Suzuki GW250 Service Manual

G
SERVICE MANUAL
9 9 5 0 0 - 3 2 1 7 0 - 0 1 E
FOREWORD
This manual contains an introductory description on the SUZUKI GW250 and procedures for its inspec­tion/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main­tenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle bet­ter so that you can assure your customers of fast and reliable service.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
1
2
3
* This manual has been prepared on the basis
of the latest specifications at the time of publi­cation. If modifications have been made since then, differences may exist between the con­tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcy­cles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.
FI SYSTEM DIAGNOSIS
FUEL SYSTEM AND THROTTLE BODY
EXHAUST SYSTEM
COOLING AND LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL INFORMATION
4
5
6
7
8
9
10
11
© COPYRIGHT SUZUKI MOTOR CORPORATION 2012
WIRING DIAGRAM
12

HOW TO USE THIS MANUAL

FWD

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 wheel
A Front axle B Brake disc bolt
ITEM N·m
A 18 1.8 13.0 B 65 6.5 47.0
kgf-m
lbf-ft

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Use SUZUKI SUPER LONG LIFE
Torque control required. Data beside it indicates specified torque.
COOLANT (BLUE). 99000-99032-20X
Use SUZUKI LONG LIFE COOLANT (GREEN) or equivalent. 99000-99032-12X
Apply oil. Use engine oil or transmis­sion 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. 99000-25010
Apply SUZUKI SILICONE GREASE or equivalent. 99000-25100
Apply SUZUKI MOLY PASTE or equivalent. 99000-25140
Apply SUZUKI BOND “1207B” or equivalent. 99000-31140
Use SUZUKI FORK OIL G10 or equivalent. 99000-99001-G10
Apply or use brake fluid.
Measure in voltage range.
Measure in current range.
Measure in resistance range.
Measure in diode test range.
Apply THREAD LOCK CEMENT SUPER “1303” or equivalent. 99000-32030
Apply THREAD LOCK CEMENT SUPER “1322” or equivalent. 99000-32110
Apply THREAD LOCK CEMENT SUPER “1360” or equivalent. 99000-32130
Apply THREAD LOCK CEMENT SUPER“1342” or equivalent. 99000-32050
Measure in continuity test range.
Use special tool.
Indication of service data.

ABBREVIATIONS USED IN THIS MANUAL

A
ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center BTDC : Before Top Dead Center B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch
(Clutch Switch) CO : Carbon Monoxide CPU : Central Processing Unit
G
GEN : Generator GND : Ground GP Switch : Gear Position Switch
H
HC : Hydrocarbons HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
IAT Sensor : Intake Air Temperature Sensor
(IATS) IG : Ignition ISC Valve : Idle Speed Control Valve (ISCV)
J
JASO : Japanese Automobile
Standards Organization
D
DC : Direct Current DRL : Daytime Running Light DTC : Diagnostic Trouble Code
E
ECM : Engine Control Module
Engine Control Unit (ECU) (FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp. Sensor (WTS)
F
FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay FWD : Forward
L
LCD : Liquid Crystal Display LED : Light Emitting Diode
(Malfunction Indicator Lamp) LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp
(LED) Min : Minimum
N
NOX : Nitrogen Oxides
O
OHC : Over Head Camshaft OPS : Oil Pressure Switch
P
PAIR : Pulsed Secondary Air Injection PCM : Power control module PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand ROM : Read Only Memory
S
SAE : Society of Automotive Engineers SDS : Suzuki Diagnosis System
T
TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

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

GENERAL INFORMATION

CONTENTS
WARNING/CAUTION/NOTICE/NOTE ......................................................... 1- 2
GENERAL PRECAUTIONS ......................................................................... 1- 2
SUZUKI GW250L3 (’13-MODEL) ................................................................ 1- 4
SERIAL NUMBER LOCATION .................................................................... 1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...................... 1- 5
FUEL...................................................................................................... 1- 5
ENGINE OIL .......................................................................................... 1- 5
BRAKE FLUID....................................................................................... 1- 6
FRONT FORK OIL................................................................................. 1- 6
ENGINE COOLANT RECOMMENDATION .......................................... 1- 6
BREAK-IN PROCEDURES.......................................................................... 1- 7
CYLINDER IDENTIFICATION...................................................................... 1- 7
INFORMATION LABELS............................................................................. 1- 8
SPECIFICATIONS........................................................................................ 1- 9
DIMENSIONS AND CURB MASS......................................................... 1- 9
ENGINE ................................................................................................. 1- 9
DRIVE TRAIN ........................................................................................ 1- 9
CHASSIS ............................................................................................... 1-10
ELECTRICAL ........................................................................................ 1-10
CAPACITIES ......................................................................................... 1-10
1
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA EFFECTIVE FRAME NO.
P-12 Indonesia LC6GJ55B0C1 100001 – P-21 E.U. LC6DC111101 100001 – P-24 Australia LC6DC111201 100001 – P-71 Mexico LC6GJ55E D1 100001 –
1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTICE/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
Indicates a potential hazard that could result in motorcycle or equipment damage.
NOTE: Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN­INGS, CAUTIONS and NOTICES stated, you must use good judgement and basic mechanical safety princi­ples. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

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. * To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
GENERAL INFORMATION 1-3
* Never use gasoline as a cleaning solvent. * After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
* 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.
1-4 GENERAL INFORMATION

SUZUKI GW250L3 (’13-MODEL)

RIGHT SIDE
LEFT SIDE
NOTE: Difference between illustration and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
GENERAL INFORMATION 1-5
SAE API JASO
10W-40 SG or higher MA

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom­mended.
ENGINE OIL
Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use oil with an API (American Petroleum Institute) classification of SG or higher with a JASO classification of MA.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according
to the right chart.
Suzuki does not recommend the use of “ENERGY CONSERV­ING” and “RESOURCE CONSERVING” oils.
E
N
E
I
P
A
10W-40
R
G
Y
E
S
SAE
C
V
R
I
C
E
S
J
G
N
I
V
R
E
S
N
O
V
R
I
C
E
S
E
I
S
P
A
J
SAE
10W-40
“Donut” without “ENERGY CONSERVING” nor “RESOURCE CONSERVING”
No recommendRecommend
V
R
I
C
E
S
E
I
S
P
SAE
10W-40
R
C
E
N
G
N
I
V
R
E
S
N
O
C
A
R
E
S
O
U
No recommend
“Donut” with “RESOURCE CONSERVING” “Donut” with “ENERGY CONSERVING”
1-6 GENERAL INFORMATION
BRAKE FLUID
Specification and classification: DOT 4
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu­facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL
Use SUZUKI FORK OIL G10 or equivalent.
ENGINE COOLANT RECOMMENDATION
RECOMMENDED ENGINE COOLANT
The factory filled engine coolant of this vehicle is SUZUKI super long life coolant (Blue). It is recommended to use this SUZUKI super long life coolant when replenishing or charging the engine coolant. SUZUKI super long life coolant (Blue) as supply part is already diluted to the 50 percentage with deionized water. Use it as it is without diluting. SUZUKI recommends to use following coolants in that order.
1)
SUZUKI super long life coolant (Blue)
2) SUZUKI long life coolant (Green) or equivalent
ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator. There are two types of engine coolant: one used after diluting with distilled water and the other used as it is (without diluting). SUZUKI super long life coolant is the latter type and SUZUKI long life coolant is the former type.
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.
LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): Approx. 1 350 ml (1.4/1.2 US/Imp qt)
For engine coolant mixture information, refer to cooling system section in page 7-2.
GENERAL INFORMATION 1-7
#2
#1

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 5 500 r/min Up to 1 600 km (1 000 miles): Below 8 250 r/min Over to 1 600 km (1 000 miles): Below 11 000 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 11 000 r/min at any time.

CYLINDER IDENTIFICATION

The two cylinders of this engine are identified as #1 and #2 cylinder, as counted from left to right (as viewed by the rider on the seat).
#1
#2
1-8 GENERAL INFORMATION

INFORMATION LABELS

NO. LABEL or PLATE NAME
1 I.D. Plate (For-P21, 24, 71) 2 Tire information label 3 General warning label 4 Brake Approval Label (For-P21, 24) 5 Fuel limitation label (For-P12) 6 Noise label (For-P24)
Frame (RH)
Chain case
GENERAL INFORMATION 1-9

SPECIFICATIONS

DIMENSIONS AND CURB MASS
Overall length .......................................................................... 2 145 mm (84.4 in)
Overall width ........................................................................... 760 mm (29.9 in)
Overall height .......................................................................... 1 075 mm (42.3 in)
Wheelbase .............................................................................. 1 430 mm (56.3 in)
Ground clearance.................................................................... 165 mm (6.4 in)
Seat height .............................................................................. 780 mm (30.7 in)
Curb mass............................................................................... 183 kg (403 lbs)
ENGINE
Type ........................................................................................ Four stroke, liquid-cooled, SOHC
Number of cylinders ................................................................ 2
Bore......................................................................................... 53.5 mm (2.106 in)
Stroke...................................................................................... 55.2 mm (2.173 in)
Displacement .......................................................................... 248 cm³ (15.1 cu. in)
Compression ratio ................................................................... 11.5 : 1
Fuel system............................................................................. Fuel injection
Air cleaner ............................................................................... Non-woven fabric element
Starter system ......................................................................... Electric
Lubrication system .................................................................. Wet sump
Idle speed................................................................................ 1 400 ± 100 r/min
DRIVE TRAIN
Clutch ...................................................................................... Wet multi-plate type
Transmission........................................................................... 6-speed constant mesh
Gearshift pattern ..................................................................... 1-down, 5-up
Primary reduction ratio ............................................................ 3.238 (68/21)
Gear ratios, Low .................................................................... 2.417 (29/12)
2nd..................................................................... 1.529 (26/17)
3rd...................................................................... 1.182 (26/22)
4th...................................................................... 1.043 (24/23)
5th...................................................................... 0.909 (20/22)
Top..................................................................... 0.808 (21/26)
Final reduction ratio................................................................. 3.286 (46/14)
Drive chain .............................................................................. DID520VF, 116 links
1-10 GENERAL INFORMATION
CHASSIS
Front suspension .................................................................... Telescopic, coil spring, oil damped
Rear suspension ..................................................................... Swingarm type, coil spring, oil damped
Front fork stroke...................................................................... 120 mm (4.7 in)
Rear wheel travel.................................................................... 125 mm (4.9 in)
Steering angle......................................................................... 40°
Caster ..................................................................................... 26°
Trail......................................................................................... 105 mm (4.13 in)
Turning radius......................................................................... 2.5 m (8.2 ft)
Front brake.............................................................................. Disc brake
Rear brake .............................................................................. Disc brake
Front tire size .......................................................................... 110/80-17 M/C 57H, tubeless
Rear tire size........................................................................... 140/70-17 M/C 66H, tubeless
ELECTRICAL
Ignition type............................................................................. Electronic ignition (Transistorized)
Ignition timing.......................................................................... 10° CA B.T.D.C.at 1 400 r/min
Spark plug............................................................................... NGK CR7E or DENSO U22ESR-N
Battery..................................................................................... 12 V 36.0 kC (8 Ah)/10 HR
Generator................................................................................ Three-phase A.C. generator
Main fuse ................................................................................ 30 A
Fuse........................................................................................ 10/10/10/15 A
Headlight................................................................................. 12 V 60/55 W
Position light............................................................................ 12 V 5 W × 2
Turn signal light....................................................................... 12 V 10 W
License plate light ................................................................... 12 V 5 W
Brake/Tail light ........................................................................ 12 V 21/5 W
Combination meter light.......................................................... LED
Neutral indicator light .............................................................. LED
High beam indicator light ........................................................ LED
Turn signal indicator light ........................................................ LED
Oil pressure/Coolant temperature/Fuel injection warning light
Engine rpm indicator light ....................................................... LED
.... LED
CAPACITIES
Fuel tank, including reserve.................................................... 13.3 L (3.5/2.9 US/lmp gal)
Engine oil, oil change ............................................................. 2 100 ml (2.2/1.8 US/Imp qt)
with filter change .................................................. 2 400 ml (2.5/2.1 US/lmp qt)
overhaul................................................................ 2 400 ml (2.5/2.1 US/lmp qt)
Coolant.................................................................................... 1 350 ml (1.4/1.2 US/lmp qt)
These specifications are subject to change without notice.
PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

CONTENTS
PERIODIC MAINTENANCE SCHEDULE .................................................... 2- 2
PERIODIC MAINTENANCE CHART..................................................... 2- 2
LUBRICATION POINTS ........................................................................ 2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ....................................... 2- 4
AIR CLEANER....................................................................................... 2- 4
EXHAUST PIPE BOLTS AND MUFFLER BOLTS ............................... 2- 5
SPARK PLUGS ..................................................................................... 2- 6
VALVE CLEARANCE............................................................................ 2- 8
ENGINE OIL AND OIL FILTER ............................................................. 2-11
FUEL LINE............................................................................................. 2-12
PAIR (AIR SUPPLY) SYSTEM.............................................................. 2-13
THROTTLE CABLE PLAY .................................................................... 2-13
ENGINE IDLE SPEED ........................................................................... 2-13
CLUTCH CABLE PLAY ........................................................................ 2-14
COOLING SYSTEM............................................................................... 2-15
DRIVE CHAIN........................................................................................ 2-17
BRAKE .................................................................................................. 2-19
TIRES..................................................................................................... 2-23
STEERING............................................................................................. 2-24
FRONT FORKS ..................................................................................... 2-24
REAR SUSPENSION ............................................................................ 2-24
CHASSIS BOLTS AND NUTS .............................................................. 2-25
COMPRESSION PRESSURE CHECK ........................................................ 2-27
COMPRESSION TEST PROCEDURE .................................................. 2-27
OIL PRESSURE CHECK ............................................................................. 2-28
SDS CHECK................................................................................................. 2-29
2
2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome­ters, miles and time for your convenience.
NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item Air cleaner element ---- I I R Exhaust pipe bolts and muffler bolts T ---- T ---­Valve clearance I I I I Spark plugs ---- I R I Fuel line ---- I I I Engine oil R R R R Engine oil filter R ---- R ---­Throttle cable play I I I I Idle speed I I I I PAIR (air supply) system ---- I ---- I
SUZUKI SUPER LONG LIFE COOLANT (Blue)
Engine coolant
Radiator hoses ---- I I I Clutch cable play I I I I
Drive chain
Brakes IIII
Brake fluid
Brake hoses
Ti re s ---- I I I St ee ri ng I ---- I ---­Fr ont fo rks ---- ---- I ---­Re ar sus pe nsi on ---- ---- I ---­Chassis bolts and nuts T T T T
SUZUKI LONG LIFE COOLANT (Green) or other than SUZUKI SUPER LONG LIFE COOLANT (Blue)
km miles months
1 000 5 000 10 000 15 000
600 3 000 6 000 9 000
3 153045
Replace every 16 000 km (9 600 miles) or 48 months.
Replace every 8 000 km (5 000 miles) or 24 months.
IIII
Clean and lubricate every 1 000 km (600 miles).
---- I I I Replace every 2 years.
---- I I I Replace every 4 years.
NOTE: I = Inspect and clean, adjust, replace or lubricate as necessary, R = Replace, T = Tighten
PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below.
1 Clutch lever pivot 5 Drive chain 2 Side-stand pivot and spring hook 6 Brake lever pivot 3 Gearshift lever pivot and front footrest pivot 7 Brake pedal pivot and front footrest pivot 4 Center stand pivot and spring hook (For P12) 8 Pillion footrest
NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.
AIR CLEANER
Inspect every 5 000 km (3 000 miles, 15 months). Replace every 15 000 km (9 000 miles, 45 months).
• Remove the fuel tank. (5-2)
• Remove the screws 1 and slide the air cleaner cover 2
upward.
• Remove the air cleaner element 3.
• Carefully use air hose to blow the dust from the cleaner ele­ment.
NOTE: Always use air pressure on the throttle body side of the air cleaner element. If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restrict­ing air flow through the air cleaner element.
• Install the cleaned element or new air cleaner element in the reverse order of removal.
NOTE: If driving under dusty conditions, clean the air cleaner element more frequently. Make sure that the air cleaner is in good condi­tion at all times. The life of the engine depends largely on this component.
DRAIN PLUG
• Remove the left frame cover. (8-4)
• Drain water by removing the drain plug 1.
EXHAUST PIPE BOLTS AND MUFFLER BOLTS
Tighten initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
• Tighten the exhaust pipe bolts, muffler support bolts, muffler chamber support bolt and exhaust connecting bolts to the specified torque.
PERIODIC MAINTENANCE 2-5
A Exhaust pipe bolt B Muffler support bolt ITEM N·m C Muffler chamber support bolt A 23 2.3 16.5 D Exhaust connecting bolt B 23 2.3 16.5
C 23 2.3 16.5 D 17 1.7 12.5
kgf-m
lbf-ft
2-6 PERIODIC MAINTENANCE
SPARK PLUGS
Inspect every 5 000 km (3 000 miles, 15 months). Replace every 10 000 km (6 000 miles, 30 months).
REMOVAL
• Disconnect the spark plug caps.
• Remove the spark plugs.
09930-10121: Spark plug wrench set
HEAT RANGE
• Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is white or glazed appearing, replace the spark plug with colder type one.
Hot type Standard Cold type
NGK CR6E CR7E CR8E
ND U20ESR-N U22ESR-N U24ESR-N
CARBON DEPOSITS
• Check carbon deposits on the spark plug.
• If carbon is deposited, remove it using a spark plug cleaner machine.
SPARK PLUG GAP
• Measure the spark plug gap A 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.
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 Ibf-ft)09930-10121: Spark plug wrench set
PERIODIC MAINTENANCE 2-7
Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.
• Connect the spark plug caps.
2-8 PERIODIC MAINTENANCE
VALVE CLEARANCE
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Remove the fuel tank covers. (8-5)
• Remove the spark plugs 1. (2-6)
• Remove the cylinder head caps 2 and reservoir tank mount­ing bolts 3.
• Disconnect the PAIR hose 4 and remove the cylinder head cover 5. (3-12)
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. : 0.05 – 0.10 mm (0.002 – 0.004 in)
EX.: 0.17 – 0.22 mm (0.007 – 0.009 in)
NOTE: * The valve clearance should be taken when each cylinder is at
Top Dead Center (TDC) of compression stroke. * The clearance specification is for COLD state. * To turn the crankshaft for valve clearance checking, be sure to
use a wrench, and rotate in the normal running direction.
• Remove the generator cover plug 6 and valve timing inspec­tion plug 7.
• Turn the crankshaft counterclockwise to set the #2 (Right) cyl­inder at TDC of compression stroke. (Align the “| R” line A on the generator rotor to the mark B of valve timing inspection hole and also bring the notch C on the left end of camshaft to the position as shown.)
PERIODIC MAINTENANCE 2-9
D Intake side
• To inspect the #2 (Right) cylinder valve clearance, use a thickness gauge between the valve stem end and adjusting screw. If the clearance is out of specification, adjust it into the specified range.
Valve clearance adjuster lock-nut:
10 N·m (1.0 kgf-m, 7.0 Ibf-ft)
09900-20803: Thickness gauge
09917-14910: Tappet adjust driver
2-10 PERIODIC MAINTENANCE
• Turn the crankshaft counterclockwise 540 degrees (1-1/2 turns) to set the #1 (Left) cylinder at TDC of compression stroke. Bring the notch C on the left end of camshaft to the position as shown.
D Intake side
• Inspect the #1 (Left) cylinder valve clearance as the same manner of #2 (Right) cylinder and adjust the clearance if nec­essary.
Valve clearance adjuster lock-nut:
10 N·m (1.0 kgf-m, 7.0 Ibf-ft)
09900-20803: Thickness gauge
09917-14910: Tappet adjust driver
• After finishing the valve clearance adjustment, reinstall the fol­lowing items.
* Cylinder head cover and cylinder head caps (3-93) * Spark plugs and plug caps (2-7) * Reservoir tank (7-7)
*Exterior parts
ENGINE OIL AND OIL FILTER
(ENGINE OIL) Replace initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
(OIL FILTER) Replace initially at 1 000 km (600 miles, 3 months) and every 10 000 km (6 000 miles, 30 months) thereafter.
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright.
• Place an oil pan below the engine, and drain oil by removing
the filler cap 1 and oil drain plug 2.
• Tighten the drain plug 2 to the specified torque, and pour
new oil through the oil filler. The engine will hold about 2.1 L (2.2/1.8 US/Imp qt) of oil. Use of SG or higher in API with MA in JASO.
PERIODIC MAINTENANCE 2-11
Oil drain plug: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
• Tighten the filler cap 1.
• Start up the engine and allow it to run for several minutes at idling speed.
• Turn off the engine and wait about three minutes.
• Hold the motorcycle vertically and 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.
2-12 PERIODIC MAINTENANCE
After contacting the gasket, tighten 2 turns. (20 N·m, 2.0 kgf-m, 14.5 lbf-ft)
OIL FILTER REPLACEMENT
• Drain the engine oil as described in the engine oil replace­ment procedure.
• Remove the clamp 1 and move the HO2 sensor lead wire 2 to left side of the oil filter.
NOTE: Be careful not to damage the HO2 sensor lead wire by the engine oil.
• Remove the oil filter 3 using the special tool.
09915-40620: Oil filter wrench
• Apply engine oil lightly to the gasket of the new oil filter before installation. Wipe off the mounting surface on the engine where the new oil filter will be seated with a clean rag.
• 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) using 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 lbf-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 : 2.1 L (2.2/1.8 US/Imp qt) Oil and filter change : 2.4 L (2.5/2.1 US/Imp qt) Engine overhaul : 2.4 L (2.5/2.1 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.
FUEL LINE
Inspect every 5 000 km (3 000 miles, 15 months).
• Remove the left fuel tank cover. (8-5)
• Inspect the fuel feed hose for damage and fuel leakage. If any defects are found, the fuel feed hose must be replaced.
PAIR (AIR SUPPLY) SYSTEM
Inspect initially at 5 000 km (3 000 miles, 15 months) and then every 10 000 km (6 000 miles, 30 months) thereafter.
• Inspect the PAIR (air supply) system periodically. (11-3)
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Adjust the throttle cable play A as follows.
PERIODIC MAINTENANCE 2-13
• Slide the boot 1.
• Loosen the lock-nut 2 of the throttle pulling cable.
• Turn the adjuster 3 clockwise or counterclockwise 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.
ENGINE IDLE SPEED
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Warm up the engine.
• Inspect the engine idle speed. If the engine idle speed is not
within the specified range, check the ISC system. (4-60)
Engine idle speed: 1 400 ± 100 r/min
2-14 PERIODIC MAINTENANCE
CLUTCH CABLE PLAY
Inspect initially at 1 000 km (600 miles, 3 months) and every 5 000 km (3 000 miles, 15 months) thereafter.
• Slide the boot 1.
• Loosen the lock-nut 2 and turn the adjuster 3 clockwise as
far as it will go.
• Slide the boot 4.
• Loosen the lock-nut 5 and turn the cable adjuster 6 clock-
wise as far as it will go.
• Drain engine oil and remove the clutch cover. (2-11 and
3-16)
• Loosen the lock-nut 7 and turn the release screw 8 clock-
wise until it stop.
• From this position, turn the release screw 8 counterclockwise 1 rotation, and tighten the lock-nut 7 while holding the release screw 8.
Clutch release adjuster lock-nut 7:
5.5 N·m (0.55 kgf-m, 4.0 lbf-ft)
• Reinstall the clutch cover and pour engine oil.
(3-85 and 2-11)
• Loosen the adjuster 3 to the 3 to 5 rotation.
• Turn the cable adjuster 6 to obtain 10 – 15 mm (0.4 – 0.6 in) of free play A at the clutch lever end.
• Minor adjustment can be made with the adjuster 3.
• Tighten the lock-nuts 2 and 5.
Clutch cable adjuster lock-nut 5:
4.5 N·m (0.45 kgf-m, 3.5 lbf-ft)
• Reinstall the boots 1 and 4.
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