A 45 1.77

Bolt

56 45 4.5 32.5 D 205 8.07 78 75 7.5 54.0 Spacer 2 30.5 1.20

Adjuster 34 40 1.57

a Left b Right

Page 65

3-12 ENGINE

• Install the engine sprocket and the washer.

• Apply a small quantity of THREAD LOCK to the driveshaft thread portion.

 99000-32050: THREAD LOCK “1342”

• Tighten the engine sprocket nut to the specified torque.

 Engine sprocket nut: 115 N·m (11.5 kgf-m, 83.0 lb-ft)

• Install the speed sensor rotor 3.

• Tighten the speed sensor rotor bolt 4 to the specified torque.

 Speed sensor rotor bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

• Apply SUZUKI SUPER GREASE “A” to the clutch push rod end.

 99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the engine sprocket cover.

• Replace the exhaust pipe gaskets and muffler connector with new ones.

NOTE: Be sure to face the tabs

on the exhaust pipe gaskets 5 to the

exhaust pipe side when installing them.

Page 66

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

 Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Muffler connecting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) Exhaust pipe bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Install the HO2 sensor 6. (For E-02, 19)

 HO2 sensor: 48 N·m (4.8 kgf-m, 34.5 lb-ft)

ENGINE 3-13

• Install the gearshift lever and adjust the lever height B.

 Gearshift lever height B

Standard: 65 – 75 mm (2.56 – 2.95 in)

• Perform service and adjustment in the following items.

* Engine oil (2-12) * Engine coolant (2-17) * Throttle cable play (2-15) *Clutch (2-16) * Idling adjustment (2-14) * Throttle valve synchronization (5-26) * EXCV cable adjustment (6-8) * Drive chain slack (2-21) * Wiring harness, cables and hoses (10-17 to -24)

Page 67

3-14 ENGINE

ENGINE DISASSEMBLY



Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions.

• Remove the spark plugs. (2-5)

STARTER MOTOR

• Remove the starter motor 1.

CYLINDER HEAD COVER

• Remove the cylinder head cover 1 and its gaskets.

• Remove the PAIR reed valves 2 with their gaskets.

CAMSHAFT

• Remove the valve timing inspection cap 1.

Page 68

• Turn the crankshaft to bring the line A on the CKP sensor rotor to the rib B behind the clutch cover and also to bring the cams to the position as shown.

ENGINE 3-15

• Remove the cam chain tension adjuster cap bolt 2 and spring.

• Remove the cam chain tension adjuster 3.

• Remove the cam chain guide No. 2 4.

• Remove the camshaft journal holders 5.



Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.

• Remove the intake camshaft 6.

• Remove the exhaust camshaft 7.

• Remove the dowel pins.

Page 69

3-16 ENGINE

CYLINDER HEAD

• Remove the thermostat cover 1.

• Remove the thermostat 2 and thermostat conector 3.

THERMOSTAT INSPECTION (7-9)

• Remove the ECT sensor 4.

ECT SENSOR INSPECTION (7-7)

• Remove the cylinder head bolts (M6) 5.

• Remove the O-rings 6.

• Remove the cylinder head bolts and washers.

NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally.

• Remove the cylinder head.

• Remove the dowel pins and gasket.

CLUTCH

• Remove the clutch cover 1 along with the CKP sensor 2.

• Remove the dowel pins and gasket.

CKP SENSOR INSPECTION (4-35)

Page 70

• Hold the clutch housing with the special tool.



Do not damage the clutch plates by the special tool.

 09920-53740: Clutch sleeve hub holder

• Remove the clutch springs.

NOTE: Loosen the clutch spring set bolts little by little and diagonally.

• Remove the pressure plate 3.

• Remove the clutch drive plates 4 and driven plates 5.

• Remove the clutch push piece 6, thrust washer 7 and bearing 8.

ENGINE 3-17

• Remove the spring washer 9 and its seat 0.

• Remove the clutch push rod A.

NOTE: If it is difficult to pull out the push rod

, use a magnetic hand or

a wire.

• Unlock the clutch sleeve hub nut.

Page 71

3-18 ENGINE

• Hold the clutch sleeve hub with the special tool.

 09920-53740: Clutch sleeve hub holder

• Remove the clutch sleeve hub nut.

• Remove the washers C, D and E from the clutch sleeve

hub.

• Remove the wave spring washers F and clutch lifter driven cam G.

• Remove the clutch lifter drive cam H and washer I.

• Remove the spacer J and bearing K.

• Remove the primary driven gear assembly L.

NOTE: If it is difficult to remove the primary driven gear, rotate the crankshaft.

Page 72

OIL PUMP DRIVE SPROCKET

• Remove the spacer 1.

• Remove the oil pump drive sprocket 2 and chain 3.

• Remove the thrust washer 4.

GEARSHIFT SYSTEM

• With the snap ring 1 and washer removed, remove the gearshift shaft assembly 2.

ENGINE 3-19

• Remove the gearshift cam plate bolt 3 and gearshift cam plate 4.

• Remove the gearshift cam stopper 5.

STARTER IDLE GEAR AND GENERATOR COVER

• Remove the starter idle gear cover.

• Remove the spring washer 1, washer 2 and starter idle gear No. 1 3.

Page 73

3-20 ENGINE

• Remove the shaft 4, bearing 5 and thrust washer 6.

• Remove the generator cover.

• Remove the dowel pins and gasket.

• Remove the starter idle gear No. 2 7 and shaft 8.

CAM CHAIN/CAM CHAIN TENSIONER/CAM CHAIN GUIDE

• While holding the generator rotor with the special tool, remove the CKP sensor rotor/cam chain drive sprocket nut.

 09930-44520: Rotor holder

• Remove the CKP sensor rotor/cam chain drive sprocket 1 and cam chain 2.

• Remove the cam chain tensioner 3 and cam chain guide No. 1 4.

Page 74

GENERATOR ROTOR AND STARTER DRIVEN GEAR

• Hold the generator rotor with the special tool.

 09930-44520: Rotor holder

• Remove the generator rotor bolt.

• Install a bolt A of suitable size to the left end of crankshaft.

SUITABLE BOLT A [M12, length: 28 – 38 mm (1.1 – 1.5 in)]

• Remove the generator rotor 1 and starter driven gear 2 with

the special tool.

 09930-34980: Rotor remover

ENGINE 3-21

WATER PUMP

• Remove the water hoses and water inlet connector 1.

28 – 38 mm (1.1 – 1.5 in)

• Remove the water pump 2.

WATER PUMP SERVICING (7-11)

Page 75

3-22 ENGINE

GEAR POSITION SWITCH

• Remove the gear position switch 1.

CRANKCASE BREATHER (PCV) COVER

• Remove the crankcase breather cover 1.

• Remove the gasket 2.

OIL PRESSURE SWITCH

• Remove the oil pressure switch 1.

OIL FILTER

• Remove the oil filter with the special tool.

 09915-40610: Oil filter wrench

Page 76

OIL COOLER

• Remove the oil cooler 1.

OIL PAN

• Remove the plate 1 and oil pan.

• Remove the gasket.

ENGINE 3-23

OIL PRESSURE REGULATOR

• Remove the oil pressure regulator 1.

OIL STRAINER

• Remove the oil strainer 2.

OIL PUMP

• Remove the oil pump 1.

• Remove the dowel pins and O-ring 2.

LOWER CRANKCASE

• Remove the clutch push rod oil seal retainer 1.

Page 77

3-24 ENGINE

• Remove the upper crankcase bolts.

• Remove the lower crankcase bolts (M8).

• Remove the crankshaft journal bolts (M9).

• Remove the lower crankcase assembly.

• Remove the dowel pins, O-ring 2 and cap 3.

COUNTERSHAFT

• Remove the dowel pin.

• Remove the retainer 1, bushing 2, gearshift shaft and fork

• Remove the oil seal 4 and countershaft assembly 5.

• Remove the C-ring 6 and bearing pin 7.

Page 78

CRANKSHAFT

• Loosen the conrod bearing cap bolts by using a 10 mm, 12-point socket wrench, and tap the bearing cap bolts lightly with a plastic hammer to remove the bearing cap.

• Remove the crankshaft and thrust bearings 1.

PISTON AND CONROD

• Push the conrod to cylinder head side and remove the piston and conrod from the upper crankcase.



Be careful not to damage the cylinder wall by the conrod.

ENGINE 3-25

• Remove the piston pin circlip 1.

• Separate the piston and conrod by driving out the piston pin.

NOTE: Scribe the cylinder number on the piston head.

Page 79

3-26 ENGINE

ENGINE COMPONENTS 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

• Clean and check the gasket grooves A and PAIR reed valve gasket mating surfaces B of cylinder head cover.

• If it is damaged, replace the cylinder head cover with a new one.

CMP SENSOR

REMOVAL

• Remove the CMP sensor 1 from the cylinder head cover.

INSPECTION

• Inspect the CMP sensor. (4-33)

INSTALLATION

• Install the CMP sensor.

NOTE: When installing, clean the CMP sensor’s face.

 CMP sensor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

PAIR REED VALVE

REMOVAL

• Remove the PAIR reed valve 1 from the gasket.

Page 80

INSPECTION

• 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.

CRANKCASE BREATHER REED VALVE

REMOVAL

• Remove the crankcase breather reed valve 1 from the crankcase breather cover.

ENGINE 3-27

INSPECTION

• Inspect the reed valve for the carbon deposit.

• If the carbon deposit is found in the reed valve, replace the crankcase breather reed valve with a new one.

INSTALLATION

• Install the reed valve to the breather cover.

• Tighten the bolts to the specified torque.

 Crankcase breather reed valve cover bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

PCV HOSE

• Remove the PCV hose from the crankcase breather reed valve cover.

• Inspect the PCV hose for wear or damage.

• If it is worn or damaged, replace the PCV hose with a new one.

Page 81

3-28 ENGINE

CAMSHAFT

CAMSHAFT IDENTIFICATION

The exhaust camshaft can be distinguished from that of the intake by the embossed letters “EX” (for exhaust) as against letters “IN” (for intake).

CAM WEAR

• Check the camshaft for wear or damage.

• Measure the cam height H with a micrometer.

 Cam height H:

Service Limit: (IN.) : 36.28 mm (1.428 in)

(EX.) : 35.68 mm (1.405 in)

 09900-20202: Micrometer (25 – 50 mm)

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 1 to read the clearance at the widest portion, which is specified as follows:

 Camshaft journal oil clearance:

Service Limit: (IN. & EX.): 0.150 mm (0.0059 in)

 09900-22301: Plastigauge

09900-22302: Plastigauge

NOTE: Install camshaft journal holders to their original positions. (



3-93)

• Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.

 Camshaft journal holder bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

Page 82

NOTE: Do not rotate the camshaft with the plastigauge in place.

• Remove the camshaft holders, and read the width of the compressed 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.

 Camshaft journal holder I.D.:

Standard: (IN. & EX.):

24.012 – 24.025 mm (0.9454 – 0.9459 in)

ENGINE 3-29

 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)

CAMSHAFT RUNOUT

• Measure the runout using the dial gauge.

• Replace the camshaft if the runout exceeds the limit.

 Camshaft runout:

Service Limit (IN. & EX.): 0.10 mm (0.004 in)

 09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)

CAM SPROCKET

• Inspect the sprocket teeth for wear.

• If they are worn, replace the sprocket/camshaft assembly and cam chain as a set.

Page 83

3-30 ENGINE

CAM CHAIN TENSION ADJUSTER

INSPECTION

• Remove the cam chain tension adjuster cap bolt and spring.

• Check that the push rod slides smoothly when releasing stop-

per 1.

• 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 guide No. 1 and No. 2.

• If they are worn or damaged, replace them with the new ones.

CYLINDER HEAD AND VALVE

VALVE AND VALVE SPRING DISASSEMBLY

• Remove the tappet 1 and shim 2 by fingers or magnetic hand.



Identify the position of each removed part.

Page 84

• Install the special tool 3 between the valve spring and cylin-

der head.

• Using the special tools, compress the valve spring and remove the two cotter halves from the valve stem.

 09916-14510: Valve lifter

09916-14530: Valve lifter attachment 09916-84511: Tweezers 09919-28610: Sleeve protector



To prevent damage of the tappet sliding surface with the special tool, use the protector.

• Remove the valve spring retainer 4 and valve spring 5.

• Pull out the valve 6 from the combustion chamber side.

ENGINE 3-31

• Remove the oil seal 7 and spring seat 8.



Do not reuse the removed oil seal.

• Remove the other valves in the same manner as described previously.

CYLINDER HEAD DISTORTION

• Decarbonize the combustion chambers.

• Check the gasketed 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: 0.20 mm

 09900-20803: Thickness gauge

Page 85

3-32 ENGINE

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.

 Valve stem runout:

Service Limit: 0.05 mm

 09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)



Be careful not to damage the valve and valve stem when handling it.

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

 09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand 09900-21304: V-block set (100 mm)



Be careful not to damage the valve and valve stem when handling it.

VALVE STEM AND VALVE FACE WEAR CONDITION

• Visually inspect each valve stem and valve face for wear and pitting. If it is worn or damaged, replace the valve with a new one.

Page 86

VALVE STEM DEFLECTION

• Lift the valve about 10 mm from the valve seat.

• Measure the valve stem deflection in two directions, perpendicular 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.

 Valve stem deflection (IN & EX):

Service Limit: 0.25 mm

 09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

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 deflection.

ENGINE 3-33

 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)

 09900-20205: Micrometer (0 – 25 mm)

NOTE: If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. (

VALVE GUIDE SERVICING

• Using the valve guide remover, drive the valve guide out toward the intake or exhaust camshaft side.

 09916-43211: Valve guide remover/installer



below)

NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement

parts. (Part No. 11115-29G70)

• Re-finish the valve guide holes in cylinder head with the reamer and handle.

 09916-33320: Valve guide reamer

09916-34542: Reamer handle



When refinishing or removing the reamer from the valve guide hole, always turn it clockwise.

Page 87

3-34 ENGINE

• Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 °C – 150 °C (212 °F – 302 °F) with a hot plate.



Do not use a burner to heat the valve guide hole to prevent cylinder head distortion.

• Apply engine oil to the valve guide hole.

• Drive the valve guide into the hole using the valve guide installer 1 and attachment 2.

 09916-43211: Valve guide installer/remover

09916-44930: Attachment 09916-53330: Attachment

NOTE: Install the valve guide until the attachment

cylinder head

A: 14.1 mm (0.555 in) (IN)

contacts with the

13.2 mm (0.520 in) (EX)



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, re-finish their guiding bores using the reamer.

• Clean and oil the guides after reaming.

 09916-33210: Valve guide reamer

09916-34542: Reamer handle

NOTE: * Be sure to cool down the cylinder head to ambient air temper-

ature.

* Insert the reamer from the combustion chamber and always

turn the reamer handle clockwise.

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 lapper set

Page 88

• 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, re-cut the seat.

VALVE SEAT SERVICING

• The valve seats 1 for both the intake valve 2 and exhaust valve 3 are machined to four different angles. The seat contact surface is cut at 45°.

INTAKE EXHAUST

Seat angle 30°, 45°, 60° 15°, 45°, 60° Seat width 0.9 – 1.1mm (0.035 – 0.043 in)

Valve diameter 27.2 mm (1.07 in) 22 mm (0.87 in)

Valve guide I.D. 4.500 – 4.512 mm (0.177 – 0.178 in)

60˚

45˚

30˚

ENGINE 3-35

60˚

15˚

45˚



* The valve seat contact area must be inspected after

each cut.

* 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 finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.

* The titanium valves are coated with an oxidized

membrane treatment to resist wear but the membrane tend to be removed if lapped after valve seat servicing.

NOTE: After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (



2-7)

• 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.

Page 89

3-36 ENGINE

VALVE SPRING

The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism.

• 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.

 Valve spring free length:

Service limit (IN & EX): 38.2 mm (1.504 in)

 09900-20102: Vernier calipers  Valve spring tension (IN & EX):

Standard: 203 – 233 N (20.7 – 23.8 kgf)/33.55 mm

(45.6 – 52.4 lbs/1.32 in)

VALVE AND VALVE SPRING REASSEMBLY

• Install the valve spring seat.

• Apply MOLYBDENUM OIL SOLUTION to the oil seal 1, and press-fit it into position.

 MOLYBDENUM OIL SOLUTION 

Do not reuse the removed oil seal.

• Insert the valve, with its stem coated with MOLYBDENUM OIL SOLUTION all around and along the full stem length without any break.



When inserting the valve, take care not to damage the lip of the oil seal.

 MOLYBDENUM OIL SOLUTION

• Install the valve spring with the small-pitch portion A facing cylinder head.

B Large-pitch portion C UPWARD D Paint

Page 90

• Put on the valve spring retainer 2, and using the special tool 3, press down the spring, fit the cotter halves 4 to the stem

end, and release the lifter to allow the cotter halves to wedge in between retainer and stem.

 09916-14510: Valve lifter

09916-14530: Valve lifter attachment 09916-84511: Tweezers 09919-28610: Sleeve protector

• Be sure that the rounded lip E of the cotter fits snugly into the groove F in the stem end.

• Install the other valves and springs in the same manner as described previously.



Be sure to restore each spring and valve to their original positions.

ENGINE 3-37



Be careful not to damage the valve and valve stem when handling it.

2 Valve spring retainer 4 Cotter

• Install the tappet shims and the tappets to their original positions.

NOTE: * Apply engine oil to the stem end, shim and tappet before fitting

them.

* When seating the tappet shim, be sure the figure printed sur-

face faces the tappet.

INTAKE PIPE

• Remove the intake pipes.

Page 91

3-38 ENGINE

• Apply SUZUKI SUPER GREASE “A” to the O-rings.

 99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the intake pipes.

• Apply THREAD LOCK to the bolts.

 99000-32050: THREAD LOCK “1342”

CLUTCH

CLUTCH DRIVE PLATE INSPECTION

NOTE: * Wipe off engine oil from the clutch drive plates with a clean

rag. * Clutch drive plate No.1: I.D. 111 mm (4.4 in)/Purple paint * Clutch drive plate No.2: I.D. 111 mm (4.4 in)/Black paint * Clutch drive plate No.3: I.D. 118 mm (4.6 in)/NIL

A Paint

• Measure the thickness of drive plates with a vernier calipers.

• If the drive plate thickness is found to have reached the limit, replace it with a new one.

 Drive plate thickness:

Service Limit: 2.42 mm (0.095 in)

 09900-20102: Vernier calipers

• 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 INSPECTION

NOTE: Wipe off engine oil from the clutch driven plates with a clean rag.

• Measure each driven plate for distortion with a thickness gauge and surface plate.

• Replace driven plates which exceed the limit.

 Driven plate distortion (No. 1 and No. 2):

Service Limit: 0.10 mm (0.004 in)

 09900-20803: Thickness gauge

Page 92

CLUTCH SPRING INSPECTION

• Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.

• Replace all the springs if any spring is not within the limit.

 Clutch spring free length:

Service Limit: 53.2 mm (2.094 in)

 09900-20102: Vernier calipers

CLUTCH BEARING INSPECTION

• Inspect the clutch release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced.

• Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

ENGINE 3-39

CLUTCH SLEEVE HUB/PRIMARY DRIVEN GEAR ASSEMBLY

• Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.

CLUTCH LIFTER

CLUTCH LIFTER DRIVE CAM AND DRIVEN CAM INSPECTION

• Inspect the clutch lifter drive cam and driven cam for wear or damage.

• If any defects are found, replace the clutch lifter drive cam or driven cam.

Page 93

3-40 ENGINE

CLUTCH LIFTER PIN ADJUSTMENT

NOTE: When adjusting the clutch lifter, it is not necessary to install the clutch onto the countershaft.

• Assemble the following parts into the primary driven gear

assembly. (3-85 to -88)

* Clutch sleeve hub * Spring washer seat, Spring washer * Clutch drive plates, Clutch driven plates * Pressure plate * Clutch springs, Clutch springs set bolts

 Clutch spring set bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Remove the clutch assembly from the primary driven gear assembly.

• Check the height H of clutch lifter adjusting pin screws at three positions using the thickness gauge.

• If the measurement is out of the specification, adjust the height H as shown in the following specification.

 Clutch lifter adjusting pin screw height H

Standard: 0.2 – 0.4 mm (0.008 – 0.016 in)

 09900-20803: Thickness gauge

NOTE: Each clutch lifter adjusting pin screw height should be as closely as possible.

• Loosen the lock-nut and turn out the adjusting pin screw.

• Set the thickness gauge to 0.3 mm (0.012 in).

• Place a proper flat plate on the thickness gauges and hold them by hand.

• Slowly turn in the adjusting pin screw until resistance is felt.

• Tighten the lock-nut.

 Clutch lifter pin lock-nut: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Page 94

WAVE SPRING WASHER INSPECTION

• Measure the free height H of each wave spring washer with a

vernier calipers.

• If each wave spring washer height H is not within the speci-

fied limit, replace it with a new one.

 09900-20102: Vernier calipers  Wave spring washer height H

Service Limit: 4.30 mm (0.169 in)

OIL PUMP

INSPECTION

• Remove the oil pump driven sprocket 1.

ENGINE 3-41

• Rotate the oil pump shaft 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 assembly. * The oil pump is available only as an assembly.

STARTER CLUTCH

INSPECTION

• Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. The gear turns one direction only. If a large resistance is felt to rotation, inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter driven gear for wear or damage.

• If they are found to be damaged, replace them with new ones.

• Inspect the starter driven gear bearing for any damages.

Page 95

3-42 ENGINE

DISASSEMBLY

• With holding the rotor with the special tool remove the starter clutch bolts.

 09930-44520: Rotor holder

• Remove the one way clutch 1 and guide 2 from the rotor.

REASSEMBLY

• When fitting the one way clutch 1 to the guide 2, position flange side A of one way clutch to the rotor side.

• When installing the starter clutch guide 2 to the rotor 3, make sure that the flange B side faces outside.

• Degrease the securing bolts and bolt holes.

• Apply THREAD LOCK SUPER “1303” to the bolts and tighten them to the specified torque while holding the rotor with the special tool.

 99000-32030: THREAD LOCK SUPER “1303”  Starter clutch securing bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)  09930-44520: Rotor holder

Page 96

GENERATOR

INSPECTION (9-10)

REASSEMBLY

• When installing the generator stator set bolts, tighten them to the specified torque.

 Generator stator set bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

NOTE: Be sure to install the grommet

to the generator cover.

WATER PUMP

7-11

GEARSHIFT SYSTEM

GEARSHIFT SHAFT/GEARSHIFT ARM DISASSEMBLY

• Remove the following parts from the gearshift shaft/gearshift arm.

1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate

ENGINE 3-43

GEARSHIFT SHAFT/GEARSHIFT ARM INSPECTION

• Inspect the gearshift shaft/gearshift arm for wear or bend.

• Inspect the return springs for damage or fatigue.

• Replace the arm or spring if there is anything unusual.

GEARSHIFT SHAFT/GEARSHIFT ARM REASSEMBLY

• Apply THREAD LOCK to the gearshift shaft screw.

 99000-32050: THREAD LOCK “1342”

NOTE: When installing the gearshift shaft return spring, position the stopper

of gearshift arm between the shaft return spring ends

Page 97

3-44 ENGINE

• Install the following parts to the gearshift shaft/gearshift arm as shown in the illustration.

1 Washer 5 Plate return spring 2 Snap ring 6 Washer 3 Gearshift shaft return spring 7 Screw 4 Gearshift cam drive plate

OIL PRESSURE REGULATOR

• Inspect the operation of the oil pressure regulator by pushing on the piston with a proper bar.

• If the piston does not operate, replace the oil pressure regulator with a new one.

OIL STRAINER

• Inspect the oil strainer body for damage.

• Clean the oil strainer if necessary.

Page 98

TRANSMISSION

DRIVESHAFT REMOVAL (3-51)

DISASSEMBLY

Disassemble the countershaft and driveshaft. Pay attention to the following points:

• Remove the 6th drive gear snap ring 1 from its groove and slide it towards the 3rd/4th drive gears 2.

• Slide the 6th 3 and 2nd 4 drive gears toward the 3rd/4th drive gears 2, then remove the 2nd drive gear circlip 5.

ENGINE 3-45

1 Countershaft/1st drive gear 8 6th driven gear 2 5th drive gear 9 3rd driven gear 3 3rd/4th drive gears 0 4th driven gear 4 6th drive gear A 5th driven gear 5 2nd drive gear B 1st driven gear  6 Driveshaft A Engine sprocket nut ITEM N·m 7 2nd driven gear A 115 11.5 83.2

kgf-m

lb-ft

Page 99

3-46 ENGINE

REASSEMBLY

Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points:

NOTE: * Rotate the bearings by hand to inspect for smooth rotation.

Replace the bearings if there is anything unusual.

* Before installing the gears, apply engine oil to the driveshaft

and countershaft.

* When installing the oil seal, apply SUZUKI SUPER GREASE

“A” to it.

 99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)



* Never reuse a snap ring. After a snap ring has been

removed from a shaft, it should be discarded and a new snap ring must be installed.

* When installing a new snap ring, do not expand the

end gap larger than required to slip the snap ring over the shaft.

* After installing a snap ring, make sure that it is com-

pletely seated in its groove and securely fitted.

NOTE: When reassembling the transmission, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. (

• When installing a new snap ring, pay attention to its direction. Fit it to the side where the thrust is as shown in the illustration.



When installing the gear bushing onto the countershaft 1 and driveshaft 2, align the shaft oil hole 3 with the bushing oil hole 4.



3-47)

A Thrust B Sharp edge

Page 100

TRANSMISSION PARTS LOCATION

ENGINE 3-47

1 Countershaft 2 Driveshaft

Suzuki GSX-R600 2006 User Manual [ru]

Specifications and Main Features

Frequently Asked Questions

User Manual

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

COMPONENT PARTS AND WORK TO BE DONE

SYMBOL

ABBREVIATIONS USED IN THIS MANUAL

GENERAL INFORMATION

COUNTRY AND AREA CODES

WARNING/CAUTION/NOTE

GENERAL PRECAUTIONS

SUZUKI GSX-R600K6 (’06-MODEL)

SERIAL NUMBER LOCATION

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

BREAK-IN PROCEDURES

CYLINDER IDENTIFICATION

INFORMATION LABELS

SPECIFICATIONS

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE AND TUNE-UP PROCEDURES

COMPRESSION PRESSURE CHECK

OIL PRESSURE CHECK

SDS CHECK

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

ENGINE REMOVAL AND INSTALLATION

ENGINE DISASSEMBLY

ENGINE COMPONENTS INSPECTION AND SERVICE