Manual usuário hayabusa

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Manual usuário hayabusa

  1. 1. SUZUKI SUZUKI MOTOR CORPORATION [ I I GSX1300R OWNER'S MANUAL L K2 9 9 0 1 1 - 2 4 F 5 3 - 0 1 A * Part No. 99011-24F53-01A August, 2001 © EN Printed in Japan
  2. 2. fffl r r1 1 ,1 i i i i i i This manual should be considered a permanent part of the mo- torcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle. IMPORTANT BREAK-IN (RUNNING-IN) INFORMATION FOR YOUR MOTORCYCLE The first 1600 km (1 OOP miles) are the most important in the life of your mo- torcycle. Proper break-in operation during this time will help ensure maxi- mum life and performance from your new motorcycle. Suzuki parts are manufactured of high quality materi- als, and machined parts are finished to close tolerances. Proper break-in operation allows the machined sur- faces to polish each other and mate smoothly. Motorcycle reliability and performance depend on special care and restraint exercised during the break-in period. It is especially important that you avoid operating the engine in a manner which could expose the engine parts to excessive heat. Please refer to the BREAK-IN (RUN- NING-IN) section for specific break-in recommendations. WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information the words WARN- ING, CAUTION and NOTE carry spe- cial meanings and should be carefully reviewed. A WARNING The personal safety of the rider may beinvolved.Disregardingthisinfor- mation could resultin injurytothe rider. A CAUTION These instructions point out spe- cial service procedures or precau- tions that must be followed to avoid damagingthemachine. NOTE: This provides special informa- tion to make maintenance easier or important instructions clearer.
  3. 3. '1 1 1 1 1 1 FOREWORD Motorcycling is one of the most exhila- rating sports and to ensure your riding enjoyment, you should become thor- oughly familiar with the information presented in this Owner's Manual be- fore riding the motorcycle. The proper care and maintenance that your motorcycle requires is outlined in this manual. By following these instruc- tions explicitly you will ensure a long trouble free operating life for your mo- torcycle. Your authorized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equipment. All information, illustrations, photo- graphs and specifications contained in this manual are based on the latest product information available at the time of publication. Due to improve- ments or other changes, there may be some discrepancies in this manual. Suzuki reserves the right to make changes at any time. Please note that this manual applies to all specifications or all respective destinations and explains all equip- ment.Therefore, your model may have differentstandardfeaturesthanshown in this manual. SUZUKI MOTOR CORPORATION i COPYRIGHT SUZUKI MOTOR CORPORATION 2001 TABLE OF CONTENTS CONSUMER INFORMATION 3 LOCATION OF PARTS 8 CONTROLS 11 KEY 11 IGNITION SWITCH 11 INSTRUMENT PANEL 13 LEFT HANDLEBAR 18 CHOKE LEVER 19 RIGHT HANDLEBAR 20 FUEL TANK CAP 22 GEARSHIFT LEVER 23 REAR BRAKE PEDAL 23 SEAT LOCK AND HELMET HOLDERS 24 SIDE STAND 26 SUSPENSION ADJUSTMENT 27 FUEL, ENGINE OIL AND COOLANT RECOMMENDATION 31 BREAK-IN (RUNNING-IN) 33 INSPECTION BEFORE RIDING 35 RIDING TIPS 37 STARTING THE ENGINE 37 STARTING OFF 38 USING THE TRANSMISSION 38 RIDING ON HILLS 39 STOPPING AND PARKING 40 INSPECTION AND MAINTENANCE 41 MAINTENANCE SCHEDULE 41 TOOLS 43 STEERING DAMPER MAINTENANCE 43 FAIRING REMOVAL 44 LUBRICATION POINTS 45 BATTERY 46 AIR CLEANER 47 SPARKPLUGS 49 FUEL LINE 52 ENGINE OIL 53 IDLE SPEED 56 THROTTLE CABLE PLAY 57 CLUTCH 58 COOLANT DRIVE CHAIN BRAKES TIRES SIDE STAND/IGNITION INTERLOCK SWITCH FRONT WHEEL REMOVAL REAR WHEEL REMOVAL LIGHT BULB REPLACEMENT. FUSES TROUBLESHOOTING MOTORCYCLE CLEANING... STORAGE PROCEDURE SPECIFICATIONS . 59 ,.60 .63 .67 .70 .71 .73 .74 .79 .81 .82 .84 .86 CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS There are a great variety of accesso- ries available to Suzuki owners. Suzuki can not have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for Suzuki to test each acces- sory on the market or combinations of all the available accessories; how- ever, your dealer can assist you in selecting quality accessories and in- stalling them correctly. Use extreme caution when selecting and installing the accessories for your Suzuki.We have developed some gen- eral guidelines which will aid you when deciding whether, and how to equip your motorcycle. A WARNING Improper accessories or modifica- tions can make your motorcycle unsafe and can lead to an accident. Never modify the motorcycle with improper or poorly installed acces- sories. Follow all instructions in this owner's manual regarding ac- cessories and modifications.Use genuine SUZUKI accessories or equivalent designed and tested for your motorcycle. Consult your SUZUKI dealer if you have any questions.
  4. 4. I 1 Never exceed the G.V.W. (Gross Vehicle Weight) of this motorcycle. The U.v.w. is tne combined weight of the machine, accessories, pay- load and rider. When selecting your accessories, keep in mind the weight of the rider as well as the weight of the accessories. The ad- ditionaj weight of the accessories may not only create an unsafe riding condition but may also affect the riding stability! G.V.W.:430 kg (938 Ibs) "at the tire pressure (cold) Tr rgnF2jgg'Rgf/cm^ (4 2"psi) Rear: ^.goTEgT/cnr (4gj)si) Anytime that additional weight or aerodynamicaffectingaccessories are installed, they should be mounted as low as possible, as close to the motorcycle and as near the center of gravity as is feasible. The mounting brackets and other attachment hardware should be carefully checked to ensure that it provides for a rigid, non-movable mount. Weak mounts can allow the shifting of the weight and create a dangerous, unstable condition. Inspect for proper ground clearance and bank angle. An improperly mounted load could critically re- duce these two safety factors. Also determine that the "load" does not interfere with the operation of the suspension, steering or other con- trol operations. Accessories fitted to the handle- bars or the front fork area can cre- ate serious stability problems. This extra weight will cause the motor- cycle to be less responsive to your steering control. The weight may also cause oscillations in the front end and lead to instability problems. Accessories added to the handle- bar or front fork should be as light as possible and kept to a minimum. The motorcycle may be affected by a lifting condition or by an instabil- ity in cross winds or when being passed or passing large vehicles. Improperly mounted or poorly de- signed accessories can result in an unsafe riding condition, therefore caution should be used when se- lecting and installing all accesso- ries. Certain accessories displace the rider from his or her normal riding position. This limits the freedom of movement of the rider and may limit his or her control ability. Additional electrical accessories may overload the existing electri- cal system. Severe overloads may damage the wiring harness or cre- ate a dangerous situation due to the loss of electrical power during the operation of the motorcycle. When carrying a load on the motor- cycle, mount it as low as possible and as close as possible to the machine. An improperly mounted load can cre- ate a high center of gravity which is very hazardous and makes the mo- torcycle difficult to handle. The size of the "load" can also affect the aerody- namics and handling of the motor- cycle. Balafice the load between the right and left side of the motorcycle and fasten it securely. A WARNING Do not carry any objects in the space behind the fairing. Objects placed in this area can interfere with steering and can cause loss of control. MODIFICATION Modification of the motorcycle, or re- moval of original equipment may ren- der the vehicle unsafe or illegal. The frame of this motorcycle is made of an aluminium allov.Therefore, never make any modifications such as drill- ing or welding to the frame as it weak- gnsthe jjren_gth_ of the frame signifT- cantly. 'Failure to heed this warning could result in an unsafe vehicle op- erating condition and subsequent ac- cident. Suzuki will not be res- ponsible in any way for personal injury or dam- age to the motorcycle caused by frame modifications. Bolt on accessories that do not modify the frame in any way may be installed provided that the GVW is not exceeded. For the GVW, refer to the ACCESSORY INSTALLA- TION AND PRECAUTION SAFETY TIPS section of this owner's manual. A WARNING Modification to an aluminum alloy frame, such as drilling or welding, weakens the frame. This could re- sult in an unsafe operating condi- tion and may lead to an accident. Never make any modifications to the frame.
  5. 5. I I 1 j SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS Motorcycle riding is great fun and an exciting sport. Motorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider and passenger. These precau- tions are: WEAR A HELMET Motorcycle safety equipment starts with a quality helmet. One of the most serious injuries that can happen is a head injury. ALWAYS wear a properly approved helmet. You should also wear suitable eye protection. RIDING APPAREL Loose, fancy clothing can be uncom- fortable and unsafe when riding your motorcycle. Choose good quality mo- torcycle riding apparel when riding your motorcycle. INSPECTION BEFORE RIDING Review thoroughly the instructions in the "INSPECTION BEFORE RIDING" section of this manual. Do not forget to perform an entire safety inspection to ensure the safety of the rider and its passenger. FAMILIARIZE YOURSELF WITH THE MOTORCYCLE Your riding skill and your mechanical knowledgeform thefoundation forsafe riding practices. We suggest that you practice riding your motorcycle in a non-traffic situation until you are thor- oughly familiar with your machine and its controls. Remember practice makes perfect. KNOW YOUR LIMITS Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you to avoid accidents. BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days, espe- cially wet ones, requires extra caution. Braking distances double on a rainy day. Stay off the painted surface marks, manhole covers and greasy appearing areas as they can be es- pecially slippery. Use extreme caution at railway crossings and on metal grat- ings and bridges. Whenever in doubt about road condition, slow down! RIDE DEFENSIVELY The most common type of motorcycle accident occurs when a car traveling towards a motorcycle turns round cor- ner in front of the motorcyclist. Ride defensively. Wise motorcyclist uses a strategy of assuming they are invis- ible to other drivers, even in broad daylight. Wear bright, reflecting cloth- ing. Turn on the headlight and taillight every time even on a bright, sunny day to attract driver's attention. Do not ride in another driver's blind spot. SERIAL NUMBER LOCATION The frame and/or engine serial num- bers are used to register the motor- cycle. They are also used to assist your dealer when ordering parts or referring to special service informa- tion. The frame number ® is stamped on the steering head tube. The engine serial number (D is stamped on the crankcase assembly. Please write down the numbers in the box provided below for your future ref- erence. Frame number: Engine number:
  6. 6. LOCATION OF PARTS o 1 ] ® Clutch lever @ Left handlebar switches © Choke lever ® Clutch fluid reservoir ® Tachometer ® Ignition switch ® Speedometer ® Front brake fluid reservoir © Right handlebar switches ® Throttle grip ® Front brake lever ® Fuel tank cap )Fuses ) Front suspension spring pre-load and rebound damping force adjuster ) Air cleaner ) Engine coolant reservoir ) Rear suspension compression damping force adjuster ) Battery ) Main fuse ) Helmet holders )Tools ) Seat lock ) Front suspension compression damping force adjuster ) Side stand ) Gearshift lever ) Rear suspension rebound damping force adjuster ) Footrests ) Passenger footrests
  7. 7. ] ] ] I 1 1 I I j CONTROLS KEY This motorcycle comes equipped with a main ignition key and a spare one. Keep the spare key in a safe place. The key number is stamped on a plate provided with the keys. This number is used when making replacement keys. Please write your key number in the box provided for your future refer- ence. I> Rear brake fluid reservoir J> Throttle stop screw D Spark plugs D Rear brake light switch D Rear brake pedal ) Engine oil filler cap ) Engine oil inspection window ) Engine oil drain plug ) Engine oil filter Key number: IGNITION SWITCH The ignition switch has four positions: 10 "OFF" POSITION All electrical circuits are cut off. The engine will not start. The key can be removed. "ON" POSITION (Except for Canada and Australia) The ignition circuit is completed and the engine can now be started. The key cannot be removed from the igni- tion switch in this position. "ON" POSITION (For Canada and Australia) The ignition circuit is completed and the engine can now be started. The headlight and taillight will automati- cally be turned on when the key is in this position. The key cannot be re- moved from the ignition switch in this position. NOTE (For Canada and Australia): Start the engine prompty after turning the key to the "ON" position, or the battery will lose power due to con- sumption by the headlight and taillight. "LOCK" POSITION To lock the steering, turn the handle- bar all the way to the left. Push down and turn the key to the "LOCK" posi- tion and remove the key. All electrical circuits are cut off. "P" (Parking) POSITION (Except for Australia) When parking the motorcycle, lock the steering and turn the key to the "P" position.The key can now be removed and the 'position light and taillight will remain lit and the steering will be locked. This position is for night time roadside parking to increase visibility. * Canadian model does not have position light. 11
  8. 8. 1 I "1 J J A WARNING Turning the ignition switch to the "P" (PARKING) or "LOCK" position while the motorcycle is moving can be hazardous. Moving the motor- cycle while the steering is locked can be hazardous.You could lose your balance and fall, or you could drop the motorcycle. Stop the motorcycle and place it on the side stand if equipped before locking the steering. Never attempt to move the motorcycle when the steering is locked. NOTE: The key hole can be covered by turning the lid for anti-theft purpose. Turn the ignition switch to "LOCK" po- sition and change the lid hole position when leaving your motorcycle. Align the lid hole position to the key hole position when inserting the key. 12 Fl, Coolant temprature, Low fuel and Oil pressure indicator lights, LCD's and meter needles work as follows to confirm their function when the igni- tion switch is turned to the "ON" posi- tion. • Fl, Coolant temprature, Low fuel and Oil pressure indicator lights come on for 2 seconds. • All LCD segments display for 2 sec- onds. • All meter needles move to the full scale and return to the home posi- tion. FUEL METER ® The fuel meter indicates amount of gasoline remaining in the fuel tank. The "E" mark indicates the fuel tank is empty or nearly so. The "F" mark indi- cates the fuel tank is full. LOW FUEL INDICATOR LIGHT ® The low fuel indicator light comes on when the fuel in the fuel tank drops below 3.5 liters (3.7/3.1 US/Imp, qt). The indicator light comes on when the ignition switch is turned on and goes offwhen the fuel tank has enough fuel. NOTE: Add fuel to the fuel tank at the first opportunity to avoid running out of fuel when the low fuel indicator light comes on. LEFTTURN SIGNAL INDICATOR LIGHT (D When the left turn signals are oper- ated, the indicator light will flash at the same time. NOTE: If the turn signal light is not operating properly due to bulb filament or circuit failure, the indicator light flick- ers more quickly to notify the rider of the existence of trouble. TACHOMETER ® The tachometer indicates the engine speed in revolutions per minutes (r/min). OIL PRESSURE INDICATOR LIGHT © The oil pressure indicator light comes on when the engine oil pressure is belowthe normal operating range.The indicator light comes on when the ig- nition switch is turned on and the en- gine is not running. As soon as the engine starts, the indicator light should go off. A CAUTION Riding the motorcycle with the oil pressureindicatorlightlitcan dam- age the engine and transmission. Whenever the oil pressure indica- tor lights up, indicating low oil pres- sure, stop the engine immediately. Check the oil level and determine if the proper amount of oil is in the | engine. If the light still does not go out, have your authorized SUZUKI dealer or qualified mechanic troubleshoot your motorcycle. 13
  9. 9. J 1 LJ 1 I 1 1 3 CLOCK/FUEL INJECTION SYSTEM INDICATOR (D The indicator displays clock under normal condition. The indicator switches from the clock to the fuel in- jection system indicator if the fuel in- jection system has any failure. Clock mode The clock indicates 12-hour mode. Follow the procedure below to adjust the clock. 1. Push the button® until the display blinks. 2. Pushing the button will advance one minute at a time. Repeat push- ing the button until the display reaches desired time. 3. Keeping the button pushed in will advance ten minutes at a time. Keep the button pushed until the display reaches desired time. Fine- tune the time by pushing the but- ton repeatedly. 4. Wait 5 seconds and push the but- ton to resume to time display. Fuel injection system indicator F I The fuel injection system indicator in- dicates "Fl" or "CHEC" if the fuel in- jection system has any trouble. The Fl indicator light (D will also come on if the fuel injection system has failure. No 1 2 3 Fuel injection system indicator Fl Fl/Clock alternately CHEC Fl indicator light Blinks Lights - Engine condition Engine does not start. Engine can start. Engine does not start. 14 If the fuel injection system indica- tor displays "Fl" and Fl indicator light blinks, the engine will not start due to a serious fuel injection sys- tem failure. If the system has seri- ous failure while riding, the engine may stop. When the fuel injection system in- dicator displays "Fl" and clock al- ternately and Fl indicator light comes on, the engine can be started and a will keep running with limited engine performance. This shows that the fuel injection sys- tem has minor failure. Bring your motorcycle to an anthorized Suzuki dealer or qualified mechanic to in- spect the motorcycle. Continuous operation in this condition may se- riously damage the motorcycle. 3. When the fuel injection system in- dicator indicates "CHEC," the en- gine will not start. Make sure that the engine stop switch is turned on and the transmission is in neutral position with the side stand fully up. If the indicator still indicates "CHEC," inspect the ignition fuse next. SPEEDOMETER ® The speedometer indicates the road speed in kilometers per hour and miles per hour. RIGHT TURN SIGNAL INDICATOR LIGHT © When the right turn signals are oper- ated, the indicator light will flash at the same time. NOTE: If the turn signal light is not op- erating properly due to bulb filament or circuit failure, the indicator light flick- ers more quickly to notify the rider of the existence of trouble. COOLANT TEMPERATURE METER ® The coolant temperature meter indi- cates coolant temperature. When the coolant temperature gets too much high, the coolant temperature indi- cator light ® comes on. A CAUTION Running the engine with high en- gine coolant temperature can cause serious engine damage. If the engine coolant temperature in- dicator light comes on, stop the engine to let it cool. Do not runthe engine run untilthe coolant temperature indicator goes off. NOTE: The needlepoints "H"when the engine stop switch is turned to the "OFF" position with the ignition switch in "ON" position. NEUTRAL INDICATOR LIGHT ® The indicator light will come on when the transmission is in neutral.The light goes off when you shift into any gear other than neutral. 15
  10. 10. 1 I I 1 1 I J ODOMETER/TRIP METER/ FUEL CONSUMPTION METER ® The meter has three functions, odom- eter, trip meter and fuel consumption meter. The meter displays all seg- ments for two seconds when the igni- tion switch is turned to the "ON" posi- tion to confirm meter function. The meter shows "— " when the odometer or trip meter malfunc- tions. TRIP12 1/100 km/I 88888.8 Odometer TRIP1 TRIP1 TRIP1 km/I I S3TRIP1 Fuel consumption I TRIP 2 TRIP2 TRIP 2 km/I IS3TRIP2 Fuel consumption 16 Push the button ® to change the meter display. The meter display changes from the odometer to trip 1, trip 1 fuel consumption, trip 2, trip 2 fuel consumption and then return to the odometer. Odometer The odometer registers the total dis- tance that the motorcycle has been ridden. The odometer ranges from 0 to 999999 miles. Trip meter The trip meter is a resettable odom- eter. It can be used for indicating the distance traveled on short trips or be- tween fuel stops.The trip meter ranges from 0.0 to 999.9. To reset the trip meter to zero, push the button ® for 2 seconds. NOTE: When the trip meter exceeds 999.9, the trip meter will return to 0.0 and count again. Fuel consumption meter (Except for U.K.) ITRIP1 km/I 8.0 TRIP1 I/ 100 km /<?.S t"km/I" mode "1/100 km" mode The fuel consumption meter displays fuel consumption ratio of trip 1 and trip 2. The fuel consumption meter ranges from 0.1 to 50.0 km/I. The meter locks at 50.0. The fuel consumption meter indicates "—.-" when the trip meter indicates 0.0. Push the button ® for 3 seconds to change "km/I" mode to "1/100 km" mode. Trip 1 fuel consump- tion mode change does not affect tip 2 fuel consumption mode. Fuel consumption meter (For U.K.) The fuel consumption meter displays fuel consumption ratio of trip 1 and trip 2. The fuel consumption meter ranges from 0.1 to 50.0 mile/I.The meter locks at 50.0. The fuel consumption meter indicates "—.-" when the trip meter indicates 0.0. HIGH BEAM INDICATOR LIGHT ® The indicator light will come on when the headlight high beam is turned on. 17
  11. 11. 1 I 1 J LEFTHANDLEBAR © (2) Except for Canada For Canada CLUTCH LEVER ® The clutch lever is used for disengag- ing the drive to the rear wheel when starting the engine or shifting the transmission gear. Squeezing the le- ver disengages the clutch. Clutch Lever Adjustment The distance between the grip and the clutch lever is adjustable among four positions.To change the position, push the clutch lever forward and turn the adjuster to the desired position. When changing the clutch lever position, al- ways be sure the adjuster stops in the proper position; a projection of the clutch lever holder should fit into the depression of the adjuster. This mo- torcycle is delivered from the factory with its adjuster set on position 2. A WARNING Adjusting the clutch lever position while riding can be hazardous. Re- moving a hand from the handlebars can reduce your ability to control the motorcycle. Always keep both hands on the handlebars while riding. HEADLIGHT FLASHER SWITCH @ (Except for Canada) Press the switch to light the headlight. 18 DIMMER SWITCH ® "K>" position The headlight low beam and taillight turn on. "ID" position The headlight high beam and taillight turn on. The high beam indicator light also turns on. TURN SIGNAL LIGHT SWITCH ® Moving the switch to the "<=^" position will flash the left turn signals. Moving the switch to the "c =>" position will flash the right turn signals. The indicator light will also flash intermittently. To cancel turn signal operation, push the switch in. A WARNING Failuretousetheturn signals,and failure to turn off the turn signals can be hazardous. Other drivers may misjudge your course and this may result in an accident. Always use the turn signals when you intend to change lanes or make a turn. Be sure to turn off the turn signals after completing the turn or lanechange. HORN SWITCH ">tr" © Press the switch to sound the horn. CHOKELEVER This motorcycle has a choke system to provide easy starting when the en- gine is cold. When starting the cold engine, turn the choke lever all the way toward you. The choke system opens the throttle valve slightly to raise idling speed. When the engine is warm, you do not need to usethe chokesystem forstart- ing. NOTE: Refer to the RIDING TIPS sec- tion of this manual forthe engine start- ing procedure. 19
  12. 12. l!I I 1 1 RIGHT HANDLEBAR 0) Except for Canada and Australia (3) (5) For Canada and Australia ENGINE STOP SWITCH (j) "IPf." position The ignition circuit is off. The engine cannot start or run. "O" position The ignition circuit is on and the en- gine can run. LIGHT SWITCH @ (Except for Canada and Australia) "-*&" position The headlight and taillight turn on. "-;oo;-" position The position light and taillight turn on. " •" position The headlight and taillight turn off. ELECTRIC STARTER BUTTON "®" ® This button is used for operating the starter motor. With the ignition switch in the "ON" position, the engine stop switch in "O" and the transmission in neutral, push the electric starter but- ton to operate the starter motor and start the engine. NOTE: This motorcycle is equipped with interlock switches for the ignition circuit and the starter circuit. The en- gine can only be started if: • The transmission is in neutral and the clutch is disengaged, or • The transmission is in gear, the side stand is fully up and the clutch is disengaged. Front Brake Lever Adjustment A CAUTION To prevent electrical system dam- age, do not operate the starter mo- tor more than five seconds at a time. If the engine does not start after several attempts, check the fuel supply and ignition system. Refer to^TROUBLESHOOTINGsection in this manual. FRONT BRAKE LEVER ® The front brake is applied by squeez- ing the brake lever gently toward the throttle grip. This motorcycle is equipped with a disk brake system and excessive pressure is not required to slow the machine down properly. The brake light will be lit when the lever is squeezed inward. 20 The distance between the throttle grip and the front brake lever is adjustable among six positions. To change the position, push the brake lever forward and turn the adjuster to the desired position. When changing the brake lever position, always be sure the ad- juster stops in the proper position; a projection of the brake lever holder should fit into the depression of the adjuster. This motorcycle is delivered from the factory with its adjuster set on position 4. A WARNING Adjusting the front brake lever po- sition while riding can be hazard- ous. Removing a hand from the handlebars can reduceyour ability to control the motorcycle. Always keep both hands on the handlebars while riding. THROTTLE GRIP ® Engine speed is controlled by the po- sition of the throttle grip.Twist it toward you to increase engine speed. Turn it away from you to decrease the engine speed. 21
  13. 13. 1 1 I J J FUEL TANK CAP To open the fuel tank cap, insert the ignition key into the lock and turn it clockwise. With the key inserted, lift up with the key and open the fuel tank cap. To close the fuel tank cap, push the cap down firmly with the key in the cap lock. I ® Fuel level @ Filler neck A WARNING Overfilling the fuel tank can cause the fuel to overflow when it ex- pands due to heat from the engine or the sun. Spilled fuel can catch onfire. Neverfill the fuel above the bottom of the filler neck. A WARNING Fuel and fuel vapor are highly flam- mable and toxic.You can be burned or poisoned when refueling. • Stop the engine and keep flames, sparks and heat sources away. • Refuel only outdoors or in a well ventilated area. • Do not smoke. • Wipe up spills immediately. • Avoid breathing fuel vapor. • Keep children and pets away. 22 rtl GEARSHIFT LEVER This motorcycle has a 6-speed trans- mission which operates as shown. To shift properly, pull the clutch lever and close the throttle at the same time you operate the gearshift lever. Lift the gearshift lever to upshift and depress the lever to downshift. Neutral is lo- cated between low and 2nd gear. When neutral is desired, depress or lift the lever halfway between low and 2nd gear. NOTE: When the transmission is in neutral the green indicator light on the instrument panel will be lit. However, even though the light is illuminated, cautiously release the clutch lever slowly to determine whether the trans- mission is positively in neutral. Reduce the motorcycle speed before down-shifting. When down-shifting, the engine speed should be increased before the clutch is engaged. This will prevent unnecessary wear on the drive train components and the rear tire. REAR BRAKE PEDAL Depressing the rear brake pedal will apply the rear disk brake. The brake light will be illuminated when the rear brake is operated. 23
  14. 14. J J SEAT LOCK AND HELMET HOLDERS Front Seat To remove the front seat. 3 i 1. Remove the bolts © (right and left). 2. Raise the front end of the seat and slide it forward. r To reinstall the seat, slide the seat hooks into the seat hook retainers on the frame and tighten the bolts se- curely. A WARNING Failure to install the seat properly could allow the seat to move and cause loss of rider control. Fasten the seat securely in its proper position. Rear Seat 24 The seat lock is located at the left side of the seat tail cover. To remove the rear seat, insert the ignition key into the lock and turn it clockwise. Raise the rear end of the seat and slide it backward. To reinstall the seat, slide the seat hooks into the seat hook retainers and push down firmly until the seat snaps into the locked position. A WARNING Failure to install the seat properly could allow the seat to move and cause loss of rider control. Latch the seat securely in its proper position. Helmet Holders There are helmet holders under the rear seat. To use them, remove the seat, hook your helmet to the helmet holder and refit the seat. A WARNING Riding with a helmet fastened to the helmet holder can interfere with rider control. Never carry a helmet fastened to the helmet holder. Fix the helmet securely atop the seat if you must carry it. 25
  15. 15. I ] SIDE STAND An interlock switch is provided to cut off the ignition circuit when the side stand is down and the transmission is in any gear other than neutral. The side stand/ignition interlock switch works as follows: • If the side stand is down and the transmission is in gear, the engine can not be started. • If the engine is running and the transmission is shifted into gear with the side stand down, the en- gine will stop running. • If the engine is running and the side stand is put down with the trans- mission in gear, the engine will stop running. A WARNING Riding with the side stand incom- pletely retracted can result in an accidentwhen you turn left. • Check operation of the si'de stand/ignition interlock system beforeriding. • Always retract the side stand completelybeforestartingoff. A CAUTION Park the motorcycle on firm, level ground to help prevent it from fall- ing over. If you must park on an incline, aim the front of the motorcycle uphill and put the transmission into 1st gear to reduce the possibility of rolling off the side stand. SUSPENSION ADJUSTMENT The standard settings of both front and rear suspensions are selected to meet various riding conditions such as low to high motorcycle speed and light to heavy load on the motorcycle. The suspension settings can be adjusted for your preference and fine-tuning. FRONT SUSPENSION Spring Pre-load Adjustment 26 To change the spring pre-load, turn the adjuster ® clockwise or counterclock- wise. Turning the adjuster clockwise will increase the spring pre-load.Turn- ing the adjuster counterclockwise will decrease the spring pre-load. There are eight grooved lines on the side of the adjuster ® for reference. Position 8 provides the minimum spring pre- load and position 0 provides the maxi- mum pre-load. This motorcycle is de- livered from the factory with its ad- juster set on position 5. Position 0 Position 5 Position 8 27
  16. 16. I I D Damping Force Adjustment The rebound and compression damp- ing force can be individually adjusted by turning the respective adjusters. The rebound damping force adjuster @ is located at the top of the front fork. The compression damping force ad- juster (3) is located at the bottom of the front fork. To adjust the damping force, set the adjuster to the standard setting first and then adjust the adjuster to the desired position. To set the rebound and compression damping force, turn the adjuster clock- wise until it stops and then turn it coun- terclockwise. As you turn the adjuster, you will notice clicks. Count the num- ber of clicks from fully turned-in posi- tion. The standard rebound damping force setting is 3 clicks. The standard compression damping force setting is 9 clicks. Turn the adjuster clockwise from the standard position to stiffen the damp- ing force. Turn the adjuster counter- clockwise to soften the damping force. The damping force should be adjusted gradually, 1 click at a time, to fine-tune the suspension. A WARNING Unequal suspension adjustment can cause poor handling and loss of stability. Adjust the right and left front forks to the same settings. REAR SUSPENSION Spring Pre-load Adjustment The adjustment can be performed by changing the adjuster ring position. However, Suzuki recommends that this adjustment be done by your au- thorized Suzuki dealer, since a spe- cial tool is needed for this job. 28 Damping Force Adjustment The rebound and compression damp- ing force can be individually adjusted by turning the respective adjusters. The rebound damping force adjuster ® and compression damping force adjuster @ are located at the left side of the rear suspension damper unit. To adjust the damping force, set the adjuster to the standard setting first and then adjust the adjuster to the desired position. To set the rebound damping force ad- juster to the standard position; 1. Turn the adjuster clockwise until it stops. 2. Turn the adjuster counterclockwise about 11 clicks. Fine-tune the ad- juster by turning it slightly until two punch marks align. To set the compression damping force adjuster to the standard position; 1. Turn the adjuster clockwise until it stops. 2. Turn the adjuster counterclockwise about 8 clicks. Fine-tune the ad- juster by turning it slightly until two punch marks align. Turn the adjuster clockwise from the standard position to stiffen the damp- ing force. Turn the adjuster counter- clockwise to soften the damping force. The damping force should be adjusted gradually, 1 click at a time, to fine-tune the suspension. 29
  17. 17. SUSPENSION SETTING The suspension can be adjusted for different riding conditions and rider preferences. The following chart shows basic recommended settings for the front and rear suspension units. NOTE: Measure the spring pre-load adjuster length to adjust the spring pre-load accurately. Solo riding Softer Standard Stiffer Two-up riding Front Spring pre-load 5 5 6 5 Damping force Rebound 4 3 3 3 Compression 11 9 9 9 Rear Damping force Rebound 13 11 10 11 Compression 9 . .- •„?; 8 -| 7 8 30 FUEL, ENGINE OIL AND COOLANT RECOMMENDATION FUEL Use unleaded gasoline with an octane rating of 91 or higher (Research method). Unleaded gasoline can ex- tend spark plug life and exhaust com- ponents life. (For Canada) Your motorcycle requires regular un- leaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method). In some areas.the only fuels that are available are oxygenated fuels. Oxy- genated fuels which meet the mini- mum octane requirement and the re- quirements described below may be used in your motorcycle without jeop- ardizing the New Vehicle Limited War- ranty or the Emission Control System Warranty. NOTE: Oxygenated fuels are fuels which contain oxygencarrying addi- tives such as MTBE or alcohol. Gasoline Containing MTBE Unleaded gasoline containing MTBE (Methyl Tertiary Butyl Ether) may be used in your motorcycle if the MTBE content is not greater than 15%. This oxygenated fuel does not contain al- cohol. Gasoline/Ethanol Blends Blends of unleaded gasoline and etha- nol (grain alcohol), also known as GASOHOL, may be used in your mo- torcycle if the ethanol content is not greater than 10%. Gasoline/Methanol Blends Fuel containing 5% or less methanol (wood alcohol) may be suitable for use in your motorcycle if they contain co- solvents and corrosion inhibitors. DO NOT USE fuels containing more than 5% methanol under any circum- stances. Fuel system damage or mo- torcycleperformanceproblemsresult- ing from the use of such fuels are not the responsibility of Suzuki and may not be covered under the New Vehicle Limited Warranty or the Emission Con- trol System Warranty. NOTE: • To help clean the air, Suzuki rec- ommends that you use the oxygen- ated fuels. • Be sure that any oxygenated fuel you use has octane ratings of at least 87 pump octane ((R+M)/2 method). • If you are not satisfied with the driveablity ofyour motorcycle when you are using an oxygenated fuel, or if engine pinging is experienced, substitute another brand as there are differences between brands. A CAUTION Spilled gasoline containing alcohol can harm your motorcycle. Alcohol can damage painted surfaces. Be careful not to spill any fuel when filling the fuel tank. Wipe spilled gasoline up immediately. 31
  18. 18. J "*] J 3 J 1 ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or SG under the API service classification. The recommended vis- cosity is SAE 10W-40. If a SAE 10W- 40 motor oil is not available, select an alternative according to the following chart. COOLANT Use an anti-freeze compatible with aluminium radiator mixed with distilled water only at the ratio of 50:50. A WARNING Engine coolant is harmful if swal- lowed or if it comes in contact with your skin or eyes. Keep engine coolant away from children andpets.Callyourphysi- cian immediately if engine coolant is swallowed, and induce vomiting. Flush eyes orskin withwater ifen- ginecoolantgetsineyesorcomes in contact with skin. A CAUTION Spilledenginecoolantcandamage painted surfaces. Do not spill any fluid when filling the radiator. Wipe spilled engine coolant up immediately. Water for mixing Use distilled water only. Water other than distilled water can corrode and clog the aluminium radiator. Anti-freeze The coolant performs as rust inhibitor and water pump lubricant as well as anti-freeze. Therefore the coolant should be used at all times even though the atmospheric temperature in your area does not go down to freez- ing point. 32 Required amount of water/coolant Solution capacity (total): 2950 ml (6.2/5.2 US/Imp, pt) 50% Water Coolant 1475 ml (3.1/2.6 US/Imp, pt) 1475 ml (3.1/2.6 US/Imp, pt) NOTE: This 50% mixture will protect the cooling system from freezing at temperatures above -31 °C. If the mo- torcycle is to be exposed to tempera- ture below -31 °C, this mixing ratio should be increased up to 55% (-40°C) or 60% (-55°C). The mixing ratio should not exceed 60%. BREAK-IN (RUNNING-IN) Previous sections explains how impor- tant proper break-in is to achieving maximum life and performance from your new Suzuki. The following guide- lines explain proper break-in proce- dures. MAXIMUM ENGINE SPEED RECOMMENDATION This table shows the maximum rec- ommended engine speed during the break-in period. Initial Up to Over 800 km (500 miles) 1600 km (1000 miles) 1 600 km (1000 miles) Below 5500 rpm Below 8000 rpm Below 11000 rpm VARY THE ENGINE SPEED The engine speed should be varied and not held at a constant speed. This allows the parts to be "loaded" with pressure, and then unloaded, allow- ing the parts to cool. This aids the mating process of the parts. It is es- sential that some stress be placed on the engine components during break- in to ensure this mating process. Do not, though, apply excessive load on the engine. 33
  19. 19. 1 1 1 1 3 1 BREAKING IN THE NEW TIRES New tires need proper break-in to as- sure maximum performance, just as the engine does. Break-in the tread surface by gradually increasing your cornering lean angles over the first 160 km (100 miles) before attempting maximum performance. Avoid hard ac- celeration, hard cornering, and hard braking forthe first 160 km (100 miles). A WARNING Failure to perform break-in of the tires could cause tire slip and loss of control. Use extra care when riding on new tires.Perform properbreak-in ofthe tires as described in this section and avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles). AVOID CONSTANT LOW SPEED Operating the engine at constant low speed (light load) can cause parts to glaze and not seat in. Allow the en- gine to accelerate freely through the gears, without exceeding the recom- mended maximum limits. Do not, how- ever, use full throttle for the first 1600 km (1000 miles). ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before apply- ing load or revving the engine. This allows time for the lubricating oil to reach all critical engine components. OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE The initial service (1000 km mainte- nance) is the most important service your motorcycle will receive. During break-in operation, all of the engine components will have mated together and seated. Maintenance required as part of the initial service includes cor- rection of all adjustments, tightening of all fasteners and replacement of dirty oil. Timely performance of this service will help make sure you get the best service life and performance from the engine. NOTE: The 1000 km (600 miles) ser- vice should be performed as outlined in the INSPECTION AND MAINTE- NANCE section of this Owner's Manual.Payparticularattention tothe CAUTION and WARNING in that sec- tion. INSPECTION BEFORE RIDING A WARNING Failure to inspect and maintain your motorcycle properly increases the chance.of an accident or equip- ment damage. Always perform a pre-ride inspec- tion before each ride. Refer to the table below for check items. For further details, referto the INSPEC- TION AND MAINTENANCE section. 34 A WARNING Using worn, improperly inflated, or incorrect tires will reduce stability and can cause an accident. Follow all instructions in theTIRES section in this owner's manual. Before riding the motorcycle, be sure to check the following items. Never underestimate the importance of these checks. Perform all of them before riding the motorcycle. A WARNING Checking maintenance items when the engine is running can be haz- ardous. You could be severely in- jured if your hands or clothing get caught in moving parts. Shut the engine off when perform- ing maintenance checks, except when checking the engine stop switch and throttle. 35
  20. 20. WHATTO CHECK Steering Throttle Clutch Brakes Suspension Fuel Drive chain Tires Engine oil Cooling system Lighting CHECK FOR: • Smoothness • No restriction of movement • No play or looseness • Correct play in the throttle cable • Smooth operation and positive return of the throttle grip to the closed position • Fluid level in the reservoir to be above "LOWER" line • Correct lever play • No fluid leakage • Smooth and progressive action • Fluid level in the reservoir to be above "LOWER" line • Correct pedal and lever play • No "sponginess" • No fluid leakage • Brake pads not to be worn down to the limit line Smooth movement Enough fuel for the planned distance of operation • Correct tension or slack • Adequate lubrication • No excessive wear or damage • Correct pressure • Adequate tread depth • No cracks or cuts Correct level • Proper coolant lever • No coolant leakage Operation of all lights and indicators Horn Engine stop switch Side stand/ Ignition interlock switch Correct function Correct function Proper operation 36 RIDING TIPS STARTING THE ENGINE Before attempting to start the engine, make sure: • The transmission is in neutral. • The engine stop switch is in the "O" position. NOTE: This motorcycle is equipped with interlock switches for the ignition circuit and the starter circuit. The engine can only be started if: • The transmission is in neutral and the clutch is disengaged, or • The transmission is in gear, the side stand is fully up and the clutch is disengaged. When the Engine is Cold: 1. Turn the choke lever all the way to- ward you. 2. Close the throttle completely and push the electric starter button. 3. Immediately after the engine starts, keep the engine speed at 2000 - 2500 r/min by varying the choke lever position. 4. Move the choke lever to the "OFF" position approximately 30 seconds after engine starts. It may be nec- essary to use the choke longer than 30 seconds in extremely cold weather. When the Cold Engine is Hard to Start: 1. Turn the choke lever all the way to- wards you. 2. Open the throttle approximately 1/8 turn and push the electric starter button. 3. Immediately after the engine starts, keep the engine speed at 2000 - 2500 r/min by varying the choke lever position. 4. Move the choke lever to the "OFF" position approximately 30 seconds after engine starts. It may be nec- essaryto usethechoke longerthan 30 seconds in extremely cold weather. When the Engine is Warm: Use of the choke should not be nec- essary. Close the throttle completely and push the electric starter button. When the Warm Engine is Hard to Start: Use of the choke should not be nec- essary. Open the throttle slightly and push the electric starter button. A WARNING Running the engine indoors or in a garage can be hazardous. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe in- jury. Only run the engine outdoors where there is fresh air. A CAUTION Running the engine too long with- out riding may cause the engine to overheat. Overheating can result in damage to internal engine compo- nents and discoloration of exhaust pipes. Shut the engine off if you cannot begin your ride promptly. 37
  21. 21. STARTING OFF 1 11 A WARNING Ridingthismotorcycleatexcessive speed increases your chances of losing control of the motorcycle. This may result in an accident. Alwaysridewithinthelimitsofyour skills, your motorcycle, and the riding conditions. A WARNING Removing your hands from the handlebars or feet from the foot- rests during operationcan behaz- ardous. If you remove even one hand or foot from the motorcycle, you can reduceyour abilityto con- trolthemotorcycle. Always keep both hands on the handlebars and both feet on the footrestsofyourmotorcycleduring operation. A WARNING Sudden sidewinds,which can oc- cur when being passed by larger vehicles,attunnel exits or in hilly areas, can upset your control. Reduce your speed and be alert to side winds. After moving the side stand to the fully up position, pull the clutch lever in and pause momentarily. Engage first gear by depressing the gear shift lever downward. Twist the throttle grip to- ward you and at the same time release the clutch lever gently and smoothly. As the clutch engages, the motorcycle will start moving forward.To shift to the next higher gear, accelerate gently, then close the throttle and pull the clutch lever in simultaneously. Lift the gear shift lever upward to select the next gear, release the clutch lever and open the throttle again. Select the gears in this manner until top gear is reached. NOTE: This motorcycle is equipped with a side stand/ignition interlock switch. Ifyou shift the transmission into gearwhen the side standis down, the engine will stop running. USING THE TRANSMISSION The transmission is provided to keep the engine operating smoothly in its normal operating speed range. The gear ratios have been carefully cho- sen to meet the characteristics of the engine. The rider should always se- lect the most suitable gear for the pre- vailing conditions. Never slip the clutch to control road speed, but rather down- shift to allow the engine to run within its normal operational range. The table below shows the approxi- mate speed range for each gear (for Canada). Shifting up schedule Gear position 1st-> 2nd 2nd -> 3rd 3rd -> 4th 4th -» 5th 5th -> 6th km/h 20 30 40 50 60 miles/h 12 19 25 31 37 Shifting down schedule Gear position 6th -> 5th 5th -» 4th 4th -» 3rd km/h 50 40 30 miles/h 31 25 19 Disengage the clutch when the mo- torcycle speed drops below 20 km/h (12 miles/h). A WARNING Downshifting when engine speed istoohighcan; • cause the rear wheel to skid and lose traction due to increased engine braking, resulting in an accident;or • force the engineto overrev in the lower gear, resulting in engine damage. Reduce speed before downshifting. A WARNING Downshifting whilethe motorcycle is leaned over in a corner may cause rear wheel skid and loss of control. Reduce your speed and downshift before entering the corner. A CAUTION Revving the engine into the red zone can cause severe engine damage. Never allow the engine to rev into the red zone in any gear. RIDING ON HILLS • When climbing steep hills, the mo- torcycle may begin to slow down and show lack of power. Atthis point you should shift to a lower gear so that the engine will again be oper- ating in its normal power range. Shift rapidly to prevent the motor- cycle from losing momentum. • When descending a long, steep slope, use engine compression to assist the brakes by shifting to a lower gear. Continuous brake ap- plication can overheat the brakes and reduce their effectiveness. • Be careful, however, not to allow the engine to over rev. 38 39
  22. 22. I 1 1 1 STOPPING AND PARKING 1. Twist the throttle grip away from yourself to close the throttle com- pletely. 2. Apply the front and rear brakes evenly and at the same time. 3. Downshift through the gears as road speed decreases. 4. Select neutral with the clutch lever squeezed toward the grip (disen- gaged position) just before the motorcycle stoos. Neutral position can be confirmed by observing the neutral indicator light. A WARNING Inexperienced riders tend to underutilize the front brake. This can cause excessive stopping dis- tance and lead to a collision. Us- ing only the front or rear brake can cause skidding and loss of control. Apply both brakes evenly and at the same time. A WARNING Hard braking while turning may cause wheel skid and loss of con- trol. Brake before you begin to turn. A WARNING Hard braking on wet, looser-rough, or other slippery surfaces can cause wheel skid and loss of con- trol. Brake lightly and with care on slip- pery or irregular surfaces. A WARNING Following another vehicle too closely can lead to a collision. As vehicle speeds increase, stopping distance increases progressively. Be sure you have a safe stopping distance between you and the ve- hicle in front of you. 5. Park the motorcycle on a firm, flat surface where it will not fall over. A WARNING A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Park the motorcycle where pedes- trians or children are not likely to touch the muffler. NOTE: If the motorcycle is to be parked on the side stand on a slight slope, the front end of the motorcycle should face "up" the incline to avoid rolling forward off the side stand. You may leave the motorcycle in 1st gear to help prevent it from rolling off the side stand. Return to neutral before starting engine. 6. Turn the ignition key to the "OFF" position. 7. Turn the handlebars all the way to the left and lock the steering for security. 8. Remove the ignition key. INSPECTIONAND MAINTENANCE MAINTENANCE SCHEDULE The chart indicates the intervals be- tween periodic services in miles, kilo- meters and months.Atthe end of each interval, be sure to inspect, check, lu- bricate and service as instructed. If your motprcycle is used under high stress conditions such as continuous full throttle operation, or is operated in a dusty climate, certain services should be performed more often to ensure reliability of the machine as explained in the maintenance section. Your Suzuki dealer can provide you with further guidelines. Steering com- ponents, suspensions andwheel com- ponents are key items and requirevery special and careful servicing. For maximum safety we suggest that you have these items inspected and ser- vicedbyyourauthorizedSuzukidealer or a qualified service mechanic. A WARNING Improper maintenance or failure to perform recommended mainte- nance increases the chance of an accident or motorcycle damage. Always follow the inspection and maintenance recommendations and schedules in this owner's manual. Ask your SUZUKI dealer or qualified mechanic to do the main- tenance items marked with an as- terisk (*).You may perform the un- marked maintenance items by re- ferring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, have your SUZUKI dealer or qualified me- chanic do them. 40 A WARNING Running the engine indoors or in a garage can be hazardous. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe in- jury. Only run the engine outdoors where there is fresh air. NOTE: The MAINTENANCE CHART specified the minimum requirements for maintenance. If you use your mo- torcycle under severe conditions, per- form maintenance more often than shown in the chart. If you have any questions regarding maintenance in- tervals, consult your SUZUKI dealer or qualified mechanic. A CAUTION Using poor quality replacement parts can causeyour motorcycle to wear more quickly and may shorten its useful life. Use only genuine Suzuki replace- ment parts or their equivalent. 41
  23. 23. 1 ] ] MAINTENANCE CHART Interval: This interval should be judged by odometer reading or months, which- ever comes first. TOOLS ^_^ Interval km ^~~~~~^^^ miles Element """"~^^_^ months Air cleaner element * Exhaust pipe bolts and muffler bolts ' Tappet clearance Spark plugs Fuel line Engine oil Engine oil filter Idle speed Throttle cable play * Throttle valve synchronization " Engine coolant Radiator hose Clutch hose Clutch fluid Drive chain " Brakes Brake hose Brake fluid Tires * Steering * Front forks * Rear suspension * Chassis bolts and nuts 1000 600 1 - T - - - 6000 4000 6 I - - I I 12000 7500 12 I T - R I 18000 11000 18 R - - I I 24000 15000 24 I T I R I 'Replace every four years R R I I - R - I I - R - I I I R R I I - R - I I I Replace every two years - - I I I I I I I I 'Replace every four years - I I I I 'Replace every two years I I I I I Clean and lubricate every 1000km (600 miles) I - I I I I I I I I 'Replace every four years - I I I I 'Replace every two years - I - - T I - - - T I I I I T I - - - T I I I I T NOTE: 1= Inspect and clean, adjust, replace or lubricate as necessary, R= Replace, T= Tighten To assist you in the performance of periodic maintenance, a tool kit is sup- plied and located under the rear seat. STEERING DAMPER MAINTENANCE 1. Keep the steering damper shaft clean at all times. 2. Wipe off any oil residue with a cloth NOTE: Do not confuse the grease-like residue on the steering damper's shaft with an oil leak. Collection of this resi- due is normal and is from oil seal lu- bricant used in the damper. You may also notice a sound as the damper shaft is stroked in and out. This "escaping air" type sound is nor- maland is made as the internal valving damps the shaft movement. 42 43
  24. 24. 1 r FAIRING REMOVAL 1. Place the motorcycle on the side stand. 2. Remove the screws © (right and left) and fasteners (2) (right and left). Unhook the hooks (3) (right and left). 3. Remove the screws (right and left). 4. Remove the fasteners (right and left). 5. Remove the fairing @. Installation Reinstall the fairing in the reverse or- der of their removal. • Fairing parts must be reinstalled securely. After reinstallation, check that they are snug and properly positioned. LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motorcycle and also for safe riding. It is a good prac- tice to lubricate the motorcycle after a long rough ride and after getting it wet it in the rain or after washing it. Major lubrication points are indicated below. B .... Motor oil s .... Grease ® ... Clutch lever holder (2) ... Side stand pivot and spring hook (3) ... Footrest pivot @ ... Drive chain © ... Throttle cables © ... Brake lever holder ® ... Brake pedal pivot and footrest pivot 44 45
  25. 25. j I BATTERY The battery is located under the front seat. Remove the front seat by refer- ring to the SEAT LOCK AND HELMET HOLDERS section. This battery is sealed type and requires no mainte- nance. Have your dealer check the battery's state of charge periodically. The standard charging rate is 1.2A x 5 to 10 hours and maximum rate is 5.0Ax 1 hour. Never exceed maximum charging rate. A WARNING Hydrogen gas produced by batter- ies can explode if exposed to flames or sparks. Keepflames and sparks awayfrom the battery. Never smoke when working near the battery. A CAUTION Exceeding the maximum charging rate for the battery can shorten its life. Never exceed the maximum charg- ing rate. A CAUTION Reversing the battery lead wires can damage the charging system and the battery. The red lead must go to the posi- tive (+) terminal and the black (or black with white tracer) lead must go to the negative (-) terminal. AIR CLEANER The air cleaner is located under the fuel tank. If the element has become clogged with dust, intake resistance will increase with a resultant decrease in power output and an increase in fuel consumption. If driving under dusty conditions, the air cleaner element must be cleaned or replaced morefre- quently than maintenance schedule. Check and clean the air cleaner ele- ment periodically according to the fol- lowing procedure. A WARNING Operating the engine without the air cleaner element in place could allow a flame to spit back from the engine to the air cleaner, or could allow dirt to enter the engine.This could cause a fire or severe engine damage. Never run the engine without the air cleaner element properly in- stalled. A CAUTION Clean or replace the air cleaner el- ement frequently if the motorcycle is used in dusty, wet or muddy con- ditions.The air cleaner element will clog under these conditions, and this may cause engine damage, poor performance, and poor fuel economy. Clean the air cleaner case and ele- ment immediately if water gets in the air cleaner box. Place the motorcycle on the side stand. Remove the front seat by referring to the SEAT LOCK AND HELMET HOLDERS section. 3. Remove the fuel tank fitting bolts 4. Remove the prop stay @. 46 47 Lift the front end of the fuel tank and prop it up as shown above. Insert the crank end of the prop stand into the hole of the steering shaft.
  26. 26. j 6. Remove the five screws (3). 7. Remove the cover (4). 8. Carefully use an air hose to blow the dust from the air cleaner ele- ment. NOTE: Always apply air pressure on the throttle body side of the air cleaner element only. If air pressure is applied on the air cleaner cover side, dirt will be forced into the pores of the cleaner element restricting the air flow through the cleaner element. 9. Reinstall the cleaned element or new air cleaner element in reverse order of removal. Be absolutely sure that the element is securely.in position and is sealing properly. A CAUTION A torn air cleaner element will al- low dirtto enter the engine and can damage the engine. Carefully examine the air cleaner element for tears during cleaning. Replace it with a new one if it is torn. Air Cleaner Drain Plug A CAUTION Failure to position the air cleaner element properly can allow dirt to bypasstheaircleaner element.This will cause engine damage. Be sure to properly install the air cleaner element. Remove the plug and drain water and .oil at the periodic maintenance inter- val. The air cleaner drain plug is lo- cated beneath the air cleaner box. SPARK PLUGS REMOVAL To remove the spark plugs, follow the procedure below: 1. Lift the fuel tank by referring to the AIR CLEANER section. 2. Remove the bolt @. 3. Loosen the screws @ (right and left) and (3). Disconnect the tubes © and ©. 48 49
  27. 27. 4. Lift the air cleaner box and discon- nect the tube ® and coupler ®. 5. Remove the air cleaner box. 6. Release the connector locks and disconnect the connectors ® from the spark plug caps. INSPECTION 7. Extract the spark plug cap. A CAUTION Improper removal of spark plug cap can damagethe ignition coil inthe spark plug cap. Extract the spark plug cap with your hand. Do not use pliers. Remove the spark plug with the spark plug wrench provided in the tool kit. A CAUTION Dirt can damage your engine if it enters an open spark plug hole. Cover the spark plug hole when- ever the spark plug is removed. 0.7-0.8mm (0.028 - 0.031 in) Remove the carbon deposits periodi- cally from the spark plug with a piece of hard wire or pin. Readjust the spark plug gap to 0.7 - 0.8 mm (0.028 - 0.031 in) by using a spark plug gap thickness gauge. The spark plug should be replaced every 12000 km (7500 miles). Whenever removing the carbon de- posits, be sure to observe the opera- tional color of each spark plug's por- celain tip. This color tells you whether or not the standard spark plug is suit- able for your type of usage. A normal operating spark plug should be very light brown in color. If the spark plug is very white or glazed appearing, it has been operating much too hot. This spark plug should be replaced with the colder plug. Plug Replacement Guide A CAUTION An improper spark plug may have an incorrect fit or heat range for yourengine.Thismaycausesevere engine damage which will not be covered under warranty. Use one of the spark plugs listed below or equivalent. Consult your Suzuki dealer or qualified me- chanic if you are not sure which spark plug is correct for type of usage. NGK CR8E CR9E CR10E DENSO U24ESR-N U27ESR-N U31ESR-N REMARKS If the standard plug is apt to get wet, replace with this plug. Standard If the standard plug is apt to overheat, replace with this plug. NOTE: This motorcycle uses resistor- type spark plug to avoidjamming elec- tronic parts. Improper spark plug se- lection may cause electronic interfer- ence with your motorcycle ignition sys- tem, resulting in motorcycle perfor- manceproblems.Userecommended spark plugs. 50 51
  28. 28. Installation A CAUTION A crossthreaded or overtightened spark plug will damage the alumi- num threads of the cylinder head. Carefully turn the spark plug by hand into the threads until it is finger tight. If the spark plug is new, tighten it with a wrench about 112 turn past finger tight. If you are reusing the old spark plug, tighten it with a wrench about 1/8 turn past finger tight. A CAUTION Improper installation of spark plug cap can damage the ignition coil in the spark plug cap. Install the spark plug caps with your hand. Never hitthe sparkplug caps with a tool. Reinstall the air cleaner box and fuel tank in the reverse order of removal. FUEL LINE Inspect the fuel line for damage and fuel leakage. If any defects are found, the fuel line must be replaced. ENGINE OIL Long engine life depends much on the selection of a quality oil and the peri- odic changing of the oil. Daily oil level checks and periodic changes are two of the most important maintenance items to be performed. ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level. 1. Start the engine and run it for a few minutes. 2. Stop the engine and wait for three minutes. 3. Hold the motorcycle vertically and inspect the engine oil level through the engine oil level inspection win- dow on the right side of the engine. A CAUTION The engine oil level must be be- tween the "L" (Low) line and "F" (Full) line, or engine damage may occur. Check the oil level, through the in- spection window, with the motor- cycle held vertically on level ground before each use of the mo- torcycle. ENGINE OIL AND FILTER CHANGE Change the engine oil and oil filter at the initial 1000 km (600 miles) and at each maintenance interval. The oil should be changed when the engine is warm so that the oil will drain thor- oughlyfromtheengine.Theprocedure is as follows: 1. Place the motorcycle on the side stand. 2. Remove the fairing by referring to the FAIRING REMOVAL section. 3. Remove the oil filler cap (T). 4. Place a drain pan under the drain plug ®. 5. Remove the drain plug with a wrench and drain out the engine oil. 52 53
  29. 29. J J J A WARNING Engine oil and exhaust pipes can be hot enough to burn you. Wait until the oil drain plug and ex- haust pipes are cool enough to touch with bare hands before drain- ing oil. A WARNING New and used oil and solvent can be hazardous. Children and pets maybeharmedbyswallowing new or used oil or solvent. Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals. Brief contact with used oil or solventmay irritate skin. • Keep new and used oil and sol- vent away from children and pets. • Wear a long-sleeve shirt and wa- terproof gloves. • Wash with soap if oil or solvent contacts your skin. NOTE: Recycle orproperly dispose of used oil and solvent. 6. Reinstall the drain plug and gasket. Tighten the plug securely'with a wrench. Available from Suzuki dealer Oil filter wrench (Part No. 09915-40610) Turn the oil filter © counterclock- wise and remove it with a Suzuki "cap type" oil filter wrench or a "strap type" filter wrench of proper size. 8. Wipe off the mounting surface ® on the engine where the new filter will be seated with a clean rag. 9. Smear a little engine oil around the rubber gasket (D of the new oil fil- ter. 10-Screw the new filter by hand until the filter gasket contacts the mount- ing surface (a small resistance will be felt). A CAUTION Using an oil filter with the wrong designorthread specificationscan cause oil leaks or engine damage. Use a genuine SUZUKI oil filter or an equivalent designed for your motorcycle. NOTE: To tighten the oil filterproperly, it is important to accurately identify the position at which the filter gasket first contacts the mounting surface. Mark top dead center Oil filter wrench Inthepositionat which the filter gasket first contacts^ the mounting surface. Tightenthefilter 2 turns. 11. Mark the top dead center position on the "cap type" filter wrench or on the oil filter. Use an oil filter wrench to tighten the filter 2 turns. 12. Pour 3300 ml (3.5/2.9 US/Imp, qt) of new engine oil through the filler hole and install the filler cap. Be sure to always use the specified engine oil described in the FUEL AND ENGINE OIL section. 54 55
  30. 30. 3 I J 1 J NOTE: About 3100 ml (3.3/2.7 US/ Imp. qt) of oil will be required when changing oil only. A CAUTION Engine damage may occur if you use oil that does not meet Suzuki's specifications. Use the oil specified in the FUEL, ENGINE OIL AND COOLANT REC- OMMENDATION section. 13. With the engine running, look care- fully for leaks at the oil filter and drain plug. Run the engine at vari- ous speeds for 2 to 3 minutes. 14. Stop the engine and wait for three minutes. Check the oil level again. Engine oil level can be inspected through the inspection window while holding the motorcycle ver- tically. If the oil level is lower than the "F" line, add new oil until it reaches the "F" line. Check for leaks again. NOTE: If you do not have a proper oil filter wrench, have your Suzuki dealer perform this service. IDLE SPEED THROTTLE CABLE PLAY Adjust the engine idle speed periodi- cally on the engine at normal operat- ing temperature. To adjust the idle speed: 1. Start up the engine and let the en- gine run until it warms up fully. 2. After engine warms up, turn the throttle stop screw knob ® in or out so that engine may run at 1050 - 1250 r/min. NOTE: The idle speed should be ad- justed with the engine fully warmed up. 2.0-4.0mm (0.08-0.16in) This motorcycle has a twin throttle cable system. Cable ® is for pulling cable and cable ® is for returning. To adjust the cable play: 1. Loosen the lock nut ®. 2. Turn in the adjuster (D fully. 3. Loosen the lock nut ®. 4. Turn the adjuster ® so that the throttle grip has 2.0 - 4.0 mm (0.08 -0.16 in) play. 5. Tighten the lock nut (3). 6. While holding the throttle grip at the closed position, turn out the ad- juster @ to feel resistance. 7. Tighten the lock nut ®. A WARNING Inadequate throttle cable play can cause engine speed to rise sud- denly when you turn the handle- bars. This can lead to loss of rider control. Adjust the throttle cable play so that engine idle speed does not rise due to handlebars movement. 56 57
  31. 31. CLUTCH J J J The clutch release mechanism of this motorcycle is operated by hydraulic pressure. There is no adjustment needed on the clutch release system because the system is self-adjusting. However, inspect the following each time before driving to make sure that the system is in good condition and functioning properly. • Fluid level in the reservoir to be above "LOWER" line. • No fluid leakage. • Smooth and sure action of clutch lever. A WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. Keep brake fluid away from chil- dren and pets. Call your doctor im- mediately if brake fluid is swal- lowed, and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin. A WARNING Failure to keep the clutch fluid res- ervoir full with the proper brake fluid can be hazardous.The clutch may not work correctly without the proper amount and type of brake fluid.This could lead to an accident. Inspect the clutch fluid level before each use. Use only DOT4 brake fluid from a sealed container. Never use or mix different types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a Suzuki dealer or qualified me- chanic for inspection. COOLANT COOLANT LEVEL A CAUTION Spilled brake fluid can damage painted surfaces and plastic parts. Avoid spillinganyfluid whenfilling the reservoir. Wipe up spills imme- diately. 58 The coolant should be kept between the "F"(FULL) and "L" (LOW) level lines in the reservoir tank at all times. In- spect the level every time before riding with the motorcycle held vertically. If the coolant is found lower than the "L" level line, add properly mixed coolant in the following way: 1. Remove the fastener ® and screw @. Unhook the hook (3). 2. While pulling the fairing, remove the filler cap and add properly mixed coolant through the filler hole until it reaches the "F" line. Refer to the FUEL, ENGINE OIL AND COOL- ANT RECOMMENDATION section. A WARNING Engine coolant is harmful if swal- lowed or if it comes in contact with your skin or eyes. Keep engine coolant away from children and pets. Call your physi- cian immediately if engine coolant is swallowed, and induce vomiting. Flush eyes or skin with water if en- gine coolant gets in eyes or comes in contact with skin. NOTE: Adding only water will dilute the engine coolant and reduce its effec- tiveness. Add 50:50 mixture of engine coolant and water. CHANGING THE COOLANT Change the coolant every two years. NOTE:About2300 ml (4.8/4.0 US/Imp, pt) of coolant will required when filling the radiator and reservoir tank. 59
  32. 32. J DRIVE CHAIN This motorcycle has a master link type drive chain. We recommend that you take your motorcycle to an authorized Suzuki dealer or qualified mechanic if the drive chain needs replacing. The condition and adjustment of the drive chain should be checked each day before you ride. Always follow the guide lines for inspecting and servic- ing the chain. A WARNING Riding with the chain in poor con- dition or improperly adjusted can lead to an accident. Inspect, adjust, and maintain the chain properly before each ride, according to this section. Inspecting the Drive Chain When inspecting the chain, look for the following: • Loose pins • Damaged rollers • Dry or rusted links • Kinked or binding links • Excessive wear • Improper chain adjustment If you find anything wrong with the drive chain condition or adjustment, correct the problem if you know how. If necessary, consult your authorized Suzuki dealer or qualified mechanic. Damage to the drive chain means that the sprockets may also be damaged. Inspect the sprockets for the follow- ing: • Excessively worn teeth • Broken or damaged teeth • Loose sprocket mounting nuts If you find any of these problems with your sprocket, consult your-Suzuki dealer or qualified mechanic. Good Worn NOTE: The two sprockets should be inspected for wear when a new chain is installed and replace them if nec- essary. DRIVE CHAIN CLEANING AND OILING This drive chain has special "0" rings that permanently seal grease inside. Clean and oil the chain periodically, as follows: 1. Clean the chain with kerosene. If the chain tends to rust, the interval must be shortened. Kerosene is a petroleum product and will provide some lubrication as well as clean- ing action. A WARNING Kerosene can be hazardous. Kero- sene is flammable. Children or pets may be harmed from contact with kerosene. Keep flames and smoking materi- als away from kerosene. Keep chil- dren and pets away from kerosene. If swallowed, do not induce vomit- ing. Call a physician immediately. Dispose of used kerosene properly. A CAUTION Cleaning the chain with gasoline or commercial cleaning solvents can damage 0-rings and ruin the chain. Clean the drive chain with kerosene only. 2. After thoroughly washing the chain and allowing it to dry, oil the links with SUZUKI chain lube or an equivalent. 60 A CAUTION Some drive chain lubricants con- tain solvents and additives which could damage the 0-rings in your chain. Use Suzuki chain lube or an equiva- lent that is specifically intended for use with 0-ring chains. DRIVE CHAIN ADJUSTMENT Adjust the drive chain slack to the proper specification. The chain may require more frequent adjustments than periodic maintenance schedule depending upon your riding condi- tions. A WARNING Too much chain slack can cause the chain to come off the sprock- ets, resulting in an accident or se- rious damage to the motorcycle. Inspect and adjust the drive chain slack before each use. 61
  33. 33. "1 J J To adjust the drive chain, follow the procedure below: 1. Place the motorcycle on the side stand. Except for Canada ForCanada 2. (Only for Canada) Remove the cot- ter pin ®. 3. Loosen the axle nut (2). 4. Loosen the lock nut (3) (right and left). A WARNING A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Wait until the muffler cools to avoid burns. 20-30 mm (0.8-1.2 in) 5. Adjust the drive chain slack by turn- ing the right and left chain adjuster bolts ®. At the same time that the chain is being adjusted, the rear sprocket must be kept in perfect alignment with the front sprocket. To assistyou in performing this pro- cedure, there are reference marks © on the swing arm and each chain adjuster which are to be aligned with each other and to be used as a reference from one side to the other. 6. Tighten the lock nut ® (right and left). 7. Tighten the axle nut @ securely. 8. (Only for Canada) Replace the cot- ter pin with a new one. 9. Recheck the chain slack after tight- ening and readjust if necessary. Rear axle nut tightening torque: 100 N-m (10.0 kgf-m, 72.5 Ib-ft) BRAKES This motorcycle utilizes front and rear disk brakes. Proper operation of brake systems are vital to safe riding. Be sure to perform the brake inspection requirements as scheduled. BRAKE SYSTEM A WARNING Failure to inspect and properly maintain the brakes increases your chance of having an accident. Inspect the brake system before each use according to the INSPEC- TION BEFORE RIDING section. Fol- low the MAINTENANCE SCHED- ULE section to maintain your brake system. Inspect your brake system for the fol- lowing items daily: • Inspect the fluid level in the reser- voirs. • Inspect the front and rear brake system for signs of fluid leakage. • Inspect the brake hose for leakage or a cracked appearance. • The brake lever and pedal should have the proper stroke and be firm at all times. • Check the wear of the disk brake pads. BRAKE FLUID A WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. Keep brake fluid away from chil- dren and pets. Call your doctor im- mediately if brake fluid is swal- lowed, and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin. LOWER Checkthe brakefluid level in both front and rear brake fluid reservoirs. Inspect for brake pad wear and leaks. 62 63
  34. 34. A WARNING Failure to keep the brake fluid res- ervoir full with proper brake fluid can be hazardous,The brakes may not work correctly without the proper amount and type of brake fluid.This could lead to an accident. Inspect the brake fluid level before each use. Use only DOT4 brake fluid from a sealed container. Never use or mix different types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a SUZUKI dealer or qualified me- chanic for inspection. A CAUTION Spilled brake fluid can damage painted surfaces and plastic parts. Avoid spilling any fluid when filling the reservoir.Wipe up spills imme- diately. BRAKE PAD FRONT NOTE: Remove the plastic cover® to inspect the rear brake pads. Use a mirror to inspect them. I NOTE: Remove the two bolts ® and caliper lid (2) to inspect the front brake pads. REAR Inspect the front and rear brake pads by noting whether or not the friction pads are worn down to the grooved limit line @. If a pad is worn to the grooved limit line it must be replaced with a new one by your authorized Suzuki dealer or qualified service mechanic. A WARNING Riding with worn brake pads will reduce braking performance and will increase your chance of hav- ing an accident. Inspectbrakepadwearbeforeeach use. Ask your SUZUKI dealer or qualified mechanic to replace brake pads if any pad is worn to the limit. A WARNING Failure to extend brake pads after repair or replacement can cause poor braking performance and may result in an accident. Before riding, "pump" the brake re- peatedly until brake pads are pressed against the brake disks and proper lever/pedal stroke and firm feel are restored. NOTE: Do not squeeze/depress the brake lever/pedal when the pads are not in their positions. It is difficult to push the pistons back and brake fluid leakage may result. 64 65
  35. 35. REAR BRAKE PEDAL ADJUSTMENT The rear brake pedal position must be properly adjusted at all times or the disk brake pads will bear against the disk causing damage to the pads and to the disk surface. Adjust the brake pedal position in the following manner: Loosen lock nut ®, and rotate push rod (D to locate the pedal 55 - 65 mm (2.2 - 2.6 in) below the top face of the footrest. Retighten lock nut ® to secure push rod (2) in the proper position. A CAUTION An incorrectly adjusted brake pedal may force brake pads to rub against the disk at all times, causing dam- age to the pads and disk. Follow the steps in this section to adjust the brake pedal properly. REAR BRAKE LIGHT SWITCH TIRES To adjust the brake light switch, raise or lower the switch so that the brake light will come on just before a pres- sure rise is felt when the brake pedal is depressed. A WARNING Failure to follow these warnings may result in an accident due to tire failure.The tires on your motorcycle form the crucial link between your motorcycle and the road. Follow these instructions; • Check tire condition and pres- sure, and adjust pressure before each ride. • Avoid overloading your motor- cycle. • Replace a tire when worn to the specified limit, or ifyou find dam- age such as cuts or cracks. • Always use the size and type of tires specified in this owner's manual. • Balance the wheel after tire in- stallation. • Read this section of owner's manual carefully. A WARNING Failure to perform break-in of the tires could cause tire slip and loss of control. Use extra care when riding on new tires. Perform proper break-in ofthe tiresreferringtothe BREAK-INsec- tion and avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles). 66 TIRE PRESSURE AND LOADING Proper tire pressure and proper tire loading are important factors. Over- loading your tires can lead to tire fail- ure and loss of vehicle control. Check tire pressure each day before you ride, and be sure the pressure is correct for the vehicle load according to the table below. Tire pressure should only be checked and adjusted before riding, since riding will heat up the tires and lead to higher inflation pressure readings. Under-inflated tires make smooth cor- nering difficult, and can result in rapid tire wear. Over-inflated tires have a smaller amount of tire in contact with the road, which can contribute to skid- ding and loss of control. Cold Tire Inflation Pressure LOAD TIRE. FRONT REAR SOLO RIDING 290 kPa 2.90 kgf/cm2 42 psi 290 kPa 2.90 kgf/cm2 42 psi TWO-UP RIDING 290 kPa 2.90 kgf/cm2 42 psi 290 kPa 2.90 kgf/cm2 42 psi NOTE: When you detect drops in tire pressure, check the tire for nails or other punctures, or a damaged wheel rim. Tubeless tires sometimes lose pressure gradually when punctured. 67
  36. 36. L [. "1 TIRE CONDITION ANDTYPE Proper tire condition and proper tire type affect vehicle performance. Cuts or cracks in the tires can lead to tire failure and loss of vehicle control. Worn tires are susceptible to puncture failures and subsequent loss of vehicle control. Tire wear also affects the tire profile, changing vehicle handling characteristics. Check tire conditions each day before you ride. Replace tires if tires show visual evidence of damage, such as cracks or cuts, or if tread depth is less than 1.6 mm (0.06 in) front, 2.0 mm (0.08 in) rear. NOTE: The "Triangle" mark indicates the place where the wear bars are molded into the tire. When the wear bars contact the road, it indicates that the tire wear limit has been reached. When you replace a tire, be sure to replace it with a tire of the size and type listed below. If you use a differ- ent size or type of tire, vehicle han- dling may be adversely affected, pos- sibly reuslting in loss of vehicle con- trol. ^ SIZE TYPE FRONT 120/70 ZR17 M/C (58W) BRIDGESTONE BT56F J REAR 190/50 ZR17 M/C (73W) BRIDGESTONE BT56R J NOTE: Motorcycle tires have two type of indication such as 120/70 ZR17 M/ C (58W) and 120/70 ZR17 (58W). M/ C stands for motorcycle and there is no difference in the tires specification and performance apart from the tire indication between tires with and with- out M/C type indication. Be sure to balance the wheel after repairing a puncture or replacing the tire. Proper wheel balance is impor- tant to avoid variable wheel-to-road contact, andto avoid uneventirewear. A WARNING Failure to follow these instructions about tubeless tires may result in an accident due to tire failure.Tube- less tires require different service procedures than tube tires. • Tubeless tires require an air-tight seal between the tire bead and wheel rim. Special tire irons and rim protectors or a specialized tire mounting machine must be used for removing and installing tires to prevent tire or rim dam- age which could result in an air leak. • Repair puncture in tubeless tires by removing the tire and apply- ing an internal patch. • Do not use an external repair plug to repair a puncture since the plug may work loose as a re- sult of the cornering forces ex- perienced in a motorcycle tire. « After repairing a tire, do not ex- ceed 80 km/h (50 mph) for the first 24 hours, 130 km/h (80 mph) thereafter.This is to avoid exces- sive heat build-up which could result in a tire repair failure and tire deflation. • Replace the tire if it is punctured in the sidewall area, or if a punc- ture in the tread area is larger than 6 mm (3/16in). These punc- tures cannot be repaired ad- equately. NOTE: The wheel has arrow marks showing the rotating direction. The arrow marks on the tire and on the wheelshouldbe in thesame direction. A WARNING An improperly repaired, installed, or balanced tire can cause loss of control or shorten tire life. • Ask your SUZUKI dealer or quali- fied mechanic to perform tire re- pair, replacement, and balancing because proper tools and expe- rience are required. • Install tires according to the ro- tation direction shown by arrows on the sidewall of each tire. 68 69
  37. 37. i: r SIDE STAND/IGNITION INTERLOCK SWITCH Check the side stand/ignition interlock switch for proper operation as follows: 1. Sit on the motorcycle in the normal riding position, with the side stand up. 2. Shift into first gear, hold the clutch in, and start the engine. 3. While continuing to hold the clutch in, move the side stand to the down position. If the engine stops running when the side stand is moved to the down posi- tion, then the side stand/ignition inter- lock switch is working properly. If the engine continues to run with the side stand down arid the transmission in gear, then the side stand/ignition in- terlock switch is not working properly. Have your motorcycle inspected by an authorized Suzuki dealer or a quali- fied service mechanic. A WARNING If the side stand/ignition interlock system is not working properly, it is possible to ride the motorcycle with the side stand in the down position. This may interfere with rider control during a left turn. Checkthe side stand/ignition inter- lock system for proper operation before riding. Check that the side stand is returned to its full up po- sition before starting off. FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand. 2. Remove the fairing by referring to the FAIRING REMOVAL section. 3. Remove both brake calipers from the front forks by removing two mounting bolts ® on each calipers. NOTE: Never squeeze the front brake lever with the caliper removed. It is very difficult to force the pads back into the caliper assembly and brake fluid leakage may result. I 4. Loosen the two axle holder bolts (D on the right front fork. NOTE: Never loosen the axle holder bolts on the left front fork. Loosen the axle shaft © tempo- rarily. Place an accessory service stand or equivalent under the swing arm to help stabilize the rear end. Carefully position a jack under the exhaust pipe and raise until the front wheel is slightly off the ground. A CAUTION Improper jacking may cause dam- age to the fairing or oil filter. Do not apply the jack head to the fairing lower part or the oil filter when jacking up the motorcycle. 8. Turn the axle shaft counterclock- wise and draw it out. 9. Slide the front wheel forward. 70 71
  38. 38. 10. To reinstall the wheel assembly, reverse the sequence as de- scribed. 11. After installing the wheel, apply the brake several times to restore the proper lever stroke. A WARNING Failure to extend brake pads after installing the wheel can cause poor braking performance and may re- sult in an accident. Before riding,"pump"the brake re- peatedly until brake pads are pressed against the brake disks and proper lever/pedal stroke and firm feel are restored. Also check that the wheel rotates freely. A WARNING Installing the front wheel in the re- verse direction can be hazardous. The tire for this motorcycle is di- rectional.Therefore, the motorcycle may have unusal handling if the wheel is installed incorrectly. Install the front wheel in a speci- fied direction, as indicated by the arrow on the sidewall of the tire. A WARNING Failure to torque bolts and nuts properly could lead to an accident. Torque bolts and nuts to the proper specifications. If you are not sure of the proper procedure, have your authorized SUZUKI dealer or quali- fied mechanic do this. Front axle tightening torque: 100 N-m (10.0 kgf-m, 72.5 Ib-ft) Front axle holder bolt tightening torque: 23 N-m (2.3 kgf-m, 16.5 Ib-ft) Front brake caliper mounting bolt tightening torque: 39 N-m (3.9 kgf-m, 28.0 Ib-ft) REAR WHEEL REMOVAL 1. Place the motorcycle on the side stand. 2. Remove the three screws ® and chain case. Except for Canada For Canada 3. (Only for Canada) Remove the cot- ter pin @. 4. Remove the axle nut (3). A WARNING A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Wait until the muffler cools to avoid burns. 5. Place an accessory service stand or equivalent under the swing arm to lift the rear wheel slightly off the ground. 6. Loosen the lock nut ® (right and left). Turn the chain adjusting nuts © clockwise (right and left). 7. Draw out the axle shaft. 8. With the wheel moved forward, re- move the chain from the sprocket. 72 73
  39. 39. 9. Pull the rear wheel assembly rear- ward. NOTE: Never depress the rear brake pedal with the rear wheel removed. It is very difficult to force the pads back into the caliper assembly. 10. To replace the wheel reverse the complete sequence listed. 11. (Only for Canada) Replace the cotter pin with a new one. 12. After installing the wheel, apply the brake several times and then checkthatthewheel rotates freely. A WARNING Failure to adjust the drive chain and failure to torque bolts and nuts properly could lead to an accident. • Adjust the drive chain as de- scribed in DRIVE CHAIN AD- JUSTMENT section after install- ing the rear wheel. • Torque bolts and nuts to the proper specifications. If you are not sure of the proper procedure, have your authorized SUZUKI dealer or qualified mechanic do this. Rear axle nut tightening torque: 100 N-m (10.0 kgf-m, 72.5 Ib-ft) A WARNING Failure to extend brake pads after installingthewheelcan causepoor braking performance and may re- sult in an accident. Before riding,"pump"the brake re- peatedly until brake pads are pressed against the brake disks and proper lever/pedal stroke and firm feel are restored. Also check that the wheel rotates freely. LIGHT BULB REPLACEMENT The wattage rating of each bulb is shown on the table below. When re- placing a burned out bulb, always use the exact same wattage rating. Using other than the specified rating can re- sult in overloading the electrical sys- tem or premature failure of a bulb. A CAUTION Using a light bulb with the wrong wattage rating can cause electrical system damage or shorten bulb life. Always use the specified light bulb. Headlight Position light Turn signal light Brake light/ Taillight License plate light 12V65W(HB3) ... High beam 12V55W(H7) ... Low beam 12V5W* 12V 21W 12V 21/5W x 2 12V 5W * Except for Canada and Australia HEADLIGHT To replace the headlight bulb, perform the following step: Remove the cover ® by removing the fasteners @ (right and left). High beam 1. Turn the socket © counterclock- wise and remove it. 2. Disconnect the coupler. Low beam 1. Disconnect the socket ® from the headlight and remove the rubber cap®. 2. Unhook the bulb holder spring (3) and pull out the bulb @. A CAUTION Oil from your skin may damage the headlight bulb or shorten its life. Grasp the new bulb with a clean cloth. 74 75 vi
  40. 40. HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted both horizontally and vertically if nec- essary. To adjust the beam horizontally: Turn the adjuster ® clockwise orcoun- terclockwise. To adjust the beam vertically: Turn the adjuster @ clockwise or coun- terclockwise. NOTE: To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically. FRONT TURN SIGNAL LIGHT To replace the turn signal light bulb, follow these directions. REAR TURN SIGNAL LIGHT To replace the turn signal light bulb, follow these directions. 1. Remove screw and take off the lens. 1. Turn the socket counterclockwise and remove it. 2. Turn the socket counterclockwise and remove it. 2. Push in on the bulb, turn it to the left, and pull it out. 3. Push in on the bulb, twisting it to the left, and pull it out. A CAUTION Overtightening the screws may cause the lens to crack. Tighten the screws only until they are snug. 76 77
  41. 41. BRAKE LIGHT/TAILLIGHT To change the brake light/taillight bulb, perform the following steps: 1. Remove the lens by removing the screws ®. 2. Push in the bulb, twist it to the left and pull it off. A CAUTION Overtightening the screws may cause the lens to crack. Tighten the screws only until they aresnug. LICENSE PLATE LIGHT To change the license plate light bulb, perform the following steps: FUSES The main fuse is located beside the battery.To access the fuse, remove the 1. Remove the lens by removing the seat by referring to the SEAT LOCK screws ®. AND HELMET HOLDERS. 2. Pull off the bulb. The fuses are located behind the fair- ing cover under the left handlebar. To access the fuses; 1. Remove the screws ®. 2. Remove the fastener @ and cover 78 79
  42. 42. One 10A and one 15A spare fuses are provided inside the fuse box. They are designed to open when an overload exists in individual electrical system circuits. If any electrical sys- tem fails to operate, then the fuses must be checked. A CAUTION Installing a fuse of incorrect rating or using aluminum foil or wire in- stead of a fuse may seriously dam- age the electrical system. Always replace a blown fuse with a fuse of the same type and rating. If the new fuse blows in a shorttime, consultyourSuzukidealerorquali- fied mechanic immediately. FUSE LIST • 30A MAIN fuse protects all electri- cal circuits. • 15A HEAD-HI fuse protects the headlight high beam and high beam indicator light. • 15A HEAD-LO fuse protects the headlight low beam. • 15A IGNITION fuse protects the ig- nition coil, cooling fan motor and ECM. • 15A SIGNAL fuse protects the neu- tral indicator light, horn, brake light/ taillight, 'position light and meter lights. • 10A FAN fuse protects the position light, brake light/taillight and starter relay. • 10A FUEL fuse protects the fuel pump, fuel injection system and ECM. • Except for Canada and Australia TROUBLESHOOTING This troubleshooting guide is provided to help you find the cause of some common complaints. A CAUTION Failure to troubleshoot a problem correctly can damage your motor- cycle. Improper repairs or adjust- ments may damage the motorcycle instead of fixing it. Such damage maynotbecoveredunderwarranty. Ifyouarenotsureabouttheproper action, consult your Suzuki dealer or qualified mechanic about the problem. If the engine refuses to start, perform the following inspections to determine the cause. Fuel Supply Check If the fuel injection indicator displays "Fl", showing signs of trouble in the fuel injection system, take your ma- chine to an authorized Suzuki dealer. Refer to the "INSTRUMENT PANEL' section for fuel injection system indi- cator explanation. If the indicator does not display "Fl", make sure there is enough fuel in the fuel tank. If the in- dicator does not display "Fl" and there is enough fuel, ignition system should be checked. Ignition System Check 1. Remove the spark plugs and reat- tach them to the spark plug caps. 2. While holding the spark plug firmly against the crank case of the en- gine, push the starter switch with the ignition switch in the "ON" posi- tion, the engine stop switch in the "O" position, the transmission in neutral, and the clutch disengaged. If the ignition system is operating properly, a blue spark should jump across the spark plug gap. 3. If there is no spark, clean the spark plug. Replace it if necessary. Retry the above procedure with the cleaned spark plug or new one. 4. If there is still no spark, consult your Suzuki dealer for repairs. A WARNING Performing the spark test improp- erly can cause a high voltage elec- trical shock or an explosion. Avoid performing this check if you are notfamiliarwith this procedure, or if you have a heart condition or wear a pacemaker. Keep the spark plug away from the spark plug hole during this test. 80 81
  43. 43. ENGINE STALLING 1. Make sure there is enough fuel in the fuel tank. 2. If the fuel injection indicator dis- plays "Fl", showing signs of trouble in the fuel injection system, take your machine to an authorized Suzuki dealer. Refer to the "IN- STRUMENT PANEL' section forfuel injection system indicator explana- tion. 3. Check the ignition system for inter- mittent spark. 4. Check the idle speed. If necessary, adjust it using a tachometer. The correct idle speed is 1050 - 1250 r/min. MOTORCYCLE CLEANING Washing the Motorcycle When washing the motorcycle, follow the instruction below: 1. Remove dirt and mud from the motorcycle with running water. You may use a soft sponge or brush. Do not use hard materials which can scratch the paint. 2. Wash the entire motorcycle with a mild detergent or car wash soap using a sponge or soft cloth. The sponge or cloth should be fre- quently soaked in the soap solution. A CAUTION Radiator and oil coolerfins can be damaged by spraying high pres- surewateronthem. Do not spray high pressure water on the radiator and oil cooler fins. NOTE: Avoid spraying or allowing water to flow over the following places: Ignition switch Spark plugs Fuel tank cap Fuel injection system Brake master cylinders Air intake duct Clutch master cylinder 3. Once the dirt has been completely removed, rinse off the detergent with running water. 4. After rinsing, wipe off the motor- cycle with a wet chamoise or cloth and allow it to dry in the shade. 5. Check carefully for damage to painted surfaces. If there is any damage, obtain "touch-up" paint and "touch-up" the damage follow- ing the procedure below. a. Clean all damaged spots and allow them to dry. b. Stir the paint and "touch-up" the damaged spots lightly with a 'small brush. c. Allow the paint to dry completely. Windshield Cleaning Clean the windshield with a soft cloth and warm water with a mild detergent. If scratched, polish with a commer- cially available plastic polish. Replace the windshield if it becomes scratched or discolored so as to obstruct view. When replacing the windshield, use a Suzuki replacement windshield. A CAUTION Cleaning with any alkaline or strong acidcleaner, gasoline,brake fluid,oranyothersolventwilldam- age the windshield. Clean only with a soft cloth and warmwaterwithamilddetergent. Waxing the Motorcycle After washing the motorcycle, waxing and polishing are recommended to further protect and beautify the paint. • Only use waxes and polishes of good quality. • When using waxes and polishes, observe the precautions specified by the manufacturers. Inspection after Cleaning For extended life of your motorcycle, lubricate according to "LUBRICATION POINTS" section. A WARNING Wet brakes can cause poor brak- ing performance and may lead to anaccident. Avoid a possible accident by ex- pectinglongerstoppingdistances after washing your motorcycle. Apply brakes several times to let heat dry the brake pads or shoes. Follow the procedures in the "INSPEC- TION BEFORE RIDING" section to check your motorcycle for any prob- lems that may have arisen during your last ride. 82 83

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