- Page 1 and 2: GSR60099500-36160-01E
- Page 3: HOW TO USE THIS MANUALTO LOCATE WHA
- Page 6 and 7: MMAL-CodeMaxMILMinNNOXOOHCOPSPPCVRS
- Page 10 and 11: GENERAL INFORMATION 1-3* If parts r
- Page 12 and 13: GENERAL INFORMATION 1-5FUEL, OIL AN
- Page 14 and 15: GENERAL INFORMATION 1-7BREAK-IN PRO
- Page 16 and 17: GENERAL INFORMATION 1-9SPECIFICATIO
- Page 18 and 19: PERIODIC MAINTENANCE 2-1PERIODIC MA
- Page 20 and 21: PERIODIC MAINTENANCE 2-3LUBRICATION
- Page 22 and 23: PERIODIC MAINTENANCE 2-5SPARK PLUGI
- Page 24 and 25: PERIODIC MAINTENANCE 2-7VALVE CLEAR
- Page 26 and 27: PERIODIC MAINTENANCE 2-9• Turn th
- Page 28 and 29: PERIODIC MAINTENANCE 2-11(INTAKE SI
- Page 30 and 31: PERIODIC MAINTENANCE 2-13ENGINE OIL
- Page 32 and 33: PERIODIC MAINTENANCE 2-15ENGINE IDL
- Page 34 and 35: PERIODIC MAINTENANCE 2-17COOLING SY
- Page 36 and 37: PERIODIC MAINTENANCE 2-19DRIVE CHAI
- Page 38 and 39: PERIODIC MAINTENANCE 2-21CLEANING A
- Page 40 and 41: PERIODIC MAINTENANCE 2-23BRAKE PADS
- Page 42 and 43: PERIODIC MAINTENANCE 2-25FRONT BRAK
- Page 44 and 45: PERIODIC MAINTENANCE 2-27FRONT FORK
- Page 46 and 47: PERIODIC MAINTENANCE 2-29CHASSIS BO
- Page 48 and 49: PERIODIC MAINTENANCE 2-31COMPRESSIO
- Page 50 and 51: PERIODIC MAINTENANCE 2-33SDS CHECKU
- Page 52 and 53: PERIODIC MAINTENANCE 2-35Data of in
- Page 54 and 55: 3-2 ENGINEENGINE COMPONENTS REMOVAB
- Page 56 and 57: 3-4 ENGINERADIATOR• Disconnect th
- Page 58 and 59:
3-6 ENGINE• Disconnect the starte
- Page 60 and 61:
3-8 ENGINE• Remove the engine spr
- Page 62 and 63:
3-10 ENGINE• Tighten the engine m
- Page 64 and 65:
3-12 ENGINE• Install the engine s
- Page 66 and 67:
3-14 ENGINEENGINE DISASSEMBLYIdenti
- Page 68 and 69:
3-16 ENGINE• Remove the intake ca
- Page 70 and 71:
3-18 ENGINE• Remove the clutch pu
- Page 72 and 73:
3-20 ENGINE• Remove the gearshift
- Page 74 and 75:
3-22 ENGINEGENERATOR COVER• Remov
- Page 76 and 77:
3-24 ENGINEOIL PRESSURE REGULATOR
- Page 78 and 79:
3-26 ENGINE• Remove the piston pi
- Page 80 and 81:
3-28 ENGINEINSPECTION• Inspect th
- Page 82 and 83:
3-30 ENGINE• If the camshaft jour
- Page 84 and 85:
3-32 ENGINE• Install the special
- Page 86 and 87:
3-34 ENGINEVALVE STEM DEFLECTION•
- Page 88 and 89:
3-36 ENGINE• If the seat width W
- Page 90 and 91:
3-38 ENGINE• Install the valve sp
- Page 92 and 93:
3-40 ENGINECLUTCHCLUTCH DRIVE PLATE
- Page 94 and 95:
3-42 ENGINE• If a large resistanc
- Page 96 and 97:
3-44 ENGINEOIL PRESSURE REGULATOR
- Page 98 and 99:
3-46 ENGINEREASSEMBLYAssemble the c
- Page 100 and 101:
3-48 ENGINECYLINDERCRANKCASE SERVIC
- Page 102 and 103:
3-50 ENGINEPISTON RING-TO-GROOVE CL
- Page 104 and 105:
3-52 ENGINEGEARSHIFT FORK THICKNESS
- Page 106 and 107:
3-54 ENGINE• Install the gearshif
- Page 108 and 109:
3-56 ENGINEInstallation• Fit new
- Page 110 and 111:
3-58 ENGINECRANKSHAFT AND CONRODCRA
- Page 112 and 113:
3-60 ENGINE• Remove the bearing c
- Page 114 and 115:
3-62 ENGINECRANKSHAFT JOURNAL BEARI
- Page 116 and 117:
3-64 ENGINE Crankshaft journal O.D.
- Page 118 and 119:
3-66 ENGINE Thrust bearing selectio
- Page 120 and 121:
3-68 ENGINE•1st ring 5 and 2nd ri
- Page 122 and 123:
3-70 ENGINE• Set the crankshaft t
- Page 124 and 125:
3-72 ENGINE• Apply SUZUKI BOND to
- Page 126 and 127:
3-74 ENGINETRANSMISSION• Install
- Page 128 and 129:
3-76 ENGINE• Tighten the crankcas
- Page 130 and 131:
3-78 ENGINEOIL PAN• Apply SUZUKI
- Page 132 and 133:
3-80 ENGINE• Tighten the water pu
- Page 134 and 135:
3-82 ENGINEGENERATOR COVER• Apply
- Page 136 and 137:
3-84 ENGINESTARTER CLUTCH• Instal
- Page 138 and 139:
3-86 ENGINENOTE:Hook the return spr
- Page 140 and 141:
3-88 ENGINE• Install the oil pump
- Page 142 and 143:
3-90 ENGINE• Insert the clutch dr
- Page 144 and 145:
3-92 ENGINECYLINDER HEAD• Fit the
- Page 146 and 147:
3-94 ENGINEPull the cam chain upwar
- Page 148 and 149:
3-96 ENGINE• Install the dowel pi
- Page 150 and 151:
3-98 ENGINE• Install the gasket 4
- Page 152 and 153:
3-100 ENGINE• Tighten the valve t
- Page 154 and 155:
FI SYSTEM DIAGNOSIS 4-1FI SYSTEM DI
- Page 156 and 157:
FI SYSTEM DIAGNOSIS 4-3PRECAUTIONS
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FI SYSTEM DIAGNOSIS 4-5• When dis
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FI SYSTEM DIAGNOSIS 4-7Continuity c
- Page 162 and 163:
FI SYSTEM DIAGNOSIS 4-9USING THE MU
- Page 164 and 165:
FI SYSTEM DIAGNOSIS 4-11COMPENSATIO
- Page 166 and 167:
FI SYSTEM DIAGNOSIS 4-13ECMJ Second
- Page 168 and 169:
FI SYSTEM DIAGNOSIS 4-15ECM TERMINA
- Page 170 and 171:
FI SYSTEM DIAGNOSIS 4-17DEALER MODE
- Page 172 and 173:
FI SYSTEM DIAGNOSIS 4-19TPS ADJUSTM
- Page 174 and 175:
FI SYSTEM DIAGNOSIS 4-21ITEMFAIL-SA
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FI SYSTEM DIAGNOSIS 4-23MOTORCYCLE/
- Page 178 and 179:
FI SYSTEM DIAGNOSIS 4-25USE OF SDS
- Page 180 and 181:
FI SYSTEM DIAGNOSIS 4-27SHOW DATA W
- Page 182 and 183:
FI SYSTEM DIAGNOSIS 4-29DTC No.C21P
- Page 184 and 185:
FI SYSTEM DIAGNOSIS 4-31DTC No.C44P
- Page 186 and 187:
FI SYSTEM DIAGNOSIS 4-33Step 21) Cr
- Page 188 and 189:
FI SYSTEM DIAGNOSIS 4-355) If OK, t
- Page 190 and 191:
FI SYSTEM DIAGNOSIS 4-374) Disconne
- Page 192 and 193:
FI SYSTEM DIAGNOSIS 4-397) Disconne
- Page 194 and 195:
FI SYSTEM DIAGNOSIS 4-41Output volt
- Page 196 and 197:
FI SYSTEM DIAGNOSIS 4-43 TP sensor
- Page 198 and 199:
FI SYSTEM DIAGNOSIS 4-45Step 21) Tu
- Page 200 and 201:
FI SYSTEM DIAGNOSIS 4-47“C15” (
- Page 202 and 203:
FI SYSTEM DIAGNOSIS 4-49Step 1 (Whe
- Page 204 and 205:
FI SYSTEM DIAGNOSIS 4-51“C21” (
- Page 206 and 207:
FI SYSTEM DIAGNOSIS 4-53Step 1 (Whe
- Page 208 and 209:
FI SYSTEM DIAGNOSIS 4-55“C22” (
- Page 210 and 211:
FI SYSTEM DIAGNOSIS 4-576) Disconne
- Page 212 and 213:
FI SYSTEM DIAGNOSIS 4-59Step 31) Re
- Page 214 and 215:
FI SYSTEM DIAGNOSIS 4-61Step 1 (Whe
- Page 216 and 217:
FI SYSTEM DIAGNOSIS 4-63Step 21) Co
- Page 218 and 219:
FI SYSTEM DIAGNOSIS 4-65Step 21) Tu
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FI SYSTEM DIAGNOSIS 4-67“C29” (
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FI SYSTEM DIAGNOSIS 4-69Step 1 (Whe
- Page 224 and 225:
FI SYSTEM DIAGNOSIS 4-718) If OK, t
- Page 226 and 227:
FI SYSTEM DIAGNOSIS 4-73Is the volt
- Page 228 and 229:
FI SYSTEM DIAGNOSIS 4-755) If OK, t
- Page 230 and 231:
FI SYSTEM DIAGNOSIS 4-77Step 1 (Whe
- Page 232 and 233:
FI SYSTEM DIAGNOSIS 4-79“C44” (
- Page 234 and 235:
FI SYSTEM DIAGNOSIS 4-81Is the volt
- Page 236 and 237:
FI SYSTEM DIAGNOSIS 4-83“C49” (
- Page 238 and 239:
FI SYSTEM DIAGNOSIS 4-85“C60” (
- Page 240 and 241:
FI SYSTEM DIAGNOSIS 4-87SENSORSCMP
- Page 242 and 243:
FI SYSTEM DIAGNOSIS 4-89TO SENSOR I
- Page 244 and 245:
FUEL SYSTEM AND THROTTLE BODY 5-1FU
- Page 246 and 247:
FUEL SYSTEM AND THROTTLE BODY 5-3FU
- Page 248 and 249:
FUEL SYSTEM AND THROTTLE BODY 5-5FU
- Page 250 and 251:
FUEL SYSTEM AND THROTTLE BODY 5-7FU
- Page 252 and 253:
FUEL SYSTEM AND THROTTLE BODY 5-9
- Page 254 and 255:
FUEL SYSTEM AND THROTTLE BODY 5-11
- Page 256 and 257:
FUEL SYSTEM AND THROTTLE BODY 5-13A
- Page 259 and 260:
5-16 FUEL SYSTEM AND THROTTLE BODYT
- Page 261 and 262:
5-18 FUEL SYSTEM AND THROTTLE BODY
- Page 263 and 264:
5-20 FUEL SYSTEM AND THROTTLE BODYA
- Page 265 and 266:
5-22 FUEL SYSTEM AND THROTTLE BODYF
- Page 267 and 268:
5-24 FUEL SYSTEM AND THROTTLE BODYT
- Page 269 and 270:
EXHAUST SYSTEM 6-1EXHAUST SYSTEMCON
- Page 271 and 272:
EXHAUST SYSTEM 6-3REMOVAL• Remove
- Page 273 and 274:
EXHAUST SYSTEM 6-5INSTALLATIONInsta
- Page 275 and 276:
7-2 COOLING AND LUBRICATION SYSTEME
- Page 277 and 278:
7-4 COOLING AND LUBRICATION SYSTEMR
- Page 279 and 280:
7-6 COOLING AND LUBRICATION SYSTEMC
- Page 281 and 282:
7-8 COOLING AND LUBRICATION SYSTEMI
- Page 283 and 284:
7-10 COOLING AND LUBRICATION SYSTEM
- Page 285 and 286:
7-12 COOLING AND LUBRICATION SYSTEM
- Page 287 and 288:
7-14 COOLING AND LUBRICATION SYSTEM
- Page 289 and 290:
7-16 COOLING AND LUBRICATION SYSTEM
- Page 291 and 292:
7-18 COOLING AND LUBRICATION SYSTEM
- Page 293 and 294:
7-20 COOLING AND LUBRICATION SYSTEM
- Page 295 and 296:
CHASSIS 8-1CHASSISCONTENTSEXTERIOR
- Page 297 and 298:
CHASSIS 8-3EXTERIOR PARTSREMOVALSEA
- Page 299 and 300:
CHASSIS 8-5MUFFLER COVER• Remove
- Page 301 and 302:
CHASSIS 8-7REMOVAL• Remove the br
- Page 303 and 304:
CHASSIS 8-9WHEEL BEARINGInspect the
- Page 305 and 306:
CHASSIS 8-11• Install the wheel b
- Page 307 and 308:
CHASSIS 8-13FRONT FORKCONSTRUCTION1
- Page 309 and 310:
CHASSIS 8-15• Remove the protecto
- Page 311 and 312:
CHASSIS 8-17CYLINDER RINGInspect th
- Page 313 and 314:
CHASSIS 8-19FRONT FORK PROTECTOR•
- Page 315 and 316:
CHASSIS 8-21STEERINGCONSTRUCTION1 S
- Page 317 and 318:
CHASSIS 8-23• Remove the steering
- Page 319 and 320:
CHASSIS 8-25• Turn the steering s
- Page 321 and 322:
CHASSIS 8-27HANDLEBARSCONSTRUCTION1
- Page 323 and 324:
CHASSIS 8-29• Set the handlebars
- Page 325 and 326:
CHASSIS 8-31REAR WHEELCONSTRUCTION1
- Page 327 and 328:
CHASSIS 8-33INSPECTION AND DISASSEM
- Page 329 and 330:
CHASSIS 8-35REASSEMBLY AND INSTALLA
- Page 331 and 332:
CHASSIS 8-37DUST SEALS• Install n
- Page 333 and 334:
CHASSIS 8-39REAR SHOCK ABSORBERCONS
- Page 335 and 336:
CHASSIS 8-41REAR SHOCK ABSORBER DIS
- Page 337 and 338:
CHASSIS 8-43REAR SUSPENSIONCONSTRUC
- Page 339 and 340:
CHASSIS 8-45• Remove the cushion
- Page 341 and 342:
CHASSIS 8-47CUSHION LEVER BEARINGIn
- Page 343 and 344:
CHASSIS 8-49REASSEMBLYReassemble th
- Page 345 and 346:
CHASSIS 8-51• Assemble the cushio
- Page 347 and 348:
CHASSIS 8-53FRONT BRAKECONSTRUCTION
- Page 349 and 350:
CHASSIS 8-55• Install new brake p
- Page 351 and 352:
CHASSIS 8-57• Remove the dust sea
- Page 353 and 354:
CHASSIS 8-59CALIPER INSTALLATIONIns
- Page 355 and 356:
CHASSIS 8-61• Pull out the dust b
- Page 357 and 358:
CHASSIS 8-63• When installing the
- Page 359 and 360:
CHASSIS 8-65* This brake system is
- Page 361 and 362:
CHASSIS 8-67CALIPER REMOVAL AND DIS
- Page 363 and 364:
CHASSIS 8-69• Tighten the brake c
- Page 365 and 366:
CHASSIS 8-71MASTER CYLINDER INSPECT
- Page 367 and 368:
CHASSIS 8-73TIRE AND WHEELTIRE REMO
- Page 369 and 370:
CHASSIS 8-75TIRE INSTALLATION• Ap
- Page 371 and 372:
CHASSIS 8-77DRIVE CHAINUse the spec
- Page 373 and 374:
CHASSIS 8-79• Apply grease on the
- Page 375 and 376:
ELECTRICAL SYSTEM 9-1ELECTRICAL SYS
- Page 377 and 378:
ELECTRICAL SYSTEM 9-3CAUTIONS IN SE
- Page 379 and 380:
ELECTRICAL SYSTEM 9-5USING THE MULT
- Page 381 and 382:
ELECTRICAL SYSTEM 9-71 CMP sensor (
- Page 383 and 384:
ELECTRICAL SYSTEM 9-9Step 51) Measu
- Page 385 and 386:
ELECTRICAL SYSTEM 9-11GENERATOR NO-
- Page 387 and 388:
ELECTRICAL SYSTEM 9-13Step 31) Meas
- Page 389 and 390:
ELECTRICAL SYSTEM 9-15COMMUTATORIns
- Page 391 and 392:
ELECTRICAL SYSTEM 9-17Measure the r
- Page 393 and 394:
ELECTRICAL SYSTEM 9-19TURN SIGNAL/S
- Page 395 and 396:
ELECTRICAL SYSTEM 9-21IMMOBILIZERDE
- Page 397 and 398:
ELECTRICAL SYSTEM 9-23TROUBLESHOOTI
- Page 399 and 400:
ELECTRICAL SYSTEM 9-25INSPECTIONIGN
- Page 401 and 402:
ELECTRICAL SYSTEM 9-27CKP SENSOR PE
- Page 403 and 404:
ELECTRICAL SYSTEM 9-29COMBINATION M
- Page 405 and 406:
ELECTRICAL SYSTEM 9-31INSPECTIONLED
- Page 407 and 408:
ELECTRICAL SYSTEM 9-33FUEL LEVEL GA
- Page 409 and 410:
ELECTRICAL SYSTEM 9-35LAMPSHEADLIGH
- Page 411 and 412:
ELECTRICAL SYSTEM 9-37RELAYSTURN SI
- Page 413 and 414:
ELECTRICAL SYSTEM 9-39SWITCHES INSP
- Page 415 and 416:
ELECTRICAL SYSTEM 9-41NOTE:If no ai
- Page 417 and 418:
SERVICING INFORMATIONSERVICING INFO
- Page 419 and 420:
SERVICING INFORMATION 10-3DTC No.C2
- Page 421 and 422:
SERVICING INFORMATION 10-5DTC No.C4
- Page 423 and 424:
SERVICING INFORMATION 10-7Complaint
- Page 425 and 426:
SERVICING INFORMATION 10-9Complaint
- Page 427 and 428:
SERVICING INFORMATION 10-11Complain
- Page 429 and 430:
SERVICING INFORMATION 10-13CHASSISC
- Page 431 and 432:
SERVICING INFORMATION 10-15ELECTRIC
- Page 433 and 434:
SERVICING INFORMATION 10-17WIRING H
- Page 435 and 436:
SERVICING INFORMATION 10-19*2*36 N
- Page 437 and 438:
SERVICING INFORMATION 10-21THROTTLE
- Page 439 and 440:
SERVICING INFORMATION 10-23COOLING
- Page 441 and 442:
SERVICING INFORMATION 10-25REAR BRA
- Page 443 and 444:
SERVICING INFORMATION 10-27FRAME CO
- Page 445 and 446:
SERVICING INFORMATION 10-29REAR FEN
- Page 447 and 448:
SERVICING INFORMATION 10-31PILLION
- Page 449 and 450:
SERVICING INFORMATION 10-33SPECIAL
- Page 451 and 452:
SERVICING INFORMATION 10-3509920-34
- Page 453 and 454:
SERVICING INFORMATION 10-37TIGHTENI
- Page 455 and 456:
SERVICING INFORMATION 10-39CHASSISI
- Page 457 and 458:
SERVICING INFORMATION 10-41SERVICE
- Page 459 and 460:
SERVICING INFORMATION 10-43OIL PUMP
- Page 461 and 462:
SERVICING INFORMATION 10-45FI SENSO
- Page 463 and 464:
SERVICING INFORMATION 10-47WATTAGEI
- Page 465 and 466:
SERVICING INFORMATION 10-49FUEL + O
- Page 467 and 468:
11-2 EMISSION CONTROL INFORMATIONEM
- Page 469 and 470:
11-4 EMISSION CONTROL INFORMATIONEX
- Page 471 and 472:
11-6 EMISSION CONTROL INFORMATIONPA
- Page 473 and 474:
11-8 EMISSION CONTROL INFORMATIONPA
- Page 475 and 476:
WIRING DIAGRAME-02, 19, 24Wiring di
- Page 477:
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