Suzuki VZ800, VZ800K5, M50, Boulevard M50, Intruder VZ800 Service Manual
99500-38050-01E
FOREWORD
This manual contains an introductory description on
the SUZUKI VZ800 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.
SAMPLE
SHAFT DRIVE
FI SYSTEM
FUEL SYSTEM AND THROTTLE
BODY
COOLING AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
4
5
6
7
8
9
10
11
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
WIRING DIAGRAM
12
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
SAMPLE
1 Front axle 6 Brake disc
2 Bearing (R) 7 Spacer
3 Front wheel ITEM N·m kgf-m lb-ft
4 Spacer A Front axle A 65 6.5 47.0
5 Bearing (L) B Brake disc mounting bolt B 23 2.3 16.5
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 SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Apply SUZUKI MOLY PASTE.
99000-25140
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply THREAD LOCK SUPER “1360”.
99000-32130
Use engine coolant.
99000-99032-11X
Use fork oil.
99000-99044-L01
Apply or use brake fluid.
Measure in voltage range.
Measure in resistance range.
1216
Apply SUZUKI BOND “1207B”.
99000-31140
Apply SUZUKI BOND “1216B”.
99000-31230
Apply THREAD LOCK SUPER “1303”.
99000-32030
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
Apply THREAD LOCK “1342”.
99000-32050
SAMPLE
Measure in current range.
Measure in diode test range.
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
ATM Pressure: Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
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
D
DC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
SAMPLE
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
EOT Sensor : Engine Oil Temperature
Sensor (EOTS), Oil Temp.
Sensor
EVAP : Evaporative Emission
EVAP
Canister
: Evaporative Emission
Canister (Canister)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
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)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
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
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
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)
SAMPLE
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 W : White
Br : Brown Lg : Light green Y : Yellow
Dg : Dark green O : Orange
G : Green P : Pink
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/B : Brown with Black tracer Br/W : Brown with White tracer
G/B : Green with Black 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
Lg/G : Light green with Green 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/W : Pink with White tracer
R/B : Red with Black tracer R/Bl : Red with Blue tracer
W/B : White with Black tracer W/Bl : White with Blue tracer
W/R : White with Red 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
SAMPLE
GENERAL INFORMATION 1-1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
SUZUKI VZ800K5 (’05-MODEL) ...................................................................1- 4
SERIAL NUMBER LOCATION ......................................................................1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .......................1- 4
FUEL (FOR USA AND CANADA) ..........................................................1- 4
FUEL (FOR OTHER COUNTRIES) ........................................................1- 4
ENGINE OIL ...........................................................................................1- 5
BRAKE FLUID ........................................................................................1- 5
FRONT FORK OIL .................................................................................1- 5
ENGINE COOLANT ...............................................................................1- 5
WATER FOR MIXING ............................................................................1- 5
ANTI-FREEZE/ENGINE COOLANT .......................................................1- 5
LIQUID AMOUNT OF WATER/ENGINE COOLANT .............................1- 5
BREAK-lN PROCEDURES ...........................................................................1- 6
CYLINDER IDENTIFICATION .......................................................................1- 6
INFORMATION LABELS ...............................................................................1- 7
SPECIFICATIONS .........................................................................................1- 8
1
SAMPLE
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-03
E-19 (VZ800)
E-19 (VZ800U)
E-24
E-28
E-33
U.K.
U.S.A. (Except for California)
E.U.
E.U.
Australia
Canada
California (U.S.A.)
JS1B4111200100001 –
JS1VS56A 52100001 –
JS1B4111100100001 –
JS1B4211100100001 –
JS1B4111300100001 –
JS1VS56A 52100001 –
JS1VS56A 52100001 –
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.
SAMPLE
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 and case bolts or 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.
SAMPLE
1-4 GENERAL INFORMATION
SUZUKI VZ800K5 (’05-MODEL)
RIGHT SIDE LEFT SIDE
* Difference between illustration and actual motorcycle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the
steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
SAMPLE
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.
GENERAL INFORMATION 1-5
ENGINE OIL
Oil quality is a major contributor to your engine’s performance
and life. Always select good quality engine oil. Use of API SF/
SG or SH/SJ with JASO MA.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available, select an alternative according to the right chart.
BRAKE FLUID
Specification and classification: DOT 4
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.
FRONT FORK OIL
Use fork oil L01 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.
SAMPLE
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): 1 750 ml (1.85/1.54 US/Imp qt)
For engine coolant mixture information, refer to cooling system section in page 5-3.
Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce
its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing point.
1-6 GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very
high standard. 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. Refer to the following break-in engine speed recommendations.
• Keep to these break-in throttle positions during the break-in period.
Break-in throttle operation
Initial 800 km ( 500 miles): Less than 1/2 throttle
Up to 1 600 km (1 000 miles): Less than 3/4 throttle
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation.
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No. 1 and No. 2 cylinder, as counted from front to rear (as
viewed by the rider on the seat).
#2
#1
SAMPLE
INFORMATION LABELS
VZ800
1 Noise label
2 Information label
3 Vacuum hose routing label
4 Manual notice label
5 Fuel caution label
6 Tire information label
7 General warning label A
8 ICES Canada label A For E-28
9 I.D. plate
0 Safety plate
A: Attached
A For E-03, 24, 33
A For E-03, 28, 33
A For E-33
A For E-03, 33
A For E-02, 24
A
A Except for E-03, 28, 33
A For E-03, 28, 33
GENERAL INFORMATION 1-7
For E-24
For E-03, 33
Except for E-03, 33
SAMPLE
For E-03, 33
1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.......................................................2 370 mm (93.3 in)
Overall width ........................................................ 920 mm (36.2 in)
Overall height.......................................................1 125 mm (44.3 in)
Wheelbase...........................................................1 655 mm (65.2 in)
Ground clearance ................................................ 140 mm (5.5 in)
Seat height........................................................... 700 mm (27.6 in)
Dry mass.............................................................. 247 kg (545 lbs)
ENGINE
Type.....................................................................4-stroke, liquid-cooled, OHC, 45° degree V-twin
Number of cylinders .............................................2
Bore .....................................................................83.0 mm (3.268 in)
Stroke...................................................................74.4 mm (2.929 in)
Displacement .......................................................805 cm³ (49.1 cu. in)
Compression ratio................................................9.4 : 1
Fuel system..........................................................Fuel injection
Air cleaner............................................................Non-woven fabric element
Starter system......................................................Electric
Lubrication system ...............................................Wet sump
Idle speed ............................................................1 100 ± 100 r/min
DRIVE TRAIN
Clutch...................................................................Wet multi-plate type
Transmission........................................................5-speed constant mesh
Gearshift pattern ..................................................1-down, 4-up
Primary reduction ratio.........................................1.690 (71/42)
Gear ratios, Low..................................................2.461 (32/13)
2nd...................................................1.631 (31/19)
3rd ...................................................1.227 (27/22)
4th....................................................1.000 (25/25)
Top ..................................................0.814 (22/27)
Final reduction ratio .............................................3.503 (17/15 × 34/11)
Drive system ........................................................Shaft drive
SAMPLE
GENERAL INFORMATION 1-9
CHASSIS
Front suspension................................................. Inverted telescopic, coil spring, oil damped
Rear suspension ................................................. Swingarm type, coil spring, oil damped
Front suspension stroke...................................... 140 mm (5.5 in)
Rear wheel travel ................................................ 105 mm (4.1 in)
Caster.................................................................. 33° 15’
Trail ..................................................................... 141 mm (5.6 in)
Steering angle ..................................................... 38° (right & left)
Turning radius ..................................................... 3.0 m (9.8 ft)
Front brake.......................................................... Disc brake, twin
Rear brake .......................................................... Drum brake
Front tire size ...................................................... 130/90-16M/C (67H), tubeless
Rear tire size ....................................................... 170/80-15M/C (77H), tubeless
ELECTRICAL
lgnition type ......................................................... Electronic ignition (Transistorized)
lgnition timing ...................................................... 5° B.T.D.C at 1 100 r/min
Spark plug ........................................................... NGK: DPR7EA-9 or DENSO: X22EPR-U9
Battery................................................................. 12 V 36.0 kC (10 Ah)/10 HR
Generator ............................................................ Three-phase A.C. Generator
Main fuse............................................................. 30 A
Fuse .................................................................... 10/10/10/10/10/15 A
Headlight ............................................................. 12 V 60/55 W (H4)
Parking or city light.............................................. 12 V 5 W......................................For E-02, 19
Front turn signal light........................................... 12 V 21/5 W................................. For E-03, 28, 33
12 V 21 W.................................... For the others
Rear turn signal light ........................................... 12 V 21 W
Brake light/Taillight.............................................. LED
Speedometer light ............................................... LED
Fuel level indicator light....................................... LED
Turn signal indicator light .................................... LED
Neutral indicator light .......................................... LED
High beam indicator light..................................... LED
Oil pressure/Coolant temperature/Fuel injection
warning light ........................................................ LED
SAMPLE
CAPACITIES
Fuel tank, including reserve................................ 15.0 L (4.0/3.3 US/Imp gal) .......For E-33
reserve............................................... 3.0 L (0.8/0.7 US/Imp gal)
Engine oil, oil change ........................................ 3 000 ml (3.2/2.6 US/Imp qt)
with filter change.............................. 3 400 ml (3.6/3.0 US/Imp qt)
overhaul ........................................... 3 700 ml (3.9/3.3 US/Imp qt)
Front fork oil (each leg) ....................................... 493 ml (16.7/17.4 US/Imp oz)
Coolant................................................................ 1.5 L (1.59/1.32 US/Imp qt)
These specifications are subject to change without notice.
15.5 L (4.1/3.4 US/Imp gal) .......For the others
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
FUEL HOSE ...........................................................................................2-10
ENGINE OIL AND OIL FILTER ..............................................................2-11
ENGINE IDLE SPEED ............................................................................2-13
THROTTLE CABLE PLAY .....................................................................2-14
THROTTLE VALVE SYNCHRONIZATION ............................................2-15
EVAPORATIVE EMISSON CONTROL SYSTEM (FOR E-33 ONLY) ...2-15
PAIR (AIR SUPPLY) SYSTEM ...............................................................2-15
CLUTCH .................................................................................................2-16
COOLING SYSTEM ...............................................................................2-17
FINAL GEAR OIL ...................................................................................2-19
BRAKE ...................................................................................................2-19
TIRE ........................................................................................................2-23
STEERING ..............................................................................................2-23
FRONT FORK ........................................................................................2-24
REAR SUSPENSION .............................................................................2-24
EXHAUST PIPE BOLT ...........................................................................2-24
CHASSIS BOLT AND NUT ....................................................................2-25
COMPRESSION PRESSURE CHECK ............................................................2-27
COMPRESSION TEST PROCEDURE ...................................................2-27
OIL PRESSURE CHECK .................................................................................2-28
OIL PRESSURE TEST PROCEDURE ...................................................2-28
SDS CHECK ....................................................................................................2-29
SAMPLE: ................................................................................................2-29
Data sampled from cold starting through warm-up ..........................2-29
Data at 3 000 r/min under no load .......................................................2-30
Data at the time of racing .....................................................................2-30
SAMPLE
2
6
6
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 performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item
Air cleaner element — I I R I
Exhaust pipe bolts and muffler bolts T — T — T
Valve clearance I — I — I
Spark plugs — I R I R
Fuel hose — I I I I
Engine oil R R R R R
Engine oil filter R — — R —
Idle speed IIIII
Throttle cable play IIIII
Throttle valve synchronization I
Evaporative emission control system
(California model only)
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Clutch —IIII
Final gear oil R — I — I
Brakes IIIII
Brake hose — I I I I
Brake fluid — I I I I
Tires —IIII
Steering I — I — I
Front fork — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T TTTT
SAMPLE
km
miles
months 2 12 24 36 48
1 000 6 000 12 000 18 000 24 000
600 4 000 7 500 11 000 14 500
(CA. only)
—— I — I
—I—I
Replace vapor hose every 4 years.
Replace every 4 years.
Replace every 2 years.
NOTE:
I = Inspect and clean, adjust, replace or lubricate as necessary
R = Replace
T = Tighten
PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Clutch lever holder
Side-stand pivot and
spring hook
Gearshift link pivot
Brake lever holder
SAMPLE
Throttle cable
Brake pedal pivot
and brake rod link
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
2-4 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
AIR CLEANER
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 18 000 km (11 000 miles, 36 months).
• Remove the air cleaner cover 1.
• Remove the air cleaner element 2.
• Carefully use air hose to blow the dust from the cleaner element.
Always use air pressure on the engine 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.
• Reinstall the cleaned or new air cleaner element in the
reverse order of removal.
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component!
SAMPLE
NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner by removing the drain plug.
SPARK PLUG
Inspect every 6 000 km (4 000 miles, 12 months) and
replace every 12 000 km (7 500 miles, 24 months).
No. 1 (FRONT) SPARK PLUG REMOVAL
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Remove the right frame cover 1.
: Hooked part
PERIODIC MAINTENANCE 2-5
• Remove the spark plug cap.
The hot radiator and the hot engine can burn you. Wait
until the radiator and the engine are cool enough to
touch.
SAMPLE
• Remove the spark plug with a spark plug wrench.
09930-14530: Universal joint
2-6 PERIODIC MAINTENANCE
No. 2 (REAR) SPARK PLUG REMOVAL
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Remove the spark plug cap.
• Remove the spark plug with a spark plug wrench.
HEAT RANGE
• Check to see the heat range of the plug.
Standard Cold type
NGK DPR7EA-9 DPR8EA-9
DENSO X22EPR-U9 X24EPR-U9
CARBON DEPOSIT
• Check to see if there are carbon deposits on the plugs. If carbon is deposited, remove it with a spark plug cleaner machine
or carefully using a tool with a pointed end.
SPARK PLUG GAP
• Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.
09900-20803: Thickness gauge
Spark plug gap A
Standard: 0.8 – 0.9 mm (0.031 – 0.035 in)
ELECTRODES CONDITION
• Check to see the worn or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug. And also replace
the plug if it has a broken insulator, damaged thread.
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine damage may result.
SAMPLE
SPARK PLUG AND PLUG CAP INSTALLATION
• Install the spark plugs to the cylinder heads by finger tight,
and then tighten them to the specified torque.
Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)
When installing a spark plug, carefully turn the spark
plug wrench by finger into the threads of the cylinder
head to prevent damage the aluminum threads.
• Install the spark plug caps.
VALVE CLEARANCE
Inspect initially at 1 000 km (600 miles, 2 months) and
every 12 000 km (7 500 miles, 24 months) thereafter.
PERIODIC MAINTENANCE 2-7
Valve clearance must be checked and adjusted when:
(1) the valve mechanism is service, and
(2) the camshafts are serviced.
Check and adjust the clearance to the specification.
Valve clearance (when cold):
IN. 0.08 – 0.13 mm (0.003 – 0.005 in)
EX. 0.17 – 0.22 mm (0.007 – 0.009 in)
NOTE:
* The clearance specification is for COLD state.
* Both intake and exhaust valves must be checked and adjusted
when the piston is at Top Dead Center (TDC) of the compression stroke.
• Remove the rear and front seats. (8-3)
• Remove the fuel tank. (6-3)
• Remove the right frame cover. (8-4)
• Remove the spark plug caps.
• Loosen the inlet pipe screws.
SAMPLE
2-8 PERIODIC MAINTENANCE
• Remove the cylinder head cover caps (1, 2).
• Remove the PAIR pipe.
• Remove the gasket 3.
Do not reuse the removed gasket.
SAMPLE
• Remove all the inspection caps.
• Remove all the spark plugs.
PERIODIC MAINTENANCE 2-9
• Remove the generator cover plug 4.
• Remove the cap 5 and the timing inspection plug 6.
SAMPLE
• Rotate the generator rotor to set the No. 1 engine’s piston at
TDC of the compression stroke. (Rotate the rotor until the “R I
T” line on the rotor is aligned with the center of hole on the
generator cover.)
• To inspect the No. 1 engine’s valve clearance, insert the thickness gauge to the clearance between the valve stem end and
the adjusting screw on the rocker arms.
RT
09900-20806: Thickness gauge
• If the clearance is out of the specification, bring it into the
specified range by using the special tool.
09917-10410: Valve adjust driver
2-10 PERIODIC MAINTENANCE
Both right and left valve clearances should be as
closely set as possible.
• Rotate the generator rotor 450 degrees (1 and 1/4 turns) and
align the “F I T” line on the rotor with the center of hole on the
generator cover.
Inspect the No. 2 engine’s valve clearance as the same manner
above.
FT
NOTE:
Use the thickness gauge from the arrow marks as shown in the
illustration.
SAMPLE
FUEL HOSE
Inspect every 6 000 km (4 000 miles, 12 months).
Inspect the fuel feed hose for damage and fuel leakage. If any
defects are found, the fuel hoses must be replaced.
FRONT
No. 2 Engine No. 1 Engine
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.
Oil should be changed while the engine is warm. Oil filter
replacement at the above intervals, should be done together
with the engine oil change.
ENGINE OIL REPLACEMENT
• Keep the motorcycle upright.
• Place an oil pan below the engine, and drain oil by removing
the drain plug 1 and filler cap 2.
PERIODIC MAINTENANCE 2-11
• Tighten the drain plug 1 to the specified torque, and pour
fresh oil through the oil filler. The engine will hold about 3.0 L
(3.2/2.6 US/Imp qt) of oil. Use of API SF/SG or SH/SJ with
JASO MA.
Oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)
SAMPLE
• 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 A. If the level is
below mark “L”, add oil to “F” level. If the level is above mark
“F”, drain oil to “F” level.
2-12 PERIODIC MAINTENANCE
OIL FILTER REPLACEMENT
• Drain engine oil in the same manner of engine oil replacement
procedure.
• Remove the oil filter 1 by using the oil filter wrench. (Special
tool)
• Apply engine oil lightly to the O-ring of the new filter before
installation.
• Install the new filter turning it by hand until you feel that the filter O-ring contacts the mounting surface. Then tighten it 2
turns using the oil filter wrench. ( 20 N·m, 2.0 kgf-m, 14.5
lb-ft)
09915-40610: Oil filter wrench
NOTE:
To properly tighten the filter, use the special tool. Never tighten
the filter by hand.
• Pour fresh engine oil and check the oil level in the same manner of engine oil replacement procedure.
Engine oil capacity
Oil change: 3.0 L (3.2/2.6 US/Imp qt)
Filter change: 3.4 L (3.6/3.0 US/Imp qt)
Overhaul engine: 3.7 L (3.9/3.3 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.
SAMPLE
After contacting the O-ring,
tighten 2 turns.
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.
• Connect the multi-circuit tester to the high-tension cord.
• Start up the engine and set its idle speed to the specified
range by turning the throttle stop screw 1.
Engine idle speed: 1 100 ± 100 r/min
09900-25008: Multi-circuit tester set
PERIODIC MAINTENANCE 2-13
SAMPLE
2-14 PERIODIC MAINTENANCE
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 with the following three steps.
MINOR ADJUSTMENT
First step:
• Loosen the lock nut 1 of the throttle returning cable 2 and
turn in the adjuster 3 fully into the threads.
Second step:
• Loosen the lock nut 4 of the throttle pulling cable 5.
• Turn the adjuster 6 in or out until the throttle cable play A
should be 2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip.
• Tighten the lock nut 4 while holding the adjuster 6.
Third step:
• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster 3 of the throttle returning cable 2
to feel resistance.
• Tighten the lock nut 1 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.
NOTE:
Major adjustment can be made by the throttle body side
adjuster.
SAMPLE
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