Suzuki DR 800 S - Owners Manual - 1997 - #3127

FAHrertnAuoauix ETARII

HANT'LE'DING

DR800S

OWNER'S MAIUUAT

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or opefator. The manual conta¡ns important safety infofmation and ¡nstructions wh¡ch should be read carefully before operating the motorcycle.

990r 1-3r D56-042 EN G

LISH

r IMPORTANT

wAB

BBEAK.IfT {BUtIilIiIG.IiI) II{FORMA. TIOTI TOB YOUR MOTOBCYCI.E The f irst '1 600 km ('1 ooo m¡les) are

instructions carefully. To emphasize

the most important in the life of your motorcycle. Proper break-in operation during this time will help ensure maximum life and performance from your

new motorcycle. Suzuk¡ parts

ftt

rñtGicAUTr0llllt{ 0TE

Please read this manual and follow its

are

manufactured of h¡gh qual¡ty materials, and machined parts are finished to close tolerances. Proper break-in operation allows the machined sur faces to pol¡sh each other and mate smoothly.

special information the words WARNlNG, CAUTION and NOTE carry spec¡al meanings añd should be carefully

reviewed.

The personal salety 0f the rider may be involved. Disregarding this infor.

mation could result in in¡ury to the r¡der.

Please refer to the BREAK lN IRUNNING-lN) section for spec¡fic

TABLE OF CO

Motorcycling is one of the mosl exh¡larating sports and to ensure your

CONSUMER

rid¡ng enjoyment, you should become

thoroughly familiar with the informa tron presented ¡n th¡s owner's manu al before r¡d¡ng the motorcycle.

The proper care and ma¡ntenance lhat your motorcycle requires is outlined ¡n this manual. By follow¡ng these instructions explicitly you will ensure a long trouble free operat¡ng life for your motorcycle. Your authorized Suzuki dealer has experienced technicians that are trained to provide your machine with the best poss¡ble ser vice with the r¡ght tools and equipment.

Motorcycle reliability añd perfor mance depend on special care and restraint exercised during the brealin period. lt is espec¡ally ¡mportant that you avoid operating the engiñe in a manner wh¡ch could expose the eng¡ne parts to excessive heat.

FOREWORD

All information, illustrations, photo-

NOTE:

Th¡s provides special infor-

mat¡on to make maintenance eas¡er or important instruct¡ons clearer.

graphs and spec¡f¡cations contained in this manual are based on the latest product ¡nformation ava¡lable at the

time of publication. Due to ¡mprovements or other changes, there may be some d¡screpancies in th¡s manual. Suzuk¡ reserves the r¡ght to make

break-¡n recommendations.

changes at any t¡me. Please note that this manual appl¡es to all specifications for all respective destinat¡ons and explains all equip ment. Therefore. your model may have d¡fferent standard features than showñ ¡n this manual.

INFORMATION. . . LOCATION OF PA

CONTROLS.......

t(EY............. tGilrTr0fi swlTcH.

.

IilSTBU]UIEf{T PAilT I.ETT HAfIOI.EBAR.. RIGHT HAilOI.E8AR.

IUEI, TAÍIK CAP,..

tuEt vaLvt...... cÍ0xE t«08..... GEARSHIIT IEVEB.

BEAB EBAI(I PTDAI. SEAT TOCI( AiD HIl

HotoEBs......... stDE sTAf{0...... SUSPEIISIOfI AOJUS

FUEL AND ENGIN RECOMMENDAT«

BREAK,IN (RUNNI

INSPECTTON BEF(

RIDING

.........

.

RIDING TIPS. , ..

.

EITGIf{E STANTIilG,

sTARTlflG

oft....

USIÍ{G IHE TBAISi/

ofl HlLLs. . STOPPIÍ{G AfiD PAR R|o|IIG

INSPECTION AND

MAINTENANCE It¡lAlf{fEf{AtlCt

,.

SCH

T00ts...........

[uBnlcaTloft P0lf{Tl

tuEt TAÚ(

tRA

EEIu0VA

C0VIR

Rt

o

BATTEBY. . . . , . , .

.

AIB CLEAf{tB..... SPABI( PI.UGS,.,.

SUZUKI MOTOB CORPORATIOI{

tuEt H0sE....... Ettctf{t 0fl-....... CAR8URETOR..,..

ctuTcfl.......... O

23

COPYRIGHT SUZUKI MOTOR CORPORATION 1996

oBtvE cHA|il.....

BnÁxts.........

I

¡.TANT

|,rr**,*n.,n, rilroRMA. h YouR moloRcYcLr It ooo t, l1 ooo mitesl are limportant in the l¡fe of vour le. Proper break-in ooe¡ation § time will help ensure maxland performance from vour

lorcycle. Suzuki parts

are lured of hiqh qual¡tv mater¡ hach¡ned parts are finished

folerances. Proper break-in I allows the machinerl srrr folish each other and mate I

wAR fi ritGtcAuTt0 fI ltI0TE Please read this manual and follow its

FOREWORD

TABLE OF CONTENTS

instruct¡ons carefully. To emphas¡ze

Motorcycling is one of the most ex h¡larat¡ng spons and to ensure your riding enjoyment, you should become

CONSUMER

spec¡al ¡nformation the words WARNlNG, CAUTION and NOTE carry special meanings and should be carefully

reviewed.

The personal safety of tho rider may be i¡yolved. Disregard¡ng this infor. mat¡on could result ¡n iniury t0 the

rider.

CAUTION

lle reliability and perfor lpend on special care and duriñg the break-

It is especially important operating the eng¡ne which could expose the

to

fe

excessive heat.

to the section

BREAK-lN specific

for

These ¡nslructions point out special or precautions lhat must be followed t0 av0id damag.

serv¡ce procedures

thoroughly famil¡ar with the information presented ¡n this owner's manual before riding the motorcycle.

fhe

proper care and ma¡ntenance that your motorcycle requ¡res ¡s outlined in this manual. By following these ¡nstructions explicitly you will ensure a loñg trouble free operating life for your motorcycle. Your authorized Suzuk¡ dealer has experienced technicians that are trained to prov¡de your mach¡ne w¡th the best possible ser-vice with the right tools and equ¡pment.

ing the mach¡ne.

NOIE: This provides special inÍormat¡on to make maintenance eas¡er ot impottant ¡nstruct¡ons clearct.

Al¡ information, illust.ations, photographs and spec¡ficat¡ons conta¡ned in th¡s manual are based on the latest product information available at the time of publicat¡on. Due to ¡mprovements or other changes, there may be

some discrepancies in this manual. Suzuk¡ reserves the r¡ght to make changes at any t¡me. Please note that th¡s manual appl¡es to all specif¡cat¡ons for all respective destinat¡ons and explains all equ¡pment. Therefore, your model may have different standard features than shown in th¡s manual.

INFORMATION. . LOCATION OF PARTS... CONTROLS

t(EY......... tciltftoft stYtfcH.... tilsTRU EilT PAilEt-.

rErr ÍAftot EBAfl.

COPYRIGHT SUZUKI MOTOR CORPORATION 1996

.

n

4 8

ll

iir l3

t4 .

15

l6 11

GEARSH|FT t-tVE8 . . . . . . . . . . . . R 8[At(E PE0A|

.

.... ..... ...

t'l l8

sEAf toct( Afto HEI Ef HotDtBs. . . .

18

SIDE STAIID.

19

susPEilstoil AoJUsTffEftT.

....

.

t9

FUEL AND ENGINE OIL

RECOMMENDATION.........

20

BREAK-IN (RUNNINC.IN)..... 20 INSPECTION BEFORE

RIDING

-.

),

-

RIDING TIPS.... EfIGIIIE STABfIÍTG. . . sTABTtftG otr. . .

ustftc THt TnAils¡

23

sstoil......

Btotl¡G ofi H[.r.s.............. sT0PPrfiG Af{D P4BKrilG........

25

INSPECTION AND

MAINTENANCE. irAtilTEftAt{cE

r00r.s..... tuSRtcATtoil

.

sotEoutr.......

P0111Ts. . . . . . . . . .

fuEt TAf{t( 8EIU0VA[.. ..

tna

CTEAfIER...

tuEt

PTUGS.

1t0sE.

EilGtftE

.

ott...

ctufcH. . . DnNE C[4til. BBAKTS .

-..

.

... ....

covEn BEfit0vAt .. .. BATÍEBY...

CAREUBETOR

O

.........

.

ruE[ vAlvt....... c[ot(E t(ft08. . . .

SPABI(

OTORCORPIORATIOI{

..

EIGIIT HATIDTIBAE. . . FUE| TAilt( CAP. . . . . . . . . . . . . .

AIB

SUZUKI

... ..

....

.

26 26 28 28 29 30

3l 32 33

34 35 31

39 39 42

I

45

CONSUMER

46

INFORMATION

.......... 4'l . 47 BEAB WrlEEl. REM0VA[. .. ...... 49 tftrEnr.ocl( swlrcll.. tR0f{T wltEEL REfrl0vAt. . . . . . .

. 50 UGHT BULB BEPl,ACEttlEflT . . . . . . 50 ........ 54 tusEs..... TROUBLESHOOTING, . , . , . , . , 55 MOTORCYCLE CLEANINC... 57 STORAGE PROCEDURE. . . . . . 58 wlflDsHlEl.D cLEAtlllc . . . . . . . . .

SPECIFICATIONS.....,......

60

ACCESS0RY lilsTALLATl0f{ AilD PBECAUTIOf{ SAFETY TIPS

There are a great var¡ety of accessor¡es available to Suzuk¡owners. Suzuki can not have direct controloverthe quality or suitability of accessories you may wish to Purchase. The addit¡on of unsuitable accessories can lead to unsafe operating conditions.

It is not poss¡ble for Suzuki to test each accessory on the market or

combinations of all the available accessories; however, Your dealer can ass¡st you in selecting qualitv accessor¡es and installing them correctly. Use extreme caution when selecting and installing the accessories for your Suzuki. We have developed some general guidelines which w¡ll aid you

when deciding whether, and how to equip your motorcycle Never exceed the GVW (Gross Vehicle Weight) of this motorcycle. The GVW is the combined weight of the machine, accessories, PaYload and r¡ders. When selecting your accessories, keep iñ mind the weight of the riders as well as the we¡ght of the accessories. The additional weight of the accessories may not only create

an unsafe riding condit¡on but may also affect the steering ease. GVW: 425 kg (935 lbs) at the tie pressure (cold) Fronr: 2.OO kg/cm1 (29 Psi) Fear: 2.50 ksicm'?(36 Psi)

Any time that additional weight or aerodynamic affecting accessories are ¡nstalled. they should be mounted as low as poss¡ble, as close to the motorcycle and as near the center of gravity as is feas¡ble. The mount¡ng brackets and other attachment hardware should be carefully checked to ensure that it provides for a r¡gid, nonmovable mount. Weak mounts can allow the shifting of the weight and create a dangerous, unstable condit¡on.

lnspect for proper ground clearance and bank angle, An im-

Certain

accessor

the r¡der from his or t position. This l¡m¡ts movement of the rid his or her control at

Additional electrical i overload the existin

tem. Severe overloa

the w¡ring harness or ous situat¡on due to

trical power dur¡ng the motorcycle. When carry¡ng a loa

properly mounted load could cr¡tically reduce these two safety factor§. Also determine that the "load" does not interfere w¡th the operat¡on of the suspension, steering or other control operations.

cycle, mount it as lov as close as possible

Accessories fitted to the handlebars or the front fork area can create seri_ ous stability problems. This extra we¡ght will cause the motorcycle to be less responsive to your steering control. The weight may also cause oscillations in the front end and lead to ¡nstability problems. Accessories added to the handlebars or front fork should be as light as possible and kept to a minimum

odynam¡cs and hand cycle. Balance the k

The motorcycle may be affected by a lifting condit¡on or by an instability in cross w¡nds or when being passed or passing large vehicles. lmproperly mounted or poorly designed accessories can result ¡n an unsafe riding condition, therefore caution should be

used when select¡ng and installing all accessories.

An ¡mproperly moun ate a high center of

very dangerous and r cycle difficult to hal the "load" can als(

right and left side o and fasten it secur( Modificat¡on

l/odification of

rhe

removal of original

render the illegal.

motorc

I

I ¡tPPtE TrGHTIrss

45 46

CONSUMER INFORMATION

47

ACCESSORY If{STAI.I.ATIOIT AIID PRECAUTIOñI SAIETY TIPS There are a great variety of accessories available to Suzuki owners. Suzu k¡ can not have direct control over the quality or su¡tability of accessor¡es you may wish to purchase. The addition of unsu¡table accessories can lead to unsafe operating conditions.

hrolrcrmor

hr swrrcr . . . . . . . . . . . l¡r¡¡r n¡uovlr h¡tt n¡rlovu. . .

l¡rn cr¡lurc

Fii

Tli::"*'

l¡snoonNc......... fvclr crennrrc... E PROCFDI ferrors I

I

]RF

.

41 49 50 50 54 55 57

58 60

It is not possible for Suzuki to test each accessory on the market or combinations of all the available accessories; however, your dealer can ass¡st you in selecting qual¡ty accessor¡es and installing them correctly. Use exlreme caution when selecting

and installing the accessories for your Suzuki. We have developed some general guidel¡nes wh¡ch w¡ll a¡d you

when decid¡ng whether, and how to equip your motorcycle. Never exceed the GVW (Gross Vehi cle Weight) of this motorcycle. The GVW ¡s the combined weight of the machine, accessories. payload and riders. When select¡ng your accessories, keep in mind the we¡ght of the riders as well as the weight of the accessor¡es. The additional we¡ght of the accessories may not only create an unsafe riding condition but may also affect the steering ease.

425 kg (935

lbs)

at the tire pressL¡re (cold) Front: 2.OO kg/cmr (29 ps ) Rear: 2.50 kg/cmz i36 psi)

Any t¡me that additional we¡ght or aerodynamic affecting accessor¡es are iñstalled, they should be mounted as low as possible, as close to the motorcycle and as near the center of

gravity as ¡s feasible. The mounting brackets and other attachment hardware should be carefully checked to ensure that it provides for a r¡gid, nonmovable mount. Weak mounts can allow the shifting of the weight and create a dangerous, unstable cond¡t¡on.

lnspect for proper ground clearance and bank angle. An im-

Certa in accessories displace the rider from his or her normal riding position. This l¡mits the freedom of movement of the rider and may lim¡t his or her control ab¡lity.

Additional electrical accessor¡es may r overload the existing electrical sys-I tem. Severe overloads may damage I the wir¡ng harness or create a dangerous situation due to lhe loss of elec. trical power dur¡ng the operation of the motorcycle.

ly reduce these two safety factors.

When carry¡ng a load on the motor, cycle, mount it as low as possible and as close as possible to the machine. An improperly mounted load can create a high center of gravíty which is

operations.

very dangerous and makes the motorcycle difficult to handle. The size of

properly mounted load could critical-

Also determ¡ne that the "load" does not interfere with the operation of the suspension, steering or other control Accessor¡es fitted to the handlebars or the front fork area can create seri-

ous stability problems. This extra we¡ght will cause the motorcycle to

be less respons¡ve to your steer¡ng control. The weight may also cause oscillations in the front end and lead to instability problems. Accessories added to the handlebars or front fork

the "load" can also affect the

r¡ght and left side of the motorcycle and fasten it securely.

Modification Modif¡cat¡on of the motorcycle, or removal of original equipment may

should be as light as possible and kept

render

to a minimum

¡llegal.

The motorcycle may be affected by a l¡fting condition or by an instability in cross winds or when be¡ng passed or passing large vehicles. lmproperly mounted or poorly designed accessor¡es can result ¡n an unsafe r¡ding con-

dit¡on, therefore caut¡on should be used when selecting and install¡ng all accessories.

aer

odynamics and handl¡ng of the motorcycle. Balance the load between the

the motorcycle unsafe

or

r

SATE BIDITIG RECOMMETTDATIOII IOR MOTOBCYCI.E RIDERS lvlotorcycle riding ¡s great fun and an exciting sport. Motorcycle r¡ding also requires that some extra precautions be taken to ensure the safety of the rider and passenger. These precau-

tions are: WEAR

A HELMET

Motorcycle safety equipment starts with a quality helmet. One of rhe most serious injuries that can happen is a head ¡njury. ALWAYS wear a properly approved helmet. You should

also wear suitable eye protection. RIDING APPAREL Loose, fancy clothing can be uncom fortable añd unsafe when riding your

KNOW YOUR LIMITS Ride with¡n the boundaries of your own sk¡ll at alltimes. Know¡ng these limits and staying with¡n them w¡ll

STRIAI. iIUMBEB I.OCATIOTI

help you to avoid acc¡dents.

BE EXTRA SAFETY CONSCIOUS ON

BAD WEATHEB DAYS R¡d¡ng on bad weather days, espec¡al-

ly wet ones, requ¡res extra caution. Braking d¡stances double on a ra¡ny day. Sray off of the pa¡nted surface marks, manhole covers and greasy appearing areas as they can be espe-

cially slippery. Use extreme caution

at ra¡lway crossings and on

metal

grat¡ngs and bridges. Whenever in doubt about road condition, slow down!

motorcycle. Choose good quality

motorcycle riding apparel when riding your motorcycle. The frame and/or engine serial num, INSPECTION BEFORE RIDING Review thoroughly the ¡nstructrons in

the "INSPECTION BEFORE RtDtNG" section of th¡s manual. Do not forget to perform an entire safety inspection to ensure the safety of the rider and

its passenger.

FAMILIARIZE YOURSELF WITH THE MOTORCYCLE YoLrr riding skill and your mechanical

knowledge form the foundation for

safe riding practices. We suggest that you practice r¡ding your motorcycle in a non traffic situation unt¡l you are

thoroughly familiar with vour machine and its controls. Remember pracl¡ce makes perfect.

bers are used to register the motorcycle. They are also used to ass¡st your dealer when ordering parts or referring to special seruice informa tion. The frame ñumber (! is stamped on the steering head. The engine seri al number Q) ¡s stamped on the crankcase assembly. Please write down the numbers iñ the

box provided below for your future reference. Frame number:

Engine number:

ioutc Rtcotumruolrror hoRcYctt RrorRs I

ble r¡dinq is oreat fun and an )port. Motorcycle riding also lhat some extra orecautions Ito en"ure the s;letv of the I passenger. These precau-

,.,-re,

pus injuries that can happen

iniurv. ALWAYS wear

a

ipproved helmet. You should

f

help you to avo¡d accidents.

BE EXTRA SAFETY CONSCIOUS ON

BAD WEATHER DAYS

ly wet ones, requires extra caut¡on.

Ile safety equipment starts luality helmet. One of the

!

stRtAt ñtuMBER tocATtot

Riding on bad weather days, espec¡al

r |

KNOW YOUR LIMITS Ride within the boundaries of your owñ skill at alltimes. Knowing these limits and stay¡ng within them will

suitable eye protection.

Brak¡ng d¡stances double on a rainy day. Stay off of rhe painted surface marks, manhole covers and greasy appeariñg areas as they can be espe cially slippery. Use extreme caution

at railway cross¡ngs and on metal

gratings and br¡dges. Whenever in doubt about road condition, slow

TPPAREL

hcy clothing can be uncom, fnd uñsafe when riding vour

fle. Choose good quality lle riding apparel when ridinq

lorcycle.

FEcloll gerone ntollvc"

The frame and/or engine serial numbers are used to register the motorcycle. They are also used to ass¡st your dealer when ordering parts or

this manual. Do not forget an entire safety inspection the safety of the rider and lger.

tion. The frame number O is stamped on the steering head. The engine serial number e) is stamped on the crank

I

foN

EEFORE RTD|NG

lorouqhlv the instructions in f

n

referring to spec¡al service informa-

case assembly. IIZE YOURSELF WITH THE YCLE g skill and your mechanical

Please write down the numbers iñ the

le form the foundation for practices. We suggest that

reference.

riding your motorcycle in situation until you are famrliar with your machine s. Remember practice

box prov¡ded below for your future Frame number:

Eng¡ne number:

r

LOCATION OF PARTS

O clutch lever O Left handlebar

switches

@ lnstrument panel @ Front brake fluid reservoir @ Right handlebar switches G) Throttle sr¡p @ Front brake lever @ choke knob

O

Fuel tank cap

@ lgn¡t¡on sw¡tch

O

(,

Spark plug Fuel valve

@ Throttle stop screw

Air cleaner @ Helmet ho¡ders OD

@)

Battery

@ Fuses @ Tools

@ Gearshift lever @ Footrests Q, S¡de stand

@ Seat lock @ Passenger footrests

ON OF PARTS

??? ?

switches panel

fluid reservoir switches lever

knob

lk

cap

sw¡tch

O

Spark plug

(l) Fuel valve

@ Throttle stop screw (a) A¡r cleaner @ Helmet holders (p) Battery O) Fuses [0 Tools @ Gearshift lever @ Footrests @ Side stand @ Seat lock

@ Passenger footrests

,,OFF" POSITION

CONTROLS

? I

All electrical circuitr

KEY

engine w¡ll not start removed.

,,ON"

Wff

fal

U

sit¡on.

This motorcycle comes equ¡pped with

a pa¡r

of identical ignition keys. Keep

the spare key ¡n a safe place.

The key number is stamped on a plate

provided with the keys. This number is used when mak¡ng replacement keys. Please write your key number

in the box provided for your future

reference.

Rear brake flu¡d reservo¡r Rear brake ¡ight switch Engine oil filler cap Rear brake peda¡ Eng¡ne o¡l dra¡n plug Eng¡ne o¡l filter

POSITION

The ignition c¡rcu¡t ¡ the engine can now

lrT:l rGfllrTr0it swlTcH

key connot be rem ,,LOCK" POSITION

To lock the steering,

bars all the way t(

down and turn tl "LOCK" position ¿ key. All elecrricalc¡r

"P"

{Park¡nSl POS|I

When parking the n the steer¡ng and tufl

"P" position. The ke moved and the ta¡llig This position is for ni( parking to increase.

Bsfors türn¡¡g thr to the "P" (P¡rkir

s¡t¡oÍ, stop lhe

or you may

The ignition switch has four positrons:

r

place the motorc¡ stand. llever atlempt to I cycle when the stt lose

,,OFF" POSITION All electrical c¡rcuits are cut off. The engine will not start. The key can be

CONTROLS KEY

removed.

,,ON" POSITION

ffff

f6l

IJ

motorcycle comes equipped w¡th pair of ident¡cal ¡gnit¡on keys. Keep the spare key in a safe p¡ace. Th¡s a

The key number ¡s stamped on a plate

prov¡ded w¡th the keys. This number

is used when making replacement keys. Please wr¡te your key number in the box provided for your future reference.

t oil filler cap

,,LOCK"

POSITION To lock the steering, turn the handle-

bars all the way to the left. Push down and turn the key to the "LOCK" position and remove the key. All electrical circuits are cut ofl.

"P"

(Parking) POSITION

When parking the motorcycle, lock the steering and turn the key to the

"P" pos¡t¡on. The key can now be removed and the taillight will remain lit. This pos¡tion ¡s for night t¡me roads¡de parking to ¡ncrease v¡sibility.

Before turning the ignit¡on sw¡tch to ihs "P" (Parking) or "L0GK" po-

)rake fluid reservoir

lrake light switch

The ignition circuit is complered and ¡ the engine can now be started. Thel key connot be removed in this po-l sition.

tGilTt0il swtTcH

tlake pedal I oil dra¡n plug r oil f¡lter

&, The ¡gnition switch has four positions:

sition, stop the molorcycle and place the motorcycle oI the s¡dc stand. f,sver attempt lo mov€ the motofcycl8 yvhsn lhe steer¡ng is locked, or you may lose balance.

r IITSTRUMETTT PAITET

NOTE: lf tum signall¡ght

is not

oper

I.CFT HAITDI-EBAB

HORN SWITCH " Ii Press the switch to

ating properly due to bulb Í¡lament ot c¡tcuit fa¡lure, the ¡ndicatot light fl¡cke6 morc qu¡ckly to not¡ce the idefof

the ex¡stence

ol

CLUTCH LEVER

trouble.

HIGH BEAM INDICATOR LIGHT E)

The blue ¡ndicator light will be l¡r when the headl¡ght high beam ¡s

lever disengages th

turned on. NEUTRAL INDICATOR LIGHT @

SPEEDOMETER

O

The speedometer ¡nd¡cates the road speed in m¡les per hour and/or k¡lometers per hour. ODOMETER @ The odometer registers the total distance that the motorcycle has been

ridden. TRIP METER @

The trip meter ¡s a resettable odome-

ter located ¡n the speedometer as. sembly. lt can be used for ¡ndicating the distance traveled on shon tr¡ps or between fuel stops. Turning the knob @ counterclockwise w¡ll return the meter to zero. TACHOMETER @ The tachometer ¡ndicates the eng¡ne

speed (r/min).

in

revolut¡ons per minute

TURN SIGNAL INDICATOR LIGHT @ When the turn s¡gnals are being oper-

ated either to the right or to the left, the indicator w¡ll flash at the same

time.

The green light will come on when the

transm¡ss¡on ¡s ¡n neutral. The light will go out when you sh¡ft ¡nto any gear other than neutral.

O

The clutch lever is u ¡ng the dr¡ve to the starting the engin€ transmission gear,

DIMMEB SWÍTCH

"

?>"

O

Position The headl¡ght low beam and ta¡l turn on, "

=D"

l¡gh1

posit¡on

The headlight h¡gh beam and tail tight

turn on. The h¡gh beam indicator ¡ight also turns on. HEADLIGHT FLASHER SWTTCH qz Press the sw¡lch to light the headlig

ht.

TURN StcNAL SWTTCH @

Moving the switch to the ,,€ ,, position w¡ll flash the left turn signals. Moving the switch to the ,, + ,, position will flash the right turn signals. The ind¡cator light will also flash ¡nterm¡ttently. To cancel turn signa¡ operation. push the switch on.

Always use the turn signals when you intend to chanoo lanes or make a lurn. Be sure to turn off the turn s¡g[als aftel completing thc turn or lsne change.

NOTE: lf tum s¡gnal light ¡s not oper' at¡ng properly due to bulb filament or citcu¡t fa¡lure. the ind¡catot light flick ers more quickly to not¡ce the ridet of

I.EFT HAITDI.EBAB

HORN SWITCH " )rr " @ Press the switch to sound the horn. CLUTCH LEVER @ The clutch lever is used for disengag ing the dr¡ve 10 the rear wheel when

the ex¡stence of ttouble. HIGH BEAM INDICATOR LIGHT Q) fhe blue indicator light w¡ll be lit

when the headlight high beam

start¡ng the eng¡ne or shift¡ng th

i:i§Thdffi*;;"#;ü iii"l

is

turned on.

ind¡cates the road

NEUTRAL INDICATOR LIGHT @) The green l¡ght will come on when the transm¡ssion is ¡n neutral. The light will go out when you shift into any

gear other than neutral.

DIMMER SWITCH

".o>"

" freter reg¡sters the total d¡s-

O

Posilion The headlighr low beam and tait light turn on.

=D"

position

The headlight high beam and tail light turn on. The h¡gh beam ¡ndicator light

also turns on.

ERO eter is a resettable odomed in the speedometer ascan be used for indicating ce traveled on short trips or

fuelstops. Turninq the knob brclockwise will return the zero.

neren 5t

bmeter indicates the eng¡ne

revolutions per minute

TNDTCATOR LrGHT (6)

turn siqnals are being oper to the righr or ro the Ieft, will flash at the same

HEADLIGHT FLASHER SWITCH @ Press the switch to light rhe headlig

h

t.

TURN StcNAL SWTTCH @ l\¡ov¡ng the switch to the " € ,, posit¡on will flash the left turn signals. lvloving the sw¡tch to the " + ,, position willflash the r¡ghf lurn s¡gnats. The indicator l¡ght will also flash intermittently. To cancel turn s¡gnal operal¡on, push the sw¡tch on.

Always use the turn s¡gnals when you inlend t0 chat¡gs lanes or make a turn. 8e sure to tuln off the turn signals

aller completing the tuln or lalls change.

r ELECTRIC STARTER BUTTON

RIGHT HATTDTEBAR

"O"

fUEt TAIIK

CAP

@ This button ¡s used for operat¡ng the stafter motor. w¡th the ¡gnit¡on sw¡tch ¡n the "ON" Pos¡t¡on, the engine stop sw¡tch in the " O " Position, the transmiss¡on ¡n neutral, push the electric starter button to operate the starter motor and start the eng¡ne.

ENGTNE STOP

SWITCH

o

"ñ" Pos¡tion The ignition circuit is off. The eng¡ne cannot start or run. " O " Position The ignition circuit is on and the engine can run.

a

a

check the luol supply and ign¡t¡on sy$ toms. (Bsfor to ths "TRoUBLESH00T' ItIG" soctionl.

is squeezed inward. LIGHT SWITCH €)

"+ "

Pos¡tion

The headl¡ght and ta¡ll¡ght turn on.

";oo-. " Pos¡t¡on The pos¡t¡on l¡ght and ta¡ll¡ght turn on. " . " Posit¡on

The headl¡ght and taill¡ght turn off.

a

A CAUTION

not start altsr several sttsmPts,

THROTTLE GRIP @ Engine speed is controlled by the po

s¡t¡on of the throttle grip. Twist it toward you to increase engine speed Turn ¡t away from you to decrease the engine speed.

::'

t.

r:

.o) Filler neck

is disengaged.

is

(".:.

o Fuel level

The trcnsmission is in neuüal and the clutch is disengaged, or The ttansm¡ssion is ¡n gear, the side stand ¡s fully up and the clutch

equ¡pped with disk brake system and excessive pressure is not required to slow the machine down properly. The brake light w¡ll be Iit when the lever

throttle gr¡p. This motorcYcle

r.t.:::.::.: ::.:..::.:.:

NOTE: Th¡s motorcycle is equiqqed with inte ock switches fot the igni' tion circu¡t and the starter cicuit The engine can only be stattered if:

Do not engage the startef motor lor more than f¡vo soconds at a t¡ms as it may ovsrhoat the wir¡ng harnsss and stsrtsr molot. ll the enÍinG doss

FRONT BRAKE LEVER (2) The front brake is applied by squeez¡ng the brake lever gently toward the

.:::.:.:.:.:.

Do not overfillths sp¡ll¡ne luel on th not f¡ll tho luoltar tom of the l¡llor r tho illustrat¡on or

whon tho luel

To open the fuel tank cap, open the lock l¡d. insert the ignition key ¡nto the

lock and turn it clockwise. W¡th the key inserted, lift up with the key and open the fuel tank cap. To close the fuel tank cap, push the cap down firmly with the key ¡n the cap lock.

.

her

expands.

Wh¿r rsfüaling, ¿ orlg¡ne off and lt key to the "0ft" refuel near an o¡

ELECTRIC STARTER BUTTON

"O"

TUEI. TAITK CAP

(4)

This button is used for operating the

starter motor. With the ignition swrtch in the "ON" pos¡tion, the engine stop sw¡tch ia the " O " posr

t¡on, the transmission in neutral, push

the electric starter button to operate the starter motor and stan the engine.

NOTE: This motorcycle ¡s equ¡pped wilh interlock switches Íot the ¡gni lsroP swrrcH

(il

losit¡on lion circuit is

off. The enqine

a

rtart or run, rosition

the clutch is d¡sengaged, ot The trcnsmiss¡on is ¡n geaL the side stand is fully up and the clutch

.

on and the en

(un.

A CAUTION

BRAKE LEVER (2) lt brake is applied by squeez-

[ake lever gently toward the lgrip. This motorcycle is lwith disk brake system and e pressure is not required to machine down properly. The

ht will be lit when the lever

Do not engage the starter motor for rnofe than five seconds at a time as ¡t may overheat the w¡r¡ng harness and starter mot0r. lf the engine does

I|ot start after several attempts, check the fuel supply and ignition sys. tems. (Befer lo the "TR0UBtESH00T. lf{G" section).

(al

,osition dlight and taillight turn on. rosition tioñ light and taillight turn on.

fosition dlight and ta¡llight turn off.

To open the fuel tank cap, open the lock lid, insert the igñition key into the lock and turn it clockwise. With the key inserted, lift up with rhe key and open the fuel tank cap. To close the fuel tank cap, push the cap down ,rmly with the lev in the cap locl.. f

zed inward.

THROTTLE GRIP @ Eng¡ne speed is controlled by the po-

sition of the throttle gr¡p. Tw¡st it loward you to iñcrease eng¡ne speed. Turn it away from you to decrease the engine speed.

Do not overlillthe lueltank. Avoid spill¡ng fuel on rhe hot engine. 0o

not fill the lueltank above the hor. tom of the liller neck as shown ir the ¡llustration or ¡t nay overflow when the fuel heats up later and

¡s disengaged.

:¡on circu¡t is

wrrcH

Q) Fuel level Filler neck

O

tion citcu¡t and the starter c¡rcu¡t. The eng¡ne can only be stattered ¡f: . The trunsmiss¡on ¡s ¡n neutral and

o

expands. When relueling, always shut the engine off and turn lhe ignit¡on key lo the "oFt" pos¡t¡on. Illever reluel near an open llame.

r cHoKE t(f{08

tuEr vAtut

GEABSHIFT TEVER

This motorcycle ¡s equiPPed with a manually operated fuel valve. There are three positionsr "ON," "RES" and "oFF. "

A \4

1

,,OFF" POSITION Turn the lever to the "OFF" Posit¡o¡ whenever stopping the engine for more than a few minutes.

\l ON

,,ON" POSITION The normaloperating position for the

fuel valve lever ¡s in the "ON"

v

OFF

po

sition.

/1

qF RES

,,RES" {RESERVE} POSITION lf the fuel level ¡n the tank is too low turn the lever to the "RES" pos¡tio; to use of reserve fuel supply.

The carburetor is equipped w¡th

a

choke system to provide easy start ing when the engine is cold. When starting the cold engine, pull the choke knob all the way toward you. The choke works best when the throttle is in the closed position. When the engine is warm, you do not need to use the choke system for starting.

NOTE: Refü to the RIDING ÍlPS

This motorcycle has mission which opera-

shift propely,

pull

and close the throt

time you operate th( Lift the gearshift lev depress the lever to

tral is located betw€ gear. When neutralis or lift the lever half\Á and 2nd gear.

sect¡on of th¡s manualfor the engine

A

statting prccedurc.

CAU.

When the transmissi the greer ird¡cator li( ment panel will be lil though rhe l¡ghr is i tiously release lhe cl

ly to

determine

traIsm¡ss¡on is pos¡t Reduce the motorcy(

downshifting. Wher

NOTE: Aftet sw¡tching the fuel valve lever to the "RES" pos¡t¡on,

the engine speed sho

line station. Aftet rcfuelinq, be sure to move the fuel valve to the "ON"

dr¡ve tra¡n componer t¡re.

relill the fueltank at lhe closest gasopos¡t¡on.

before the clutch is er

prevent unnecessar\

LvE

CHOKE KIIIOB

torcycle is equipped w¡th a operated fuel valve. There positioñs: "ON," "BES"

GEARSHIFT TEVEB

F."

OFF

,,OFF"

POSITION Turñ the lever to the "OFF" position

whenever stopping the engine for more than a few minutes.

bs,r'o* hal operating position for the

ie lever ¡s in the "ON" po

The carburetor is equipped with

a

choke system to provide easy starting when the engine is cold. When startiñg the cold eng¡ne, pull the choke knob all the way toward you. The choke works best when the throttle is in the closed pos¡tion. When the eng¡ne ¡s warm, you do not need to use the choke system for start¡ng.

A

Q RES

RESERVE) POSITION level in the tank is too low,

to the " RES" position reserve fuel supply.

Aftet switch¡ng the fuel to the "RES" position, tank at the closest gaso. After refuelinq, be sure Ihe fuel valve to the "ON"

NOTE: Refü to the RIDING TIPS

This motorcycle has a 5-speed trans mission which operates as shown. To shift properly, pull the cfutch lever and close the throttle at the same

time vou operate the gearshift tever Lift the gearshift lever to upsh¡ft and depress the lever to downsh¡ft. Neutral is located between low and 2nd gear. When neutral¡s desired, depress or l¡ft the lever halfway between low and 2nd gear.

section of th¡s ¡nanualfot the enq¡ne statt¡ng procedurc.

A

CAUTION

When the transmission is in neutral the green indicator light 0n the instrument panel w¡ll be lit. However, even

thoügh the light is illuminated, cau. tiously release the clutch leyer slow.

ly to

determine whether the

transm¡ssion is posit¡vely in neutral.

Reduce the motorcycle speed before

downshifting. When downshift¡ng,

the eng¡ne speed should be increased before the clurch is engaged. This will prevent unnecessary wear on the dr¡ve train compoñents and the rear t¡re.

BEAR BRAKE PEOAT

To unlock the seat lock, insert the ig-

n¡t¡on key into the lock and turn clockwise. To lock the seat, hook seat hook to the seat holding brack et and push down the seat firmly t¡l the seat snaPs into the

SIDE STAÍIO

NOTE: After riding the motorcycle under the muddy cond¡t¡on, clean and lubicate the s¡de stand p¡vot and in-

terlock sw¡tch.

position. There are helmet holders der the seat. To use them, remove

SUSPEITSIOfi ADJUSIMEITT REAR SUSPENSION Spr¡ng Preload Ad¡ustment The adjustment can be performed by chang¡ng the adjuster r¡ng posit¡on.

seat, hook your helmet fastener

to the holder and refit the seat.

However, Suzuk¡ recommends that

Depressing the rear brake pedal will apply the rear disc brake. The brake light will be ¡lluminated when the rear

lhis motorcycle

¡s equipped w¡th a stand to support the motorcycle .\ hen parking. An ¡nterlock sw¡tch ¡s provided to cut off the ¡gn¡tion c¡rcu¡t ,,vhen the s¡de stand is down and the transmission is ¡n any gear other than s de

brake is operated. SEAT TOCK AITD HETTET HOTOERS

! eLrtral.

Helmet holders

a

.

Do not oForale the with a helmet lastened to thg met holder. The helmst may inter' fsre w¡th the safe operation of motorcYcle.

After you have reinsialled seat, pull up on it f¡rmlY to be cor' tain ¡t ¡s sccurely latch8d. lf the

seat is not latched securely, it may come loose and with the rider's control.

-e side stand/ignirion interlock .rrvitch works as follows: . lf the side stand is down añd the transm¡ssion is in gear, the eng¡ne can not be started. . ¡f the engine is running and the .

transmission is shifted ¡nto gear with the side stand down, the engine will stop running. lf the engine is running and the s¡de stand is put down with the transmission ¡n gear, the eng¡ne will stop running.

Always check the side srandlignit¡or interlock sw¡tch for proper operation hefore riding, according t0 the ¡nstruc. tions in the SIDE STAtl0,lGfllTl0ft lft.

TEBL0CK SWITCH sect¡on. lf the switch ¡s not working and the side stand is left down, ¡t may ¡nterfere with r¡der c0ntrol during a left turn.

¡,-

this adjustment be done by your author¡zed Suzukidealer, s¡nce a spec¡al tool ¡s needed for th¡s job.

FUEL AND ENGINE OIL RECOMMENDATION TUEI.

Use unleaded gasoline with an octane

rat¡ng

of 91 or higher

(Research

method). Unleaded gasol¡ne can extend spark plug life and exhaust components life. lf pinking or knocking is experienced, substitute higher octane grade gasoline or another brand, because there are differences between brands.

EilGtttE

BREAK-IN (RUNNINGThe open¡ng explain how proper break-in ¡s to achieving mum life and performance from new Suzuk¡. The follow¡ng explain proper break-in

i,AXIiIUT IilGItTE

REC0ttEftDATl0ll This table shows the recommended engine speed the break-in per¡od.

I:TP, ts #-30-20-t0

o to 20 30 ¡¡o io 6l aa r(x

^ km 600

(1 OOO

miles).

AI.LflW THE ETTGITE OII. TO CIRCU. IATE BEFORE RIDIÍIG

. tow sufficient idling time after .",'arm or cold eng¡ne start up before

!onenls,

OBSERVE YOUR TIRST AiIO MOST CRITICAT SEBVICE

the initial service

(1OOO

km mainte-

nance) is the most important se.v¡ce your motorcycle w¡ll receive. Dur¡ng break-in operat¡on, all of the engine

::H::,*':

ffiT3,,T,ff :TJ

part of the init¡al ^;jl"iil: service includes cor-

rection of all adjustments, tightening of all fasteners and replacement of d¡rty o¡1. Timely performance of this service will help make sure you get the best serv¡ce l¡fe and performance

from the eng¡ne.

A

CAUTION

The 1000 km (600 milesl service should be performed as outl¡ned ¡n tho IiISPECTIOil AtID MAIfTTEIIA]TGE sect¡0n 0f th¡s owner's ilanual. Pay

particular attent¡on t0 the CAUT|0fl and WABfllfIG in that section.

VABY THE EITGII{E SPEED The engine speed should be allows the pans to be "loaded" pressure. and then unloaded, ing the parts to cool. fhis a¡ds mating process of the pans. lt is

I

,,rended maximum limits. Do not, r o ever, use full throttle for the first

L,plying load or revving the engine. rhis allows time for the lubr¡cating oil , 'each all critical engine com-

0tt

ott

sPtED

SPEED

and not held at a constant speed.

Iftc t

tow

ooer¿ting the engine at constant low .oeed {light load) can cause parts to ll"re und not seat ¡n. Allow the enr..e to accelerate freely through the iears, without exceeding the recom-

I

Use a prem¡um qual¡ty 4-stroke motor oil to ensure longer service life of

your motorcycle. Use only oils which are rated SF or SG under the API service class¡f ¡cat¡on. The recommended viscosity ¡s sAE 1ow-4o. lf a sAE 'l OW-4O motor oil ¡s not available, select an alternat¡ve according to the follow¡ng chart.

av0r0 collsTAilT

sential that some stress be Placed the engine components during break in to ensure this mat¡ng process. not, though, apply excessive load the eng¡ne.

E[

INSPECTION BEFORE RIDING Before r¡ding the motorcycle, be sure

to check the follow¡ng items. Never

the

underestimate

RIDING TIPS

.

imPortance of

CHECK

Steering

CHECK FOR:

a Smoothness a No restrict¡on of a No play or looseness

trols alld opo]ation

.

throttle cable a Smooth operat¡on

añd posit¡ve relurn

.

of the throttle gr¡P 10 the closed pos¡tion

Clutch

a .

Brakes

Suspensions Fuel

Dr¡ve chain

f¡res

Engine o¡l

Correct play in the

.

cable

Smooth and progressive action

.

Fluid ¡evel in the reservo¡r 1o be above ,,LOWER" IiNE . No flu¡d leakage . Brake pads not to be worn down to the l¡mit line a Correct pedal and lever play . No "sponginess" Smooth movement Enough fuel for the planñed distance of operation a Proper lens¡on or slack a Adequate lubr¡cation

a Correct pressure a Adequate tread depth a No cracks or cuts Correct level

flovsr start tho sng¡ne or lst ¡t run indoors or wh8r0 lhsre is l¡ttl0 0r flo ventillation. Exhau¡t gas Eontains carbon monoxido, a potcntially lethal gas that ¡s colorless and odorless.

or a [on-public road lo bscome thoroughly familiar with lho Don.

Correct play in the

Throttle

lf lhi$ ¡s tho f¡rst t¡me that you have ridd¿n a mach¡ne of this type, we suggest that you practico

these checks. Perform all of them before rid¡ng the motorcYcle. WHAT TO

EfTGItIT STABTITG

.

th8

Do not doyrnshift in tho midst ol cornering. Slow dow[ to a safe sFosd bcfore negot¡ating a corner.

When the rosd sürlaco i$ wet ol slushy, there is a reduction ¡n tire tractio[. You should r0duc-s speed

whsllsYer thesa condit¡ons sxist as braking and cornering ability arg rcduced. At sids ur¡nds which may bo ex. perioncGd at ths sx¡sts of tunnels, when pass¡ng by tho cüt of I h¡ll, or when teing ovortaken by larg-

er yehicles, you should

.

ol

motorcyclo. one-hand riding is sxtremely dan. geroús. l(0op both hands firmly on the handlohars and both feet sccurely on tho footrssts. Under no c¡rGümstancos shoüld both hsnds be removad fiom tho ha[dlebars.

reduce speed and r¡de alertly. ohey the speed limit and traffic

rogulat¡ons at all times.

A

CAUTION

Do not let lhe sngim run too long vuithout rid¡ng, or il w¡ll overh8at and

may damage intornal engine

com-

ponents. Before attempt¡ng to start the eng¡ne, maks sufe: a The transmiss¡on is in neutral. o The fuel valve is in the "ON" po-

.

sit¡on. The eng¡ne stop switch is ¡n the

"O"

position.

NOTE: Th¡s mototcycle is equipped w¡th inte ock switches fot the ign¡t¡on circuit and the stattet citcuit. The engine can only be statted ¡f:

.

a

The üansmission is in neutrcl and the clutch is d¡sengaged, ot The transmission ¡s in gear, the s¡de stand is fully up and the clútch

¡s d¡sengaged.

When the engine is cold: 1. Pull the choke knob all the way up (full choke Position). 2. Close the throttle completely and push the electric starter button

3.

4.

lmmed¡ately after

the

engine starts, return the choke knob halfway and warm uP the eng¡ne. When the eng¡ne become run

smoothly without use of choke system, return the choke knob all the way back to ¡ts normal d¡sengaged Posit¡on.

When the egn¡ne is warm: Close the throttle comPletelY and push the electric starter button, Ope' ation of the carburetor choke sy§tem is not necessary when the engine ¡s warm.

NOTE: Opening the thtottle giP when start¡ng the eng¡ne will make the eng¡ne hard to statt.

STARTIT{G OTT

1. 2.

Warm up the engine. Squeeze the clutch lever and

depress the

g ea

rshift

lever

downward. 3.

Twist the throttle grip toward you. At the same t¡me release the

clutch lever gently and the motorcycle will move forward.

4.

As speed ¡ncreases, change uP to

the next higher gear. Close the throttle and squeeze the clutch

lever simultaneously. Lift the

gearshift lever uPward. Release the clutch lever gently and oPen

the throttle griP again.

NOÍE:

This motorcycle is

w¡th a s¡de stand/ign¡t¡on switch. lf you sh¡ft the

¡nto ge when the side stand down, the engine will stoq

ustilG THE TRAflSMlSSl0il The transm¡ssion is provided to the eng¡ne operating smoothlY in normal operating speed range. gear ratios have been carefullY eñ to meet the characteristics of engine. The rider should always the most suitable gear for the ing conditions. Never sl¡P the

to control road sPeed, but

downshift to allow the engine to within its normal operational ra

A

OII HITI.S When climb¡ng steep h¡lls, motorcycle may begin to

BIDITTG

.

I

Turn the throttle grip away from

yourself

2 3 I

down and show lack of power. th¡s point you should shift to a er gear so that the eng¡ne

again be operating ln its power range. Shift raP¡dlY to vent the motorcycle from momentum.

When riding down a steep hill, engine may be used for braking shifting to a lower gear. Be careful, however, not to

the engine to overrev.

to

close the throttle

completely. Apply the front and rear brakes evenly and at the same t¡me. Downshift through the gears as road speed decreases. Select neutral with the clutch lever squeezed toward the grip (disengaged position) ¡ust before the motorcycle stops. Neutralpo.

The mulfle¡ and sxhaust p¡pe ¡s very hot during and after operat¡on. At o¡d hurns by he¡ng careful rot to touch thesc parts. Park the motorcycle where others are not likely to touch

¡t.

sition can be confirmed by ob. serv¡ng the neutral ¡ndicator light.

a As motorcycle speed incleases, stopp¡ng distaIce increases progress¡vely. Be sure you haye a

safe stopping d¡stance hetween you and the vehicle or object

CAUTION

f{ever allow the engine t0 rev ¡nto red zone ¡n lhG tschomotef in any qea¡.

Park the motorcycle on a f¡rm, level surface where it will not fall ovet.

STOPPIIIIG AITD PARKIiIG

. .

ahead ol you. lrsing only the lront or rear brake is dangerous and can cause skid. dinO and loss

of

co

rol.

Apply the brakes lightly and w¡th gleat cafe on a $ret highway pave. ment or other slippery surlaces and at all corners. Any ahrupt

braking on slippery or irregular roads can cause loss of ridef contfol.

',|OTE: Reduce your road speed be'orc downshifting. When downshift-

ing, the engine speed should be .crcased befote the clutch ¡s engaged, Th¡s will prevent unnecessary

weat on the

d

vetrcin components

NOTE: lf the mototcycle ¡s to be parked on the s¡de stand on a slight slope, the front end of the mototcycle should face "up" the ¡ncl¡ne to avoid tolling fotward olf the side stand. You ñay leave the motorcycle in l st gear to help prcvent ¡t frcm rolling off the s¡de stand. Return to neuüal before starting eng¡ne.

6. 7.

Turn the ignition key to the "OFF" position. Turn the handlebars all the way

to the left and lock the steering

8.

for secur¡ty. Remove the ignition key.

MAINTENANCE CHART This interval should be judged by odometer reading or months, wh¡chever comes first.

INSPECTION AND MAINTENANCE MAIIITEITATTCE SCH EOUTE

The chart ind¡cates the intervals be-

tween periodic services in miles,

k¡lometers and months. At the end of

each ¡nterval, be sure

to

inspect,

check, lubricate and service as ¡nstructed. lf your motorcycle is used under h¡gh stress condit¡ons such as continuous full throttle operation, or is operated in a dusty climate, certain serv¡ces should be performed more

often to ensure reliability of the machine as explained in the main'

tenance section. Your Suzuki dealer can prov¡de you with further guidel¡nes. Steering components, suspens¡ons and wheel components are key ¡tems and require very special and careful servic¡ng. For maximum safety we suggest that you have these items inspected and serv¡ced by your

P0riodical inspect¡0ns msy rsvsal 0n0 0r m0fe parts that may nssd feplsce. ment. Vlrhsneyer replacing parts on youf moiorcycle, ¡t ¡s fccommsnded that you use oeltu¡n0 Suzuki replace. ment parts or their squ¡valent. Whsthor yoü ar6 an expcrt or do-ityourself mechanic, Suzuki recom' msrds that those items 0n the "[tlAlll' TEÍIAilCE GHABT" mark¿d with an

t 2OOO

km {7500 m¡les)

aster¡sk {*), be performed by your authorized Suzuki doaler or qualified ssrvice mechanic. You may perform ths unmarksd itoms by relerring to tho instruct¡ons in this sect¡oll,

Eng ne

oil and

Drive chaan r 00O

km (600 m¡les)

authorized Suzukidealer or a qualif¡ed

service mechanic.

Proper break.in maintenance (t00 miles or 1000 km) is a MAiIDAT0BY item for making certain lhat youl motorcycle ¡s reliable and gives full porlormance at alltimes. Be sure that this periodic mainlenance is psr. lormed thoroughly and in accordance vÍ¡th the instructi0ns in this manual.

'Cy¡inder head nuts and exhaust prpe botts

l:lnspect and clean, ad¡ust, replace ot lubricate as necessaty, R= Replace, T: T¡ghten

NOTE:

27

T00Ls

tuBRtcATl0l{ P0lfilTs Proper lubrication ¡s ¡mPortant smooth operatlon and long life each working Part of Your cle and also for safe riding lt is a

pract¡ce to lubricate the alter a long rough r¡de and after t¡ng ¡t wet it ¡n the rain or after

FUÉT TAÍTK RETIOUAI.

fhe fuel tank can be removed when sefvicing some parts of your motof.ycle. When remov¡ng the tank, folow the procedure below, L Stop the engine and turn the fuel valve to the "OFF" position.

2

NOTE: When removing the fueltank side covers, take care not to brcak the¡r hooks.

Remove the seat.

¡ng ¡t. Major lubr¡cation Points indicated as follows.

assist you ¡n the Performance of periodic maintenance, a tool kit is

fo

5.

supplied and located under the seat

6.

Loosen

two bolts @.

Remove the fuel hose

fuel valve.

)

Remove ten screws O (r¡g¡t & left s¡de) and the screw @ and remove the fuel tank side covers.

O...Clutch lever holder and

7.

cha¡n

@...Throttle cable O... Brake lever holder @...Brake pedal pivot

o...Motor oil

i

t

G-..Grease

lusl ¡n a contailer

and

avoid sp¡lling lu0l or a hot engine. D0 nol smoke, and maks süre thelc are no open flames or sparks ill the a]ea.

c

cable O...Side stand pivot and spring

O...Drive

Catch thc

O from the

'1.

Loosen

two bolts O.

Remove the fuel tank by sliding ¡t rearward.

FRATE GOVER BETOVAT

A

CAUTION

lilhsn reirstalling ths fuel tank,

bB

careful not t0 damagc the fucl hosos.

tusl tank, sg¡t al¡d tank covofs musl bs rs¡nstallsd secursly. Aftor r€instaf lat¡on. ch0ck that they aro posit¡onod withoút loosensss. 1.

2. 3.

Bemove the seat, Remove the screws O. unhook the frame cover @ and remove the frame

Ihe battery

¡s

located under the seat.

'his battery ¡s sealed type and re)uires no ma¡ntenance. Have your l?aler check the charging condit¡on )f battery periodically.

A

CAUTION

f{ever charge a battery while still ¡n the mach¡ne as damage may result to lhe battery 0r rcgulat0rl

rectif¡er. When disconnecting the battery term¡nals, be sulo to lemoye the negatilre tsrm¡nal first, lhsn remove the pos¡tiye term¡nal. The standard charg¡ng rat8 ¡s 1.4A x 5 l¡s¡rs ¿¡6 ,aximum rate is 6.0A x hour. Jleyer excesd max¡mum charging rate.

I

ftleyer attempt to open the battery sealing caps euen when charging

the battery.

SPARI( PTUGS A normally operat¡ng spark plugs are ight brown. lf the standard plugs are 1ot su¡table for your r¡d¡ng. change

AIB CIEAIIEB

lf the element has become clogged with dust, iñtake resistance will increase with a resultant decrease in power output and an increase in fuel consumption. Check and clean the cleaner periodically according to the

lrem according to the chart below:

following procedure.

1.

Remove the seat.

A

CAUTION

Always apply air pressure to the out' side 0f the air cleaner elGment 0nly. ll air pressure is used on the insida, dirt will bB forced into the porss 0f the air clsaner element restricting the

a¡r llow through the air

cleaner

0.8

element.

4.

Ref¡t the cleaned element or new air cleaner element in reverse order of removal. Be solutely sure that the air element is securely ¡n

A lf driving 2.

3.

Loosen the screws O and take off the a¡r cleaner element. Carefully use an a¡r hose to blow the dust from the air cleaner

element.

-O.9

mm

(0.031-0.035 ini

CAUTION under dusty conditions,

the a¡r cleaner element mrst bs cleatted or replaced mole frs. quently than it is with psr¡odic maintenance. ever operate the engine !¡vithout

the air cleaner element in position. 0perating the engine u,¡thout the air cleaner elsmort will increase engine wsar. Always bs súre that the air clcanel element is ¡n excsllent operat¡onal c0ndi. tion. The life of the eng¡ne depends largely on this single

componeÍt.

Remove the carbon deposits per¡odically from the spark plug with a p¡ece of hard w¡re or pin, Readjust the spark

plug gap to O.8 O.9

NOTE: Th¡s mototcycle ¡s equipped w¡th two spark plugs fot its one cylinder. To rcmove the r¡ght s¡de lug, the luel tank must be rcmoved. lhe r¡ght s¡de plug's condit¡on can be Dresumed by inspect¡ng the left s¡de plug-

mm

(0.031-O.035 in) by using a spark

plug gap thickness gauge.

Whenever removing the carbon

deposits, be sure to observe the oper ational color of each spark plug's porcela¡n t¡p. Th¡s color tells you whether or not the standard spark plug is suitable for your type of usage. A normal

operating spark plug should be light brown.

Plug Replacement Guide NGK

REMARKS

DPR8EA.9

ll the standard Plug ¡s wet in appearance orvery dark in colour, replace with th¡s

TUET HOSE

engine o¡l level checks and per¡odic rdlges are two of the most ¡mpor."-t maintenance items to be perf ormed.

plú9. DPR9EA.9

EñIGIfTE OII.

Long eng¡ne life depends much on the 5" ecflon of a quality o¡l and the periodic chang¡ng of the engine o¡1. Da¡ly

Standard

ENGINE OIL LEVEL CHECK

tuhen replacing spark Plugs, r0plsco tho ri0ht and lelt Plugs 8t ths same tims and employ lhe same tYPe ol plug for both sidos.

Replace the fuel hoses everY 4

4

A

CAUTION

tsyGr opsrats tho motorcycls if tho engine oil level is below thc "[" [ow] line on thc ong¡ne o¡l dipstick. tever f¡ll the 0ng¡n0 oil leusl aboye tho ,,F,' (full) line.

Do not ovcrtorque or cfoss thrcad

tho spark plugs or the aluminrm threads ol lhe cylinder hsad ¡Y¡ll be damaged. Do not allow contaminants to sntcr tho engino through rhe spark plug holes vuhen ths Plu$ ,ra

ENGINE OIL AND FILTER CHANGE Change the eng¡ne o¡l and oil filter ar

the initial 100O km (600 m¡tes) and at each maintenance interval. The engine oil should be changed when the eng¡ne is hot so that the eng¡ne oil w¡ll drain thoroughly from the engine. The

removgd. The standard sparl plug for this

procedure ¡s as follows:

motorcyclo has heen careflllY solected to msst the vast maiori ty of all oporational ranoes. lf lhe spark plug color indicatss that othcr lhar 8 standard spark Plug bG ussd, it ¡s hest to consult Your

' eck the engine oillevel with engine

Suzuki dealer belore selecting an altsrnste plug or hsat range. The

0ut together w¡th the oilfiller cap. The cngine o¡l ¡evel should be between the

seloct¡on

of an imProPer sPark to severe engine

plug can lead damagc.

I dipstick

(r.

The dipstick come§

F" (full) and "L" (low) levetl¡nes. To :.heck the eng¡ne oil level, hold the

r¡otorcycle venically and insert the

.ripstick unt¡lthe filler cap touches the

I ler hole upper edge.

4.

Refit the drain Plug and Tighten the Plug securelY with wrench.

CAREURTTOR

The carburetor is factory set for the best performance. Do not attempt to alter its setting. There are two items

of adjustment, however. under your care: idle speed and throttle cable play.

IDLE SPEED ADJUSTMENT

7.

Remove the eng¡ne oil filler cap

1. 2.

a¡. llace a drain

Pan under the drain

Remove the bolts @ hold¡ng filter cap @ ¡n Place.

plug.

Before f¡tt¡ng the engine o¡lfilter cover. be sure to check that the filter spring @ and the "O" ring i, are f¡tt¡ng correctly.

I I

l0 3.

Remove the drain Plug @ with a wrench and drain out the engine

6.

oil while holding the motorcYcle verticallY.

a

A

lnssrt the filtor with the oPen end thB engine and maks sure that l¡lter is ssat¡ng ProPerly.

The sngine o¡l tomporsturemay bs hioh enoüqh to burn You whon thG d¡iin Dlulis loosened. Vuait until

tho dr8¡n Plug is cool enough to

.

touch with bare hand' Be careflll not to touch the ex' haüst pipe whGn it is hot; a hot exhaüst pipe can burn You.

36

Pour approx¡mately 27OO ml (2.9/2.4 US/lmp qt) of new oil through the filler hole and refit the filler cap. Be sure to always use the specif¡ed engine

o¡1.

With the eng¡ne runn¡ng, look

various speeds

l'l CAUTION

Tighten the bolts securely.

carefully for leaks at the oil f¡lter and dra¡n plug. Run the engine at

Replace the oil f¡lter @

new one.

Use a new "O" r¡ng each the f¡ltet element is rcplaced.

.AfE:

!ñe

for 2 to

3

minutes. Stop the engine and wa¡t a few

the o¡l level again. lf the oillevel¡s lowerthan the "F" line, add new o¡l until ¡t reaches the "F" l¡ne. Check for ¡eaks aga¡n, minutes. Check

't. Start up the eng¡ne and let the 2.

engine run until it warms up fully. After eng¡ne warms up, turn the throttle stop screw O located on the carburetor ¡n or out so that

engine may run t

lmin.

at l3OOl'lOO

Pull¡ng cable play

THROTTLE CABLE ADJUSTMENT

DBIVE CHAIT This motorcycle has an endless drive

CTUTCH

O to-tsi

cha¡n constructed from special materials. lt does not use a master link. We recommend that you take your motorcycle to an authorized

ñ:""" qlr.i

Suzuki dealer if the dr¡ve chain needs replacing. The condition and adjust-

ment of the dr¡ve chain should be

checked each day before you ride. Arways follow the gu¡del¡nes below for inspecting and servicing the cha¡n.

A twin throttle cable system is used in this motorcycle: One cable @is for pulling and the other cable @ for returning. To adiust the cable play, adjust the returning cable lirst and then adiust the PUlling cable.

The pulling cable should be adjust to have a cable PlaY G) of o 5- 1 mm (O.02-O.O4 in) as shown in

Fig. lt the adiustment is ne adiust the cable PlaY in the t way: 1. Turn the handlebars all the

to the left.

Roturning cable PlaY

-he play of the clutch lever should be 0 '1 5 mm (0.4-0.6 inl as measred at the clutch lever end, lf you ,nd the play of the clutch incorrect, .,¡tust ¡t ¡n the following way. r Loosen the lock nut @ and turn ln the adjuster O as far as it will go.

play @

4.

the following:

to obta¡n the of O.5-1.O

a o

(O.02-O.04 in). Tighten the loct nuts (@,@l

CAUTION

After the ad¡ustmont is make sure that ihc throttle The returning cable should be adiusted to have a thread length @ of 2-3 mm (0.O8-0.1 2 ¡n) as shown in the F¡g. lf the ad¡ustment ¡s necessary, adjust the thread length in the follo\ /¡ng way:

'1.

2. 3.

Loosen lock nuts e). Move the adjuster O to obta¡n the thread length O) of 2-3 mm (O.08 O.12 in).

Tiqhten the lock nuts @ curely.

se-

pos¡tively and its operat¡on is aod smooth.

Loose pins Damaged rollers Dry or rusted l¡nks

. . Kinked or b¡nding links o Excess¡ve wear . lmproper chain adjustment

curely.

A

motorcycle.

lnspecting the Drive Cha¡n When ¡nspecting the chain, look for

Loosen the lock nuts Turn the adiusterO or move

adjuster @

[o] maximum salety, the drive chain condit¡on and adiustmqnt should be checksd pr¡or to operat¡nq the

Loosen the lock nuts @ and relocate the adjuster@ to obta¡n the

correct play. Minor adjustment can be made

with the clutch lever side

ad-

T¡ghten the lock nuts

O.

juster @.

A

O

and

CAUTION

Any maintenanco 0f the clutch other than the clutch cahle play adiuslment should be porlormed bv vour Suzuki dealer.

lf you find anything wrong with the drive chain condition or adjustmenl, correct the problem ¡f you know how. lf necessary, consult your authorized Suzuki dealer.

Damage to the dr¡ve cha¡n means that the so-rockets may also be damaged'

lnsp;ct the sprockets for the following: a Excessively worn teeth a Broken or damaged teeth a Loose sprocket mounting nuts

1.

Cleaninq the chain with is strongly recommended. lf cha¡n tends to rust, the must be shortened. Kerosene a petroleum Product and will P v¡de some lubrication as well

clean¡ng action.

DRIVE CHAIN ADJUSTMENT

Adjust the drive chain slack to the proper specification. The chain may ,equire more frequent adiustments

rÉan it is with periodic maintenance depend¡ng upon your rid¡ng con_ d

The slack of the drive chain should be JU-4b mm ( 1.2 - 1.8 ¡n) as meaured

at the m¡d-point between the two

sprockets.

1.

Place the motorcycle on the s¡de stand.

it¡ons.

lf vou find any of these problems with

your sprocket, consult Your Suzuki dealer.

0o not üss m¡olim, trichlene or commg¡ci¡l cle¡nino solvents. fluids have a strong dissolving er that could dam8ge tho "0"

¡n ths chain. Thi¡ will allow to run out of the chain-and ihain would havo to be rePlaced. greasG

Excessiyo ch¡in shcl coüld crú¡r ths cha¡fl to comc off tho $rockots and result in ¡n acddo ot sorioüt sno¡tte damage. Tho drivo cha¡tl ld¡urtm-ert

should be chactad avory i¡ms the mach¡m ¡s opcrslod.

2.

Allow the chain to drY. then cate the l¡nks with a dr¡ve

lubricant 20w/50).

or motor

3.

o¡l

DRIVE CHAIN CLEANING AND OILING Soms d¡ivs chain hhr¡carts

solvonts ¡nd addiiivos wh¡ch dsmago the "0" rings in Your lhe ¡ rüive chain lubriGtnt thal is cil¡cslly intsnded lor use on "0" chains.

Th¡s dr¡ve chain has special

"O"

r¡ngs

that permanently seal grease ins¡de' Clean and o¡l the chain per¡odically, as follows:

30-45 mm (1.2- 1.8 ¡n)

4.

Loosen the axle nut

O.

Turn tho r¡ght and tefúdiusters (?) to obtain the correct slack. At the same time, align both r¡oht and left adjusters by referrino-to

the reference marks O.

T¡ghten the axle nut securely.

NOTE: The two sprockets should be ¡nspected for wear when a new chain ¡s ¡nstalted and replace them if necessary. NOTE: The cha¡n is an endless type cnan lno mastet link) for maximum

strength. Chain replacement reauires thdt the sw¡ngarm be removed. Ttust this wo* only to a qualif¡ed technic¡an, Never ¡nstall a master l¡nk tvDe

chain.

BRAI(ES Th¡s motorcycle util¡zes front and rear

BRAKE FLUID

BRAKE PAD

disc brakes. Properly operating brake

systems are vital to safe r¡ding. Be sure to perform the brake inspect¡on requirements as scheduled.

Braks flü¡d msy bo harmful ¡l lowod or if it comcs ill Dontact skin or eyes. Contact your swallowed int ¡mm8distely. vomiting. lf brake flu¡d gs$ ¡nto tho sldn. sf,llr fIll] or ln in conIaGI contact IUru! w¡th uro ayea Ol SYeA thoroughly with plonty of w¡tor.

lf

BRAKE SYSTEM

a lf tho brakc aystom or pads nsod to bo r8paired or ssrY¡csd wo

ÉRONT

FRONT

strongly adYiso yoü to have youf

a

a[thorir0d Suzt¡ki d0al0] porlorm service. Holshe has ths Propor tools and proper tra¡n¡no to Por'

This motorcycle uses

form the lob in a safe and econom' ical manner. Dkc brake systems opGrate under

such as

ertromsly high pressures. tor safety, the brak8 hose and brake flu¡d should bo chsnged at inlcr'

uals

of no longor thar

schedulsd

in

those

tlAltlTEflAtGE

SCHEDULE section

ol this manual.

lnspect your brake system for the fol-

low¡ng items daily:

a

o

. .

lnspect the front and rear brake system for signs of fluid leakage. lnspect the brake hose for leakage or a cracked appearance. Check the wear of the disc brake

a

based brake fluid. Do not uso m¡x diffsront types of braks

silicons-bassd

pstroloum.based f lüid, serioüs demsgc will rosult to brako system. ilovsr úss any brake flu¡d that heon stored in I used or conta¡nsr. tevsr roüss brako

loft ovcr from the last and stored for long periods as absorhs mo¡sture lrom tho air Use only DoT 4 brats lluid.

0o not sp¡ll any brake fluid painted or plasl¡c sürfaces as

will

damage tho surlace

REAR

C\eck the brake fluid level in both lont and fear brake fluid reservoirs. l' the level ¡n e¡ther reservoir is below '\e lower mark, add DOT4 brake fluid

-1d rnspect brake pad wear and leaks.

NOrE:

Reat brake fluid rese¡voi¡ is

b h¡nd the ight Írcme cover. Check .ap lluid level thrcugh the inspection 'vtndow of the f¡ame cove¡_

REAR

Inspect the front and rear brake pads by noting whether or not the friction pads are worn down to the grooved lrm¡t line. lf a pad is worn to the grooved limit l¡ne it must be replaced wrth a new one by your author¡zed

Suzuki dealer mechanic.

or qualifíed service

pads.

The brake lever and pedal should have the proper stroke and be f¡rm at all t¡mes.

Aftsr

lrolt or roar disc brake oad

roplscemsrt, do rot r¡do tho moio¡cycle ünt¡l tho brske leyer,lsdal has been "pumped" seyeral times to or. tend thc pads ard rsstore the oroool revorlpedal str.te and firm fder_'

_-o Ttt

ffi FRONT

lk§ t[N

t§

IN t§ LN

REAR BRAKE PEDAL The rear brake pedal Position must properly adiusted at all t¡mes or disk brake pads w¡ll bear against d¡sk causing damage to the Pads

to the disk surface. Adjust the

pedal pos¡t¡on ¡n the f

BEAR BRAKE LIGHT SwlTCH

TIRE PRESSURE AND LOADING

Proper t¡re pressure and proper t¡re Ioadrng are ¡mportant lactors. Over_

-l

loading your t¡res can ¡ead

.¿

REAR

the brake light switch, tu¡n -rir switch body and raise or lower it I o adjúst

CAUTION

:,r rhat the brake Iight will come on

Do not squeez8ldeprsss the brake

st before a pressure r¡se ¡s felt when iIc brake pedal is depressed_

lGverlpedal whsr the Fads sre not in their pos¡tions. lt is d¡fficult t0 PUsh

L

adjusted before riding, since rjd¡ng will heat up the tires and lead to higher inflation pressure ¡eadings. Cold Tire lnflation pressure

the p¡stons back and brake flu¡d le¿k'

8ge may result.

TIBE S

The tires 0n your molorcyclo lorm

FRONT

REAR

the

crucial link between your motorcrcle

1.

Loosen lock nut O, and push rod @ to locate the

5 mm (O.2-0.6 in) the top face of the footrestl Ret¡ghten lock nut O to push rod @ ¡n the proper

5-

2.

1

sition.

NOTE: Aftet the rcat brake ¡ustment, check if the bruke l¡t when the reat bnke ¡s oqerated. adjust the bñke light sw¡tch, tum adjuster so that the brcke light come on just beforc a prcssure

felt when the brcke pedal

deprcssed.

tire

Check tire pressure each day before you ride. and be sure the pressure ¡s correct for the motorcycle load accord¡ng to the table as follows. Tire pressure should only be checked and

mannet:

@ Grooved wear limit l¡ne

A

to

failure and loss of motorcycle control.

and the road. Proper t¡re inflaiion pressure, condition, loading, and t¡re rype are rmpoIlanl condit¡on§ fol you r0 monitor. Failure to follow tháse warnings may fosult ill an accident due to tire failure 0r motorcyclo Don.

trol d¡fliculty:

.

Check t¡re pressure and condilion each day before you ride.

a 0o nol oyerload Ioür t¡rcs. o Replace t¡res whsn tread ¡s worr t0 specifiod limits, 0r if tires show visual eyidsnco of damage, such

as cfacka ot cttts.

SOLO RIDING

TWO UP

175 kPa 1 .75 kg/cm, 25 ps¡

200 kPa

2.00 kg/cm:

2OO kPa 2.OO kg/cmr 29 P"¡

2.50 kg/cm,

RIDING

29 ps¡ 250 kPa 36 ps¡

Under-inflated tires make smooth cor_ nering d¡fficult, and can result ¡n raD¡d

t¡re wear. Over-¡nflated t¡res have a smaller amount of tire in contact w¡th

the road, which can contr¡bute to skidding and loss of control_

SPOKE IIIPPI.E TIGHTTTESS

TIRE TREAD CONDITION

stDE sTAlIoflcxlll0t ttTERtoct( swlTCH

TROilT WHEEI. BEMOUAI. 1. Place the motorcycle on the s¡de stand-

Operating the motorcycle with excessivelv worn tires w¡ll decrease rldlng stabiiitv and can lead to loss of control- lt is recommended that a tire be reDlaced when the rema¡ning depth of ti; tread become§ 4,0 mm (O 16 in) or less.

Check the tension of spokes to ty the tightness of the spoke The tension of the §Pokes can

checked bY squeezing the with your f¡ngers. lt a spoke loose, the sPoke will bend more the others. The tension can also checked bY hitting the sPokes small metal bar. lf the sPoke

loose, it's sound will be dull.

The standard tirc 0n this m0torcycle

is

90190'21 54S

in lront

and

a

t30180.17 65S on the rear. The uss of tvDe wh¡ch is other than original stabil¡tY equíp'meÍt can lead problems.

to

To t¡ghten the sPoke niPPles

Check the side stand/ignition interock switch for proper operat¡on as

2.

'

:. 3

Remove four bohs @ and remove

ths eng¡n6 under guard.

lollows: S¡t on the motorcycle in the normal r¡ding pos¡t¡on, with the s¡de stand up.

Shift into f¡rst gear, hold the

clutch in, and stan the engine. While continu¡ng to hold the clutch in, move the side stand to the down pos¡tion.

lv, tighten them equallY to the

fied torque.

Loosened

overtightened spoke

niPPles

cause unequaltension of spokes mav result in distonion of the wt rim. Contact your Suzuki dealer this service to be Performed.

f the eng¡ne

stops running when the

de stand is moved to the down po,on, then the side stand/ignition ¡n:¿rlock switch is work¡ng properly. lf l're engine continues to run with the s de stand down and the transm¡ssion

3.

Loosen th€ sxl6 holder bolt

4.

Lift the front end of the motorcy cle up and ptace a ja;k .; ;;;k

O.

qear, then the side stand/¡gnition

r"rlock sw¡tch is not working

'operly. Have your motorcycle in-

"cted by an author¡zed Suzukideal-

rl'or a qualified service mechanic_

lllake suro thst the sids standli¡nition Interlock switch is working properly

hefore r¡ding. ll the sw¡tch ¡s not work¡ng ard the s¡de stand is left

down, ¡t may ¡nterlere

with r¡der con. trol dur¡ng a left turit.

under the chassis tubes or the engine.

BEAR WIIEET BETOVAI. Place the motorcycle on the s¡de

L

flovef soueezs the ffont braks lcr with thc front whsel remoY8d. lt vsrv difficult io lorce thc Pads ¡ ó tho csl¡per assembly and

stand.

lluid leakagó maY result.

7. 5.

To reinstall the wheel

reverse the sequence descr¡bed,

Unscrew the axle shaft, then draw it out.

After installing the wheel. the brake several times to the proper lever stroke.

a

2.

Remove the axl€ nut.

Do not ride the motorcYcle

the front brake levor

ha§

"pumped" s8versl t¡m8§ to r

ths oads and rsstoro ths I levei stroke and lirm fool.

4.

. lf the lro[t whGel has to bc

importrnt is YerY verY lmponl it ls moved, ¡t haue the loosoned nuts 8nd torquod to tho Propsr thal You iions. Wo suggoí suoooí that tions. tto this perlormod bY 8n suth Suzuki dealer.

5.

Draw out the axle shaft. W¡th the wheel moved forward,

remove the cha¡n from the

3.

L¡ft the rear end of the motorcycle up and place a jack or a block under the engine or chassis

6.

sprocket.

Pull the rear wheel assembly

rearward.

A

tubes.

CAUTTON

ilever depross the rea¡ b¡ak¡ oed¡l

Locate the speedomoter drivo hox so that the Gablo is smoothly withoüt 8n excoss¡Ye

6.

Sl¡de the front wheel forward

Do not loüch lhe hot mufflor or a hot mufflor csll bürn you.

w¡th tho reer whesl rsmoysd.'lt is yery difficult to forcc the os& hsck

i 7. 8.

4A

o rhe caliper sssombly.'

To replace the wheel reverse the

complete sequence listed. After instslling the wheel, applv the brake several times ánd rhcn check that the wheel ¡otates freely.

TIGHT BUTB REPTACEi,,IEiIT

. a

fhe wattage rating of each bulb shown on the chart below WhBn rsinstall¡ng the ¡ear wheel, be sure 10 follow the Procedure

outlined in thc 0BIVE GHAlfl AD' Jl.lSTftlE[lT section. ll You havc found it nscessafy io remove the rear wheel, il is verY important that the nuts and bolts be torqued lo the Proper sp8cllr'

replacing a burned out bulb, use the exact same wattage Us¡ng other than the sPecified can result in overloading the cal system or Premature fa¡lure

HEADLIGHT replace the headl¡ght bulb, follow

lo

the procedure below:

bulb.

cation. We stlon0ly fecommend

.

that vou have theso bolts Gh8cked and ótorqued bY Your authorized Suzuki dsaler. Do not ride the motorcycle unt¡l

the brake Pedal has

been "pumped" several l¡mes to extend the Dads and lsstole ths PloPer

3.

Disconnect socket

O

from the

headl¡ght and remove the rubber

I

cap @.

Remove four screws O (right & left s¡de) and remove the w¡ndshield.

pedil travel and firm leel.

wrt0sHlEtD ctEAf{lilG

4.

Unhook the butb hotder spring @,

and pull out bulb @. Remove four bolts @ (r¡ght & left

side) and sl¡de

housing forwards.

Clean the w¡ndshield with a soft cloth

and warm water with a mild deteroent. lf scratched, polish with a com-

áercially available plastic

polish Replace the windshield if it becomes scratched or discolored so as to ob-

struct view. When replacing wind-

shield, use Suzuki rePlacement w¡ndshield.

the

headtight

-l _ac4qMN ññt.r.úñ|, rr.t---- t"^^,

Thisc motorcycle nG6. - halogen head. uses a light hulb. When replacing ihe head. l¡ght bulb, light hulb, be carefui careft-l not noI 6 to rouch r0uch the glsss bulb, or the life of the hulb be shortened.

I

wi

NOTE:

When re¡nsta ¡ng the rubber cap, make súrc that ¡ts affow matk faces upward-

l

I.}i¡I¡EIFIIITIIT§.I¡

Er¡tr rrr-F

HEADLIGHT BEAM ADJUSTMENT u""t can be adiusted

tilñ""iiint'i -r,roti.L.a"rrv and verticallv ¡.in

TURN SIGNAL LIGHT

¡f

fAlL/BRAKE LIGHT fo replace the tail/brake l¡ght bulb, fo low the Procedure below:

LICENSE PLATE LIGHT To replace the license plate l¡ght bulb,

follow the procedure below:

necessary.

1

1.

2.

To adiust thé beam iorizontally:

Remove screws and the I Push in on the bulb, turn it

the lens.

pushing.

left, and pu¡l it out.

3.

trrrn ihe adiuster (D clockwrse or counterclockwise' To adiust the beam verticallY:.

frrrn the adiuster Q) clockwlse or counterclockwise'

l-

a

q4!r!9!-

1 After setting the lens, be carelul secu 1 to overtighten the threG ¡rg should lens the lest 1 screws

Remove

two rubber caps O.

Loosen the screws and remove

left, and Pull ¡t out'

To fit the rePlacement bulb, it in and turn it to the right

.

Push in on the bulb, turn ¡t to the

2.

Remove two nuts @ and remove

the lens.

fit the replacement bulb, push it in and turn it to the right while To

pushing.

A

CAUTION

After sett¡ng the lsns, be careful not lo overtighten lhs two secur¡ng screws lest the lens should hreak.

3.

Push in on the bulb. turn ¡t to the

left, and pull it out. :

I

I 52

TROUBLESHOOTING NOTE:

iller

use fuses other than tho

iYoss soeDilied.

l'tiavs' be sure lo

rePlace

hlown fuse with the cofrect ¡eraog fuse. fleYer use a su

iute.-Ior eramPle, aluminum ulown lf I fuse blown out in a short ;d of fime, it means that You have a malor electrical Prr You should Gonsult Yoür I dealer immediatelY'

oi a'wire to reitace

4.

To fit the replacement bulb' Push it in and turn it to the r¡ght whlle Pusing.

rusEs

a

FUSE LISf 1. 2OA MAIN fuse Protects

arr

tr¡cal circuits

Protects 2. 2OA DECOMP fuse decomPression sYstem' 3. lOA HEAD fuse Protects beam

4.

lt

¡s best to consult yout

f the eng¡ne refuses to start, perform

e following inspections to deter

-rine the cause.

{-uel Supply Check Make sure there is enough fuel in

'

the fuel tank.

.'

Check that the fuel valve is in the

"ON"

posit¡on.

Make sure there is enough fuel reaching the carburetor from the

headlight and high tor light. 1OA SIGNAL fuse Protecls turn signal light, turn slgnal cator lights and brakeltght'

fuel valve.

a.

Loosen the drain screw located under the carburetor. Drain

the fuel from the carburetor

iot

engine or exhaust system. Ex-

,nguish

ary smoking materials before erforming this check, and stay away lrom any other fire or he¡t source. .

b.

Place the empty container un, der the carburetor. Turn the fuel valve to the "OFF" position and see if the fuel flows from the drain hole. c. Turn the fuel valve lever to the

54

crank the eng¡ne reffer¡ng to

the STARTING THE

f.

.\arrcnty may affect wafianty con-

not allow the luel t0 sp¡ll. Catch rhe fuel in a conta¡ner. D0 not allow rny fuel to come in contact with the

tuse oox' are Prov¡ded inside the

e. Push the electric starter button for a several seconds to

'hen the Suzuki dealet should be con-ulted before any repairs arc attempt. d on the machine by yourself. Tampeing w¡th the machine while in

D0

i.i..i"""t"-

dra¡n screw.

Suzuki dealer beforc attempting to ttoubleshoot any prcblem, tf the mach¡ne ¡s st¡ll w¡th¡n the warrunty

into a container. seal' The fuses are located under the a clrThev are designed to open when elec ind¡vidual in exists cuit;verload ll any electrical to oPerate' then tne .r.t", l"il""lr"u¡ts tuses iu"es mrst be checked Spare

"ON" position. d. Drain the fuel and tighten the

4.

ENGTNE

sect¡on.

Loosen the dra¡n screw and check that the carburetor is filled back up with fuet. g. Tighten the drain screw. lf fuel ¡s reach¡ng the carburetor,

ignition system should checked next.

be

ENGINE STALLING 1. Check the fuel suPPlY ¡n the

lgnition Syst€m Check

tank. 2.

Check the ¡gn¡tion system for

termittent spark. 3.

1.

2.

two spark Plugs

and reattach one of them to the spark plug lead. While holding the spark Plug firmly against the engine. Push the staner sw¡tch with the ign¡t¡on switch ¡n the "ON" Posit¡on, the engine stop switch ¡n the " O " pos¡tion. the transmiss¡on in neutral, and the clutch d¡sengaged.

Remove

Check the ¡dle speed.

CLEANING

Wash¡ng the Motorcycle

washing the motorcycle, folow the ¡nstruction below: r Remove dirt and mud from the motorcycle w¡th running water. You may use a soft sponge or brush. Do not use hard materials wh¡ch can scratch the paint. 2 Wash the entire motorcycle w¡th a mild detergent or car wash

.tlen

soap us¡ng

Do not hold ths sparl Plug close to

the opon spark pluo hol€ ¡n ths

cyl¡n&r hsad as gasoline vapor insi& tho cylindsr could be ignited, cr0at'

A

cal ¡hock, anyollc with

¡

Eond¡tion or pscsmaker should

this

Ghock.

hoart

¡void

sponge or soft

CAUTION

Oil cooler f¡ns can be damaged by

spraying high prsssure wator on them.0o not spray high pressure

Check carefully for damage to

painted surfaces. lf there ¡s any damage, obtain "touch-up" pa ¡nt and "touch-up" the damage follow¡ng the procedure

below:

a. Clean all damaged spots and allow them to dry. b. St¡r the paint and "touch-up,, the damaged spots l¡9htly wilh a small brush. c. Allow the pa¡nt to dry completely.

Waxing the Motorcyclo After washing the motorcycle, wax¡ng and polishing are recommended

to

further protect and beautify the paint. o Only use waxes and polishes of good qual¡ty. . When us¡ng waxes and polishes, observe the precaut¡ons spec¡fied by the manufacturers.

water on the oil cooler fins.

i'¡OTE: Avoid sprcy¡ng or allow¡ng

'.'/atet to flow over tlaces: . lgn¡t¡on switch . Spark plugs

. . .

the follow¡ng

Fuel tank cap

Carbureto$ Brcke master cyl¡nders Once the dirt has been complete-

ing a lire hazard. To reduco the chance of electrical shock, hold thg metal shell 0f the spark plug aga¡nst all unpsintod metal portion ol ths sll. girs. bue t0 the possih¡lity of sloctr¡'

a

cloth. The sponge or cloth should be frequently soaked in the soap solution.

lf the ¡gnition sYstem is operating properly, a blue sPark should jump across the sPark Plug gap. lf there is no spark, consult Your Suzuk¡ dealer for rePairs.

5.

N,{OTORCYCLE

I

ly removed, r¡nse off the detergent with runn¡ng water, After rinsing, w¡pe off the motorcycle with a wet chamo¡se or cloth and allow it to dry in the shade-

lnspection after Cleaning For extended l¡fe of your motorcycle, lubricate according to "LUBRICA TION POINTS" section.

operat¡ng the motorcycle w¡th wet brakes can

ts

haza¡dous. Wet brakss

may not prov¡de as much stopp¡ng power as dry brakes. Th¡s could lead t0 an acc¡dcnt. Tost your brales after washing the notorcycle, while rid. ing at slow speed. ll necessary, apply brakes seyor¡l timos to let lriction dry out thc lining.

Follow the procedures in the "lNSPECTION BEFORE RlDlNG" section

to check your motorcycle for

any

problems that may have arisen dur¡ng your last ride.

STORAGE PROCEDURE lf the motorcycle is to be left unused for extended period of t¡me for winter

storage or any other reason, the

mach¡ne needs special servicing re quir¡ng appropriate materials, equipment ánd skill. For this reason, Suzuki recommends that you trust this main tenance work to your Suzuki dealer' lf you need to serv¡ce the mach¡ne for storage yourself, follow the general guidelines as f ollows. MOTORCYCLE Clean the entire motorcycle. Placethe

motorcycle on the side stand on a firm, flat surface where it will not fall over. Turn the handlebars allthe way to the left and lock the steering, and remove the iqnition keY.

BATTERY

o

Remove

the batterY

from

motorcycle.

I]

a crurtoru-

Be sure to remove the nsgat¡vc minal first, then remove the Pos

I torminal. t-_--

.

Clean the outside of the with a mild detergent and any corrosion from the and wir¡ng harness Store the batterY in a room

a

a

freez¡ng. TIRES

lnflate the tires to the normal cations. EXTERNAL

FUEL

.

Fill the fuel tank to the top with fuel mixed with the amount of gasoline stabilizer recommended by the stab¡lizer manufacturer. a Run the engine for a few minutes until the stabilized gasol¡ne f¡lls the carburetors.

NOTE: Make sure that the fuel valve is in "OFF" position.

.

Spray all v¡nYl and rubber

a o

with rubber Preservative. Spray the unPainted surfaces

rust preventative

Coat the painted surfaces with

PROCEDURE FOR RETURNING SERVICE

a

.

Clean the entire motorcycle.

Reinstall the battery.

A

ENGINE

a

.

Pour one tablespoon of motor oil into the spark plug holes. Reinstall the spark plugs and crank the en o¡ne a few times órain the engine oilthoroughly añd fillthe crankcase with the fresh engine oil all the waY uP to the filler hole.

f8. .rr.

J4!I!9\

to connect the Pos¡tive minal f¡rst. theI connect the nc0i

lre¡minal.

L-

Remove the spark plugs. Turn the engine a few t¡mes by putt¡ng the transm¡ss¡on ¡n top gear and turn-

ng the rear wheel. Reinstall the spark plugs. Drain the engine oil thoroughly. Beplace the o¡l filter with a new one and pour fresh oil as outlined n this manual. Adjust the pressure of t¡res as descr¡bed in the TIRES section. Lubricate all places as ¡nstructed iñ th¡s manual. Do the "lnspect¡on Before Riding" as listed ¡n this manual.

SPECIFICATIONS

ELECfRICAI.

,.¡on type.- . ..

.r.ton timing......

DIMENSIOf{S AI{D DRY MASS

2365 mm {93.1 in} -.. For Swirzerland a¡d

Overáll length.

GermanY

2230 mm (87.8 in) .. For others 465 mm 134.1 inl 1325 mm {52.2 ¡n) 152O mm f59.8 in) 23O mm ( 9.1 in) 89o mm 135.0 in) 194 ks (428 lbs)

Elecrronic rsnrrron (CDt) 5o B.T.D.C. below 22OO mñ án¿, 28o B.T.D.C. ábove 43Oo rm,n NGK DPAgEA 9 12V 43.2 kct12 Ah)/]0 HR Three phase A.C qéner¿to¡

20t20t10t10 a 12V 60/55W 12V 21W 12V 5/21W x2 12V 5W

-

]2V 3W 12V 3W

ENGINE

Tvpe..... -..-... Number ol cyliñder ' Bore.-.... Sroke .... Displacemeñt Compression ratio.....

Four stroke, air-cooled,

105 mm {4.134 in) 90 mm (3.543 in) 779 cm' {47.5 cu in)

9.5:

.

1

MIKUNI BST33. two Non-woven fabric element Electric starter motor

cleaner.

Starter system.

Lubrication system. TRANSMISSIof{

Wet mult¡ plate type s-speed constanl mesh

Clutch............

Transmission....... Gearsh¡ft pattern..

-..

-

Primary reduct¡on rat¡o........... Gear ratios, 1ow.....

Final

2nd......... 3rd ' ' 4rh fop....... reduction ratio......

D ve chain.

.

cHASStS Front sLrspension-.. Rear suspension. . .

12V 2W

1

Carburetor.

An

with SACS, SOHC

...

1.848 t61/33)

2.461 t32l13l 1.578 {30/19) 1 .2OO t24t2ot

o.9561221231 0.800 {20/25)

133 147115) D|D525V9, 116 links 3_

TelescoDic, coil spring, oil damped Link type, coil spring, gas/oil damped. preload lully adiustabls

29.00'

135 mm {5.31 in) 43o {r¡ght & left} 2.5 m {a.2 ft) Disc brake Disc brake

90/9G21 54S, tube

13O/8O '17 655, tube

,tAPAClflEs

.,

rank, including

Beserve........... with fitter change..........

r.e ol, oil chañge.._.

24 L 16-315.3 t,S/lmp. oat) 5.5 L (1.5/t.2 Us/tmo. oall 2600 ml (2.7/2.3 US/tm; od 27OO ml 12.9/2.4 US/tm;. qr)