IMPORTANT NOTICE

WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.

! WARNING
Indicates a potential hazard that could result in death or serious injury.

! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.

NOTICE
Indicates a potential hazard that could result in motorcycle or equipment damage.
NOTE
Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all poten-
tial hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS, CAU-
TIONS and NOTICES stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

FOREWORD
This manual contains an introductory description on the SUZUKI GSX-R1000/A and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
Use this section as well as other sections to use as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable
service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content of this manual and the
actual motorcycle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They
may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for
servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.

! WARNING
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the
rider and passenger.

Copyright © SUZUKI MOTOR CORPORATION 2017 All Rights Reserved

 00
TABLE OF CONTENTS

Precautions............................................................... 00-i Driveline / Axle............................................................ 3-i

Precautions ............................................................ 00-1 Precautions .............................................................. 3-1 1
Drive Chain / Drive Train / Drive Shaft ...................3A-1
General Information ................................................... 0-i
General Information ............................................... 0A-1 Brakes ......................................................................... 4-i
Maintenance and Lubrication ................................. 0B-1 Precautions .............................................................. 4-1
Service Data...........................................................0C-1 Brake Control System and Diagnosis ....................4A-1 2
Front Brakes...........................................................4B-1
Engine ......................................................................... 1-i Rear Brakes ...........................................................4C-1
Precautions .............................................................. 1-1 ABS ........................................................................4E-1
Engine General Information and Diagnosis ........... 1A-1
Emission Control Devices ...................................... 1B-1 Transmission / Transaxle .......................................... 5-i 3
Engine Electrical Devices.......................................1C-1 Precautions .............................................................. 5-1
Engine Mechanical.................................................1D-1 Manual Transmission .............................................5B-1
Engine Lubrication System .................................... 1E-1 Clutch .....................................................................5C-1
Engine Cooling System.......................................... 1F-1
Steering ....................................................................... 6-i 4
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1 Precautions .............................................................. 6-1
Starting System....................................................... 1I-1 Steering General Diagnosis ...................................6A-1
Charging System.....................................................1J-1 Steering / Handlebar ..............................................6B-1
Exhaust System ..................................................... 1K-1 Body and Accessories............................................... 9-i 5
Suspension................................................................. 2-i Precautions .............................................................. 9-1
Precautions .............................................................. 2-1 Wiring Systems ......................................................9A-1
Suspension General Diagnosis.............................. 2A-1 Lighting Systems ....................................................9B-1
Front Suspension ................................................... 2B-1 Combination Meter / Fuel Meter / Horn ..................9C-1
Rear Suspension....................................................2C-1 Exterior Parts .........................................................9D-1 6
Wheels and Tires ...................................................2D-1 Body Structure .......................................................9E-1

10

11
 Table of Contents 00- i

Section 00
00

Precautions
CONTENTS

Precautions ...............................................00-1 Precautions for Circuit Tester.............................. 00-8

Precautions........................................................... 00-1 Precautions for SDS-II ........................................ 00-8
General Precautions ........................................... 00-1 Precautions for Identification............................... 00-8
Precautions for Electrical Circuit Service ............ 00-2
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions • When removing the battery, disconnect the
BENH17K10000001 negative (–) cable first and then the
! WARNING positive (+) cable.
• When reconnecting the battery, connect
• Proper service and repair procedures are
the positive (+) cable first and then the
important for the safety of the service
negative (–) cable, and replace the terminal
mechanic and the safety and reliability of
cover on the positive (+) terminal.
the motorcycle.
• When performing service to electrical
• When 2 or more persons work together,
parts, if the service procedures do not
pay attention to the safety of each other.
require use of battery power, disconnect
• When it is necessary to run the engine the negative (–) cable from the battery.
indoors, make sure that exhaust gas is
• When tightening the cylinder head or case
forced outdoors.
bolts and nuts, tighten the larger sizes
• When working with toxic or flammable first. Always tighten the bolts and nuts
materials, make sure that the area you diagonally from the inside toward outside
work in is well ventilated and that you and to the specified tightening torque.
follow all of the material manufacturer’s
• Whenever you remove oil seals, gaskets,
instructions.
packing, O-rings, locking washers, self-
• To avoid getting burned, do not touch the locking nuts, cotter pins, circlips and
engine, engine oil, radiator and exhaust certain other parts as specified, be sure to
system until they have cooled. replace them with new ones. Also, before
installing these new parts, be sure to
NOTICE remove any left over material from the
mating surfaces.
• Before removal and disassembly, remove
all dirt, mud and dust. • Never reuse a circlip. When installing a
new circlip, take care not to expand the
• Never use gasoline as a cleaning solvent.
end gap larger than required to slip the
• After servicing the fuel, oil, water, exhaust circlip over the shaft. After installing a
or brake systems, check all lines and circlip, always ensure that it is completely
fittings related to the system for leaks. seated in its groove and securely fitted.
• If parts replacement is necessary, replace • Use a torque wrench to tighten fasteners
the parts with Suzuki Genuine Parts or to the specified torque. Wipe off grease
their equivalent. and oil if a thread is smeared with them.
• When removing parts that are to be reused, • After reassembling, check parts for
keep them arranged in an orderly manner tightness and proper operation.
so that they may be reinstalled in the
• To protect the environment, do not
proper order and orientation.
unlawfully dispose of used motor oil,
• Be sure to use special tools when engine coolant and other fluids: batteries,
instructed. and tires.
• Make sure that all parts used in • To protect Earth’s natural resources,
reassembly are clean. Lubricate them properly dispose of used motorcycle and
when specified. parts.
• Use the specified lubricant, bond, or
sealant.
 Precautions: 00-2

Precautions for Electrical Circuit Service • Inspect each lead wire circuit for poor connection by
BENH17K10000002 shaking it by hand lightly. If any abnormal condition is
When handling the electrical parts or servicing the found, repair or replace.
electric system, observe the following points for the
safety of the system.

Electrical Parts
Connector / Coupler
• Faulty electrical system is often related to poor
electrical contact of connector/coupler. Before
servicing individual electrical part, check electrical
contact of the connector/coupler.
• When connecting a connector, be sure to push it in
until a click is felt.
I310G1000003-02

• When taking measurements at electrical coupler (1)

using a tester probe (2), be sure to insert the probe
from the wire harness side (rear) of the coupler.

I310G1000001-01

• With a lock type coupler, be sure to release the lock 1

when disconnecting, and push it in fully to engage the
lock when connecting.
IF04K1000002-02
• When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires. • When connecting meter probe (2) from the terminal
side of the coupler (1) because it cannot be connected
• Inspect each terminal on the connector/coupler for
from harness side, use extra care not to bend the
looseness or bending.
male terminal of coupler of force its female terminal
• Push in the coupler straightly. An angled or skewed open for connection.
insertion may cause the terminal to be deformed, In case of such coupler as shown connect probe as
possibly resulting in poor electrical contact. shown to avoid opening female terminal.
• Inspect each terminal for corrosion and Never connect probe where male terminal is
contamination. The terminals must be clean and free supposed to fit.
of any foreign material which could impede proper
terminal contact.
• Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.

IF42J1000007-01

• Avoid applying grease or other similar material to

connector/coupler terminals to prevent electric
trouble.

I310G1000002-01
00-3 Precautions:

Clamp ECM / CDI UNIT / ABS control unit/HU / Various

• Clamp the wire harness at such positions as indicated sensors
in “Wiring Harness Routing Diagram” in Section 9A • Since each component is a high-precision part, great
(Page 9A-13). care should be taken not to apply any severe impacts
• Bend the clamp properly so that the wire harness is during removal and installation.
clamped securely.
• In clamping the wire harness, use care not to allow it
to hang down.
• Do not use wire or any other substitute for the band
type clamp.

IH17K1000002-01

IH17K1000001-01

Fuse
• When a fuse is blown, always investigate the cause to
correct it and then replace the fuse.
• Do not use a fuse of different capacity.
• Do not use wire or any other substitute for the fuse.

IH17K1000003-01

• Be careful not to touch the electrical terminals of the

electrical parts (ECM / CDI UNIT, etc.). The static
electricity from your body may damage them.

I649G1000001-02

Switch
Never apply grease material to switch contact points to
prevent damage.

IH17K1000004-01
 Precautions: 00-4

• When disconnecting and connecting the coupler, Battery

make sure to turn OFF the ignition switch (1), or • Select the same type MF battery when replacing the
electrical parts may get damaged. battery.
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the FI system and ABS instantly when
reverse power is applied.

IE39J1000001-01

• Never allow dust or water to contact the ABS control

unit/HU.

I718H1000004-01

• Removing any battery terminal of a running engine is

strictly prohibited. The moment such removal is made,
damaging counter electromotive force will be applied
to the electronic unit which may result in serious
damage.

IH17K1000005-01

• The ABS control unit/HU cannot be disassembled.

Replace the whole unit with a new one.

IH17K1000007-01

• Before measuring voltage at each terminal, check to

make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis.
IH17K1000006-01

• Never connect any tester (voltmeter, ohmmeter, or

whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit
may result.
• Never connect an ohmmeter to the electronic unit with
its coupler connected. If attempted, damage to ECM /
CDI UNIT / ABS control unit/HU or sensor may result.
• Be sure to use a specified voltmeter/ohmmeter.
Otherwise, accurate measurements may not be I310G1000012-02

obtained and personal injury may result.

00-5 Precautions:

Electrical Circuit Inspection Procedure 3) Using a test male terminal, check the female
While there are various methods for electrical circuit terminals of the circuit being checked for contact
inspection, described here is a general method to check tension.
for open and short circuit using an ohmmeter and a Check each terminal visually for poor contact
voltmeter. (possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
Open circuit check make sure that each terminal is fully inserted in the
Possible causes for the open circuit are as follows. As coupler and locked.
the cause can exist in the connector/coupler or terminal, If contact tension is not enough, rectify the contact to
they need to be checked carefully. increase tension or replace. The terminals must be
• Loose connection of connector/coupler clean and free of any foreign material which could
impede proper terminal contact.
• Poor contact of terminal (due to dirt, corrosion or rust,
poor contact tension, entry of foreign object etc.)
• Wire harness being open.
• Poor terminal-to-wire connection. [A]
When checking system circuits including an electronic
control unit such as ECM, etc., it is important to perform
careful check, starting with items which are easier to
[B]
check.
IH08K1000003-01
1) Disconnect the negative (–) cable from the battery.
[A]: Check contact tension by inserting and removing.
2) Check each connector/coupler at both ends of the [B]: Check each terminal for bend and proper alignment.
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped. 4) Using continuity inspect or voltage check procedure
as described below, inspect the wire harness
[A] terminals for open circuit and poor connection.
Locate abnormality, if any.

[A]
2
1

IH08K1000002-01 [A] [C]

[A]: Check for loose connection
1. Sensor [B]
IH08K1000004-01
2. Electrical part
[A]: Looseness of crimping
[B]: Open
[C]: Thin wire (A few strands left)
 Precautions: 00-6

Continuity check Voltage check

1) Measure resistance across coupler [B] (between [A] If voltage is supplied to the circuit being checked, voltage
and [C] in the figure). check can be used as circuit check.
If no continuity is indicated (infinity or over limit), the 1) With all connectors/couplers connected and voltage
circuit is open between terminals [A] and [C]. applied to the circuit being checked, measure
voltage between each terminal and body ground.
[A] 2) If measurements were taken as shown in the figure
and results were listed in the following, it means that
[B] the circuit is open between terminals [A] and [B].
1 Voltage between
[A] and body ground: 0 V
[B] and body ground: Approx. 5 V
[C] [C] and body ground: Approx. 5 V
3) Also, if measured values are as listed following, a
resistance (abnormality) exists which causes the
IH08K1000005-01
voltage drop in the circuit between terminals [A] and
1. Electrical part [B].
Voltage between
2) Disconnect the coupler [B] and measure resistance
[A] and body ground: 3 V – 2 V voltage drop
between couplers [A] and [B-1].
[B] and body ground: Approx. 5 V
If no continuity is indicated, the circuit is open
[C] and body ground: Approx. 5 V
between couplers [A] and [B-1]. If continuity is
indicated, there is an open circuit between couplers
[A]
[B-2] and [C] or an abnormality in coupler [B-2] or
coupler [C].

[A]

[B-2]
[B]
[C]
1

[B] [C]

[B-1]

IH08K1000006-01

1. Electrical part

[A] [B] [C]

IH08K1000007-01
00-7 Precautions:

Short circuit check (Wire harness to ground) 4) Disconnect the connector/coupler included in circuit
1) Disconnect the negative (–) cable from the battery. (coupler [B]) and measure resistance between
terminal [A] and body ground. If continuity is
2) Disconnect the connectors/couplers at both ends of
indicated, the circuit is shorted to the ground
the circuit to be checked.
between terminals [A] and [B].
NOTE
[A]
If the circuit to be checked branches to other
parts as shown, disconnect all connectors/
[D]
couplers of those parts. Otherwise, diagnosis
will be wrong.

3) Measure resistance between terminal at one end of

circuit ([A] terminal in the figure) and body ground. If [B]
continuity is indicated, there is a short circuit to
ground between terminals [A] and [C].

IF40J2000003-01

[D]: To other parts

Twist Pair Wire Harness

• A twist (1) in the twist pair wire harnesses except
around the connectors (2) should be within 100 mm
(3.94 in). Excessively-loose lines can be affected by
electric noise.

2 2

1
IH17K1000009-01

• Do not connect twist pair line terminals using a bypass

wire (1). Doing so makes the twist pair line receive
electric noise interference.
IF40J2000002-01

[D]: To other parts [E]: Other parts 1

IH17K1000010-01
 Precautions: 00-8

Precautions for Circuit Tester Precautions for SDS-II

BENH17K10000003 BENH17K10000004
• Use the Suzuki multi circuit tester set. • In some models of the SUZUKI motorcycles, the DTC
can be confirmed by using SDS-II.
Special tool
(A): 09900–25008 • Read the instruction manual when using SDS-II and
operate it properly.
Special tool
(A): 09904–41030
09904–41040

(A)

B A

IH18K1000001-01

• Read the instruction manual to use the tester IH18K1000002-01

correctly.
• Be sure to set the tester to the correct testing range.
Precautions for Identification
BENH17K10000005
• If the voltage and current are not known, make When viewed from the state in sitting on the seat, the
measurements using the highest range. cylinders of this engine are identified as No. 1 (1), No. 2
(2), No. 3 (3) and No. 4 (4), counting from left to right.
Symbols The sensor, actuator, etc. in No. 1 cylinder are identified
Symbol Definition as #1 and the ones in No. 2, No. 3 and No. 4 cylinder are
DC as #2, #3 and #4 respectively.
AC
Ω Resistance
Continuity
Diode 1, #1 2, #2 3, #3 4, #4

Using Needle Pointed Prove

NOTICE
• When using the multi circuit tester, do not
strongly touch the terminal of the electrical
part couplers with a needle pointed tester
probe to prevent the terminal damage or IH17K1000008-01

terminal bend.
• When connecting the multi circuit tester,
use the needle pointed probe to the back
side of the lead wire coupler and connect
the probes of tester to them.
• Use the needle pointed probe to prevent
the rubber of the water proof coupler from
damage.

Special tool
09900–25009
00-9 Precautions:
 Table of Contents 0- i

Section 0

General Information
0
CONTENTS

General Information ................................ 0A-1 Throttle Cable Play Inspection and

General Description .............................................0A-1 Adjustment ........................................................0B-4
Abbreviations ...................................................... 0A-1 PAIR System Inspection .....................................0B-4
Symbols .............................................................. 0A-2 Throttle Valve Synchronization ...........................0B-4
Wire Color Symbols ............................................ 0A-3 Engine Coolant Replacement .............................0B-4
Applicable Model / VIN........................................ 0A-3 Radiator Hose Inspection....................................0B-4
Vehicle Side View ............................................... 0A-4 Clutch Cable Play Inspection and Adjustment ....0B-4
Vehicle Identification Number ............................. 0A-4 Drive Chain Inspection and Adjustment ..............0B-4
Warning, Caution and Information Labels Drive Chain Cleaning and Lubricating.................0B-4
Location ............................................................ 0A-5 Brake System Inspection ....................................0B-4
Brake Hose Inspection ........................................0B-5
Component Location ...........................................0A-6
Brake Hose Replacement ...................................0B-5
Electrical Components Location ......................... 0A-6
Brake Fluid Inspection.........................................0B-5
Maintenance and Lubrication................. 0B-1 Brake Fluid Replacement....................................0B-5
Tire Inspection.....................................................0B-5
Precautions...........................................................0B-1
Steering System Inspection ................................0B-5
Precautions for Maintenance .............................. 0B-1
Front Fork Inspection ..........................................0B-5
Scheduled Maintenance ......................................0B-2
Rear Suspension Inspection ...............................0B-5
Periodic Maintenance Schedule Chart................ 0B-2
Chassis Bolt and Nut Inspection .........................0B-5
Repair Instructions ..............................................0B-4 Lubrication Points................................................0B-7
Air Cleaner Element Inspection .......................... 0B-4
Special Tools and Equipment .............................0B-7
Air Cleaner Element Replacement...................... 0B-4
Recommended Service Material .........................0B-7
Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-4
Exhaust Control Valve Inspection ....................... 0B-4 Service Data ............................................. 0C-1
Valve Clearance Inspection and Adjustment ...... 0B-4
Precautions...........................................................0C-1
Spark Plug Inspection ......................................... 0B-4
Precautions for Service Data ..............................0C-1
Spark Plug Replacement .................................... 0B-4
Fuel Hose Inspection .......................................... 0B-4 Specifications .......................................................0C-1
Evaporative Emission Control System Specifications ......................................................0C-1
Inspection (If Equipped) .................................... 0B-4 Service Data........................................................0C-3
Engine Oil Replacement ..................................... 0B-4 Fasteners Information .......................................0C-12
Engine Oil Filter Replacement ............................ 0B-4 Special Tools and Equipment ...........................0C-14
Fuel / Oil / Fluid / Coolant Recommendation ....0C-14
Special Tool ......................................................0C-16
0A-1 General Information:

General Information
General Information

General Description
Abbreviations I:
BENH17K10101001 IAP: Intake Air Pressure
A:
IAT: Intake Air Temperature
AAT: Ambient Air Temperature
I.D.: Inside Diameter
ABDC: After Bottom Dead Center
IG: Ignition
ABS: Anti-lock Brake System
IMU: Inertial Measurement Unit
AC: Alternating Current
IN.: Intake
ACL: Air Cleaner
ISC: Idle Speed Control
AKI: Anti-knock Index
J:
AP: Atmospheric Pressure
JASO: Japanese Automobile Standards Organization
API: American Petroleum Institute
L:
ATDC: After Top Dead Center
LCD: Liquid Crystal Display
A/F: Air Fuel Ratio
LED: Light Emitting Diode
B:
LH: Left Hand
BBDC: Before Bottom Dead Center
LO: Low
BTDC: Before Top Dead Center
M:
B+: Battery Positive Voltage
Max: Maximum
C:
MIL: Malfunction Indicator Light
CAN: Controller Area Network
Min.: Minimum
CDI: Capacitive Discharge Ignition
MTBE: Methyl Tertiary Butyl Ether
CKP: Crankshaft Position
N:
CKT: Circuit
NOx: Nitrogen Oxides
CLP: Clutch Lever Position
O:
CMP: Camshaft Position
O2: Oxygen
CO: Carbon Monoxide
OBD: On-Board Diagnostic System
CPU: Central Processing Unit
OHC: Over Head Camshaft
CVT: Continuously Variable Transmission
O.D.: Outside Diameter
D:
P:
DC: Direct Current
PAIR: Pulsed Secondary Air Injection
DOHC: Double Over Head Camshaft
PCV: Positive Crankcase Ventilation
DRL: Daytime Running Light
PP: Pulley Position
DTC: Diagnostic Trouble Code
R:
E:
RH: Right Hand
ECM: Engine Control Module
ROM: Read Only Memory
ECT: Engine Coolant Temperature
RON: Research Octane Number
ET: Engine Temperature
RPM: Engine Speed
ETV: Electric Throttle Valve
S:
EVAP: Evaporative Emission
SAE: Society of Automotive Engineers
EX.: Exhaust
SDS: Suzuki Diagnosis System
EXCV: Exhaust Control Valve
SRAD: Suzuki Ram Air Direct
EXCVA: Exhaust Control Valve Actuator
STCS: Secondary Throttle Control System
F:
STD: Standard
FI: Fuel Injection, Fuel Injector
STP: Secondary Throttle Position
FP: Fuel Pump
STV: Secondary Throttle Valve
FPR: Fuel Pressure Regulator
STVA: Secondary Throttle Valve Actuator
FTPC: Fuel Tank Pressure Control
T:
FWD: Forward
TC: Traction Control
G:
TDC: Top Dead Center
GEN: Generator
TO: Tip-over
GND: Ground
TP: Throttle Position
GP: Gear Position
TPS: Throttle Position Sensor
H:
V:
HC: Hydrocarbons
VVT: Variable Valve Timing
HI: High
HO2: Heated Oxygen
HU: Hydraulic Unit
 General Information: 0A-2

Symbols
BENH17K10101002
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The
meaning of each symbol is also included in the table.

NOTE
The table below shows generally used symbols, and includes some symbols not used in this manual.

Symbol Definition
Torque control required.
Data beside it indicate specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1).
Apply SUZUKI SUPER GREASE A.
99000-25011
Apply SUZUKI SUPER GREASE C.
99000-25030
Apply SUZUKI MOLYBDENUM GREASE L.
99000-25280
Apply SUZUKI MOLY PASTE.
99000-25140
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply SUZUKI WATER RESISTANT GREASE EP2.
99000-25350
Apply SUZUKI BOND 1207B.
99000-31140
Apply SUZUKI BOND 1215.
99000-31110
Apply SUZUKI BOND 1216B.
99000-31230
Apply THREAD LOCK CEMENT 1303B.
99000-32030
Apply THREAD LOCK CEMENT 1322D.
99000-32150
Apply THREAD LOCK CEMENT 1342H.
99000-32160
Apply THREAD LOCK CEMENT 1360.
99000-32130
Use SUZUKI SUPER LONG LIFE COOLANT (BLUE).
99000-99032-20X
Use SUZUKI LONG LIFE COOLANT (GREEN).
99000-99032-12X
Apply or use fork oil.
Apply or use brake fluid.
Use special tool.
Do not reuse.
Note on reassembly.
0A-3 General Information:

Wire Color Symbols

BENH17K10101003
Symbol Wire Color Symbol Wire Color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dbr Dark brown R Red
Dg Dark green V Violet
G Green W White
Gr Gray Y Yellow
Lbl Light blue

There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored
(striped) wire.
The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses two color symbols (i.e. G/Y).
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.

ID26J1010224-02

1. G (Base color) 3. G (Base Color)

2. Y (Stripe color)

Applicable Model / VIN

BENH17K10101008
Applicable Model
GSX-R1000/A L7

Applicable VIN

NOTE
• “#” indicates any check digit from 0 to 9 and X.
• “@” indicates the year of manufacture or the month and year of manufacture.

Applicable Model VIN Number Country or Area

JS1DM11B#H2100001 - U.S.A. except for California State
GSX-R1000L7 JS1DM11B#H2100001 - Canada
JS1DM11F#H2100001 - California State
JS1DM11B#H2100001 - U.S.A. except for California State
JS1DM11DN#2100001 - Indonesia
JS1DM11DZ02100001 - Thailand
JS1DM11AZH2100001 - E.U.
JS1DM11AZ02100001 - Australia
GSX-R1000AL7
JS1DM11B#H2100001 - Canada
JS1DM11F#H2100001 - California State
JS1DM21EZH2100001 - Taiwan
JS1DM11A#H2100001 - Middle East
JS1DM11DZH2100001 - Korea
 General Information: 0A-4

Vehicle Side View Vehicle Identification Number

BENH17K10101004 BENH17K10101005
SUZUKI GSX-R1000/A The frame serial number or V.I.N. (Vehicle Identification
Number) (1) is stamped on the steering head tube. The
engine serial number (2) is located on the crankcase
assembly.

1
IH17K1010001-01

IH17K1010002-01

IH17K1010003-01
0A-5 General Information:

Warning, Caution and Information Labels Location

BENH17K10101007

[A] [D]
6

7
1

[B]
4

8
[E]

10
11

9
[C]

IH17K1010004-02

[A]: Fuel tank 2. Helmet label or Fuel information label (If equipped) 8. Un noise label, EPA noise label or Information
label (If equipped)
[B]: Chain case 3. Fuel limitation label or Gasoline label (If equipped) 9. Noise approval mark label (If equipped)
[C]: Body cowling 4. Tire information label 10. ICES label (If equipped)
[D]: Frame (LH) 5. Manual notice label (If equipped) 11. Vacuum hose routing label (If equipped)
[E]: Frame (RH) 6. ID plate, Manufacturer label or Safety plate (If equipped)
1. General warning label (If equipped) 7. Information label or Noise label (If equipped)
 General Information: 0A-6

Component Location
Electrical Components Location
BENH17K10103001

3 3
2 8
1 7
4 5

10 10
9

11

12

13
21
14
15

19 20
16 17 18

24

23

22
IH17K1010005-01

1. Fuel pump/Fuel level gauge 9. PAIR control solenoid valve 17. Side-stand relay
2. IAT sensor 10. Ignition coil 18. Fuse box
3. Secondary fuel injector 11. CMP sensor 19. ABS control unit/HU (With ABS)
4. IAP sensor 12. Throttle valve motor 20. TO sensor
5. EVAP system purge control solenoid valve (If equipped) 13. Battery 21. Inertial sensor
6. Steering damper solenoid valve 14. Fuel pump relay 22. Rear wheel speed sensor
7. Ambient air temperature sensor 15. Cooling fan relay 23. Cooling fan motor (RH)
8. Front wheel speed sensor 16. High beam relay 24. Engine stop / starter switch
0A-7 General Information:

2 3 7 8 23
1 2
10
4

5
11 9
6

12
13

14 20
16
19
17
22
18

15 21
IH17K1010006-02

1. Ignition switch 9. Mode select coupler (6P) 17. Oil pressure switch
2. Primary fuel injector 10. Starter relay/Main fuse 18. HO2 sensor
3. TP sensor 11. AP sensor 19. Side-stand switch
4. Accelerator position sensor 12. Select switch 20. CKP sensor
5. ECT sensor 13. Mode switch 21. Generator
6. Starter motor 14. Horn 22. GP sensor
7. ECM 15. Cooling fan motor (LH) 23. EXCVA / EXCVA position sensor
8. Mode select coupler (2P) (With ABS) 16. Regulator/rectifier
 Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

General Information

Precautions
Precautions for Maintenance
BENH17K10200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed
in terms of months, kilometers and miles for your convenience.

NOTE
More frequent servicing may be required on motorcycles that are used under severe conditions.
0B-2 Maintenance and Lubrication:

Scheduled Maintenance
Periodic Maintenance Schedule Chart
BENH17K10205001
NOTE
• I = Inspect and clean, adjust, replace or lubricate as necessary.
R = Replace.
T = Tighten.
• (CA. only) means that the item or the maintenance interval is to be applied only for the California
model.

For Europe and Oceania Countries

Interval
months 2 12 24 36 48
Item
km 1000 12000 24000 36000 48000
miles 600 7500 15000 22500 30000
Air cleaner element (I: (Page 0B-4), R: (Page 0B-4)) — I I R I
Exhaust pipe bolts and muffler bolts (T: (Page 0B-4)) T T T T T
Exhaust control valve (I: (Page 0B-4)) I Inspect every 6000 km (4000 miles).
Valve clearance (I: (Page 0B-4)) Inspect every 24000 km (15000 miles).
Spark plugs (I: (Page 0B-4), R: (Page 0B-4)) Replace every 12000 km (7500 miles).
— I I I I
Fuel hose (I: (Page 0B-4))
Replace every 4 years.
Evaporative emission control system (If equipped) (I:
— — I — I
(Page 0B-4))
Engine oil (R: (Page 0B-4)) R Replace every year or 6000 km (4000 miles).
Replace every 2 years or 12000 km (7500
Engine oil filter (R: (Page 0B-4)) R
miles).
Throttle cable play (I: (Page 0B-4)) I I I I I
PAIR (air supply) system (I: (Page 0B-4)) — — I — I
Throttle valve synchronization (I: (Page 0B-4)) — I I I I
“SUZUKI SUPER
LONG LIFE COOLANT” — — — — R
(Blue)
“SUZUKI LONG LIFE
Engine coolant (R: (Page 0B-
COOLANT” (Green) or
4))
an engine coolant other
— — R — R
than “SUZUKI SUPER
LONG LIFE COOLANT”
(Blue)
Radiator hose (I: (Page 0B-4)) — I I I I
Clutch cable play (I: (Page 0B-4)) — I I I I
I Inspect every 6000 km (4000 miles).
Drive chain (I: (Page 0B-4), I: (Page 0B-4))
Clean and lubricate every 1000 km (600 miles).
Brakes (I: (Page 0B-4)) I I I I I
— I I I I
Brake hose (I: (Page 0B-5), R: (Page 0B-5))
Replace every 4 years.
Inspect every year or 6000 km (4000 miles).
Brake fluid (I: (Page 0B-5), R: (Page 0B-5))
Replace every 2 years.
Tires (I: (Page 0B-5)) — I I I I
Steering (I: (Page 0B-5)) I I I I I
Front forks (I: (Page 0B-5)) — I I I I
Rear suspension (I: (Page 0B-5)) — I I I I
Chassis bolts and nuts (T: (Page 0B-5)) T T T T T
Lubrication (I: (Page 0B-7)) Lubricate every 1000 km (600 miles).
 Maintenance and Lubrication: 0B-3

Except for Europe and Oceania Countries

Interval
months 2 12 24 36 48
Item
km 1000 6000 12000 18000 24000
miles 600 4000 7500 11000 14500
Air cleaner element (I: (Page 0B-4), R: (Page 0B-4)) — I I R I
Exhaust pipe bolts and muffler bolts (T: (Page 0B-4)) T — T — T
Exhaust control valve (I: (Page 0B-4)) I I I I I
Valve clearance (I: (Page 0B-4)) Inspect every 24000 km (15000 miles).
Spark plugs (I: (Page 0B-4), R: (Page 0B-4)) Replace every 12000 km (7500 miles).
— I I I I
Fuel hose (I: (Page 0B-4))
Replace every 4 years.
Evaporative emission control system (If equipped) (I:
— — I — I
(Page 0B-4))
Engine oil (R: (Page 0B-4)) R R R R R
Engine oil filter (R: (Page 0B-4)) R — R — R
Throttle cable play (I: (Page 0B-4)) I I I I I
PAIR (air supply) system (I: (Page 0B-4)) — — I — I
I
Throttle valve synchronization (I: (Page 0B-4)) — I — I
(CA. only)
“SUZUKI SUPER
LONG LIFE COOLANT” Replace every 4 years or 48000 km (29000 miles).
(Blue)
“SUZUKI LONG LIFE
Engine coolant (R: (Page 0B-
COOLANT” (Green) or
4))
an engine coolant other
— — R — R
than “SUZUKI SUPER
LONG LIFE COOLANT”
(Blue)
Radiator hose (I: (Page 0B-4)) — I I I I
Clutch cable play (I: (Page 0B-4)) — I I I I
I I I I I
Drive chain (I: (Page 0B-4), I: (Page 0B-4))
Clean and lubricate every 1000 km (600 miles).
Brakes (I: (Page 0B-4)) I I I I I
— I I I I
Brake hose (I: (Page 0B-5), R: (Page 0B-5))
Replace every 4 years.
— I I I I
Brake fluid (I: (Page 0B-5), R: (Page 0B-5))
Replace every 2 years.
Tires (I: (Page 0B-5)) — I I I I
Steering (I: (Page 0B-5)) I — I — I
Front forks (I: (Page 0B-5)) — — I — I
Rear suspension (I: (Page 0B-5)) — — I — I
Chassis bolts and nuts (T: (Page 0B-5)) T T T T T
Lubrication (I: (Page 0B-7)) Lubricate every 1000 km (600 miles).
0B-4 Maintenance and Lubrication:

Repair Instructions
Air Cleaner Element Inspection Throttle Cable Play Inspection and Adjustment
BENH17K10206001 BENH17K10206012
Refer to “Air Cleaner Element Inspection” in Section 1D Refer to “Throttle Cable Play On-Vehicle Inspection and
(Page 1D-7). Adjustment” in Section 1C (Page 1C-5).

Air Cleaner Element Replacement PAIR System Inspection

BENH17K10206002 BENH17K10206013
Refer to “Air Cleaner Element Removal and Installation” Refer to “PAIR System Inspection” in Section 1B (Page
in Section 1D (Page 1D-5). 1B-11).

Exhaust Pipe Bolt and Muffler Bolt Inspection Throttle Valve Synchronization
BENH17K10206003 BENH17K10206014
Refer to “Exhaust System Inspection” in Section 1K Refer to “Throttle Valve Synchronization” in Section 1C
(Page 1K-28). (Page 1C-9).

Exhaust Control Valve Inspection Engine Coolant Replacement

BENH17K10206004 BENH17K10206015
Refer to “Exhaust Control System On-Vehicle Refer to “Engine Coolant Replacement” in Section 1F
Inspection” in Section 1K (Page 1K-7). (Page 1F-6).

Valve Clearance Inspection and Adjustment Radiator Hose Inspection

BENH17K10206005 BENH17K10206016
Refer to “Valve Clearance Inspection and Adjustment” in Refer to “Radiator Hose Inspection” in Section 1F (Page
Section 1D (Page 1D-21). 1F-8).

Spark Plug Inspection Clutch Cable Play Inspection and Adjustment

BENH17K10206006 BENH17K10206017
Refer to “Spark Plug Inspection” in Section 1H (Page Refer to “Clutch Cable Play Inspection and Adjustment”
1H-7). in Section 5C (Page 5C-4).

Spark Plug Replacement Drive Chain Inspection and Adjustment

BENH17K10206007 BENH17K10206018
Refer to “Spark Plug Removal and Installation” in Refer to “Drive Chain Inspection and Adjustment” in
Section 1H (Page 1H-6). Section 3A (Page 3A-2).

Fuel Hose Inspection Drive Chain Cleaning and Lubricating

BENH17K10206008 BENH17K10206019
Refer to “Fuel Hose Inspection” in Section 1G (Page 1G- Refer to “Drive Chain Cleaning and Lubricating” in
6). Section 3A (Page 3A-3).

Evaporative Emission Control System Brake System Inspection

BENH17K10206020
Inspection (If Equipped) Brake Pad
BENH17K10206009
Refer to “EVAP Control System Inspection (If Equipped)” • Front: (Page 4B-2)
in Section 1B (Page 1B-15). • Rear: (Page 4C-2)

Engine Oil Replacement Brake Disc

BENH17K10206010
Refer to “Engine Oil Replacement” in Section 1E (Page • Front: (Page 4B-7)
1E-4). • Rear: (Page 4C-9)

Engine Oil Filter Replacement Brake Light Switch

BENH17K10206011 Refer to “Rear Brake Light Switch Inspection” in Section
Refer to “Oil Filter Replacement” in Section 1E (Page 4A (Page 4A-11).
1E-5).
Brake Pedal Height
Refer to “Brake Pedal Height Inspection and
Adjustment” in Section 4A (Page 4A-14).
 Maintenance and Lubrication: 0B-5

Brake Hose Inspection Tire Inspection

BENH17K10206023 BENH17K10206025
Refer to “Brake Hose Inspection” in Section 4A (Page Refer to “Tire Inspection and Cleaning” in Section 2D
4A-13). (Page 2D-13).

Brake Hose Replacement Steering System Inspection

BENH17K10206024 BENH17K10206026
• Front: (Page 4A-20) Refer to “Steering On-Vehicle Inspection” in Section 6B
(Page 6B-9).
• Rear: (Page 4A-21)

Front Fork Inspection

Brake Fluid Inspection BENH17K10206027
BENH17K10206021
Refer to “Front Fork On-Vehicle Inspection” in Section
Refer to “Brake Fluid Level Check” in Section 4A (Page
2B (Page 2B-2).
4A-12).

Rear Suspension Inspection

Brake Fluid Replacement BENH17K10206028
BENH17K10206022
Refer to “Rear Suspension On-Vehicle Inspection” in
Refer to “Brake Fluid Replacement” in Section 4A (Page
Section 2C (Page 2C-3).
4A-18).

Chassis Bolt and Nut Inspection

BENH17K10206029
Check that all chassis bolts and nuts are tightened to their specified torque.

1, (a)

8, (e)

2, (b)

7, (d)

4, (b)

3, (c)
1 1 , ( i)
9, (f)

12, (g)
5, (b)
13, (h)
10, (b)

14, (f)
6, (b)

IH17K1020001-02
0B-6 Maintenance and Lubrication:

1. Steering stem head nut 9. Swingarm pivot nut (c): 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
2. Handlebar clamp bolt 10. Front footrest bolt (d): 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Steering stem lock-nut 11. Rear brake master cylinder bolt (e): 7.5 Nm (0.76 kgf-m, 5.55 lbf-ft)
4. Front fork upper clamp bolt 12. Rear brake master cylinder rod lock-nut (f): 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
5. Brake hose union bolt 13. Footrest holder bolt (g): 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
6. Front fork lower clamp bolt 14. Rear axle nut (h): 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
7. Front brake master cylinder holder bolt (a): 90 Nm (9.2 kgf-m, 66.5 lbf-ft) (i): 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
8. Brake air bleeder valve (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

2, (b)
1, (a) 7, (f)

5, (d)

2, (b)
9, (g)

10, (g)

8, (a)
2, (b)
10, (g)

5, (d)

11, (a)

3, (c)
4, (b)

2, (b)

7, (f)

6, (e)

IH17K1020002-02
 Maintenance and Lubrication: 0B-7

1. Rear shock absorber upper mounting nut 7. Brake air bleeder valve (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Brake hose union bolt 8. Rear shock absorber lower mounting nut (c): 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
3. Front axle nut 9. Cushion lever nut (d): 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
4. Front axle pinch bolt 10. Cushion rod nut (e): 39 Nm (4.0 kgf-m, 29.0 lbf-ft)
5. Brake disc bolt 11. Seat rail bolt (f): 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
6. Front brake caliper mounting bolt (a): 50 Nm (5.1 kgf-m, 37.0 lbf-ft) (g): 80 Nm (8.2 kgf-m, 59.0 lbf-ft)

Lubrication Points
BENH17K10206030
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated as follows.

NOTE
• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the
motorcycle has been operated under wet or rainy conditions.

1 5

2 6
4
IH17K1020003-02

1. Clutch lever pivot 5. Brake lever pivot : Apply silicone grease.

2. Side-stand pivot and spring hook 6. Brake pedal pivot and footrest pivot : Apply water resistant grease EP2.
3. Gearshift lever pivot and footrest pivot : Apply oil.

4. Drive chain : Apply grease.

Special Tools and Equipment

Recommended Service Material
BENH17K10208001
NOTE
Required service material(s) is also described in:
“Lubrication Points” (Page 0B-7)
0C-1 Service Data:

Service Data
General Information

Precautions
Precautions for Service Data
BENH17K10300001
NOTE
Specifications and service data are subject to change without notice.

Specifications
Specifications
BENH17K10307001

Dimensions and curb mass

Item Specification Remark
Overall length 2075 mm (81.69 in) —
Overall width 705 mm (27.76 in) —
Overall height 1145 mm (45.08 in) —
Wheelbase 1420 mm (55.91 in) —
Ground clearance 130 mm (5.12 in) —
Seat height 825 mm (32.5 in) —
GSX-R1000
200 kg (441 lbs) (Except for
California State)
GSX-R1000
(For California
State)
201 kg (443 lbs)
Curb mass GSX-R1000A
(For U.S.A. and
Canada)
GSX-R1000A
(Except for
202 kg (445 lbs)
U.S.A. and
Canada)

Engine
Item Specification Remark
Type Four-stroke, liquid-cooled, DOHC —
Number of cylinders 4 —
Bore 76.0 mm (2.992 in) —
Stroke 55.1 mm (2.169 in) —
Displacement 1000 cm3 (61.0 cu. in) —
Compression ratio 13.2 : 1 —
Fuel system Fuel injection —
Air cleaner Paper element —
Starter system Electric —
Lubrication system Wet sump —
Idle speed 1250 ± 100 r/min —
 Service Data: 0C-2

Drive train
Item Specification Remark
Clutch Mechanical, wet multi-plate type —
Transmission 6-speed constant mesh —
Gearshift pattern 1-down, 5-up —
Primary reduction ratio 1.652 (76/46) —
Low 2.562 (41/16) —
2nd 2.052 (39/19) —
3rd 1.714 (36/21) —
Gear ratios
4th 1.500 (36/24) —
5th 1.360 (34/25) —
Top 1.269 (33/26) —
Final reduction ratio 2.647 (45/17) —
Drive chain DID525HV3, 120 links —

Chassis
Item Specification Remark
Front suspension Inverted telescopic, coil spring, oil damped —
Rear suspension Swingarm, coil spring, oil damped —
Front fork stroke 120 mm (4.7 in) —
Rear wheel travel 135 mm (5.31 in) —
Steering angle 27° (right and left) —
Caster 23° 20’ —
Trail 95 mm (3.7 in) —
Turning radius 3.5 m (11.5 ft) —
Front brake Double disc —
Rear brake Single disc —
Front tire size 120/70ZR17M/C (58W), tubeless —
Rear tire size 190/55ZR17M/C (75W), tubeless —

Electrical
Item Specification Remark
Ignition type Electronic ignition (Transistorized) —
Spark plug NGK CR9EIA-9 or DENSO IU27D —
Battery 12 V 36.0 kC (10 Ah)/10 HR —
Generator Three-phase A.C. generator —
Main fuse 30 A —
Fuse 7.5/7.5/10/10/10/10/15/15 A —
ABS fuse 30 A GSX-R1000A
Headlight LED —
Position light LED If equipped
Brake light/Tail light LED —
For U.S.A.,
12 V 21 W x 4 Canada and
California State
Turn signal light Except for
U.S.A., Canada
LED
and California
State
License plate light LED —
Instrument panel light LED —
Neutral indicator light LED —
High beam indicator light LED —
Turn signal indicator light LED —
Engine coolant temperature
indicator light/Oil pressure LED —
indicator light
MIL LED —
0C-3 Service Data:

Item Specification Remark

Traction control system indicator
LED —
light
ABS indicator light LED GSX-R1000A
Immobilizer indicator light LED If equipped
Freeze indicator light LED —
Engine rpm indicator light LED —

Capacities
Item Specification Remark
Fuel tank 16.0 L (4.2 US gal, 3.5 Imp gal) —
Oil change 3100 ml (3.28 US qt, 2.73 Imp qt) —
Engine oil
With filter change 3300 ml (3.49 US qt, 2.90 Imp qt) —
Engine coolant 2.45 L (2.59 US qt, 2.16 Imp qt) —

Service Data
BENH17K10307002
Emission Control Devices
Item Specification Standard Limit
EVAP system purge control solenoid
valve power supply voltage (If Battery voltage —
equipped)
EVAP system purge control solenoid
20 °C (68 °F) 30 – 34 Ω —
valve resistance (If equipped)
PAIR control solenoid valve power
Battery voltage —
supply voltage
PAIR control solenoid valve
20 – 30 °C (68 – 86 °F) 20 – 24 Ω —
resistance

Engine Electrical Devices

Item Specification Standard Limit
AP sensor power supply voltage 4.75 – 5.25 V —
IAP sensor power supply voltage 4.75 – 5.25 V —
IAP sensor output voltage Idle speed at 1 atm. Approx. 2.7 V —
IAT sensor power supply voltage 4.5 – 5.5 V —
IAT sensor resistance 40 °C (104 °F) 1041 – 1231 Ω —
ECT sensor power supply voltage 4.5 – 5.5 V —
20 °C (68 °F) 2320 – 2590 Ω
ECT sensor resistance —
80 °C (176 °F) 310 – 326 Ω
TP sensor power supply voltage 4.5 – 5.5 V —
Closed 3.635 – 3.785 V
TP sensor 1 output voltage —
Opened Approx. 0.7 V
Closed 4.235 – 4.385 V
TP sensor 2 output voltage —
Opened Approx. 1.3 V
Idle speed 0.6 V or less
HO2 sensor output voltage —
5000 r/min 0.6 V or more
HO2 sensor heater power supply
Battery voltage —
voltage
HO2 sensor heater resistance 23 °C (73.4 °F) 11.5 – 17.5 Ω —
CKP sensor peak voltage When cranking 0.5 V or more —
CKP sensor resistance 148 – 222 Ω —
CMP sensor power supply voltage 4.5 – 5.5 V —
IMU power supply voltage Battery voltage —
TO sensor power supply voltage 4.5 – 5.5 V —
Normal 0.4 – 1.4 V
TO sensor output voltage —
Leaning 65° 3.7 – 4.4 V
TO sensor resistance 19313 – 19507 Ω —
ECM power supply voltage Battery voltage —
Accelerator position sensor power
4.5 – 5.5 V —
supply voltage
 Service Data: 0C-4

Item Specification Standard Limit

Accelerator position sensor 1 output Closed 0.54 – 0.58 V
—
voltage Opened Approx. 3.51 V
Accelerator position sensor 2 output Closed 0.75 – 1.05 V
—
voltage Opened Approx. 4.59 V
ECM resistance Approx. 120 Ω —
Combination meter resistance Approx. 120 Ω —

Engine Mechanical
Item Specification Standard Limit
For U.S.A. and Canada 17K0 —
Throttle body I.D. No. Except for U.S.A. and
17K1 —
Canada
Throttle body bore size 46 mm (1.8 in) —
Throttle cable play 2.0 – 4.0 mm (0.079 – 0.157 in) —
Idle speed When engine warmed 1250 ± 100 r/min —
Fast idle speed 1500 – 2000 r/min —
1200 – 1600 kPa 1000 kPa
Compression pressure (12.2 – 16.3 kgf/cm2, 174 – 232 (10.2 kgf/cm2,
psi) 145 psi)
200 kPa (2.0
Compression pressure difference — kgf/cm2, 29.0
psi)
35.68 – 35.73 mm 35.38 mm
Intake
(1.405 – 1.406 in) (1.393 in)
Cam height
35.68 – 35.73 mm 35.38 mm
Exhaust
(1.405 – 1.406 in) (1.393 in)
0.032 – 0.066 mm 0.150 mm
Intake
(0.0013 – 0.0025 in) (0.0059 in)
Camshaft journal oil clearance
0.032 – 0.066 mm 0.150 mm
Exhaust
(0.0013 – 0.0025 in) (0.0059 in)
24.012 – 24.025 mm
Intake
(0.9454 – 0.9458 in)
Camshaft journal holder I.D. —
24.012 – 24.025 mm
Exhaust
(0.9454 – 0.9458 in)
23.959 – 23.980 mm
Intake
(0.9433 – 0.9440 in)
Camshaft journal O.D. —
23.959 – 23.980 mm
Exhaust
(0.9433 – 0.9440 in)
0.10 mm
Camshaft runout Intake & Exhaust —
(0.004 in)
Clearance between camshaft
0.2 – 0.8 mm
sprocket and camshaft sprocket ball —
(0.008 – 0.031 in)
guide
Unevenness of the clearance
between camshaft sprocket and 0.5 mm
—
camshaft sprocket ball guide at 4 (0.019 in)
points
8.000 – 8.015 mm
Intake
(0.3150 – 0.3155 in)
Rocker arm I.D. —
8.000 – 8.015 mm
Exhaust
(0.3150 – 0.3155 in)
7.978 – 7.987 mm
Intake
(0.3141 – 0.3144 in)
Rocker arm shaft O.D. —
7.978 – 7.987 mm
Exhaust
(0.3141 – 0.3144 in)
0.07 – 0.15 mm
Intake
When engine (0.0028 – 0.0059 in)
Valve clearance —
cold 0.16 – 0.24 mm
Exhaust
(0.0063 – 0.0094 in)
0C-5 Service Data:

Item Specification Standard Limit

Intake 31.5 mm (1.24 in)
Valve diameter —
Exhaust 24 mm (0.94 in)
0.05 mm
Valve stem runout Intake & Exhaust —
(0.0019 in)
0.03 mm
Valve head radial runout Intake & Exhaust —
(0.0011 in)
0.25 mm
Valve stem deflection Intake & Exhaust —
(0.0098 in)
4.475 – 4.490 mm
Intake —
(0.1762 – 0.1767 in)
Valve stem O.D.
4.455 – 4.470 mm
Exhaust —
(0.1754 – 0.1759 in)
0.9 – 1.1 mm
Intake —
(0.036 – 0.043 in)
Valve seat width
0.9 – 1.1 mm
Exhaust —
(0.036 – 0.043 in)
4.500 – 4.512 mm
Intake —
(0.1772 – 0.1776 in)
Valve guide I.D.
4.500 – 4.512 mm
Exhaust —
(0.1772 – 0.1776 in)
0.010 – 0.037 mm
Intake —
(0.0004 – 0.0014 in)
Valve guide to valve stem clearance
0.030 – 0.057 mm
Exhaust —
(0.0012 – 0.0022 in)
35.9 mm
Inner —
(1.42 in)
Valve spring free length
38.8 mm
Outer —
(1.53 in)
When 50.2 – 57.8 N
Intake —
compressed to (5.1 – 5.9 kgf, 11.3 – 13.0 lbs)
Inner valve spring pre-load
30.50 mm 50.2 – 57.8 N
Exhaust —
(1.201 in) (5.1 – 5.9 kgf, 11.3 – 13.0 lbs)
When 117.2 – 134.8 N
Intake —
compressed to (12.0 – 13.7 kgf, 26.3 – 30.3 lbs)
Outer valve spring pre-load
34.50 mm 117.2 – 134.8 N
Exhaust —
(1.358 in) (12.0 – 13.7 kgf, 26.3 – 30.3 lbs)
0.20 mm
Cylinder head distortion —
(0.0078 in)
0.20 mm
Cylinder distortion —
(0.0078 in)
76.000 – 76.015 mm No nicks or
Cylinder bore
(2.9922 – 2.9927 in) Scratches
Measure at 8 mm (0.3 in) 75.970 – 75.985 mm 75.850 mm
Piston diameter
from the skirt end. (2.9910 – 2.9915 in) (2.9862 in)
0.025 – 0.035 mm 0.120 mm
Piston to cylinder clearance
(0.0010 – 0.0013 in) (0.0047 in)
0.180 mm
1st —
(0.0070 in)
Piston ring to groove clearance
0.150 mm
2nd —
(0.0059 in)
0.83 – 0.85 mm
(0.0327 – 0.0334 in)
1st —
1.30 – 1.32 mm
(0.0512 – 0.0519 in)
Piston ring groove width
0.81 – 0.83 mm
2nd —
(0.0319 – 0.0326 in)
1.51 – 1.53 mm
Oil —
(0.0595 – 0.0602 in)
 Service Data: 0C-6

Item Specification Standard Limit

0.76 – 0.81 mm
(0.0300 – 0.0318 in)
1st —
1.08 – 1.10 mm
Piston ring thickness
(0.0426 – 0.0433 in)
0.77 – 0.79 mm
2nd —
(0.0304 – 0.0311 in)
Approx. 7.5 mm 6.0 mm
1st
(0.3 in) (0.24 in)
Piston ring free end gap
Approx. 9 mm 7.2 mm
2nd
(0.4 in) (0.29 in)
0.06 – 0.18 mm 0.50 mm
1st
(0.0024 – 0.0070 in) (0.019 in)
Piston ring end gap
0.06 – 0.18 mm 0.50 mm
2nd
(0.0024 – 0.0070 in) (0.019 in)
16.002 – 16.008 mm 16.030 mm
Piston pin bore I.D.
(0.6300 – 0.6302 in) (0.6311 in)
15.993 – 16.000 mm 15.980 mm
Piston pin O.D.
(0.6297 – 0.6299 in) (0.6292 in)
16.018 – 16.026 mm 16.040 mm
Conrod small end I.D.
(0.6307 –0.6309 in) (0.6314 in)
0.10 – 0.20 mm 0.3 mm
Conrod big end side clearance
(0.0040 – 0.0078 in) (0.011 in)
19.95 – 20.00 mm
Conrod big end width —
(0.7855 – 0.7874 in)
38.000 – 38.016 mm
Conrod big end I.D. —
(1.4961 – 1.4966 in)
0.040 – 0.064 mm 0.080 mm
Conrod big end oil clearance
(0.0016 – 0.0025 in) (0.0031 in)
20.10 – 20.15 mm
Crank pin width —
(0.7914 – 0.7933 in)
34.976 – 35.000 mm
Crank pin O.D. —
(1.3770 – 1.3779 in)
1.476 – 1.492 mm
Crank pin bearing thickness —
(0.0582 – 0.0587 in)
34.976 – 34.994 mm
Crankshaft journal O.D. —
(1.3770 – 1.3777 in)
0.016 – 0.034 mm 0.080 mm
Crankshaft journal oil clearance
(0.0007 – 0.0013 in) (0.0031 in)
38.000 – 38.018 mm
Crankcase journal I.D. —
(1.4961 – 1.4967 in)
1.492 – 1.507 mm
Crankcase journal bearing thickness —
(0.0588 – 0.0593 in)
2.42 – 2.44 mm
Right side —
(0.0953 – 0.0960 in)
Crankshaft thrust bearing thickness
2.36 – 2.50 mm
Left side —
(0.0930 – 0.0984 in)
0.060 – 0.110 mm
Crankshaft thrust clearance —
(0.0024 – 0.0043 in)
0.05 mm
Crankshaft runout —
(0.0019 in)

Engine Lubrication System

Item Specification Standard Limit
At 60 °C (140 °F), 100 – 500 kPa
Oil pressure —
3000 r/min (1.0 – 5.1 kgf/cm2, 14.5 – 72.5 psi)
Oil change 3100 ml (3.28 US qt, 2.73 Imp qt)
Necessary amount of engine oil Oil and filter change 3300 ml (3.49 US qt, 2.90 Imp qt) —
Engine overhaul 4100 ml (4.33 US qt, 3.61 Imp qt)
0C-7 Service Data:

Cooling System
Item Specification Standard Limit
Approx. 2200 ml
Engine side
(2.32 US qt, 1.94 Imp qt)
Engine coolant —
Approx. 250 ml
Reservoir tank side
(0.26 US qt, 0.22 Imp qt)
93.3 – 122.7 kPa
Radiator cap valve opening pressure —
(1.0 – 1.3 kgf/cm2, 13.5 – 17.8 psi)
Cooling fan relay power supply
Battery voltage —
voltage
Approx. 105 °C
OFF → ON
(221 °F)
Cooling fan operating temperature —
Approx. 100 °C
ON → OFF
(212 °F)
Thermostat valve opening Approx. 82 °C
—
temperature (179.6 °F)
Thermostat valve lift 95 °C (203 °F) 8 mm (0.3 in) or more —

Fuel System
Item Specification Standard Limit
Fuel injector power supply voltage Battery voltage
Fuel injector resistance 20 °C (68 °F) 11.5 – 12.5 Ω —
FP relay power supply voltage Battery voltage —
194 ml
FP discharge amount Per 10 seconds —
(6.56 US oz, 6.83 Imp oz) or more
338 – 348 kPa
Fuel pressure (3.45 – 3.54 kgf/cm2, 49.1 – 50.4 —
psi)

Ignition System
Item Specification Standard Limit
Firing order 1243 —
Type NGK: CR9EIA-9 / DENSO: IU27D
Spark plug —
Gap 0.8 – 0.9 mm (0.032 – 0.035 in)
Spark performance At 1 atm 8 mm (0.3 in) or more —
Ignition coil primary peak voltage 80 V or more —
10 – 30 °C
Primary 1.1 – 1.9 Ω
(50 – 86 °F)
Ignition coil resistance —
10 – 30 °C
Secondary 6400 – 9600 Ω
(50 – 86 °F)
Immobilizer antenna power supply
Battery voltage —
voltage (If equipped)

Starting System
Item Specification Standard Limit
8.5 mm
Starter motor brush length 3.5 mm (0.14 in)
(0.33 in)
Starter relay resistance 3–7Ω —
ON (Side-stand retracted) 0.4 – 0.6 V
Side-stand switch voltage OFF (Side-stand on the —
1.4 V or more
ground)
 Service Data: 0C-8

Charging System
Item Specification Standard Limit
Battery leakage current 3 mA or less —
Charging At 5000 r/
Regulated voltage 14.0 – 15.5 V —
output min
Generator coil resistance 0.1 – 0.2 Ω —
When engine At 5000 r/
Generator no-load voltage 85 V (AC) or more —
cold min
Standard charging 1.2 A for 5 to 10 hours
Recharging time —
Fast charging 5 A for 1 hour
Generator Max. output At 5000 r/min Approx. 420 W —
Type designation FT12A-BS
Battery —
Capacity 12 V 36.0 kC (10Ah)/10 HR

Exhaust System
Item Specification Standard Limit
1.5 – 2.0 mm
Front EXCV lever clearance —
(0.059 – 0.078 in)
EXCVA position sensor power supply
4.5 – 5.5 V —
voltage
EXCVA position sensor output Closed 0.45 – 1.40 V
—
voltage Opened 3.60 – 4.55 V
EXCVA position sensor resistance At adjustment position Approx. 4000 Ω —

Front Suspension
Item Specification Standard Limit
Front fork inner tube O.D. 43 mm (1.7 in) —
83 mm (3.3 in) —
Front fork oil level
10 min. after adjustment 77 mm (3.0 in) —
230 mm
Front fork spring free length 235 mm (9.25 in)
(9.06 in)
538 ml
Front fork oil capacity Each leg —
(18.19 US oz, 18.93 Imp oz)
4-3/4 turns clockwise from softest
Front fork spring adjuster —
position
4 turns counterclockwise from
Rebound side
stiffest position
Front fork damping force adjuster —
4-3/4 turns counterclockwise from
Compression side
stiffest position

Rear Suspension
Item Specification Standard Limit
Rear shock absorber spring pre-set
179.1 mm (7.051 in) —
length
2-3/4 turns counterclockwise from
Rebound side —
stiffest position
Rear shock absorber damping force 1-3/4 turns counterclockwise from
Low speed
adjuster Compression stiffest position
—
side 2-3/4 turns counterclockwise from
High speed
stiffest position
0.3 mm
Swingarm pivot shaft runout —
(0.011 in)
0C-9 Service Data:

Wheels and Tires

Item Specification Standard Limit
Axial & 2.0 mm
Front —
Radial (0.08 in)
Wheel rim runout
Axial & 2.0 mm
Rear —
Radial (0.08 in)
0.25 mm
Wheel axle runout Front & Rear —
(0.010 in)
Front 120/70ZR17M/C (58W)
Tire size —
Rear 190/55ZR17M/C (75W)
Front BRIDGESTONE/RS10F E
Tire type —
Rear BRIDGESTONE/RS10R E
1.6 mm
Front —
Recommend (0.062 in)
Tire tread depth
depth 2.0 mm
Rear —
(0.078 in)
Front 250 kPa (2.50 kgf/cm2, 36 psi)
Solo riding —
Rear 290 kPa (2.90 kgf/cm2, 42 psi)
Cold inflation tire pressure
Front 250 kPa (2.50 kgf/cm2, 36 psi)
Dual riding —
Rear 290 kPa (2.90 kgf/cm2, 42 psi)
Front 17 M/C x MT 3.50
Wheel rim size —
Rear 17 M/C x MT 6.00

Drive Chain / Drive Train / Drive Shaft

Item Specification Standard Limit
Type DID525HV3 —
Drive chain
Links 120 links —
319.4 mm
Drive chain 20-pitch length —
(12.57 in)
20 – 30 mm
Drive chain slack On side-stand —
(0.79 – 1.18 in)

Brake Control System and Diagnosis

Item Specification Standard Limit
Rear brake pedal height 65 – 75 mm (2.6 – 2.9 in) —
Front Approx. 19.05 mm (0.750 in)
Master cylinder bore / piston diameter —
Rear Approx. 14.0 mm (0.551 in)

Front Brakes
Item Specification Standard Limit
4.5 mm
Front brake disc thickness 5.0 mm (0.20 in)
(0.18 in)
0.30 mm
Front brake disc runout —
(0.012 in)
Front brake caliper cylinder bore /
Approx. 32 mm (1.3 in) —
piston diameter

Rear Brakes
Item Specification Standard Limit
4.5 mm
Rear brake disc thickness 5.0 mm (0.20 in)
(0.18 in)
0.30 mm
Rear brake disc runout —
(0.012 in)
Rear brake caliper cylinder bore /
Approx. 30.23 mm (1.19 in) —
piston diameter
 Service Data: 0C-10

ABS
Item Specification Standard Limit
0.33 – 1.55 mm
Front —
Wheel speed sensor – sensor rotor (0.0130 – 0.0610 in)
clearance 0.98 – 1.70 mm
Rear —
(0.0386 – 0.0669 in)
IMU power supply voltage Battery voltage

Manual Transmission
Item Specification Standard Limit
0.5 mm
No.1 0.1 – 0.3 mm (0.004 – 0.011 in)
(0.019 in)
Gearshift fork to groove clearance
0.5 mm
No.3 0.1 – 0.3 mm (0.004 – 0.011 in)
(0.019 in)
No.1 5.0 – 5.1 mm (0.197 – 0.200 in)
Gearshift fork groove width —
No.3 5.0 – 5.1 mm (0.197 – 0.200 in)
No.1 4.8 – 4.9 mm (0.189 – 0.192 in)
Gearshift fork thickness —
No.3 4.8 – 4.9 mm (0.189 – 0.192 in)
Gearshift lever height 65 – 75 mm (2.6 – 2.9 in) —
GP sensor power supply voltage 4.5 – 5.5 V —
1st 0.525 – 0.725 V —
Neutral 1.076 – 1.256 V —
2nd 1.607 – 1.807 V —
GP sensor voltage 3rd 2.274 – 2.474 V —
4th 2.941 – 3.141 V —
5th 3.608 – 3.808 V —
6th 4.275 – 4.475 V —

Clutch
Item Specification Standard Limit
10 – 15 mm
Clutch lever play —
(0.4 – 0.6 in)
Clutch release screw 1 turn counterclockwise —
3.22 – 3.38 mm 2.92 mm
Drive plate thickness
(0.127 – 0.133 in) (0.115 in)
13.7 – 13.8 mm 13.2 mm
Drive plate claw width
(0.5394 – 0.5433 in) (0.520 in)
0.10 mm
Driven plate distortion —
(0.0039 in)
53.1 mm
Clutch spring free length 55.8 mm (2.20 in)
(2.09 in)

Steering / Handlebar
Item Specification Standard Limit
2–5N
Steering tension initial force —
(0.21 – 0.50 kgf, 0.45 – 1.12 lbf)
Steering damper solenoid valve
20 °C (68 °F) 12.5 Ω —
resistance
0C-11 Service Data:

Wiring Systems
Item Specification Standard Limit
HI 7.5 A —
Headlight
LO 7.5 A —
Ignition 10 A —
Signal 10 A —
Fuel 10 A —
Fuse size
Fan (RH) 15 A —
Fan (LH) 15 A —
Park 10 A —
Main 30 A —
ABS (If equipped) 30 A —

Lighting Systems
Item Specification Standard Limit
HI LED —
Headlight
LO LED —
Position light (If equipped) LED —
Brake light/Taillight LED —
For U.S.A., Canada and
12 V 21 W x 4 —
California State
Turn signal light
Except for U.S.A., Canada
LED —
and California State
License plate light LED —

Combination Meter / Fuel Meter / Horn

Item Specification Standard Limit
Wheel speed sensor power supply Front Battery voltage —
voltage Rear Battery voltage —
Instrument panel light LED —
Turn signal indicator light LED —
High beam indicator light LED —
Neutral indicator light LED —
Engine coolant temperature indicator
LED —
light/Oil pressure indicator light
MIL LED —
Traction control system indicator light LED —
ABS indicator light (If equipped) LED —
Immobilizer indicator light
LED —
(If equipped)
Freeze indicator light LED —
Engine rpm indicator light LED —
–20 °C (–4 °F) 13779 – 19083 Ω —
–10 °C (14 °F) 8100 – 10609 Ω —
0 °C (32 °F) 4928 – 6125 Ω —
Ambient air temperature sensor 10 °C (50 °F) 3089 – 3656 Ω —
resistance 20 °C (68 °F) 1992 – 2251 Ω —
25 °C (77 °F) 1615 – 1785 Ω —
30 °C (86 °F) 1290 – 1456 Ω —
40 °C (104 °F) 838 – 986 Ω —
 Service Data: 0C-12

Fasteners Information Fastener Strength Identification

BENH17K10307003 Most commonly used strength classes of metric
Metric Fasteners fasteners are 4T, 6.8, 7T and 8.8. Strength class is
Most of the fasteners used for this vehicle are JIS- indicated by a number or radial line(s) embossed on the
defined and ISO-defined metric fasteners. When head of each bolt. Some metric nuts have a punched
replacing any fasteners, it is most important that number, 6 or 8 on their end surfaces. Figure shows
replacement fasteners are of the correct diameter, different strength markings.
thread pitch and strength. When replacing metric fasteners, use bolts and nuts of
NOTICE the same strength class as or higher class than the
original bolts and nuts. It is also important to select
Combining male and female fasteners with replacement fasteners of the correct diameter and
different thread pitches will damage both thread pitch. Correct replacement bolts and nuts are
fasteners. available as SUZUKI spare parts.
It is important to note that, even when the Metric bolts and nuts: Strength class numbers or marks
nominal diameter (1) of the threads is the (The larger the number, the greater the strength).
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the
mating fastener.

JIS-TO-ISO main fasteners comparison table

Nominal diameter
M6 M8 M10 M12 M14
Thread pitch 1.0 1.25 1.25 1.25 1.5
JIS
Width across flats 10 12 14 17 19
Thread pitch 1.0 1.25 1.5 1.5 1.5
ISO
Width across flats 10 13 16 18 21
IE31J1030002-01

1. Nut strength identification

IE31J1030001-01

Standard Tightening Torques

Each fastener should be tightened to the torque specified in each section. If no torque description or specification is
provided in the relevant section, refer to the following tightening torque chart for the applicable torque for each
fastener. When a fastener of greater strength than the original one is used, use the torque specified for the original
fastener.

NOTE
• For flanged bolts, flanged nuts and self-locking nuts of the 4T and 7T strength classes, add 10% to
the applicable tightening torques given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel or light alloy.
0C-13 Service Data:

Tightening torque chart

Thread diameter (Nominal diameter) (mm)
Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to Nm 1.5 3.0 5.5 13 29 45 65 105 160
4T kgf-m 0.15 0.31 0.56 1.3 3.0 4.6 6.6 10.7 16.3
lbf-ft 1.5 2.5 4.0 9.5 21.5 33.5 48.0 77.5 118.0

IE31J1030003-01
Fastener of strength class equivalent to Nm 2.4 4.7 8.4 20 42 80 125 193 280
6.8 kgf-m 0.24 0.48 0.86 2.0 4.3 8.2 12.7 19.7 28.6
lbf-ft 2.0 3.5 6.5 15.0 31.0 59.0 92.5 142.5 206.5

IE31J1030004-01
Flanged fastener of strength class Nm 2.4 4.9 8.8 21 44 84 133 203 298
equivalent to 6.8 kgf-m 0.24 0.50 0.90 2.1 4.5 8.6 13.6 20.7 30.4
*: Self-locking nut (6 strength) lbf-ft 2.0 4.0 6.5 15.5 32.5 62.0 98.5 150.0 220.0

IE31J1030005-01
Fastener of strength class equivalent to Nm 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.46 1.0 2.3 5.1 8.7 13.8 21.4 24.5
lbf-ft 2.0 3.5 7.5 17.0 37.0 63.0 99.5 155.0 177.0

IE31J1030006-01
Fastener of strength class equivalent to Nm 3.1 6.3 11 27 56 105 168 258 373
8.8 (bolt) or 8 (nut) kgf-m 0.32 0.64 1.1 2.8 5.7 10.7 17.1 26.3 38
lbf-ft 2.5 5.0 8.5 20.0 41.5 77.5 124.0 190.5 275.5

IE31J1030007-01
Flanged fastener of strength class Nm 3.2 6.5 12 29 59 113 175 270 395
equivalent to 8.8 (bolt) or 8 (nut) kgf-m 0.33 0.66 1.2 3.0 6.0 11.5 17.8 27.5 40.3
lbf-ft 2.5 5.0 9.0 21.5 43.5 83.5 129.0 199.5 291.5

IE31J1030008-01

Width across flats Thread diameter Unit

Small crown shape bolt
“b” [mm] “a” [mm] Nm kgf-m lbf-ft
7 5 4.5 0.46 3.5
8 6 10 1.0 7.5

ID26J1030004-01

*: Self-locking nut
 Service Data: 0C-14

Special Tools and Equipment

Fuel / Oil / Fluid / Coolant Recommendation Suzuki does not recommend the use of engine oils
BENH17K10308001 which have an “ENERGY CONSERVING” or
Fuel
“RESOURCE CONSERVING” indication in the API
NOTICE service symbol for any of its motorcycles / ATVs.
They can affect the engine life and the clutch
Do not use leaded gasoline. If it is used, the performance.
engine and the emission control system will
be damaged.
SERVICE SERVICE
For U.S.A. and Canada PI PI

SJ

SJ
A

A
SAE SAE
Use unleaded gasoline with an octane rating of 90 AKI or 10W-40 10W-40

EN E

NG
higher.

VI
GY

R
R
Unleaded gasoline containing up to 10% ethanol by CONSE

volume may be used. IF04K1030002-02

For other countries For U.S.A. and Canada

Use unleaded gasoline with an octane rating of 95 RON Suzuki recommends the use of SUZUKI
or higher. PERFORMANCE 4 MOTOR OIL.
Unleaded gasoline containing up to 10% ethanol by
volume may be used. (if E10 label is attached) Brake Fluid
Specification and classification: DOT 4
Engine Oil
Use engine oils which meet the following requirements. ! WARNING
Engine oil Since the brake system of this motorcycle is
API service filled with a glycol-based brake fluid by the
SG, SH, SJ or SL
classification manufacturer, do not use or mix different
JASO T903 standard MA types of fluid such as silicone-based and
Viscosity SAE 10W-40 petroleum-based fluid for refilling the
system, otherwise serious damage will
If SAE 10W-40 engine oils are not available, select oils
result.
of an appropriate viscosity grade according to the
Do not use any brake fluid taken from old or
following chart.
used or unsealed containers.
Never reuse brake fluid left over from a
previous servicing, which has been stored
for a long period.
ENGINE OIL

Engine Coolant
Suzuki recommends the use of SUZUKI LONG LIFE
COOLANT or SUZUKI SUPER LONG LIFE COOLANT.

IF04K1030001-01
Coolant 99000–99032–12X (SUZUKI LONG LIFE
COOLANT (GREEN))
Coolant 99000–99032–20X (SUZUKI SUPER LONG
LIFE COOLANT (BLUE))
If SUZUKI COOLANT is not available, use an anti-
freeze/engine coolant compatible with an aluminum
radiator, mixed with distilled water only.
0C-15 Service Data:

For SUZUKI LONG LIFE COOLANT For SUZUKI SUPER LONG LIFE COOLANT
NOTICE NOTICE
• Use a high quality ethylene glycol base • Ethanol or methanol base coolant or water
anti-freeze, mixed with distilled water. Do alone should not be used in cooling
not mix an alcohol base anti-freeze and system at any time as damage to cooling
different brands of anti-freeze. system could occur.
• Do not put in more than 60% anti-freeze or • Do not mix the distilled water, SUZUKI
less than 50%. (Refer to Fig. 1 and 2.) LONG LIFE COOLANT (coolant color:
Green) or equivalent.
The 50:50 mixture of distilled water and ethylene glycol
anti-freeze will provide the optimum corrosion protection SUZUKI SUPER LONG LIFE COOLANT will provide the
and excellent heat protection, and will protect the cooling optimum corrosion protection and excellent heat
system from freezing at temperatures above –31 °C (– protection, and will protect the cooling system from
24 °F). freezing at temperatures above –36 °C (–33 °F).
If the vehicle is to be exposed to temperatures below –
Anti-freeze concentration table
31 °C (–24 °F), this mixing ratio should be increased up
to 55% or 60% according to the figure. Anti-freeze density Freezing point
50% –36 °C (–33 °F)
Anti-freeze Proportioning Chart
Anti-freeze density Freezing point Water for mixing
50% –31 °C (–24 °F) Use distilled water only. Water other than distilled water
55% –40 °C (–40 °F) can corrode and clog the aluminum radiator.
60% –55 °C (–67 °F) For engine coolant mixture information, refer to “Engine
Coolant” (Page 0C-14).
Fig.1: Engine coolant density-freezing point curve
NOTICE
Mixing of anti-freeze/engine coolant should
be limited to 60%. Mixing beyond it would
reduce its efficiency. If the anti-freeze/engine
coolant mixing ratio is below 50%, rust
inhabiting performance is greatly reduced.
Be sure to mix it above 50% even though the
atmospheric temperature does not go down
to the freezing point.

Anti-freeze / Engine coolant

The engine coolant perform as a corrosion and rust
inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the
atmospheric temperature in your area does not go down
I310G1160001-01
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT anti-
freeze/engine coolant. If this is not available, use an
Fig.2: Engine coolant density-boiling point curve
equivalent which is compatible with an aluminum
radiator.

Front Fork Oil

Use SUZUKI FORK OIL SS-47.
Fork oil 99000–99001–47S (SUZUKI FORK OIL SS-
47)

I310G1160002-01
 Service Data: 0C-16

Special Tool
BENH17K10308002
NOTE
Torx® is the registered trademark of Camcar Division of Textron inc. U.S.A.

09900–06104 09900–06107 09900–06108 09900–18740 09900–20102

Snap ring pliers Snap ring pliers Snap ring pliers Hexagon bit socket Vernier calipers (200
(External: Bent nose) (External) (Internal) (24 mm: 1/2 sq.) mm)

09900–20202 09900–20204 09900–20530 09900–20602 09900–20605

Micrometer (25 - 50 Micrometer (75 - 100 Cylinder gauge set Dial gauge (1 x 0.001 Dial calipers (10 - 34
mm) mm) mm) mm)

09900–20607 09900–20701 09900–20803 09900–20805 09900–20806

Dial gauge (10 x 0.01 Dial gauge chuck Thickness gauge Tire depth gauge Thickness gauge
mm)

09900–21304 09900–22301 09900–22302 09900–22401 09900–22402

V blocks Plastigage (0.025 - Plastigage (0.051 - Small bore gauge (10 Small bore gauge
0.076 mm) 0.152 mm) - 18 mm) attachment (6-10mm)

B A B A

09900–22403 09900–25008 09900–25009 09904–41030 09904–41040

Small bore gauge (18 Multi circuit tester set Needle point probe set SDS-II set SDS-II (oscilloscope)
- 35 mm) set
0C-17 Service Data:

09904–41051 09910–60620 09912–66310 09913–50121 09913–70210

Conversion cable Adjustable wrench Micrometer (0 - 25 Oil seal remover Bearing installer set
mm)

09915–40620 09915–63311 09915–64512 09915–74521 09915–74540

Oil filter wrench Compression gauge Compression gauge Oil pressure gauge Oil pressure gauge
adapter set (2500 kPa) hose attachment

09915–77331 09916–10911 09916–14510 09916–14522 09916–33210

Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment Valve guide reamer
(1000 kPa) (ø4.5)

09916–33320 09916–34542 09916–51710 09916–77310 09916–84511

Valve guide outer Reamer handle Valve guide installer / Piston ring Tweezers
reamer (ø9.8) remover set compressor

09917–47011 09918–78211 09918–78220 09920–31020 09920–34830

Vacuum pump gauge Radiator cap tester kit Radiator cap tester Extension handle Starter clutch rotor
set adapter holder
 Service Data: 0C-18

09920–53740 09921–20210 09921–20240 09921–21710 09922–22712

Clutch sleeve hub Bearing remover (ø12) Bearing remover set Bearing remover Drive chain cut / rivet
holder (φ22) tool set

09923–12410 09923–74511 09924–84510 09924–84521 09925–18011

Socket (46 mm: 1/2 Bearing remover (ø20 Bearing installer set Bearing installer set Bearing installer
sq.) - 35)

09930–10121 09930–11940 09930–30104 09930–34970 09930–44530

Spark plug socket set Torx® bit holder (3/8 Rotor remover sliding Rotor remover Rotor holder
sq.) shaft

09930–82720 09930–82760 09940–14710 09940–14911 09940–14940

Mode selection switch Mode selection switch Steering stem head Steering stem nut Swingarm pivot
nut wrench socket adjuster wrench

09940–14960 09940–14990 09940–40211 09940–40220 09940–52861

Steering stem nut Engine mounting Fuel pressure gauge Fuel pressure gauge Front fork oil seal
socket wrench adjuster wrench adapter attachment installer set
0C-19 Service Data:

09940–63110 09940–84711 09941–34513 09941–53671 09943–74111

Torx® bit (E8) Rod guide case Bearing installer set Front fork cap socket Front fork oil level
wrench wrench (45 mm) gauge

09943–88211 09944–28321
Pinion bearing installer Hexagon bit socket
(19 mm : 1/2 sq.)
 Table of Contents 1- i

Section 1

Engine
CONTENTS

Precautions .................................................1-1 DTC P0351 (C24) / P0352 (C25) / P0353

Precautions............................................................. 1-1 (C26) / P0354 (C27)........................................1A-48
Precautions for Engine.......................................... 1-1 DTC P0418 (C49) .............................................1A-48
DTC P0443 (C62) [If Equipped] ........................1A-50
Engine General Information and DTC P0480 (C60) .............................................1A-52
Diagnosis ................................................. 1A-1 DTC P0500 (C16) / P2158 (C91) [Without
ABS] ................................................................1A-54
Precautions...........................................................1A-1
DTC P0500 (C16) / P2158 (C91) [With ABS]....1A-57
Precautions for DTC Trouble Shooting ............... 1A-1
DTC P0607 .......................................................1A-59
General Description .............................................1A-1 DTC P0914 / P0915 / P0916 (C31)...................1A-60
Injection Timing Description ................................ 1A-1 DTC P1400 / P1402 (C46) ................................1A-62
Electronic Throttle Control System DTC P1403 (C46) .............................................1A-65
Description ........................................................ 1A-2 DTC P1610 (C42) .............................................1A-67
Traction Control System Description................... 1A-3 DTC P1650 .......................................................1A-67
IMU Description .................................................. 1A-3 DTC P1651 .......................................................1A-67
CAN Communication System Description........... 1A-4 DTC P1700 / P1702 (C23) ................................1A-69
Engine Easy Start System Description ............... 1A-4 DTC P1750 / P1751 / P1752 (C93)...................1A-71
Self-Diagnosis Function ...................................... 1A-4 DTC P2100 (C28) .............................................1A-73
Comparison Table of DTC Name........................ 1A-8 DTC P2120 / P2125 (C14) ................................1A-75
Schematic and Routing Diagram........................1A-9 DTC P2226 / P2228 (C22) ................................1A-77
FI System Wiring Diagram .................................. 1A-9 DTC P2505 .......................................................1A-79
Component Location .........................................1A-11 Special Tools and Equipment ...........................1A-79
FI System Component Location........................ 1A-11 Special Tool ......................................................1A-79
Diagnostic Information and Procedures..........1A-12
Engine Symptom Diagnosis .............................. 1A-12 Emission Control Devices ...................... 1B-1
DTC Check ....................................................... 1A-17 Precautions...........................................................1B-1
DTC Clearance ................................................. 1A-17 Precautions for Emission Control Devices ..........1B-1
DTC Table......................................................... 1A-18 General Description .............................................1B-1
Fail-Safe Function Table ................................... 1A-21 Fuel Injection System Description.......................1B-1
FI System Troubleshooting ............................... 1A-21 Crankcase Emission Control System
DTC P0030 (C44) ............................................. 1A-24 Description ........................................................1B-2
DTC P0105 / P0107 (C17) ................................ 1A-26 Exhaust Emission Control System
DTC P0110 / P0112 (C21) ................................ 1A-28 Description ........................................................1B-3
DTC P0115 / P0117 (C15) ................................ 1A-30 Noise Emission Control System Description.......1B-5
DTC P0120 (C14) / P0220 (C29) ...................... 1A-32 PAIR System Diagram ........................................1B-6
DTC P0130 (C44) ............................................. 1A-34 Evaporative Emission Control System
DTC P0170 (C45) ............................................. 1A-36 Diagram (If Equipped) .......................................1B-7
DTC P0201 (C32) / P0202 (C33) / P0203
Schematic and Routing Diagram ........................1B-8
(C34) / P0204 (C35)........................................ 1A-38
PAIR System Hose Routing Diagram .................1B-8
DTC P0207 (C36) / P0208 (C37) / P0209
EVAP Canister Hose Routing Diagram (If
(C38) / P0210 (C39)........................................ 1A-40
Equipped)..........................................................1B-9
DTC P0231 / P0232 (C41) ................................ 1A-42
Repair Instructions ............................................1B-10
DTC P0335 (C12) ............................................. 1A-44
PAIR Reed Valve Removal and Installation......1B-10
DTC P0340 (C11) ............................................. 1A-46
PAIR Control Solenoid Valve Removal and
Installation .......................................................1B-10
1-ii Table of Contents

PAIR System Inspection ...................................1B-11 Specifications .....................................................1C-23

Crankcase Breather (PCV) Hose Inspection.....1B-12 Tightening Torque Specifications......................1C-23
Crankcase Breather (PCV) Hose / Cover Special Tools and Equipment ...........................1C-23
Removal and Installation................................. 1B-12 Recommended Service Material .......................1C-23
Crankcase Breather (PCV) Cover Inspection ... 1B-13 Special Tool ......................................................1C-23
EVAP Control System Removal and
Installation (If Equipped) ................................. 1B-13 Engine Mechanical .................................. 1D-1
EVAP Control System Inspection (If Precautions...........................................................1D-1
Equipped)........................................................ 1B-15 Precautions for Engine Mechanical.....................1D-1
Specifications.....................................................1B-17 General Description .............................................1D-1
Tightening Torque Specifications......................1B-17 VVT System Description .....................................1D-1
Special Tools and Equipment ...........................1B-17 Diagnostic Information and Procedures ............1D-2
Recommended Service Material ....................... 1B-17 Engine Mechanical Symptom Diagnosis .............1D-2
Special Tool ......................................................1B-17 Compression Pressure Check ............................1D-2
Repair Instructions ..............................................1D-4
Engine Electrical Devices ....................... 1C-1 Intake System Construction ................................1D-4
Precautions...........................................................1C-1 Air Cleaner Element Removal and Installation ....1D-5
Precautions for Engine Electrical Device ............1C-1 Air Cleaner Box Removal and Installation...........1D-6
Schematic and Routing Diagram........................1C-2 Air Cleaner Element Inspection...........................1D-7
Throttle Cable Routing Diagram..........................1C-2 Intake Pipe Removal and Installation..................1D-7
Component Location ...........................................1C-3 Cylinder Head Cover Removal and
Engine Electrical Components Location .............1C-3 Installation .........................................................1D-8
Diagnostic Information and Procedures............1C-3 Cylinder Head Cover Inspection .......................1D-11
Engine Symptom Diagnosis ................................1C-3 Cam Chain Tension Adjuster / Camshaft
Repair Instructions ..............................................1C-4 Removal ..........................................................1D-11
Throttle Body Components .................................1C-4 Cam Chain Tension Adjuster / Camshaft
Throttle Cable Play On-Vehicle Inspection Installation .......................................................1D-13
and Adjustment .................................................1C-5 Camshaft Inspection .........................................1D-18
Throttle Cable Removal and Installation .............1C-5 VVT Inspection..................................................1D-20
Throttle Body Removal and Installation ..............1C-5 Cam Chain Tension Adjuster Inspection ...........1D-21
Throttle Body Disassembly and Reassembly......1C-6 Valve Clearance Inspection and Adjustment ....1D-21
Throttle Body Inspection and Cleaning ...............1C-8 Engine Assembly Removal ...............................1D-26
Throttle Valve Synchronization ...........................1C-9 Engine Assembly Installation ............................1D-29
ISC Aperture Learned Value Reset...................1C-10 Cylinder Head Removal ....................................1D-32
ECM Removal and Installation..........................1C-10 Cylinder Head Installation .................................1D-33
AP Sensor Inspection........................................1C-11 Rocker Arm Shaft / Rocker Arm Removal and
AP Sensor Removal and Installation.................1C-12 Installation .......................................................1D-33
IAP Sensor Inspection.......................................1C-12 Rocker Arm Shaft / Rocker Arm Inspection ......1D-35
IAP Sensor Removal and Installation................1C-13 Valve / Valve Spring Removal and Installation ..1D-36
IAT Sensor Inspection.......................................1C-13 Valve Inspection................................................1D-37
IAT Sensor Removal and Installation................1C-13 Valve Seat Repair .............................................1D-39
ECT Sensor Inspection .....................................1C-14 Valve Spring Inspection ....................................1D-40
ECT Sensor Removal and Installation ..............1C-14 Cylinder Head Disassembly and Reassembly ..1D-40
TP Sensor Inspection........................................1C-14 Cylinder Head Inspection ..................................1D-42
HO2 Sensor Inspection .....................................1C-15 Valve Guide Replacement ................................1D-42
HO2 Sensor Removal and Installation ..............1C-16 Cam Chain Guide / Cam Chain Tensioner /
Long Term Fuel Trim Reset ..............................1C-16 Cam Chain / Cam Chain Drive Sprocket
CMP Sensor Inspection ....................................1C-17 Removal and Installation.................................1D-43
CMP Sensor Removal and Installation .............1C-17 Cam Chain Guide Inspection ............................1D-45
CKP Sensor Inspection .....................................1C-18 Cam Chain Tensioner Inspection......................1D-45
CKP Sensor Removal and Installation ..............1C-19 Cam Chain Drive Sprocket Inspection ..............1D-45
TO Sensor Inspection .......................................1C-19 Crankshaft / Piston / Cylinder Removal ............1D-45
TO Sensor Removal and Installation ................1C-20 Crankshaft / Piston / Cylinder Installation .........1D-49
Accelerator Position Sensor Inspection ............1C-20 Cylinder Inspection............................................1D-55
Accelerator Position Sensor Removal and Piston Ring Removal and Installation ...............1D-56
Installation .......................................................1C-20 Piston / Piston Ring Inspection .........................1D-57
Throttle Valve Motor Inspection ........................1C-22 Upper Crankcase / Lower Crankcase
IMU Inspection ..................................................1C-22 Disassembly and Reassembly ........................1D-59
IMU Removal and Installation ...........................1C-22
 Table of Contents 1-iii

Conrod Crank Pin Bearing Removal and Repair Instructions .............................................. 1F-5
Installation .......................................................1D-63 Engine Coolant Level Inspection......................... 1F-5
Conrod / Crankshaft Inspection ........................1D-63 Engine Coolant Replacement ............................. 1F-6
Conrod Crank Pin Bearing Inspection and Engine Cooling System Inspection ..................... 1F-7
Selection .........................................................1D-64 Radiator Cap Inspection...................................... 1F-7
Crankshaft Journal Bearing Inspection and Cooling Fan On-Vehicle Inspection..................... 1F-7
Selection .........................................................1D-66 Radiator Hose Inspection.................................... 1F-8
Crankshaft Thrust Clearance Inspection and Radiator / Cooling Fan Motor Removal and
Selection .........................................................1D-69 Installation ......................................................... 1F-8
Specifications.....................................................1D-71 Radiator Inspection and Cleaning ..................... 1F-10
Tightening Torque Specifications......................1D-71 Radiator Reservoir Tank Inspection.................. 1F-10
Special Tools and Equipment ...........................1D-72 Radiator Reservoir Tank Removal and
Recommended Service Material .......................1D-72 Installation ....................................................... 1F-10
Special Tool ......................................................1D-72 Water Hose Inspection...................................... 1F-11
Water Hose Removal and Installation............... 1F-11
Engine Lubrication System .................... 1E-1 Cooling Fan Relay Inspection ........................... 1F-12
Precautions........................................................... 1E-1 Thermostat Removal and Installation................ 1F-12
Precautions for Engine Oil .................................. 1E-1 Thermostat Inspection....................................... 1F-13
Water Pump Assembly Components ................ 1F-14
Schematic and Routing Diagram........................ 1E-2
Water Pump Removal and Installation.............. 1F-14
Engine Lubrication System Chart Diagram ......... 1E-2
Water Pump Disassembly and Reassembly ..... 1F-15
Diagnostic Information and Procedures............ 1E-3
Water Pump Related Parts Inspection .............. 1F-18
Engine Lubrication Symptom Diagnosis ............. 1E-3
Specifications ..................................................... 1F-19
Oil Pressure Check ............................................. 1E-3
Tightening Torque Specifications...................... 1F-19
Repair Instructions .............................................. 1E-4
Special Tools and Equipment ........................... 1F-19
Engine Oil Inspection .......................................... 1E-4
Recommended Service Material ....................... 1F-19
Engine Oil Replacement ..................................... 1E-4
Special Tool ...................................................... 1F-20
Oil Filter Replacement ........................................ 1E-5
Oil Pan / Oil Strainer / Oil Pressure Regulator
Fuel System ............................................. 1G-1
Removal and Installation................................... 1E-5
Oil Pressure Regulator / Oil Strainer Precautions.......................................................... 1G-1
Inspection.......................................................... 1E-7 Precautions for Fuel System .............................. 1G-1
Oil Cooler / Oil Cooler Hose Inspection and General Description ............................................ 1G-2
Cleaning ............................................................ 1E-7 Fuel System Description .................................... 1G-2
Oil Cooler Removal and Installation.................... 1E-8 Schematic and Routing Diagram ....................... 1G-3
Oil Pressure Switch Removal and Installation .. 1E-10 Fuel Tank Water Drain Hose and Fuel Tank
Oil Pressure Switch Inspection ......................... 1E-10 Breather Hose Routing Diagram ...................... 1G-3
Oil Jet / Piston Cooling Jet Removal and Diagnostic Information and Procedures ........... 1G-4
Installation ....................................................... 1E-11 Fuel System Diagnosis ...................................... 1G-4
Oil Jet / Piston Cooling Jet Inspection .............. 1E-12 Repair Instructions ............................................. 1G-4
Oil Pump Removal and Installation ................... 1E-12 Fuel Pressure Inspection ................................... 1G-4
Oil Pump Inspection .......................................... 1E-14 Fuel Discharge Amount Inspection .................... 1G-5
Specifications..................................................... 1E-14 Fuel Feed Hose Disconnection and
Tightening Torque Specifications...................... 1E-14 Reconnection ................................................... 1G-6
Special Tools and Equipment ........................... 1E-15 Fuel Hose Inspection ......................................... 1G-6
Recommended Service Material ....................... 1E-15 Fuel Feed Hose Removal and Installation ......... 1G-6
Special Tool ...................................................... 1E-15 Fuel Tank Construction ...................................... 1G-7
Fuel Tank Cap Removal and Installation ........... 1G-9
Engine Cooling System ...........................1F-1 Fuel Tank Removal and Installation................... 1G-9
Precautions........................................................... 1F-1 Fuel Pump Components .................................. 1G-11
Precautions for Engine Cooling System.............. 1F-1 Fuel Pump On-Vehicle Inspection.................... 1G-12
Precautions for Engine Coolant .......................... 1F-1 Fuel Pump Assembly Removal and
General Description ............................................. 1F-1 Installation ...................................................... 1G-12
Engine Coolant Description ................................ 1F-1 Fuel Pump Disassembly and Reassembly....... 1G-13
Fuel Filter Inspection........................................ 1G-15
Schematic and Routing Diagram........................ 1F-1
Fuel Level Gauge Inspection ........................... 1G-16
Cooling Circuit Diagram ...................................... 1F-1
Fuel Pump Relay Inspection ............................ 1G-16
Water Hose Routing Diagram ............................. 1F-2
Fuel Injector On-Vehicle Inspection ................. 1G-16
Diagnostic Information and Procedures............ 1F-5
Fuel Injector / Fuel Delivery Pipe Removal
Engine Cooling Symptom Diagnosis................... 1F-5
and Installation ............................................... 1G-17
1-iv Table of Contents

Fuel Injector Inspection and Cleaning.............. 1G-21 Special Tools and Equipment ............................ 1I-14
Specifications.................................................... 1G-21 Recommended Service Material ........................ 1I-14
Tightening Torque Specifications..................... 1G-21 Special Tool ....................................................... 1I-14
Special Tools and Equipment .......................... 1G-22
Recommended Service Material ...................... 1G-22 Charging System ...................................... 1J-1
Special Tool ..................................................... 1G-22 Schematic and Routing Diagram ........................ 1J-1
Charging System Diagram .................................. 1J-1
Ignition System........................................ 1H-1 Component Location ........................................... 1J-1
General Description .............................................1H-1 Charging System Components Location............. 1J-1
Immobilizer Description (If Equipped) .................1H-1 Diagnostic Information and Procedures ............ 1J-2
Schematic and Routing Diagram........................1H-2 Charging System Symptom Diagnosis................ 1J-2
Ignition System Diagram .....................................1H-2 Battery Runs Down Quickly ................................ 1J-3
Ignition System Components Location................1H-2 Repair Instructions .............................................. 1J-4
Diagnostic Information and Procedures............1H-3 Battery Current Leakage Inspection.................... 1J-4
Ignition System Symptom Diagnosis...................1H-3 Regulated Voltage Inspection ............................. 1J-4
No Spark or Poor Spark ......................................1H-4 Generator Inspection........................................... 1J-4
Repair Instructions ..............................................1H-5 Generator Removal............................................. 1J-5
Ignition Coil Removal and Installation .................1H-5 Generator Installation .......................................... 1J-6
Spark Plug Removal and Installation ..................1H-6 Regulator / Rectifier Inspection ........................... 1J-7
Spark Plug Inspection .........................................1H-7 Regulator / Rectifier Removal and Installation .... 1J-8
Ignition Coil Inspection ........................................1H-7 Battery Charging ................................................. 1J-9
Engine Stop / Starter Switch Inspection..............1H-8 Battery Removal and Installation ........................ 1J-9
Ignition Switch Inspection....................................1H-9 Battery Visual Inspection................................... 1J-10
Ignition Switch Removal and Installation.............1H-9 Specifications ..................................................... 1J-10
Specifications.....................................................1H-10 Tightening Torque Specifications...................... 1J-10
Tightening Torque Specifications......................1H-10 Special Tools and Equipment ........................... 1J-10
Special Tools and Equipment ...........................1H-11 Recommended Service Material ....................... 1J-10
Recommended Service Material .......................1H-11 Special Tool ...................................................... 1J-10
Special Tool ......................................................1H-11
Exhaust System....................................... 1K-1
Starting System ......................................... 1I-1 Precautions...........................................................1K-1
Schematic and Routing Diagram......................... 1I-1 Precautions for Exhaust System .........................1K-1
Starting System Diagram ..................................... 1I-1 General Description .............................................1K-1
Component Location ............................................ 1I-1 Exhaust Control System Description...................1K-1
Starting System Components Location................ 1I-1 Exhaust Control System Operation .....................1K-2
Diagnostic Information and Procedures............. 1I-1 Repair Instructions ..............................................1K-4
Starting System Symptom Diagnosis................... 1I-1 Exhaust Control System Construction ................1K-4
Starter Motor Will Not Run ................................... 1I-2 Exhaust System Components .............................1K-6
Starter Motor Runs But Does Not Crank the Exhaust Control System On-Vehicle
Engine ................................................................ 1I-2 Inspection..........................................................1K-7
Repair Instructions ............................................... 1I-3 EXCVA / EXCV Cable No. 1 / No. 2 Removal
Starter Relay Protector Construction ................... 1I-3 and Installation ..................................................1K-8
Starter Motor Components................................... 1I-4 EXCV Cable No. 3 Removal and Installation ....1K-13
Starter Motor Assembly Removal and EXCV Cable No. 3 On-Vehicle Adjustment.......1K-13
Installation .......................................................... 1I-4 EXCVA Inspection.............................................1K-19
Starter Motor Disassembly and Reassembly ....... 1I-5 EXCV Cable Visual Inspection ..........................1K-20
Starter Motor Inspection....................................... 1I-6 EXCVA Pulley Inspection ..................................1K-20
Starter Relay Removal and Installation................ 1I-6 EXCVA Adjustment ...........................................1K-21
Starter Relay Inspection....................................... 1I-7 EXCV Inspection ...............................................1K-23
Side-stand Relay Removal and Installation ......... 1I-7 Rear EXCV Shaft Inspection.............................1K-24
Starter Interlock System Parts Inspection ............ 1I-8 Exhaust Pipe / Muffler Removal........................1K-24
Starter Idle Gear / Starter Clutch Removal Exhaust Pipe / Muffler Installation .....................1K-26
and Installation ................................................... 1I-9 Exhaust System Inspection ...............................1K-28
Starter Clutch Inspection.................................... 1I-12 Specifications .....................................................1K-29
Engine Stop / Starter Switch Inspection............. 1I-13 Tightening Torque Specifications......................1K-29
Specifications...................................................... 1I-13 Special Tools and Equipment ...........................1K-29
Tightening Torque Specifications....................... 1I-13 Recommended Service Material .......................1K-29
Special Tool ......................................................1K-29
 Precautions: 1-1

Precautions
Engine

Precautions
Precautions for Engine
BENH17K11000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-8) and “Precautions for SDS-II” in Section 00
(Page 00-8).
1A-1 Engine General Information and Diagnosis:

Engine General Information and Diagnosis

Engine

Precautions
Precautions for DTC Trouble Shooting
BENH17K11100001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-8) and “Precautions for SDS-II” in Section 00
(Page 00-8).

NOTE
After repairing the trouble, clear the DTC using the special tool. (Page 1A-17)

General Description
Injection Timing Description
BENH17K11101001
Injection Time (Injection Volume)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the
intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are
determined according to the signals from various sensors that detect the engine and driving conditions.

ECM

Intake Air Pressure Intake air pressure

Sensor (IAP Sensor) signal
Basic
Crankshaft Position Engine speed fuel
Sensor (CKP Sensor) signal injection
time
Throttle Position
Sensor (TP Sensor) Throttle opening
Accelerator Position signal
Sensor

Various Various signals Corrective

Sensors variables

Definitive
Injection signal fuel
Injectors
injection
time

IH17K1110160-01
 Engine General Information and Diagnosis: 1A-2

Compensation of Injection Time (Volume)

The following different signals are output from the respective sensors for compensation of the fuel injection time
(volume).
Signal Descriptions
When atmospheric pressure is low, the sensor sends the signal to the ECM
AP sensor signal
and reduce the injection time (volume).
ECT sensor signal When engine coolant temperature is low, injection time (volume) is increased.
IAT sensor signal When intake air temperature is low, injection time (volume) is increased.
Air/fuel ratio is compensated to the theoretical ratio from density of oxygen in
HO2 sensor signal exhaust gasses. The compensation occurs in such a way that more fuel is
supplied if detected air/fuel ratio is lean and less fuel is supplied if it is rich.
ECM operates on the battery voltage and at the same time, it monitors the
Battery voltage signal voltage signal for compensation of the fuel injection time (volume). A longer
injection time is needed to adjust injection volume in the case of low voltage.
Engine rpm signal At high speed, the injection time (volume) is increased.
Starting signal When starting engine, additional fuel is injected during cranking engine.
During acceleration, the fuel injection time (volume) is increased, in
Acceleration signal / deceleration
accordance with the throttle opening speed and engine rpm. During
signal
deceleration, the fuel injection time (volume) is decreased.

Injection Stop Control

Signal Descriptions
When the motorcycle tips over, the TO sensor sends a signal to the ECM.
TO sensor signal Then, this signal cuts OFF current supplied to the fuel pump, fuel injectors
and ignition coils.
When actual engine speed reaches a programmed maximum, the fuel
Over-rev. limiter signal
injection pulses are suppressed.

Electronic Throttle Control System Description

BENH17K11101003
Receiving signals from the accelerator position sensor, CKP sensor, TP sensor, GP sensor and select / mode switch,
ECM in the electronic throttle control system calculates the throttle grip opening angle, engine speed, throttle valve
opening angle and gear position, and controls the throttle valve motor for optimum throttle valve opening angle
corresponding to the running conditions of the motorcycle.

Throttle grip opening angle signal

Accelerator Position Sensor

Engine speed signal

CKP Sensor

Throttle valve opening angle signal

TP Sensor

ECM
GP signal
GP Sensor

TC mode signal
Select / Mode Switch

Throttle Valve Motor

IH17K1110001-01
1A-3 Engine General Information and Diagnosis:

Traction Control System Description

BENH17K11101004
When the traction control system senses rear wheel spin (revolution difference between the front wheel and rear
wheel) during start up or acceleration, the system regulates the engine torque to restore gripping power of the rear
wheel and insure the running stability. An IMU adopted in the traction control system senses inclination of the
motorcycle and the system has realized the traction control at cornering in high accuracy.
There are 10 steps of traction control levels (from mode 1 to mode 10) and the higher figure has higher effect of the
control. If “TC OFF” is selected, the engine output is not regulated even when the rear wheel spins freely.
Receiving signals from the wheel speed sensors (front and rear), CKP sensor, accelerator position sensor, GP sensor,
IMU and select / mode switch, ECM in the traction control system calculates the wheel speed (front and rear), throttle
grip opening angle, engine speed, gear position and angle of the motorcycle inclination. Based on the calculation
result, ECM controls retard of the ignition timing and the throttle valve opening angle for optimum engine torque and
then restrains rear wheel spin. The signal from the IMU is transmitted to ECM through CAN communication.

Front wheel speed signal

Front Wheel Speed Sensor

Rear wheel speed signal

Rear Wheel Speed Sensor

Engine speed signal

CKP Sensor

Throttle grip opening angle signal

Accelerator Position Sensor

GP signal ECM
GP Sensor

IMU signal
IMU

TC mode signal
Select / Mode Switch

Ignition Coils

Throttle Valve Motor

TC indicator light

IH17K1110002-02

IMU Description
BENH17K11101005
Refer to “IMU Description” under “ABS Description” in Section 4E (Page 4E-1).
 Engine General Information and Diagnosis: 1A-4

CAN Communication System Description

BENH17K11101006
ECM (1), ABS control unit (If equipped) (2), IMU (3) and combination meter (4) are transmitted / received data through
two communication lines (CAN High (5) and CAN Low (6)) connected through CAN communication. Data obtained by
a specific control module can be shared with every control module.

1 2 3 4

5 6 5 6 5 6 5 6

IH17K1110003-01

Engine Easy Start System Description

BENH17K11101007
The engine easy start system controls the engine start by one-push of the starter switch to operate the starter motor
automatically until the engine starts.

IH17K1110004-01

Self-Diagnosis Function
BENH17K11101002
The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”.
The user can only be notified by the LCD (DISPLAY) panel and LED (MIL). To check the function of the individual FI
system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the
malfunction items.

Warning Function
The ECM warns riders to turn the MIL (1) on or blink it depending on the failure place or its content.
And the ECM turns the MIL off when detecting 3 D/C-correct continuously after detecting the first abnormality.

IH17K1110006-02
1A-5 Engine General Information and Diagnosis:

Supplementation
• The driving cycle (D/C) means the cycle beginning from turning the ignition switch ON through starting the engine
until turning the ignition switch OFF. The 3 driving cycles are the term repeating 3 times of the above mentioned
cycle.
• The warm up cycle means the cycle of engine warm up operation that the engine coolant temperature reaches
more than 71 °C (159.8 °F) and also rises more than 22.2 °C (72.0 °F) from the one at engine starting.

Diagnostic coupler location

Mode select coupler (6P) (1) is located under the rear seat. This coupler can use SDS-II tool and OBD conversion
cable.
Special tool
09904–41051

IH17K1110005-01
 Engine General Information and Diagnosis: 1A-6

User Mode
LCD (display)
Malfunction MIL indication (2) Indication mode
indication (1)
“NO” — — —
Engine can start “FI” letters *1 MIL turns ON. “FI” is indicated continuously.
“YES” MIL turns ON and
Engine can not start “FI” letters *2 “FI” is indicated continuously.
blinks.

*1
When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case,
“FI” is indicated in the LCD panel and motorcycle can run.
*2
The injection signal is stopped, when the CMP sensor signal, CKP sensor signal, TO sensor signal, #1, #2, #3 and #4
ignition signals, #1, #2, #3 and #4 fuel injector signals, FP relay signal or ignition switch signal is not sent to ECM. In
this case, “FI” is indicated in the LCD panel. Motorcycle does not run.
For Example:
The ignition switch is turned ON, and the engine stop / starter switch is turned “STOP” position. In this case, the
combination meter does not receive any signal from the ECM, and the panel indicates “CHEC”.
If “CHEC” is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness
between ECM and combination meter couplers.
The possible cause of this indication is as follows:
Engine stop / starter switch is in “STOP” position. Starter interlock system is not working. Ignition fuse is burnt.
“SD”:
The LCD panel indicates “SD” when the steering damper solenoid malfunction, battery abnormal voltage and wheel
speed sensor malfunction occurred.

NOTE
The MIL (2) turns ON about 3 seconds after turning the ignition switch ON.

1
IH17K1110007-02
1A-7 Engine General Information and Diagnosis:

Dealer Mode
The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the mode select switch.
The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not
receive signal from the devices. These affected devices are indicated in the code form.

NOTE
• Before checking the malfunction code, do not disconnect the ECM couplers.
If the couplers from the ECM is disconnected, the malfunction code memory is erased and the
malfunction code can not be checked.
• Some DTCs do not have the corresponding C codes.

Special tool
(A): 09930–82720

(A)

(A)

IH17K1110008-01 IH17K1110015-01

Malfunction LCD (display) indication MIL indication Indication mode

“NO” C00 —
C** code is indicated from small MIL turns OFF.
“YES” For each 2 sec., code is indicated.
numeral to large one.
 Engine General Information and Diagnosis: 1A-8

Comparison Table of DTC Name

BENH17K11101008
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
The comparison with the terms used in DTC name and this service manual are shown in the table below.
DTC name Term in the service manual
AP Sensor Circuit
AP Sensor
AP Sensor Circuit Low
CKP Sensor “A” Circuit CKP Sensor
CMP Sensor “A” Circuit Bank 1 or Single Sensor CMP Sensor
Control Module Performance ECM
ECT Sensor Circuit
ECT Sensor
ECT Sensor Circuit Low
EVAP System Purge Control Valve Circuit EVAP System Purge Control Solenoid Valve
EXCVA Position Sensor Circuit
EXCVA Position Sensor
EXCVA Position Sensor Circuit High
EXCVA Circuit Low EXCVA Motor
Fan 1 Control Circuit Cooling Fan
FP Secondary Circuit Low
Fuel Pump
FP Secondary Circuit High
GP Sensor Circuit
GP Sensor
GP Sensor Circuit Low
HO2 Sensor Heater Control Circuit Bank 1 Sensor 1 HO2 Sensor
IAP Sensor Circuit
IAP Sensor
IAP Sensor Circuit Low
IAT Sensor 1 Circuit
IAT Sensor
IAT Sensor 1 Circuit Low
Ignition Coil “A” Primary / Secondary Circuit Ignition Coil #1
Ignition Coil “B” Primary / Secondary Circuit Ignition Coil #2
Ignition Coil “C” Primary / Secondary Circuit Ignition Coil #3
Ignition Coil “D” Primary / Secondary Circuit Ignition Coil #4
Ignition Switch Signal Circuit Ignition Switch
Inertial Measurement Unit
IMU
Inertial Measurement Unit Lost Communication
Injector Circuit / Open – Cylinder 1 Primary Fuel Injector #1
Injector Circuit / Open – Cylinder 2 Primary Fuel Injector #2
Injector Circuit / Open – Cylinder 3 Primary Fuel Injector #3
Injector Circuit / Open – Cylinder 4 Primary Fuel Injector #4
Injector Circuit / Open – Cylinder 7 Secondary Fuel Injector #1
Injector Circuit / Open – Cylinder 8 Secondary Fuel Injector #2
Injector Circuit / Open – Cylinder 9 Secondary Fuel Injector #3
Injector Circuit / Open – Cylinder 10 Secondary Fuel Injector #4
O2 Sensor Circuit Bank 1 Sensor 1 HO2 Sensor
PAIR System Control “A” Circuit PAIR Control Solenoid Valve
Steering Damper Solenoid Circuit
Steering Damper Solenoid Circuit Low Steering Damper Solenoid Valve
Steering Damper Solenoid Circuit High
Throttle Actuator “A” Control Motor Circuit Throttle Valve Motor
TO Sensor Circuit
TO Sensor
TO Sensor Circuit High
TP Sensor / Switch “D” Circuit Accelerator Position Sensor 1
TP Sensor / Switch “E” Circuit Accelerator Position Sensor 2
TP Sensor / Switch “A” Circuit TP Sensor 1
TP Sensor / Switch “B” Circuit TP Sensor 2
Vehicle Speed Sensor “A” Front Wheel Speed Sensor
Vehicle Speed Sensor “B” Rear Wheel Speed Sensor
1A-9 Engine General Information and Diagnosis:

Schematic and Routing Diagram

FI System Wiring Diagram
BENH17K11102001

49 50
R/W

T51 R/W 51 52
O/B [A]: T76 T49
G/R
R/Y [A]: T64 T68
1 18
Gr/W
O/W T59
[B]: T53
Lg 19
2 G/W T12
T72

20
G/Bl
T11 T57 Gr/B

T71
Lg/W 21 40
3
R T23
B/Y Gr/Y 22
T26 T83

T70
Lg/B 23 41
4 G/B T24
T81 Gr/R
24

G/Y Lg/R 25
5 T25 T69 42
Y/R
53
T32
Y/B
B/Bl T40 T67
6 54
[C]: B
T16
[D]: W/Y
Dg
T41
43 55
7 26 44 57
W/Bl
T60
B T43
8 B/Br
W T47 27
T21 B
T58 58
B/R
T1
R/B
T17
9 28
Y Y
T18 T84

W/G 39 29
T42 G 45
T82 30
10 W/B G
T56 T55

T79 W/G
31
11 B/O T65 Bl
T52 56
12 Bl/Y
T50 T27
P
32 [H]
O/Bl T63 33 46
13 [I]
O/R T62 Y/G
T77
B/Y
T54
W/R T19 T34
G/W 47
[E] Gr/R T35 T33
B/G 34
T3 W/B
[F] T2 B/Bl 35 48
G
T20 T10 R/Y
14 15 T9 P/W
16 T8 Br/W
P/Bl
T4 T6 R/G 36
T7 B/Bl
B/Lg
T22
[G] T38 B/O
B/Y Bl/R
T20 T39
14 15 P/B 37
T37
W/R
T4 T36 R/W
B/Lg
Br/B T73
T15
B/G P/W 38
T31 T61
17 Br/Y [A]: T53 B/W
T48
P/W T5 T80 B/W
Y/W T75 B/W
T78

IH17K1110009-02
 Engine General Information and Diagnosis: 1A-10

[A]: With immobilizer system 9. EXCVA / EXCVA position sensor 26. Ignition coil #1 43. Engine stop switch
[B]: Without immobilizer system 10. HO2 sensor 27. Ignition coil #2 44. Side-stand relay
[C]: For E.U. and China 11. Clutch lever position switch 28. Ignition coil #3 45. Side-stand switch
[D]: Except for E.U. and China 12. Mode switch 29. Ignition coil #4 46. Neutral indicator light (LED)
[E]: To mode select coupler (6P) 13. Select switch 30. EVAP system purge control 47. Starter relay
solenoid valve (If equipped)
[F]: With ABS 14. Front wheel speed sensor 31. PAIR control solenoid valve 48. Starter motor
[G]: Without ABS 15. Rear wheel speed sensor 32. GP sensor 49. Cooling fan motor (RH)
[H]: To ECM coupler terminal “T23” 16. ABS control unit 33. Starter switch 50. Fan (RH) fuse (15 A)
[I]: To ECM coupler terminal “T47” 17. Combination meter 34. Steering damper solenoid valve 51. Cooling fan motor (LH)
1. Ignition switch/Immobilizer (If 18. Primary fuel injector #1 35. IMU 52. Fan (LH) fuse (15 A)
equipped)
2. CKP sensor 19. Secondary fuel injector #1 36. Accelerator position sensor 53. Fuel fuse (10 A)
3. CMP sensor 20. Primary fuel injector #2 37. TP sensor 54. Ignition fuse (10 A)
4. IAP sensor 21. Secondary fuel injector #2 38. Throttle valve motor 55. Ignition switch
5. AP sensor 22. Primary fuel injector #3 39. ECM 56. Signal fuse (10 A)
6. ECT sensor 23. Secondary fuel injector #3 40. Cooling fan relay 57. Main fuse (30 A)
7. IAT sensor 24. Primary fuel injector #4 41. Fuel pump 58. Battery
8. TO sensor 25. Secondary fuel injector #4 42. FP relay

Terminal Arrangement of ECM Coupler “T”

IH17K1110010-01

Terminal No. Circuit Terminal No. Circuit

T1 EXCVA power (+) T43 TO sensor signal
T2 CAN signal (Low) T44 —
T3 CAN signal (High) T45 —
T4 Front wheel speed sensor signal T46 —
T5 Speed sensor output signal T47 Sensor ground (E2)
Power source for accelerator position
T6 T48 Control circuit ground (E1)
sensor 2
T7 Accelerator position sensor 2 signal T49 Power source for throttle body
T8 Accelerator position sensor 1 ground T50 Mode switch
T9 Accelerator position sensor 1 signal T51 Power source for back-up
Power source for accelerator position
T10 T52 Clutch lever position switch
sensor 1
Ignition switch signal/Immobilizer indicator
T11 CKP sensor signal (CKP–) T53
(If equipped)
T12 CKP sensor signal (CKP+) T54 Starter motor relay
EVAP system purge control solenoid valve
T13 — T55
(If equipped)
T14 — T56 HO2 sensor heater
T15 Tachometer T57 Primary fuel injector #2
T16 Power source T58 Ignition coil #2
T17 EXCVA power (–) T59 Primary fuel injector #1
T18 EXCVA position sensor T60 Ignition coil #1
T19 Mode select switch T61 Throttle valve motor (–)
T20 Rear wheel speed sensor signal T62 Select switch (DOWN)
T21 — T63 Select switch (UP)
T22 Accelerator position sensor 2 ground T64 Immobilizer communication (If equipped)
T23 Power source for sensors T65 Neutral signal
1A-11 Engine General Information and Diagnosis:

T24 IAP sensor signal T66 —

T25 AP sensor signal T67 FP relay
T26 CMP sensor signal T68 Cooling fan relay
T27 GP sensor signal T69 Secondary fuel injector #4
T28 — T70 Secondary fuel injector #3
T29 — T71 Secondary fuel injector #2
T30 — T72 Secondary fuel injector #1
T31 Serial data for combination meter T73 Throttle valve motor (+)
T32 Power source for fuel injectors T74 —
T33 Steering damper solenoid valve (–) T75 —
T34 Steering damper solenoid valve (+) T76 Immobilizer communication (If equipped)
T35 Serial data for self-diagnosis T77 Starter switch
T36 TP sensor ground T78 General power ground (E01)
T37 TP sensor 2 signal T79 PAIR control solenoid valve
T38 Power source for TP sensor T80 Ignition system ground (E03)
T39 TP sensor 1 signal T81 Primary fuel injector #4
T40 ECT sensor signal T82 Ignition coil #4
T41 IAT sensor signal T83 Primary fuel injector #3
T42 HO2 sensor signal T84 Ignition coil #3

Component Location
FI System Component Location
BENH17K11103001

1 2
8
6
12
7
4 5 13
3
10
14 9
15

11

16
17

IH17K1110011-02

1. ECM 7. Primary fuel injectors 13. TP sensor

2. Combination meter 8. Secondary fuel injectors 14. ECT sensor
3. ABS control unit (If equipped) 9. PAIR control solenoid valve 15. Accelerator position sensor
4. FP relay 10. Throttle valve motor 16. Front wheel speed sensor
5. Cooling fan relay 11. Cooling fan motor (RH) 17. Rear wheel speed sensor
6. Fuel pump 12. IAT sensor
 Engine General Information and Diagnosis: 1A-12

14

6
7 5 3
12 2
4
11

13 8
9

10

IH17K1110012-02

1. ECM 6. AP sensor 11. EVAP system purge control solenoid valve (If equipped)
2. Cooling fan relay 7. CMP sensor 12. Ignition coil
3. TO sensor 8. GP sensor 13. Cooling fan motor (LH)
4. IMU 9. CKP sensor 14. EXCVA / EXCVA position sensor
5. IAP sensor 10. HO2 sensor

Diagnostic Information and Procedures

Engine Symptom Diagnosis
BENH17K11104001

Condition Possible cause Correction / Reference Item

Engine will not start or is Valve clearance out of adjustment. Adjust. (Page 1D-21)
hard to start Worn valve guides or poor seating of Repair or replace. (Page 1D-42)
(Compression too low) valves.
Mistimed valves. Adjust. (Page 1D-21)
Excessively worn piston rings. Replace. (Page 1D-56)
Worn-down cylinder bores. Replace.
• Removal: (Page 1D-32)
• Installation: (Page 1D-42)
Too slow starter motor cranking. Repair or replace.
• Replace: (Page 1I-4)
• Repair: (Page 1I-6)
Poor seating of spark plugs. Retighten. (Page 1H-6)
Engine will not start or is Defective spark plugs. Replace. (Page 1H-6)
hard to start (Plug not Too wide spark plug gap. Replace. (Page 1H-6)
sparking) Fouled spark plugs. Replace. (Page 1H-6)
Wet spark plugs. Dry or replace. (Page 1H-6)
Defective ignition coils. Replace. (Page 1H-5)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective ECM. Replace. (Page 1C-10)
Open-circuited wiring connections. Repair or replace. (Page 9A-5)
1A-13 Engine General Information and Diagnosis:

Condition Possible cause Correction / Reference Item

Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace.
hard to start (No fuel • Fuel filter: (Page 1G-15)
reaching the intake port)
• Fuel hose: (Page 1G-6)
Defective fuel pump. Replace. (Page 1G-12)
Defective fuel pressure regulator. Replace. (Page 1G-13)
Defective fuel injectors. Replace. (Page 1G-17)
Defective fuel pump relay. Replace. (Page 1G-16)
Defective ECM. Replace. (Page 1C-10)
Open-circuited wiring connections. Repair or replace. (Page 9A-5)
Engine will not start or is Defective fuel pump. Replace. (Page 1G-12)
hard to start (Incorrect Defective fuel pressure regulator. Replace. (Page 1G-13)
fuel/air mixture) Defective TP sensor. Replace. (Page 1C-5)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective IAP sensor. Replace. (Page 1C-13)
Defective ECM. Replace. (Page 1C-10)
Defective ECT sensor. Replace. (Page 1C-14)
Defective IAT sensor. Replace. (Page 1C-13)
Defective throttle valve motor. Replace. (Page 1C-5)
Engine idles poorly Valve clearance out of adjustment. Adjust. (Page 1D-21)
Poor seating of valves. Repair. (Page 1D-39)
Defective valve guides. Replace. (Page 1D-42)
Worn down camshafts and/or camshafts Replace.
surface. • Removal: (Page 1D-11)
• Installation: (Page 1D-13)
Too wide spark plug gaps. Replace. (Page 1H-6)
Defective ignition coils. Replace. (Page 1H-5)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective ECM. Replace. (Page 1C-10)
Defective TP sensor. Replace. (Page 1C-5)
Defective fuel pump. Replace. (Page 1G-12)
Imbalanced throttle valve. Adjust. (Page 1C-9)
Damaged or cracked vacuum hose. Replace.
Defective throttle valve motor Replace. (Page 1C-5)
Dirty throttle body. Clean. (Page 1C-8)
Throttle valve system incorrect leaning. Reset learned value. (Page 1C-10)
Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Page 1C-12)
(Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. (Page 1G-15)
Defective fuel pump. Replace. (Page 1G-12)
Defective fuel pressure regulator. Replace. (Page 1G-13)
Defective ECT sensor. Replace. (Page 1C-14)
Defective thermostat. Replace. (Page 1F-12)
Defective IAT sensor. Replace. (Page 1C-13)
Damaged or cracked vacuum hose. Replace.
Defective throttle valve motor Replace. (Page 1C-5)
Engine stalls often (Fuel Defective fuel injectors. Replace. (Page 1G-17)
injector improperly No injection signal from ECM. Repair or replace. (Page 1A-38)
operating) Open or short circuited wiring Repair or replace. (Page 9A-5)
connection.
Defective battery or low battery voltage. Replace or recharge. (Page 1J-9)
 Engine General Information and Diagnosis: 1A-14

Condition Possible cause Correction / Reference Item

Engine stalls often Defective ECM. Replace. (Page 1C-10)
(Control circuit or sensor Defective fuel pressure regulator. Replace. (Page 1G-13)
improperly operating) Defective TP sensor. Replace. (Page 1C-5)
Defective IAT sensor. Replace. (Page 1C-13)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective CMP sensor. Replace. (Page 1C-17)
Defective ECT sensor. Replace. (Page 1C-14)
Defective fuel pump relay. Replace. (Page 1G-16)
Defective throttle valve motor. Replace. (Page 1C-5)
Throttle valve system incorrect learning. Reset learned value. (Page 1C-10)
Engine stalls often Fouled spark plugs. Replace. (Page 1H-6)
(Engine internal parts Defective CKP sensor. Replace.
improperly operating) • Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective ECM. Replace. (Page 1C-10)
Clogged fuel hose. Clean or replace. (Page 1G-6)
Valve clearance out of adjustment. Adjust. (Page 1D-21)
Dirty throttle body. Clean. (Page 1C-8)
Noisy engine (Excessive Too large valve clearance. Adjust. (Page 1D-21)
valve chatter) Weakened or broken valve springs. Replace. (Page 1D-36)
Worn rocker arm or cam surface. Replace.
• Camshaft:
– Removal: (Page 1D-11)
– Installation: (Page 1D-13)
• Rocker arm: (Page 1D-33)
Worn or burnt camshaft journals. Replace.
• Removal: (Page 1D-11)
• Installation: (Page 1D-13)
Noisy engine (Noise Worn down pistons. Replace.
seems to come from • Removal: (Page 1D-45)
piston)
• Installation: (Page 1D-49)
Worn down cylinders. Replace.
• Removal: (Page 1D-45)
• Installation: (Page 1D-49)
Combustion chamber fouled with Clean. (Page 1D-42)
carbon.
Worn piston pins or piston pin bores. Replace.
• Removal: (Page 1D-45)
• Installation: (Page 1D-49)
Worn piston rings or ring grooves. Replace. (Page 1D-56)
Noisy engine (Noise Stretched cam chain. Replace. (Page 1D-43)
seems to come from cam Worn sprockets. Replace.
chain) • Camshaft sprocket:
– Removal: (Page 1D-11)
– Installation: (Page 1D-13)
• Cam chain drive sprocket: (Page 1D-43)
Cam chain tension adjuster not working. Repair or replace. (Page 1D-21)
Noisy engine (Noise Rattling bearing due to wear. Replace. (Page 1D-59)
seems to come from Worn or burnt conrod crank pin Replace. (Page 1D-63)
crankshaft) bearings.
Worn or burnt journal bearings. Replace. (Page 1D-59)
1A-15 Engine General Information and Diagnosis:

Condition Possible cause Correction / Reference Item

Noisy engine (Noise Too much play on pump shaft bearings. Replace. (Page 1F-15)
seems to come from Worn or damaged impeller shaft. Replace. (Page 1F-15)
water pump) Worn or damaged mechanical seal. Replace. (Page 1F-15)
Contact between pump case and Replace. (Page 1F-15)
impeller.
Engine runs poorly in Weakened valve springs. Replace. (Page 1D-36)
high speed range Worn camshafts. Replace.
(Defective engine internal/ • Removal: (Page 1D-11)
electrical parts)
• Installation: (Page 1D-13)
Valve timing out of adjustment. Adjust. (Page 1D-21)
Too narrow spark plug gaps. Replace. (Page 1H-6)
Ignition not advanced sufficiently due to Replace ECM. (Page 1C-10)
poorly working timing advance circuit.
Defective ignition coils. Replace. (Page 1H-5)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective ECM. Replace. (Page 1C-10)
Clogged air cleaner element. Replace. (Page 1D-5)
Clogged fuel hose, resulting in Clean and prime.
inadequate fuel supply to injector.
Defective fuel pump. Replace. (Page 1G-12)
Defective TP sensor. Replace. (Page 1C-5)
Defective accelerator position sensor. Replace. (Page 1C-20)
Defective throttle valve motor. Replace. (Page 1C-5)
Engine runs poorly in Clogged air cleaner element. Replace. (Page 1D-5)
high speed range Defective throttle valve motor. Replace. (Page 1C-5)
(Defective air flow Sucking air from throttle body joint or Retighten or replace.
system) intake pipe joint. • Throttle body joint: (Page 1D-6)
• Intake pipe joint: (Page 1D-7)
Defective ECM. Replace. (Page 1C-10)
Unbalancing throttle valve Adjust. (Page 1C-9)
synchronization.
Defective accelerator position sensor. Replace. (Page 1C-20)
Engine runs poorly in Low fuel pressure. Repair or replace.
high speed range • Fuel feed hose: (Page 1G-6)
(Defective control circuit
• Fuel pump: (Page 1G-13)
or sensor)
Defective TP sensor. Replace. (Page 1C-5)
Defective IAT sensor. Replace. (Page 1C-13)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective CMP sensor. Replace. (Page 1C-17)
Defective IAP sensor. Replace. (Page 1C-13)
Defective ECM. Replace. (Page 1C-10)
Defective accelerator position sensor. Replace. (Page 1C-20)
Defective throttle valve motor. Replace. (Page 1C-5)
 Engine General Information and Diagnosis: 1A-16

Condition Possible cause Correction / Reference Item

Engine lacks power Loss of valve clearance. Adjust. (Page 1D-21)
(Defective engine internal/ Weakened valve springs. Replace. (Page 1D-36)
electrical parts) Valve timing out of adjustment. Adjust. (Page 1D-21)
Worn piston rings or cylinders. Replace.
• Piston ring: (Page 1D-56)
• Cylinder:
– Remove: (Page 1D-45)
– Installation: (Page 1D-49)
Poor seating of valves. Repair. (Page 1D-39)
Fouled spark plugs. Replace. (Page 1H-6)
Incorrect spark plugs. Replace. (Page 1H-6)
Clogged fuel injectors. Clean or replace. (Page 1G-21)
Clogged air cleaner element. Replace. (Page 1D-5)
Sucking air from throttle body joint or Retighten or replace.
intake pipe joint. • Throttle body joint: (Page 1D-6)
• Intake pipe joint: (Page 1D-7)
Too much engine oil. Drain out excess oil.
Defective fuel pump. Replace. (Page 1G-12)
Defective ECM. Replace. (Page 1C-10)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective ignition coils. Replace. (Page 1H-5)
Defective accelerator position sensor. Replace. (Page 1C-20)
Defective throttle valve motor. Replace. (Page 1C-5)
Engine lacks power Low fuel pressure. Repair or replace.
(Defective control circuit • Fuel feed hose: (Page 1G-6)
or sensor)
• Fuel pump: (Page 1G-13)
Defective TP sensor. Replace. (Page 1C-5)
Defective IAT sensor. Replace. (Page 1C-13)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective IAP sensor. Replace. (Page 1C-13)
Defective ECM. Replace. (Page 1C-10)
Defective accelerator position sensor. Replace. (Page 1C-20)
Defective throttle valve motor. Replace. (Page 1C-5)
Engine overheats Heavy carbon deposit on piston crown. Clean.
(Defective engine internal Not enough oil in the engine. Add oil. (Page 1E-4)
parts) Defective oil pump or clogged oil circuit. Replace or clean. (Page 1E-12)
Sucking air from throttle body joint or Retighten or replace.
intake pipe joint. • Throttle body joint: (Page 1D-6)
• Intake pipe joint: (Page 1D-7)
Use of incorrect engine oil. Replace. (Page 1E-4)
Defective cooling system. Refer to “Engine Cooling Symptom Diagnosis”
in Section 1F (Page 1F-5).
Engine overheats (Lean Short-circuited IAP sensors/lead wire. Repair or replace. (Page 1C-13)
fuel/air mixture) Short-circuited IAT sensor/lead wire. Repair or replace. (Page 1C-13)
Sucking air from throttle body joint or Repair or replace.
intake pipe joint. • Throttle body joint: (Page 1D-6)
• Intake pipe joint: (Page 1D-7)
Defective fuel injectors. Replace. (Page 1G-17)
Defective ECT sensor. Replace. (Page 1C-14)
1A-17 Engine General Information and Diagnosis:

Condition Possible cause Correction / Reference Item

Engine overheats (Other Ignition timing is too advanced due to Replace.
factors) defective timing advance system (ECT
sensor, CKP sensor or ECM).
Dirty or heavy exhaust Too much engine oil. Drain out excess oil.
smoke Worn piston rings or cylinders. Replace.
• Piston ring: (Page 1D-56)
• Cylinder:
– Removal: (Page 1D-45)
– Installation: (Page 1D-49)
Worn valve guides. Replace. (Page 1D-42)
Scored or scuffed cylinder walls. Replace.
• Removal: (Page 1D-45)
• Installation: (Page 1D-49)
Worn valve stems. Replace. (Page 1D-36)
Defective stem seals. Replace. (Page 1D-36)
Worn oil ring side rails. Replace. (Page 1D-56)

DTC Check 4) Turn the special tool’s switch ON.

BENH17K11104002
NOTE
• Do not disconnect the coupler from ECM,
battery cable from battery, ECM ground
wire from engine or main fuse before
confirming DTC stored in memory. Such
disconnection will erase memorized
information in ECM memory.
• Before checking DTC, read self-diagnosis
function “User mode and dealer mode”
(Page 1A-4) carefully to have good
ID26J1110213-01
understanding as to what functions are
5) Check the DTC to determine the malfunction part.
available and how to use it.
(Page 1A-18)
• DTC can be checked by using the SDS-II.
Refer to the SDS-II operation manual for
further details.

1) Remove the rear seat. (Page 9D-19)

2) Connect the special tool to the mode select coupler
(6P) at the wiring harness.
Special tool
(A): 09930–82720

(A) IH17K1110014-01

DTC Clearance
BENH17K11104003
NOTE
The malfunction code is memorized in the
ECM also when the lead wire coupler of any
sensor is disconnected. Therefore, when a
lead wire coupler has been disconnected in
IH17K1110013-01
the diagnosis, erase the DTC.
3) Start the engine or crank the engine for more than 4
After repairing the trouble, clear the DTC using the SDS-
seconds.
II. Refer to the SDS-II operation manual for further
details.
 Engine General Information and Diagnosis: 1A-18

DTC Table
BENH17K11104004
DTC DTC name DTC detecting condition
— C00 None —
HO2 Sensor Heater Control
P0030 C44 Circuit Bank 1 Sensor 1 HO2 sensor heater drive circuit is shorted to ground or open.
(Page 1A-24)
IAP Sensor Circuit
P0105 The sensor output voltage is higher than 4.85 V.
(Page 1A-26)
C17
IAP Sensor Circuit Low
P0107 The sensor output voltage is lower than 0.50 V.
(Page 1A-26)
IAT Sensor 1 Circuit
P0110 The sensor output voltage is higher than 4.85 V.
(Page 1A-28)
C21
IAT Sensor 1 Circuit Low
P0112 The sensor output voltage is lower than 0.15 V.
(Page 1A-28)
ECT Sensor Circuit
P0115 The sensor output voltage is higher than 4.85 V.
(Page 1A-30)
C15
ECT Sensor Circuit Low
P0117 The sensor output voltage is lower than 0.15 V.
(Page 1A-30)
TP Sensor / Switch “A” Circuit
P0120 C14 TP sensor 1 output voltage is lower than 0.45 V.
(Page 1A-32)
O2 Sensor Circuit Bank 1
P0130 C44 Sensor 1 HO2 sensor is not activated.
(Page 1A-34)
Fuel Trim Bank 1
P0170 C45 The fuel trim correction is out of its threshold value.
(Page 1A-36)
Injector Circuit / Open –
Primary fuel injector #1 signal is interrupted by 4 times or more
P0201 C32 Cylinder 1
continuity although CKP signal is detected.
(Page 1A-38)
Injector Circuit / Open –
Primary fuel injector #2 signal is interrupted by 4 times or more
P0202 C33 Cylinder 2
continuity although CKP signal is detected.
(Page 1A-38)
Injector Circuit / Open –
Primary fuel injector #3 signal is interrupted by 4 times or more
P0203 C34 Cylinder 3
continuity although CKP signal is detected.
(Page 1A-38)
Injector Circuit / Open –
Primary fuel injector #4 signal is interrupted by 4 times or more
P0204 C35 Cylinder 4
continuity although CKP signal is detected.
(Page 1A-38)
Injector Circuit / Open –
Secondary fuel injector #1 signal is interrupted by 4 times or
P0207 C36 Cylinder 7
more continuity although CKP signal is detected.
(Page 1A-40)
Injector Circuit / Open –
Secondary fuel injector #2 signal is interrupted by 4 times or
P0208 C37 Cylinder 8
more continuity although CKP signal is detected.
(Page 1A-40)
Injector Circuit / Open –
Secondary fuel injector #3 signal is interrupted by 4 times or
P0209 C38 Cylinder 9
more continuity although CKP signal is detected.
(Page 1A-40)
Injector Circuit / Open –
Secondary fuel injector #4 signal is interrupted by 4 times or
P0210 C39 Cylinder 10
more continuity although CKP signal is detected.
(Page 1A-40)
TP Sensor / Switch “B” Circuit
P0220 C29 TP sensor 2 output voltage is lower than 0.45 V.
(Page 1A-32)
FP Secondary Circuit Low
P0231 No voltage is detected, although the FP relay is ON.
(Page 1A-42)
C41
FP Secondary Circuit High Voltage is applied to fuel pump even though the FP relay is
P0232
(Page 1A-42) OFF.
CKP Sensor “A” Circuit No CKP signal is detected, although the CKP signal is input to
P0335 C12
(Page 1A-44) ECM.
1A-19 Engine General Information and Diagnosis:

DTC DTC name DTC detecting condition

CMP Sensor “A” Circuit Bank 1
The signal does not reach ECM for 2 sec. or more, after
P0340 C11 or Single Sensor
receiving the starter signal.
(Page 1A-46)
Ignition Coil “A” Primary /
Ignition coil #1 signal is interrupted by 8 times or more
P0351 C24 Secondary Circuit
continuity although CKP signal is detected.
(Page 1A-48)
Ignition Coil “B” Primary /
Ignition coil #2 signal is interrupted by 8 times or more
P0352 C25 Secondary Circuit
continuity although CKP signal is detected.
(Page 1A-48)
Ignition Coil “C” Primary /
Ignition coil #3 signal is interrupted by 8 times or more
P0353 C26 Secondary Circuit
continuity although CKP signal is detected.
(Page 1A-48)
Ignition Coil “D” Primary /
Ignition coil #4 signal is interrupted by 8 times or more
P0354 C27 Secondary Circuit
continuity although CKP signal is detected.
(Page 1A-48)
PAIR System Control “A”
PAIR control solenoid valve does not operate although the
P0418 C49 Circuit
command is sent.
(Page 1A-48)
EVAP System Purge Control
EVAP system purge control solenoid valve does not operate
P0443 *1 C62 *1 Valve Circuit
although the command is sent.
(Page 1A-50)
Fan 1 Control Circuit
P0480 C60 Cooling fan relay signal is not input to ECM.
(Page 1A-52)
Vehicle Speed Sensor “A”
• Without ABS
P0500 C16 (Page 1A-54) The front wheel speed sensor signal is not input to ECM.
• With ABS
(Page 1A-57)
Control Module Performance
P0607 — Internal failure in ECM is detected.
(Page 1A-59)
GP Sensor Circuit Gear position signal voltage is higher than 4.65 V for 6 sec. or
P0914
(Page 1A-60) more continuity.
GP Sensor Circuit Range/
The sensor output voltage of each gear position is out of the
P0915 C31 Performance
specified range.
(Page 1A-60)
GP Sensor Circuit Low Gear position signal voltage is lower than 0.18 for 6 sec. or
P0916
(Page 1A-60) more continuity.
EXCVA Position Sensor Circuit
P1400 The sensor output voltage is lower than 0.14 V.
(Page 1A-62)
EXCVA Position Sensor Circuit
P1402 High The sensor output voltage is higher than 4.90 V.
C46
(Page 1A-62)
EXCVA control signal is not supplied from the ECM.
EXCVA Circuit Low Voltage
P1403 ECM does not receive communication signal from the EXCVA
(Page 1A-65)
or operation voltage does not reach EXCVA motor.
Ignition Switch Signal Circuit
P1610 C42 Ignition switch signal is not input to the ECM.
(Page 1A-67)
Inertial Measurement Unit
P1650 — ECM receives abnormal signal from IMU.
(Page 1A-67)
Inertial Measurement Unit Lost
P1651 — Communication Communication between ECM and IMU is interrupted.
(Page 1A-67)
TO Sensor Circuit
P1700 The sensor output voltage is lower than 0.20 V.
(Page 1A-69)
C23
TO Sensor Circuit High
P1702 The sensor output voltage is higher than 4.80 V.
(Page 1A-69)
 Engine General Information and Diagnosis: 1A-20

DTC DTC name DTC detecting condition

Steering Damper Solenoid
ECM detects abnormality of the steering damper solenoid
P1750 Circuit
valve.
(Page 1A-71)
Steering Damper Solenoid
Steering damper solenoid valve circuit is open or shorted to
P1751 C93 Circuit Low
ground.
(Page 1A-71)
Steering Damper Solenoid
Steering damper solenoid valve circuit wires are shorted to
P1752 Circuit High
each other or shorted to power supply.
(Page 1A-71)
Throttle Actuator “A” Control
P2100 C28 Motor Circuit ECM detects abnormality of the throttle valve motor.
(Page 1A-73)
TP Sensor / Switch “D” Circuit
P2120 ECM detects abnormality of the accelerator position sensor 1.
(Page 1A-75)
C14
TP Sensor / Switch “E” Circuit
P2125 ECM detects abnormality of the accelerator position sensor 2.
(Page 1A-75)
Vehicle Speed Sensor “B”
• Without ABS: (Page 1A-
P2158 C91 The rear wheel speed sensor signal is not input to ECM.
54)
• With ABS: (Page 1A-57)
AP Sensor Circuit
P2226 The sensor output voltage is higher than 4.85 V.
(Page 1A-77)
C22
AP Sensor Circuit Low
P2228 The sensor output voltage is lower than 0.50 V.
(Page 1A-77)
ECM Power Input Signal
P2505 — Power source for ECM is not supplied.
(Page 1A-79)

In the LCD (DISPLAY) panel, the DTC is indicated from small code to large code.
*1
If equipped.
1A-21 Engine General Information and Diagnosis:

Fail-Safe Function Table

BENH17K11104005
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum
performance necessary even under malfunction condition.
Item Fail-safe mode Starting ability Running ability
When camshaft position signal has failed
during running, the ECM determines
CMP sensor “NO” “YES”
cylinder as # before occurrence of such a
failure.
When IAP sensor is fail-safe, intake air
IAP sensor pressure value is fixed to 101.1 kPa (758 “YES” “YES”
mmHg)
Engine coolant temperature value is fixed to
ECT sensor 80 °C (176 °F). “YES” “YES”
Cooling fan is fixed on position.
Intake air temperature value is fixed to 25 °C
IAT sensor “YES” “YES”
(77 °F).
Atmospheric pressure is fixed to 101.1 kPa
AP sensor “YES” “YES”
(758 mmHg).
“YES” “YES”
#1 fuel-cut
#2, #3 & #4 cylinders can run.
“YES” “YES”
#2 fuel-cut
#1, #3 & #4 cylinders can run.
Ignition signal
“YES” “YES”
#3 fuel-cut
#1, #2 & #4 cylinders can run.
“YES” “YES”
#4 fuel-cut
#1, #2 & #3 cylinders can run.
Gear position signal is fixed the position
Gear position signal “YES” “YES”
before occurrence of failure.
Throttle valve motor ECM stops controlling throttle valve motor. “YES” “YES”
ECM stops controlling PAIR control solenoid
PAIR control solenoid valve “YES” “YES”
valve.
Cooling fan relay ECM stops controlling cooling fan relay. “YES” “YES”
EVAP system purge control ECM stops controlling EVAP system purge
“YES” “YES”
solenoid valve (If equipped) control solenoid valve.
Feedback compensation is inhibited.
HO2 sensor “YES” “YES”
(Air/fuel ratio is fixed to normal.)
HO2 sensor heater ECM stops controlling HO2 sensor heater. “YES” “YES”
Steering damper solenoid ECM stops controlling steering damper
“YES” “YES”
valve solenoid valve.
ECM stops controlling steering damper
Battery voltage “YES” “YES”
solenoid valve.
Front vehicle speed is fixed to 0 km/h (0
Front vehicle speed sensor “YES” “YES”
mile/h).
Rear vehicle speed is fixed to 0 km/h (0
Rear vehicle speed sensor “YES” “YES”
mile/h).

The engine can start and can run even if the signal in the table is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to
bring the motorcycle to the workshop for complete repair.
When two ignition signals or two injector signals are not received by ECM, the fail-safe circuit can not work and ignition
or injection is stopped.

FI System Troubleshooting
BENH17K11104006
Customer Complaint Analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form such as following will facilitate collecting information to the point required for proper
analysis and diagnosis.
 Engine General Information and Diagnosis: 1A-22

NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristic of each market.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN:
Date of issue: Date Reg.: Date of problem: Mileage:

MIL condition (LED)

□ Always ON / □ Sometimes ON / □ Always OFF / □ Good condition
Malfunction display/code User mode: □ No display / □ Malfunction display ( )
(LCD) Dealer mode: □ No code / □ Malfunction code ( )

PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Driveability
□ No cranking □ Hesitation on acceleration
□ No initial combustion □ Back fire / □ After fire
□ No combustion □ Lack of power
□ Poor starting at □ Surging
(□ cold / □ warm / □ always) □ Abnormal knocking
□ Other □ Engine rpm jumps briefly
□ Other

□ Poor Idling □ Engine Stall when

□ Poor fast Idle □ Immediately after start
□ Abnormal idling speed □ Throttle valve is opened
(□ High / □ Low) ( r/min) □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting ( r/min to r/min) □ Other
□ Other

□ OTHERS:

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □ Fair / □ Cloudy / □ Rain / □ Snow / □ Always / □ Other
Temperature □ Hot / □ Warm / □ Cool / □ Cold (°C / °F) / □ Always
Frequency □ Always / □ Sometimes (times / day, month) / □ Only once
□ Under certain condition
Road □ Urban / □ Suburb / □ Highway / □ Mountainous (□ Uphill / □ Downhill)
□ Tarmacadam / □ Gravel / □ Other
Motorcycle condition
Engine condition □ Cold / □ Warming up phase / □ Warmed up / □ Always / □ Other at starting
□ Immediately after start / □ Racing without load / □ Engine speed ( r/min)
Motorcycle condition During driving: □ Constant speed / □ Accelerating / □ Decelerating
□ Right hand corner / □ Left hand corner
□ At stop / □ Motorcycle speed when problem occurs ( km/h, mile/h)
□ Other:
IF04K1110009-01
1A-23 Engine General Information and Diagnosis:

Visual Inspection
Prior to diagnosis using the mode select switch or SDS-II, perform the following visual inspections. The reason for
visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of
mode select switch or SDS-II.
Inspection item Referring section
Level
Engine oil (Page 1E-4)
Leakage
Level (Page 1F-5)
Engine coolant
Leakage (Page 1F-7)
Level —
Fuel
Leakage (Page 1G-4)
Dirt
Air cleaner element (Page 1D-7)
Clogging
Battery Corrosion of terminal (Page 1J-10)
Throttle cable Play (Page 1C-5)
Disconnection —
Vacuum hoses of air intake system Looseness —
Bend —
Fuses Burning —
MIL Operation (Page 1A-4)
Each indicator light Operation (Page 9C-7)
Combination meter Operation (Page 9C-11)
Leakage of exhaust gas
Exhaust system (Page 1K-28)
Noise
Disconnection
Harness coupler (Page 00-2)
Poor contact
 Engine General Information and Diagnosis: 1A-24

DTC P0030 (C44)

BENH17K11104007
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0030 (C44): HO2 Sensor Heater Control Circuit Bank • HO2 sensor heater
1 Sensor 1 • HO2 sensor heater circuit
HO2 sensor heater drive circuit is shorted to ground or
• ECM
open.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

T47 B/Br
3 4 5
T42 W/G
W/Y
T56 W/B

W B Gr W

2
IH17K1110016-01

1. ECM 3. Ignition fuse 5. Main fuse

2. HO2 sensor 4. Ignition switch

Troubleshooting Step 2
HO2 sensor heater drive circuit check
Step 1
HO2 sensor heater power supply voltage check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers. (Page 1C-10)
2) Disconnect the HO2 sensor coupler. (Page 1C- 3) Check for proper terminal connection to the ECM
16) couplers.
3) Check for proper terminal connection to the HO2 4) If connections are OK, check the following points.
sensor coupler. • Resistance
4) If connections are OK, turn ignition switch ON. – W/B wire: less than 1 Ω
5) Measure the voltage between W/Y wire and
ground.
HO2 sensor heater power supply voltage
[Standard]: Battery voltage

T56

V
IH17K1110017-01
IE31J1110202-01
– Between W/B wire and ground: infinity
Is check result OK?

Yes Go to Step 2.

No Repair or replace the W/Y wire.

ID26J1110062-03
1A-25 Engine General Information and Diagnosis:

– Between W/B wire terminal and other Step 3

terminal at HO2 sensor coupler: infinity HO2 sensor heater resistance check
1) Turn the ignition switch OFF.
2) Measure the HO2 sensor resistance. Refer to
“HO2 Sensor Heater Resistance” under “HO2
Sensor Inspection” in Section 1C (Page 1C-15).
Is check result OK?
ID26J1110055-05 Yes Replace the ECM with a known good one,
• Voltage and inspect it again. (Page 1C-10)
– Turn the ignition switch ON. No Replace the HO2 sensor with a new one.
– W/B wire: approx. 0 V (Page 1C-16)

ID26J1110064-03

Is check result OK?

Yes Go to Step 3.

No Repair or replace the W/B wire.

 Engine General Information and Diagnosis: 1A-26

DTC P0105 / P0107 (C17)

BENH17K11104008
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0105 (C17): IAP Sensor Circuit • Vacuum passage between throttle body and IAP sensor
The sensor output voltage is higher than 4.85 V. • IAP sensor
P0107 (C17): IAP Sensor Circuit Low
• IAP sensor circuit
The sensor output voltage is lower than 0.50 V.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

B/Br T47

G/B T24

R T23

IH17K1110018-01

1. IAP sensor 2. ECM

Troubleshooting Step 2
IAP sensor ground circuit check
Step 1
IAP sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the IAP sensor coupler. (Page 1C-
13)
3) Check for proper terminal connection to the IAP
sensor coupler.
4) If connections are OK, turn the ignition switch ON. V
5) Measure the voltage between the R wire and B/Br ID26J1110028-04
wire.
Is voltage same as Step 1?
IAP sensor power supply voltage
[Standard]: 4.75 – 5.25 V Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

V
IH17K1110019-01

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
1A-27 Engine General Information and Diagnosis:

Step 3 Step 4
IAP sensor signal circuit check IAP sensor output voltage at idle speed check
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10) 2) Connect the ECM couplers and IAP sensor
3) Check for proper terminal connection to the ECM coupler.
couplers. 3) Measure the IAP sensor output voltage at idle
4) If connections are OK, check the following points. speed. Refer to “IAP Sensor Output Voltage at
Idle Speed” under “IAP Sensor Inspection” in
• Resistance
Section 1C (Page 1C-12).
– G/B wire: less than 1 Ω
Is check result OK?

Yes Go to Step 5.

No Check the vacuum hose for crack or

damage.
If vacuum hose is OK, replace the IAP
T24 sensor with a new one. (Page 1C-13)

Step 5
IAP sensor output voltage check
IH17K1110020-01
1) Turn the ignition switch OFF.
– Between G/B wire and ground: infinity
2) Remove the IAP sensor. (Page 1C-13)
3) Measure the IAP sensor output voltage. Refer to
“IAP Sensor Output Voltage” under “IAP Sensor
Inspection” in Section 1C (Page 1C-12).
Is check result OK?

Yes Replace the ECM with a known good one,

IH17K1110021-01
and inspect it again. (Page 1C-10)
– G/B wire terminal and other terminal at IAP No Replace the IAP sensor with a new one.
sensor coupler: infinity (Page 1C-13)

ID26J1110031-05

• Voltage
– Turn the ignition switch ON.
– G/B wire: approx. 0 V

IH17K1110022-01

Is check result OK?

Yes Go to Step 4.

No Repair or replace the G/B wire.

 Engine General Information and Diagnosis: 1A-28

DTC P0110 / P0112 (C21)

BENH17K11104009
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0110 (C21): IAT Sensor 1 Circuit • IAT sensor
The sensor output voltage is higher than 4.85 V. • IAT sensor circuit
P0112 (C21): IAT Sensor 1 Circuit Low
• ECM
The sensor output voltage is lower than 0.15 V.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 2

Dg T41

B/Br T47

IH17K1110023-01

1. IAT sensor 2. ECM

Troubleshooting
Step 2
IAT sensor circuit check
Step 1
IAT sensor input voltage check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers. (Page 1C-10)
2) Disconnect the IAT sensor coupler. (Page 1C- 3) Check for proper terminal connection to the ECM
13) couplers.
3) Check for proper terminal connection to the IAT 4) If connections are OK, check the following points.
sensor coupler. • Resistance
4) If connections are OK, turn the ignition switch ON. – Dg wire and B/Br wire: less than 1 Ω
5) Measure the voltage between the Dg wire and
ground.
6) If OK, measure the voltage between the Dg wire
and B/Br wire.
IAT sensor power supply voltage
[Standard]: 4.5 – 5.5 V

T41 T47
IH17K1110025-01

IH17K1110024-01

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
1A-29 Engine General Information and Diagnosis:

– Between Dg wire and ground: infinity Step 3

– Between B/Br wire and ground: infinity IAT sensor resistance check
1) Turn the ignition switch OFF.
2) Measure the IAT sensor resistance. (Page 1C-
13)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Replace the IAT sensor with a new one.

IH17K1110026-01 (Page 1C-13)
– Between Dg wire terminal and B/Br wire
terminal at IAT sensor coupler: infinity

IH17K1110027-01

• Voltage
– Turn the ignition switch ON.
– Dg wire and B/Br wire: approx. 0 V

IH17K1110028-01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Repair or replace the defective wire

harness.
 Engine General Information and Diagnosis: 1A-30

DTC P0115 / P0117 (C15)

BENH17K11104010
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0115 (C15): ECT Sensor Circuit • ECT sensor
The sensor output voltage is higher than 4.85 V. • ECT sensor circuit
P0117 (C15): ECT Sensor Circuit Low
• ECM
The sensor output voltage is lower than 0.15 V.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 2

B/Bl T40

B/Br T47

IH17K1110029-01

1. ECT sensor 2. ECM

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 3.

ECT sensor power supply voltage check
No Go to Step 2.
1) Turn the ignition switch OFF.
2) Disconnect the ECT sensor coupler. (Page 1C- Step 2
14) ECT sensor circuit check
3) Check for proper terminal connection to the ECT 1) Turn the ignition switch OFF.
sensor coupler. 2) Disconnect the ECM couplers. (Page 1C-10)
4) If connections are OK, turn the ignition switch ON. 3) Check for proper terminal connection to the ECM
5) Measure the voltage between the B/Bl wire and couplers.
ground. 4) If connections are OK, check the following points.
6) If OK, measure the voltage between the B/Bl wire • Resistance
and B/Br wire. – B/Bl wire and B/Br wire: less than 1 Ω
ECT sensor power supply voltage
[Standard]: 4.5 – 5.5 V

V
V
T40 T47
ID26J1110036-04 IH17K1110030-01
1A-31 Engine General Information and Diagnosis:

– Between B/Bl wire and ground: infinity Step 3

– Between B/Br wire and ground: infinity ECT sensor resistance check
1) Turn the ignition switch OFF.
2) Measure the ECT sensor resistance. (Page 1C-
14)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

ID26J1110038-03 No Replace the ECT sensor with a new one.

– Between B/Bl wire terminal and B/Br wire (Page 1C-14)
terminal at ECT sensor coupler: infinity

ID26J1110039-03

• Voltage
– Turn the ignition switch ON.
– B/Bl wire and B/Br wire: approx. 0 V

ID26J1110040-02

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Repair or replace the defective wire

harness.
 Engine General Information and Diagnosis: 1A-32

DTC P0120 (C14) / P0220 (C29)

BENH17K11104011
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0120 (C14): TP Sensor / Switch “A” Circuit • TP sensor 1
TP sensor 1 output voltage is lower than 0.45 V. • TP sensor 1 circuit
• ECM
P0220 (C29): TP Sensor / Switch “B” Circuit • TP sensor 2
TP sensor 2 output voltage is lower than 0.45 V. • TP sensor 2 circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

B/O T38
1
Bl/R T39

2 P/B T37

R/W T36

IH17K1110031-01

1. TP sensor 1 3. ECM
2. TP sensor 2

Troubleshooting

Step 1
TP sensor power supply circuit check
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (Page 1G-9)
3) Remove the air cleaner box. (Page 1D-6)
4) Disconnect the TP sensor coupler (1).
IH17K1110033-01

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.

Step 2
1 TP sensor ground circuit check
1) Measure the voltage between the B/O wire and
ground.

IH17K1110032-01

5) Check for proper terminal connection to the TP

sensor coupler.
6) If connections are OK, turn the ignition switch ON.
7) Measure the voltage between the B/O wire and R/
W wire.
TP sensor power supply voltage
[Standard]: 4.5 – 5.5 V
IH17K1110034-01
1A-33 Engine General Information and Diagnosis:

Is voltage same as Step 1? TP sensor 2

Yes Repair or replace the R/W wire.

No Repair or replace the B/O wire.

Step 3
TP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers. IH17K1110049-01

4) If connections are OK, check the following points. • Voltage

• Resistance – Turn the ignition switch ON.
– Bl/R (TP sensor 1) or P/B (TP sensor 2) wire: – Bl/R (TP sensor 1) or P/B (TP sensor 2) wire:
less than 1 Ω approx. 0 V

IH17K1110038-02

Is check result OK?

T37 T39
IH17K1110035-02
Yes Go to Step 4.
– Between Bl/R (TP sensor 1) or P/B (TP
sensor 2) wire and ground: infinity No Repair or replace the defective wire
harness.

Step 4
TP sensor output voltage check
1) Turn the ignition switch OFF.
2) Connect the TP sensor coupler and ECM
couplers.
3) Measure the TP sensor output voltage. (Page
1C-14)
IH17K1110036-02 Is check result OK?
– Between Bl/R (TP sensor 1) or P/B (TP
sensor 2) wire terminal and other terminal at Yes Replace the ECM with a known good one,
TP sensor coupler: infinity and inspect it again. (Page 1C-10)
TP sensor 1 No Replace the throttle body assembly with a
new one. (Page 1C-5)

IH17K1110037-01
 Engine General Information and Diagnosis: 1A-34

DTC P0130 (C44)

BENH17K11104012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0130 (C44): O2 Sensor Circuit Bank 1 Sensor 1 • HO2 sensor
HO2 sensor is not activated. • HO2 sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

T47 B/Br
3 4 5
T42 W/G
W/Y
T56 W/B

W B Gr W

2
IH17K1110016-01

1. ECM 3. Ignition fuse 5. Main fuse

2. HO2 sensor 4. Ignition switch

Troubleshooting – Between W/G wire and ground: infinity

– Between B/Br wire and ground: infinity
Step 1
HO2 sensor circuit check
1) Turn the ignition switch OFF.
2) Disconnect the HO2 sensor coupler and ECM
couplers.
• HO2 sensor: (Page 1C-16)
• ECM: (Page 1C-10) ID26J1110054-03

3) Check for proper terminal connection to the HO2 – Between W/G wire terminal and other
sensor coupler and ECM couplers. terminal at HO2 sensor coupler: infinity
4) If connections are OK, check the following points.
• Resistance
– W/G wire and B/Br wire: less than 1 Ω

ID26J1110208-01

– Between B/Br wire terminal and other

terminal at HO2 sensor coupler: infinity

T42 T47
IH17K1110040-01
ID26J1110209-01
1A-35 Engine General Information and Diagnosis:

• Voltage Step 2
– Turn the ignition switch ON. HO2 sensor output voltage check
– W/G wire and B/Br wire: approx. 0 V 1) Turn the ignition switch OFF.
2) Connect the ECM couplers and HO2 sensor
V coupler.
3) Measure the HO2 sensor output voltage. Refer to
“HO2 Sensor Output Voltage” under “HO2 Sensor
V Inspection” in Section 1C (Page 1C-15).
ID26J1110057-02
Is check result OK?
Is check result OK?
Yes Replace the ECM with a known good one,
Yes Go to Step 2. and inspect it again. (Page 1C-10)

No Repair or replace the defective wire No Replace the HO2 sensor with a new one.
harness. (Page 1C-16)
 Engine General Information and Diagnosis: 1A-36

DTC P0170 (C45)

BENH17K11104013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0170 (C45): Fuel Trim Bank 1 • Fuel system
The fuel trim correction is out of its threshold value. • Air intake system
• Exhaust system
• Emission control system
• HO2 sensor
• HO2 sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

T47 B/Br
3 4 5
T42 W/G
W/Y
T56 W/B

W B Gr W

2
IH17K1110016-01

1. ECM 3. Ignition fuse 5. Main fuse

2. HO2 sensor 4. Ignition switch

Troubleshooting
Step 2
Exhaust system and air intake system check
Step 1
Fuel system and emission control system check 1) Check exhaust system and air intake system for
clogging and leakage.
1) Check the following points related to fuel and
emission control systems. • Exhaust system: (Page 1K-28)
• Fuel pressure: (Page 1G-4) • Air intake system:
• Fuel injector circuit: Refer to “Wiring Diagram”
under “DTC P0201 (C32) / P0202 (C33) /
P0203 (C34) / P0204 (C35)” (Page 1A-38) and
“DTC P0207 (C36) / P0208 (C37) / P0209
(C38) / P0210 (C39)” (Page 1A-40).
• Fuel injector: (Page 1G-21)
• IAP sensor: (Page 1C-12)
• PAIR system: (Page 1B-11)
• EVAP control system (If equipped): (Page
1B-15)
• PCV hose: (Page 1B-12) IH17K1110041-01

Is check result OK? Is check result OK?

Yes Go to Step 2. Yes Go to Step 3.

No Repair or replace defective parts. No Repair or replace defective part.

1A-37 Engine General Information and Diagnosis:

Step 3 Step 4
HO2 sensor circuit check DTC recheck
1) Check HO2 sensor circuit. Refer to “Step 1” under 1) Replace the HO2 sensor. (Page 1C-16)
“DTC P0130 (C44)” (Page 1A-34). 2) Perform “DTC Check” (Page 1A-17) and check
Is check result OK? DTC.

Yes Go to Step 4. Is DTC P0170 (C45) still detected?

No Repair or replace defective wire harness. Yes Replace the ECM with a known good one,
and inspect it again. (Page 1C-10)

No End.
 Engine General Information and Diagnosis: 1A-38

DTC P0201 (C32) / P0202 (C33) / P0203 (C34) / P0204 (C35)

BENH17K11104014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0201 (C32): Injector Circuit / Open – Cylinder 1 • Primary fuel injector #1
Primary fuel injector #1 signal is interrupted by 4 times • Primary fuel injector #1 circuit
or more continuity although CKP signal is detected.
• ECM
P0202 (C33): Injector Circuit / Open – Cylinder 2 • Primary fuel injector #2
Primary fuel injector #2 signal is interrupted by 4 times • Primary fuel injector #2 circuit
or more continuity although CKP signal is detected.
• ECM
P0203 (C34): Injector Circuit / Open – Cylinder 3 • Primary fuel injector #3
Primary fuel injector #3 signal is interrupted by 4 times • Primary fuel injector #3 circuit
or more continuity although CKP signal is detected.
• ECM
P0204 (C35): Injector Circuit / Open – Cylinder 4 • Primary fuel injector #4
Primary fuel injector #4 signal is interrupted by 4 times • Primary fuel injector #4 circuit
or more continuity although CKP signal is detected.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
6 7 8
Y/R
[A]
T59 Gr/W
T57 Gr/B
T83 Gr/Y
T81 Gr/R

5 4 3 2
IH17K1110042-01

[A]: To engine stop switch 3. Primary fuel injector #2 6. FP relay

1. ECM 4. Primary fuel injector #3 7. Fuel fuse
2. Primary fuel injector #1 5. Primary fuel injector #4 8. Main fuse

Troubleshooting Primary fuel injector power supply voltage

[Standard]: Battery voltage
Step 1
Primary fuel injector power supply voltage check
1) Turn the ignition switch OFF.
2) Disconnect the primary fuel injector coupler. Refer V
to “Fuel Injector On-Vehicle Inspection” in Section
1G (Page 1G-16).
IF04K1110023-01
3) Check for proper terminal connection to the
primary fuel injector coupler. Is check result OK?
4) If connections are OK, turn the ignition switch ON. Yes Go to Step 2.
5) Measure the voltage between Y/R wire and
ground. No Repair or replace the Y/R wire.

NOTE
Primary fuel injector power supply voltage
can be detected only for 3 seconds after
ignition switch is turned ON.
1A-39 Engine General Information and Diagnosis:

Step 2 • Voltage
Primary fuel injector drive circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – Gr/W (#1), Gr/B (#2), Gr/Y (#3) or Gr/R (#4)
wire: approx. 0 V
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points. V
• Resistance
– Gr/W (#1), Gr/B (#2), Gr/Y (#3) or Gr/R (#4) IF04K1110027-01
wire: less than 1 Ω
Is check result OK?

Yes Go to Step 3.

No Repair or replace the defective wire

harness.

Step 3
Primary fuel injector resistance check
T57 T59
1) Turn the ignition switch OFF.
2) Measure the primary fuel injector resistance.
(Page 1G-16)
T81 T83
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)
IH17K1110043-01

– Between Gr/W (#1), Gr/B (#2), Gr/Y (#3) or No Replace the primary fuel injector with a
Gr/R (#4) wire and ground: infinity new one. (Page 1G-17)

IF04K1110025-01

– Between Gr/W (#1), Gr/B (#2), Gr/Y (#3) or

Gr/R (#4) wire terminal and Y/R wire terminal
at primary fuel injector coupler: infinity

IF04K1110026-01
 Engine General Information and Diagnosis: 1A-40

DTC P0207 (C36) / P0208 (C37) / P0209 (C38) / P0210 (C39)

BENH17K11104015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0207 (C36): Injector Circuit / Open – Cylinder 7 • Secondary fuel injector #1
Secondary fuel injector #1 signal is interrupted by 4 • Secondary fuel injector #1 circuit
times or more continuity although CKP signal is
• ECM
detected.
P0208 (C37): Injector Circuit / Open – Cylinder 8 • Secondary fuel injector #2
Secondary fuel injector #2 signal is interrupted by 4 • Secondary fuel injector #2 circuit
times or more continuity although CKP signal is
• ECM
detected.
P0209 (C38): Injector Circuit / Open – Cylinder 9 • Secondary fuel injector #3
Secondary fuel injector #3 signal is interrupted by 4 • Secondary fuel injector #3 circuit
times or more continuity although CKP signal is
• ECM
detected.
P0210 (C39): Injector Circuit / Open – Cylinder 10 • Secondary fuel injector #4
Secondary fuel injector #4 signal is interrupted by 4 • Secondary fuel injector #4 circuit
times or more continuity although CKP signal is
• ECM
detected.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
6 7 8
Y/R
[A]
T72 Lg
T71 Lg/W
T70 Lg/B
T69 Lg/R

5 4 3 2
IH17K1110044-01

[A]: To engine stop switch 3. Secondary fuel injector #2 6. FP relay

1. ECM 4. Secondary fuel injector #3 7. Fuel fuse
2. Secondary fuel injector #1 5. Secondary fuel injector #4 8. Main fuse

Troubleshooting NOTE
Secondary fuel injector power supply voltage
Step 1
can be detected only for 3 seconds after
Secondary fuel injector power supply voltage
ignition switch is turned ON.
check
1) Turn the ignition switch OFF. Secondary fuel injector power supply voltage
2) Disconnect the secondary fuel injector coupler. [Standard]: Battery voltage
Refer to “Fuel Injector On-Vehicle Inspection” in
Section 1G (Page 1G-16).
3) Check for proper terminal connection to the
secondary fuel injector coupler. V
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between Y/R wire and IF04K1110029-01
ground.
Is check result OK?

Yes Go to Step 2.

No Repair or replace the Y/R wire.

1A-41 Engine General Information and Diagnosis:

Step 2 • Voltage
Secondary fuel injector drive circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – Lg (#1), Lg/W (#2), Lg/B (#3) or Lg/R (#4)
wire: approx. 0 V
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points. V
• Resistance
– Lg (#1), Lg/W (#2), Lg/B (#3) or Lg/R (#4) IF04K1110033-01
wire: less than 1 Ω
Is check result OK?

Yes Go to Step 3.

No Repair or replace the defective wire

harness.

Step 3
Secondary fuel injector resistance check
T70 T72
1) Turn the ignition switch OFF.
2) Measure the secondary fuel injector resistance.
(Page 1G-16)
T69 T71
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)
IH17K1110045-01

– Between Lg (#1), Lg/W (#2), Lg/B (#3) or Lg/ No Replace the secondary fuel injector with a
R (#4) wire and ground: infinity new one. (Page 1G-17)

IF04K1110031-01

– Between Lg (#1), Lg/W (#2), Lg/B (#3) or Lg/

R (#4) wire terminal and Y/R wire terminal at
secondary fuel injector coupler: infinity

IF04K1110032-01
 Engine General Information and Diagnosis: 1A-42

DTC P0231 / P0232 (C41)

BENH17K11104017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0231 (C41): FP Secondary Circuit Low • Fuel pump relay
No voltage is detected, although the FP relay is ON. • Fuel pump relay circuit
P0232 (C41): FP Secondary Circuit High
• ECM
Voltage is applied to fuel pump even though the FP
relay is OFF.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

2 8
1
M

4 6 9

[A] 7
T32 Y/R R/W
5
T67 Y/B W/R
3
IH17K1110052-01

[A]: To side-stand switch 4. Engine stop switch 8. Fuel fuse

1. ECM 5. Side-stand relay 9. Main fuse
2. Fuel pump 6. Ignition fuse
3. FP relay 7. Ignition switch

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 2.

FP relay power supply voltage check
No Repair or replace the defective wire
1) Turn the ignition switch OFF. harness.
2) Remove the FP relay. (Page 1G-16)
3) Check for proper terminal connection to the FP Step 2
relay terminal. FP relay check
Check the FP relay. (Page 1G-16)
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between W/R wire and Is check result OK?
ground. Yes Go to Step 3.
6) If OK, measure the voltage between R/W wire and
ground. No Replace the FP relay with a new one.
(Page 1G-16)
NOTE
FP relay power supply voltage can be
detected only for 3 seconds after ignition
switch is turned ON.

FP relay power supply voltage

[Standard]: Battery voltage

IH17K1110053-01
1A-43 Engine General Information and Diagnosis:

Step 3 • Voltage
FP relay drive circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – Y/R wire and Y/B wire: approx. 0 V
2) Disconnect the fuel pump coupler and ECM
couplers.
• Fuel pump: (Page 1G-9)
• ECM: (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers. IH17K1110056-01
4) If connections are OK, check the following points.
Is check result OK?
• Resistance
– Y/R wire and Y/B wire: less than 1 Ω Yes Replace the ECM with a known good one,
and inspect it again. (Page 1C-10)

No Repair or replace the defective wire

harness.

T32 T67

IH17K1110054-02

– Between Y/R wire and ground: infinity

– Between Y/B wire and ground: infinity

IH17K1110055-01
 Engine General Information and Diagnosis: 1A-44

DTC P0335 (C12)

BENH17K11104018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0335 (C12): CKP Sensor “A” Circuit • Metal particles or foreign material being stuck on the
No CKP signal is detected, although the CKP signal is CKP sensor and rotor tip
input to ECM. • CKP sensor
• CKP sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

R G/W T12

G G/BI T11

IH17K1110057-02

1. CKP sensor 2. ECM

Troubleshooting – Between G/W wire and ground: infinity

– Between G/Bl wire and ground: infinity
Step 1
CKP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the CKP sensor coupler and ECM
couplers.
• CKP sensor: (Page 1C-18)
• ECM: (Page 1C-10) IF04K1110046-01

3) Check for proper terminal connection to the CKP – Between the G/W wire terminal and G/Bl
sensor coupler and ECM couplers. wire terminal at CKP sensor coupler: infinity
4) If connections are OK, check the following points.
• Resistance
– G/W wire and G/Bl wire: less than 1 Ω

IF04K1110047-01

T11 T12

IH17K1110058-01
1A-45 Engine General Information and Diagnosis:

• Voltage Step 3
– Turn the ignition switch ON. CKP sensor peak voltage check
– G/W wire and G/Bl wire: approx. 0 V 1) Connect the ECM couplers.
2) Measure the CKP sensor peak voltage with the
peak volt adapter. Refer to “CKP Sensor Peak
V Voltage” under “CMP Sensor Inspection” in
Section 1C (Page 1C-17).
V Is check result OK?
IF04K1110048-01 Yes Replace the ECM with a known good one,
Is check result OK? and inspect it again. (Page 1C-10)

Yes Go to Step 2. No Go to Step 4.

No Repair or replace the defective wire Step 4

harness. CKP sensor and generator rotor check
1) Turn the ignition switch OFF.
Step 2
CKP sensor resistance check 2) Remove the generator cover. (Page 1J-5)
1) Turn the ignition switch OFF. 3) Check that end face of the CKP sensor (1) and
signal generator rotor teeth (2) are free from any
2) Measure the CKP sensor resistance. Refer to
metal particles and damage.
“CKP Sensor Resistance” under “CMP Sensor
Inspection” in Section 1C (Page 1C-17).
Is check result OK? 2

Yes Go to Step 3.

No Replace the CKP sensor with a new one. 1

(Page 1C-19)

IH17K1110059-01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Clean or replace defective parts.

 Engine General Information and Diagnosis: 1A-46

DTC P0340 (C11)

BENH17K11104032
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0340 (C11): CMP Sensor “A” Circuit Bank 1 or Single Sensor • Metal particles or foreign material being stuck
The signal does not reach ECM for 2 sec. or more, after receiving on the CMP sensor and intake camshaft dent
the starter signal. • CMP sensor
• CMP sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 2

Bl R T23

W B/Y T26

B B/Br T47

IH17K1110060-01

1. CMP sensor 2. ECM

Troubleshooting Step 2
CMP sensor ground circuit check
Step 1
CMP sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the CMP sensor coupler. (Page 1C-
17)
3) Check for proper terminal connection to the CMP
sensor coupler.
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the R wire and B/Br V
wire.
CMP sensor power supply voltage IH17K1110062-01
[Standard]: 4.5 – 5.5 V
Is voltage same as Step 1?

Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

V
IH17K1110061-01

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
1A-47 Engine General Information and Diagnosis:

Step 3 Is check result OK?

CMP sensor signal circuit check Yes Go to Step 4.
1) Turn the ignition switch OFF.
No Repair or replace the B/Y wire.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM Step 4
couplers. CMP sensor check
4) If connections are OK, check the following points. 1) Check the CMP sensor. (Page 1C-17)
• Resistance Is check result OK?
– B/Y wire: less than 1 Ω
Yes Go to Step 5.

No Replace the CMP sensor with a new one.

(Page 1C-17)

Step 5
CMP sensor and camshaft check
T26 1) Turn the ignition switch OFF.
2) Check that end face of the CMP sensor (1) and
intake camshaft (2) are free from any metal
IH17K1110063-01
particles and damage.
– Between B/Y wire and ground: infinity

1
2

IH17K1110064-01
IH17K1110067-01
– Between B/Y wire terminal and other
terminal at CMP sensor coupler: infinity Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Clean or replace defective parts.

IH17K1110065-01

• Voltage
– Turn the ignition switch ON.
– B/Y wire: approx. 0 V

IH17K1110066-01
 Engine General Information and Diagnosis: 1A-48

DTC P0351 (C24) / P0352 (C25) / P0353 (C26) / P0354 (C27)

BENH17K11104033
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0351 (C24): Ignition Coil “A” Primary / Secondary Refer to “No Spark or Poor Spark” in Section 1H (Page
Circuit 1H-4).
Ignition coil #1 signal is interrupted by 8 times or more
continuity although CKP signal is detected.
P0352 (C25): Ignition Coil “B” Primary / Secondary
Circuit
Ignition coil #2 signal is interrupted by 8 times or more
continuity although CKP signal is detected.
P0353 (C26): Ignition Coil “C” Primary / Secondary
Circuit
Ignition coil #3 signal is interrupted by 8 times or more
continuity although CKP signal is detected.
P0354 (C27): Ignition Coil “D” Primary / Secondary
Circuit
Ignition coil #4 signal is interrupted by 8 times or more
continuity although CKP signal is detected.

DTC P0418 (C49)

BENH17K11104021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0418 (C49): PAIR System Control “A” Circuit • PAIR control solenoid valve
PAIR control solenoid valve does not operate although the • PAIR control solenoid valve circuit
command is sent.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
3 4 5
[A] : B
T79 W/G
[B] : W/Y

IH17K1110068-01

[A]: For E.U. and China 2. PAIR control solenoid valve 5. Main fuse
[B]: Except for E.U. and China 3. Ignition fuse
1. ECM 4. Ignition switch
1A-49 Engine General Information and Diagnosis:

Troubleshooting – Between W/G wire and ground: infinity

Step 1
PAIR control solenoid valve power supply voltage
check
1) Turn the ignition switch OFF.
2) Disconnect the PAIR control solenoid valve IF04K1110101-01

coupler. (Page 1B-10) – Between W/G wire terminal and W/R wire
3) Check for proper terminal connection to the PAIR terminal at PAIR control solenoid valve
control solenoid valve coupler. coupler: infinity
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the B or W/Y wire
and ground.
PAIR control solenoid valve power supply
IF04K1110103-01
voltage
[Standard]: Battery voltage • Voltage
– Turn the ignition switch ON.
– W/G wire: approx. 0 V

V
V
IF04K1110099-02

Is check result OK? IF04K1110104-01

Yes Go to Step 2. Is check result OK?

No Repair or replace the B or W/Y wire. Yes Go to Step 3.

No Repair or replace the W/G wire.

Step 2
PAIR control solenoid valve driver circuit check Step 3
1) Turn the ignition switch OFF. PAIR control solenoid valve resistance check
2) Disconnect the ECM couplers. (Page 1C-10) 1) Turn the ignition switch OFF.
3) Check for proper terminal connection to the ECM 2) Measure the PAIR control solenoid valve
couplers. resistance. Refer to “PAIR Control Solenoid Valve”
4) If connections are OK, check the following points. under “PAIR System Inspection” in Section 1B
• Resistance (Page 1B-11).
– W/G wire: less than 1 Ω Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Replace the PAIR control solenoid valve

with a new one. (Page 1B-10)

T79
IH17K1110069-01
 Engine General Information and Diagnosis: 1A-50

DTC P0443 (C62) [If Equipped]

BENH17K11104022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0443 (C62): EVAP System Purge Control Valve • EVAP system purge control solenoid valve
Circuit • EVAP system purge control solenoid valve circuit
EVAP system purge control solenoid valve does not
• ECM
operate although the command is sent.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
3 4 5
[A] : B
T55 G
[B] : W/Y

G W/Y

IH17K1110070-01

[A]: For E.U. and China 2. EVAP system purge control solenoid valve 5. Main fuse
[B]: Except for E.U. and China 3. Ignition fuse
1. ECM 4. Ignition switch

Troubleshooting Step 2
EVAP system purge control solenoid valve driver
Step 1
circuit check
EVAP system purge control solenoid valve power
supply voltage check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM couplers. (Page 1C-10)
2) Disconnect the EVAP system purge control 3) Check for proper terminal connection to the ECM
solenoid valve coupler. (Page 1B-13) couplers.
3) Check for proper terminal connection to the EVAP 4) If connections are OK, check the following points.
system purge control solenoid valve coupler. • Resistance
4) If connections are OK, turn the ignition switch ON. – G wire: less than 1 Ω
5) Measure the voltage between the B or W/Y wire
and ground.
EVAP system purge control solenoid valve
power supply voltage (If equipped)
[Standard]: Battery voltage

T55

V
IH17K1110071-01

ID26J1110239-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the B or W/Y wire.

1A-51 Engine General Information and Diagnosis:

– Between G wire and ground: infinity Step 3

EVAP system purge control solenoid valve
resistance check
1) Turn the ignition switch OFF.
2) Measure the EVAP system purge control solenoid
ID26J1110241-01 valve resistance. Refer to “EVAP System Purge
– Between G wire terminal and W/R wire Control Solenoid Valve” under “EVAP Control
terminal at EVAP system purge control System Removal and Installation (If Equipped)” in
solenoid valve coupler: infinity Section 1B (Page 1B-13).
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)
ID26J1110242-01
No Replace the EVAP system purge control
• Voltage solenoid valve with a new one. (Page
– Turn the ignition switch ON. 1B-13)
– G wire: approx. 0 V

V
ID26J1110243-01

Is check result OK?

Yes Go to Step 3.

No Repair or replace the G wire.

 Engine General Information and Diagnosis: 1A-52

DTC P0480 (C60)

BENH17K11104023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0480 (C60): Fan 1 Control Circuit • Cooling fan relay
Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
2 8
5 9
T68 G/R W/Y
R

B
6
B/R

B/W B/Bl
B/W 7

B/W
B Bl B Bl

3 4

IH17K1110072-02

1. ECM 4. Cooling fan motor (LH) 7. Fan (LH) fuse

2. Cooling fan relay 5. Ignition fuse 8. Ignition switch
3. Cooling fan motor (RH) 6. Fan (RH) fuse 9. Main fuse

Troubleshooting Step 2
Cooling fan relay check
Step 1
Check the cooling fan relay. (Page 1F-12)
Cooling fan relay power supply voltage check
1) Turn the ignition switch OFF. Is check result OK?
2) Disconnect the cooling fan relay. (Page 1F-12) Yes Go to Step 3.
3) Check for proper terminal connection to the
cooling fan relay terminal. No Replace the cooling fan relay with a new
one. (Page 1F-12)
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between W/Y wire and
ground.
Cooling fan relay power supply voltage
[Standard]: Battery voltage

IH17K1110073-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the W/Y wire.

1A-53 Engine General Information and Diagnosis:

Step 3 • Voltage
Cooling fan relay drive circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – G/R wire: approx. 0 V
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points.
• Resistance
– G/R wire: less than 1 Ω IH17K1110076-01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Repair or replace the G/R wire.

T68

IH17K1110074-01

– Between G/R wire and ground: infinity

IH17K1110075-01
 Engine General Information and Diagnosis: 1A-54

DTC P0500 (C16) / P2158 (C91) [Without ABS]

BENH17K11104024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500 (C16): Vehicle Speed Sensor “A” • Front wheel speed sensor
The front wheel speed sensor signal is not input to • Front wheel speed sensor rotor
ECM.
• Front wheel speed sensor circuit
• ECM
P2158 (C91): Vehicle Speed Sensor “B” • Rear wheel speed sensor
The rear wheel speed sensor signal is not input to • Rear wheel speed sensor rotor
ECM.
• Rear wheel speed sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 5
4 6
W/Y
T4 W/R
T20 B/Y

W G W G

3 2
IH17K1110077-01

1. ECM 3. Rear wheel speed sensor 5. Ignition switch

2. Front wheel speed sensor 4. Ignition fuse 6. Main fuse

Troubleshooting 5) Measure the voltage between the W/Y wire and

ground.
Step 1
Wheel speed sensor power supply voltage check Wheel speed sensor power supply voltage
(Without ABS)
1) Turn the ignition switch OFF. Front [Standard]: Battery voltage
2) Disconnect the speed sensor coupler. Rear [Standard]: Battery voltage
• Front: (Page 4E-49)
• Rear: (Page 4E-49)
3) Check for proper terminal connection to the wheel
speed sensor coupler.
4) If connections are OK, turn the ignition switch ON.

IH17K1110078-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the W/Y wire.

1A-55 Engine General Information and Diagnosis:

Step 2 – Between W/R (Front) or B/Y (Rear) wire and

Wheel speed sensor circuit check ground: infinity
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points.
• Resistance
– W/R (Front) or B/Y (Rear) wire: less than 1 Ω IH17K1110081-01

Front – Between W/R (Front) or B/Y (Rear) wire

terminal and W/Y wire terminal at wheel
speed sensor coupler: infinity

T4

IH17K1110082-01

IH17K1110079-01 • Voltage
Rear – Turn the ignition switch ON.
– W/R (Front) or B/Y (Rear) wire: approx. 0 V

T20

IH17K1110083-01

Is check result OK?

IH17K1110080-01

Yes Go to Step 3.

No Repair or replace the defective wire

harness.
 Engine General Information and Diagnosis: 1A-56

Step 3 Step 5
Wheel speed sensor – sensor rotor Speed sensor mounting check
clearance check 1) Check that the wheel speed sensor (1) is mounted
1) Turn the ignition switch OFF. securely.
2) Inspect the clearance between the wheel speed Front
sensor and sensor rotor. Refer to “Wheel Speed
Sensor – Sensor Rotor Clearance” under “Wheel
Speed Sensor and Sensor Rotor Inspection” in
Section 4E (Page 4E-50).
Is check result OK?

Yes Go to Step 4.

No Adjust the clearance. 1

Step 4
Sensor rotor visual check IH17K1110084-01
1) Inspect the wheel speed sensor rotor for damage Rear
and check that no foreign objects are caught in
the rotor openings. Refer to “Wheel Speed Sensor
Rotor” under “Wheel Speed Sensor and Sensor
Rotor Inspection” in Section 4E (Page 4E-50).
Is check result OK?

Yes Go to Step 5.

No Clean or replace the wheel speed sensor 1

rotor.
• Front: (Page 4E-49)
• Rear: (Page 4E-50) IH17K1110085-01

Is check result OK?

Yes Go to Step 6.

No Tighten the mounting bolt.

Step 6
Wheel speed sensor current check
1) Measure the wheel speed sensor current. Refer to
“Wheel Speed Sensor Current” under “Wheel
Speed Sensor and Sensor Rotor Inspection” in
Section 4E (Page 4E-50).
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Replace the wheel speed sensor with a

new one.
• Front: (Page 4E-49)
• Rear: (Page 4E-49)
1A-57 Engine General Information and Diagnosis:

DTC P0500 (C16) / P2158 (C91) [With ABS]

BENH17K11104025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0500 (C16): Vehicle Speed Sensor “A” • Front wheel speed sensor circuit
The front wheel speed sensor signal is not input to • ABS control unit
ECM.
• ECM
P2158 (C91): Vehicle Speed Sensor “B” • Rear wheel speed sensor
The rear wheel speed sensor signal is not input to • ABS control unit
ECM.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

T16 T7
1 3 4

T4 P/Bl

T20 G

IH17K1110086-01

1. ECM 3. Front wheel speed sensor

2. ABS control unit 4. Rear wheel speed sensor

Troubleshooting Step 2
Speed sensor signal circuit check (From ABS
Step 1
control unit to ECM)
ABS DTC check
1) Turn the ignition switch OFF.
1) Check that DTC is detected in ABS. (Page 4E-
18) 2) Disconnect the ABS control unit coupler and ECM
couplers.
Is the DTC detected?
• ABS control unit: (Page 4E-45)
Yes Go to troubleshooting for DTCs. Refer to • ECM: (Page 1C-10)
“DTC Table” in Section 4E (Page 4E-21). 3) Check for proper terminal connection to the ABS
No Go to Step 2. control unit coupler and ECM couplers.
 Engine General Information and Diagnosis: 1A-58

4) If connections are OK, check the following points. – P/Bl (Front), G (Rear) wire and ground:
• Resistance infinity
– P/Bl (Front), G (Rear) wire: less than 1 Ω Front
Front

16

T4

IH17K1110089-01
T4
Rear

IH17K1110087-01

Rear

T20

IH17K1110090-01

Is check result OK?

Yes Replace the ECM with a known good one,

T20 and inspect again. (Page 1C-10)

No Repair or replace the defective wire

harness.
IH17K1110088-01
1A-59 Engine General Information and Diagnosis:

DTC P0607
BENH17K11104034
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0607: Control Module Performance • ECM coupler connection
Internal failure in ECM is detected. • ECM

Troubleshooting

Step 1
ECM coupler connection check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, reconnect the ECM
couplers.
5) Perform “DTC Check” (Page 1A-17) and check
DTC.
Is DTC P0607 (C68) still detected?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No End.
 Engine General Information and Diagnosis: 1A-60

DTC P0914 / P0915 / P0916 (C31)

BENH17K11104027
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P0914 (C31): GP Sensor Circuit • GP sensor
Gear position signal voltage is higher than 4.65 V for 6 • GP sensor circuit
sec. or more continuity.
• ECM
P0915 (C31): GP Sensor Circuit Range/Performance
The sensor output voltage of each gear position is out of
the specified range.
P0916 (C31): GP Sensor Circuit Low
Gear position signal voltage is lower than 0.18 V for 6 sec.
or more continuity.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 3 8
4 9
[A]
T65 Bl
2

Bl 5
6
T27 P P
T23 R R
T47 B/Br B/W 7

IH17K1110091-02

[A]: To engine stop switch 3. Side-stand relay 6. Signal fuse 9. Main fuse
1. ECM 4. Ignition fuse 7. Side-stand switch
2. GP sensor 5. Neutral indicator light 8. Ignition switch

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 3.

GP sensor power supply voltage check
No Go to Step 2.
1) Turn the ignition switch OFF.
2) Disconnect the GP sensor coupler. (Page 5B- Step 2
15) GP sensor ground circuit check
3) Support the motorcycle with a jack. 1) Measure the voltage between the R wire and
4) Fold the side-stand to up position. ground.
5) Check for proper terminal connection to the GP
sensor coupler.
6) If connections are OK, turn the ignition switch ON.
7) Measure the voltage between the R wire and B/Br
wire.
IH17K1110092-01
GP sensor power supply voltage
Is voltage same as Step 1?
[Standard]: 4.5 – 5.5 V
Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

IH17K1110093-01
1A-61 Engine General Information and Diagnosis:

Step 3 • Voltage
GP sensor signal circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – P wire and Bl wire: approx. 0 V
2) Disconnect the ECM couplers and combination
meter coupler.
• ECM: (Page 1C-10)
• Combination meter: (Page 9C-7)
3) Check for proper terminal connection to the ECM
couplers and combination meter coupler. IH17K1110098-01
4) If connections are OK, check the following points.
Is check result OK?
• Resistance
– P wire and Bl wire: less than 1 Ω Yes Go to Step 4.

No Repair or replace the defective wire

harness.

Step 4
GP sensor voltage check
1) Turn the ignition switch OFF.
2) Connect the ECM couplers, combination meter
coupler and GP sensor coupler.
T27 T65 3) Measure the GP sensor voltage. Refer to “GP
sensor” under “Starter Interlock System Parts
Inspection” in Section 1I (Page 1I-8).
IH17K1110094-01
Is check result OK?
– Between P wire and ground: infinity
– Between Bl wire and ground: infinity Yes Replace the ECM with a known good one,
and inspect it again. (Page 1C-10)

No Replace the GP sensor with a new one.

(Page 5B-15)

IH17K1110095-01

– Between P wire terminal and other terminal

at GP sensor coupler: infinity

IH17K1110096-01

– Between Bl wire terminal and other terminal

at GP sensor coupler: infinity

IH17K1110097-01
 Engine General Information and Diagnosis: 1A-62

DTC P1400 / P1402 (C46)

BENH17K11104036
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1400 (C46): EXCVA Position Sensor Circuit • EXCVA
The sensor output voltage is lower than 0.14 V. • EXCVA maladjustment
P1402 (C46): EXCVA Position Sensor Circuit High
• EXCVA position sensor circuit
The sensor output voltage is higher than 4.90 V.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
2

Gr
P
B R T23
Y Y T18
W B/Br T47

IH17K1110099-02

1. ECM 2. EXCVA

Troubleshooting
Step 2
EXCVA position sensor ground circuit check
Step 1
EXCV position sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the EXCVA coupler. (Page 1K-8)
3) Check for proper terminal connection to the
EXCVA coupler.
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the R wire and B/Br
wire.
EXCVA position sensor power supply voltage
[Standard]: 4.5 – 5.5 V

IH17K1110101-01

Is voltage same as Step 1?

Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

IH17K1110100-01

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
1A-63 Engine General Information and Diagnosis:

Step 3 • Voltage
EXCVA position sensor signal circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – Y wire: approx. 0 V
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points.
• Resistance
– Y wire: less than 1 Ω

IH17K1110105-01

Is check result OK?

Yes Go to Step 4.

No Repair or replace the Y wire.

T18 Step 4
EXCV cable check
1) Turn the ignition switch OFF.
IH17K1110102-03
2) Remove the right side cowling. (Page 9D-21)
– Between Y wire and ground: infinity 3) Check the installation of EXCV cables. Refer to
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation” in Section 1K (Page 1K-8) and “EXCV
Cable No. 3 Removal and Installation” in Section
1K (Page 1K-13).
Rear EXCV

IH17K1110103-01

– Between Y wire terminal and other terminal

at EXCVA coupler: infinity

IH17K1110106-01

Front EXCV

IH17K1110104-01

IH17K1110161-02
 Engine General Information and Diagnosis: 1A-64

Is check result OK? Step 7

Yes Go to Step 5. EXCV cable adjusting check

No Replace or adjust the EXCV cables. NOTICE

• Replacement: • Adjusting the No.2 cable with the EXCV
– EXCVA / EXCV cable No.1 / No.2: fully opened or the No.1 cable with the
(Page 1K-8) EXCV fully closed can damage the EXCVA.
Be sure to adjust the cables with the EXCV
– EXCV cable No.3: (Page 1K-13) set in the adjustment position. (Page 1K-
• Adjustment: (Page 1K-21) 8)
• Do not turn the EXCVA pulley using the
Step 5 wrench.
EXCVA position sensor resistance check
1) Connect the ECM couplers and EXCVA coupler. 1) If the EXCVA position sensor output voltage is
2) Set the EXCVA to adjustment position. Refer to 0.45 V or less at EXCV fully closed position,
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and adjust the output voltage to the specified value by
Installation” in Section 1K (Page 1K-8). turning the No. 1 cable adjuster (1). (Page 1K-8)
3) Turn the ignition switch OFF and disconnect the 2) Repeat the procedure in Step 6 until the output
EXCVA coupler. voltage is set within the specified value. (If P1400
(C46) code is indicated after adjusting the voltage,
4) Measure the EXCVA position sensor resistance.
increase the voltage to 0.15 V).
Refer to “EXCVA Position Sensor Resistance”
under “Exhaust Control System On-Vehicle 3) If the EXCVA position sensor output voltage is
Inspection” in Section 1K (Page 1K-7). 4.55 V and more at EXCV fully opened position,
adjust the output voltage to the specified value by
Is check result OK? turning the No. 2 cable adjuster (2). Refer to
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Yes Go to Step 6.
Installation” in Section 1K (Page 1K-8). Repeat
No Replace the EXCVA with a new one. the procedure in Step 6 until the output voltage is
(Page 1K-8) set within the specified value.

Step 6
EXCVA position sensor output voltage check 2
1) Connect the EXCVA coupler. 1
2) Measure the EXCVA position sensor output
voltage. Refer to “EXCVA Position Sensor Output
Voltage” under “EXCVA Inspection” in Section 1K
(Page 1K-19).
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10) IH17K1110107-01

Is the voltage OK?

No Go to Step 7.
Yes Replace the ECM with a known good one,
and inspect it again. (Page 1C-10)

No Replace the EXCVA with a new one.

(Page 1K-8)
1A-65 Engine General Information and Diagnosis:

DTC P1403 (C46)

BENH17K11104037
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1403 (C46): EXCVA Circuit Low Voltage • EXCVA
EXCVA control signal is not supplied from the ECM. • EXCVA motor circuit
ECM does not receive communication signal from the
• ECM
EXCVA or operation voltage does not reach EXCVA
motor.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1
2

Gr B/R T1
P R/B T17
B
Y
W

IH17K1110108-01

1. ECM 2. EXCVA

Troubleshooting – Between B/R wire and ground: infinity

– Between R/B wire and ground: infinity
Step 1
EXCVA motor circuit check
1) Turn the ignition switch OFF.
2) Disconnect the EXCVA coupler and ECM
couplers.
• EXCVA: (Page 1K-8)
• ECM: (Page 1C-10)
3) Check for proper terminal connection to the
EXCVA coupler and ECM couplers.
4) If connections are OK, check the following points. IH17K1110111-01
• Resistance – Between B/R wire terminal and other
– B/R wire and R/B wire: less than 1 Ω terminal at EXCVA coupler: infinity

T1

T17

IH17K1110112-01
IH17K1110109-01
 Engine General Information and Diagnosis: 1A-66

– Between R/B wire terminal and other Rear EXCV

terminal at EXCVA coupler: infinity

IH17K1110115-01

Front EXCV
IH17K1110113-01

• Voltage
– Turn the ignition switch ON.
– B/R wire and R/B wire: approx. 0 V

IH17K1110161-02

Is check result OK?

Yes Go to Step 3.
IH17K1110114-01
No Replace or adjust the EXCV cables.
Is check result OK? • Replacement:
Yes Go to Step 2. – EXCVA / EXCV cable No.1 / No.2:
(Page 1K-8)
No Repair or replace the defective wire
harness. – EXCV cable No.3: (Page 1K-13)
• Adjustment: (Page 1K-21)
Step 2
EXCV cable check Step 3
1) Turn the ignition switch OFF. EXCVA motor check
2) Remove the right side cowling. (Page 9D-21) 1) Check the operation of EXCVA motor. Refer to
“EXCVA Motor” under “EXCVA Inspection” in
3) Check the installation of EXCV cables. Refer to
Section 1K (Page 1K-19).
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation” in Section 1K (Page 1K-8) and “EXCV Is check result OK?
Cable No. 3 Removal and Installation” in Section
1K (Page 1K-13). Yes Replace the ECM with a known good one,
and inspect it again. (Page 1C-10)

No Replace the EXCVA with a new one.

(Page 1K-8)
1A-67 Engine General Information and Diagnosis:

DTC P1610 (C42)

BENH17K11104029
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1610 (C42): Ignition Switch Signal Circuit • Ignition switch
Ignition switch signal is not input to the ECM. • Ignition switch circuit
• ECM
• Immobilizer system (If equipped)
• Immobilizer system circuit (If equipped)

Troubleshooting
Refer to “Ignition Switch Inspection” in Section 1H (Page 1H-9) for details.

DTC P1650
BENH17K11104038
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1650: Inertial Measurement Unit • IMU
ECM receives abnormal signal from IMU. • IMU circuit
• ECM

Troubleshooting
Refer to “DTC C1671 (71)” in Section 4E (Page 4E-42) for details.

DTC P1651
BENH17K11104039
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1651: Inertial Measurement Unit Lost • IMU
Communication • CAN communication circuit
Communication between ECM and IMU is interrupted.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

4 5 6

W/B B/Bl
B/Bl W/B B/Bl W/B
T3 T2

1 2 3

IH17K1110124-03

1. ECM 3. Combination meter 5. Ignition switch

2. IMU 4. Signal fuse 6. Main fuse
 Engine General Information and Diagnosis: 1A-68

Troubleshooting

Step 1
IMU power supply circuit check
1) Turn the ignition switch OFF.
2) Disconnect the IMU coupler. (Page 4E-47)
3) Check for proper terminal connection to the IMU
coupler. IH17K1110163-01

4) If connections are OK, turn the ignition switch ON. Is resistance about 60 Ω?
5) Measure the voltage between the W/G wire and B/
W wire. Yes Replace the IMU with a new one. (Page
4E-47)
IMU power supply voltage
[Standard]: Battery voltage No Go to Step 4.

Step 4
ECM and combination meter check
1) Disconnect the ECM couplers. (Page 1C-10)
2) Measure the resistance between “T2” and “T3”
terminals of the ECM.
ECM resistance
IH17K1110117-01 [Standard]: Approx. 120 Ω
Is check result OK?

Yes Go to Step 3.

No Go to Step 2.

Step 2 T3 T2
IMU ground circuit check
1) Measure the voltage between the W/G wire and
ground.
IH17K1110166-01

3) Disconnect the combination meter coupler. Refer

to “Body Cowling Removal and Installation” in
Section 9D (Page 9D-22).
4) Measure the resistance between W/B and B/Bl
wire terminals of the combination meter.
IH17K1110118-01 Combination meter resistance
Is voltage same as Step 1? [Standard]: Approx. 120 Ω

Yes Repair or replace the B/W wire.

No Repair or replace the W/G wire.

Step 3
IMU resistance check
1) Turn the ignition switch OFF.
2) Measure the resistance between W/B and B/Bl
wires. IH17K1110165-01

Is check result OK?

Yes Repair or replace the defective wire

harness.

No Replace the defective part(s).

1A-69 Engine General Information and Diagnosis:

DTC P1700 / P1702 (C23)

BENH17K11104030
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1700 (C23): TO Sensor Circuit • TO sensor
The sensor output voltage is lower than 0.20 V. • TO sensor circuit
P1702 (C23): TO Sensor Circuit High
• ECM
The sensor output voltage is higher than 4.80 V.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 2

R T23

B T43

B/Br T47

W T21

IH17K1110127-01

1. TO sensor 2. ECM

Troubleshooting
Step 2
TO sensor ground circuit check
Step 1
TO sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the TO sensor coupler. (Page 1C-
20)
3) Check for proper terminal connection to the TO
sensor coupler.
4) If connections are OK, turn the ignition switch ON.
V
5) Measure the voltage between the R wire and B/Br
wire. ID26J1110154-02

TO sensor power supply voltage Is voltage same as Step 1?

[Standard]: 4.5 – 5.5 V
Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

V
ID26J1110153-02

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
 Engine General Information and Diagnosis: 1A-70

Step 3 Step 4
TO sensor signal circuit check TO sensor output voltage check
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10) 2) Connect the ECM couplers and TO sensor
3) Check for proper terminal connection to the ECM coupler.
couplers. 3) Measure the TO sensor output voltage. Refer to
4) If connections are OK, check the following points. “TO Sensor Output Voltage” under “TO Sensor
Inspection” in Section 1C (Page 1C-19).
• Resistance
– B wire: less than 1 Ω Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Replace the TO sensor with a new one.

(Page 1C-20)

T43
IH17K1110128-01

– Between B wire and ground: infinity

ID26J1110156-03

– Between B wire terminal and other terminal

at TO sensor coupler: infinity

ID26J1110157-03

• Voltage
– Turn the ignition switch ON.
– B wire: approx. 0 V

V
ID26J1110158-02

Is check result OK?

Yes Go to Step 4.

No Repair or replace the B wire.

1A-71 Engine General Information and Diagnosis:

DTC P1750 / P1751 / P1752 (C93)

BENH17K11104040
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P1750 (C93): Steering Damper Solenoid Circuit • Steering damper solenoid valve
ECM detects abnormality of the steering damper solenoid • Steering damper solenoid valve circuit
valve.
• ECM
P1751 (C93): Steering Damper Solenoid Circuit Low
Steering damper solenoid valve circuit is open or shorted
to ground.
P1752 (C93): Steering Damper Solenoid Circuit High
Steering damper solenoid valve circuit wires are shorted
to each other or shorted to power supply.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 2

G/W T34

B/G T33

IH17K1110129-01

1. Steering damper solenoid valve 2. ECM

Troubleshooting 4) If connections are OK, check the following points.

• Resistance
Step 1
– G/W wire and B/G wire: less than 1 Ω
Steering damper solenoid valve circuit check
1) Turn the ignition switch OFF.
2) Disconnect the steering damper solenoid valve
coupler and ECM couplers.
• Steering damper solenoid valve: (Page 6B-7)
• ECM: (Page 1C-10)
3) Check for proper terminal connection to the
steering damper solenoid valve coupler and ECM
couplers.
T33
T34
IH17K1110130-01

– Between G/W wire and ground: infinity

IH17K1110131-01
 Engine General Information and Diagnosis: 1A-72

– Between B/G wire and ground: infinity Step 2

Steering damper solenoid valve resistance check
1) Turn the ignition switch OFF.
2) Measure the steering damper solenoid valve
resistance. Refer to “Steering Damper Inspection”
in Section 6B (Page 6B-8).
Is check result OK?

Yes Replace the ECM with a known good one,

IH17K1110132-01 and inspect it again. (Page 1C-10)
– Between G/W wire terminal and B/G wire
terminal at steering damper solenoid valve No Replace the steering damper solenoid
coupler: infinity valve with a new one. (Page 6B-7)

IH17K1110133-01

• Voltage
– Turn the ignition switch ON.
– G/W wire and B/G wire: approx. 0 V

IH17K1110134-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.
1A-73 Engine General Information and Diagnosis:

DTC P2100 (C28)

BENH17K11104031
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2100 (C28): Throttle Actuator “A” Control Motor • Throttle valve motor
Circuit • Throttle valve motor circuit
ECM detects abnormality of the throttle valve motor.
• Throttle valve sticking
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

2
1

B/Lg T73

P/W T61

IH17K1110135-01

1. Throttle valve motor 2. ECM

Troubleshooting 7) If connections are OK, check the following points.

• Resistance
Step 1
– B/Lg wire and P/W wire: less than 1 Ω
Throttle valve motor circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Lift and support the fuel tank. (Page 1G-9)
4) Remove the air cleaner box. (Page 1D-6)
5) Disconnect the throttle valve motor coupler (1).

T61

1
T73
IH17K1110136-01

– Between B/Lg wire and ground: infinity

IH17K1110162-01

6) Check for proper terminal connection to the

throttle valve motor coupler and ECM couplers.

IH17K1110137-01
 Engine General Information and Diagnosis: 1A-74

– Between P/W wire and ground: infinity Step 2

Throttle valve operation check
1) Turn the ignition switch OFF.
2) Connect the throttle valve motor coupler and ECM
couplers.
3) Check the throttle valve operation using SDS-II.
Refer to “Throttle Valve Motor Inspection” in
Section 1C (Page 1C-22).
IH17K1110138-01 Is check result OK?
– Between B/Lg wire terminal and P/W wire
Yes Replace the ECM with a known good one,
terminal at throttle valve motor coupler:
and inspect it again. (Page 1C-10)
infinity
No Replace the throttle body assembly with a
new one. (Page 1C-5)

IH17K1110139-01

• Voltage
– Turn the ignition switch ON.
– B/Lg wire and P/W wire: approx. 0 V

IH17K1110140-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.
1A-75 Engine General Information and Diagnosis:

DTC P2120 / P2125 (C14)

BENH17K11104041
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2120 (C14): TP Sensor/Switch “D” Circuit • Accelerator position sensor 1
ECM detects abnormality of the accelerator position • Accelerator position sensor 1 circuit
sensor 1.
• ECM
P2125 (C14): TP Sensor/Switch “E” Circuit • Accelerator position sensor 2
ECM detects abnormality of the accelerator position • Accelerator position sensor 2 circuit
sensor 2.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

3
R/Y T10

1 P/W T9
Br/W T8

R/G T6
2 B/Bl T7

B/Lg T22
IH17K1110141-01

1. Accelerator position sensor 1 2. Accelerator position sensor 2 3. ECM

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 3.

Accelerator position sensor power supply voltage
No Go to Step 2.
check
1) Turn the ignition switch OFF. Step 2
2) Disconnect the accelerator position sensor Accelerator position sensor ground circuit check
coupler. (Page 1C-20) 1) Measure the voltage between the R/Y wire and
3) Check for proper terminal connection to the ground (accelerator position sensor 1), between
accelerator position sensor coupler. the R/G wire and ground (accelerator position
4) If connections are OK, turn the ignition switch ON. sensor 2).
5) Measure the voltage between R/Y wire and Br/W
wire (accelerator position sensor 1), between the
R/G wire and B/Lg wire (accelerator position
sensor 2).
Accelerator position sensor power supply
voltage
[Standard]: 4.5 – 5.5 V

IH17K1110143-02

Is voltage same as Step 1?

Yes Repair or replace the Br/W wire

(accelerator position sensor 1) or B/Lg
wire (accelerator position sensor 2).

IH17K1110142-02
No Repair or replace the R/Y wire
(accelerator position sensor 2) or R/G wire
(accelerator position sensor 2).
 Engine General Information and Diagnosis: 1A-76

Step 3 Accelerator position sensor 2

Accelerator position sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers.
4) If connections are OK, check the following points.
• Resistance
– P/W (accelerator position sensor 1) or B/Bl
(accelerator position sensor 2) wire: less
IH17K1110153-01
than 1 Ω
• Voltage
– Turn the ignition switch ON.
– P/W (accelerator position sensor 1) or B/Bl
(accelerator position sensor 2) wire: approx.
0V

T7 T9

IH17K1110144-02

– Between P/W (accelerator position sensor 1)

or B/Bl (accelerator position sensor 2) wire
and ground: infinity
IH17K1110147-02

Is check result OK?

Yes Go to Step 4.

No Repair or replace the defective wire

harness.

Step 4
Accelerator position sensor output voltage check
IH17K1110145-02
1) Turn the ignition switch OFF.
– Between P/W (accelerator position sensor 1)
or B/Bl (accelerator position sensor 2) wire 2) Connect the accelerator position sensor coupler
terminal and other terminal at accelerator and ECM couplers.
position sensor coupler: infinity 3) Measure the accelerator position sensor output
Accelerator position sensor 1 voltage. (Page 1C-20)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-10)

No Replace the accelerator position sensor

with a new one. (Page 1C-20)

IH17K1110146-02
1A-77 Engine General Information and Diagnosis:

DTC P2226 / P2228 (C22)

BENH17K11104043
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2226 (C22): AP Sensor Circuit • Clogged vacuum passage with dust
The sensor output voltage is higher than 4.85 V. • AP sensor
P2228 (C22): AP Sensor Circuit Low
• AP sensor circuit
The sensor output voltage is lower than 0.5 V.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

B/Br T47

G/Y T25

R T23

IH17K1110155-02

1. AP sensor 2. ECM

Troubleshooting Step 2
AP sensor ground circuit check
Step 1
AP sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the AP sensor coupler. (Page 1C-
12)
3) Check for proper terminal connection to the AP
sensor coupler.
4) If connections are OK, turn the ignition switch ON. V
5) Measure the voltage between the R wire and B/Br ID26J1110028-04
wire.
Is voltage same as Step 1?
AP sensor power supply voltage
[Standard]: 4.75 – 5.25 V Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

V
ID26J1110027-04

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
 Engine General Information and Diagnosis: 1A-78

Step 3 Step 4
AP sensor signal circuit check AP sensor output voltage check
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. (Page 1C-10) 2) Remove the AP sensor. (Page 1C-12)
3) Check for proper terminal connection to the ECM 3) Measure the AP sensor output voltage. (Page
couplers. 1C-11)
4) If connections are OK, check the following points. Is check result OK?
• Resistance
Yes Replace the ECM with a known good one,
– G/Y wire: less than 1 Ω
and inspect it again. (Page 1C-10)

No Replace the AP sensor with a new one.

(Page 1C-12)

T25

IH17K1110156-01

– Between G/Y wire and ground: infinity

ID26J1110030-07

– G/Y wire terminal and other terminal at AP

sensor coupler: infinity

ID26J1110031-05

• Voltage
– Turn the ignition switch ON.
– G/Y wire: approx. 0 V

ID26J1110032-05

Is check result OK?

Yes Go to Step 4.

No Repair or replace the G/Y wire.

1A-79 Engine General Information and Diagnosis:

DTC P2505
BENH17K11104044
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
P2505: ECM Power Input Signal • Fuel fuse
Power source for ECM is not supplied. • ECM power supply circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-9).

1 8
[A]
T51 R/W
2

4 5 7
6 9
3
[B]
T32 Y/R R/W
T67 Y/B W/R

IH17K1110157-02

[A]: To combination meter 2. Fuel pump 5. Side-stand relay 8. Fuel fuse

[B]: To side-stand switch 3. FP relay 6. Ignition fuse 9. Main fuse
1. ECM 4. Engine stop switch 7. Ignition switch

Troubleshooting

Step 1
ECM power supply voltage check
1) Turn the ignition switch OFF. T51
2) Disconnect the ECM couplers. (Page 1C-10)
3) Check for proper terminal connection to the ECM
couplers. IH17K1110158-01

4) If connections are OK, measure the voltage Is check result OK?

between the R/W wire and ground.
Yes Replace the ECM with a known good one,
ECM power supply voltage and inspect it again. (Page 1C-10)
[Standard]: Battery voltage
No Check FUEL fuse for blowout. If fuse is
not blown, repair or replace the R/W wire.

Special Tools and Equipment

Special Tool
BENH17K11108001
09904–41051 09930–82720
Conversion cable Mode selection switch
(Page 1A-5) (Page 1A-7) /
(Page 1A-17)
 Emission Control Devices: 1B-1

Emission Control Devices

Engine

Precautions
Precautions for Emission Control Devices
BENH17K11200001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

General Description
Fuel Injection System Description
BENH17K11201001
GSX-R1000 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system
is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine
conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to
reduce CO, NOX and HC. Adjusting, interfering with, improper replacement, or resetting of any of the fuel injection
components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission
level limits.

5
2

[A]
6
[B]
[C] 4
IH17K1120001-01

[A]: Before-pressurized fuel 1. Fuel tank 4. Fuel feed hose 7. Secondary fuel delivery pipe
[B]: Pressurized fuel 2. Fuel pump 5. Primary fuel delivery pipe 8. Secondary fuel injector
[C]: Relieved fuel 3. Fuel pressure regulator 6. Primary fuel injector
1B-2 Emission Control Devices:

Crankcase Emission Control System Description

BENH17K11201002
The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is
returned to the combustion chamber through the crankcase breather (PCV) hose (1), air cleaner (2) and throttle body
(3).

1
4

[A]
[B]
[C]
[D]
[E]

IH17K1120002-01

[A]: Fresh air [C]: Blow-by gas [E]: Exhaust gas

[B]: Fuel/Air mixture [D]: Return oil 4. PAIR control solenoid valve
 Emission Control Devices: 1B-3

Exhaust Emission Control System Description

BENH17K11201003
The exhaust emission control system is composed of the PAIR system, exhaust control system, HO2 sensor, three-
way catalyst system and ISC system. The fresh air is drawn into the exhaust ports through the PAIR control solenoid
valve and PAIR reed valves. The PAIR control solenoid valve is operated by the ECM, which is controlled according to
the signals from TP sensor, ECT sensor, IAP sensor and CKP sensor. The exhaust gas flow is performed by the
exhaust control valve actuator which is controlled by the ECM by changing the rear EXCV and front EXCV angle.
Throttle valve motor adjusts the air volume of the throttle body to control engine idling speed with various sensor
signals by varying engine running conditions.
1B-4 Emission Control Devices:

3 5

1
7

2
6

10

[A]
[B]

12 11

IH17K1120003-01

[A]: Fresh air 3. Air cleaner box 7. ECM 11. Three-way catalyst
[B]: Exhaust gas 4. Primary fuel injector 8. Exhaust control valve actuator 12. HO2 sensor
1. PAIR control solenoid valve 5. Secondary fuel injector 9. Rear EXCV
2. PAIR reed valve 6. Throttle valve 10. Front EXCV
 Emission Control Devices: 1B-5

Noise Emission Control System Description

BENH17K11201004
TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local law or federal law prohibits the following
acts or the causing thereof:
• The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use.
• The use of the vehicle after such device or element of design has been removed or rendered inoperative by any
person.

Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below:
• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other
component which conducts exhaust gases.
• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts
intake air.
• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as
the code listed on the Motorcycle Noise Emission Control Information label.
1B-6 Emission Control Devices:

PAIR System Diagram

BENH17K11201006

1
2

[A]
[B]
IH17K1120004-01

[A]: Fresh air [B]: Exhaust gas 1. PAIR control solenoid valve 2. PAIR reed valve
 Emission Control Devices: 1B-7

Evaporative Emission Control System Diagram (If Equipped)

BENH17K11201005

11

7
5

6 2

10

[A]

[B]
9
[C]
IH17K1120005-04

[A]: Fuel 3. Fuel tank 8. Fuel feed hose

[B]: HC vapor 4. Fuel pump 9. EVAP system purge control solenoid valve
[C]: Vacuum 5. EVAP canister 10. Purge hose No.2
1. Throttle body 6. Purge hose No.1 11. Fuel shut-off valve
2. IAP sensor 7. Surge hose
1B-8 Emission Control Devices:

Schematic and Routing Diagram

PAIR System Hose Routing Diagram
BENH17K11202001

(a)

[A]
1

2 7

6
4 5

[B]

(a)
2

“a”
8

[C]
IH17K1120006-02

[A]: Align the blue marking of the PAIR hose with the hose stopper of the PAIR reed valve cover. 5. Clamp
: Clamp end should face upward.
[B]: Align the pink marking of the PAIR hose with the hose stopper of the PAIR reed valve cover. 6. PAIR reed valve
[C]: Align the yellow markings of the PAIR hoses with the match mark of the PAIR control solenoid valve. 7. Yellow marking
1. Clamp 8. White marking
: Face the clamp end forward.
Do not contact the cylinder head cover bolt.
2. Clamp “a”: 15°
: Face the clamp end downward.
3. Clamp : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Align the clamp end with the white marking of the PAIR hose.
Do not contact the frame and air cleaner box.
4. PAIR control solenoid valve
 Emission Control Devices: 1B-9

EVAP Canister Hose Routing Diagram (If Equipped)

BENH17K11202002

4 [H] [E]

[I]
7 [F]
[B] [D]
6
[C] 5
[B]
5 [A]

3 [J]

[G]
2 (a)
1 [B]

1
IH17K1120007-02

[A]: Face the clamp end downward. [J]: To throttle body

[B]: Face the clamp end forward. 1. EVAP canister
[C]: Face the clamp end backward. 2. Purge hose No. 1
[D]: Face the clamp end upward. 3. Surge hose
: Pass the surge hose over the fuel feed hose.
[E]: Face the clamp end to right side. 4. Fuel feed hose
[F]: Face the yellow mark upward. 5. EVAP purge control solenoid valve
[G]: Face the white mark backward. 6. Purge hose No. 2
[H]: Face the yellow mark forward. 7. Crankcase breather (PCV) hose
[I]: To fuel tank : 6.7 Nm (0.68 kgf-m, 4.95 lbf-ft)
1B-10 Emission Control Devices:

Repair Instructions
PAIR Reed Valve Removal and Installation PAIR Control Solenoid Valve Removal and
BENH17K11206001
Removal
Installation
BENH17K11206002
1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the air cleaner box. (Page 1D-6) Removal
3) Disconnect the PAIR control solenoid valve coupler 1) Lift and support the fuel tank. (Page 1G-9)
(1). 2) Remove the air cleaner box. (Page 1D-6)
4) Remove the PAIR control solenoid valve (2) with 3) Disconnect the PAIR control solenoid valve coupler
PAIR reed valve covers (3). (1).

1
2 1

IH17K1120008-01 IH17K1120011-01

5) Remove the PAIR reed valves (1). 4) Remove the PAIR control solenoid valve with the
PAIR reed valve covers. (Page 1B-10)
5) Disconnect the PAIR hoses (1).

IH17K1120009-01
1
Installation IH17K1120012-01
Install the PAIR reed valve in the reverse order of
removal. Pay attention to the following point: Installation
• Tighten the PAIR reed valve cover bolts (1) to the Install the PAIR control solenoid valve in the reverse
specified torque. order of removal. Pay attention to the following point:
Tightening torque • Connect the PAIR hoses properly. Refer to “PAIR
PAIR reed valve cover bolt (a): 10 N·m (1.0 kgf-m, System Hose Routing Diagram” (Page 1B-8).
7.5 lbf-ft)

1, (a) 1, ( a)

IH17K1120010-01
 Emission Control Devices: 1B-11

PAIR System Inspection PAIR Control Solenoid Valve

BENH17K11206003
PAIR Hose 1) Remove the PAIR control solenoid valve. (Page
1B-10)
1) Lift and support the fuel tank. (Page 1G-9)
2) Check that air flows through the air inlet port to the
2) Remove the air cleaner box. (Page 1D-6)
air outlet ports. If air does not flow out, replace the
3) Inspect the PAIR hoses (1) for wear or damage. If it PAIR control solenoid valve with a new one.
is worn or damaged, replace the PAIR hose with a
new one. Refer to “PAIR System Hose Routing
Diagram” (Page 1B-8).

IF04K1120008-01

3) Connect the 12 V battery to the PAIR control

solenoid valve terminals and check the air flow. If air
IH17K1120013-01
does not flow out, the solenoid valve is in normal
4) Install the removed parts. condition.

PAIR Reed Valve

1) Remove the PAIR reed valves. (Page 1B-10)
2) Inspect the reed valves for carbon deposit.
If carbon deposit is found on the reed valve, replace
the PAIR reed valve with a new one.

IF04K1120009-01

4) Check the resistance between the terminals of the

PAIR control solenoid valve.
PAIR solenoid valve resistance
20 – 30 °C (68 – 86 °F) [Standard]: 20 – 24 Ω

IH17K1120028-01

3) Install the PAIR reed valves. (Page 1B-10)

IF04K1120010-01

5) Reinstall the PAIR control solenoid valve. (Page

1B-10)
1B-12 Emission Control Devices:

Crankcase Breather (PCV) Hose Inspection Installation

BENH17K11206004 Installation is in the reverse order of removal.
1) Lift and support the fuel tank. (Page 1G-9) Pay attention to the following points:
2) Inspect the crankcase breather (PCV) hose (1) for • Apply sealant to the mating surface of the crankcase
wear and damage. breather cover (1).
If it is worn or damaged, replace the crankcase
breather (PCV) hose with a new one. NOTE
3) Check that the crankcase breather (PCV) hose (1) is • Make surfaces free from moisture, oil dust
securely connected. and other foreign materials.
• Spread on surface thinly to form an even
layer and assemble the crankcase breather
cover within a few minutes.
1
“A”: Sealant 99000–31140 (SUZUKI BOND 1207B)

IH17K1120014-01

4) Install the removed parts.

Crankcase Breather (PCV) Hose / Cover

Removal and Installation “A”
BENH17K11206005 IH17K1120016-01
Removal
• Tighten the crankcase breather (PCV) cover bolts (1)
1) Remove the fuel tank. (Page 1G-9) to the specified torque.
2) Remove the EVAP canister (If equipped). Refer to
“EVAP Control System Removal and Installation (If NOTE
Equipped)” (Page 1B-13). Fit the harness clamp to the bolt (2).
3) Disconnect the crankcase breather (PCV) hose (1).
Tightening torque
4) Remove the crankcase breather (PCV) cover (2). Crankcase breather (PCV) cover bolt (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)
1
2
1 , (a )

2 , (a )

IH17K1120015-01 1 , (a )
IH17K1120017-02

• Connect the crankcase breather (PCV) hose securely.

Refer to “Intake System Construction” in Section 1D
(Page 1D-4).
 Emission Control Devices: 1B-13

Crankcase Breather (PCV) Cover Inspection EVAP Canister

BENH17K11206006 Refer to “EVAP Canister Hose Routing Diagram (If
Inspect the crankcase breather (PCV) cover in the Equipped)” (Page 1B-9).
following procedures:
1) Remove the crankcase breather (PCV) cover. Refer Removal
to “Crankcase Breather (PCV) Hose / Cover 1) Remove the EVAP system purge control solenoid
Removal and Installation” (Page 1B-12). valve. (Page 1B-14)
2) Inspect the crankcase breather (PCV) cover (1) for 2) Remove the canister bracket bolts (1).
carbon deposit. If carbon deposit is found in the
crankcase breather (PCV) cover, remove the carbon.

IH17K1120019-01

3) Remove the EVAP canister (1).

IH17K1120018-01

3) Install the crankcase breather (PCV) cover. Refer to

“Crankcase Breather (PCV) Hose / Cover Removal
and Installation” (Page 1B-12). 1

EVAP Control System Removal and Installation

(If Equipped)
BENH17K11206007
Hose
Refer to “EVAP Canister Hose Routing Diagram (If
Equipped)” (Page 1B-9).

Removal IH17K1120020-01

1) Remove the fuel tank. (Page 1G-9) 4) Disconnect the surge hose (1).
2) Remove the EVAP hoses. 5) Remove the canister bracket (2) and canister
cushion (3).
Installation
1) Install the EVAP hoses. 1
3
2) Install the removed parts.

IH17K1120021-02
1B-14 Emission Control Devices:

Installation 5) Remove the bracket (1).

Install the EVAP canister in the reverse order of removal. 6) Disconnect the purge hose No. 1 (2).
Pay attention to the following point:
• Tighten the canister bracket bolts (1) to the specified
torque. 1
Tightening torque
Canister bracket bolt (a): 10 N·m (1.0 kgf-m, 7.5 2
lbf-ft)

IH17K1120025-01

Installation
Install the EVAP system purge control solenoid valve in
1, ( a) the reverse order of removal. Pay attention to the
following point:
IH17K1120022-01
• Tighten the EVAP system purge control solenoid valve
nut (1) to the specified torque.
EVAP System Purge Control Solenoid Valve Tightening torque
Removal EVAP system purge control solenoid valve nut
1) Remove the fuel tank. (Page 1G-9) (a): 6.7 N·m (0.68 kgf-m, 4.95 lbf-ft)
2) Disconnect the coupler (1).

1 , (a )
IH17K1120026-01

IH17K1120023-01

3) Disconnect the purge hose No. 1 (1) from the EVAP

canister and purge hose No. 2 (2) from the EVAP
system purge control solenoid valve.
4) Remove the EVAP system purge control solenoid
valve (3) with its bracket.

2 1

IH17K1120024-02
 Emission Control Devices: 1B-15

EVAP Control System Inspection (If Equipped) 3) Check the resistance between the terminals of the
BENH17K11206008 EVAP system purge control solenoid valve (1). If the
Refer to “EVAP Control System Removal and Installation resistance is not within the standard range, replace
(If Equipped)” (Page 1B-13). the EVAP system purge control solenoid valve with a
new one.
Hose
Inspect the hoses for wear or damage. If it is worn or EVAP system purge control solenoid valve
damage, replace the hose with a new one. resistance (If equipped)
20 °C (68 °F) [Standard]: 30 – 34 Ω
EVAP Canister
Inspect the EVAP canister body for damage to the body.
If any defect is found, replace the EVAP canister (1) with
1
a new one.

IF04K1120028-02

Fuel Shut-off Valve

Refer to “Fuel Tank Cap Removal and Installation” in
IH17K1120027-01 Section 1G (Page 1G-9).
1) Hold the fuel tank cap so that the fuel tank cap
EVAP System Purge Control Solenoid Valve breather hole (1) is aligned with and closely contacts
1) Check that no air flows through both of the air inlet the packing breather port (2) and the fuel tank cap
and outlet ports. If air flows out, replace the EVAP upper surface (3) is located lower than the fuel tank
system purge control solenoid valve with a new one. cap ring upper surface (4).

IF04K1120026-01
4
2) Connect the 12 V battery to the terminals of the
EVAP system purge control solenoid valve (1) and
check the air flow. If air flows out, the solenoid valve
is in normal condition.

3
1

IH13K1120032-03

IF04K1120027-02
1B-16 Emission Control Devices:

2) Keep the step 1), connect the vacuum pump gauge 3) Keep the step 1), connect the vacuum pump gauge
to the breather port (1) with the fuel tank cap turned to the breather port (1) with the fuel tank cap turned
upright, and give positive pressure to check that air upside down, and give negative pressure to check
can pass through. that air cannot pass through.
If any defect is found, replace the fuel tank cap with a
Special tool
new one.
(A): 09917–47011
Special tool
(A): 09917–47011
(A)

(A)
1

IH13K1120033-03

IH13K1120034-03
 Emission Control Devices: 1B-17

Specifications
Tightening Torque Specifications
BENH17K11207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
PAIR reed valve cover bolt 10 1.0 7.5 (Page 1B-10)
Crankcase breather (PCV) cover bolt 10 1.0 7.5 (Page 1B-12)
Canister bracket bolt 10 1.0 7.5 (Page 1B-14)
EVAP system purge control solenoid valve nut 6.7 0.68 4.95 (Page 1B-14)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“PAIR System Hose Routing Diagram” (Page 1B-8)
“EVAP Canister Hose Routing Diagram (If Equipped)” (Page 1B-9)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K11208001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1B-12)

Special Tool
BENH17K11208002
09917–47011
Vacuum pump gauge set
(Page 1B-16) /
(Page 1B-16)
1C-1 Engine Electrical Devices:

Engine Electrical Devices

Engine

Precautions
Precautions for Engine Electrical Device
BENH17K11300001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-8) and “Precautions for SDS-II” in Section 00
(Page 00-8).
 Engine Electrical Devices: 1C-2

Schematic and Routing Diagram

Throttle Cable Routing Diagram
BENH17K11302001

[A]

7, “1”

6
7, “2”

3 1 2 4

3
“a” 3

8
1 2
1 1

2
2
[B] 6

10 2
[C]
IH17K1130001-02

[A]: Pass the throttle cables and clutch cable under the air 3. Clutch cable 8. Front brake hose (With ABS)
cleaner duct.
[B]: Fix the throttle cable with the white mark to the clamp 4. Right side cowling bracket 9. Clamp
center and the throttle cable with yellow mark to the lower
side. Position each mark in the center of the clamp.
[C]: Pass the throttle cables under the brake pipe. (With ABS) 5. Air cleaner box 10. Brake pipe (With ABS)
1. Throttle cable No.1 6. Cable guide “a”: 5 – 9 mm (0.20 – 0.35 in)
2. Throttle cable No.2 7. Cable guide screw
: Tighten the screws in order of “1” → “2”.
1C-3 Engine Electrical Devices:

Component Location
Engine Electrical Components Location
BENH17K11303001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).

Diagnostic Information and Procedures

Engine Symptom Diagnosis
BENH17K11304001
Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-12).
 Engine Electrical Devices: 1C-4

Repair Instructions
Throttle Body Components
BENH17K11306026

2
(a)

8 4
1

9
7

10

[A]

(b)

IH17K1130002-02

[A]: If equipped 4. O-ring 8. Vacuum hose : 6.7 Nm (0.68 kgf-m, 4.95 lbf-ft)
1. Primary fuel delivery 5. Primary fuel injector 9. Throttle body : Apply engine oil.
pipe
2. Nipple joint 6. Cushion seal 10. EVAP system purge control : Do not reuse.
solenoid valve
3. Gasket 7. Synchronizing screw : 3.5 Nm (0.36 kgf-m, 2.60 lbf-ft)
: Do not turn or remove the screw
with white paint (one in four).
1C-5 Engine Electrical Devices:

Throttle Cable Play On-Vehicle Inspection and Throttle Cable Removal and Installation
BENH17K11306029
Adjustment Removal
BENH17K11306028
Inspection 1) Lift and support the fuel tank. (Page 1G-9)
Turn the throttle grip slowly and inspect the throttle cable 2) Remove the right handle switch. Refer to “Handlebar
play “a” at the periphery of the grip. Removal and Installation” in Section 6B (Page 6B-3).
Throttle cable play 3) Remove the accelerator position sensor. (Page
[Standard]: 2.0 – 4.0 mm (0.079 – 0.157 in) 1C-20)
4) Remove the throttle cables as shown in the cable
routing diagram. Refer to “Throttle Cable Routing
Diagram” (Page 1C-2).

Installation
Install the throttle cables in the reverse order of removal.
“a” Pay attention to the following points:
• Install the throttle cables as shown in the cable routing
diagram. Refer to “Throttle Cable Routing Diagram”
(Page 1C-2).
• Check the throttle cable play and proper operation.
IH17K1130003-01
(Page 1C-5)
Adjustment
Throttle Body Removal and Installation
1) Remove the rubber boot (1). BENH17K11306033
2) Loosen the lock-nut (2) of the throttle pulling cable. Removal
3) Turn the adjuster (3) in or out until the throttle cable 1) Lift and support the fuel tank. (Page 1G-9)
play (at the throttle grip) is within the specification. 2) Remove the air cleaner box. (Page 1D-6)
4) Tighten the lock-nut (2) while holding the adjuster 3) Remove the side cowling assemblies. (Page 9D-
(3). 21)
4) Disconnect the fuel feed hose (1). (Page 1G-6)
! WARNING
After the adjustment is completed, check that
handlebar movement does not raise the 1
engine idle speed and that the throttle grip
returns smoothly and automatically.

1 IH17K1130004-01

5) Disconnect the wiring harness No. 3 couplers (1).

2 3
IE31J1130081-01

5) Reinstall the rubber boot. 1

IH17K1130005-01
 Engine Electrical Devices: 1C-6

6) Remove the IAP sensor (1). Installation

7) Disconnect the EVAP system purge control solenoid Install the throttle body in the reverse order of removal.
valve coupler (2) and purge hose No. 2 (3). (If Pay attention to the following points:
equipped) • Tighten the intake pipe clamp screws (1) to the
specified torque.
3 Tightening torque
Intake pipe clamp screw (a): 1.5 N·m (0.15 kgf-m,
1.10 lbf-ft)
2

IH17K1130006-01

8) Loosen the intake pipe clamp screws (1) and remove 1, (a)
the throttle body. 1, (a)

NOTICE
IH17K1130008-01
• Do not snap the throttle valve from the • Reset the ISC aperture learned value. (Page 1C-10)
open to full close. It may cause damage to
the gear inside the throttle body.
Throttle Body Disassembly and Reassembly
• If foreign materials like mud and sand are BENH17K11306030
adhered to the intake pipe or the throttle Refer to “Throttle Body Removal and Installation” (Page
body, they are likely to get into the intake 1C-5).
port.
When foreign materials like mud or sand Disassembly
are adhered, remove them before starting
NOTICE
the work.
• Identify the position of each removed part.
Organize the parts in their respective
groups so that they can be reinstalled in
their original positions.
• Do not apply the battery voltage to the
throttle valve motor (1) directly. Otherwise
the gear inside the throttle body may get
damaged.
1 1 • Never remove the throttle valve motor.

IH17K1130007-01

IH17K1130009-01
1C-7 Engine Electrical Devices:

• Never remove the throttle valves (1) and TP 1) Disconnect the TP sensor coupler (1) and throttle
sensor (2). valve motor coupler (2).

2
1
2

IH17K1130010-01 IH17K1130013-01

• The screw (1) is factory-adjusted at the 2) Remove the primary fuel injectors / delivery pipes (1)
time of delivery and therefore avoid along with the secondary fuel injectors / delivery
removing of turning it unless otherwise pipes (2). Refer to “Fuel Injector / Fuel Delivery Pipe
necessary. Removal and Installation” in Section 1G (Page 1G-
17).

1
1
IH17K1130011-01

• Do not turn or remove the synchronizing IH17K1130014-01

screw with white paint (one in four). The 3) Disconnect the vacuum hoses (1).
white painted screw is fixed in the factory 4) Disconnect the purge hoses (2). (If equipped)
default setting.

1
2

IH17K1130015-01
IH17K1130012-01
 Engine Electrical Devices: 1C-8

5) Before removing the synchronizing screws without Throttle Body Inspection and Cleaning
white paint, make sure the setting by turning each BENH17K11306031

one clockwise slowly and count the number of turns Refer to “Throttle Body Disassembly and Reassembly”
until the screw is lightly seated. (Page 1C-6).
This counted number is important when
reassembling synchronizing screw to the original Inspection
position. Check following items for any defects or clogging.
Replace the damaged part or throttle body, if necessary.
6) Remove the synchronizing screws without white
paint. NOTICE
Do not snap the throttle valve from the open
to full close. It may cause damage to the gear
inside the throttle body.

• O-rings
• Throttle valves
• Vacuum hoses
• Fuel delivery pipes
• Cushion seals
• Fuel injectors
IH17K1130012-01 • Purge hoses (If equipped)
7) Remove the O-ring (1), washer (2) and spring (3).
Cleaning
Clean the main bore, throttle valve and passage(s) using
a cotton swab moistened with a carburetor cleaning
chemical.
3 2
NOTICE
1
• Some carburetor cleaning chemicals are
very corrosive. Always follow the chemical
manufacturer’s instructions for proper
use, handling and storage.
• Do not dip the throttle body in a carburetor
IH18K1140033-02 cleaning chemical or do not splay the
cleaning chemical directly to the throttle
Reassembly valve. Cleaning chemical will penetrate
Reassemble the throttle body in the reverse order of into electronic parts resulting in cause of
disassembly. Pay attention to the following point: malfunction.
• Apply a thin coat of the engine oil to the new O-rings • Do not use wire to clean passages. Wire
(1) and install each synchronizing screw (2) to the may damage them.
original setting by turning the synchronizing screw in
• Do not apply any cleaning chemical to
until it lightly seats, and then backing it out the same
parts made of rubber and plastic materials.
number of turns counted during disassembly.
Cleaning chemical may damage these
parts.

1
2

IH17K1130016-01
1C-9 Engine Electrical Devices:

Throttle Valve Synchronization 14) Check for the synchronization of vacuum from #1 to
BENH17K11306032 #4 cylinders.
Check and adjust the throttle valve synchronization
among four cylinders.
1) Start the engine and run it in idling condition for
warming up.
2) Stop the warmed-up engine.
3) Lift and support the fuel tank. (Page 1G-9)
4) Disconnect the respective vacuum hoses (1) from
vacuum nipples on the throttle body.
5) Disconnect the IAP sensor coupler (2).

1 1 IH17K1130019-01

15) Equalize the vacuum of the cylinders as follows:

a) Check that the engine idle speed is within the
specified value.

2 NOTICE
A cylinder with the white painted
synchronizing screw is fixed to the specified
vacuum (default setting). Do not turn the
IH17K1130017-01
synchronizing screw with the white paint.
6) Connect the respective vacuum tester hoses (1) to
NOTE
the vacuum nipples.
Cylinder position with the white painted
synchronizing screw depends on the throttle
body.

b) Equalize the vacuum of the cylinders by turning

each synchronizing screw except the one with
the white paint.

NOTE
1 1
Always set the engine rpm at idle rpm.

IH17K1130018-01

7) Set up the SDS-II tool referring to the SDS-II

operation manual for further details.
8) Start the engine.
9) Click “Data monitor”.
10) Warm up the engine enough.
11) Click “Active control”.
12) Click “ISC air volume control”.
13) Click “ON” to fix the ISC air volume of four cylinders.
IH17K1130020-02

16) If the adjustment is not yet correct, inspect and clean

the throttle body. (Page 1C-8)
17) Repeat the procedures from 7) to 15).
18) Close the SDS-II tool and turn the ignition switch
OFF.
19) Disconnect the vacuum tester and install the
removed parts.
IF04K1140337-02
 Engine Electrical Devices: 1C-10

20) After completing the throttle valve synchronization, 6) Click the “Reset” button to clear the ISC aperture
clear the DTC and reset the ISC aperture learned learned value.
value. (Page 1C-10)

ISC Aperture Learned Value Reset

BENH17K11306003
When replacing the throttle body assembly with a new
one or adjusting the throttle valve synchronization, reset
the ISC aperture learned value in the following
procedures:
1) Remove the rear seat. (Page 9D-19)
2) Set up the SDS-II tool referring to the SDS-II
operation manual for further details.
3) Turn the ignition switch ON.
4) Click the “Active control”.
5) Click the “ISC aperture learned value reset”.

IF04K1130053-03

NOTE
The learned value of the ISC system is set at
Preset position.

IF04K1130057-02

7) Close the SDS-II tool and turn the ignition switch

IH17K1130021-01
OFF.

NOTE
The throttle valve opening initialization is
automatically started after the ignition switch
is turned OFF position.

ECM Removal and Installation

BENH17K11306004
Removal

NOTICE
Be careful not to disconnect the ECM coupler
at least 5 seconds after ignition switch is
turned to OFF. If the ECM coupler is
disconnected within 5 seconds after ignition
switch is turned to OFF, there is a possibility
of an unusual valve position being written in
ECM and causing an error of throttle valve
operation.
1C-11 Engine Electrical Devices:

1) Disconnect the battery (–) lead wire. (Page 1J-9) b. Insert the couplers to ECM (3) it stop with lock
2) Remove the frame covers. (Page 9D-26) levers in unlocked position.
3) Disconnect the starter relay coupler (1) and battery c. Turn the lock levers in direction of arrow to lock
(+) lead wire (2). the couplers securely.
4) Remove the starter relay (3).

3
1
2 2

1
3
IH17K1130025-01

IH17K1130022-01
AP Sensor Inspection
5) Remove the electric parts holder (1). BENH17K11306005
1) Turn the ignition switch OFF.
2) Remove the AP sensor. (Page 1C-12)
3) Connect the vacuum pump gauge to the vacuum
port of the AP sensor.
4) Arrange 3 new 1.5 V batteries (1) in series (check
that total voltage is 4.5 – 5.0 V) and connect (–)
terminal to the ground terminal (2) and (+) terminal to
the terminal (3).
5) Measure the voltage between terminal (4) and
1 ground. Also, check if voltage reduces when vacuum
IH17K1130023-01 is applied using the vacuum pump gauge. If the
6) Disconnect the ECM couplers (1) as follows: voltage is not within the specified value, replace the
AP sensor. (Page 1C-12)
a) Push the lock (2) to release locking of the lock
levers (3). Special tool
b) Turn the lock levers in direction of arrow until and (A): 09917–47011
disconnect the ECM couplers.
4 (A )
2

3
2 2 3

1 V
IH17K1130027-02
1
IH17K1130024-01 ATOMOSPHERIC OUTPUT
ALTITUDE (Reference)
PRESSURE VOLTAGE
7) Remove the ECM. m ft kPa mmHg V
0 – 610 0 – 2001 100 – 94 760 – 705 3.4 – 4.0
Installation 611 – 1524 2005 – 5000 94 – 85 705 – 638 3.0 – 3.7
Install the ECM in the reverse order of removal. Pay 1525 – 2438 5003 – 7999 85 – 76 638 – 570 2.6 – 3.4
attention to the following point: 2439 – 3048 8002 – 10000 76 – 70 570 – 525 2.4 – 3.1
IF04K1130058-02
• Connect the ECM couplers (1) as follows: 6) After finishing the AP sensor inspection, install the
a. Make sure that lock levers (2) are in unlock removed parts.
position.
 Engine Electrical Devices: 1C-12

AP Sensor Removal and Installation IAP Sensor Output Voltage

BENH17K11306006
Removal 1) Turn the ignition switch OFF.
1) Remove the frame covers. (Page 9D-26) 2) Remove the IAP sensor. (Page 1C-13)
2) Disconnect the AP sensor coupler (1) and remove 3) Connect the vacuum pump gauge to the vacuum
the AP sensor (2). port of the IAP sensor.
4) Arrange 3 new 1.5 V batteries (1) in series (check
that total voltage is 4.5 – 5.0 V) and connect (–)
terminal to the ground terminal (2) and (+) terminal to
the terminal (3).
2 5) Measure the voltage between terminal (4) and
ground. Also, check if voltage reduces when vacuum
is applied using the vacuum pump gauge. If the
voltage is not within the specified value, replace the
IAP sensor. (Page 1C-13)
1 Special tool
(A): 09917–47011
IH17K1130028-01

4 (A)
Installation
Install the AP sensor in the reverse order of removal. 2

IAP Sensor Inspection

BENH17K11306007
IAP Sensor Output Voltage at Idle Speed 3

1) Check the IAP sensor power supply voltage and

circuit. (Page 1A-26) 1 V
2) Turn the ignition switch OFF.
3) Connect the IAP sensor coupler and ECM couplers. IH17K1130027-02

4) Insert the needle point probes to the lead wire

ATOMOSPHERIC OUTPUT
coupler. ALTITUDE (Reference)
PRESSURE VOLTAGE
m ft kPa mmHg V
5) Run the engine at idle speed, measure the IAP
0 – 610 0 – 2001 100 – 94 760 – 705 3.1 – 3.6
sensor output voltage between the G/B wire and B/ 611 – 1524 2005 – 5000 94 – 85 705 – 638 2.8 – 3.4
Br wire. If the voltage is not within the specified 1525 – 2438 5003 – 7999 85 – 76 638 – 570 2.6 – 3.1
value, replace the IAP sensor. (Page 1C-13) 2439 – 3048 8002 – 10000 76 – 70 570 – 525 2.4 – 2.9
IF04K1130059-01
IAP sensor output voltage 6) After finishing the IAP sensor inspection, install the
Idle speed at 1 atm. removed parts.
[Standard]: Approx. 2.7 V

IH17K1130029-01

6) After finishing the IAP sensor inspection, install the

removed parts.
1C-13 Engine Electrical Devices:

IAP Sensor Removal and Installation 4) Remove the O-ring (1).

BENH17K11306008
Removal
1) Lift and support the fuel tank. (Page 1G-9) 1
2) Remove the IAP sensor (1) from the air cleaner box.
3) Disconnect the IAP sensor coupler (2) and vacuum
hose (3).

2
1

IH17K1130060-01

Installation
3
Install the IAT sensor in the reverse order of removal.
Pay attention to the following points:
• Install the new O-ring (1) securely.
IH17K1130030-01

1
Installation
Install the IAP sensor in the reverse order of removal.

IAT Sensor Inspection

BENH17K11306009
Refer to “IAT Sensor Removal and Installation” (Page
1C-13).
Measure the IAT sensor resistance. Make sure that the
resistance value decreases as temperature increase. If
measured resistance does not change as specified,
IH17K1130060-01
replace IAT sensor with a new one.
• Install the IAT sensor facing the protrusion (1)
NOTE backward and tighten the IAT sensor screws (2) to the
IAT sensor resistance measurement method specified torque.
is the same way as that of the ECT sensor. Tightening torque
(Page 1C-14) IAT sensor screw (a): 1.3 N·m (0.13 kgf-m, 0.95
lbf-ft)
IAT sensor resistance
40 °C (104 °F) [Standard]: 1041 – 1231 Ω

IAT Sensor Removal and Installation

BENH17K11306010 1
Removal
1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the air cleaner box. (Page 1D-6)
3) Remove the IAT sensor (1).

2 , (a )
IH17K1130032-01

IH17K1130031-02
 Engine Electrical Devices: 1C-14

ECT Sensor Inspection 5) Disconnect the ECT sensor coupler (1) and remove
BENH17K11306011 the ECT sensor (2).
Refer to “ECT Sensor Removal and Installation” (Page
1C-14). NOTICE
Measure the resistance between terminals of the ECT
Take special care when handling the ECT
sensor (1). Make sure that the resistance value
sensor. It may cause damage if it gets an
decreases as temperature increase. If measured
excessive impact.
resistance does not change as specified, replace ECT
sensor with a new one.

NOTICE
1
• Handle the ECT sensor carefully as it will
easily be broken if it receives excessively
large shocks or forces.
• Keep the ECT sensor and thermometer (2)
not in contact with the heater’s water
container. 2

ECT sensor resistance

20 °C (68 °F) [Standard]: 2320 – 2590 Ω IH17K1130033-01
80 °C (176 °F) [Standard]: 310 – 326 Ω
Installation
(  ) Install the ECT sensor in the reverse order of removal.
(5740) Pay attention to the following point:
• Install the new gasket (1) and tighten the ECT sensor
(2) to the specified torque.
2320 - 2590 Tightening torque
ECT sensor (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft)
(1150)
(584)
310 - 326
0 20 40 60 80
ID26J1130061-02

1
Ω 2 , (a )
1

IH17K1130034-01
3

ID26J1130060-01 TP Sensor Inspection

BENH17K11306013
3. Heater
1) Check that the throttle cable play is within the
specification. (Page 1C-5)
ECT Sensor Removal and Installation 2) Remove the air cleaner box. (Page 1D-6)
BENH17K11306012
Removal 3) Check the TP sensor power supply voltage and
1) Drain engine coolant. (Page 1F-6) circuit. Refer to “DTC P0120 (C14) / P0220 (C29)” in
2) Lift and support the fuel tank. (Page 1G-9) Section 1A (Page 1A-32).
3) Remove the right side cowling assembly. (Page 4) Turn the ignition switch OFF.
9D-21) 5) Connect the TP sensor coupler and ECM couplers.
4) Remove the accelerator position sensor. (Page 6) Insert the needle point probes to the lead wire
1C-20) coupler.
7) Turn the ignition switch ON.
1C-15 Engine Electrical Devices:

8) Measure the voltage of TP sensor 1 and 2 signals as HO2 sensor output voltage
follows. If the voltage is not within the specified Idle speed [Standard]: 0.6 V or less
value, replace the throttle body assembly. (Page 5000 r/min [Standard]: 0.6 V or more
1C-5)
• TP sensor 1: Between the Bl/R wire and R/W wire
by turning the throttle grip open and close. 1

TP sensor 1 output voltage

V
Closed [Standard]: 3.635 – 3.785 V
Opened [Standard]: Approx. 0.7 V

IH17K1130037-01

7) If the HO2 sensor output voltage is not within the

standard range, replace the HO2 sensor. (Page
1C-16)
8) After finishing the HO2 sensor inspection, remove a
proper hose clamp and install the removed parts.
IH17K1130035-01

• TP sensor 2: Between the P/B wire and R/W wire HO2 Sensor Heater Resistance
by turning the throttle grip open and close. 1) Move the coupler cover (1) and disconnect the HO2
sensor coupler (2).
TP sensor 2 output voltage
Closed [Standard]: 4.235 – 4.385 V
Opened [Standard]: Approx. 1.3 V 1

IH17K1130038-01

2) Measure the HO2 sensor heater resistance between

the terminals of the HO2 sensor. If the resistance is
IH17K1130036-01
out of the specified value, replace the HO2 sensor.
9) After finishing the TP sensor inspection, install the (Page 1C-16)
removed parts.
HO2 sensor heater resistance
HO2 Sensor Inspection 23 °C (73.4 °F) [Standard]: 11.5 – 17.5 Ω
BENH17K11306017
HO2 Sensor Output Voltage
1) Lift and support the fuel tank. (Page 1G-9)
2) Start the engine and warm up the engine enough.
3) Disconnect the HO2 sensor coupler. (Page 1C-15)
4) Measure the HO2 sensor output voltage between the
B wire and Gr wire, in idling condition.
5) If OK, then pinch the PAIR hose (1) with a proper
hose clamp (2).
Ω
IE31J1110206-01
6) Measure the HO2 sensor output voltage while 3) After finishing the HO2 sensor inspection, install the
holding the engine speed at 5000 r/min. removed parts.
 Engine Electrical Devices: 1C-16

HO2 Sensor Removal and Installation

BENH17K11306018
Removal

! WARNING 1 , (a )
Do not remove the HO2 sensor while it is hot.

NOTICE
• Be careful not to expose the HO2 sensor to
excessive shock.
• Do not use an impact wrench when IH17K1130041-01
removing or installing the HO2 sensor.
• Route the HO2 sensor lead wire. Refer to “Wiring
• Be careful not to twist or damage the Harness Routing Diagram” in Section 9A (Page 9A-
sensor lead wire. 13).
1) Remove the left side cowling assembly. (Page 9D- • Reset the long term fuel trim (HO2 sensor feedback
21) learned value). (Page 1C-16)
2) Move the coupler cover (1) and disconnect the HO2
sensor coupler (2).
Long Term Fuel Trim Reset
BENH17K11306041
When replacing the HO2 sensor with a new one, reset
the long term fuel trim in the following procedures:
1
1) Remove the rear seat. (Page 9D-19)
2) Set up the SDS-II tool referring to the SDS-II
operation manual for further details.
3) Turn the ignition switch ON.
4) Click the “Active control”.
2
5) Click the “Long term fuel trim reset”.

IH17K1130039-01

3) Remove the HO2 sensor (1).

IH17K1130040-01

Installation
Install the HO2 sensor in the reverse order of removal.
Pay attention to the following points:
• Apply nickel based anti seize to the thread part of IH17K1130021-01

HO2 sensor (1).

• Tighten the HO2 sensor (1) to the specified torque.
Tightening torque
HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
1C-17 Engine Electrical Devices:

6) Click the “Reset” button to clear the long term fuel CMP Sensor Inspection
trim (HO2 sensor feedback learned value). BENH17K11306034
Refer to “CMP Sensor Removal and Installation” (Page
1C-17).
1) Arrange 3 new 1.5 V batteries (1) in series (check
that total voltage is 4.5 – 5.0 V), 1000 Ω resistor (2)
and connect (–) terminal to the ground terminal (3)
and (+) terminal to the terminal (4).

V
3

1
Yes No IH17K1130042-01

2) Under this condition, if a suitable screwdriver

IH12J1130030-01 touching the pick-up surface of the CMP sensor is
NOTE moved, the tester reading voltage changes (0.8 V
and less ↔ 4.3 V and more). If the voltage reading
The learned value of the long term fuel trim does not change, replace the CMP sensor with a
(HO2 sensor feedback learned value) is set at new one.
preset position.

IH12J1130031-01

7) Close the SDS-II tool and turn the ignition switch

OFF.
I823H1110007-01
NOTE
The long term fuel trim (HO2 sensor feedback CMP Sensor Removal and Installation
BENH17K11306035
learned value) initialization is automatically
Removal
started after the ignition switch is turned OFF
position. 1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the CMP sensor coupler (1).
4) Remove the CMP sensor (2).

IH17K1130043-01
 Engine Electrical Devices: 1C-18

Installation 4) Connect the multi circuit tester with the peak volt
Install the CMP sensor in the reverse order of removal. adapter (1) as follows.
Pay attention to the following points:
CKP sensor – circuit tester connection
• When installing the CMP sensor, make sure to clean
(+) Probe (–) Probe
the sensor surface.
CKP sensor (2) R lead wire G lead wire
• Tighten the CMP sensor bolt (1) to the specified
torque.
2
Tightening torque
CMP sensor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
R
1
V
G
IH17K1130046-02
1, ( a) 5) Measure the CKP sensor peak voltage in the
following procedures:
a) Shift the transmission into neutral, turn the
ignition switch ON.
b) Push the engine stop / starter switch to the
“START” position and allow the engine to crank
for a few seconds, and then measure the CKP
sensor peak voltage.
6) Repeat the b) procedure several times and measure
IH17K1130044-01 the highest peak voltage.
If the voltage is lower than standard range, inspect
CKP Sensor Inspection for coupler connection and metal particles or foreign
BENH17K11306019
material being stuck on the CKP sensor and rotor tip.
CKP Sensor Peak Voltage
If the peak voltage is within the standard range,
NOTE check the continuity between the CKP sensor
coupler and ECM coupler.
Be sure that all the couplers are connected
properly and the battery used is in fully CKP sensor peak voltage
charged condition. When cranking [Standard]: 0.5 V or more
7) After measuring the CKP sensor peak voltage, install
1) Lift and support the fuel tank. (Page 1G-9)
the removed parts.
2) Disconnect the primary and secondary fuel injector
couplers. Refer to “Fuel Injector / Fuel Delivery Pipe CKP Sensor Resistance
Removal and Installation” in Section 1G (Page 1G-
1) Move the coupler cover (1) and disconnect the CKP
17).
sensor coupler (2).
3) Move the coupler cover (1) and disconnect the CKP
sensor coupler (2).
1

IH17K1130045-01

2) Check that the resistance between R lead wire of

IH17K1130045-01
CKP sensor and ground is infinity.

G
IH17K1130047-02
1C-19 Engine Electrical Devices:

3) Measure the resistance between the R lead wire and

G lead wire. If the resistance is not within the [A]
standard range, replace the CKP sensor. (Page
1C-19)
CKP sensor resistance
[Standard]: 148 – 222 Ω

G
IH17K1130048-02

4) After measuring the CKP sensor resistance, install

the removed parts.
[B]

CKP Sensor Removal and Installation

BENH17K11306020
Refer to “Generator Removal” in Section 1J (Page 1J-5)
and “Generator Installation” in Section 1J (Page 1J-6).

TO Sensor Inspection
BENH17K11306021 “a”
TO Sensor Output Voltage
1) Check the TO sensor power supply voltage and
circuit. (Page 1A-69) IH17K1130049-02

2) Turn the ignition switch OFF and connect the ECM [A]: When sensor is horizontal (normal) level.
couplers. [B]: When sensor is leaned 65° “a” or more, left and right, from the
horizontal level.
3) Dismount the TO sensor from its bracket and
connect the TO sensor coupler. 6) After finishing the TO sensor inspection, install the
4) Insert the needle point probes to the lead wire removed parts.
coupler.
5) Turn the ignition switch ON, measure the TO sensor TO Sensor Resistance
output voltage between the B wire and B/Br wire. If 1) Remove the TO sensor. (Page 1C-20)
the voltage is not within the specified value, replace 2) Measure the resistance between R wire terminal (1)
the TO sensor. (Page 1C-20) and B/Br wire terminal (2). If the resistance is out of
TO sensor output voltage the specified value, replace the TO sensor. (Page
Normal [Standard]: 0.4 – 1.4 V 1C-20)
Leaning 65° [Standard]: 3.7 – 4.4 V TO sensor resistance
[Standard]: 19313 – 19507 Ω

2 1

IF04K1130039-02

3) After finishing the TO sensor inspection, install the

removed parts.
 Engine Electrical Devices: 1C-20

TO Sensor Removal and Installation 7) Measure the voltage of accelerator position sensor 1
BENH17K11306022 and 2 signals as follows. If the voltages are not
Removal within the specified value, replace the accelerator
1) Lift and support the fuel tank. (Page 1G-9) position sensor. (Page 1C-20)
2) Remove the TO sensor (1) and disconnect the • Accelerator position sensor 1:
coupler (2). Between the P/W wire and Br/W wire by turning
the throttle grip open and close.
Accelerator position sensor 1 output voltage
1 Closed [Standard]: 0.54 – 0.58 V
Opened [Standard]: Approx. 3.51 V

IH17K1130050-01

Installation
Install the TO sensor in the reverse order of removal.
Pay attention to the following point:
IH17K1130052-01
• When installing the TO sensor, bring the “UPPER”
letters (1) upward. • Accelerator position sensor 2:
Between the B/Bl wire and B/Lg wire by turning
the throttle grip open and close.
1 Accelerator position sensor 2 output voltage
Closed [Standard]: 0.75 – 1.05 V
Opened [Standard]: Approx. 4.59 V

IH17K1130051-01

Accelerator Position Sensor Inspection

BENH17K11306036
NOTICE
Do not attempt to disassemble the IH17K1130053-01
accelerator position sensor. It is 8) After finishing the accelerator position sensor
unserviceable. inspection, install the removed parts.
1) Check that the throttle cable play is within the
specification. (Page 1C-5) Accelerator Position Sensor Removal and
2) Check the accelerator position sensor power supply
Installation
BENH17K11306037
voltages and circuits. (Page 1A-75) Removal
3) Turn the ignition switch OFF. 1) Lift and support the fuel tank. (Page 1G-9)
4) Connect the accelerator position sensor coupler and 2) Remove the right side cowling assembly. (Page
ECM couplers. 9D-21)
5) Insert the needle point probes to the lead wire.
6) Turn the ignition switch ON.
1C-21 Engine Electrical Devices:

3) Disconnect the accelerator position sensor coupler Installation

(1). Install the accelerator position sensor in the reverse
4) Remove the accelerator position sensor No. 1 order of removal. Pay attention to the following points:
bracket bolt (2). • Tighten the accelerator position sensor No. 2 bracket
bolts (1) to the specified torque.
Tightening torque
2 Accelerator position sensor No. 2 bracket bolt
(a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1 , (a )
1

IH17K1130054-01

5) Remove the accelerator position sensor No. 2

bracket (1).

IH17K1130057-01
1
• Tighten the accelerator position sensor No. 1 bracket
bolt (1) to the specified torque.
Tightening torque
Accelerator position sensor No. 1 bracket bolt
(a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1 , (a )
IH17K1130055-02

6) Move the accelerator position sensor outside of the

motorcycle.
7) Remove the screw (1), and then disconnect the
throttle cables (2) from the accelerator position
sensor.

IH17K1130058-01

• Check the throttle cable play and proper operation.

1
(Page 1C-5)
2

IH17K1130056-02
 Engine Electrical Devices: 1C-22

Throttle Valve Motor Inspection

BENH17K11306038
NOTICE
For checking the throttle valve operation, direct apply of the battery voltage to the throttle valve motor
is prohibited.

1) Remove the rear seat. (Page 9D-19)

2) Set up the SDS-II tool referring to the SDS-II operation manual for further details.
3) Turn the ignition switch ON.
4) Click the “Active control”.
5) Click the “STV/ETV drive control”.

IH17K1130021-01

6) Click “Fully open” and “Fully closed” button.

At this time, if an operation sound is heard from the throttle valve motor, the function is normal.
If the sound is not heard from the throttle valve motor, replace the throttle body assembly. (Page 1C-5)

IH17K1130059-01

7) Close the SDS-II tool and turn the ignition switch OFF.

IMU Inspection IMU Removal and Installation

BENH17K11306039 BENH17K11306040
Refer to “IMU Inspection” in Section 4E (Page 4E-47). Refer to “IMU Removal and Installation” in Section 4E
(Page 4E-47).
1C-23 Engine Electrical Devices:

Specifications
Tightening Torque Specifications
BENH17K11307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Intake pipe clamp screw 1.5 0.15 1.10 (Page 1C-6)
IAT sensor screw 1.3 0.13 0.95 (Page 1C-13)
ECT sensor 18 1.8 13.5 (Page 1C-14)
HO2 sensor 25 2.5 18.5 (Page 1C-16)
CMP sensor bolt 10 1.0 7.5 (Page 1C-18)
Accelerator position sensor No. 2 bracket bolt 10 1.0 7.5 (Page 1C-21)
Accelerator position sensor No. 1 bracket bolt 10 1.0 7.5 (Page 1C-21)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Throttle Body Components” (Page 1C-4)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K11308001
NOTE
Required service material(s) is also described in:
“Throttle Body Components” (Page 1C-4)

Special Tool
BENH17K11308002
09917–47011
Vacuum pump gauge set
(Page 1C-11) /
(Page 1C-12)
 Engine Mechanical: 1D-1

Engine Mechanical
Engine

Precautions
Precautions for Engine Mechanical
BENH17K11400001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

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

General Description
VVT System Description
BENH17K11401001
The new VVT system installed in the intake camshaft sprocket assembly uses centrifugal force of steel balls.
This simplified system is compact and light weight and has high reliability. Also this system does not consume any
power to operate.
In the performance, increase in high-rpm power without sacrificing any low-rpm or mid-range performance.
The VVT system in the intake camshaft sprocket assembly is composed of a camshaft sprocket base (1), camshaft
sprocket springs (2), ball guide (3), balls (4), camshaft sprocket (5) and the circlip.
Effective revolution range of the VVT system has been adjusted by the preset pressure of the camshaft sprocket
springs.

4 3

2
5
6

IH17K1140287-01

6. Intake camshaft
1D-2 Engine Mechanical:

Operation Description
12 steel balls are positioned in grooves in the intake cam sprocket and camshaft sprocket ball guide. Moved outward
by centrifugal force, balls stack in different grooves in low and high rpm, rotate the intake cam at high rpm, retarding
intake cam timing.
The grooves in the camshaft sprocket ball guide is radial and the grooves in the camshaft sprocket is slanted.
Therefore, when balls go outward at high engine speed, the intake camshaft rotates to retard the cam timing shown
below. The Intake cam timing is thus optimized for both high-rpm and low and mid-rpm ranges.

[A] [B]

IH17K1140289-02

[A]: Low engine speed [B]: High engine speed

Diagnostic Information and Procedures

Engine Mechanical Symptom Diagnosis NOTE
BENH17K11404001
Refer to “Engine Symptom Diagnosis” in Section 1A • Before checking the engine for
(Page 1A-12). compression pressure, make sure that the
cylinder head bolts are tightened to the
Compression Pressure Check specified torque values and the valves are
BENH17K11404002 properly adjusted.
The compression pressure reading of a cylinder is a
• Make sure that the battery is in fully-
good indicator of its internal condition.
charged condition.
The decision to overhaul the cylinder is often based on
the results of a compression test. Periodic maintenance 1) Warm up the engine.
records kept at your dealership should include
compression readings for each maintenance service. 2) Lift and support the fuel tank. (Page 1G-9)
3) Remove the air cleaner box. (Page 1D-6)
4) Remove the spark plugs. (Page 1H-6)
 Engine Mechanical: 1D-3

5) Disconnect the primary and secondary fuel injector 8) Push the engine stop / starter switch to the “START”
couplers. Refer to “Fuel Injector / Fuel Delivery Pipe position and crank the engine for a few seconds.
Removal and Installation” in Section 1G (Page 1G- Record the maximum gauge reading as the cylinder
17). compression.
6) Install the compression gauge and adapter in the 9) Repeat this procedure with the other cylinders.
spark plug hole. Make sure that the connection is
Compression pressure
tight.
[Standard]: 1200 – 1600 kPa (12.2 – 16.3 kgf/cm2,
Special tool 174 – 232 psi)
(A): 09915–64512
Compression pressure difference
(B): 09915–63311
[Limit]: 200 kPa (2.0 kgf/cm2, 29.0 psi)
If compression pressure is less than the service
(A)
limit, it is considered any of the following
reasons:
• Excessively worn cylinder walls
• Worn piston or piston rings
• Piston rings stuck in grooves
• Poor valve seating
(B)
• Ruptured or otherwise defective cylinder head
gasket
IH17K1140002-01 Overhaul the engine in the following cases:
7) Keep the throttle grip in the fully-opened position. • Compression pressure in one of the cylinders is
1000 kPa (10.2 kgf/cm2, 145 psi) and less.
• The difference in compression pressure between
any two cylinders is 200 kPa (2.0 kgf/cm2, 29.0
psi) and more.
• All compression pressure readings are below
1200 kPa (12.2 kgf/cm2, 174 psi) even when they
measure 1000 kPa (10.2 kgf/cm2, 145 psi) and
more.
10) After checking the compression pressure, install the
removed parts.

IH17K1140003-01
1D-4 Engine Mechanical:

Repair Instructions
Intake System Construction
BENH17K11406001

(c)
(c)

9 FWD 9
1
(d)

(f) 8
(b) (a) (b)

(e)

4 2 6
3
[J]
(e)
10
FWD

11

18 [C]
[I] [D]
[A]
FWD
[C] 16
19
[B]
20

17
FWD
16
12

[E] [H]
8
7
13

15
14

[G] [F]

IH17K1140004-02
 Engine Mechanical: 1D-5

[A]: To EVAP system purge control solenoid valve 3. Air cleaner element 15. Surge hose
[B]: Lower side 4. Air cleaner duct plate 16. AP sensor
[C]: Range of the clamp end. 5. Secondary fuel delivery pipe assembly 17. AP sensor holder
[D]: Install the IAT sensor facing the hook for the coupler 6. IAT sensor 18. Seat rail
backward.
[E]: Face the clamp end forward. 7. Crankcase breather (PCV) hose 19. Starter relay
[F]: Route the hoses in order of the surge hose, fuel feed 8. Fuel feed hose 20. PAIR hose nipple
hose and crankcase breather (PCV) hose from top.
[G]: Face the clamp end backward. 9. Intake pipe : 8.4 Nm (0.86 kgf-m, 6.20 lbf-ft)
[H]: Fit the AP sensor holder in the cutout of the rear 10. Throttle body assembly : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft)
fender front.
[I]: Fit the AP sensor holder on the seat rail. 11. Clamp : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
[J]: To upper crankcase 12. IAP sensor : 1.8 Nm (0.18 kgf-m, 1.35 lbf-ft)
: Fit to projection on the air cleaner box.
1. Air cleaner cap 13. EVAP system purge control solenoid valve : 1.3 Nm (0.13 kgf-m, 0.95 lbf-ft)
2. Air cleaner box 14. EVAP canister : 4.3 Nm (0.44 kgf-m, 3.20 lbf-ft)

Air Cleaner Element Removal and Installation 4) Remove the air cleaner element (1).
BENH17K11406002
Removal
1
1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the secondary fuel delivery pipe mounting
bolts (1).

NOTE
Before removal of the secondary fuel
injectors and the air cleaner cap, remove all
dirt, mud and dust to prevent such dirts
dropping into clean side of the air cleaner.
IH17K1140007-01

Installation
Install the air cleaner element in the reverse order of
removal. Pay attention to the following points:
• Tighten the air cleaner cap screws to the specified
1 torque.
Tightening torque
Air cleaner cap screw (a): 1.8 N·m (0.18 kgf-m,
1.35 lbf-ft)

IH17K1140005-01

3) Open the air cleaner cap (1) with the secondary fuel
delivery pipe.

(a)

IH17K1140008-01

IH17K1140006-01
1D-6 Engine Mechanical:

• Tighten the secondary fuel delivery pipe mounting 4) Remove the air cleaner bolt (1).
bolts to the specified torque.
Tightening torque
Secondary fuel delivery pipe mounting bolt (a):
10 N·m (1.0 kgf-m, 7.5 lbf-ft) 1

(a)
IH17K1140010-01

5) Remove the funnels (1).

IH17K1140293-01

Air Cleaner Box Removal and Installation

BENH17K11406003

Removal
1
1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the secondary fuel delivery pipe mounting
bolts (1).
IH17K1140011-01

NOTE 6) Remove the IAP sensor (1).

Before removal of the secondary fuel
injectors and the air cleaner cap, remove all
dirt, mud and dust to prevent such dirts
dropping into clean side of the air cleaner.

1 IH17K1140012-02

7) Disconnect PAIR hose (1), IAT sensor coupler (2)

and crankcase breather (PCV) hose (3).

IH17K1140005-01

3) Remove the air cleaner cap (1).

1
1

2
3
IH17K1140013-01

8) Remove the air cleaner box.

IH17K1140009-01
 Engine Mechanical: 1D-7

Installation NOTICE
Install the air cleaner box in the reverse order of
• Do not blow the air cleaner element with
removal. Pay attention to the following points:
compressed air.
• Route the hoses properly. Refer to “Intake System
Construction” (Page 1D-4). • If driving under dusty conditions, replace
the air cleaner element more frequently.
• Tighten the funnel bolts (1) to the specified torque. Make sure that the air cleaner is in good
Tightening torque condition at all times. Life of the engine
Funnel bolt (a): 4.3 N·m (0.44 kgf-m, 3.20 lbf-ft) depends largely on this component.

1, (a)
IH17K1140014-01
IH17K1140016-01
• Tighten the air cleaner bolt (1) to the specified torque.
2) Remove the drain plug (1) and drain water from the
Tightening torque air cleaner box.
Air cleaner bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1, ( a)

1
IH17K1140017-02
IH17K1140015-01
3) Install the drain plug.
• Install the new fuel injector cushion seals. Refer to
“Fuel Injector / Fuel Delivery Pipe Removal and
Intake Pipe Removal and Installation
Installation” in Section 1G (Page 1G-17). BENH17K11406012
• Tighten the secondary fuel delivery pipe mounting Refer to “Throttle Body Removal and Installation” in
bolts and air cleaner cap screws to the specified Section 1C (Page 1C-5).
torque. Refer to “Air Cleaner Element Removal and
Installation” (Page 1D-5). Removal
1) Remove the intake pipe clamps (1).
Air Cleaner Element Inspection 2) Remove the intake pipes (2).
BENH17K11406004
Refer to “Air Cleaner Element Removal and Installation”
(Page 1D-5). 2
1) Inspect the air cleaner element for clogging. If it is
clogged with dirt, replace it with a new one.

IH17K1140018-01
1D-8 Engine Mechanical:

Installation 3) Disconnect the cooling fan motor couplers (1), horn

Install the intake pipe in the reverse order of removal. coupler (2) and wiring harness clamps (3).
Pay attention to the following points:
• Install the new O-rings (1) to the intake pipes.

1 3 3

2 1
IH17K1140023-01

4) Remove the radiator mounting bolts (1) and move

IH17K1140019-01 the radiator downward.
• Tighten the intake pipe screws (1) to the specified
torque. 1
Tightening torque 1
Intake pipe screw (a): 8.4 N·m (0.86 kgf-m, 6.20
lbf-ft)

1 , (a)
1
IH17K1140024-01

5) Release the right handle switch lead wire coupler

(1), left handle switch lead wire couplers (2) and
wiring harness clamp (3) from radiator heat shield.

IH17K1140020-01 3

Cylinder Head Cover Removal and Installation

BENH17K11406013
Refer to “Throttle Body Removal and Installation” in
Section 1C (Page 1C-5).

Removal 1
1) Remove the oil cooler. (Page 1E-8) 2
2) Remove the lower bracket cover (1).
IH17K1140025-02

6) Remove the radiator heat shield (1).

1

IH17K1140022-01

IH17K1140026-01
 Engine Mechanical: 1D-9

7) Remove the following cables. 15) Lift the cylinder head cover (1) from the cylinder
• Clutch cable from clutch lever side: (Page 5C-7) head and turn the cylinder head cover 90 degrees.
• Throttle cables from accelerator position sensor 16) Remove the cylinder head cover.
side: (Page 1C-5)
8) Remove the right side cowling bracket (1).

IH17K1140030-01

1 17) Remove the dowel pins (1) and O-rings (2).

IH17K1140027-01

9) Remove the regulator/rectifier with its bracket.

(Page 1J-8) 1
10) Remove the front brake hose clamp (1) (If
equipped).

1 2
IH17K1140031-01

18) Remove the gaskets (1) and (2).

IH17K1140028-01

11) Remove the air intake pipe bolts (1) and move each
air intake pipe outward.

1
1 1
IH17K1140032-01

Installation
1) Install the dowel pins (1) and new O-rings (2).

IH17K1140029-01 1
12) Remove the ignition coils. (Page 1H-5)
13) Disconnect the PAIR solenoid valve coupler and
remove the PAIR reed valves. (Page 1B-10)
14) Remove the CMP sensor. (Page 1C-17)

2
IH17K1140031-01

2) Install new gaskets to the cylinder head cover.

1D-10 Engine Mechanical:

3) Apply sealant to the cam end cap points of the

gasket and cylinder head as shown.
1 , (a )
“A”: Sealant 99000–31140 (SUZUKI BOND
1207B)

“A”

1 , (a )
IH17K1140036-01

8) Install the CMP sensor. (Page 1C-17)

9) Install the PAIR reed valves and connect the PAIR
“A”
solenoid valve coupler. (Page 1B-10)
IH17K1140033-01 10) Install the ignition coils. (Page 1H-5)
11) Install the air intake pipe bolts. Refer to “Body
“A” Cowling Removal and Installation” in Section 9D
(Page 9D-22).
12) Install the front brake hose clamp (If equipped).
(Page 4A-1)
13) Install the regulator/rectifier with its bracket. (Page
1J-8)
14) Install the right side cowling bracket (1).

IH17K1140034-01

4) Place the cylinder head cover on the cylinder head.

NOTICE
Never stick sealant on the cam face when
installing the cylinder head cover.

5) Inspect if the cylinder head cover gasket is properly 1

fit between the cylinder head cover and the cylinder
IH17K1140037-02
head.
15) Install the following cables.
6) Set the new gaskets (1) to each cylinder head cover
bolt and coat the both sides of the gasket with • Clutch cable to clutch lever side: (Page 5C-7)
engine oil. • Throttle cables to accelerator position sensor side:
(Page 1C-5)
16) Install the radiator heat shield (1) by fitting
1 projections (2) into the holes on the cylinder head.

IH17K1140035-02

7) Tighten the cylinder head cover bolts (1) to the

specified torque. 2
IH17K1140038-01
Tightening torque
Cylinder head cover bolt (a): 14 N·m (1.4 kgf-m,
10.5 lbf-ft)
 Engine Mechanical: 1D-11

17) Connect the right handle switch lead wire coupler, 2) Remove the crankshaft hole plug (1).
left handle switch lead wire couplers and wiring
harness clamp to radiator heat shield. (Page 9A-
13)
18) Install the radiator. (Page 1F-8)
1
19) Install the lower bracket cover (1).

IH17K1140041-01

3) Turn the crankshaft to bring the “ ” mark (1) on the

starter clutch to the slit (2) of cap hole thread and
also to bring the camshafts to the position as shown.

IH17K1140022-01

20) Install the oil cooler. (Page 1E-8)

21) After finishing the cylinder head cover installation,
check the following items.
• Throttle cable play: (Page 1C-5)
• Clutch cable play: (Page 5C-4)
• Engine oil leakage: (Page 1E-4)

Cylinder Head Cover Inspection

BENH17K11406014 IH17K1140042-01
Refer to “Cylinder Head Cover Removal and Installation”
(Page 1D-8).
Clean and check the gasket grooves (1) and PAIR reed 1
2
valve mating surfaces (2) of the cylinder head cover.
If there is anything unusual, replace the cylinder head
cover with a new one.

IH17K1140043-01

15 14 13
2 3 2 1

2 IN. 2
EX.

IH17K1140040-02 1

Cam Chain Tension Adjuster / Camshaft

Removal
BENH17K11406015
Refer to “Cylinder Head Cover Removal and Installation”
(Page 1D-8).
1) Remove the spark plugs. (Page 1H-6)
IH17K1140049-01
1D-12 Engine Mechanical:

4) Remove the cam chain tension adjuster (1). 7) Remove the dowel pins (1).
8) Remove the intake camshaft (2) and exhaust
camshaft (3).
1 NOTE
When the camshafts have been removed, the
rocker arms could be lifted widely and the
shims between rocker arms and valves may
fall away. Pick the shims up from the top of
valves beforehand, if necessary. Refer to
“Rocker Arm Shaft / Rocker Arm Removal
and Installation” (Page 1D-33).
IH17K1140045-01

5) Remove the gasket (1).

1
3
1

1
2
IH17K1140048-01

IH17K1140046-01
9) Hold hexagonal section of each camshaft (3) with an
adjustable wrench and remove the intake camshaft
6) Remove the cam chain guide No. 2 (1) and camshaft
sprocket (1) and exhaust camshaft sprocket (2).
journal holders (2).
NOTICE
NOTICE
Be sure to loosen the camshaft journal • If the camshaft sprocket is removed on the
holder bolts evenly by shifting the wrench in engine using the cam chain tension, the
the descending order of numbers. cam chain or VVT could be damaged.
Remove the camshaft first and then
remove the camshaft sprocket.
2 1 • If the camshaft is held with a vise,
excessive tightening may damage the
hollow camshaft, or insufficient tightening
allows the camshaft to slip off and may
damage the hexagonal section.
To avoid damaging the camshaft, hold it by
using an adjustable wrench.

3
2
IH17K1140047-01

1 2
IH17K1140050-01
 Engine Mechanical: 1D-13

10) Remove the sprocket angle pin (1) from the intake NOTICE
camshaft sprocket assembly. Minute loose fitting is configured between
the intake camshaft sprocket and camshaft,
and oblique insertion may catch the
camshaft.
Without hammering, carefully insert the
1 intake camshaft sprocket.

“A”

IH17K1140052-01
2

Cam Chain Tension Adjuster / Camshaft

Installation
BENH17K11406016
1) Install the shims, if removed. Refer to “Rocker Arm 1
Shaft / Rocker Arm Removal and Installation” (Page IH17K1140053-03
1D-33). d. Tighten the intake camshaft sprocket bolt to
2) Hold hexagonal section of each camshaft with an the specified torque.
adjustable wrench and install the intake camshaft
sprocket assembly and exhaust camshaft sprocket. Tightening torque
Intake camshaft sprocket bolt (a): 60 N·m (
NOTICE 6.1 kgf-m, 44.5 lbf-ft)
If the camshaft is held with a vise, excessive
tightening may damage the hollow camshaft,
or insufficient tightening allows the camshaft
to slip off and may damage the hexagonal
section.
To avoid damaging the camshaft, hold it by
using an adjustable wrench.

• Intake camshaft sprocket

a. Install the sprocket angle pin (1) into the
(a )
intake camshaft sprocket assembly.
IH17K1140054-01

• Exhaust camshaft sprocket

a. Positioning “ ” with “2” (2) above the cutout
(1) of the exhaust camshaft as shown, set the
1 exhaust camshaft sprocket.

IH17K1140052-01

b. Apply engine oil “A” to the camshaft and

camshaft sprocket base inside surface.
c. Align the sprocket angle pin (1) with the intake
camshaft groove (2) and install the intake
camshaft sprocket assembly to the camshaft. IH17K1140055-01
1D-14 Engine Mechanical:

b. Apply thread lock to the exhaust camshaft 4) Turn the crankshaft clockwise and align the “ ”
sprocket bolts (1) and tighten them to the mark (1) on the starter clutch to the slit (2) of cap
specified two-step torque. hole thread while keeping the cam chain pulled
upward.
“A”: Thread lock cement 99000–32030
(THREAD LOCK CEMENT 1303B) NOTICE
Tightening torque • Pull the cam chain upward, or the chain
Exhaust camshaft sprocket bolt (a): 16 → will be caught between crankcase and cam
25 Nm (1.6 → 2.5 kgf-m, 12.0 → 18.5 lbf-ft) drive sprocket.
• To adjust the camshaft timing correctly, be
sure to align the “ ” mark (1) with slit (2)
and hold this position when installing the
camshafts.

1, “A”, (a)

IH17K1140056-01

3) Apply engine oil to the camshaft journals.

NOTE
Identify the camshafts according to the
following embosses letters. IH17K1140058-02
Intake camshaft (1): [A]
Exhaust camshaft (2): [B]
1
2

[B]

1
IH17K1140043-01

[A]
IH17K1140057-01

[A]: IN [B]: EX
 Engine Mechanical: 1D-15

5) Pull the cam chain lightly. NOTE

6) Turn the exhaust camshaft so that the “ ” mark is The cam chain should now be on all three
aligned with the gasket surface of the cylinder head. sprockets. Be careful not to move the
(The exhaust camshaft sprocket has an “ ” with “1” crankshaft until the camshaft journal holders
(1).) and cam chain tension adjuster are secured.
7) Engage the cam chain with the exhaust camshaft
sprocket.
2
NOTE
Before installing the camshaft, check that the
shims are installed correctly. 2

8) The other “ ” with “2” (2) should now be pointing

1
straight up. Starting from the roller pin that is directly
above the “ ” with “2” (2), count out 15 roller pins 1
(from the exhaust camshaft side going towards the
intake camshaft side).
9) Engage the 15th roller pin (3) on the cam chain with IH17K1140060-01
the cutout (4) on the intake camshaft sprocket ball
guide.
3
4

IH17K1140061-01

IN. EX.

15 14 13
3 2 1

IH17K1140063-01
1D-16 Engine Mechanical:

10) Install the dowel pins (1).

11) Apply engine oil to the camshaft journals and cam
1 [B]
faces. 2
[B]

1
1

[A]

[A] 1
IH17K1140065-01

1 [A]: IN [B]: EX

IH17K1140064-01 14) Tighten the camshaft journal holder bolts in

12) Install the camshaft journal holders (1) and cam ascending order of numbers to the specified torque.
chain guide No. 2 (2). Tightening torque
13) Have the camshaft journal holders seated evenly by Camshaft journal holder bolt: 10 N·m (1.0 kgf-
tightening the camshaft journal holder bolts lightly, in m, 7.5 lbf-ft)
the ascending order of numbers.
NOTICE
NOTICE
The camshaft journal holder bolts are made
Damage to head or camshaft journal holder of a special material and much superior in
thrust surfaces may result if the camshaft strength, compared with other types of high
journal holders (1) are not drawn down strength bolts.
evenly. Take special care not to use other types of
bolts.
NOTE
• Each camshaft journal holder (1) is
identified with a cast-on letters.
• The ascending order of numbers are
indicated on the camshaft journal holders
(1).

5 (1) 9 (3) 13
7 11
(2) (4)
6 8 10 12 14

5 (1) 9 (3) 13
7 11
(2) (4)
6 8 10 12 14

IH17K1140066-01
 Engine Mechanical: 1D-17

15) Holding the cam chain tension adjuster (1),

compress the plunger (2) by turning the adjuster
body until the groove (4) reaches the outer circlip (3).

NOTICE
1
When turning the adjuster body, do not make
the groove (4) to cross the outer circlip (3).
If the inner circlip (5) is caught in the groove
(4), plunger may not come out automatically
from the adjuster body even if pushing force
is applied on the head.
In such a case, it needs to be disassembled. IH17K1140046-01

18) Install the cam chain tension adjuster (1) and tighten
NOTE
the bolts to the specified torque.
If it is difficult to compress the plunger
because of internal engine oil, disassemble Tightening torque
the adjuster by releasing the inner circlip (5) Cam chain tension adjuster bolt (a): 10 N·m (1.0
and spill out the oil. kgf-m, 7.5 lbf-ft)
19) Remove the cylinder head plug (2) and gasket.

(a)
1
1

5
2 (a)
3 2

IH17K1140067-01
IH17K1140070-02

20) Unhook the outer circlip (1) from its groove by

pushing the stepped part (2) of the plunger head with
a screwdriver.

1
IH17K1140068-01

16) Turn the plunger head (1) clockwise more than 90°
2
to make a little play in the inner thread mechanism.
IH17K1140071-01

1 2
IH17K1140069-01

17) Fit a new gasket (1). IH17K1140072-02

1D-18 Engine Mechanical:

21) Rotate the crankshaft (some turns) and recheck the Camshaft Inspection
valve timing. BENH17K11406017
Refer to “Cam Chain Tension Adjuster / Camshaft
NOTICE Removal” (Page 1D-11) and “Cam Chain Tension
Adjuster / Camshaft Installation” (Page 1D-13).
Make sure that the adjuster works properly
by checking no slack at point [A].
Camshaft Identification
The camshafts can be identified by the embossed letter.
[A]

[B]

IH17K1140073-01
[A]
22) Install the new gasket (1) and tighten the cylinder IH17K1140076-01

head plug (2) to the specified torque. [A]: IN (Intake camshaft) [B]: EX (Exhaust camshaft)

Tightening torque
Cylinder head plug (a): 10 N·m (1.0 kgf-m, 7.5 Cam Wear
lbf-ft) Check the camshaft for wear or damage.
Measure the cam height “a” with a micrometer.
Replace a camshaft if the cams are worn to the service
limit.
1
Cam height
Intake [Limit]: 35.38 mm (1.393 in)
Exhaust [Limit]: 35.38 mm (1.393 in)
Special tool
09900–20202
2, (a)

IH17K1140074-01

23) Check and adjust the valve clearance. (Page 1D-

“a”
21)
24) Install the new O-ring (1) and tighten the crankshaft
hole plug (2) to the specified torque.
Tightening torque I649G1140199-02

Crankshaft hole plug (a): 11 N·m (1.1 kgf-m, 8.5

lbf-ft)

1
2, (a)

IH17K1140075-01
 Engine Mechanical: 1D-19

Camshaft Runout 4) Tighten the camshaft journal holder bolts in

Measure the runout using the dial gauge. Replace the ascending order of numbers to the specified torque.
camshaft if the runout exceeds the limit. Refer to “Cam Chain Tension Adjuster / Camshaft
Installation” (Page 1D-13).
Camshaft runout
Intake & Exhaust [Limit]: 0.10 mm (0.004 in) NOTE
Special tool Do not rotate the camshafts with the
(A): 09900–20607 plastigauge in place.
(B): 09900–20701
(C): 09900–21304 Tightening torque
Camshaft journal holder bolt: 10 N·m (1.0 kgf-
(A)
m, 7.5 lbf-ft)

(B)

(C)
IF04K1140086-01

Camshaft Journal Wear

Inspect the camshaft journal wear in the following I947H1140066-01
procedures:
5) Remove the camshaft journal holders and measure
1) Determine whether or not each journal is worn down the width of the compressed plastigauge using the
to the limit by measuring the oil clearance with the envelope scale.
camshaft installed in place.
6) This measurement should be taken at the widest
2) Use the plastigauge to read the clearance at the part of the compressed plastigauge.
widest portion, which is specified as follows.
Camshaft journal oil clearance
Special tool Intake [Limit]: 0.150 mm (0.0059 in)
(A): 09900–22301 Exhaust [Limit]: 0.150 mm (0.0059 in)
(B): 09900–22302

(A), (B)

IF04K1140087-01 I947H1140067-01
3) Install each camshaft journal holder to its original
position. Refer to “Cam Chain Tension Adjuster /
Camshaft Installation” (Page 1D-13).
1D-20 Engine Mechanical:

7) If the camshaft journal oil clearance exceeds the Camshaft Sprocket

limit, remove the engine assembly, and measure the Inspect the teeth of each camshaft sprocket for wear or
inside diameter of the camshaft journal holder and damage.
the outside diameter of the camshaft journal. If they are worn or damaged, replace the sprockets and
Replace the camshaft or the cylinder head cam chain as a set.
depending upon which one exceeds the
specification.
Camshaft journal holder I.D.
Intake [Standard]: 24.012 – 24.025 mm (0.9454 –
0.9458 in)
Exhaust [Standard]: 24.012 – 24.025 mm (0.9454
– 0.9458 in)
Camshaft journal O.D.
Intake [Standard]: 23.959 – 23.980 mm (0.9433 –
0.9440 in)
Exhaust [Standard]: 23.959 – 23.980 mm (0.9433
IH17K1140077-01
– 0.9440 in)
Special tool VVT Inspection
BENH17K11406049
(A): 09900–20602
Refer to “Cam Chain Tension Adjuster / Camshaft
(B): 09900–22403
Removal” (Page 1D-11) and “Cam Chain Tension
(C): 09912–66310
Adjuster / Camshaft Installation” (Page 1D-13).
Check the following items in the state that VVT is
installed to the intake camshaft. At least, one item is
found defective, replace the intake camshaft sprocket
assembly.
1) Hold the camshaft, move the camshaft sprocket (1),
camshaft sprocket springs (2) and washer (3)
(B)
clockwise and check that no noticeable play is felt.
(A)

IF04K1140088-01

(C)

IH17K1140078-01

2) Visually check that the camshaft sprocket balls (1)

IF04K1140089-01 are positioned in the center and the circlip (2) is fixed
normally.

2 2

1
1
IH17K1140079-02
 Engine Mechanical: 1D-21

3) Using a thickness gauge, measure clearance “a” 2) Check that the plunger goes out automatically when
between the camshaft sprocket and camshaft its head (1) is tapped. If it does not work smoothly,
sprocket ball guide at 4 points, and check difference replace the cam chain tension adjuster with a new
between the maximum value and minimum value is one.
within the standard range.
Clearance between camshaft sprocket and
camshaft sprocket ball guide
[Standard]: 0.2 – 0.8 mm (0.008 – 0.031 in)
Unevenness of the clearance between camshaft
sprocket and camshaft sprocket ball guide at 4
points
[Limit]: 0.5 mm (0.019 in)
Special tool
(A): 09900–20803 1
IH17K1140082-01

(A) “a” Valve Clearance Inspection and Adjustment

BENH17K11406019
Refer to “Cylinder Head Cover Removal and Installation”
(Page 1D-8) and “Spark Plug Removal and Installation”
in Section 1H (Page 1H-6).

Inspection
Valve clearance adjustment must be checked and
adjusted, a) at the time of periodic inspection, b) when
the valve mechanism is serviced, and c) when the
IH17K1140080-01 camshafts are removed for servicing.

Cam Chain Tension Adjuster Inspection NOTE

BENH17K11406018
Refer to “Cam Chain Tension Adjuster / Camshaft • The cam must be at positions, (1) or (2),
Removal” (Page 1D-11) and “Cam Chain Tension when checking the valve clearance.
Adjuster / Camshaft Installation” (Page 1D-13). Clearance readings should not be taken
with the cam in any other position than
1) Turn the plunger (1) into the adjuster body until the
these two positions.
groove (3) reaches the outer circlip (2). Refer to
“Cam Chain Tension Adjuster / Camshaft • The valve clearance should be taken when
Installation” (Page 1D-13). each cylinder is at Top Dead Center (TDC)
of compression stroke.
• The clearance specification is for COLD
state.
• To turn the crankshaft for valve clearance
checking, be sure to use a wrench, and
rotate in the normal running direction.

2
IN. EX.
2 1 1 2
3
1
IH17K1140081-02

IH17K1140083-01
1D-22 Engine Mechanical:

1) Remove the crankshaft hole plug (1).

1

1 1
IH17K1140087-01
IH17K1140084-01

2) Turn the crankshaft to bring the “ ” mark (1) on the

starter clutch to the slit (2) of cap hole thread and
also to bring the cutout (3) on the right end of
exhaust camshaft to the position as shown.

1
2
(A )

IH17K1140088-02

(A)

IH17K1140043-01

IN. EX.
3

IH17K1140089-01

4) Turn the crankshaft 360 degrees (one rotation) to

bring the “ ” mark on the starter clutch to the slit of
cap hole thread and also to bring the cutout (1) to the
IH17K1140086-01 position as shown.
3) In this condition, read the valve clearance between
the cam face and rocker arm at the valves (1) (IN
and EX of cylinder #4, EX of #3 and IN of #2). If the IN. EX.
clearance is out of specification, adjust the
clearance. 1

Valve clearance
When engine cold
Intake [Standard]: 0.07 – 0.15 mm (0.0028 –
0.0059 in)
Exhaust [Standard]: 0.16 – 0.24 mm (0.0063 –
0.0094 in) IH17K1140090-02

Special tool
(A): 09900–20803
 Engine Mechanical: 1D-23

5) Read the clearance at the rest of the valves (1) and 3) Check the figures printed on the shim. These figures
adjust the clearance if necessary. indicate the thickness of the shim, as illustrated.

1.70 mm

I837H1020014-01

4) Select a replacement shim that will provide a

clearance within the specified range. For the
purpose of this adjustment, a total of 21 sizes of
shim are available ranging from 1.70 to 2.70 mm in
1
IH17K1140091-01 steps of 0.05 mm.
5) Fit the selected shim (1) to the valve stem end, with
Adjustment numbers toward valve stem. Be sure to check shim
The clearance is adjusted by replacing the existing shim size with micrometer to ensure its size.
with a thicker or thinner shim.
1) Remove the intake or exhaust camshaft. (Page NOTE
1D-11) • Be sure to apply engine oil to shim top and
2) Raise the rocker arm (1) and remove the shim (2) by bottom faces.
fingers or magnetic hand. • When seating the shim, be sure the figure
printed surface faces the valve stem.

1
2

IH17K1140092-01

IH17K1140093-01
 SHIM SELECTION TABLE [INTAKE]
SHIM NO. (12892-05C00-XXX)

SHIM SET (12800-05830)

SUFFIX 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270
1D-24 Engine Mechanical:

NO.
MEASURED
VALVE PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70

0.00-0.01 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60
0.02-0.06 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65
0.07-0.15 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.16-0.20 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.21-0.25 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.26-0.30 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.31-0.35 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.36-0.40 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.41-0.45 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.46-0.50 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
(INTAKE SIDE)

0.51-0.55 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.56-0.60 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.61-0.65 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.66-0.70 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.71-0.75 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.76-0.80 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.81-0.85 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.86-0.90 2.45 2.50 2.55 2.60 2.65 2.70
0.91-0.95 2.50 2.55 2.60 2.65 2.70 HOW TO USE THIS CHART:
0.96-1.00 2.55 2.60 2.65 2.70 I. Measure valve clearance. “ENGINE IS COLD”
1.01-1.05 2.60 2.65 2.70
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
1.06-1.10 2.65 2.70
column.
1.11-1.15 2.70
EXAMPLE
Valve clearance is 0.18 mm
Present shim size 2.20 mm
Shim size to be used 2.25 mm

IH17K1140094-02
 SHIM SELECTION TABLE [EXHAUST]
SHIM NO. (12892-05C00-XXX)

SHIM SET (12800-05830)

SUFFIX 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270
NO.
MEASURED
VALVE PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70

0.01-0.05 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55
0.06-0.10 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60
0.11-0.15 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65
0.16-0.24 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.25-0.29 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.30-0.34 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.35-0.39 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.40-0.44 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.45-0.49 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.50-0.54 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
(EXHAUST SIDE)

0.55-0.59 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.60-0.64 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.65-0.69 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.70-0.74 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.75-0.79 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.80-0.84 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.85-0.89 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.90-0.94 2.40 2.45 2.50 2.55 2.60 2.65 2.70
0.95-0.99 2.45 2.50 2.55 2.60 2.65 2.70 HOW TO USE THIS CHART:
1.00-1.04 2.50 2.55 2.60 2.65 2.70 I. Measure valve clearance. “ENGINE IS COLD”
1.05-1.09 2.55 2.60 2.65 2.70
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
1.10-1.14 2.60 2.65 2.70
column.
1.15-1.19 2.65 2.70
EXAMPLE
1.20-1.24 2.70
Valve clearance is 0.28 mm
Engine Mechanical:

Present shim size 2.20 mm

Shim size to be used 2.25 mm

IH17K1140095-02
1D-25
1D-26 Engine Mechanical:

6) Install the camshafts and cam chain tension adjuster. 13) Release the clamp (1) and remove the fuel tank
(Page 1D-13) water drain hose (2) and breather hose (If equipped)
7) Rotate the engine so that the rocker arm is (3) from engine.
depressed fully. This will squeeze out oil trapped
between the shim and the rocker arm that could
cause an incorrect measurement, then check the
clearance again to confirm that it is within the 1
specified range.
8) After finishing the valve clearance adjustment, check
the engine for smooth starting and free from any
abnormal noise.

Engine Assembly Removal 3 2

BENH17K11406020
Before taking the engine out of the frame, wash the IH17K1140098-01
engine using a steam cleaner. Engine removal is 14) Remove the radiator heat shield. Refer to “Cylinder
sequentially explained in the following steps: Head Cover Removal and Installation” (Page 1D-8).
1) Remove the front seat. (Page 9D-19) 15) Remove the exhaust system components. Refer to
2) Disconnect the battery (–) lead wire (1). “Exhaust Pipe / Muffler Removal” in Section 1K
(Page 1K-24).
16) Remove the radiator lower bracket (1) and hose
guide bracket (2).

1
IH17K1140096-01 2
3) Jack up the motorcycle and fix it for safety.
1
4) Drain engine oil. (Page 1E-4)
5) Drain engine coolant. (Page 1F-6) IH17K1140099-01

6) Remove the fuel tank. (Page 1G-9) 17) Remove the regulator/rectifier with its bracket.
(Page 1J-8)
7) Remove the air cleaner box. (Page 1D-6)
18) Disconnect the oil pressure switch lead wire coupler
8) Remove the throttle body assembly. (Page 1C-5) (1), side-stand switch lead wire coupler (2) and CKP
9) Remove the EVAP canister (If equipped). Refer to sensor lead wire coupler (3).
“EVAP Control System Removal and Installation (If
Equipped)” in Section 1B (Page 1B-13).
10) Remove the oil cooler and hoses. (Page 1E-8) 2
3

11) Remove the radiator assembly. (Page 1F-8)

1
12) Disconnect the air bleed hose (1) and radiator inlet
hose (2).

IH17K1140100-01

1
2
IH17K1140097-01
 Engine Mechanical: 1D-27

19) Remove the side-stand (1) with the switch (2) and 24) Remove the ignition coils (4). (Page 1H-5)
bracket (3).
1

4 4

2 2 2
1 3
3 IH17K1140105-01

IH17K1140101-01 25) Remove the clamp (1) and disconnect the GP

20) Disconnect the starter motor lead wire (1), engine sensor lead wire coupler (2).
ground lead wire (2) and ECT sensor coupler (3). 26) Disconnect the clutch cable (3) from clutch release
arm and remove the clutch cable from the clutch
cable stopper (4). (Page 5C-7)

3
1 1

2
IH17K1140102-01

21) Remove the accelerator position sensor (1) and 3 4

throttle cables. IH17K1140106-01

27) Remove the right side cowling bracket (1).

1
IH17K1140103-01 1
22) Remove the crankcase breather (PCV) hose (1). IH17K1140107-01

28) Remove the gearshift link arm and then remove the
gearshift lever bracket (1).

IH17K1140104-01

23) Disconnect the PAIR solenoid valve coupler (1), 1

ignition coil couplers (2) and CMP sensor lead wire IH17K1140108-01
coupler (3).
1D-28 Engine Mechanical:

29) Remove the engine sprocket cover and engine 33) Remove the engine mounting nut (1).
sprocket (1). Refer to “Engine Sprocket Removal 34) Remove the engine mounting thrust adjuster lock-
and Installation” in Section 3A (Page 3A-3). nut (2) with the special tool.
35) Loosen the engine mounting thrust adjuster (3) fully.

NOTE
Do not remove the engine mounting bolt at
this stage.

Special tool
(A): 09940–14990

1
IH17K1140109-01

30) Support the engine with a proper jack.

31) Remove the engine mounting bolt (RH) (1).

IH17K1140112-01

1 (A)

IH17K1140110-01

32) Remove the engine mounting bolt (LH) (1).

2 3

IH17K1140113-01

3 2
1

IH17K1140111-01

IH17K1140114-01
 Engine Mechanical: 1D-29

36) Remove the engine mounting nut (1). Engine Assembly Installation
BENH17K11406021
37) Loosen the engine mounting thrust adjuster lock-nut Install the engine in the reverse order of engine removal.
(2) with the special tool. Pay attention to the following points:
38) Loosen the engine mounting thrust adjuster (3) fully. • Gradually raise the rear side of the engine assembly,
NOTE and then put the drive chain on the driveshaft.

Do not remove the engine mounting bolt at NOTICE

this stage. Be careful not to catch the wiring harness
between the frame and the engine.
Special tool
(A): 09940–14990

1
IH17K1140118-01
IH17K1140115-01
• Install all engine mounting bolts and tighten them
temporarily.
• Tighten the engine mounting thrust adjusters (1) to the
specified torque.
(A) Tightening torque
Engine mounting thrust adjuster (a): 23 N·m (2.3
kgf-m, 17.0 lbf-ft)

2 3
1, (a)
IH17K1140116-01

3 2
1

IH17K1140119-01

IH17K1140117-01
1, (a)
39) Remove the engine mounting bolts and gradually
lower the front side of the engine. Then, take off the
drive chain from the driveshaft.
40) Remove the engine assembly.

IH17K1140120-01
1D-30 Engine Mechanical:

• Tighten the engine mounting thrust adjuster lock-nuts • Tighten the new engine mounting nuts (1) to the
(1) to the specified torque with the special tool. specified torque.
Special tool NOTE
(A): 09940–14990
The engine mounting nuts are self-locking.
Tightening torque Once the nuts have been removed, they are
Engine mounting thrust adjuster lock-nut (a): 45 no longer of any use.
N·m (4.6 kgf-m, 33.5 lbf-ft)
Tightening torque
Engine mounting nut (a): 75 N·m (7.6 kgf-m, 55.5
lbf-ft)
(A) 1, (a)

1 , (a )
IH17K1140121-01

1, (a) IH17K1140123-02
(A)

IH17K1140122-01

1 , (a )

IH17K1140124-01

• Tighten the engine mounting bolts (Front) to the

specified torque, as shown in the following illustration.
Tightening torque
Engine mounting bolt (Front): 75 N·m (7.6 kgf-m,
55.5 lbf-ft)
 Engine Mechanical: 1D-31

2, “4” (a)
LH RH

1, “4” (a)

“a”
7, “1” (c)
“a”
8, “2” (b)

4, “3” (a)
3

“b”
9, “1” (c)

10, “2” (b)

6, “3” (a)
5

“b”

3, 4
1
2

5, 6

IH17K1140292-01

1. Engine mounting bolt (Front, LH) 7. Engine mounting thrust adjuster (Rear upper) : 75 Nm (7.6 kgf-m, 55.5 lbf-ft)
: Tighten the bolts, nuts and adjusters in : Tighten the bolts, nuts and adjusters in order of “1” →
order of “1” → “2” → “3” → “4”. “2” → “3” → “4”.
2. Engine mounting bolt (Front, RH) 8. Engine mounting thrust adjuster lock-nut (Rear upper) : 45 Nm (4.6 kgf-m, 33.5 lbf-ft)
: Tighten the bolts, nuts and adjusters in : Tighten the bolts, nuts and adjusters in order of “1” →
order of “1” → “2” → “3” → “4”. “2” → “3” → “4”.
3. Engine mounting bolt (Rear upper) 9. Engine mounting thrust adjuster (Rear lower) : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Tighten the bolts, nuts and adjusters in order of “1” →
“2” → “3” → “4”.
4. Engine mounting nut (Rear upper) 10. Engine mounting thrust adjuster lock-nut (Rear lower) : Do not reuse.
: Tighten the bolts, nuts and adjusters in : Tighten the bolts, nuts and adjusters in order of “1” →
order of “1” → “2” → “3” → “4”. “2” → “3” → “4”.
5. Engine mounting bolt (Rear lower) “a”: 45 mm (1.8 in)
6. Engine mounting nut (Rear lower) “b”: 275 mm (10.8 in)
: Tighten the bolts, nuts and adjusters in
order of “1” → “2” → “3” → “4”.
1D-32 Engine Mechanical:

• Install the engine sprocket. (Page 3A-3) Cylinder Head Removal

BENH17K11406022
• Install the gearshift lever. (Page 5B-17) Refer to “Engine Assembly Removal” (Page 1D-26) and
• Install the accelerator position sensor. (Page 1C-20) “Engine Assembly Installation” (Page 1D-29).
• Install the side-stand. (Page 9E-3) 1) Remove the camshafts. (Page 1D-11)
• Install the regulator/rectifier. (Page 1J-8) 2) Remove the cylinder head bolts (L65) (1).
• Install the radiator lower bracket (1) and hose guide
bracket (2), and tighten the bolts to the specified
torque.
Tightening torque
Radiator lower bracket bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
1
Hose guide bracket bolt (b): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

(b)
(a) IH17K1140127-01

3) Remove the cylinder head bolts (L95) (1) and (2).

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

1 4) Remove the cylinder head (3).

IH17K1140126-02
1
• Install the exhaust pipe assembly and muffler. 2
(Page 1K-26)
• Install the radiator. (Page 1F-8)
• Install the oil cooler. (Page 1E-8)
• Install the EVAP canister (If equipped). (Page 1B-
13)
• Install the throttle body. (Page 1C-5)
• Install the air cleaner box. (Page 1D-6)
3 1 2
• Check the radiator hose routing. (Page 1F-2) IH17K1140128-01
• Check the wiring harness routing. (Page 9A-13) 5) Remove the dowel pins (1) and cylinder head gasket
• After finishing the engine installation, check the (2).
following items.
– Throttle cable play: (Page 1C-5) 1 2 1
– Throttle valve synchronization: (Page 1C-9)
– Clutch cable play: (Page 5C-4)
– Gearshift lever height: (Page 5B-18)
– Engine oil leakage: (Page 1E-4)
– Engine coolant leakage: (Page 1F-7)

IH17K1140129-01
 Engine Mechanical: 1D-33

Cylinder Head Installation 7) Tighten the cylinder head bolts (L65) (1) to the
BENH17K11406023 specified torque.
1) Install the dowel pins (1) and a new cylinder head
gasket (2) to the cylinder. Tightening torque
Cylinder head bolt (L65) (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
1 2 1

1 , (a )

IH17K1140129-01

2) Place the cylinder head on the gasket.

IH17K1140133-01

NOTE 8) Install the camshafts. (Page 1D-13)

When installing the cylinder head, keep the
cam chain taut. Rocker Arm Shaft / Rocker Arm Removal and
Installation
3) Apply engine oil to the both side of the washer (1) BENH17K11406050

and thread portion (2) of the bolts before installing Refer to “Engine Assembly Removal” (Page 1D-26) and
the cylinder head bolts (L95). “Engine Assembly Installation” (Page 1D-29).

Removal
1) Remove the camshafts. (Page 1D-11)
2) Remove the shims (1) by fingers or magnetic hand.
2
NOTE
1
When removing the rocker arms, the shims
may stick to the rocker arms and then fall
IH17K1140131-02
away. Pick the shims up before removing the
4) Tighten the cylinder head bolts (L95) (1) and (2) to rocker arms.
25 Nm (2.5 kgf-m, 18.5 lbf-ft) in numerical order “1”
– “10”.
5) In the same manner as in Step 4), tighten them to 31
Nm (3.2 kgf-m, 23.0 lbf-ft).
1 1 1 1
6) Additionally tighten the all cylinder head bolts with
the specified angles gradually in numerical order
using an angular torque gauge.
Tightening torque
Cylinder head bolt (L95) (a): 25 → 31 Nm (2.5 →
3.2 kgf-m, 18.5 → 23.0 lbf-ft) → turn clockwise 63°

1 , “ 9 ” , ( a) 1, “ 1” , ( a) 2, “ 8”, (a ) 1 1 1 1
IH17K1140143-02
1, “ 3” , ( a) 1, “ 6” , ( a)

1, “ 5” , ( a) 1, “ 4” , ( a)
1 , “ 7 ” , ( a) 1, “ 2” , ( a) 2, “ 10”, (a )
IH17K1140132-01
1D-34 Engine Mechanical:

3) Remove the cylinder head plugs (1). 3) Set the rocker arms #1 and #2 (1) inserting the
rocker arm shafts (2) from the left side.

2 1 2 1

1 1

IH17K1140144-01
2 1 2 1
4) Remove the rocker arm shaft pins (1). IH17K1140149-01

5) Pull out the rocker arm shafts (2) and remove the 4) Install the intake rocker arm shaft pin (1) and
rocker arms (3). exhaust rocker arm shaft pin (2).

NOTE
3
2 3 Length of the intake rocker arm shaft pin and
2 3
2 3
exhaust rocker arm shaft pin are not
identical.
1
Intake side pin: 23.6 – 23.8 mm (0.930 – 0.937
in)
Exhaust side pin: 34.6 – 34.8 mm (1.363 –
1.370 in)

2 2 2
3 3 3 3 1
IH17K1140146-02

Installation
1) Apply engine oil to the rocker arm shaft (1) and
rocker arm inside surface (2).

IH17K1140150-01

5) Degrease the cylinder head plug holes (1).

2
IH17K1140147-02

2) Set the rocker arms #3 and #4 (1) inserting the

rocker arm shafts (2) from the right side.
1

1 2 1 2 1

IH17K1140151-01

1 2 1 2
IH17K1140148-01
 Engine Mechanical: 1D-35

6) Apply sealant to the thread part of cylinder head Special tool

plugs (1) and tighten them to the specified torque. (A): 09912–66310
“A”: Sealant 99000–31140 (SUZUKI BOND
1207B)
Tightening torque
Cylinder head plug (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)

IH17K1140154-01

Rocker Arm
1) Visually check contact surface of the rocker arm. If
1, “A”, (a) any abnormality is found, replace the rocker arm.
1, “A”, (a)

IH17K1140152-01

7) Apply engine oil to the valve stem ends and shims

(1).
8) Install the shims to their original positions.

NOTE
When seating the shim, be sure the figure
printed surface faces the valve stem end.

IH17K1140155-01

2) Measure the inside diameter of each rocker arm in

1 1 1 1 two places. If any of the measurements exceeds the
standard value, replace the rocker arm with a new
one.
Rocker arm I.D.
Intake [Standard]: 8.000 – 8.015 mm (0.3150 –
0.3155 in)
Exhaust [Standard]: 8.000 – 8.015 mm (0.3150 –
0.3155 in)
1 1 1 1
IH17K1140143-02 Special tool
9) Install the camshafts. (Page 1D-13) (A): 09900–20602
(B): 09900–22402
Rocker Arm Shaft / Rocker Arm Inspection
BENH17K11406051
Refer to “Rocker Arm Shaft / Rocker Arm Removal and
Installation” (Page 1D-33).

Rocker Arm Shaft

Measure the outside diameter of each rocker arm shaft.
If any of the measurements is less than the standard (A) (B)
value, replace the rocker arm shaft with a new one.
Rocker arm shaft O.D.
Intake [Standard]: 7.978 – 7.987 mm (0.3141 – 0.3144
IH17K1140156-01
in)
Exhaust [Standard]: 7.978 – 7.987 mm (0.3141 –
0.3144 in)
1D-36 Engine Mechanical:

Valve / Valve Spring Removal and Installation 6) Remove the oil seal (1) and spring seat (2).
BENH17K11406027
Refer to “Cylinder Head Removal” (Page 1D-32) and 7) Remove the other valves in the same manner as
“Cylinder Head Installation” (Page 1D-33). described previously.

Removal
1) Removal the rocker arms. (Page 1D-33)
1
2) Insert the special tool between the valve springs and
cylinder head.
3) Using the special tools, compress the valve springs
and remove the two cotter halves (1) from the valve
stem. 2
NOTICE
Be careful not to damage the camshaft IH17K1140159-01
journal with the special tool.
Installation
Special tool
1) Install the valve spring seat (1).
(A): 09916–14522
(B): 09916–14510 2) Apply engine oil to the new oil seal (2), and press-fit
09916–84511 it into the position.

1 2

1
(A)
(B)
IH17K1140157-01 IH17K1140160-01

4) Remove the valve spring retainer (1) and valve 3) Insert the valve, with its stem coated with
springs (2). molybdenum oil solution all around and along the full
stem length without any break.
5) Pull out the valve (3) from the combustion chamber
side. NOTICE
When inserting the valve, take care not to
damage the lip of the oil seal.

“A”: Assembly lubrication (Molybdenum oil

solution)

3
1

IH17K1140158-01

“A”
IF04K1140149-01
 Engine Mechanical: 1D-37

4) Install each valve spring with the small-pitch portion 6) Be sure that the rounded lip (1) of the cotter fits
(1) facing cylinder head. snugly into the groove (2) in the stem end.

4 3 2 1

3 2
4

IF04K1140150-01

2. Large-pitch portion 4. Paint

3. Upward IH17K1140162-02

3. Valve spring retainer 4. Cotter

5) Put on the valve spring retainer (1), and using the
special tools, press down the springs, fit the cotter 7) Install the rocker arms. (Page 1D-33)
halves to the stem end, and release the lifter to allow
the cotter halves to wedge in between retainer and Valve Inspection
stem. BENH17K11406028
Refer to “Valve / Valve Spring Removal and Installation”
NOTICE (Page 1D-36).
• Be sure to restore each spring and valve to
their original positions. Valve Stem Runout
Support the valve using V-blocks, as shown in the figure,
• Be careful not to damage the valve and and check its runout using the dial gauge. If the runout
valve stem when handling it. exceeds the service limit, replace the valve.
• Compressing of the valve springs must be
limited to the extent only necessary to Valve stem runout
prevent the springs from fatigue. Intake & Exhaust [Limit]: 0.05 mm (0.0019 in)
Special tool
Special tool (A): 09900–20607
(A): 09916–14522 (B): 09900–20701
(B): 09916–14510 (C): 09900–21304
09916–84511

(A)

(B)

1
(A) (B)
(C)
IH17K1140161-01 IF04K1140154-01
1D-38 Engine Mechanical:

Valve Head Radial Runout Valve Stem Wear

Place the dial gauge at a right angle to the valve head Measure the valve stem O.D. using the micrometer. If it
face and measure the valve head radial runout. If it is out of specification, replace the valve with a new one.
measures more than the service limit, replace the valve. If the valve stem O.D. is within specification but the valve
stem deflection is not, replace the valve guide. After
Valve head radial runout
replacing the valve or valve guide, recheck the
Intake & Exhaust [Limit]: 0.03 mm (0.0011 in)
deflection.
Special tool
Valve stem O.D.
(A): 09900–20607
Intake [Standard]: 4.475 – 4.490 mm (0.1762 – 0.1767
(B): 09900–20701
in)
(C): 09900–21304
Exhaust [Standard]: 4.455 – 4.470 mm (0.1754 –
0.1759 in)
(A)
Special tool
(A): 09912–66310

(B)

(C)

IF04K1140155-01

Valve Stem Deflection

Lift the valve about 10 mm (0.39 in) “a” from the valve (A)
seat. Measure the valve stem deflection in two directions
(1) and (2), perpendicular to each other. Position the dial IF04K1140158-01

gauge as shown. If the deflection exceeds the service

limit, then determine whether the valve or the guide Valve Seat Width
should be replaced with a new one. 1) Visually check for valve seat width on each valve
face. If the valve face has worn abnormally, replace
Valve stem deflection
the valve.
Intake & Exhaust [Limit]: 0.25 mm (0.0098 in)
2) Coat the valve seat with a red lead (Prussian Blue)
Special tool and set the valve in place.
(A): 09900–20607
3) Rotate the valve with light pressure.
09900–20701
Special tool
(A) (A): 09916–10911
“a”

(A )

2
1

IH17K1140163-01

IH17K1140164-01
 Engine Mechanical: 1D-39

4) Check that the transferred red lead (blue) on the Valve Seat Repair
valve face is uniform all around and in center of the BENH17K11406029

valve face. The valve seats (1) for both the intake and exhaust
If the seat width “a” measured exceeds the standard valves are machined to three different angles. The seat
value, or seat width is not uniform reface the seat contact surface is cut at 45°.
using the seat cutter. (Page 1D-39) NOTICE
Valve seat width • The valve seat contact area must be
Intake [Standard]: 0.9 – 1.1 mm (0.036 – 0.043 in) inspected after each cut.
Exhaust [Standard]: 0.9 – 1.1 mm (0.036 – 0.043
• Do not use lapping compound after the
in)
final cut is made. The finished valve seat
should have a velvety smooth finish but
not a highly polished or shiny finish. This
will provide a soft surface for the final
seating of the valve which will occur
“a” during the first few seconds of engine
operation.

NOTE
After servicing the valve seats, be sure to
I649G1140246-02 check the valve clearance after the cylinder
head has been reinstalled. (Page 1D-21)
Valve Seat Sealing Condition
1) Clean and assemble the cylinder head and valve
components.
45°
2) Fill the intake and exhaust ports with gasoline to 60°
check for leaks. If any leaks occur, inspect the valve
seat and face for burrs or other things that could 30°
prevent the valve from sealing. (Page 1D-39)

IH17K1140166-01

Intake Exhaust
Seat angle 30°/45°/60° ←
0.9 – 1.1 mm
Seat width ←
(0.036 – 0.043 in)
Valve 31.5 mm 24 mm
diameter (1.24 in) (0.94 in)
Valve guide 4.500 – 4.512 mm
IH17K1140165-01
←
I.D. (0.1772 – 0.1776 in)
1D-40 Engine Mechanical:

Valve Spring Inspection Cylinder Head Disassembly and Reassembly

BENH17K11406030 BENH17K11406031
Refer to “Valve / Valve Spring Removal and Installation” Refer to “Cylinder Head Removal” (Page 1D-32) and
(Page 1D-36). “Cylinder Head Installation” (Page 1D-33).
The force of the coil spring keeps the valve seat tight.
Weakened spring results in reduced engine power Disassembly
output and often accounts for the chattering noise 1) Remove the ECT sensor (1). (Page 1C-14)
coming from the valve mechanism.
2) Remove the thermostat (2). (Page 1F-12)
Check the valve springs for proper strength by
measuring its free length and also by the force required 3) Remove the water bypass hose union (3).
to compress it. If the spring length is less than the
service limit or if the force required to compress the
spring does not fall within the range specified, replace
spring as a set.
Valve spring free length
Intake
Inner [Limit]: 35.9 mm (1.42 in) 1
Outer [Limit]: 38.8 mm (1.53 in)
Exhaust
Inner [Limit]: 35.9 mm (1.42 in) 3
2
Outer [Limit]: 38.8 mm (1.53 in)
IH17K1140167-01
Inner valve spring pre-load 4) Remove the oil jet (for cam chain tension adjuster)
When compressed to 30.50 mm (1.201 in) (1). (Page 1E-11)
Intake [Standard]: 50.2 – 57.8 N (5.1 – 5.9 kgf, 11.3 –
13.0 lbs)
Exhaust [Standard]: 50.2 – 57.8 N (5.1 – 5.9 kgf, 11.3
– 13.0 lbs)
Outer valve spring pre-load
When compressed to 34.50 mm (1.358 in)
Intake [Standard]: 117.2 – 134.8 N (12.0 – 13.7 kgf,
26.3 – 30.3 lbs)
Exhaust [Standard]: 117.2 – 134.8 N (12.0 – 13.7 kgf,
1
26.3 – 30.3 lbs)
Special tool
IH17K1140168-01
(A): 09900–20102
5) Remove the oil gallery plug (1) and cylinder head
plug (2).
(A)

IF04K1140161-01

1 2

IH17K1140169-01

ID26J1140263-01
 Engine Mechanical: 1D-41

6) Remove the following parts.

• Intake pipes (1): (Page 1D-7)
• Valves (2) and valve springs: (Page 1D-36)
2
• Valve guides: (Page 1D-42)

1, (a)

IH17K1140172-01

4) Install the oil jet (1) (for cam chain tension adjuster).
(Page 1E-11)
2
IH17K1140170-01

Reassembly 1
1) Install the following parts.
• Valve guides: (Page 1D-42)
• Valves and valve springs: (Page 1D-36)
• Intake pipes: (Page 1D-7)
2) Install the oil gallery bolt (1) with new gasket (2) and
tighten it to the specified torque.
IH17K1140173-01
Tightening torque 5) Apply sealant to the thread part of bypass hose
Oil gallery bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) union (1) and tighten it to the specified torque.
“A”: Sealant 99000–31140 (SUZUKI BOND
1207B)
2 Tightening torque
Bypass hose union (a): 12 N·m (1.2 kgf-m, 9.0
lbf-ft)

1, (a)

IH17K1140171-01

3) Install the cylinder head plug (1) with new gasket (2)
and tighten it to the specified torque.
Tightening torque
Cylinder head plug (a): 23 N·m (2.3 kgf-m, 17.0 “A” 1, (a)
lbf-ft)
IH17K1140174-01

6) Install the thermostat. (Page 1F-12)

7) Install the ECT sensor. (Page 1C-14)
1D-42 Engine Mechanical:

Cylinder Head Inspection 2) Refinish the valve guide holes in the cylinder head
BENH17K11406032 using the reamer and handle.
Refer to “Cylinder Head Removal” (Page 1D-32) and
“Cylinder Head Installation” (Page 1D-33). 3) Remove the special tools by turning clockwise and
raising them at the same time.
1) Decarbonize the combustion chambers.
2) Check the gasket surface of the cylinder head for NOTICE
distortion with a straightedge and thickness gauge, Never turn the special tools
taking a clearance reading at several places as counterclockwise, as this will dull the blades.
indicated. If the largest reading at any position of the
straightedge exceeds the limit, replace the cylinder Special tool
head. (A): 09916–33320
(B): 09916–34542
Cylinder head distortion
[Limit]: 0.20 mm (0.0078 in)
Special tool
09900–20803 (B)

(A )

IH17K1140177-01

4) Cool down the new valve guides in a freezer for

about one hour and heat the cylinder head to 100 –
150 °C (212 – 302 °F) with a hot plate.
IH17K1140175-01
NOTICE
Valve Guide Replacement Do not use a burner to heat the valve guide
BENH17K11406033
hole to prevent cylinder head distortion.
Refer to “Valve / Valve Spring Removal and Installation”
(Page 1D-36).
5) Apply engine oil to each valve guide and valve guide
1) Using the special tool fitted with an appropriate hole.
attachment (1), drive the valve guide out toward the
intake or exhaust camshaft side. NOTICE
Failure to oil the valve guide hole before
NOTE
driving the new guide into place may result in
• Discard the removed valve guide sub- a damaged guide or head.
assemblies.
• Only oversized valve guides are available 6) Screw the sleeve (1) onto the special tool used in
as replacement parts. (Part No. 11115- Step 1) and adjust the measurements “a” by turning
29G70) the sleeve.
Special tool
Special tool (A): 09916–51710
(A): 09916–51710

(A)
(A)

(A)

1 “a”

1 IH17K1140178-04
IH17K1140176-02
“a”: 14.4 – 14.6 mm (0.567 – 0.574 in)
 Engine Mechanical: 1D-43

7) Drive the guide into the guide hole using the special
tool.

NOTE ( B)
Install the valve guide until the special tool
contacts the cylinder head.
(A )
Special tool
(A): 09916–51710

IH17K1140181-01

(A) Cam Chain Guide / Cam Chain Tensioner / Cam

Chain / Cam Chain Drive Sprocket Removal and
Installation
BENH17K11406024

1 Removal
Cam chain guide No. 2
IH17K1140179-02
1) Remove the cylinder head cover. (Page 1D-8)
1. Cylinder head
2) Remove the cam chain guide No. 2 (1).

(A)

IH17K1140134-01

IH17K1140180-01
Cam chain guide No. 1 / cam chain tensioner / cam
8) After installing the valve guides, refinish their guiding
chain / cam chain drive sprocket
bores using the reamer. Be sure to clean and oil the
guides after reaming. 1) Remove the cylinder head. (Page 1D-32)
2) Remove the starter clutch. (Page 1I-9)
NOTE
3) Remove the cam chain guide No. 1 (1) and cam
• Be sure to cool down the cylinder head to chain tensioner (2).
ambient air temperature.
• Insert the reamer from the combustion 2
chamber and always turn the reamer
handle clockwise.

Special tool
(A): 09916–33210
(B): 09916–34542 1

IH17K1140135-01
1D-44 Engine Mechanical:

4) Remove the cam chain (1) and cam chain drive 3) Insert the cam chain tensioner (1).
sprocket (2). 4) Apply a small quantity of thread lock to the cam
chain tensioner bolt (2) and tighten it to the specified
torque.
1
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Cam chain tensioner bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
5) While the cam chain is engaged in the cam drive
2
sprocket, insert the cam chain guide No. 1 (3).
6) Apply a small quantity of thread lock to the cam
IH17K1140136-01
chain guide No. 1 bolt (4) and tighten it to the
Installation specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
Cam chain guide No. 1 / cam chain tensioner / cam LOCK CEMENT 1322D)
chain / cam chain drive sprocket
Tightening torque
1) Install the cam chain drive sprocket (1).
Cam chain guide No. 1 bolt (b): 23 N·m (2.3 kgf-
NOTE m, 17.0 lbf-ft)
When installing the cam chain drive sprocket,
1
align the wide spline tooth (2) and (3).
2 , “A ”, (a )

2
3

4 , “A ”, (b )
IH17K1140139-02

7) Install the starter clutch. (Page 1I-9)

1 8) Install the cylinder head. (Page 1D-33)
IH17K1140137-01

2) Install the cam chain (1). Cam chain guide No. 2

1) Install the cam chain guide No. 2 (1).
2) Tighten the camshaft journal holder bolts (2) to the
specified torque.
Tightening torque
Camshaft journal holder bolt (a): 10 N·m (1.0
kgf-m, 7.5 lbf-ft)

1 1

IH17K1140138-01

2 , (a )

IH17K1140140-01

3) Install the cylinder head cover. (Page 1D-8)

 Engine Mechanical: 1D-45

Cam Chain Guide Inspection

BENH17K11406025
Refer to “Cam Chain Guide / Cam Chain Tensioner /
Cam Chain / Cam Chain Drive Sprocket Removal and
Installation” (Page 1D-43).
Check the contacting surface of the cam chain guides. If
it is worn or damaged, replace it with a new one.

IH17K1140182-01

Crankshaft / Piston / Cylinder Removal

BENH17K11406034
Refer to “Engine Assembly Removal” (Page 1D-26) and
“Engine Assembly Installation” (Page 1D-29).

IH17K1140141-01 Cylinder Head

Remove the cylinder head assembly. (Page 1D-32)
Cam Chain Tensioner Inspection
BENH17K11406026 Crankcase Breather (PCV) Cover
Refer to “Cam Chain Guide / Cam Chain Tensioner / Remove the crankcase breather (PCV) cover. (Page
Cam Chain / Cam Chain Drive Sprocket Removal and 1B-12)
Installation” (Page 1D-43).
Check the contacting surface of the cam chain tensioner. Starter Motor
If it is worn or damaged, replace it with a new one. Remove the starter motor. (Page 1I-4)

Clutch
Remove the clutch component parts (1). (Page 5C-15)

IH17K1140142-01

Cam Chain Drive Sprocket Inspection

BENH17K11406052
Refer to “Cam Chain Guide / Cam Chain Tensioner / IH17K1140187-01

Cam Chain / Cam Chain Drive Sprocket Removal and

Installation” (Page 1D-43). Starter Idle Gear / Starter Clutch
Inspect teeth of the cam chain drive sprocket for wear or Remove the starter idle gear No. 1 (1) and starter clutch
damage. (2). (Page 1I-9)
If it is worn or damaged, replace the sprocket and cam
chain as a set. 1

IH17K1140183-01
1D-46 Engine Mechanical:

Cam Chain Guide No. 1 / Cam Chain Tensioner / Cam Generator

Chain / Cam Chain Drive Sprocket Remove the generator cover (1) and rotor. Refer to
1) Remove the cam chain guide No. 1 (1). (Page 1D- “Generator Removal” in Section 1J (Page 1J-5).
43)
2) Remove the cam chain tensioner (2). (Page 1D-
43)
3) Remove the cam chain (3). 1

4) Remove the cam chain drive sprocket (4).

2
IH17K1140188-01
3
Water Hose / Water Pump
1) Remove the radiator outlet hose (1) and cylinder
1 inlet hose (2).
4 2) Remove the cylinder water inlet connector (3).
IH17K1140184-01
3) Remove the water pump (4). (Page 1F-14)
Oil Pump Drive Gear / Oil Pump Drive Chain
Remove the oil pump drive gear (1) and oil pump drive 3
chain (2). Refer to “Oil Pump Removal and Installation”
in Section 1E (Page 1E-12). 2

1 1
IH17K1140189-01

Oil Filter / Oil Hose Plate / Oil Pressure Switch

1) Remove the oil filter (1). (Page 1E-5)
IH17K1140185-01 2) Remove the oil hose plate (2). (Page 1E-8)
3) Remove the oil pressure switch (3). (Page 1E-10)
Transmission
Remove the transmission component parts (1). (Page
5B-3)

3
1 2 1
IH17K1140190-01

IH17K1140186-01
 Engine Mechanical: 1D-47

Oil Pan
Remove the oil pan (1) and gasket. (Page 1E-5) 2

1 2 1
IH17K1140194-01
1

IH17K1140191-03 1 2 2

Oil Strainer / Oil Pump

Remove the oil strainer (1) and oil pump (2). (Page
1E-5)

3
1 3 3
2 2 2

IH17K1140195-01

3) Make sure that all of the bolts are removed. Then,

tap the sides of the lower crankcase (1) using a
plastic hammer to separate the upper and lower
2 crankcase halves and then lift the lower crankcase
off the upper crankcase.
IH17K1140192-01

Lower Crankcase
1
1) Remove the clutch push rod oil seal retainer (1).

IH17K1140196-01

4) Remove the dowel pins (1) and O-ring (2).

IH17K1140193-01 1
2) Remove the crankcase upper / lower bolts (M6) (1),
(M8) (2) and crankcase lower bolts (M9) (3).

NOTE
Loosen the crankcase bolts diagonally and
smaller size ones first.
1
1 2

IH17K1140197-01
1D-48 Engine Mechanical:

5) Remove the clutch push rod oil seal (1), countershaft Piston Cooling Jet
bearing (2) and pin. Remove the piston cooling jets (1). (Page 1E-11)

1
1
2

IH17K1140198-01 IH17K1140202-01

Crankshaft Piston / Conrod

1) Loosen the conrod cap bolts (1). 1) Push the conrod to cylinder head side and remove
the piston and conrod from the upper crankcase.
1
1
NOTICE
Be careful not to damage the cylinder wall by
the conrod.

1
IH17K1140199-01

2) Remove the conrod caps (1) by tapping the bolts (2)

lightly with a plastic hammer.

IH17K1140203-01

IH17K1140200-01

3) Remove the crankshaft (1) and thrust bearings (2).

IH17K1140204-01
2 1

IH17K1140201-02
 Engine Mechanical: 1D-49

2) Remove the piston pin circlip (1).

“A”
1
IH17K1140207-01

IH17K1140205-01 3) Install the new piston pin circlip (1).

3) Draw out the piston pin (1) and piston (2).
NOTE
NOTE Install the piston pin circlip so that the end
Scribe the cylinder number on the piston gap is positioned as shown in the figure.
head.

“a”
2
1 IH17K1140208-01

IH17K1140206-01 “a”: 110 – 160°

Crankshaft / Piston / Cylinder Installation 4) Apply a small quantity of molybdenum oil solution to
BENH17K11406035 the sliding surface of the pistons and cylinder walls.
Piston / Conrod “A”: Assembly lubrication (Molybdenum oil
1) Apply a small quantity of molybdenum oil solution solution)
onto each piston pin. NOTE
“A”: Assembly lubrication (Molybdenum oil Be sure to install the pistons in the cylinders
solution) from which they were removed in
2) Assemble the piston and conrod. disassembly, referring to the cylinder
numbers, #1 through #4, scribed on the
NOTE piston.
When installing the pistons, the indent (1) on
the piston head must be brought to the other
side of I.D. code (2) on the conrod big end. “A”

“A”
IH17K1140209-01
1D-50 Engine Mechanical:

5) Install the pistons with conrods into the cylinders Crankshaft

from topside using the special tool. 1) Apply engine oil to each crank pin bearing surface
(1) and crankshaft journal bearing surface (2).
NOTE
When installing the pistons, the indent (1) of
2
each piston head must be brought to the
exhaust side.

Special tool
(A): 09916–77310

1
IH17K1140212-01

2) Position the conrod big ends #2 and #3 (1) on the

same side, and the conrod big ends #1 and #4 (2) on
the opposite side of #2 and #3.
(A)
1
IH17K1140210-01

6) Clean each conrod big end.

7) Check that I.D. code (1) on each conrod faces intake
side.

2
IH17K1140213-01

3) Set the crankshaft onto the conrods and upper

crankcase.
4) Clean each conrod big end.
5) Apply engine oil to each crank pin (1) and bearing
1 surface (2).
IH17K1140211-01

2
Piston Cooling Jet
Install each position cooling jet (1). (Page 1E-11)

1
1

IH17K1140214-01

IH17K1140202-01
 Engine Mechanical: 1D-51

6) When fitting the conrod cap (1), make sure that I.D. 9) Apply engine oil to the conrod big end side surfaces
code (2) on each conrod faces intake side. (1).
7) Apply engine oil to the flange and thread portion of 10) Apply engine oil to each crankshaft journal (2) and
the new conrod cap bolts (3). bearing lightly.
11) Check the conrod movement for smooth turning.

3
1 1 1
1 1

IH17K1140215-01 2 2 2
8) Tighten the conrod cap bolts by using a 10 mm, 12 IH17K1140218-01
point socket wrench in the following two steps. 12) Insert the right and left thrust bearings with the oil
Tightening torque grooves (1) facing towards the crankshaft web.
Conrod cap bolt (a): 27 Nm (2.8 kgf-m, 20.0 lbf- NOTE
ft) → turn clockwise 90°
• Right-thrust bearing (2) has green painting.
• Inspect and select the crankshaft thrust
clearance if necessary. (Page 1D-69)

(a)

IH17K1140216-01

1 1

IH17K1140219-01

Lower Crankcase
1) Install the dowel pins (1) and new O-ring (2).
2) Install the countershaft bearing (3). (Page 5B-6)
“a”

1
IH17K1140217-01

“a”: 90°

1
2
1
IH17K1140220-02
1D-52 Engine Mechanical:

3) Clean the mating surfaces of lower and upper

crankcase halves. Apply sealant to the mating “6 ”, (a ) “4 ”, (a )
surface of the lower crankcase (1).
1 , “1 0 ”, (a ) “2 ”, (a ) 1 , “8 ”, ( a )
NOTE
• Make surfaces free from moisture, oil, dust
and other foreign materials.
• Spread on surfaces thinly to form an even
layer, and assemble the crankcases within 1 , “9 ”, (a ) 1 , “7 ”, ( a )
few minutes. “1 ”, (a )
“5 ”, (a )
• Take extreme care not to apply any sealant “3 ”, (a )
IH17K1140222-01
to the oil hole, oil groove and bearing.
8) Install the new gaskets (1) to the crankcase upper
• Apply to distorted surfaces as it forms a
bolts (M8).
comparatively thick film.
9) Tighten the crankcase upper bolts (M8) (2) and (3),
“A”: Sealant 99000–31140 (SUZUKI BOND and crankcase lower bolts (M8) (4), (5) and (6) to the
1207B) specified torque in the following two steps.
Tightening torque
“A”
Crankcase upper bolt (M8) (a): 15 → 26 Nm (1.5
→ 2.7 kgf-m, 11.0 → 19.5 lbf-ft)
Crankcase lower bolt (M8) (b): 15 → 26 Nm (1.5
→ 2.7 kgf-m, 11.0 → 19.5 lbf-ft)

2, (a)

2, (a)
“A”
1, 2, (a)
1

3, (a)
IH17K1140223-01

4, (b) 4, (b)
IH17K1140221-01

4) Match the upper and lower crankcase.

5) Install the new gaskets (1) to the crankcase lower
bolts (M9).
6) Tighten the crankcase lower bolts (M9) to the
specified torque in numerical order “1” – “10”.
7) Additionally tighten the crankcase lower bolts (M9) 5, (b)
6, (b) 5, (b)
with the specified angles gradually in numerical
order “1” – “10” using an angular torque gauge. IH17K1140224-01

Tightening torque
Crankcase lower bolt (M9) (a): 18 Nm (1.8 kgf-m,
13.5 lbf-ft) → turn clockwise 50°
 Engine Mechanical: 1D-53

10) Tighten the crankcase upper bolts (M6) (1) and 12) Install the new clutch push rod oil seal (1) and oil
crankcase lower bolt (M6) (2) to the specified torque. seal retainer (2). (Page 5C-12)
Tightening torque
Crankcase upper bolt (M6) (a): 11 N·m (1.1 kgf- 1
m, 8.5 lbf-ft)
Crankcase lower bolt (M6) (b): 11 N·m (1.1 kgf-
m, 8.5 lbf-ft)

IH17K1140228-01

Oil Pump / Oil Strainer

Install the oil pump (1) and oil strainer (2). (Page 1E-5)

1, (a)
IH17K1140225-01

2, (b) 2

1
IH17K1140229-01

Oil Pan
IH17K1140226-01 Install the new gasket and oil pan (1). (Page 1E-5)
11) After crankcase bolts have been tightened, check
that the crankshaft rotates smoothly.

IH17K1140191-03

IH17K1140227-01
1D-54 Engine Mechanical:

Oil Pressure Switch / Oil Hose Plate / Oil Filter Generator

Install the following parts. Install the generator rotor (1) and cover (2). (Page 1J-
• Oil pressure switch (1): (Page 1E-10) 6)
• Oil hose plate (2): (Page 1E-8)
• New oil filter (3): (Page 1E-5)

2
1
1
IH17K1140234-01

2 3
Transmission
IH17K1140231-02 Install the transmission component parts (1). (Page
5B-3)
Water Pump / Water Hose
1) Install the water pump assembly. (Page 1F-14)
2) Apply engine coolant to the new O-ring (1).
3) Tighten the cylinder water inlet connector bolts (2) to
the specified torque.
Tightening torque
Cylinder water inlet connector bolt (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft) 1

IH17K1140186-01
2, (a)

Oil Pump Drive Chain / Oil Pump Drive Gear

Install the oil pump drive chain (1) and oil pump drive
gear (2). Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-12).

1
1
IH17K1140232-01

4) Install the cylinder inlet hose (1) and radiator outlet

hose (2). (Page 1F-2)

1 2

IH17K1140236-02

2
IH17K1140233-01
 Engine Mechanical: 1D-55

Cam Chain Drive Sprocket / Cam Chain / Cam Chain Cylinder Inspection
Tensioner / Cam Chain Guide No. 1 BENH17K11406036
Refer to “Crankshaft / Piston / Cylinder Removal” (Page
Install the cam chain drive sprocket (1), cam chain (2),
1D-45) and “Crankshaft / Piston / Cylinder Installation”
cam chain tensioner (3) and cam chain guide No. 1 (4).
(Page 1D-49).
(Page 1D-43)
Cylinder Distortion
2 Check the gasket surface of the cylinder for distortion.
Use a straightedge and thickness gauge. Take clearance
readings at several places. If any reading exceeds the
service limit, replace the crankcase set.
1 Cylinder distortion
3 [Limit]: 0.20 mm (0.0078 in)
Special tool
09900–20803
4
IH17K1140238-01

Starter Clutch / Starter Idle Gear

Install the starter clutch (1) and starter idle gear No. 1
(2). (Page 1I-9)

IH17K1140240-01

Cylinder Bore
Check the cylinder wall for any scratches, nicks or other
1 damage. Measure the cylinder bore diameter at six
places.
IH17K1140239-01
Cylinder bore
Clutch [Standard]: 76.000 – 76.015 mm (2.9922 – 2.9927 in)
Install the clutch component parts (1). (Page 5C-17) [Limit]: No nicks or Scratches
Special tool
1
(A): 09900–20530

(A)

IH17K1140237-01

Starter Motor IF04K1140327-02

Install the starter motor. (Page 1I-4)

Crankcase Breather (PCV) Cover

Install the crankcase breather (PCV) cover. (Page 1B-
12)

Cylinder Head
Install the cylinder head assembly. (Page 1D-33)
1D-56 Engine Mechanical:

Installation

NOTE
• When installing the piston ring, be careful
not to damage the piston.
• Do not expand the piston ring excessively
since it is apt to be broken down.

1) Install the piston rings in the order of the oil ring, 2nd
I837H1140180-01
ring and 1st ring.
Piston-to-cylinder Clearance a) The first member to go into the oil ring groove is
Refer to “Piston / Piston Ring Inspection” (Page 1D-57). the spacer (1).
After placing the spacer, fit the two side rails (2).
Piston Ring Removal and Installation
BENH17K11406037
Removal
1) Remove the piston. Refer to “Crankshaft / Piston /
Cylinder Removal” (Page 1D-45). 2
2) Carefully spread the ring opening with your thumbs 1
and then push up the opposite side of the 1st ring to
remove it. 2

NOTE
Do not expand the piston ring excessively IF04K1140328-02
since it is apt to be broken down.
NOTICE
When installing the spacer, be careful not to
allow its two ends to overlap in the groove.

[A]

I837H1140181-01

3) Remove the 2nd ring and oil ring in the same

manner. [B]
IH17K1140241-01

[A]: Incorrect [B]: Correct

 Engine Mechanical: 1D-57

b) Install the 2nd ring (1) and 1st ring (2) to piston. Piston / Piston Ring Inspection
BENH17K11406038
NOTE Refer to “Piston Ring Removal and Installation” (Page
1D-56).
• 1st ring (2) and 2nd ring (1) differ in shape.
• 2nd ring (1) has letter [T] marked on the Piston Diameter
side. Be sure to bring the marked side to Measure the piston diameter using the micrometer at 8
the top when fitting it to the piston. mm (0.3 in) “a” from the skirt end. If the piston diameter
• Bring the concave side of 1st ring (2) to the is less than the service limit, replace the piston.
top when fitting. Piston diameter
Measure at 8 mm (0.3 in) from the skirt end
[Limit]: 75.850 mm (2.9862 in)
2
Special tool
(A): 09900–20204

IH17K1140242-02

“a”
IF04K1140240-01

(A)
IH17K1140290-01

2) Position the gaps of the three rings and side rails as

IF04K1140241-01
shown. Before inserting piston into the cylinder,
check that the gaps are so located. Piston-to-cylinder Clearance
Subtract the piston diameter from the cylinder bore
diameter. If the piston-to-cylinder clearance exceeds the
2 service limit, replace both the cylinder and the piston.
120° Piston-to-cylinder clearance
[Limit]: 0.120 mm (0.0047 in)
IN. 1 EX.
120°
Piston Ring-to-groove Clearance
120° Measure the side clearances of the 1st and 2nd piston
rings using the thickness gauge. If any of the clearances
3 exceed the limit, replace both the piston and piston
rings.
IH17K1140244-02

1. 1st ring and upper side rail Piston ring to groove clearance
2. Spacer 1st [Limit]: 0.180 mm (0.0070 in)
3. 2nd ring and lower side rail 2nd [Limit]: 0.150 mm (0.0059 in)
Piston ring groove width
3) Install each piston and piston pin. (Page 1D-49)
1st [Standard]: 0.83 – 0.85 mm (0.0327 – 0.0334 in)
1st [Standard]: 1.30 – 1.32 mm (0.0512 – 0.0519 in)
2nd [Standard]: 0.81 – 0.83 mm (0.0319 – 0.0326 in)
Oil [Standard]: 1.51 – 1.53 mm (0.0595 – 0.0602 in)
Piston ring thickness
1st [Standard]: 0.76 – 0.81 mm (0.0300 – 0.0318 in)
1st [Standard]: 1.08 – 1.10 mm (0.0426 – 0.0433 in)
2nd [Standard]: 0.77 – 0.79 mm (0.0304 – 0.0311 in)
1D-58 Engine Mechanical:

Special tool Special tool

(A): 09900–20803 (A): 09900–20102
(B): 09912–66310 (B): 09900–20803

(A)

(A)

IF04K1140242-01
IF04K1140244-01

(B)
(B)

IF04K1140243-01

IF04K1140245-01

Piston Pin and Pin Bore

Measure the piston pin bore inside diameter using the
small bore gauge. If either is out of specification or the
IE31J1140200-01
difference between these measurements surpass limits,
replace the piston.
“a”: 0.83 – 0.85 mm (0.0327 – 0.0334 in)
“b”: 1.30 – 1.32 mm (0.0512 – 0.0519 in) Piston pin bore I.D.
“c”: 0.76 – 0.81 mm (0.0300 – 0.0318 in) [Limit]: 16.030 mm (0.6311 in)
“d”: 1.08 – 1.10 mm (0.0426 – 0.0433 in)
Special tool
Piston Ring Free End Gap and Piston Ring End Gap (A): 09900–20602
Measure the piston ring free end gap using vernier (B): 09900–22401
calipers. Next, fit the piston ring squarely into the
cylinder and measure the piston ring end gap using the
(A)
thickness gauge. If any of the measurements exceed the (B)
service limit, replace the piston ring with a new one.
Piston ring free end gap
1st [Limit]: 6.0 mm (0.24 in)
2nd [Limit]: 7.2 mm (0.29 in)
Piston ring end gap IF04K1140246-01
1st [Limit]: 0.50 mm (0.019 in) Measure the piston pin outside diameter at three
2nd [Limit]: 0.50 mm (0.019 in) positions using the micrometer. If any of the
measurements are out of specification, replace the
piston pin.
 Engine Mechanical: 1D-59

Piston pin O.D.

[Limit]: 15.980 mm (0.6292 in)
Special tool 3
(A): 09912–66310

(A)

1
IH17K1140246-01

2. Upper crankcase 3. Lower crankcase

Oil jet
IF04K1140323-02
Remove the oil jet (1) (for transmission). (Page 1E-11)
Upper Crankcase / Lower Crankcase
Disassembly and Reassembly
BENH17K11406039
Refer to “Crankshaft / Piston / Cylinder Removal” (Page
1D-45) and “Crankshaft / Piston / Cylinder Installation”
(Page 1D-49).

Disassembly
Crankshaft journal bearing
1
Remove the crankshaft journal bearings (1).

NOTICE
IH17K1140247-02

• When removing the crankshaft journal

bearings, be careful not to scratch the Oil gallery plug
crankcase and the crankshaft journal Upper crankcase
bearings. 1) Remove the oil gallery upper plugs (1).
• Do not touch the bearing surfaces with
your hands. Grasp the bearings by their
edges.

NOTE
• Do not remove the crankshaft journal
bearings unless absolutely necessary.
• Make a note of where the crankshaft
journal bearings are removed from so that 1
they can be reinstalled in their original
positions. IH17K1140248-02

1
2

IH17K1140249-02
IH17K1140245-02
1D-60 Engine Mechanical:

Lower crankcase Water jacket plug

1) Remove the oil gallery plugs (1). Remove the water jacket plugs (1).

1
1
IH17K1140250-01 IH17K1140254-01

1
1

IH17K1140251-01 IH17K1140255-01

Oil seal / bearing

1) Remove the gearshift shaft oil seal (1) and gearshift
shaft bearing (2). (Page 5B-23)

IH17K1140252-01
1

IH17K1140256-01

2) Remove the driveshaft oil seal (1), driveshaft bearing

(2) and gearshift cam bearing (3). (Page 5B-6)

IH17K1140253-01

2
1
IH17K1140257-01
 Engine Mechanical: 1D-61

Reassembly 2) Apply thread lock to the each oil gallery upper plug
Oil seal / bearing (1) and tighten them to the specified torque.
1) Install the new gearshift cam bearing, new driveshaft “A”: Thread lock cement 99000–32150 (THREAD
bearing and new driveshaft oil seal. (Page 5B-6) LOCK CEMENT 1322D)
2) Install the new gearshift shaft bearing and new
Tightening torque
gearshift shaft oil seal. (Page 5B-23)
Oil gallery upper plug (M10) (a): 18 N·m (1.8 kgf-
m, 13.5 lbf-ft)
Water jacket plug
1) Apply engine coolant to the new O-rings (1) of the
water jacket plugs.
2) Tighten each plug (2) to the specified torque.
Tightening torque
Water jacket plug (a): 9.5 N·m (0.97 kgf-m, 7.00
lbf-ft)

1, “A”, (a) 1, “A”, (a)

IH17K1140261-02

Lower crankcase
1) Install the new gaskets (1) to the oil gallery plugs.
2) Tighten the each oil gallery plug to the specified
2, ( a) 1 torque.
Tightening torque
IH17K1140258-01
Oil gallery plug (M16) (a): 35 N·m (3.6 kgf-m,
26.0 lbf-ft)
Oil gallery plug (M6) (b): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
1

2, ( a)

IH17K1140259-01

Oil gallery plug (a)

Upper crankcase IH17K1140262-01

1) Install the new gasket (1) to the each oil gallery

upper plug (M10) (2) as shown.

(b)

1 2
IH17K1140263-01
3
IH17K1140260-01

3. Upper crankcase
1D-62 Engine Mechanical:

3) Install the new gasket (1) to the oil gallery plug (M12) Crankshaft journal bearing
(2) as shown. Install the crankshaft journal bearings to the upper and
4) Tighten the oil gallery plug (M12) to the specified lower crankcases, be sure to fix the stopper part (1) first
torque. and press the other end.

Tightening torque NOTE

Oil gallery plug (M12) (a): 15 N·m (1.5 kgf-m,
• Do not touch the bearing surfaces with
11.0 lbf-ft)
your hands. Grasp by the edge of the
bearing shell.
2
• There are two types of bearing halves in
2, (a)
the crankshaft journal bearing with oil
groove (2) and without oil groove (3).
1 • Inspect and select the crankshaft journal
bearing if necessary. Refer to “Crankshaft
Journal Bearing Inspection and Selection”
(Page 1D-66).

3
IH17K1140264-02

3. Lower crankcase

5) Apply thread lock to the oil gallery plug (1) and

tighten it to the specified torque.
1
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Oil gallery plug (a): 7.0 N·m (0.71 kgf-m, 5.20 lbf-
IH17K1140266-01
ft)

1, “ A ” , ( a)
3
4
IH17K1140267-01
IH17K1140265-01

Oil jet
Install the oil jet (for transmission). (Page 1E-11) 2

3 5

IH17K1140268-01

4. Upper crankcase 5. Lower crankcase

 Engine Mechanical: 1D-63

Conrod Crank Pin Bearing Removal and Conrod / Crankshaft Inspection

BENH17K11406045
Installation Refer to “Crankshaft / Piston / Cylinder Removal” (Page
BENH17K11406044
Refer to “Crankshaft / Piston / Cylinder Removal” (Page 1D-45) and “Crankshaft / Piston / Cylinder Installation”
1D-45) and “Crankshaft / Piston / Cylinder Installation” (Page 1D-49).
(Page 1D-49).
Conrod Small End I.D.
Removal Measure the conrod small end inside diameter using the
Remove the conrod crank pin bearings (1). small bore gauge.
If the conrod small end inside diameter exceeds the
NOTICE service limit, replace the conrod.
• When removing the bearings, be careful Conrod small end I.D.
not to scratch the conrods and the [Limit]: 16.040 mm (0.6314 in)
bearings.
Special tool
• Do not touch the bearing surfaces with
(A): 09900–20602
your hands. Grasp the bearings by their
(B): 09900–22401
edges.

NOTE
• Do not remove the bearings (1) unless
absolutely necessary. (B)
(A)
• Make a note of where the bearings are
removed from so that they can be
reinstalled in their original positions.

IF04K1140291-01
1
Conrod Big End Side Clearance
1) Check the conrod big end side clearance using the
thickness gauge.
Conrod big end side clearance
IF04K1140329-02 [Limit]: 0.3 mm (0.011 in)
Special tool
Installation
(A): 09900–20803
When installing the bearings into the conrod cap and
conrod, be sure to fix the stopper part (1) first, and then
press in the other end.
(A)
1

IF04K1140292-01
1

IH17K1140269-01
1D-64 Engine Mechanical:

2) If the clearance exceeds the limit, remove the conrod Inspection

and measure the conrod big end width and crank pin 1) Inspect the bearing surfaces for any signs of fusion,
width. Refer to “Crankshaft / Piston / Cylinder pitting, burn or flaws. If any, replace them with a
Removal” (Page 1D-45). If any of the measurements specified set of bearings.
are out of specification, replace the conrod or
crankshaft.
Conrod big end width
[Standard]: 19.95 – 20.00 mm (0.7855 – 0.7874 in)
Crank pin width
[Standard]: 20.10 – 20.15 mm (0.7914 – 0.7933 in) I718H1140285-01

Special tool 2) Place the plastigauge axially along the crank pin,
(A): 09912–66310 avoiding the oil hole, as shown in the figure.
(B): 09900–20605
Special tool
(A): 09900–22301
(B)

(A)

(A)

IF04K1140293-01
IF04K1140295-01

Crankshaft Runout 3) Apply engine oil to the flange and thread portion of
Support the crankshaft using V-blocks as shown, with the new conrod cap bolts.
the two end journals resting on the blocks. Set up the 4) Tighten the conrod cap bolts to the specified torque,
dial gauge as shown, and rotate the crankshaft slowly to in two stages.
read the runout. Replace the crankshaft if the runout
NOTE
exceeds the service limit.
Crankshaft runout • When installing the conrod cap bolts to the
[Limit]: 0.05 mm (0.0019 in) crank pin, make sure that I.D. code (1) on
the conrod faces towards the intake side.
Special tool • Never rotate the crankshaft or conrod
(A): 09900–20607 when a piece of plastigauge is installed.
(B): 09900–20701
(C): 09900–21304 Tightening torque
Conrod cap bolt: 27 Nm (2.8 kgf-m, 20.0 lbf-ft) →
turn clockwise 90°
(A)

(C)
(C)

(B)
IH17K1140270-01

1
Conrod Crank Pin Bearing Inspection and IF04K1140296-01

Selection
BENH17K11406046
Refer to “Crankshaft / Piston / Cylinder Removal” (Page
1D-45) and “Crankshaft / Piston / Cylinder Installation”
(Page 1D-49).
 Engine Mechanical: 1D-65

5) Remove the conrod cap bolts and measure the width 2) Check the corresponding crank pin O.D. code
of the compressed plastigauge using the envelope numbers ([1], [2] or [3]) (1).
scale. This measurement should be taken at the
widest part of the compressed plastigauge.
If the oil clearance exceeds the service limit, select
the specified bearings from the bearing selection
table.
Conrod big end oil clearance
[Standard]: 0.040 – 0.064 mm (0.0016 – 0.0025 in)
[Limit]: 0.080 mm (0.0031 in)
Special tool 1
(A): 09900–22301
IH17K1140271-01

3) Measure the conrod crank pin O.D. with the special

tool. If any of the measurements are out of
specification, replace the crankshaft.
Crank pin O.D.
[Standard]: 34.976 – 35.000 mm (1.3770 – 1.3779
in)
Crank pin O.D. specification
Code (1) O.D. specification
34.992 – 35.000 mm
1
(A) (1.3777 – 1.3779 in)
IF04K1140297-01
34.984 – 34.992 mm
2
(1.3774 – 1.3776 in)
Selection
34.976 – 34.984 mm
1) Check the corresponding conrod I.D. code numbers 3
(1.3770 – 1.3773 in)
([1] or [2]) (1).
Special tool
(A): 09900–20202

1 (A)

IF04K1140298-01

Conrod big end I.D.

[Standard]: 38.000 – 38.016 mm (1.4961 – 1.4966 IF04K1140300-01

in)
Conrod I.D. specification
Code (1) I.D. specification
38.000 – 38.008 mm
1
(1.4961 – 1.4963 in)
38.008 – 38.016 mm
2
(1.4964 – 1.4966 in)
1D-66 Engine Mechanical:

4) Select the specified bearings from the bearing Crankshaft Journal Bearing Inspection and
selection table. Selection
BENH17K11406047
NOTICE Refer to “Crankshaft / Piston / Cylinder Removal” (Page
The bearings should be replaced as a set. 1D-45) and “Crankshaft / Piston / Cylinder Installation”
(Page 1D-49).
NOTE
Inspection
Upper half of the conrod crank pin bearing
1) Inspect each upper and lower crankcase bearing (1)
has an oil groove (1).
for any damage.

Bearing selection table

1
Crank pin O.D.
Code 1 2 3
Conrod 1 Green Black Brown
I.D. 2 Black Brown Yellow
IH17K1140272-01

Crank pin bearing thickness

[Standard]: 1.476 – 1.492 mm (0.0582 – 0.0587 in)
Bearing thickness specification IH17K1140274-01
Color (2) (Part No.) Thickness
Yellow
1.488 – 1.492 mm
(Upper: 12164-17K00-0D0)
(0.0586 – 0.0587 in)
(Lower: 12164-17K10-0D0)
Brown
1.484 – 1.488 mm
(Upper: 12164-17K00-0C0)
(0.0584 – 0.0586 in)
(Lower: 12164-17K10-0C0)
Black
1.480 – 1.484 mm
(Upper: 12164-17K00-0B0)
(0.0583 – 0.0584 in)
(Lower: 12164-17K10-0B0)
Green
1.476 – 1.480 mm 1
(Upper: 12164-17K00-0A0)
(0.0582 – 0.0583 in) IH17K1140275-01
(Lower: 12164-17K10-0A0)
2) Set the crankshaft onto the upper crankcase.
3) Install the plastigauge onto each crankshaft journal.
4 Special tool
1 (A): 09900–22301
3

2
IH17K1140273-02

2. Color code (A )
3. Upper conrod crank pin bearing
4. Lower conrod crank pin bearing
IH17K1140276-01
 Engine Mechanical: 1D-67

4) Mate the lower crankcase with the upper crankcase. Selection

5) Tighten the crankcase lower bolts (M9) to the 1) Check the corresponding crankcase journal I.D.
specified torque in numerical order “1” – “10”. codes (1) ([A], [B] or [C]), which are stamped on the
6) Additionally tighten the crankcase lower bolts (M9) upper crankcase.
with the specified angles gradually in numerical
order “1” – “10” using an angular torque gauge.

NOTE
Do not rotate the crankshaft when a piece of
plastigauge is installed.

Tightening torque
Crankcase lower bolt (M9) (a): 18 Nm (1.8 kgf-m,
AAABC
13.5 lbf-ft) → turn clockwise 50°
1
“ 6” , ( a) “ 4” , ( a) IH17K1140279-01

“ 1 0 ” , (a) “ 2” , ( a) “ 8 ”, (a ) Crankcase journal I.D.

[Standard]: 38.000 – 38.018 mm (1.4961 – 1.4967
in)
Crankcase journal I.D. specification
Code (1) I.D. specification
38.000 – 38.006 mm
“ 9 ” , (a) “ 7 ”, (a ) A
“ 1” , ( a) (1.4961 – 1.4962 in)
“ 5” , ( a)
“ 3” , ( a) 38.006 – 38.012 mm
B
IH17K1140277-01 (1.4963 – 1.4965 in)
7) Remove the lower crankcase and measure the width 38.012 – 38.018 mm
C
of compressed plastigauge using the envelope (1.4966 – 1.4967 in)
scale. This measurement should be taken at the
widest part of the compressed plastigauge. If the oil 2) Check the corresponding crankshaft journal O.D.
clearance exceeds the service limit, select the codes (1) ([A], [B] or [C]), which are stamped on the
specified bearings from the bearing selection table. crankshaft.

Crankshaft journal oil clearance

[Standard]: 0.016 – 0.034 mm (0.0007 – 0.0013 in)
[Limit]: 0.080 mm (0.0031 in)

IH17K1140280-01

IH17K1140278-02
1D-68 Engine Mechanical:

3) Measure the crankshaft journal O.D. with the special Crankshaft journal bearing thickness
tool. If any of the measurements are out of [Standard]: 1.492 – 1.507 mm (0.0588 – 0.0593 in)
specification, replace the crankshaft.
Bearing thickness specification
Crankshaft journal O.D. Color (3) (Part No.) Thickness
[Standard]: 34.976 – 34.994 mm (1.3770 – 1.3777 Blue
in) (With oil groove: 12229-
1.504 – 1.507 mm
Crankshaft journal O.D. specification 17K00-0E0)
(0.05922 – 0.05933 in)
(Without oil groove: 12229-
Code (1) O.D. specification
17K10-0E0)
34.988 – 34.994 mm
A Yellow
(1.3775 – 1.3777 in)
(With oil groove: 12229-
34.982 – 34.988 mm 1.501 – 1.504 mm
B 17K00-0D0)
(1.3773 – 1.3774 in) (0.05910 – 0.05921 in)
(Without oil groove: 12229-
34.976 – 34.982 mm
C 17K10-0D0)
(1.3770 – 1.3772 in)
Brown
(With oil groove: 12229-
Special tool 1.498 – 1.501 mm
17K00-0C0)
(A): 09900–20202 (0.05898 – 0.05909 in)
(Without oil groove: 12229-
17K10-0C0)
Black
(With oil groove: 12229-
1.495 – 1.498 mm
17K00-0B0)
(0.05886 – 0.05897 in)
(Without oil groove: 12229-
17K10-0B0)
Green
(With oil groove: 12229-
1.492 – 1.495 mm
17K00-0A0)
(0.05874 – 0.05885 in)
(Without oil groove: 12229-
(A) 17K10-0A0)
IH17K1140281-01

4) Select the specified bearings from the bearing

selection table.

NOTICE 2

The bearings should be replaced as a set. 1

NOTE
There are two types of bearing halves in the
crankshaft journal bearing with oil groove (1) 3
and without oil groove (2). For positioning of
each bearing, refer to “Upper Crankcase / 3
Lower Crankcase Disassembly and IH17K1140283-01

Reassembly” (Page 1D-59). 3. Color code

Bearing selection table

Crankshaft O.D.
Code A B C
A Green Black Brown
Crankcase
B Black Brown Yellow
I.D.
C Brown Yellow Blue
IH17K1140282-01
 Engine Mechanical: 1D-69

Crankshaft Thrust Clearance Inspection and Selection

Selection 1) Remove the right-side thrust bearing and measure
BENH17K11406048
its thickness using the micrometer. If the thickness of
Refer to “Crankshaft / Piston / Cylinder Removal” (Page
the right-side thrust bearing is below standard,
1D-45) and “Crankshaft / Piston / Cylinder Installation”
replace it with a new bearing and measure the thrust
(Page 1D-49).
clearance again, as described in Inspection 1) and
2).
Inspection
1) With the crankshaft’s right-side and left-side thrust Thrust bearing thickness
bearings inserted into the upper crankcase. Right side [Standard]: 2.42 – 2.44 mm (0.0953 –
2) Measure the thrust clearance “a” between the left- 0.0960 in)
side thrust bearing and crankshaft using the Left side [Standard]: 2.36 – 2.50 mm (0.0930 –
thickness gauge. If the thrust clearance exceeds the 0.0984 in)
standard range, adjust the thrust clearance. Special tool
(A): 09912–66310
NOTE
Pull the crankshaft to the left (generator side)
so that there is no clearance on the right-side
thrust bearing.

Crankshaft thrust clearance (A)

[Standard]: 0.060 – 0.110 mm (0.0024 – 0.0043 in)
Special tool
(A): 09900–20803

IF04K1140314-01

[B] 2 1 2) If the right-side thrust bearing is within the standard

range, reinsert the right-side thrust bearing and
remove the left-side thrust bearing.
3) With the left-side thrust bearing removed, measure
the clearance “a” using the thickness gauge as
shown.
Special tool
[A] (A): 09900–20803
IH17K1140284-01

[A]: Front side 1. Right-side thrust bearing

[B]: Left side 2. Left-side thrust bearing “a”

“a”

(A)

IH17K1140286-01

(A)

IH17K1140285-02
1D-70 Engine Mechanical:

4) Select a left-side thrust bearing from the selection table.

NOTE
Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) of left-side
thrust bearing.

Thrust bearing selection table

Clearance before inserting
Color (1) (Part No.) Thrust bearing thickness Thrust clearance
left-side thrust bearing
2.570 – 2.590 mm Brown 2.480 – 2.500 mm
(0.1012 – 0.1019 in) (12228-48B00-0B0) (0.0977 – 0.0984 in)
2.550 – 2.570 mm Red 2.460 – 2.480 mm
(0.1004 – 0.1011 in) (12228-48B00-0C0) (0.0969 – 0.0976 in)
2.530 – 2.550 mm Yellow 2.440 – 2.460 mm
(0.0996 – 0.1003 in) (12228-48B00-0D0) (0.0961 – 0.0968 in) 0.070 – 0.110 mm
2.510 – 2.530 mm Green 2.420 – 2.440 mm (0.0028 – 0.0043 in)
(0.0989 – 0.0996 in) (12228-48B00-0E0) (0.0953 – 0.0960 in)
2.490 – 2.510 mm Blue 2.400 – 2.420 mm
(0.0980 – 0.0988 in) (12228-48B00-0F0) (0.0945 – 0.0952 in)
2.470 – 2.490 mm Orange 2.380 – 2.400 mm
(0.0973 – 0.0980 in) (12228-48B00-0G0) (0.0937 – 0.0944 in)
2.440 – 2.470 mm Black 2.360 – 2.380 mm 0.060 – 0.110 mm
(0.0961 – 0.0972 in) (12228-48B00-0H0) (0.0930 – 0.0937 in) (0.0024 – 0.0043 in)

IF04K1140316-01

1. Color code

5) After selecting a left-side thrust bearing, install it and then measure the thrust clearance again.
 Engine Mechanical: 1D-71

Specifications
Tightening Torque Specifications
BENH17K11407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Air cleaner cap screw 1.8 0.18 1.35 (Page 1D-5)
Secondary fuel delivery pipe mounting bolt 10 1.0 7.5 (Page 1D-6)
Funnel bolt 4.3 0.44 3.20 (Page 1D-7)
Air cleaner bolt 10 1.0 7.5 (Page 1D-7)
Intake pipe screw 8.4 0.86 6.20 (Page 1D-8)
Cylinder head cover bolt 14 1.4 10.5 (Page 1D-10)
Intake camshaft sprocket bolt 60 6.1 44.5 (Page 1D-13)
Exhaust camshaft sprocket bolt 16 → 25 Nm (1.6 → 2.5 kgf-m, 12.0 → (Page 1D-14)
18.5 lbf-ft)
Camshaft journal holder bolt (Page 1D-16) /
10 1.0 7.5 (Page 1D-19) /
(Page 1D-44)
Cam chain tension adjuster bolt 10 1.0 7.5 (Page 1D-17)
Cylinder head plug (Page 1D-18) /
10 1.0 7.5
(Page 1D-35)
Crankshaft hole plug 11 1.1 8.5 (Page 1D-18)
Engine mounting thrust adjuster 23 2.3 17.0 (Page 1D-29)
Engine mounting thrust adjuster lock-nut 45 4.6 33.5 (Page 1D-30)
Engine mounting nut 75 7.6 55.5 (Page 1D-30)
Engine mounting bolt (Front) 75 7.6 55.5 (Page 1D-30)
Radiator lower bracket bolt 10 1.0 7.5 (Page 1D-32)
Hose guide bracket bolt 10 1.0 7.5 (Page 1D-32)
Cylinder head bolt (L95) 25 → 31 Nm (2.5 → 3.2 kgf-m, 18.5 → (Page 1D-33)
23.0 lbf-ft) → turn clockwise 63°
Cylinder head bolt (L65) 10 1.0 7.5 (Page 1D-33)
Oil gallery bolt 10 1.0 7.5 (Page 1D-41)
Cylinder head plug 23 2.3 17.0 (Page 1D-41)
Bypass hose union 12 1.2 9.0 (Page 1D-41)
Cam chain tensioner bolt 23 2.3 17.0 (Page 1D-44)
Cam chain guide No. 1 bolt 23 2.3 17.0 (Page 1D-44)
Conrod cap bolt 27 Nm (2.8 kgf-m, 20.0 lbf-ft) → turn (Page 1D-51) /
clockwise 90° (Page 1D-64)
Crankcase lower bolt (M9) 18 Nm (1.8 kgf-m, 13.5 lbf-ft) → turn (Page 1D-52) /
clockwise 50° (Page 1D-67)
Crankcase upper bolt (M8) 15 → 26 Nm (1.5 → 2.7 kgf-m, 11.0 → 19.5 (Page 1D-52)
lbf-ft)
Crankcase lower bolt (M8) 15 → 26 Nm (1.5 → 2.7 kgf-m, 11.0 → 19.5 (Page 1D-52)
lbf-ft)
Crankcase upper bolt (M6) 11 1.1 8.5 (Page 1D-53)
Crankcase lower bolt (M6) 11 1.1 8.5 (Page 1D-53)
Cylinder water inlet connector bolt 10 1.0 7.5 (Page 1D-54)
Water jacket plug 9.5 0.97 7.00 (Page 1D-61)
Oil gallery upper plug (M10) 18 1.8 13.5 (Page 1D-61)
Oil gallery plug (M16) 35 3.6 26.0 (Page 1D-61)
Oil gallery plug (M6) 10 1.0 7.5 (Page 1D-61)
Oil gallery plug (M12) 15 1.5 11.0 (Page 1D-62)
Oil gallery plug 7.0 0.71 5.20 (Page 1D-62)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Intake System Construction” (Page 1D-4)
“Engine Assembly Installation” (Page 1D-29)
“Fasteners Information” in Section 0C (Page 0C-12)
1D-72 Engine Mechanical:

Special Tools and Equipment

Recommended Service Material
BENH17K11408001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution — (Page 1D-36) / (Page
1D-49) / (Page 1D-49)
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1D-10) / (Page
1D-35) / (Page 1D-41) /
(Page 1D-52)
Thread lock cement THREAD LOCK CEMENT 1303B P/No.: 99000–32030 (Page 1D-14)
THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1D-44) / (Page
1D-44) / (Page 1D-61) /
(Page 1D-62)

Special Tool
BENH17K11408002
09900–20102 09900–20202
Vernier calipers (200 mm) Micrometer (25 - 50 mm)
(Page 1D-40) / (Page 1D-18) /
(Page 1D-58) (Page 1D-65) /
(Page 1D-68)

09900–20204 09900–20530
Micrometer (75 - 100 mm) Cylinder gauge set
(Page 1D-57) (Page 1D-55)

09900–20602 09900–20605
Dial gauge (1 x 0.001 mm) Dial calipers (10 - 34 mm)
(Page 1D-20) / (Page 1D-64)
(Page 1D-35) /
(Page 1D-58) /
(Page 1D-63)

09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 1D-19) / (Page 1D-19) /
(Page 1D-37) / (Page 1D-37) /
(Page 1D-38) / (Page 1D-38) /
(Page 1D-38) / (Page 1D-38) /
(Page 1D-64) (Page 1D-64)
09900–20803 09900–21304
Thickness gauge V blocks
(Page 1D-21) / (Page 1D-19) /
(Page 1D-22) / (Page 1D-37) /
(Page 1D-42) / (Page 1D-38) /
(Page 1D-55) / (Page 1D-64)
(Page 1D-58) /
(Page 1D-58) /
(Page 1D-63) /
(Page 1D-69) /
(Page 1D-69)
 Engine Mechanical: 1D-73

09900–22301 09900–22302
Plastigage (0.025 - 0.076 Plastigage (0.051 - 0.152
mm) mm)
(Page 1D-19) / (Page 1D-19)
(Page 1D-64) /
(Page 1D-65) /
(Page 1D-66)
09900–22401 09900–22402
Small bore gauge (10 - 18 Small bore gauge
mm) attachment (6-10mm)
(Page 1D-58) / (Page 1D-35)
(Page 1D-63)

09900–22403 09912–66310
Small bore gauge (18 - 35 Micrometer (0 - 25 mm)
mm)
(Page 1D-20) (Page 1D-20) /
(Page 1D-35) /
(Page 1D-38) /
(Page 1D-58) /
(Page 1D-59) /
(Page 1D-64) /
(Page 1D-69)
09915–63311 09915–64512
Compression gauge adapter Compression gauge set
(2500 kPa)
(Page 1D-3) 1. Gauge 2. Hose (Adapter)
(Page 1D-3)

09916–10911 09916–14510
Valve lapper set Valve lifter
(Page 1D-38) 1. Main unit 2. Attachment
(Page 1D-36) /
(Page 1D-37)

09916–14522 09916–33210
Valve lifter attachment Valve guide reamer (ø4.5)
(Page 1D-36) / (Page 1D-43)
(Page 1D-37)

09916–33320 09916–34542
Valve guide outer reamer Reamer handle
(ø9.8)
(Page 1D-42) (Page 1D-42) /
(Page 1D-43)
1D-74 Engine Mechanical:

09916–51710 09916–77310
Valve guide installer / Piston ring compressor
remover set
(Page 1D-42) / (Page 1D-50)
(Page 1D-42) /
(Page 1D-43)

09916–84511 09940–14990
Tweezers Engine mounting adjuster
wrench
(Page 1D-36) / (Page 1D-28) /
(Page 1D-37) (Page 1D-29) /
(Page 1D-30)
 Engine Lubrication System: 1E-1

Engine Lubrication System

Engine

Precautions
Precautions for Engine Oil
BENH17K11500001
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-14).
1E-2 Engine Lubrication System:

Schematic and Routing Diagram

Engine Lubrication System Chart Diagram
BENH17K11502001

INTAKE CAMSHAFT INTAKE CAMSHAFT

JOURNAL HOLDER

CAMSHAFT JOURNALS, VVT

CAMFACES AND ROCKER ARMS

EXHAUST CAMSHAFT
EXHAUST CAMSHAFT
JOURNAL HOLDER

CAMSHAFT JOURNALS, ORIFICE

CAMFACES AND ROCKER ARMS

SUB-GALLERY CAM DRIVE CHAIN

STARTER CLUTCH
PISTON COOLING PISTON COOLING PISTON COOLING PISTON COOLING
JET #1 JET #2 JET #3 JET #4

PISTON #1 AND PISTON #2 AND PISTON #3 AND PISTON #4 AND

CYLINDER WALL CYLINDER WALL CYLINDER WALL CYLINDER WALL
CAM CHAIN
TENSION ADJUSTER

CRANK PIN CRANK PIN CRANK PIN CRANK PIN

BEARING #1 BEARING #2 BEARING #3 BEARING #4 OIL JET

CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT

ORIFICE
JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING JOURNAL BEARING

GENERATOR
MAIN GALLERY
OIL PRESSURE
SWITCH OIL JET
OIL FILTER

COUNTERSHAFT TRANSMISSION
LEFT-SIDE COVER
BEARING ORIFICE OIL COOLER

DRIVESHAFT
PRIMARY DRIVEN CLUTCH PUSH COUNTERSHAFT DRIVESHAFT RIGHT-SIDE
GEAR BEARING PIECE BEARING OIL PRESSUER OIL PUMP
REGULATOR
COUNTERSHAFT DRIVESHAFT
GEARS AND GEARS AND
CLUTCH PLATES BUSHINGS BUSHINGS OIL STRAINER

OIL PAN
IH17K1150001-03
 Engine Lubrication System: 1E-3

Diagnostic Information and Procedures

Engine Lubrication Symptom Diagnosis
BENH17K11504003

Condition Possible cause Correction / Reference Item

Engine overheats Insufficient amount of engine oil. Add engine oil. (Page 1E-4)
Defective oil pump. Replace. (Page 1E-12)
Clogged oil circuit. Clean.
Incorrect engine oil. Change. (Page 1E-4)
Exhaust smoke is dirty or Excessive amount of engine oil. Drain out excess engine oil. (Page 1E-4)
thick
Engine lacks power Excessive amount of engine oil. Drain out excess engine oil. (Page 1E-4)

Oil Pressure Check

BENH17K11504002
Check the engine oil pressure periodically. This will give (A )
a good indication of the condition of the moving parts.

NOTE
(C)
Before checking the oil pressure, check the ( B)
following:
• Oil level: (Page 1E-4)
• Oil leaks (If leak is found, repair it.)
• Oil quality (If oil is discolored or
deteriorated, replace it.) IH17K1150003-01

5) Warm up the engine as follows:

1) Remove the right side cowling. (Page 9D-21) Summer: 10 min. at 2000 r/min
2) Start the engine and check if the oil pressure Winter: 20 min. at 2000 r/min
indicator light is turned on. If the light stays on, check 6) After warm up, increase the engine speed to 3000 r/
the oil pressure indicator light circuit. If the circuit is min and read the oil pressure gauge.
OK, check the oil pressure in the following manner. If the oil pressure is lower or higher than the
3) Remove the oil gallery plug (M16) (1). specification, the following causes may be
considered.
Oil pressure
At 60 °C (140 °F), 3000 r/min
[Standard]: 100 – 500 kPa (1.0 – 5.1 kgf/cm2, 14.5
1 – 72.5 psi)
High oil pressure Low oil pressure
• Engine oil viscosity is • Clogged oil filter
too high • Oil leakage from the oil
• Clogged oil passage passage
• Combination of the • Damaged O-ring
IH17K1150002-01 above items • Defective oil pump
4) Install the oil pressure gauge and attachment into • Combination of the
the oil gallery. above items
Special tool
(A): 09915–77331 7) Stop the engine and remove the oil pressure gauge
(B): 09915–74521 and attachment.
(C): 09915–74540 ! WARNING
To avoid the risk of being burned, remove the
oil pressure gauge when the oil has cooled.
1E-4 Engine Lubrication System:

8) Install the new gasket to the oil gallery plug (M16)

(1).
9) Install the oil gallery plug (M16) (1) and tighten it to
the specified torque.
Tightening torque 1, (a)
Oil gallery plug (M16) (a): 35 N·m (3.6 kgf-m,
26.0 lbf-ft)

IH17K1150004-01

10) Check the engine oil level. (Page 1E-4)

11) Install the removed parts.

Repair Instructions
Engine Oil Inspection ! CAUTION
BENH17K11506001
Engine Oil Leakage Inspection To avoid getting burned, do not touch the
Visually check the cylinder, crankcase, etc. for oil engine, engine oil and exhaust system.
leakage.

Engine Oil Level Inspection

1) Keep the motorcycle upright on a level surface.
1
2) Start the engine at idle speed for a few minutes. Turn
off the engine and wait for about three minutes.
3) Check the oil level and deterioration through the
inspection window.
If the oil level is below mark “L”, add new oil until the
level is brought between “F” and “L”. However, if the
oil is deteriorated or discoloration, replace it. 2

IH28K1150029-01

5) Install the new gasket washer (1) to the oil drain plug
as shown.

IH17K1150049-01

6) Tighten the oil drain plug (1) to the specified torque.

IH28K1150028-02
Tightening torque
Oil drain plug (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
Engine Oil Replacement
BENH17K11506002
1) Keep the motorcycle upright on a level surface.
2) Start the engine at idle speed for a few minutes and
then turn off the engine.
3) Place an oil pan under the engine and remove the oil
filler cap (1).
4) Drain engine oil by removing the oil drain plug (2).
1, (a)
IH17K1150050-01
 Engine Lubrication System: 1E-5

7) Pour new oil through the oil filler hole. 5) Install a new oil filter. Turn it by hand until you feel
that the oil filter O-ring contacts the oil filter mounting
Necessary amount of engine oil
surface. Then, tighten the oil filter two full turns (or to
Oil change [Standard]: 3100 ml (3.28 US qt, 2.73
specified torque) with the special tool.
Imp qt)
Oil and filter change [Standard]: 3300 ml (3.49 US NOTE
qt, 2.90 Imp qt)
To properly tighten the oil filter, use the
Engine overhaul [Standard]: 4100 ml (4.33 US qt,
special tool. Never tighten the oil filter by
3.61 Imp qt)
hand only.
8) Install the oil filler cap.
9) Start the engine and check for oil leakage. Special tool
(A): 09915–40620
10) Stop the engine and check the engine oil level again.
Refer to “Engine Oil Inspection” (Page 1E-4). Tightening torque
Oil filter (a): 20 N·m (2.0 kgf-m, 15.0 lbf-ft)
Oil Filter Replacement
BENH17K11506003 1, (a)
(A)
1) Drain engine oil. (Page 1E-4)
2) Remove the left side cowling. (Page 9D-21)
3) Remove the oil filter (1) with the special tool.

NOTE
Detach the special tool once the oil filter has
come loose, and then remove the filter by
hand.
IH17K1150051-01
Special tool
6) Add new engine oil. (Page 1E-4)
(A): 09915–40620
7) Check the engine oil level. (Page 1E-4)
8) Install the removed parts.
1
Oil Pan / Oil Strainer / Oil Pressure Regulator
Removal and Installation
BENH17K11506004
Removal
1) Drain engine oil. (Page 1E-4)
2) Remove the exhaust pipe. (Page 1K-24)
(A)
3) Remove the oil pan (1) and gasket (2).

IH17K1150005-01

4) Apply engine oil lightly to the O-ring of new oil filter

(1) before installation.

NOTICE
ONLY USE A GENUINE SUZUKI
MOTORCYCLE OIL FILTER.
Other manufacturer’s oil filters may differ in
thread specifications (thread diameter and
pitch), filtering performance and durability 1
2
which may lead to engine damage or oil
IH17K1150006-01
leaks. Also, do not use a genuine Suzuki
automobile oil filter on this motorcycle.
1E-6 Engine Lubrication System:

4) Remove the oil strainer (1) and oil pressure regulator 3) Apply engine oil to the new O-ring (1).
(2). 4) Install the oil strainer (2).
5) Tighten the oil strainer bolts (3) to the specified
torque.
2
Tightening torque
Oil strainer bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

3, (a)

IH17K1150007-01

5) Remove the O-ring (1). 1

IH17K1150010-02

6) Fit the new gasket (1) and oil pan (2).

IH17K1150008-01

Installation
1) Apply engine oil to the new O-ring (1).
1
2) Install the oil pressure regulator (2). 2
IH17K1150011-01

7) Tighten the bolts (1) to the specified torque.

Tightening torque
Oil pan bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1, (a)
1

IH17K1150009-01

IH17K1150012-01

8) Install the exhaust pipe. (Page 1K-26)

9) Pour engine oil. (Page 1E-4)
 Engine Lubrication System: 1E-7

Oil Pressure Regulator / Oil Strainer Inspection Oil Cooler / Oil Cooler Hose Inspection and
BENH17K11506005
Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator
Cleaning
BENH17K11506006
Removal and Installation” (Page 1E-5). Refer to “Side Cowling Removal and Installation” in
Section 9D (Page 9D-21).
Oil Pressure Regulator
Inspect the operation of the oil pressure regulator by Oil Cooler Hose Inspection
pushing on the piston with a proper bar. Inspect the oil cooler hoses for any damage and oil
If the piston does not operate, replace the oil pressure leakage. If any defects are found, replace the oil cooler
regulator with a new one. hose with a new one.

I947H1150013-02 IH17K1150014-01

Oil Strainer Oil Cooler Inspection

Clean the oil strainer if necessary. Inspect the oil strainer 1) Remove the oil cooler guard (1).
body for damage. If necessary, replace it with a new one.

IH17K1150015-01
IH17K1150013-01
2) Inspect the oil cooler for oil leakage. If any defects
are found, replace the oil cooler with a new one. If
the fins are bent or dented, repair them by carefully
straightening them with the blade of a small
screwdriver.

IH17K1150016-01

3) Reinstall the removed parts.

1E-8 Engine Lubrication System:

Oil Cooler Cleaning 3) Remove the oil hoses (1) and (2).
1) Remove the oil cooler guard (1).
2) Remove the oil cooler mounting bolts.
1

2
1 IH17K1150019-01

4) Remove the O-rings (1).

IH17K1150017-01

3) Blow out any foreign matter that is stuck in the oil

cooler fins using compressed air.

NOTICE
• Do not bend the fins when using
compressed air.
• Apply compressed air from the engine
side. If compressed air is applied from the 1
other side, dirt will be forced into the pores
of oil cooler.
IH17K1150020-01

5) Remove the O-rings (1) and oil cooler (2).

1 2

IH17K1150018-01
IH17K1150021-01
4) Reinstall the removed parts.
6) Remove the oil cooler guard (1).
Oil Cooler Removal and Installation
BENH17K11506007
Removal
1) Remove the side cowlings. (Page 9D-21)
2) Drain engine oil. (Page 1E-4)

IH17K1150022-01
 Engine Lubrication System: 1E-9

7) Remove the oil hose plate (1).

2
1, “A”, (a)
1, “A”, (a)

1
IH17K1150025-01

IH17K1150023-01 4) Tighten the oil cooler guard bolts (1) to the specified
8) Remove the O-rings (1). torque.
Tightening torque
Oil cooler guard bolt (a): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft)

1, (a)
IH17K1150024-01
1, (a)
Installation
1) Apply engine oil to the new O-rings (1). IH17K1150026-01

5) Apply thread lock to the bolts (1) and install the oil
cooler (2).
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
6) Tighten the oil cooler mounting bolts to the specified
torque.

1 Tightening torque
Oil cooler mounting bolt (a): 5.5 N·m (0.56 kgf-
m, 4.05 lbf-ft)
IH17K1150024-01
1, “A”, (a)
2) Apply thread lock to the bolts (1) and install the oil 1, “A”, (a)
hose plate (2).
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
2
3) Tighten the oil hose plate bolts to the specified
torque.
Tightening torque 2
Oil hose plate bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
1, “A”, (a)
ft) IH17K1150027-01
1E-10 Engine Lubrication System:

7) Apply engine oil to the new O-rings (1). Installation

1) Install the oil pressure switch (1), apply the sealant to
its thread part and tighten it to the specified torque.

NOTE
Do not apply sealant to oil pressure switch
hole.

“A”: Sealant 99000–31140 (SUZUKI BOND

1 1207B)
1 Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
IH17K1150028-01 lbf-ft)
8) Apply thread lock to the bolts (1) and install the oil
hoses (2) and (3).
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D) 1
9) Tighten the oil hose bolts to the specified torque.
Tightening torque
Oil hose bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) “A”
1, (a)

1, “A”, (a)
2
IH17K1150031-02

2) Connect the oil pressure switch lead wire (1).

(Page 9A-13)
Tightening torque
Oil pressure switch lead wire connecting screw
(a): 1.5 N·m (0.15 kgf-m, 1.10 lbf-ft)
1, “A”, (a)
3
IH17K1150029-01

10) Pour engine oil. (Page 1E-4) (a)

11) Install the side cowlings. (Page 9D-21)

Oil Pressure Switch Removal and Installation

BENH17K11506008

Removal
1
1) Turn the ignition switch OFF.
2) Remove the left side cowling. (Page 9D-21) IH17K1150032-02

3) Drain engine oil. (Page 1E-4) 3) Pour engine oil. (Page 1E-4)
4) Disconnect the oil pressure switch lead wire (1). 4) Install the removed parts.
5) Remove the oil pressure switch (2).
Oil Pressure Switch Inspection
BENH17K11506009
Refer to “Oil Pressure Indicator Inspection” in Section 9C
(Page 9C-11).

IH17K1150030-01
 Engine Lubrication System: 1E-11

Oil Jet / Piston Cooling Jet Removal and Installation

Installation Install the oil jet (for transmission) in the reverse order of
BENH17K11506010 removal.
Oil Jet (For Cam Chain Tension Adjuster)
Removal Piston Cooling Jet
1) Remove the cam chain tension adjuster. (Page Removal
1D-11) 1) Remove the crankshaft assembly. (Page 1D-45)
2) Remove the oil jet (1). 2) Remove the piston cooling jets (1).

IH17K1150033-01
IH17K1150035-01

Installation Installation
Install the oil jet (for cam chain tension adjuster) in the Install the piston cooling jet in the reverse order of
reverse order of removal. Pay attention to the following removal. Pay attention to the following points:
point:
• Apply engine oil to the new O-ring (1).
• Apply engine oil to the new O-ring (1).
• Apply thread lock to the piston cooling jet bolt (2) and
tighten it to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Piston cooling jet bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)
1

2 , “A”, (a )
1
IF04K1150035-02

Oil Jet (For Transmission)

Removal
1) Separate the crankcases, upper and lower. Refer to
“Crankshaft / Piston / Cylinder Removal” in Section
1D (Page 1D-45).
2) Remove the oil jet (for transmission) (1). IH17K1150036-01

IH17K1150034-01
1E-12 Engine Lubrication System:

Oil Jet / Piston Cooling Jet Inspection 5) Remove the oil pump assembly (1).
BENH17K11506011
Refer to “Oil Jet / Piston Cooling Jet Removal and
1
Installation” (Page 1E-11).
Make sure that the oil jets and piston cooling jet are not
clogged. If they are clogged, clean their oil passage
using a wire of the proper size and compressed air.

1 2 3

IH17K1150039-01

6) Remove the O-ring (1) and dowel pins (2).

1
IH17K1150037-01

1. Piston cooling jet

2. Oil jet (for transmission)
3. Oil jet (for cam chain tension adjuster)

Oil Pump Removal and Installation

BENH17K11506012
NOTE 2
Be careful not to drop any parts into the IH17K1150040-02

crankcase. 7) Flatten the oil pump sprocket bolt retainer (1).

8) Remove the oil pump driven sprocket bolt (2), oil
Removal pump sprocket bolt retainer and oil pump driven
1) Remove the clutch components. (Page 5C-15) sprocket (3).
2) Remove the oil pan, oil strainer and oil pressure
regulator. (Page 1E-5)
3) Remove the spacer (1) and bearing (2).
1
4) Remove the oil pump drive sprocket (3) and chain
(4).

2 1
2

3
IH17K1150041-01

9) Remove the washer (1).

3
4

IH17K1150038-01

IH17K1150042-02
 Engine Lubrication System: 1E-13

Installation 5) Install the dowel pins (1).

1) Install the washer (1). 6) Apply engine oil to the new O-ring (2).

1
1
IH17K1150042-02 IH17K1150045-02

2) Install the oil pump driven sprocket (1) and new oil 7) Apply thread lock to the bolts (1) and install the oil
pump sprocket bolt retainer (2). pump with the slot on the shaft end (2) securely
3) Apply thread lock to the oil pump driven sprocket bolt engaged with the groove on the water pump shaft.
(3) and tighten it to the specified torque. “A”: Thread lock cement 99000–32150 (THREAD
“A”: Thread lock cement 99000–32150 (THREAD LOCK CEMENT 1322D)
LOCK CEMENT 1322D) 8) Tighten the oil pump bolts to the specified torque.
Tightening torque Tightening torque
Oil pump driven sprocket bolt (a): 15 N·m (1.5 Oil pump bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
kgf-m, 11.0 lbf-ft)

1, “A”, (a)

3, “A”, (a)
1, “A”, (a)
1 IH17K1150046-01
IH17K1150043-01
9) Install the oil pump drive sprocket (1) and chain (2).
4) Bend the oil pump sprocket bolt retainer (1) at one
10) Apply engine oil to the bearing (3) and install it.
side.
11) Install the spacer (4).

1 3 4

1
2
IH17K1150044-01
IH17K1150047-01

12) Install the oil pressure regulator, oil strainer and oil
pan. (Page 1E-5)
13) Install the clutch components. (Page 5C-17)
1E-14 Engine Lubrication System:

Oil Pump Inspection

BENH17K11506013
Refer to “Oil Pump Removal and Installation” (Page 1E-
12).
Rotate the oil pump shaft by hand and check that it
moves smoothly. If it does not move smoothly, replace
the oil pump assembly.

IH17K1150048-02

Specifications
Tightening Torque Specifications
BENH17K11507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil gallery plug (M16) 35 3.6 26.0 (Page 1E-4)
Oil drain plug 23 2.3 17.0 (Page 1E-4)
Oil filter 20 2.0 15.0 (Page 1E-5)
Oil strainer bolt 10 1.0 7.5 (Page 1E-6)
Oil pan bolt 10 1.0 7.5 (Page 1E-6)
Oil hose plate bolt 10 1.0 7.5 (Page 1E-9)
Oil cooler guard bolt 5.5 0.56 4.05 (Page 1E-9)
Oil cooler mounting bolt 5.5 0.56 4.05 (Page 1E-9)
Oil hose bolt 10 1.0 7.5 (Page 1E-10)
Oil pressure switch 13 1.3 9.5 (Page 1E-10)
Oil pressure switch lead wire connecting screw 1.5 0.15 1.10 (Page 1E-10)
Piston cooling jet bolt 10 1.0 7.5 (Page 1E-11)
Oil pump driven sprocket bolt 15 1.5 11.0 (Page 1E-13)
Oil pump bolt 10 1.0 7.5 (Page 1E-13)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-12)
 Engine Lubrication System: 1E-15

Special Tools and Equipment

Recommended Service Material
BENH17K11508001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1E-10)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1E-9) / (Page 1E-
9) / (Page 1E-10) /
(Page 1E-11) / (Page
1E-13) / (Page 1E-13)

Special Tool
BENH17K11508002
09915–40620 09915–74521
Oil filter wrench Oil pressure gauge hose
(Page 1E-5) / (Page 1E-3)
(Page 1E-5)

09915–74540 09915–77331
Oil pressure gauge Oil pressure gauge (1000
attachment kPa)
(Page 1E-3) (Page 1E-3)
1F-1 Engine Cooling System:

Engine Cooling System

Engine

Precautions
Precautions for Engine Cooling System
BENH17K11600001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

! WARNING

• You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot.
After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a
quarter turn to allow pressure to escape and then turn the cap all the way off.
• The engine must be cool before servicing the cooling system.
• Coolant is harmful:
– If it comes in contact with skin or eyes, flush with water.
– If swallowed accidentally, do not induce vomiting and call physician immediately.
– Keep it away from children.

Precautions for Engine Coolant

BENH17K11600002
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-14).

General Description
Engine Coolant Description
BENH17K11601001
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-14).

Schematic and Routing Diagram

Cooling Circuit Diagram
BENH17K11602001

RESERVOIR THERMOSTAT
TANK CYLINDER HEAD ECT SENSOR

CYLINDER

RADIATOR
WATER
PUMP

IH17K1160001-01
 Engine Cooling System: 1F-2

Water Hose Routing Diagram

BENH17K11602002

20 9

7
1
(b)
8 4
[A] (a)
21

2
[D]
20
18

[C] (a) [B] (a)

16
10

(b)
(b) 6
3 18
[C] (a)

22

[E]

[F]

11

13 [G] (a)

“a” 12
19

[K]

(b)

23
[J]

[L] 15

(c)
14 [H]

[I]
17
IH17K1160002-03
1F-3 Engine Cooling System:

[A]: Position the clamp screw upside and tighten it 2. Reservoir tank 15. Bypass union
from left side.
[B]: Position the clamp screw backward and tighten 3. Oil cooler 16. Water pump
it from left side.
: Make space of 3 – 5 mm (0.12 – 0.20 in.)
between the clamp and hose end. Avoid the
clamp to contact with the water pump.
[C]: Position the clamp screw downward and 4. Water inlet connector 17. White mark
tighten it from left side. : Align the white mark with the projection on
the cylinder head.
[D]: Face the clamp end leftward. 5. Cylinder inlet hose 18. White mark
: Align the white mark with the match mark
on the water pump.
[E]: Align “” mark on the reservoir tank cap with 6. Radiator outlet hose 19. White mark
white mark on the reservoir tank overflow hose. : Align the white mark with the match mark
on the thermostat connector cover.
[F]: Face the clamp end downward avoiding 7. Water bypass hose 20. Yellow mark
contact with the radiator cap. : Pass the water bypass hose above : Face the yellow mark leftward.
the rectifier bracket bolt.
: Pass the water bypass hose through
the groove of radiator heat shield.
[G]: Tighten the clamp screw from rear right side. 8. Rectifier bracket bolt 21. Yellow mark
: Align the yellow mark with the match mark
on the water inlet connector.
[H]: Face the clamp end backward. 9. Radiator heat shield 22. Yellow mark
: Align the yellow mark with the center of the
radiator cap.
[I]: Align the clamp end with the projection on the 10. Radiator hose bracket 23. Match mark
cylinder head.
[J]: Insert the hose up to the stopper. 11. Radiator inlet hose “a”: 2 – 5 mm (0.08 – 0.19 in)
[K]: Keep clearance between the bulge and clamp. 12. Radiator cap : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft)
[L]: If there is no stopper on the pipe, insert the 13. Reservoir tank cap : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
hose to align mark on the hose with the bulge
of the pipe.
1. Radiator 14. Thermostat connector cover : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
 Engine Cooling System: 1F-4

1
10

2
8
3

[A]

4
[B]
[D]
(b)

9
[C] (a)
6

(c)
(c)

(b)
7
IH17K1160003-03

[A]: Clamp reservoir tank inlet hose to the reservoir tank aligning the white mark on 3. Reservoir tank overflow 9. White mark
the hose with lower end of the reservoir tank hook. hose
[B]: Pass the reservoir tank overflow hose lower side of the reservoir tank inlet hose. 4. Reservoir tank 10. Yellow mark
[C]: Position the clamp screw downward and tighten it from right side. 5. Reservoir tank inlet hose : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft)
[D]: Align the clamp end with the white mark on the reservoir tank inlet hose. 6. Radiator : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
1. Radiator cap 7. Oil cooler : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. Reservoir tank cap 8. Radiator inlet hose
1F-5 Engine Cooling System:

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis
BENH17K11604002

Condition Possible cause Correction / Reference Item

Engine overheats Not enough engine coolant. Add engine coolant. (Page 1F-5)
Radiator core clogged with dirt or scale. Clean. (Page 1F-10)
Faulty cooling fan. Repair or replace. (Page 1F-8)
Defective cooling fan relay, or open-or- Repair or replace. (Page 1F-12)
short circuited.
Clogged water passage. Clean.
Air trapped in the cooling circuit. Bleed air. (Page 1F-6)
Defective water pump. Replace. (Page 1F-15)
Use of incorrect engine coolant. Replace. (Page 1F-6)
Defective thermostat. Replace. (Page 1F-12)
Defective ECT sensor. Replace. (Page 1C-14)
Defective ECM. Replace. (Page 1C-10)
Engine over cools Defective cooling fan relay, or open-or- Repair or replace. (Page 1F-12)
short circuited.
Extremely cold weather. Put on radiator cover.
Defective thermostat. Replace. (Page 1F-12)
Defective ECT sensor. Replace. (Page 1C-14)
Defective ECM. Replace. (Page 1C-10)

Repair Instructions
Engine Coolant Level Inspection b) Remove right intake cover (1) by removing screw
BENH17K11606001 (2) and clips (3).
1) Keep the motorcycle upright.
2) Check the engine coolant level by observing the full 2
3 [A]
(1) and lower (2) lines on the engine coolant
reservoir tank.

3
[B]
2 IH17K1160004-02

[A] [B]

IH17K1160006-01

3) If the level is below the lower line, add engine

coolant as follows.
a) Remove the following parts.
• Right side cowling assembly: (Page 9D-21)
• Remove the body cowling cover: (Page 9D-
20)

IH17K1160005-01

c) Add engine coolant to the bottom of full line from

the engine coolant reservoir tank filler.
 Engine Cooling System: 1F-6

4) Install the reservoir tank cap by aligning the match 5) Flush the radiator with fresh water if necessary.
mark (1) and reservoir tank overflow hose (2). 6) Connect the radiator outlet hose. (Page 1F-2)
7) Pour the specified engine coolant up to the radiator
1 inlet.
Engine coolant
Engine side [Standard]: Approx. 2200 ml (2.32 US
qt, 1.94 Imp qt)
2 Reservoir tank side [Standard]: Approx. 250 ml
(0.26 US qt, 0.22 Imp qt)

IH17K1160007-01

5) Install the removed parts.

Engine Coolant Replacement

BENH17K11606002
Refer to “Engine Coolant Description” (Page 1F-1).
1) Support the motorcycle upright.
2) Remove the following parts.
IH17K1160010-01
• Right intake cover: (Page 1F-5)
8) Slowly swing the motorcycle, right and left, to bleed
• Left side cowling assembly: (Page 9D-21) the air trapped in the cooling circuit.
3) Remove the radiator cap (1). 9) Add engine coolant up to the radiator inlet.
10) Start up the engine and bleed air from the radiator
1 inlet completely.
11) Add engine coolant up to the radiator inlet.
12) Repeat the 9), 10) procedures until no air bleeds
from the radiator inlet.
13) Close the radiator cap securely. (Page 1F-7)
14) After warming up and cooling down the engine
several times, add the engine coolant up to the full
level of the reservoir tank. (Page 1F-5)
15) Install the removed parts.
IH17K1160008-01

4) Disconnect the radiator outlet hose (1) and drain

engine coolant.

IH17K1160009-01
1F-7 Engine Cooling System:

Engine Cooling System Inspection

BENH17K11606004
1
1) Remove the air intake pipe. (Page 9D-22)
2) Remove the radiator cap (1). (Page 1F-7)
3) Connect the special tool to the filler.
4) Pressurize the cooling system with approx. 122.7
kPa (1.3 kgf/cm2, 17.8 psi) of pressure, and then
check if it holds the pressure for 10 seconds.

NOTICE
Do not exceed the radiator cap release
pressure, or the radiator cap and IH17K1160008-01

subsequently the radiator, can be damaged. 3) Attach the radiator cap (1) to the special tool as
shown in the figure.
Special tool 4) Slowly apply pressure to the radiator cap.
(A): 09918–78211 If the radiator cap does not hold the pressure for at
(B): 09918–78220 least 10 seconds, replace it with a new one.
Radiator cap valve opening pressure
1
[Standard]: 93.3 – 122.7 kPa (1.0 – 1.3 kgf/cm2,
13.5 – 17.8 psi)
Special tool
(A): 09918–78211
(B): 09918–78220

1
(B)

IH17K1160008-01 (A)

(B)
ID26J1160007-04
(A)
Cooling Fan On-Vehicle Inspection
BENH17K11606006

ID26J1160006-05
NOTE
5) Install the radiator cap. (Page 1F-7) For on-vehicle inspection of cooling fan, the
6) Install the removed parts. same procedures are applicable to both the
right and left sides.
Radiator Cap Inspection 1) Remove the right side cowling assembly. (Page
BENH17K11606005
Refer to “Engine Cooling System Inspection” (Page 1F- 9D-21)
7). 2) Disconnect the cooling fan motor coupler (1).
1) Remove the right intake cover. (Page 1F-5)
2) Remove the radiator cap (1). 1

IH17K1160011-02
 Engine Cooling System: 1F-8

3) Test the cooling fan motor (3) for load current with an
ammeter (2) connected as shown in the figure.
If the fan motor does not turn, replace the cooling fan 1
assembly with a new one. (Page 1F-8)

NOTE 1

• When making this test, it is not necessary

to remove the cooling fan.
• Make sure that the battery (1) has a
capacity enough to supply the motor with
12 V.
IH17K1160013-01
• With the motor running at full speed, the
ammeter should indicate an amperage not
higher than 5.4 A. Radiator / Cooling Fan Motor Removal and
Installation
BENH17K11606008
Cooling fan operating temperature
Removal
(OFF→ON) [Standard]: Approx. 105 °C (221 °F)
(ON→OFF) [Standard]: Approx. 100 °C (212 °F) 1) Remove the side cowling assemblies. (Page 9D-
21)
2) Drain engine coolant. (Page 1F-6)
3) Remove the oil cooler from the bracket. (Page 1E-
8)
3 2 4) Disconnect the radiator inlet hose (1).
1 5) Disconnect the right side cooling fan motor coupler
(2).

2
ID26J1160029-01

4) After finishing the cooling fan inspection, install the

removed parts.
1

Radiator Hose Inspection

BENH17K11606007
1) Remove the side cowling assemblies. (Page 9D-
21)
2) Lift and support the fuel tank. (Page 1G-9) IH17K1160014-01
3) Check the radiator hoses for crack, damage or 6) Disconnect the radiator outlet hose (1), water bypass
engine coolant leakage. If any defect is found, hose (2).
replace the radiator hose with a new one. 7) Disconnect the left side cooling fan motor coupler (3)
4) Any leakage from the connecting section (1) should and horn coupler (4).
be corrected by proper tightening. (Page 1F-2)
2

1 1
3

1
4

IH17K1160015-01
IH17K1160012-02
1F-9 Engine Cooling System:

8) Remove the radiator mounting bolts (1). • Install the horn. (Page 9C-12)
• Install the radiator reservoir tank. (Page 1F-10)
• Tighten the cooling fan assembly mounting bolts (1) to
1 the specified torque.
1
Tightening torque
Cooling fan assembly mounting bolt (a): 4.9 N·m
(0.50 kgf-m, 4.00 lbf-ft)

IH17K1160016-01

1, (a) 1, (a)
IH17K1160020-01

• Tighten the radiator mounting upper bolts (1) to the

specified torque.
Tightening torque
Radiator mounting upper bolt (a): 10 N·m (1.0
IH17K1160017-01 kgf-m, 7.5 lbf-ft)
9) Remove the radiator (1).
• Apply thread lock to the radiator mounting lower bolts
(2) and tighten them to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
1 LOCK CEMENT 1322D)
Tightening torque
Radiator mounting lower bolt (b): 5.5 N·m (0.56
kgf-m, 4.05 lbf-ft)

1, (a)
1, (a)
IH17K1160018-01

10) Remove the cooling fan motors (1).

IH17K1160021-01

2, “A”, (b)

1
1
IH17K1160019-01

11) Remove the radiator reservoir tank. (Page 1F-10)

12) Remove the horn. (Page 9C-12)

Installation
Install the radiator in the reverse order of removal. Pay
attention to the following points: IH17K1160022-01
 Engine Cooling System: 1F-10

• Tighten the water hose clamp screws (1) to the Cleaning

specified torque. 1) Remove the side cowling assemblies. (Page 9D-
Tightening torque 21)
Water hose clamp screw (a): 1.5 N·m (0.15 kgf-m, 2) Blow out any foreign matter that is stuck in the
1.10 lbf-ft) radiator fins using compressed air.

NOTICE
• Do not bend the fins when using
compressed air.
• Apply compressed air from the engine
side. If compressed air is applied from the
other side, dirt will be forced into the pores
of radiator.
1, (a)
1, (a)

IH17K1160023-01

• Connect the radiator hoses securely. (Page 1F-2)

• Pour engine coolant. (Page 1F-6)

Radiator Inspection and Cleaning

BENH17K11606009
Inspection
1) Remove the side cowling assemblies. (Page 9D-
21)
2) Inspect the radiator for coolant leaks. If any defects IH17K1160025-01

are found, replace the radiator with a new one.

3) If the fins are bent or dented, repair them by carefully Radiator Reservoir Tank Inspection
BENH17K11606010
straightening them with the blade of a small 1) Remove the right side cowling assembly. (Page
screwdriver. 9D-21)
2) Inspect the radiator reservoir tank (1) coolant leaks.
If any defects are found, replace the radiator
reservoir tank with a new one.

IH17K1160024-01

4) Install the removed parts.

IH17K1160026-01

3) Install the removed parts.

Radiator Reservoir Tank Removal and

Installation
BENH17K11606011
Removal
1) Remove the right side cowling assembly. (Page
9D-21)
1F-11 Engine Cooling System:

2) Remove the reservoir tank bolt (1) and reservoir tank Water Hose Inspection
(2). BENH17K11606012
1) Lift and support the fuel tank. (Page 1G-9)
3) Disconnect the reservoir tank inlet hose (3) and drain
engine coolant. 2) Remove the side cowling assemblies. (Page 9D-
21)
4) Disconnect the reservoir tank overflow hose (4).
3) Check the water hoses for crack, damage or engine
4 coolant leakage. If any defect is found, replace the
radiator hose with a new one.
4) Any leakage from the connecting section (1) should
be corrected by proper tightening. (Page 1F-2)
1 2

3
IH17K1160027-01

1
Installation
Install radiator reservoir tank in the reverse order of
removal. Pay attention to the following points:
• Apply thread lock to the reservoir tank mounting bolt IH17K1160030-01

(1) and then tighten the reservoir tank mounting bolt

(1) to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Reservoir tank mounting bolt (a): 5.5 N·m (0.56
kgf-m, 4.05 lbf-ft)

1 , “ A” , ( a ) IH17K1160031-01

IH17K1160028-01

• Fill the reservoir tank to the upper level (1). (Page

1
1F-5)

IH17K1160032-02

5) After finishing the water hose inspection, install the

1 removed parts.

Water Hose Removal and Installation

BENH17K11606013

Removal
1) Drain engine coolant. (Page 1F-6)
2) Remove the fuel tank. (Page 1G-9)
IH17K1160029-01
3) Remove the side cowling assemblies. (Page 9D-
21)
 Engine Cooling System: 1F-12

4) Remove the water hose. (Page 1F-2) Thermostat Removal and Installation
BENH17K11606015

Installation Removal
Install the water hose in the reverse order of removal. 1) Drain engine coolant. (Page 1F-6)
Pay attention to the following point. 2) Remove EVAP canister, if equipped. (Page 1B-13)
• Tighten the water hose clamp screw (1) to the 3) Remove the radiator inlet hose (1) from thermostat
specified torque. connector cover (2), if necessary.
Tightening torque
Water hose clamp screw (a): 1.5 N·m (0.15 kgf-m,
1.10 lbf-ft) 2

1, (a)

1, (a) 1
IH17K1160035-01

4) Place a rag under the thermostat connector cover (1)

and then remove the thermostat connector cover (1).
IH17K1160033-01

1
Cooling Fan Relay Inspection
BENH17K11606014
1) Remove the front seat. (Page 9D-19)
2) Disconnect the battery (–) lead wire (1) and remove
the cooling fan relay (2).

IH17K1160036-01

5) Remove the thermostat (1).

2
1

IH17K1160034-02

3) First check the insulation between (3) and (4)

terminals with a circuit tester. Then apply 12 V to (1)
and (2) terminals, (+) to (1) and (–) to (2), and check 1
the continuity between (3) and (4).
If there is no continuity, replace it with a new one.
IH17K1160037-01

2
4
3
IE31J1160038-01

4) Install the removed parts.

1F-13 Engine Cooling System:

Installation • Pour engine coolant and bleed air from the cooling
Install the thermostat in the reverse order of removal. system.
Pay attention to the following points: Refer to “Engine Coolant Replacement” (Page 1F-6).
• Install the thermostat (1).
Thermostat Inspection
NOTE BENH17K11606016

The jiggle valve (2) of the thermostat faces 1) Inspect the thermostat pellet for signs of cracking.
upside. 2) Test the thermostat at the bench for control action.

NOTE
• Do not contact the thermostat (1) and the
2 column thermometer (2) with a pan.
• As the thermostat operating response to
water temperature change is gradual, do
not raise water temperature too quickly.
• The thermostat with its valve open even
slightly under normal temperature must be
1 replaced.

3) Immerse the thermostat (1) in the water contained in

IH17K1160038-01
a beaker and note that the immersed thermostat is in
• Install the thermostat connector cover (1) and tighten suspension.
the bolts (2) to the specified torque. 4) Heat the water by placing the beaker on a heater (3)
Tightening torque and observe the rising temperature on a
Thermostat connector cover bolt (a): 10 N·m (1.0 thermometer (2).
kgf-m, 7.5 lbf-ft)

4
1

2, ( a)
ID26J1160035-04

4. String
IH17K1160039-01

• Install radiator inlet hose (1) and tighten the water

5) Read the thermometer just when opening the
hose clamp screw (2) to the specified torque, if
thermostat. If this reading, which is the temperature
removed.
level at which the thermostat valve begins to open, is
Tightening torque out of the standard value, replace the thermostat
Water hose clamp screw (a): 1.5 N·m (0.15 kgf-m, with a new one.
1.10 lbf-ft)
Thermostat valve opening temperature
[Standard]: Approx. 82 °C (179.6 °F)
2, ( a)
6) Keep on heating the water to raise its temperature.
7) Just when the water temperature reaches specified
value, the thermostat valve should have been lifted
by at least 8 mm (0.3 in) “a”. A thermostat failing to
satisfy either of the two requirements (start-to-open
temperature and valve lift) must be replaced.
Thermostat valve lift
At 95 °C (203 °F) [Standard]: 8 mm (0.3 in) or
1 more
IH17K1160040-01
 Engine Cooling System: 1F-14

“a”

I944H1160022-01

Water Pump Assembly Components

BENH17K11606017

(b)

10

7
(c)
6

5
4
3

D
FW 2
1

(a)
IH17K1160041-01

1. Water pump case 7. Oil seal : 8.0 Nm (0.82 kgf-m, 5.90 lbf-ft)
2. O-ring 8. O-ring : Apply grease.
3. Washer 9. Washer : Apply molybdenum oil solution.

4. Seal washer 10. Impeller shaft : Apply engine coolant.

5. Impeller : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Do not reuse.
6. Mechanical seal : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)

Water Pump Removal and Installation 3) Disconnect the radiator outlet hose (1) and cylinder
BENH17K11606018 inlet hose (2).
Removal
1) Drain engine oil. (Page 1E-4)
2) Drain engine coolant. (Page 1F-6)
1F-15 Engine Cooling System:

2 1 , (a )

1
IH17K1160042-02 IH17K1160045-01

4) Remove the water pump (1). 4) Connect the radiator outlet hose (1) and cylinder
inlet hose (2) and tighten the water hose clamp
screw (3) to the specified torque.
Tightening torque
Water hose clamp screw (a): 1.5 N·m (0.15 kgf-
m, 1.10 lbf-ft)

1
IH17K1160043-01

3, (a)
Installation
1) Apply grease to the new O-ring.
“A”: Grease 99000–25011 (SUZUKI SUPER 1
GREASE A) IH17K1160046-02

5) Pour engine oil. (Page 1E-4)

2) Install the water pump assembly (1) with the slot of
the pump shaft end (2) securely engaged with the 6) Pour engine coolant. (Page 1F-6)
flat (3) of the oil pump shaft.
Water Pump Disassembly and Reassembly
BENH17K11606019
3 Refer to “Water Pump Removal and Installation” (Page
1F-14).
2
Disassembly
1) Remove the water pump case (1).

“A”
1
IH17K1160044-01

3) Tighten the water pump bolts (1) to the specified

torque.
Tightening torque
Water pump bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft) 1
IH17K1160047-02

2) Remove the O-ring (1).

 Engine Cooling System: 1F-16

Special tool
(A): 09921–20240

( A)

IH17K1160048-01

3) Remove the impeller securing bolt by holding the

impeller (1) with a water pump pliers. IH17K1160052-01

4) Remove the impeller (1). 8) Remove the oil seal (1).

IH17K1160049-01 IH17K1160053-01

5) Remove the mechanical seal ring (1) and rubber

Reassembly
seal (2).
1) Install the new oil seal with the special tool.

NOTE
Face the flat side “A” of the oil seal to the
2
mechanical seal side.

1 Special tool
(A): 09913–70210

IH17K1160050-01

6) Remove the O-ring (1), impeller shaft (2) and washer

(3).

1
“A”

IF04K1160065-01

IH17K1160051-02

7) Remove the mechanical seal using the special tool.

1F-17 Engine Cooling System:

(A)

“A”

IH17K1160054-01 IH17K1160057-01

2) Apply grease to the oil seal lip. 6) Install the rubber seal (1) into the impeller.
“A”: Grease 99000–25011 (SUZUKI SUPER 7) After wiping off the oily or greasy matter from the
GREASE A) mechanical seal ring, install it into the impeller.

NOTE
• The paint marked side (2) of the
“A” mechanical seal ring faces the rubber seal
(1).
• Make sure the mechanical seal ring is fit
into the impeller.

IH17K1160055-01

3) Install the new mechanical seal using a suitable size

socket wrench.

NOTE 2
On the new mechanical seal, the sealer has
been applied.
1
IH17K1160058-01

8) Install the washer (1) and seal washer (2) onto the
impeller securing bolt.

NOTE
The metal side (3) of seal washer and the
curved side (4) of washer face the impeller
securing bolt head.

IH17K1160056-01 2
4) Apply molybdenum oil solution to the impeller shaft
(1) and washer (2). 1 3
“A”: Assembly lubrication (Molybdenum oil
solution)
5) Install the impeller shaft (1) and washer (2) to the 4
water pump holder.

IF04K1160053-01

9) Install the impeller (1).

10) Hold the impeller with water pump pliers and tighten
the impeller securing bolt to the specified torque.
 Engine Cooling System: 1F-18

Tightening torque
Impeller securing bolt (a): 8.0 N·m (0.82 kgf-m,
5.90 lbf-ft)

1
1

IH17K1160062-01

(a)
Oil Seal
IH17K1160059-01 Visually inspect the oil seal (1) for damage, with
11) Install the new O-ring (1) to the water pump case (2) particular attention given to the lip.
and apply engine coolant to it. Replace the oil seal (1) that shows indications of
leakage.

IH17K1160060-01
IH17K1160053-01
12) Tighten the screws (1) to the specified torque.
Tightening torque Seal Washer
Water pump case screw (a): 5.5 N·m (0.56 kgf- Visually inspect the seal washer (1) for damage, with
m, 4.05 lbf-ft) particular attention given to the sealing face.
Replace the oil seal washer (1) that shows indications of
leakage.

1, ( a)

IH17K1160061-01

13) Pour engine coolant. (Page 1F-6)

IF04K1160059-01
14) Bleed air from the cooling system. (Page 1F-6)
Impeller / Shaft
Water Pump Related Parts Inspection Visually inspect the impeller (1) and its shaft for damage.
BENH17K11606020
Refer to “Water Pump Disassembly and Reassembly” Replace the impeller (1) or shaft (2) if necessary.
(Page 1F-15).

Mechanical Seal
Visually inspect the mechanical seal (1) for damage, with
particular attention given to the sealing face.
Replace the mechanical seal (1) that shows indications
of leakage.
1F-19 Engine Cooling System:

Replace the holder if necessary.

1
1

IH17K1160063-01

IH17K1160064-01
Impeller Shaft Journal
Visually inspect the journal (1) for damage or scratch.

Specifications
Tightening Torque Specifications
BENH17K11607001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Cooling fan assembly mounting bolt 4.9 0.50 4.00 (Page 1F-9)
Radiator mounting upper bolt 10 1.0 7.5 (Page 1F-9)
Radiator mounting lower bolt 5.5 0.56 4.05 (Page 1F-9)
Water hose clamp screw (Page 1F-10) /
(Page 1F-12) /
1.5 0.15 1.10
(Page 1F-13) /
(Page 1F-15)
Reservoir tank mounting bolt 5.5 0.56 4.05 (Page 1F-11)
Thermostat connector cover bolt 10 1.0 7.5 (Page 1F-13)
Water pump bolt 10 1.0 7.5 (Page 1F-15)
Impeller securing bolt 8.0 0.82 5.90 (Page 1F-18)
Water pump case screw 5.5 0.56 4.05 (Page 1F-18)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Water Hose Routing Diagram” (Page 1F-2)
“Water Pump Assembly Components” (Page 1F-14)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K11608001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution — (Page 1F-17)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 1F-15) / (Page
1F-17)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1F-9) / (Page 1F-
11)
 Engine Cooling System: 1F-20

NOTE
Required service material(s) is also described in:
“Water Pump Assembly Components” (Page 1F-14)

Special Tool
BENH17K11608002
09913–70210 09918–78211
Bearing installer set Radiator cap tester kit
(Page 1F-16) (Page 1F-7) /
(Page 1F-7)

09918–78220 09921–20240
Radiator cap tester adapter Bearing remover set
(Page 1F-7) / (Page 1F-16)
(Page 1F-7)
1G-1 Fuel System:

Fuel System
Engine

Precautions
Precautions for Fuel System
BENH17K11700001
! WARNING

• Keep away from fire or spark.

• During disassembling, use care to minimize spillage of gasoline.
• Spilled gasoline should be wiped off immediately.
• Work in a well-ventilated area.

! CAUTION

• To prevent the fuel system (fuel tank, fuel hose, etc.) from contamination with foreign particles, blind
all openings.
• After removing the throttle body, tape the cylinder intake section to prevent foreign particles from
entering.
 Fuel System: 1G-2

General Description
Fuel System Description
BENH17K11701001
Fuel System
The fuel delivery system consists of the fuel tank (1), fuel pump (2) (incorporating fuel pressure regulator (3) and fuel
filter (4)), fuel feed hose (5), primary fuel delivery pipe (6), primary fuel injectors (7), secondary fuel delivery pipe (8)
and secondary fuel injectors (9). There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump
and pressurized fuel flows into the injectors installed in the fuel delivery pipes. Fuel pressure is regulated by the fuel
pressure regulator. As the fuel pressure applied to the fuel injectors through the fuel delivery pipes is always kept at
the specified level, the fuel is injected into the throttle body below the throttle valve and funnel (10) in conic dispersion
when each injector opens according to the injection signal from the ECM. Secondary fuel injectors are mounted in the
air cleaner box and activated at high rpm.
The fuel relieved by the fuel pressure regulator flows back into the fuel tank.

6
10 2

[A]
7
[B] 4
[C] 5
IH17K1170001-01

[A]: Before-pressurized fuel [B]: Pressurized fuel [C]: Relieved fuel

1G-3 Fuel System:

Schematic and Routing Diagram

Fuel Tank Water Drain Hose and Fuel Tank Breather Hose Routing Diagram
BENH17K11702001

[A] [B]
8 1
1
[E] 2

[H] [H]

10
10
4 2
5 [E]
3

[G]
6

[C]

[F]
3

1 7

“a”

“a”

[J]
3
[D]

9 3 1
9
3

3 6 4 [I]

1 3

5 1
4 2
9

“b”
IH17K1170002-03
 Fuel System: 1G-4

[A]: Without EVAP control system 2. Fuel tank breather hose No. 1
[B]: With EVAP control system 3. Fuel tank breather hose No. 2
[C]: To fuel tank 4. Fuel tank breather hose No. 3
[D]: Pass the hoses right side of the crankcase. 5. Breather hose clamp
[E]: Pass the fuel tank water drain hose and fuel tank breather hose No. 2 under the wiring 6. 3-way joint
harness and fuel pump harness.
Pass the fuel tank water drain hose and fuel tank breather hose No.2 over the clutch cable.
[F]: Pass the hoses under the frame. 7. Clamp
: Clamp the marking of the hose.
Fit the clamp to the clutch cover bolt.
[G]: Face the white marking of the hose forward. 8. Surge hose
[H]: Pass the hoses inside of the wiring harness. 9. Clamp
: Clamp the marking of the hose.
Insert the clamp to the right under cowling.
Cut off the excess of the clamp at 5 – 15 mm
(0.20 – 0.59 in) from the tip.
[I]: Match the direction of the hose end. 10. Wiring harness
[J]: Do not pinch the hoses between the right under cowling and engine mounting bolt. “a”: 15°
1. Fuel tank water drain hose “b”: 10 – 20 mm (0.40 – 0.78 in)

Diagnostic Information and Procedures

Fuel System Diagnosis
BENH17K11704001
Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-12).

Repair Instructions
Fuel Pressure Inspection 3) Install the special tools between the fuel pump and
BENH17K11706001 fuel feed hose.
1) Lift and support the fuel tank. (Page 1G-9)
Special tool
2) Place a clean rag under the fuel feed hose and
(A): 09940–40211
remove the fuel feed hose (1). (Page 1G-6)
(B): 09940–40220
(C): 09915–77331
(D): 09915–74521

1
(B )

(C)

(A )

IH17K1170003-01

(D)
IH17K1170004-01
1G-5 Fuel System:

4) Turn the ignition ON and check for fuel pressure. 3) Connect a special tool to the fuel pump.
If the fuel pressure is lower than the specification, 4) Place the measuring cylinder (1) and insert the
check for the followings: special tool into the measuring cylinder (1).
• Fuel hose leakage
Special tool
• Clogged fuel filter (A): 09940–40220
• Pressure regulator
• Fuel pump
If the fuel pressure is higher than the specification,
check for the followings:
(A )
• Fuel pump
• Pressure regulator
Fuel pressure
[Standard]: 338 – 348 kPa (3.45 – 3.54 kgf/cm2,
49.1 – 50.4 psi) 1
5) Remove the special tools.
IH17K1170005-01

! WARNING 5) Remove the fuel pump relay. (Page 1G-16)

Before removing the special tools, turn the 6) Connect the fuel pump relay lead wire terminal
ignition switch OFF and release the fuel (between Y/R wire terminal (1) and R/W wire
pressure slowly. terminal (2)) using a jumper wire (3) for 10 seconds
and measure the amount of fuel discharged.
6) After finishing the fuel pressure inspection, install the If the discharge amount is out of the specification,
removed parts. the following cause may be considered.
Possible cause Correction
Clogged fuel filter Replace
Fuel Discharge Amount Inspection
BENH17K11706002 Defective fuel pump Replace
1) Lift and support the fuel tank. (Page 1G-9)
NOTE
2) Place a clean rag under the fuel feed hose (1) and
disconnect the fuel feed hose (1). (Page 1G-6) The battery must be in fully charged
condition.

FP discharge amount
Per 10 seconds
1 [Standard]: 194 ml (6.56 US oz, 6.83 Imp oz) or
more

IH17K1170003-01

1
2

IH17K1170006-01

7) After finishing the fuel discharge inspection, install

the removed parts.
 Fuel System: 1G-6

Fuel Feed Hose Disconnection and Fuel Feed Hose Removal and Installation
BENH17K11706005
Reconnection Removal
BENH17K11706003
Disconnection 1) Lift and support the fuel tank. (Page 1G-9)
1) Pull the retainer (1). 2) Place a clean rag under the fuel feed hose (1).
2) Disconnect the fuel feed hose joint (2) from fuel pipe. 3) Disconnect the fuel feed hose joints (2) and remove
the fuel feed hose (1). (Page 1G-6)
1

2
IE31J1170034-01
2
Reconnection
1) Insert the fuel feed hose joint (1) to fuel pipe.
2) Lock the retainer (2). 1
IH17K1170008-01
2
1 Installation
Install the fuel feed hose in the reverse order of removal.

IE31J1170035-01

3) Confirm that fuel feed hose joint is not disconnected

by hand.

Fuel Hose Inspection

BENH17K11706004
1) Lift and support the fuel tank. (Page 1G-9)
2) Inspect the fuel feed hose (1) for damage and fuel
leakage. If any defects are found, the fuel feed hose
(1) must be replaced.

IH17K1170007-01

3) After finishing the fuel feed hose inspection, install

the removed parts.
1G-7 Fuel System:

Fuel Tank Construction

BENH17K11706006
Fuel Tank Cover
Refer to “Fuel Tank Front Cover Construction” in Section 9D (Page 9D-9).

Fuel Tank

2
1
(a)

5
(a)
1

[B]
4

(a)

[A] 3
5
(b)

(b)
5
[C]
6

[D]

[E] 8

IH17K1170009-04
 Fuel System: 1G-8

[A]: Face the hole of the fuel tank inner vessel backward and align the 4. Velcro fastening
protrusion on the fuel tank with the groove of the fuel tank inner vessel. : Clean the adhesive surface before sticking the velcro fastening.
Stick the velcro fastening aligning with the concave portion.
Press the velcro fastening after sticking.
[B]: Insert the fuel tank inner vessel into the fuel tank until the end face 5. Fuel tank inner vessel
becomes flush with the fuel pump fitting surface on the fuel tank.
[C]: Insert the cushion into the bracket crossing the hooks securely. 6. Fuel tank cover cushion
[D]: Clean the adhesive surface before sticking the protector. Stick the 7. Fuel tank protector
protector aligning the holes and cutout with ends of the curved surfaces.
Press the protector after sticking.
[E]: Adhere the cushion to the fuel tank with an adhesive at the flange inside. 8. Fuel tank side cushion
: Stick the cushion starting from the protrusion.
1. Fuel tank 9. Fuel tank rear molding
: Insert the moldings to the fuel tank flange aligning each end
with the flange corner.
2. Fuel tank front bracket : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
3. Fuel tank No. 1 bracket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

(a)

(c)

(b) 3

(a)

IH17K1170010-02
1G-9 Fuel System:

1. Fuel tank : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

2. Fuel tank rear bracket : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
3. Fuel tank cap : 3.0 Nm (0.31 kgf-m, 2.25 lbf-ft)
4. Fuel tank rear cushion
: Insert the cushion to the frame until it contacts the frame edge.

Fuel Tank Cap Removal and Installation Fuel Tank Removal and Installation
BENH17K11706018 BENH17K11706007
Removal Removal
1) Open the fuel tank cap with the ignition key. 1) Remove the frame front covers. (Page 9D-18)
2) Remove the fuel tank cap (1). 2) Remove the front seat. (Page 9D-19)
3) Remove the fuel tank front screws (1).

IH13K1170066-06

Installation IH17K1170011-01

Install the fuel tank cap in the reverse order of removal. 4) Lift and support the fuel tank with the prop stay or the
Pay attention to the following point: like.
• Tighten the fuel tank cap bolts (1) to the specified
torque.
Tightening torque
Fuel tank cap bolt (a): 3.0 N·m (0.31 kgf-m, 2.25
lbf-ft)

IH17K1170012-02

5) Disconnect the fuel pump lead wire coupler (1).

6) Place a clean rag under the fuel feed hose (2) and
disconnect the fuel feed hose (2). (Page 1G-6)
1, (a)

IH13K1170067-04

1 2

IH17K1170013-01
 Fuel System: 1G-10

7) Disconnect the fuel tank breather hose (1) and fuel Installation
tank water drain hose (2). Install the fuel tank in the reverse order of removal. Pay
attention to the following points:

NOTICE
Be sure not to bend or twist the hoses when
installing.
2
1
• Connect the fuel tank water drain hose and fuel tank
breather hose. (Page 1G-3)
• Tighten the fuel tank rear nut (1) to the specified
torque.
Tightening torque
IH17K1170014-01 Fuel tank rear nut (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
8) Remove the fuel tank (1).

1 1 , (a )

IH17K1170016-02
IH17K1170015-02 • Tighten the fuel tank front screws (2) to the specified
torque.
Tightening torque
Fuel tank front screw (b): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft)

2 , (b )

IH17K1170017-01
1G-11 Fuel System:

Fuel Pump Components

BENH17K11706008

12
4

11

5
1

10

(a)
IH17K1170018-02

1. Fuel pump 7. Fuel pump case : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
2. Fuel filter 8. Fuel feed hose : Apply grease.
3. Fuel level gauge 9. Fuel pump inner plate : Apply engine oil.

4. Fuel level gauge attachment 10. Fuel pump outer plate : Do not reuse.
5. Fuel pressure regulator 11. Fuel pump lead wire
6. Flange 12. Spacer
 Fuel System: 1G-12

Fuel Pump On-Vehicle Inspection 4) Remove the fuel pump assembly (1) with the O-ring
BENH17K11706009 (2).
Turn the ignition switch ON and check that the fuel pump
operates for a few seconds.
If the fuel pump motor does not make operating sound,
inspect the fuel pump circuit connections, the fuel pump
relay and TO sensor. 1
• Fuel pump relay: (Page 1G-16)
• TO sensor: (Page 1C-19) 2
If the fuel pump relay, TO sensor and fuel pump circuit
connections are OK, the fuel pump may be faulty,
replace the fuel pump with a new one. (Page 1G-12)
IH17K1170021-01
Fuel Pump Assembly Removal and Installation 5) Remove the fuel tank inner vessel (1).
BENH17K11706010
Refer to “Fuel Tank Removal and Installation” (Page 1G-
9).

Removal
1) Remove the fuel pump mounting bolts (1) diagonally. 1

2) Remove the fuel pump outer plate (2).

IH17K1170022-01
2
Installation
1) Check that the fuel pump fitting surface (1) on the
fuel tank is free from any deformation and damage.

IH17K1170019-01

3) Remove the fuel pump inner plate (1).

IH17K1170023-01

2) Align the groove (1) of the fuel tank inner vessel with
the protrusion (2) of the fuel tank.
IH17K1170020-01
2

1
IH17K1170024-01
1G-13 Fuel System:

3) Insert the fuel tank inner vessel (1) into the fuel tank 6) Align the protrusion (1) of the fuel pump assembly
until the end face becomes flush with the fuel pump with the cutout (2) of the fuel pump outer plate (3)
fitting surface on the fuel tank. and tighten all the fuel pump mounting bolts (4)
lightly in the numerical order (“1” – “6”) and then
tighten them to the specified torque.
1 Tightening torque
Fuel pump mounting bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

“2” “5”
4 , (a )
1

IH17K1170025-01
1

4) Apply grease to the new O-ring (1) and set the fuel “4” “3”
pump assembly (2) into the fuel tank.
“A”: Grease 99000–25011 (SUZUKI SUPER 2
GREASE A) “1 ”, “6 ”
IH17K1170028-01

Fuel Pump Disassembly and Reassembly

BENH17K11706011
Refer to “Fuel Pump Assembly Removal and
2 Installation” (Page 1G-12).

Disassembly
1, “ A ”
1) Remove the O-ring (1).
2) Disconnect the lead wires (2).

IH17K1170026-01

5) Align the protrusion (1) of the fuel pump assembly

with the punch mark (2) of the fuel pump inner plate. 1

1
2

IH17K1170029-01

2 3) Remove the fuel level gauge (1).

IH17K1170027-01
1

IH17K1170030-01
 Fuel System: 1G-14

4) Remove the fuel level gauge attachment (1). 8) Remove the fuel pump (1) and fuel pressure
regulator (2).

1
1

IH17K1170031-01

5) Remove the fuel pump case (1). IH17K1170034-02

9) Remove the O-rings (1) and spacer (2).

10) Disconnect the lead wires (3).

1
1

IH17K1170032-01

6) Remove the O-ring (1) from the flange.

IH17K1170071-01

1 2

IH17K1170033-01
3
7) Remove the fuel filter (1). IH17K1170035-02

IH17K1170070-01
1G-15 Fuel System:

Reassembly
Reassemble the fuel tank pump in the reverse order of
the disassembly. Pay attention to the following points:
• Apply engine oil lightly to the new O-rings (1) and 4
install them.

2
3
1
IH17K1170040-01
1
1. Fuel pump (+) lead wire (Bl)
2. Fuel level gauge (+) lead wire (R)
3. Fuel pump (–) lead wire (B)
4. Fuel level gauge (–) lead wire (B)

IH17K1170037-02
• Install the new O-ring (1).

1
1

IH17K1170038-02
IH17K1170041-01
• Connect all lead wires securely so as not to cause
contact failure.
Fuel Filter Inspection
• Route all lead wires securely. BENH17K11706012
Refer to “Fuel Pump Disassembly and Reassembly”
(Page 1G-13).
1 3
Inspect the fuel filter for dirt. If the fuel filter is dirtied
excessively, replace the fuel filter with a new one.

4
2

IH17K1170039-01

IH17K1170042-01
 Fuel System: 1G-16

Fuel Level Gauge Inspection 3) First, check for insulation with a circuit tester
BENH17K11706013 between terminals (3) and (4). Next, check for
Refer to “Fuel Pump Assembly Removal and continuity between (3) and (4) with 12 V voltage
Installation” (Page 1G-12). applied, positive (+) to terminal (1) and negative (–)
Measure the resistance at each fuel level gauge in float to terminal (2). If continuity does not exist, replace
position. If the resistance is incorrect, replace fuel level the relay with a new one.
gauge with a new one.
Float position Resistance
“a” 235 mm (9.25 in) 8 – 12 Ω
“b” 19 mm (0.75 in) 267 – 273 Ω
1

2 3 4
IE31J1170030-01

4) After finishing the fuel pump relay inspection, install

the removed parts.

“a” Fuel Injector On-Vehicle Inspection

BENH17K11706015
1) Lift and support the fuel tank. (Page 1G-9)
2) Turn the ignition switch OFF.
3) Disconnect the fuel injector coupler (1).

[A]

“b”

IH17K1170043-03

Fuel Pump Relay Inspection 1

BENH17K11706014
1) Remove the front seat. (Page 9D-19)
2) Disconnect the battery (–) lead wire (1) and remove
the fuel pump relay (2). [B]

2
1

IH17K1170045-01

[A]: Primary side

IH17K1170044-01 [B]: Secondary side
1G-17 Fuel System:

4) Measure the fuel injector resistance between 2) Place a clean rag under the fuel feed hose (1) and
terminals using the multi circuit tester. If resistance is disconnect the fuel feed hose (1). (Page 1G-6)
out of specification, replace the fuel injector with a
new one. (Page 1G-17)
Fuel injector resistance
20 °C (68 °F) [Standard]: 11.5 – 12.5 Ω

1
[A]

IH17K1170047-01

3) Remove the clamps (1) and disconnect the primary

fuel injector couplers (2).

1 1

[B]

2 2

IH17K1170048-02

4) Remove the primary fuel delivery pipe assembly (1).

IH17K1170046-01

[A]: Primary side

[B]: Secondary side

5) After finishing the fuel injector inspection, install the

removed parts.

Fuel Injector / Fuel Delivery Pipe Removal and

Installation
BENH17K11706016 1
Primary Side
Removal
IH17K1170049-01
NOTE 5) Remove the primary fuel injectors (1) from the
The fuel injector can be removed without primary fuel delivery pipes.
removing the throttle body.
1
1) Remove the air cleaner box. (Page 1D-6)
1

IH17K1170050-02
 Fuel System: 1G-18

6) Remove the nipple joint (1) from the primary fuel NOTICE
delivery pipes (2). Never turn the primary fuel injector while
pushing it.

1
1

2 2
IH17K1170051-02

Installation IH17K1170054-01
Install the primary fuel injector and primary fuel delivery
• Install the new gasket (1) to each primary fuel delivery
pipe in the reverse order of removal. Pay attention to the
pipe mounting screw.
following points:
• Apply a thin coat of engine oil to the new O-rings (1)
and new cushion seals (2).
1

IH17K1170055-01

• Install the primary fuel delivery pipe assembly (1) to

the throttle body.
IH17K1170052-01

NOTICE
Never turn the primary fuel injectors while
installing them.

• Tighten the fuel delivery pipe mounting screws (2) to

the specified torque.
Tightening torque
Fuel delivery pipe mounting screw (a): 3.5 N·m (
0.36 kgf-m, 2.60 lbf-ft)
1
2, (a)
IH17K1170053-02 2 , (a )
• Align the coupler (1) of primary fuel injector with boss
(2) of the primary fuel delivery pipe, install each
primary fuel injector by pushing it straight to the
primary fuel delivery pipe.

IH17K1170056-02

• Clamp the wiring harness. Refer to “Wiring Harness

Routing Diagram” in Section 9A (Page 9A-13).
1G-19 Fuel System:

Secondary Side
Removal
1) Lift and support the fuel tank. (Page 1G-9) 1
2) Place a clean rag under the fuel feed hose (1) and
disconnect the fuel feed hose (1). (Page 1G-6)

1 IH17K1170060-02

6) Remove the secondary fuel injectors (1) from the

secondary fuel delivery pipes.

1
IH17K1170057-01

3) Remove the clamps (1) and disconnect the

1
secondary fuel injector couplers (2).

1
1

IH17K1170061-02

7) Remove the secondary fuel delivery pipe clip (1).

2

IH17K1170058-02

4) Remove the secondary fuel delivery pipe assembly 1

(1).

IH17K1170062-01

8) Remove the nipple joint (1) from the secondary fuel

delivery pipes (2).

IH17K1170059-02

5) Remove the secondary fuel injector brackets (1). 1

IH17K1170063-02
 Fuel System: 1G-20

Installation • Install the new gasket (1) to each secondary fuel

Install the secondary fuel injector and secondary fuel injector bracket mounting screw.
delivery pipe in the reverse order of removal. Pay
attention to the following points:
• Apply a thin coat of engine oil to the new O-rings (1) 1
and new cushion seals (2).

2
1
IH17K1170055-01

• Tighten the secondary fuel injector bracket mounting

screws to the specified torque.
Tightening torque
IH17K1170064-01
Secondary fuel injector bracket mounting screw
(a): 3.5 N·m (0.36 kgf-m, 2.60 lbf-ft)

1
(a) (a)
IH17K1170065-02

• Align the coupler (1) of secondary fuel injector with IH17K1170072-01

boss (2) of the secondary fuel delivery pipe, install • Install the secondary fuel delivery pipe assembly (1)
each secondary fuel injector by pushing it straight to to the air cleaner cover.
the secondary fuel delivery pipe.
NOTICE
NOTICE
Never turn the secondary fuel injectors while
Never turn the secondary fuel injector while installing them.
pushing it.
• Tighten the secondary fuel delivery pipe mounting
bolts (2) to the specified torque.

1 Tightening torque
Secondary fuel delivery pipe mounting bolt (a):
10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1
2

IH17K1170066-01

2 , (a )

IH17K1170067-02

• Clamp the wiring harness. Refer to “Wiring Harness

Routing Diagram” in Section 9A (Page 9A-13).
1G-21 Fuel System:

Fuel Injector Inspection and Cleaning

BENH17K11706017
Refer to “Fuel Injector / Fuel Delivery Pipe Removal and [B]
Installation” (Page 1G-17).
Check the fuel injector filter for evidence of dirt and
contamination. If present, clean and check for presence
of dirt in the fuel line and fuel tank.

[A]

IH17K1170069-01

[A]: Primary fuel injector

[B]: Secondary fuel injector

IH17K1170068-01

Specifications
Tightening Torque Specifications
BENH17K11707001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel tank cap bolt 3.0 0.31 2.25 (Page 1G-9)
Fuel tank rear nut 10 1.0 7.5 (Page 1G-10)
Fuel tank front screw 5.5 0.56 4.05 (Page 1G-10)
Fuel pump mounting bolt 10 1.0 7.5 (Page 1G-13)
Fuel delivery pipe mounting screw 3.5 0.36 2.60 (Page 1G-18)
Secondary fuel injector bracket mounting screw 3.5 0.36 2.60 (Page 1G-20)
Secondary fuel delivery pipe mounting bolt 10 1.0 7.5 (Page 1G-20)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel Tank Construction” (Page 1G-7)
“Fuel Pump Components” (Page 1G-11)
“Fasteners Information” in Section 0C (Page 0C-12)
 Fuel System: 1G-22

Special Tools and Equipment

Recommended Service Material
BENH17K11708001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 1G-13)

NOTE
Required service material(s) is also described in:
“Fuel Pump Components” (Page 1G-11)

Special Tool
BENH17K11708002
09915–74521 09915–77331
Oil pressure gauge hose Oil pressure gauge (1000
kPa)
(Page 1G-4) (Page 1G-4)

09940–40211 09940–40220
Fuel pressure gauge Fuel pressure gauge
adapter attachment
Discontinued (Page 1G-4) /
(Page 1G-4) (Page 1G-5)
1H-1 Ignition System:

Ignition System
Engine

General Description
Immobilizer Description (If Equipped)
BENH17K11801001
The immobilizer verifies that the key ID (1) agrees with 6
ECM ID by means of radio communication through the 1
immobilizer antenna (2). When the ID agreement is R O
verified, the system makes the engine ready to start. ON
OFF
4

5
2

3 [A]

IH17K1180003-01

[A]: To side-stand switch

2

IH17K1180001-01
Also, when the ignition switch is turned ON, the indicator
light (1) flashes as many as the number of IDs registered
in ECM. Thereafter, if the IDs are in agreement, the
3
indicator light turns on for two seconds to notify of
4 completion in successful communication.
If the indicator light (LED) (1) flashes fast, it notifies of
communication error or disagreement of ID.

NOTE
1 5 • If the indicator light (1) flashes fast, turn
2 the ignition switch OFF then ON to make
IH17K1180002-01 judgment again as there is possible
misjudgment due to environmental radio
3. Indicator light 5. ECM
4. Transponder
interference.
• When the battery performance is lowered
Operation in winter (low temperature), the system
When the ignition switch (1) is turned ON with the engine may at times makes a re-judgment at the
stop / starter switch (2) in the “RUN” position and side- time of beginning the starter motor
stand relay (3) in ON, the immobilizer antenna (4) and operation. In this case, the indicator light
ECM (5) are powered ON. (1) operation starts immediately after the
The ECM transmits a signal to the transponder (6) starter operation.
through the immobilizer antenna (4) in order to make
comparison between the key ID and ECM ID.
With the signal received, the transponder transmits the
key ID signal to ECM (5) so that ECM (5) can make
comparison with its own ID, and if it matches, the engine
is made ready to start.
1

IH17K1180004-01
 Ignition System: 1H-2

Flashing Lighting

2 registered Normal

3 registered Normal

4 registered Normal

Abnormal

Fast flashing
Approx. 1.6 sec. Approx. 2.0 sec.
I705H1180006-01

Schematic and Routing Diagram

Ignition System Diagram
BENH17K11802001

[A]: B, [B]: W/Y

10

6
11

T16
1 7
12

8 13
5

T80 9 14

B/W 15

2 3 4

IH17K1180005-02

[A]: For E.U. and China 5. ECM 11. Side-stand relay

[B]: Except for E.U. and China 6. Ignition coil #1 12. Ignition fuse
1. CKP sensor 7. Ignition coil #2 13. Ignition switch
2. TP sensor 8. Ignition coil #3 14. Main fuse
3. ECT sensor 9. Ignition coil #4 15. Battery
4. GP sensor 10. Engine stop / starter switch

Ignition System Components Location

BENH17K11802002
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
1H-3 Ignition System:

Diagnostic Information and Procedures

Ignition System Symptom Diagnosis
BENH17K11804003

Condition Possible cause Correction / Reference Item

Spark plug not sparking Damaged spark plugs. Replace. (Page 1H-6)
Fouled spark plugs. Replace. (Page 1H-6)
Wet spark plugs. Dry or replace. (Page 1H-7)
Defective ignition coils. Replace. (Page 1H-5)
Defective CKP sensor. Replace. (Page 1C-19)
Defective ECM. Replace. (Page 1C-10)
Open-circuited wiring connections. Repair or replace. (Page 9A-5)
Engine stalls easily (No Fouled spark plugs. Replace. (Page 1H-6)
spark) Defective CKP sensor. Replace. (Page 1C-19)
Defective ECM. Replace. (Page 1C-10)
Spark plug is wet or Excessively rich air/fuel mixture. Inspect FI system.
quickly becomes fouled Excessively high idling speed. Inspect FI system.
with carbon Incorrect gasoline. Change.
Dirty air cleaner element. Replace. (Page 1D-7)
Incorrect spark plugs (Cold type). Change to standard spark plug. (Page 1H-6)
Spark plug quickly Worn piston rings. Replace. (Page 1D-56)
becomes fouled with oil Worn pistons. Replace. (Page 1D-45)
or carbon (Page 1D-49)
Worn cylinders. Replace. (Page 1D-45)
(Page 1D-49)
Excessive valve-stem to valve-guide Replace. (Page 1D-36)
clearance.
Worn valve stem oil seals. Replace. (Page 1D-36)
Spark plug electrodes Incorrect spark plugs (Hot type). Change to standard spark plug. (Page 1H-6)
overheat or burn Overheated engine. Tune-up.
Loose spark plugs. Tighten. (Page 1H-6)
Excessively lean air/fuel mixture. Inspect FI system.
 Ignition System: 1H-4

No Spark or Poor Spark Step 3

BENH17K11804002
Troubleshooting Measure the ignition coil primary peak voltage. Refer
to “Ignition Coil Inspection” (Page 1H-7).
NOTE
Is the peak voltage OK?
Check that the transmission is in neutral and
the engine stop / starter switch is in the Yes Go to Step 4.
“RUN” position. Check that the fuse is not
blown and the battery is fully-charged before No Go to Step 5.
diagnosing.
Step 4
Inspect the spark plug(-s). (Page 1H-7)
Step 1
Is the spark plug(-s) OK?
1) Check the ignition system couplers for poor
connections. Yes Go to Step 5.
Is there connection in the ignition system No Faulty spark plug(-s).
couplers?

Yes Go to Step 2. Step 5

Inspect the ignition coil(-s). (Page 1H-7)
No Poor connection of couplers.
Is the ignition coil(-s) OK?
Step 2 Yes Go to Step 6.
1) Turn the ignition switch ON.
No Faulty ignition coil(-s).
2) Measure the battery voltage between B (For E.U.
and China) or W/Y (Except for E.U. and China) Step 6
wire (+) and B/W wire (–) of ECM. Refer to Measure the CKP sensor peak voltage and its
“Ignition System Diagram” (Page 1H-2). resistance. Refer to “CKP Sensor Inspection” in
Is the voltage OK? Section 1C (Page 1C-18).

Yes Go to Step 3. Are the peak voltage and resistance OK?

No • Faulty ignition switch. Yes • Faulty ECM.

• Faulty side-stand relay. • Open or short circuit in wire harness.

• Faulty engine stop / starter switch. • Poor connection of ignition couplers.

• Broken wire harness or poor connection No • Faulty CKP sensor.

of related circuit couplers. • Metal particles or foreign material being
stuck on the CKP sensor and rotor tip.
1H-5 Ignition System:

Repair Instructions
Ignition Coil Removal and Installation a) Turn the ignition coil counterclockwise about 45°.
BENH17K11806001
Removal

! WARNING
The hot engine can burn you.
Wait until the engine is cool enough to touch.

1) Turn the ignition switch OFF.

2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the ignition coil lead wire couplers (1).

NOTICE
Disconnect the lead wire coupler before
removing the ignition coil to avoid lead wire
coupler damage.

IH17K1180022-02

b) Pull out the ignition coil.

1 1
IH17K1180006-02 Installation
4) Remove the ignition coils (1) as follows. 1) Turning the ignition coil about 45° from the normal
position, install each ignition coil to the spark plug.
NOTICE
• Do not pry up the ignition coil with a screw
driver or a bar to avoid its damage.
• Be careful not to drop the ignition coil to
prevent short/open circuit.

1
1

IH17K1180027-01

IH17K1180021-01
 Ignition System: 1H-6

NOTICE Spark Plug Removal and Installation

BENH17K11806002
Do not hit the ignition coil with a plastic Refer to “Ignition Coil Removal and Installation” (Page
hammer when installing it. 1H-5).

Removal
Remove the spark plugs with a spark plug wrench.
Special tool
(A): 09930–10121

ID26J1180025-02

2) Turn each ignition coil so that the “ ” mark (1)

faces forward.
(A )

IH17K1180008-01

1 Installation
Screw the spark plugs into the cylinder head with
fingers, and then tighten them to the specified torque.

NOTICE
Do not cross thread or over tighten the spark
plug, or such an operation will damage the
aluminum threads of the cylinder head.
IH17K1180024-01

3) Connect the ignition coil lead wire couplers (1). Special tool
(A): 09930–10121
Tightening torque
Spark plug: 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

1 1
IH17K1180025-01

4) Install the air cleaner box. (Page 1D-6)

(A)
IH17K1180009-01
1H-7 Ignition System:

Spark Plug Inspection Heat Range

BENH17K11806003 Check spark plug heat range by observing electrode
Refer to “Spark Plug Removal and Installation” (Page color. If the electrode of the spark plug is wet appearing
1H-6). or dark color, replace the spark plug with hotter type one.
If it is white or glazed appearing, replace the spark plug
Spark Plug Inspection with colder type one.
Check spark plug for:
• Electrode wear Heat range
• Carbon deposits Hot type Cold type
Standard
(Option) (Option)
• Insulator damage NGK CR8EIA-9 CR9EIA-9 CR10EIA-9
• Spark plug gap “a” DENSO IU24D IU27D IU31D
If any abnormality is found, replace it with new plug.

NOTICE Ignition Coil Inspection

BENH17K11806004
Confirm the thread size and reach when Refer to “Ignition Coil Removal and Installation” (Page
replacing the plug. If the reach is too short, 1H-5).
carbon will be deposited on the screw
portion of the plug hole and engine damage Ignition Coil Primary Peak Voltage
may result. 1) Disconnect the primary and secondary fuel injector
couplers. Refer to “Fuel Injector / Fuel Delivery Pipe
Spark plug Removal and Installation” in Section 1G (Page 1G-
Type [Standard]: NGK CR9EIA-9 / DENSO IU27D 17).
Gap [Standard]: 0.8 – 0.9 mm (0.032 – 0.035 in) 2) Connect new spark plug (1) to each ignition coil.
3) Connect all the ignition coil lead wire couplers to the
ignition coils respectively, and ground them on the
cylinder head.

NOTE
Be sure that all the spark plugs are
connected properly and the battery used is in
fully-charged condition.

I823H1020005-01

“a”

ID26J1180010-02
1
[A]

IH17K1180010-01

[A]: Contact the spark plug to the cylinder head.

 Ignition System: 1H-8

4) Insert the needle point probe to the lead wire Ignition Coil Resistance
coupler. 1) Measure the ignition coil for resistance in both
5) Connect the multi circuit tester with the peak volt primary and secondary coils. If the resistance is not
adapter (1) as follows. within the standard range, replace the ignition coil
with a new one.
Special tool
(A): 09900–25008 Ignition coil resistance
(B): 09900–25009 Primary
10 – 30 °C (50 – 86 °F) [Standard]: 1.1 – 1.9 Ω
Ignition coil – circuit tester connection Secondary
(+) Probe (4) (–) Probe (5) 10 – 30 °C (50 – 86 °F) [Standard]: 6400 – 9600 Ω
Ignition coil #1 (2) W/Bl wire terminal Ground
Special tool
Ignition coil #2 (2) B wire terminal Ground
(A): 09900–25008
Ignition coil #3 (2) Y wire terminal Ground
Ignition coil #4 (2) G wire terminal Ground
(A)

2
(A)

(B) 1
3
5 IF04K1180023-01

ID26J1180013-02 ( ) ( ) ( )
3. New spark plug

6) Measure the ignition coil primary peak voltage in the

following procedures:
1 2
! WARNING
Do not touch the tester probes and spark ( )
plugs to prevent an electric shock while IH17K1180011-01
testing. 1. Primary coil 2. Secondary coil

a) Shift the transmission into neutral and turn the Engine Stop / Starter Switch Inspection
ignition switch ON. BENH17K11806005
b) Push the engine stop / starter switch to the 1) Turn the ignition switch OFF.
“START” position and allow the engine to crank 2) Remove the air cleaner box. (Page 1D-6)
for a few seconds, and then measure the ignition 3) Disconnect the right handle switch coupler (1).
coil primary peak voltage.
7) Repeat the b) procedure several times and measure
the highest peak voltage.
If the voltage is lower than standard range, replace
the ignition coil. (Page 1H-5) 1
Ignition coil primary peak voltage
[Standard]: 80 V or more

IH17K1180012-01
1H-9 Ignition System:

4) Inspect the engine stop / starter switch for continuity Ignition Switch Removal and Installation
with a circuit tester. If any abnormality is found, BENH17K11806007

replace the right handle switch with a new one. Refer to “Air Cleaner Box Removal and Installation” in
(Page 6B-3) Section 1D (Page 1D-6).

Removal
Color
O/B O/W Y/G O/R Y/W 1) Disconnect the ignition switch lead wire coupler(-s)
Position
OFF ( ) (1).
RUN ( )
START ( ) 1
IH17K1180013-02

5) After finishing the engine stop / starter switch

inspection, install the removed parts.

Ignition Switch Inspection

BENH17K11806006
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the ignition switch lead wire coupler(-s) IH17K1180015-01
(1).
2) Remove the harness clamp (1).

1
1

IH17K1180015-01
IH17K1180016-01
4) Inspect the ignition switch for continuity with a circuit
3) Remove the ignition switch as follows.
tester. If any abnormality is found, replace the
ignition switch with a new one. • For E.U., Middle East and China:
With immobilizer system a. Remove the steering stem upper bracket.
Refer to “Handlebar Removal and Installation”
Color
R O Gr Br in Section 6B (Page 6B-3).
Position
b. Remove the ignition switch mounting bolts (1)
ON
with a chisel.
OFF
LOCK
P
IF04K1180015-01

Without immobilizer system

Color R O O/Y Gr Br
Position
ON 1
OFF
LOCK IH17K1180017-01
P
IH17K1180026-01

5) After finishing the ignition switch inspection, reinstall

the removed parts.
 Ignition System: 1H-10

• Except for E.U., Middle East and China:

Remove the ignition switch mounting bolts (1).
2

1 IH17K1180019-01

• Except for E.U., Middle East and China:

IH17K1180018-01 When reusing the ignition switch mounting bolts (1),
clean the thread part and apply the thread lock to
Installation them.
Install the ignition switch in the reverse order of removal.
Pay attention to the following points: “A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
• For E.U., Middle East and China:
Tighten new ignition switch mounting bolts (1) with the
special tools until head (2) of each bolt is broken off.
Special tool
09930–11940
09940–63110

1 , “A ”

IH17K1180020-01

Specifications
Tightening Torque Specifications
BENH17K11807001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 11 1.1 8.5 (Page 1H-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-12)
1H-11 Ignition System:

Special Tools and Equipment

Recommended Service Material
BENH17K11808001
Material SUZUKI recommended product or Specification Note
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1H-10)

Special Tool
BENH17K11808002
09900–25008 09900–25009
Multi circuit tester set Needle point probe set
1. Multi circuit tester (09900- (Page 1H-8)
25004) 2. Revolution sensor
(09900-25005) 3. Lead wire
(09900-25006) 4. Peak volt
adapter (09900-25007)
(Page 1H-8) /
(Page 1H-8)
09930–10121 09930–11940
Spark plug socket set Torx® bit holder (3/8 sq.)
(Page 1H-6) / Torx® is the registered
(Page 1H-6) trademark of Camcar
Division of Textron inc.
U.S.A.
(Page 1H-10)
09940–63110
Torx® bit (E8)
Torx® is the registered
trademark of Camcar
Division of Textron inc.
U.S.A.
(Page 1H-10)
 Starting System: 1I-1

Starting System
Engine

Schematic and Routing Diagram

Starting System Diagram
BENH17K11902001

2 7
11
5

W/R
10

1 6 12
9

3
B/Y
[A] 13
8
4

IH17K1190001-02

[A]: CPU determines to turn on the starter relay by the conditions 4. Clutch switch 8. Side-stand switch 12. Battery
of starter switch, clutch switch and GP sensor signals.
1. Starter motor 5. Engine stop / starter switch 9. GP sensor 13. CPU
2. Starter relay 6. Side-stand relay 10. Ignition fuse
3. ECM 7. Ignition switch 11. Main fuse

Component Location
Starting System Components Location
BENH17K11903001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).

Diagnostic Information and Procedures

Starting System Symptom Diagnosis
BENH17K11904001

Condition Possible cause Correction / Reference Item

Engine does not turn Faulty starter clutch. Replace. (Page 1I-9)
though the starter motor
runs
Starter switch is not Run down battery. Repair or replace. (Page 1J-9)
effective Defective switch contacts. Replace. (Page 6B-3)
Brushes not seating properly on starter Repair or replace. (Page 1I-6)
motor commutator.
Defective starter relay or starter interlock Replace. (Page 1I-6)
switch.
Defective main fuse. Replace.
1I-2 Starting System:

Starter Motor Will Not Run Step 4

BENH17K11904002
NOTE Check the starter relay. (Page 1I-7)
Make sure the fuse is not blown and the Is the starter relay OK?
battery is fully-charged before diagnosing.
Yes Poor contact of the starter relay.
Troubleshooting
No Faulty starter relay.
Step 1
1) Shift the transmission into neutral. Starter Motor Runs But Does Not Crank the
2) Turn on the ignition switch with the engine stop / Engine
starter switch in the “RUN” position and listen for a BENH17K11904003
click from the starter relay when the engine stop / The starter motor runs when the transmission is in
starter switch is pushed to the “START” position. neutral, but does not run when the transmission is in any
position other than neutral, with the side-stand up.
Is a click sound heard?
Step 1
Yes Go to Step 2.
Check the side-stand switch. (Page 1I-8)
No Go to Step 3. Is the side-stand switch OK?
Step 2 Yes Go to Step 2.
Check if the starter motor runs when its terminal is
connected to the battery (+) terminal. No Faulty side-stand switch.

NOTICE Step 2
Do not use thin “wire” because a large Check the starter clutch. (Page 1I-12)
amount of current flows. Is the starter clutch OK?

Does the starter motor run? Yes • Open circuit in wire harness.
• Poor contact of coupler.
Yes • Faulty starter relay.
• Loose or disconnected starter motor No Faulty starter clutch.
lead wire.
• Loose or disconnected between starter
relay and battery (+) terminal.

No Faulty starter motor.

Step 3
Measure the voltage between W/R wire (+) and B/Y
wire (–) at the starter relay coupler when the engine
stop / starter switch is pushed to the “START” position.
Refer to “Starting System Diagram” (Page 1I-1).
Is the voltage OK?

Yes Go to Step 4.

No • Faulty ignition switch.

• Faulty engine stop / starter switch.
• Faulty clutch switch.
• Faulty ECM.
• Faulty GP sensor.
• Faulty side-stand relay.
• Faulty side-stand switch.
• Poor contact of coupler.
• Open circuit in wire harness.
 Starting System: 1I-3

Repair Instructions
Starter Relay Protector Construction
BENH17K11906001

“a”
1

“b”

IH17K1190002-02

1. Starter relay protector 2. Seat rail “a”: 30 – 40 mm (1.19 – 1.57 in) “b”: 5 – 10 mm (0.20 – 0.39 in)
1I-4 Starting System:

Starter Motor Components

BENH17K11906002

4 3

(a)

5
2 (b)

IH17K1190003-02

1. Frame assembly 5. Starter motor case : Apply grease.

2. Armature 6. Oil seal : Apply moly paste.
3. Starter housing assembly : 4.0 Nm (0.41 kgf-m, 2.95 lbf-ft) : Do not reuse.
4. O-ring : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)

Starter Motor Assembly Removal and

Installation
BENH17K11906003 1

Removal
1) Turn the ignition switch OFF and disconnect the
battery (–) lead wire. (Page 1J-9) 3
2) Lift and support the fuel tank. (Page 1G-9)
3) Remove the EVAP canister (If equipped). Refer to
“EVAP Control System Removal and Installation (If
Equipped)” in Section 1B (Page 1B-13). 2
4) Disconnect the starter motor lead wire (1) and IH17K1190004-01

remove the starter motor bolts (2).

5) Remove the starter motor (3).
 Starting System: 1I-5

Installation
Install the starter motor in the reverse order of removal.
Pay attention to the following points:
• Apply grease to the new O-ring.
“A”
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

IH17K1190007-01
“A” • Apply grease to the lock plate (1) and washer (2).
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

IH17K1190005-01 2 , “A ”
• Fit the engine ground lead wire (1) to the starter motor
bolt (2).
• Tighten the starter motor bolts (2), (3) and starter
motor terminal screw (4) to the specified torque.
Tightening torque 1 , “A ”
Starter motor bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft)
Starter motor terminal screw (b): 4.0 N·m (0.41
IH17K1190008-02
kgf-m, 2.95 lbf-ft)
• Apply a small quantity of moly paste to the armature
shaft.
4, ( b)
“A”: Assembly lubrication 99000–25140 (SUZUKI
MOLY PASTE)

2, ( a)

1
3, ( a)

“A”
IH17K1190006-02

Starter Motor Disassembly and Reassembly

BENH17K11906004
Refer to “Starter Motor Assembly Removal and
IH17K1190009-01
Installation” (Page 1I-4).
• Align the groove (1) on the frame assembly with the
projection (2) on the starter motor case.
Disassembly
Disassemble the starter motor. (Page 1I-4)

Reassembly
2
Reassemble the starter motor in the reverse order of
removal. Pay attention to the following points:
• Replace the O-rings with new ones.
• Apply grease to the lip of the oil seal and bearing.
“A”: Grease 99000–25011 (SUZUKI SUPER 1
GREASE A)

IH17K1190010-01
1I-6 Starting System:

Starter Motor Inspection

BENH17K11906005
Refer to “Starter Motor Disassembly and Reassembly”
(Page 1I-5).

Carbon Brush
Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If any damages are found, replace the frame assembly
with a new one.
Make sure that the length “a” is not less than the service
limit. If this length becomes less than the service limit,
replace the frame assembly with a new one. IH17K1190012-01

Starter motor brush length Oil Seal / Bearing (Starter Housing Assembly)
[Limit]: 3.5 mm (0.14 in)
1) Check the oil seal lip (1) for damage. If any damage
Special tool is found, replace the oil seal with a new one.
09900–20102 2) Check the bearing (2) for abnormal noise and
smooth movement. If any defects are found, replace
the starter housing assembly with a new one.

“a” 1

IH17K1190011-01

Commutator
Inspect the commutator for discoloration, abnormal wear
or undercut “a”.
If the commutator is abnormally worn, replace the
armature assembly. 2
If the commutator surface is discolored, polish it with
IH17K1190013-01
#400 sandpaper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator (1) with a
saw blade. Starter Relay Removal and Installation
BENH17K11906006
Removal
1) Remove the frame covers. (Page 9D-26)
2) Disconnect the battery (–) lead wire from the battery.
(Page 1J-9)
3) Disconnect the starter relay coupler (1) and remove
the starter relay cover (2).
IE31J1190009-01

2. Segment

Armature Coil 1
Measure for continuity between each segment. Measure
for continuity between each segment and the armature
shaft. 2
If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
armature assembly with a new one.

IH17K1190014-01
 Starting System: 1I-7

4) Disconnect the starter motor lead wire (1) and

battery (+) lead wire (2).

NOTE
Be sure to disconnect the starter motor lead
wire (1) first, then disconnect the battery (+)
lead wire (2).

5) Remove the starter relay (3).

3 IE31J1190016-02

2) Measure the relay coil resistance between the

terminals using the circuit tester. If the resistance is
not within the specified value, replace the starter
relay with a new one.
2 Starter relay resistance
[Standard]: 3 – 7 Ω
1

IH17K1190015-01

Installation
Install the starter relay in the reverse order of removal.

Starter Relay Inspection

BENH17K11906007
Refer to “Starter Relay Removal and Installation” (Page
1I-6).
1) Apply 12 V to (1) and (2) terminals and check for IH17K1190017-01
continuity between the positive and negative
terminals using the multi circuit tester. If the starter Side-stand Relay Removal and Installation
relay clicks and continuity is found, the relay is OK. BENH17K11906008
Removal
NOTICE 1) Turn the ignition switch OFF.
Do not apply battery voltage to the starter 2) Remove the front seat. (Page 9D-19)
relay for five seconds or more, otherwise the
3) Remove the cap and side-stand relay (1).
relay coil may overheat and get damaged.

1 2

IH17K1190018-01

IH17K1190016-01
Installation
Install the side-stand relay in the reverse order of
removal.
1I-8 Starting System:

Starter Interlock System Parts Inspection Side-stand Relay

BENH17K11906009 Refer to “Side-stand Relay Removal and Installation”
Check the interlock system for proper operation. If the (Page 1I-7).
interlock system does not operate properly, check each First check the insulation between (3) and (4) terminals
component for damage or abnormalities. If any with a circuit tester. Then apply 12 V to (1) and (2)
abnormality is found, replace the component with a new terminals, (+) to (1) and (–) to (2), and check the
one. continuity between (3) and (4).
If there is no continuity, replace it with a new one.
Side-stand Switch
1) Turn the ignition switch OFF.
2) Move the coupler cover (1) and disconnect the side-
stand switch coupler (2).
1

2
2
4
3
IE31J1190021-01

Diode
1) Turn the ignition switch OFF.
IH17K1190019-01
2) Remove the front seat. (Page 9D-19)
3) Set the “Diode test” of the multi circuit tester. Refer to 3) Remove the fuse box cap and diode (1).
“Precautions for Circuit Tester” in Section 00 (Page
00-8).
4) Check that the tester reads 1.4 V or more.

NOTE
If the tester reads less than 1.4 V when the
tester probes are not connected, replace its
battery.

5) Measure the voltage between G ((+) probe) and B/W 1

((–) probe) lead wires of the side-stand switch.
Side-stand switch voltage IH17K1190042-01
ON (Side-stand retracted) [Standard]: 0.4 – 0.6 V 4) Set the “Diode test” of the multi circuit tester. Refer to
OFF (Side-stand on the ground) [Standard]: 1.4 V “Precautions for Circuit Tester” in Section 00 (Page
or more 00-8).
5) Check that the tester reads 1.4 V or more.

NOTE
If the tester reads less than 1.4 V when the
tester probes are not connected, replace its
battery.

IH17K1190020-01
 Starting System: 1I-9

6) Measure the voltage between the (1), (2) and (3) 6) Remove the circlip (1) from the starter idle gear No.
terminals. 2 pin.
Diode voltage Special tool
09900–06107

3 1 2
1

3 1 2
IH18K1190023-02
IH17K1190023-01

(+) Probe of tester to: 7) Hold the starter clutch (1) with the special tool.
2, 3 1 Special tool
(–) Probe of

(A): 09920–34830
tester to:

1.4 V or more
2, 3
(Tester's battery voltage) 8) Remove the bolt (2) and starter clutch.
1 0.4 – 0.6 V
IE31J1190049-01
2
GP Sensor
Refer to “GP Sensor Inspection” in Section 5B (Page 5B-
15).

Starter Idle Gear / Starter Clutch Removal and 1

Installation
BENH17K11906010
Removal (A )
1) Remove the right side cowling assembly. (Page IH17K1190024-01
9D-21) 9) Remove the washer (1).
2) Remove the clutch cover. Refer to “Clutch Removal”
in Section 5C (Page 5C-15).
3) Remove the bushing (1), washer (2) and limiter
driven gear (3).
4) Remove the washer (4) and starter idle gear No. 2
(5).
1
5) Remove the starter idle gear No. 2 pin (6), bearing
(7) and washer (8).

3 IH17K1190025-01
8
2

1 7 6
4

IH17K1190022-01
1I-10 Starting System:

10) Remove the bearing (1) and starter clutch gear (2). 14) Remove the circlips (1).
Special tool
09900–06107

2 1

IH17K1190026-02

11) Remove the clutch assembly. (Page 5C-15)

12) Remove the starter idle gear No. 1 shaft/starter idle IH17K1190029-01
gear No. 1 (1).
Installation
1) Install the new circlips (1).

1
Special tool
09900–06107

IH17K1190027-01

13) Remove the circlip (1), bushing (2), washer (3),

circlip (4) and starter idle gear No. 1 (5).
Special tool
09900–06107 IH17K1190029-01

2) Install the starter idle gear No. 1 (1), new circlip (2),
and washer (3).
4
Special tool
2 09900–06107
1
3) Apply molybdenum oil solution to the inside of the
bushing (4) and install it.
5 “A”: Assembly lubrication (Molybdenum oil
solution)
3 4) Install the new circlip (5).
IH17K1190028-01
Special tool
09900–06107

2
4 , “A ”

IH17K1190030-01
 Starting System: 1I-11

5) Apply molybdenum oil solution to the starter idle 10) Install the washer (1).
gear No. 1 shaft hole. 11) Install the starter clutch (2) aligning the wide spline
“A”: Assembly lubrication (Molybdenum oil tooth (3) with that of crankshaft (4).
solution)
6) Install the starter idle gear No. 1 shaft/starter idle 3 1
gear No. 1 (1).

“A” 1 4

2
IH17K1190034-01

12) Apply engine oil to the washer (1) and thread part of
the starter clutch bolt (2).
IH17K1190031-01

7) Install the clutch assembly. (Page 5C-17)

8) Apply engine oil to the bearing (1) and install it to the 1
starter clutch.

1 2

IF04K1190028-01

13) Hold the starter clutch (1) with the special tool and
tighten the starter clutch bolt (2) to the specified
torque.

IH17K1190032-02
Special tool
(A): 09920–34830
9) Install the starter clutch gear (1) to the starter clutch
(2). Tightening torque
Starter clutch bolt (a): 54 N·m (5.5 kgf-m, 40.0
lbf-ft)

1 1

2 , (a )
IH17K1190033-02
(A )
IH17K1190035-01
1I-12 Starting System:

14) Install the new circlip (1) to the starter idle gear No. 2 19) Install the limiter driven gear (1) and washer (2).
pin. 20) Apply molybdenum oil solution to the inside of the
bushing (3) and install it.
“A”: Assembly lubrication (Molybdenum oil
solution)

1
3 , “A ”
2

IH17K1190023-01

15) Apply molybdenum oil solution to the starter idle

gear No. 2 pin hole.
“A”: Assembly lubrication (Molybdenum oil IH17K1190038-01
solution) 21) Install the clutch cover. Refer to “Clutch Installation”
16) Install the starter idle gear No. 2 pin (1), washer (2) in Section 5C (Page 5C-17).
and bearing (3). 22) Install the right side cowling assembly. (Page 9D-
17) Apply engine oil to the bearing. 21)

Starter Clutch Inspection

BENH17K11906011
2
“A” Starter Clutch
3
1) Install the starter clutch gear onto the starter clutch.
2) Turn the starter clutch gear by hand to inspect the
starter clutch for a smooth movement. The gear
turns in one direction only. If a large resistance is felt
for rotation, inspect the starter clutch or the starter
1
clutch contacting surface on the starter clutch gear
for wear or damage.
IH17K1190036-01
If they are found to be damaged, replace them with
18) Install the starter idle gear No. 2 (1) and washer (2).
new ones.

IH17K1190037-01
IH17K1190039-02
 Starting System: 1I-13

Starter Clutch Bearing / Starter Clutch Gear Starter Idle Gear No. 1 / Starter Idle Gear No. 2 /
Inspect the starter clutch bearing (1) and starter clutch Limiter Driven Gear
contacting surface on the starter clutch gear (2) for wear Inspect the starter idle gear No. 1 (1), No. 2 (2) and
and damage. If they are found to be damaged, replace limiter driven gear (3) for wear or damage. If any defects
them with new ones. are found, replace it with a new one.

1 3
2

IH17K1190040-03 IH17K1190041-01

Engine Stop / Starter Switch Inspection

BENH17K11906012
Refer to “Engine Stop / Starter Switch Inspection” in
Section 1H (Page 1H-8).

Specifications
Tightening Torque Specifications
BENH17K11907001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starter motor bolt 10 1.0 7.5 (Page 1I-5)
Starter motor terminal screw 4.0 0.41 2.95 (Page 1I-5)
Starter clutch bolt 54 5.5 40.0 (Page 1I-11)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Starter Motor Components” (Page 1I-4)
“Fasteners Information” in Section 0C (Page 0C-12)
1I-14 Starting System:

Special Tools and Equipment

Recommended Service Material
BENH17K11908001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution — (Page 1I-10) / (Page 1I-
11) / (Page 1I-12) /
(Page 1I-12)
SUZUKI MOLY PASTE P/No.: 99000–25140 (Page 1I-5)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 1I-5) / (Page 1I-5)
/ (Page 1I-5)

NOTE
Required service material(s) is also described in:
“Starter Motor Components” (Page 1I-4)

Special Tool
BENH17K11908002
09900–06107 09900–20102
Snap ring pliers (External) Vernier calipers (200 mm)
(Page 1I-9) / (Page 1I-6)
(Page 1I-10) /
(Page 1I-10) /
(Page 1I-10) /
(Page 1I-10) /
(Page 1I-10)
09920–34830
Starter clutch rotor holder
(Page 1I-9) /
(Page 1I-11)
 Charging System: 1J-1

Charging System
Engine

Schematic and Routing Diagram

Charging System Diagram
BENH17K11A02001

2 3
1

5
4

IF04K11A0001-01

1. Generator 3. Ignition switch 5. Load

2. Regulator/rectifier 4. Battery 6. Main fuse

Component Location
Charging System Components Location
BENH17K11A03001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
1J-2 Charging System:

Diagnostic Information and Procedures

Charging System Symptom Diagnosis
BENH17K11A04003

Condition Possible cause Correction / Reference Item

Generator does not Open- or short-circuited lead wires, or Repair, replace or connect properly.
charge loose lead connections.
Short-circuited, grounded or open Replace.
generator coil. • Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Short-circuited or punctured regulator/ Replace. (Page 1J-8)
rectifier.
Generator does charge, Lead wires tend to get short- or open- Repair or retighten.
but charging rate is below circuited or loosely connected at
the specification terminals.
Grounded or open-circuited generator Replace.
coil. • Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective regulator/rectifier. Replace. (Page 1J-8)
Defective cell plates in the battery. Replace the battery. (Page 1J-9)
Generator overcharges Internal short-circuit in the battery. Replace the battery. (Page 1J-9)
Damaged or defective regulator/rectifier. Replace. (Page 1J-8)
Poorly grounded regulator/rectifier. Clean and tighten ground connection.
Unstable charging Lead wire insulation frayed due to Repair or replace.
vibration, resulting in intermittent short-
circuiting.
Internally short-circuited generator. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-6)
Defective regulator/rectifier. Replace. (Page 1J-8)
Battery overcharges Faulty regulator/rectifier. Replace. (Page 1J-8)
Faulty battery. Replace. (Page 1J-9)
Poor contact of generator lead wire Repair.
coupler.
Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and
circuit connections and make necessary
adjustments to obtain specified charging
operation. (Page 1J-4)
Cell plates have lost much of their active Replace the battery and correct the charging
materials a result of overcharging. system. (Page 1J-9)
Internal short-circuit in the battery. Replace the battery. (Page 1J-9)
Too low battery voltage. Recharge the battery fully. (Page 1J-9)
Too old battery. Replace the battery. (Page 1J-9)
Battery “sulfation” Incorrect charging rate. (When not in Replace the battery. (Page 1J-9)
use battery should be checked at least
once a month to avoid sulfation.)
The battery was left unused in a cold Replace the battery if badly sulfated. (Page
climate for too long. 1J-9)
“Sulfation”, acidic white Cracked battery case. Replace the battery. (Page 1J-9)
powdery substance or Battery has been left in a run-down Replace the battery. (Page 1J-9)
spots on surface of cell condition for a long time.
plates
 Charging System: 1J-3

Battery Runs Down Quickly Step 4

BENH17K11A04002
Troubleshooting Measure the resistance of the generator coil. (Page
1J-4)
Step 1
Is the resistance of generator coil OK?
Check accessories which use excessive amounts of
electricity. Yes Go to Step 5.
Are accessories installed? No • Faulty generator coil.
Yes Remove accessories. • Poor contact of couplers.

No Go to Step 2. Step 5
Measure the generator no-load performance. (Page
Step 2 1J-4)
Check the battery for current leakage. (Page 1J-4)
Is the generator no-load performance OK?
Is the battery for current leakage OK?
Yes Go to Step 6.
Yes Go to Step 3.
No Faulty generator.
No • Short circuit of wire harness.
• Faulty electrical equipment. Step 6
Inspect the regulator/rectifier. (Page 1J-7)
Step 3
Is the regulator/rectifier OK?
Measure the regulated voltage between the battery
terminals. (Page 1J-4) Yes Go to Step 7.
Is the regulated voltage OK? No Faulty regulator/rectifier.
Yes • Faulty battery.
Step 7
• Abnormal driving condition. Inspect wirings.
No Go to Step 4. Is the wirings OK?

Yes Faulty battery.

No • Short circuit of wire harness.

• Poor contact of couplers.
1J-4 Charging System:

Repair Instructions
Battery Current Leakage Inspection
BENH17K11A06001
1) Turn the ignition switch OFF.
2) Remove the front seat and disconnect the battery (–)
lead wire. (Page 1J-9)
3) Measure the current between battery (–) terminal
and the battery (–) lead wire using the multi circuit
tester. If the reading exceeds the specified value,
leakage is evident.

NOTICE
• In case of a large current leak, turn the IH17K11A0001-01

tester to high range first to avoid tester

damage. Generator Inspection
BENH17K11A06003
• Do not turn the ignition switch to ON Generator Coil Resistance
position when measuring current.
1) Remove the left side cowling assembly. (Page 9D-
Battery leakage current 21)
[Standard]: 3 mA or less 2) Disconnect the generator coupler (1).

I649G11A0002-02 IH17K11A0002-01

4) Connect the battery (–) terminal and install the front 3) Measure the resistance between the three lead
seat. (Page 1J-9) wires.
If the resistance is out of specified value, replace the
Regulated Voltage Inspection stator with a new one. Also, check that the generator
BENH17K11A06002 core is insulated properly.
1) Remove the front seat. (Page 9D-19) Generator coil resistance
2) Start the engine and keep it running at 5000 r/min Terminal to terminal [Standard]: 0.1 – 0.2 Ω
with the dimmer switch turned HI position. Terminal to ground [Standard]: ∞ Ω
3) Measure the DC voltage between the battery (+) and
(–) terminals using the multi circuit tester. If the
voltage is not within the specified value, inspect the Y
Ω
generator and regulator/rectifier.
Y Ω
• Generator: (Page 1J-4) Ω
• Regulator/rectifier: (Page 1J-7) Y

NOTE Ω
When making this test, be sure that the IF40J21A0004-02
battery is in fully charged condition.

Regulated voltage
Charging output
At 5000 r/min [Standard]: 14.0 – 15.5 V
 Charging System: 1J-5

No-load Performance 5) Move the coupler cover (1) and disconnect the CKP
1) Remove the left side cowling assembly. (Page 9D- sensor coupler (2).
21)
2) Disconnect the generator coupler (1).
1

IH17K11A0003-01
1
6) Remove the generator cover (1).
IH17K11A0002-01

3) Start the engine and keep it running at 5000 r/min.

4) Using the multi circuit tester, measure the voltage
between three lead wires.
If the tester reads under the specified value, replace
1
the generator stator with a new one.
Generator no-load voltage
When engine is cold
At 5000 r/min [Standard]: 85 V (AC) or more

IH17K11A0004-02
Y
7) Remove the dowel pins (1) and gasket (2).
Y

Y 1
2
IF40J21A0005-01

Generator Removal
BENH17K11A06004 1
1) Disconnect the battery (–) lead wire. (Page 1J-9)
2) Drain engine oil. (Page 1E-4)
3) Remove the left side cowling assembly. (Page 9D-
21)
IH17K11A0005-01
4) Disconnect the generator coupler (1). 8) Hold the generator rotor (1) with the special tool and
remove the generator rotor bolt (2).
Special tool
(A): 09930–44530

1
(A)

1
2
IH17K11A0002-01

IH17K11A0006-01
1J-6 Charging System:

9) Remove the generator rotor (1) with the special tool. 4) Degrease the tapered portion (1) of crankshaft and
also the generator rotor (2). Use nonflammable
Special tool
cleaning solvent to wipe off oily or greasy matter and
(A): 09930–34970
make these surfaces completely dry.

1
2

(A)

IH17K11A0007-01
IH17K11A0010-01
10) Remove the generator stator (1), CKP sensor (2),
5) Install the generator rotor (1) on the crankshaft.
lead wire clamp (3) and grommet (4).
6) Hold the generator rotor with the special tool and
4
tighten its bolt (2) to the specified torque.
3
Special tool
(A): 09930–44530

1 Tightening torque
2
Generator rotor bolt (a): 145 N·m (14.8 kgf-m,
107.0 lbf-ft)

IH17K11A0008-01

Generator Installation
BENH17K11A06005
1) Install the grommet (1) to the generator cover. 2 , (a )
(A )
2) Install the generator stator (2) and tighten the new
generator stator bolts to the specified torque.
Tightening torque IH17K11A0011-01
Generator stator bolt (a): 13 – 14 N·m (1.3 – 1.4 7) Apply a sealant lightly to the mating surfaces at the
kgf-m, 9.5 – 10.5 lbf-ft) parting line between the upper and lower crankcases
3) Install the CKP sensor (3) and lead wire clamp (4), as shown.
and then tighten the bolts to the specified torque. “A”: Sealant 99000–31140 (SUZUKI BOND
Tightening torque 1207B)
Generator lead wire clamp bolt (b): 6.5 N·m (0.66
kgf-m, 4.80 lbf-ft) “A”

1 (b)
4

3 2

IH17K11A0012-01
(a)

IH17K11A0009-01
 Charging System: 1J-7

8) Install the dowel pins (1) and new gasket (2). 11) Connect the CKP sensor coupler (1) and install the
coupler cover (2).

1
2
2

1
1

IH17K11A0005-01

9) Apply sealant to the mating surface at the parting IH17K11A0020-01

lines between the generator cover and grommet as 12) Connect the generator coupler (1).
shown.
“A”: Sealant 99000–31140 (SUZUKI BOND
1207B)

“A”

IH17K11A0002-01

13) Connect the battery (–) lead wire. (Page 1J-9)

14) Install the left side cowling assembly. (Page 9D-
IH17K11A0021-01 21)
10) Install the generator cover (1) and tighten the 15) Pour engine oil. (Page 1E-4)
generator cover bolts to the specified torque.
Regulator / Rectifier Inspection
! CAUTION BENH17K11A06006

Be careful not to pinch the finger between the 1) Turn the ignition switch to OFF position.
generator cover and the crankcase. 2) Remove the regulator/rectifier. (Page 1J-8)
3) Set the “Diode test” of the multi circuit tester. Refer to
NOTE “Precautions for Circuit Tester” in Section 00 (Page
00-8).
• Fit the left under cowling bracket to the
bolts (2). 4) Check that the tester reads 1.4 V or more.
• Fit the clamp to the bolt (3). NOTE

Tightening torque If the tester reads less than 1.4 V when the
Generator cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 tester probes are not connected, replace its
lbf-ft) battery.

(a)

1 (a)

2 , ( a) 3, ( a)

IH17K11A0013-02
1J-8 Charging System:

5) Measure the voltage between the terminals using the circuit tester as indicated in the following table. If the voltage
is not within the specified value, replace the regulator/rectifier with a new one.

1 2 3 4 5

ID26J11A0035-03

(+) probe of tester to:

(1) (2) (3) (4) (5)
(1) — * * * 0.3 – 0.6 V
(2) * — * * 0.3 – 0.6 V
(–) probe of tester to: (3) * * — * 0.3 – 0.6 V
(4) 0.06 – 0.10 V 0.06 – 0.10 V 0.06 – 0.10 V — 0.3 – 0.6 V
(5) * * * * —
* 1.4 V or more (tester’s battery voltage)

Regulator / Rectifier Removal and Installation 4) Remove the regulator/rectifier (1) with its bracket.
BENH17K11A06007
Removal
1) Remove the left side cowling. (Page 9D-21)
2) Disconnect the regulator/rectifier couplers (1).

IH17K11A0016-01

5) Remove the regulator/rectifier (1) from its bracket

(2).
1
IH17K11A0014-01

3) Remove the harness clamp (1) and harness bracket 1

bolts (2).
2
2

1
IH17K11A0017-01

Installation
Install the regulator/rectifier in the reverse order of
IH17K11A0015-01 removal.
 Charging System: 1J-9

Battery Charging 3) After recharging, wait at least 30 minutes and then

BENH17K11A06008 measure the battery voltage using the multi circuit
NOTICE
tester.
• For charging the battery, follow the If the battery voltage is 12.4 V or less, recharge the
specified charging current and time. battery again.
Otherwise, the battery may be overcharged If the battery voltage is still 12.4 V or less after
and resulted in shortened service life of recharging, replace the battery with a new one.
the battery. 4) Install the battery to the motorcycle. (Page 1J-9)
• Do not remove the cap during charging.
(V) [B]
• Position the battery with the cap facing 14
upward during charging.
13
• It is recommended to recharge the battery
periodically with reference to the battery 12
self-discharge rate by ambient
11
temperature, so as not to drop the battery
voltage below 12.4 V during the motorcycle 10
storage to avoid shortening of the battery
service life. 100 75 50 25 0 (%)
[A]
• If the battery is left discharged to 11.5 V or IH28K11A0036-01
less, the battery voltage may not recover
[A]: Battery charged condition
fully after recharging and the battery may
[B]: Ambient temperature 0 – 40 °C (32 – 104 °F)
be discharged quickly during use.
Battery Removal and Installation
Self discharge rate by environment BENH17K11A06009
Removal
13 V [B] 1) Remove the front seat. (Page 9D-19)
5 °C (41 °F) 2) Disconnect the battery (–) lead wire (1) first, then
12.4 V 25 °C (77 °F) disconnect the battery (+) lead wire (2).
3) Remove the battery (3) from the motorcycle.
12 V 40 °C (104 °F)

60 °C (140 °F)
2 1
11 V
0 1 2 3 4 5 6
[A]
IH28K11A0035-01

[A]: Time (Month)

[B]: Ambient temperature 3

NOTE
It is recommended to use the charger IH17K11A0018-01
specially designed for MF battery.

1) Remove the battery from the motorcycle. (Page

1J-9)
2) Measure the battery voltage.
If the voltage reading is 12.4 V or less, recharge the
battery.
Recharging time
Standard charging [Standard]: 1.2 A for 5 to 10
hours
Fast charging [Standard]: 5 A for 1 hour
1J-10 Charging System:

Installation Battery Visual Inspection

Install the battery in the reverse order of removal. Pay BENH17K11A06010

attention to the following points: 1) Remove the front seat. (Page 9D-19)
2) Visually inspect the surface of the battery container.
NOTICE If any signs of cracking or electrolyte leakage from
Never use anything except the specified the sides of the battery have occurred, replace the
battery. battery with a new one.
If the battery terminals are found to be coated with
• Connect the battery (+) lead wire (1) first, then rust or an acidic white powdery substance, clean the
connect battery (–) lead wire (2). battery terminals with sandpaper.
• Tighten the battery lead wire mounting bolts securely. 3) Install the front seat.

1 2

IH17K11A0019-01

Specifications
Tightening Torque Specifications
BENH17K11A07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Generator stator bolt 13 – 14 1.3 – 1.4 9.5 – 10.5 (Page 1J-6)
Generator lead wire clamp bolt 6.5 0.66 4.80 (Page 1J-6)
Generator rotor bolt 145 14.8 107.0 (Page 1J-6)
Generator cover bolt 10 1.0 7.5 (Page 1J-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K11A08001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1J-6) / (Page 1J-
7)

Special Tool
BENH17K11A08002
09930–34970 09930–44530
Rotor remover Rotor holder
(Page 1J-6) (Page 1J-5) /
(Page 1J-6)
 Exhaust System: 1K-1

Exhaust System
Engine

Precautions
Precautions for Exhaust System
BENH17K11B00001
! WARNING
To avoid the risk of being burned, do not touch the exhaust system when the system is hot.

NOTICE
After installation of the muffler, make sure that there is no leakage of exhaust gas.

General Description
Exhaust Control System Description
BENH17K11B01001
The SUZUKI Advanced Exhaust System is designed to increase high-rpm horsepower without reducing mid-range
and lower-rpm power and torque. The SUZUKI Advanced Exhaust System consists of the main exhaust control valve
(rear EXCV) located after the catalyzer and the new SUZUKI Exhaust Tuning-Alpha valves (front EXCV) located on
the joint pipes connecting exhaust pipes. Both Front and Rear EXCVs are controlled by the common Exhaust control
valve actuator (EXCVA) mounted on the seat rail through the cables.
• The rear EXCV controls exhaust flow and improve the engine torque at the engine speed of low to high.
• The front EXCV remains closed at low-rpm to mid-range of the engine speed to keep low to mid-range power, then
opens at high-rpm to add power at higher rpm.

4
2

IH17K11B0001-03

1. Rear EXCV 4. EXCV cable No. 1 and No. 2

2. Front EXCV 5. EXCV cable No. 3
3. EXCVA
1K-2 Exhaust System:

Exhaust Control System Operation

BENH17K11B01002
The Exhaust Control system is operated by the ECM. The open/close operation of the front and rear EXCVs is
performed by the EXCVA which is controlled by the ECM through cables. The position sensor in the EXCVA sends the
EXCVA movement data by voltage and then the ECM monitors the EXCV opening angles related to the engine speed
and gear positions.
Every time the ignition switch is turned ON, the EXCVA automatically drives the front and rear EXCVs and detects full
close/open position and sets the rear EXCV to middle position.
FULL CLOSE

IH17K11B0002-04
 Exhaust System: 1K-3

FULL OPEN

IH17K11B0003-04
1K-4 Exhaust System:

Repair Instructions
Exhaust Control System Construction
BENH17K11B06001

(c) (b)
13
14 (a) 7

6 [A]

(c) 5 14 (a)

(c) 9
(c)
8
10 11 (d)

(b)

13 12

3
2

14 (g)

(e)

[B]
2

1 4 (f)
IH17K11B0004-06

[A]: Pass the EXCV cable No. 1 and No. 2 between the seat rail and rear fender 11. Muffler connector bolt
front toward the front. : Apply nickel based anti seize to the thread part of bolt.
[B]: Route the EXCV cable No. 1 and No. 2 along the rear fender front groove. 12. Muffler rear cover (If equipped)
1. Exhaust pipe assembly 13. Muffler cover cushion
2. Exhaust pipe gasket 14. Lock-nut
3. EXCV cable No. 3 : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
4. HO2 sensor : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
5. EXCV cover : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
6. EXCV cable bracket : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
7. Muffler front cover : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
8. Muffler connector : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
9. Muffler cover grommet : 9.0 Nm (0.92 kgf-m, 6.65 lbf-ft)
10. Muffler connector clamp : Do not reuse.
: Insert a tag on the muffler joint portion into an oblong hole of the muffler
connector clamp.
 Exhaust System: 1K-5

13 14 16 22 (a)

12
7
11 15
8 5

6 5 17
20 (e) 6 23 (c)

9
[C]
10
6 5 [B]

[A] 7
2

3
1
4
21 (d) 1

19

10 18
10
“a”
(b)

19

FWD

19

IH17K11B0078-04

[A]: Pass the EXCV cable No. 1 and No. 2 between the rear brake hose and rear 14. Muffler support washer
brake light switch lead wire.
[B]: Route the EXCV cable No. 1 and No. 2 along the seat frame. 15. EXCVA
[C]: Pass the EXCV cable No. 1 and No. 2 through outside of the swingarm. 16. EXCVA pulley
1. Exhaust pipe assembly 17. EXCVA cable guide
2. Frame 18. EXCV cable No. 3
3. Rear master to union hose 19. Oil pan
4. Rear brake light switch lead wire 20. Muffler support bolt
5. EXCV cable No. 2 21. Exhaust support bolt
6. EXCV cable No. 1 22. Controller pulley bolt
7. Muffler 23. EXCVA mounting bolt
8. Swingarm “a”: 75° – 105°
9. Front footrest bracket RH : 5.0 Nm (0.51 kgf-m, 3.70 lbf-ft)
10. EXCV cable clamp : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
11. Muffler support spacer : 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
12. Muffler support cushion : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
13. Pillion footrest bracket RH : 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
1K-6 Exhaust System:

Exhaust System Components

BENH17K11B06002

4
7

8
1

12
5

3 11
2

10
13
IH17K11B0005-02

1. Exhaust pipe assembly 6. Muffler connector clamp 11. EXCV cover

2. Muffler 7. EXCVA pulley 12. Muffler front cover
3. Muffler connector 8. EXCV cable No. 1 13. Muffler rear cover (If equipped)
4. Exhaust pipe gasket 9. EXCV cable No. 2 : Do not reuse.
5. HO2 sensor 10. EXCV cable No. 3
 Exhaust System: 1K-7

Exhaust Control System On-Vehicle Inspection

BENH17K11B06003
EXCVA Operation
1) Turn the ignition switch OFF.
2) Remove the rear fender front. (Page 9D-28)
3) Connect the ECM couplers (1) to the ECM, starter
relay coupler and battery lead wires. (Page 1C-10)

1
IH17K11B0010-03

3) Check that the front EXCV lever (1) rotates to full

open/close positions right after the ignition ON. If
not, check the following points.
• Defect EXCV cable(s): (Page 1K-20)
• Loose rear EXCV shaft: (Page 1K-24)
• Adjust cable: (Page 1K-13)
IH17K11B0011-01

4) Check the EXCVA (1) for its smooth movement when • EXCVA motor operation: (Page 1K-19)
the ignition switch is turned on. If the EXCVA does • EXCV rotation: (Page 1K-23)
not move smoothly, check EXCVA electrical circuit.
Refer to “EXCVA Inspection” (Page 1K-19) and
“EXCVA Pulley Inspection” (Page 1K-20).

IH17K11B0080-02

4) Turn the ignition switch OFF.

IH17K11B0007-02 Front EXCV Lever Clearance

5) Check that the voltage of EXCVA position sensor is 1) Check that the cable slots of the EXCVA pulley
within the specification. comes to the middle (Adjustment position). (Page
If not, perform EXCVA adjustment. Refer to “EXCVA 1K-8)
Adjustment” (Page 1K-21). 2) Check that the clearance “a” between the front
6) Turn the ignition switch OFF. EXCV lever and the stopper on the joint pipe is
within 1.5 – 2.0 mm (0.059 – 0.078 in). If not, adjust
EXCV Operation the front EXCV lever clearance. Refer to “EXCV
1) Turn the ignition switch ON. Cable No. 3 On-Vehicle Adjustment” (Page 1K-13).
2) Check that the rear EXCV lever (1) rotates to full
open/close stopper positions right after the ignition
ON. If not, check the following points.
• Defect EXCV cable(s): (Page 1K-20)
• Adjust cable: (Page 1K-8)
• EXCVA motor operation: (Page 1K-19)
• EXCV rotation: (Page 1K-23)
“a”

IH17K11B0093-01
1K-8 Exhaust System:

Tightening State 1) Turn the ignition switch OFF.

1) Check the lock-nuts (1) and adjuster nut (2) of EXCV 2) Remove the rear fender front. (Page 9D-28)
cable No. 1, No. 2 and No. 3 for tightness. If the lock- 3) Connect the ECM couplers (1) to the ECM, starter
nuts (1) and adjuster nut (2) are loose, tighten them relay coupler and battery lead wires. (Page 1C-10)
after adjusting the cable length and rear EXCV
clearance. Refer to “EXCVA / EXCV Cable No. 1 /
No. 2 Removal and Installation” (Page 1K-8) and
“EXCV Cable No. 3 On-Vehicle Adjustment” (Page
1
1K-13).

1
1
IH17K11B0011-01

4) Connect the special tool to the mode select coupler

(6P). (Page 1A-17)
2 5) After turning the mode select switch ON, turn the
IH17K11B0008-03
ignition switch ON.
2) Check the lock-nut (1) of EXCV cable No. 3 for 6) Check that the cable slots of the EXCVA pulley
tightness. If the lock-nut is loose, tighten it after comes to the middle (Adjustment position) (1).
adjusting the rear EXCV clearance. Refer to “EXCV
Cable No. 3 Removal and Installation” (Page 1K-13).

1
IH17K11B0012-01

7) Turn the ignition switch OFF.

IH17K11B0009-01 8) Remove the right side cowling. (Page 9D-21)
9) Remove the EXCV cover (1).
EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation
BENH17K11B06004

Removal 1

NOTICE
When the EXCV cables are removed from the
EXCV lever and turn the ignition switch ON,
the EXCV cables will be coiled up. In this
case, EXCVA must be removed.
Do not turn the ignition switch ON after the
EXCV cables are removed from the EXCV IH17K11B0013-03

lever.

NOTE
Before removing the EXCV cables, be sure to
set the EXCVA pulley to the adjustment
position.
 Exhaust System: 1K-9

10) Hold the rear EXCV shaft (1) with a wrench (2) and 15) Remove the EXCV cables (1) from the clamp (2).
remove the EXCV cable No. 3 lever (3).

NOTICE
When loosening or tightening the EXCV
cable No. 3 lever mounting nut (4), be sure to
hold the rear EXCV shaft (1) with a wrench 1
(2). If not, it may cause damage to the rear
EXCV or rear EXCV shaft. 2

IH17K11B0017-02

16) Disconnect the EXCV cables (1) from the brackets

2 3 (2).

4 1 2
IH17K11B0014-03 1
11) Loosen the EXCV cable No. 1 and No. 2 lock-nuts
(1).
2
12) Remove the EXCV cable bracket (2) from the rear
EXCV.
13) Remove the EXCV cable No. 1 (3) and No. 2 (4) IH17K11B0018-01
from the EXCV lever (5). 17) Disconnect the EXCVA coupler (1).
18) Remove the bolts (2), EXCVA (3) and washers (4).

2 2
1
4

4
5 1 4

IH17K11B0015-03
3

14) Remove the EXCV cables (1) from the EXCV cable IH17K11B0019-01
bracket (2).
19) Remove the EXCV cable guide (1).
20) Disconnect the EXCV cables (2) from the EXCVA
2 pulley (3).

1
2

3
IH17K11B0016-03

IH17K11B0020-01
1K-10 Exhaust System:

21) Hold the EXCVA pulley with a box end wrench, and
remove the pulley bolt (1).

NOTICE 2

• When loosening or tightening the pulley

bolt (1), be sure to fix the pulley (2) with a 1
box end wrench, or EXCVA may be
damaged.
• Do not use the box end wrench to turn
EXCVA pulley so as not to cause damage
to the internal gear of EXCVA.
IH17K11B0024-01
22) Remove the pulley (2) from the EXCVA body. 3) Hold the pulley with a box end wrench, and then
tighten the pulley bolt (1) to the specified torque.

NOTICE
1
When loosening or tightening the pulley bolt,
2
be sure to fix pulley with a box end wrench,
or EXCVA may be damaged.

Tightening torque
EXCVA pulley bolt (a): 5.0 N·m (0.51 kgf-m, 3.70
lbf-ft)

IH17K11B0021-01

23) Remove the spacers (1) and rubber cushions (2). 1 , (a )

IH17K11B0025-01

4) Check the identified mark of the EXCV cable No. 1

2 1 and No. 2.
IH17K11B0022-01
NOTE
Installation The EXCV cables are identified by the letters
(1).
1) Install the rubber cushions (1) and spacers (2).
No. 1 cable: 17K0CL
No. 2 cable: 17K00P
2

1 2

IH17K11B0023-01 1
2) Install the EXCVA pulley to the shaft.
IH17K11B0026-01
NOTE
Align the shaft’s line (1) and cable slots (2).
 Exhaust System: 1K-11

5) Pass the EXCV cable No. 1 (1) and No. 2 (2) Tightening torque
between the brackets (3). EXCV cable lock-nut (b): 4.5 N·m (0.46 kgf-m,
3.35 lbf-ft)
12) Adjust the inner cable length “b” of No. 2 cable (2) in
52.6 – 53.6 mm (2.07 – 2.11 in) by turning the
2 adjuster (7), then tighten the lock-nut (8) to the
specified torque.
Tightening torque
EXCV cable lock-nut (b): 4.5 N·m (0.46 kgf-m,
1
3.35 lbf-ft)
3

5
IH17K11B0027-01 6 , (b ) 7
6) Pass the EXCV cable No. 1 (1) and No. 2 (2)
between the rear brake hose (3) and rear brake light
switch lead wire (4). 3

8, (b)
1

3 4 , (a )
2
IH17K11B0030-02
1 2

[A]

“b” “a”
4
IH17K11B0028-01
1
7) Fix the EXCV cable No. 1 (1) and No. 2 (2) with the
2
clamp (3).

IH17K11B0031-01
1
2
[A]: EXCVA side

13) Remove the EXCV cable bracket (1) by removing

3 the nut (2).
14) Remove the EXCV cables (3) from the EXCV lever
(4).

1
IH17K11B0029-01

8) Temporarily install the EXCV cable No. 1 (1) and No.

2 (2) to the EXCV cable bracket (3). 2
9) Install the EXCV cable bracket and tighten the nut
(4) to the specified torque.
3
Tightening torque
EXCV cable bracket mounting nut (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft) 4
IH17K11B0032-03
10) Install the EXCV cable No. 1 (1) and No. 2 (2) to the
EXCV lever.
11) Adjust the inner cable length “a” of No. 1 cable (1) in
44.2 – 45.2 mm (1.74 – 1.77 in) by turning the
adjuster (5), then tighten the lock-nut (6) to the
specified torque.
1K-12 Exhaust System:

15) Install the EXCV cable No. 1 (1) and No. 2 (2) to the 21) Inspect the EXCVA position sensor voltage. Refer to
EXCVA pulley (3). “EXCVA Adjustment” (Page 1K-21).
16) Install the EXCVA cable guide (4). 22) Position the EXCV cables (1) along the seat rail (2).

4
3

1
1
IH17K11B0033-02 IH17K11B0036-02

17) Install the washers (1), EXCVA (2) and tighten the 23) Set the EXCV cable No. 3 (1) to the EXCV cable No.
bolts (3) to the specified torque. 3 lever (2).
Tightening torque 24) Temporarily install the EXCV cable No. 3 lever (2) to
EXCVA mounting bolt (a): 11 N·m (1.1 kgf-m, 8.5 the rear EXCV shaft (3) with the EXCV cable No. 3
lbf-ft) lever mounting nut (4).
25) Hold the rear EXCV shaft (3) with a wrench (5) and
18) Connect the EXCVA coupler (4).
tighten the EXCV cable No. 3 lever mounting nut (4)
to the specified torque.
3, ( a)
NOTICE
1 When loosening or tightening the EXCV
cable No. 3 lever mounting nut (4), be sure to
hold the rear EXCV shaft (3) with a wrench
(5). If not, it may cause damage to the rear
EXCV or rear EXCV shaft.
4 1

2 Tightening torque
EXCV cable No. 3 lever mounting nut (a): 10 N·m
IH17K11B0034-01 (1.0 kgf-m, 7.5 lbf-ft)
19) Install the EXCV cable No. 1 (1) and No. 2 (2) to the
EXCV lever (3).
1
20) Install the EXCV cable bracket (4) and tighten the
nut (5) to the specified torque.
5
Tightening torque
EXCV cable bracket mounting nut (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)
2

4 4 , (a ) 3

IH17K11B0037-03

5, ( a)
1

2
3
IH17K11B0035-02
 Exhaust System: 1K-13

26) Install the EXCV cover (1) and tighten the nuts (2) to Installation
the specified torque. 1) Set the EXCV cable No. 3 (1) to the front EXCV lever
Tightening torque (2), and tighten the lock-nut (3) to the specified
EXCV cover nut (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) torque.
Tightening torque
EXCV cable lock-nut (a): 9.0 N·m (0.92 kgf-m,
6.65 lbf-ft)
2, (a) 1

IH17K11B0038-02
2
27) Install the rear fender front. (Page 9D-28) 3 , (a )
1
28) Install the right side cowling. (Page 9D-21)
IH17K11B0040-01

EXCV Cable No. 3 Removal and Installation 2) Install the muffler and exhaust pipe assembly.
BENH17K11B06011 (Page 1K-26)
Removal
3) After installing the muffler and exhaust pipe
1) Remove the muffler and exhaust pipe assembly. assembly, adjust the front EXCV lever clearance.
(Page 1K-24) (Page 1K-13)
2) Loosen the lock-nuts (1) and remove the EXCV
cable No. 3 (2). EXCV Cable No. 3 On-Vehicle Adjustment
BENH17K11B06012
1) Turn the ignition switch OFF.
2) Connect the special tool to the mode select coupler
(6P). (Page 1A-17)
3) After turning the mode select switch ON, turn the
ignition switch ON.
4) Check that the cable slots of the EXCVA pulley
comes to the middle (Adjustment position). (Page
1 1K-8)
5) Remove the side cowling. (Page 9D-21)
6) Remove the EXCV cover (1).

IH17K11B0039-02

IH17K11B0013-03
1K-14 Exhaust System:

7) Check the lock-washer and nut (1), lock-nuts (2) and

clamp (3) for tightness. [A]

1 1

IH17K11B0086-02

IH17K11B0082-01
[B]

IH17K11B0087-03

[A]: Correct [B]: Incorrect

IH17K11B0083-01

9) Check the clearance “a” between the EXCV cable

No. 3 (1) and exhaust pipe support bracket (2). If the
clearance is less than the specified value, adjust the
EXCV cable position.

IH17K11B0084-01
1
2

“a”
IH17K11B0113-02

3 “b ”

1
IH17K11B0085-01

8) Check the EXCV cable No. 3 guide tube (1) is not

protruded from the EXCV cable No. 3 bracket (2). 2

NOTE IH17K11B0114-01

If the EXCV cable No. 3 guide tube (1) is “a”: Minimum 15 mm (0.59 in) “b”: Incorrect
protruded from the bracket (2), correct the
guide tube position.
 Exhaust System: 1K-15

10) Hold the rear EXCV shaft (1) with a wrench (2) and 14) Temporarily install the EXCV cable No. 3 lever (1) to
remove the EXCV cable No. 3 lever (3). the rear EXCV shaft (2) with the EXCV cable No. 3
mounting nut (3).
NOTICE
15) Hold the rear EXCV shaft (2) with a wrench (4) and
When loosening or tightening the EXCV tighten the EXCV cable No. 3 lever mounting nut (3)
cable No. 3 lever mounting nut (4), be sure to to the specified torque.
hold the rear EXCV shaft (1) with a wrench
(2). If not, it may cause damage to the rear NOTICE
EXCV or rear EXCV shaft. When loosening or tightening the rear EXCV
cable No. 3 lever mounting nut (3), be sure to
hold the rear EXCV shaft (2) with a wrench
(4). If not, it may cause damage to the rear
EXCV or rear EXCV shaft.
3
2 Tightening torque
EXCV cable No. 3 lever mounting nut (a): 10 N·m
(1.0 kgf-m, 7.5 lbf-ft)

4 1 1

IH17K11B0088-01

11) Remove the EXCV cable bracket (1) from the rear
EXCV. 4
12) Remove the EXCV cables (2) from the rear EXCV
lever (3).
2
3 , (a )

IH17K11B0091-01

1 16) When adjusting the EXCV cable No. 3 at the front

EXCV, arrange the rear EXCV as follows.
a) Using a clamp (1), pull up the rear EXCV lever
(2).

NOTICE
2
3 When using a clamp (1), the rear EXCV lever
returns by spring force and may hit your
IH17K11B0089-01 finger.
13) Set the EXCV cable No. 3 (1) to the EXCV cable No. Be careful not to hurt your finger when
3 lever (2). releasing the clamp.

b) Touch the EXCV cable No. 3 lever (3) to the

bracket (4).
1

1
3

2
2

IH17K11B0090-01
4

IH17K11B0092-01
1K-16 Exhaust System:

17) As a preparation for accurate adjustment of the front b) Close the front EXCV lever (1) and hold the
EXCV lever clearance, perform the following steps: closed position by hand until the next step c).
a) Check clearance “a” of the front EXCV lever.
NOTICE
Front EXCV lever clearance Touching the EXCV cable No. 3 (2) with your
[Standard]: 1.5 – 2.0 mm (0.059 – 0.078 in) arm during the cable adjustment may change
the cable tension and disturbs the EXCV
lever adjustment.
Do not touch the EXCV cable No. 3 with your
arm etc. when adjusting the cable.

“a”
1

IH17K11B0093-01

b) If the clearance is less than the specified range,

adjust the front EXCV lever clearance, loosening
the EXCV cable No. 3 lock-nut (1) and turning
the EXCV cable No. 3 adjuster nut (2) clockwise
viewed from the lower side. IH17K11B0096-01

IH17K11B0094-02 IH17K11B0097-02
c) Temporarily tighten the EXCV cable No. 3 lock-
nut (1).
18) 0 (zero) adjustment:
a) Loosen the EXCV cable No. 3 lock-nut (1).

NOTE
Too much loosening of the EXCV cable No. 3
lock-nut (1) causes unsteady positioning of
the cable (2) and disturbs the adjustment.

IH17K11B0095-02
 Exhaust System: 1K-17

c) Move the EXCV cable No. 3 lever (1) back and 19) Put a mark (1) on the EXCV cable No. 3 adjuster nut
forth, and turn the EXCV cable No. 3 adjuster nut (2).
(2) counterclockwise (viewed from the lower
side) confirming the EXCV cable No. 3 lever (1)
until it stops moving.

NOTE 1
• Too much loosening of the EXCV cable No.
3 lock-nut (3) causes unsteady positioning
of the cable and disturbs the adjustment.
2
• Moving EXCV cable No. 3 lever (1) back
and forth while holding the front EXCV
lever (4) in the closed position enable
adjustment of the cable play. IH17K11B0101-02

• When movement of the EXCV cable No. 3 20) Loosen the EXCV cable No. 3 lock-nut (1).
lever (1) stops, the point shows 0 (zero) 21) Turn the EXCV cable No. 3 adjuster nut (2) 1.5 turns
point “a”. clockwise (viewed from the lower side), and then
tighten the EXCV cable No. 3 lock-nut (1) to the
specified torque.
Tightening torque
1 EXCV cable No. 3 lock-nut (a): 4.5 N·m (0.46 kgf-
m, 3.35 lbf-ft)
3

1, (a)

2
2

IH17K11B0098-02

IH17K11B0102-02

22) Move the EXCV cable No. 3 lever (1) several times
for steady movement of the EXCV cable No. 3.

4 “a”

IH17K11B0099-01

d) Temporarily tighten the EXCV cable No. 3 lock-

nut (1).

1
IH17K11B0103-02

IH17K11B0100-01
1K-18 Exhaust System:

23) Check clearance “a” of the front EXCV lever. 26) Hold the rear EXCV shaft (1) with a wrench (2) and
remove the EXCV cable No. 3 lever (3).
Front EXCV lever clearance
[Standard]: 1.5 – 2.0 mm (0.059 – 0.078 in) NOTICE
When loosening or tightening the EXCV
cable No. 3 lever mounting nut (4), be sure to
hold the rear EXCV shaft (1) with a wrench
(2). If not, it may cause damage to the rear
EXCV or rear EXCV shaft.

“a” 3

IH17K11B0093-01

24) If the clearance is not within the specified range, 2

repeat the procedures from 17) to 23) until the
specified value is obtained. 1
25) Release the clamp (1) and slowly turn back the rear 4
EXCV lever.
IH17K11B0105-02
NOTICE
27) Install the EXCV cable No. 1 (1) and No. 2 (2) to the
When releasing the clamp (1), the rear EXCV rear EXCV lever (3).
lever returns by spring force and may hit 28) Install the EXCV cable bracket (4) and tighten the
your finger. nut (5) to the specified torque.
Be careful not to hurt your finger when
releasing the clamp. Tightening torque
EXCV cable bracket mounting nut (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)

1 5, (a)

2
3
IH17K11B0104-01

IH17K11B0106-03
 Exhaust System: 1K-19

29) Temporarily install the EXCV cable No. 3 lever (1) to 34) Install the side cowling. (Page 9D-21)
the rear EXCV shaft (2) with the EXCV cable No. 3
lever mounting nut (3). EXCVA Inspection
BENH17K11B06005
30) Hold the rear EXCV shaft (2) with a wrench (4) and
EXCVA Position Sensor Resistance
tighten the EXCV cable No. 3 lever mounting nut (3)
to the specified torque. 1) Set the EXCVA to adjustment position. Refer to
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
NOTICE Installation” (Page 1K-8).
When loosening or tightening the EXCV 2) Turn the ignition switch OFF and disconnect the
cable No. 3 lever mounting nut (3), be sure to EXCVA coupler.
hold the rear EXCV shaft (1) with a wrench 3) Measure the resistance between the Y wire and W
(2). If not, it may cause damage to the rear wire.
EXCV or rear EXCV shaft.
EXCVA position sensor resistance
Tightening torque At adjustment position [Standard]: Approx. 4000
EXCV cable No. 3 lever mounting nut (a): 10 N·m Ω
(1.0 kgf-m, 7.5 lbf-ft)

3, ( a) 2
IH17K11B0046-01

IH17K11B0107-02
EXCVA Position Sensor Output Voltage
31) Turn the ignition switch ON, and check the EXCV
Refer to “EXCVA Adjustment” (Page 1K-21).
operation. (Page 1K-7)
32) Start the engine and run the engine at idle speed. EXCVA Motor
Hear noises around exhaust pipes. Then, disengage
1) Turn the ignition switch OFF.
the clutch and shift into 1st gear. Hear noises around
exhaust pipes and compere noises on 1st gear and 2) Disconnect the EXCVA coupler (1). Refer to “EXCVA
noises on neutral gear. / EXCV Cable No. 1 / No. 2 Removal and
If the noise volume on 1st gear is remarkably bigger Installation” (Page 1K-8).
than the same on neutral, the front EXCV lever
clearance may be less than the specified range.
Therefore, EXCV cable No. 3 is to be readjusted to
the specified clearance.
Stop the engine and shift to the neutral.
33) Install the EXCV cover (1) and tighten the nuts (2) to
the specified torque.
Tightening torque
EXCV cover nut (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 1

IH17K11B0047-01

2, (a) 1

IH17K11B0038-02
1K-20 Exhaust System:

3) Apply 12 V to the terminals and check the operation EXCV Cable Visual Inspection
of EXCVA. BENH17K11B06016
Refer to “EXCVA / EXCV Cable No. 1 / No. 2 Removal
and Installation” (Page 1K-8).
Visually check the cables (1) for wear or damage. If any
defects are found, replace the cable(s) with new one(s).
• EXCV cable No. 1 and No. 2: (Page 1K-8)
• EXCV cable No. 3: (Page 1K-13)

1
IH17K11B0048-01

IH17K11B0111-01

IH17K11B0049-01

4) Then, switch the wires supplied 12 V and check the

1
operation of EXCVA. (Check the operation of EXCVA
in both ways.)

IH17K11B0112-01

EXCVA Pulley Inspection

BENH17K11B06006
Refer to “EXCVA / EXCV Cable No. 1 / No. 2 Removal
and Installation” (Page 1K-8).
• Visually inspect the EXCVA pulley for wear and
damage. If there is anything unusual, replace the
pulley with a new one.
IH17K11B0050-01

IF04K11B0026-01

IH17K11B0051-01

5) If the EXCVA pulley does not rotate, replace the

EXCVA with a new one.
 Exhaust System: 1K-21

EXCVA Adjustment
BENH17K11B06007
Step 1
1) Set the EXCVA to the adjustment position. Refer to
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation” (Page 1K-8).

Step 2
1) Turn the ignition switch OFF.
2) Connect the special tool to the mode select coupler
(6P). (Page 1A-17)
3) Turn the ignition switch ON and check the operation
of EXCVA.
(EXCVA operation order: Full close → Full open →
Initial angle)

[A] [B] [C]

IF04K11B0064-02

6) Click “Fully closed”.

IH17K11B0052-03

[A]: Full close [C]: Initial angle

[B]: Full open

4) Turn the mode select switch ON. If DTC “C46” is not

indicated on the LCD display (1), the adjustment is
correctly completed. If “C46” is indicated, repeat the
procedures from Step 3 to Step 4. IF04K11B0065-03

7) Insert the needle point probes to the lead wire

coupler, measure the EXCVA position sensor output
voltage between the Y wire and W wire at EXCV fully
1 closed position.
EXCVA position sensor output voltage
Closed [Standard]: 0.45 – 1.40 V
Special tool
09900–25009

IH17K11B0053-02

Step 3
1) Turn the ignition switch OFF.
2) Remove the rear seat. (Page 9D-19)
3) Set up the SDS-II tool referring to the SDS-II
operation manual for further details.
4) Turn the ignition switch ON.
5) Click “Exhaust valve drive control”. IH17K11B0054-01
1K-22 Exhaust System:

8) If the measured voltage is less than specification, 2) Insert the needle point probes to the lead wire,
adjust the No. 1 cable adjuster as follows: measure the EXCVA position sensor output voltage
a) Set the EXCVA to the adjustment position. Refer between the Y wire and W wire at EXCV fully
to “EXCVA / EXCV Cable No. 1 / No. 2 Removal opened position.
and Installation” (Page 1K-8). EXCVA position sensor output voltage
NOTICE Opened [Standard]: 3.60 – 4.55 V

Adjusting the No. 1 cable with the EXCV fully Special tool
closed can damage the EXCVA. 09900–25009
Be sure to adjust the No. 1 cable with the
EXCV set in the adjustment position.

b) Remove the EXCV cover (1).

IH17K11B0054-01

3) If the measured voltage is more than the

specification, adjust the No. 2 cable adjuster as
follows:
IH17K11B0013-03 a) Set the EXCVA to the adjustment position. Refer
c) Turn the No. 1 cable adjuster (1) in or out to set to “EXCVA / EXCV Cable No. 1 / No. 2 Removal
the voltage within the specified value. and Installation” (Page 1K-8).
NOTE NOTICE
If C46 code is indicated after adjusting the Adjusting the No. 2 cable with the EXCV fully
voltage, increase the voltage to 0.15 V. opened can damage the EXCVA.
Be sure to adjust the No. 2 cable with the
EXCV set in adjustment position.
1
b) Hold the rear EXCV shaft (1) with a wrench (2)
and remove the EXCV cable No. 3 lever (3).

NOTICE
When loosening or tightening the EXCV
cable No. 3 lever mounting nut (4), be sure to
hold the rear EXCV shaft (1) with a wrench
(2). If not, it may cause damage to the rear
EXCV or rear EXCV shaft.
IH17K11B0055-03

Step 4
1) Click “Fully open”.

2 3

4 1

IH17K11B0014-03

IF04K11B0066-03
 Exhaust System: 1K-23

c) Turn the No. 2 cable adjuster (1) in or out to set 4) Connect the EXCVA coupler.
the output voltage within the specified value. 5) Check the EXCVA to the adjustment position. Refer
to “EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation” (Page 1K-8).
1
6) Turn the ignition switch OFF.
7) Connect the EXCV cables to the EXCVA pulley.
Refer to “EXCVA / EXCV Cable No. 1 / No. 2
Removal and Installation” (Page 1K-8).
8) Inspect the EXCVA position sensor voltage.

EXCV Inspection
BENH17K11B06014
Refer to “Exhaust Pipe / Muffler Removal” (Page 1K-24)
IH17K11B0056-02
and “Exhaust Pipe / Muffler Installation” (Page 1K-26).
4) After adjusting the EXCV cables, perform Step 2 to Rotate the rear EXCV (1) and front EXCV (2) by hand
confirm DTC “C46” is not indicated. and inspect for abnormal noise and smooth rotation.
5) Install the removed parts. Replace the exhaust pipe assembly if there is anything
unusual.
Repair (EXCV pulley does not rotate when turning • Removal: (Page 1K-24)
the ignition switch ON, during EXCVA adjustment) • Installation: (Page 1K-26)
1) Turn the ignition switch OFF.
2) Disconnect the EXCVA coupler and EXCV cables
from the EXCVA pulley. (Page 1K-8)
3) Apply 12 V to the EXCVA lead wire between the Gr
wire and P wire to rotate the motor so that the line (1)
or pulley comes to the adjacent position as shown.

IH17K11B0108-01

IH17K11B0048-01

IH17K11B0109-01

IH17K11B0057-01
1K-24 Exhaust System:

Rear EXCV Shaft Inspection 2) Loosen the muffler connector bolt (1).
BENH17K11B06015
Refer to “EXCVA / EXCV Cable No. 1 / No. 2 Removal 3) Remove the support bolt (2), spacer, nut and muffler
and Installation” (Page 1K-8), “Exhaust Pipe / Muffler (3).
Removal” (Page 1K-24) and “Exhaust Pipe / Muffler
Installation” (Page 1K-26). 2
Check the rear EXCV shaft (nut portion) (1) for tightness.
If the shaft is loose, tighten it to the specified torque, and
then bend the lock-washer (2).

NOTICE
Tightening the rear EXCV shaft without
stopping the shaft rotation may damage the 3
inside valve.
When tightening the nut portion, hold the 1
EXCV lever (3) by hand to stop the rotation. IH17K11B0059-01

4) Remove the muffler connector (1).

Tightening torque
Rear EXCV shaft (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1, ( a)

2
1

3
IH17K11B0060-02

5) Remove the muffler rear cover (1) (if equipped).

IH17K11B0110-01

Exhaust Pipe / Muffler Removal

BENH17K11B06008

Muffler
1) Remove the muffler front cover (1).

IH17K11B0061-01

IH17K11B0058-01
 Exhaust System: 1K-25

Exhaust Pipe 4) Hold the rear EXCV shaft (1) with a wrench (2) and
1) Remove the radiator assembly (1) and oil cooler remove the EXCV cable No. 3 lever (3).
assembly (2).
NOTICE
• Radiator assembly: (Page 1F-8)
When loosening or tightening the EXCV
• Oil cooler assembly: (Page 1E-8) cable No. 3 lever mounting nut (4), be sure to
hold the rear EXCV shaft (1) with a wrench
(2). If not, it may cause damage to the rear
EXCV or rear EXCV shaft.
1

2
2 3

IH17K11B0062-01

2) Disconnect the HO2 sensor lead wire coupler (1)

and detach the lead wire from the clamp (2). 4 1

IH17K11B0014-03

5) Remove the EXCV cable bracket (1) with EXCV

cables (2). Refer to “EXCVA / EXCV Cable No. 1 /
1 No. 2 Removal and Installation” (Page 1K-8).

2 1

IH17K11B0063-01

3) Remove the EXCV cover (1).

2
IH17K11B0064-03
1
6) Remove the exhaust pipe bolts (1).

IH17K11B0013-03

IH17K11B0065-01
1K-26 Exhaust System:

7) Remove the exhaust support bolt (1). Exhaust Pipe / Muffler Installation
BENH17K11B06009
8) Disconnect the EXCV cable No. 3 from the clamp Exhaust Pipe
(2).
1) Install the HO2 sensor. (Page 1C-16)
9) Remove the exhaust pipe (3).
2) Install the new exhaust pipe gaskets (1).
NOTE
Support the exhaust pipe assembly to
prevent it from falling.

1
1

IH17K11B0068-01

3) Apply thread lock to the exhaust support bolt (2).

2
3 “A”: Thread lock bolt cement 99000–32130
(THREAD LOCK CEMENT 1360)
IH17K11B0067-02

10) Remove the exhaust pipe gaskets (1). 4) Temporarily install the exhaust pipe (1) with the
exhaust support bolt (2).
5) Connect the EXCV cable No. 3 to the clamp (3).

2 , “A ”

1
1

IH17K11B0068-01 3
1
11) Remove the HO2 sensor (1). (Page 1C-16)
IH17K11B0070-02

6) Tighten the exhaust pipe bolts (1) to the specified

torque.
Tightening torque
Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
1

1 , (a )

IH17K11B0069-02

IH17K11B0071-01
 Exhaust System: 1K-27

7) Tighten the exhaust support bolt (1) to the specified 10) Install the EXCV cable No. 3 lever. Refer to “EXCVA
torque. / EXCV Cable No. 1 / No. 2 Removal and
Installation” (Page 1K-8).
Tightening torque
Exhaust support bolt (a): 23 N·m (2.3 kgf-m, 17.0 11) Install the EXCV cover (1) and tighten the nuts (2) to
lbf-ft) the specified torque.
Tightening torque
EXCV cover nut (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

1, ( a)

2 , (a ) 1

IH17K11B0072-02

8) Check that the front EXCV lever clearance “a” is

within 1.5 – 2.0 mm (0.059 – 0.078 in). If not, adjust IH17K11B0038-02
the EXCV cable No. 3. (Page 1K-13) 12) Install the radiator assembly (1) and oil cooler
assembly (2).
• Radiator assembly: (Page 1F-8)
• Oil cooler assembly: (Page 1E-8)

1
“a”

IH17K11B0093-01 2
9) Install the EXCV cables (1) and bracket (2). Refer to
“EXCVA / EXCV Cable No. 1 / No. 2 Removal and
Installation” (Page 1K-8).
IH17K11B0062-01

13) Connect the HO2 sensor lead wire coupler (1) and
clamp the lead wire to the clamp (2).
2

1
1

2
IH17K11B0073-02

IH17K11B0063-01
1K-28 Exhaust System:

Muffler 3) Install the muffler (1) with the muffler support bolt,
1) Install the muffler rear cover (1) and tighten the spacer, nut and tighten the muffler support bolt (2) to
muffler rear cover bolts (2) to the specified torque (if the specified torque.
equipped). Tightening torque
Tightening torque Muffler support bolt (a): 30 N·m (3.1 kgf-m, 22.5
Muffler rear cover bolt (a): 5.5 N·m (0.56 kgf-m, lbf-ft)
4.05 lbf-ft) 4) Apply nickel based anti seize to the thread part of
muffler connector bolt (3) and tighten it to the
specified torque.
Tightening torque
Muffler connector bolt (b): 18 N·m (1.8 kgf-m,
13.5 lbf-ft)

2 , (a )

2, (a)

IH17K11B0074-02 1
2) Put the edge (2) of a new muffler connector (1) to the
3 , (b )
exhaust pipe stopper (3).
IH17K11B0076-01

5) Install the muffler front cover (1) and tighten the

1 muffler front cover bolt (2) to the specified torque.
Tightening torque
3 Muffler front cover bolt (a): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft)

2
2 , (a )

IH17K11B0075-01

IH17K11B0077-01

Exhaust System Inspection

BENH17K11B06010
Inspect the exhaust pipe connection and muffler
connection for exhaust gas leakage and mounting
condition. If any defect is found, replace the exhaust
pipe assembly or muffler with a new one.
Check the exhaust pipe bolts, muffler connector bolt,
exhaust support bolt and muffler support bolt are
tightened to their specified torque. Refer to “Exhaust
Control System Construction” (Page 1K-4) and “Exhaust
System Components” (Page 1K-6).
 Exhaust System: 1K-29

Specifications
Tightening Torque Specifications
BENH17K11B07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
EXCVA pulley bolt 5.0 0.51 3.70 (Page 1K-10)
EXCV cable bracket mounting nut (Page 1K-11) /
10 1.0 7.5 (Page 1K-12) /
(Page 1K-18)
EXCV cable lock-nut (Page 1K-11) /
4.5 0.46 3.35
(Page 1K-11)
EXCVA mounting bolt 11 1.1 8.5 (Page 1K-12)
EXCV cable No. 3 lever mounting nut (Page 1K-12) /
10 1.0 7.5 (Page 1K-15) /
(Page 1K-19)
EXCV cover nut (Page 1K-13) /
10 1.0 7.5 (Page 1K-19) /
(Page 1K-27)
EXCV cable lock-nut 9.0 0.92 6.65 (Page 1K-13)
EXCV cable No. 3 lock-nut 4.5 0.46 3.35 (Page 1K-17)
Rear EXCV shaft 10 1.0 7.5 (Page 1K-24)
Exhaust pipe bolt 23 2.3 17.0 (Page 1K-26)
Exhaust support bolt 23 2.3 17.0 (Page 1K-27)
Muffler rear cover bolt 5.5 0.56 4.05 (Page 1K-28)
Muffler support bolt 30 3.1 22.5 (Page 1K-28)
Muffler connector bolt 18 1.8 13.5 (Page 1K-28)
Muffler front cover bolt 5.5 0.56 4.05 (Page 1K-28)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust Control System Construction” (Page 1K-4)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K11B08001
Material SUZUKI recommended product or Specification Note
Thread lock bolt cement THREAD LOCK CEMENT 1360 P/No.: 99000–32130 (Page 1K-26)

Special Tool
BENH17K11B08002
09900–25009
Needle point probe set
(Page 1K-21) /
(Page 1K-22)
1K-30 Exhaust System:
 Table of Contents 2- i

Section 2

Suspension
CONTENTS

Precautions .................................................2-1 Swingarm Removal and Installation..................2C-10

2
Precautions............................................................. 2-1 Swingarm Inspection.........................................2C-12
Precautions for Suspension .................................. 2-1 Swingarm Bearing Removal and Installation ....2C-14
Specifications .....................................................2C-15
Suspension General Diagnosis.............. 2A-1 Tightening Torque Specifications......................2C-15
Diagnostic Information and Procedures............2A-1 Special Tools and Equipment ...........................2C-16
Suspension and Wheel Symptom Diagnosis ...... 2A-1 Recommended Service Material .......................2C-16
Special Tool ......................................................2C-16
Front Suspension .................................... 2B-1
Repair Instructions ..............................................2B-1 Wheels and Tires ..................................... 2D-1
Front Fork Components ...................................... 2B-1 Precautions...........................................................2D-1
Front Fork On-Vehicle Inspection ....................... 2B-2 Precautions for Wheel and Tire...........................2D-1
Front Suspension Adjustment ............................. 2B-2 Repair Instructions ..............................................2D-2
Front Fork Assembly Removal and Front Wheel Components ...................................2D-2
Installation ......................................................... 2B-3 Front Wheel Assembly Construction...................2D-3
Front Fork Disassembly and Reassembly .......... 2B-5 Front Wheel Assembly Removal and
Front Fork Inspection ........................................ 2B-11 Installation .........................................................2D-4
Specifications.....................................................2B-12 Front Wheel Dust Seal / Front Wheel Bearing
Tightening Torque Specifications...................... 2B-12 Removal and Installation...................................2D-5
Special Tools and Equipment ...........................2B-12 Rear Wheel Components....................................2D-7
Recommended Service Material ....................... 2B-12 Rear Wheel Assembly Construction ...................2D-8
Special Tool ...................................................... 2B-12 Rear Wheel Assembly Removal and
Installation .........................................................2D-9
Rear Suspension ..................................... 2C-1 Rear Wheel Dust Seal / Rear Wheel Bearing
Repair Instructions ..............................................2C-1 Removal and Installation.................................2D-10
Rear Suspension Components ...........................2C-1 Wheel / Wheel Axle Inspection .........................2D-11
Rear Suspension Assembly Construction...........2C-2 Rear Wheel Damper Removal and Installation ..2D-13
Rear Suspension On-Vehicle Inspection ............2C-3 Rear Wheel Damper Inspection ........................2D-13
Rear Shock Absorber Adjustment.......................2C-3 Tire Inspection and Cleaning ............................2D-13
Rear Shock Absorber Removal and Tire Removal and Installation............................2D-14
Installation .........................................................2C-4 Wheel Rim / Air Valve Inspection and
Rear Shock Absorber Inspection ........................2C-5 Cleaning ..........................................................2D-15
Rear Shock Absorber Bearing Removal and Air Valve Removal and Installation ...................2D-15
Installation .........................................................2C-6 Wheel Balance Check and Adjustment.............2D-16
Rear Shock Absorber Disposal ...........................2C-7 Specifications .....................................................2D-16
Cushion Lever Removal and Installation.............2C-7 Tightening Torque Specifications......................2D-16
Cushion Lever Inspection ...................................2C-8 Special Tools and Equipment ...........................2D-17
Cushion Rod Removal and Installation ...............2C-8 Recommended Service Material .......................2D-17
Cushion Rod Inspection ......................................2C-8 Special Tool ......................................................2D-17
Cushion Rod Bearing Removal and
Installation .........................................................2C-9
2-1 Precautions:

Precautions
Suspension

Precautions
Precautions for Suspension
BENH17K12000001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING

• Never attempt to heat, quench or straighten any suspension part. If any damage or deformation is
found, replace the part with a new one without correct it.
• When removing or installing the suspension or wheel, place the motorcycle on a level surface and
support it securely with a hoist or jack etc.
• Do not support the motorcycle with the muffler.
 Suspension General Diagnosis: 2A-1

Suspension General Diagnosis

Suspension

Diagnostic Information and Procedures

Suspension and Wheel Symptom Diagnosis
BENH17K12104001

Condition Possible cause Correction / Reference Item

Wobbly front wheel Distorted wheel rim. Replace. (Page 2D-14)
Worn front wheel bearings. Replace. (Page 2D-5)
Defective or incorrect tire. Replace. (Page 2D-14)
Loose front axle nut. Tighten. (Page 0B-5)
Loose front axle pinch bolts. Tighten. (Page 0B-5)
Incorrect fork oil level. Adjust. (Page 2B-5)
Incorrect front wheel weight balance. Adjust. (Page 2D-16)
Front suspension too soft Insufficiently viscous fork oil. Replace. (Page 2B-5)
Insufficient fork oil. Check level and add. (Page 2B-5)
Weak spring. Replace. (Page 2B-5)
Improperly set front fork spring adjuster. Adjust. (Page 2B-2)
Improperly set front fork damping force Adjust. (Page 2B-2)
adjuster.
Front suspension too stiff Excessively viscous fork oil. Replace. (Page 2B-5)
Excessive fork oil. Check level and drain. (Page 2B-5)
Bent front axle. Replace. (Page 2D-4)
Improperly set front fork spring adjuster. Adjust. (Page 2B-2)
Improperly set front fork damping force Adjust. (Page 2B-2)
adjuster.
Front suspension too Insufficient fork oil. Check level and add. (Page 2B-5)
noisy Loose front fork clamp bolt. Tighten. (Page 0B-5)
Wobbly rear wheel Distorted wheel rim. Replace. (Page 2D-14)
Worn rear wheel bearings. Replace. (Page 2D-10)
Defective or incorrect tire. Replace. (Page 2D-14)
Worn swingarm bearings. Replace. (Page 2C-14)
Loose rear suspension related bolt and Tighten. (Page 0B-5)
nut.
Loose rear axle nut. Tighten. (Page 2D-9)
Worn rear suspension bearings. Replace. (Page 2C-6)
Incorrect rear wheel weight balance. Adjust. (Page 2D-16)
Rear suspension too soft Weak rear shock absorber spring. Replace. (Page 2C-4)
Rear shock absorber leaks oil. Replace. (Page 2C-4)
Improperly set rear shock absorber Adjust. (Page 2C-3)
spring adjuster.
Improperly set rear shock absorber Adjust. (Page 2C-3)
damping force adjuster.
Rear suspension too stiff Bent rear shock absorber shaft. Replace. (Page 2C-4)
Worn swingarm bearings. Replace. (Page 2C-14)
Worn rear suspension bearings. Replace. (Page 2C-6)
Bent swingarm pivot shaft. Replace. (Page 2C-10)
Improperly set rear shock absorber Adjust. (Page 2C-3)
spring adjuster.
Improperly set rear shock absorber Adjust. (Page 2C-3)
damping force adjuster.
Rear suspension too Loose rear suspension related bolt and Tighten. (Page 0B-5)
noisy nut.
Worn swingarm bearings. Replace. (Page 2C-14)
Worn rear suspension bearings. Replace. (Page 2C-6)
2B-1 Front Suspension:

Front Suspension
Suspension

Repair Instructions
Front Fork Components
BENH17K12206001

5 (b) 12

1 (a)
6 17

2
7 18

13
19
8 (c)
3 20

14 21
9
15

4 10

22

11
16

23 (d)

IH17K1220001-02

1. Front fork cap 9. Spring 17. Guide bushing : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
2. O-ring 10. Piston rod 18. Oil seal spacer : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
3. Rebound damping force adjuster rod 11. Piston ring 19. Oil seal : 23 Nm (2.3 kgf-m, 16.5 lbf-ft)
4. Compression damping force adjuster rod 12. Spring collar B 20. Oil seal stopper ring : Apply fork oil.
5. Piston rod nut 13. Spring 21. Dust seal : Do not reuse.
6. O-ring 14. Spring collar 22. Inner tube
7. Piston ring B 15. Slide bushing 23. Front axle pinch bolt
8. Rod guide case 16. Outer tube : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
 Front Suspension: 2B-2

Front Fork On-Vehicle Inspection Damping Force Adjustment

BENH17K12206002
Rebound damping force
Inspect the front forks (1) for oil leakage and damage.
Fully turn the rebound damping force adjuster (1)
If any defect is found, replace any defective parts.
clockwise. From that position (stiffest), turn it
(Page 2B-5)
counterclockwise to standard setting position.
Front fork damping force adjuster
Rebound side
[Standard]: 4 turns counterclockwise from stiffest
position

1
1

IH17K1220002-01

Front Suspension Adjustment

BENH17K12206003
! WARNING
IH17K1220004-01
Adjust the left and right front forks to the
same setting. Compression damping force
Fully turn the compression damping force adjuster (1)
NOTICE clockwise. From that position (stiffest), turn it
When the dirty front fork is adjusted as it is, counterclockwise to the standard setting position.
an oil leakage might occur due to adjuster Front fork damping force adjuster
firmly fixing or seal damage. Compression side
Before adjustment, wash the dirt completely [Standard]: 4-3/4 turns counterclockwise from
off from the front fork. stiffest position
Spring Pre-load Adjustment
Turn the spring pre-load adjuster (1) counterclockwise
fully. From that position (softest), turn it clockwise to the
specified position. 1

Front fork spring adjuster

[Standard]: 4-3/4 turns clockwise from softest
position

IH17K1220005-01

IH17K1220003-01
2B-3 Front Suspension:

Front Fork Assembly Removal and Installation 7) Loosen the front fork upper clamp bolt (1) and
BENH17K12206004 handlebar clamp bolt (2).
NOTE
NOTE
The right and left front forks are installed
Slightly loosen the front fork cap (3) with the
symmetrically and therefore the removal
special tool to facilitate later disassembly.
procedure for one side is the same as that for
the other side. Special tool
09941–53671
Removal
1) Remove the body cowling. (Page 9D-22)
3
2) Remove the front wheel. (Page 2D-4)
3) Remove the reflex reflectors (If equipped). Refer to
“Reflex Reflector Construction (If Equipped)” in 1
Section 9B (Page 9B-15).
4) Remove the front wheel speed sensor lead wire
clamp (1).
5) Disconnect the brake hose clamp (2) on the front 2
fender.
6) Remove the front fender (3).
IH17K1220008-01

8) Loosen the front fork lower clamp bolts (1), and then
remove the front fork (2) by supporting it.

1 1

2
IH17K1220006-01

IH17K1220009-01

2
Installation
1) Set the front fork (1) to the steering stem lower
bracket temporarily by tightening the front fork lower
3
clamp bolts (2).

IH17K1220007-01

IH17K1220010-01
 Front Suspension: 2B-4

2) Tighten the front fork cap (1) to the specified torque 6) Insert the protrusion (1) of the handlebar into the
using the special tool. hole (2) of the steering stem upper bracket.

NOTE
When the front fork was disassembled, 2
tighten the front fork cap firmly with specified
torque.

Special tool
09941–53671
Tightening torque
1
Front fork cap (a): 35 N·m (3.6 kgf-m, 26.0 lbf-ft)
3) Loosen the front fork lower clamp bolts.
IH17K1220013-01
4) Set the top end of outer tube to the upper surface (2)
7) Tighten the front fork upper clamp bolt (1) and
of the steering stem upper bracket.
handlebar clamp bolt (2) to the specified torque.
Tightening torque
1, ( a)
Front fork upper clamp bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
Handlebar clamp bolt (b): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
2

1 , (a )

IH17K1220011-01

5) Tighten the front fork lower clamp bolts (1) to the

specified torque.
Tightening torque
2 , (b )
Front fork lower clamp bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft) IH17K1220014-02

1, ( a)

IH17K1220012-01
2B-5 Front Suspension:

8) Install the front fender and tighten the front fender 2) Turn the spring pre-load adjuster (1) to the softest
mounting bolts to the specified torque in order of “1” position.
→ “2”.
Tightening torque
Front fender mounting bolt (a): 8.4 N·m (0.86
kgf-m, 6.20 lbf-ft)
1

“1”, (a)
IH17K1220018-01

“ 2” , ( a) 3) Clamp the outer tube with a vise. Protect the outer

tube with a rag when using a vise.
4) Loosen and remove the front fork cap using the
IH17K1220015-01 special tool.

NOTICE
Do not clamp the outer tube too tight.

Special tool
(A): 09941–53671
“2”, (a)
“ 1” , ( a)

(A )

IH17K1220016-01

9) Install the removed parts.

Front Fork Disassembly and Reassembly

BENH17K12206005
Refer to “Front Fork Assembly Removal and Installation”
(Page 2B-3). IH17K1220019-01

5) Slowly move the outer tube down.

Disassembly 6) Clamp the axle holder with a vise. Protect the axle
1) Remove the front axle pinch bolts (1). holder with a rag when using a vise.
7) Loosen the rod guide case installed in the inner tube
using the special tool.
Special tool
(A): 09940–84711
8) Hold the front fork cap when removing the rod guide
case.

1 (A )

IH17K1220017-01

IH17K1220020-01
 Front Suspension: 2B-6

9) Remove the piston rod assembly (1). 13) Remove the piston ring B (1) and O-ring (2) from the
rod guide case.

1 2

IH17K1220021-01

10) Hold the piston rod assembly (1) with the special tool IH17K1220024-01

and vise. 14) Remove the spring collar B (1) and spring (2).
Special tool
(A): 09941–53671
2
11) Loosen the piston rod nut (2) and remove the piston
rod assembly (1). 1

2
IH17K1220025-01

15) Drain fork oil and remove the spring collar (1).
(A)

IH17K1220022-01

12) Remove the following parts from the piston rod (1). 1

• O-ring (2)
• Front fork cap (3)
• Rebound damping force adjuster rod (4)
• Compression damping force adjuster rod (5)
• Piston rod nut (6)
• Rod guide case (7) IH17K1220026-01

• Spring (8)
• Piston ring (9)

4
3
9

8
7 2
6
IH17K1220023-02
2B-7 Front Suspension:

16) Remove the dust seal (1). Reassembly

17) Remove the oil seal stopper ring (2).
NOTICE
NOTICE • Thoroughly wash all the component parts
• Scratches on the inner tube could cause being assembled.
oil leaks. Insufficient washing can result in oil
leakage or premature wear of the parts.
• Avoid scratching when removing.
• When reassembling the front fork, use new
fork oil.
• Use the specified fork oil for the front fork.
2
1) Cover the inner tube with a plastic film.

NOTICE
Scratches on the oil seal lip may cause oil
leakage. When installing the seals, place a
plastic film over the slide bushing groove
and edges of the inner tube to avoid
1 damaging the seals’ lip.
IH17K1220027-01
2) Install the following parts to the inner tube.
18) Remove the oil seal (1) by pulling out the inner tube
a) New dust seal (1)
(2).
b) Stopper ring (2)
c) New oil seal (3)

1 NOTE
2
Face the stamp mark side of the oil seal to
the dust seal side.

3) Apply fork oil to the dust seal lip and oil seal lip.
“A”: Fork oil 99000–99001–47S (SUZUKI FORK
OIL SS-47)

IH17K1220028-01

19) Remove the following parts from the inner tube.

a) Slide bushing (1)
b) Guide bushing (2)
c) Oil seal spacer (3)
d) Oil seal (4)
e) Oil seal stopper ring (5)
f) Dust seal (6)
IE31J1220030-01

3
2

1
6

5
4

IH17K1220029-01
 Front Suspension: 2B-8

4) Remove the plastic film and install the oil seal spacer 9) Press fit the dust seal (1).
(1), new guide bushing (2) and new slide bushing (3)
keep them free from dust.

NOTICE
• Face the grooved side [a] of the oil seal
spacer (1) to the outer tube side.
• Position the slit [b] of slide bushing 90°
against the traveling direction.
1
5) Apply fork oil to the guide bushing and slide bushing.
“A”: Fork oil 99000–99001–47S (SUZUKI FORK
IH17K1220032-02
OIL SS-47)
10) Insert the spring collar (1) and spring (2) into the
inner tube.
1
2, “ A ” NOTE
Face the convex side [a] of the spring collar
[b ]
(1) to the bottom side.

[ a]
1 2
3, “ A ”
IH17K1220030-02

6) Insert the inner tube into the outer tube.

7) Press fit the oil seal (1) using the special tool until [a]
the stopper ring groove on the outer tube can be
seen.
Special tool
(A): 09940–52861 IH17K1220033-01

11) Insert the spring collar B (1) into the inner tube.

NOTE
Face the flange [a] of the collar to the spring
side.

(A)

1
1

[a]
ID26J1220024-02

8) When installing the stopper ring (1), make sure that

the stopper ring is fitted securely into the groove.

1
IH17K1220034-01

IH17K1220031-01
2B-9 Front Suspension:

12) Pour specified front fork oil until its surface passes “A”: Fork oil 99000–99001–47S (SUZUKI FORK
the side holes of the inner tube. OIL SS-47)
“A”: Fork oil 99000–99001–47S (SUZUKI FORK
OIL SS-47)

2 , “A ”

1
“A”

IH17K1220037-01

18) Tighten the piston rod nut (1) with the special tool
ID26J1220030-01
and vise.
13) Slowly stroke the outer tube more than ten times to
pump out air. Special tool
(A): 09941–53671
NOTE
Tightening torque
Take extreme attention to pump out air Piston rod nut (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
completely.

1 , (a )

(A )

IH17K1220038-01

19) Insert the piston rod assembly into the inner tube
IH17K1220035-01
with the outer tube lifted up and temporarily tighten
14) Apply fork oil to the new oil seal (1) and new piston the rod guide case by hand.
ring B (2).
15) When installing the new oil seal (1) and new piston NOTICE
ring B (2) to the rod guide case, apply fork oil. Insert the piston rod assembly into the inner
“A”: Fork oil 99000–99001–47S (SUZUKI FORK tube with the outer tube lifted up. Be sure not
OIL SS-47) to damage the piston ring B (1) of the rod
guide case.

1, “A” 2, “A” Special tool

(A): 09940–84711

(A)

IH17K1220036-01

16) Install the piston rod parts to the piston rod (1) in the
reverse order of removal. 1
17) Apply fork oil to the piston ring (2). IH17K1220039-02
 Front Suspension: 2B-10

20) Tighten the rod guide case in the following 21) Pour specified fork oil up to the top of the rod guide
procedures: case.
Measure the effective length L of the torque wrench.
Fork oil 99000–99001–47S (SUZUKI FORK OIL
Calculate the reading torque on the torque wrench
SS-47)
by use of the formula shown below.
Special tool
(A): 09940–84711
Tightening torque
Rod guide case: 90 N·m (9.2 kgf-m, 66.5 lbf-ft)

Ls IH17K1220042-01

22) Push the front fork cap, then stroke the outer tube
several times to pump out air.

(A)
NOTE

IH17K1220040-01
Take extreme attention to pump out the air
completely.

I933H1310046-01

T: Reading torque on the torque wrench

Ts: Specified torque
Ls: 0.05 m (1.97 in)
L: Effective length of the torque wrench

( A) IH17K1220048-01

23) Hold the front fork vertically and adjust the oil level
“a” using the special tool.
Front fork oil level
[Standard]: 83 mm (3.3 in)
[Standard]: 77 mm (3.0 in) 10 min. after
adjustment
IH17K1220041-01 Special tool
(A): 09943–74111

(A)

“a”

IH17K1220043-02
2B-11 Front Suspension:

24) Apply fork oil to the new O-ring (1). Fork Spring
Measure the fork spring free length “a”. If it is shorter
“A”: Fork oil 99000–99001–47S (SUZUKI FORK
than the service limit, replace it with a new one.
OIL SS-47)
Front fork spring free length
25) Tighten the front fork cap temporarily.
[Limit]: 230 mm (9.06 in)
Special tool
(A): 09941–53671

“a”
1, “ A ” (A)

IH17K1220046-02

IH17K1220044-01 Piston Rod / Piston Ring

26) Install the front axle pinch bolts. Inspect the piston rod (1) and piston ring A (2) for wear
or damage. If any defects are found, replace the piston
27) Install the front fork temporarily and tighten the front
rod or piston ring A with a new one.
fork cap to the specified torque.
Tightening torque
Front fork cap: 35 N·m (3.6 kgf-m, 26.0 lbf-ft)
2
28) After installing the front fork, adjust the spring and
two kinds of damping force. (Page 2B-2)
1
Front Fork Inspection
BENH17K12206006
Refer to “Front Fork Disassembly and Reassembly”
(Page 2B-5).

Inner Tube / Outer Tube IH17K1220047-01

Inspect the inner tube sliding surface and outer tube
sliding surface for scuffing. If any defect is found, replace
the part with a new one.

IH17K1220045-01
 Front Suspension: 2B-12

Specifications
Tightening Torque Specifications
BENH17K12207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front fork cap (Page 2B-4) /
35 3.6 26.0
(Page 2B-11)
Front fork lower clamp bolt 23 2.3 17.0 (Page 2B-4)
Front fork upper clamp bolt 23 2.3 17.0 (Page 2B-4)
Handlebar clamp bolt 23 2.3 17.0 (Page 2B-4)
Front fender mounting bolt 8.4 0.86 6.20 (Page 2B-5)
Piston rod nut 28 2.9 21.0 (Page 2B-9)
Rod guide case 90 9.2 66.5 (Page 2B-10)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Fork Components” (Page 2B-1)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K12208001
Material SUZUKI recommended product or Specification Note
Fork oil SUZUKI FORK OIL SS-47 P/No.: 99000–99001– (Page 2B-7) / (Page 2B-
47S 8) / (Page 2B-9) / (Page
2B-9) / (Page 2B-9) /
(Page 2B-10) / (Page
2B-11)

NOTE
Required service material(s) is also described in:
“Front Fork Components” (Page 2B-1)

Special Tool
BENH17K12208002
09940–52861 09940–84711
Front fork oil seal installer Rod guide case wrench
set
1. Hammer (09941-53610) (Page 2B-5) /
2. Attachment (09940- (Page 2B-9) /
52870) 3. Attachment (Page 2B-10)
(09940-52880)
(Page 2B-8)
09941–53671 09943–74111
Front fork cap socket Front fork oil level gauge
wrench (45 mm)
(Page 2B-3) / (Page 2B-10)
(Page 2B-4) /
(Page 2B-5) /
(Page 2B-6) /
(Page 2B-9) /
(Page 2B-11)
2C-1 Rear Suspension:

Rear Suspension
Suspension

Repair Instructions
Rear Suspension Components
BENH17K12306001

8 (d)

7 (e)
13
10

12

13

2 (a)

1
11

14

9 (c)
5
6 (b)
5

4 (b)
3

2 (a)

4 (b)
IH17K1230001-01

1. Rear shock absorber 9. Swingarm pivot nut : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
2. Rear shock absorber mounting nut 10. Swingarm : 15 Nm (1.5 kgf-m, 11.0 lbf-ft)
3. Cushion rod 11. Chain case : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
4. Cushion rod mounting nut 12. Plate : Apply grease to the bearing.
5. Cushion lever 13. Chain adjuster : Apply thread lock to the thread part.
6. Cushion lever mounting nut 14. Chain buffer : Do not reuse.
7. Swingarm pivot lock-nut : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
8. Swingarm pivot shaft : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
 Rear Suspension: 2C-2

Rear Suspension Assembly Construction

BENH17K12306002

LH RH

1 (a)

2 (a)

“a” “a”

5 (b)

2
3
“b” “b” 4

4 (b)

8 (e)
“a” “a”

6 (c)
7 (d)

“c” “c”

3 (b)

“a” “a”
IH17K1230002-01

1. Rear shock absorber upper mounting nut 7. Swingarm pivot shaft : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
2. Rear shock absorber lower mounting nut 8. Swingarm pivot lock-nut : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
3. Cushion rod (front) mounting nut “a”: 0.5 mm (0.02 in) : 15 Nm (1.5 kgf-m, 11.0 lbf-ft)
4. Cushion rod (rear) mounting nut “b”: 1.5 mm (0.059 in) : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
5. Cushion lever mounting nut “c”: 0 – 0.5 mm (0 – 0.019 in) : Apply grease.
6. Swingarm pivot nut : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
2C-3 Rear Suspension:

Rear Suspension On-Vehicle Inspection Spring Pre-load Adjustment

BENH17K12306003
Inspect the rear shock absorber (1) for oil leakage and • The set length 173.3 mm (6.823 in) provides the
check that there is no play in the swingarm (2). maximum spring pre-load.
Replace any defective parts, if necessary. • The set length 183.3 mm (7.217 in) provides the
• Rear shock absorber replace: (Page 2C-4) minimum spring pre-load.
• Swingarm pivot shaft and bearing inspection: (Page Rear shock absorber spring pre-set length
2C-12) [Standard]: 179.1 mm (7.051 in)
• Cushion lever inspection: (Page 2C-8)
• Cushion rod inspection: (Page 2C-8)
• Swingarm inspection: (Page 2C-12)

1
IH17K1230005-01

Damping Force Adjustment

IH17K1230003-01 NOTE
• Turn the adjuster clockwise to stiffen the
damping force and turn it
counterclockwise to soften the damping
force.
• Fine-tuning can be made by turning the
adjusters slightly.

Rebound side
2 Fully turn the rebound damping force adjuster (1)
clockwise. From that position (stiffest), turn it
counterclockwise to standard setting position.
IH17K1230004-01
Rear shock absorber damping force adjuster
Rebound side
Rear Shock Absorber Adjustment [Standard]: 2-3/4 turns counterclockwise from
BENH17K12306004
NOTICE stiffest position
When the dirty rear shock absorber is
adjusted as it is, an oil leakage might occur
due to adjuster firmly fixing or seal damage.
Before adjustment, wash the dirt completely
off from the rear shock absorber.
1

IH17K1230006-01
 Rear Suspension: 2C-4

Compression side (Low speed) 3) Remove the rear brake reservoir tank mounting bolt
Fully turn the compression damping force (Low speed) (1).
adjuster (1) clockwise. From that position (stiffest), turn it
counterclockwise to standard setting position.
Rear shock absorber damping force adjuster
Compression side (Low speed)
[Standard]: 1-3/4 turns counterclockwise from
stiffest position

IH17K1230009-02

1 4) Remove the rear shock absorber lower mounting

bolt and nut (1).

IH17K1230007-01

Compression side (High speed)

Fully turn the compression damping force (High speed)
adjuster (1) clockwise. From that position (stiffest), turn it
counterclockwise to standard setting position.
1
Rear shock absorber damping force adjuster
Compression side (High speed)
IH17K1230010-01
[Standard]: 2-3/4 turns counterclockwise from
stiffest position 5) Remove the rear shock absorber upper mounting
bolt and nut (1).

IH17K1230008-01
IH17K1230011-01

Rear Shock Absorber Removal and Installation 6) Remove the rear shock absorber (1) upward.
BENH17K12306005

Removal
1) Remove the side cowlings. (Page 9D-21)
2) Support the motorcycle with a jack to relieve load on
the rear shock absorber. 1

IH17K1230012-01
2C-5 Rear Suspension:

7) Remove the spacer (1) from the rear shock • After the stopper (1) of rear brake reservoir tank
absorber. bracket has contacted the seat rail, tighten the bolt
(2).

1
1
IH17K1230013-01

IH17K1230016-03
Installation
Install the rear shock absorber in the reverse order of Rear Shock Absorber Inspection
removal. Pay attention to the following points: BENH17K12306006
Refer to “Rear Shock Absorber Removal and
• Tighten the new rear shock absorber mounting nuts to
Installation” (Page 2C-4).
the specified torque.
Tightening torque Rear Shock Absorber
Rear shock absorber mounting nut (a): 50 N·m ( Inspect the rear shock absorber for damage and oil
5.1 kgf-m, 37.0 lbf-ft) leakage, and absorber bushing for wear and damage. If
any defect is found, replace the rear shock absorber with
a new one.

NOTICE
Do not attempt to disassemble the rear shock
absorber. It is unserviceable.

(a)

IH17K1230014-01

(a)

IH17K1230017-01

IH17K1230015-01
 Rear Suspension: 2C-6

Spacer Installation
Inspect the spacer for any flaws or other damage. If any 1) Apply a small quantity of the grease to housing when
defect is found, replace the spacer with a new one. installing the bearing.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
2) Press the new bearing into the rear shock absorber
to the depth “a” of 0.5 mm (0.02 in) from the edge
with the special tool and suitable size socket wrench.
Special tool
(A): 09924–84521

IE31J1230012-01
(A )

Rear Shock Absorber Bearing

1) Insert the spacer into bearing.
2) Check the play by moving the spacer up and down. If
excessive play is noted, replace the bearing with a
new one. (Page 2C-6)

IH17K1230020-01

“A”

IH17K1230018-01

Rear Shock Absorber Bearing Removal and

“a” “a”
Installation IF04K1230019-02
BENH17K12306007
Refer to “Rear Shock Absorber Removal and 3) Apply grease to the bearing and dust seals.
Installation” (Page 2C-4). “A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
Removal
1) Remove the rear shock absorber bearing (1) with the
special tool.
Special tool
(A): 09943–88211

(A)
“A ”

IH17K1230021-01
1

IH17K1230019-01
2C-7 Rear Suspension:

Rear Shock Absorber Disposal Cushion Lever Removal and Installation

BENH17K12306008 BENH17K12306009
Refer to “Rear Shock Absorber Removal and
Installation” (Page 2C-4). Removal
The rear shock absorber unit contains high-pressure 1) Remove the side cowlings. (Page 9D-21)
nitrogen gas.
2) Support the motorcycle with a jack to relieve load on
! WARNING the cushion levers.
3) Remove the cushion levers (1) and washers.
• Mishandling the rear shock absorber can
cause explosion.
• Keep away from fire and heat. High gas
pressure caused by heat can cause an
explosion.
• Never apply heat or disassemble the
damper unit since it can explode or oil can
splash hazardously. 1
• Release gas pressure before disposing.

Gas Pressure Release

IH17K1230024-01
1) Wrap rear shock absorber (1) with a plastic bag (2)
and fix it on a vise. Installation
2) Make a hole to the rubber part into the reservoir tank Install the cushion lever in the reverse order of removal.
cap hole (3) with a needle (4). Pay attention to the following points:
• Install the washers (1) between the cushion rod and
! WARNING
cushion levers.
• When making a hole, oil may spring out. • Set the cushion levers (2) so that the arrow mark (3)
Be sure to wear protective goggles or the points forward.
like to protect your eyes. • Tighten each new nuts to the specified torque.
• Do not bring your face close to the hole Tightening torque
position to avoid the oil from splashing to Cushion lever mounting nut (a): 80 N·m (8.2 kgf-
your face or mouth. m, 59.0 lbf-ft)
Cushion rod mounting nut (b): 80 N·m (8.2 kgf-
m, 59.0 lbf-ft)
4 Rear shock absorber lower mounting nut (c): 50
N·m (5.1 kgf-m, 37.0 lbf-ft)
1

3 (a)

2
2

IH17K1230022-01

(c) 1
(b)
IH17K1230025-01

IH17K1230023-01
 Rear Suspension: 2C-8

Cushion Lever Inspection Installation

BENH17K12306010 Install the cushion rod in the reverse order of removal.
Refer to “Cushion Lever Removal and Installation” (Page
Pay attention to the following points:
2C-7).
• Insert the spacer (1) into the bearing from the left side.
Cushion Lever
Inspect the cushion levers for damage and bend. If any
defects are found, replace the cushion levers with new
ones.

IH17K1230029-01

• Tighten the new nut to the specified torque.

Tightening torque
Cushion rod mounting nut (a): 80 N·m (8.2 kgf-m,
IH17K1230026-01
59.0 lbf-ft)

Cushion Rod Removal and Installation

BENH17K12306011

Removal
1) Remove the cushion levers. (Page 2C-7)
2) Remove the cushion rod (1).

(a)

IH17K1230030-01

Cushion Rod Inspection

BENH17K12306012
Refer to “Cushion Rod Removal and Installation” (Page
1 2C-8).

IH17K1230027-01 Spacer
3) Remove the spacers (1). Inspect the spacers for any flaws or other damage. If any
defects are found, replace it with a new one.

IH17K1230028-01
IE31J1230029-01
2C-9 Rear Suspension:

Cushion Rod Bearing Installation

1) Insert the spacers into bearings. 1) Apply a small quantity of the grease to housing.
2) Check the play by moving the spacers up and down. “A”: Grease 99000–25011 (SUZUKI SUPER
If excessive play is noted, replace the bearing with a GREASE A)
new one. (Page 2C-9)
2) Press the new bearings into the cushion rod to the
depth “a” of 0.5 mm (0.02 in) from the edge with the
special tool and suitable size socket wrench.
Special tool
(A): 09924–84521

I947H1230026-02 (A )

Cushion Rod
Inspect the cushion rod for damage. If any defect is
found, replace the cushion rod with a new one.
IH17K1230032-01

“A”

“a” “a”

I947H1230027-01

Cushion Rod Bearing Removal and Installation

BENH17K12306013
Refer to “Cushion Rod Removal and Installation” (Page “A”
2C-8).

Removal
1) Remove the cushion rod bearings (1) with the
special tool.
Special tool
(A): 09921–20240 “a” “a”
IF04K1230031-04

(A)

IH17K1230031-01
 Rear Suspension: 2C-10

3) Apply grease to the bearings and dust seals. 7) Remove the rear shock absorber (1). (Page 2C-4)
“A”: Grease 99000–25011 (SUZUKI SUPER 8) Remove the cushion lever mounting bolt and nut (2).
GREASE A)

1 2

“A” “A”

IH17K1230036-01

IH17K1230033-02 9) Remove the swingarm pivot shaft lock-nut (1) with

the special tool.
Swingarm Removal and Installation Special tool
BENH17K12306014
(A): 09940–14940
Removal
1) Cut the drive chain. Refer to “Drive Chain
Replacement” in Section 3A (Page 3A-7). 1
2) Remove the rear wheel assembly. (Page 2D-9)
3) Set the rear brake caliper assembly to the swingarm (A)
temporarily.
4) Remove the brake pads. (Page 4C-2)
5) Remove the rear brake caliper (1) and caliper
bracket (2).

IH17K1230037-01

10) Hold the swingarm pivot shaft (1) with the special
tool and remove the swingarm pivot nut (2).
Special tool
(A): 09944–28321
1

2 1
2
(A)
IH17K1230034-01

6) Remove the rear brake hose guides (1).

IH17K1230038-01

1 1

IH17K1230035-01
2C-11 Rear Suspension:

11) Remove the swingarm assembly by removing the 15) Remove the left and right drive chain adjuster bolts
swingarm pivot shaft (1) with the special tool. and nuts.
Special tool
Installation
(A): 09944–28321
Install the swingarm in the reverse order of removal. Pay
attention to the following points:
1 • Apply thread lock to the screw.
“A”: Thread lock cement 99000–32150 (THREAD
(A) LOCK CEMENT 1322D)

“A”

IH17K1230039-01

12) Remove the chain case (1) and chain buffer (2) from
the swingarm.

1
IH17K1230043-01

• When installing the swingarm assembly (1), pass the

chain (2) to the swingarm.

2
1

IH17K1230040-01

13) Remove the spacers (1) from the swingarm.

IH17K1230044-01

• Insert the swingarm pivot shaft (1) and tighten it to the

specified torque.
Special tool
(A): 09944–28321
Tightening torque
1
Swingarm pivot shaft (a): 15 N·m (1.5 kgf-m, 11.0
IH17K1230041-01 lbf-ft)
14) Remove the plate (1).

(A )
1 1 , (a )

IH17K1230045-01

IH17K1230042-01
 Rear Suspension: 2C-12

• Hold the swingarm pivot shaft (1) with the special tool • Install the rear shock absorber (1). (Page 2C-4)
and tighten the new swingarm pivot nut (2) to the • Tighten the new cushion lever mounting nut (2) to the
specified torque. specified torque.
Special tool Tightening torque
(A): 09944–28321 Cushion lever mounting nut (a): 80 N·m (8.2 kgf-
Tightening torque m, 59.0 lbf-ft)
Swingarm pivot nut (a): 100 N·m (10.2 kgf-m, 74.0
lbf-ft)

1 2, (a)

2, (a)
1
(A)

IH17K1230048-01

• Install the rear brake hose guides. Refer to “Rear

IH17K1230046-01 Brake Hose Routing Diagram” in Section 4A (Page
• Tighten the swingarm pivot lock-nut (1) to the 4A-4).
specified torque with the special tool. • Install the rear brake caliper to the caliper bracket.
Refer to “Rear Brake Caliper Removal and
Special tool
Installation” in Section 4C (Page 4C-3).
(A): 09940–14940
• Connect the drive chain. Refer to “Drive Chain
Tightening torque Replacement” in Section 3A (Page 3A-7).
Swingarm pivot lock-nut (a): 90 N·m (9.2 kgf-m,
• Adjust the drive chain slack, after connecting it. Refer
66.5 lbf-ft)
to “Drive Chain Inspection and Adjustment” in Section
3A (Page 3A-2).

1, ( a) Swingarm Inspection
BENH17K12306015
Refer to “Swingarm Removal and Installation” (Page 2C-
10).
(A)
Spacers
Inspect the spacers for wear and damage. If any defects
are found, replace the spacers with new ones.

IH17K1230047-01

IE31J1230055-01
2C-13 Rear Suspension:

Chain Buffer Swingarm

Inspect the chain buffer for wear and damage. If any Inspect the swingarm for damage. If any defect is found,
defect is found, replace the chain buffer with a new one. replace the swingarm with a new one.

IH17K1230049-01 IH17K1230051-01

Plate Swingarm Pivot Shaft

Inspect the plate for damage and excessive bend. If any Using a dial gauge, check the swingarm pivot shaft
defect is found, replace the plate with a new one. runout. If the runout exceeds the service limit, replace
the pivot shaft.
Swingarm pivot shaft runout
Service limit: 0.3 mm (0.011 in)
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09900–21304

IF04K1230048-01

Swingarm Bearing
1) Insert the spacers into bearings.
2) Check the play by moving the spacers up and down.
If excessive play is noted, replace the bearings with
new ones. (Page 2C-14)
IE31J1230060-01

IH17K1230050-01
 Rear Suspension: 2C-14

Swingarm Bearing Removal and Installation Installation

BENH17K12306016
Refer to “Swingarm Removal and Installation” (Page 2C- 1) Apply a small quantity of the grease to housing when
10). installing the bearing.
“A”: Grease 99000–25011 (SUZUKI SUPER
Removal GREASE A)
1) Remove the swingarm pivot bearings (1) on both 2) Press the new cushion lever bearing into the
sides using the special tool. swingarm to the depth “a” of 1.5 mm (0.059 in) from
Special tool the edge with the special tool and suitable size
(A): 09921–20240 socket wrench.
Special tool
(A): 09924–84521
( A)

( A)

IH17K1230052-01

2) Remove the center spacer (1).

IH17K1230055-01

“A”

IH17K1230053-01

3) Remove the cushion lever bearing (1) using the

special tool.
Special tool
“a” “a”
(A): 09921–20240 IF04K1230055-01

3) Install the center spacer.

(A)

1
IH17K1230054-01
2C-15 Rear Suspension:

4) Apply a small quantity of the grease to housing,

when installing the bearings. “A”

NOTE
The stamped mark side of the pivot bearing
faces outside.

“A”: Grease 99000–25011 (SUZUKI SUPER

GREASE A)
“a” “a”
IF04K1230057-01
5) Press the new pivot bearings into the swingarm to
the depth “a” of 0 – 0.5 mm (0 – 0.019 in) from the 6) Apply grease to the bearings and dust seals.
edge with the special tool and suitable size socket. “A”: Grease 99000–25011 (SUZUKI SUPER
Special tool GREASE A)
(A): 09941–34513

(A)

“A”
IH17K1230057-01

IH17K1230056-01

Specifications
Tightening Torque Specifications
BENH17K12307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber mounting nut 50 5.1 37.0 (Page 2C-5)
Cushion lever mounting nut (Page 2C-7) /
80 8.2 59.0
(Page 2C-12)
Cushion rod mounting nut (Page 2C-7) /
80 8.2 59.0
(Page 2C-8)
Rear shock absorber lower mounting nut 50 5.1 37.0 (Page 2C-7)
Swingarm pivot shaft 15 1.5 11.0 (Page 2C-11)
Swingarm pivot nut 100 10.2 74.0 (Page 2C-12)
Swingarm pivot lock-nut 90 9.2 66.5 (Page 2C-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Suspension Components” (Page 2C-1)
“Rear Suspension Assembly Construction” (Page 2C-2)
“Fasteners Information” in Section 0C (Page 0C-12)
 Rear Suspension: 2C-16

Special Tools and Equipment

Recommended Service Material
BENH17K12308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 2C-6) / (Page 2C-
6) / (Page 2C-9) / (Page
2C-10) / (Page 2C-14) /
(Page 2C-15) / (Page
2C-15)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 2C-11)

NOTE
Required service material(s) is also described in:
“Rear Suspension Components” (Page 2C-1)
“Rear Suspension Assembly Construction” (Page 2C-2)

Special Tool
BENH17K12308002
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 2C-13) (Page 2C-13)

09900–21304 09921–20240
V blocks Bearing remover set
(Page 2C-13) (Page 2C-9) /
(Page 2C-14) /
(Page 2C-14)

09924–84521 09940–14940
Bearing installer set Swingarm pivot adjuster
wrench
(Page 2C-6) / (Page 2C-10) /
(Page 2C-9) / (Page 2C-12)
(Page 2C-14)

09941–34513 09943–88211
Bearing installer set Pinion bearing installer
(Page 2C-15) (Page 2C-6)

09944–28321
Hexagon bit socket (19 mm :
1/2 sq.)
(Page 2C-10) /
(Page 2C-11) /
(Page 2C-11) /
(Page 2C-12)
2D-1 Wheels and Tires:

Wheels and Tires

Suspension

Precautions
Precautions for Wheel and Tire
BENH17K12400001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING

• Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion,
crack, nick or scratch.
• When tire replacement is necessary, the original equipment type tire should be used.
• Replacement wheel must be equivalent to the original equivalent wheel.
 Wheels and Tires: 2D-2

Repair Instructions
Front Wheel Components
BENH17K12406001

12 (a)

11
3

2 (b) 5

10
9

4 2 (b)

7 8
13 1

IH17K1240001-02

1. Front axle 6. Dust seal 11. Front wheel speed sensor rotor : Apply grease.
2. Brake disc bolt 7. Front wheel 12. Front axle nut : Apply thread lock to the thread part.
3. Brake disc 8. Air valve 13. Wheel tape : Do not reuse.
4. Bearing 9. Wheel balancer : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
5. Spacer 10. Front tire : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
2D-3 Wheels and Tires:

Front Wheel Assembly Construction

BENH17K12406002

LH RH

2 (a)

3 (b)

4 (c) “a” 4 (c)

5

1 (d)
1 (d)
“b”

IH17K1240003-01

1. Brake disc bolt “a”: Clearance : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
2. Brake caliper mounting bolt “b”: 0.33 – 1.55 mm (0.013 – 0.061 in) : Apply grease.
3. Front axle nut : 42 Nm (4.3 kgf-m, 31.0 lbf-ft) : Apply thread lock to the thread part.
4. Front axle pinch bolt : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
5. Front wheel speed sensor : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
 Wheels and Tires: 2D-4

Front Wheel Assembly Removal and Installation 9) Remove the spacer (1).
BENH17K12406003

Removal
1) Remove the front wheel speed sensor (1).
2) Disconnect the front wheel speed sensor lead wire
from the clamp (2). 1
3) Remove the front brake calipers (3).

2
IH17K1240007-03

Installation
1) Install the spacer (1) into the right side of the wheel.

3
1 3
IH17K1240004-02

4) Remove the front axle nut (1).

1
5) Loosen the two axle pinch bolts (2) on the right front
fork leg.

IH17K1240007-03

2) Install the front wheel with the front axle and tighten
the front axle nut temporarily.
2
! WARNING
The directional arrow on the tire should point
to the wheel rotation, when installing the
IH17K1240005-02 wheel.
6) Raise the front wheel off the ground and support the
motorcycle with a jack or a wooden block.
7) Loosen two axle pinch bolts (1) on the left front fork
leg.
8) Draw out the front axle (2) and remove the front
wheel.

IH17K1240008-01

2 3) Remove a jack or a wooden block.

4) Install the front brake calipers and tighten the front
caliper mounting bolts to the specified torque. Refer
to “Front Brake Caliper Removal and Installation” in
IH17K1240006-01 Section 4B (Page 4B-3).
2D-5 Wheels and Tires:

5) Hold the front axle with the special tool and tighten Front Wheel Dust Seal / Front Wheel Bearing
the front axle nut (1) to the specified torque. Removal and Installation
BENH17K12406004
Special tool Refer to “Front Wheel Assembly Removal and
(A): 09900–18740 Installation” (Page 2D-4).
Tightening torque
Front axle nut (a): 100 N·m (10.2 kgf-m, 74.0 lbf- Removal
ft) 1) Remove the front wheel speed sensor rotor. (Page
4E-49)
6) Tighten the two axle pinch bolts (2) on the right front
fork leg to the specified torque. 2) Remove the dust seals (1) on both sides with the
special tool.
Tightening torque
Front axle pinch bolt (b): 23 N·m (2.3 kgf-m, 17.0 Special tool
lbf-ft) (A): 09913–50121

(A)

1, (a) (A)

1
2, (b)

IH17K1240013-01
IH17K1240010-01

7) Move the front fork up and down 4 or 5 times to 3) Remove the bearings (1) on both sides with the
stabilize the front axle. special tool.
Special tool
(A): 09921–20240

(A)

IH17K1240011-01
1
8) Tighten the two axle pinch bolts (1) on the left front
fork leg to the specified torque. IH17K1240014-01

Tightening torque 4) Remove the spacer (1).

Front axle pinch bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)

1
1, ( a)

IH17K1240015-01

IH17K1240012-01

9) Install the front wheel speed sensor. (Page 4E-49)

 Wheels and Tires: 2D-6

Installation
1) Apply grease to the new wheel bearings. LH RH

Grease 99000–25011 (SUZUKI SUPER GREASE

A) (B)

(A)
(A)

“a”
I649G1240019-02
(B)
2) First install the right wheel bearing, then install the
spacer (1) and left wheel bearing with the special
tools.

NOTICE
The sealed cover of the bearing must face (A) 1 (A)
outside.
IH17K1240016-01
Special tool “a”: Clearance
(A): 09924–84510
(B): 09941–34513 3) Install the new dust seals (1) on both sides with the
special tool.
(B) Special tool
(A): 09913–70210

(A)

(A)

IH17K1240022-01
1

IH17K1240017-01

4) Apply grease to the lip of the dust seals.

“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A”

IH17K1240018-04
2D-7 Wheels and Tires:

5) Install the front wheel speed sensor rotor. (Page

4E-49)

Rear Wheel Components

BENH17K12406005

16 (a)

17

3 4
15 (c)
5

18 (d)
13

10
5
3
8
9

6
12
11
14 (b)
3
7

1
19 5
4

IH17K1240019-02

1. Rear axle 10. Rear wheel 19. Wheel tape

2. Brake disc 11. Rear tire : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
3. Spacer 12. Air valve : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
4. Dust seal 13. Wheel balancer : 100 Nm (10.2 kgf-m, 74.0 lbf-ft)
5. Bearing 14. Rear sprocket nut : 6.3 Nm (0.64 kgf-m, 4.65 lbf-ft)
6. Rear wheel damper 15. Rear axle nut : Apply grease.
7. Retainer 16. Brake disc bolt : Apply thread lock to the thread part.
8. Rear sprocket mounting drum 17. Wheel speed sensor rotor : Do not reuse.
9. Rear sprocket 18. Wheel speed sensor rotor bolt
 Wheels and Tires: 2D-8

Rear Wheel Assembly Construction

BENH17K12406006

LH RH

1 (a)
3 (c)
(c)

“b”
6
4 (d) 4 (d)

5 (e)

2 (b)

“a”

IH17K1240020-01

1. Rear sprocket nut “a”: Clearance : 6.3 Nm (0.64 kgf-m, 4.65 lbf-ft)
2. Rear axle nut “b”: 0.98 – 1.70 mm (0.039 – 0.066 in) : Apply grease.
3. Brake disc bolt : 60 Nm (6.1 kgf-m, 44.5 lbf-ft) : Apply thread lock to the thread part.
4. Chain adjuster lock-nut : 100 Nm (10.2 kgf-m, 74.0 lbf-ft) : Do not reuse.
5. Rear wheel speed sensor rotor : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
bolt
6. Rear wheel speed sensor : 22 Nm (2.2 kgf-m, 16.5 lbf-ft)
2D-9 Wheels and Tires:

Rear Wheel Assembly Removal and Installation 8) Remove the rear brake caliper (1) from the
BENH17K12406007 swingarm.
Removal 9) Remove the rear wheel.
1) Remove the rear wheel speed sensor (1).
2) Loosen the rear axle nut (2). 1

IH17K1240025-01
1
10) Remove the left and right spacers (1).

IH17K1240021-03

3) Raise the rear wheel off the ground and support the
motorcycle with a jack or wooden block.
4) Loosen the left and right chain adjuster lock-nuts (1)
and turn in the chain adjuster bolts (2).
5) Remove the rear axle nut (3) and washer (4).

1 1
3
2 1 1 2
IH17K1240026-01

Installation
1) Install the left and right spacers (1).

IH17K1240023-01

6) Draw out the rear axle.

7) Remove the drive chain (1) from the rear sprocket.

1
1 1

IH17K1240026-01

2) Install the rear wheel.

3) Install the rear brake caliper to the swingarm.
4) Install the drive chain to the rear sprocket.

IH17K1240024-01
 Wheels and Tires: 2D-10

5) Install the left chain adjuster (1) and right chain

adjuster (2) to the swingarm.
(A)
NOTE
Right and left shape is different.

1 2
1

IH17K1240028-01

4) Remove the bearings (1) on both sides with the

special tool.
Special tool
(A): 09921–20240
IF04K1240024-01

6) Install the rear axle (1) and washer (2). (A) (A)
7) Tighten the new rear axle nut (3) temporarily.

1 3

1
1
IH17K1240029-01

2 5) Remove the spacer (1).

IH17K1240027-01
1
8) Remove the jack or a wooden block.
9) Adjust the chain slack. Refer to “Drive Chain
Inspection and Adjustment” in Section 3A (Page 3A-
2).
10) Install the rear wheel speed sensor. (Page 4E-49)

Rear Wheel Dust Seal / Rear Wheel Bearing

Removal and Installation
BENH17K12406008
IH17K1240030-01
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” in Section 3A (Page 3A-5). Installation
Removal 1) Apply grease to the new wheel bearings.
1) Remove the rear wheel dampers. (Page 2D-13) Grease 99000–25011 (SUZUKI SUPER GREASE
2) Remove the rear wheel speed sensor rotor. (Page A)
4E-50)
3) Remove the dust seal (1) with the special tool.
Special tool
(A): 09913–50121

I649G1240019-02
2D-11 Wheels and Tires:

2) First install the right wheel bearing, then install the

spacer (1) and left wheel bearing with the special
tools.
(A )
NOTICE
The sealed cover of the bearing must face
outside.

Special tool
(A): 09941–34513
(B): 09924–84510 1

IH17K1240033-01

(A) (A) 4) Apply grease to the dust seal lip.

“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A”

(B) (B)

IH17K1240031-01

LH RH

(A) IH17K1240034-01

5) Install the rear wheel speed sensor rotor. (Page

4E-50)
6) Install the rear wheel dampers. (Page 2D-13)

(B) Wheel / Wheel Axle Inspection

(B) BENH17K12406009
Refer to “Front Wheel Assembly Removal and
Installation” (Page 2D-4).
Refer to “Rear Wheel Assembly Removal and
“a”
Installation” (Page 2D-9).

Wheel
(A)
1) Remove the brake pads.
• Front: (Page 4B-2)
• Rear: (Page 4C-2)
2) Make sure that the wheel runout checked as shown
(B) (B) does not exceed the service limit. An excessive
1
runout is usually due to worn or loosened wheel
IH17K1240032-02 bearings and can be reduced by replacing the
“a”: Clearance
bearings.
• Front: (Page 2D-5)
3) Install a new dust seal (1) with the special tool. • Rear: (Page 2D-10)
Special tool If bearing replacement fails to reduce the runout,
(A): 09913–70210 replace the wheel.
Wheel rim runout
Front
Axial & Radial [Limit]: 2.0 mm (0.08 in)
Rear
Axial & Radial [Limit]: 2.0 mm (0.08 in)
 Wheels and Tires: 2D-12

Special tool
(A): 09900–20607 1

(A)

IH17K1240035-01

ID26J1240033-01
Wheel Bearing
3) Install the brake pads.
1) Remove the rear sprocket mounting drum assembly.
• Front: (Page 4B-2) (Page 3A-5)
• Rear: (Page 4C-2) 2) Inspect the play of the wheel bearings by hand while
they are in the wheel. Rotate the inner race by hand
Wheel Axle to inspect for abnormal noise and smooth rotation.
Using a dial gauge, check the wheel axle for runout, If Replace the bearing if there is anything unusual.
the runout exceeds the limit, replace the wheel axle.
• Front: (Page 2D-5)
Wheel axle runout • Rear: (Page 2D-10)
Front & Rear [Limit]: 0.25 mm (0.010 in)
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09900–21304

I649G1240015-02
(A)
(B) 3) Install the rear sprocket mounting drum assembly.
(Page 3A-5)

Brake Disc
Refer to “Front Brake Disc Inspection” in Section 4B
(Page 4B-7).
Refer to “Rear Brake Disc Inspection” in Section 4C
(C)
(Page 4C-9).
ID26J1240034-03

Dust Seal Wheel Speed Sensor Rotor

Inspect the dust seals lip (1) for wear or damage. If any Refer to “Wheel Speed Sensor and Sensor Rotor
defects are found, replace the dust seals with new ones. Inspection” in Section 4E (Page 4E-50).
• Front: (Page 2D-5)
Rear Sprocket
• Rear: (Page 2D-10) Refer to “Rear Sprocket Mounting Drum / Sprocket
Inspection” in Section 3A (Page 3A-6).
1

IH17K1240038-02
2D-13 Wheels and Tires:

Rear Wheel Damper Removal and Installation

BENH17K12406010
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” in Section 3A (Page 3A-5).

Removal
Remove the rear wheel dampers (1).

I649G1240042-02

1
Tire Tread Condition
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a
1
dangerous situation. It is highly recommended to replace
a tire when the remaining depth of tire tread reaches the
following specification.
Tire tread depth
IH17K1240036-01 Recommend depth
Front [Standard]: 1.6 mm (0.062 in)
Installation Rear [Standard]: 2.0 mm (0.078 in)
Install the rear wheel dampers in the reverse order of
Special tool
removal.
09900–20805

Rear Wheel Damper Inspection

BENH17K12406011
Inspect the rear wheel dampers for wear and damage.
Replace the damper if there is anything unusual.

I310G1020068-02

Tire Pressure
If the tire pressure is too high or too low, steering will be
adversely affected and tire wear increased. Therefore,
maintain the correct tire pressure for good roadability or
IF04K1240035-01
shorter tire life will result. Cold inflation tire pressure is as
follows.
Tire Inspection and Cleaning
BENH17K12406012 Cold inflation tire pressure
Wipe the tire clean and check for the following points: Solo riding
• Nick and rupture on side wall Front [Standard]: 250 kPa (2.50 kgf/cm2, 36 psi)
• Tread separation Rear [Standard]: 290 kPa (2.90 kgf/cm2, 42 psi)
Dual riding
• Abnormal, uneven wear on tread
Front [Standard]: 250 kPa (2.50 kgf/cm2, 36 psi)
• Surface damage on bead Rear [Standard]: 290 kPa (2.90 kgf/cm2, 42 psi)
• Localized tread wear due to skidding (Flat spot)
• Abnormal condition of inner liner
Tire size
Front [Standard]: 120/70ZR17M/C (58W)
Rear [Standard]: 190/55ZR17M/C (75W)
Tire type
Front [Standard]: BRIDGESTONE/RS10F E
Rear [Standard]: BRIDGESTONE/RS10R E

I310G1020069-02
 Wheels and Tires: 2D-14

Tire Removal and Installation 2) Install the tire aligning the arrow (1) on the side wall
BENH17K12406013 with the direction of the wheel rotation.
Refer to “Front Wheel Assembly Removal and
Installation” (Page 2D-4). NOTICE
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” in Section 3A (Page 3A-5). • When installing the front tire, align the
rotation direction of the tire with the
Removal rotation indication arrow (2) on the front
wheel.
! CAUTION • When installing a repaired tire, align the
For removal and installation procedure of chalk mark put on the tire at the time of
tire, follow the instructions given by the tire removal with the valve position.
changer manufacturer. • When installing a new tire, align the light
point mark (3) on the tire side wall with the
NOTE valve position.
When removing the tire in case of repair or
inspection, mark the tire with a chalk to
indicate the tire position relative to the valve
position.

IH17K1240039-01

IE31J1240036-01

1. Chalk mark

Installation
1) Apply tire lubricant to the tire bead. 3
1
IH17K1240040-01
NOTICE
3) Bounce the tire several times while rotating. This
• Do not use oil, grease or gasoline in place makes the tire bead expand outward to contact the
of tire bead lubricant. wheel, thereby facilitating air inflation.
• Do not reuse the air valve which has been 4) Inflate the tire.
once removed.
! WARNING

• Do not stand over a tire being inflated. Tire

bead may break when the bead snaps over
rim’s safety hump and cause serious
personal injury.
• Do not inflate tires exceeding 400 kPa (4.0
kgf/cm2, 57 psi). Over-inflation may cause
the bead to break, which may cause
serious personal injury.

I649G1240038-02
2D-15 Wheels and Tires:

5) Check the “rim line” (1) cast on the tire side walls. Air Valve
The line must be equidistant from the wheel rim all Inspect the air valve (1) for peeling and damage. If any
around. If the distance between the rim line (1) and defect is found, replace the air valve with a new one.
wheel rim varies, this indicates that the bead is not
properly seated. If this is the case, deflate the tire
completely and unseat the bead for both sides. Coat
the bead with lubricant and fit the tire again.

IE31J1240038-01

Inspect the valve core seal (1) for wear and damage. If
IE31J1240037-01
any defect is found, replace the valve core with a new
one.
6) When the bead has been fitted properly, install the
valve core and adjust the pressure to specification.
(Page 2D-13)
7) As necessary, adjust the tire balance. (Page 2D-
16)

Wheel Rim / Air Valve Inspection and Cleaning IE31J1240039-01

BENH17K12406014
Refer to “Tire Removal and Installation” (Page 2D-14).
Refer to “Air Valve Removal and Installation” (Page 2D- Air Valve Removal and Installation
BENH17K12406015
15).
Refer to “Tire Removal and Installation” (Page 2D-14).
Wheel Rim
Removal
Wipe the wheel clean and check for the following points:
1) Remove the air valve (1) from the wheel.
• Distortion and crack.
• Any flaws and scratches at the bead seating area.
• Wheel rim runout. (Page 2D-11)
Wheel rim size
Front [Standard]: 17 M/C x MT 3.50
Rear [Standard]: 17 M/C x MT 6.00

IE31J1240040-01

Installation
1) Clean off the dirt around the valve hole (1).

I649G1240041-02

IE31J1240041-01
 Wheels and Tires: 2D-16

2) Install the new air valve (1) into the air valve hole 1) Check the wheel balance using the balancer and
with a special tire lubricant or neutral soapy liquid adjust the wheel balance if necessary.
applied at the valve lip (2).
NOTICE
NOTICE For operating procedures, refer to the
Be careful not to damage the valve lip of the instructions supplied by the wheel balancer
air valve. manufacturer.

2) When installing the new balancer weight (1) to the

wheel (2), set the balancer weight on center rib of
3
wheel.

2 1
1

ID26J1240049-02

3. Wheel

Wheel Balance Check and Adjustment 2

BENH17K12406016
Refer to “Front Wheel Assembly Removal and IH17K1240037-01
Installation” (Page 2D-4). 3) Recheck the wheel balance.
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” in Section 3A (Page 3A-5).

Specifications
Tightening Torque Specifications
BENH17K12407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front axle nut 100 10.2 74.0 (Page 2D-5)
Front axle pinch bolt (Page 2D-5) /
23 2.3 17.0
(Page 2D-5)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Wheel Components” (Page 2D-2)
“Front Wheel Assembly Construction” (Page 2D-3)
“Rear Wheel Components” (Page 2D-7)
“Rear Wheel Assembly Construction” (Page 2D-8)
“Fasteners Information” in Section 0C (Page 0C-12)
2D-17 Wheels and Tires:

Special Tools and Equipment

Recommended Service Material
BENH17K12408001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 2D-6) / (Page 2D-
6) / (Page 2D-10) /
(Page 2D-11)

NOTE
Required service material(s) is also described in:
“Front Wheel Components” (Page 2D-2)
“Front Wheel Assembly Construction” (Page 2D-3)
“Rear Wheel Components” (Page 2D-7)
“Rear Wheel Assembly Construction” (Page 2D-8)

Special Tool
BENH17K12408002
09900–18740 09900–20607
Hexagon bit socket (24 mm: Dial gauge (10 x 0.01 mm)
1/2 sq.)
(Page 2D-5) (Page 2D-12) /
(Page 2D-12)

09900–20701 09900–20805
Dial gauge chuck Tire depth gauge
(Page 2D-12) (Page 2D-13)

09900–21304 09913–50121
V blocks Oil seal remover
(Page 2D-12) (Page 2D-5) /
(Page 2D-10)

09913–70210 09921–20240
Bearing installer set Bearing remover set
(Page 2D-6) / (Page 2D-5) /
(Page 2D-11) (Page 2D-10)

09924–84510 09941–34513
Bearing installer set Bearing installer set
(Page 2D-6) / (Page 2D-6) /
(Page 2D-11) (Page 2D-11)
 Table of Contents 3- i

Section 3

Driveline / Axle
CONTENTS

Precautions .................................................3-1 Rear Sprocket Removal and Installation.............3A-5

Precautions............................................................. 3-1 Rear Sprocket Mounting Drum Assembly
Precautions for Driveline / Axle ............................. 3-1 Removal and Installation...................................3A-5
Rear Sprocket Mounting Drum / Sprocket
Drive Chain / Drive Train / Drive Shaft... 3A-1 Inspection..........................................................3A-6
Diagnostic Information and Procedures............3A-1 Rear Sprocket Mounting Drum Dust Seal / 3
Drive Chain and Sprocket Symptom Bearing Removal and Installation .....................3A-6
Diagnosis .......................................................... 3A-1 Drive Chain Replacement ...................................3A-7
Repair Instructions ..............................................3A-1 Specifications .....................................................3A-10
Drive Chain Related Components....................... 3A-1 Tightening Torque Specifications......................3A-10
Drive Chain Inspection and Adjustment .............. 3A-2 Special Tools and Equipment ...........................3A-11
Drive Chain Cleaning and Lubricating................. 3A-3 Recommended Service Material .......................3A-11
Engine Sprocket Removal and Installation ......... 3A-3 Special Tool ......................................................3A-11
3-1 Precautions:

Precautions
Driveline / Axle

Precautions
Precautions for Driveline / Axle
BENH17K13000001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING
Never inspect or adjust the drive chain while the engine is running.

NOTICE
• Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings
of the drive chain.
• Clean the drive chain with a spray-type chain cleaner and blow dry with compressed air. If the drive
chain cannot be cleaned with a spray cleaner, it may be necessary to use a kerosine. Always follow
the chemical manufacturer’s instructions on proper use, handling and storage.
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant.
Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.
• When drive chain replacement is necessary, the original equipment type drive chain should be used.
 Drive Chain / Drive Train / Drive Shaft: 3A-1

Drive Chain / Drive Train / Drive Shaft

Driveline / Axle

Diagnostic Information and Procedures

Drive Chain and Sprocket Symptom Diagnosis
BENH17K13104002

Condition Possible cause Correction / Reference Item

Noisy Drive Chain Worn sprocket. Replace. (Page 3A-3)
(Page 3A-5)
Worn drive chain. Replace. (Page 3A-7)
Stretched drive chain. Replace. (Page 3A-7)
Too large drive chain slack. Adjust. (Page 3A-2)
Drive chain out of adjustment. Adjust. (Page 3A-2)

Repair Instructions
Drive Chain Related Components
BENH17K13106001

8
7

6 (b)

5
1
9
4
10

3 (a)
2
IH17K1310001-01

1. Engine sprocket 6. Rear sprocket nut : 145 Nm (14.8 kgf-m, 107.0 lbf-ft)
2. Drive chain 7. Rear sprocket : 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
3. Engine sprocket nut 8. Rear sprocket mounting drum : Apply grease.
4. Dust seal 9. Wheel damper : Do not reuse.
5. Bearing 10. Retainer
3A-2 Drive Chain / Drive Train / Drive Shaft:

Drive Chain Inspection and Adjustment 6) After finishing the drive chain length inspection,
BENH17K13106002 adjust the drive chain slack.
Drive Chain Visual Check
1) With the transmission in neutral, support the Drive Chain Slack Adjustment
motorcycle with a jack and turn the rear wheel slowly 1) Place the motorcycle on the side-stand.
by hand.
2) Loosen the rear axle nut (1).
2) Visually check the drive chain for the possible
defects listed as follows. If any defects are found, the 3) Loosen the left and right chain adjuster lock-nuts (2).
drive chain must be replaced. (Page 3A-7) 4) Loosen or tighten both chain adjuster bolts (3) until
there is 20 – 30 mm (0.79 – 1.18 in) “a” of slack at
NOTE the middle of the chain between the engine and rear
When replacing the drive chain, replace the sprockets.
drive chain and sprockets as a set.
NOTICE
• Loose pins The reference marks (4) on both sides of the
• Damaged rollers swingarm and the edge of each chain
adjuster must be aligned to ensure that the
• Dry or rusted links
front and rear wheels are correctly aligned.
• Kinked or binding links
• Excessive wear Drive chain slack “a”
• Improper chain adjustment On side-stand
[Standard]: 20 – 30 mm (0.79 – 1.18 in)
• Missing O-ring seals

Drive Chain Length Inspection

1) Place the motorcycle on the side-stand.
1 3 2 2 3
2) Loosen the rear axle nut (1).
3) Loosen the left and right chain adjuster lock-nuts (2).
4) Give tension to the drive chain fully by turning both
chain adjuster bolts (3).

4 4
IH17K1310003-01
1 3 2 2 3

“a”
IH17K1310002-01 I649G1020036-02
5) Count out 21 pins (20 pitches) on the chain and 5) After adjusting the drive chain, tighten the rear axle
measure the distance between the two points. If the nut to the specified torque.
distance exceeds the service limit, the chain must be
replaced. (Page 3A-7) Tightening torque
Rear axle nut: 100 N·m (10.2 kgf-m, 74.0 lbf-ft)
Drive chain 20-pitch length
[Limit]: 319.4 mm (12.57 in) 6) Recheck the drive chain slack after tightening the
axle nut.
1 2 3 19 20 21 7) Tighten both chain adjuster lock-nuts to the specified
torque.
Tightening torque
Chain adjuster lock-nut: 22 N·m (2.2 kgf-m, 16.5
lbf-ft)

I649G1020034-02
 Drive Chain / Drive Train / Drive Shaft: 3A-3

Drive Chain Cleaning and Lubricating Engine Sprocket Removal and Installation
BENH17K13106003 BENH17K13106004
1) Place the motorcycle on the side-stand.
Removal
2) Remove dirt and dust from the drive chain (1). Be
careful not to damage the seal ring. 1) Remove the gearshift link arm (1).
3) Clean the drive chain (1) with a sealed drive chain
cleaner, or water and neutral detergent.
1
NOTICE
Cleaning the drive chain improperly can
damage seal rings and ruin the drive chain.
• Do not use a volatile solvent such as paint
thinner, kerosene and gasoline.
• Do not use high pressure cleaner to clean
the drive chain.
• Do not use wire brush to clean the drive IH17K1310005-01
chain. 2) Remove the engine sprocket cover (1).
4) Use a soft brush to clean the drive chain (1). Be
careful not to damage the seal ring even through
using a soft brush.
5) Wipe off water and neutral detergent.
6) Lubricate with a motorcycle sealed drive chain
lubricant or high viscosity oil.
1
NOTICE
Some drive chain lubricant contains solvents
and additives which could damage the seal
rings in the drive chain. IH17K1310006-01
Use sealed drive chain lubricant which is
3) Remove the engine sprocket nut (1) while
specifically intended for use with sealed
depressing the rear brake pedal.
drive chains.
4) Remove the washer (2).
7) Lubricate both front and back plates of the drive
chain (1).
1
8) Wipe off excess lubricant after lubricating all around
of the drive chain (1).
2

IH17K1310007-01

IH17K1310004-01
3A-4 Drive Chain / Drive Train / Drive Shaft:

5) Loosen the rear axle nut (1).

6) Support the motorcycle with a jack or wooden block.
1
7) Loosen the left and right chain adjuster lock-nuts (2)
and turn in the chain adjuster bolts (3) to provide
additional chain slack.
[a]

1 3 2 2 3

IH17K1310011-01

2) Tighten the new engine sprocket nut (1) to the

specified torque.
Tightening torque
Engine sprocket nut (a): 145 N·m (14.8 kgf-m,
107.0 lbf-ft)
IH17K1310008-01

8) Remove the engine sprocket (1).

1, (a)

IH17K1310012-01

3) Install the engine sprocket cover (1) and tighten the

IH17K1310009-01
bolts to the specified torque.
Installation Tightening torque
1) Install the engine sprocket (1) and washer (2). Engine sprocket cover bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)
NOTE
The concave side of the engine sprocket (1)
should face to the outside [a].

(a)
2 1

IH17K1310013-01

IH17K1310010-01
 Drive Chain / Drive Train / Drive Shaft: 3A-5

4) Install the gearshift link arm (1) to the gearshift shaft • Tighten the new rear sprocket nuts (1) to the specified
and tighten the bolt to the specified torque. torque.
Tightening torque NOTE
Gearshift link arm bolt (a): 12 N·m (1.2 kgf-m,
The stamped mark (2) on the sprocket should
9.0 lbf-ft)
face outside.
1
(a) Tightening torque
Rear sprocket nut (a): 60 N·m (6.1 kgf-m, 44.5 lbf-
ft)

“a”

1, (a)
1 , (a )

IH17K1310014-01
1 , (a )
“a”: 90°
IH17K1310016-01

5) Check the gearshift lever height. (Page 5B-18)

Rear Sprocket Mounting Drum Assembly
6) Adjust the drive chain slack. Refer to “Drive Chain
Removal and Installation
Inspection and Adjustment” (Page 3A-2). BENH17K13106006
Refer to “Rear Wheel Assembly Removal and
Rear Sprocket Removal and Installation Installation” in Section 2D (Page 2D-9).
BENH17K13106005
Refer to “Rear Wheel Assembly Removal and Removal
Installation” in Section 2D (Page 2D-9).
1) Remove the rear sprocket mounting drum assembly
(1).
Removal
1) Remove the rear sprocket (1).

IH17K1310017-01

2) Remove the retainer (1).

IH17K1310015-01

Installation
1
Install the rear sprocket in the reverse order of removal.
Pay attention to the following point:

IF04K1310015-01
3A-6 Drive Chain / Drive Train / Drive Shaft:

Installation Sprocket
Install the rear sprocket mounting drum assembly in the 1) Remove the engine sprocket cover. (Engine
reverse order of removal. Pay attention to the following sprocket only) (Page 3A-3)
point:
2) Inspect the sprocket teeth for wear. If they are worn
• Apply grease to the contacting surface between the as shown, replace the engine sprocket, rear
rear wheel hub and rear sprocket mounting drum. sprocket and drive chain as a set.
“A”: Grease 99000–25011 (SUZUKI SUPER • Engine: (Page 3A-3)
GREASE A) • Rear: (Page 3A-5)
• Drive chain: (Page 3A-7)
“A”

IE31J1310022-01

IH17K1310018-01 1. Normal wear 2. Excessive wear

Rear Sprocket Mounting Drum / Sprocket 3) Install the engine sprocket cover. (Engine sprocket
Inspection only) (Page 3A-3)
BENH17K13106007
Refer to “Rear Wheel Assembly Removal and Wheel Damper
Installation” in Section 2D (Page 2D-9). Refer to “Rear Wheel Damper Inspection” in Section 2D
(Page 2D-13).
Dust Seal
Inspect the sprocket mounting drum dust seal lip (1) for Drive Chain
wear or damage. If any damage is found, replace the Refer to “Drive Chain Inspection and Adjustment” (Page
dust seal with a new one. (Page 3A-6) 3A-2).

1
Rear Sprocket Mounting Drum Dust Seal /
Bearing Removal and Installation
BENH17K13106008
Refer to “Rear Sprocket Mounting Drum Assembly
Removal and Installation” (Page 3A-5).

Removal
1) Remove the dust seal (1) using the special tool.
Special tool
(A): 09913–50121
IH17K1310019-01

Bearing (A)
Inspect the play of the sprocket mounting drum bearing
by hand while they are in the drum. Rotate the inner race
by hand to inspect for abnormal noise and smooth
rotation. Replace the bearing if there is anything
unusual. (Page 3A-6)

IF04K1310018-01

I649G1310015-02
 Drive Chain / Drive Train / Drive Shaft: 3A-7

2) Remove the bearing (1) with the special tool. 3) Install a new dust seal (1) with the special tool.
Special tool Special tool
(A): 09921–20240 (A): 09913–70210

(A) (A)

1
1
IF04K1310019-01 IF04K1310021-01

4) Apply grease to the dust seal lip.

Installation
“A”: Grease 99000–25011 (SUZUKI SUPER
1) Apply grease to the new bearing.
GREASE A)
Grease 99000–25011 (SUZUKI SUPER GREASE
A)
“A”

IF04K1310022-01

I649G1310020-02

2) Install the bearing (1) with the special tool.

Drive Chain Replacement
BENH17K13106009
Use the special tool in the following procedure, to cut
NOTICE and rejoin the drive chain.
The sealed cover of the bearing must face
inside. NOTE
When using the special tool, apply a small
Special tool quantity of grease to the threaded parts of
(A): 09924–84510 the special tool.

Special tool
(A) 09922–22712

IF04K1310020-01

IF04K1310024-02
3A-8 Drive Chain / Drive Train / Drive Shaft:

Drive Chain Cutting 4) Place the drive chain link being disjointed on the
1) Set up the special tool. guide plate (1) of the tool.
5) Turn in both the adjuster bolt (2) and pressure bolt A
1 (3) so that each of their end hole fits over the chain
5 joint pin properly.
6 6) Tighten the pressure bolt A (3).
4
3

2 1 3

IF04K1310025-03

1. Tool body 4. Pressure bolt B 2

2. Grip handle 5. Adjuster bolt
3. Pressure bolt A 6. Cutting pin

2) Select the correct guide plate (1) from table below, IF04K1310026-04
and mount it to the tool body.
7) Turn in the pressure bolt B (1) with the wrench (2)
Drive chain size Guide plate and force out the drive chain joint pin (3).
520, 525, 530 (50) 500
532 532 NOTE
Continue turning in the pressure bolt B (1)
until the joint pin should been completely
1
pushed out of the chain.

8) After the joint pin (3) is removed, loosen the pressure

bolt B (1) and then pressure bolt A (4).

1
4

IF04K1310033-02 2
3) The tip of cutting pin (1) should be positioned inside
“a” approximately 5 mm (0.2 in) from the end face of
pressure bolt A (2).

IF04K1310027-06

IE31J1310029-01

IE31J1310032-01
 Drive Chain / Drive Train / Drive Shaft: 3A-9

Drive Chain Connecting 3) Connect both ends of the drive chain with the joint
pins (1) inserted from the wheel side [a] as installed
! WARNING on the motorcycle.
Do not use joint clip type of drive chain. The Joint set part number
joint clip may have a chance to drop which [Option]: 27620 – 17K00
may cause severe damage to motorcycle and
severe injury.

Joint plate installation

1) Set up the special tool.

1
3

4 5
IF04K1310035-01

2. O-ring 3. Joint plate

2 4) Apply grease on the recessed portion of the

pressure holder (1). Then install the joint plate (2) on
IF04K1310028-05
the tool, its stamp mark must face the pressure
holder (1) side.
1. Tool body 4. Adjuster bolt
2. Grip handle 5. Pressure bolt A “A”: Grease 99000–25011 (SUZUKI SUPER
3. Wedge holder GREASE A)

2) Select the correct pressure holder (1) from table 5) Set the drive chain on the tool as illustrated and turn
below, and set it to pressure bolt A (2). in the adjuster bolt (3) to secure the wedge holder (4)
with joint pin.
Drive chain size / Type Pressure holder
530 (50), 532 / Riveting type F-50
520, 525 / Riveting type F-520 1, “A”
2
530 (50), 532 / Clip type C-50
520, 525 / Clip type C-520

NOTE 4
In case joint plate is too large to fit on “520 3
pressure holder”. Please select “50 pressure
holder”.

IF04K1310029-04
1 6) Turn in the pressure bolt A (1) and align two joint
pins (2) properly with the respective holes of the joint
2 plate (3).
7) Turn in the pressure bolt A (1) further using the
wrench (4) to press the joint plate over the joint pins.

2
1

IF04K1310034-02
3
4

IF04K1310030-04
3A-10 Drive Chain / Drive Train / Drive Shaft:

8) Continue pressing the joint plate until the distance 2) Apply grease to the flare pin (1).
between the two joint plates come to the
“A”: Grease 99000–25011 (SUZUKI SUPER
specification.
GREASE A)
Joint plate distance specification “a”
3) Stake the joint pin by turning (approximately 7/8 turn)
[Standard]: 19.50 – 19.70 mm (0.7678 – 0.7755 in)
the pressure bolt A (2) until the pin end diameter
NOTICE becomes the specified dimension.
If pressing of the joint plate makes the 4) After joining of the chain has been completed, check
dimension out of specification excessively, to make sure that the link is smooth and no abnormal
the work must be carried out again by using condition is found.
new joint parts. Pin end diameter specification “a”
[Standard]: 5.50 – 5.80 mm (0.217 – 0.228 in)

“a”
2
1, “A”
I649G1310033-03

Joint pin staking

1) Set up the special tool.

1
5 IF04K1310032-03
6
4

2 “a”

IF04K1310031-03

1. Tool body 4. Adjuster bolt I649G1310036-03

2. Grip handle 5. Flare pin 5) Adjust the drive chain slack, after connecting it.
3. Pressure bolt A 6. Back-up pin Refer to “Drive Chain Inspection and Adjustment”
(Page 3A-2).

Specifications
Tightening Torque Specifications
BENH17K13107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear axle nut 100 10.2 74.0 (Page 3A-2)
Chain adjuster lock-nut 22 2.2 16.5 (Page 3A-2)
Engine sprocket nut 145 14.8 107.0 (Page 3A-4)
Engine sprocket cover bolt 10 1.0 7.5 (Page 3A-4)
Gearshift link arm bolt 12 1.2 9.0 (Page 3A-5)
Rear sprocket nut 60 6.1 44.5 (Page 3A-5)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Drive Chain Related Components” (Page 3A-1)
“Fasteners Information” in Section 0C (Page 0C-12)
 Drive Chain / Drive Train / Drive Shaft: 3A-11

Special Tools and Equipment

Recommended Service Material
BENH17K13108001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 3A-6) / (Page 3A-
7) / (Page 3A-7) / (Page
3A-9) / (Page 3A-10)

NOTE
Required service material(s) is also described in:
“Drive Chain Related Components” (Page 3A-1)

Special Tool
BENH17K13108002
09913–50121 09913–70210
Oil seal remover Bearing installer set
(Page 3A-6) (Page 3A-7)

09921–20240 09922–22712
Bearing remover set Drive chain cut / rivet tool set
(Page 3A-7) (Page 3A-7)

09924–84510
Bearing installer set
(Page 3A-7)
3A-12 Drive Chain / Drive Train / Drive Shaft:
 Table of Contents 4- i

Section 4

Brakes
CONTENTS

Precautions .................................................4-1 Specifications .....................................................4A-37

Precautions............................................................. 4-1 Tightening Torque Specifications......................4A-37
Precautions for Brake System .............................. 4-1 Special Tools and Equipment ...........................4A-38
Brake Fluid Information ......................................... 4-1 Recommended Service Material .......................4A-38
Special Tool ......................................................4A-38
Brake Control System and Diagnosis ... 4A-1
Schematic and Routing Diagram........................4A-1 Front Brakes ............................................ 4B-1
Front Brake Hose Routing Diagram .................... 4A-1 Repair Instructions ..............................................4B-1
Rear Brake Hose Routing Diagram..................... 4A-4 Front Brake Components ....................................4B-1
Front Wheel Speed Sensor Routing Diagram Front Brake Pad Inspection.................................4B-2 4
(Without ABS) ................................................... 4A-8 Front Brake Pad Replacement............................4B-2
Rear Wheel Speed Sensor Routing Diagram Front Brake Caliper Removal and Installation.....4B-3
(Without ABS) ................................................... 4A-9 Front Brake Caliper Disassembly and
Diagnostic Information and Procedures..........4A-10 Reassembly ......................................................4B-4
Brake Symptom Diagnosis................................ 4A-10 Front Brake Caliper Parts Inspection ..................4B-5
Repair Instructions ............................................4A-11 Front Brake Disc Removal and Installation .........4B-6
Front Brake Light Switch Inspection ................. 4A-11 Front Brake Disc Inspection ................................4B-7
Rear Brake Light Switch Inspection .................. 4A-11 Specifications .......................................................4B-8
Rear Brake Light Switch Inspection and Tightening Torque Specifications........................4B-8
Adjustment ...................................................... 4A-12 Special Tools and Equipment .............................4B-8
Brake Fluid Level Check ................................... 4A-12 Recommended Service Material .........................4B-8
Brake Hose Inspection ...................................... 4A-13 Special Tool ........................................................4B-8
Brake Pedal Height Inspection and
Adjustment ...................................................... 4A-14 Rear Brakes.............................................. 4C-1
Air Bleeding from Brake Line ............................ 4A-14 Repair Instructions ..............................................4C-1
Brake Fluid Replacement.................................. 4A-18 Rear Brake Components.....................................4C-1
Front Brake Hose Removal and Installation...... 4A-20 Rear Brake Pad Inspection .................................4C-2
Rear Brake Hose Removal and Installation ...... 4A-21 Rear Brake Pad Replacement ............................4C-2
Front Brake Master Cylinder Assembly / Rear Brake Caliper Removal and Installation .....4C-3
Brake Lever Components ............................... 4A-23 Rear Brake Caliper Disassembly and
Front Brake Master Cylinder Assembly Reassembly ......................................................4C-5
Removal and Installation................................. 4A-24 Rear Brake Caliper Parts Inspection...................4C-7
Front Brake Master Cylinder Assembly / Rear Brake Disc Removal and Installation..........4C-8
Brake Lever Disassembly and Reassembly ... 4A-25 Rear Brake Disc Inspection.................................4C-9
Front Brake Master Cylinder Parts Inspection .. 4A-28 Specifications .......................................................4C-9
Rear Brake Master Cylinder Assembly Tightening Torque Specifications........................4C-9
Components.................................................... 4A-29 Special Tools and Equipment ...........................4C-10
Rear Brake Master Cylinder Assembly Recommended Service Material .......................4C-10
Removal and Installation................................. 4A-30 Special Tool ......................................................4C-10
Rear Brake Master Cylinder Disassembly and
Reassembly .................................................... 4A-31 ABS ........................................................... 4E-1
Rear Brake Master Cylinder Parts Inspection ... 4A-33 Precautions...........................................................4E-1
Rear Brake Pedal Components ........................ 4A-33 Precautions for ABS Service...............................4E-1
Rear Brake Pedal Removal and Installation ..... 4A-34 Precautions for Diagnosing Troubles ..................4E-1
Rear Brake Pedal Inspection ............................ 4A-36 Precautions for ABS............................................4E-1
4-ii Table of Contents

Precautions for IMU ............................................ 4E-1 DTC C1643 (43)................................................4E-34

General Description ............................................. 4E-1 DTC C1644 (44)................................................4E-35
ABS Description .................................................. 4E-1 DTC C1645 (45)................................................4E-36
Wheel Speed Sensor Description ....................... 4E-4 DTC C1646 (46)................................................4E-38
Self-diagnosis Function and ABS Indicator DTC C1647 (47) / C1648 (48) ...........................4E-39
Light Description ............................................... 4E-5 DTC C1655 (55)................................................4E-40
Fail-safe Function Description............................. 4E-6 DTC C1661 (61)................................................4E-41
Schematic and Routing Diagram........................ 4E-7 DTC C1671 (71)................................................4E-42
ABS Circuit Diagram ........................................... 4E-7 DTC C1672 (72)................................................4E-43
Front Wheel Speed Sensor Routing Diagram..... 4E-9 Repair Instructions ............................................4E-45
Rear Wheel Speed Sensor Routing Diagram ... 4E-10 ABS Control Unit Coupler Disconnection and
Component Location .........................................4E-11 Reconnection ..................................................4E-45
ABS Components Location ...............................4E-11 ABS Control Unit / HU Removal and
Diagnostic Information and Procedures.......... 4E-12 Installation .......................................................4E-45
ABS Check........................................................ 4E-12 IMU Inspection ..................................................4E-47
Visual Inspection ...............................................4E-14 IMU Removal and Installation ...........................4E-47
ABS Symptom Diagnosis ..................................4E-15 Front Wheel Speed Sensor Removal and
ABS Indicator Light Inspection .......................... 4E-15 Installation .......................................................4E-49
DTC (Diagnostic Trouble Code) Output ............4E-18 Rear Wheel Speed Sensor Removal and
DTC (Diagnostic Trouble Code) Deleting.......... 4E-19 Installation .......................................................4E-49
ABS Hydraulic Unit Operation Check................ 4E-20 Front Wheel Speed Sensor Rotor Removal
DTC Table.........................................................4E-21 and Installation ................................................4E-49
Fail-Safe Table..................................................4E-22 Rear Wheel Speed Sensor Rotor Removal
Scan Tool Data ................................................. 4E-23 and Installation ................................................4E-50
DTC C1613 (13)................................................4E-25 Wheel Speed Sensor and Sensor Rotor
DTC C1614 (14)................................................4E-26 Inspection........................................................4E-50
DTC C1622 (22)................................................4E-27 Specifications .....................................................4E-52
DTC C1623 (23)................................................4E-28 Tightening Torque Specifications......................4E-52
DTC C1625 (25)................................................4E-29 Special Tools and Equipment ...........................4E-52
DTC C1635 (35)................................................4E-30 Recommended Service Material .......................4E-52
DTC C1641 (41)................................................4E-31 Special Tool ......................................................4E-52
DTC C1642 (42)................................................4E-32
 Precautions: 4-1

Precautions
Brakes

Precautions
Precautions for Brake System
BENH17K14000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2) and “Precautions for Circuit Tester” in Section 00 (Page 00-8).

Brake Fluid Information

BENH17K14000002
! WARNING

• This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid, such as silicone-based or petroleum-based.
• Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left
over from the last servicing or which has been stored for a long period of time.
• When storing brake fluid, seal the container completely and keep it away from children.
• When replenishing brake fluid, take care not to get dust into the fluid.
• When washing brake components, use new brake fluid. Never use cleaning solvent.
• A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads
and clean the disc with high quality brake cleaner or neutral detergent.
• After removal and installation of the brake caliper, master cylinder, brake hose and ABS control unit/
HU (if equipped), be sure to carry out the air bleeding operation.
• Brake hose seal washers should be replaced with the new ones to prevent fluid leakage.

NOTICE
The brake fluid is damaging to painted surfaces, plastics and rubber materials, and do not allow the
fluid to spill on the surrounding parts.
If the fluid is spilled, flush it with water immediately.
4A-1 Brake Control System and Diagnosis:

Brake Control System and Diagnosis

Brakes

Schematic and Routing Diagram

Front Brake Hose Routing Diagram
BENH17K14102001
Without ABS

[C]
[D]
[A]
“e”

[A]
“a”

“b” 2

2
(a)

[E]
[B]

[F]

[G]

[B]
[B]

(a)
“d”
“c” 1 (a)
“c”

1
IH17K1410001-04
 Brake Control System and Diagnosis: 4A-2

[A]: Face the clamp end as shown. 2. Front brake hose

[B]: After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. “a”: 37.0 mm (1.46 in)
[C]: Pass the brake hose behind the throttle cables. “b”: 44.5 mm (1.75 in)
[D]: Fix the brake hose to the hose guide firmly. “c”: 40°
[E]: Fix the hose sleeve to the front brake hose clamp firmly. “d”: 55°
[F]: After the clamp has contacted the stopper, tighten the bolt. “e”: 60°
[G]: Clamp the hose sleeve and insert the clamp into the hole. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
1. Seal washer : Do not reuse.

With ABS

[A]

[D]
“a”

[B]
“b”

(a)
“c”

2
2
[E]
“d”
“ c” 1

[F]

(a)
[C] 3

(a)

[G]

[C]
1

IH17K1410002-02
4A-3 Brake Control System and Diagnosis:

[A]: Face the clamp end as shown. 2. Front brake hose (ABS control unit/HU to front brake caliper)
[B]: Fix the hose sleeve to the front brake hose clamp firmly. 3. Front brake hose (Front brake master cylinder to ABS control
unit/HU)
[C]: After the brake hose union has contacted the stopper, tighten the union bolt “a”: 37.0 mm (1.46 in)
to the specified torque.
[D]: Clamp the hose sleeve and insert the clamp into the hole. “b”: 44.5 mm (1.75 in)
[E]: After the clamp has contacted the stopper of frame head, tighten the bolt. “c”: 40°
[F]: After the brake hose joint has contacted the stopper, tighten the bolt. “d”: 55°
[G]: Pass the brake hose above the throttle cables and under the clutch cable. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
1. Seal washer : Do not reuse.

(a) [B]

3
[A]

[D]

[C] (a)

4 3

IH17K1410104-01

[A]: After the brake hose union has contacted the ABS control unit/HU, 3. Front brake hose (Front brake master cylinder to ABS control unit/HU)
tighten the union bolt to the specified torque.
[B]: Fix the hose sleeve to the front brake hose clamp firmly. 4. Mounting rubber
[C]: After the stopper of brake hose union has inserted into the hole of 5. ABS control unit/HU
ABS control unit/HU, tighten the union bolt to the specified torque.
[D]: Clamp the brake pipe at the marking portion. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
1. Seal washer : Do not reuse.
2. Front brake hose (ABS control unit/HU to front brake caliper)
 Brake Control System and Diagnosis: 4A-4

Rear Brake Hose Routing Diagram

BENH17K14102002
Without ABS

2
[A]

[C]

[D]

[B]

“a”
2
[A]
[E]

“b”
(a)

[A]

[L]
[M] [F] [H]

[E] [G]

[N] “c”

(a) [B]
[O]
[I]

“d” [J]
[L]
[G]

[H]
(b)

[K]

IH17K1410003-04
4A-5 Brake Control System and Diagnosis:

[A]: After the clamp has contacted the stopper, tighten the bolt. [M]: Center
[B]: After the brake hose union has contacted the stopper, tighten the union bolt to the specified [N]: Position the master cylinder connector aligning with
torque. the master cylinder center line.
[C]: After the stopper of clamp has contacted the seat rail, tighten the bolt. [O]: After the stopper of rear brake reservoir tank
bracket has contacted the seat rail, tighten the bolt.
[D]: After the brake hose joint has contacted the stopper, tighten the bolt. 1. Seal washer
[E]: Fix the hose sleeve to the rear brake hose clamp firmly. 2. Rear brake hose
[F]: Face the white paint making to outside. “a”: 35°
[G]: Face the clamp end as shown. “b”: 30°
[H]: Insert the reservoir hose firmly. “c”: 25°
[I]: Install the reservoir tank without making clearance between the reservoir tank and clamp. “d”: 45°
[J]: Face the yellow paint making to outside. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
[K]: Outside : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
[L]: Clearance : Do not reuse.
 Brake Control System and Diagnosis: 4A-6

With ABS

2
[A]

[C]

[D]

2
3

[B]

[A]
“a”
2
[E]
“b”
(a)

[A]

[G] [F]
[M]
[H]
[L]
[E]
“d”
[N]

(a) [B]

“ c” [L] [O]
[I]
[G]
[J]

[H]
(b)
3
[K]

IH17K1410004-05
4A-7 Brake Control System and Diagnosis:

[A]: After the clamp has contacted the stopper, tighten the bolt. [N]: Position the master cylinder connector aligning with the master
cylinder center line.
[B]: After the brake hose union has contacted the stopper, tighten the [O]: After the stopper of rear brake reservoir tank bracket has contacted
union bolt to the specified torque. the seat rail, tighten the bolt.
[C]: After the stopper of clamp has contacted the seat rail, tighten the bolt. 1. Seal washer
[D]: After the brake hose joint has contacted the stopper, tighten the bolt. 2. Rear brake hose (ABS control unit/HU to rear brake caliper)
[E]: Fix the hose sleeve to the rear brake hose clamp firmly. 3. Rear brake hose (Rear brake master cylinder to ABS control unit/HU)
[F]: Face the white paint making to outside. “a”: 30°
[G]: Face the clamp end as shown. “b”: 35°
[H]: Insert the reservoir hose firmly. “c”: 45°
[I]: Install the reservoir tank without making clearance between the “d”: 20°
reservoir tank and clamp.
[J]: Face the yellow paint making to outside. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
[K]: Outside : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
[L]: Clearance : Do not reuse.
[M]: Center

[B] 2 4 [C]

(a)

[A] “a”

3
IH17K1410105-02

[A]: After the brake hose union has contacted the ABS control 3. Rear brake hose (Rear brake master cylinder to ABS control unit/HU)
unit/HU, tighten the union bolt to the specified torque. : Pass the rear brake hose (rear brake master cylinder to ABS control unit/HU)
above and forward the rear brake hose (ABS control unit/HU to rear brake caliper).
[B]: After the stopper of brake hose union has inserted into the 4. Clamp
hole of ABS control unit/HU, tighten the union bolt to the : Face the tip of clamp as shown.
specified torque. Cut off the excess tip of the clamp.
[C]: Pass the rear brake hose (rear brake master cylinder to ABS “a”: 10 mm (0.39 in)
control unit/HU) in front of the rear brake piping.
1. Seal washer : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Rear brake hose (ABS control unit/HU to rear brake caliper) : Do not reuse.
 Brake Control System and Diagnosis: 4A-8

Front Wheel Speed Sensor Routing Diagram (Without ABS)

BENH17K14102003

[A]
4

2
“a”

[B]

1 [A] 5

IH17K1410106-01

[A]: After the clamp has contacted the stopper, tighten the bolt. 4. Front brake hose
[B]: Pass the front wheel speed sensor lead wire behind the brake hose end fitting. 5. Front wheel speed sensor
1. Clamp 6. Front wheel speed sensor lead wire
: Fix the front wheel speed sensor lead wire sleeve to the clamp firmly.
2. Clamp “a”: 15 mm (0.59 in)
: Clamp the sleeve portion of the front wheel speed sensor lead wire.
Face the tip of clamp downward.
Cut off the excess tip of the clamp.
3. Clamp
: Clamp the front wheel speed sensor lead wire in outside of the brake hose at the brake
hose end fitting aligning the lead wire protector upper end with the clamp lower end.
Face the clamp opening backward.
4A-9 Brake Control System and Diagnosis:

Rear Wheel Speed Sensor Routing Diagram (Without ABS)

BENH17K14102004

“a”

2 [D]

“b”
[A]

“c”

[B]

6
4

[C]

[A]
IH17K1450016-03
 Brake Control System and Diagnosis: 4A-10

[A]: Pass the rear wheel speed sensor lead wire outside of the brake hose. 4. Clamp
: Clamp the rear wheel speed sensor lead wire in front of the brake
hose at the marking point.
[B]: Fix the rear wheel speed sensor lead wire sleeve to the clamp firmly. 5. Clamp
: Fix the rear wheel speed sensor lead wire sleeve to the clamp firmly.
[C]: Touch the clamp end to the stopper on the rear brake caliper bracket 6. Rear wheel speed sensor
and tighten the bolt.
[D]: Clamp the rear wheel speed sensor lead wire under the seat rail. 7. Rear brake caliper
1. Clamp “a”: 100 mm (3.93 in)
: Clamp the rear wheel speed sensor lead wire outside of the brake
hose at the marking point.
2. Clamp “b”: 10 – 20 mm (0.39 – 0.78 in)
: Clamp the rear wheel speed sensor lead wire outside of the brake
hose.
3. Clamp “c”: 5.0 mm (0.2 in)
: Clamp the rear wheel speed sensor lead wire above the brake hose.

Diagnostic Information and Procedures

Brake Symptom Diagnosis
BENH17K14104002

Condition Possible cause Correction / Reference Item

Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace.
system.
Worn pads and/or disc. Replace.
• Front brake pad: (Page 4B-2)
• Rear brake pad: (Page 4C-2)
• Front brake disc: (Page 4B-6)
• Rear brake disc: (Page 4C-8)
Oil adhesion on friction surface of pads. Clean disc and pads.
Air in hydraulic system. Bleed air. (Page 4A-14)
Not enough brake fluid in the reservoir Replenish. (Page 4A-12)
tank.
Brake squeaking Carbon adhesion on pad surface. Repair surface with sandpaper.
Tilted pad. Correct pad fitting or replace.
• Front: (Page 4B-2)
• Rear: (Page 4C-2)
Damaged wheel bearing. Replace.
• Front: (Page 2D-5)
• Rear: (Page 2D-10)
Loose front wheel axle or rear wheel Tighten to specified torque. (Page 0B-5)
axle.
Worn pads and/or disc. Replace.
• Front brake pad: (Page 4B-2)
• Rear brake pad: (Page 4C-2)
• Front brake disc: (Page 4B-6)
• Rear brake disc: (Page 4C-8)
Foreign material in brake fluid. Replace brake fluid. (Page 4A-18)
Clogged return port of master cylinder. Disassemble and clean master cylinder.
Excessive brake lever Air in hydraulic system. Bleed air. (Page 4A-14)
stroke Insufficient brake fluid. Replenish fluid to specified level. (Page 4A-
12)
Improper quality of brake fluid. Replace with correct fluid. (Page 4A-18)
4A-11 Brake Control System and Diagnosis:

Condition Possible cause Correction / Reference Item

Leakage of brake fluid Insufficient tightening of connection Tighten to specified torque. (Page 0B-5)
joints.
Cracked hose. Replace.
• Front: (Page 4A-20)
• Rear: (Page 4A-21)
Worn master cylinder piston and/or cup. Replace master cylinder piston and/or cup.
• Front: (Page 4A-25)
• Rear: (Page 4A-31)
Worn brake caliper piston seals and Replace brake caliper piston seal and dust
dust seals. seal.
• Front: (Page 4B-4)
• Rear: (Page 4C-5)
Brake drags Rusty part. Clean and lubricate. (Page 0B-7)
Insufficient front brake lever or rear Lubricate. (Page 0B-7)
brake pedal pivot lubrication.

Repair Instructions
Front Brake Light Switch Inspection Tightening torque
BENH17K14106001 Brake light switch screw: 1.2 N·m (0.12 kgf-m,
1) Grasp the front brake lever, remove the front brake 0.90 lbf-ft)
light switch (1).
2) Disconnect the front brake light switch lead wire
coupler (2).
3

2
2
1
IH17K1410006-01

Rear Brake Light Switch Inspection

IH17K1410005-01
BENH17K14106002

3) Inspect the switch for continuity with a circuit tester. 1) Remove the right frame front cover. (Page 9D-18)
If any abnormality is found, replace the front brake 2) Disconnect the rear brake light switch lead wire
light switch with a new one. coupler (1).

Color
Terminal (B/R) Terminal (B/Bl)
Position
OFF 1
ON
ID26J1410033-02

4) Connect the front brake light switch lead wire coupler

(1).
5) When installing the brake light switch, align the
projection (2) on the switch with the hole (3) in the
master cylinder.
6) Tighten the brake light switch screw to the specified IH17K1410007-01

torque.
 Brake Control System and Diagnosis: 4A-12

3) Inspect the switch for continuity with a tester. Brake Fluid Level Check
If any abnormality is found, replace the rear brake BENH17K14106004

light switch with a new one. 1) Place the motorcycle on a level surface and keep the
handlebars straight.
Color 2) Check the brake fluid level by observing the lower
Position
Terminal (O) Terminal (W/B) limit lines (1) on the front and rear brake fluid
reservoir tanks. When the brake fluid level is below
OFF
the lower limit line, inspect for brake pad wear and
ON leaks and replenish with brake fluid that meets the
IF04K1410008-01
following specification.
4) Connect the rear brake light switch lead wire coupler.
Brake fluid (DOT 4)
5) Install the right frame front cover. (Page 9D-18)

Rear Brake Light Switch Inspection and

Adjustment
BENH17K14106003
1
Check the rear brake light switch so that the brake light
will come on just before pressure is felt when the brake
pedal is depressed. If the brake light switch adjustment
is necessary, turn the adjuster nut (1) in or out while
holding the brake pedal.

IH17K1410009-01

IH17K1410010-01

IH17K1410008-01
4A-13 Brake Control System and Diagnosis:

Brake Hose Inspection

BENH17K14106005
1) Lift and support the fuel tank. (Page 1G-9)
2) Inspect the brake hoses and hose joints for crack,
damage or brake fluid leakage. If any defects are
found, replace the brake hose with a new one.
• Front: (Page 4A-20)
• Rear: (Page 4A-21)

IH17K1410015-01

IH17K1410011-01

IH17K1410016-01

[A]

IH17K1410012-02

IH17K1410017-01

[A]: With ABS

3) Install the removed parts.

IH17K1410013-02

IH17K1410014-01
 Brake Control System and Diagnosis: 4A-14

Brake Pedal Height Inspection and Adjustment Air Bleeding from Brake Line
BENH17K14106006 BENH17K14106007
1) Inspect the brake pedal height “a” between the pedal Air trapped in the brake fluid circuit acts like a cushion to
top face and footrest. absorb a large proportion of the pressure developed by
Adjust the brake pedal height if necessary. the master cylinder and thus interferes with the full
braking performance of the brake caliper. The presence
Brake pedal height “a” of air is indicated by “sponginess” of the brake lever and
[Standard]: 65 – 75 mm (2.6 – 2.9 in) also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider, it
“b” is essential that after remounting the brake and restoring
the brake system to the normal condition, the brake fluid
circuit be purged of air in the following manner:

1 NOTICE
• Spilled brake fluid can damage painted
surfaces and plastic parts. Be careful not
to spill any fluid when filling the brake fluid
“c”
reservoir. Wipe spilled fluid up and wash
1 stained parts immediately.
IH17K1410018-01
• It is essential to purge air from the fluid
circuit before inspecting the function of
the brake fluid pressure-decreasing mode.
1 Without air bleeding, trapped air in the
circuit will enter the HU.

“a” 1 Front Brake

1) Place the motorcycle on a level surface and adjust
the horizontal upper face of reservoir tank.
2) Remove the reservoir cap plate (1).
3) Remove the reservoir cap (2) and diaphragm.

IH17K1410019-01

1. Measuring point “c”: 24 mm (0.9 in)

2
“b”: 86 mm (3.4 in)
1
2) Loosen the lock-nut (1).
3) Turn the push rod (2) in or out until the brake pedal
height is within the specification.
4) Tighten the lock-nut (1) to the specified torque.
Tightening torque
Rear brake master cylinder rod lock-nut (a): 18
IH17K1410021-01
N·m (1.8 kgf-m, 13.5 lbf-ft)

1, ( a)

IH17K1410020-01

5) After finishing the brake pedal height inspection and

adjustment, check the rear brake light switch.
(Page 4A-12)
4A-15 Brake Control System and Diagnosis:

4) Fill the reservoir tank with new brake fluid to the

upper line (1).
Brake fluid (DOT 4)

NOTE
• While bleeding the brake system, replenish
the brake fluid in the reservoir as
necessary. Make sure that there is always
some fluid visible in the reservoir.
• Slowly pour fluid to prevent air bubbles.
• Do not release the brake lever when IH17K1410024-01
opening the air breeder valve. 10) Remove the clear hose from the front brake master
cylinder air bleeder valve.
5) Pinch the reservoir hose (2) by finger until all air in
the hose has released. 11) Attach a clear hose to the left side front brake caliper
air bleeder valve (1), and insert the free end of the
hose into a receptacle.
1
2 12) Squeeze and release the brake lever several times
in rapid succession then squeeze and hold the lever
fully without releasing it. Loosen the left side front
brake caliper air bleeder valve by turning it a 1/6 of a
turn then tighten it.
13) Repeat this process until the clean fluid flowing into
the clear hose.

IH17K1410022-02

6) Place the reservoir cap (1) to prevent dirt from

entering.
7) Attach a clear hose to the front brake master cylinder
air bleeder valve (2), and insert the free end of the 1
hose into a receptacle.
8) Squeeze and release the brake lever several times
in rapid succession and squeeze and hold the lever
fully without releasing it. Loosen the front brake
IH17K1410025-01
master cylinder air bleeder valve by turning it a 1/6 of
a turn then tighten it.
9) Repeat this process until the fluid flowing into the
clear hose no longer contains air bubbles.

2 IH17K1410024-01

IH17K1410023-01
 Brake Control System and Diagnosis: 4A-16

14) Remove the clear hose from the left side front brake 19) Confirm the brake lever feeling after air breeding. If
caliper air bleeder valve. lever feeling is still spongy, repeat again the air
15) Right side front brake caliper air breeding after the breeding from 11).
same method 11) to 14). 20) Remove the clear hose from the front brake master
cylinder.
NOTE
21) Tighten the front brake caliper air bleeder valves (1)
Fluid of reservoir tank amount should be use and front brake master cylinder air bleeder valve (2)
due to completely change to fresh fluid. to the specified torque, and then connect the air
bleeder caps.
Tightening torque
Front brake caliper air bleeder valve (a): 7.5 N·m
(0.76 kgf-m, 5.55 lbf-ft)
Front brake master cylinder air bleeder valve
(b): 6.0 N·m (0.61 kgf-m, 4.45 lbf-ft)

1, (a)

IH17K1410108-01

16) Attach a clear hose to the front brake master cylinder

air bleeder valve (1), and insert the free end of the
1, (a)
hose into a receptacle.
17) Squeeze and release the brake lever several times
in rapid succession and squeeze and hold the lever
IH17K1410029-02
fully without releasing it. Loosen the front brake
master cylinder air bleeder valve by turning it a 1/6 of
a turn then tighten it.
18) Repeat 5 times for this process until the fluid flowing
into the clear hose no longer contains air bubbles
from air breeder valve.
2, ( b )

IH17K1410030-01

22) Fill the reservoir tank with new brake fluid to the
1 upper line (1).
Brake fluid (DOT 4)

IH17K1410028-01
1

IH17K1410031-01

IH17K1410024-01
4A-17 Brake Control System and Diagnosis:

23) Install the diaphragm, reservoir cap (1) and the 6) Attach a clear hose to the rear brake caliper air
reservoir cap plate (2) with a screw (3). bleeder valve, and insert the free end of the hose
into a receptacle.
1 7) Operate the brake pedal several times and, while
pushing the pedal, loosen the rear brake caliper air
2
bleeder valve (1) and drain the brake fluid into a
receptacle.

3
1

IH17K1410032-01

Rear Brake
1) Place the motorcycle on a level surface.
2) Remove the right frame front cover. (Page 9D-18)
IH17K1410035-01
3) Remove the reservoir tank mounting bolt (1) and
move the reservoir tank outside of the seat rail.

IH17K1410036-01

IH17K1410033-01 8) Tighten the rear brake caliper air bleeder valve and
4) Remove the reservoir cap and diaphragm (1). release the brake pedal slowly.
5) Fill the reservoir tank with brake fluid up to the upper 9) Repeat the steps 7) and 8) until the fluid is flowing
line (2) of the reservoir tank. Place the reservoir cap out without bubbles.
to prevent dirt from entering.
NOTE
While bleeding the brake system, replenish
1 the reservoir tank with the brake fluid as
necessary to keep the fluid above the lower
limit line.

10) Tighten the rear brake caliper air bleeder valve to the
specified torque.
2
Tightening torque
Rear brake caliper air bleeder valve: 6.0 N·m (
0.61 kgf-m, 4.45 lbf-ft)
IH17K1410034-01
 Brake Control System and Diagnosis: 4A-18

11) Fill the reservoir tank with brake fluid to the upper
line (1) of the reservoir tank. [B] “a”

1 3 1

IH17K1410040-02

[A]: Correct [B]: Incorrect

IH17K1410037-01

12) Install the diaphragm and reservoir cap (1). 14) Install the right frame front cover. (Page 9D-18)

Brake Fluid Replacement

BENH17K14106008

1 Front Brake
1) Place the motorcycle on a level surface and keep the
handlebars straight.
2) Remove the reservoir cap plate (1).
3) Remove the reservoir cap (2) and diaphragm.

2
IH17K1410038-01
1
13) Install the reservoir tank.

NOTICE
When install the reservoir tank (1), hold the
reservoir tank to touch it to the bracket (2)
and tighten the bolt (3). After tightening,
check that the clearance “a” between the
reservoir tank (1) and the bracket (2) is zero. IH17K1410021-01

4) Suck up the old brake fluid as much as possible.

[A] “a”

3 1

IH17K1410039-02
IH17K1410041-01

5) Fill the reservoir tank with new brake fluid.

Brake fluid (DOT 4)
4A-19 Brake Control System and Diagnosis:

6) Attach a clear hose to the front brake caliper air 4) Remove the reservoir cap and diaphragm.
bleeder valve (1) and insert the free end of the hose 5) Suck up the old brake fluid as much as possible.
into a receptacle.
7) Loosen the front brake caliper air bleeder valve,
squeeze and release the brake lever and drain the
old brake fluid out of the brake system.

NOTE
While replacement the brake system,
replenish the reservoir tank with the brake
fluid as necessary to keep the fluid above the
lower limit line.

IH17K1410043-01

6) Fill the reservoir tank with new brake fluid.

1
Brake fluid (DOT 4)
7) Attach a clear hose to the rear brake caliper air
bleeder valve (1) and insert the free end of the hose
into a receptacle.
8) Loosen the rear brake caliper air bleeder valve (1)
and pump the brake pedal until the old brake fluid
flows out of the brake system.
IH17K1410027-04 NOTE
While replacement the brake system,
replenish the reservoir tank with the brake
fluid as necessary to keep the fluid above the
lower limit line.

IH17K1410042-01

8) Bleed the air from the front brake system. (Page

4A-14)

Rear Brake
1) Place the motorcycle on a level surface. IH17K1410035-01

2) Remove the right frame front cover. (Page 9D-18)

3) Remove the reservoir tank mounting bolt (1) and
move the reservoir tank outside of the seat rail.

IH17K1410036-01

9) Bleed the air from the rear brake system. (Page

4A-14)
IH17K1410033-01 10) Install the right frame front cover. (Page 9D-18)
 Brake Control System and Diagnosis: 4A-20

Front Brake Hose Removal and Installation 5) With ABS model:

BENH17K14106009
Removal a) Remove the throttle body assembly. (Page 1C-
5)
1) Drain brake fluid. (Page 4A-18)
b) Remove the EVAP canister. (Page 1B-13)
2) Disconnect the speed sensor lead wire from the
clamp. c) Disconnect the TO sensor coupler (1) and IMU
sensor coupler (2).
• Without ABS model: (Page 4A-8)
d) Remove the fuel tank rear bracket (3).
• With ABS model: (Page 4E-9)
3) Without ABS model:
a) Remove the body cowling cover (1). (Page 9D-
2
22)

IH17K1410045-01

1
e) Remove the front master to unit hose and unit to
front caliper hose. (Page 4A-1)

IH17K1940029-01 Installation
b) Remove the lower bracket cover (1). 1) Apply grease to the new seal washers.
“A”: Grease 99000–25100 (SUZUKI SILICONE
1 GREASE)

IH17K1410044-02
“A ”
4) Remove the brake hose No. 1 and No. 2. (Page
4A-1)
IH17K1410046-01

2) Install the brake hose union bolts and new seal

washers to the brake hoses.
3) Install the union to front caliper hose and front
master to unit hose. (Page 4A-1)
4) Install the brake hose No. 1 and No. 2. (Page 4A-
1)
4A-21 Brake Control System and Diagnosis:

5) Without ABS model: Rear Brake Hose Removal and Installation

BENH17K14106010
a) Install the lower bracket cover (1). Removal
1) Drain brake fluid. (Page 4A-18)
1 2) Remove the rear shock absorber assembly. (Page
2C-4)
3) Disconnect the speed sensor lead wire.
• Without ABS model: (Page 4A-9)
• With ABS model: (Page 4E-10)
4) Without ABS model, remove the rear brake hose.
(Page 4A-4)
5) With ABS model:
IH17K1410044-02 a) Remove the front seat. (Page 9D-19)
b) Install the body cowling cover (1). (Page 9D- b) Disconnect the TO sensor coupler (1) and IMU
22) sensor coupler (2).
c) Remove the fuel tank rear bracket (3).

1 1

3
IH17K1940029-01

6) With ABS model, install the unit to front caliper hose IH17K1410045-01
and front master to unit hose. (Page 4A-1) d) Remove the rear master to union hose and unit
7) Connect the speed sensor lead wire. to rear brake caliper hose. (Page 4A-4)
• Without ABS model: (Page 4A-8)
Installation
• With ABS model: (Page 4E-9)
1) Apply grease to the new seal washers.
8) Bleed air from the front brake system. (Page 4A-
14) “A”: Grease 99000–25100 (SUZUKI SILICONE
9) With ABS model: GREASE)
a) Install the fuel tank rear bracket (1).
b) Connect the IMU sensor coupler (2) and TO
sensor coupler (3).

“A ”

3 IH17K1410046-01

IH17K1410047-01

c) Install the EVAP canister. (Page 1B-13)

d) Install the throttle body assembly. (Page 1C-5)
 Brake Control System and Diagnosis: 4A-22

2) Install the brake hose union bolts and new seal

washers to the brake hoses.
3) Without ABS model, install the rear brake hose.
(Page 4A-4)
4) With ABS model: Install the unit to rear brake caliper
hose and rear master to union hose. (Page 4A-4)
5) Connect the speed sensor lead wire.
• Without ABS model: (Page 4A-9)
• With ABS model: (Page 4E-10)
6) Bleed air from the rear brake system. (Page 4A-
14)
7) With ABS model:
a) Install the fuel tank rear bracket (1).
b) Connect the IMU sensor coupler (2) and TO
sensor coupler (3).

IH17K1410047-01

c) Install the front seat. (Page 9D-19)

8) Install the rear shock absorber assembly. (Page
2C-4)
4A-23 Brake Control System and Diagnosis:

Front Brake Master Cylinder Assembly / Brake Lever Components

BENH17K14106011

6
17
19
20 (e)

16

18 (c)

10 (a)

9
(d) 21 (c)

15
23

14
11
22 (b)

12

13
IH17K1410048-01

1. Reservoir cap 12. Push rod 23. Brake hose

2. Diaphragm plate 13. Piston/cup set : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Diaphragm 14. Return spring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
4. Reservoir tank 15. Return spring guide : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
5. Reservoir tank hose 16. Brake hose connector : 1.2 Nm (0.12 kgf-m, 0.90 lbf-ft)
6. Reservoir tank holder 17. Dust rubber : 1.0 Nm (0.10 kgf-m, 0.75 lbf-ft)
7. Reservoir cap plate 18. Front brake master cylinder air bleeder valve : Apply silicone grease.
8. Master cylinder 19. Brake lever : Apply brake fluid.

9. Front brake master cylinder holder 20. Brake lever pivot bolt : Do not reuse.
10. Front brake light switch 21. Brake lever pivot bolt lock-nut
11. Dust boot 22. Brake hose union bolt
 Brake Control System and Diagnosis: 4A-24

Front Brake Master Cylinder Assembly Removal Installation

and Installation Install the front brake master cylinder in the reverse
BENH17K14106012 order of removal. Pay attention to the following points:
• When installing the front brake master cylinder
Removal
assembly (1) onto the handlebar, align the edge (2) of
1) Drain brake fluid. (Page 4A-18) master cylinder with the punch mark (3) on the
2) Place a rag underneath the brake hose union bolt (1) handlebar and tighten the upper bolt (4) first.
on the master cylinder to catch any spilt brake fluid.
NOTE
3) Remove the brake hose union bolt (1) and
disconnect the brake hose. Face the up mark (5) upward.

Tightening torque
Front brake master cylinder holder bolt (a): 10
N·m (1.0 kgf-m, 7.5 lbf-ft)

1
2

IH17K1410049-01

4) Remove the reservoir tank holder (1) and front brake 3

master cylinder holder (2).
IH17K1410052-01

2
4, (a)
3

1 2
5

IH17K1410050-01 (a)
“a”
5) Disconnect the front brake light switch lead wire
IH17K1410053-01
coupler (1) and front brake master cylinder assembly
(2). “a”: Clearance

• Apply grease to the new seal washers.

“A”: Grease 99000–25100 (SUZUKI SILICONE
2 GREASE)

IH17K1410051-01

“A ”

IH17K1410046-01
4A-25 Brake Control System and Diagnosis:

• Install the brake hose union bolt (1) and new seal 2) Remove the front brake light switch (1).
washers (2) to brake hose.
• Align the projection (3) and groove (4) of master
cylinder. 1

IH17K1410057-01

1 3) Remove the brake lever (1).

IH17K1410054-02

• Tighten the brake hose union bolt (1) to the specified 1

torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)

IH17K1410058-01

4) Remove the dust boot (1) and push rod (2).

5) Remove the snap ring (3) with the special tool.
Special tool
1, ( a) 09900–06108

IH17K1410055-01

• Bleed air from the brake system. (Page 4A-14) 2

Front Brake Master Cylinder Assembly / Brake

Lever Disassembly and Reassembly
BENH17K14106013
Refer to “Front Brake Master Cylinder Assembly
Removal and Installation” (Page 4A-24).
1 3
Disassembly
IH17K1410059-01
1) Remove the reservoir cap (1), plate (2), diaphragm
(3) reservoir tank (4) and reservoir tank hose (5).

4 5

3
2

IH17K1410056-01
 Brake Control System and Diagnosis: 4A-26

6) Remove the following parts from the master cylinder. Reassembly

• Piston/cup set (1) Reassemble the front brake master cylinder and brake
lever in the reverse order of disassembly. Pay attention
• Return spring (2)
to the following points:
• Return spring guide (3)
NOTICE
• Wash the front brake master cylinder
3
components with new brake fluid before
2 reassembly.
• Do not wipe the brake fluid off after
1
washing the components.
• When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvents such as
gasoline, kerosine, etc.
IH17K1410060-01 • Apply brake fluid to the front brake master
7) Remove the dust rubber (1) and snap ring (2) with cylinder bore and all of the master cylinder
the special tool. component to be inserted into the bore.

Special tool Brake fluid (DOT 4)

09900–06108

1 2

I837H1410034-01

IH17K1410061-01
• Apply brake fluid to the new O-ring and install it to the
brake hose connector.
8) Remove the brake hose connector (1), O-ring (2)
and air bleeder valve (3). • Install the connector (1) and new snap ring (2) with
the special tool.

3
Special tool
09900–06108
2
• Temporary install the air bleeder valve (3).
• Set the dust rubber (4) to the front brake master
1 cylinder securely.

1
2 4

IH17K1410062-01

IH17K1410063-01
4A-27 Brake Control System and Diagnosis:

• When installing the return spring guide (1) and return • Apply grease to the brake lever pivot bolt and brake
spring (2), fit the spring guide end (3) into the hole (4) lever sliding surfaces.
of the front brake master cylinder.
“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE)
1

“A”
“A”

2 4

3
“A”

IH17K1410064-01

• Install the new snap ring (1) with the special tool. IH17K1410067-01

Special tool • Tighten the brake lever pivot bolt (1) and new lock-nut
09900–06108 (2) to the specified torque.
Tightening torque
Brake lever pivot bolt (a): 1.0 N·m (0.10 kgf-m,
0.75 lbf-ft)
Brake lever pivot bolt lock-nut (b): 6.0 N·m (0.61
kgf-m, 4.45 lbf-ft)
1

1 , (a )

IH17K1410065-01

• Apply grease to the push rod end.

“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE) 2 , (b )
• Set the dust boot (1) to the front brake master cylinder IH17K1410068-01
securely.
• When installing the front brake light switch, align the
projection (1) on the switch with the hole (2) in the
front brake master cylinder.
“A” • Tighten the front brake light switch mounting screw (3)
to the specified torque.
Tightening torque
Brake light switch screw (a): 1.2 N·m (0.12 kgf-m,
0.90 lbf-ft)

1 1 3, (a)
IH17K1410066-01 2
• Apply grease to the contact point between push rod
and brake lever.

IH17K1410069-01
 Brake Control System and Diagnosis: 4A-28

• When connecting the reservoir tank hose (1) between Piston / Cup Set
the master cylinder and reservoir tank, pay attention Inspect the piston/cup set surface for any scratches or
to the length of the hose. other damage. Inspect the primary cup (1) and
secondary cup (2) for wear or damage. If any damage is
found, replace the piston/cup with new one.
“a”

1
“b”

IH17K1410070-01
1 2
“a”: 37.0 mm (1.46 in) “b”: 44.5 mm (1.75 in)
IH17K1410072-01

Front Brake Master Cylinder Parts Inspection

BENH17K14106014
Refer to “Front Brake Master Cylinder Assembly / Brake
Lever Disassembly and Reassembly” (Page 4A-25).

Master Cylinder
Inspect the front brake master cylinder bore (1) for any
scratches corrosion or other damage. If any damage is
found, replace it with a new one.

IH17K1410071-01
4A-29 Brake Control System and Diagnosis:

Rear Brake Master Cylinder Assembly Components

BENH17K14106015

2
6 (b)
7
3

5 9

(a)
8

10

11

12

13 (c)

IH17K1410073-01

1. Reservoir cap 8. Brake hose connector : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Diaphragm plate 9. Rear brake master cylinder : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
3. Diaphragm 10. Piston/cup set : Apply thread lock to the thread part.
4. Reservoir tank 11. Push rod : Apply silicone grease.
5. Reservoir tank hose 12. Dust boot : Apply brake fluid.

6. Brake hose union bolt 13. Rear brake master cylinder rod lock-nut : Do not reuse.
7. Brake hose : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
 Brake Control System and Diagnosis: 4A-30

Rear Brake Master Cylinder Assembly Removal Installation

and Installation Install the rear brake master cylinder in the reverse order
BENH17K14106016 of removal. Pay attention to the following points:
• Apply thread lock to the rear brake master cylinder
Removal
mounting bolts (1) and tighten them to the specified
1) Remove the right frame front cover. (Page 9D-18) torque.
2) Drain brake fluid. (Page 4A-18)
“A”: Thread lock cement 99000–32150 (THREAD
3) Remove the reservoir tank mounting bolt (1). LOCK CEMENT 1322D)
Tightening torque
Rear brake master cylinder mounting bolt (a): 13
1 N·m (1.3 kgf-m, 9.5 lbf-ft)
• Tighten the rear brake master cylinder rod lock-nut (2)
to the specified torque.
Tightening torque
Rear brake master cylinder rod lock-nut (b): 18
N·m (1.8 kgf-m, 13.5 lbf-ft)

IH17K1410033-01

4) Place a clean rag underneath the brake hose union

bolt (1) on the master cylinder to catch any spilt
brake fluid.
5) Remove the brake hose union bolt (1) and
disconnect the brake hose.
2 , (b )

1 , “A” , ( a )
IH17K1410076-01
1 • Apply grease to the new seal washers.
“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE)

IH17K1410074-01

6) Loosen the rear brake master cylinder rod lock-nut

(1).
7) Remove the rear brake master cylinder mounting
bolts (2).
8) Remove the master cylinder with the reservoir tank
“A ”
by turning the push rod (3).
IH17K1410046-01

IH17K1410075-01
4A-31 Brake Control System and Diagnosis:

• Install the brake hose union bolt and new seal 3) Remove the snap ring (1) with the special tool.
washers to the brake hose.
Special tool
• After the brake hose union (1) has contacted the 09900–06108
stopper (2), tighten the union bolt (3) to the specified
torque. 4) Remove the brake hose connector (2) and O-ring
(3).
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft) 2

3, ( a)

1 1
3

2 IH17K1410079-01

5) Pull out the dust boot (1) and remove the snap ring
(2) with the special tool.
IH17K1410077-01

• Install the reservoir tank. Refer to “Rear Brake Hose Special tool
Routing Diagram” (Page 4A-4). 09900–06108
• Bleed air from the system after installing the rear
brake master cylinder. (Page 4A-14)
• Adjust the brake pedal height. (Page 4A-14)

Rear Brake Master Cylinder Disassembly and

Reassembly
BENH17K14106017
Refer to “Rear Brake Master Cylinder Assembly
Removal and Installation” (Page 4A-30).
1 2

Disassembly
IH17K1410080-01
1) Disconnect the reservoir tank hose (1).
6) Remove the following parts from the master cylinder.
2) Remove the rear brake master cylinder rod lock-nut
(2). • Push rod (1)
• Piston/cup set (2)

2
1 2
IH17K1410078-01
IH17K1410081-01
 Brake Control System and Diagnosis: 4A-32

Reassembly • Apply grease to the lip of the dust boot (1).

Reassemble the rear brake master cylinder in the
“A”: Grease 99000–25100 (SUZUKI SILICONE
reverse order of disassembly. Pay attention to the
GREASE)
following points:
• Set the dust boot (1) to the rear brake master cylinder
NOTICE securely.
• Wash the rear brake master cylinder
components with new brake fluid before
reassembly. 1
• Do not wipe the brake fluid off after
washing the components.
• When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvents such as
gasoline, kerosine, etc.
• Apply brake fluid to the rear brake master “A ”
cylinder bore and all of the master cylinder
IH17K1410083-01
component to be inserted into the bore.
• Apply brake fluid to the new O-ring (1) and install to
Brake fluid (DOT 4) the brake hose connector (2).
• Install the new snap ring (3) with the special tool.
Special tool
09900–06108

IB14J1410051-02

• Apply grease to the push rod end.

“A”: Grease 99000–25100 (SUZUKI SILICONE 2 3
GREASE)
IH17K1410084-01
• Install the new snap ring (1) with the special tool.
• Connect the reservoir tank hose (1) and set the clips
Special tool (2). Refer to “Rear Brake Hose Routing Diagram”
09900–06108 (Page 4A-4).
• Install the lock-nut (3).

“A” 1

3 2
IH17K1410082-01

IH17K1410085-01
4A-33 Brake Control System and Diagnosis:

Rear Brake Master Cylinder Parts Inspection

BENH17K14106018
Refer to “Rear Brake Master Cylinder Disassembly and
Reassembly” (Page 4A-31).

Master Cylinder
1 2
Inspect the rear brake master cylinder bore for any IF04K1410069-02
scratches or other damage. If any damage is found,
replace the rear brake master cylinder with a new one. Dust Boot
Inspect the dust boot for wear or damage. If any defects
are found, replace it with a new one.

I947H1410040-02

Piston / Cup Set IF04K1410070-01

Inspect the piston surface for any scratches or other
damage. Inspect the primary cup (1) and secondary cup
(2) for wear or damage. If any damage is found, replace
the piston/cup with new ones.

Rear Brake Pedal Components

BENH17K14106019

2
1
6 (a)

8
4

5
3

9 11

10

13 (c)

12 (b)

IH17K1410103-04
 Brake Control System and Diagnosis: 4A-34

1. Front footrest bar RH 11. Front footrest bracket RH

2. Front footrest spring 12. Front footrest holder bolt
3. Front footrest holder 13. Front footrest bracket bolt
4. E-ring : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
5. Front footrest pin : 39 Nm (4.0 kgf-m, 29.0 lbf-ft)
6. Bank sensor bolt : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
7. Rear brake light switch : Apply water resistant grease to the sliding surface.
8. Rear brake light switch spring : Apply thread lock to the thread part.
9. Rear brake pedal spring : Do not reuse.
10. Rear brake pedal

Rear Brake Pedal Removal and Installation 5) Loosen the lock-nut (1) and turning the push rod (2),
BENH17K14106020 separate the rod from the rear brake master cylinder
Removal
yoke (3).
1) Remove the right frame front cover. (Page 9D-18)
6) Remove the rear brake master cylinder bolts (4) and
2) Remove the EXCV cables (1) from the clamp (2). front footrest guard RH (5).
7) Remove the front footrest bracket RH (6).

5
4

2
1

2 3
IH17K1410086-01
6
3) Disconnect the EXCV cables (1) from the brackets IH17K1410089-04
(2).
8) Remove the cotter pin (1) and the rear brake master
cylinder yoke (2).

2
IH17K1410087-01

4) Disconnect the rear brake light switch lead wire IH17K1410090-01

coupler (1) and clamp (2).
9) Remove the rear brake light switch (1).

1
2 1

IH17K1410088-01
IH17K1410091-03
4A-35 Brake Control System and Diagnosis:

10) Remove the brake pedal spring (1). • When installing the front footrest bar RH, align the
cutaway (1) on the bar with the projection (2).

1 1

IH17K1410092-01

11) Remove the footrest holder bolt (1), brake pedal (2) IH17K1410096-01

and front footrest bar RH. • Apply thread lock to the footrest holder bolt (1), and
tighten the bolt to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
2
Footrest holder bolt (a): 39 N·m (4.0 kgf-m, 29.0
lbf-ft)
1

IH17K1410093-01

Installation
Install the rear brake pedal in the reverse order of
removal. Pay attention to the following points:
• Apply grease to the sliding surfaces of the front 1 , “A ”, (a )
footrest holder and rear brake pedal.
IH17K1410097-01
“A”: Grease 99000–25350 (SUZUKI WATER
• Install the rear brake light switch spring (1). Refer to
RESISTANT GREASE EP2)
“Front Footrest Bracket Construction” in Section 9E
(Page 9E-2).
“A”

“A”

IH17K1410094-01

IH17K1410095-04
 Brake Control System and Diagnosis: 4A-36

• Use new cotter pin (1). • Connect the rear brake light switch lead wire coupler
(1). Refer to “Wiring Harness Routing Diagram” in
Section 9A (Page 9A-13).

1
1

IH17K1410098-01

• Apply thread lock to the front footrest bracket bolts (1),

and tighten the bolts (1) to the specified torque. IH17K1410100-01

• Fix the EXCV cable No. 1 (1) and No. 2 (2) with the
“A”: Thread lock cement 99000–32150 (THREAD
clamp (3).
LOCK CEMENT 1322D)
• Tighten the lock-nut (2) to the specified torque.
2
• Apply thread lock to the rear brake master cylinder 1
bolts (3), and tighten the bolts to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D) 3

Tightening torque
Front footrest bracket bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
Rear brake master cylinder rod lock-nut (b): 18
N·m (1.8 kgf-m, 13.5 lbf-ft) IH17K1410101-02
Rear brake master cylinder bolt (c): 10 N·m (1.0 • Adjust the brake pedal height. (Page 4A-14)
kgf-m, 7.5 lbf-ft)
Rear Brake Pedal Inspection
BENH17K14106021
3, “A”, (c) 1, “ A ” , (a ) Refer to “Rear Brake Pedal Removal and Installation”
(Page 4A-34).
Inspect the brake pedal for wear and damage. If any
defect is found, replace rear brake pedal with new ones.
2, (b)

IH17K1410099-01

IH17K1410102-01
4A-37 Brake Control System and Diagnosis:

Specifications
Tightening Torque Specifications
BENH17K14107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake light switch screw (Page 4A-11) /
1.2 0.12 0.90
(Page 4A-27)
Rear brake master cylinder rod lock-nut (Page 4A-14) /
18 1.8 13.5 (Page 4A-30) /
(Page 4A-36)
Front brake caliper air bleeder valve 7.5 0.76 5.55 (Page 4A-16)
Front brake master cylinder air bleeder valve 6.0 0.61 4.45 (Page 4A-16)
Rear brake caliper air bleeder valve 6.0 0.61 4.45 (Page 4A-17)
Front brake master cylinder holder bolt 10 1.0 7.5 (Page 4A-24)
Brake hose union bolt (Page 4A-25) /
23 2.3 17.0
(Page 4A-31)
Brake lever pivot bolt 1.0 0.10 0.75 (Page 4A-27)
Brake lever pivot bolt lock-nut 6.0 0.61 4.45 (Page 4A-27)
Rear brake master cylinder mounting bolt 13 1.3 9.5 (Page 4A-30)
Footrest holder bolt 39 4.0 29.0 (Page 4A-35)
Front footrest bracket bolt 23 2.3 17.0 (Page 4A-36)
Rear brake master cylinder bolt 10 1.0 7.5 (Page 4A-36)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Hose Routing Diagram” (Page 4A-1)
“Rear Brake Hose Routing Diagram” (Page 4A-4)
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-23)
“Rear Brake Master Cylinder Assembly Components” (Page 4A-29)
“Rear Brake Pedal Components” (Page 4A-33)
“Fasteners Information” in Section 0C (Page 0C-12)
 Brake Control System and Diagnosis: 4A-38

Special Tools and Equipment

Recommended Service Material
BENH17K14108001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 4 — (Page 4A-12) / (Page
4A-15) / (Page 4A-16) /
(Page 4A-18) / (Page
4A-19) / (Page 4A-26) /
(Page 4A-32)
Grease SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4A-20) / (Page
4A-21) / (Page 4A-24) /
(Page 4A-27) / (Page
4A-27) / (Page 4A-30) /
(Page 4A-32) / (Page
4A-32)
SUZUKI WATER RESISTANT P/No.: 99000–25350 (Page 4A-35)
GREASE EP2
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 4A-30) / (Page
4A-35) / (Page 4A-36) /
(Page 4A-36)

NOTE
Required service material(s) is also described in:
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-23)
“Rear Brake Master Cylinder Assembly Components” (Page 4A-29)
“Rear Brake Pedal Components” (Page 4A-33)

Special Tool
BENH17K14108002
09900–06108
Snap ring pliers (Internal)
(Page 4A-25) /
(Page 4A-26) /
(Page 4A-26) /
(Page 4A-27) /
(Page 4A-31) /
(Page 4A-31) /
(Page 4A-32) /
(Page 4A-32)
4B-1 Front Brakes:

Front Brakes
Brakes

Repair Instructions
Front Brake Components
BENH17K14206001

8 (a)

3
2
(b)

1
1

1
2

(c)

IH17K1420001-02

1. Piston seal 6. Front brake disc : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
2. Dust seal 7. Brake caliper : Apply thread lock to the thread part.
3. Piston 8. Front brake caliper air breeder valve : Apply brake fluid.

4. Brake pad spring : 7.5 Nm (0.76 kgf-m, 5.55 lbf-ft) : Do not reuse.
5. Brake pad : 39 Nm (4.0 kgf-m, 29.0 lbf-ft)
 Front Brakes: 4B-2

Front Brake Pad Inspection 2) Remove the brake pads (1).

BENH17K14206002
The extent of brake pads (1) wear can be checked by NOTE
observing the grooved limit line “a” on the pads. When
Do not operate the front brake lever while
the wear exceeds the grooved limit line, replace the
removing the brake pads.
pads with new ones. (Page 4B-2)

“a”
1

IH17K1420002-02 IH17K1420004-01

3) Clean up the caliper especially around the caliper

Front Brake Pad Replacement pistons.
BENH17K14206003
4) Install the new brake pads.
NOTICE
NOTE
The right and left brake pads are installed
symmetrically and therefore the removal • Replace the brake pads as a set.
procedure for one side is the same as that for • Pushing back the caliper pistons into the
the other side. caliper will facilitate installation of the
brake pads. At the time, observe the
NOTE reservoir tank level not to exceed the
After replacing the brake pads, pump the upper line.
brake lever several times to check for proper
brake operation and then check the brake
fluid level.

1) Remove the front brake caliper mounting bolts (1)

and brake caliper (2).

IF04K1420004-01

IH17K1420003-02
4B-3 Front Brakes:

5) Install the brake caliper (1). 4) Remove the front brake caliper (1).
6) Tighten the front brake caliper mounting bolts (2) to
the specified torque.
Tightening torque
Front brake caliper mounting bolt (a): 39 N·m (
4.0 kgf-m, 29.0 lbf-ft) 1

2, (a)

IH17K1420007-01

Installation
1) Install the front brake caliper (1).
1
2) Tighten front brake caliper mounting bolts (2) to the
IH17K1420005-02
specified torque.
Tightening torque
Front Brake Caliper Removal and Installation Front brake caliper mounting bolt (a): 39 N·m (
BENH17K14206004
4.0 kgf-m, 29.0 lbf-ft)
NOTE
The right and left calipers are installed
symmetrically and therefore the removal 2 , (a )
procedure for one side is the same as that for
the other side. 1

Removal
1) Drain brake fluid. (Page 4A-18)
2) Place a rag underneath the brake hose union bolt on
the front brake caliper to catch any spilt brake fluid.
3) Remove the brake hose from the front brake caliper IH17K1420008-01
by removing the brake hose union bolt (1) and catch
3) Apply grease to the new seal washers.
the brake fluid in a suitable receptacle.
“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE)
1

IH17K1420006-01
“A ”
IH17K1420009-02
 Front Brakes: 4B-4

4) Install the brake hose union bolt (1) and new seal Disassembly
washers to brake hoses. 1) Remove the brake pads (1).
5) After setting the brake hoses to the stoppers (2),
tighten the brake hose union bolt (1) to the specified
torque. Refer to “Front Brake Hose Routing 1
Diagram” in Section 4A (Page 4A-1).
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

1, ( a) IH17K1420011-01

2) Remove the pad spring (1).

IH17K1420010-03

6) Route the speed sensor lead wire correctly.

• Without ABS model: (Page 4A-8)
• With ABS model: (Page 4E-9)
7) Bleed air from the brake system after installing the
caliper. (Page 4A-14) IH17K1420012-01

8) Check the brake fluid leakage referring to “Brake 3) Remove the pistons applying compressed air
Hose Inspection” in Section 4A (Page 4A-13) and gradually from the hole for the brake hose.
brake operation.
! WARNING
Front Brake Caliper Disassembly and Do not apply highly compressed air to the
Reassembly piston as it is. Place a cloth to prevent piston
BENH17K14206005
Refer to “Front Brake Caliper Removal and Installation” from jumping-out. Gradually apply
(Page 4B-3). compressed air. Do not place your fingers in
front of piston while applying compressed
! CAUTION air.
Take care not to damage piston and brake
caliper cylinder wall of front brake caliper.

NOTE
The right and left calipers are installed
symmetrically and therefore the disassembly
procedure for one side is the same as that for
the other side.

IH17K1420013-01
4B-5 Front Brakes:

4) Remove the dust seals (1) and piston seals (2). • Apply the brake fluid to new piston seals (1) and new
dust seals (2).
Brake fluid (DOT 4)
• Install the piston seals (1) and dust seals (2).

2 1 1 2

IF04K1420012-01

Reassembly
Reassemble the brake caliper in the reverse order of
disassembly. Pay attention to the following points: IH28K1430022-01

• Wash the brake caliper bores and pistons with • When installing the brake pad spring, fit the brake pad
specified brake fluid. Particularly wash the dust seal spring claws to the grooves of the brake caliper.
grooves and piston seal grooves.

NOTICE
• Wash the brake caliper components with
fresh brake fluid before reassembly. Never
use cleaning solvent or gasoline to wash
them.
• Do not wipe the brake fluid off after
washing the brake caliper components.
• When washing the brake caliper
components, use the specified brake fluid. IH17K1420014-01
Never use different types of fluid or
cleaning solvent such as gasoline,
Front Brake Caliper Parts Inspection
kerosine or the others. BENH17K14206006
Refer to “Front Brake Caliper Disassembly and
Brake fluid (DOT 4) Reassembly” (Page 4B-4).

Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any damage is found,
replace the brake caliper with a new one.

I649G1420012-02

IF04K1420014-01
 Front Brakes: 4B-6

Brake Caliper Piston

Inspect the pistons surface for any scratches or other
1
damage. If any damage is found, replace them with new
ones.

IH17K1420016-01

Installation
1) Make sure that the brake disc is clean and free of
IF04K1420015-01 any grease.
2) Apply thread lock to the brake disc bolts.
Brake Pad Spring
Inspect the brake pad spring for damage and excessive “A”: Thread lock cement 99000–32130 (THREAD
bend. If any defects are found, replace it with a new one. LOCK CEMENT 1360)
3) Install the front brake disc:
• Install the front brake disc LH with the brake disc
bolts.
• Install the front brake disc RH first, and then put
on the front wheel speed sensor rotor with the
brake disc bolts.

NOTE
The stamped mark (1) on the brake disc and
speed sensor rotor should face to the
outside.
IF04K1420016-01

Front Brake Disc Removal and Installation [A]

BENH17K14206007
Refer to “Front Wheel Assembly Removal and 1
Installation” in Section 2D (Page 2D-4).

Removal
1) Remove the front wheel speed sensor rotor (1) and
front brake disc RH (2).

2
IH17K1420017-01

[B]
1

IH17K1420015-01

2) Remove the front brake disc LH (1).

IH17K1420018-01

[A]: Front brake disc [B]: Front wheel speed sensor rotor
4B-7 Front Brakes:

4) Tighten the brake disc bolts (1) the specified torque. Front Brake Disc Inspection
BENH17K14206008
Tightening torque Brake Disc Thickness
Brake disc bolt (a): 18 N·m (1.8 kgf-m, 13.5 lbf-ft) Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
[A] Replace the brake disc if the thickness is less than the
1, ( a) service limit or if defect is found.
Front brake disc thickness
[Limit]: 4.5 mm (0.18 in)
Special tool
(A): 09912–66310

(A)
IH17K1420019-02

[B]

1, ( a)

ID26J1420029-01

Brake Disc Runout

1) Dismount the front brake pads.
Refer to “Front Brake Pad Replacement” (Page 4B-
2).
IH17K1420020-02
2) Measure the runout using the dial gauge.
[A]: RH side [B]: LH side Replace the disc if the runout exceeds the service
limit.
5) After installing the front wheel, check the clearance
between the front wheel speed sensor and sensor Front brake disc runout
rotor. Refer to “Wheel Speed Sensor and Sensor [Limit]: 0.30 mm (0.012 in)
Rotor Inspection” in Section 4E (Page 4E-50). Special tool
(A): 09900–20607
09900–20701

(A)

ID26J1420030-04

3) Remount the front brake pads.

Refer to “Front Brake Pad Replacement” (Page 4B-
2).
 Front Brakes: 4B-8

Specifications
Tightening Torque Specifications
BENH17K14207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front brake caliper mounting bolt (Page 4B-3) /
39 4.0 29.0
(Page 4B-3)
Brake hose union bolt 23 2.3 17.0 (Page 4B-4)
Brake disc bolt 18 1.8 13.5 (Page 4B-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Components” (Page 4B-1)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K14208001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 4 — (Page 4B-5) / (Page 4B-
5)
Grease SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4B-3)
Thread lock cement THREAD LOCK CEMENT 1360 P/No.: 99000–32130 (Page 4B-6)

NOTE
Required service material(s) is also described in:
“Front Brake Components” (Page 4B-1)

Special Tool
BENH17K14208002
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 4B-7) (Page 4B-7)

09912–66310
Micrometer (0 - 25 mm)
(Page 4B-7)
4C-1 Rear Brakes:

Rear Brakes
Brakes

Repair Instructions
Rear Brake Components
BENH17K14306001

4
2
10
3 (a)

9 (b)

(f)
5
9 (c)

8 (d)

(e)

IH17K1430033-03

1. Rear brake caliper bracket 8. Rear brake pad pin plug : 35 Nm (3.6 kgf-m, 26.0 lbf-ft)
2. Piston 9. Rear brake caliper sliding pin : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
3. Piston seal 10. Rubber boot : Apply silicone grease to the sliding surface.
4. Dust seal : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft) : Apply thread lock to the thread part.
5. Rear brake pad/Shim set : 27 Nm (2.8 kgf-m, 20.0 lbf-ft) : Apply thread lock to the thread part.
6. Rear brake disc : 17 Nm (1.7 kgf-m, 12.5 lbf-ft) : Apply brake fluid.

7. Pad spring : 2.5 Nm (0.25 kgf-m, 1.85 lbf-ft) : Do not reuse.
 Rear Brakes: 4C-2

Rear Brake Pad Inspection 2) Remove the rear brake pad mounting pin (1).
BENH17K14306002
The extent of brake pads (1) wear can be checked by 3) Remove the brake pads (2).
observing the grooved limit line “a” on the pads. When NOTE
the wear exceeds the grooved limit line, replace the
pads with new ones. (Page 4C-2) Do not operate the brake pedal while
removing the brake pads.

“a” 1

2 1

IH17K1430001-02

IH17K1430003-01
Rear Brake Pad Replacement 4) Clean up the caliper especially around the caliper
BENH17K14306003
piston.
NOTE
5) Assemble the new brake pads (1), insulators (2) and
After replacing the brake pads, pump the shims (3).
brake pedal several times to check for proper
brake operation and then check the brake NOTE
fluid level. • Replace the brake pads as a set.
1) Remove the rear brake pad pin plug (1). • Pushing back the caliper piston into the
caliper will facilitate installation of the
brake pads. At the time, observe the
reservoir tank level not to exceed the
upper line.

1 1
1

IH17K1430002-01
3
3
2

IH17K1430004-02
4C-3 Rear Brakes:

6) Install the new brake pads. Rear Brake Caliper Removal and Installation
BENH17K14306004
NOTE Removal
Check the pads end (1) for proper fit to the 1) Drain brake fluid. (Page 4A-18)
brake pad spring. 2) Remove the rear wheel. (Page 2D-9)
3) Set the rear brake caliper bracket to the swingarm
temporarily.
4) Remove the brake pads. (Page 4C-2)
1 1
5) Remove the speed sensor lead wire clamp bolt (1).

IH17K1430005-01
1
7) Tighten the rear brake pad mounting pin (1) to the
specified torque.
Tightening torque IH17K1430008-01
Rear brake pad mounting pin (a): 17 N·m (1.7 6) Place a rag underneath the union bolt on the brake
kgf-m, 12.5 lbf-ft) caliper to catch any spilt brake fluid.
7) Remove the rear brake hose from the brake caliper
by removing the union bolt (1) and catch the brake
fluid in a suitable receptacle.

1, ( a) 1

IH17K1430006-01

8) Tighten the rear brake pad pin plug (1) to the

specified torque.
Tightening torque IH17K1430009-01

Rear brake pad pin plug (a): 2.5 N·m (0.25 kgf- 8) Remove the brake caliper sliding pin (1) and the rear
m, 1.85 lbf-ft) brake caliper (2) from the rear brake caliper bracket.

1, ( a)
2

IH17K1430007-01 IH17K1430010-01
 Rear Brakes: 4C-4

9) Remove the rear brake caliper bracket (1) from the 4) Check that the boot ends (1) into the sliding pin
swingarm. groove.

1
1 1
IH17K1430011-01 IH17K1430014-01

5) Apply grease to the new seal washers.

Installation
“A”: Grease 99000–25100 (SUZUKI SILICONE
1) Set the rear brake caliper bracket to the swingarm
GREASE)
temporarily.
2) Apply grease to the rear brake caliper sliding pins.
“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE)

“A”

“A ”

IH17K1430015-01

6) Temporally install the rear brake hose to the rear

brake caliper with the union bolt (1) and new seal
“A” washers.
IH17K1430012-01 7) Install the speed sensor lead wire clamp (2) with the
3) Install the rear brake caliper to the rear brake caliper bolt (3).
bracket and tighten the rear brake caliper sliding pin
(1) to the specified torque.
1
Tightening torque
Rear brake caliper sliding pin (a): 27 N·m (2.8
kgf-m, 20.0 lbf-ft)

1, ( a ) IH17K1430016-02

8) Remove the rear brake caliper bracket from the

swingarm.
9) Install the rear wheel. (Page 2D-9)
10) Install the brake pads. (Page 4C-2)
IH17K1430013-01
4C-5 Rear Brakes:

11) After setting the brake hose union to the stopper (1), 2) Remove the rear brake caliper sliding pin (1).
tighten the rear brake hose union bolt (2) to the
specified torque.
1
Tightening torque
Rear brake hose union bolt (a): 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)

2 , ( a)
1

IH17K1430019-01

3) Remove the pad spring (1).

4) Remove the rubber boot (2).

IH17K1430017-01 1
12) Bleed air from the brake system after installing the
caliper. (Page 4A-14)
13) Check the brake fluid leakage referring to “Brake
Hose Inspection” in Section 4A (Page 4A-13) and
brake operation.
2

Rear Brake Caliper Disassembly and

Reassembly
BENH17K14306005 IH17K1430020-01
Refer to “Rear Brake Caliper Removal and Installation” 5) Remove the piston applying compressed air
(Page 4C-3). gradually from the hole for the brake hose.
! CAUTION ! WARNING
Take care not to damage piston and brake
Do not apply highly compressed air to the
caliper cylinder wall of rear brake caliper.
piston as it is. Place a cloth to prevent piston
from jumping-out. Gradually apply
Disassembly
compressed air. Do not place your fingers in
1) Remove the pad spring (1) and rubber boot (2). front of piston while applying compressed
air.
2

IH17K1430018-01

IH17K1430021-01
 Rear Brakes: 4C-6

6) Remove the dust seal (1) and piston seal (2). • Apply the brake fluid to new piston seal (1) and new
dust seal (2).
Brake fluid (DOT 4)
• Install the piston seal (1) and dust seal (2).
1

IH17K1430022-01

Reassembly
Reassemble the brake caliper in the reverse order of
disassembly. Pay attention to the following points: IH28K1430022-01

• Wash the brake caliper bore and piston with specified • Set the pad spring (1).
brake fluid. Particularly wash the dust seal groove and • Set the rubber boot (2) to the sleeve securely.
piston seal groove.

NOTICE 1

• Wash the brake caliper components with

fresh brake fluid before reassembly. Never
use cleaning solvent or gasoline to wash
them.
• Do not wipe the brake fluid off after 2
washing the brake caliper components.
• When washing the brake caliper
components, use the specified brake fluid.
IH17K1430020-01
Never use different types of fluid or
cleaning solvent such as gasoline,
kerosine or the others.

Brake fluid (DOT 4)

I649G1430018-02
4C-7 Rear Brakes:

• Apply thread lock to the thread part and install the rear Rear Brake Caliper Parts Inspection
brake caliper sliding pin (1) and tighten them to the BENH17K14306006

specified torque. Refer to “Rear Brake Caliper Disassembly and

Reassembly” (Page 4C-5).
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D) Brake Caliper Cylinder
Tightening torque Inspect the brake caliper cylinder wall for nicks,
Rear brake caliper sliding pin (a): 12 N·m (1.2 kgf- scratches or other damage. If any damage is found,
m, 9.0 lbf-ft) replace the brake caliper with a new one.

“A”

IH17K1430023-01
IH17K1430031-01

Piston
Inspect the piston surface for any scratches or other
1 damage. If any defects are found, replace the piston with
a new one.

(a)

IH17K1430032-01

• Install the pad spring (1) and rubber boot (2).

2
IH17K1430024-01

Rear Brake Pad Mounting Pin

1
Inspect the rear brake pad mounting pin for wear and
other damage. If any damage is found, replace the rear
brake pad mounting pin with a new one.

IH17K1430018-01

IH17K1430025-01
 Rear Brakes: 4C-8

Rubber Boot Rear Brake Disc Removal and Installation

Inspect the rubber boots for damage and wear. If any BENH17K14306007

defects are found, replace them with new ones. Refer to “Rear Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-9).

Removal
1) Remove the rear brake disc (1).

IH17K1430026-01

Pad Spring
Inspect the pad springs for damage and excessive bend.
If any defects are found, replace the pad spring with new IH17K1430029-01

ones.
Installation
1) Make sure that the brake disc (1) is clean and free of
any grease.
2) Apply thread lock to the brake disc bolts.
“A”: Thread lock cement 99000–32130 (THREAD
LOCK CEMENT 1360)
3) Install the rear brake disc (1) with the brake disc
bolts.

NOTE
IH17K1430027-01 The stamped mark (2) on the brake disc
should face to the outside.
Rear Brake Caliper Sliding Pin
Inspect the rear brake caliper sliding pins for wear and 4) Tighten the brake disc bolts to the specified torque.
other damage. If any damage is found, replace the rear Tightening torque
brake caliper sliding pin with a new one. Brake disc bolt (a): 35 N·m (3.6 kgf-m, 26.0 lbf-ft)

(a)
IH17K1430028-01
IH17K1430030-02
4C-9 Rear Brakes:

Rear Brake Disc Inspection Brake Disc Runout

BENH17K14306008
Brake Disc Thickness 1) Dismount the rear brake pads.
Check the brake disc for damage or cracks and measure Refer to “Rear Brake Pad Replacement” (Page 4C-
the thickness using the micrometer. 2).
Replace the brake disc if the thickness is less than the 2) Measure the runout using the dial gauge.
service limit or if defect is found. Replace the disc if the runout exceeds the service
limit.
Rear brake disc thickness
[Limit]: 4.5 mm (0.18 in) Rear brake disc runout
[Limit]: 0.30 mm (0.012 in)
Special tool
(A): 09912–66310 Special tool
(A): 09900–20607
09900–20701

(A)

(A)

ID26J1430036-01

ID26J1430037-04

3) Remount the rear brake pads.

Refer to “Rear Brake Pad Replacement” (Page 4C-
2).

Specifications
Tightening Torque Specifications
BENH17K14307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear brake pad mounting pin 17 1.7 12.5 (Page 4C-3)
Rear brake pad pin plug 2.5 0.25 1.85 (Page 4C-3)
Rear brake caliper sliding pin 27 2.8 20.0 (Page 4C-4)
Rear brake hose union bolt 23 2.3 17.0 (Page 4C-5)
Rear brake caliper sliding pin 12 1.2 9.0 (Page 4C-7)
Brake disc bolt 35 3.6 26.0 (Page 4C-8)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Brake Components” (Page 4C-1)
“Fasteners Information” in Section 0C (Page 0C-12)
 Rear Brakes: 4C-10

Special Tools and Equipment

Recommended Service Material
BENH17K14308001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 4 — (Page 4C-6) / (Page 4C-
6)
Grease SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4C-4) / (Page 4C-
4)
Thread lock cement THREAD LOCK CEMENT 1360 P/No.: 99000–32130 (Page 4C-8)
THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 4C-7)

NOTE
Required service material(s) is also described in:
“Rear Brake Components” (Page 4C-1)

Special Tool
BENH17K14308002
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 4C-9) (Page 4C-9)

09912–66310
Micrometer (0 - 25 mm)
(Page 4C-9)
4E-1 ABS:

ABS
Brakes

Precautions
Precautions for ABS Service • Be sure to follow the trouble diagnosis procedure
BENH17K14500001 described in “ABS Check” (Page 4E-12). If the trouble
• Battery voltage is always applied to the ABS control diagnosis procedure is not followed properly, incorrect
unit. Therefore, disconnect the battery (–) lead wire diagnosis may result. (If the incorrect procedure is
before disconnecting the ABS control unit coupler. performed, other DTC may be stored in the ABS
• When the ABS control unit coupler is connected, do control unit.)
not disconnect the sensor coupler(s) with the ignition
switch turned ON. If the sensor coupler is Precautions for ABS
disconnected with the ignition ON, DTC will be stored BENH17K14500003
in the ABS control unit. Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-2) and “Precautions for ABS
• The wheel speed sensor and IMU cannot be
Service” (Page 4E-1).
disassembled.

Precautions for IMU

Precautions for Diagnosing Troubles BENH17K14500004
BENH17K14500002
To ensure that the trouble diagnosis is done accurately • Pay attention not to expose the IMU to strong shocks,
and smoothly, observe the following and follow “ABS such as striking or dropping it.
Check” (Page 4E-12). • When IMU is removed / installed, do not use an
• The information on the DTCs detected by the ABS impact wrench, as shock it generates may damage
control unit can be checked and cleared using the the IMU.
special tool.

NOTE
After repairing the trouble, clear the DTC
using special tool. (Page 4E-19)

• If the motorcycle was operated in any of the following

conditions, ABS indicator light may light but this does
not indicate any fault in ABS.
– The motorcycle is stuck in mud, sand, etc.
– Wheel spins while driving.
IH17K1450088-02
– Wheels are rotated while the motorcycle is jacked
up.

General Description
ABS Description
BENH17K14501008
ABS control unit (1) calculates signals from IMU (2), front wheel speed sensor and rear wheel speed sensor and
transmits control signals to Hydraulic Unit (HU) (3). HU controls braking force based on the control signals. This ABS
control unit/HU and IMU cannot be disassembled.

1
3
2

IH17K1450004-04
 ABS: 4E-2

2 1

4 3

12

5 5

6 6

7 7

9 8
13

11 10

14

16 15

17
IH17K1450009-01

1. Front brake lever/master cylinder 10. Front wheel speed sensor

2. Rear brake pedal/master cylinder 11. Rear wheel speed sensor
3. Front brake switch 12. HU
4. Rear brake switch 13. ABS control unit
5. Inlet solenoid valve 14. ABS indicator light
6. Outlet solenoid valve 15. Front system
7. Reservoir 16. Rear system
8. Front brake caliper 17. IMU
9. Rear brake caliper
4E-3 ABS:

IMU
IMU (1) consists of 3-axis G sensor and 3-axis gyro sensor. These sensors detect the longitudinal acceleration, lateral
acceleration, vertical acceleration, pitch rate, roll rate and yaw rate of the vehicle, and transmit their signals to ABS
control unit and ECM through CAN communication. ABS controls rear lift adjusting the braking force based on the
signals from IMU.

[F] [D]

[A]

[B]
1 [E]

[C]
IH17K1450093-01

[A]: Longitudinal acceleration [C]: Vertical acceleration [E]: Roll rate

[B]: Lateral acceleration [D]: Pitch rate [F]: Yaw rate

Motion Track Brake System

Rear wheel lift-up restraint control
In response to harsh braking, ABS control unit calculates the inputted IMU signal and controls front brake fluid
pressure to restrain rear wheel lift up and achieves high running performance of the motorcycle.
 ABS: 4E-4

ABS Control Unit Calculating Process

In the ABS control unit calculating process, calculation for ABS control and self-diagnosis with fail-safe operation are
carried out. The control unit executes self-diagnosis continuously and, when any malfunction is detected, the unit
cancels the ABS control and returns the brake system to the normal brake. The malfunction is stored as DTC.

Normal calculating process Calculating process when a malfunction occurs

Ignition switch turned to ON

ABS control unit Initialization

Malfunction
Self-diagnosis indicated
(during start up)
No malfunction

Wheel speed sensor signal and ABS indicator light

IMU signal enters lights up

YES
ABS control calculation Is ABS under control ?
NO

Hydraulic unit control signal Prohibition of ABS control Interim ABS control
output

Self-diagnosis (while riding) Diagnostic trouble code

Malfunction memorized
indicated
Correct
IH17K1450008-02

Wheel Speed Sensor Description

BENH17K14501009
The wheel speed is detected by the hall IC type wheel speed sensor (1) and sensor ring (2). The wheel speed sensor
is fixed to the body and includes a hall IC (3) having 2 hall elements. As the sensor ring is located on the wheel hub, it
turns along with the wheel. The wheel speed sensor feeds pulse signals in proportion to the wheel speed to ABS
control unit, which then calculates the wheel speed based on such signal information.

1 3 5
IH17K1450091-02

4. Magnet 5. Magnetic field lines

4E-5 ABS:

Self-diagnosis Function and ABS Indicator Light Description

BENH17K14501004
The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic
trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of the malfunction. The
special tool, when connected to the mode select coupler (2P), enables the ABS indicator light to display the diagnostic
trouble codes.

ABS Indicator Light

The ABS indicator light (1) informs the rider of any ABS malfunctions. If a malfunction occurred, the ABS indicator light
flashes, during the self-diagnosis, to indicate the diagnostic trouble code so that the correct part can be repaired.
• When the ignition switch is turned to ON, the ABS indicator light lights up even if no malfunction has occurred, to
indicate that the LED is not burnt out. It will go off after the motorcycle is ridden at more than 10 km/h (6 mile/h).
• If an ABS malfunction has occurred, the ABS indicator light keeps lighting up.

IH17K1450010-02

NOTE
When a malfunction has occurred in the ABS, connect the special tool to the mode select coupler (2P)
to display the diagnostic trouble code on the ABS indicator light. (Page 4E-18)

Special tool
(A): 09930–82760

(A )

IH17K1450011-01
 ABS: 4E-6

ABS Operation and ABS Indicator Light

The ABS indicator light (1) shows the ABS operating condition. During normal operation, the ABS indicator light lights
up when the ignition switch is turned to ON and goes off after the motorcycle is ridden at more than 10 km/h (6 mile/h).
If a malfunction has occurred, the ABS indicator light keeps lighting up.
The ABS indicator light goes off when the motorcycle is The ABS is normally activated.
ridden at more than 10 km/h (6 mile/h).
The ABS indicator light keeps lighting up even though the One or more malfunction has been found and ABS
motorcycle is ridden at more than 10 km/h (6 mile/h). activation been hanged up.
The ABS indicator light does not light up when turning the Check the wire harness and combination meter. (Page
ignition switch ON. 4E-15)

IH17K1450010-02

Stored DTCs (Diagnostic Trouble Codes)

As for the diagnostic trouble code, the code of the first malfunction occurred during one ignition ON period will be
stored. Pay attention to the fact that even though there may occur several malfunctions in one ON period, only one
code will be stored. Codes of malfunction that occurred in the past are all stored, but the same diagnostic trouble code
will not be redundant.
Check and see if any diagnostic trouble code remains, by actually running the machine to activate ABS and by
carrying out the self-diagnosis after deleting the diagnostic trouble code once the malfunctioned part is repaired.

Fail-safe Function Description

BENH17K14501005
If the main CPU detects an occurrence of a malfunction in the ABS, the fail-safe relay is set OFF and ABS indicator
light is turned ON. Consequently, no current will be applied to the motor and solenoid valves and the ABS is not
activated. In this case, the brake system functions as a conventional brake. The main and sub CPUs monitor each
other and if a CPU detects a malfunction, the fail-safe relay is set OFF, ABS indicator light is turned ON and brake
system is fixed in a conventional brake. However, if a malfunction occurs while the ABS is being activated and the
main CPU judges that the ABS control can be continued, the ABS indicator light is turned ON and the provisional
control of the ABS is set. Upon the moment when the ABS provisional control is over, the fail-safe relay will be set
OFF.
4E-7 ABS:

Schematic and Routing Diagram

ABS Circuit Diagram
BENH17K14502001

15
W/Y T3 10
T14 O
W/B T8
2 3
B/Bl T17 T7 G 18

16

W/R T2
4 T16 P/Bl 18
B/R T11
17
14
19

R/Bl
B/Y T4
5
W/Y T13
T10
19
11 12
6

[A] Br/R T15

10 1
7
13
11 2
12 3 W/B T6
13 4
14 5
15 6
16 7
17 8 8 9 Gr/R T5

18 9

B/W T1
[a]

IH17K1450013-02

[A]: ABS control coupler (View: [a]) 7. Brake light switch 14. Main fuse (30A)
1. ABS hydraulic unit / control module assembly 8. Brake light 15. Ignition fuse (10A)
2. Ignition switch 9. Mode select coupler (6P) 16. Signal fuse (10A)
3. IMU 10. Mode select coupler (2P) 17. ABS fuse (30A)
4. Front wheel speed sensor 11. Fail safe relay 18. To ECM
5. Rear wheel speed sensor 12. ABS motor 19. To battery
6. ABS indicator light 13. Solenoid valves
 ABS: 4E-8

Terminal Wire color Circuit

1 B/W ABS control unit ground circuit
2 W/R Front wheel speed sensor power supply circuit
3 W/Y Ignition power supply circuit
4 B/Y Right rear wheel speed sensor power supply circuit
5 Gr/R Mode select coupler (6P) circuit
6 W/B Brake light signal circuit
7 G Front wheel speed sensor output circuit
8 W/B CAN communication line (High)
10 R/Bl Pump motor and solenoid valve power supply circuit
11 B/R Front wheel speed sensor signal circuit
13 W/Y Rear wheel speed sensor signal circuit
14 O Mode select coupler (2P) circuit
15 Br/R ABS indicator light drive circuit
16 P/Bl Rear wheel speed sensor output circuit
17 B/Bl CAN communication line (Low)
4E-9 ABS:

Front Wheel Speed Sensor Routing Diagram

BENH17K14502003

[A]

[B]

4 7

[D] [C]
5

IH17K1450015-03

[A]: Pass the front wheel speed sensor lead wire through the right 3. Clamp
side of the pipe joint. : Clamp the front wheel speed sensor lead wire in front of the brake hose at
the marking point.
[B]: Pass the wheel speed sensor lead wire along the front of the 4. Clamp
brake hose surely. : Clamp the front wheel speed sensor lead wire in outside of the brake
hose at the brake hose end fitting aligning the lead wire protector upper
end with the clamp lower end. Face the clamp opening backward.
[C]: Touch the clamp end to the stopper on the front fork and 5. Clamp
tighten the bolt. : Fix the front wheel speed sensor lead wire sleeve to the clamp.
[D]: Pass the front wheel speed sensor lead wire behind the brake 6. Front wheel speed sensor
hose end fitting.
1. Clamp 7. Front wheel speed sensor lead wire
: Clamp the sleeve portion of the front wheel speed sensor
lead wire behind the brake pipe securely.
 ABS: 4E-10

2. Clamp
: Clamp the front wheel speed sensor lead wire above the
brake hose at the marking point.

Rear Wheel Speed Sensor Routing Diagram

BENH17K14502004

“a”

2 [D]

“b”
[A]

“c”

[B]

6
4

[C]

[A]
IH17K1450016-03
4E-11 ABS:

[A]: Pass the rear wheel speed sensor lead wire outside of the brake hose. 4. Clamp
: Clamp the rear wheel speed sensor lead wire in front of the brake
hose at the marking point.
[B]: Fix the rear wheel speed sensor lead wire sleeve to the clamp. 5. Clamp
: Fix the rear wheel speed sensor lead wire sleeve to the clamp.
[C]: Touch the clamp end to the stopper on the rear brake caliper bracket and 6. Rear wheel speed sensor
tighten the bolt.
[D]: Clamp the rear wheel speed sensor lead wire under the seat rail. 7. Rear brake caliper
1. Clamp “a”: 100 mm (3.94 in)
: Clamp the rear wheel speed sensor lead wire outside of the brake hose
at the marking point.
2. Clamp “b”: 10 – 20 mm (0.4 – 0.7 in)
: Clamp the rear wheel speed sensor lead wire outside of the brake hose.
3. Clamp “c”: 5 mm (0.2 in)
: Clamp the rear wheel speed sensor lead wire above the brake hose.

Component Location
ABS Components Location
BENH17K14503001

7 4
6
IH17K1450017-02
 ABS: 4E-12

1. ABS control unit/HU 3. Mode select coupler (6P) 5. Front wheel speed sensor rotor 7. Rear wheel speed sensor rotor
2. Mode select coupler (2P) 4. Front wheel speed sensor 6. Rear wheel speed sensor 8. IMU

Diagnostic Information and Procedures

ABS Check Step 4
BENH17K14504001
Refer to the description after the following general flow Brakes diagnosis
for details of each step. 1) Inspect and repair the ABS. (Page 4E-15)

Step 1 Is the malfunction detected?

Malfunction analysis Yes Repair or replace the malfunction part,
1) Perform “Customer Complaint Analysis” (Page and then go to Step 6.
4E-13).
No Go to Step 5.
2) Perform “Problem Symptom Confirmation” (Page
4E-14). Step 5
3) Perform “DTC Check, Record and Clearance” Intermittent problem check
(Page 4E-14) and recheck DTC. 1) Check for intermittent troubles. (Page 00-2)
Is the same DTC detected again after performing Is the malfunction detected?
the DTC clearance?
Yes Repair or replace the malfunction part,
Yes Inspect and repair referring to the
then go to step 6.
applicable DTC troubleshooting, and then
go to Step 6. No Go to Step 6.
No Go to Step 2. Step 6
Final confirmation test
Step 2
Visual inspection 1) Perform “Final Confirmation Test” (Page 4E-14).
1) Perform “Visual Inspection” (Page 4E-14). Does the trouble recur?
Is there any faulty condition? Yes Go to Step 4.
Yes Repair or replace the malfunction part, No End.
and then go to Step 6.

No Go to Step 3.

Step 3
Riding test
1) Perform “Riding Test” (Page 4E-14).
Is the malfunction detected?

Yes Repair or replace the malfunction part,

and then go to Step 6.

No Go to Step 4.
4E-13 ABS:

Customer Complaint Analysis

Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following table will facilitate collecting the
information to the point required for the proper analysis and diagnosis.

IH17K1450018-01

NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristic of each market.
 ABS: 4E-14

Problem Symptom Confirmation NOTE

If a symptom in “Customer Questionnaire” is found or After deleting the DTC, perform “Riding Test”
reproduced in the vehicle, confirm the symptom is (Page 4E-14) and then recheck the DTC.
problem or not. (This step should be done with the
customer if possible.) Check the ABS indicator light.
(Page 4E-15) Riding Test
Ride the motorcycle at more than 30 km/h (19 mile/h)
DTC Check, Record and Clearance and quickly apply the brakes to check that the ABS
Perform “DTC (Diagnostic Trouble Code) Output” (Page activates correctly.
4E-18) procedure, record it and then clear it. (Page
4E-19) Final Confirmation Test
Recheck DTC. (Page 4E-18) Confirm that the problem symptom is not observed any
more and ABS is free from any abnormal conditions. If
what has been repaired is related to the malfunction
DTC, clear the DTC referring to “DTC (Diagnostic
Trouble Code) Deleting” (Page 4E-19) and perform test
riding and confirm that the DTC is not indicated.

Visual Inspection
BENH17K14504002
Check the following parts and systems visually.
Inspection item Referring section
Couplers of electric wire harness Disconnection, friction “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-2)
Fuses Burning “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-2)
Brake pad Worn “Front Brake Pad Inspection” in
Section 4B (Page 4B-2) and “Rear
Brake Pad Inspection” in Section 4C
(Page 4C-2)
Brake fluid Level, leakage “Brake Fluid Level Check” in Section
4A (Page 4A-12)
ABS indicator light Operation “ABS Indicator Light Inspection” (Page
4E-15)
Tire Pressure “Tire Inspection and Cleaning” in
Section 2D (Page 2D-13)
Type, size “Tire Inspection and Cleaning” in
Section 2D (Page 2D-13)
Damage, wear “Tire Inspection and Cleaning” in
Section 2D (Page 2D-13)
Wheel Runout, play “Wheel / Wheel Axle Inspection” in
Section 2D (Page 2D-11)
Other parts that can be checked visually —

NOTICE
• The standard tire fitted on this motorcycle is 120/70ZR17M/C (58W) for front and 190/55ZR17M/C
(75W) for rear. The use of tires other than those specified may cause instability. It is highly
recommended to use a SUZUKI Genuine Tire.
• Replace the tire as a set, otherwise the DTC C1625 (25) may be stored.
4E-15 ABS:

ABS Symptom Diagnosis

BENH17K14504003

Condition Possible cause Correction / Reference Item

The ABS indicator light Malfunctioning the ABS function. Perform the ABS check. (Page 4E-12)
keeps lighting up even Malfunctioning the ABS indicator light Check the ABS indicator light circuit. (Page
though the motorcycle is circuit. 4E-15)
ridden at more than 10
km/h (6 mile/h).
The ABS indicator light Malfunctioning the ABS function. Perform the ABS check. (Page 4E-12)
does not light up when Malfunctioning the ABS indicator light Check the ABS indicator light circuit. (Page
turning the ignition switch circuit. 4E-15)
to ON. Malfunctioning the combination meter. Check the combination meter. (Page 9C-7)

ABS Indicator Light Inspection Step 3

BENH17K14504004
Circuit Diagram (The ABS indicator light does not light up)
Refer to “ABS Circuit Diagram” (Page 4E-7). 1) Turn the ignition switch OFF.
2) Remove the front seat. (Page 9D-19)
Troubleshooting
3) Open the fuse box and inspect the signal fuse (10
Step 1 A) (1).
1) Check if the ABS indicator light (1) lights up when NOTE
turning the ignition switch ON.
If a fuse is blown, find the cause of the
problem and correct it before replacing the
1
fuse.

IH17K1450010-02

Does the ABS indicator light up?

Yes Go to Step 2.

No Go to Step 3.
IH17K1450020-02
Step 2
Is the signal fuse OK?
(The ABS indicator light lights up)
1) Ride the motorcycle at more than 10 km/h (6 mile/ Yes Go to Step 4.
h).
No Replace the signal fuse.
Does the ABS indicator light go off?

Yes Normal (No DTC exists)

No • DTC output. (Page 4E-18)

• If DTC can not be output (the ABS
indicator light does not flash), go to
Step 6.
 ABS: 4E-16

Step 4 Step 6
1) Disconnect the ABS control unit coupler. (Page (The ABS indicator light does not go off)
4E-45) 1) Turn the ignition switch OFF.
2) Turn the ignition switch ON with the ABS control 2) Remove the front seat. (Page 9D-19)
unit coupler disconnected, measure the voltage 3) Open the fuse box and inspect the ignition fuse
between “T15” (Br/R) and “T1” (B/W) at the (10 A) (1).
coupler.
NOTE
If a fuse is blown, find the cause of the
problem and correct it before replacing the
fuse.
1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450021-01

Is voltage 7.5 – 9.5 V?

Yes Go to Step 5.

No • Inspect the wire harness. (Faulty

indicator light wire or ground wire) IH17K1450023-01

• Faulty combination meter. Is the ignition fuse OK?

Step 5 Yes Go to Step 7.
1) Turn the ignition switch OFF.
No Replace the ignition fuse.
2) Check for continuity between “T1” (B/W) at the
ABS control unit coupler and body ground. Step 7
1) Disconnect the ABS control unit coupler. (Page
4E-45)
1 2 3 4 5 6 7 8
10 11 13 14 15 16 17 2) Turn the ignition switch ON with the ABS control
unit coupler disconnected, measure the voltage
between “T3” (W/Y) terminal and “T1” (B/W)
terminal at the coupler.

IH17K1450022-01

Is continuity indicated?

Yes Replace the ABS control unit/HU. (Page 1 2 3 4 5 6 7 8

10 11 13 14 15 16 17
4E-45)

No Inspect the wire harness. (Faulty ground

wire)

IH17K1450024-01

Is the voltage 12.0 V or more?

Yes Go to Step 8.

No Inspect the wire harness. (Faulty ignition

wire or ground wire)
4E-17 ABS:

Step 8 Step 9
1) Measure the voltage between “T15” (Br/R) 1) Turn the ignition switch OFF.
terminal and “T1” (B/W) terminal at the ABS 2) Short the mode select coupler (2P) terminals
control unit coupler. using the special tool.
Special tool
(A): 09930–82760

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

(A )

IH17K1450021-01

Is voltage 7.5 – 9.5 V?

Yes Go to Step 9.
IH17K1450011-01
No Inspect the wire harness. (Faulty indicator
3) Check for continuity between “T14” (O) and “T1”
light wire)
(B/W) at the ABS control unit coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450025-01

Is continuity indicated?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Inspect the wire harness. (Faulty mode

select coupler wire)
 ABS: 4E-18

DTC (Diagnostic Trouble Code) Output

BENH17K14504005
NOTE
• If there is a DTC recorded, the ABS
(A )
indicator light repeatedly flashes in a
cyclic manner.
• If no DTCs are memorized, the ABS
indicator light keeps lighting up.
• In the case that the mode select switch is
turned OFF or the vehicle speed (both
wheels) exceeds 2 km/h (1 mile/h), the
output of DTC will be interrupted. IH17K1450011-01

• Don’t disconnect couplers from ABS HU, 4) Switch the special tool to ON.
the battery cable from the battery, ABS HU
ground wire harness from the engine or
main fuse before confirming the
malfunction code (self-diagnostic trouble
code) stored in memory. Such
disconnection will erase the memorized
information in ABS HU memory.
• Be sure to read “Precautions for Electrical
Circuit Service” in Section 00 (Page 00-2)
and “Precautions for ABS Service” (Page
4E-1) before inspection and observe what
is written there. I718H1450040-02

• After carrying out DTC deleting and ABS 5) Turn the ignition switch ON.
operation check, explain to the customer The ABS indicator light (1) starts flashing to indicate
that the ABS is operating correctly. the DTC. (Page 4E-21)
(Page 4E-19) NOTE
• DTC can be checked by using the SDS-II.
If the DTCs are to be output for a long time,
Refer to the SDS-II operation manual for
remove the HEAD-LO fuse in order to prevent
further details.
the battery from discharging.
1) Turn the ignition switch OFF.
2) Remove the rear seat. (Page 9D-19) 1
3) Connect the special tool to the mode select coupler
(2P) (1).
Special tool
(A): 09930–82760

IH17K1450010-02
1 6) Turn the ignition switch OFF and disconnect the
special tool.
7) Install the rear seat. (Page 9D-19)

IH17K1450026-01
4E-19 ABS:

Understanding the DTC (Diagnostic Trouble Code)

A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is
represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation
between the tens and ones are indicated by the light staying off for 1.6 seconds. In addition, the separation between
the start code and the DTC is indicated by the light being off for 3.6 seconds. After the start code is displayed, DTCs
appear from the smallest number code.
If no DTCs are memorized, the ABS indicator light keeps lighting up.

Output finish
Mode select switch ON

OFF
OFF
Brake light switch
ON

Ignition switch OFF Output start

“a” “b”
Code 12 Code 31

ABS indicator light OFF ON

(Malfunction exists)
“c” “b”
“e” “d”
“f”
“g”
ON
ABS indicator light
(No malfunction exists) OFF
IH17K1450027-02

“a”: Initial minimum light ON time (About 2 seconds) “e”: Main-sub code interval (1.6 seconds)
“b”: Error code interval (About 3.6 seconds) “f”: Sub code light ON time (0.4 seconds)
“c”: Main code light ON time (0.4 seconds) “g”: Sub code light OFF time (0.4 seconds)
“d”: Main code light OFF time (0.4 seconds)

DTC (Diagnostic Trouble Code) Deleting 1) Connect the special tool to the mode select coupler
BENH17K14504006 (2P). (Page 4E-18)
NOTE
2) Switch the special tool to ON and turn the ignition
• The previous malfunction history code switch ON.
(Past DTC) still remains stored in the ABS 3) While the DTCs are being output, set the special tool
HU. Therefore, erase the history code to OFF. The DTC deletion mode is started after the
memorized in the ABS HU using special switch is set to OFF.
tool.
• The DTC is memorized in the ABS HU also
when the wire coupler of any sensor is
disconnected. Therefore, when a wire
coupler has been disconnected at the time
of diagnosis, erase the stored malfunction
history code.
• DTC can be checked by using the SDS-II.
Refer to the SDS-II operation manual for
further details.

I718H1450050-01
 ABS: 4E-20

4) In the DTC deletion mode, switch the special tool from OFF to ON three times within 12.5 seconds, each time
leaving it at ON for more than 1 second.

NOTE
After deleting DTC with the mode select switch in ON position, the system resumes the self-diagnosis
mode again and outputs the DTC.

I718H1450051-01

DTC Deleting Diagram

IH17K1450028-01

5) After deleting the DTCs, repeat the code output ABS Hydraulic Unit Operation Check
procedure and make sure that no DTCs remain (the BENH17K14504025

ABS indicator light no longer flashes). NOTE

• A false diagnosis may result if operation
NOTE
check of the ABS hydraulic unit is
If any DTCs remain, perform the appropriate performed without satisfying all of the
procedures, then delete the codes. If DTCs specified condition below.
are left stored, confusion may occur and Check that all the following conditions are
unnecessary repairs may be made. met before performing operation check of
the ABS hydraulic unit.
6) Turn the ignition switch OFF and disconnect the
– Battery voltage is 12 V or more.
special tool.
– No air is trapped in the brake system.
7) Install the removed parts.
– Brakes do not drag.
8) Afterwards, ride the motorcycle at more than 30 km/
h (19 mile/h) and quickly apply the brakes to check – No DTC is stored in ABS hydraulic unit /
that the ABS activates correctly. control module.
• Operation check must be performed by 2
persons.
4E-21 ABS:

1) Remove the rear seat. (Page 9D-19) NOTE

2) Raise the front and rear wheels off the ground and Depressurization by SDS-II tool is available
support the motorcycle with a jack or a wooden for 5 seconds.
block.
3) Shift the transmission into neutral.
4) Set up the SDS-II tool referring to the SDS-II
operation manual for further details.
5) Turn the ignition switch ON.
6) Click the “Active control”.
7) Click the “ABS HU operating”.
8) Perform the following procedures.
a) Apply the front brake.
b) Select front wheel by SDS-II tool.
c) Check whether the front wheel rotates freely by IH17K1450092-01
hand due to brake depressurization.
9) If any faulty condition is found, replace ABS
d) Check the rear wheel in the same manner as hydraulic unit / control module assembly.
described previously.
10) Close the SDS-II tool and turn the ignition switch
OFF.

DTC Table
BENH17K14504007
Indicator
DTC Malfunction cause Reference
status
None Normal ON *1 —
C1613 (13) Wheel speed sensor rotor malfunction (F) ON (Page 4E-25)
C1614 (14) Wheel speed sensor rotor malfunction (R) ON (Page 4E-26)
C1622 (22) ABS actuator circuit malfunction (F) ON (Page 4E-27)
C1623 (23) ABS actuator circuit malfunction (R) ON (Page 4E-28)
C1625 (25) Wheel speed sensor related malfunction ON (Page 4E-29)
C1635 (35) ABS motor malfunction ON (Page 4E-30)
C1641 (41) Wheel speed sensor signal malfunction (F) *2 ON (Page 4E-31)
C1642 (42) Wheel speed sensor circuit open (F) *2 ON (Page 4E-32)
C1643 (43) Wheel speed sensor circuit short (F) *2 ON (Page 4E-34)
C1644 (44) Wheel speed sensor signal malfunction (R) *2 ON (Page 4E-35)
C1645 (45) Wheel speed sensor circuit open (R) *2 ON (Page 4E-36)
C1646 (46) Wheel speed sensor circuit short (R) *2 ON (Page 4E-38)
C1647 (47) Supply voltage (Increased) ON *3 (Page 4E-39)
C1648 (48) Supply voltage (Decreased) ON *3 (Page 4E-39)
C1655 (55) ABS control unit malfunction ON (Page 4E-40)
C1661 (61) ABS solenoid malfunction ON (Page 4E-41)
C1671 (71) Inertial sensor malfunction ON (Page 4E-42)
C1672 (72) Inertial sensor circuit open ON (Page 4E-43)

*1: It goes off after running at more than 10 km/h (6 mile/h).

*2: The wheel speed sensor lead wire is connected to the ABS control unit, but a short-circuit or faulty continuity inside
the ABS control unit caused this DTC to appear, therefore, the ABS control unit/HU assembly must be replaced. An
insufficient wheel speed sensor output voltage is the cause of a malfunction in which the ABS is activated even if the
brakes are not suddenly applied. If this occurs frequently even though the wheel speed sensor is operating correctly,
the ABS control unit/HU assembly should be replaced.
*3: When the voltage resumes the normal level, the ABS indicator light will go off.

NOTE
When disconnecting couplers and turning the ignition switch ON, disconnect the ABS control unit
coupler in order to prevent a DTC from being stored. Each time a resistance is measured, the ignition
switch should be set to OFF.
 ABS: 4E-22

Fail-Safe Table
BENH17K14504026
When any of the following DTCs is detected, ABS control unit enters fail-safe mode and ABS function is deactivated
until ABS control module judges the system is normal.
DTC Fail-safe operation Fail-safe cancel condition
When ABS is activated, the control unit enters
After switching ignition from “OFF” to “ON” and the
provisional control *1.
motorcycle runs normally at 30 km/h (19 mile/h) or
C1613 When ABS is not activated or after completion of
more for 1 second or more, control unit recovers
provisional control *1 (provisional control becomes
normal ABS control.
unnecessary), the control unit stops ABS control.
When ABS is activated, the control unit enters
After switching ignition from “OFF” to “ON” and the
provisional control *1.
motorcycle runs normally at 30 km/h (19 mile/h) or
C1614 When ABS is not activated or after completion of
more for 1 second or more, control unit recovers
provisional control *1 (provisional control becomes
normal ABS control.
unnecessary), the control unit stops ABS control.
When ABS is activated, the control unit enters
After switching ignition from “OFF” to “ON” and the
provisional control *1.
motorcycle runs normally at 30 km/h (19 mile/h) or
C1622 When ABS is not activated or after completion of
more for 1 second or more, control unit recovers
provisional control *1 (provisional control becomes
normal ABS control.
unnecessary), the control unit stops ABS control.
When ABS is activated, the control unit enters
After switching ignition from “OFF” to “ON” and the
provisional control *1.
motorcycle runs normally at 30 km/h (19 mile/h) or
C1623 When ABS is not activated or after completion of
more for 1 second or more, control unit recovers
provisional control *1 (provisional control becomes
normal ABS control.
unnecessary), the control unit stops ABS control.
After switching ignition from “OFF” to “ON”, control unit
C1625 Control unit stops ABS control.
resumes diagnosis.
After switching ignition from “OFF” to “ON”, control unit
C1635 Control unit stops ABS control.
resumes diagnosis.
After switching ignition from “OFF” to “ON” and the
motorcycle runs normally at 30 km/h (19 mile/h) or
C1641 Control unit stops ABS control.
more for 1 second or more, control unit recovers
normal ABS control.
When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1642 When ABS is not activated or after completion of
resumes diagnosis.
provisional control *1 (provisional control becomes
unnecessary), the control unit stops ABS control.
When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1643 When ABS is not activated or after completion of
resumes diagnosis.
provisional control *1 (provisional control becomes
unnecessary), the control unit stops ABS control.
After switching ignition from “OFF” to “ON” and the
motorcycle runs normally at 30 km/h (19 mile/h) or
C1644 Control unit stops ABS control.
more for 1 second or more, control unit recovers
normal ABS control.
When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1645 When ABS is not activated or after completion of
resumes diagnosis.
provisional control *1 (provisional control becomes
unnecessary), the control unit stops ABS control.
When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1646 When ABS is not activated or after completion of
resumes diagnosis.
provisional control *1 (provisional control becomes
unnecessary), the control unit stops ABS control.
When the system voltage is within the standard range
C1647 Control unit stops ABS control. for 10 seconds or more, control unit recovers normal
ABS control.
4E-23 ABS:

DTC Fail-safe operation Fail-safe cancel condition

When the system voltage is within the standard range
C1648 Control unit stops ABS control. for 10 seconds or more, control unit recovers normal
ABS control.
After switching ignition from “OFF” to “ON”, control unit
C1655 Control unit stops ABS control.
resumes diagnosis.
Control unit stops ABS control or enters provisional After switching ignition from “OFF” to “ON”, control unit
C1661
control *1 depending on the diagnosis. resumes diagnosis.
When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1671 When ABS is not activated or after completion of
resumes diagnosis.
provisional control (provisional control becomes
*1

unnecessary), the control unit stops ABS control.

When ABS is activated, the control unit enters
provisional control *1.
After switching ignition from “OFF” to “ON”, control unit
C1672 When ABS is not activated or after completion of
resumes diagnosis.
provisional control (provisional control becomes
*1

unnecessary), the control unit stops ABS control.

: Provisional control selects any one of the following functions.

*1

• Repeats increase and hold of brake fluid pressure for specified time.
• Continues ABS function.
• Suspends use of IMU signals and continues ABS control using signals from wheel speed sensors.

Scan Tool Data

BENH17K14504027
As the data values are standard values estimated on the basis of values obtained from the new vehicles of the
following conditions by using a scan tool, use them as reference values.
• Suspension is not modified.
• Specified new tires are installed.
• Tire pressure is adjusted to specified value.
• Vehicle is parked on level surface.
Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each
specified data range. Therefore, judgment as abnormal should not be made by checking with these data alone.

NOTE
If communication between SDS-II and ABS control unit is not possible, perform the following checks:
• Check diagnosis cable. If necessary, check diagnosis cable by substituting a known-good diagnosis
cable.
• Check ABS control unit power circuit and ground circuit.
 ABS: 4E-24

ABS
Scan tool data Vehicle condition Condition / Reference value
Wheel speed sensor (F) At stop (Stationary vehicle) 0 km/h (0 mph)
Wheel speed sensor (R) At stop (Stationary vehicle) 0 km/h (0 mph)
IG monitoring voltage Ignition “ON” (Engine stopped) Battery voltage
Brake switch Ignition “ON” (Engine stopped) OFF
Side-stand position with steering fully turned
–1.58 to 1.65 m/s2
Inertial sensor Output Ax Axis to left side
Upright position –1.61 to 1.62 m/s2
Side-stand position with steering fully turned
–3.80 to –0.60 m/s2
Inertial sensor Output Ay Axis to left side
Upright position –1.61 to 1.61 m/s2
Inertial sensor Output Az Axis Detected value is displayed.
ABS solenoid Inlet Valve open or
Ignition “ON” (Engine stopped) Normal
shorted (F)
ABS solenoid outlet Valve open or
Ignition “ON” (Engine stopped) Normal
shorted (F)
ABS solenoid Inlet Valve open or
Ignition “ON” (Engine stopped) Normal
shorted (R)
ABS solenoid outlet Valve open or
Ignition “ON” (Engine stopped) Normal
shorted (R)
ABS solenoid valve relay lock Ignition “ON” (Engine stopped) Normal
ABS motor Ignition “ON” (Engine stopped) Normal
Service check signal condition Ignition “ON” (Engine stopped) Normal

Engine 2
Scan tool data Vehicle condition Condition / Reference value
Side-stand position with steering fully turned to left
–1.58 to 1.65 m/s2
Inertial sensor Output Ax Axis side
Upright position –1.61 to 1.62 m/s2
Side-stand position with steering fully turned to left
–3.80 to –0.60 m/s2
Inertial sensor Output Ay Axis side
Upright position –1.61 to 1.61 m/s2
Inertial sensor Output Az Axis Detected value is displayed.
Side-stand position with steering fully
Static –3.5 to 3.5 deg/s
turned to left side
Inertial sensor Output Yaw
Raise to upright position from side-stand
Dynamic –3.5 to 3.5 deg/s
position (While raising)
Side-stand position with steering fully
Static –3.5 to 3.5 deg/s
turned to left side
Inertial sensor Output Roll
Raise to upright position from side-stand
Dynamic Value increases to positive side
position (While raising)
Side-stand position with steering fully
Static –3.5 to 3.5 deg/s
turned to left side
Inertial sensor Output Pitch
Raise to upright position from side-stand
Dynamic –3.5 to 3.5 deg/s
position (While raising)
4E-25 ABS:

DTC C1613 (13)

BENH17K14504017
Possible cause
C1613 (13): Wheel Speed Sensor Rotor Malfunction (F)
• Front wheel speed sensor rotor distortion
• Faulty front wheel speed sensor or wiring discontinuity, etc.

Troubleshooting
Step 4
Step 1 1) Inspect the front tire type, size, pressure and
wheel runout. Refer to “Wheel / Wheel Axle
1) Inspect the clearance between the front wheel
Inspection” in Section 2D (Page 2D-11) and “Tire
speed sensor and sensor rotor using the
Inspection and Cleaning” in Section 2D (Page 2D-
thickness gauge. (Page 4E-50)
13).
Is the clearance OK?
Are the front tire type, size, pressure and wheel
Yes Go to Step 2. runout OK?

No Adjust the clearance. Yes Go to step 5.

Step 2 No Adjust or replace the front tire and wheel.

1) Inspect the front wheel speed sensor rotor for Step 5
damage and check that no foreign objects are
1) Measure the front wheel speed sensor current.
caught in the rotor openings. (Page 4E-50)
Refer to “Wheel Speed Sensor Circuit” under
Is the sensor rotor OK? “Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-50).
Yes Go to Step 3.
Is the current OK?
No Clean or replace the sensor rotor. (Page
4E-49) Yes Replace the ABS control unit/HU. (Page
4E-45)
Step 3
No Faulty front wheel speed sensor. (Page
1) Check that the front wheel speed sensor (1) is 4E-49)
mounted securely.

IH17K1450029-01

Is the sensor mounted securely?

Yes Go to Step 4.

No Tighten the mounting bolt.

 ABS: 4E-26

DTC C1614 (14)

BENH17K14504018
Possible cause
C1614 (14): Wheel Speed Sensor Rotor Malfunction (R)
• Rear wheel speed sensor rotor distortion
• Faulty rear wheel speed sensor or wiring discontinuity, etc.

Troubleshooting
Step 4
Step 1 1) Inspect the rear tire type, size, pressure and
wheel runout. Refer to “Wheel / Wheel Axle
1) Inspect the clearance between the rear wheel
Inspection” in Section 2D (Page 2D-11) and “Tire
speed sensor and sensor rotor using the
Inspection and Cleaning” in Section 2D (Page 2D-
thickness gauge. (Page 4E-50)
13).
Is the clearance OK?
Are the rear tire type, size, pressure and wheel
Yes Go to Step 2. runout OK?

No Adjust the clearance. Yes Go to step 5.

Step 2 No Adjust or replace the rear tire and wheel.

1) Inspect the rear wheel speed sensor rotor for Step 5
damage and check that no foreign objects are
1) Measure the rear wheel speed sensor current.
caught in the rotor openings. (Page 4E-50)
Refer to “Wheel Speed Sensor Current” under
Is the sensor rotor OK? “Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-50).
Yes Go to Step 3.
Is the current OK?
No Clean or replace the sensor rotor. (Page
4E-50) Yes Replace the ABS control unit/HU. (Page
4E-45)
Step 3
No Faulty rear wheel speed sensor. (Page
1) Check that the rear wheel speed sensor (1) is 4E-49)
mounted securely.

IH17K1450030-01

Is the sensor mounted securely?

Yes Go to Step 4.

No Tighten the mounting bolt.

4E-27 ABS:

DTC C1622 (22)

BENH17K14504019
Possible cause
C1622 (22): ABS Actuator Circuit Malfunction (F)
• Wire harness discontinuity
• Front wheel locking, etc.

Troubleshooting
Step 3
Step 1 1) Check that the front wheel speed sensor (1) is
mounted securely.
1) Raise the front wheel off the ground and support
the motorcycle with a jack or wooden block.
2) Inspect the dragging of the front brake.
Is there any dragging in the front brake?

Yes Inspect the front brake master cylinder

and the calipers.

No Go to Step 2. 1

Step 2
1) Inspect the clearance between the front wheel
IH17K1450029-01
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-50) Is the sensor mounted securely?
Is the clearance OK? Yes Replace the ABS control unit/HU. (Page
4E-45)
Yes Go to Step 3.
No Tighten the mounting bolt.
No Adjust the clearance.
 ABS: 4E-28

DTC C1623 (23)

BENH17K14504020
Possible cause
C1623 (23): ABS Actuator Circuit Malfunction (R)
• Wire harness discontinuity
• Rear wheel locking, etc.

Troubleshooting
Step 3
Step 1 1) Check that the rear wheel speed sensor (1) is
mounted securely.
1) Raise the rear wheel off the ground and support
the motorcycle with a jack or wooden block.
2) Inspect the dragging of the rear brake.
Is there any dragging in the rear brake?

Yes Inspect the rear brake master cylinder and

the caliper.

No Go to Step 2.
1
Step 2
1) Inspect the clearance between the rear wheel
IH17K1450030-01
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-50) Is the sensor mounted securely?
Is the clearance OK? Yes Replace the ABS control unit/HU. (Page
4E-45)
Yes Go to Step 3.
No Tighten the mounting bolt.
No Adjust the clearance.
4E-29 ABS:

DTC C1625 (25)

BENH17K14504008
Possible cause
C1625 (25): Wheel Speed Sensor Related Malfunction
• Incorrect tire size, poor tire pressure
• Deformed wheel, etc.

Troubleshooting
Step 3
Step 1 1) Inspect both wheel speed sensor rotors for
damage and check that no foreign objects are
1) Check that the specified tires are installed.
caught in the rotor openings. (Page 4E-50)
(Page 2D-13)
Are the rotors OK?
Are the tires OK?
Yes Go to Step 4.
Yes Go to Step 2.
No Clean or replace the rotor.
No Use the specified tires.
• Front wheel speed sensor rotor:
Step 2 (Page 4E-49)
1) Make sure the tire pressure for each tire. (Page • Rear wheel speed sensor rotor:
2D-13) (Page 4E-50)
Is the tire pressure for each tire correct?
Step 4
Yes Go to Step 3. 1) Inspect the clearances of the front and rear wheel
speed sensor – sensor rotor using the thickness
No Adjust the tire pressure. gauge. (Page 4E-50)
Are the clearances OK?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Adjust the clearance.

 ABS: 4E-30

DTC C1635 (35)

BENH17K14504009
Possible cause
C1635 (35): ABS Motor Malfunction
Faulty HU motor

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting

Step 1
1) Delete DTCs and repeat the code output
procedure. Refer to “DTC (Diagnostic Trouble
Code) Deleting” (Page 4E-19) and “DTC
(Diagnostic Trouble Code) Output” (Page 4E-18).
Is the DTC C1635 (35) output again?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Intermittent trouble.
4E-31 ABS:

DTC C1641 (41)

BENH17K14504010
Possible cause
C1641 (41): Wheel Speed Sensor Signal Malfunction (F)
• Poor contact in the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.

Troubleshooting
Step 3
Step 1 1) Check that the front wheel speed sensor (1) is
mounted securely.
1) Inspect the clearance between the front wheel
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-50)
Is the clearance OK?

Yes Go to Step 2.

No Adjust the clearance.

Step 2 1

1) Inspect the front wheel speed sensor rotor for

damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-50) IH17K1450029-01

Is the sensor rotor OK? Is the sensor mounted securely?

Yes Go to Step 3. Yes Go to DTC C1642 (42). (Page 4E-32)

No Clean or replace the sensor rotor. (Page No Tighten the mounting bolt.
4E-49)
 ABS: 4E-32

DTC C1642 (42)

BENH17K14504011
Possible cause
C1642 (42): Wheel Speed Sensor Circuit Open (F)
• Poor contact in the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting Step 2
Step 1 1) Check for continuity between “T2” (W/R) and
ground at the ABS control unit coupler.
1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (Page 1G-9)
3) Remove the air cleaner box. (Page 1D-6)
4) Check the ABS control unit coupler (1) and front 1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
wheel speed sensor coupler (2) for loose or poor
contacts. If OK, then disconnect the ABS control
unit coupler. (Page 4E-45)

IH17K1450033-01

2 Is no continuity indicated?

Yes Go to Step 4.

No Go to Step 3.

1 Step 3
1) Disconnect the front wheel speed sensor coupler.
IH17K1450031-01 2) Check for continuity between Green wire and
5) Check for continuity between “T2” (W/R) and ground at the front wheel speed sensor lead wire
“T11” (B/R) at the ABS control unit coupler. coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450034-01

Is no continuity indicated?
IH17K1450032-01

Is no continuity indicated? Yes Inspect the wire harness. (Faulty W/R

wire)
Yes Go to Step 2.
No Faulty front wheel speed sensor. (Page
No • Inspect the wire harness. (Faulty 4E-49)
sensor wire)
• Faulty front wheel speed sensor.
(Page 4E-49)
4E-33 ABS:

Step 4 Step 6
1) Check for continuity between “T11” (B/R) and 1) Disconnect the front wheel speed sensor coupler.
ground at the ABS control unit coupler. 2) Check for continuity between “T2” (W/R) on the
ABS control unit coupler and W/R wire on the front
wheel speed sensor coupler.
1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
IH17K1450035-01

Is no continuity indicated?

Yes Go to Step 6.

No Go to Step 5. IH17K1450037-01

Is continuity indicated?
Step 5
1) Disconnect the front wheel speed sensor coupler. Yes Go to Step 7.
2) Check for continuity between White wire and No Inspect the wire harness. (Faulty W/R
ground at the front wheel speed sensor lead wire wire)
coupler.
Step 7
1) Check for continuity between “T11” (B/R) on the
ABS control unit coupler and B/R wire on the front
wheel speed sensor coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
IH17K1450036-01

Is no continuity indicated?

Yes Inspect the wire harness. (Faulty B/R wire)

No Faulty front wheel speed sensor. (Page

4E-49)
IH17K1450038-01

Is continuity indicated?

Yes Go to Step 8.

No Inspect the wire harness. (Faulty B/R wire)

Step 8
1) Measure the front wheel speed sensor current.
Refer to “Wheel Speed Sensor Circuit” under
“Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-50).
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Faulty front wheel speed sensor. (Page

4E-49)
 ABS: 4E-34

DTC C1643 (43)

BENH17K14504021
Possible cause
C1643 (43): Wheel Speed Sensor Circuit Short (F)
• Poor contact in the front wheel speed sensor coupler
• Faulty front wheel speed sensor, etc.

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting Step 2
Step 1 1) Turn the ignition switch ON with the ABS control
unit coupler disconnected, measure the voltage
1) Turn the ignition switch OFF.
between “T2” (W/R) and “T1” (B/W) at the coupler.
2) Lift and support the fuel tank. (Page 1G-9)
3) Remove the air cleaner box. (Page 1D-6)
4) Check the ABS control unit coupler for loose or
poor contacts. If OK, then disconnect the ABS
control unit coupler. (Page 4E-45) 1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
5) Check for continuity between “T2” (W/R) and
“T11” (B/R) at the ABS control unit coupler.

1 2 3 4 5 6 7 8 IH17K1450039-01
10 11 13 14 15 16 17
Is the voltage 0 V?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Inspect the wire harness. (Faulty sensor

IH17K1450032-01
signal or power supply wire)
Is the continuity indicated?

Yes • Inspect the wire harness. (W/R or B/R

wires short)
• Faulty front wheel speed sensor.
(Page 4E-49)

No Go to Step 2.
4E-35 ABS:

DTC C1644 (44)

BENH17K14504012
Possible cause
C1644 (44): Wheel Speed Sensor Signal Malfunction (R)
• Poor contact in the rear wheel speed sensor coupler
• Faulty rear wheel speed sensor, etc.

Troubleshooting
Step 3
Step 1 1) Check that the rear wheel speed sensor (1) is
mounted securely.
1) Inspect the clearance between the rear wheel
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-50)
Is the clearance OK?

Yes Go to Step 2.

No Adjust the clearance.

Step 2 1
1) Inspect the rear wheel speed sensor rotor for
damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-50) IH17K1450030-01

Is the sensor rotor OK? Is the sensor mounted securely?

Yes Go to Step 3. Yes Go to DTC C1645 (45). (Page 4E-36)

No Clean or replace the sensor rotor. (Page No Tighten the mounting bolt.
4E-50)
 ABS: 4E-36

DTC C1645 (45)

BENH17K14504013
Possible cause
C1645 (45): Wheel Speed Sensor Circuit Open (R)
• Poor contact in the rear wheel speed sensor coupler
• Faulty rear wheel speed sensor, etc.

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting Step 2
Step 1 1) Check for continuity between “T13” (W/Y) and
ground at the ABS control unit coupler.
1) Turn the ignition switch OFF.
2) Remove the front seat. (Page 9D-19)
3) Check the ABS control unit coupler (1) and rear 1 2 3 4 5 6 7 8
wheel speed sensor coupler (2) for loose or poor 10 11 13 14 15 16 17

contacts. If OK, then disconnect the ABS control

unit coupler. (Page 4E-45)

IH17K1450042-01
2
Is no continuity indicated?

Yes Go to Step 4.

No Go to Step 3.
1 Step 3
1) Disconnect the rear wheel speed sensor coupler.
IH17K1450040-01
2) Check for continuity between White wire and
4) Check for continuity between “T13” (W/Y) and ground at the rear wheel speed sensor lead wire
“T4” (B/Y) at the ABS control unit coupler. coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450036-01

IH17K1450041-01 Is no continuity indicated?

Is no continuity indicated? Yes Inspect the wire harness. (Faulty W/Y
Yes Go to Step 2. wire)

No • Inspect the wire harness. (Faulty No Replace the rear wheel speed sensor.
sensor wire) (Page 4E-49)

• Faulty rear wheel speed sensor.

(Page 4E-49)
4E-37 ABS:

Step 4 Step 6
1) Check for continuity between “T4” (B/Y) and 1) Disconnect the rear wheel speed sensor coupler.
ground at the ABS control unit coupler. 2) Check for continuity between “T13” (W/Y) on the
ABS control unit coupler and W/Y wire on the rear
wheel speed sensor coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450043-01

Is no continuity indicated?

Yes Go to Step 6. IH17K1450044-01

Is continuity indicated?
No Go to Step 5.
Yes Go to Step 7.
Step 5
1) Disconnect the rear wheel speed sensor coupler. No Inspect the wire harness. (Faulty W/Y
wire)
2) Check for continuity between Green wire and
ground at the rear wheel speed sensor lead wire Step 7
coupler.
1) Check for continuity between “T4” (B/Y) on the
ABS control unit coupler and B/Y wire on the rear
wheel speed sensor coupler.

1 2 3 4 5 6 7 8
IH17K1450034-01 10 11 13 14 15 16 17

Is no continuity indicated?

Yes Inspect the wire harness. (Faulty B/Y wire)

No Replace the rear wheel speed sensor.

(Page 4E-49) IH17K1450045-01

Is continuity indicated?

Yes Go to Step 8.

No Inspect the wire harness. (Faulty B/Y wire)

Step 8
1) Measure the rear wheel speed sensor current.
Refer to “Wheel Speed Sensor Current” under
“Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-50).
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Replace the rear wheel speed sensor.

(Page 4E-49)
 ABS: 4E-38

DTC C1646 (46)

BENH17K14504022
Possible cause
C1646 (46): Wheel Speed Sensor Circuit Short (R)
• Poor contact in the rear wheel speed sensor coupler
• Faulty rear wheel speed sensor, etc.

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting Step 2
Step 1 1) Turn the ignition switch ON with the ABS control
unit coupler disconnected, measure the voltage
1) Turn the ignition switch OFF.
between “T13” (W/Y) and “T1” (B/W) at the
2) Lift and support the fuel tank. (Page 1G-9) coupler.
3) Remove the air cleaner box. (Page 1D-6)
4) Check the ABS control unit coupler for loose or
poor contacts. If OK, then disconnect the ABS
control unit coupler. (Page 4E-45)
5) Check for continuity between “T13” (W/Y) and 1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
“T4” (B/Y) at the ABS control unit coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17 IH17K1450046-01

Is the voltage 0 V?

Yes Replace the ABS control unit/HU. (Page

4E-45)
IH17K1450041-01
No Inspect the wire harness. (Faulty sensor
Is the continuity indicated? signal or power supply wire)
Yes • Inspect the wire harness. (W/Y or B/Y
wires short)
• Faulty rear wheel speed sensor.
(Page 4E-49)

No Go to Step 2.
4E-39 ABS:

DTC C1647 (47) / C1648 (48)

BENH17K14504014
Possible cause
C1647 (47): Supply Voltage (Increased)
C1648 (48): Supply Voltage (Decreased)
• Faulty generator or regulator/rectifier
• Faulty battery
• Faulty ABS control unit
• Faulty wire harness, etc.

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting
Step 3
Step 1 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Check the ABS control unit coupler (1) for loose or
poor contacts. If OK, then disconnect the ABS
2) Remove the front seat. (Page 9D-19)
control unit coupler. (Page 4E-45)
3) Measure the voltage between the (+) and (–)
battery terminals.

IH17K1450048-01

3) Start the engine at 5000 r/min with the dimmer

IH17K1450047-01
switch set to HI.
Is voltage 12 V or more? 4) Measure the voltage between “T3” (W/Y) and “T1”
Yes Go to Step 2. (B/W) at the ABS control unit coupler.

No Charge or replace the battery. (Page 1J-

9)

Step 2 1 2 3 4 5 6 7 8
1) Start the engine at 5000 r/min with the dimmer 10 11 13 14 15 16 17
switch set to HI.
2) Measure the voltage between the (+) and (–)
battery terminals.
Is voltage 14.0 – 15.5 V?
IH17K1450024-01

Yes Go to Step 3. Is voltage 14.0 – 15.5 V?

No Inspect the generator and regulator/ Yes Replace the ABS control unit/HU. (Page
rectifier. 4E-45)
• Generator: (Page 1J-4)
No Inspect the wire harness. (Faulty ignition
• Regulator/rectifier: (Page 1J-7) or ground wire)
 ABS: 4E-40

DTC C1655 (55)

BENH17K14504015
Possible cause
C1655 (55): ABS Control Unit Malfunction
Faulty ABS control unit

Troubleshooting Step 3
Step 1 1) Check that the front and rear wheel speed
sensors (1) are mounted securely.
1) Inspect the clearances of the front and rear wheel
speed sensor – sensor rotor using the thickness
gauge. (Page 4E-50)
Are the clearances OK?

Yes Go to Step 2.

No Adjust the clearance.

1
Step 2
1
1) Inspect both of the wheel speed sensor rotors for
damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-50) IH17K1450049-01

Are the rotors OK? Are the sensors mounted securely?

Yes Go to Step 3. Yes Go to Step 4.

No Clean or replace the rotor. No Tighten the mounting bolts.

• Front wheel speed sensor rotor: Step 4
(Page 4E-49)
1) Delete DTCs and repeat the code output
• Rear wheel speed sensor rotor: procedure. Refer to “DTC (Diagnostic Trouble
(Page 4E-50) Code) Deleting” (Page 4E-19) and “DTC
(Diagnostic Trouble Code) Output” (Page 4E-18).
Is the DTC C1655 (55) output again?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Intermittent trouble.
4E-41 ABS:

DTC C1661 (61)

BENH17K14504016
Possible cause
C1661 (61): ABS Solenoid Malfunction
ABS valve relay circuit open or short, broken fuse for valve relay, faulty ABS valve relay,
interruption of valve, failure output from ABS control unit, etc.

Troubleshooting Step 2
Step 1 1) Check the ABS control unit coupler (1) for loose or
poor contacts. If OK, then disconnect the ABS
1) Turn the ignition switch OFF.
control unit coupler. (Page 4E-45)
2) Remove the front seat. (Page 9D-19)
3) Open the fuse box and inspect the ABS fuse (30
A) (1).

NOTE
If a fuse is blown, find the cause of the
problem and correct it before replacing the
fuse.

1 IH17K1450048-01

2) Measure the voltage between “T10” (R/Bl) and

“T1” (B/W) at the ABS control unit coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450050-01

Is the ABS fuse OK?

Yes Go to Step 2.
IH17K1450051-01

No Replace the ABS fuse. Is voltage 12.0 V or more?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Inspect the wire harness. (Faulty solenoid

or ground wire)
 ABS: 4E-42

DTC C1671 (71)

BENH17K14504023
Possible cause
C1671 (71): Inertial Sensor Malfunction
• Abnormality in installation position of IMU
• Faulty IMU, etc.

Troubleshooting
Step 3
Step 1 1) Delete DTC and repeat the code output
procedure. Refer to “DTC (Diagnostic Trouble
1) Remove the fuel tank. (Page 1G-9)
Code) Deleting” (Page 4E-19) and “DTC
2) Check the IMU coupler (1) for loose or poor (Diagnostic Trouble Code) Output” (Page 4E-18).
contacts.
Is the DTC C1671 (71) output again?

1 Yes Go to Step 4.

No End.

Step 4
1) Inspect the IMU. (Page 4E-47)
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-45)
IH17K1450052-01
No Replace the IMU. (Page 4E-47)
Is check result OK?

Yes Go to Step 2.

No Repair or replace defective parts.

Step 2
1) Check that IMU (1) is mounted securely. Refer to
“IMU Removal and Installation” (Page 4E-47).

IH17K1450053-02

Is check result OK?

Yes Go to Step 3.

No Repair or replace defective parts.

4E-43 ABS:

DTC C1672 (72)

BENH17K14504024
Possible cause
C1672 (72): Inertial Sensor Circuit Open
• Poor contact in the IMU coupler
• Faulty IMU, etc.
• Faulty ABS control unit

Circuit Diagram
Refer to “ABS Circuit Diagram” (Page 4E-7).

Troubleshooting
Step 2
Step 1 1) Measure the voltage between W/G wire and
ground.
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (Page 1G-9)
3) Check the ABS control unit coupler (1) and IMU
coupler (2) for loose or poor contacts. If OK, then
disconnect the IMU coupler.

2
IH17K1450056-01

Is voltage same as Step 1?

Yes Inspect the wire harness. (Faulty B/W

wire)

No Inspect the wire harness. (Faulty W/G

1 wire)

Step 3
IH17K1450054-01
1) Turn the ignition switch OFF.
4) Turn the ignition switch ON.
2) Disconnect the ECM couplers. (Page 1C-10)
5) Measure the voltage between W/G wire and B/W
wire at the IMU coupler. 3) Disconnect the combination coupler. (Page 9C-
7)
4) Disconnect the ABS control unit coupler. (Page
4E-45)
5) Check for continuity between “T8” (W/B) and
“T17” (B/Bl) at the ABS control unit coupler.

IH17K1450055-01

Is voltage 12.0 V or more? 1 2 3 4 5 6 7 8

10 11 13 14 15 16 17
Yes Go to Step 3.

No Go to Step 2.

IH17K1450057-01

Is no continuity indicated?

Yes Go to Step 4.

No Inspect the wire harness. (Faulty W/B or

B/Bl wires short)
 ABS: 4E-44

Step 4 Step 6
1) Check for continuity between “T8” (W/B) and 1) Check for continuity between “T17” (B/Bl) and
ground at the ABS control unit coupler. ground at the ABS control unit coupler.

1 2 3 4 5 6 7 8
10 11 13 14 15 16 17
1 2 3 4 5 6 7 8
10 11 13 14 15 16 17

IH17K1450060-01
IH17K1450058-01
Is no continuity indicated?
Is no continuity indicated?
Yes Go to Step 7.
Yes Go to Step 5.
No Inspect the wire harness. (Faulty B/Bl
No Inspect the wire harness. (Faulty W/B wire)
wire)
Step 7
Step 5
1) Check for continuity between “T17” (B/Bl) on the
1) Check for continuity between “T8” (W/B) on the ABS control unit coupler and B/Bl wire on the IMU
ABS control unit coupler and W/B wire on the IMU coupler.
coupler.

1 2 3 4 5 6 7 8
10 11 12 13 14 15 16 17

1 2 3 4 5 6 7 8
10 11 12 13 14 15 16 17

IH17K1450061-01

Is continuity indicated?

IH17K1450059-01 Yes Go to Step 8.

Is continuity indicated? No Inspect the wire harness. (Faulty B/Bl
wire)
Yes Go to Step 6.

No Inspect the wire harness. (Faulty W/B Step 8

wire) 1) Inspect the IMU. (Page 4E-47)
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-45)

No Replace the IMU. (Page 4E-47)

4E-45 ABS:

Repair Instructions
ABS Control Unit Coupler Disconnection and ABS Control Unit / HU Removal and Installation
BENH17K14506007
Reconnection Refer to “Fuel Tank Removal and Installation” in Section
BENH17K14506001
Disconnection 1G (Page 1G-9).
1) Turn the ignition switch OFF.
Removal
2) Remove the front seat. (Page 9D-19)
3) Disconnect the ABS control unit coupler (1) as ! WARNING
follows.
When storing the brake fluid, seal the
a) Push the lock (2) to release locking of the lock container completely and keep away from
lever (3). children.
b) Turn the lock lever in direction of arrow until and
disconnect the ABS control unit coupler. NOTICE
• This brake system is filled with an ethylene
1 glycol-based DOT 4 brake fluid. Do not mix
different types of fluid such as silicone-
based or petroleum-based.
3
• Do not use any brake fluid taken from old,
used or unsealed containers. Never reuse
brake fluid left over from the last servicing
2 or stored for long periods.
• Handle brake fluid with care: the fluid
reacts chemically with paint, plastics,
IH17K1450062-01 rubber materials etc. and will damage then
severely.
Reconnection
• The ABS control unit/HU cannot be
1) Connect the ABS control unit coupler (1) as follows. disassembled.
a) Make sure that lock lever (2) is in unlock
position. 1) Turn the ignition switch OFF.
b) Insert the coupler to ABS control unit (3) it stop 2) Remove the battery. (Page 1J-9)
with lock lever in unlocked position. 3) Drain the brake fluid. (Page 4A-18)
c) Turn the lock lever in direction of arrow to lock 4) Disconnect the TO sensor coupler (1).
the coupler securely. 5) Disconnect the IMU coupler (2).
6) Remove the fuel tank rear bracket (3).
1

2
3

2
1

3
IH17K1450063-01

2) Install the front seat. (Page 9D-19) IH17K1450075-01

7) Disconnect the ABS control unit coupler. (Page

4E-45)
 ABS: 4E-46

8) Disconnect the brake hoses by removing the union 13) Remove the brake hose from the guide.
bolts (1).

IH17K1450080-01
IH17K1450076-01 14) Remove the ABS control unit/HU (1) from the holder.
9) Remove the fuse box (1) from the battery holder.
10) Remove the fastener (2) and fixed clamp (3).

IH17K1450081-01

3
IH17K1450077-01
Installation
Install the ABS control unit/HU in the reverse order of
11) Remove the fixed clamp (1).
removal. Pay attention to the following points:
• Route the brake hoses correctly. Refer to “Front Brake
Hose Routing Diagram” in Section 4A (Page 4A-1)
and “Rear Brake Hose Routing Diagram” in Section
4A (Page 4A-4).
• Tighten the brake hose union bolts (1) to the specified
torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m, 17.0
1
lbf-ft)

IH17K1450078-01

12) Move the wiring harness No.1 (1) upward and

remove the ABS control unit/HU bolts (2).
1, (a)
1

1 , (a )

2
2 IH17K1450082-01

• Bleed air from the brake fluid circuit. (Page 4A-14)

• Install the removed parts.

IH17K1450079-01
4E-47 ABS:

IMU Inspection 4) Remove the IMU holder (1), bushings (2) and
BENH17K14506010 spacers (3).
NOTE
Do not give any shock to the vehicle during
the inspection. If the IMU in the vehicle body
is exposed to an impact, the measurement 3
value will be disturbed. 3

Check the output values of IMU. Refer to “Scan Tool

Data” (Page 4E-23). 2

2
IMU Removal and Installation
BENH17K14506011
NOTICE
• Be careful not to expose the IMU to
excessive shock. 1
• Do not use an impact wrench when
removing or installing the IMU.

Removal
1) Remove the fuel tank rear bracket. Refer to “ABS
Control Unit / HU Removal and Installation” (Page
4E-45).
2) Remove the TO sensor. (Page 1C-20)
3) Remove the IMU (1). 1

IH17K1450094-01
1

1
2

IH17K1450095-01
 ABS: 4E-48

5) Remove the IMU holder bracket (1) and the IMU • Tighten the IMU holder bracket bolts to the specified
holder bracket spacers (2). torque.
Tightening torque
IMU holder bracket bolt (a): 6.0 N·m (0.61 kgf-m,
4.50 lbf-ft)

(a)

IH17K1450097-01
2
• Apply thread lock to the IMU holder bolts (1) and then
tighten the bolts to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
IMU holder bolt (a): 6.0 N·m (0.61 kgf-m, 4.50 lbf-
ft)
• Tighten the IMU bolts (2) to the specified torque.
1
Tightening torque
IMU bolt (b): 8.0 N·m (0.82 kgf-m, 5.90 lbf-ft)
IH17K1450096-01

Installation
Install the IMU in the reverse order of removal. Pay
attention to the following points:
• There is no abnormality in installation position or
angle of the IMU and the IMU holder bracket spacers.
• There is no deformation of the fuel tank rear bracket,
IMU holder bracket and IMU holder.
• If bushing is worn or damaged, replace the bushing
with a new one. 1, “A”, (a)
• When replacing the bushing, replace all three
bushings. 2, (b)

1, “A”, (a)
IH17K1450098-01
4E-49 ABS:

Front Wheel Speed Sensor Removal and Rear Wheel Speed Sensor Removal and
Installation Installation
BENH17K14506002 BENH17K14506003
Refer to “Front Wheel Speed Sensor Routing Diagram” Refer to “Rear Wheel Speed Sensor Routing Diagram”
(Page 4E-9). (Page 4E-10).

Removal Removal
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Lift and support the fuel tank. (Page 1G-9) 2) Remove the right frame front cover. (Page 9D-18)
3) Remove the air cleaner box. (Page 1D-6) 3) Disconnect the rear wheel speed sensor lead wire
4) Disconnect the front wheel speed sensor lead wire coupler (1).
coupler (1).

IH17K1450066-01

IH17K1450064-01 4) Remove the rear wheel speed sensor (1).

5) Remove the front wheel speed sensor (1).

IH17K1450067-01

IH17K1450065-01
Installation
Installation Install the rear wheel speed sensor in the reverse order
Install the front wheel speed sensor in the reverse order of removal. Pay attention to the following point:
of removal. Pay attention to the following point: • After installing the rear wheel speed sensor, check the
• After installing the front wheel speed sensor, check clearance between the rear wheel speed sensor and
the clearance between the front wheel speed sensor sensor rotor. Refer to “Wheel Speed Sensor and
and sensor rotor. Refer to “Wheel Speed Sensor and Sensor Rotor Inspection” (Page 4E-50).
Sensor Rotor Inspection” (Page 4E-50).
Front Wheel Speed Sensor Rotor Removal and
Installation
BENH17K14506004
Refer to “Front Brake Disc Removal and Installation” in
Section 4B (Page 4B-6).

NOTICE
• Do not hit the front wheel speed sensor
rotor when dismounting the front wheel.
• When replacing the tire, make sure not to
damage the sensor rotor.
 ABS: 4E-50

Rear Wheel Speed Sensor Rotor Removal and Wheel Speed Sensor and Sensor Rotor
Installation Inspection
BENH17K14506005 BENH17K14506006
Refer to “Rear Wheel Assembly Removal and Wheel Speed Sensor – Sensor Rotor Clearance
Installation” in Section 2D (Page 2D-9). Check the clearance between the wheel speed sensor
(1) and sensor rotor (2) using the thickness gauge.
NOTICE
Wheel speed sensor – Sensor rotor clearance
• Do not hit the rear wheel speed sensor Front [Standard]: 0.33 – 1.55 mm (0.0130 – 0.0610 in)
rotor when dismounting the rear wheel. Rear [Standard]: 0.98 – 1.70 mm (0.0386 – 0.0669 in)
• When replacing the tire, make sure not to
Special tool
damage the sensor rotor.
(A): 09900–20803
Removal (B): 09900–20806
1) Remove the rear wheel speed sensor rotor (1) by
[A]
removing the bolts.

1 2

(A ), (B )

IH17K1450070-01

IH17K1450068-01
[B]

Installation
1) Install the wheel speed sensor rotor as the letters 2
“50T” face outside.
2) Tighten the rear wheel speed sensor rotor bolts (1)
to the specified torque. 1
Tightening torque (A ), (B )
Wheel speed sensor rotor bolt (a): 6.3 N·m (0.64
kgf-m, 4.65 lbf-ft) IH17K1450071-01

[A]: Front [B]: Rear

1, ( a)

IH17K1450069-01

3) After installing the rear wheel, check the clearance

between the rear wheel speed sensor and sensor
rotor. Refer to “Wheel Speed Sensor and Sensor
Rotor Inspection” (Page 4E-50).
4E-51 ABS:

Wheel Speed Sensor Wheel Speed Sensor Rotor

1) Remove the wheel speed sensor. 1) Raise the wheel off the ground and support the
• Front: (Page 4E-49) motorcycle with a jack or wooden block.
• Rear: (Page 4E-49) 2) Check that no wheel speed sensor rotor teeth are
broken and that no foreign objects are caught in the
2) Inspect the wheel speed sensor for damage.
wheel speed sensor. If any defects are found,
Clean the sensor if any metal particle or foreign
replace the wheel speed sensor rotor with a new
material stuck on it.
one.
[A] [B]
• Front: (Page 4E-49)
• Rear: (Page 4E-50)

[A] [B]

IH17K1450072-01

[A]: Front wheel speed sensor

[B]: Rear wheel speed sensor
IH17K1450074-01

3) After finishing the speed sensor inspection, install [A]: Front wheel speed sensor rotor
the wheel speed sensor. [B]: Rear wheel speed sensor rotor

• Front: (Page 4E-49)

• Rear: (Page 4E-49)

Wheel Speed Sensor Current

1) Disconnect the wheel speed sensor coupler.
• Front: (Page 4E-49)
• Rear: (Page 4E-49)
2) Connect three 1.5 V dry cells (1) in series as shown
and make sure that their total voltage is more than
4.5 V. Measure the current between (+) dry cells
terminal and Green wire terminal (2) on the wheel
speed sensor coupler.
Normal value
7 – 14 mA

A
IH17K1450073-01

3) Install the removed parts.

 ABS: 4E-52

Specifications
Tightening Torque Specifications
BENH17K14507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake hose union bolt 23 2.3 17.0 (Page 4E-46)
IMU holder bracket bolt 6.0 0.61 4.50 (Page 4E-48)
IMU holder bolt 6.0 0.61 4.50 (Page 4E-48)
IMU bolt 8.0 0.82 5.90 (Page 4E-48)
Wheel speed sensor rotor bolt 6.3 0.64 4.65 (Page 4E-50)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K14508001
Material SUZUKI recommended product or Specification Note
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 4E-48)

Special Tool
BENH17K14508002
09900–20803 09900–20806
Thickness gauge Thickness gauge
(Page 4E-50) (Page 4E-50)

09930–82760
Mode selection switch
(Page 4E-5) /
(Page 4E-17) /
(Page 4E-18)
4E-53 ABS:
 Table of Contents 5- i

Section 5

Transmission / Transaxle
CONTENTS

Precautions .................................................5-1 Special Tools and Equipment ...........................5B-24

Precautions............................................................. 5-1 Recommended Service Material .......................5B-24
Precautions for Transmission / Transaxle............. 5-1 Special Tool ......................................................5B-25

Manual Transmission.............................. 5B-1 Clutch ....................................................... 5C-1

Diagnostic Information and Procedures............5B-1 Precautions...........................................................5C-1
Manual Transmission Symptom Diagnosis ......... 5B-1 Precautions for Clutch System............................5C-1
Repair Instructions ..............................................5B-2 Schematic and Routing Diagram ........................5C-2
Transmission Components ................................. 5B-2 Clutch Cable Routing Diagram............................5C-2
Transmission Removal and Installation .............. 5B-3 Diagnostic Information and Procedures ............5C-3
Transmission Related Bearing / Oil Seal Clutch System Symptom Diagnosis ....................5C-3
Inspection.......................................................... 5B-5 Repair Instructions ..............................................5C-4
Transmission Related Bearing / Oil Seal Clutch Switch Inspection .....................................5C-4
Removal and Installation................................... 5B-6 Clutch Cable Play Inspection and Adjustment ....5C-4 5
Transmission Construction................................ 5B-10 Clutch Control System Components ...................5C-6
Countershaft Gear / Driveshaft Gear Clutch Cable Removal and Installation ...............5C-7
Disassembly and Reassembly ........................ 5B-11 Clutch Lever Removal and Installation................5C-7
Gearshift Fork / Gearshift Cam Inspection........ 5B-14 Clutch Push Rod (Left) / Clutch Release
GP Sensor Inspection ....................................... 5B-15 Camshaft Removal and Installation ..................5C-9
GP Sensor Removal and Installation ................ 5B-15 Clutch Push Rod (Left) Inspection ....................5C-12
Gearshift Lever Construction ............................ 5B-16 Clutch Push Rod Oil Seal Removal and
Gearshift Lever Removal and Installation ......... 5B-17 Installation .......................................................5C-12
Gearshift Lever Height Inspection and Clutch Push Rod Oil Seal Inspection ................5C-13
Adjustment ...................................................... 5B-18 Clutch Components...........................................5C-14
Gearshift Shaft / Gearshift Cam Plate Clutch Removal.................................................5C-15
Components.................................................... 5B-18 Clutch Installation..............................................5C-17
Gearshift Shaft Construction ............................. 5B-19 Clutch Parts Inspection .....................................5C-21
Gearshift Shaft / Gearshift Cam Plate Specifications .....................................................5C-23
Removal and Installation................................. 5B-19 Tightening Torque Specifications......................5C-23
Gearshift Linkage Inspection ............................ 5B-22 Special Tools and Equipment ...........................5C-24
Gearshift Shaft Oil Seal / Bearing Removal Recommended Service Material .......................5C-24
and Installation ................................................ 5B-23 Special Tool ......................................................5C-24
Specifications.....................................................5B-24
Tightening Torque Specifications...................... 5B-24
5-1 Precautions:

Precautions
Transmission / Transaxle

Precautions
Precautions for Transmission / Transaxle
BENH17K15000001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Manual Transmission: 5B-1

Manual Transmission
Transmission / Transaxle

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis
BENH17K15204002

Condition Possible cause Correction / Reference Item

Engine is noisy (Noise Worn or rubbing gear. Replace. (Page 5B-11)
seems to come from the Worn countershaft spline. Replace countershaft. (Page 5B-11)
transmission) Worn driveshaft spline. Replace driveshaft. (Page 5B-11)
Worn bearing. Replace. (Page 5B-11)
Transmission will not Broken gearshift cam. Replace. (Page 5B-3)
shift Distorted gearshift fork. Replace. (Page 5B-3)
Worn gearshift pawl. Replace. (Page 5B-19)
Transmission will not Broken return spring on shift shaft. Replace. (Page 5B-19)
shift back Rubbing or stuck gearshift shaft. Repair or replace. (Page 5B-19)
Worn or distorted gearshift fork. Replace. (Page 5B-3)
Transmission jumps out Worn shifting gears on driveshaft or Replace. (Page 5B-11)
of gear countershaft.
Worn or distorted gearshift fork. Replace. (Page 5B-3)
Weakened gearshift stopper spring. Replace. (Page 5B-19)
Worn gearshift cam plate. Replace. (Page 5B-19)
5B-2 Manual Transmission:

Repair Instructions
Transmission Components
BENH17K15206001

(c)
(e)
(c) 23

24
(c)
22

(c)
(b)
21

20

6 19 (d)
(b)
(a)
(b)
18

25
(b)

16
17 4

25
15 3

14
(b)
2
1
13

12
11 9

10

(b)
8
7

(b)
IH17K1520001-01
 Manual Transmission: 5B-3

1. 2nd drive gear 13. 3rd driven gear 25. Driveshaft bearing retainer
2. 6th drive gear 14. 4th driven gear : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)
3. 3rd/4th drive gear 15. 5th driven gear : 8.4 Nm (0.86 kgf-m, 6.20 lbf-ft)
4. 5th drive gear 16. 1st driven gear : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
5. Countershaft/1st drive gear 17. 1st driven gear spacer : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
6. Countershaft bearing retainer 18. Gearshift fork No. 1 : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
7. Engine sprocket spacer 19. Gearshift fork No. 3 : Apply grease.
8. Clutch push rod oil seal retainer 20. Gearshift fork shaft : Apply thread lock to the thread part.
9. Driveshaft bearing retainer 21. GP sensor : Apply engine oil.

10. Driveshaft 22. Gearshift cam : Do not reuse.

11. 2nd driven gear 23. Gearshift cam stopper
12. 6th driven gear 24. Gearshift cam plate

Transmission Removal and Installation 9) Remove the dowel pins (1).

BENH17K15206002
Removal
1) Drain engine oil. (Page 1E-4) 1
2) Remove the oil pump drive chain and thrust washer.
(Page 1E-12)
3) Remove the gearshift shaft assembly and gearshift
cam plate. (Page 5B-19)
4) Remove the clutch release holder and clutch push
rod (left). (Page 5C-9)
5) Remove the GP sensor. (Page 5B-15)
6) Remove the engine sprocket. (Page 3A-3) IH17K1520004-02
7) Remove the engine sprocket spacer (1) and O-ring 10) Remove the gearshift fork shafts (1) and gearshift
(2). forks (2).
11) Remove the gearshift cam (3).

1 2
2
IH17K1520002-01 1
3
8) Remove the transmission assembly (1).
IH17K1520005-02

NOTE 12) Remove the driveshaft assembly (1) and

countershaft assembly (2).
To prevent the inner parts from coming apart,
remove the transmission assembly slowly
keeping them at a level.

IH17K1520006-01

IH17K1520003-01
5B-4 Manual Transmission:

13) Remove the transmission cover oil gallery plug (1), if • Apply thread lock to the transmission cover oil gallery
necessary. plug (1) and tighten it to the specified torque, if
removed.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Transmission cover oil gallery plug (a): 12 N·m (
1.2 kgf-m, 9.0 lbf-ft)

IH17K1520007-01

14) Remove the gearshift fork shaft retainers (1), if

necessary.

NOTICE
Do not use an impact driver when removing 1 , “A”, (a )
the gearshift fork shaft retainer screws.
IH17K1520010-01

• Fit the gearshift forks (1) and (2) to the respective

gears and the fork ends (3) into the respective cam
grooves, and insert the fork shafts (4).

NOTE
The gearshift forks No. 1 (1) are same parts.

1 1

IH17K1520008-02

Installation 3
Install the transmission in the reverse order of removal. 3
Pay attention to the following points:
• Apply thread lock to the gearshift fork shaft retainer
screws (1) and tighten them to the specified torque, if 2 4
removed. IH17K1520011-02

• Apply grease to the left driveshaft bearing inner

“A”: Thread lock cement 99000–32150 (THREAD
surface.
LOCK CEMENT 1322D)
“A”: Grease 99000–25011 (SUZUKI SUPER
Tightening torque
GREASE A)
Gearshift fork shaft retainer screw (a): 10 N·m (
1.0 kgf-m, 7.5 lbf-ft)

1 , “A”, ( a )

“A”

IH17K1520012-01
1 , “A”, ( a )
IH17K1520009-01
 Manual Transmission: 5B-5

• Install the transmission assembly (1) and temporarily • Apply grease to the new O-ring (1) and install it.
tighten the transmission cover bolts (specified 3 bolts)
“A”: Grease 99000–25011 (SUZUKI SUPER
to the specified torque.
GREASE A)
NOTE • Facing the stepped side (2) inward, install the engine
When installing the transmission assembly, sprocket spacer into the transmission.
put the drive chain (3) on the driveshaft (2).

Tightening torque
Transmission cover bolt (a): 15 N·m (1.5 kgf-m,
11.0 lbf-ft)

(a)

1 , “A” 2

IH17K1520016-02

1
Transmission Related Bearing / Oil Seal
(a) Inspection
BENH17K15206017
IH17K1520013-01 Refer to “Transmission Removal and Installation” (Page
5B-3).

Oil Seal
Inspect the driveshaft oil seal lip (1) for damage or wear.
3
If any defect is found, replace the oil seal with a new
one. (Page 5B-6)

IH17K1520014-01

• Tighten all of the transmission cover bolts to the

specified torque.
Tightening torque
1
Transmission cover bolt (a): 26 N·m (2.7 kgf-m,
19.5 lbf-ft) IH17K1520017-01

(a)
IH17K1520015-01
5B-6 Manual Transmission:

Bearing 3) Remove the gearshift cam bearing (1).

Inspect the countershaft bearings (1), driveshaft
bearings (2) and gearshift cam bearings (3) for abnormal
noise and smooth rotation. Replace the bearing if there
is anything unusual. (Page 5B-6)

3
1

IH17K1520092-01

4) Remove the countershaft bearing retainer (1).

2

IH17K1520018-01

1
IH17K1520093-01

2 5) Remove the countershaft bearing (1) using the

1 special tool.
IH17K1520019-02
Special tool
(A): 09921–20240
Transmission Related Bearing / Oil Seal
Removal and Installation
BENH17K15206018
Removal
Right side bearing
(A )
1) Remove the driveshaft assembly and countershaft
assembly. (Page 5B-3)
2) Remove the gearshift cam bearing retainers (1).

NOTICE
1
Do not use an impact driver when removing
the gearshift cam bearing retainer screws.
IH17K1520021-01

6) Remove the driveshaft bearing retainers (1).

IH17K1520020-02

IH17K1520022-01
 Manual Transmission: 5B-7

7) Remove the driveshaft bearing (1) using the special Left side bearing
tools.
NOTE
Special tool
Removal and installation of the driveshaft
(A): 09921–20240
bearing and gearshift cam bearing are
(B): 09921–21710
possible while the engine is mounted on the
frame.

( A) 1) Remove the engine assembly. (Page 1D-26)

2) Separate the crankcases, upper and lower. Refer to
“Crankshaft / Piston / Cylinder Removal” in Section
1D (Page 1D-45).
3) Remove the clutch push rod oil seal (1) and
countershaft bearing (2).
( B)

1
IH17K1520023-03

Driveshaft oil seal

1) Remove the transmission assembly. (Page 5B-3)
2) Remove the clutch push rod oil seal retainer (1). 1

IH17K1520026-02

4) Remove the countershaft bearing pin (1).

1

IH17K1520024-01

3) Remove the driveshaft oil seal (1) using the special

tool.
1
Special tool
(A): 09913–50121
IH17K1520027-01

5) Remove the gearshift cam bearing (1) using the

1 special tools.
Special tool
(A): 09923–74511
(B): 09930–30104
( A)
1

IH17K1520025-01

(A )

(B )
IH17K1520028-01
5B-8 Manual Transmission:

6) Remove the driveshaft bearing retainer (1).

1 , “A”, (a )
1

IH17K1520032-01

IH17K1520029-01 3) Install the new gearshift cam bearing (1) using the
7) Remove the driveshaft bearing (1) using the special special tool.
tool.
Special tool
Special tool (A): 09913–70210
(A): 09913–70210

(A )
(A)

1
1

IH17K1520033-01

IH17K1520030-01 4) Install the countershaft bearing pin (1).

Installation
Left side bearing
1) Install the new driveshaft bearing (1) using the
special tool.
Special tool
(A): 09913–70210
1

(A)
IH17K1520034-01

5) Aligning the hole (1) in the countershaft bearing with

the countershaft bearing pin (2), install the
countershaft bearing.

IH17K1520031-01

2) Apply thread lock to the driveshaft bearing retainer

screws (1) and tighten them to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
1
Tightening torque 2
Left driveshaft bearing retainer screw (a): 8.4
N·m (0.86 kgf-m, 6.20 lbf-ft) IH17K1520035-01
 Manual Transmission: 5B-9

6) Reassemble the upper and lower crankcases. Refer Right side bearing
to “Crankshaft / Piston / Cylinder Installation” in 1) Install the new driveshaft bearing (1) using the
Section 1D (Page 1D-49). special tool.
7) Install the new clutch push rod oil seal. (Page 5C-
Special tool
12)
(A): 09913–70210
8) Install the engine assembly. (Page 1D-29)

Driveshaft oil seal

1) Install the new driveshaft oil seal (1) using the (A)
special tool.
Special tool
(A): 09913–70210

(A) 1 IH17K1520038-02

2) Apply thread lock to the driveshaft bearing retainer

screws (1) and tighten them to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
IH17K1520036-01
Right driveshaft bearing retainer screw (a): 8.4
N·m (0.86 kgf-m, 6.20 lbf-ft)
2) Apply grease to the oil seal lip.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

1 , “A”, ( a )

IH17K1520039-01

“A” 3) Install the gearshift cam bearing (1).

4) Install the new countershaft bearing (2) using the
IH17K1520037-01
special tool.
3) Install the clutch push rod oil seal retainer. Refer to
“Clutch Push Rod Oil Seal Removal and Installation” Special tool
in Section 5C (Page 5C-12). (A): 09913–70210
4) Install the transmission assembly. (Page 5B-3)

(A )

2
1
IH17K1520040-01
5B-10 Manual Transmission:

5) Apply thread lock to the gearshift cam bearing

retainer screws (1) and countershaft bearing retainer
screws (2), and tighten them to the specified torque. 1 , “A”, (a )

“A”: Thread lock cement 99000–32150 (THREAD

LOCK CEMENT 1322D)
Tightening torque
Gearshift cam bearing retainer screw (a): 10 2 , “A”, ( b )
N·m (1.0 kgf-m, 7.5 lbf-ft)
Countershaft bearing retainer screw (b): 12 N·m
(1.2 kgf-m, 9.0 lbf-ft)
IH17K1520042-01

6) Install the driveshaft assembly and countershaft

assembly. (Page 5B-3)

Transmission Construction
BENH17K15206004

3
1

IH17K1520041-02

1. Countershaft 2. Driveshaft 3. Snap ring

: Face the sharp edge outside.
 Manual Transmission: 5B-11

Countershaft Gear / Driveshaft Gear

Disassembly and Reassembly
BENH17K15206005
Refer to “Transmission Removal and Installation” (Page
5B-3).

Disassembly

! CAUTION 1

Identify the position of each removed part.

Organize the parts in their respective groups 3 2
(i.e., drive or driven) so that they can be
IH17K1520045-01
reinstalled in their original positions.
5) Remove the 6th drive gear bushing (1), washer (2)
Countershaft and snap ring (3).
1) Remove the oil seal (1).

2
1

1 IH17K1520046-01

6) Remove the 3rd/4th drive gear (1).

IH17K1520043-01

2) Remove the 6th drive gear snap ring (1) from its
groove and slide it towards the 3rd/4th drive gears
(2).
Special tool
09900–06104

1
1

IH17K1520047-01

7) Remove the snap ring (1) and washer (2).

8) Remove the 5th drive gear (3) and 5th drive gear
bushing (4).
2

IH17K1520044-01 1
4
3) Slide the 6th (1) and 2nd (2) drive gears toward the 3
3rd/4th drive gear, then remove the 2nd drive gear
circlip (3).
4) Remove the 2nd drive gear (2) and 6th drive gear
(1).

IH17K1520048-01
5B-12 Manual Transmission:

Driveshaft 6) Remove the washer (1), 3rd driven gear (2) and 3rd
1) Remove the 1st driven gear spacer (1). driven gear bushing (3).

2 3

1
1

IH17K1520049-01 IH17K1520053-01

2) Remove the 1st driven gear (1) and bearing (2). 7) Remove the washer (1), snap ring (2) and 6th driven
gear (3).

1
2 3
1
IH17K1520050-01
IH17K1520054-01
3) Remove the washer (1) and 5th driven gear (2).
8) Remove the snap ring (1) and washer (2).
9) Remove the 2nd driven gear (3), 2nd driven gear
bearing (4) and 2nd driven gear bushing (5).

1 2 3

2
1 4
IH17K1520051-01
5
4) Remove the snap ring (1) with the special tool.
Special tool IH17K1520055-01
09900–06107
5) Remove the washer (2), 4th driven gear (3) and 4th
driven gear bushing (4).

1 4
3

IH17K1520052-01
 Manual Transmission: 5B-13

Reassembly Driveshaft
Install the countershaft gear / driveshaft gear in the • When installing the 3rd driven gear bushing (1) onto
reverse order of removal. Pay attention to the following the driveshaft, align the shaft oil hole (2) with the
points: bushing oil hole (3).
NOTE
• When reassembling the transmission
gears, attention must be given to the 1
locations and positions of washers and
snap rings. The cross sectional view
shows the correct position of the gears,
bushings, washers and snap rings. Refer
to “Transmission Construction” (Page 5B- 2
10).
• When installing a new snap ring, do not 3
expand the end gap larger than required to IH17K1520056-01
slip the snap ring over the shaft. • When installing the 4th driven gear bushing (1) onto
• After installing a snap ring, make sure that the driveshaft, align the shaft oil hole (2) with the
it is completely seated in the groove and bushing oil hole (3).
securely fitted.
• Rotate the bearing by hand to inspect if
there is any abnormal noise and for
smooth rotation. Replace the bearing if
1
there is anything unusual.
• Before installing the gears, apply engine
oil to the driveshaft and countershaft.

• When installing a new snap ring (1), pay attention to

its direction. Fit it to the side where the thrust (2) is as 2
shown in the figure. 3
IH17K1520057-01

2 Countershaft
• When installing the 6th drive gear bushing (1) onto the
countershaft, align the shaft oil hole (2) with the
bushing oil hole (3).
1

IF04K1520031-01

3. Sharp edge

IH17K1520058-01
5B-14 Manual Transmission:

• Apply grease to the new oil seal lip (1). Gearshift Fork Groove Width
Measure the gearshift fork groove width using the
NOTE vernier calipers.
The oil seal (2) is directional. Install the oil
Gearshift fork groove width
seal as shown in the illustration.
No.1 [Standard]: 5.0 – 5.1 mm (0.197 – 0.200 in)
“A”: Grease 99000–25011 (SUZUKI SUPER No.3 [Standard]: 5.0 – 5.1 mm (0.197 – 0.200 in)
GREASE A) Special tool
(A): 09900–20102

(A)

1, “A”
IF04K1520040-01
IH17K1520059-02

Gearshift Fork Thickness

Gearshift Fork / Gearshift Cam Inspection Measure the gearshift fork thickness using the vernier
BENH17K15206006
Refer to “Transmission Removal and Installation” (Page calipers.
5B-3) and “Countershaft Gear / Driveshaft Gear Gearshift fork thickness
Disassembly and Reassembly” (Page 5B-11). No. 1 [Standard]: 4.8 – 4.9 mm (0.189 – 0.192 in)
No. 3 [Standard]: 4.8 – 4.9 mm (0.189 – 0.192 in)
Gearshift Fork to Groove Clearance
Special tool
NOTE (A): 09900–20102
The clearance for each gearshift fork plays
an important role in the smoothness and
positiveness of the shifting action.

Using the thickness gauge, check the gearshift fork (A)

clearance in the groove of its gear.
If the clearance checked is noted to exceed the limit
specified, replace the fork or its gear, or both.
Gearshift fork to groove clearance
No. 1 IF04K1520041-01

[Standard]: 0.1 – 0.3 mm (0.004 – 0.011 in)

[Limit]: 0.5 mm (0.019 in) Gearshift Cam
No. 3 Inspect the gearshift cam groove for abnormal wear and
[Standard]: 0.1 – 0.3 mm (0.004 – 0.011 in) damage. If any defects are found, replace the gearshift
[Limit]: 0.5 mm (0.019 in) cam with a new one.

Special tool
(A): 09900–20803

(A)

IF04K1520039-01 IH17K1520060-01
 Manual Transmission: 5B-15

Gearshift Cam Bearing GP Sensor Removal and Installation

Refer to “Transmission Related Bearing / Oil Seal BENH17K15206008

Inspection” (Page 5B-5). Removal

1) Turn the ignition switch OFF.
GP Sensor Inspection 2) Remove the engine sprocket cover. Refer to “Engine
BENH17K15206007 Sprocket Removal and Installation” in Section 3A
1) Check the GP sensor power supply voltage and (Page 3A-3).
circuit. (Page 1A-60) 3) Lift and support the fuel tank. (Page 1G-9)
2) Turn the ignition switch OFF. 4) Release the GP sensor lead wire from the clamps (1)
3) Connect the GP sensor lead wire coupler and ECM and disconnect the GP sensor coupler (2).
couplers.
4) Insert the needle point probes to the lead wire
coupler.
5) Turn the ignition switch ON.
6) Measure the voltage between P and B/W lead wires
when shifting the gearshift lever from low to top. 2
GP sensor voltage 1
1st [Standard]: 0.525 – 0.725 V
Neutral [Standard]: 1.076 – 1.256 V
2nd [Standard]: 1.607 – 1.807 V
3rd [Standard]: 2.274 – 2.474 V IH17K1520094-01
4th [Standard]: 2.941 – 3.141 V
5th [Standard]: 3.608 – 3.808 V
6th [Standard]: 4.275 – 4.475 V

IH17K1520095-01

5) Remove the GP sensor (1).

IH17K1520062-01

7) Turn the ignition switch OFF.

IH17K1520064-01
5B-16 Manual Transmission:

Installation • Apply thread lock to the GP sensor bolts (1).

Install the GP sensor in the reverse order of removal.
“A”: Thread lock cement 99000–32150 (THREAD
Pay attention to the following points:
LOCK CEMENT 1322D)
• Apply grease to the new O-ring.
• Tighten the GP sensor bolts (1) to the specified
“A”: Grease 99000–25011 (SUZUKI SUPER torque.
GREASE A)
Tightening torque
• Align the GP sensor pin (1) with the gearshift cam GP sensor bolt (a): 6.0 N·m (0.61 kgf-m, 4.45 lbf-
hole (2). ft)

1 2 1 , “A ”, (a )

“A”

IH17K1520065-01
IH17K1520066-01

• Route the GP sensor lead wire. (Page 9A-13)

Gearshift Lever Construction

BENH17K15206009

1
(b)

“b”

(a)
[A]

“a”

(a)

“b”

5 (c)
3
7

5 6 (d)

IH17K1520067-04
 Manual Transmission: 5B-17

[A]: Footrest top surface 6. Oil seal : 40 Nm (4.1 kgf-m, 29.5 lbf-ft)
1. Gearshift link arm 7. Washer : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
2. Gearshift link rod “a”: 65 – 75 mm (2.6 – 2.9 in) : Apply thread lock to the thread part.
3. Gearshift lever “b”: 90° : Apply grease to the contact point and oil seal lips.
4. Gearshift lever bracket : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Do not reuse.
: Degrease the thread portion.
5. Gearshift lever shaft : 12 Nm (1.2 kgf-m, 9.0 lbf-ft)

Gearshift Lever Removal and Installation

BENH17K15206010
Refer to “Gearshift Lever Construction” (Page 5B-16).
(A )
Removal
1) Loosen the lock-nuts (1) and remove the gearshift
link rod (2).
1

IH17K1520097-01
2
2) Apply grease to contact surface of the gearshift lever
and oil seal lips.
“A”: Grease 99000–25011 (SUZUKI SUPER
1
GREASE A)
3) Apply thread lock to the gearshift lever shaft (1).
IH17K1520098-01

2) Remove the gearshift lever. “B”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
3) Remove the oil seals (1).
4) Install the gearshift lever (2) with washers (3), and
tighten the gearshift lever shaft to the specified
torque.

NOTE
Before installing the gearshift lever shaft,
degrease thread portion of the gearshift lever
bracket (4).

Tightening torque
1 Gearshift lever shaft (a): 40 N·m (4.1 kgf-m, 29.5
lbf-ft)
IH17K1520096-01

1, (a)
Installation “A” 2
1) Install the new oil seal (1) at each inside and outside 3
of the gearshift lever with the special tool.
Special tool
(A): 09913–70210
3

“B”
4

IH17K1520099-01

5) After installing the gearshift lever, check the gearshift

lever height. (Page 5B-18)
5B-18 Manual Transmission:

Gearshift Lever Height Inspection and Adjustment

Adjustment 1) Loosen the lock-nuts (1).
BENH17K15206011
Inspection 2) Turn the gearshift link rod (2) until the gearshift lever
Inspect the gearshift lever height “a” between the pedal height is within the specification.
top face and footrest. Gearshift lever height
Gearshift lever height [Standard]: 65 – 75 mm (2.6 – 2.9 in)
[Standard]: 65 – 75 mm (2.6 – 2.9 in) 3) Tighten the lock-nuts (1) to the specified torque.
Tightening torque
Gearshift link rod lock-nut (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)

“a” 1 , (a )

IH17K1520068-01

1 , (a )

IH17K1520069-01

Gearshift Shaft / Gearshift Cam Plate Components

BENH17K15206012

9 (c) 10 (d)

2 1

8
5 (b)

7
6 (a)

3
IH17K1520070-01

1. Gearshift shaft 6. Gearshift cam plate bolt : 13 Nm (1.3 kgf-m, 9.5 lbf-ft) : Apply thread lock to the thread part.
2. Gearshift cam drive plate 7. Gearshift shaft oil seal : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Apply engine oil.

3. Gearshift cam plate 8. Gearshift shaft bearing : 8.4 Nm (0.86 kgf-m, 6.20 lbf-ft) : Do not reuse.
4. Gearshift cam stopper 9. Gearshift shaft end screw : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
5. Gearshift cam stopper bolt 10. Gearshift arm stopper : Apply grease.
 Manual Transmission: 5B-19

Gearshift Shaft Construction

BENH17K15206013

2
4
4

11 (c)
3

5 6
7

12
(d)

“a” 1

5
10
(b)

9
13

8 (a)
IH17K1520071-01

1. Gearshift shaft 12. Gearshift shaft end screw

: Degrease the thread portion.
2. Washer 13. Gearshift cam
: Degrease the thread portion.
3. Gearshift shaft oil seal “a”: 1.5 – 2.5 mm (0.059 – 0.098 in)
4. Snap ring : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Face the sharp edge outside.
5. Gearshift shaft bearing : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
: Face the stamped mark side faces outside.
6. Gearshift shaft return spring : 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
7. Gearshift plate return spring : 8.4 Nm (0.86 kgf-m, 6.20 lbf-ft)
8. Gearshift cam stopper bolt : Apply grease.
9. Gearshift cam stopper arm spring : Apply thread lock to the thread part.
10. Gearshift cam plate bolt : Apply engine oil.

11. Gearshift arm stopper : Do not reuse.

Gearshift Shaft / Gearshift Cam Plate Removal

and Installation
BENH17K15206014 1

Removal
1) Remove the clutch components. (Page 5C-15)
2) Remove the gearshift link arm (1).

IH17K1310005-01
5B-20 Manual Transmission:

3) Remove the snap ring (1) and washer (2) from the Installation
gearshift shaft. Refer to “Gearshift Shaft Construction” (Page 5B-19).
Special tool 1) Set the gearshift cam stopper arm spring (1) to the
09900–06107 transmission cover.

4) Remove the gearshift shaft assembly (3).

1 2 3 1

IH17K1520075-02

2) Assemble the gearshift cam stopper (1), bolt (2) and

IH17K1520072-01
washer (3), and install them.
5) Remove the following parts from the gearshift shaft
3) Tighten the gearshift cam stopper bolt to the
(1).
specified torque.
• Washer (2)
• Snap ring (3) NOTE
• Gearshift shaft return spring (4) Hook the return spring end (4) to the stopper.
• Gearshift shaft end screw (5) Tightening torque
• Gearshift plate return spring (6) Gearshift cam stopper bolt (a): 10 N·m (1.0 kgf-
• Gearshift cam drive plate (7) m, 7.5 lbf-ft)
Special tool
09900–06107

4
2
1
4 6

3 (a)
IH17K1520076-01
3 7
2 2 4) Check the gearshift cam stopper moves smoothly.
1 5
IH17K1520073-01 5) Locate the gearshift cam in the neutral position.
6) Remove the gearshift cam plate bolt (1) and
gearshift cam plate (2).
7) Remove the gearshift cam stopper (3).

1
2

IH17K1520074-01
 Manual Transmission: 5B-21

6) Install the gearshift cam plate (1). NOTE

NOTE Before installing the gearshift shaft end

screw, degrease thread portion of the
Align the gearshift cam pin (2) with the gearshift shaft.
gearshift cam plate hole (3).
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
1 Gearshift shaft end screw (a): 8.4 N·m (0.86 kgf-
m, 6.20 lbf-ft)

2
3 3
1
3 2
IH17K1520077-01

7) Apply a small quantity of thread lock to the gearshift

cam plate bolt (1) and tighten it to the specified
torque. 4, “A”, (a)

NOTE IH17K1520079-01

Before installing the gearshift cam plate bolt, 10) Install the gearshift shaft return spring (1).
degrease thread portion (2) of the gearshift
NOTE
cam.
Position the stopper (2) of gearshift arm
“A”: Thread lock cement 99000–32150 (THREAD between the shaft return spring ends (3).
LOCK CEMENT 1322D)
Tightening torque
Gearshift cam plate bolt (a): 13 N·m (1.3 kgf-m,
9.5 lbf-ft)

“A” 2

3
1 , ( a)
IH17K1520080-01

2 11) Install the new snap ring (1) and washer (2).
Special tool
IH17K1520078-01 09900–06107
8) Install the gearshift cam drive plate (1), gearshift
plate return spring (2) and washer (3).

NOTE
Facing the chamfered side outward, install
the washer (3). 1

2
9) Apply a small quantity of thread lock to the gearshift
shaft end screw (4) and tighten it to the specified
torque.

IH17K1520081-01
5B-22 Manual Transmission:

12) Install the gearshift shaft assembly (1). 16) After installing the gearshift lever, check the gearshift
lever height. (Page 5B-18)
NOTE
Pinch the gearshift arm stopper (2) with Gearshift Linkage Inspection
return spring ends (3). BENH17K15206015
Refer to “Gearshift Shaft / Gearshift Cam Plate Removal
and Installation” (Page 5B-19).
3 2
Gearshift Shaft
Check the gearshift shaft (1) for bend or wear.
Check the return spring (2) for damage or fatigue.
3 If any defects are found, replace the defective part(-s).
1

IH17K1520082-01

13) Install the washer (1) and new snap ring (2).
2
Special tool
09900–06107
1

2 IH17K1520084-01

Gearshift Shaft Oil Seal

1 Inspect the gearshift shaft oil seal lip (1) for damage or
wear. If any defect is found, replace the oil seal with a
new one.

IH17K1520083-01

14) Install the gearshift link arm (1) to the gearshift shaft
and tighten the bolt to the specified torque.
Tightening torque
1
Gearshift link arm bolt (a): 12 N·m (1.2 kgf-m,
9.0 lbf-ft)
IH17K1520085-01
1
(a)
Gearshift Shaft Bearing
Inspect the gearshift shaft bearings (1) for abnormal
noise and smooth rotation. Replace the bearing if there
“a” is anything unusual.

IH17K1310014-01

“a”: 90°
1 1
15) Install the clutch components. (Page 5C-17)
IH17K1520086-01
 Manual Transmission: 5B-23

Gearshift Shaft Oil Seal / Bearing Removal and Installation

Installation Install the oil seal and bearing in the reverse order of
BENH17K15206016 removal. Pay attention to the following points:
Removal
• Apply engine oil to the new bearings (1) and install
1) Remove the gearshift shaft assembly. Refer to them with the special tool.
“Gearshift Shaft / Gearshift Cam Plate Removal and
Installation” (Page 5B-19). NOTE
2) Remove the gearshift shaft oil seal (1). The stamped mark side of gearshift shaft
bearing faces outside.

Special tool
(A): 09913–70210
1

IH17K1520087-01

3) Remove the bearings (1) with the special tools. 1

(A) 1
Special tool (A)
(A): 09921–20210 IH17K1520089-01
(B): 09930–30104
• Install the new oil seal (1) with the special tool.
Special tool
1 1 (A): 09913–70210

2
“a”

(A)
(B) (A)
(B) 1
1
IH17K1520088-01

(A )

IH17K1520090-01

2. Crankcase “a”: 1.5 – 2.5 mm (0.059 – 0.098 in)

• Apply grease to the oil seal lip.

“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A ”

IH17K1520091-01
5B-24 Manual Transmission:

Specifications
Tightening Torque Specifications
BENH17K15207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Gearshift fork shaft retainer screw 10 1.0 7.5 (Page 5B-4)
Transmission cover oil gallery plug 12 1.2 9.0 (Page 5B-4)
Transmission cover bolt 15 1.5 11.0 (Page 5B-5)
Transmission cover bolt 26 2.7 19.5 (Page 5B-5)
Left driveshaft bearing retainer screw 8.4 0.86 6.20 (Page 5B-8)
Right driveshaft bearing retainer screw 8.4 0.86 6.20 (Page 5B-9)
Gearshift cam bearing retainer screw 10 1.0 7.5 (Page 5B-10)
Countershaft bearing retainer screw 12 1.2 9.0 (Page 5B-10)
GP sensor bolt 6.0 0.61 4.45 (Page 5B-16)
Gearshift lever shaft 40 4.1 29.5 (Page 5B-17)
Gearshift link rod lock-nut 10 1.0 7.5 (Page 5B-18)
Gearshift cam stopper bolt 10 1.0 7.5 (Page 5B-20)
Gearshift cam plate bolt 13 1.3 9.5 (Page 5B-21)
Gearshift shaft end screw 8.4 0.86 6.20 (Page 5B-21)
Gearshift link arm bolt 12 1.2 9.0 (Page 5B-22)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-16)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-18)
“Gearshift Shaft Construction” (Page 5B-19)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K15208001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 5B-4) / (Page 5B-
5) / (Page 5B-9) / (Page
5B-14) / (Page 5B-16) /
(Page 5B-17) / (Page
5B-23)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 5B-4) / (Page 5B-
4) / (Page 5B-8) / (Page
5B-9) / (Page 5B-10) /
(Page 5B-16) / (Page
5B-17) / (Page 5B-21) /
(Page 5B-21)

NOTE
Required service material(s) is also described in:
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-16)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-18)
“Gearshift Shaft Construction” (Page 5B-19)
 Manual Transmission: 5B-25

Special Tool
BENH17K15208002
09900–06104 09900–06107
Snap ring pliers (External: Snap ring pliers (External)
Bent nose)
(Page 5B-11) (Page 5B-12) /
(Page 5B-20) /
(Page 5B-20) /
(Page 5B-21) /
(Page 5B-22)
09900–20102 09900–20803
Vernier calipers (200 mm) Thickness gauge
(Page 5B-14) / (Page 5B-14)
(Page 5B-14)

09913–50121 09913–70210
Oil seal remover Bearing installer set
(Page 5B-7) (Page 5B-8) /
(Page 5B-8) /
(Page 5B-8) /
(Page 5B-9) /
(Page 5B-9) /
(Page 5B-9) /
(Page 5B-17) /
(Page 5B-23) /
(Page 5B-23)
09921–20210 09921–20240
Bearing remover (ø12) Bearing remover set
(Page 5B-23) (Page 5B-6) /
(Page 5B-7)

09921–21710 09923–74511
Bearing remover (φ22) Bearing remover (ø20 - 35)
(Page 5B-7) (Page 5B-7)

09930–30104
Rotor remover sliding shaft
This tool is included in Rotor
remover set (09930-30135).
(Page 5B-7) /
(Page 5B-23)
5C-1 Clutch:

Clutch
Transmission / Transaxle

Precautions
Precautions for Clutch System
BENH17K15300001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Clutch: 5C-2

Schematic and Routing Diagram

Clutch Cable Routing Diagram
BENH17K15302001

[A]

7, “1”

6
7, “2”

1 2 3 4

“a”
1
[B]
1
8
2 2

3
3

12

11 (a) 10 9 [C] 1

(b)

13 2 3
IH17K1530001-02
5C-3 Clutch:

[A]: Pass the clutch cable and throttle 5. Air cleaner box 12. Clamp
cables under the air cleaner duct.
[B]: Clamp the clutch cable at the end of 6. Cable guide 13. Front brake hose (If equipped)
the protector.
[C]: Pass the clutch cable above the 7. Cable guide screw “a”: 0 – 4 mm (0 – 0.15 in)
front brake hose (If equipped). : Tighten the screws in order of “1” → “2”.
1. Clutch cable 8. Brake hose : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
2. Throttle cable No. 1 9. Clutch cable adjuster : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: Adjust the clearance between the clutch cable adjuster
nut end and adjoining nut within one pitch of the screw.
3. Throttle cable No. 2 10. Nut
4. Right side cowling bracket 11. Clutch cable lock-nut

Diagnostic Information and Procedures

Clutch System Symptom Diagnosis
BENH17K15304002

Condition Possible cause Correction / Reference Item

Noisy engine (Noise Worn countershaft spline. Replace countershaft. (Page 5B-11)
seems to come from the Worn clutch sleeve hub spline. Replace clutch sleeve hub.
clutch) • Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Worn clutch plate teeth. Replace clutch plate.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Distorted clutch plates, driven and drive. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Worn clutch release bearing. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Weakened clutch damper spring. Replace primary driven gear assembly.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Clutch slips Clutch cable play out of adjustment. Adjust. (Page 5C-4)
Weakened clutch springs. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Worn or distorted clutch pressure plate. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Distorted clutch plates. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Clutch drags Clutch cable play out of adjustment. Adjust. (Page 5C-4)
Some clutch springs are weak, while Replace.
others are not. • Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Worn or distorted clutch pressure plate. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
Distorted clutch plates. Replace.
• Removal: (Page 5C-15)
• Installation: (Page 5C-17)
 Clutch: 5C-4

Repair Instructions
Clutch Switch Inspection 1) Lift and support the fuel tank. (Page 1G-9)
BENH17K15306001
2) Turn in the cable adjuster nut (1) all the way into the
1) Disconnect the clutch switch couplers (1).
clutch lever assembly.

1
1
IH17K1530002-01
IH17K1530004-01
2) Inspect the clutch switch for continuity with the circuit
3) Loosen the lock-nut (1), fix the nut (3) and turn the
tester.
clutch cable adjuster (2) to obtain proper cable play.
If any abnormality is found, replace the switch with a
new one. Refer to “Clutch Lever Removal and
Installation” (Page 5C-7).
Clutch switch
3 1
Color 2
Terminal (B/Y) Terminal (B/W)
Position
FREE

I649G1530004-03

3) Connect the clutch switch lead wires.

Clutch Cable Play Inspection and Adjustment IH17K1530005-02

BENH17K15306002 4) Remove the clutch release adjuster cap (1).
Inspect and adjust the clutch cable play “a” as follows.
5) Loosen the lock-nut (2) and turn out the clutch
Clutch cable play release adjuster screw (3) two or three rotations.
[Standard]: 10 – 15 mm (0.4 – 0.6 in) 6) From that position, slowly turn in the clutch release
adjuster screw (3) until resistance is felt.
7) From this position, turn out the clutch release
adjuster screw (3) 1 rotation, and tighten the lock-nut
(2) while holding the screw (3).
Tightening torque
Clutch release adjuster lock-nut (a): 5.5 N·m (
0.56 kgf-m, 4.05 lbf-ft)

“a”

IH17K1530003-01

3
2, (a)
1

IH17K1530006-01
5C-5 Clutch:

8) While fixing the nut (1), turn the clutch cable adjuster 10) Install the clutch release adjuster cap.
(2) fully.
Tightening torque
9) Tighten the lock-nut (3) to the specified torque. Clutch release adjuster cap: 11 N·m (1.1 kgf-m,
Tightening torque 8.5 lbf-ft)
Clutch cable lock-nut (a): 4.5 N·m (0.46 kgf-m, 11) Install the removed parts.
3.35 lbf-ft)
12) Turn the cable adjuster nut (1) to obtain 10 – 15 mm
(0.4 – 0.6 in) of free play “a” at clutch lever end.

1 3, (a)

IH17K1530007-01 “a”

IH17K1530008-01
 Clutch: 5C-6

Clutch Control System Components

BENH17K15306003

10

(a)

(b)

5
(c)
6

(d)

1
2

(e)

(a)
4

IH17K1530009-01

1. Clutch push rod (Left) 8. Clutch lever holder : 8.8 Nm (0.90 kgf-m, 6.50 lbf-ft)

2. Clutch release camshaft 9. Cable adjuster nut : Apply grease.

3. Clutch release arm 10. Spring : Apply engine oil.

4. Clutch release holder : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Apply thread lock to the thread part.
5. Clutch cable : 6.5 Nm (0.66 kgf-m, 4.80 lbf-ft) : Do not reuse.
6. Clutch lever : 0.6 Nm (0.06 kgf-m, 0.45 lbf-ft)
7. Clutch switch : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
5C-7 Clutch:

Clutch Cable Removal and Installation 9) Release the clutch cable (1) from the clamp (2) and
BENH17K15306004 remove the clutch cable.
Removal
1) Remove the right side cowling assembly. (Page
9D-21) 2
1
2) Remove the air cleaner box. (Page 1D-6) 1
3) Loosen the cable adjuster nut (1).
4) Align the clutch lever and cable adjuster nut (1) with
the cutaway.
5) Disconnect the clutch cable (2) from the clutch lever.

1
IH17K1530013-01

10) Remove the clutch cable stopper (1).

IH17K1530010-01

6) Disconnect the clutch cable (1) from clutch release

arm.
1

IH17K1530014-01

Installation
Install the clutch cable in the reverse order of removal.
Pay attention to the following points:
• Install the clutch cable as shown in the clutch cable
routing diagram. Refer to “Clutch Cable Routing
1 Diagram” (Page 5C-2).
• After install the removed parts, adjust the clutch cable
play. (Page 5C-4)
IH17K1530011-01

7) Remove the lock-nut (1) from clutch cable adjuster

(2). Clutch Lever Removal and Installation
BENH17K15306005
8) Remove the clutch cable (3) from the clutch cable
stopper (4). Removal
1) Disconnect the clutch switch couplers (1).
4

2
1

IH17K1530012-01 1
IH17K1530002-01

2) Disconnect the clutch cable from the clutch lever

side. (Page 5C-7)
3) Remove the left handle switch and handlebar grip.
(Page 6B-3)
 Clutch: 5C-8

4) Remove the clutch lever assembly (1). Installation

Install the clutch lever in the reverse order of removal.
Pay attention to the following points:
1 • Apply grease to the collar and clutch lever pivot bolt.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

IH17K1530015-01

5) Remove the clutch switch (1) and clutch lever (2).

6) Remove the spring (3) and cable adjuster nut (4). “A”

1 “A”

4 IH17K1530018-01

• Tighten the new clutch lever pivot nut (1) to the

specified torque.
2 Tightening torque
Clutch lever pivot nut (a): 6.5 N·m (0.66 kgf-m,
4.80 lbf-ft)

IH17K1530016-01

7) Remove the collar (1).

1, (a)

IH17K1530019-01
1
• When installing the clutch switch (1), align the
projection (2) on the switch with the groove (3) in the
clutch lever holder.
IH17K1530017-01

2
1

IH17K1530020-01
5C-9 Clutch:

• Apply a small quantity of thread lock to the clutch Clutch Push Rod (Left) / Clutch Release
switch screw (1) and tighten it to the specified torque. Camshaft Removal and Installation
BENH17K15306006
“A”: Thread lock cement 99000–32160 (THREAD
LOCK CEMENT 1342H) Removal
Tightening torque 1) Remove the gearshift link arm (1).
Clutch switch screw (a): 0.6 N·m (0.06 kgf-m, 0.45
lbf-ft)
1

1 , “ A ” , ( a)
IH17K1530023-01

2) Remove the engine sprocket cover (1).

IH17K1530021-01

• When installing the clutch lever assembly (1) to the

left handlebar (2), align the slit (3) of clutch lever
holder with the punch mark (4) on the left handlebar
and tighten the bolt (5) to the specified torque.
Tightening torque
Clutch lever holder bolt (a): 10 N·m (1.0 kgf-m, 1
7.5 lbf-ft)

2 1

IH17K1530024-01

3) Disconnect the clutch cable from the clutch release

arm. (Page 5C-7)
4 5, (a) 4) Remove the clutch release arm (1), spring (2) and
washer (3).

3
IH17K1530022-01

• After installing the removed parts, adjust the clutch 1

cable play. (Page 5C-4)

2
3
IH17K1530025-01
 Clutch: 5C-10

5) Remove the clutch release holder (1). Installation

Install the clutch push rod (left) and clutch release
camshaft in the reverse order of removal. Pay attention
1 to the following points:
• Apply grease to the new bearings.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A”

IH17K1530026-01

6) Remove the clutch push rod (Left) (1) and dowel pins
(2).

IF04K1530024-02
2
• Install the clutch release camshaft lower bearing (1)
and upper bearing (2).

NOTE
The stamped mark side of bearings faces
1 outside.

IH17K1530027-01

7) Remove the clutch push rod cap (1) and oil seal (2).
2
1

1
IH17K1530030-01
2
• Apply grease to the contact position of clutch release
IH17K1530028-01 camshaft (1).
8) Remove the oil seal (1) and clutch release camshaft
“A”: Grease 99000–25011 (SUZUKI SUPER
upper bearing (2) with clutch release camshaft (3).
GREASE A)
9) Remove the clutch release camshaft lower bearing
(4).

4 1, “A”

2
1

IH17K1530031-01

IH17K1530029-01
5C-11 Clutch:

• Install the new oil seal (1) at the specified position in • Apply engine oil to oil seal lip (1) and grease to the
the clutch release holder (2) and apply grease to the clutch push rod end (2), and then install the clutch
oil seal lip. push rod (Left).
“A”: Grease 99000–25011 (SUZUKI SUPER “A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A) GREASE A)

1 2

“A”

1 2, “A”
1 “a”

IH17K1530032-01 IH17K1530035-03

“a”: 1.0 – 1.5 mm (0.04 – 0.05 in) • Install the clutch release holder (1) and tighten the
bolts to the specified torque.
• Apply grease to the contact position of clutch push rod Tightening torque
cap (1) and install it. Clutch release holder bolt (a): 10 N·m (1.0 kgf-m,
“A”: Grease 99000–25011 (SUZUKI SUPER 7.5 lbf-ft)
GREASE A)

(a)

(a)

1, “A” IH17K1530036-01

IH17K1530033-01 • Install the engine sprocket cover (1) and tighten the
• Apply grease to the new oil seal lip (1) and install it. bolts to the specified torque.
“A”: Grease 99000–25011 (SUZUKI SUPER Tightening torque
GREASE A) Engine sprocket cover bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lbf-ft)

1, “A”

(a)
1

IH17K1530034-01
IH17K1530037-01
 Clutch: 5C-12

• Install the gearshift link arm (1) to the gearshift shaft Clutch Push Rod (Left) Inspection
and tighten the bolt to the specified torque. BENH17K15306007
Refer to “Clutch Push Rod (Left) / Clutch Release
Tightening torque Camshaft Removal and Installation” (Page 5C-9).
Gearshift link arm bolt (a): 12 N·m (1.2 kgf-m, 9.0 Inspect the push rod for wear or bend. If any defects are
lbf-ft) found, replace it with a new one.

1
(a)

“a”

IF04K1530031-01

Clutch Push Rod Oil Seal Removal and

IH17K1530038-01
Installation
“a”: 90° BENH17K15306012
Removal
• When installing the clutch release arm, align the 1) Remove the following parts.
punch mark (1) of clutch release arm with slit (2) of • Water pump: (Page 1F-14)
clutch release camshaft.
• Engine sprocket: (Page 3A-3)
• Hook the spring end (3) to the clutch release arm and
clutch release holder. 2) Remove the clutch push rod (Left) (1) and clutch
push rod oil seal retainer (2).
• Tighten the clutch release arm bolt to the specified
torque.
Tightening torque 1
Clutch release arm bolt (a): 8.8 N·m (0.90 kgf-m,
6.50 lbf-ft)

2 2

IH17K1530074-01

3) Remove the clutch push rod oil seal (1).

1
(a) 3
IH17K1530039-02

• After installing the removed parts, check the following

items.
– Clutch cable play: (Page 5C-4)
– Gearshift lever height: (Page 5B-18)
1

IH17K1530075-01
5C-13 Clutch:

Installation Clutch Push Rod Oil Seal Inspection

Install the clutch push rod oil seal in the reverse order of BENH17K15306013

removal. Pay attention to the following points: Refer to “Clutch Push Rod (Left) / Clutch Release
Camshaft Removal and Installation” (Page 5C-9).
• Install the new oil seal (1) with the special tool. Inspect the clutch push rod oil seal lip (1) for damage or
Special tool wear. If any defect is found, replace the oil seal with a
(A): 09913–70210 new one. (Page 5C-12)

1
( A)

IH17K1530076-02 IH17K1530079-01

• Apply engine oil to the oil seal lip (1).

IH17K1530077-02

• Apply thread lock to the clutch push rod oil seal

retainer screws (1) and tighten them to the specified
torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Clutch push rod oil seal retainer screw (a): 8.4
N·m (0.86 kgf-m, 6.20 lbf-ft)

1, “ A ” , ( a)

1, “A”, (a)
IH17K1530078-01
 Clutch: 5C-14

Clutch Components
BENH17K15306008

(a) 2

4
5 (b)
4
6/7/8 3
(c)
9
6/7/8
9
6
9
6
9
6
9
6
9
10
4
11
12

14 16
13
17

15

18

IH17K1530040-01

1. Stopper plate 9. Drive plate No. 1 (6 pcs.) 17. Bearing

2. Clutch pressure plate 10. Driven plate No. 2 (1 pc.) 18. Clutch push rod
3. Clutch push piece 11. Wave washer : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
4. Drive plate No. 2 (3 pcs.) 12. Wave washer seat : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
5. Driven plate No. 4 (1 pc.) 13. Clutch sleeve hub : 150 Nm (15.3 kgf-m, 111.0 lbf-ft)
6. Driven plate No. 1 (4 – 6 pcs.) 14. Thrust washer : Apply engine oil.

7. Driven plate No. 3 (0 – 2 pcs.) 15. Primary driven gear assembly : Do not reuse.
8. Driven plate No. 5 (0 – 2 pcs.) 16. Spacer
5C-15 Clutch:

Clutch Removal 6) Remove the clutch spring set bolts (1), stopper plate
BENH17K15306009 (2) and clutch springs.
1) Drain engine oil. (Page 1E-4)
2) Remove the right side cowling assembly. (Page NOTE
9D-21) Loosen the clutch spring set bolts little by
3) Remove the clutch cover (1) and right under cowling little and evenly.
bracket (2).

2 2
IH17K1530044-01
IH17K1530041-01

4) Remove the gasket (1) and dowel pins (2). 7) Remove the clutch pressure plate (1) with the clutch
drive plate (2) and clutch driven plate (3).

2
1

2
2

3
1
IH17K1530042-01
IH17K1530045-01
5) Remove the limiter driven gear (1), starter idle gear
No. 2 (2) and starter idle gear No. 2 pin (3). (Page 8) Remove the clutch driven plate (1) and clutch drive
1I-9) plate (2) from clutch pressure plate (3).

3
1

3
2
1

IH17K1530046-01
IH17K1530043-01
 Clutch: 5C-16

9) Remove the clutch spring seat (1) from clutch 13) Remove the clutch push rod (1).
pressure plate (2).
NOTE
If it is difficult to pull out the push rod (1), use
a magnetic hand or wire.

1
1
2
IH17K1530047-01

10) Remove the clutch drive plates (1) and driven plates
(2).

IH17K1530051-01

14) Unlock the clutch sleeve hub nut.

2

1
IH17K1530048-01

11) Remove the wave washer (1) and wave washer seat
(2).
IH17K1530052-01

15) Hold the clutch sleeve hub with the special tools and
remove the clutch sleeve hub nut (1).
Special tool
2
(A): 09920–53740
(B): 09920–31020

1
1

(A )
IH17K1530049-01
(B )
12) Remove the thrust washer (1), clutch release
bearing (2) and clutch push piece (3).

IH17K1530053-01

3
2 1
IH17K1530050-01
5C-17 Clutch:

16) Remove the spring washer (1), washer (2) and Clutch Installation
clutch sleeve hub (3). BENH17K15306010
1) Aligning cutouts (1) of the primary driven gear
assembly with lugs (2) on the oil pump drive gear,
install the primary driven gear assembly.
3

2 2

IH17K1530054-01

17) Remove the thrust washer (1).

IH17K1530057-01

2) Apply engine oil to the bearing (1) and install it.

1 3) Install the spacer (2).

IH17K1530055-01

18) Remove the primary driven gear assembly (1).

2
19) Remove the bearing (2) and spacer (3).

IH17K1530058-01
3
4) Install the thrust washer (1).
1

IH17K1530056-01

IH17K1530055-01
 Clutch: 5C-18

5) Install the clutch sleeve hub (1), washer (2) and 7) Lock the clutch sleeve hub nut (1) with a center
spring washer (3). punch.

NOTE
The conical curve side of spring washer (3)
faces outside.
1

IH17K1530061-01

8) Install the clutch push rod (1) into the countershaft.

IH17K1530059-01

2 1

IH17K1530051-01

9) Apply engine oil to the bearing (1).

10) Install the clutch push piece (2), bearing (1) and
thrust washer (3) to the countershaft.
IF04K1530051-01

6) Hold the clutch sleeve hub with the special tools and NOTE
tighten the new clutch sleeve hub nut (1) to the Thrust washer (3) is located between the
specified torque. pressure plate and bearing (1).
Special tool
(A): 09920–53740
(B): 09920–31020
Tightening torque
Clutch sleeve hub nut (a): 150 N·m (15.3 kgf-m,
111.0 lbf-ft)

1, ( a) 2

1
3
(A) IH17K1530062-01

(B )

IH17K1530060-01
5C-19 Clutch:

11) Install the wave washer seat (1) and wave washer
(2) onto the clutch sleeve hub correctly. 4 3 4

1 2
[C]

8 5 5/6/7 9

[A] [B]
IH17K1530065-02

IF04K1530056-01 [A]: Insert the plates to the 5. Driven plate No. 1 (4 – 6 pcs.)
clutch sleeve hub. : The driven plates No. 1, No. 3
12) Install the clutch spring seat (1) to the clutch and No. 5 are 6 pcs. in total.
pressure plate (2). [B]: Insert the plates to the 6. Driven plate No. 3 (0 – 2 pcs.)
clutch pressure plate. : The driven plates No. 1, No. 3
and No. 5 are 6 pcs. in total.
[C]: Direction of outside (Clutch 7. Driven plate No. 5 (0 – 2 pcs.)
pressure plate side) : The driven plates No. 1, No. 3
and No. 5 are 6 pcs. in total.
3. Drive plate No. 1 8. Driven plate No. 2
4. Drive plate No. 2 9. Driven plate No. 4
1
NOTE
The clutch system is equipped with two kinds
of drive plate (No. 1 and No. 2). They can be
1 distinguished by the inside diameter “a”.
2
IH17K1530047-01

13) Apply engine oil to the clutch drive plates.

14) Insert the clutch drive plates and driven plates one
by one into the clutch sleeve hub (1) and clutch
pressure plate (2) in the prescribed order.
“a” “a”

IE31J1530077-01

Drive plate I.D. “a”

No. 1 112.0 mm (4.41 in)
No. 2 122.5 mm (4.82 in)

IH17K1530063-01

IH17K1530064-01
 Clutch: 5C-20

NOTE
• The clutch system is equipped with five 3
kinds of driven plate (No. 1, No. 2, No. 3, 1
2
No.4 and No. 5). They can be distinguished
by the inside diameter “a”, thickness “b”
and with or without nailing process.
• In this motorcycle, 6 pcs. of the driven
plate No. 1, 1 pc. of No. 2 and 1 pc. of No. 4
are installed basically. But, sometimes, 1
or 2 pcs. of No. 1 are substituted by No. 3
or No. 5 at the factory for fine adjustment
IH17K1530066-01
of the overall thickness of clutch plates.
However, when replacing the driven plate 16) Install the clutch springs, stopper plate (1) and clutch
in the aftermarket, always use 6 pcs. of No. spring set bolts (2).
1, 1 pc. of No. 2 and 1 pc. of No. 4. 17) Tighten the clutch spring set bolts to the specified
• The driven plate No. 2 should be installed torque.
in the deep recesses of the clutch sleeve NOTE
hub.
Tighten the clutch spring set bolts little by
• The driven plate No. 4 should be installed
little and evenly.
in the pressure plate side.
Tightening torque
Clutch spring set bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)

“a” “a” 2 , (a )

2 , (a )

“b”
IE31J1530078-01
1
Thickness Nailing
Driven plate I.D. “a” IH17K1530067-01
“b” process 18) Loosen the lock-nut (1) and turn in the clutch release
103.7 mm 2.3 mm adjusting screw (2) until resistance is felt.
No. 1 Processed
(4.083 in) (0.091 in)
103.7 mm 2.3 mm Not 19) From that position, turn out the clutch release
No. 2 adjusting screw (2) 1 turn and tighten the lock-nut (1)
(4.083 in) (0.091 in) processed
103.7 mm 2.6 mm while holding the screw (2).
No. 3 Processed
(4.083 in) (0.102 in) Tightening torque
112.0 mm 2.6 mm Not Clutch release adjuster lock-nut (a): 5.5 N·m (
No. 4
(4.409 in) (0.102 in) processed 0.56 kgf-m, 4.05 lbf-ft)
103.7 mm 2.0 mm
No. 5 Processed
(4.083 in) (0.079 in)

15) Install the clutch pressure plate (1) with the clutch
plates. 1, (a)

NOTE
Insert the outermost drive plate (No. 2) claws
(2) to the other slits (3) of clutch housing as 2
shown.

IH17K1530068-01
5C-21 Clutch:

20) Install the starter idle gear No. 2 pin, starter idle gear 24) Install the clutch cover.
No. 2 and limiter driven gear. (Page 1I-9) 25) Fit the new gasket to the clutch cover bolt (1).
21) Apply sealant lightly to the mating surfaces at the 26) Tighten the clutch cover bolts to the specified torque.
parting line between the upper and lower crankcases
as shown in the figure. NOTE
“A”: Sealant 99000–31140 (SUZUKI BOND Fit the clamp to the bolt (2) and right under
1207B) cowling bracket to the bolts (3).

Tightening torque
“A”
Clutch cover bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-
ft)

(a)

“A”
1, (a)

IH17K1530069-01

22) Install the dowel pins (1) and new gasket (2).
3, (a)
2, (a)
1 IH17K1530072-01

27) Install the right side cowling assembly. (Page 9D-

21)
28) Pour engine oil. (Page 1E-4)
1
Clutch Parts Inspection
BENH17K15306011
Refer to “Clutch Removal” (Page 5C-15) and “Clutch
Installation” (Page 5C-17).
2
IH17K1530070-01 Clutch Drive and Driven Plate
23) Apply molybdenum oil solution to the starter idle
gear No. 2 pin and starter idle gear No. 1 shaft holes. NOTE

“A”: Assembly lubrication (Molybdenum oil Wipe off the engine oil from the drive and
solution) driven plates with a clean rag.

• Measure the thickness of drive plates with a vernier

calipers. If the drive plate thickness is found to have
“A”
reached the limit, replace it with a new one.
Drive plate thickness
[Limit]: 2.92 mm (0.115 in)
Special tool
(A): 09900–20102

(A)
IH17K1530071-01

IF04K1530064-01
 Clutch: 5C-22

• Measure the claw width of drive plates with a vernier Clutch Release Bearing
calipers. Replace the drive plates found to have worn Inspect the clutch release bearing (1) for any
down to the limit. abnormality, especially cracks. When removing the
bearing from the clutch, decide whether it can be reused
Drive plate claw width
or if it should be replaced.
[Limit]: 13.2 mm (0.520 in)
Smooth engagement and disengagement of the clutch
Special tool depends on the condition of this bearing.
(A): 09900–20102

(A)
1

IF04K1530068-01

Clutch Push Rod

Inspect the clutch push rod for wear and damage.
IF04K1530065-01
If any defects are found, replace the clutch push rod with
• Measure each driven plate for distortion with a a new one.
thickness gauge and surface plate.
Replace driven plates which exceed the limit.
Driven plate distortion
[Limit]: 0.10 mm (0.0039 in)
Special tool
(A): 09900–20803

(A)

IF04K1530069-01

Clutch Pressure Plate / Clutch Sleeve Hub / Primary

Driven Gear Assembly
Inspect the slot of the clutch pressure plate (1), clutch
IF04K1530066-01
sleeve hub (2) and primary driven gear assembly (3) for
Clutch Spring damage or wear caused by the clutch plates. If
Measure the free length of each coil spring with a vernier necessary, replace it with a new one.
calipers, and compare the length with the specified limit. Inspect the cam faces on clutch pressure plate and
Replace all the springs if any spring is not within the clutch sleeve hub for wear and damage. If necessary,
limit. replace it with a new one.
Inspect the springs of primary driven gear assembly for
Clutch spring free length any damages. If necessary, replace primary driven gear
[Limit]: 53.1 mm (2.09 in) assembly with a new one.
Special tool
(A): 09900–20102 3
2

(A) 1

IF04K1530067-01 IH17K1530073-01
5C-23 Clutch:

Specifications
Tightening Torque Specifications
BENH17K15307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Clutch release adjuster lock-nut (Page 5C-4) /
5.5 0.56 4.05
(Page 5C-20)
Clutch cable lock-nut 4.5 0.46 3.35 (Page 5C-5)
Clutch release adjuster cap 11 1.1 8.5 (Page 5C-5)
Clutch lever pivot nut 6.5 0.66 4.80 (Page 5C-8)
Clutch switch screw 0.6 0.06 0.45 (Page 5C-9)
Clutch lever holder bolt 10 1.0 7.5 (Page 5C-9)
Clutch release holder bolt 10 1.0 7.5 (Page 5C-11)
Engine sprocket cover bolt 10 1.0 7.5 (Page 5C-11)
Gearshift link arm bolt 12 1.2 9.0 (Page 5C-12)
Clutch release arm bolt 8.8 0.90 6.50 (Page 5C-12)
Clutch push rod oil seal retainer screw 8.4 0.86 6.20 (Page 5C-13)
Clutch sleeve hub nut 150 15.3 111.0 (Page 5C-18)
Clutch spring set bolt 10 1.0 7.5 (Page 5C-20)
Clutch cover bolt 10 1.0 7.5 (Page 5C-21)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Clutch Cable Routing Diagram” (Page 5C-2)
“Clutch Control System Components” (Page 5C-6)
“Clutch Components” (Page 5C-14)
“Fasteners Information” in Section 0C (Page 0C-12)
 Clutch: 5C-24

Special Tools and Equipment

Recommended Service Material
BENH17K15308001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution — (Page 5C-21)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 5C-8) / (Page 5C-
10) / (Page 5C-10) /
(Page 5C-11) / (Page
5C-11) / (Page 5C-11) /
(Page 5C-11)
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 5C-21)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 5C-13)
THREAD LOCK CEMENT 1342H P/No.: 99000–32160 (Page 5C-9)

NOTE
Required service material(s) is also described in:
“Clutch Control System Components” (Page 5C-6)
“Clutch Components” (Page 5C-14)

Special Tool
BENH17K15308002
09900–20102 09900–20803
Vernier calipers (200 mm) Thickness gauge
(Page 5C-21) / (Page 5C-22)
(Page 5C-22) /
(Page 5C-22)

09913–70210 09920–31020
Bearing installer set Extension handle
(Page 5C-13) (Page 5C-16) /
(Page 5C-18)

09920–53740
Clutch sleeve hub holder
(Page 5C-16) /
(Page 5C-18)
5C-25 Clutch:
 Table of Contents 6- i

Section 6

Steering
CONTENTS

Precautions .................................................6-1 Steering Damper Removal and Installation.........6B-7

Precautions............................................................. 6-1 Steering Damper Inspection................................6B-8
Precautions for Steering ....................................... 6-1 Steering Stem Components ................................6B-9
Steering On-Vehicle Inspection...........................6B-9
Steering General Diagnosis.................... 6A-1 Steering Tension Adjustment ............................6B-10
Diagnostic Information and Procedures............6A-1 Steering Stem Removal and Installation ...........6B-10
Steering Symptom Diagnosis.............................. 6A-1 Steering Stem Inspection ..................................6B-13
Steering Stem Bearing Removal and
Steering / Handlebar................................ 6B-1 Installation .......................................................6B-14
Repair Instructions ..............................................6B-1 Specifications .....................................................6B-15
Handlebar Components ...................................... 6B-1 Tightening Torque Specifications......................6B-15
Handlebar Construction ...................................... 6B-2 Special Tools and Equipment ...........................6B-16
Handlebar Removal and Installation ................... 6B-3 Recommended Service Material .......................6B-16
Handlebar Inspection .......................................... 6B-6 Special Tool ......................................................6B-16
Steering Damper Construction............................ 6B-7

6
6-1 Precautions:

Precautions
Steering

Precautions
Precautions for Steering
BENH17K16000001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Steering General Diagnosis: 6A-1

Steering General Diagnosis

Steering

Diagnostic Information and Procedures

Steering Symptom Diagnosis
BENH17K16104002

Condition Possible cause Correction / Reference Item

Heavy steering Over tightened steering stem adjust-nut. Adjust. (Page 6B-10)
Broken bearing in steering stem. Replace. (Page 6B-14)
Distorted steering stem. Replace. (Page 6B-10)
Not enough pressure in tires. Adjust. (Page 2D-13)
Defective steering damper. Replace. (Page 6B-7)
Wobbly handlebar Loss of balance between right and left Replace fork, adjust fork oil level or replace
front forks. fork spring.
• Replace fork: (Page 2B-3)
• Adjust fork oil level or replace fork spring:
(Page 2B-5)
Distorted front fork. Repair or replace. (Page 2B-3)
Distorted front axle or crooked tire. Replace.
• Front axle: (Page 2D-4)
• Front tire: (Page 2D-14)
Loose steering stem adjust-nut. Adjust. (Page 6B-10)
Worn or incorrect tire. Replace. (Page 2D-14)
Incorrect tire pressure. Adjust. (Page 2D-13)
Worn bearing/race in steering stem. Replace. (Page 6B-14)
6B-1 Steering / Handlebar:

Steering / Handlebar
Steering

Repair Instructions
Handlebar Components
BENH17K16206001

(a)

1 [A]
7
(a)

(a)

6
[A]
(a)
IH17K1620001-04

[A]: Apply handle grip glue. 4. Left handlebar grip : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
1. Throttle grip 5. Right handlebar : Apply water resistant grease EP2.
2. Right handle switch 6. Left handlebar
3. Left handle switch 7. Handlebar balancer
 Steering / Handlebar: 6B-2

Handlebar Construction
BENH17K16206002

5 4

[A] 1

[B]

(e)

(a)
2

(f) 3
(b)

[C]
(c)

4
(g) (d)
5 (h)
IH17K1620002-02

[A]: Align the matching surface of clutch lever 3. Steering stem upper : 6.5 Nm (0.66 kgf-m, 4.80 : 5.9 Nm (0.60 kgf-
holder with punch mark of handlebar. bracket lbf-ft) m, 4.35 lbf-ft)
[B]: Align the punch mark of handlebar with the 4. Front brake light switch : 1.2 Nm (0.12 kgf-m, 0.90 : Apply grease.
edge of front brake master cylinder. lbf-ft)
[C]: Insert the protrusion of the handlebar into the 5. Clutch switch : 1.0 Nm (0.10 kgf-m, 0.75 : Apply silicone
hole of the steering stem upper bracket. lbf-ft) grease.
1. Front brake master cylinder assembly : 23 Nm (2.3 kgf-m, 17.0 : 10 Nm (1.0 kgf-m, 7.5
lbf-ft) lbf-ft)
2. Clutch lever assembly : 90 Nm (9.2 kgf-m, 66.5 : 0.6 Nm (0.06 kgf-m, 0.45
lbf-ft) lbf-ft)
6B-3 Steering / Handlebar:

Handlebar Removal and Installation 3) Loosen the handlebar clamp bolts (1) and front fork
BENH17K16206003 upper clamp bolts (2).
Removal
1) Remove the following parts from the left side of the 2
2
handlebar.
a) Left handle switch (1)
b) Handlebar balancer (2)
c) Left handlebar grip (3)
d) Clutch cable (4)
1
1
4
1 IH17K1620005-01

4) Remove the steering stem head nut (1) with the

special tools.
3
2
Special tool
(A): 09940–14710
(B): 09923–12410

IH17K1620003-01

2) Remove the following parts from the right side of the

handlebar.
a) Right handle switch (1)
b) Handlebar balancer (2)
c) Throttle grip (3)
d) Front brake master cylinder assembly (4) 1

NOTE
IH17K1620006-01
Do not turn the front brake master cylinder
upside down.

4
1

3 ( B)
2
(A )

IH17K1620007-01

IH17K1620004-01
 Steering / Handlebar: 6B-4

5) Remove the washer (1) and steering stem upper 8) Remove the clutch lever assembly (1) from the left
bracket assembly (2). handlebar.

NOTICE
Place a rag under the steering stem upper
bracket to prevent scratching the body 1
cowling and the combination meter.

IH17K1620011-01

Installation
1) Align the matching surface of the clutch lever holder
1
with the punch mark (1) on the left handlebar and
tighten the clutch lever holder bolt to the specified
IH17K1620008-01 torque.
6) Disconnect the clutch switch couplers (1).
Tightening torque
Clutch lever holder bolt (a): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)

(a)

IH17K1620009-01

7) Remove the handlebars (1) upward. 1

IH17K1620012-01

2) Install the handlebars temporarily to the front forks.

3) Install the steering stem upper bracket (1), washer
(2) and steering stem head nut (3) temporarily.

NOTE
Face the chamfer side of the washer
downward.

IH17K1620010-01

1
3
1
2

IH17K1620013-01
6B-5 Steering / Handlebar:

4) Insert the protrusion (1) of the handlebar into the

hole (2) of the steering stem upper bracket.

2 2

(B)

1 1 (A )

IH17K1620017-01

7) Install the front brake master cylinder assembly.

IH17K1620014-01 (Page 4A-24)
5) Tighten the front fork upper clamp bolts (1) and 8) Apply grease onto the handlebar before installing the
handlebar clamp bolts (2) to the specified torque. throttle grip.
Tightening torque “A”: Grease 99000–25350 (SUZUKI WATER
Front fork upper clamp bolt (a): 23 N·m (2.3 kgf- RESISTANT GREASE EP2)
m, 17.0 lbf-ft)
Handlebar clamp bolt (b): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

1, (a)
1, (a)
IE31J1620008-01

9) Install the right handlebar balancer and tighten the

handlebar balancer screw.
Tightening torque
Handlebar balancer screw: 23 N·m (2.3 kgf-m,
2, (b) 17.0 lbf-ft)
2, (b) 10) Insert the projection (1) of the right handle switch
into the hole (2) of the right handlebar.
IH17K1620015-01

6) Tighten the steering stem head nut (1) to the

specified torque with the special tools.
Special tool
(A): 09940–14710 2
(B): 09923–12410
Tightening torque
1
Steering stem head nut (a): 90 N·m (9.2 kgf-m,
66.5 lbf-ft)

IH17K1620018-01

1, ( a)

IH17K1620016-01
 Steering / Handlebar: 6B-6

11) Clean, decrease and dry both the left handlebar 15) Connect the clutch cable (1).
outer surface (1) on which the grip is being fitted and 16) Connect the clutch switch couplers (2).
internal surface of the left handlebar grip (2).
12) Apply handle grip glue to both the left handlebar
outer surface (1) on which the grip is being fitted and
internal surface of the left handlebar grip (2) evenly.
“A”: Adhesive (Handle grip glue)
1

2
IH17K1620020-01

17) Check to make sure that the wire harnesses, cables

and hoses are properly routed.
• Wire harness: (Page 9A-13)
IE31J1620012-01 • Cable: (Page 1C-2)
13) Install the left handlebar balancer and tighten the • Hose: (Page 4A-1)
handlebar balancer screw. 18) Check the throttle cable for the play and smooth
Tightening torque operation. (Page 1C-5)
Handlebar balancer screw: 23 N·m (2.3 kgf-m, 19) Check the clutch cable for the play and smooth
17.0 lbf-ft) operation. (Page 5C-4)
14) Insert the projection (1) of the left handle switch into
the hole (2) of the left handlebar. Handlebar Inspection
BENH17K16206004
Refer to “Handlebar Removal and Installation” (Page 6B-
3).
Inspect the handlebars for distortion and damage.
If any defect is found, replace the handlebar with a new
1 one.

IH17K1620019-01
6B-7 Steering / Handlebar:

Steering Damper Construction

BENH17K16206012

3
2

(a)

IH17K1620021-02

1. Steering damper 2. Dust seal 3. Bearing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft) : Apply water resistant grease EP2.

Steering Damper Removal and Installation 4) Disconnect the steering damper solenoid valve
BENH17K16206013 coupler (1).
Removal
1) Remove the body cowling cover. (Page 9D-20)
1
2) Remove the lower bracket cover (1).

IH17K1620022-02

5) Remove the steering damper rod end nut (1) while

holding the rod end bolt (2).
6) Remove the steering damper mounting bolt (3).
IH17K1620023-01
7) Remove the steering damper (4).
3) Turn the ignition switch OFF.

IH17K1620024-02
 Steering / Handlebar: 6B-8

Installation Steering Damper Inspection

Install the steering damper in the reverse order of BENH17K16206014

removal. Pay attention to the following points: Refer to “Steering Damper Removal and Installation”
(Page 6B-7).
• Apply grease to the bearings and dust seals.
• Inspect the steering damper body, bearing and oil seal
“A”: Grease 99000–25350 (SUZUKI WATER for damage and oil leaking. If any defects are found,
RESISTANT GREASE EP2) replace the steering damper with a new one.
• Move the steering damper rod by hand to inspect for a
smooth movement. If it does not move smoothly,
replace the steering damper with a new one.
“A”

“A”
“A”

IH17K1620025-01

• Install the steering damper and tighten the bolt (1) and
nut (2) to the specified torque.
Tightening torque
Steering damper mounting bolt (a): 23 N·m (2.3
kgf-m, 17.0 lbf-ft) IH17K1620027-01
Steering damper rod end nut (b): 23 N·m (2.3 kgf- • Measure the steering damper solenoid valve
m, 17.0 lbf-ft) resistance between terminals using the multi circuit
tester. If resistance is out of specification, replace the
steering damper with a new one.
Steering damper solenoid valve resistance
20 °C (68 °F) [Standard]: 12.5 Ω

1, ( a)
2, ( b)

IH17K1620026-02

IH17K1620028-01
6B-9 Steering / Handlebar:

Steering Stem Components

BENH17K16206005

1 (b)

3 (c)

4
(a)
5 (d)

9 7

11 8
14
10

15 12

13

(a)
IH17K1620029-01

1. Steering stem head nut 8. Steering stem upper bearing outer race 15. Steering stem lower bracket
2. Steering stem upper bracket 9. Steering stem upper bearing : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Steering stem lock-nut 10. Steering stem upper bearing inner race : 90 Nm (9.2 kgf-m, 66.5 lbf-ft)
4. Washer 11. Steering stem lower bearing : 80 Nm (8.2 kgf-m, 59.0 lbf-ft)
5. Steering stem adjust-nut 12. Steering stem lower bearing inner race : 20 Nm (2.0 kgf-m, 15.0 lbf-ft) → turn counterclockwise 0 – 1/4
6. Dust cover 13. Steering stem lower bearing outer race : Apply grease.
7. Dust seal 14. Lower seal : Do not reuse.

Steering On-Vehicle Inspection b) With the front wheel on the ground and applying
BENH17K16206006 the front brake(s), move the handlebar back-
Steering should be adjusted properly for smooth turning and-forth and up-and-down to check there is no
of handlebars and safe running. Overtighten steering play in the stem bearings.
prevents smooth turning of the handlebars and too loose
steering will cause poor stability.
1) Check that there is no play in the front fork.
a) Support the motorcycle with its front wheel off
the ground, grasp the bottoms of the front forks
and move the forks back-and-forth to check
there is no play in the stem bearings.

IH17K1620031-01

2) If play is found, readjust the steering. (Page 6B-

10)

IH17K1620030-01
 Steering / Handlebar: 6B-10

Steering Tension Adjustment b) Tighten the steering stem lock-nut, steering stem
BENH17K16206007 head nut, handlebar clamp bolts and front fork
1) By supporting the motorcycle with a jack, lift the front upper clamp bolts to the specified torque, and
wheel until it is off the floor 20 – 30 mm (0.8 – 1.2 in). recheck the initial force with the spring scale
2) Remove the steering damper. (Page 6B-7) according to the previously described procedure.
3) Check to make sure that the cables and wire Special tool
harnesses are properly routed. 09940–14710
4) With the front wheel in the straight ahead state, hitch 09923–12410
the spring scale on one handlebar grip end as shown
Tightening torque
in the figure and read the graduation when the
Steering stem lock-nut: 80 N·m (8.2 kgf-m,
handlebar start moving.
59.0 lbf-ft)
Steering tension initial force Steering stem head nut: 90 N·m (9.2 kgf-m,
[Standard]: 2 – 5 N (0.21 – 0.50 kgf, 0.45 – 1.12 lbf) 66.5 lbf-ft)
Handlebar clamp bolt: 23 N·m (2.3 kgf-m,
17.0 lbf-ft)
Front fork upper clamp bolt: 23 N·m (2.3 kgf-
m, 17.0 lbf-ft)
c) Make sure that the initial force is within the
specified range and the steering is not loose.

IF04K1620033-01

5) Do the same on the other grip end.

6) If the initial force reading on the scale when the
handlebar starts turning is either too heavy or too
light, adjust the tension until it satisfies the
specification as follows.
a) First, loosen the front fork upper clamp bolts,
handlebar clamp bolts, steering stem head nut IH17K1620030-01
and steering stem lock-nut, and then adjust the d) Install the removed parts.
steering stem adjust-nut by loosening or
tightening it. Steering Stem Removal and Installation
BENH17K16206009
Special tool
(A): 09910–60620 Removal
09940–14710
09923–12410 1) Remove the front forks. (Page 2B-3)
2) Remove the lower bracket cover (1).
3) Remove the steering damper rod end nut (2) while
holding the rod end bolt.
4) Disconnect the steering damper rod from the
steering stem lower bracket.

(A)
2
1
IH17K1620032-01

IH17K1620033-01
6B-11 Steering / Handlebar:

5) Remove the steering stem head nut (1) with the 8) Remove the steering stem lower bracket.
special tools.
Special tool
(A): 09940–14710
(B): 09923–12410
(A )
1

(B )

2
1 3
IH17K1620037-01

9) Remove the dust cover (1), dust seal (2), steering

stem upper bearing outer race (3) and steering stem
upper bearing (4).
IH17K1620034-01

1 2

(B)

IH17K1620038-01
( A)
IH17K1620035-01

6) Remove the washer (1) and steering stem upper

bracket assembly (2). 3 4

NOTICE
Place a rag under the steering stem upper
bracket to prevent scratching the
combination meter.

2
IH17K1620039-01

10) Remove the steering stem lower bearing (1).

1
1

IH17K1620036-01

7) While holding the steering stem lower bracket,

remove the steering stem lock-nut (1), washer (2)
and steering stem adjust-nut (3) with the special
tools. IH17K1620040-01

Special tool
(A): 09940–14911
(B): 09940–14960
 Steering / Handlebar: 6B-12

Installation 5) In this condition, check that the steering stem lower

1) Apply grease to the bearings, races, lower seal and bracket can turn smoothly without rattle and
new dust seal lip, and install the steering stem lower stiffness. If there is a rattle or heavy movement,
bracket to the frame. readjust the tightness by the stem adjust-nut.
6) When installing the washer (1), align the lug (2) of
“A”: Grease 99000–25030 (SUZUKI SUPER
the washer to the groove of the steering stem.
GREASE C)

“A”
1

IH17K1620043-01
IH17K1620041-01
7) Tighten the steering stem lock-nut (1) to the
2) Install the steering stem adjust-nut (1) and
specified torque with the special tools.
temporarily tighten it to the specified torque (20 Nm
(2.0 kgf-m, 15.0 lbf-ft)) with the special tools. Special tool
(A): 09940–14911
Special tool
(B): 09940–14960
(A): 09940–14911
(B): 09940–14960 Tightening torque
Steering stem lock-nut (a): 80 N·m (8.2 kgf-m,
3) Turn the steering stem lower bracket to the left and
59.0 lbf-ft)
right about five or six times so that the taper roller
bearings seat properly.
4) Loosen the steering stem adjust-nut 0 – 1/4 turn “a”.
Tightening torque
Steering stem adjust-nut (a): 20 Nm (2.0 kgf-m,
15.0 lbf-ft) → turn counterclockwise 0 – 1/4 (A)
(B )

1 , (a )
(A) IH17K1620044-01

8) Connect the steering damper rod end (1). Refer to

“Steering Damper Removal and Installation” (Page
1 , ( a) (B) 6B-7).
9) Install the lower bracket cover (2).

IH17K1620042-01

1
“a”
2

IH17K1620045-01

I649G1620026-02
6B-13 Steering / Handlebar:

10) Install the steering stem upper bracket (1), washer Steering Stem Inspection
(2) and steering stem head nut (3) temporarily. BENH17K16206010
Refer to “Steering Stem Removal and Installation” (Page
NOTE 6B-10).
Inspect the removed parts for the following
Face the chamfer side of the washer (2)
abnormalities:
downward.
• Distortion of the steering stem
11) Install the front forks (4) and handlebars (5) • Bearing wear or damage
temporarily. • Abnormal bearing noise
12) Tighten the steering stem head nut (3) to the • Race wear or damage
specified torque with the special tools.
• Bearing lower seal damage
Special tool • Dust seal wear or damage
(A): 09940–14710 If any abnormal points are found, replace defective parts
(B): 09923–12410 with new ones.
Tightening torque
Steering stem head nut (a): 90 N·m (9.2 kgf-m,
66.5 lbf-ft)

4 1 4

3, ( a)
IH17K1620048-01
5 2
5

IH17K1620046-01

(B)

IH17K1620049-01

( A)
IH17K1620047-01

13) Install the front forks and handlebars in proper

position. Refer to “Front Fork Assembly Removal
and Installation” in Section 2B (Page 2B-3).
14) Tighten the steering damper rod end nut to the
specified torque. Refer to “Steering Damper
Removal and Installation” (Page 6B-7).
15) Install the removed parts.
16) Check the steering tension. (Page 6B-10)
 Steering / Handlebar: 6B-14

Steering Stem Bearing Removal and Installation Installation

BENH17K16206011
1) Press in the new upper and lower outer races using
Removal the special tools.
1) Remove the steering stem upper bearing (1) and Special tool
steering stem lower bearing (2). Refer to “Steering (A): 09941–34513
Stem Removal and Installation” (Page 6B-10). (B): 09913–70210

(A) (A)
1

(B) (B)
IH17K1620050-01 IH17K1620051-01

2) Remove the steering stem lower bearing inner race 2) Set the dust seal (1) and press in the new lower
with a chisel. inner race (2) using the special tool.
3) Remove the dust seal. Special tool
(A): 09925–18011

(A )

1 2

I649G1620033-02

4) Remove the steering stem upper and lower bearing

IH17K1620052-01
outer races using the steel rod.
3) Install the steering stem lower bracket to the frame.
(Page 6B-10)

I837H1620033-01
6B-15 Steering / Handlebar:

Specifications
Tightening Torque Specifications
BENH17K16207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Clutch lever holder bolt 10 1.0 7.5 (Page 6B-4)
Front fork upper clamp bolt (Page 6B-5) /
23 2.3 17.0
(Page 6B-10)
Handlebar clamp bolt (Page 6B-5) /
23 2.3 17.0
(Page 6B-10)
Steering stem head nut (Page 6B-5) /
90 9.2 66.5 (Page 6B-10) /
(Page 6B-13)
Handlebar balancer screw (Page 6B-5) /
23 2.3 17.0
(Page 6B-6)
Steering damper mounting bolt 23 2.3 17.0 (Page 6B-8)
Steering damper rod end nut 23 2.3 17.0 (Page 6B-8)
Steering stem lock-nut (Page 6B-10) /
80 8.2 59.0
(Page 6B-12)
Steering stem adjust-nut 20 Nm (2.0 kgf-m, 15.0 lbf-ft) → turn (Page 6B-12)
counterclockwise 0 – 1/4

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Damper Construction” (Page 6B-7)
“Steering Stem Components” (Page 6B-9)
“Fasteners Information” in Section 0C (Page 0C-12)
 Steering / Handlebar: 6B-16

Special Tools and Equipment

Recommended Service Material
BENH17K16208001
Material SUZUKI recommended product or Specification Note
Adhesive Handle grip glue — (Page 6B-6)
Grease SUZUKI SUPER GREASE C P/No.: 99000–25030 (Page 6B-12)
SUZUKI WATER RESISTANT P/No.: 99000–25350 (Page 6B-5) / (Page 6B-
GREASE EP2 8)

NOTE
Required service material(s) is also described in:
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Damper Construction” (Page 6B-7)
“Steering Stem Components” (Page 6B-9)

Special Tool
BENH17K16208002
09910–60620 09913–70210
Adjustable wrench Bearing installer set
(Page 6B-10) (Page 6B-14)

09923–12410 09925–18011
Socket (46 mm: 1/2 sq.) Bearing installer
(Page 6B-3) / (Page 6B-14)
(Page 6B-5) /
(Page 6B-10) /
(Page 6B-10) /
(Page 6B-11) /
(Page 6B-13)
09940–14710 09940–14911
Steering stem head nut Steering stem nut socket
wrench
(Page 6B-3) / (Page 6B-11) /
(Page 6B-5) / (Page 6B-12) /
(Page 6B-10) / (Page 6B-12)
(Page 6B-10) /
(Page 6B-11) /
(Page 6B-13)
09940–14960 09941–34513
Steering stem nut socket Bearing installer set
wrench
(Page 6B-11) / (Page 6B-14)
(Page 6B-12) /
(Page 6B-12)
6B-17 Steering / Handlebar:
 Table of Contents 9- i

Section 9

Body and Accessories

CONTENTS

Precautions .................................................9-1 LED License Plate Light Components ..............9B-10

Precautions............................................................. 9-1 LED License Plate Light Removal and
Precautions for Electrical System ......................... 9-1 Installation .......................................................9B-11
LED License Plate Light Replacement..............9B-11
Component Location ............................................. 9-1
Rear Reflex Reflector Removal and
Electrical Components Location ........................... 9-1
Installation .......................................................9B-11
Wiring Systems........................................ 9A-1 Front Turn Signal Light / Front LED Turn
Signal Light Construction ................................9B-12
General Description .............................................9A-1
Turn Signal Light / LED Turn Signal Light
Abbreviations ...................................................... 9A-1
Components....................................................9B-13
Wire / Connector Color Symbols......................... 9A-1
Front Turn Signal Light Removal and
How to Read Terminal Nos. ................................ 9A-1
Installation .......................................................9B-14
Glossary .............................................................. 9A-2
Front LED Turn Signal Light Removal and
Schematic and Routing Diagram........................9A-5
Installation .......................................................9B-14
Wiring Diagram ................................................... 9A-5
Rear Turn Signal Light Removal and
Wiring Harness Routing Diagram...................... 9A-13
Installation .......................................................9B-14
Component Location .........................................9A-22 Rear LED Turn Signal Light Removal and
Electrical Components Location ....................... 9A-22 Installation .......................................................9B-15
Specifications.....................................................9A-22 Turn Signal Light Bulb Replacement.................9B-15
Tightening Torque Specifications...................... 9A-22 LED Turn Signal Light Replacement.................9B-15
Special Tools and Equipment ...........................9A-22 Reflex Reflector Construction (If Equipped)......9B-15
Recommended Service Material ....................... 9A-22 Turn Signal Relay Inspection (For Bulb Type) ..9B-16
Turn Signal Relay Removal and Installation
Lighting Systems..................................... 9B-1 (For Bulb Type) ...............................................9B-16
Precautions...........................................................9B-1 Turn Signal Switch Inspection...........................9B-16
Precautions for Lighting Systems ....................... 9B-1 Hazard Switch Inspection..................................9B-16
Diagnostic Information and Procedures............9B-1 Passing Light Switch Inspection........................9B-17
LED Headlight Symptom Diagnosis .................... 9B-1 Dimmer Switch Inspection.................................9B-17
Turn Signal Light and Hazard Light Symptom Specifications .....................................................9B-17
Diagnosis .......................................................... 9B-1 Tightening Torque Specifications......................9B-17
LED Rear Combination Light Symptom
Diagnosis .......................................................... 9B-1 Combination Meter / Fuel Meter / Horn.. 9C-1 9
Repair Instructions ..............................................9B-2 General Description .............................................9C-1
LED Headlight Construction................................ 9B-2 Combination Meter System Description..............9C-1
LED Headlight Components ............................... 9B-4 Service Reminder Indicator Description..............9C-2
LED Headlight Removal and Installation............. 9B-4 Diagnostic Information and Procedures ............9C-3
LED Position Light Removal and Installation Combination Meter Symptom Diagnosis.............9C-3
(For LED Headlight Side) .................................. 9B-6 Horn Symptom Diagnosis ...................................9C-3
LED Headlight / LED Position Light Repair Instructions ..............................................9C-4
Replacement ..................................................... 9B-7 Combination Meter Construction.........................9C-4
LED Headlight Beam Adjustment ....................... 9B-7 Combination Meter Components ........................9C-4
Rear Lighting System Construction..................... 9B-8 Service Reminder Reset .....................................9C-5
LED Rear Combination Light Removal and Combination Meter On-Vehicle Inspection..........9C-7
Installation ......................................................... 9B-9 Combination Meter Removal and Installation .....9C-7
LED Rear Combination Light Replacement ...... 9B-10
9-ii Table of Contents

Combination Meter Disassembly and Meter Panel Cushion Construction ...................9D-13

Reassembly ......................................................9C-7 Body Cowling Cushion / Velcro Fastening /
Engine Coolant Temperature Indicator / Tape Construction...........................................9D-14
Engine Coolant Temperature Indicator Light Air Intake Pipe Cushion Construction ...............9D-15
Inspection..........................................................9C-8 Intake Cover Cushion Construction ..................9D-16
ECT Sensor Removal and Installation ................9C-8 Battery Holder Protector Construction ..............9D-17
Fuel Level Indicator Inspection ...........................9C-8 Fastener Removal and Installation....................9D-17
Fuel Level Gauge Inspection ..............................9C-9 Frame Front Cover Removal and Installation ...9D-18
Ambient Air Temperature Indicator / Freeze Front Seat Removal and Installation .................9D-19
Indicator Light Inspection ................................9C-10 Rear Seat Removal and Installation..................9D-19
Ambient Air Temperature Sensor Inspection ....9C-10 Rear View Mirror Removal and Installation .......9D-19
Speedometer On-Vehicle Inspection ................9C-11 Windscreen Removal and Installation ...............9D-20
Speed Sensor Removal and Installation ...........9C-11 Body Cowling Cover / Under Inner Cowling
Speed Sensor Inspection ..................................9C-11 Removal and Installation.................................9D-20
Oil Pressure Indicator Inspection ......................9C-11 Side Cowling Removal and Installation .............9D-21
Ignition Switch Removal and Installation...........9C-11 Body Cowling Removal and Installation ............9D-22
Horn Inspection .................................................9C-11 Cowling Brace Removal and Installation...........9D-25
Horn Removal and Installation ..........................9C-12 Fuel Tank Front Cover Removal and
Mode Switch Inspection ....................................9C-12 Installation .......................................................9D-25
Select Switch Inspection ...................................9C-13 Frame Cover / Frame Center Rear Cover
Specifications.....................................................9C-13 Removal and Installation.................................9D-26
Tightening Torque Specifications......................9C-13 Frame Center Front Cover Removal and
Special Tools and Equipment ...........................9C-13 Installation .......................................................9D-26
Special Tool ......................................................9C-13 Rear Fender Outer Removal and Installation....9D-27
Rear Fender Front Removal and Installation ....9D-28
Exterior Parts........................................... 9D-1 Specifications .....................................................9D-29
Schematic and Routing Diagram........................9D-1 Tightening Torque Specifications......................9D-29
Seat Lock Cable Routing Diagram......................9D-1 Special Tools and Equipment ...........................9D-29
Repair Instructions ..............................................9D-1 Recommended Service Material .......................9D-29
Windscreen / Body Cowling Construction ...........9D-1
Body Cowling / Side Cowling Construction .........9D-3 Body Structure......................................... 9E-1
Side Cowling Construction ..................................9D-4 Repair Instructions ..............................................9E-1
Rear Fender Construction...................................9D-6 Body Frame Construction ...................................9E-1
Front Fender Construction ..................................9D-7 Front Footrest Bracket Construction ...................9E-2
Frame Cover Construction ..................................9D-8 Side-stand Construction......................................9E-3
Fuel Tank Front Cover Construction ...................9D-9 Side-stand Removal and Installation...................9E-3
Frame Front Cover Cushion Construction ........9D-10 Pillion Footrest Construction ...............................9E-4
Frame Cover Cushion Construction..................9D-10 Pillion Footrest Removal and Installation ............9E-4
Fuel Tank Front Cover Cushion / Velcro Specifications .......................................................9E-5
Fastening Construction ...................................9D-11 Tightening Torque Specifications........................9E-5
Body Cowling Cover Cushion / Under Inner Special Tools and Equipment .............................9E-5
Cowling Cushion Construction ........................9D-12 Recommended Service Material .........................9E-5
Under Center Cowling Cushion Construction ...9D-12
 Precautions: 9-1

Precautions
Body and Accessories

Precautions
Precautions for Electrical System
BENH17K19000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2) and “Precautions for Circuit Tester” in Section 00 (Page 00-8).

Component Location
Electrical Components Location
BENH17K19003001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
9A-1 Wiring Systems:

Wiring Systems
Body and Accessories

General Description
Abbreviations
BENH17K19101001
Refer to the “Abbreviations” in Section 0A (Page 0A-1) for the general abbreviations.

Wire / Connector Color Symbols

BENH17K19101002
Refer to “Wire Color Symbols” in Section 0A (Page 0A-3).

How to Read Terminal Nos.

BENH17K19101003
The connector shape and terminal layout shown in this manual are those when viewed from “Z” in the illustration.

NOTE
• Molded terminal numbers that are different from the above can be found on some connectors in rare
cases.
• These molded numbers are not applied in this manual.

View Z

Male terminal A40

4 3 2 1
Z
8 7 6 5

(View Z)
Female terminal D18
1 2 3 4 View Z’
5 6 7 8
(View Z’)
Terminal No. Z’

IE31J1910901-02
 Wiring Systems: 9A-2

Glossary
BENH17K19101004
English
ABS
ABS CONTROL UNIT
ABS MOTOR
ABS VALVE
ACCELERATOR POSITION SENSOR
AP SENSOR
AMBIENT AIR TEMP SENSOR
BATTERY
BRAKE LIGHT SWITCH
CARBURETOR SWITCH
CDI UNIT
CKP SENSOR
CLUTCH LEVER POSITION SWITCH
CLUTCH SWITCH
CMP SENSOR
COMBINATION METER
COOLING FAN MOTOR
COOLING FAN RELAY
DIMMER
DIMMER SWITCH
DIMMER/PASSING LIGHT SWITCH
ECM
ECT SENSOR
ENGINE STOP SWITCH
ENGINE STOP/STARTER SWITCH
ET SENSOR
EVAP SYSTEM PURGE CONTROL SOLENOID VALVE
EXCV ACTUATOR
FAN
FAN RELAY
FI INDICATOR LIGHT
FRONT BRAKE LIGHT SWITCH
FRONT TURN SIGNAL LIGHT
FRONT WHEEL SPEED SENSOR
FUEL
FUEL INJECTOR
FUEL LEVEL GAUGE
FUEL METER
FUEL PUMP
FUEL PUMP RELAY
FUSE BOX
GEARSHIFT SENSOR
GENERATOR
GP SENSOR
GP SWITCH
HANDLE SWITCH
HAZARD SWITCH
HEADLIGHT
HEADLIGHT HI
HEADLIGHT LO
HI BEAM INDICATOR LIGHT
HIGH BEAM INDICATOR LIGHT
HIGH BEAM RELAY
HO2 SENSOR
HORN
HORN SWITCH
IAP SENSOR
9A-3 Wiring Systems:

English
IAP/TP SENSOR
IAP/TP/IAT SENSOR
IAT SENSOR
IF EQUIPPED
IGNITER
IGNITION
IGNITION COIL
IGNITION SWITCH
ILLUMINATION LIGHT
IMMOBILIZER ANTENNA
IMU
INSTRUMENT PANEL LIGHT
ISC VALVE
LICENSE PLATE LIGHT
LIGHTING SWITCH
LIGHT/HORN RELAY
LOW BEAM RELAY
MAIN FUSE
MALFUNCTION INDICATOR LAMP
MODE SELECT COUPLER
MODE SWITCH
NEUTRAL INDICATOR LIGHT
NEUTRAL SWITCH
O2 SENSOR
OIL PRESSURE SWITCH
OPTION
PASSING LIGHT SWITCH
PASSING RELAY
PAIR CONTROL SOLENOID VALVE
PARK
POSITION LIGHT
POWER SOURCE
PRIMARY FUEL INJECTOR
REAR BRAKE LIGHT SWITCH
REAR COMBINATION LIGHT
REAR TURN SIGNAL LIGHT
REAR WHEEL SPEED SENSOR
REGULATOR/RECTIFIER
SECONDARY FUEL INJECTOR
SELECT SWITCH
SIDE-STAND DIODE
SIDE-STAND RELAY
SIDE-STAND SWITCH
SIGNAL
SPEED SENSOR
SPEEDOMETER
SPEEDOMETER LIGHT
STARTER SWITCH
STARTER MOTOR
STARTER RELAY
STEERING DAMPER SOLENOID VALVE
STV ACTUATOR
SUB FUSE
THROTTLE VALVE MOTOR
TO SENSOR
TP SENSOR
TRACTION CONTROL SYSTEM SWITCH
TURN SIGNAL INDICATOR LIGHT
TURN SIGNAL RELAY
 Wiring Systems: 9A-4

English
TURN SIGNAL SWITCH
9A-5 Wiring Systems:

Schematic and Routing Diagram

Wiring Diagram
BENH17K19102001
For E.U.

HANDLE SWITCH (RH)

ENGINE STOP/ FRONT
STARTER BRAKE
HAZARD SWITCH LIGHT
SWITCH STOP SWITCH
OFF RUN OFF
ON START ON

OIL SIDE-STAND
PRESSURE IGNITION REAR IGNITION IGNITION
IMMOBILIZER SWITCH BRAKE
SWITCH ANTENNA SWITCH COIL #2 COIL #4 PAIR
LIGHT IGNITION IGNITION CONTROL
ON
OFF
PUSH SWITCH COIL #1 COIL #3 SOLENOID
IMU OFF
FUEL PUMP
LOCK
FREE
ON VALVE
ON P OFF

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl

W/B
Lg
G
B

B
Y

B/W

O
G
Br/W
Bl/W

W/Bl
W/G

B/Bl

B/Bl
B/Bl
B/Bl
B/Bl

Bl/R

W/G

W/G

W/G

W/G
W/B

B/W

W/B
W/B
W/B
W/B

B/W

B/W

W/R

W/B

B/W

W/B

W/R

W/R

W/R

W/R
B/G

O/B

O/B

Y/G
R/Y
Y/R

Y/R
Lg

Br
W

G
B

B
Y

Y
COMBINATION METER
Br/W
Lg/R

B/Lg

Bl/W
Lg/Y

Br/R

Br/B
Br/Y
W/G

Bl/B

B/Bl

Bl/R
B/W

R/W

W/B
Y/W

P/W
B/O

B/G
G/Y
B/R
B/Y

Lg

Bl
G
B
Y

POSITION LIGHT (RH)

(IF EQUIPPED)
B/W B/W B/G
B Br/W Br/W
Br/Y
FRONT TURN SIGNAL LIGHT (RH)
B B/O W/G
G Lg/Y Br/B
B/G
FRONT TURN SIGNAL LIGHT (LH) Bl/B
B B/O G/W
W B/Y Y/W

POSITION LIGHT (LH) B/G

(IF EQUIPPED) G
B/W B/W P/W
B Br/W B/W
R/W
R W
B B/W
G Y
B/Lg
HEADLIGHT
Lg/R
G/W B/R
B/G B/Bl
STEERING DAMPER W/B
SOLENOID VALVE Br/R
Bl W
B/W Y
Lg
AMBIENT B
AIR TEMP
Bl/R
SENSOR
Bl/W
Br/W

Br/W
B/Bl

W/Bl

W/Bl

B/W
O/Bl
B/Bl

G/B

Bl/B

W/G

R/Bl

B/Bl
Bl/Y
B/R

B/W

B/W

W/R

R/W

B/W

Y/Bl

Y/Bl

R/W

B/R
W/Y

W/Y
W/Y

W/Y
Y/W

Y/W
O/R

B/O

G/R

G/B

O/B

G/B

B/R
Y/B

Y/R

Y/R
Lg

Br
G

Bl

W
B

B
R

R
Y

Y
B/Bl
B/W

B/G

Y/G
B/Y

1 2 3 4 5 6 7 8 9 10
Lbl

Bl
Lg

B
W
O

G
B

HORN A B C D
SIDE-STAND A. FUEL PUMP RELAY 1. FAN (RH) 15A
DIODE B. COOLING FAN RELAY 2. IGNITION 10A
C. HIGH BEAM RELAY 3. SIGNAL 10A
D. SIDE-STAND RELAY 4. HEADLIGHT HI 7.5A
5. DIMMER 10A COOLING
6. ABS 30A
7. HEADLIGHT LO 7.5A
FAN
8. PARK 10A MOTOR
9. FAN (LH) 15A (RH)
10. FUEL 10A
FUSE BOX

UP FREE L HI FREE FREE

FREE PUSH PUSH LO PUSH
DOWN R PASS
SELECT CLUTCH
MODE HORN TURN DIMMER/ SWITCH SWITCH
SWITCH SWITCH SIGNAL PASSING
SWITCH LIGHT
SWITCH
HANDLE SWITCH (LH)

IH17K1910901-05
 Wiring Systems: 9A-6

ECM
AP ABS CONTROL UNIT
SENSOR

Lg/W
Gr/W
Br/W

Lg/B
B/Lg

W/Bl

Lg/R

B/Lg
Gr/R

Gr/B

Gr/R

Gr/R

Gr/R
Gr/Y
Br/B

B/Br

B/Br

Br/R
Br/Y
G/Bl

O/Bl
B/Bl

B/Bl

G/W

G/W

Bl/R
B/Bl

W/G

W/G

R/Bl

B/Bl
B/W
Bl/Y
W/B
P/Bl

W/R

R/W

B/W
R/W

R/W

W/B

B/W

W/R

B/W

P/Bl

B/W
W/R

W/B

W/B
W/Y

W/Y
P/W

P/W

P/W

Y/W
R/G

G/B

B/G

B/G

B/O

B/O

O/R

G/R

O/B
G/Y

G/Y
B/R

R/B

B/Y

Y/G

B/R
R/Y

B/Y

R/Y

B/Y
Y/R

P/B

Y/B
Dg

Lg
Bl
W
G

G
B

R
Y

W/R

B/W
W/Y
B/R

B/Y

O
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
REAR TURN SIGNAL LIGHT (RH)
Lg/R G
B/Lg B

REAR COMBINATION LIGHT

Br/W Gr
B/W B/W
W/B W/Bl

LICENSE PLATE LIGHT

Br/W W
B/W B

REAR TURN SIGNAL LIGHT (LH)

B/R W
B/Lg B
Lg/W
Gr/W
Br/W
B/Lg

B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br
G/Bl
B/Bl

G/W

B/Bl

Bl/R

B/Bl

W/G
B/W

W/R

B/W

B/W

R/W

W/B
W/Y
P/W

P/W
R/G

B/O

G/B

B/R
R/B
B/Y

R/Y

B/Y
Y/R

P/B
Dg

Lg

Bl

W
G
R
R

R
B

B
B
B
B
B
P

Y
B/W

Lg/W
Gr/W
B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br
Bl/R
R/W

W/Y
P/W
B/O

G/B
Y/R

P/B

B/Bl
Bl/Y
B/W
Dg
R

Lg
Bl

Gr

Gr
G
R
B

Bl

W
G
R

B
P

REGULATOR/ ACCELERATOR
STARTER RECTIFIER
MOTOR 1. MAIN FUSE 30A POSITION SENSOR TO
STARTER CKP SENSOR SENSOR
BATTERY GP CMP EXCV HO2
COOLING RELAY
GENERATOR SENSOR SENSOR ACTUATOR SENSOR
FAN
MOTOR
(LH)

ECT
SENSOR

IAP THROTTLE
SENSOR VALVE
EVAP IAT PRIMARY PRIMARY SECONDARY SECONDARY
SYSTEM MOTOR TP SENSOR FUEL FUEL FUEL FUEL
PURGE SENSOR INJECTOR INJECTOR INJECTOR INJECTOR
CONTROL #1 #3 #1 #3
SOLENOID PRIMARY PRIMARY SECONDARY SECONDARY
VALVE FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
#2 #4 #2 #4

IH17K1910902-04
9A-7 Wiring Systems:

For U.S.A. and Canada (Without ABS)

HANDLE SWITCH (RH)

ENGINE STOP/ FRONT
STARTER BRAKE
HAZARD SWITCH LIGHT
SWITCH STOP SWITCH
OFF RUN OFF
ON START ON

OIL SIDE-STAND
PRESSURE IGNITION REAR IGNITION IGNITION
SWITCH BRAKE
SWITCH SWITCH COIL #2 COIL #4 PAIR
LIGHT IGNITION IGNITION CONTROL
ON
OFF
PUSH SWITCH COIL #1 COIL #3 SOLENOID
IMU OFF
FUEL PUMP
LOCK
FREE
ON VALVE
ON P OFF

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl

W/B
Lg
B

B/W

O
G
Bl/W

W/Bl
W/G

B/Bl

B/Bl
B/Bl

B/Bl

Bl/R

W/G

O/W
W/G

W/G

W/G
W/B

B/W

W/B
W/B

W/B

B/W

W/R

W/B

B/W

W/B

W/R

W/R

W/R

W/R

W/Y
B/G

O/B

Y/G
Y/R

Y/R
Lbl
Lg

Br
W

G
B

B
Y

Y
COMBINATION METER
Bl/W
Br/B
W/G

Bl/B

B/Bl

Bl/R
B/W

R/W

W/B
Y/W

P/W

B/G
G/Y
Lg

Bl
G
B
Y

B/G

FRONT TURN SIGNAL LIGHT (RH)

B/W B/W W/G
G Lg Br/B
B/G
FRONT TURN SIGNAL LIGHT (LH) Bl/B
B/W B/W G/W
B B Y/W
B/G
G
P/W
B/W
R/W
R W
B B/W
G Y

HEADLIGHT
G/W
B/G B/Bl
STEERING DAMPER W/B
SOLENOID VALVE
Bl W
B/W Y
Lg
AMBIENT B
AIR TEMP
Bl/R
SENSOR
Bl/W
Br/W

Br/W
B/Bl

W/Bl

W/Bl

B/W
O/Bl
B/Bl

G/B

Bl/B

W/G

B/Bl
Bl/Y
B/R

B/W

B/W

W/R

R/W

B/W

Y/Bl

Y/Bl

R/W

B/R
W/Y

W/Y
W/Y

W/Y
Y/W

Y/W
O/R

B/O

G/R

G/B

O/B

G/B
Lbl

B/R
Y/B

Y/R

Y/R
Lbl
Lg

Br
G

Bl

W
B

B
R

R
Y

Y
B/Bl
B/W

B/G

Y/G
B/Y

1 2 3 4 5 6 7 8 9 10
Lbl

Bl
Lg

B
W
O

G
B

HORN TURN A B C D

SIGNAL SIDE-STAND A. FUEL PUMP RELAY 1. FAN (RH) 15A

RELAY DIODE B. COOLING FAN RELAY 2. IGNITION
3. SIGNAL
10A
10A
C. HIGH BEAM RELAY
D. SIDE-STAND RELAY 4. HEADLIGHT HI 7.5A
5. DIMMER 10A COOLING
6.
7. HEADLIGHT LO 7.5A
FAN
8. PARK 10A MOTOR
9. FAN (LH) 15A (RH)
10. FUEL 10A
FUSE BOX

UP FREE L HI FREE FREE

FREE PUSH PUSH LO PUSH
DOWN R PASS
SELECT CLUTCH
MODE HORN TURN DIMMER/ SWITCH SWITCH
SWITCH SWITCH SIGNAL PASSING
SWITCH LIGHT
SWITCH
HANDLE SWITCH (LH)

IH17K1910903-05
 Wiring Systems: 9A-8

ECM
AP
SENSOR

Lg/W
Gr/W
Br/W

Lg/B
B/Lg

W/Bl

Lg/R

B/Lg
Gr/R

Gr/B

Gr/R

Gr/R
Gr/Y
Br/B

B/Br

B/Br
G/Bl

O/Bl
B/Bl

B/Bl

G/W

G/W

Bl/R
B/Bl

W/G

O/W

W/G
B/W
Bl/Y
W/B
W/R

W/R

R/W

B/W
R/W

R/W

W/B

B/W

W/R

B/W
W/Y

W/Y
P/W

P/W

P/W

Y/W
R/G

G/B

B/G

B/G

B/O

B/O

O/R

G/R
G/Y

G/Y
B/R

R/B

B/Y

Y/G
R/Y

B/Y

B/Y

Y/R

P/B

Y/B
Dg

Lg
Bl
W

G
R

R
Y

W/R
W/Y

W/Y
B/Y
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
REAR TURN SIGNAL LIGHT (RH)
Lg G
B/W B/W

REAR COMBINATION LIGHT

Br/W Gr
B/W B/W
W/B W/Bl

LICENSE PLATE LIGHT

Br/W W
B/W B

REAR TURN SIGNAL LIGHT (LH)

B B
B/W B/W
Lg/W
Gr/W
Br/W
B/Lg

B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br
G/Bl
B/Bl

G/W

B/Bl

Bl/R

B/Bl

W/G
B/W

W/R

B/W

B/W

R/W

W/B
W/Y

W/Y
P/W

P/W
R/G

B/O

G/B

B/R
R/B
B/Y

R/Y

B/Y
Y/R

P/B
Dg

Lg

Bl

W
G
R
R

R
B
P

Y
B/W

Lg/W
Gr/W
B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br
Bl/R
R/W

W/Y
P/W
B/O

G/B
Y/R

P/B

B/Bl
Bl/Y
B/W
Dg

Lg
Bl

Gr

Gr
G
R
B

Bl

W
G
R

B
P

REGULATOR/ ACCELERATOR
STARTER RECTIFIER
MOTOR 1. MAIN FUSE 30A POSITION SENSOR TO
STARTER CKP SENSOR SENSOR
BATTERY GP CMP EXCV HO2
COOLING RELAY
GENERATOR SENSOR SENSOR ACTUATOR SENSOR
FAN
MOTOR
(LH)

ECT
SENSOR

IAP THROTTLE
SENSOR VALVE
EVAP IAT PRIMARY PRIMARY SECONDARY SECONDARY
SYSTEM MOTOR TP SENSOR FUEL FUEL FUEL FUEL
PURGE SENSOR INJECTOR INJECTOR INJECTOR INJECTOR
CONTROL #1 #3 #1 #3
SOLENOID PRIMARY PRIMARY SECONDARY SECONDARY
VALVE FUEL FUEL FUEL FUEL
(IF EQUIPPED) INJECTOR INJECTOR INJECTOR INJECTOR
#2 #4 #2 #4

IH17K1910904-04
9A-9 Wiring Systems:

For U.S.A. and Canada (With ABS)

HANDLE SWITCH (RH)

ENGINE STOP/ FRONT
STARTER BRAKE
HAZARD SWITCH LIGHT
SWITCH STOP SWITCH
OFF RUN OFF
ON START ON

OIL SIDE-STAND
PRESSURE IGNITION REAR IGNITION IGNITION
SWITCH BRAKE
SWITCH SWITCH COIL #2 COIL #4 PAIR
LIGHT IGNITION IGNITION CONTROL
ON
OFF
PUSH SWITCH COIL #1 COIL #3 SOLENOID
IMU OFF
FUEL PUMP
LOCK
FREE
ON VALVE
ON P OFF

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl

W/B
Lg
B

B/W

O
G
Bl/W

W/Bl
W/G

B/Bl

B/Bl
B/Bl
B/Bl
B/Bl

Bl/R

W/G

O/W
W/G

W/G

W/G
W/B

B/W

W/B
W/B
W/B
W/B

B/W

W/R

W/B

B/W

W/B

W/R

W/R

W/R

W/R

W/Y
B/G

O/B

Y/G
Y/R

Y/R
Lbl
Lg

Br
W

G
B

B
Y

Y
COMBINATION METER
Bl/W
Br/R

Br/B
W/G

Bl/B

B/Bl

Bl/R
B/W

R/W

W/B
Y/W

P/W

B/G
G/Y
Lg

Bl
G
B
Y

B/G

FRONT TURN SIGNAL LIGHT (RH)

B/W B/W W/G
G Lg Br/B
B/G
FRONT TURN SIGNAL LIGHT (LH) Bl/B
B/W B/W G/W
B B Y/W
B/G
G
P/W
B/W
R/W
R W
B B/W
G Y

HEADLIGHT
G/W
B/G B/Bl
STEERING DAMPER W/B
SOLENOID VALVE Br/R
Bl W
B/W Y
Lg
AMBIENT B
AIR TEMP
Bl/R
SENSOR
Bl/W
Br/W

Br/W
B/Bl

W/Bl

W/Bl

B/W
O/Bl
B/Bl

G/B

Bl/B

W/G

R/Bl

B/Bl
Bl/Y
B/R

B/W

B/W

W/R

R/W

B/W

Y/Bl

Y/Bl

R/W

B/R
W/Y

W/Y
W/Y

W/Y
Y/W

Y/W
O/R

B/O

G/R

G/B

O/B

G/B
Lbl

B/R
Y/B

Y/R

Y/R
Lbl
Lg

Br
G

Bl

W
B

B
R

R
Y

Y
B/Bl
B/W

B/G

Y/G
B/Y

1 2 3 4 5 6 7 8 9 10
Lbl

Bl
Lg

B
W
O

G
B

HORN TURN A B C D

SIGNAL SIDE-STAND A. FUEL PUMP RELAY 1. FAN (RH) 15A

RELAY DIODE B. COOLING FAN RELAY 2. IGNITION
3. SIGNAL
10A
10A
C. HIGH BEAM RELAY
D. SIDE-STAND RELAY 4. HEADLIGHT HI 7.5A
5. DIMMER 10A COOLING
6. ABS 30A
7. HEADLIGHT LO 7.5A
FAN
8. PARK 10A MOTOR
9. FAN (LH) 15A (RH)
10. FUEL 10A
FUSE BOX

UP FREE L HI FREE FREE

FREE PUSH PUSH LO PUSH
DOWN R PASS
SELECT CLUTCH
MODE HORN TURN DIMMER/ SWITCH SWITCH
SWITCH SWITCH SIGNAL PASSING
SWITCH LIGHT
SWITCH
HANDLE SWITCH (LH)

IH17K1910905-05
 Wiring Systems: 9A-10

ECM
AP ABS CONTROL UNIT
SENSOR

Lg/W
Gr/W
Br/W

Lg/B
B/Lg

W/Bl

Lg/R

B/Lg
Gr/R

Gr/B

Gr/R

Gr/R

Gr/R
Gr/Y
Br/B

B/Br

B/Br

Br/R
G/Bl

O/Bl
B/Bl

B/Bl

G/W

G/W

Bl/R
B/Bl

W/G

O/W

W/G

R/Bl

B/Bl
B/W
Bl/Y
W/B
P/Bl

W/R

R/W

B/W
R/W

R/W

W/B

B/W

W/R

B/W

P/Bl

B/W
W/R

W/B

W/B
W/Y

W/Y

W/Y

W/Y
P/W

P/W

P/W

Y/W
R/G

G/B

B/G

B/G

B/O

B/O

O/R

G/R
G/Y

G/Y
B/R

R/B

B/Y

Y/G

B/R
R/Y

B/Y

B/Y
Y/R

P/B

Y/B
Dg

Lg
Bl
W
G

G
R

R
Y

W/R

B/W
W/Y
B/R

B/Y

O
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
REAR TURN SIGNAL LIGHT (RH)
Lg G
B/W B/W

REAR COMBINATION LIGHT

Br/W Gr
B/W B/W
W/B W/Bl

LICENSE PLATE LIGHT

Br/W W
B/W B

REAR TURN SIGNAL LIGHT (LH)

B B
B/W B/W
Lg/W
Gr/W
Br/W
B/Lg

B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br
G/Bl
B/Bl

G/W

B/Bl

Bl/R

B/Bl

W/G
B/W

W/R

B/W

B/W

R/W

W/B
W/Y

W/Y
P/W

P/W
R/G

B/O

G/B

B/R
R/B
B/Y

R/Y

B/Y
Y/R

P/B
Dg

Lg

Bl

W
G
R
R

R
B
P

Y
B/W

Lg/W
Gr/W
B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br
Bl/R
R/W

W/Y
P/W
B/O

G/B
Y/R

P/B

B/Bl
Bl/Y
B/W
Dg
R

Lg
Bl

Gr

Gr
G
R
B

Bl

W
G
R

B
P

REGULATOR/ ACCELERATOR
STARTER RECTIFIER
MOTOR 1. MAIN FUSE 30A POSITION SENSOR TO
STARTER CKP SENSOR SENSOR
BATTERY GP CMP EXCV HO2
COOLING RELAY
GENERATOR SENSOR SENSOR ACTUATOR SENSOR
FAN
MOTOR
(LH)

ECT
SENSOR

IAP THROTTLE
SENSOR VALVE
EVAP IAT PRIMARY PRIMARY SECONDARY SECONDARY
SYSTEM MOTOR TP SENSOR FUEL FUEL FUEL FUEL
PURGE SENSOR INJECTOR INJECTOR INJECTOR INJECTOR
CONTROL #1 #3 #1 #3
SOLENOID PRIMARY PRIMARY SECONDARY SECONDARY
VALVE FUEL FUEL FUEL FUEL
(IF EQUIPPED) INJECTOR INJECTOR INJECTOR INJECTOR
#2 #4 #2 #4

IH17K1910906-04
9A-11 Wiring Systems:

For Others

HANDLE SWITCH (RH)

ENGINE STOP/ FRONT
STARTER BRAKE
HAZARD SWITCH LIGHT
SWITCH STOP SWITCH
OFF RUN OFF
ON START ON

OIL SIDE-STAND
PRESSURE IGNITION REAR IGNITION IGNITION
IMMOBILIZER SWITCH BRAKE
SWITCH ANTENNA SWITCH COIL #2 COIL #4 PAIR
LIGHT IGNITION IGNITION CONTROL
ON
OFF
PUSH SWITCH COIL #1 COIL #3 SOLENOID
IMU OFF
FUEL PUMP
LOCK
FREE
ON VALVE
ON P OFF

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl

W/B
Lg
G
B

B
Y

B/W

O
G
Br/W
Bl/W

W/Bl
W/G

B/Bl

B/Bl
B/Bl
B/Bl
B/Bl

Bl/R

W/G

W/G

W/G

W/G
W/B

B/W

W/B
W/B
W/B
W/B

B/W

B/W

W/R

W/B

B/W

W/B

W/R

W/R

W/R

W/R
W/Y

W/Y
B/G

O/B

O/B

Y/G
R/Y
Y/R

Y/R
Lg

Br
W

G
B

B
Y

Y
COMBINATION METER
Br/W
Lg/R

B/Lg

Bl/W
Lg/Y

Br/R

Br/B
Br/Y
W/G

Bl/B

B/Bl

Bl/R
B/W

R/W

W/B
Y/W

P/W
B/O

B/G
G/Y
B/R
B/Y

Lg

Bl
G
B
Y

B/G
Br/W
Br/Y
FRONT TURN SIGNAL LIGHT (RH)
B B/O W/G
G Lg/Y Br/B
B/G
FRONT TURN SIGNAL LIGHT (LH) Bl/B
B B/O G/W
W B/Y Y/W
B/G
G
P/W
B/W
R/W
R W
B B/W
G Y
B/Lg
HEADLIGHT
Lg/R
G/W B/R
B/G B/Bl
STEERING DAMPER W/B
SOLENOID VALVE Br/R
Bl W
B/W Y
Lg
AMBIENT B
AIR TEMP
Bl/R
SENSOR
Bl/W
Br/W

Br/W
B/Bl

W/Bl

W/Bl

B/W
O/Bl
B/Bl

G/B

Bl/B

W/G

R/Bl

B/Bl
Bl/Y
B/R

B/W

B/W

W/R

R/W

B/W

Y/Bl

Y/Bl

R/W

B/R
W/Y

W/Y
W/Y

W/Y
Y/W

Y/W
O/R

B/O

G/R

G/B

O/B

G/B

B/R
Y/B

Y/R

Y/R
Lg

Br
G

Bl

W
B

B
R

R
Y

Y
B/Bl
B/W

B/G

Y/G
B/Y

1 2 3 4 5 6 7 8 9 10
Lbl

Bl
Lg

B
W
O

G
B

HORN A B C D
SIDE-STAND A. FUEL PUMP RELAY 1. FAN (RH) 15A
DIODE B. COOLING FAN RELAY 2. IGNITION 10A
C. HIGH BEAM RELAY 3. SIGNAL 10A
D. SIDE-STAND RELAY 4. HEADLIGHT HI 7.5A
5. DIMMER 10A COOLING
6. ABS 30A
7. HEADLIGHT LO 7.5A
FAN
8. PARK 10A MOTOR
9. FAN (LH) 15A (RH)
10. FUEL 10A
FUSE BOX

UP FREE L HI FREE FREE

FREE PUSH PUSH LO PUSH
DOWN R PASS
SELECT CLUTCH
MODE HORN TURN DIMMER/ SWITCH SWITCH
SWITCH SWITCH SIGNAL PASSING
SWITCH LIGHT
SWITCH
HANDLE SWITCH (LH)

IH17K1910907-05
 Wiring Systems: 9A-12

ECM
AP ABS CONTROL UNIT
SENSOR

Lg/W
Gr/W
Br/W

Lg/B
B/Lg

W/Bl

Lg/R

B/Lg
Gr/R

Gr/B

Gr/R

Gr/R

Gr/R
Gr/Y
Br/B

B/Br

B/Br

Br/R
Br/Y
G/Bl

O/Bl
B/Bl

B/Bl

G/W

G/W

Bl/R
B/Bl

W/G

W/G

R/Bl

B/Bl
B/W
Bl/Y
W/B
P/Bl

W/R

R/W

B/W
R/W

R/W

W/B

B/W

W/R

B/W

P/Bl

B/W
W/R

W/B

W/B
W/Y

W/Y

W/Y

W/Y
P/W

P/W

P/W

Y/W
R/G

G/B

B/G

B/G

B/O

B/O

O/R

G/R

O/B
G/Y

G/Y
B/R

R/B

B/Y

Y/G

B/R
R/Y

B/Y

R/Y

B/Y
Y/R

P/B

Y/B
Dg

Lg
Bl
W
G

G
R

R
Y

W/R

B/W
W/Y
B/R

B/Y

O
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
REAR TURN SIGNAL LIGHT (RH)
Lg/R G
B/Lg B

REAR COMBINATION LIGHT

Br/W Gr
B/W B/W
W/B W/Bl

LICENSE PLATE LIGHT

Br/W W
B/W B

REAR TURN SIGNAL LIGHT (LH)

B/R W
B/Lg B
Lg/W
Gr/W
Br/W
B/Lg

B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br

B/Br

B/Br

B/Br

B/Br

B/Br

B/Br
G/Bl
B/Bl

G/W

B/Bl

Bl/R

B/Bl

W/G
B/W

W/R

B/W

B/W

R/W

W/B
W/Y

W/Y
P/W

P/W
R/G

B/O

G/B

B/R
R/B
B/Y

R/Y

B/Y
Y/R

P/B
Dg

Lg

Bl

W
G
R
R

R
B
P

Y
B/W

Lg/W
Gr/W
B/Lg

Lg/B
Lg/R
Gr/B

Gr/R
Gr/Y
B/Br
Bl/R
R/W

W/Y
P/W
B/O

G/B
Y/R

P/B

B/Bl
Bl/Y
B/W
Dg
R

Lg
Bl

Gr

Gr
G
R
B

Bl

W
G
R

B
P

REGULATOR/ ACCELERATOR
STARTER RECTIFIER
MOTOR 1. MAIN FUSE 30A POSITION SENSOR TO
STARTER CKP SENSOR SENSOR
BATTERY GP CMP EXCV HO2
COOLING RELAY
GENERATOR SENSOR SENSOR ACTUATOR SENSOR
FAN
MOTOR
(LH)

ECT
SENSOR

IAP THROTTLE
SENSOR VALVE
EVAP IAT PRIMARY PRIMARY SECONDARY SECONDARY
SYSTEM MOTOR TP SENSOR FUEL FUEL FUEL FUEL
PURGE SENSOR INJECTOR INJECTOR INJECTOR INJECTOR
CONTROL #1 #3 #1 #3
SOLENOID PRIMARY PRIMARY SECONDARY SECONDARY
VALVE FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
#2 #4 #2 #4

IH17K1910908-04
9A-13 Wiring Systems:

Wiring Harness Routing Diagram

BENH17K19102005

[b]

[a]

[B]

[M]

[Q]

[N]

[G] [O]
[A]
4 [F]
[P]

FWD 6 [L]
[C]
2

[E]

2
5

FWD
4

3 2
[H]
1

[K]

[J]

[D] [I]

IH17K1910909-05
 Wiring Systems: 9A-14

[A]: View [a] [I]: Align the starter motor lead wire and [Q]: Pass the starter motor lead wire inside the fuse
battery (–) lead wire without overlapping box lead wire and rear combination light lead
each other. wire.
: Do not twist the harness.
[B]: View [b] [J]: Pass the battery (–) lead wire under the 1. Clamp
brake pipe (If equipped). : Positioning the wiring harness outside and
starter motor lead wire inside, clamp the wiring
harness, GP sensor lead wire and starter motor
lead wire at the rear of the fuel tank cushion.
: Face the clamp lock upward and the tip inward.
[C]: Insert the lugs of the harness [K]: Pass the wiring harness branch wire 2. Harness attached clamp
protector into the frame holes. under the starter motor lead wire and
brake pipe (If equipped).
[D]: Pass the fuel pump lead wire through [L]: Fit the turn signal relay to the harness 3. Starter motor lead wire
the right side of the fuel tank. protector lib (If equipped).
[E]: Push the fuse box until the hooks [M]: Pass the starter motor lead wire through 4. Harness protector
lock. the grooves of the electric parts holder.
[F]: Do not pinch the wiring harness in the [N]: Pass the battery (+) lead wire through the 5. Clip
electric parts holder. groove of the electric parts holder.
[G]: Fix the mode select coupler (6P) cap [O]: Fit the starter relay firmly to the electric 6. Harness protector clamp
into the frame hole. parts holder.
[H]: Pass the starter motor lead wire [P]: Pass the AP sensor lead wire through the
behind the brake hose (If equipped). groove of the AP sensor holder.
9A-15 Wiring Systems:

[A]
3
[a] [b]

[D]

FWD
[C] 2

[B]

8
[F]

3
4

FWD
3

8
[E]
9
10
11

12 6 5
13
IH17K1910910-03
 Wiring Systems: 9A-16

[A]: View [a] 2. Wiring harness No.3 9. Right rear turn signal light lead wire
[B]: View [b] 3. Harness attached clamp 10. Left rear turn signal light lead wire
[C]: Fix the wiring harness couplers to the right 4. Clamp 11. license plate light lead wire
side cowling bracket. : Clamp the rear wheel speed sensor lead wire.
: Face the clamp lock inward and the tip
downward.
[D]: Pass the cooling fan motor lead wire 5. Rear brake light switch lead wire 12. Rear combination light lead wire
inside the reservoir tank inlet hose. : Pass the lead wire between the EXCV cable : Position the rear combination light
clamps and behind the seat rail. lead wire at the lowest part.
[E]: Do not cross the branch wires each other. 6. Clamp 13. Frame
Front side: Branch wire with 2 couplers : Insert the clamp to the lower side hole in the
Rear side: Branch wire with 4 couplers frame plate.
[F]: Pass the rear combination light lead wire, 7. Cushion
rear turn signal light lead wires and : Stick the cushion along the frame.
license plate light lead wire outside the
seat rail.
1. Wiring harness clamp 8. Clamp
: Clamp the right handle switch lead wire : Clamp the license plate light lead wire, rear
at the end fitting of the front brake hose. combination light lead wire and rear turn signal
: Face the clamp lock downward. light lead wires.
: Face the clamp lock upward and the tip
inward.
9A-17 Wiring Systems:

[A] [E]

[a] FWD

[b]

2 [F] 3

[H]
[C]

[D]
[G]

[I] 4

[B] 5
4 5

[Q] 7

[R] 8
6

[M] 4 [N] FWD 4

[O]

[S]
[P]
[K]

[T] 9

[V]

11 12
11
[J]
[L]
[U]
10

IH17K1910911-03
 Wiring Systems: 9A-18

[A]: View [a] [M]: Clamp the horn lead wire on the blue tape. 3. Ignition coil #3
: After positioning the wiring harness, face
the coupler backward.
[B]: View [b] [N]: Pass the wiring harness above the water 4. Harness attached clamp
bypass hose.
[C]: Pass the ignition switch lead wire(s) [O]: Fix the clamp inserting into the bracket 5. Clamp
above the left handle switch lead wire. hole. : Clamp the wiring harness, starter motor
lead wire and battery (–) lead wire at the
blue tape and fix the clamp to the inside
hole in the regulator/rectifier bracket.
: Cut off the excess tip of the clamp.
[D]: Fix the clamp inserting into the lead wire [P]: Pass the cooling fan motor lead wire 6. Clamp
bracket hole. inside the water bypass hose. : Clamp the oil pressure switch lead wire,
side-stand switch lead wire and HO2
sensor lead wire.
[E]: After connection, push in the ignition [Q]: After connection, fix the wiring harness 7. Wiring harness
switch lead wire coupler(s) between the No.2 coupler to the upper hole in the
frame and air cleaner box. regulator/rectifier bracket.
[F]: Pass the wiring harness under the ignition [R]: After connection, fix the wiring harness 8. Starter motor lead wire and battery (–)
coil branch wires. No.2 coupler to the outside hole in the lead wire
regulator/rectifier bracket.
[G]: Pass the PAIR control solenoid valve lead [S]: Do not cross the branch wires each other. 9. Side-stand switch lead wire and HO2
wire under the PAIR control solenoid Front side: Branch wire to regulator/ sensor lead wire
valve. rectifier
Rear side: Branch wire to wiring harness
No.2
[H]: After connection, fix the handle switch [T]: Clamp the oil pressure switch lead wire on 10. Oil pressure switch lead wire
lead wire couplers to the radiator heat the blue tape.
shield holes.
[I]: Pass the right handle switch lead wire [U]: Fit the cap facing the hole for the lead wire 11. Lower crankcase
under the wiring harness. downward.
[J]: Pass the regulator/rectifier lead wire [V]: Pass the side-stand switch lead wire and 12. Radiator inlet hose
under the cylinder water inlet connector HO2 sensor lead wire inside the radiator
and generator lead wire. outlet hose.
[K]: After connecting the couplers, cover them 1. Lead wire bracket
with the boot.
: Facing the open end downward, push in
the boot inward.
[L]: Pass the lead wires between the lower 2. Ignition coil #1
crankcase and radiator inlet hose. : After positioning the wiring harness, face
the coupler backward.
9A-19 Wiring Systems:

[B] [B]

[A] 1

[C] [C]

[D]
1 1
IH17K1910912-02

[A]: Push in the combination meter coupler boot [C]: Pass the wiring harness between the air 1. Harness attached clamp
to cover the connector fully. intake pipe and intake cover.
[B]: Pass the wiring harness above the brace [D]: Pass the steering damper solenoid valve
fitting. Do not pinch the harness in the lead wire under the combination meter lead
brace. wire.
 Wiring Systems: 9A-20

2 [A]
2
1

[B]

[C]

[A] 3 [A]

4 3
5

IH17K1910913-03

[A]: Pass the fuel injector branch wire above the 1. Blue tube 4. Wiring harness No.3
wiring harness at each position.
[B]: Pass the wiring harness above the fuel 2. Clamp 5. Fuel delivery pipe
delivery pipe nipple. : Clamp the wiring harness No.3 and fuel
delivery pipe on the gray tape.
: Face the clamp lock backward and the tip
downward. Cut off the excess tip of the clamp.
[C]: Pass the wiring harness No.3 between the 3. Harness attached clamp
air cleaner box and TP sensor coupler. : Cut off the excess tip of the clamp.
9A-21 Wiring Systems:

[F] 1207B

(b)

(b)
3

(a)

(c)
1 “a”
6

[C] [E]
7

“g”

“f”
[D]
8

(d)
10
9

9
“b” 10
(a)

12
13
“d”

[A] “e”

“c” 11 (e)
[B] (f)

IH17K1910915-03
 Wiring Systems: 9A-22

[A]: Install the oil pressure switch lead wire 7. Generator lead wire “f”: 10 – 30 mm (0.40 – 1.18 in)
facing the crimped side of the terminal
forward.
[B]: Install the starter motor lead wire facing the 8. GP sensor “g”: 0 – 30°
crimped side of the terminal backward.
[C]: Bend the clamp into the shape as shown 9. Oil pressure switch lead wire : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
and then install it.
[D]: Parallel to the rib 10. Oil pressure switch lead wire clamp : 6.5 Nm (0.66 kgf-m, 4.80 lbf-ft)
[E]: Clamp the GP sensor lead wire on the 11. Oil pressure switch lead wire : 13 – 14 Nm (1.3 – 1.4 kgf-m, 9.5 – 10.5 lbf-ft)
tape. connecting screw
[F]: Apply sealant to the mating surface at the 12. Starter motor : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
parting lines between the generator cover
and grommet as shown.
1. Ignition coil #1 13. Battery (–) lead wire : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft)
2. Ignition coil #2 “a”: 0 – 20° : 4.0 Nm (0.41 kgf-m, 2.95 lbf-ft)
3. Ignition coil #3 “b”: 75 – 105° : Apply sealant.
4. Ignition coil #4 “c”: 45 – 75° : Do not reuse.
5. CMP sensor “d”: 90°
6. CKP sensor “e”: 0 ± 15°

Component Location
Electrical Components Location
BENH17K19103001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).

Specifications
Tightening Torque Specifications
BENH17K1910S001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Wiring Harness Routing Diagram” (Page 9A-13)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K1910T001
NOTE
Required service material(s) is also described in:
“Wiring Harness Routing Diagram” (Page 9A-13)
9B-1 Lighting Systems:

Lighting Systems
Body and Accessories

Precautions
Precautions for Lighting Systems
BENH17K19200001
NOTICE
• When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol
or soap water to prevent premature bulb failure.
• Do not use the bulb of a wattage other than specification.

Diagnostic Information and Procedures

LED Headlight Symptom Diagnosis
BENH17K19204004

Condition Possible cause Correction / Reference Item

Low beam does not light Faulty regulator/rectifier. Replace regulator/rectifier. (Page 1J-8)
up Faulty LED. Replace headlight assembly. (Page 9B-4)
Faulty wiring or ground. Repair wiring. (Page 9A-5)
Faulty dimmer switch. Check dimmer switch. (Page 9B-17)
High beam does not light Faulty regulator/rectifier. Replace regulator/rectifier. (Page 1J-8)
up Faulty LED. Replace headlight assembly. (Page 9B-4)
Faulty wiring or ground. Repair wiring. (Page 9A-5)
Faulty dimmer switch. Check dimmer switch. (Page 9B-17)

Turn Signal Light and Hazard Light Symptom Diagnosis

BENH17K19204005

Condition Possible cause Correction / Reference Item

Flash rate high or one Bulb blown. Replace bulb. (Page 9B-15)
side only flashes (For Incorrect bulb. Replace bulb. (Page 9B-15)
Bulb Type) Faulty turn signal relay. Check turn signal relay. (Page 9B-16)
Open circuit or high resistance existing Repair wiring. (Page 9A-5)
either; between turn signal switch and
non lighting bulb, or between hazard
switch and non lighting bulb.
Faulty hazard switch. Check hazard switch. (Page 9B-16)
Flash rate low (For Bulb Supply voltage low or high resistance. Check charging system. (Page 1J-4)
Type) Repair wiring. (Page 9A-5)
Faulty turn signal relay. Check turn signal relay. (Page 9B-16)
Flash rate high or one Faulty combination meter. Replace combination meter. (Page 9C-7)
side only flashes (For LED Faulty LED. Replace turn signal light.
Type) • Front: (Page 9B-14)
• Rear: (Page 9B-15)
Faulty wiring or ground. Repair wiring. (Page 9A-5)
Flash rate low (For LED Supply voltage low or high resistance. Check charging system. (Page 1J-4)
Type) Faulty combination meter. Replace combination meter. (Page 9C-7)

LED Rear Combination Light Symptom Diagnosis

BENH17K19204006

Condition Possible cause Correction / Reference Item

All lights do not light up Faulty wiring or grounding. Repair wiring. (Page 9A-5)
Some lights do not light Faulty LED. Replace LED rear combination light assembly
up and check short circuit.
Faulty wiring or grounding. Repair wiring. (Page 9A-5)
 Lighting Systems: 9B-2

Condition Possible cause Correction / Reference Item

Brake light do not light up Faulty front brake light switch. Check front brake light switch. (Page 4A-11)
Faulty rear brake light switch. Check rear brake light switch. (Page 4A-12)
Faulty wiring or grounding. Repair wiring. (Page 9A-5)
Faulty LED. Replace rear combination light assembly.
(Page 9B-9)
Brake light stay on Faulty front brake light switch. Check front brake light switch. (Page 4A-11)
Faulty rear brake light switch. Check rear brake light switch. (Page 4A-12)
Faulty LED. Replace rear combination light assembly.
(Page 9B-9)

Repair Instructions
LED Headlight Construction
BENH17K19206001
Without Position Light

1 8 7

3
1
3
6
2

9
3 2 4 10
10 9
2 3

[A]

14

14

13

12
11

9
9
IH17K1920001-02
9B-3 Lighting Systems:

[A]: Use the lower holes. 5. Body cowling 10. Screw

1. Headlight assembly 6. Intake cover 11. Air intake pipe LH
2. Headlight cover cushion 7. Intake upper cover RH 12. Cowling brace
3. Headlight cushion 8. Intake upper cover LH 13. Air intake pipe RH
4. Headlight lens fastener 9. Headlight screw 14. Fastener

With Position Light

3
1
3

2 6

2
7
7
8
3 2 4 7
2 7 8
3

14

7
14

13

12

9
11
10

8
IH17K1920002-01

1. Headlight assembly 6. Intake cover 11. Cowling brace

2. Headlight cover cushion 7. Screw 12. Air intake pipe RH
3. Headlight cushion 8. Headlight screw 13. Intake cover RH
4. Headlight lens fastener 9. Air intake pipe LH 14. Fastener
5. Body cowling 10. Intake cover LH
 Lighting Systems: 9B-4

LED Headlight Components

BENH17K19206025

IH17K1920049-02

1. LED Headlight

LED Headlight Removal and Installation Installation

BENH17K19206003 Installation is in the reverse order of removal. Pay
attention to the following points:
Without Position Light
• Install the headlight assembly to the body cowling,
Removal
use the lower holes (1).
1) Remove the body cowling. (Page 9D-22)
• Install the main harness No. 2 (2) and connect the
2) Remove the fasteners (1). headlight coupler (3).
3) Disconnect the headlight coupler (2).
4) Disconnect the clamps (3). 2
5) Remove the screws and headlight (4).

3 3
2
3 1 1
1 4

IH17K1920004-01

• Install the body cowling. (Page 9D-22)

• After installing, be sure to inspect the headlight beam.
IH17K1920003-01 (Page 9B-7)
9B-5 Lighting Systems:

With Position Light 3) Disconnect the AAT sensor coupler (1).

Removal
1) Remove the body cowlings. (Page 9D-22) 1
2) Remove the screw (1), fasteners (2) and move the
intake cover (3) backward.

NOTE
The same procedures are applicable to both
the right and left cover.

1 IH17K1920008-01

4) Disconnect the wiring harness No. 2 clamps (1).

2
IH17K1920005-01

IH17K1920009-01

5) Disconnect the position light couplers (1).

2
IH17K1920006-01

1 1
IH17K1920010-01

6) Disconnect the headlight coupler (1) and wiring

harness No. 2 clamps (2).

IH17K1920011-01

3
IH17K1920007-01
 Lighting Systems: 9B-6

7) Remove the air intake pipes (1). LED Position Light Removal and Installation
(For LED Headlight Side)
BENH17K19206026
Removal
1) Remove the LED headlight assembly. (Page 9B-4)
2) Remove the position light (1).

NOTE
The same procedures are applicable to both
the right and left parts.
1

IH17K1920012-02

8) Remove the headlight assembly (1).

IH17K1920051-02

IH17K1920013-01

Installation
Install the headlight in the reverse order of removal. Pay
attention to the following points:
• Install the main harness No. 2 (1) and connect the
headlight coupler (2). 1

1
IH17K1920015-01

Installation
Install the headlight in the reverse order of removal. Pay
attention to the following point.
• When installing the position light, align the projections
(1) on the position light with the holes (2) in the
headlight.
2

IH17K1920017-01

• Install the body cowling. (Page 9D-22) 1

• After installing, be sure to inspect the headlight beam.

(Page 9B-7)

2
IH17K1920016-01
9B-7 Lighting Systems:

LED Headlight / LED Position Light LED Headlight Beam Adjustment

BENH17K19206005
Replacement
BENH17K19206004 1) Adjust the headlight beam horizontally turning the
LED Headlight bolt (1) with a screwdriver.
NOTE 2) Adjust the headlight beam vertically turning the bolt
(2) with a screwdriver.
If LED operation is abnormal, replace the
headlight assembly with a new one. (Page
9B-4)

LED Position Light (For LED Headlight Side)

NOTE
[a]
If LED operation is abnormal, replace the LED
position light with a new one. (Page 9B-6)

[A]

IH17K1920019-02

[B]

IH17K1920054-02

[A]: View [a]

[B]: Headlight beam adjusting hole
 Lighting Systems: 9B-8

Rear Lighting System Construction

BENH17K19206006

(a)
(d)

(c)

7
1
6

[A]

2
5

(d)

3
(b)
(a) 4 9
8

10

10

(b)

IH17K1920020-03

[A]: Drain hole downward. 5. Rear turn signal light (For LED type) 10. Cushion
1. License plate light 6. Rear turn signal light (For bulb type) : 1.8 Nm (0.18 kgf-m, 1.35 lbf-ft)
2. Rear reflex reflector 7. License plate light spacer : 2.0 Nm (0.20 kgf-m, 1.50 lbf-ft)
3. License plate bracket (If equipped) 8. License plate bracket screw (If equipped) : 3.0 Nm (0.31 kgf-m, 2.25 lbf-ft)
4. Rear side reflex reflector (If equipped) 9. Rear combination light : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
9B-9 Lighting Systems:

[B]

[A]

IH17K1920021-03

[A]: Do not slacken the lead wires in this area.

[B]: Pass the rear turn signal light lead wires and license plate light lead wire through the arch of rear fender outer.

LED Rear Combination Light Removal and 3) Remove the rear combination light (1).
Installation
BENH17K19206007

Removal
1) Remove the rear fender front. (Page 9D-28)
2) Disconnect the rear combination light coupler (1)
and lead wire clamp (2).

2
1

IH17K1920023-02

IH17K1920022-03
 Lighting Systems: 9B-10

Installation LED Rear Combination Light Replacement

Install the rear combination light in the reverse order of BENH17K19206008

removal. Pay attention to the following point: NOTE

• Tighten the rear combination light screws (1) to the If LED operation is abnormal, replace the rear
specified torque. combination light with a new one after
checking its wire harness/coupler. (Page
Tightening torque 9B-9)
Rear combination light screw (a): 2.0 N·m (0.20
kgf-m, 1.50 lbf-ft)

1, ( a)

1, ( a)
IH17K1920024-02

LED License Plate Light Components

BENH17K19206009

IH17K1920050-03

1. LED License plate light

9B-11 Lighting Systems:

LED License Plate Light Removal and Rear Reflex Reflector Removal and Installation
BENH17K19206012
Installation Removal
BENH17K19206010
1) Remove the rear fender outer. Refer to “Rear Fender
Removal Outer Removal and Installation” in Section 9D (Page
1) Remove the rear fender outer. Refer to “Rear Fender 9D-27).
Outer Removal and Installation” in Section 9D (Page 2) Remove the nut (1), washer and rear reflex reflector
9D-27). (2).
2) Remove the nuts (1), washers and license plate light
assembly (2).

1 2

IH17K1920028-01
1

IH17K1920026-01 Installation
1) Fit the protrusion (1) to the hole (2).
Installation 2) Install the rear reflex reflector (3).
Install the license plate light in the reverse order of
removal. Pay attention to the following point:
• Tighten the license plate light nuts (1) to the specified
torque. 3 1 2

Tightening torque
License plate light nut (a): 3.0 N·m (0.31 kgf-m,
2.25 lbf-ft)

1, ( a)

IH17K1920029-01

3) Tighten the rear reflex reflector nut (1) to the

specified torque.
Tightening torque
Rear reflex reflector nut (a): 1.8 N·m (0.18 kgf-
m, 1.35 lbf-ft)

IH17K1920027-01

1 , (a )
LED License Plate Light Replacement
BENH17K19206011
NOTE
If LED operation is abnormal, replace the
license plate light with a new one. (Page
9B-11)

IH17K1920030-01

4) Install the removed parts.

 Lighting Systems: 9B-12

Front Turn Signal Light / Front LED Turn Signal Light Construction
BENH17K19206013

[A]

(a)

1
3

IH17K1920031-03

[A]: RH side: 2. Front turn signal light (For Bulb type) : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
• Clamp the front turn signal lead wire.
• After the clamp has contacted the collar
of front turn signal light, tighten the nut.
1. Front turn signal light (For LED type) 3. Side cowling assembly
9B-13 Lighting Systems:

Turn Signal Light / LED Turn Signal Light Components

BENH17K19206014

[A] 4
3

4
(a)

(a)
(a)
3
1

2 (a)

1
2
IH17K1920032-01

[B]

(a)
5

6
(a)
(a)

(a)

IH17K1920052-01

[A]: For bulb type 2. Front turn signal light lens 5. Front LED turn signal light
[B]: For LED type 3. Rear turn signal light bulb (12 V 21 W x 2) 6. Rear LED turn signal light
1. Front turn signal light bulb (12 V 21 W x 2) 4. Rear turn signal light lens : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
 Lighting Systems: 9B-14

Front Turn Signal Light Removal and • LH side, tighten the front turn signal light mounting nut
Installation (1) to the specified torque.
BENH17K19206015
Tightening torque
NOTE Front turn signal light mounting nut (a): 5.5 N·m (
The same procedures are applicable to both 0.56 kgf-m, 4.05 lbf-ft)
the right and left lights.

Removal
1) Remove the body cowling cover. (Page 9D-20)
2) Disconnect the front turn signal light coupler (1).
3) RH side, release the turn signal lead wire from the
clamp (2).
4) Remove the nut (3), washer (4) and front turn signal
light (5). 1 , (a )

1 IH17K1920034-01

Front LED Turn Signal Light Removal and

Installation
BENH17K19206027
3 2
Removal
5 4 Remove the front LED turn signal light. (Page 9B-14)

Installation
IH17K1920033-02
Install the front LED turn signal light. (Page 9B-14)

Installation Rear Turn Signal Light Removal and Installation

Install the front turn signal light in the reverse order of BENH17K19206016

removal. Pay attention to the following points: NOTE

• RH side, after the clamp (1) has contacted the collar The same procedures are applicable to both
(2) of front turn signal light, tighten the front turn signal the right and left lights.
light mounting nut (3) to the specified torque.
Tightening torque Removal
Front turn signal light mounting nut (a): 5.5 N·m ( 1) Remove the rear fender outer. Refer to “Rear Fender
0.56 kgf-m, 4.05 lbf-ft) Outer Removal and Installation” in Section 9D (Page
9D-27).
1 2) Remove the nut (1), washer and rear turn signal light
(2).

3, (a)

IH17K1920053-01

2 1
IH17K1920035-01
9B-15 Lighting Systems:

Installation 2) Replace the bulb (1) with a new one.

Install the rear turn signal light in the reverse order of
removal. Pay attention to the following points:
• Tighten the rear turn signal light mounting nut (1) to
the specified torque.
Tightening torque
Rear turn signal light mounting nut (a): 5.5 N·m (
0.56 kgf-m, 4.05 lbf-ft)

IH17K1920038-01

3) Reinstall the lens.

LED Turn Signal Light Replacement

BENH17K19206029
NOTE
1, ( a) If LED operation is abnormal, replace the LED
turn signal light with a new one.
IH17K1920036-01

• Route the turn signal light lead wire. Refer to “Rear • Front LED turn signal light: (Page 9B-14)
Lighting System Construction” (Page 9B-8). • Rear LED turn signal light: (Page 9B-14)

Rear LED Turn Signal Light Removal and Reflex Reflector Construction (If Equipped)
Installation BENH17K19206018
BENH17K19206028 Front Side Reflex Reflector

Removal
Remove the rear LED turn signal light. (Page 9B-14)

Installation
Install the rear LED turn signal light. (Page 9B-14)
1
Turn Signal Light Bulb Replacement
BENH17K19206017
1) Remove the screw (1) and lens (2).

4 (a)

5 (b)
IH17K1920039-02
1 2
1. Front fender
2. Front fender cushion
IH17K1920037-01 3. Front side reflex reflector washer (If equipped)
4. Front side reflex reflector bolt (If equipped)
5. Front side reflex reflector (If equipped)
: 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
: 1.8 Nm (0.18 kgf-m, 1.35 lbf-ft)

Rear Side Reflex Reflector (If Equipped)

Refer to “Rear Lighting System Construction” (Page 9B-
8).
 Lighting Systems: 9B-16

Turn Signal Relay Inspection (For Bulb Type) 3) Disconnect the left handle switch coupler (1).
BENH17K19206019
Refer to “Electrical Components Location” in Section 0A
(Page 0A-6).

NOTE
Make sure that the battery is fully charged.

Before removing the turn signal relay, check the

operation of the turn signal light.
1
If the turn signal light does not illuminate, inspect the
bulb, turn signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are
OK, the turn signal relay may be faulty; therefore, IH17K1920042-04

replace the turn signal relay with a new one. (Page 9B- 4) Inspect the turn signal switch for continuity with a
16) circuit tester. If any abnormality is found, replace the
left handle switch with a new one. Refer to
Turn Signal Relay Removal and Installation (For “Handlebar Removal and Installation” in Section 6B
Bulb Type) (Page 6B-3).
BENH17K19206020
Removal Color
Lg Lbl B
1) Turn the ignition switch OFF. Position
2) Remove the front seat. (Page 9D-19) L
3) Remove the turn signal relay (1) from mounting stay. PUSH
4) Disconnect the coupler (2). R
IH17K1920043-03

5) After finishing the turn signal switch inspection,

2 install the removed parts.
1
Hazard Switch Inspection
BENH17K19206022
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the right handle switch coupler (1).

IH17K1920040-01

Installation
Install the turn signal relay in the reverse order of
removal. Pay attention to the following point:
• Fix the turn signal relay (1) to the stay (2) firmly.
1
1

IH17K1920044-02

4) Inspect the hazard switch for continuity with a circuit

2
tester.
If any abnormality is found, replace the right handle
switch with a new one. Refer to “Handlebar Removal
and Installation” in Section 6B (Page 6B-3).

Color
B Lbl Lg
IH17K1920041-01 Position
OFF
Turn Signal Switch Inspection ON
BENH17K19206021 IH17K1920045-03
1) Turn the ignition switch OFF. 5) After finishing the hazard switch inspection, install
2) Remove the air cleaner box. (Page 1D-6) the removed parts.
9B-17 Lighting Systems:

Passing Light Switch Inspection Dimmer Switch Inspection

BENH17K19206023 BENH17K19206024
1) Turn the ignition switch OFF. 1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (Page 1D-6) 2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the left handle switch coupler (1). 3) Disconnect the left handle switch coupler (1).

1 1

IH17K1920042-04 IH17K1920042-04

4) Inspect the passing light switch for continuity with a 4) Inspect the dimmer switch for continuity with a circuit
circuit tester. tester.
If any abnormality is found, replace the left handle If any abnormality is found, replace the left handle
switch with a new one. Refer to “Handlebar Removal switch with a new one. Refer to
and Installation” in Section 6B (Page 6B-3). “Handlebar Removal and Installation” in Section 6B
(Page 6B-3).
Color
Y O W
Position Color
Y O W
PASS Position
IH17K1920047-01 HI
5) After finishing the passing light switch inspection, LO
install the removed parts. IH17K1920048-01

5) After finishing the dimmer switch inspection, install

the removed parts.

Specifications
Tightening Torque Specifications
BENH17K19207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear combination light screw 2.0 0.20 1.50 (Page 9B-10)
License plate light nut 3.0 0.31 2.25 (Page 9B-11)
Rear reflex reflector nut 1.8 0.18 1.35 (Page 9B-11)
Front turn signal light mounting nut (Page 9B-14) /
5.5 0.56 4.05
(Page 9B-14)
Rear turn signal light mounting nut 5.5 0.56 4.05 (Page 9B-15)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Lighting System Construction” (Page 9B-8)
“Front Turn Signal Light / Front LED Turn Signal Light Construction” (Page 9B-12)
“Turn Signal Light / LED Turn Signal Light Components” (Page 9B-13)
“Reflex Reflector Construction (If Equipped)” (Page 9B-15)
“Fasteners Information” in Section 0C (Page 0C-12)
 Combination Meter / Fuel Meter / Horn: 9C-1

Combination Meter / Fuel Meter / Horn

Body and Accessories

General Description
Combination Meter System Description
BENH17K19301001
This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
The LCD indicates, Fuel level indicator (3), Engine coolant temperature indicator display (4), Engine coolant
temperature indicator / Oil pressure indicator (5), Tachometer (6), Speed (7), Driving mode indicator (8), Traction
control system indicator (9), Gear position indicator (10), Service reminder indicator (11), Engine rpm indicator (12)
and Multifunction display (13) respectively.

LED (Light Emitting Diode)

LED is used for the illumination light and each indicator light.
LED is maintenance free. LED is less power consuming and more resistant to vibration compared to the bulb.

Multifunction Display
The Multifunction display indicates the Instantaneous fuel consumption, Odometer, Driving range, Trip meter, A / B,
Average fuel consumption, Battery voltage, Instrument panel light brightness, FI (DTC) / SD (Steering damper
system), Clock and Ambient air temperature indicator respectively.

NOTE
The Instantaneous fuel consumption (14) (Except LAP TIME mode), Clock (15) and Ambient air
temperature (16) is always displayed.

The Multifunction display can be selected and set in the following “MENU” by the select switch (2).
• DISPLAY
• RPM SET
• TACHO SET
• DATE & TIME
• UNIT
• SERVICE
9C-2 Combination Meter / Fuel Meter / Horn:

7 27 26 27 12 10 5
6

24 24

21 23

22
18
11

19 17

25 20

14

4 8 3 9 15 13 16

2
IH17K1930001-05

1. Mode switch 22. LED (Engine coolant temperature indicator light / Oil pressure indicator light)
17. LED (Freeze indicator light) 23. LED (TC indicator light)
18. LED (Neutral indicator light) 24. LED (Turn signal indicator light)
19. LED (MIL) 25. LED (Immobilizer indicator light) (If equipped)
20. LED (Hi beam indicator light) 26. LED (Engine rpm indicator light (Main))
21. LED (ABS indicator light) (If equipped) 27. LED (Engine rpm indicator light (Sub))

Service Reminder Indicator Description

BENH17K19301002
The service reminder indicator comes on to notify the rider of the preset date and distance for the service
maintenance.
The service reminder is set using the mode select switch (special tool), monitoring the multifunction display and
pushing the select switch in the left handle switch (UP or DOWN) for the setting.
Special tool
09930–82720
 Combination Meter / Fuel Meter / Horn: 9C-3

Diagnostic Information and Procedures

Combination Meter Symptom Diagnosis
BENH17K19304003
1) Check combination meter power and ground circuit.
2) Check DTC. (Page 1A-17)
• If some DTC appears during inspection in Step 2), go to applicable DTC diagnosis flow.
• If any of troubles described in table below has occurred independently even though DTC display is normal
during inspection is Step 2), inspect subject place according to instructions in table below.

Condition Possible cause Correction / Reference Item

Speedometer does not Front wheel speed sensor Check front wheel speed sensor. (Page 4E-
operate 50)
Speedometer Check speedometer. (Page 9C-11)
ECM Check ECM.
• Without ABS: (Page 1A-54)
• With ABS: (Page 1A-57)
Speedometer circuit Repair circuit. (Page 9A-5)
Front wheel speed sensor circuit Repair circuit. (Page 9A-5)
Fuel level indicator does Fuel level gauge Check fuel level sensor. (Page 9C-9)
not operate Fuel level indicator Check fuel level indicator. (Page 9C-8)
Fuel level gauge circuit Repair circuit. (Page 9A-5)
Oil pressure indicator Oil pressure switch Check oil pressure switch. (Page 9C-11)
light does not operate Oil pressure indicator Check oil pressure indicator. (Page 9C-11)
Oil pressure switch circuit Repair circuit. (Page 9A-5)
Engine coolant ECT sensor Check ECT sensor. (Page 1C-14)
temperature indicator ECT indicator Check ECT indicator. (Page 9C-8)
does not operate ECT sensor circuit Repair circuit. (Page 9A-5)
Ambient air temperature Ambient air temperature sensor Check ambient air temperature sensor.
indicator (Page 9C-10)
Ambient air temperature indicator Check ambient air temperature indicator.
(Page 9C-10)
Ambient air temperature sensor circuit Repair circuit. (Page 9A-5)

Horn Symptom Diagnosis

BENH17K19304004

Condition Possible cause Correction / Reference Item

Horn does not operate Faulty horn switch Check horn switch. (Page 9C-11)
Faulty wiring or grounding Repair circuit.
Faulty horn Check horn. (Page 9C-11)
9C-4 Combination Meter / Fuel Meter / Horn:

Repair Instructions
Combination Meter Construction
BENH17K19306001

[A]

(a)

IH17K1930002-01

[A]: Install the coupler boots to the combination meter securely. 2. Cowling brace
1. Combination meter : 2.0 Nm (0.20 kgf-m, 1.50 lbf-ft)

Combination Meter Components

BENH17K19306003

2
1
3

(a)

IH17K1930003-04

1. Upper case 3. Lower case

2. Combination meter unit : 2.0 Nm (0.20 kgf-m, 1.50 lbf-ft)
 Combination Meter / Fuel Meter / Horn: 9C-5

Service Reminder Reset 5) Press the select switch (UP or DOWN) to select
BENH17K19306020 “SERVICE”.
NOTE
• Before set up the service reminder, check
that the multifunction display indicates the
current calendar.
• The date and distance inputted in the
service reminder will not be reset even if
the battery cable is disconnected.

1) Remove the rear seat. (Page 9D-19)

2) Connect the special tool to the mode select coupler
(6P) at the wiring harness.
Special tool
(A): 09930–82720
IH17K1930025-02

6) Press the select switch (DOWN) for about 2

seconds. “SERVICE” starts blinking and changes the
(A) screen for setting.

IH17K1930026-01

• Before the service reminder indicator comes on:

IH17K1930023-01

3) Turn the ignition switch ON. NOTE

4) Press the select switch (UP) for about 2 seconds to In this initial screen, 1000 km (600 mile) is
switch the screen to “MENU”. shown but the date is not shown.

IH17K1930027-02

• When the service reminder indicator comes on:

IH17K1930024-02

IH17K1930028-01
9C-6 Combination Meter / Fuel Meter / Horn:

7) Turn the special tool’s switch ON and “RESET” 11) Press the select switch (UP or DOWN) to select
appears on the screen. month, day, distance and “SET” indication. The
selected item is highlighted.

IH17K1930031-01

ID26J1110213-01

IH17K1930032-01

12) Press the select switch (DOWN) for about 2 seconds

to make arrow marks appear above and below the
indication.
IH17K1930029-01

8) By pressing the select switch (DOWN) for about 2 NOTE

seconds, “YES” and “NO” appear on the screen. Even if the special tool’s switch is set OFF,
the setting mode continues.

IH17K1930026-01

IH17K1930026-01

IH17K1930030-01

9) Press the select switch (UP or DOWN) to select

“YES”. IH17K1930033-02

10) Press the select switch (DOWN) for about 2 seconds 13) Press the select switch (UP or DOWN) to set month,
to select month, day and distance to setting screen. day and distance indications.
NOTE NOTE
If “NO” is selected and press the select • Month can be selected from present month
switch (DOWN) for about 2 seconds or press plus within one year in 12 steps.
the select switch (UP) for about 2 seconds, Example (if this month is 2017/5): Possible
the screen returns to Step 7). setting is 2018/5 – 2017/6.
• Day can be selected within the range of 1 –
31.
• Distance can be selected within 1000 –
12000 km in every 1000 km or 600 mile and
within 1000 – 7500 mile in every 500 mile.
 Combination Meter / Fuel Meter / Horn: 9C-7

14) Press the select switch (DOWN) for about 2 Combination Meter Removal and Installation
seconds. The arrow marks above and below the BENH17K19306005

indication disappear and the setting is confirmed.

Removal
NOTE 1) Remove the body cowling assembly. (Page 9D-22)
If the following conditions appear, the setting 2) Remove the combination meter (1).
data is canceled.
• Ignition switch is OFF.
• The setting operation is suspended for one
minute.
• Speed sensor signal is imputed and the
display is changed automatically.

15) Press the select switch (UP or DOWN) to select

“SET”. 1
16) Press the select switch (DOWN) for about 2 seconds
and the service reminder setting is confirmed before
IH17K1930005-01
returning to setting screen in Step 7).
17) Turn the ignition switch OFF and disconnect the Installation
special tool. Install the combination meter in the reverse order of
18) Install the removed parts. removal. Pay attention to the following point:
• Tighten the screw (1) to the specified torque.
Combination Meter On-Vehicle Inspection
BENH17K19306004 Tightening torque
LED Inspection Speedometer screw (a): 2.0 N·m (0.20 kgf-m, 1.50
Check that the LEDs (MIL (1), ABS indicator light (2) (if lbf-ft)
equipped), Engine coolant temperature indicator light /
Oil pressure indicator light (3), TC indicator light (4),
Neutral indicator (5), Freeze indicator light (6) and
Immobilizer indicator light (7) (If equipped)) immediately
light up when the ignition switch is turned to ON.
Check that other LEDs (Hi beam indicator light (8) and
Turn signal indicator lights (9)) light up/go off by
operating the dimmer and turn signal switches.
If abnormal condition is found, replace the combination
meter unit with a new one after checking its wire
harness/coupler. (Page 9C-7) 1 , (a )

IH17K1930006-01
9 9

Combination Meter Disassembly and

2 4
Reassembly
BENH17K19306006

5 3
Refer to “Combination Meter Removal and Installation”
(Page 9C-7).
1 6
Disassembly
7 8
Disassemble the combination meter as shown in the
IH17K1930004-04
combination meter components. (Page 9C-4)

Reassembly
Assemble the combination meter as shown in the
combination meter components. (Page 9C-4)
9C-8 Combination Meter / Fuel Meter / Horn:

Engine Coolant Temperature Indicator / Engine

Coolant Temperature Indicator Light Inspection
BENH17K19306007
1) Disconnect the ECT sensor coupler. Refer to “ECT
Sensor Removal and Installation” in Section 1C
(Page 1C-14).
2) Connect a variable resistor (1) between the
terminals.

ID26J1930009-01

3) Turn the ignition switch ON.

4) Check the LCD (1) (2) and LED (3) operations when the resistance is adjusted to the specified values.
If either one or both indications are abnormal, replace the combination meter assembly with a new one. (Page
9C-7)

1
IH17K1930007-04

LCD (1)
Resistance LED (3) LCD (2) Engine coolant temperature
°C °F
2550 Ω or more “- - -” “- - -” OFF — 19 °C (67 °F) or less
98 – 2550 Ω “19” – “125” “67” – “257” OFF — 19 – 125 °C (67 – 257 °F)
0 Ω (Jumper wire) “HI” “HI” ON Flicker 125 °C (257 °F) or more

5) Connect the ECT sensor coupler.

6) Install the removed parts.

ECT Sensor Removal and Installation Fuel Level Indicator Inspection

BENH17K19306008 BENH17K19306009
Refer to “ECT Sensor Removal and Installation” in 1) Lift and support the fuel tank. (Page 1G-9)
Section 1C (Page 1C-14).
2) Disconnect the fuel pump coupler (1).

IH17K1930008-01
 Combination Meter / Fuel Meter / Horn: 9C-9

3) Connect a variable resistor (1) between the Bl/W and

Bl/R lead wires of the wire harness side coupler.
Resistance Fuel level indicator

Flicker Flicker

181.0 – 195.8 Ω
Flicker

Flicker

1
IH17K1930009-01 144.3 – 155.9 Ω
4) Turn the ignition switch ON. ON
5) Check the display of fuel level indicator (LCD) as
shown in the figure.
ON
If any abnormality is found, replace the combination
meter with a new one. (Page 9C-7)
118.6 – 128.4 Ω
NOTE ON
It takes approx. 40 seconds that the fuel level
indicator indicates the detected fuel level.
ON

90.5 – 98.1 Ω
ON

ON

56.5 – 61.9 Ω
ON

ON

12.9 – 15.9 Ω
ON

IH17K1930010-01

6) Connect the fuel pump coupler and reinstall the fuel

tank. (Page 1G-9)

Fuel Level Gauge Inspection

BENH17K19306010
Refer to “Fuel Level Gauge Inspection” in Section 1G
(Page 1G-16).
9C-10 Combination Meter / Fuel Meter / Horn:

Ambient Air Temperature Indicator / Freeze

Indicator Light Inspection Freeze Ambient air
BENH17K19306018 indicator temperature
Temperature
1) Remove the right meter panel (1). light indicator
(LED) (2) (LCD) (1)
Flicker Flicker

[A] [B]

OFF

IH17K1930014-01

[A]: When increasing the temperature

IH17K1930011-01 [B]: When decreasing the temperature
2) Remove the ambient air temperature sensor (1).

1
1
IH17K1930015-05

6) Install the ambient air temperature sensor.

IH17K1930012-01

3) Disconnect the ambient air temperature sensor 7) Install the right meter panel.
coupler and connect the variable resistor (1)
between the terminals. Ambient Air Temperature Sensor Inspection
BENH17K19306019
Refer to “Ambient Air Temperature Indicator / Freeze
Indicator Light Inspection” (Page 9C-10).
Measure the resistance between terminals of ambient air
temperature sensor.
If any abnormality is found, replace the ambient air
temperature sensor with a new one.

NOTE
Ambient air temperature sensor resistance
measurement method is the same way as
1 that of the ECT sensor. (Page 1C-14)
IH17K1930013-01

4) Turn the ignition switch ON. Ambient air temperature sensor resistance
5) Check the ambient air temperature indicator (LCD) Temperature Standard resistance
(1) and freeze indicator light (LED) (2) operations –20 °C (–4 °F) 13779 – 19083 Ω
when the resistance is adjusted to the specified –10 °C (14 °F) 8100 – 10609 Ω
values. If either one or both indications are 0 °C (32 °F) 4928 – 6125 Ω
abnormal, replace the combination meter with a new 10 °C (50 °F) 3089 – 3656 Ω
one. (Page 9C-7) 20 °C (68 °F) 1992 – 2251 Ω
25 °C (77 °F) 1615 – 1785 Ω
Resistance LCD
30 °C (86 °F) 1290 – 1456 Ω
Approx. 1700 Ω 25 °C (78 °F)
40 °C (104 °F) 838 – 986 Ω
Approx. 4300 Ω 5 °C (41 °F)
Approx. 9700 Ω –10 °C (14 °F)
 Combination Meter / Fuel Meter / Horn: 9C-11

2) Turn the ignition switch ON.

3) Check if the oil pressure indicator (LED) (1) and LCD
(2) will light up when grounding the lead wire (3).
If the oil pressure indicator does not light up, replace
the combination meter assembly with a new one
after checking the connection of couplers.

2 1

Ω
ID26J1930016-01

Speedometer On-Vehicle Inspection 3

BENH17K19306011
If the speedometer, odometer or tripmeter does not
function properly, inspect the front wheel speed sensor
and the coupler connections. If the front wheel speed
sensor and coupler connections are OK, replace the
IH17K1930017-02
combination meter with a new one. (Page 9C-7)

Ignition Switch Removal and Installation

Speed Sensor Removal and Installation BENH17K19306015
BENH17K19306012 Refer to “Ignition Switch Removal and Installation” in
Refer to “Front Wheel Speed Sensor Removal and
Section 1H (Page 1H-9).
Installation” in Section 4E (Page 4E-49).

Horn Inspection
Speed Sensor Inspection BENH17K19306016
BENH17K19306013 Horn Switch Inspection
Refer to “Wheel Speed Sensor and Sensor Rotor
Inspection” in Section 4E (Page 4E-50). 1) Remove the air cleaner box. (Page 1D-6)
2) Disconnect the left handle switch coupler (1).
Oil Pressure Indicator Inspection
BENH17K19306014
NOTE
1
Before inspecting the oil pressure switch,
check if the engine oil level is correct. Refer
to “Engine Oil Inspection” in Section 1E
(Page 1E-4).

1) Disconnect the oil pressure switch lead wire (1).

Refer to “Oil Pressure Switch Removal and
Installation” in Section 1E (Page 1E-10).
IH17K1930018-01

3) Inspect the horn switch for continuity with a tester.

If any abnormality is found, replace the left handle
1 switch with a new one. (Page 6B-3)

I718H1930028-03

IH17K1930016-02
9C-12 Combination Meter / Fuel Meter / Horn:

Horn Inspection Installation

1) Remove the body cowling cover and under inner Install the horn in the reverse order of removal. Pay
cowlings. (Page 9D-20) attention to the following point:
2) Disconnect the horn coupler (1). • Tighten the horn bolts (1) to the specified torque.
Tightening torque
Horn bolt (a): 6.0 N·m (0.61 kgf-m, 4.45 lbf-ft)

1 1 , (a )

IH17K1930019-01

3) Connect a 12 V battery to the horn terminals. If the

sound is not heard from the horn, replace the horn IH17K1930022-01
with a new one.
Mode Switch Inspection
BENH17K19306021
1) Turn the ignition switch OFF.
2) Remove the air cleaner box. (Page 1D-6)
3) Disconnect the left handle switch coupler (1).

IH17K1930020-01

Horn Removal and Installation

BENH17K19306017
Removal
1) Remove the left side cowling assembly. (Page 9D-
IH17K1930034-01
21)
4) Inspect the mode switch for continuity with a multi
2) Disconnect the horn coupler (1).
circuit tester.
3) Remove the horn (2). If any abnormality is found, replace the left handle
switch with a new one. Refer to “Handlebar Removal
and Installation” in Section 6B (Page 6B-3).

Color
2 P B/G
Position
FREE
PUSH
IH17K1930035-01

1 5) Connect the left handle switch coupler. Refer to

“Wiring Harness Routing Diagram” in Section 9A
(Page 9A-13).
IH17K1930021-01
6) Install the air cleaner box. (Page 1D-6)
 Combination Meter / Fuel Meter / Horn: 9C-13

Select Switch Inspection 4) Inspect the select switch for continuity with a multi
BENH17K19306022 circuit tester.
1) Turn the ignition switch OFF. If any abnormality is found, replace the left handle
2) Remove the air cleaner box. (Page 1D-6) switch with a new one. Refer to “Handlebar Removal
3) Disconnect the left handle switch coupler (1). and Installation” in Section 6B (Page 6B-3).

Color
Y/G G B/G
Position
UP
1
FREE
DOWN
IH17K1930036-01

5) Connect the left handle switch coupler. Refer to

“Wiring Harness Routing Diagram” in Section 9A
(Page 9A-13).
6) Install the air cleaner box. (Page 1D-6)
IH17K1930034-01

Specifications
Tightening Torque Specifications
BENH17K19307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Speedometer screw 2.0 0.20 1.50 (Page 9C-7)
Horn bolt 6.0 0.61 4.45 (Page 9C-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Combination Meter Construction” (Page 9C-4)
“Combination Meter Components” (Page 9C-4)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Special Tool
BENH17K19308001
09930–82720
Mode selection switch
(Page 9C-2) /
(Page 9C-5)
9D-1 Exterior Parts:

Exterior Parts
Body and Accessories

Schematic and Routing Diagram

Seat Lock Cable Routing Diagram
BENH17K19402001

7
2
8

4
5
[A]
3
3
[B]
1
9 (a)

4 5

IH17K1940001-02

[A]: Set the seat lock cable firmly. 5. Seat rail

[B]: Align the rib of seat lock and groove of each part. 6. Left frame cover
1. Seat lock plate 7. Right frame cover
: Install the seat lock plate behind of the seat lock cable guide.
2. Seat lock cable 8. Striker support bracket
3. Seat lock 9. Frame center front cover
4. Seat lock cable guide : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)

Repair Instructions
Windscreen / Body Cowling Construction
BENH17K19406038
NOTE
Symbols such as [a] – [a] indicate a connection between 2 points.
 Exterior Parts: 9D-2

[A]

[A]
[A] 3

[ a]

[ b]

[A] [ d]
[c]

11
3
4

[e]
8
[f]

5
[ a] 9
9

[ b]

10

[c]
[ d]

[f]

[ e] 1

2
6
2

IH17K1940002-02

[A]: Tighten the windscreen screws until each screw end protrudes 6. Air intake pipe
1.5 – 3.0 mm (0.06 – 0.11 in) from the nut end.
1. Body cowling cover 7. Right intake cover
2. Under inner cowling 8. Left intake cover
3. Meter panel 9. Intake upper cover
4. Windscreen 10. Intake cover
5. Headlight 11. Body cowling
9D-3 Exterior Parts:

Body Cowling / Side Cowling Construction

BENH17K19406039

7
5
8

[A], “1”
[A], “1” [A], “2”

2
[A], “2”

3
4 3

IH17K1940003-02

[A]: Tighten the screws in order of “1” → “2”. 5. Body cowling assembly
1. Body cowling cover 6. Cowling brace
2. Under inner cowling 7. Lower bracket cover
3. Side cowling assembly 8. Frame
4. Under center cowling
 Exterior Parts: 9D-4

Side Cowling Construction

BENH17K19406040

2
3

11
7
12
77
13
14 16 8
98

“a”
10 “b” “c”

15
5
6
“d”

IH17K1940004-02
9D-5 Exterior Parts:

1. Right front side cowling 11. Side rear right cushion No. 1
: Stick the cushion aligning with the emboss line.
2. Right rear side cowling 12. Side rear right cushion No. 2
: Stick the cushion aligning with the emboss line.
3. Right under cowling 13. Side rear left cushion No. 1
: Stick the cushion aligning with the emboss line.
4. Left front side cowling 14. Side rear left cushion No. 2
: Stick the cushion aligning with the edge.
5. Left rear side cowling 15. Under right cushion
: Stick the cushion aligning with the heat shield.
6. Left under cowling 16. Side rear right cushion No. 3
: After tightening the screw, stick the cushion aligning with the cowling edge.
7. Side front cushion “a”: 40 mm (1.57 in)
: Stick the cushion aligning with the emboss line.
8. Under cowling right heat shield “b”: 30 mm (1.18 in)
: Stick the heat shield aligning with the emboss line.
9. Under cowling left heat shield “c”: 4 – 6 mm (0.16 – 0.23 in)
: Stick the heat shield aligning with the emboss line.
10. Under cowling heat shield No. 2 “d”: 0 – 2 mm (0.00 – 0.08 in)
: Stick the heat shield aligning with the emboss line.
 Exterior Parts: 9D-6

Rear Fender Construction

BENH17K19406041

[C]
“a”

5 [B]

[A]
[A] [A]
2
[A]
“b” [D]

4, “3”
4, “4”

6
4, “2”

4, “1”

IH17K1940005-01

[A]: To seat rail 4. Rear fender rear bolt

: Tighten the bolts in order of “1” → “2” → “3” → “4”.
[B]: Locating screw 5. Rear fender rear cushion
[C]: Stick the cushion aligning with the edge of the rear fender outer. 6. Rear fender rear tape
[D]: Stick the cushion aligning with the emboss line. “a”: 13 – 16 mm (0.52 – 0.62 in)
Do not stick the cushion out of the emboss line.
1. Rear fender front “b”: 0 – 1 mm (0.00 – 0.04 in)
2. Rear fender inner : Apply thread lock to the thread part.
3. Rear fender outer
9D-7 Exterior Parts:

Front Fender Construction

BENH17K19406042

6
[A], “1”
3
7 (a)

2 8

[A], “1”
4 (a)
[A], “2”
5 (a)
IH17K1940006-02

[A]: Tighten the screws in order of “1” → “2”. 5. Front fender rear screw
1. Front fender 6. Front side reflex reflector washer (If equipped)
2. Front fender rear cushion 7. Front side reflex reflector bolt (If equipped)
3. Front fender front cushion 8. Front side reflex reflector (If equipped)
4. Front fender front screw (If equipped) : 8.4 Nm (0.86 kgf-m, 6.20 lbf-ft)
 Exterior Parts: 9D-8

Frame Cover Construction

BENH17K19406043

6 (a)

3
4
2
1

6 (a)

1
IH17K1940007-02

1. Frame front cover 5. Frame center front cover

2. Frame front No.2 cover 6. Frame cover rear screw
3. Frame cover : 8.0 Nm (0.82 kgf-m, 5.90 lbf-ft)
4. Frame center rear cover
9D-9 Exterior Parts:

Fuel Tank Front Cover Construction

BENH17K19406009

(a)

IH17K1940008-01

1. Fuel tank front cover : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
 Exterior Parts: 9D-10

Frame Front Cover Cushion Construction

BENH17K19406044

7
“a”
2 5
3 1

6
IH17K1940009-02

1. Velcro fastening 5. Frame front No. 2 cover

: Stick the velcro fastening aligning with the emboss line.
2. Frame cover upper cushion 6. Frame cover lower cushion
: Stick the cushion aligning with the emboss line. : Stick the velcro fastening aligning with the emboss line.
3. Frame cover No. 2 cushion 7. Frame cover upper No. 2 cushion
: Stick the cushion aligning with the emboss line. : Stick the cushion aligning with the emboss line.
4. Frame front cover “a”: 0 – 1 mm (0.00 – 0.04 in)

Frame Cover Cushion Construction

BENH17K19406045

“a” “a”

2
3
2
1

“b”

IH17K1940083-02

1. Right frame cover “a”: 0 – 1.5 mm (0 – 0.06 in)

2. Right frame cover cushion No. 2 “b”: 0 – 7 mm (0 – 0.3 in)
9D-11 Exterior Parts:

Fuel Tank Front Cover Cushion / Velcro Fastening Construction

BENH17K19406046

1 2 1

2
2

2
4

IH17K1940010-01

1. Fuel tank front cover cushion 4. Fuel tank front cover

: Stick the cushion aligning with the emboss line.
2. Velcro fastening 5. Rib edge
: Stick the velcro fastening aligning with the emboss line.
3. Fuel tank cover cushion
: Stick the cushion aligning with the rib edge.
 Exterior Parts: 9D-12

Body Cowling Cover Cushion / Under Inner Cowling Cushion Construction

BENH17K19406047

5
“a”

“a”

3
1 [A]

6 6
[A]
IH17K1940011-02

[A]: Stick the cushion aligning with the emboss line. 4. Under inner cowling cushion
1. Body cowling cover 5. Emboss line
2. Body cowling cover cushion 6. Body cowling cover tape
3. Right under inner cowling “a”: 0 – 1 mm (0.00 – 0.04 in)

Under Center Cowling Cushion Construction

BENH17K19406048

IH17K1940084-01

1. Under center cowling 3. Under cowling cushion No. 2

: Stick the cushion aligning with the emboss line.
2. Under cowling cushion No. 1
: Stick the cushion aligning with the emboss line.
9D-13 Exterior Parts:

Meter Panel Cushion Construction

BENH17K19406054

“b”
“a”

[A]
[B] 2

“b”
5
3

“b”
5

IH17K1940085-01

[A]: Stick the cushion aligning with the end of curved surface. 4. Meter panel cushion No. 2
[B]: Stick the cushion edge aligning with the cover edge. 5. Emboss line
1. Meter panel “a”: 9 mm (0.35 in)
2. Meter panel cushion No. 3 “b”: 0 – 1 mm (0.00 – 0.04 in)
3. Meter panel cushion No. 1
 Exterior Parts: 9D-14

Body Cowling Cushion / Velcro Fastening / Tape Construction

BENH17K19406049

5
“b”

“a”

[B]

[A]

“a”

“a” 5 4
2
3

“b” 5
3

“b”

[B]

IH17K1940012-02

[A]: Stick the cushion aligning with the emboss line. 4. Body cowling tape
[B]: Stick the velcro fastening and tape aligning with the emboss line. 5. Emboss line
1. Body cowling “a”: 0 – 2 mm (0.00 – 0.08 in)
2. Body cowling cushion “b”: 0 – 1 mm (0.00 – 0.04 in)
3. Body cowling velcro fastening
9D-15 Exterior Parts:

Air Intake Pipe Cushion Construction

BENH17K19406050

[A]
“a”

3
4

“a”
[A]
[A]

4
1

“a”

“a”
1

[A]

IH17K1940013-01

[A]: Stick the cushion aligning with the emboss line. 3. Air intake pipe No. 2 cushion
1. Right (Left) air intake pipe 4. Emboss line
2. Air intake pipe cushion “a”: 0 – 1 mm (0.00 – 0.04 in)
 Exterior Parts: 9D-16

Intake Cover Cushion Construction

BENH17K19406051

7
[A]

“a”

7
2
2 “a”

“a”

7 7

“a”
“a”

5
3

“a”

IH17K1940014-01

[A]: Stick the cushion aligning with the emboss line. 5. Intake cover No. 1 cushion
1. Intake cover 6. Intake cover No. 2 cushion
2. Intake cover center cushion 7. Emboss line
3. Right (Left) intake cover “a”: 0 – 1 mm (0.00 – 0.04 in)
4. Intake cover cushion
9D-17 Exterior Parts:

Battery Holder Protector Construction

BENH17K19406052

1 2
2 2

[A]

[B] [C] “a”

[C] [D]
2

2
[C]

2 “b”

IH17K1940015-02

[A]: Stick the protector to the concavity of the battery holder. 1. Battery holder
[B]: Stick the protector aligning with the emboss line. 2. Battery protector
[C]: Stick the protector aligning with the end of curved surface. “a”: 2 – 7 mm (0.08 – 0.27 in)
[D]: Stick the protector aligning with the edge. “b”: 10 – 15 mm (0.40 – 0.59 in)

Fastener Removal and Installation Installation

BENH17K19406013
Type 1 1) Let the center piece stick out toward the head so that
the claws (1) closes.
Removal
2) Insert the fastener into the installation hole.
1) Depress the head of fastener center piece (1).
2) Pull out the fastener (2). NOTE
To prevent the claws (1) from damage, insert
the fastener all the way into the installation
hole.
1

ID26J1940192-01

ID26J1940160-01
 Exterior Parts: 9D-18

3) Push in the head of center piece until it becomes Frame Front Cover Removal and Installation
flush with the fastener outside face. BENH17K19406018

NOTE
For removal and installation of the frame
front cover, the same procedures are
applicable to both the right and left parts.

Removal
1) Remove the screw (1).
2) Remove the frame front cover assembly (2).

[B]
I649G1940007-02 [A]
2
Type 2
Removal
1) Pry up the head of fastener center piece (1).
2) Pull out the fastener (2). 1
3

IH17K1940060-01

1
[A] [B]
2 2

IH17K1940016-01

Installation 2
1) Insert the fastener into the installation hole.

NOTE IH17K1940061-01

[A]: Hooked point 3. Velcro fastening position

To prevent the claws (1) from damage, insert
[B]: Bushing
the fastener all the way into the installation
hole.
3) Remove the frame front No.2 cover (1) from the
frame front cover (2).

1
IH17K1940017-01

2) Push in the head of center piece. 2

IH17K1940062-01

Installation
Install the frame front cover in the reverse order of
removal.

IH17K1940018-01
9D-19 Exterior Parts:

Front Seat Removal and Installation Installation

BENH17K19406030 Slide the seat hooks into the seat hook retainers and
Removal push down firmly until the seat snaps into the locked
1) Remove the frame front covers. (Page 9D-18) position.
2) Remove the front seat (1).

IH17K1940020-01

IH17K1940021-01 Rear View Mirror Removal and Installation

BENH17K19406031

Installation NOTE
1) Slide the seat hooks into the seat hook retainers on For removal and installation of the rear view
frame. mirror, the same procedures are applicable to
both the right and left parts.
2) Tighten the bolt securely.
Removal
1) Remove the caps (1).

IH17K1940022-01

Rear Seat Removal and Installation

BENH17K19406014
Removal IH17K1940023-01

1) Unlock the rear seat with the ignition key (1). 2) Remove the rear view mirror (1).
2) Remove the rear seat (2).

2 1

IH17K1940024-01

IH17K1940019-02
 Exterior Parts: 9D-20

Installation Installation
Install the rear view mirror in the reverse order of Install the windscreen in the reverse order of removal.
removal. Pay attention to the following point: Pay attention to the following points:
• Tighten the rear view mirror bolts to the specified • Insert two nuts into the holes of cowling brace.
torque.
Tightening torque
Rear view mirror bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)

IH17K1940027-01
(a)
• Insert four nuts into the windscreen at the positions as
shown.

NOTE
IH17K1940025-01
When installing the windscreen to the body
cowling, use care so that the lower nuts will
Windscreen Removal and Installation
BENH17K19406032 not fall off.

Removal
1) Remove the rear view mirrors. (Page 9D-19)
2) Remove the windscreen (1).

IH17K1940028-01

Body Cowling Cover / Under Inner Cowling

IH17K1940026-01
Removal and Installation
BENH17K19406033

Removal
1) Remove the body cowling cover (1).

IH17K1940029-01
9D-21 Exterior Parts:

2) Remove the under inner cowlings (1). Side Cowling Removal and Installation
BENH17K19406034

NOTE
For removal and Installation of the side
1 1 cowlings, the same procedures are
applicable to both the right and left sides
except the fuel tank water drain hose clamp
[A] at the right side.
[A]
Removal
1) Remove the body cowling cover and under inner
cowlings. (Page 9D-20)
IH17K1940030-01
2) Disconnect the front turn signal light lead wire
coupler (1).
[A]

1
1

IH17K1940031-01

[A]: Hooked point IH17K1940033-01

3) Remove the fastener (1).

Installation
Install the body cowling cover and under inner cowling in
the reverse order of removal. Pay attention to the
following point:
1
• Insert the convex part of the under inner cowling (1) to
the hole of the radiator heat shield.

IH17K1940034-02

1 1

IH17K1940032-01
 Exterior Parts: 9D-22

4) Remove the screws (1) and side cowling assembly 7) Remove the under center cowling (1).
(2).

[B] [B]
1

[A]

[A] [A]
1 1
1
2

[C]
IH17K1940038-02

IH17K1940035-01

[A]
[A] [B] [C]
1

2
2
2
IH17K1940031-01

IH17K1940036-01 [A]: Hooked point

[A]: Bushing
[B]: Hooked point Installation
[C]: Hooked point Install the side cowling in the reverse order of removal.
Pay attention to the following point:
5) For the right side cowling assembly, release the fuel • Tighten the screws in order of “1” → “2”.
tank water drain hose clamp (1).

“2”

1
“1”

IH17K1940039-01
IH17K1940037-01

6) Remove the front side cowling, rear side cowling and Body Cowling Removal and Installation
under cowling. Refer to “Side Cowling Construction” BENH17K19406035
(Page 9D-4).
Removal
1) Remove the side cowling assemblies. (Page 9D-
21)
2) Remove the rear view mirrors. (Page 9D-19)
9D-23 Exterior Parts:

3) Remove the windscreen screws (1). 8) Move the body cowling assembly (1) forward.

1
1

IH17K1940040-01 IH17K1940044-01

4) Disconnect the wiring harness No. 2 couplers (1). 9) Disconnect the combination meter coupler (1) and
5) Release the clamp (2). steering damper solenoid valve coupler (2).
10) Remove the body cowling assembly.

1
1

2 2

IH17K1940041-02 2
6) Remove the meter panels (1). IH17K1940045-02

11) Remove the windscreen. (Page 9D-20)

12) Remove the headlight. (Page 9B-4)
13) Release the wiring harness No. 2 clamps (1).

IH17K1940042-01

7) Remove the bolts (1).

1

IH17K1940046-01

14) Remove the ambient air temperature sensor (1) from

the right air intake pipe.

1 1

IH17K1940043-01

IH17K1940047-01
 Exterior Parts: 9D-24

15) Remove the fasteners (1) and air intake pipes (2). 17) Remove the intake upper cover (1).

NOTE
The same procedures are applicable to both
the right and left covers.

1 1
1

IH17K1940048-01

IH17K1940051-01

18) Remove the body cowling (1) from the intake cover
(2).

2
IH17K1940049-01 1
16) Remove the fastener (1), screw (2) and intake cover
(3).

NOTE 2

The same procedures are applicable to both

the right and left covers.
IH17K1940052-01

Installation
Install the body cowling in the reverse order of removal.
2
Pay attention to the following points:
3 • Fix the boot (1) of the combination meter coupler
firmly.

IH17K1940050-01

IH17K1940053-01

• Route the wiring harness No. 2 correctly. Refer to

“Wiring Harness Routing Diagram” in Section 9A
(Page 9A-13).
• After installation of the body cowling assembly, check
the headlight aiming. (Page 9B-7)
9D-25 Exterior Parts:

Cowling Brace Removal and Installation 4) Remove the fuel tank front cover (1).
BENH17K19406036

Removal
1) Remove the body cowling assembly. (Page 9D-22)
1
2) Remove the combination meter. (Page 9C-7)
3) Remove the cowling brace (1).

IH17K1940057-01

1
2 2

3 3
IH17K1940054-01

Installation
Install the cowling brace in the reverse order of removal.
2 2
Fuel Tank Front Cover Removal and Installation
BENH17K19406017
IH17K1940058-01

Removal 2. Velcro fastening position

3. Hooked point
1) Lift and support the fuel tank. (Page 1G-9)
2) Remove the fasteners (1). Installation
Install the fuel tank front cover in the reverse order of
removal. Pay attention to the following point:
• Tighten the fuel tank front cover screw to the specified
torque.
Tightening torque
Fuel tank front cover screw (a): 5.5 N·m (0.56 kgf-
1
1 m, 4.05 lbf-ft)

IH17K1940055-02

3) Remove the screw (1).

(a)

IH17K1940059-01

IH17K1940056-01
 Exterior Parts: 9D-26

Frame Cover / Frame Center Rear Cover

Removal and Installation [A] [B]
BENH17K19406019

Removal
1) Remove the frame front covers. (Page 9D-18)
1
2) Remove the front and rear seats.
• Front: (Page 9D-19)
3
• Rear: (Page 9D-19)
1
3) Remove the screws (1) and fasteners (2).
IH17K1940066-01
1
1 [A]: Bushing
[B]: Hooked point
1 2
6) Remove the frame covers (1) from the frame center
rear cover (2).

1
IH17K1940063-01

1 1

2
IH17K1940067-01

2 Installation
Install the frame cover and frame center rear cover in the
reverse order of removal. Pay attention to the following
point:
IH17K1940064-01
• Tighten the frame cover rear screws to the specified
4) Widen the frame covers (1) outward, move the frame torque. Refer to “Frame Cover Construction” (Page
covers with the frame center rear cover (2) backward 9D-8).
and then release the hooks of the rear fender front
(3).
Frame Center Front Cover Removal and
5) Remove the frame covers with the frame center rear Installation
cover. BENH17K19406037

[B] Removal
2
1 1) Remove the frame front cover. (Page 9D-18)
2) Remove the front and rear seats.
• Front: (Page 9D-19)
[A] [B] • Rear: (Page 9D-19)

1
[A]
IH17K1940065-01
9D-27 Exterior Parts:

3) Remove the screws (1) and fasteners (2).

5 1
1
1

1 2 4

2
3

1 IH17K1940070-01
IH17K1940063-01
Installation
Install the frame center front cover in the reverse order of
removal. Pay attention to the following points:
• Align the rib of the seat lock assembly with each
groove of the frame center front cover, seat lock cable
2 guide and seat lock assembly plate.

IH17K1940064-01

4) Widen the frame covers (1) outward and remove the

frame center rear cover (2).

1
IH17K1940071-01

• Tighten the frame cover rear screws to the specified

torque. Refer to “Frame Cover Construction” (Page
[A]
9D-8).
2

Rear Fender Outer Removal and Installation

BENH17K19406020
1
[A] Removal
IH17K1940068-01
1) Remove the frame covers with frame center rear
cover. (Page 9D-26)
[A] 2) Disconnect the license plate light lead wire coupler
(1) and rear turn signal light lead wire couplers (2).
3) Release the clamp (3).

1
2

IH17K1940069-01
3
[A]: Bushing

5) Disconnect the seat lock cable (1). 1

6) Remove the seat lock assembly plate (2), seat lock IH17K1940072-02
cable guide (3) and seat lock assembly (4) from the
frame center front cover (5).
 Exterior Parts: 9D-28

4) Remove the screws (1). 3) Disconnect the rear combination light lead wire
coupler (1).

1 1

IH17K1940073-01

5) Remove the rear fender outer (1). IH17K1940077-02

4) Remove the screws (1).

1
1

IH17K1940075-01

IH17K1940078-02
Installation 5) Remove the rear fender inner (1) with rear fender
Install the rear fender outer in the reverse order of front (2).
removal. Pay attention to the following points:
• Tighten the screws (1) first and tighten the other
screws (2).

2
2
1

IH17K1940079-01

6) Remove the rear fender inner (1) from the rear

fender front (2).
IH17K1940076-01

• Route the turn signal light lead wires and license plate
light lead wire correctly. Refer to “Rear Lighting 2
System Construction” in Section 9B (Page 9B-8).

1
Rear Fender Front Removal and Installation
BENH17K19406021

Removal
1) Remove the rear fender outer. (Page 9D-27)
2) Remove the ECM. (Page 1C-10)
IH17K1940080-01
9D-29 Exterior Parts:

7) Remove the rear combination light (1) from the rear • Tighten the rear combination light screws to the
fender front (2). specified torque. Refer to “LED Rear Combination
Light Removal and Installation” in Section 9B (Page
9B-9).
2
• Apply thread lock to the rear fender bolts and tighten
them in order of “1” → “2” → “3” → “4”.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
1

“A”, “1” “A”, “2”

IH17K1940081-01
“A”, “4” “A”, “3”
Installation
Install the rear fender front in the reverse order of
removal. Pay attention to the following points:

IH17K1940082-02

Specifications
Tightening Torque Specifications
BENH17K19407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear view mirror bolt 10 1.0 7.5 (Page 9D-20)
Fuel tank front cover screw 5.5 0.56 4.05 (Page 9D-25)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Seat Lock Cable Routing Diagram” (Page 9D-1)
“Front Fender Construction” (Page 9D-7)
“Frame Cover Construction” (Page 9D-8)
“Fuel Tank Front Cover Construction” (Page 9D-9)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K19408001
Material SUZUKI recommended product or Specification Note
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 9D-29)

NOTE
Required service material(s) is also described in:
“Rear Fender Construction” (Page 9D-6)
 Body Structure: 9E-1

Body Structure
Body and Accessories

Repair Instructions
Body Frame Construction
BENH17K19506001

(a)

IH17K1950001-01

1. Frame 2. Seat rail : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)

9E-2 Body Structure:

Front Footrest Bracket Construction

BENH17K19506002

16
17
[A]
10 1 (b)

12 3 FWD
9

5 (d)

11 13

[B]

16

2
17
“a”

12 12 4
“b”
9

“c” “d”
4 2
14 (e)

5 (d) 6 (a) 10

15
11
7

13

8 18 (c)

IH17K1950002-05
 Body Structure: 9E-3

[A]: Align the cutaway with the projection. 10. Front footrest pin “c”: 41 mm (1.6 in)
[B]: To prevent the spring from falling off, the hook 11. Front footrest spring “d”: 24 mm (0.9 in)
can be bent.
: The spring end must be inside as shown.
1. Rear brake master cylinder bolt 12. Front footrest bar RH : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
2. Front footrest bracket RH 13. E-ring : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
3. Front footrest guard RH 14. Front footrest holder bolt : 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
4. Rear brake pedal 15. Front footrest bar LH : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
5. Front footrest bracket bolt 16. Rear brake light switch spring : 39 Nm (4.0 kgf-m, 29.0 lbf-ft)
6. Front footrest guard screw 17. Rear brake pedal spring : Apply water resistant grease to the sliding surface.
7. Front footrest guard LH 18. Bank sensor bolt : Apply thread lock to the thread part.
8. Front footrest bracket LH “a”: 86 mm (3.4 in) : Do not reuse.
9. Front footrest holder “b”: 65 – 75 mm (2.6 – 2.9 in)

Side-stand Construction
BENH17K19506003

3 (b)
8

4 (b) 2

7 (a)

1 [A]

6
5
1
FWD

IH17K1950003-02

[A]: Take care of spring direction. 5. Side-stand No. 1 spring : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
1. Side-stand 6. Side-stand No. 2 spring : Apply water resistant grease to the sliding surface.
2. Side-stand bracket 7. Side-stand nut : Apply thread lock to the thread part.
3. Side-stand bracket bolt 8. Side-stand washer : Do not reuse.
4. Side-stand bolt : 40 Nm (4.1 kgf-m, 29.5 lbf-ft)

Side-stand Removal and Installation

BENH17K19506004
Refer to “Side-stand Construction” (Page 9E-3).

Removal
1) Support the motorcycle with a jack or wooden block.

! CAUTION

• Do not support the motorcycle with the exhaust pipes.

• Make sure that the motorcycle is supported securely.

2) Remove the side-stand.

Installation
Install the side-stand.
9E-4 Body Structure:

Pillion Footrest Construction

BENH17K19506005

4
2 (a)

5
9

6
8
7
IH17K1950004-02

1. Seat rail 6. Pillion footrest spring : Apply water resistant grease to the sliding surface.
2. Pillion footrest bolt 7. Pillion footrest ball : Apply thread lock to the thread part.
3. Pillion footrest bracket 8. Pillion footrest plate : Do not reuse.
4. Pillion footrest pin 9. E-ring
5. Pillion footrest bar : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

Pillion Footrest Removal and Installation

BENH17K19506006
Refer to “Pillion Footrest Construction” (Page 9E-4).
 Body Structure: 9E-5

Specifications
Tightening Torque Specifications
BENH17K19507001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Body Frame Construction” (Page 9E-1)
“Front Footrest Bracket Construction” (Page 9E-2)
“Side-stand Construction” (Page 9E-3)
“Pillion Footrest Construction” (Page 9E-4)
“Fasteners Information” in Section 0C (Page 0C-12)

Special Tools and Equipment

Recommended Service Material
BENH17K19508001
NOTE
Required service material(s) is also described in:
“Front Footrest Bracket Construction” (Page 9E-2)
“Side-stand Construction” (Page 9E-3)
“Pillion Footrest Construction” (Page 9E-4)
 Prepared by

January, 2017
Part No. 99500-39420-01E
Printed in Japan

704