Assembly and Pre-DeliveryService GuideK6January 06 Printed in Japan (TK) 0399505-01096-03EFOREWORDThis motorcycle has been designed and produced utilizing Suzukis most moderntechnology. The finest product, however, cannot perform properly unless it is cor-rectly assembled and serviced. This service guide has been produced to aid you inproperly assembling and servicing this motorcycle.Please review this service guide carefully before performing any work. Take spe-cial care to properly perform the required assembly and servicing marked by eitheraWarningoraCaution.Failuretofollowthedirectionsineitherofthesetwo(2)categoriescouldleadtoseriousproblems.andareas are denoted to emphasize certain areas and carry the following meanings:. . . . . . .Indicatesapotentialhazardthatcouldresultindeath or injury.. . . . . . . . . .Indicatesapotentialhazardthatcouldresultinmotorcycle damage.Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by thedealer shall be deemed by your Suzuki distributor to be performed at the dealerssoleriskandresponsibility.TheSuzukidistributordisclaimsanyandallliability,obligationorresponsibilityforanydefectsresultingfromsaidassemblyandpre-deliveryset-up,andforanyclaims,demandsorcausesofactionfordamagetopropertyorforpersonalinjuriesresultingfromtheDealersassemblyandpre-delivery set-up of Suzuki motorcycle.ThisAssemblyandPre-DeliveryServiceGuidemaycontainphotographsofproducts sold in other markets. The assembly and pre-delivery service proceduresin this guide, however, apply to this market.1PREPARATIONWORKSHOP

A: Packed motorcycleB: Working spaceSELF PROTECTION

UNCRATING THE MOTORCYCLERemove the carton.

A: CrateRemove the strap.Take the front wheel assembly and handlebars assem-bly off the crate base.A: StrapB: Front wheel assemblyC: Handlebars assemblyThe workshop where the machine is assembledshouldbeclean,spacious,andhavealevelfloor.The technician should wear protective clothingsuch as leather gloves, a long sleeve shirt, eyeprotectionandsafetyshoesasshownintheillustration when handling metal crates.Metalcratesmayhavesharpedgesandmaycause injury.2Remove the bolts of the bracket.A: BoltRemove the bolts from the crate.A: BoltLift the steel frame to separate it from the base of thecrate.Carefullyremovethevariouscomponentpartspack-aged around the motorcycle.

A: Steel frameB: Crate baseHandling crates requires two operators. Be careful not to scratch the motorcycle.3LOCATION OF PARTSCheck all the components which have been removed from the base of the crate.Parts listed above are installed respectively into the positions as follows.Item Part Name Qty RemarksAHandlebars assembly 1Clamp 2Allen bolt 4 8 35 mmPlastic cap 4OD:14.5 For handlebar clamp boltScrew 15 35 mmFor throttle assemblyScrew 15 30 mmFor left switchScrew 15 45 mmFor left switchClutch lever cover 1Strap 5 L:140Plastic cap 2OD:36.0For handlebar endBHolder 1For front brake master cylinderAllen bolt 2 6 20 mmCO-ring 1 For throttle cableStrap 1 L:90DFront fender 1Stepped Allen bolt 4 6 16 mmItem Part Name Qty RemarksE Rear view mirror 2 Right and LeftFFrame body cover 2 Right and LeftFrame body lower cover1Fastener 1 LargeFastener 2 MediumTapping screw 2 5 16 mmG Fastener 1 SmallHSeat tail cover 1Hexagonal wrench 1 5 mmI Front wheel spacer 1J Front wheel assembly 1KReflex reflector 2 Right and LeftBracket 2 Right and LeftFlange nut 2 5 mmFlange bolt 1 6 12 mmLBattery electrolyte container1M Owners manual 1OD : Outside diameter (mm)ID : Inside diameter (mm)L : Length (mm)T : Thickness (mm)T LOD IDNOTE:Please hand over the parts shown as Item H in the above table to your customer together with motor-cycle.J D E A HI F KGF C KE B4The photograph shown indicates the parts dismountedfromthemotorcycleinadditiontotheitemsshowninthe preceding page.A: Front brake master cylinderB: Throttle assemblyC: Left switchClutch cableABMCDEFGHIJKL5The certificationof vehiclepre-delivery form mustbe filled out in duplicate for every motorcycle. Useofthisformismandatoryandservesaspro-tection for yourself andyour customer,aswellasassuringthatallnecessaryassemblyandservicefunctions have been completed.ASSEMBLYREMOVING THE BRACKETRemove the bolt to take off the front brake master cyl-inder from the bracket.

A: Front brake master cylinderB: BoltC: BracketRemovethebracketfromthehandlebarmountingposition.

A: BracketB: BoltHANDLEBARSLoosen the throttle housing retaining screws.Insert the throttle assembly onto the handlebars.A: Throttle assemblyB: HandlebarsKeepthepositionoffrontbrakemastercylin-derwithitscapfacingupwardsuntilitisinstalled.NOTE:Theboltisnolongerneededandthismaybediscarded.Be careful not to scratch the fuel tank.NOTE:Thebracketandboltsarenolongerneededand these may be discarded.6Install thehandlebars assemblyusing thetwo clampsand four bolts.A: ClampB: 8 35 mm Allen boltC: Punch markD: Dot markE: Plastic cap OD:14.5 mmTightenthehandlebarclampboltstothespecifiedtorque. Handlebar clamp bolt: 23 Nm (2.3 kgf-m, 16.5 lb-ft)

After installing the handlebars, fit the plastic cap on thehead of each bolt.A: 8 35 mm Allen boltB: 8 35 mm Allen boltC: Plastic cap OD:14.5 mm

A: Front brake hoseB: Throttle cablesC: Right switch wiring harnessD: Clutch cableE: Left switch wiring harnessF: Tachometer lead wireNOTE:Thepunchmarkontheclampsshowsfrontside.Alignthedotmarkonthehandlebarswiththemating surface of the front side of left clamp.NOTE:To install the handlebars correctly, first tightentheboltAofthefrontsidewithspecifiedtorqueandthentightentheboltBoftherearside.Makesurethattheclamphasnoclearanceatthe front side as shown in the illustration.FORWARDThe line drawingson page 37,38 and39showtheproperroutingofthecontrolcables,hoseand wirings.Refertotheminadditiontofollowingtheinstructions carefully.7THROTTLEInsert the boss of the throttle housing into the hole onthe handlebars.Tighten the throttle assembly with two screws.

A: BossB: HoleC: 5 45 mm screwD: 5 35 mm screwFRONT BRAKE MASTER CYLINDERInstall the front brake master cylinder onto the handle-bars.Alignthedotmark onthehandlebarswiththemastercylinder-to-holder fitting surface.Tightenthemastercylindermountingboltstothespecified torque. Front brake master cylinder mounting bolt: 10 Nm (1.0 kgf-m, 7.0 lb-ft)A: HolderB: Front brake master cylinderC: 6 20 mm Allen boltD: 6 20 mm Allen boltE: Dot mark

A: BoltB: HolderC: Front brake master cylinderD: HandlebarsChecktoensurethatthethrottleoperatesfreely and closes automatically.NOTE:Toinstalltheholdercorrectly,firsttightentheboltCoftheuppersidewithspecifiedtorqueand then tighten the bolt D of the lower side.NOTE:Installtheholderinpositionaccordingtothemark UP.Makesurethattheholderhasnoclearanceatthe upper side as shown.Check for brake fluid leakage.8Connect the front brake light switch lead wires couplerto the brake light switch.A: Front brake light switchB: Lead wire couplerLEFT SWITCHInsert the boss of the left switch holder into the hole onthe handlebars.Tighten the left switch assembly with the two screws.

A: BossB: HoleC: 5 45 mm screwD: 5 30 mm screwConnect the clutch lever position switch lead wire cou-pler to the switch.A: Clutch lever position switchB: Lead wire couplerBecarefulnottopinchthewiringharnessbetween the housing and holder.9CLUTCH CABLEPass the clutch cable through the lever cover.A: Clutch cableB: Clutch lever coverTurn the clutch cable adjuster and lock nut in as far aspossible and align the slots.Insert the inner cable end into the recess in the clutchlever, then pull on the outer cable housing and insert itinto the adjuster.Do not adjust at this time.Adjustment will be covered in the SERVICING section.Install the lever cover.A: Clutch cableB: AdjusterC: Lock nutD: Cable endE: Clutch lever coverRIGHTCLAMPClamp the right handlebar switch wiring harness, frontbrake hose union or front brake hoses with straps.A: Strap L:140 mmB: Right switch wiring harnessC: Front brake hose unionD: Front brake hoseNOTE:Beforeinstallingthecable,greasethecableend.NOTE:Cuttheremainingofthestrap asshowninthephotograph.OUTSIDE,10LEFTClamp the handlebar left switch wiring harness, clutchcable and tachometer lead wire with strap.A: Strap L:140 mmB: Left switch wiring harnessC: Clutch cableD: Tachometer lead wireClampthethrottlecabletotheheadlightstaywithO-ring.A: Throttle cablesB: O-ringC: Strap L:90 mmD: Headlight stayPLASTIC CAPInstall the plastic cap on the handlebars end.A: Plastic cap OD:36.0 mmAttachahoistband,Passthehoistbandthroughthehandlebar as shown in the photograph.

A: Hoist bandB: TachometerNOTE:Cut theremaining of thestrap as shown in thephotograph.OUTSIDEOUTSIDENOTE:Cuttheremainingofthestrap asshowninthephotograph.Becarefuldosenottouchthehoistbandandtachometer.11Remove the crate axle bracket from the crate base.A: Crate axle bracketB: Bolt1. Lift the front of motorcycle by using a hoist.2. Raise the rear of motorcycle.3. Pullthecratebaseforward,thenbalancethemotorcycle.FRAME BODY COVERRemove the seat using the key.A: Seat lockB: SeatRemove the fastener.A: FastenerNOTE:Thebracketandboltsarenolongerneededand these may be discarded.NOTE:Toremovethefastener, push inthe centerpinand pull out the fastener.12Remove the screws.Remove the frame covers.A: Frame coverB: Allen screwC: BossD: Hook (Frame cover)E: Rubber cushion (Fuel tank)Remove the fuel tank fitting bolt.Slide the fuel tank backward a little.A: Fuel tankB: BoltRemove the screws.A: Frame body upper coverB: Stepped Allen screwUnhook the clicks.Remove the frame body upper cover assembly.A: Frame body upper coverB: Frame body head coverC: ClickFORWARD13RIGHTFixtheframebodycovertotheframebodyuppercover assembly with screw. (Right)A: Frame body coverB: Frame body upper coverC: GuideD: HoleE: HookF: ClickG: 5 16 mm tapping screwLEFTFixtheframebodycovertotheframebodyuppercover assembly with screw. (Left)A: Frame body coverB: Frame body upper coverC: GuideD: HoleE: HookF: ClickG: 5 16 mm tapping screwLEFTFitthe framebody coverassembly(Left) to theframebody lower cover.A: Frame body lower coverB: Frame body cover assembly (Left)C: GuideD: HoleE: BossF: Hole (rubber cushion)G: HookFix the frame body cover assembly (Left) to the framebody lower cover with fastener.A: FastenerB: GuideC: HookNOTE:Toinstallthefastener,pullthecenterpinandfix the fastener by pushing the center pin.14RIGHTFittheframebodycoverassembly(Right)totheframe body lower cover assembly.A: Frame body lower cover assemblyB: Frame body cover assembly (Right)C: GuideD: HoleE: BossF: Hole (rubber cushion)G: HookFixtheframebodycoverassembly(Right)totheframe body lower cover assembly with fastener.A: FastenerB: HookCheck the engine coolant and brake fluid level.If the level is lower than the LOW level line, carry outthe SERVICING procedure.A: Engine coolant reservoirB: Rear brake master reservoirC: Upper level lineD: Lower level lineInsert the breather hose to the hole.

A: Breather hoseB: Hole (Frame body lower cover)NOTE:Toinstallthefastener,pullthecenterpinandfix the fastener by pushing the center pin.Besurenottobendortwistthehosewheninstalling.15LEFT RIGHTInstalltherecessofframebodylowercovertotheboss of frame.A: Recess (Frame body lower cover)B: Boss (Frame)RIGHTInstall the fastener by pushing.A: Fastener (Large)B: Boss (Frame)Install the frame body cover assembly.Pass the throttle cable (Pulling) through over the bossof frame body head cover.A: Throttle cable (Pulling)B: Throttle cable (Returning)C: Clutch cableD: BossFit the frame body cover (Right and Left).A: Frame body cover assemblyB: Click16Tighten the screws.Install the fastener.A: Stepped Allen screwB: Fastener (Small)Reinstall the fuel tank.Reinstall the frame cover.Reinstall the seat.Inserttheseathookintotheseathookretainerandpush down the seat firmly.A: Seat assemblyB: Seat hookC: Seat hook retainerFRONT FENDERRemove the bolts.A: 6 16 mm stepped Allen boltInstallthefrontfendertothefrontforklegswithsixbolts.A: Front fenderB: 6 16 mm stepped Allen boltC: Front forkD: Bracket (Front brake hose)NOTE:Toinstallthefastener,pullthecenterpinandfix the fastener by pushing the center pin.17FRONT REARBRAKE DISCTopreventbrakesqueakingandpadcontamination,carefully clean the front and rear brake disc plates withalcohol or other non-petroleum based solvent. This will remove the rust-preventive coating and dirt.FRONT WHEELWheninstallingthefrontwheelontotheaxle,specialattentionmustbepaidtothearrowoftherotationaldirection on the tire sidewall.When the tire is properly installed, the arrow must indi-cate forward rotation of the wheel.Loosen the axle clamp bolt. Remove the front axle from the fork legs.A: Axle clamp boltB: Front axleMount the front wheel assembly properly.A: Right fork legB: Left fork legC: Front wheel spacerD: Front axle FRONT18Temporarily remove the left front brake caliper.

A: SupporterB: Brake caliper (Left)C: Caliper mounting boltRemove the supporter fromthe brake pad of the rightfront brake caliper.A: SupporterAttach the front wheel spacer to the front wheel hub.Carefullyinsert the front brake disc platebetween thecaliper brake pads.

A: Front wheel spacerB: Oil seal (Lip)C: PadsD: Disc plateDo not remove the supporterinserted betweenthebrakepadsuntilthebrakecaliperisinstalled.When install the front wheelspacer,becarefulnot to scratch the oil seal lip.19Insert the front axle from the right side of fork legandfix the front wheel assembly to the front fork.

A: Front axleB: Oil seal (Lip)Tighten the front axle to the specified torque. Front axle: 100 Nm (10.0 kgf-m, 72.5 lb-ft)A: Front axleTighten the axle clamp bolt to the specified torque. Front axle clamp bolt: 23 Nm (2.3 kgf-m, 16.5 lb-ft)A: Axle clamp boltWheninstallthefrontaxle,becarefulnottoscratch the oil seal lip.Never use force to install the front axle. Ifitcannotbeinstalledbyhand,itisnotcor-rectly aligned.20FRONT BRAKE CALIPERRemovethesupporterfromthebrakepadoftheleftfront brake caliper.A: SupporterB: Brake caliper Setthefrontbrakecalipersothebrakediscplateisinserted between two brake pads.Install the front brake caliper.

A: PadsB: Disc plateC: Brake caliper (Left)D: Caliper mounting boltRIGHT LEFTTightenthefrontbrakecalipermountingboltstothespecified torque.

Front brake caliper mounting bolt:39 Nm (3.9 kgf-m, 28.0 lb-ft)A: Brake caliperB: Caliper mounting boltBe careful not to scratch the front wheel.Makesurethatboththerightandleftcalipermountingboltsaretightenedwithspecifiedtorque.21Placethemotorcycleonthesidestand,thenremovethe hoist hook.REAR VIEW MIRRORInstalltherearviewmirrorandtightenlocknutssecurely after positioning them properly.A: Rear view mirrorB: Lock nutREFLEX REFLECTOR (RIGHT)Align the boss of reflex reflector to the hole of bracket.Install the reflex reflector to the bracket.A: Reflex reflectorB: BracketC: BossD: HoleE: Mark RF: 5 mm nutVIEWInstallthereflexreflectorassemblytotheframewithbolt.A: Reflex reflector assemblyB: 6 12 mm flange boltNOTE:Fixthemirrorinthepositionsoastosecurerear view.22REFLEX REFLECTOR (LEFT)Align the boss of reflex reflector to the hole of bracket.Install the reflex reflector to the bracket.A: Reflex reflectorB: BracketC: BossD: HoleE: Mark LF: 5 mm nutRemove the bolt.Installthereflexreflectorassemblytotheframewithbolt.A: 6 12 mm flange boltB: Bracket (Helmet lock assembly)C: Reflex reflector assemblySEAT TAIL COVERWheninstallingtheseattailcovertothemotorcycle,following the procedures below.1. Remove the bolts to take off the rear seat.A: Rear seatB: Allen bolt2. Insert the seat hook to the seat hook retainer.3. Tighten the bolt.A: Seat tail coverB: Seat hookC: Seat hook retainerD: Allen bolt23REMOVING THE TAPERemove the tapes from the muffler and cover.A: TapeB: MufflerC: CoverOWNERS MANUALRemove the seat using the key.Store the owners manual in place.A: Owners manual24SERVICINGBATTERYThe battery is located under the seat.Remove the seat using the key.Pull the fastener knob.Remove the battery holder lid.Remove the battery from the motorcycle.A: Battery holder lidB: FastenerFilling electrolyteRemovethealuminiumtapesealingthebatteryelec-trolyte filler holes.A: Aluminium tapeB: Electrolyte filler holeRemove the caps from the electrolyte container.A: CapsB: Sealed areaNOTE:Usetheremovedcapsasthesealedcapsofbattery filler holes.Do not remove or pierce the sealed areas of theelectrolyte container.25With just enough force to break the nozzle seal of elec-trolytecontainer,pusheachnozzleoftheelectrolytecontainerintothebatteryselectrolytefillerportsandhold the container firmly so that it does not fall.Take precaution not to allow any of the fluid to spill.A: Electrolyte containersMake sure air bubbles are coming up in each electro-lytecontainer,andleaveinthispositionforabout20minutes.A: Air bubblesNOTE:Ifnoairbubblesarecomingupfromafillerport,tapthebottomofthecontainertwoorthree times.Never remove the container from the battery.26Afterconfirmingthattheelectrolytehasenteredthebatterycompletely,removetheelectrolytecontainersfrom the battery.Wait for around 20 minutes.Insert the caps into the filler holes, pressing in firmly sothat the top of the each caps does not protrude abovethe upper surface of the batterys top cover.A: Caps

Charge the battery with a battery charger.

Afterchargingthebattery,installthebatteryinthemotorcycle as follows.

Never use anything except the specified batteryelectrolyte. Oncethesealing caphasbeeninstalledinthebattery, do not remove the sealing cap.For charging the battery, makesure touse thecharger specially designed for MF battery. Otherwise,thebatterymaybeoverchargedresulting in shortened service life.Do not remove the cap during charging.Position the battery with the cap facing upwardduring charging.Whenattachingthewiringharnessbatteryleads to the battery terminals, observe the cor-rect polarity.NOTE:The terminal bolts and nuts are attached to thebattery.271. Reinstall the battery in the motorcycle.2. Firstconnectthe +leadto the +positive terminalof the battery.3. Cover + terminal with rubber boot.4. Connectthe-leadtothe-negativeterminalofthe battery.A: + leadB: - leadC: Rubber boot5. Reinstallthebatteryholderlidandfixthefastenerby pushing knob.6. Reinstall the seat.A: Battery holder lidB: FastenerFRONT REARBRAKE FLUIDKeep the motorcycle upright and place the handlebarsstraight.Checkthebrakefluidlevelinboththefrontandrearmaster cylinder reservoirs.If the fluid level is below the lower level indicated in thefigure, add the correct type of brake fluid.Refer to the chart below for the proper selection.

A: Upper level lineB: Lower level lineSpecification and ClassificationDOT 4Becarefulnottospillanybrakefluidonthepaintorplasticcomponentsastheywillbedamaged.28FRONTBRAKE AIR BLEEDINGAny air which may have been trapped in the brake fluidcircuit must be bled completely.If the brake lever or brake pedal feels spongy or weak,then most likely there is air in the hydraulic circuit.To bleed the air from the front brake, use the followingprocedure:1. Connectaclearhosetotheairbleedervalveandrun the hose into a suitable clear container.2. Pour approximately 1/2 in of brake fluid into the con-tainersothattheendoftheclearhoseissub-merged and cannot draw any additional air back intothe circuit during the air bleeding servicing.3. Closethevalve,pumpandsqueezethelever,andopen the valve while squeezing brake lever.4. Repeatthisprocessuntilthefluidflowingintothereceptacle no longer contains air bubbles.5. Afterbleedingthebrakecircuit,tightenthebleedervalve to the specified torque.Reinstall the rubber protective cap.6. Be sure to check the brake fluid level in the reservoirtank. Brake caliper air bleeder valve:7.5 Nm (0.75 kgf-m, 5.5 lb-ft)A: Bleeder valveREARTheproceduretobleedtherearbrakeisidenticaltothat of the front.A: Bleeder valveNOTE:Do notdrop brake fluid level belowlowerlevelline while bleeding air.RIGHT LEFT29FRONT BRAKE LEVERMake sure the front brake lever position is correct.The standard setting for this motorcycle is as indicatedin the table below.A: AdjusterTHROTTLE CABLEThis motorcycle has a twin throttle cable system.Cable A is for pulling cable and cable B is for return-ing.Check the throttle cable play at the throttle grip.Throttle cable play: 2.04.0 mm (0.080.16 in)Ifadjustmentisnecessary,carryouttheprocedurebelow:1. Loosen the throttle cable adjuster lock nut C.2. Turn the adjuster D in or out until the correct play.3. Tighten the lock nut C while holding the adjuster D.

Standard setting 32.04.0 mm(0.080.16 in)Aftertheadjustmentiscompleted,checkthathandlebar movement does not raise the engineidlespeedandthatthethrottlegripreturnssmoothly and automatically.30CLUTCH CABLEChecktheclutchleverplayattheclutchleverendwhen the lever is lightly pulled in towards the grip.Clutch lever play: 1015 mm (0.40.6 in)Ifadjustmentisnecessary,carryouttheprocedurebelow:1. Remove the bolts to take off the secondary gear boxcover.A: Secondary gear boxB: Allen bolt2. LoosenthelocknutAoftheclutchleveradjusterand turn in the adjuster B as far as possible.3. Loosen the cable adjuster lock nuts C and slide thecable D to obtain the correct play.4. Tighten the lock nuts C. 5. Tighten the lock nut A and place the lever cover E.6. Reinstallthesecondarygearboxcovertotheorigi-nal position correctly.NOTE:Minoradjustmentscannowbemadewiththeclutch lever adjuster A.31REAR BRAKE PEDALCheck the rear brake pedal height.Rear brake pedal height: 2535 mm (1.01.4 in)Iftherearbrakepedalheightisnotcorrect,adjustinthe following manner:1. Loosen the lock nut A.2. RotatethepushrodBtolocatethepedaltothecorrect height above the top face of the footrest C.Be sure to measure this height carefully.3. Tighten the lock nut A to the specified torque. Rear brake push rod lock nut A:18 Nm (1.8 kgf-m, 13.0 lb-ft)REAR SUSPENSIONChecking spring settingCheck for the spring setting of the rear suspension. Thismotorcycleisdeliveredfromthefactorywithitsadjuster set on position 4.A: AdjusterTIRE PRESSUREUsing an accurate air gauge, check the air pressure ofthe front and rear tires.The pressure should be as shown.COLD INFLATION TIRE PRESSURE5 4 3 2 1 7 6SOLO RIDING DUAL RIDINGFRONT250 kPa2.50 kgf/cm236 psi250 kPa2.50 kgf/cm236 psiREAR290 kPa2.90 kgf/cm242 psi290 kPa2.90 kgf/cm242 psi32HEADLIGHT BEAM ADJUSTMENTThe headlight beam can be adjusted both horizontallyand vertically if necessary.To adjust the beam horizontally:Turn the adjuster A clockwise or counterclockwise.To adjust the beam vertically:Turn the adjuster B clockwise or counterclockwise.ENGINE COOLANTTheenginecoolantlevelshouldbekeptbetweentheFULLandLOWlevellinesasshowninthephoto-graph.Inspectthelevelwiththemotorcyclehelduprightonlevel ground.A: Engine coolant reservoirB: FULL level lineC: LOW level lineIfthelevelis lowerthan the LOW level line, add theproperly mixed engine coolant as follows.1. Remove the frame body cover.2. Remove the reservoir tank cap and add 50 : 50 mix-tureofenginecoolantanddistilledwatertotheFULL level line from the engine coolant filler hole.3. Reinstall the reservoir tank cap.4. Reinstall the frame body cover.D: Reservoir tank cap33ENGINE OIL

Check the engine oil level with the engine oildipstick.The motorcycle held vertically on level ground.1. Start the engine and allow it to run for 15 minutes atidling speed.Stop the engine and wait about three minutes.2. Remove the oil filler plug.The engineoildipstickcomesouttogether with theoil filler plug.Wipe the oil from the dipstick with a clean rag.3. Holdingthemotorcyclevertically,reinsertthedip-stickuntilthethreadstouchthefillerneck,butdonot screw the plug in.4. Draw out the dipstick and check the oil level.ThelevelfoundonthedipstickshouldbebetweenL (Low) and F (Full) line.5. If the oil level is below the L line, add fresh oil fromthe filler hole until the oil level reaches to F line.If the level is above the F line, drain oil to F line.6. Reinstall the drain plug and engine oil filler plug.Tighten them securely. Oil drain plug: 23 Nm (2.3 kgf-m, 16.5 lb-ft)A: Engine oil filler plugB: Engine oil dipstickEngine oilOilqualityisamajorcontributortoyourenginesper-formance and life. Always select good quality engine oil.SuzukirecommendstheuseofSUZUKIPERFOR-MANCE 4 MOTOR OIL or equivalent engine oil. UseSF/SGorSH/SJinAPI(AmericanPetroleumInstitute) classification, with MA in JASO.Thismotorcycleisshippedfromfactorywiththe engine filled with engine oil. Be sure to check oil level.FLSAE API JASO10W-40 SF or SG 10W-40 SH or SJ MAAPI: American Petroleum InstituteJASO: Japanese Automobile Standards Organization34SAE Engine Oil ViscositySuzukirecommendstheuseofSAE10W-40engineoil. IfSAE10W-40engineoilisnotavailable,selectanalternative according to the following chart.JASO T903The JASO T903 standard is an index to select engineoils for 4-stroke motorcycle and ATV engines. MotorcycleandATVengineslubricateclutchandtransmission gears with engine oil. JASOT903specifiesperformancerequirementsformotorcycle and ATV clutches and transmission.There are two classes, MA and MB. Theoilcontainerhasfollowingclassificationforcon-firming the standard.A: Code number of oil sales companyB: Oil classificationEnergy ConservingSuzukidoesnotrecommendtheuseofENERGYCONSERVING oils. SomeengineoilswhichisAPISHorgreaterhasENERGY CONSERVING indication in API classifica-tion doughnut mark. Theseoilscanaffectenginelifeandclutchperfor-mance.-30 -20 -10 0 10 20 30 40-22 -4 14 32 50 68 86 10410W - 3020W - 5010W - 40 10W - 5015W - 40 15W - 50CFENGINE OIL VISCOSITY RATING SELECTION CHARTENGINE OILTEMP.Recommended Not recommendedENERGYCONSERVINGAPISERVICESJSAE10W-40APISERVICESJSAE10W-4035FINAL DRIVE GEAR OIL1. Keep the motorcycle upright.2. Remove the oil filler plug. 3. Check the oil level.4. If the oillevel isbelow thefiller hole, add finalgearoilintothefillerholeuntiltheoilreachesthefillerhole level and stop pouring just before oil flows out.5. Reinstall the oil filler plug. Tighten it firmly.A: Oil filler plugIDLE SPEED ADJUSTMENTCheck the engine idle speed.Engine idle speed: 8001 000 r/minFUEL

Test ride the motorcycle checking all mechanical func-tions.Tightenallnuts,bolts,andmiscellaneousmountingparts to the proper torque specs.Confirm that all cables andwiring harnesses are con-nected and routed correctly.NOTE:Use hypoid gear oil SAE 90, API grade GL-5.Ifthemotorcycleisriddenwheretheambienttemperatureisbelow0Cor32F,usehypoidgear oil SAE 80, API grade GL-5.NOTE:If the engine idle speed is not within the speci-fied range, ask your Suzuki dealer or a qualifiedmechanic to inspect and repair the motorcycle.Use only premium unleaded gasoline of at least90 pump octane (R/2+M/2 method) or 95 octaneor higher rated by the research method.GasolinecontainingMTBE(MethylTertiaryButyl Ether), less that 10% ethanol, or less than5%methanolwithappropriatecosolventsandcorrosion inhibitor is permissible.36TIGHTENING TORQUEFor other bolts and nuts not listed, refer to this chart.Item Part Name Nm kgf-m lb-ftFRONT FORKA Handlebar clamp bolt 23 2.3 16.5B Steering stem head nut 90 9.0 65.0C Handlebar holder bolt 85 8.5 61.5D Front fork upper bracket bolt 23 2.3 16.5E Front fork lower bracket bolt 23 2.3 16.5F Front axle clamp bolt 23 2.3 16.5BRAKEGFront brake master cylinder mounting bolt10 1.0 7.0H Front brake caliper mounting bolt 39 3.9 28.0IRear brake master cylinder mounting bolt10 1.0 7.0J Rear brake caliper mounting bolt 39 3.9 28.0K Rear brake push rod lock nut 18 1.8 13.0L Brake caliper air bleeder 7.5 0.75 5.5Item Part Name Nm kgf-m lb-ftAXLEM Front axle 100 10.0 72.5N Rear axle nut 100 10.0 72.5ABSORBERO Rear shock absorber nut (Front) 45 4.5 32.5P Rear shock absorber nut (Rear) 45 4.5 32.5OTHERSQ Rear swingarm pivot shaft 100 10.0 72.5R Front footrest bolt (Right) 60 6.0 43.5S Front footrest bolt (Left) 50 5.0 36.0Bolt Diameter(mm)Conventional or 4 marked bolt 7 marked boltNm kgf-m lb-ft Nm kgf-m lb-ft4 1.5 0.15 1.0 2.3 0.23 1.55 3 0.3 2.0 4.5 0.45 3.06 5.5 0.55 4.0 10 1.0 7.08 13 1.3 9.5 23 2.3 16.510 29 2.9 21.0 50 5.0 36.012 45 4.5 32.5 85 8.5 61.514 65 6.5 47.0 135 13.5 97.516 105 10.5 76.0 210 21.0 152.018 160 16.0 115.5 240 24.0 173.5Conventional bolt 4 marked bolt7 marked boltI H F ML J LRK O P NQH L SADBCGE37HARNESS ROUTINGWiring harnessWiring harnessClampClampSet the speedometer wiring harness to the right side.Be careful not to pinch the wiring harnessbetween the fuel tank and frame.Do not touch regulator/rectifier lead wire to the other part.ClampClampClampClampClampClampClampWiring harnessClampClampClampClampClampClamp ClampSide stand switch lead wireSide-stand switchHandlebar switch lead wire (R) Handlebar switch lead wire (L)Speedometer wiring harness Wiring harnessClampFrameWiring harnessSpeed sensor lead wireSpeed sensor lead wireSide stand switch lead wireGenerator lead wireHO2 sensor lead wire38Handlebar switch lead wire (R) Handlebar switch lead wire (L)Pass the handlebar switch lead wire through upper the brake switch coupler.Clamp ClampClampClampClampClampClampWiring harnessPass the wiring harness through upper the breather hose.Pass the wiring harness through upper the breather hose.Pass the starter motor lead wire through inside of the rear brake hose.Do not touch the starter motor lead wire to the brake hose.Keep the starter motor lead wire inside of the brake pipe.HornHigh tension cordBrake hoseBrake hoseFront brake hoseClutch cableTachometer lead wireMagneto lead wireStarter motor lead wireStarter motor lead wire39CABLE ROUTINGVIEW AAClutch cableClutch cableClutch cablePass the clutch cable through inside of heat shield plate. Cable guideFront brake hosePass the throttle cable through between the handlebar and brake hose.Throttle cable must be passed under the handlebar switch lead wire and brake switch coupler.Throttle cable (Pulling cable)Throttle cable (Pulling cable)Throttle cable (Returning cable)Throttle cable (Pulling cable)Pass the throttle cable (pulling) through over the boss of the frame body head cover.0 mm0 mm0 mmThrottle cable (Returning cable)Throttle cable (Returning cable)Boss