Manual de Servicio Suzuki GZ 150 (Ingles)

GZ150
99500H33381H000
GZ150
FOREWORD GROUP INDEX
This manual contains an introductory description on the
SUZUKI Gw250 and procedures for its inspection
/service and overhaul of its main components. Other
information considered as generally known is not
GENERAL INFORMATION 1
included.
Read the GENERAL INFORMATION section to familia-
rize yourself with the motorcycle and its maintenance.
Use this section as well as other sections to use as a
PERIODIC MAINTENANCE 2
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. ENGINE 3
8
* This manual has been prepared on the basis of the
latest specifications at the time of publication. If DCP SYSTEM AND FUEL
modifications have been made since then, differ-
ences may exist between the content of this manual SYSTEM 4
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 CHASSIS 5
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
ELECTRICAL SYSTEM 6
authorized SUZUKI motorcycle dealer to help you.
WARNING SERVICING INFORMATION 7

Inexperienced mechanics or mechanics without
proper tools, not to 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.
JIANGMEN DACHANGJIANG GROUP CO., LTD.

NOVEMBER, 2011
(The First Edition)
HOW TO USE THIS MANU A L
T O LOCATE WHAT Y O U ARE LOOKING F O R :
1 . T h e t e xt o f t h is manual is d i vide d into sections.
2 . T h e section titl e s are l isted in the G R OUP IN D EX.
3 . Ho l d i ng the manual as shown a t the ri g ht wi l l a l l o w
y ou to find the first page of t he s e ction e as i ly.
4 . The contents are listed on t h e first page of each
sect i o n to he l p you find the item and page you n e ed.
C O MPO N ENT PARTS A ND WO RK T O B E DONE

U n der t h e na m e of eac h syst e m o r unit , is its exp lo d e d vi ew. work in s truction s a n d oth e r s ervi ce
in f o r ma t io n su ch as t h e tig h t e n in g torque, lu b ricating p o ints a n d l o cking a g e n t po in t s, are p rov id e d .
Exam p le : Fr o nt w h eel
18~28N.m
50~80N.m
SYMBOL
The following symbols are instructions and necessary information for maintenance.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Data beside it indicates specified A P P L Y O R US E F RONT DA M P ER OIL
torque.
APPLY oil. Use engine oil unless

OIL
APPLY THREAD LOCK “1322”

otherwise specified.
APPLY MOLY PASTE. Mix engine oil APPLY THREAD LOCK SUPER “1342”
and MOLY PASTE at a ratio of 1:1.
APPLY SUPER GREASE “A” APPLY THREAD LOCK SUPER “1303”
APPLY SUPER GREASE “C” APPLY THREAD LOCK SUPER “1360”
APPLY SUPER SILICONE GREASE APPLY OR USE BREAK FLUID
APPLY MOLY PASTE MEASURE IN VOLTAGE RANGE
APPLY HEAT TRANSFER OIL MEASURE IN RESISTANCE RANGE
APPLY SEALANT THREE

MEASURE IN CURRENT RANGE.
BOND “1215”
APPLY SEALANT THREE MEASURE THE TESTING RANGE OF

BOND “1216” THE DIODE
APPLY SEALANT THREE

MEASURE THE BREAK OVER RANGE
BOND “1207B”
No.4 Apply BOND No.4 USE SPECIAL TOOL
It refers to the date of

APPLY OR USE COOLANT
maintenance.
Note:
All symbols are shown in the table above, including those not used in this Service Manual.
GENERAL INFORMATION
1
1
CONTENTS
WARNING/CAUTION/NOTICE/NOTE 1-1
GENERAL PRECAUTIONS 1-1
SERIAL NUMBER LOCATIONS 1-2
FUEL AND OIL RECOMMENDATIONS 1-3
BREAK-IN PROCEDURE 1-4
SPECIFICATIONS 1-5
GENERAL INFORMATION
WARNING/CAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. Toemphasize special information, the symbol
and the words WARNING, CAUTION, NOTICE AND NOTE have special meanings.Pay particular
attention to 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 moderade injury.
NOTICE
Indicates a potential hazard that could result in vehicle or equipment damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the
WARNINGS and CAUTIONS stated, you must use good judgment and basic mechanical safety principles.
If you are unsure about how to perform a particular service operation, ask a more experienced mechanic
for advice.
GENERAL PRECAUTIONS
WARNING
● Proper service and repair procedures are important for the safety of the service mechanic and
thesafety and reliability of the vehicle.
● When 2 or more persons work together, pay attention to safety of each other.
● When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor.
● When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all off the material manufacturer's instructions.
● Never use gasoline as a cleaning solvent.
● To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a
while after engine operation.
● After servicing fuel, oil, exhaust or brake system, check all lines and fittings related to the
system for leaks.
1-1
GENERAL INFORMATION
NOTICE
● If parts replacement is necessary, replace the parts with SUZUKI GENUINE PARTS or their equivalent.
● When removing parts that are to be reused, keep them arranged in an orderly manner so that they may
be reinstalled in the proper order and orientation .
● Be sure to use special tools when instructed.
● Make sure that all parts used in reassembly are clean, and also lubricated when specified.
● When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
● When performing service to electrical parts, if the service procedures not require used of battery power,
disconnect the positive terminal.
● When removing the battery, disconnect the negative cable first and then the positive cable.
● When reconnecting the battery, connect the positive cable first and then the negative cable, and
replace the terminal cover on the positive terminal.
● Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
● Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and
certain other parts as specified, be sure to replace them with new ones. Also, before installing these
new parts, be sure to remove any left over material from the mating surfaces.
● Never reuse a circlip. When installing a new circlip, take care not to expend the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
● Do not use self-locking nuts a few times over.
● Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil if a
thread is smeared with them.
● After reassembly, check parts for tightness and operation.
NOTE:
● To protect environment, do not unlawfully dispose of used Engine oil and other fluids, batteries and tires.
● To protect Earth's natural resources, properly dispose of used vehicles and parts.
SERIAL NUMBER LOCATIONS

The frame serial number ① is stamped on on the steering stem. The engine serial number ② is located on
the right side of the crankcase.
These numbers are required especially for registering the machine and ordering spare parts.
1-2
GENERAL INFORMATION
FUEL AND OIL RECOMMENDATION

FUEL
Use nonleaded gasoline with an octane rating of 90 or higher
(Research method). Nonleaded gasoline can extend spark plug life
and muffler life.
ENGINE OIL
Oil quality is a major contributor to your engine’s performance and
life. Always select good quality engine oil. Use oil with an API
classification of SF/SG or SH/SJ, or with JASO classification of MA.
SAE API JASO

10W-40 SF/SG -
10W-40 SH/SJ MA
API :American Petroleum Institute
JASO: Japanese Automobile Standards Organization
SAE ENGINE OIL VISCOSITY
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-
40 engine oil is not available, select an alternative according to the
chart. ENGINE OIL
NOTE:
Dispose used engine oil properly to avoid environment pollution. We TEMP.
suggest you to collect the used oil in a sealed container and take it to
a nearby recycling facility.
Do not place it into a trash bin and do not pour it onto the ground.
JASO T903
The JASO T903 standard is an index to select engine oil for 4-
stroke motorcycle and ATV engines. Motorcycle and ATV engines
lubricate clutch and transmission gears with engine oil. JASO T903
specifies performance requirements for motorcycle and ATV
clutches and transmissions.
There are two classes, MA and MB.
The oil container shows the classification as follows.
① ----------
② MA
① Code number of oil sales company
② Oil classification
Engine conserving
Suzuki does not recommend the use of "ENERGY CONSERV-
ING" oil. Some kinds of engine oil which have an API classifi-cation
of SH or higher have an "ENERGY CONSERVING" indication in
the API classification doughnut mark. Thus oil can affect engine life
and clutch performance.
Not recommend Recommend
1-3
GENERAL INFORMATION
BREAK-IN PROCEDURES
Previous sections explains how important proper break-in is to achieving maximum life
and perfor-mance from your new Suzuki motorcycle.
The following guidelines explain proper break-in procedures.
RECOMMENDED THROTTLE OPENING LIMIT
Throttle opening must not reach maximum during new motorcycle brake-in period, it is
suggested to be less than 3/4 of the maximum while snap-acceleration must be avoided in
driving.
VARY THE ENGINE SPEED
The engine speed should be varied and not held at a constant speed. This allows the parts to
be ''loaded'' with pressure, and then unloaded, allowing the parts to cool. This aids the mating
process of the parts, It is essential that some stress be placed on the engine components
during break-in to ensure this mating process. Do not, though, apply excessive load on the
engine.
BREAK-IN THE NEW TIRES
New tires need proper break-in to assure maximum performance, just as the engine does.
Wear in the tread surface by gradually increasing your cornering lean angles over the first 160
km before attempting maximum performance. Avoid hard acceleration, hard cornering, and
hard braking for the first 160 km.
WARNING
● Fail to perform break-in of the tires could cause tires slip and loss of control .
Use extra care when riding on new tires hard acceleration, hard cornering and
hard braking for the first 160 km .
AVOID CONSTANT LOW SPEED

Operating the engine at constant low speed (light load) can cause parts to glaze and not seat
in. Allow thw engine to accelerate freely through the gears without exceeding the
recommended maximum limit. Do not, however,use full throttle for the initial 500 km.
ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING
Allow sufficient idling time after warm or cold engine start up before applying load or revving
the engine. This allows time for the lubricating oil to reach all critical engine components.
OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE
The initial service (1000 km maintenance) is the most important service your motorcycle will
receive. During break-in operation, all of the engine components will have mated together and
seated. Maintenance required as part of the initial service includes correction of all
adjustments, tightening of all fasteners and replacement of dirty oil. Timely performance of this
service will help make sure you get the best service life and performance from the engine.
1-4
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 2250mm

Overall width 900mm
Overall height 1160mm
Wheelbase 1460mm
Ground clearance 150mm
Curb weight 150kg
ENGINE
Type four-stroke, air-cooled, Single-cylinder vertical type
Number of cylinders 1
Bore 57.0mm
Stroke 58.6mm
Piston displacement 149ml
Compression ratio 8.9: 1
Fuel system Fuel injection
Air cleaner paper filter
Starter system Electric
Lubrication system Pressure splash lubrication
TRANSMISSION
Clutch Wet multi-plate
Transmission 5-speed gear transmission
Primary reduction 3.500
Final reduction 2.867
Gear ratios, low 3.000
2nd 1.875
3rd 1.368
4th 1.143
5th 0.957
Drive chain KMC 428H
1-5
GENERAL INFORMATION
ELECTRICAL
Ignition type Electronic ignition

Ignition timing 13°B.T.D.C. Below 1 500 r/min
Spark plug CR6E
Battery 12V,6Ah
Fuse 10A,20A
Headlight 12V,35W/35W
Tail/Brake light 12V,5W/21W
Turn signal light 12V,10W
Position light 12V,5W
CHASSIS
Front suspension Telescopic, coil spring, oil dampened
Rear suspension Swing arm, oil dampened
spring 5-way adjustable
Steering angle 40°
Caster 32.5°
Trail 132 mm
Front brake Disc
Rear brake Drum
Front tire size 90/90-18 51P
Rear tire size 120/80-16 60P
Stroke of front absorber 120 mm
CAPACITIES
Fuel tank including reserve 11.5 L
reserve 2L
Engine oil 1 000 ml
Front shock absorber oil 385±3 ml
1-6
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE 2-1

MAINTENANCE PROCEDURES 2-3
BATTERY/FUSE 2-3
AIR CLEANER ELEMENT 2-4
EXHAUST PIPE AND MUFFLER BOLTS
BOLTS/NUTS OF THE CYLINDER HEAD & CYLINDER
2-4
2-5
2
VALVE CLEARANCE 2-5
SPARK PLUG 2-6
ENGINE OIL 2-6
ENGINE OIL FILTER 2-7
OIL SUMP FILTER 2-7
CLUTCH CABLE 2-7
THROTTLE BODY 2-8
EVAPORATIVE EMISSION CONTROL SYSTEM 2-8
FUEL HOSE 2-8
FUEL FILTER 2-9
DRIVE CHAIN 2-9
BRAKES 2-10
TIRES 2-13
STEERING 2-13
FRONT/REAR SUSPENSION 2-13
ILLUMINATION AND SIGNAL 2-14
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-14
COMPRESSION PRESSURE INSPECTION 2-16
The chart below lists recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of
kilometer, miles and time for your convenience.
Clean after the first 1,000 km and every 2,000-3,000 km afterwards

NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

INTERVAL Km 1 000 4 000 8 000
PAGE
ITEM month 3 6 12
Battery/fuse Inspect Inspect 2-3
Air cleaner element Clean Clean Replace 2-4
Exhaust pipe and Muffler bolts Inspect Inspect 2-4
Nuts of cylinder head and
Inspect Inspect 2-5
cylinder
Valve clearance (cold engine) Inspect Inspect 2-5
Inspect Inspect
Spark plug 2-6
Replace every 12 000 km
Initial replacement after the first 500 km, the second replace-
Engine oil ment at 1,000km total mileage, while further replacement for 2-6
every 4,000 km.
Oil filter (filter element) Replace Replace 2-7
Oil sump filter Clean every 12000 km 2-7
Clutch cable Inspect Inspect 2-8
Throttle body Clean 2-8
Inspect Inspect
Fuel hose 2-8
Replace every four years
Fuel filter Inspect Inspect Replace 2-8
Drive chain Clean & lubricate for every 1,000 km 2-9
Brake Inspect Inspect 2-10
Tires Inspect Inspect 2-13
Steering Inspect Inspect 2-13
Front and rear absorber Inspect 2-13
Illumination and signal Inspect Inspect 2-14
Chassis and engine
Inspect Inspect 2-14
mounting bolts and nuts
Compression pressure Inspect 2-16
2-1
LUBRICATION CHART
The following is a basic lubrication requirement for a motorcycle operated in an economical manner and
based on the mileage displayed by the odometer.
INTERVAL km Initial and every 6 000 km Every 12 000 km

ITEM month 6 12
Throttle cable Engine oil _
Throttle grip _ Grease

Clutch cable Engine oil _
Brake cable Engine oil _
Transmission Chain Engine oil every 1000 km

Brake pedal axle Grease or oil _
Brake camshaft _ Grease

Steering stem bearing
Grease every 2 years or 20000 km
Swing arm bearings
NOTE:
“-"stands for not required
WARNING
Do not apply too much lubrication grease on the brake cam to prevent the brake from slipping.
When driving on wet roads or under rainy conditions, lubricate the parts with engine oil or grease to avoid
rust. Be sure to remove oily contamination or rust.
2-2
MAINTENANCE PROCEDURES
This section introduces the maintenance and adjustment
methods of each part during regular maintenance.
BATTERY/FUSE
Inspect Initial 1 000 km and Every 4 000 km
BATTERY
The battery is located below the saddle. This type of battery
is totally sealed, thus eliminating the need for replenishing
battery fluids. However, re-charging is required once the
voltage falls below 12.5V.
Follow the steps below on uninstalling the battery:

● Support the motorcycle by side stand.
● Dismount the right cover.
● Dismount the “ _ ” negative wire.
Dismount the “ + ” positive wire.
● Take out the battery.
Install the battery in the reverse order as described above.
NOTICE
While installing the battery, fasten the wire to the
positive terminal first, then the negative.
FUSE
The fuse is located on the battery fasten belt. If the engine
suddenly stops or the circuit breaks down, check the fuse
first.
WARNING
Do not to use fuse beyond the stipulated specification
range. Otherwise it may seriously damage the electric
system, or even cause fire, motorcycle burning, or
engine power failure.
NOTICE
Be sure to use fuse with an operating current of 15A.
Do not use substitutes such as aluminum or iron wires.
A fuse that melts frequently suggests malfunctioning
of the electrical system, which should be checked.
2-3
AIR CLEANER ELEMENT

Clean after the first 1 000 km and every 4 000 km
afterwards
If the air cleaner is clogged with dust, intake resistance will be

increased with a resultant decrease in power output and an
increase in fuel consumption.
Check and clean the element in the following manner:
● Remove the left frame cover.

● Remove the screws and take out the air cleaner element
assembly.
● Use compressed air to remove the dust on the air filter
assembly.
● Get rid of the dust in the air filter box and cover.
● Reinstall the cleaned or new air cleaner element in the
reverse order of removal.
NOTICE
Always use pressured air to blow from the inside of air
cleaner element to the outside. If pressured air is blow in
the opposite direction, dirt will be forced into the pores
of the air cleaner element thus restricting air flow
through the air cleaner element.
NOTICE
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element or
to use a ruptured element. Make sure that the air cleaner
is in good condition at all times. Life of the engine
depends largely on this component!
EXHAUST PIPE AND MUFFLER BOLTS

● Tighten the exhaust pipe clamp bolts and muffler mounting

bolt to the specified torque with a torque wrench.
Exhaust pipe c la m p b o l t s : 1 8~2 8 N·m
Muffler mounting bolt : 40~60N·m
2-4
NUTS OF THE CYLINDER HEAD &

CYLINDER
NUTS OF THE CYLINDER HEAD

● Take off the saddle and the fuel tank (refer to page 3-2).
● Tighten the four M10 nuts ① with the specified torque
through a torque wrench under cool engine conditions.
Nuts o n th e cyl in d e r hea d : 2 8 ~32 N·m
NUTS OF THE CYLINDER

● Tighten the nuts ② and ③ on side of the cylinder head with
the specified torque.
Nu ts o n t he c y lin d e r : 8~1 2 N·m
VALVE CLEARANCE
Too big valve clearance will result in valve noise; and too
small valve clearance will lead to valve damage and power
output decrease. The valve clearance should be inspected at
the mileages mentioned above, and adjusted by following
order.
● Remove the saddle and fuel tank.
● Remove the cap of the cylinder head cover.
● Remove spark plug, valve timing inspection plug and
inlet/exhaust valve plug.
● Unscrew the plug of the generator cover, and rotate the
generator rotor anticlockwise with a box wrench till the “T”
scribed line on the generator rotor aligns with the center
(the position pointed by the arrow) of the valve timing
inspection plug hole on the crankcase, to set the piston at
TDC of compression stroke.
● Insert the thickness gauge of the standard specification
into the space between the valve end and the adjusting
screw of the rocker arm.
09900-20803: Thickness gauge
Valve clearance (when cold):

Standard: IN:0.04-0.07mm
EX:0.10-0.13mm
2-5
● If the valve clearances are not between the dimensions

above, it should be adjusted with special tools.
11F14-016 : Adjustment wrench
● Remount the screw plugs on the spark plug and on the
generator cover.
NOTE:
The valve clearance should be inspected and adjusted when
the engine is cold. The inspection and adjustment of both the
inlet valve and the exhaust valve should be done when they
are at the TDC of compression stroke.
SPARK PLUG
Inspect Initial 1 000 km and Every 4 000 km..
Replace it every 12 000 km.
Measure the spark plug gap with a thickness gauge. The

standard spark plug gap is 0.7-0.8mm. If the measured spark plug
gap is out of standard range, adjust or replace it with a new one.
Whenever removing the carbon deposit, be sure to observe the
operational color of the spark plug’s porcelain tip. This color tells
you whether or not the standard spark plug is suitable for your
type usage. A normal operating spark plug should be very light
brown in color. If the spark plug is very white or glazed app-
earance, it has been operating much too hot. This spark plug
should be replaced with the colder plug.
KIND TYPE
HOT TYPE NGK CR5HSA

0.7-0.8mm
STANDARD NGK CR6HSA
COLD TYPE NGK CR7HSA
ENGINE OIL
Engine oil replacement should be made when the engine is 1
warm as follows:
● Support the motorcycle by side stand.
● Drain the oil by removing the drain plug ① and filler cap ② .
● Fit the drain plug ① securely and add fresh oil through the
filler. The engine will hold about 1 000 ml of oil.
* Use 10W/40 viscosity of oil under API classification of SF
or SG.
● Start the engine and run it for 3 minutes.
● Stop the engine and wait 3 minutes.
● Hold the motorcycle vertically and check the engine oil
level through the engine oil level check window. If the
level is below the "L" mark, add oil until the level reaches
the "F" mark.
2-6
ENGINE OIL FILTER

The oil filter elements should be replaced according to the

order below:
● Unscrew the oil brain bolt to brain out the engine oil.
● Unscrew the two bolts of the oil filter cover.
● Unscrew the oil filter cover and take out the filter.
● Replace a new filter.
● Make sure the O-ring ① has been installed well before
reassembling the new filter.
● Make sure the spring ② and the O-ring ③ have been
installed correctly before reassembling the oil filter.
④ ③ ② ①
● Install the oil filter cover and fasten the bolts.
● Fill proper engine oil and inspect the dip stick.
NOTE: ⑤
If the engine oil and the oil filter element are replaced at the
same time, 1 100 ml of engine oil should be fed. If an overhaul
of the engine, 1 350 ml of engine oil should be fed.
NOTICE
The oil filter element should be installed in strict line
with the requirements above; otherwise the engine
will be seriously damaged.
OIL SUMP FILTER

Clean Every 12 000 km
Clean the sump filter screen to remove any foreign matter that
may be collected there. Inspect the screen to insure that it is
free of any sign of damage.
2-7
CLUTCH CABLE 4mm
Inspect Initial 1 000 km and Every 4 000 km 1

2
Clutch play should be 4mm as measured at the clutch level

holder before the clutch begins to disengage. If the play in the
clutch is incorrect, adjust it in the following way:
● Loosen the lock nut ① and turn the clutch lever adjuster ②
as far as it will go.
● Loosen clutch cable adjuster lock nut ③.

● Turn the clutch cable adjuster ④ in or out to acquire the 3 4
specified play.
● Tighten lock nut while holding the adjuster in position.
The clutch cable should be lubricated with a light weight oil

whenever it is adjusted.
THROTTLE BODY
Clean Every 8 000 km
Clean the throttle body. (Refer to page 4-24)
FUEL HOSE
Inspect the first 1 000km and every 4 000km afterward
and replace every four years.
Inspect whether the joint of the fuel hose is damaged or fuel

leakage. If it is, replace the fuel hose.
FUEL FILTER
The fuel filter is installed under the fuel cock. The fuel filter
element should be replaced or cleaned at regular intervals.
During its replacement or cleaning, pay attention to its
direction of installation.
2-8
DRIVE CHAIN
Clean & lubricate for every 1,000 km
Check (eyeballing) whether the drive chain has the following

defects (support the motorcycle with the main stand to make
the rear wheel leave the ground. Pull out the access hole plug
at the neutral position, and rotate the rear wheel slowly by
hand to check).
1. The chain pins are loose;
2. The roller is damaged;
3. The chain links are rusty;
4. The chain links are twisted or block;
5. The wear is excessively serious.
If any defect above, please replace the drive chain.
● Clean the driven chain with kerosene. If the drive chain is

rusty too fast, the cleaning interval should be shortened.
● After being cleaned and dried, the drive chain should be
applied with chain oil or SAE #90 gear oil for lubrication.
ADJUSTMENT
● Loosen the rear wheel shaft nut ① .
● Loosen the regulator of drive chain ② to adjust the drive
chain carefully.
● Loosen the regulator to make 10-20mm chain sag between
the engine and the rear chain wheel.
● The mark ③ on both sides of the regulator should be on the
same position for centering of the front wheel and the rear
wheel.
● After adjustment of the drive chain, tighten the rear wheel
shaft nut. 10~20mm
● After adjustment, inspect the rear brake gap (see page 2-
12).
WEAR OF DRIVE CHAIN

There are 21 pins on the drive chain. Measure their lengths. If
their length is over 259.0mm, the drive chain should be
replaced.
Drive chain 20pitch length:

Service limit: 259.0mm
09900-20101: Slide caliper
2-9
BRAKERS
Inspect initial 1 000 km and every 4 000 km
Replace brake hose every 4 years.
Change brake fluid every 2 years.
FRONT BRAKE
Brake fluid level
Support the motorcycle body on the center stand, and
place the handlebars straight.
Check the brake fluid level by observing the lower limit line
on the brake fluid reservoir.
When the level is below the lower limit line, replenish with
brake fluid that meets the following specification.
Brake fluid specification: only use DOT3 or DOT4
NOTICE
The brake system of this motorcycle is filled with a glycol-
based brake fluid. Do not use or mix different types of
fluid such as silicone-based and petroleum-based fluid for
refilling the system, otherwise serious damage will be
caused. Do not use any brake fluid taken from old or used
or unsealed containers. Never re-use the brake fluid left
over from the last servicing and stored for long periods.
WARNI NG
Brake fluid, if it leaks, will interfere with safe running and
immediately discolor painted surfaces.
Check the brake hose for cracks and hose joint for leakage
before riding.
Brake disc
Inspect the thickness ① of the brake disc by using caliper. If
the thickness is less than 4.5mm, replace the disc
immediately.
TOOL 09900-20101 : Vernier caliper (1/50 mm,150 mm)
Service limit 4.5 mm

4.5mm
Brake pads
Inspect the brake pads by noting whether or not the friction pads
are worn down to the grooved limit line② . If a pad is worn to the
grooved wear line, it must be replaced. (Refer to page 5-15)
2-10
Air bleeding the brake fluid circuit

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it 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:
Fill up the master cylinder reservoir to the "HIGH"level line.
Replace the reservoir cap to prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and insert the
free end of the pipe into a receptacle.
Bleeder valv e tightening torque : 7~9N·m
Squeeze and release the brake lever several times in rapid

succession, and squeeze the lever fully without releasing
it. Loosen the bleeder valve by turning it a quarter of a turn
so that the brake fluid runs into the receptacle; this will
remove the tension of the brake lever causing it to touch
the handlebar grip. Then, close the valve, pump and
squeeze the lever, and open the valve. Repeat this process
until the fluid flowing into the receptacle no longer contains
air bubbles.
NOTE:
Replenish the brake fluid reservoir as necessary while bleeding
the brake system.
Make sure that there is always some fluid visible in the reservoir.
Close the bleeder valve, and disconnect the pipe.

Fill the reservoir to the "HIGH" level line.
NOTICE
Handle the brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials, etc.
REAR BRAKE
● Adjust the limit screw of the brake pedal to put the brake
pedal at a position 62.5mm top the brake pedal. Finally
fasten the nut.
Height of the rear brake pedal H : 62.5mm
2-11
● After adjusting the height of the rear brake pedal, adjust its
stroke to realize a free stroke ① of 20-30mm.
Free travel : 20-30mm
● Adjust the free stroke of the rear brake pedal by turning the
adjusting nut②. After adjustment, inspect the running state
of the rear brake switch. If necessary, the rear brake switch
should be adjusted.
BRAKE WEAR-OFF
As shown in the right picture, the wear limitation of the brake
shoe for a GZ150 motorcycle is carved on the brake drum.
Under normal wear conditions, the extension line ③ of the
brake cam shaft should be within the range of the angle
carved on the brake drum. Inspect the wear situation of the
brake shoe by following the order.
● Inspect whether the brake system has been properly

adjusted.
● After the adjustment, inspect whether the extension line ③
is within the range of the angle carved on the brake drum
when the braking-system is working.
● If the extension line ③ is beyond the range of the angle
carved on the brake drum, the brake shoe should also be
replaced.
BRAKE LIGHT SWITCH

Step on the rear brake pedal to inspect the brake light switch.
If the brake light switch works inflexible, it may be adjusted by
turning the adjusting nut of the brake switch.
2-12
TIRES
There are multiple indicators ① of the wear sign position on

the peripheral direction of the tyre. Inspect the wear signs (the
bosses in the grooves) ② near the indicators ①, to make sure
the tread depth is enough and, if they have been worn, replace
the tyre.
Eyeballing the worn conditions and the damages ③ (piercing
or cracks) of the tires surfaces. Excessive wear of tires or too
much damage on surfaces will lower the stability of riding. In
this case, please replace the tires.
③
TIRE PRESSURE
Inspect the tyre pressure and check whether the valve cock
has air leakage.
SOLD RIDING DUAL RIDING

2 2
②
1.75 kgf/cm 1.75 kgf/cm
FRONT
175 Kpa 175 Kpa ①
2 2
2.25 kgf/cm 2.25 kgf/cm
REAR
225 Kpa 225 Kpa
STEERING
Properly adjust the bearing of the steering to make the

steering rotate flexibly and ensure safety during riding.
Too tight steering will make the rotation of the steering
inflexible.
Too loose steering will result in vibration and further damage
to the bearing. Inspect the steering to make sure it has no
shaking.
If the steering has shake, adjust it with the method stated in
page 5-11.
FRONT/REAR SUSPENSION
Inspect Every 8 000 km
FRONT SUSPENSION
● Grasp the front brake, squeeze the front suspension to
check its motion, check for leaks or damage.
● Replace damaged parts and tighten all bolts and nuts.
REAR SUSPENSION
● Press down the rear of the motorcycle repeatedly to check
the performance of the rear suspension
● Check for leaks or damage; tighten all bolts and nuts.
2-13
ILLUMINATION AND SIGNAL

Inspect the headlight, the left and right turn signal indicator
lights, the taillights or the brake lights and the signal lights on
the dashboard. If any problem, replace relevant light(s) in time
(see page 6-9).
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

Check the tightening torque of the bolts and nuts for the motorcycle according to the table below:
ITEM N·m Kg·m
1 Front axle bolt 50~80 5.0~8.0

2 Front axle limiting bolt 18~28 1.8~2.8
3 Handlebar lock-up bolt 12~20 1.2~2.0
4 L 18~28 1.8~2.8
Clamping bolt of the stem head
5 R 18~28 1.8~2.8
6 Steering bolt 50~80 5.0~8.0
7 Stem bolt (clamping bolt of the front absorber) 25~40 2.5~4.0
8 Brake pedal mounting bolt 18~28 1.8~2.8
9 Caliper mounting bolt 27~43 2.7~4.3
10 Brake hose union bolt 20~25 2.0~2.5
11 Bolts of the exhaust pipe 18~28 1.8~2.8
12 Rear shock absorber bolt/nut 22-35 2.2-3.5
13 Brake cam lever bolt/nut 8~12 0.8~1.2
14 Rear axle nut 50~80 5.0~8.0
15 Bolt/nut of the rear swing arm shaft 50~80 5.0~8.0
16 33-39 3.3-3.9
17 Engine mounting bolt/nut 33-39 3.3-3.9
18 33-39 3.3-3.9
2-14
5 4
1
5
3
2
4
9
10
8
7
12
12
11
14
13
15
18
17
16
17
2-15
COMPRESSION PRESSURE
Inspect Every 8 000 km
INSPECTION
NOTE:
Before testing the compression pressure of the engine, be
sure that the nuts and bolts of the cylinder head are securely
tightened with specified torque, and the air valve clearance is
correct.
Keep the engine running idle for several minutes before
carrying-out the test.
1
● Remove spark plug.
● Fit the compression gauge ① and adapter ② to the plug
hole, taking care to make the connection absolutely tight.
● Twist the throttle grip into wide-open position.
● Crank the engine several times with the starter motor, and 2
read the highest gauge indication as the compression of
the cylinder.
09915-64510 : Compression gauge ①

09915-63210 : Adapter ②
Compression pressure
Standard Limit
10-14 kgf/cm2 8 kgf/cm2
A low compression pressure may indication any of the

following malfunctions:
* Excessively worn cylinder wall.
* Worn piston or piston rings.
* Piston rings stuck in the grooves.
* Poor seating contact of valves.
* Defective cylinder head gasket.
When the compression pressure noted is down to or below the
limit indication above, the engine must be disassembled,
inspected and repaired as required.
2-16
ENGINE
CONTENTS
REMOVING ENGINE PARTS WI TH ENGINE UN-REMOVED 3-1

ENGINE REMOVAL AND REMOUNTING 3-2
CYLINDER HERD AND VALVE 3-7
CYLINDER AND PISTON & CAM 3-18
CLUTCH AND GEAR SHIFT MECHANISM 3-26
GENERATOR AND START CLUTCH 3-36
CRANKSHAFT, TRANSMISSION AND KICK START DEVICE
SECONDARY AIR SYSTEM
3-43
3-56 3
ENGINE
REMOVING ENGINE PARTS WITH ENGINE UN-REMOVED

The following parts can be removed and remounted without removing the engine. Refer to sections about
parts removing and remounting.
UPPER PART OF THE ENGINE
Cam chain tensioner 3-7

Cylinder head cover 3-8
Cam shaft 3-8
Cylinder head 3-8
Cylinder 3-18
Piston 3-18
RIGHT SIDE OF ENGINE

Engine oil filter 3-22
Clutch cover 3-22
Clutch 3-22
Oil pump 3-23
Gear shifting fork shaft 3-26
LIFT SIDE OF ENGINE
Gear lever 3-26

Chain wheel cover 3-27
Start motor 3-27
Primary decelerate gear 3-27
Generator cover 3-28
2nd decelerate gear 3-28
Generator rotor 3-28
Start clutch 3-29
Generator dtator 3-31
3-1
ENGINE
ENGINE REMOVAL AND REOUUNTING

ENGINE REMOVAL
Before taking the engine out of the frame, thoroughly clean
the engine with a suitable cleaner.
● Remove the seat by using the key.
● Take off the right and left frame covers.

● Disconnect the and lead wires of battery.
NOTICE
First, disconnect the lead wire.
● Take off the fuel tank bolts.
● Take off the fuel tank put in hose, the pastern stopple fuel
hose.
● Take off the hose of fuel cut-off valve and charcoal tin.
● Take off fuel air filter hose.
● Disconnection the couplers of the fuel gauge , take off fuel
tank.
● Disconnection the hose fuel pump ①.

● Disconnection the input hose fuel pump ②.
● Take off the fuel filter ③. 2
1
3-2
ENGINE
● Remove the bolt of 3 way hose, take off the 3 way and hose.
● Disconnection the couplers of DCP ① and FIAV ②.

● Disconnection the couplers of MAQS ③.
1
● Disconnection the couplers of ETS.
● Disconnection the PVC hose .
● Remove the electronegative hose ④.

Loosen the throttle cable nuts ⑤ and ⑥ , remove the 4
throttle. 5
3-3
ENGINE
●Remove the nuts and screw of the throttle body, and detach
the throttle body from right side of the frame .
● Takeoff the clutch cable by removing the clutch lever bolt

and adjuster lock nut.
● Remove the exhaust pipe bolts and muffler mounting bolt,

then take off the muffler.
● Disconnect the couplers of generator ① and gear position

indicator ②.
● Take off the engine sprocket cover.
3-4
ENGINE
●Take
off the gear shifting pole.
Remove the nut of rear under the engine .
Mounting bolt (rear under) :33-39N•m
● Take off the drive chain by removing the clip.
● Take off the lead wire of starter motor.

● Take off the engine temperature sensor.
● Take off the breather pipe.

● Disconnect the ground wire from the starter motor.
● Take off the spark plug cap.

● Take off left and right decorate cover of the cylinder.
3-5
ENGINE
● Remove engine mounting bolts.
Mounting bolt (top) : 33-39N•m

Mounting bolt (front) : 33-39N•m
Mounting bolt (rear) :33-39N•m
● Remove swing arm pivot nut and brackets.

● Use both hands, and lift the engine from the frame.
Bolt of the rear swing arm shaft : 50-80N•m
NOTICE
Be careful not to draw out the swing arm pivot shaft
completely from the left side swing arm pivot hole. Insert
the shaft or rod into the right side pivot hole from the
right side of the frame to keep the alignment of the frame
holes and swing arm pivot holes.
ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal.
● Temporarily fasten the engine mounting bracket before

inserting the engine mounting bolts.
NOTE:
The engine mounting nuts are self-lock nuts. Once the nut has
been removed, it is no longer of any use. Be sure to use new
nuts and tighten them to the specified torque.
ENGINE OIL REPLACE

● Pour 1 000mL of engine oil SAE 10W/40 graded SF or SG
into the engine after overhauling engine.
● Start up the engine and allow it run for several seconds at

idle speed. About one minute after stopping engine, check
oil level.
● If the level is below the “L” mark, add oil with the level
reaches the “F” mark.
● After remounting the engine, inspections should be done for

the following parts:
* Clutch cable (see page 2-8)
* Throttle cable (see page 2-9)
* Idle speed (see page 2-9)
* Drive chain (see page 2-10)
3-6
ENGINE
CYLINDER HEAD AND VALVE

CYLINDER HEAD
REMOVAL
● Remove the engine (see page 3-2).
● Drain out the engine oil.
NOTE:
If top end repair only is being performed, it is not necessary to
remove the engine from the frame. As already noted, seat, fuel
tank, frame covers etc. must be removed.
● Remove the timing inspection screw plug of valve and the
screw plug of the generator rotor.
● Remove the bolt of chain tensioner and the tensioner.
● Remove the access hole covers of the inlet valve and the
exhaust valve as well as the spark plug.
● Raise the piston to the TDC (see page 2-5).
NOTE:
When take down the cylinder head cover, the piston must
locate at the TDC of the compressions stroke.
3-7
ENGINE
● Loosen the cylinder head cover bolts in the order indicated

● in the illustration and remove brack comps of cylinder head Do not
cap. remove
Detach the cylinder head cover.
NOTE:
When removing cylinder head cover, piston must be at top dead
center on compression stroke.
● Remove camshaft sprocket bolts and detach the camshaft.
NOTICE
Do not make sprocket, chain and bolts drop into the
crankcase.
● Loosen the nuts of the cylinder head and of the cylinder .
● Loosen the six cylinder head nuts diagonally then detach

the cylinder head.
NOTE:
When unscrew the bolts of the cylinder head, the bolts should
be diagonally loosened for two or three times.
DISASSEMBLY
● Remove rock arm shaft set bolts.
3-8
ENGINE
● Pull out the rocker arm shaft with pliers.
● Remove rocker arm and spring and undee waher.
● Remove the valve spring with specified tools.
11F14-003 : valve knocked-down tool
● Take out the valve spring retainer, inner spring and outer
spring.
● Pull out the valve from the other side.
● Remove oil seal, using long-nose pliers.

Take out the spring seat.
NOTICE
Removed oil seal should be replaced with a new one.
3-9
ENGINE
● Remove valve guide by using the special tool.
09916-44910 : Valve guide remover
NOTICE
Only oversize valve guide is available as a spare part.
CYLINDER HEAD INSPECTION

CYLINDER HEAD COVER
● After removing sealant (SUZUKI BOND No.1215) from the
fitting surface of the cylinder head cover, place the cylinder
head cover on a surface plate and check for distortion with a
thickness gauge. Check points are shown in Fig.
Service limit 0.05mm
09900-20803 : Thickness guage

SWING ARM SHAFT
● Measure the outer diameter of the swing arm shaft.
Standard 11.977-11.995mm
09900-20205 : Micrometer (0-25mm)
SWING ARM
● Measure the inner diameter of the swing arm, and inspect
the wear situation of the swing arm contact surface with the
cam.
Standard 12.000~12.018mm
09900-20605: Internal micrometer
CAMSHAFT Inlet open TDC Exhaust open

● If the engine has abnormal sound, shaking or insufficient (B.T.D.C.) (B.B.D.C.)
output power, should inspect the cam wear situation and the
camshaft run-out.
● The wear of the camshaft always results in the poor
operation of the inlet valve and the exhaust valve and
further declined engine power. The wear loss of the Inlet close Exhaust close
camshaft is determined by the heights ① of the inlet cam (A.B.D.C.) (A.T.D.C.)
and the exhaust cam. If the wear losses of the cams exceed B.D.C.
the limit values, please replace the camshaft. Valve timing diagram
3-10
ENGINE
CAM HEIGHT
Height ① Inlet cam 33.350mm

(limit) 1
Exhaust cam 33.000mm
09900-20202: Micrometer (25~50mm)
Measure the outside diameter of camshaft journal.

Replace either the cylinder head set or the cam shaft if the
O.D. is incorrect.
Standard 21.959-21.980mm
09900-20205: Micrometer (0~25mm)
Measure the runout with a dial gauge. Replace the camshaft if

the runout exceeds the limit.
09900-20701 : Magnetic stand

09900-20606 : Dial gauge (1/100mm)
09900-21304 : V-block (100mm)
VALVE SPRING
● Measure the free lengths of the valve springs.
IN 31.24 mm
Service limit
EX 33.58 mm
09900-20201: Slide caliper (150mm)
CYLINDER HEAD
● Inspect whether the spark plug hole and the valve base
have scratches.
● Inspect the cylinder head with a thickness gauge to see
whether it has deformed.
3-11
ENGINE
VALVES
● If the valve stem is worn down to the limit, when measured
with a micrometer, replace the valve.
IN 4.975-4.990mm
Standard
EX 4.955-4.970mm
09900-20205 : Micrometer (0-25mm)
● Measure the thickness ① and, if the thickness is found to

have been reduced to the limit, replace the valve.
NOTE:
Visually inspect each valve for wear of its seating face.
Replace any valve with an abnormally worn face. 1
● Support the valve with “v” block, as shown, and check its
runout with a dial gauge. The valve must be replace if the
runout exceeds the limit.
09900-20701: Magnetic stand

09900-20606: Dial indicator
09900-21304: V-shaped block
● As shown in the right picture, support valves with a V-

shaped block and measure its run-out with a dial indicator. If
the measured value exceeds the limit value, the valves
should be replaced.
09900-20701: Magnetic stand
09900-20606: Dial indicator
09900-21304: V-shaped block
THE VALVE STEM SEAL

● Lubricate valve stem seal with oil, and press-fit the seal into
position with a finger tip.
NOTICE
Do not reuse the oil seals.
3-12
ENGINE
VALVE SEAT WIDTH

● Coat the valve seat with prussian blue uniformly. Fit the
valve and tap the coated seat with the valve face in a
rotating manner, in order to obtain a clear impression of the
seating contact. In this operation, use the valve lapper to
hold the valve head.
● The ring-like dye impression left on the valve face must be

continuous any break. In addition, the width of the dye ring,
which is the visualized seat “width”, must be within the
specification.
VALVE SEAT SERVICING

The inlet and exhaust valve seat should be machined into four
different angles (the contact surface of valve seat should be
cut into 45°angle).
INTAKE SINDE EXHAUST SINDE
N-122 N-122
45 o 45 o
N116 N-120
30 o N126 15 o N-121
60 o N111
45 o
09916-20610 : Valve seat cutter (N121)

09916-20620 : Valve seat cutter (N122)
09916-20630 : Valve seat cutter (N126 ) 30o 60o
09916-24311 : Solid pilot (N-100-5.0)
09916-21110 : Valve seat cutter set
NOTE:
After cutting each time, the contact surfaces of the valve seats
must be inspected.
3-13
ENGINE
● Grind the uneven or irregular surface with 45° tooling.
NOTE:
Finish the air valve seat surface with 45 ° tooling after the valve
is replaced.
● Grind the top surface of the original valve seat by 1/4 of its
W alv
id e
v
width with 30° tooling.
th se
s at
of s
30 o
● Grind the bottom of the original valve seat by 1/4 of its width
W alv
with 60° tooling.
id e
v
th se
so a t
f s
60 o
● Process the valve seat surface to standard height with 45°

tooling. 0.9-1.1mm
● Make sure all pitting and irregular surfaces have been cut. If
necessary, adjust it again.
Standard 0.9～1.1mm
● Apply a thin coat of Prussian blue onto the valve seat.

● Press the valve onto the valve seat and make it rotate for
45 o
couple times. After that, take out the valve and observe the
contract surface of the valve seat. There should be clear
traces on the contract surface.
NOTE:
The position of the valve seat has affect on the contract
surface of the valve, which is of great significance for good
sealing. 30 o
● If the contract surface of the valve is too high, cut it lower Contract surface of the valve is too high
with a 30°angle milling cutter.
● If the contract surface of the valve is too low, adjust it with a
60°angle milling cutter.
● Cut the valve seat to the standard width with a 45° angle
milling cutter. Contract surface of the valve is too low 60 o
3-14
ENGINE
● After cutting the valve seat, apply an abrasive coat onto the
valve surface, and gently grind the valve. After grinding,
clean all left abrasive of the cylinder head and the valve.
Inspect the contact surface of the valve seat again.
NOTICE
Too big grinding force will possibly result in deformation
or damage to the valve seat. Please change the working
angle of the grinding tool frequently, in order to avoid
uneven grinding of the valve seat. If the abrasive enters
into the space between the valve stem and the valve
guide pipe, it will possibly result in damage.
CYLINDER HEAD ASSEMBLY
● Clean the cylinder head thoroughly with a cleaning liquid

and blow all passages with compressed air.
● Mount a new valve oil seal.
● Lubricate all valves with molybdenum grease.
● Insert the valves into air guide pipes and mount spring
washers, springs and spring bases for the valves.
99000-25140: Molybdenum grease
3-15
ENGINE
NOTE:
When a valve spring is mounted, the seal ring side should face
the combustion chamber. In order to avoid oil seal damage,
the valve oil seal should be mounted while the valve is rotating
slowly.
● Mount a valve lock clamp.
11F14-003 : Valve knocked-down tool
CYLINDER HEAD COVER REASSEMBLY

● Apply SUZUKI MOLY PASTE to the rocker arms and shafts.
● Place the spring and the wave washer and arm in the
exhaust side.
● Place the wave washer and arm in the inlet side.
● After inserting the shafts, tighten the set bolts.
M 99000-25140: SUZUKI MOLY PASTE
NOTICE
Use a new O-ring on the rocker arm shafts to prevent oil
leakage.
Use a new gasket on the set bolts to prevent oil leakage.
REASSEMBLY
● Clean feculence from the surface of the cylinder head.
● Fitdowel pins ① to cylinder head and then, attach new

gasket to cylinder head.
3-16
ENGINE
● Mount the nuts of the cylinder head , and tighten them with
the specified torques. EX
Copper
washer Copper
washer
Cylinder head nut : 25~32N•m
Copper
IN Copper
washer
washer
● Mount nuts of the cylinder head and cylinder, and tighten

them with the specified torques.
Cylinder head nut : 8~12N•m

Cylinder nut : 8~12N•m
● Apply THREAD LOCK SUPER “1303B” to the bolts and the

tighten the cam sprocket.
NOTE:
Do not rotate magneto rotor while doing this. When the
sprocket is not positioned correctly, turn the sprocket.
When installing the camshaft into the cam sprocket, pay
attention not to dislodge the locating pin or it may fall into
the crankcase.
1303B 99000-32030 : THREAD LOCK SUPER“1303B”
● Thoroughly wipe off oil from the fitting surface of cylinder
head.
● Fit two dowel pins to the cylinder head side.
● Uniformly apply SUZUKI BOND No.1215 to the cylinder
head surface.
99000-31110 : SUZUKI BOND No.1215
● Mount cylinder head cover and the bolts.
3-17
ENGINE
CYLINDER AND PISTON

CYLINDER DISASSEMBLY
● Remove the cylinder head (see 3-6 Page ).
● Remove the washer and the pin.
● Remove the cylinder .
CYLINDER INSPECTION
● Remove the residual gasket of the cylinder surface.
● Inspect the plainness of the cylinder with a ruler and a
thickness gauge
● Inspect whether the inner part of the cylinder is worn or

damaged.
● Measure the inner diameter of the cylinder along directions
X and Y respectively. Three horizontal planes vertical to the
axis should be selected for measurement. Using the
maximum valve as reference when judging whether the
cylinder is worn.
Servicing limit 57.135mm
TOOL 09900-20508 : Cylinder gauge set

DISASSEMBLY AND INSPECTION
OF THE PISTON
DISASSEMBLY
NOTE:
Block the crankshaft plane with a piece of clean cloth lest the
piston pin or other parts drop into the crankcase.
● Remove piston pin retainer with pliers.
● Remove piston pin and piston.
● Remove the piston ring.
NOTICE
Be careful not to damage the piston ring during
disassembly.
3-18
ENGINE
● Remove the carbon in the piston ring slot with the old piston
ring.
INSPECTION
● Push the piston ring into the slot, measure the clearance
between the piston ring and the ring slot.
Piston ring Servicing limit
1st 0.180mm
2nd 0.150mm
● Check for damage or wearing of the piston.

● Measure the piston O.D. at 8mm along the vertical direction
of the piston pin.
8mm
TOOL 09900-20202 : Micrometer (25~50mm)
● Measure the hole inner diameter of the piston pin.

● Measure the outer diameter of the piston pin.
TOOL 09900-20605 : Dial calipers

09900-20205 : Micrometer (0~25mm)
● Measure the inner diameter of the smaller end of connecting

rod.
Servicing limit 15.040
09900-20605 : Dial calipers
3-19
ENGINE
● Put the piston ring horizontally on the cylinder bottom to

measure the opening clearance.
Piston ring Servicing limit
1st 0.5mm
2nd 0.5mm

NOTE:
When using the piston head to jack the piston rings into the
cylinder, make sure they enter evenly.
PISTON RING ASSEMBLY

● Clean the piston ring slot completely and assemble the
piston ring.
NOTE:
Apply engine oil on all piston rings.
Avoid damaging the piston and piston ring during assembly.
Align the mark on the piston ring upward during assembly, pay
attention to distinguish the marks of the top ring and the
second ring.
● Keep the opening of each ring cross at 120°, do not leave

the oil ring opening on the same line.
● The piston ring must be able to rotate freely in the ring slot
after installation.
3-20
ENGINE
PISTON REASSEMBLY
The following are reminders for piston installation:
● Rub a small quantity of SUZUKI MOLY PASTE onto the
piston pin.
● Place a clean rag over the cylinder base to prevent piston
pin circlip from dropping into crankcase, and then fit the
piston pin circlip with long-nose pliers.
M 99000-25140: SUZUKI MOLY PASTE
NOTICE
Use a new piston pin circlip to prevent circlip failure
which will occur with a bent one.
● When fitting the piston, turn hole on the piston head to

exhaust side.
CYLINDER
Before mounting the cylinder, oil the big end and small end of
the conrod and also the sliding surface of the piston.
● Fit dowel pins ① to crankcase and then fit gasket.

NOTICE
To prevent oil leakage, do not use the old gasket again,
always use new one.
● Hold each piston ring with the piston rings properly spaced
and insert them into the cylinder. Check to insure that the
piston rings are properly inserted into the cylinder.
NOTE: 2
When mounting the cylinder, after attaching camshaft drive
chain ② , keep the camshaft drive chain taut. The camshaft
drive chain must not be caugth between cam drive chain
sprocket and crankcase when crankshaft is rotated.
NOTE:
There is a holder for the bottom end of the cam chain guide
cast in the crankcase. Be sure that the guide is inserted
properly or binding of the cam chain and guide may result.
● Install the cylinder head (see page 3-13).
3-21
ENGINE
CLUTCH AND GEAR SHAFT

MECHANISM
CLUTCH COVER DISASSEMBLY 1
2
● Drain out the engine oil completely.
● Loosen the adjusting bolts ① and ② of the clutch.
● Make the cable and the release swing arm separate.
● Remove oil filter cover bolts and oil filter cover.

● Remove oil filter.
● Remove clutch cover bolts and clutch cover.
● Remove the gasket and the positioning pin.
CLUTCH
DISASSEMBLY
● Remove clutch spring mounting bolts diagonally while
holding the primary driven gear, and remove clutch
pressure plate.
3-22
ENGINE
● Remove clutch handspike and gear & plate.
● Remove the clutch drive plate and driven plate.
● Flatten the lock washer and remove the clutch sleeve hub
nut by using the special tool.
11F14-005 : Clutch sleeve hub holder
● Put the conrod holder for fixing the crank. Remove the
primary drive gear nut.
● Remove the primary drive gear.
11F14-1019 : Conrod holder
Clutch driven hub : 40~60N•m
● Remove oil pump driven gear and primary drive gear.
3-23
ENGINE
INSPECTION
● Ifthe drive friction discs of the clutch have scratches or
discoloration phenomenon, they should be replaced.
● Measure the thicknesses of the friction discs.
09900-20101: slide caliper (150mm) Checking thickness
● Measure the thicknesses of the drive friction discs.
09900-20101: slide caliper (150mm)
NOTE:
If the drive friction discs exceed the use limit, the whole set
Checking claw width
friction discs must be replaced.
● Measure each driven disc for distortion with a thickness

gauge. Replace driven disc which exceed the limit.
09900-20803 : Thickness gauge
Checking distortion
● Measure the free lengths of the clutch springs
09900-20101: slide caliper (150mm)
NOTE:
If one or more clutch springs exceed the use limit, the whole
set springs must be replaced.
● Inspect the release bearing for any abnormality, particularly

crank, to decide whether it can be reused or should be
replaced.
● Smooth engagement and disengagement of the clutch
depends much on the condition of this bearing.
3-24
ENGINE
● Primary driven gear is composed as shown.
① Primary driven gear ④ Rivet

② Damper ⑤ Clutch housing
③ Plate
If the internal damper wears, play is generated between gear
and housing, causing abnormal noise. If the play is extreme,
replace the primary driven gear assembly with a new one.
REASSEMBLY
● Install primary drive gear and oil pump driven gear.
● Install gasket and bush & primary driven gear & clutch
sleeve hub.
● Install lock gasket, and tighten clutch sleeve hub nut using
the special tool to the specified torque.
Clutch sleeve hub nut : 30~50N•m
11F14-005 : Clutch sleeve hub holder
● Install drive plates and driven plates to the sleeve hub.

● Insert push rod in the countershaft.
● Tighten clutch spring bolts diagonally.
● Install the new gasket and pin.

● Install clutch cover, and tighten clutch cover bolts.
● Install oil filter and oil filter cover.

● Install and adjust clutch cable, and add engine oil.
3-25
ENGINE
GEAR SHAFT MECHANISM

DISASSEMBLY
● Remove the bolts, the retainer rings and the gear shift
pedal.
● Remove the clutch (see page 3-22).
● Remove oil pump driven gear.

● Remove the gear shift.
● Loose the bolt, remove cover board ① and ② .
NOTE:
When removing cam driven gear, do not lose gear shifting pawl
④ , pin ⑤ and spring ⑥ .
99000-32050 : Apply thread lock super “1342” 1
INSPECTION
● Inspect whether the gearshift shaft is bent, worn or
damaged.
● Inspect whether the gearshift arm spring and the return 7
spring are damaged or fatigued.

8
3
6
5
4
REASSEMBLY
● Gearshafter can be mounted in the reverse order of
removal.
3-26
ENGINE
GENERATOR AND START CLUTCH

DISASSEMBLY OF THE GENERATOR COVER
● Remove the generator connector ① , the gear switch
1
connector ② , electron instrument connector ③. 2
● Remove the engine sprocket cover.
● Remove the bolts and the starter motor.
● Remove the starter motor gear cover and generator wiring

harness.
● Remove the pin and the gasket.

● Remove the primary decelerate gear and shaft.
3-27
ENGINE
● Remove magneto cover bolts and detach magneto cover.

● Remove the gear position switch.
● Remove the bolts and drive sprocket wheel.
● Remove the pin and the gasket.
● Remove the second decelerate gear and shaft.
ROTOR
DISASSEMBLY
● Remove magneto rotor nut.
11F14-001 : Rotor holder
● Remove magneto rotor and key.
11F14-005 : Rotor separator
NOTE:
Be careful when Remove the keys; avoid damaging the key
slot and the crank.
3-28
ENGINE
DISASSEMBLY
● Inspect if starter idle gear rotation in one direction is easy
and difficult in another.
● Remove the starter idle gear.
● Fix rotor with rotor holder and remove overriding clutch bolt.
NOTE:
Unless necessary for inspection, please do not remove
overriding clutch.
● Remove the starter clutch.
STARTER CLUTCH INSPECTION

● Inspect the starter clutch linear spacer ring for wear,
damage and irregular motion.
● Clean starter clutch and coat spacer ring with engine oil.
NOTE:
In case starter clutch spring is removed, it must be replaced as
a whole.
● Install clutch housing/ starter clutch on rotor.
3-29
ENGINE
● Fix the rotor with rotor holder.
● Clean hexagon-socket bolt thread and coat it with bond.

● Fit starter clutch screw and tighten it at tightening torque.
Starter clutch bolt : 10~15N·m
1 3 05 99000-32100 : THREAD LOCK SUPER

● Install the gear on rotor by rotating it counter clockwise.
REASSEMBLY
● Install the gear on rotor by rotating it counter clockwise.
● Make the key slot of the rotor align with the key of the crank
to install the rotor.
● Install the bolt of the rotor of the generator and tighten it with
the specified torque.
Bol t s f o r t h e rotor : 5 0 ~70N·m
3-30
ENGINE
● Remove the second decelerate gear and shaft.
STATOR
DISASSEMBLY
● Remove the bolts, cable guide, the stator and the induction
coil.
REASSEMBLY
● Install the stator and the cable guide, apply the proper
amount of anti-loosening glue of the screws and finally
tighten the screws.
● Install the induction coil, apply proper amount of anti-
loosening glue on the screw heads and finally tighten the
screws with the specified torque.
99000-32050 : Apply thread lock super “1342”
REASSEMBLY GENERATOR COVER

● Install the new gasket and the pin.
● Install the generator and tighten bolts.
3-31
ENGINE
● Install the primary decelerate gear and shaft.
● Install the new gasket and the decelerate gear cover.
● Install the bolts and starter motor.
● Install the engine sprocket cover.
● Install the generator connector ① , the gear switch

connector ② , electron instrument connector ③.
1
2
3-32
ENGINE
CRANKSHAFT, TRANSMISSION
AND KICK STARTER
CRANKCASE DISASSEMBLY
● Remove cylinder head and cylinder. (Refer to page 3-5)
Remove clutch and primary drive gear & oil pump. (Refer to
page 3-16)
Remove generator. (Refer to page 3-27)
● Remove sump filter cap and neutral cam stopper..
● Remove balance shaft nut with special tool.
● Remove crankcase bolts.
● Separate the crankcase into 2 parts, right and left with

crankcase separating tool.
Fit the crankcase separating tool, so that the tool plate is
parallel with the end face of the crankcase.
11F14-004 : Crankcase separating tool
CAUTION
Do not pry crankcase with screwdriver.
3-33
ENGINE
TRANSMISSION
● Remove gear shifting cam stopper spring.
● Draw out gear shifting fork shafts and take off forks.
● Remove clusters of gears and gear shifting cam.
CRANKSHAFT AND BALANCE SHAFT
● Remove crankshaft and balance shaft with crankcase.
INSPECTION
● Measure the connecting rod large end side play with a
thickness gauge.
Service limit 0.5mm
09900-20803 : Thickness gauge
3-34
ENGINE
● Place crankshaft on a V-block and measure radial run-out of

crankshaft with a dial gauge.
Standard 0.05mm
09900-20606 : Dial gauge（1/100）

09900-21304 : V-block（100mm）
● Rotate inner races of bearings with finger.

● Bearing rotation should be smooth and silent.
● Simultaneously inspect if bearing outer race rotates in
crankcase.
● In case of difficult rotation of bearing inner race or rotation
of outer race, replace bearing with a new one.
● Inspect balance shaft drive gear for wear and damage.

● When replacing balance shaft drive gear, align the hole of
the gear with the heave of crankshaft.
● Inspectbalance shaft gear for wear and damage.

● When replacing balance shaft gear, do not lose the spring
when remove circlip .
● Using a thickness gauge, check the shifting fork clearance

in the groove of its gear. If the clearance limit is exceeded by
any of the three gears, determine whether the gear or the
gear shifting fork should be replaced by measuring the
thickness and groove width.
Standard 0.10~0.30mm
09900-20803 : Thickness gauge Checking clearance
3-35
ENGINE
No.1&No.2 4.80-4.90mm
Standard
No.3 5.30-5.40mm
09900-20101 : Vernier calipers

Checking groove width
No.1&No.2 5.00-5.10mm
Standard
No.3 5.50-5.60mm
09900-20101 : Vernier calipers
Checking thickness
● Inspect gearshift cam guide slot.

● In case of damage of gearshift cam guide slot, replace
gearshift cam with a new one.
● Inspect
all bushes, gear inner faces, and gear faces for
abnormal wear or poor lubrication.
GEARSHIFT BEARING REPLACING

● Inspect
bearings for easy rotation by rotating each of them
and simultaneously inspect if bearing outer race rotates in
crankcase. Replace it in case of rotation.
3-36
ENGINE
● Remove main shaft bearing from right crankcase.

● Remove auxiliary shaft needle bearing from right crankcase
with special tool.
09923-73210 : Bearing puller

09930-30102 : Rotor remover slide shaft
● Remove auxiliary shaft bearing from left crankcase.

● Remove main shaft bearing from left crankcase with special
tool.

● Mount new bearings with special tool.
09940-53311 : Bearing installer

3-37
ENGINE
REASSEMBLY
CRANKSHAFT AND BALANCE SHAFT
● Decidethe width between the webs referring to the figure

below when rebuilding the crankshaft.
STD 52.9~53.1mm
● When mounting the crankshaft in the crankcase, it is

necessary to pull its left end into the crankcase.
09910-32812 : Crankshaft installer

09910-20116 : Conrod holder
3-38
ENGINE
NOTICE
Never fit the crankshaft into the crankcase by striking it
with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.
● When installing the balance shaft into the crankcase. The

sign “O” and sign of the balance shaft drive gear must like
right picture.
TRANSMISSION
3-39
ENGINE
NOTICE
Never reuse a circlip. After a circlip has been removed
from a shaft, it should be discarded and a new circlip
must be installed.
When installing a new circlip, care must be taken not to
expand the end gap larger than required to slip the
circlip over the shaft.
After installing a circlip, always insure that it is
completely seated in its groove and securely fitted.
● Press-fit 2nd drive gear onto the counter shaft. Before

reassembling, coat the internal face of the 2nd drive gear
with THREAD LOCK SUPER “1303” and install it so that the
length A as shown in fig.
99000-32030 : APPLY THREAD LOCK SUPER “1303”
A
Counter shaft length 0
88.0± 0.2 mm
(Low to 2nd)
NOTE:
this procedure may be performed only twice before shaft
replacement is required.
GEAR SHIFTING CAM AND FORK
3-40
ENGINE
● Fitthe gear shifting cam on the crankcase. Position the cam

as shown in Fig. so that the gear shifting fork can be
installed easily.
NOTE:
Two kinds of gear shifting forks, ① and ② are used. They
resemble each other very closely in external appearance and
configuration.
Carefully examine the illustration for correct installing positions
and directions.
● Aftercam stopper and gear shifting forks have been fitted,

hook cam stopper spring onto the crankcase.
CRANKCASE
When reassembling the crankcase pay attention to the
following.
Coat SUZUKI SUPER GREASE "A" to the lip of oil seals.

Remove sealant material on the fitting surfaces of right and
left halves of crankcase and thor-oughly remove oil stains.
Fit dowel pins on the left half.
Apply engine oil to the big end of the crankshaft conrod and
all parts of the transmission gears.
Apply SUZUKI BOND No.1215 (99000-31110) uniformly to
the fitting surface of the left half of the crankcase, and after
waiting a few minutes, fit the right half on the left half.
A 99000-25010 : SUZUKI SUPER GREASE "A"

99000-31110 : SUZUKI BONDNo.1215
3-41
ENGINE
After the crankcase bolts have been tightened, check if

driveshaft and countershaft rotate smoothly.
If a large resistance is felt to rotation, try to free the shafts

by tapping the driveshaft or countershaft with a plastic
hammer as shown in Fig.
GEAR SHIFTING CAM DRIVEN GEAR

When installing the gear shifting pawls into the cam driven
gear. The large shoulder A must face to the outside as shown.
Next, install cam guide and pawl lifter, Apply a small

quantity of THREAD LOCK "1342" to the threaded parts of
the securing screws.
99000-32050 : THREAD LOCK “1342"
GEAR SHIFTING SHAFT

Install the gear shifting shaft. Match the center teeth of the
gear on the shifting shaft with the center teeth on the
shifting driven gear as shown.
NOTE:
After the cam driven gear, cam guide, gear shifting shaft and
neutral cam stopper have been fitted, confirm that gear change
is normal while turning the countershaft and driveshaft. If gear
change is not obtained, it means that assembly of gears or
installation of gear shifting fork is incorrect. If this is the case,
disassemble and trace the mistake.
Fit key in the key slot on the crankshaft, and install the
primary drive gear.
3-42
FI SYSTEM A N D FUEL SYSTEM
CONTENTS
ELECTRICAL DIAGRAM FOR THE DCP-FI SYSTEM ............ 4-1
DCP-FI SYSTEM ................................... 4-3
INJECTION VOLUME ...... .......................... 4-3
CONTROLLING THE END OF THE INJECTION ............... 4-3
WIRE DIAGRAM OF THE DCP-FI SYSTEM .................. 4-4
ECU (CONTROL UNIT OF FI) ........................... 4-5
SELF-DIAGNOSIS .................................. 4-6
CURRENT FAULT CODE/HISTORY FAULT CODE ........... 4-6
FI WARNING LIGHT---FLASHING MODE ................. 4-6
CHECK FI WARNING LIGHT .......................... 4-6
FAULT DIAGNOSIS DEVICE ......................... 4-7
TROUBLESHOOTING FOR THE DCP-FI SYSTEM ............. 4-9
PRE-DIAGNOSIS INSPECTION ........................ 4-9
FAULT ANALYSIS FOR THE ELECTRONIC INJECTION SYSTEM . 4-9
TABLE OF DIAGNOSTIC TROUBLE CODE (DTC) ............ 4-10
DTC '12': CRANK SHAFT POSITION SENSOR ............... 4-11
DTC ‘15': ENGINE TEMPERATURE SENSOR ............... 4-12
DTC ‘23': TIP-OVER SENSOR ......................... 4-13
DTC ‘24': IGNITION COIL ............................
DTC '32': (DCP) ..................................
4-14
4-15
4
DTC '40’: (IDLE SPEED CONTROL VALVE) . . . . . . . . . . . . . . 4-16
DTC '44’ ( OXYGEN SENSOR) . . . . . . . . . . . . . . . . . . . . . . . 4-18
DTC '13', '14' OR '21': INTAKE AIR PRESSURE, THROTTLE
POSITION OR INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . 4-19
DISMOUNTING THE ELECTRONIC INJECTION UNIT........... 4-20
ECU AND TIP-OVER SENSOR .......................... 4-20
CRANK SHAFT POSITION SENSOR .................... 4-20
DCP ........................................... 4-21
THROTTLE POSITION SENSOR AND MAQ SENSOR .......... 4-21
OXYGEN SENSOR ................................ 4-22
ENGINE TEMPERATURE ............................. 4-22
FUEL SYSTEM ..................................... 4-23
ELECTRICAL DIAGRAM FOR THE DCP-FI SYSTEM

3
2 6
5
4
1
13
12
9
10
7
11
8
① ECU ⑦ ETS(Engine temperature sensor)

② TOS(Tip-over sensor) ⑧ Starter motor
③ Turn signal relay ⑨ REG/REC
④ Fuel gauge ⑩ Oxygen sensor
⑤ Ignition SW 11 Fuse box
⑥ Ignition coil 12 Starter relay
13 Battery
4-1
2
4
① ISCV-Idling speed control valve ⑤ CKPS -Crank shaft position sensor

② DCP ⑥ MAQ sensor
③ Throttle body IAPS : Intake air pressure sensor
④ TS plug IATS : Intake air temperature sensor
TPS : Throttle Position Sensor
4-2
DCP-FI SYSTEM
INJECTION VOLUME
The three major signals that determine the injection volume are: Intake air pressure from the Intake air
pressure sensor, rotational speed from the crank shaft position sensor and the throttle opening from the
throttle position sensor. These signals calculate the basic injection volume. This basic volume, combined
with modification signals produced by other sensors and the storage battery voltage, will lead to an
optimized injection volume.
IAPS
Basic fuel
injection
CKPS
volume
Throttle position sensor
IATS
Oxygen sensor Modifications
ETS of the injection
Battery voltage volume
Final
DCP injection
volume
MODIFICATION OF THE INJECTION VOLUME

SIGNAL CONTENT
Oxygen sensors will check the oxygen content in the exhaust
Oxygen sensor signal
pipe, modifying the injection volume.
When engine temperature rises, the injection volume should
Engine temperature signal
be reduced, and vice versa.
When intake air temperature rises, the injection volume
Intake air temperature sensor signal
should be reduced, and vice versa.
Start up signal. (produced by the crank Make sure fuel injection is done in a timely manner. When the
shaft sensor) vehicle slows down, the fuel supply should be cut off.
Acceleration/deceleration signal. When engine speed rises, the injection volume should be
(produced by the air throttle position increased. When the engine slows down, the fuel supply
sensor) should be cut off.
CONTROLLING THE END OF THE INJECTION

SIGNAL CONTENT
When the vehicle has a tilting angle greater than 45° for more
Tip-over sensor signal than 5 seconds, the ECU will cut off the DCP and the
ignition coil.
When engine speed reaches 9000rpm, the ECU will cut off the
Speed limit signal fuel supply for the injection units to limit engine speed.
Throttle position sensor signal When engine starts with a throttle opening larger than 3/10,
the fuel supply and ignition coil will be cut off.
When the rider releases the accelerator abruptly (deceleration),
the throttle position sensor will send a deceleration signal to
Deceleration control signal the ECU, cutting off fuel supply to the injection units. When
engine speed is down to 2000 rpm, the ECU will restart the fuel
supply.
4-3
4-4
YG
OW
START
Gr
FREE
PUSH
O
YW
LIGHTS
CLUTCH-SW
L BBr
G G
B
P
OFF
ON
OY OY
B
B R R
MAGNETO
O O
Gr Gr
Br Br
M
IGNITION-SW
RB RB
G
STARTER-MOTOR
NE
YG OY
AT
YB P
VTA
GB
PM
Gg
THA
OG
OL
THE
LB
10A
NT
20A
R
FUSE-BOX(Y)
RW
O
FUSE-BOX(B)
DCP+
STARTER-RELAY
R R WR
TS
WL DCP-
BG
DIAG
12V
BW BW BY
IG
BATTERY
WG
ECU
OX
PB
GP
BrW
DON
R RB
ST
TPS P R
VCC
MAP GB OW
KS
AT Dg W
OXH
MAQS
BBr O
+B
BBr
E2
OW BW
E1
YR YR
ISCV
ISCV
BW
E0
RW
WL R
DCP
BrW P
W OW BBr
+B
GND Gr BBr
OX B WG
W W
FUEL-CUT,SNSR
OXH
0 2-SNSR
FI
B BBr
B OL WR
ETS
BW
TS
BG
BY
OW
IGNITION-COIL
FI SYSTEM WIRING
( +)
18 DCP+
CRANK SHAFT DISCHARGE PUMP
POSITION SENSOR
16 DCP- ( -)
NE 26
ANTI THEFT SIGNAL
25 AT
O 2 SENSOR HEATER
6 OXH
THROTTLE POSITION SENSOR GND VTA VCC VCC 9
VTA 23
MANIFOLD PRESSSENSOR GND PM VCC
PM 24
FUEL CUT SENSOR GND DON VCC
DON 11
14 IG
ENG TEMP SENSOR THE 21 IGN. COIL
INTAKE AIR TEMP SENSOR THA 22

ISCV SOLENOID
OXYGEN SENSOR OX 13 2 ISCV IGNITION SW
1KΩ
SPEEDOMETER ASSY
+ Bs DIAG LAMP
E2 4
15 DIAG
4-5
R(2.74KΩ 1/8W) NEUTRAL LAMP
KILL SW
R(1.5KΩ 1/8W)
5 +B
R(825Ω 1/8W) GP 12
MAGNETO
RECTIFIER
R(825Ω 1/8W)
15A
WIRE DIAGRAM OF THE FI SYSTEM
+Bs
8 KS
STG SW
GEAR POSITION SW 4 3 2 1 3 E1
BATTERY
1 E0
STG RELAY
DIAGNOSIS 10 ST
DEVICE TS 17
TEST SW
20 NT CLUTCH-SW
NEUTRAL SW M STG MOTOR
ECU TERMINAL
1 3 12 11 10 9 8 6 5 4 3 2 1
26 25 24 2 3 22 21 20 18 1 7 16 15 14
NO. CYCLE NO. CYCLE

1 ECU grounding 14 Ignition coil
2 ISCV(Idle Speed Control valve) 15 FI light
3 ECU grounding 16 DCP _
4 Sensor system grounding 17 TS signal
5 Power supply 18 DCP +

6 Heater of the oxygen sensor 20 Neutral signal
8 Power supply of starter check 21 ETS (Engine Temperature Sensor )
9 ECU power supply 22 IATS (Intake Air Temperature Sensor)
10 Starter motor 23 IAPS (Intake Air Pressure Sensor)
11 TOS (Tip-Over Sensor) 24 TPS (Throttle Position Sensor)
12 Gear pistion light 25 Starter switch
13 Oxygen sensor 26 Crankshaft position sensor +
4-6
SELF-DIAGNOSIS FUNCTION
The ECU is capable of self-diagnosis. Abnormal operations within the DCP-FI system will trigger the ECU,
which will turn on the FI warning light (fault signals) and store DTC in an erasable memory.
CURRENT DTC/HISTORY DTC
There are two kinds of DTC under different conditions.

● If the ECU detects an on-going fault, the FI warning light will
blink in a fault-specific mode, which can be read and converted
into the current DTC. Alternatively, special tools can be used
to read the DTC directly.
● If the ECU hasn't detected any on going faults, but a previous
fault is stored, the FI warning light will not blink. Special tools
can be used to extract the fault history, a s well as read or delete
previous DTC.
FI WARNING LIGHT---FLASHING MODE

● DTC can be read from the blinking pattern of the FI warning light. They can also be extracted using a
diagnosis device.
● If the ECU hasn't detected any ongoing faults, when the ignition switch is turned 'ON', the FI warning light
will light up for several seconds before switching off again.
● If the ECU detects an ongoing fault, when the ignition switch is turned 'ON', the FI warning light will light up
for a few seconds, turn off and then blink in a fault-specific manner.
FAULT-SPECIFIC BLINKING METHOD

For first number, the warning light goes on for 1 second and for units digit numbers for 0.3second.
The blinking interval is 0.3 second while the interval between first and second number is 1 second.
The interval between two DTC is 3 seconds.
How to read a current DTC: As shown in the figure below: '23'
The warning light will blink twice, going on 1 second each time, with an interval of 0.3 second.
After these two long blinks, the light will go off for 1 second and then blink faster three times, turning on for
0.3 second each time. 3 seconds later, the warning light will repeat the above mentioned sequence.
First number Second number

On
Interval Next DTC
Off
CHECK FI WARNING LIGHT

If the FI warning light cannot conduct self-inspection when the ignition switch is turned 'ON', the control
circuit fuse for the central relay and the warning light should be checked for burning damage or open circuit.
4-7
FAULT DIAGNOSIS DEVICE

NTRODUCTION TO FAULT DIAGNOSIS DEVICE
Screen Esc Enter
Up
Imposed
upgrade
Power indicator Next page
Previous
page
Down
Communication indicator
USB updating interface Diagnosis interface Power switch
Screen brightness
adjustment DC12V power Intake air socket
STEPS TO USE THE FAULT DIAGNOSIS

DEVICE
● Make sure the ignition switch and the power switch for the
diagnosis device are both turned off.
4-8
● Dismantle the storage battery cover, take out the wiring

harness plug for the diagnosis device. Connect the wiring
harness plug to the diagnosis device.
● Turn on the ignition switch first and then the diagnosis device.
This will lead to the static diagnosis stage. Alternatively, the
engine can be switched on and then the diagnosis device
turned on, which will lead to the dynamic diagnosis stage.
NOTE:
When the diagnosis has been completed, follow the
same steps in the opposite order to disconnect the
diagnosis device.
● A system menu will pop up on starting the diagnosis device.

●Select 'Fault Diagnosis', press 'Enter' and access the
diagnosis menu.
●Select 'HJ125T - 16A' and press 'Enter'.
●Click on the 'DCP' menu and enter the 'Function Selection'

menu.
●Select to read the current fault code and take appropriate
measures to fix it after confirmation.
●Then select to read the fault history to make sure there are
no hidden faults to fix.
●When all the faults have been fixed, select 'Clear Fault
Codes' to delete the fault codes.
●Select 'Read Data Stream' to make sure the vehicle can
display the fault codes.
●'TPS idling setting' refers to the pre-set value of the air
throttle position stored in the ECU.
WARNING:
No adjustment of idling speed is allowed.
* FUNCTIONAL KEY
F1 will read current fault code: An ongoing fault is one that the vehicle
currently possesses. Once the problem has been solved, it will be erased
by the system. Fault information will be stored in the ECU memory under
the fault history folder.
F2 will read the fault history: F2 will read the current fault code, including the
fault code for loose connections, which come and go and may not be
recurrent, as well as fault codes left undeleted from the last repair. Note:
The current fault code will be written into the memory each time the ignition
switch is fired. (a maximum of 16 items can be stored.)
F3 will erase the fault codes: Eliminate the fault history.
F4 will read the data stream.
F5 will set the TPS idling speed.
F6 will read the current computer version.
4-9
TROUBLESHOOTING FOR THE DCP-FI SYSTEM

PRE-DIAGNOSIS INSPECTION
The following inspections should be carried out before the fault diagnosis.
●Engine oil volume and oil leakage ●Melted fuse
●Fuel volume and leakage ●Working condition of the FI warning light
●Air filter blockage ●Working condition of the speedometer
●Storage battery condition ●Exhaust leakage
●Clearance of air throttle cable ●Connection of plugs and sockets
●Cracking, damaging or loosening of vacuum throat
FAULT ANALYSIS FOR THE ELECTRONIC INJECTION SYSTEM
◇Fault with specific DTC: System faults that have specific fault codes corresponding to it.
Features: FI warning light displays a single DTC.
Causes: Short or broken circuits in the signal circuit or control circuit of electronic control components;
short or broken circuits in the electronic control components; Short or broken circuits in the ECU
For example: Faults in the engine temperature sensor and its wiring.
Processing steps:
Follow the instructions
in the fault diagnosis Check the connection of
Check the terminals of the plugs and sockets.
device. the plugs and sockets.
Faults in electronic control Check the connection

components or the ECU of the electric wires.
◇Faults without specific DTC: The actual fault is not the one indicated by the FI warning light or the
diagnosis device.
Features: FI shows several DTC at the same time.
Causes: Short or broken circuits in the bus wiring.
For example: Faults in the central relay, relay fuse, sensor power supply or sensor wiring.
Processing steps:
Check all the Check the bus wiring based Follow the steps mentioned above to solve faults
related fuses. on the fault pattern. in bus wiring.
◇ The vehicle tests 'normal' using a diagnosis device but will not start or will not work normally after
starting.
Features: The FI warning light doesn't display any DTC.
Causes: Non-electrical faults or inaccurate signals in the electrical controlled components.
For example: Fuel spray blockage, blocked air throttle or increased resistance in the signal circuit.
Processing steps:
Extract data stream of the vehicle

Analyze the data stream for anomalies.
from the fault diagnosis device.
Solve problems with the Find the fault based on an

electric controlled abnormal data stream.
components.
4-10
TABLE OF DIAGNOSTIC TROUBLE CODE (DTC)
DTC BLINKING OF FI WARNING LIGHT SENSORS/LOAD
Crank shaft position

12
sensor
13 Intake Air Pressure

Sensor
14 Throttle Position Sensor
15 Engine temperature
Sensor
Intake Air Temperature

21
Sensor
23 Tip-Over Sensor
24 Ignition coil
31 Gear position signal
32 DCP
40 Idle speed control valve
Heater of the
44
oxygen sensor
4-11
DTC '12': CKPS

INSPECTION
Sequence 1
1) Switch the ignition switch 'OFF'
2) Remove the seat cushion/helmet box.
3) Check if there is any looseness or poor contact with the
socket connector of the CKPS.
4) If not, measure the resistance of the CKPS.
5) Remove the socket connector of the CKPS, and measure

its resistance.
Resistance of the crank shaft position sensor:

150-230 KΏ (G-L)
09900-25008 : Pocket tester
Dose the resistance fall within the normal range?

Yes-Go to sequence 2.
No-Replace crank shaft position sensor.
Sequence 2
1) Check if there is any looseness or poor contact with the ECU
socket connector.
2) If not, replace the ECU.
3) Delete the fault code with specific tools after repairing.
4-12
DTC '15': ETS

INSPECTION
Sequence 1
socket connector of the ETS.
4) If not, measure the resistance of the ETS.
5) Remove the socket connector of the ETS, and measure its

resistance.
Electric resistance of the ETS: 5-14kΏ under

temperature of 20-40℃(B-B)
Dose the resistance fall within the normal range?

Yes-Go to sequence 2.
No-Replace the ETS.
Sequence 2
ECU socket connector.
4-13
DTC '23': TOS

INSPECTION
Sequence 1
2) Remove the front-slanted plate.
socket connector of the TOS.
4) If not, measure the resistance of the TOS.
5) Remove the socket connector of TOS, and measure its

voltage.
Input voltage of the TOS:
4.5 - 5.5V(R-Grounding)
6) Check the output voltage of the Tip-Over Sensor
Output voltage of theTOS:
Upright position: 0.4 - 1.4V
Tip-Over: 3.7 - 4.4V (Br/W-B/Br)

Dose the voltage fall in the normal range?
Yes-Sequence 2.
No- Replace the TOS.
Sequence 2

socket connector.
4-14
DTC '24': IGNITION COIL

INSPECTION
Sequence 1
socket connector of the IG. coil.
4) If not, measure the resistance of the IG. Coil.
5) Remove the socket connector of the IG. coil, and measure

its resistance.
IG. coil resistance: 3.4 - 4.6Ώ (Υ/Β-O/W)
Dose the resistance fall in the normal range?

Yes-Sequence 2.
No- Replace the IG. coil.
Sequence 2
socket connector.
4-15
DTC’32': (DCP)
INSPECTION
Sequence 1
socket connector of the DCP.
4) If not, measure the resistance of the DCP.
5) Remove the socket connector of the DCP, and measure its

resistance.
Electric resistance of the DCP: 1.9Ώ (R/W-W/L)
Does the resistance fall in the normal range?

Yes-Sequence 2.
No- Replace the DCP
Sequence 2
socket connector.
4-16
DTC '40’: IDLE SPEED CONTROL VALVE

INSPECTION
Sequence 1
socket connector of the ISCV.
4) If not, measure the resistance of the ISCV.
5) Remove the socket connector of the ISCV, and measure its

resistance.
Electric resistance of the ISCV:

31 - 39Ώ (Y/R-O/W)
Does the resistance fall in normal range?

Yes- Sequence 2.
No- Replace the ISCV.
Sequence 2
4-17
DTC ‘44’: (O 2 S)
INSPECTION
Sequence 1
2) Remove the left lateral strip.
socket connector of the O 2 S.
4) If not, measure the resistance of the O 2 S.
5) Remove the socket connector of the O 2 S, and measure its

resistance.
Resistance of the heater: 11.7 - 14.3Ώ (Early stage)

11.7 - 15.6Ώ (After endurance)(B - Gr)
Dose the resistance fall in normal range?

Yes-Sequence 2.
No- Replace the oxygen sensor
Sequence 2
4-18
DTC ‘13’,'14' OR '21': INTAKE AIR PRESSURE, THROTTLE

POSITION OR INTAKE AIR TEMPERATURE SENSOR
INSPECTION
Sequence 1
socket connector of the air-throttle housing.
4) If not, measure the resistance of the air-throttle housing.
5) Remove the socket connector of the air-throttle housing,

and measure its resistance.
Output voltage of the Intake Air Pressure Sensor:

2.0-3.5V at idle speed (G/B-B/Br)
Resistance of the Throttle Position Sensor
Fully open 2.9-5.1KΏ (P-B/Br)
Completely closed 0.61-0.97KΏ (P-B/Br)
Resistance of the Intake Air Temperature

Sensor: About 2.9KΏ ( Dg - B/Br)
Are the output voltages and electric resistances normal?

Yes-Sequence 2.
No- Replace the air-throttle housing.
Sequence 2
socket connector.
4-19
DISMOUNTING THE ELECTRONIC

INJECTION UNIT
WARNING:
Components of the sensors are not shock resistance,
so be careful not to drop them during operation. Also,
do not pull the wiring.
ECU and TOS

DISASSEMBLY
● Turn the ignition switch 'OFF'.
● Dismantle the screws in the front panel and the panel itself.
● Pull off the ECU plug and the Tip-over sensor plug.
● Loosen the fastening screw for the Tip-over sensor and
dismantle the tiling sensor.
●Take the ECU out of the safety box.
REMOUNTING
To mount, reverse the procedure described above.
CRANKSHAFT POSITION SENSOR

2
DISASSEMBLY
Dismantle the cover of the electro-magnetic engine.
Dismantle the crank shaft position sensor and stator coil. 1
REMOUNTING
Mounting should follow the exact steps in the opposite order
of disassembly with special attention paid to the following points.
Apply the fastening gel to the stator coil and fastening screws
for the crank shaft position sensor.
99000 - 32110: THREAD LOCK SUPER “1322"
4-20
DCP
● Open the pad lock and dismantle the helmet box.
● Put a clean, oil-resistant vessel next to the fuel filter, pull off
the fuel pipe and empty the fuel tank.
WARNING:
Petroleum is explosive. Handle with care.
● Pull off the DCP plug and all the fuel pipes. Remove the
screws for the DCP and the pump itself.
REMOUNTING
To mont, reverse the procedure described above.
THROTTLE POSITION SENSOR AND MAQ

SENSOR
WARNING:
The MAQ sensor and idling control valves cannot be
dismantled separately. Dismantle the air throttle
housing as a whole.
DISASSEMBLY
● Dismantle the seat pad and helmet box.
● Disconnect the MAQ sensor, idling control valve and air
throttle housing plug.
● Release the installation bolts on the air Intake air pipe and the
fastening screws on air filter Intake air pipe.
● Dismantle the accelerator cable and the air throttle housing.
REMOUNTING
To mount, reverse the procedure described above.
4-21
OXYGEN SENSOR
DISASSEMBLY
● Dismantle the seat pad and the helmet box.
● Dismantle the rear cover and the right lower cover.
● Disconnect the oxygen sensor plug.
● Dismantle the oxygen sensor.
REMOUNTING
To mountl, reverse the procedure described above.
ENGINE TEMPERATURE SENSOR

DISASSEMBLY
● Dismantle the seat pad and helmet box.
● Dismantle the left and right cover and the side panel.
● Remove the Throttle Position Sensor as a whole and
dismantle the air Intake air pipe.
● Dismantle the upper and lower air deflector of the engine.
● Dismantle the engine temperature.
REMOUNTING
Mounting should be conducted following the exact steps in
the opposite order of disassembly. Special attention should
be paid to the following key points.
Don't twist the temperature sensor wiring during mounting.
WARNING:
Don't pull the engine temperature sensor wires.
4-22
FUEL SYSTEM
4-23
FUEL REMOVAL AND DISASSEMBLY

● Take off the seat and the left & right frame covers.
● Clamp the hose ① and ②，take off the hose, vent fuel tank 1
gasoline.
● Take off the right and left side cover, remove the mounting bolts, 3
clamp the hose ③ , disconnect the coupler of fuel sensor,
then take off the fuel tank.
● The fuel tank can be mounted in the reverse order of

removal.
THROTTLE BODY
● Take off the right and left frame covers & the seat & the fuel tank.
5
● Take off the fuel pump hose ④. 4
● Take off the fuel pump intake hose⑤ 。

● Remove the fuel filter⑥ .
● Disconnect the couple of fuel pump⑦.

● Disconnect the couple of ISCV ⑧.
● Disconnect the couple of 3-in-1 sensor ⑨. 7
● Disconnect the couple of engine temperature sensor.
4-24
● Take off the PVC hose.
● Remove the hose ①.

● Loosen the throttle cable adjuster lock nuts , and take off the 1
throttle cable ② and ③. 3
● Remove the throttle body from the right side of frame by

unscrewing clamp screws.
● Remove the fuel pump by unscrewing clamp screws.
4-25
THROTTLE VALVE CLEANING ISC
WARNI NG
Some carburetor cleaning chemicals, especially dip-type
soaking solutions, are very corrosive and must be handled
carefully. Always follow the chemical manufacturer’s in-
structions on proper use, handling and storage.
MAQS
● Use a swab moistened with a carburetor cleaner (petroleum
solvent) to clean the passageways, throttle valve, and main
bore and then dry the cleaned surfaces with compressed air.
NOTICE
Do not use wire to clean passageways. Wire can damage
passageways.
Never spray a cleaner (petroleum solvent) directly to the
throttle valve and and ISC by pass passage.
The cleaner, if sprayed, would work its way into the
inside of ISC valve and attack the insulation film of the
coil there, causing a short circuit and eventual
malfunction of ISC valve. In addition, if a short circuit
occurs in the coil, an overcurrent would flow through the
ISC valve drive circuit causing the ECU to brake down.
When the throttle valve is molybdenum-coated, avoid
applying the cleaner to the coated surfaces. The cleaner
will peel off the coating and this will impair the air-
Bypass passage
tightness of the throttle valve.
If the components cannot be cleaned with a spray
cleaner it may be necessary to use a dip-type cleaning
solution and allow them to soak. Always follow the
chemical manufacturer’s instructions for proper use
and cleaning of the throttle body components. Do not
apply carburetor cleaning chemicals to the rubber and
plastic materials.
REMOUNTING
● The throttle body can be mounted in the reverse order of

removal.
4-26
CHASSIS
CONTENTS
FRONT WHEEL 5-1

FRONT ABSORBER 5-3
STEERING STEM 5-10
FRONT BRAKE 5-13
REAR WHEEL AND REAR BRAKE 5-19
REAR SWING ARM 5-25
5
CHASSIS
FRONT WHEEL
18~28N. m
5 0 ~ 8 0 N .m
REMOVAL AND DISASSEMBLY

FRONT WHEEL
● Support the motorcycle by center stand.
● Remove front wheel nut.
● Draw out the axle shaft and take off the wheel.
NOTE:
Do not operate the front brake lever while dismounting the
front wheel.
● Using the appropriate drift, drive out the wheel bearings.
5-1
CHASSIS
● Unlock the washers and remove the four bolts.

● Separate the disc from the wheel.
NOTICE
Do not reuse the lock washers.
INSPECTION
PLAY
WHEEL BEARING
PLAY
Inspect the play of wheel bearings inner race by hand while
fixing it in the wheel hub.
Rotate the inner race by hand to inspect whether abnormal
noise occurs or rotating smoothly.
Replace the bearing if there is something unusual.
AXLE SHAFT
Using the special tools, check the axle shaft for runout and
replace it if the runout exceeds the limit.
TOOL 09900-20606 : Dial gauge(1/100)

09900-21304 : V-block(100mm)
THICKNESS OF BRAKE DISC

Using the special tools, check the thickness of the brake disc
and replace it if the thickness exceeds the limit. (Refer to page
2-10)
TOOL 09900-20101 : Vernier caliper (1/50 mm,150 mm)
5-2
CHASSIS
REASSEMBLY
Reassembly and remount the front wheel and front brake in
the reverse order of disassembly and removal, and also carry
out the following steps.
BRAKE DISC
● Make sure that the brake disc is clean and free of any
greasy matter, after securing bolts, be sure to lock with
specified torque.
Brake disc bolt : 18~28N•m
NOTE:
Always use new lock washers.
● Bend the washer to the bolts.
WHEEL BEARING
● Apply grease to the bearings before installing.
APPLY SUPER GREASE “A”
● Install the wheel bearings by using the special tool.
TOOL 09913-75820 : bearing installer
SPEEDOMETER GEAR BOX

● Before installing the speedometer gear box grease it and
align groove on the wheel hub with two drive pawls on
speedometer drive gear box.
1
APPLY SUPER GREASE “A”

2
● When tightening the front axle, check to be sure that the

speedometer gear box is in the position shown.
TIRE
(Refer to page 2-13)
5-3
CHASSIS
FRONT SHOCK ABSORBER
50~80N.m
1 8 ~28N.m
12~20N.m
25~40N.m
1 5~30N.m
18~28N.m
15~25N . m
5-4
CHASSIS

● Remove the front wheel (Refer to page 5-1).
● Remove the two bolts and dismount the front caliper.
● Remove the four bolts and take off the front fender.
● Remove the two screws and take off the headlight.
● Disconnect the couplers and lead wires.

● Remove the lead wires from the headlight housing.
● Remove the two bolts and take off the headlight housing.
● Remove the two bolts and take off the combination meter
assembly.
5-5
CHASSIS
● Disconnect the clutch inner cable from the clutch lever.
● Remove the brake hose clamp bolt.

● Take off the throttle cable by removing the right handle
switch assy.
● Remove the handlebars clamp bolts after take off the caps.
● Loosen the front shock absorber upper clamp bolts.

● Remove the stem head bolt.
● Remove the head of steering stem.
NOTE:
Slightly loosen the front shock absorber cap bolts to facilitate
later disassembly.
● Remove the brackets of headlamp right and left.

● Remove the cover of steering stem after remove the
flashers right and left.
5-6
CHASSIS
● Loosen the front shock absorber lower clamp bolts.
● Pull down right and left front shock absorber.
● Remove the cap bolt and draw out the shock absorber
spring.
● Invert the shock absorber and stroke it several times to

remove the oil.
● Hold the shock absorber inverted for a few minutes.
● Remove damper rod bolt by using the special tools and

8mm hexagon wrench.
11F14-010-01 ： “T”handle
11F14-010-02 : Shock absorber knocked-down tool
5-7
CHASSIS
● Remove the oil lock piece and damper rod with rebound
spring.
● Separate the inner tube from the outer tube.
● Remove the stopper ring.
● Remove the oil seal by using the special tool.
09913-50121 ： Oil seal remover
NOTICE
The oil seal removed should be replaced with a new one.
INSPECTION
DAMPER ROD RING
● Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE
● Inspect the inner tube and outer tube sliding surface for any
scuffing or flaws.
5-8
CHASSIS
SHOCK ABSORBER SPRING

● Measure the shock absorber spring free length. If it is
shorter than the service limit, replace it.
Service limit 338mm
REASSEMBLY
Reassembly and remount the front shock absorber in the
reverse order of disassembly and removal, and also carry out
the following steps:
DAMPER ROD BOLT

● Apply SUZUKI BOND No.4 and THREAD LOCK CEMENT to THREAD LOCK SUZUKI BOND NO.4
the damper rod bolt and tighten the bolt by using the 8mm CEMENT
hexagon wrench and special tools.
No.4
99100-31030 ： SUZUKI BOND No.4
99000-32040 ： THREAD LOCK CEMENT
11F14-010-01 ：“T”handle
11F14-010-02 : Shock absorber rempver
D a mper r o d b o lt : 2 0 ~26 N·m
OIL SEAL
● Install the oil seal to the outer tube by using the special tool
as shown.
09940-50112 ： Oil seal installer
SHOCK ABSORBER
● For the shock absorber oil, be sure to use a front shock
absorber oil whose viscosity rating meets specifications
below.
Absorber oil type ：Special absorber oil
Capacity (each leg) 3 8 5±3 m l
5-9
CHASSIS
● Hold the front shock absorber vertical and adjust the shock
absorber oil level with the special tool.
NOTE:
When adjusting oil level, remove the shock absorber spring
and compress the inner tube fully.
09943-74111 ： Shock absorber oil level gauge
Oil level 120mm
SHOCK ABSORBER SPRING

上边
Upside
● When installing the front fork spring, the close pitch end
should position upside.
下边
REMOUNTING
● When installing the front fork assembly, align the top ① of
inner tube to the upper surface ② of the steering stem
head.
1
2
● Tighten the upper ④ and lower clamp bolt ③ to the

specified torque.
The upper clamp bolt ： 18~28N·m

The lower clamp bolt ： 25~35N·m
● Tighten the stem head bolt ⑤ to the specified torque.
The stem head bolt ： 35~55N·m
5-10
CHASSIS
STEERING STEM
● Remove the front wheel ( Refer to page 5-1).
● Remove the front shock absorber (Refer to page 5-3 ).
● Remove the steering stem nut and draw outsteering stem.
NOTE:
Hold the steering stem by hand to prevent from falling.
● Remove the upper and lower steel balls.
Upper 14pcs
Number of balls
Lower 14pcs
● Remove the outer race fitted on the steering stem. This be

done with a chisel.
● Draw out the two inner races fitted to the top and bottom
ends of the head pipe.
INSPECTION
● Inspect and check the remove parts for the following
abnormalities.
* Handlebars distortion.
* Handlebars clamp wear.
* Race wear and denudation.
* Worn or damaged steel balls.
* Distortion of steering stem.
5-11
CHASSIS
REASSEMBLY
Reassemble and remount the steering stem in the reverse
order of disassembly and removal, and also carry out the
following steps:
INNER RACES
● Press in the upper and lower inner races using the special
tool.
09941-34513 ： Steering race installer
OUTER RACE
● Press in the outer race by using the special tool.
09941-74910 ： Steering bearing installer
STEEL BALL
● Apply grease to the upper and lower inner races when
installing the steel balls.
99000-25010 ： SUZUKI SUPER GREASE “A”
Upper 14pcs
Number of balls
Lower 14pcs
STEERING STEM NUT

● Tighten the steering stem nut to 40-50N· m by using the
special tool.
09941-14911 ： Steering nut socket wrench
● Turn the steering stem right ang left, lock-to-lock, five or

six time to “seat”the ball bearings.
5-12
CHASSIS
● Turn back the stem nut by 1/4-1/2 turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
● Tighten the steering stem head bolt, the upper and lower
clamp bolts to the special torque (Refer to page 5-12).
T he steering stem ： 35~55N·m
WARING
After performing the adjustment and installing the
steering stem upper head, “rock”the front wheel
assembly forward and back-ward to ensure that there is
no play and that the procedure was accomplished
correctly.
Finally check to be sure that the steering stem moves
freely from left to right with itsown weight. If play or
stiffness is noticeable, readjust the steering stem nut.
HANDLEBARS
● Set the handlebars to match its punched mark to the mating
face of the holder.
● Secure the each handlebars clamp in such a way that the

clearances Ａ ahead of and behind the handlebars should
be equalized.
Tightening torque ： 20~30N·m
5-13
CHASSIS
FRONT BRAKE
5-14
CHASSIS
BRAKE PAD REPLACEMENT

● Lossen the tow pins of caliper ①.
● Remove the caliper mounting bolts ② and take off the
caliper.
NOTICE
2
Do not operate the brake level while dismounting the
caliper.
● Push the piston and piston holder all the way to the caliper
when removing the brake pads.
● Remove the bracket.

● Pull out the pins.
● Remove the brake pads and replace them.
NOTICE
Replace the brake pad with a set, otherwise braking
performance will be adversely affected.
● Reassemble the brake pads and the caliper in the reverse

orders.
● Tighten the caliper mounting bolts to the specified torque.
Tightening torque ： 18~28N·m
NOTE:
Push in the piston and piston holder all the way to the caliper
when remounting the caliper.
CALIPER REMOVAL AND DISASSEMBLY

● Disconnect the brake hose from the caliper by remove the
bolt ① and catch the brake fluid in a suitable receptacle
(Refer to page 2-13).
● Loosen the two pins ② of caliper.
● Remove the caliper mounting bolts ③ and take off the
caliper.
2
5-15
CHASSIS
CAUTION
Never re-use the brake fluid left over from the last
servcing and stored for long periods.
Do not operate the brake lever while dismounting the
caliper.
● Remove the bracket.

● Pull out the pins.
● Remove the brake pads.
● Place a rag over the piston to prevent popping up. Force out
the piston by using air gun.
CAUTION
Do not use high pressure air to prevent piston damage.
● Remove the piston, piston boot and piston seal.
INSPECTION
CALIPER CYLINDER
● Inspect the cylinder bore wall for nick, scratch or other damage.
PISTON
● Inspect the piston surface for any scratches or damage.
5-16
CHASSIS
RUBBER PARTS
● Inspect the each rubber part for damage and wear.
BRAKE DISC
● Measure the disc thickness by using the
micrometer.
09900-20205 ： Micrometer (0~25 mm)
● With the disc mounted on the wheel check thedisc for

face runout with a dial gauge, as shown.
09900-20606 ： Dial gauge (1/100mm)

09900-20701 ： Magnetic stand
REASSEMBLY
Reassemble and remount the caliper in the reverse orders of
disassembly and removal, and also carry out the following
steps:
WARNING
Wash the caliper components with fresh brake fluid
before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the caliper bore and all internal
parts before inserting into the bore.
● Apply SUZUKI SUPER GREASE to the piston holder.
99000-25010 ： SUZUKI SUPER GREASE“A”
5-17
CHASSIS
Tightening torque
Hose bolt ① : 20~25N·m
Caliper mounting bolt ② : 18~28N·m
2
WARNING
Bleed air from the brake fluid circuit after reassembling
the caliper (Refer to page 2-13).
MASTER CYLINDER
● Place a cloth underneath the union bolt on the master
cylinder to catch spilled drops of brake fluid. Unscrew the
union bolt and disconnect the brake hose from the master
cylinder joint.
NOTICE
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics, rubber materials, etc. And
will damage them severely.
● Remove two clamp bolts and take off the master cylinder.
● Remove two fitting screws, and remove the cap and

diaphragm.
● Drain brake fluid.
● Remove the dust seal boot.

● Remove the circlip by using the special tool.
09900-06108 ： Snap ring pliers
5-18
CHASSIS
INSPECTION
● Inspect the master cylinder bore for any scraches or other
damage.
● Inspect the piston surface for scratches or other damage.

● Inspect the primary cup, secondary cup and dust seal boot
for wear or damage.
REASSEMBLY
Reassemble and remount the master cylinder in the reverse
orders of disassembly and removal, and also carry out the
following steps.
NOTICE
Wash the master cylinder components with fresh brake
fluid before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all internal
parts before inserting into the bore.
● When remounting the master cylinder on the handlebars, Master cylinder

first tighten the clamp bolt for upside as shown.
WARNING UP
Bleed air from the brake fluid circuit after reassembling
master cylinder (See page 2-13).
Handlebar
Clearance
5-19
CHASSIS
REAR WHEEL AND REAR BRAKE
50~80N.m
8~12N.m
1 8 ~28N.m
REMOVAL
● Support the machine by the center stand.
● Remove the rear brake adjuster nut ① and disconnect the
brake rod ②. 2
1
● Pull off the cotter pin ③ and remove the torque link nut ④
and bolt.
3
5-20
CHASSIS
● Pull off the cotter pin and remove the rear axle nut ⑤.
● Loosen the chain adjuster lock nut ⑥ and adjuster bolt ⑦,
5
right and left.
● Draw out the axle shaft and take off the chain from rear
sprocket.
● Take off the rear wheel and separate the brake panel from
the wheel.
DISASSEMBLY
REAR WHEEL
● Flatten the washers and remove the four nuts.
● Separate the rear sprocket and mounting drum from the
wheel.
● Remove the oil seal by using the special tool.
09913-50121 ： Oil seal remover
● Remove the bearing and retainer from the mounting drum.
5-21
CHASSIS
● Remove the cushion from the wheel.
● Remove the right and left side wheel bearings.
NOTE:
Removing the left side bearing first makes the job easier.
REAR BRAKE
● Take off the brake shoes.
● Remove the cam lever nut and bolt.
● Pull off the brake cam, washer, O-ring and cam lever.
5-22
CHASSIS
INSPECTION
PLAY
WHEEL BEARING
PLAY
Inspection the wheel bearings for play by hand. Rotate the
inner race by hand to inspect whether abnormal noise occurs
and it rotates smoothly. Replace the bearing if there are any
defects.
AXLE SHAFT
● Using the special tools, check the axle shaft for runout and
09900-20606 : Dial gauge (1/100)

09900-21304 : V-block (100mm)
SPROCKET
● Inspect the sprocket teeth for wear. If they are worn as
illustrated, replace the sprocket and drive chain.
Normal wear Excessive wear
REAR BRAKE DRUM

● Measure the brake drum I.D. to determine the extent of
wear and, if the limit is exceeded by the wear noted, replace
the drum. The value of this limit is indicated inside the
drum.
BRAKE SHOE
● Check the brake shoes and decide whether it should be
replaced or not from the thickness of the brake shoe linings.
Service limit 1.5mm
CAUTION
Replace the brake shoes as a set, otherwise braking
performance will be adversely affected.
5-23
CHASSIS
CUSHION
● Inspect the cushion for wear and damage.
REASSEMBLY
Reassemble and remount the rear wheel and rear brake in the
reverse order of disassembly and removal, and also carry out
the following steps:
WHEEL BEARING
● Apply grease to the bearings before installing.
99000-25010 ： SUZUKI SUPER GREASE "A"
● Install the wheel bearings by using the special tool.
NOTE:
First install the wheel bearing for right side.
09913-80112 ： Bearing installer
MOUNTING DRUM
● Insert the bearing by using the special tool.
09940-53311 ： Bearing installer
● Apply grease to the mounting drum as shown.
5-24
CHASSIS
SPROCKET
● After tightening the four nuts to specification, bend the lock
washers.
Tightening t o r q u e : 18~28N·m
BRAKE CAM
● Apply grease to the brake cam.
WARNING
Be careful not to apply too much grease to the brake cam.

If grease gets on the lining, brake slippage will result.
BRAKE CAM LEVER

● Install the brake cam lever and tighten the cam lever nut
with specified torque.
Tigh t ening t o r q u e : 6 ~ 8 N·m
TIRE (Refer to page 2-13)
5-25
CHASSIS
REAR SWING ARM
1 0 ~ 1 6 N .m
50~80N . m

● Remove the rear wheel (Refer to page 5-19).
● Remove the rear shock absorber units and take off the
shock absorber units.
5-26
CHASSIS
● Remove the two screws and take off the chain case.
● Remove the swing arm pivot nut and draw out the shaft.
● Remove the swing arm.
● Pull off the cotter pin and remove the nut and bolt.
● Remove the torque link.
● Remove the chain buffer

● Remove the dust seal covers and draw out the spacers.
● Draw out the bushings by using the special tools.

5-27
CHASSIS
INSPECTION
BUSHING
Inspect the bushing for wear and damage.
SWING ARM PIVOT SHAFT
Using a dial gauge, check the pivot shaft for runout and
09900-20606 ：Dial gauge (1/100)

09900-21304 : V-block (100mm)
Service limit 0.6mm
REASSEMBLY
Reassemble and remount the swing arm in the reverse order
of disassembly and removal, and also carry out the following
steps:
SWING ARM BUSHINGS

● Force-fit the bushings into the swing arm by using the
special tool.
09924-84510 ： Bearing installer set
SPACER AND DUST SEAL COVER

● Apply grease to the spacer and dust seal cover when
installing.
5-28
CHASSIS
LEFT & RIGHT SIDE BOX AND

BRACKET REMOVE
DISASSEMBLY
● Open the side box, take off the side box bolts, remove the
side box.
● Take off the decorative covers.
● Disconnect the couplers of turn light.
● Take off the side box bracket.
REMOUNTING
● The side box can be mounted in the reverse order of

removal.
5-29
ELECTRICAL
CONTENTS
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6
ELECTRICAL
IGNITION SYSTEM
ECU
Ignition coil
CKP sensor
ECU Ignition switch

ERC
Battery
MAGNETO IGNITION COIL
6-1
ELECTRICAL
INSPECTION
PICK-UP
● Using the pocket tester(RX1Ω range), measure the
resistance between the lead wires in the following table .
09900-25002 ： Pocket tester
L-G
Pick-up coil resistance
Approx. 90-300Ω
B-B
Charging coil resistance
Approx. 0.5-1.3Ω
WIRE COLOR
L : Blue
NOTE: G : Green
When mounting the stator on the generator cover, apply a
B : Black
small quantity of THREAD LOCK "1342" to the threaded
parts of screws.
99000-32050 ： THREAD LOCK “1342"
IGNITION COIL
● Check the ignition coil with electro tester.
● Test the ignition coil for sparking performance.
● Test connection is as indicated. Make sure that the three-
needle sparking distance is at least 8 mm.
09900-28106 ： Electro tester
STD Spark performance 8mm
● Check the ignition coil with pocket tester.
Ignition coil resistance
Primary O/W -W Approx.3.5-4.5Ω
Secondary Plug cap-O/ W Approx.16-30kΩ
6-2
ELECTRICAL
SPARK PLUG
● Clean
the plug with a wire brush and pin. Use the pin to
remove carbon, taking care not to damage the porcelain.
● Check the gap with a thickness gauge.
09900-20803 ： Thickness gauge
Spark plug gap 0.7-0.8mm

0.7-0.8mm
6-3
ELECTRICAL
CHARGING SYSTEM
CHARGING OUTPUT CHECK
Start the engine and keep it running at 5 000r/min. Using the
pocket tester, measure the DC voltage between the battery
terminal and .
If the tester reads under 13.5V or over 16.0V, check the AC
generator no-load performance and regulator/rectifier.
NOTE:
When making this test, be sure that the battery is full-charged
condition. IG. SWITCH
Regulator
Rectifier
STD charging output
Battery
14.0V-15.0V 5000r/min
AC GENERATOR NO-LOAD PERFORMANCE

Disconnect the three lead wires from the AC generator
terminal.
Start the engine and keep it running at 5 000r/min.
Using the pocket tester, measure the AC voltage between the
three lead wires.
If the tester reads under 70V, the AC generator is faulty.
STD No-load performance
More than 70V (AC) at 5 000r/min
REGULATOR/RECTIFIER
● Replace the new regulator/rectifier, if it is the question.
6-4
ELECTRICAL
STARTER SYSTEM
DESCRIPTION
The starter system is shown in the diagram below: namely, the starter motor, relay, engine kill switch, IG
switch, starter button and battery. Depressing the starter button (on the right handlebar switch box)
energizes the relay, causing the contact points to close which connects the starter motor to the battery.
The motor draws about 80 amperes to start the engine.
STARTER MOTOR REMOVAL AND DISASSEMBLY

● Remove the starter motor .
● Disassemble the starter motor as follows.
6-5
ELECTRICAL
STARTER MOTOR INSPECTION

CARBON BRUSHES
When the brushes are worn, the motor will be unable to
produce sufficient torque, and the engine will be difficult to
turn over. To prevent this, periodically, inspect the length of
the brushes, replacing them when they are too short or
chipping.
COMMUTATOR
If the commutator surface is dirty, starting per-formance
decreases. Polish the commutator with #400 or similar fine SEGMENT
emery paper when it is dirty. After polishing it, wipe the ①
commutator with a clean dry cloth.
Check the commutator under cut ¢.

MICA
ARMATURE COIL
Using a pocket tester, check the coil for open and ground by
placing probe pins on each commutator segment and rotor
core (to test for ground) and on any two segments at various
places (to test for open), with the brushes lifted off the
commutator surface.
If the coil is found to be open-circuited or ground-ed, replace

the armature. Continuous use of a defective armature will
cause the starter motor to suddenly fail.
STARTER MOTOR REASSEMBLY
BRUSH HOLDER AND HOUSING END

When fixing brush holder to starter motor case, align the
protrusion ① of the starter motor case with the notch ② of the 2
brush holder.
When installing housing end, fix the protrusion ③ of the 1
starter motor case to the notch ④ on the housing end.
6-6
ELECTRICAL
SECURING SCREWS
Apply THREAD LOCK "1342" to starter motor securing
screws.
99000-32050 ： THREAD LOCK "1342"
STARTER RELAY INSPECTION

Disconnect lead wire of the starter motor at starter relay.
Turn on the ignition switch, inspect the continuity between the
terminals, positive and negative, when pushing the starter
button.
If the starter relay is in sound condition, continuity is found.
6-7
ELECTRICAL
COMBINATION METER
Remove the combination meter (Refer to page 6-6).
Disassemble the combination meter.
INSPECTION
Using the pocket tester, check the continuity be-tween lead
wires in following diagram.
速度表
If the continuity measured is incorrect, replace the respective SPEEDOMETER
part.
档位灯
燃油表 FI GPI
09900-25002 ： Pocket tester FU EL-ME TER
NOTE: FUEL
BW
Gr
Lg
B
When making this test, it is not necessary to remove the R(2.74 Ω 1/8 W)
R(1.5k Ω 1/8 W)
combination meter. R(82 5Ω 1/8 W)

R(82 5Ω 1/8 W)
Lg
B
BW
Y
Gr
BW
BW
YB
Gr
BrR
O
WY
GR
BG
RB
PB
YL
O
6-8
ELECTRICAL
LIGHTS
HEADLIGHT TURN SIGNAL LIGHT
TAIL/BRAKE LIGHT
SWITCHES
Inspect each switch for continuity with the pocket tester
referring to the chart. If it is found any abnormality, replace
the respective switch as-sembly with new one.
IGNITION SWITCH ①
R O Br Gr OY
OFF
ON ○ ○ ○ ○ ○
P ○ ○
6-9
ELECTRICAL
LIGHTING SWITCH①
②
Gr O Y/W
○ ○
○ ○ ○
③ ①
ENGINE KILL SWITCH ②
O O/W
○ ○
STARTER SWITCH ③
O/W Y/G
OFF
○ ○
FRONT BRAKE LIGHT SWITCH ④ ④

Y O/W
OFF
ON ○ ○
DIMMER SWITCH ⑤
Y/W Y W
○ ○
○ ○ 5
TURN SIGNAL LIGHT SWITCH ⑥ 6

B Sb Lg
○ ○
7
○ ○
HORN SWITCH ⑦
G B/W
OFF
○ ○
6-10
ELECTRICAL
REAR BRAKE LIGHT SWITCH ①

O W/B
OFF
ON ○ ○ ①
GEAR POSITION INDICATOR LIGHT SWITCH

GRD L W/Y R/B G/L Y/L Br/R
○ ○
N
○ ○
Low
○ ○
2nd
○ ○
3rd
○ ○
4th
○ ○
Top
WIRE COLOR
B ........... Black B/W .......... Black with White tracer
Br .......... Brown Br/R ......... Brown with Red tracer
G ........... Green G/L ........... Green with Blue tracer
Gr ......... Gray O/W ......... Orange with White tracer
L ........... Blue R/B .......... Red with Black tracer
Lg ......... Light green W/B .......... White with Black tracer
O ........... Orange W/Y .......... White with Yellow tracer
R .......... Red Y/B .......... Yellow with Black tracer
P ........... Pink Y/G........... Yellow with Green tracer
Sb ......... Light blue Y/L ........... Yellow with Blue tracer
W .......... White Y/W .......... Yellow with White tracer
Y .......... Yellow
6-11
ELECTRICAL
BATTERY
SPECIFICATIONS
Type designation YTX7L-BS
Capacity 6AH/(10HR)
Standard electrolyte S.G. 1.320±0.01 (20℃)
INTIAL CHARGING
FILLING ELECTROLYTE
Remove aluminium strip ① which seals battery electrolyte
filling hole.
Remove special electrolyte cover ②.
NOTE:
After filing electrolyte, seal battery filing hole with the remove
cover②.
Do not remove or pierce sealing part ③ of electrolyte bottle.
Insert electrolyte container port into battery electrolyte

filling hole, holding bottle fast to prevent dropping.
CAUTION
Do not splash the fluid.
Ensure that there are bubbles coming up in every

electrolyte container and keep this state for over 20
minutes.
6-12
ELECTRICAL
NOTE:
If there are no bubbles coming up the filling hole, pat the bottle
bottom for twice or three times. In so doing, there is no need to
remove electrolyte container from battery.
● After ascertaining that electrolyte is fully filled into battery,

remove electrolyte container from battery and wait for about 20
minutes;
● Insert cover into filling hole, press it hard to make cover surface
flush with battery upper surface;
CAUTION
Never use anything except the specified battery.
Once install the caps to the battery; do not remove the caps.
Insert cover securely
Inspect battery voltage by means of circuit tester. Circuit tester

reading should reach 12.5～ 12.6V as illustrated (DC). If battery
voltage is below specified value, charge battery with charger (Refer
to recharge operation).
NOTE:
If production date is two years ago, it is advised to effect initial
charge of the new battery. (V) 25℃
30 seconds
13
SERVICING 12
Inspect battery surface visually. If there are fissures round battery 11

or there is electrolyte leakage traces, the new battery should be
replaced. If battery connecting terminal is covered with rust or an 10
acidic powdery sludge, remove it with sandpaper.
0 2 4 6 8 10(minute)
time
RECHARGE OPERATION
Inspect battery voltage by means of circuit tester. If voltage reading
is below 12.0V (DC), charge battery with charger. charging time
(V) stop charging
18
CAUTION 17
16
When recharging the battery, remove the battery from the 15
motorcycle. 14
13
12
NOTE:
Do not remove the cover on battery when charging. 60
time 0 10 20 30 40 50
(minute)
CAUTION
Be carful not o permit the charging current to exceed 3A at any (V) O O
0 ~ 40 C
time. 14
13
● After recharging, wait for over 30 minutes before inspecting
12
battery voltage with circuit tester;
● If battery voltage is below 12.5V, charge battery again; 11
● If measured voltage is still below 12.5V, use a new battery for 10
replacement;
In case motorcycle is not in use for a long time, battery should be
● 100 75 50 25 0（%）
inspected once a month to prevent battery discharge. battery state after charging
6-13
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
WIRE AND CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7
SERVICE INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
ENGINE
COMPLAINT SYMPTOM AND POSSIBLE CAUSE REMEDY
ENGINE WILL NOT Compression too low

START OR IS HARD 1. Valve clearance out of adjustment Adjust.
TO START 2. Worn valve guides or poor seating of valves Repair or replace.
3. Mistiming valves Adjust.
4. Excessively worn piston rings Replace.
5. Worn-down cylinder bores Replace.
6. Too slowly starter motor cranks See electrical section.
7. Poor seating of spark plug Retighten.
Plug not sparking

1. Fouled spark plug Clean.
2. Wet spark plug Clean and dry.
3. Defective ignition coils Replace.
4. Defective CKP sensor Replace.
5. Defective ECU Replace.
6. Open-circuited wiring connections Repair or replace.
7. Open or short in high-tension cords Replace.
No fuel reaching the intake manifold

1. Clogged fuel filter or fuel hose Clean or replace.
2. Defective fuel pump Replace.
3. Defective fuel pressure regulator Replace.
4. Defective fuel injector Replace.
5. Defective fuel pump relay Replace.
7. Open-circuited wiring connections Check and repair.
Incorrect fuel/air mixture

1. TP sensor out of adjustment Adjust.
4. Defective TP sensor Replace.
6. Defective IAP sensor Replace.
8. Defective ECT sensor Replace.
9. Defective IAT sensor Replace.
10. Clogged ISC valve air passage way Repair or replace.
7-1
SERVICE INFORMATION

ENGINE IDLES 1. Valve clearance out of adjustment
POORLY 2. Poor seating of valves Adjust.
3. Defective valve guides Replace or repair.
4. Worn down camshaft Replace.
5. Too wide spark plug gaps Replace.
6. Defective ignition coils Adjust or replace.
11. Imbalanced throttle valve Replace.
12. Damaged or cracked vacuum hose Adjust.
13. Damaged or clogged ISC valve Replace.
14. ISC bad learning Replace or repair.
Reset learned value.
ENGINE STALLS OFTEN Incorrect fuel/air mixture

1. Defective IAP sensor or circuit Repair or replace.
2. Clogged fuel filter Clean or replace.
6. Defective thermostat Replace.
8. Damaged or cracked vacuum hose Replace.
9. Damaged or clogged ISC valve Replace or repair.
Fuel injector improperly operating

1. Defective fuel injectors Replace.
2. No injection signal from ECU Repair or replace.
3. Open or short circuited wiring connection Repair or replace.
4. Defective battery or low battery voltage Replace or recharge.
Control circuit or sensor improperly operating

7. Defective fuel pump relay Replace.
8. Defective ISC valve Replace.
9. ISC bad learning Reset learned value.
Engine internal parts improperly operating

1. Fouled spark plug Clean.
2. Defective CKP sensor or ECU Replace.
3. Clogged fuel hose Clean.
4. Out of adjustment valve clearance Adjust.
7-2
SERVICE INFORMATION
Complaint Symptom and possible causes Remedy
Noisy engine Excessive valve chatter

1. Too large valve clearance Adjust.
2. Weakened or broken valve springs Replace.
3. Worn rocker arm or cam surface Replace.
4. Worn and burnt camshaft journal Replace.
Noise seems to come from piston

1. Worn down pistons or cylinders Replace.
2. Carbon combustion chambers fouled with carbon Clean.
3. Worn piston pins or piston pin bore Replace.
4. Worn piston rings or ring grooves Replace.
Noise seems to come from timing chain

1. Stretched chain Replace.
2. Worn sprockets Replace.
3. Tension adjuster not working Repair or replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub Replace.
2. Worn teeth of clutch plates Replace.
3. Distorted clutch plates, driven and drive Replace.
4. Worn clutch release bearing Replace.
Noise seems to come from crankshaft

1. Rattling bearings due to wear Replace.
2. Worn and burnt big-end bearings Replace.
3. Worn and burnt journal bearings Replace.
4. Too large thrust clearance Replace thrust bearing.
Noise seems to come from balancer

1. Worn and burnt journal bearings Replace.
Noise seems to come from transmission

1. Worn or rubbing gears Replace.
2. Worn splines Replace.
3. Worn or rubbing primary gears Replace.
4. Worn bearings Replace.
Noise seems to come from water pump

1. Too much play on pump shaft bearing Replace.
2. Worn or damaged impeller shaft Replace.
3. Worn or damaged mechanical seal Replace.
4. Contact between pump case and impeller Replace.
7-3
SERVICE INFORMATION
Engine runs poorly Defective engine internal/electrical parts

in high speed range 1. Weakened valve springs Replace.
2. Worn camshaft Replace.
3. Valve timing out of adjustment Adjust.
4. Too narrow spark plug gaps Adjust.
5. Ignition not advanced sufficiently due to poorly Replace ECU.
working timing advance circuit
6. Defective ignition coils Replace.
9. Clogged air cleaner element Clean.
10. Clogged fuel hose, resulting in inadequate fuel Clean and prime.
spply to injector
Defective air flow system

1. Clogged air cleaner element Replace.
2. Defective throttle valve Adjust or replace.
3. Sucking air from throttle body joint Repair or replace.
5. Imbalancing throttle valve synchronization Adjust.
Defective control circuit or sensor

1. Low fuel pressure Repair or replace.
5. Defective GP sensor Replace.
8. TP sensor out of adjustment Replace.
Engine overheats Defective engine internal parts

1. Heavy carbon deposit on piston crowns Clean.
2. Not enough oil in the engine Add oil.
3. Defective oil pump or clogged oil circuit Replace or clean.
4. Sucking air from intake pipes Retighten or replace.
5. Use incorrect engine oil Change.
6. Defective cooling system See radiator section.
Lean fuel/air mixture

1. Short-circuited IAP sensor/lead wire Repair or replace.
2. Short-circuited IAT sensor/lead wire Repair or replace.
3. Sucking air from intake pipe joint Repair or replace.
4. Defective fuel injectors Replace.
Other factors
1. Ignition timing is too advanced due to defective Replace.
timing advance system (ECT sensor, GP sensor,
CKP sensor and ECU) Adjust.
2. Drive chain is too tight Reset learned value.
3. ISC bad learning
7-4
SERVICE INFORMATION
Engine lacks power Defective engine internal/electrical parts

1. Loss of valve clearance Adjust.
2. Weakened valve springs Replace.
3. Valve timing out of adjustment Adjust.
4. Worn piston rings or cylinders Replace.
5. Poor seating of valves Repair.
6. Fouled spark plug Clean or replace.
7. Incorrect spark plug Adjust or replace.
8. Clogged fuel injectors Replace.
10. Clogged air cleaner element Replace.
11. Imbalancing throttle valve synchronization Adjust.
12. Sucking air from throttle valve or vacuum Retighten or replace.
hose
13. Too much engine oil Drain out excess oil.
14. Defective fuel pump or ECU Replace.
15. Defective CKP sensor and ignition coils Replace.
Defective control circuit or sensor

1. Low fuel pressure Repair or replace.
5. Defective GP sensor Replace.
10. Imbalanced throttle valve synchronization Adjust.
Dirty or heavy 1. Too much engine oil in the engine Check with inspection window, drain
exhaust smoke out excess oil.
2. Worn piston rings or cylinders Replace.
3. Worn valve guides Replace.
4. Scored or scuffed cylinder walls Replace.
5. Worn valves stems Replace.
6. Defective stem seal Replace.
7. Worn oil ring side rails Replace.
Slipping clutch 1. Weakened clutch springs Replace.

2. Worn or distorted pressure plates Replace.
3. Distorted clutch plates or pressure plates Replace.
4. Clutch release screw out of adjustment Adjust.
Dragging clutch 1. Some clutch spring weakened while others Replace.

are not
2. Distorted pressure plates or clutch plates Replace.
3. Clutch release screw out of adjustment Adjust.
7-5
SERVICE INFORMATION
Transmission will 1. Broken gearshift cam Replace.

not shift 2. Distorted gearshift forks Replace.
3. Worn gearshift pawl Replace
Transmission will 1. Broken return spring on shift shaft Replace.

not shift back. 2. Rubbing or stickily shift shaft Repair or replace.
3. Distorted or worn gearshift forks Replace.
Transmission jumps 1. Worn shifting gears on driveshaft or Replace.
out of gear countershaft
2. Distorted or worn gearshift forks Replace.
3. Weakened stopper spring on gearshift stopper Replace.
4. Worn gearshift cam plate Replace.
CHASSIS
Heavy steering 1. Overtightened steering stem nut Adjust.

2. Broken bearing in steering stem Replace.
3. Distorted steering stem Replace.
4. Not enough pressure in tires Adjust.
Steering oscillation. 1. Loss of balance between right and left front suspensions. Replace.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobbly front wheel. 1.Distorted wheel rim. Replace.

2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.
Front suspension too 1. Weakened springs. Replace.
soft. 2. Not enough fork oil. Refill.
Front suspension too 1. For oil too viscous. Replace.

stiff. 2. Too much fork oil. Remove excess oil.
Noisy front suspension. 1. Not enough fork oil. Refill.
2. Loose nuts on suspension. Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Remedy

2. Worn-down rear wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushings. Replace.
6. Loosen nuts on the rear shock. Retighten.
Rear suspension too 1. Weakened springs. Replace.

soft. 2. Rear suspension adjuster improperly set. Adjust.
Rear suspension too 1. Rear suspension adjuster improperly set. Adjust.

stiff. 2. Warn swing arm bushings. Replace.
Noisy rear suspension. 1. Loose nuts on suspension. Retighten.

2. Worn swing arm bushings. Replace.
7-6
SERVICE INFORMATION
BRAKES
Poor braking. 1. Not enough brake fluid in the reservoir. Refill to level mark.
2. Air trapped in brae fluid circuit. Bleed air out.
3. Pads worn down. Replace.
4. Top much play on brake lever or pedal. Adjust.
5. Linings worn down. Replace.
Insufficient brake power. 1. Leakage of brake fluid from hydraulic system. Repair or replace.
2. Worn pads. Replace.
3. Oil adhesion on engaging surface of pads. Clean disc and park
4. Worn disc. Replace
5. Air in hydraulic system. Bleed air
Brake squeaking. 1.Carbon adhesion on pad surface. Repair surface with sandpaper.
2.Tilted pad. Modify pad fitting.
3.Damaged wheel bearing. Replace.
4.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5.Worn pads. Replace.
6.Foreign material in brake fluid. Replace brake fluid.
7.Clogged return port of matter cylinder Disassemble and clean master
cylinder.
Excessive brake lever 1.Air in hydraulic system. Bleed air.

stoke. 2.Warn brake lever cam. Replace brake lever.
3.Insufficient brake fluid. Replenish fluid to specified lever;
bleed air.
4.Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake fluid. 1.Insufficlent tightening of connection joints. Tighten to specified torque.
2.Cracked hose. Replace.
3.Worn piston and/or cup. Replace piston and/or cup.
7-7
SERVICE INFORMATION
ELECTRICAL
No sparking or poor 1. Defective ignition coils Replace.
sparking 2. Defective spark plug Replace.
5. Defective TO sensor Replace.
6. Open-circuited wiring connections Check and repair.
Spark plug soon 1. Mixture too rich Inspect FI system.

become fouled with 2. Idling speed set too high Adjust fast idle or throttle
carbon stop screw.
3. Incorrect gasoline Change.
4. Dirty air cleaner element Replace.
5. Too cold spark plug Replace with hot type plug.
Spark plug become 1. Worn piston rings Replace.

fouled too soon 2. Worn piston or cylinders Replace.
3. Excessive clearance of valve stems in valve Replace.
guides
4. Worn stem oil seal Replace.
Spark plug electrodes 1. Too hot spark plug Replace with cold typeplugs.
overheat or burn Tune up.
2. Overheated the engine Retighten.
3. Loose spark plug Inspect FI system.
4. Too lean mixture
Generator does not 1. Open- or short-circuited lead wires, or loose lead Repair or replace or
charge connections retighten.
2. Short-circuited, grounded or open generator coil Replace.
3. Short-circuited or punctured regulator/rectifier Replace.
Generator does 1. Lead wires tend to get shorted or open-circuited Repair or retighten.
charge, but charging or loosely connected at terminals
rate is below the 2. Grounded or open-circuited generator coil Replace.
specification 3. Defective regulator/rectifier Replace.
4. Defective cell plates in the battery Replace the battery.
Generator overcharges 1. Internal short-circuit in the battery Replace the battery.
2. Damaged or defective regulator/rectifier Replace.
3. Poorly grounded regulator/rectifier Clean and tighten ground
connection.
Unstable charging 1. Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent short-circuiting
2. Internally shorted generator Replace.
3. Defective regulator/rectifier Replace.
Starter button is not 1. Run down battery Repair or replace.
effective 2. Defective switch contacts Replace.
3. Brushes not seating properly on starter motor Repair or replace.
commutator
4. Defective starter relay/starter interlock switch Replace.
5. Defective main fuse Replace.
7-8
SERVICE INFORMATION
BATTERY
“Sulfation”, acidic white
powdery substance or 1.storage battery case with fissure Replace storage battery
spots on surface of cell 2.long period of battery storage Replace storage battery
plates
Storage battery 1.incorrct charging system Inspect generator, stabilized
consumption too fast rectifier and electric terminals,
effect necessary adjustment
to ensure specified charging
2.battery plate with no active substance due to overcharging Replace storage battery and
rectify charging system
3.short circuit in storage battery Replace storage battery
4.storage battery voltage too low Recharge storage battery
5.stale storage battery Replace storage battery
Storage battery 1.overcharging or undercharging (When storage is not in use, Replace battery
sulphation inspect it at least once a month to prevent it from sulphation)
2.storage battery not in use for a long time in cold weather In case of serious sulphation,
replace storage battery
Storage battery
dirty battery top and flanks clean
discharge too quick
7-9
SERVICE INFORMATION
SPECIAL TOOLS
09900-20101 09900-20203 09900-20205

09900-06107 09900-06108 vernier caliper micrometer micrometer
snapring pliers snapring pliers (1/50mm,150mm) (1/100mm,50~75mm) (1/100mm,0~25mm)
09900-20508 09900-20606 09900-21304

cylinder bore gauge kit dial gauge 09900-20701 09900-20803 V-block (set)
(1/100mm,40~80mm) (1/100mm,10mm) magnetic gauge bracket thickness gauge (100mm)
09900-22401
small bore gauge 09900-25002 09900-28403 09910-20116 09910-32812
(10~18mm) circuit tester hydrometer Conrod holder crankshaft installer
09910-34510 09913-50121 09913-75520 09913-75820 09913-75830

piston pin remover oil seal remover bearing installer bearing installer bearing installer
09915-64510 09915-74531
09913-80112
cylinder pressure gauge 09915-74510 oil pressure gauge 09916-20610
bearing installer
09915-63310 (adapter) oil pressure gauge adapter valve seat cutter (N-121)
09916-34570
09916-20620 09916-20630 09916-21110 09916-34542 valve tube reamer
valve seat cutter (N-122) valve seat cutter (N-126) valve seat cutter kit valve tube reamer arm (5.0mm)
7-10
SERVICE INFORMATION
09921-20210
09920-13120 11F14-019 09920-53710 bearing remover 09922-55131
crankcase separator valve adjustor clutch sleeve hub holder (12mm) bearing remover
09923-73210 09923-74510
bearing puller bearing remover 09924-84510 09924-84521 09925-98221
(15 17mm) (20 35mm) bearing installer set bearing mounting kit bearing installer
09930-40113 09930-30190 09930-30180 09930-30102 09940-14921

rotor and sprocket holder gear remover rotor separator, M28 slide shaft four claw wrench
09940-34561 09930-44400 09940-53311 09941-34513

09930-44511
front fork tool rotor holder rotor holder bearing installer steering race installer
09943-74111 09940-50112 09941-74910 09943-88211 09951-76010

front fork oil level gauge front fork oil seal installer steering bearing installer bearing installer bearing installer
11F14-003 11F14-005 11F14-006 11F14-012 11F14-018

rotor separator rotor separator,M30 rotor separator, M33 clutch nut socket wrench valve spring tool
7-11
TIGHTENING TORQUE
ENGINE
ITEM Kg·m N·m
Cylinder head nut 2.8-3.2 28-32
Cylinder bolt 0.8-1.2 8-12
Cylinder head cover bolt 0.9-1.1 9-11
Generator rotor nut 9.0-11.0 90-110
Clutch nut 3.0-5.0 30-50
Adjusting nut of valve clearance 1.3-1.6 13-16
Mounting bolt of the engine (front) 3.3-3.9 33-39
Mounting bolt of the engine (rear) 3.3-3.9 33-39
Mounting bolt of the engine (top) 3.3-3.9 33-39
Bolts on the starting clutch hub 1.9-2.3 19-23
Primary drive gear nut 4.0-6.0 40-60
CHASSIS
ITEM Kg·m N·m
Front axle nut 5.0-8.0 50-80
L 1.8-2.8 18-28
S teering upper bracket bolts R 1.8-2.8 18-28
M 5.0-8.0 50-80
Steering lower bracket bolts 2.5-4.0 25-40
Clamping bolt on the handlebar 1.2-2.0 12-20
Bolt on the exhaust pipe 1.8-2.8 18-28
Bolt/nut on the engine cover 3.3-3.9 33-3.9
(top and front)
Front footrest bolt 1.8-2.8 18-28
Front brake disc bolt 1.8-2.8 18-28
Front brake caliper mounting bolt 2.7-4.3 27-43
Front brake hose union bolt 2.0-2.5 20-25
Nuts on the rear absorbers 2.2-3.5 22-35
Rear brake link bolt 1.0-1.6 10-16
Rear axle nut 5.0-8.0 50-80
Bolt/nut on the rear swing arm 5.0-8.0 50-80
7-12
TIGHTENING TORQUE CHART

For other bolt and nuts who's torque is not listed, refer to this chart:
Bolt Diameter Conventional or "4" marked bolt "7" marked bolt

(mm) kg·m N·m kg·m N·m
4 0.1-0.2 1.0-2.0 0.15-0.3 1.5-3.0
5 0.2-0.4 2.0-4.0 0.3-0.6 3.0-6.0
6 0.4-0.7 4.0-7.0 0.8-1.2 8.0-12.0
8 1.0-1.6 10.0-16.0 1.8-2.8 18.0-28.0
10 2.2-3.5 22.0-35.0 4.0-6.0 40.0-60.0
12 3.5-5.5 35.0-55.0 7.0-10.0 70.0-100.0
14 5.0-8.0 50.0-80.0 11.0-16.0 110.0-160.0
16 8.0-13.0 80.0-130.0 17.0-25.0 170.0-250.0
18 13.0-19.0 130.0-190.0 20.0-28.0 200.0-280.0
Conventional bolt "4" marked bolt "7" marked bolt
SERVICE DATA
CYLINDER + VALVE Unit：mm
ITEM STANDARD LIMIT
IN 25.40-25.60 ——
Valve diam
EX 22.40-22.60 ——
IN 0.04-0.07 ——
Valve clearance (when cold)
EX 0.10-0.13 ——
Valve guide to valve stem IN 0.010-0.035 ——
clearance EX 0.055-0.085 ——
Valve guide I.D. IN&EX 5.000-5.010 ——
IN 4.975-4.990 ——
Valve stem O.D.
EX 4.955-4.970 ——
Valve stem runout IN&EX —— 0.05

Valve stem deflection IN&EX —— 0.35
Valve head thickness IN&EX —— 0.03
Valve seat width IN&EX 0.9-1.1 ——
IN —— 31.24
Valve spring free length
EX —— 33.58
Compression pressure 10-14kg/cm² 8kg/cm²
Cylinder head distortion —— 0.05
7-13
CAMSHAFT Unit：mm
ITEM STANDARD LIMIT

IN 33.650-33.690 33.350
Cam height
EX 33.300-33.340 33.000
Camshaft O.D. 21.959-21.980 ——
Camshaft runout —— 0.10mm

Rocker arm I.D. 12.000-12.018 ——
Rocker arm shaft O.D. 11.977-11.995 ——
CYLINDER + PISTON + PISTON RING Unit：mm
ITEM STANDARD LIMIT

Cylinder b o re 57.000-57.015 57.135
P i ston diam 56 .95 5- 56 .97 0 (Mea su re at 8 mm from the sk irt en d) 56.835
Cyl i nder d istortio —— 0.05
1st —— 0.50
Piston ring end gap
2nd —— 0.50
1st —— 0.180
Piston ring groove clearance
2nd —— 0.180
1st 1.01-1.03 ——
Piston ring groove width 2nd 1.01-1.03 ——
Oil ring 2.01-2.03 ——
1st 0.97-0.99 ——
Piston ring thickness
2nd 0.97-0.99 ——
Piston pin bore 15.002-15.008 15.030
Piston to pin clearance 0.002-0.014 ——
Piston pin O.D. 14.996-15.000 14.980
7-14
CONROD + CRANKSHAFT Unit：mm
ITEM STANDARD LIMIT

Conrod small end I.D. 15.006-15.014mm 15.040mm
Conrod deflection —— 3.0mm
Conrod bag end clearance 0.10-0.45mm 1.00mm
Conrod big end width 15.95-16.00mm ——
Cranksha ft web to web widt h 52.9-53.1mm ——
Crankshaft runout —— 0.08mm
CLUTCH Unit：mm
ITEM STANDARD LIMIT

Clutch cable play 4 ——
Drive plate thickness 2.70-2.90 2.40

Drive plate claw width —— 0.10
Driven plate distortion —— 29.45
Clutch spring free length 11.80-12.00 11.40
TRANSMISSION + DRIVE CHAIN Unit：mm
ITEM STANDARD LIMIT

Primary reduction ratio 3.500(70/20) ——
Final reduction ratio 2.867(43/14) ——

Low 3.000(33/11) ——
2nd 1.875(26/14) ——
Gear ratio 3rd 1.368(26/19) ——
4th 1.142(24/21) ——
5th 0.956(22/23) ——
Shift fork to groove clearance 0.10-0.30 0.50
1& 2 4.80-4.90 mm ——
Shift fork thickness
3 5.30-5.40 mm ——
Type KMC 428H ——
Drive chain Links 130 ——
20-pitc h length —— 259.0 mm
Drive chain slack 10-20 mm ——
7-15
FI-SENSORS
ITEM STD/SPEC NOTE
CKP sensor resistance 150~230 kΩ
IAP sensor input voltage 4.5~5.5V
IAP sensor output voltage 2.0~3.5V at idle speed
TP sensor input voltage 4.5~5.5V
TP sensor resistance Closed 0.61~0.97 kΩ
Opened 2.9~5.1 kΩ
ET sensor input voltage 4.5~5.5
ET sensor resistance 5~14 kΩ (20~40℃)
IAT sensor input voltage 4.5~5.5V
IAT sensor resistance About 2.5 kΩ (20℃）
TO sensor output voltage Nutural 0.4~1.4V When
Leaning 3.7~4.4V leaning 65°
TO sensor resistance 19.1~19.7 kΩ
FUEL PUMP + FIAV

ITEM SPECIFICATION NOTE
Fuel pump resistance 1.9 Ω (20℃)
FIAV resistance 31 -39 Ω
ELECTRICAL
Ignition timing
Type NGK CR7E

Spark plug
Gap 0.7mm-0.8mm
Spark performance Over 8mm at 1atm
Primary 3.4Ω-4.6Ω W-O/W
Ignition coil resistance
Secondary About 10.4KΩ-15.6KΩ Plug cap-O/W
Pick up 130-180Ω G-Bl
Generator coil resistance
Charging About:0.7Ω B-B
Generator no-load voltage More than 70V (AC) at 5000 r/min
Regulated voltage 14-15V at 5 000 r/min
Type designation YTX7L-BS
Battery Capacity 6Ah
Standard electrolyte S.G. 1.32±0.01 (20oC)
Fuse 10A, 20A
7-16
ITEM SPECIFICATION ITEM SPECIFICATION

HI 35W Neutral indicator light 2W
Headlight
LO 35W Turn light 10W
Taillight/brake light 5/21W Position light 5W
BRAKE + WHEEL Unit：mm

ITEM STANDARD LIMIT
Rear brake pedal free travel 20-30
Rear brake pedal height 62.5
Brake disc thickness F 5.0±2 4.5
Brake disc runout F 0.30

Brake cylinder bore F 12.700-12.743
Master cylinder piston diam F 12.657-12.684
Brake caliper cylinder bore F 27.000
Brake drum I.D. R 130.7
Brake lining thickness R 1.5
F 0.25
Wheel axle runout
R 0.25
F 90/90-18 51P
Tire size
R 120/80-16 60P
SUSPENSION Unit：mm
ITEM STANDARD LIMIT
(Front absorber) stroke 120
Front absorber spring 338
free length 345
Front absorber oil level 120
Rear absorber stroke 68

Swingarm pivot shaft 0.6
runout
7-17
TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING DUAL RIDING
TIRE PRESSURE
2
kpa kg/cm psi kpa kg/cm2 psi
FRONT 175 1.75 25 175 1.75 25
REAR 225 2.25 33 225 2.25 33
FUEL + OIL
Use gasoline with an octane number of 90-97

Fuse type
(Research Method), preferably nonleaded.
Including reserve 11.5 L

Fuel tank
Reserve 2.0 L
Engine oil type and grade SAE10W/40,API SF orSG
Change 1000 ml
Engine oil
capacity Filter change 1100 ml
Overhaul 1350 ml
Front shock absorber oil 385±3 ml

capacity (each leg)
7-18
FRAME
INSIDE OUTSIDE
DATUMPLANE EXCEPT VALVE ASSY, PURGE CUT

UPPER BRACKET HOSE, BRTHR VALVE&JOINT
IGNITION SW HOSE, CANISTER VACUUM WELDING HARNESS
THROTTLE CABLE 2 TOOL BOX
REG & REC
IGNITION COIL 工具盒
HOSE, BRTHR VALVE&JOINT PVC BOOT(TS)
FUEL-CUT, SNSR
WIRING HARNESS
WIRING HARNESS
O-SNSR
WIRING HARNESS TURN RELAY ECU
THE HAND OF CLAMP MUST
REG&REC CLIP ALARM
BE BACK WARDS
ECU FRAME
ECU
BATTERY PLUS TERMINAL ASSEMBLING MARKER(WHITE TAPE) ECU PROTECTOR
STARTER MOTOR RELAY TERMINAL

WIRING HARNESS FUEL GAUGE
MAGNETO STARTER-RELAY STARTER-RELAY BRKT

WIRING HARNESS FUSE WIRING HARNESS(ETS)
STOP-LAMP,SW FRAME
CABLE GUIDE
BATTERY BRKT
WIRING HARNESS(ECU)
PVC BOOT
O-SNSR STARTER MOTOR
STOP- LAMP, SW WIRING HARNESS NO.2 REAR- TURN, R
BATTERY
REAR- TURN, R BASE FOR ASSEMBLING
WIRING HARNESS
WELDING CLAMP
WELDING CLAMP
STOP-LAMP,SW STARTER MOTOR RELAY TERMINAL STARTER MOTOR LEAD
INCLUDE VALVE ASSY, PURGE CUT WELDING HARNESS PROTECTOR
BATTERY BRKT
HOSE, CANISTER VACUUM
ENGINE EARTH FRAME
ENGINE EARTH BASE FOR ASSEMBLING
STARTER MOTOR LEAD WIRING HARNESS
STARTER MOTOR LEAD REAR- TURN, R
STARTER MOTOR LEAD VALVE ASSY, PURGE CUT REAR-TURN, L
FRAME
ENGINE EARTH WIRING HARNESS(W)
INSIDE (ETS) HOSE PURGE(PVC TO TB)
CUT AFTER CLAMPING BOLT
GPS
OUTSIDE REAR-TURN, L
BRIKT MAGNETO
O-SNSR PROTECTOR
GPS
FRAME REAR-TURN, L
HOSE, FUEL INJECTOR & 3 WAY
BREATHER HOSE CAN`T PUT MAGNETO BETWEEN HOSE, PURGE(PVC TO TB) AND CLEANER ASSY, AIR
CLAMPING WIRING HARNESS THROTTLE CABLE 2 GPS
ETS
WELDING HARNESS
ENGINE EARTH
WIRE AND CABLE ROUNTING
INSIDE
GPS OUTSIDE
STARTER MOTOR LEAD IGNITION COIL
7-19
MAGNETO
PUT THE OF CLAMP OUTSIDE THE
HOSE,CANISTER VACUUM FRAME AND CUT AFTER CLAMPING HOSE, FUEL 3 WAY& TANK
FRONT-TURN LAMP,L&R WIRING HARNESS HOLE(Φ12)
SPEEDOMETER
HANDLE-SW,R HOSE, FUEL INJECTOR & 3 WAY CLAMP
HANDLE-SW,L
FUEL-METER WELDING HARNESS
GPI
WIRING HARNESS
HANDLE-SW,L&R HANDLE-SW,R HANDLE-SW,L

CLUTCH CABLE WELDING HARNESS
FUEL-METER FRONT-BRAKE HOSE
CUT AFTER CLAMPING GPS

GPI CUT AFTER CLAMPING
SPEEDOMETER
FRONT-TURN LAMP,L&R
HANDLE-SW,R
HEAD-LAMP
FRONT-BRAKE HOSE WIRING HARNESS NO.2
THROTTLE CABLE 2 CLUTCH CABLE REAR TURN, L
CUT AFTER CLAMPING BASE FOR ASSEMBLING
HANDLE-SW,L HORN
NOT TO MAKE THE SUPERABUNDANCE LEAD CLUTCH CABLE
WIRE INSIDE OF HEAD LAMP IN ASSEMBLING
THROTTLE CABLE 2
SPEEDOMETER LEAD MAGNETO
ETS
FUEL-METER SPEEDOMETER CABLE GPS
HANDLE-SW,R MAQS
WIRINGHARNESS THE END OF CLAMP MUST WIRING HARNESS NO.2
FRONT-BRAKE HOSE BE INSIDE THE FRAME
AREA OF ENGINE CUT AFTER CLAMP
FRONT-TURN,R FRONT-TURN,L
LEAD WIRE (SURPLUS:2-3 TEETH)
WELDING CLAMP
REAR TURN, L CUT AFTER CLAMP
WELDING CLAMP
BOOT, WELDING HARNESS
BASE FOR ASSEMBLING
REAR-COMB, LAMP
EXCEPT FRAME VIEW ISC HOSE
HORN ASSY, HIGH PICTHED
REAR-TURN, R
HORN ASSY, LOW PICTHED
LONG WIRE SHORT WIRE
HOSE, PURGE(PVC TO TB)

SPEEDOMETER HANDLE-SW,R
IGNITION-SW
START LIGHTS KILL ECU
ON
OFF FUEL-CUT,SNSR
P STOP-LAMP,SW
FUEL-METER
NE
AT
VTA
PM
THA
THE
NT
DCP+
TS
DCP-
DIAG
IG
OX
GP
DON
ST
VCC
KS
OXH
+B
E2
E1
FIAV
E0
TS
O
R
P
Br
Gr
OY
REG&REC
O
WB
FRONT-BRAKE
GPI IGNITION-COIL
R
O
Br
ON
Gr
FI
OY
BW
R
Y
Y
Y
OFF
BW
WR
BG
FUEL
B
BW
Y
Gr
Lg
G
OY
P
GB
Gg
OL
LB
RW
WR
WL
BG
BY
WG
PB
BrW
RB
R
OW
W
O
BBr
BW
YR
BW
BBr
R
BrW
B
Gr
OB
OW
YG
YW
WB
OG
N 燃油传感器
R
BW
B
Y
FUEL-GAUGE
Lg
Gr
BW
BY
OW
Gr
Gr
O
YB
BW
BW
YG
OG
WB
OW
R(2.74Ω 1/8W)
R(1.5kΩ 1/8W)
R(825Ω 1/8W)
Gr
YB
OG
R(825Ω 1/8W)
BW
BW
WIRING DIAGRAM
BW
YB
O
PB
L
BG
YL
BrR
GR
WY
RB
YB
BW
LB
YL
PB
RB
BG
GR
OG
WY
BrR
FRONT-TURN,R REAR-TURN,R
BW BW
7-20
BW BW
Lg Lg
Lg Lg
HEAD-LAMP
Y Y REAR-COMB,LAMP
Br Br
BW BW
BW BW
W W
WB WB
Br
Br LICENSE-LAMP
Br Br
BW
BW BW
POSITION-LAMP
B B
B B
BW BW
BW BW
FRONT-TURN,L REAR-TURN,L
HARNESS,WIRING NO.2
B
OG O
Lg
G
O
BW
R
Y
OG
B
Sb
YB
Lg
B
BL
BL
B
BW
YR
BL
OW
WL
RW
W
FUSE-BOX(Y)
OL
BBr
WG
OW
BBr
RB
YW
10A
R
YB
YG
BBr
Dg
R
P
GB
Y
O
BBr
O
Sb
ALARM
BL
YB
B
W
Lg
YW
BW
Sb
FUSE-BOX(B)
B
B
LB
RB
WY
GR
BrR
YL
HORN-R HORN-L
RB
B
BW
W
W
Gr
20A
L
B
B
B
G
+B
OX
L
GND
OXH
YL
RB
GR
WY
BrR
STARTER-RELAY
AT
M
TPS
MAP
FIAV DCP 0 2-SNSR ETS TURN-RELAY

R
BW
N
PUSH 1 STARTER-MOTOR MAQS
FREE
2 MAGNETO
PASS
CLUTCH-SW 3 12V
TURNSIGNAL HORN
DIMMER PASS 4
5 BATTERY
HANDLE-SW,L
GPS
JIANG MEN DACHANGJIANG GROUP CO., LTD
Customer service department
1st Ed. DEC, 2011
Printed in China
JIANGMEN DACHANGJIANG GROUP CO., LTD.
Add:No.5,Jiandabei Road,Jiangmen City,Guangdong Provice P.R.C
Tele: 86-750-3288999 Fax:86-750-3288333 Postcode:529000

Manual de Servicio Suzuki GZ 150 (Ingles)

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Manual de Servicio Suzuki GZ 150 (Ingles)

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GZ150

WARNING SERVICING INFORMATION 7

JIANGMEN DACHANGJIANG GROUP CO., LTD.

C O MPO N ENT PARTS A ND WO RK T O B E DONE

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

APPLY oil. Use engine oil unless

APPLY THREAD LOCK “1322”

APPLY SUPER GREASE “A” APPLY THREAD LOCK SUPER “1303”

APPLY SUPER GREASE “C” APPLY THREAD LOCK SUPER “1360”

APPLY SUPER SILICONE GREASE APPLY OR USE BREAK FLUID

APPLY MOLY PASTE MEASURE IN VOLTAGE RANGE

APPLY HEAT TRANSFER OIL MEASURE IN RESISTANCE RANGE

APPLY SEALANT THREE

APPLY SEALANT THREE MEASURE THE TESTING RANGE OF

APPLY SEALANT THREE

No.4 Apply BOND No.4 USE SPECIAL TOOL

It refers to the date of

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

Indicates a potential hazard that could result in minor or moderade injury.

Indicates a potential hazard that could result in vehicle or equipment damage.

SERIAL NUMBER LOCATIONS

FUEL AND OIL RECOMMENDATION

SAE API JASO

Not recommend Recommend

AVOID CONSTANT LOW SPEED

Overall length 2250mm

Ignition type Electronic ignition

PERIODIC MAINTENANCE 2-1

Clean after the first 1,000 km and every 2,000-3,000 km afterwards

PERIODIC MAINTENANCE CHART

INTERVAL km Initial and every 6 000 km Every 12 000 km

Throttle grip _ Grease

Brake cable Engine oil _

Transmission Chain Engine oil every 1000 km

Brake camshaft _ Grease

Follow the steps below on uninstalling the battery:

Install the battery in the reverse order as described above.

AIR CLEANER ELEMENT

If the air cleaner is clogged with dust, intake resistance will be

Check and clean the element in the following manner:

● Remove the left frame cover.

EXHAUST PIPE AND MUFFLER BOLTS

● Tighten the exhaust pipe clamp bolts and muffler mounting

Exhaust pipe c la m p b o l t s : 1 8~2 8 N·m

Muffler mounting bolt : 40~60N·m

NUTS OF THE CYLINDER HEAD &

NUTS OF THE CYLINDER HEAD

Nuts o n th e cyl in d e r hea d : 2 8 ~32 N·m

NUTS OF THE CYLINDER

Nu ts o n t he c y lin d e r : 8~1 2 N·m

09900-20803: Thickness gauge

Valve clearance (when cold):

● If the valve clearances are not between the dimensions

Measure the spark plug gap with a thickness gauge. The

HOT TYPE NGK CR5HSA

Engine oil replacement should be made when the engine is 1

ENGINE OIL FILTER

The oil filter elements should be replaced according to the

OIL SUMP FILTER

CLUTCH CABLE 4mm

Inspect Initial 1 000 km and Every 4 000 km 1

Clutch play should be 4mm as measured at the clutch level