VS1400

FOREWORD
This service manual has been produced primarily for experienced mechanics whose job is
to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-it-
yourself mechanics, will also find this manual an extremely useful repair guide. This manual
contains the most up-to-date information at the time of publication. The rights are reserved
to update or make corrections to this manual at any time. Latermade modifications and
changes will be explained to each SUZUKI distributor in respective markets, to whom you
are kindly requested to make query about updated information, if any.

IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50cc or greater are subject
to Environmental Protection Agency emission regulations. These regulations set specific
standards for exhaust emission output levels as well as particular servicing requirements.
This manual includes specific information required to properly inspect and service the
VS1400GL in accordance with all EPA regulations. It is strongly recommended that the
chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed
before any type of service work is performed.

Further information concerning the EPA emission regulations and U.S. Suzuki's emission
control program can be found in the U.S SUZUKI EMISSION CONTROL PROGRAM
MANUA L/SER VICE BULLETIN.
 • GROUP INDEX ^^ S 4

GENERAL INFORMATIO
PERIODIC MAINTANANCE AND TUNE-UP PROCEDURES
ENGINE
SHAFT DRIVE
FUEL AND LUBRICATION SYSTEM
EMISSION CONTROL INFORMATIONS
ELECTRICAL SYSTEM
CHASSIS
SEARVICING INFORMATION
APPENDIX APR.
 SUPPLEMENTS
VS1400 GLJ C88-M0DEL) 10
VS1400 GLFL/GLPL (VO-MODEL) WMIM
VS1400 GLFM/GLPM ('91-MODEL) 12
VS1400 GLFN/GLPN ('92-MODEL) 13
VS1400 GLFP/GLPP ('93-MODEL) 14
VS1400 GLFR/GLPR/GLFS/GLPS{'94/'95-MODEL)\ 15 %
VS1400 GLFT/GLPT ('96-MODEL) 16
VS1400 GLFV/GLPV ('97-MODEL) \ 17
VS1400 GLFW/GLPW ('98-MODEL)
VS1400 GLFX/GLPX ('99-MODEL) 19
VS1400 GLPY/GLPK1/GLPK2/GLPK3 C00/V1/V2/V3-MODEL)

VS1400GLPK4 ('04-MODEL) 21
VS1400K5 ('05 MODEL) 22 '
VS1400K6 ('06 MODEL) 23
 GENERAL INFORMATION

CONTENTS
SERIAL NUMBER LOCATIONS /- 1
FUEL AND OIL RECOMMENDATIONS 1- 1
BREAKING-IN PROCEDURES 1- 2
CYLINDER IDENTIFICATION 1- 2
SPECIAL MATERIALS 1-3
PRECAUTIONS AND GENERAL INSTRUCTIONS 1- 5
SPECIFICATIONS 1- 6
1-1 GENERAL I N F O R M A T I O N

SERIAL NUMBER LOCATIONS

The frame serial number of V . I . N . (Vehicle Identi-
fication Number) ® is stamped on the steering
head pipe. The engine serial number (2) is located
on the left side of the crankcase. These numbers
are required especially for registering the machine
and ordering spare parts.

F U E L AND OIL
RECOMMENDATIONS

FUEL
Use only unleaded or low-lead type gasoline of at
MULTIGRADE
least 85 - 95 pump octane (-^±i!i-method) or 89 m EEEESZSiI
octane or higher rated by the Research method. 10W-30

ENGINE OIL
-30 -20 -10 0 10 20 30 40
S U Z U K I recommends the use of S U Z U K I PER- TEMP. —H \H h - H 1 I
F O R M A N C E 4 MOTOR O I L or an oil which is - 2 2 - 4 14 32 50 68 8G 104

rated SE or SF under the API (American Petro-

leum Institute) classification system. The viscosity
rating is SAE 10W/40. If an SAE 1QW/40 motor
oil is not available, select an alternate according to
the chart.
 GENERAL INFORMATION 1-2

FINAL GEAR OIL B R A K E AND C L U T C H FLUID

Use SAE 90 hypoid gear oil which is rated GL-5
under API classification system. If you operate the Specification and
D 0 T 3 or D 0 T 4
motorcycle where ambient temperature is below classification:
0°C (32°F), use SAE 80 hypoid gear oil.

WARNING:
• Since the brake system and the clutch
FRONT FORK OIL system of this motorcycle are filled w i t h a
Use fork oil # 10. glycol-based brake fluid by the manufac-
turer, do not use or mix different types of
f l u i d such as silicone-based and petroleum-
based fluid for refilling the system,
otherwise serious damage w i l l result.
• Do not use any brake fluid taken f r o m old
or used or unsealed containers.
• Never re-use brake fluid left over f r o m the
previous servicing and stored for a long
period.

BREAKING-IN PROCEDURES Keep the these breaking-in engine speed limits:

Initial Up to Over
During manufacture only the best possible materi- 500 miles 1 000 miles 1 000 miles
als are used and all machined parts are finished t o a (800 km) (1 600 km) (1 600 km)
very high standard, but it is still necessary to allow Maximum
recommended 4 000 r/min 5 000 r/min 6 000 r/min
the moving parts t o " B R E A K - I N " before subject- engine speed
ing the engine to maximum stresses. The future Corresponding vehicle speed
performance and reliability of the engine depends miles/h 27 34 40
1st
on the care and restraint exercised during its early km/h 40 50 65
miles/h 44 56 67
life. The general rules are as follows. 2nd
km/h 70 90 105
miles/h 61 76 92
• Upon reaching an odometer reading of 1 600 3rd
km/h 95 120 \5
km (1 000 mi) you can subject the motorcycle miles/h 78 98 ' 117
Top
to full t h r o t t l e operation. km/h 125 155 185

• Do not maintain constant engine speed for an

extended time period during any portion of the
break-in. T r y t o vary the t h r o t t l e position.

CYLINDER IDENTIFICATION
The t w o cylinders of this engine are identified as
No. 1, and No. 2 cylinder, as counted from rear to
f r o n t (as viewed by the rider on the seat).
1-3 GENERAL INFORMATION

SPECIAL MATERIALS

The materials listed below are needed f o r maintenance w o r k o n the V S 1 4 0 0 G L , and should be kept on
hand f o r ready use. They supplement such standard materials as cleaning fluids, lubricants, emery c l o t h
and the like. How t o use them and where t o use them are described in the t e x t of this manual.

Material Part Page Part Page

• 0 ring of oil jet 3-25 • Drive joint 0 ring and final 8-36
• De-comp shaft oil seal 3-28 gear spline
• Clutch push piece retaining 3- 53 • Swing arm bearing 8-40
hole
• Secondary driven bevel gear 4- 7
oil seal
• Final driven bevel gear 4-28
coupling
• Housing inside oil seal 7- 13
• Front wheel bearing 8- 4
SUZUKI • Steering inner race 8-22
SUPER GREASE " A "
99000-25030
• Valve stem 3-37
• De-comp shaft 3-38
• Rocker arm shaft 3-38
• Crank pin and bearing 3-48
• Countershaft 3-58
• Drive shaft 3-59
• Camshaft journal 3-78
• Clutch master cylinder 8-44

SUZUKI MOLY PASTE

99000-25140

• Oil pressure switch 3- 24

• Mating surface of crankcases ' 3-61
• Mating surface of swingarm 4- 28
and final gear case 8-40
• Mating surface of the final 4-27
gear case and cover

SUZUKI BOND
No. 1207B
99104-31140

• Oil separator 3-25 • Bearing retainer bolt 4-7

• Bearing retainer 3-26 • Secondary dirven bevel gear 4-7
• Starter clutch alien bolt 3-55 spacer
• Oil pump case screw 3-56 • Final driven gear bearing 4-21
• Secondary drive gear bearing 3-60 retainer screw
retainer bolt • Hub flange securing bolt 8-5
• Rotor bolt 3-63 • Driven joint stopper bolt 8-36
• Secondary driven gear housing 3-68
bolt
• Cam sprocket bolt 3-77
THREAD LOCK SUPER
"1303"
99000-32030
 GENERAL INFORMATION 1-4

Material Part Page Part Page

• Starter motor housing screw 7-13
• Damper rod bolt 8-17
• De-comp cable holder screw 3-29

THREAD LOCK " 1 3 4 2 '

99000-32050

• Front wheel brake disc bolt 8-5

• Rear wheel brake disc bolt 8-35

THREAD LOCK SUPER

"1360"
99000-32130

• Mating surface of cylinder 3-80

head and cylinder head cover
• Cylinder head cover plug 3-81

SUZUKI BOND
No. 1216
99104-31160

• Pawl lifter stud bolt 3-64

• Bearing retainer 3-64
• Neutral stopper stud bolt 3-64
• Gear shift cam retainer set bolt 3-64
• Neutral stopper spring 3-65
retainer nut
• Final gear case bolt 4-22
• Final gear case and bearing 4-28
case

THREAD LOCK SUPER

"1333B"
99000-32020
1-5 GENERAL INFORMATION

P R E C A U T I O N S AND G E N E R A L I N S T R U C T I O N S

Observe the following items w i t h o u t fail when servicing, disassembling and reassembling motorcycles.

• Do not run engine indoors w i t h little or no ventilation.

• Be sure to replace packings, gaskets, circlips, O-rings and cotter pins w i t h new ones.

CAUTION:
Never reuse a circlip after a circlip has been removed f r o m a shaft, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken not t o expand the end gap larger than required t o
slip the circlip over the shaft.
A f t e r installing a circlip, always insure that it is completely seated in its groove and securely f i t t e d .

• Tighten cylinder head and case bolts and nuts beginning w i t h larger diameter and ending w i t h smaller
diameter, and f r o m inside to outside diagonally, to the specified tightening torque.

• Use special tools where specified.

a Use genuine parts and recommended oils.

• When t w o or more persons work together, pay attention t o the safety of each other.

• After the reassembly, check parts for tightness and operation.

• Treat gasoline, which is extremely flammable and highly explosive, w i t h greatest care. Never use gasoline
as cleaning solvent.

Warning, Caution and Note are included in this manual occasionally, describing the following contents.

WARNING When personal safety of the rider or the mechanic is involved, disregard of the
information could result in injury.
CAUTION For the protection of the motorcycle, the instruction or rule must be strictly
adhered to.

NOTE Advice calculated to facilitate the use of the motrcycle is given under this
heading.

U S E OF GENUINE SUZUKI P A R T S
To replace any part of the machine, use a genuine
S U Z U K I replacement part. Imitation parts or
parts supplied from any other source than
S U Z U K I , if used to replace S U Z U K I parts can
reduce the machine's performance and, even worse,
could induce costly mechanical troubles.
 GENERAL INFORMATION 1-6

SPECIFICATIONS

DIMENSIONS AND D R Y M A S S CHASSIS

Overall length 2330 m m (91.7 in) Front suspension Telescopic, coil spring,
Overall w i d t h 710 m m (28.0 in) ... G L F oil damped
770 m m (30.3 in) ... GLP Rear suspension Swinging arm, oil damped,
Overall height 1135 m m (44.7 in) ... G L F spring pre-load 5-way
1220 m m (48.0 in) ... GLP adjustable

Wheel base 1620 mm (63.8 in) Steering angle 40° (right & left)

Ground clearance 145 m m (5.7 in) Caster 54°00'

Dry mass 242kg(533lbs)...E03GLF Trail 166 mm (6.5 in)

243kg(535lbs)...E03GLP, Turning radius 2.8 m (9.2 f t )
E33GLF
Front brake Disc brake
244kg(537ibs)...E33GLP
Rear brake Disc brake
Front tire size 110/90 - 19 62H
ENGINE Rear tire size 170/80 - 15 77H
Type Four-stroke, 3 valves, Front fork stroke 160 m m (6.3 in)
OHC, 45-degree V - t w i n Rear wheel travel 105 m m (4.1 in)
Number of cylinders 2
Bore 94.0 m m (3.701 in)
ELECTRICAL
Stroke 98.0 m m (3.858 in)
Piston displacement 1360 cm^ (83.0 cu. in) Ignition type Transistorized

Compression ratio 9.3 : 1 Ignition timing 2° B.T.D.C. below 1500

r/min and 30° B.T.D.C.
Carburetor M I K U N I BDS36SS ....
above 4 000 r/min
front
M I K U N I BS36SS ... rear Spark plug N.G.K.: DP8EA-9
N.D.: X24EP-U9
A i r cleaner Polyurethane foam
Battery 12V 50.4 kC (14 A h ) /
element
10HR
Starter system Electric starter motor
Generator Three phase A.C.Generator
Lubrication system Wet sump
Fuse 10Ax4, 25Ax 1

TRANSMISSION
CAPACITIES
Clutch Wet multi-plate type
Fuel tank including
Transmission 4-speed constant mesh reserve 13.0 L (3.4 US gal)
Gearshift pattern 1-down, 3-up reserve 3.0 L (3.2 US qt)
Primary reduction 1.645 (79/48) Engine oil w i t h
4.3 L (4.5 U S q t )
Secondary reduction 0.852 (29/34 X 19/19) filter change
Final reduction 2.666 (32/12) without
3.7 L (3.9 US qt)
Gear ratios, Low 3.000 (36/12) filter change
2nd 1.823 (31/17) Front fork oil 354 ml (12.0 US oz)
3rd 1.333 (28/21) Final bevel gear oil 200 - 220 ml
Top 1.041 (25/24) (6.8 - 7.4 US oz)

These specifications are subject to change w i t h o u t

notice.
 PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES

CONTENTS
PERIODIC MAINTENANCE SCHEDULE 2- 1
MAINTENANCE AND TUNE-UP PROCEDURES 2- 2
BATTERY 2- 2
AIR CLEANER 2- 3
SPARKPLUG 2- 4
ENGINE OIL AND OIL FILTER 2-6
CARBURETOR 2- 7
AUTOMATIC DE-COMPRESSION CABLE 2- 8
FUEL AND VAPOR HOSE 2- 9
CLUTCH 2- 9
FINAL GEAR OIL 2-10
BRAKE 2-11
TIRE 2-13
STEERING 2-14
FRONT FORK 2-14
CHASSIS BOLTS AND NUTS 2-15
LUBRICATION POINTS 2-17
2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

PERIODIC MAINTENANCE S C H E D U L E

I M P O R T A N T : The periodic maintenance intervals and service requirements have been established in acoord-
ance w i t h EPA regulations. Following these instructions w i l l ensure that the motorcycle w i l l not exceed
emission standards and it w i l l also ensure the reliability and performance of the motorcycle.

NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions,
however, it is not necessary for ensuring emission level compliance.

The chart below lists the recommended intervals f o r all the required periodic service work necessary to
keep the motorcycle operating at peak performance and t o maintain proper emission levels. Mileages are
expressed in terms of kilometer, miles and time for your convenience.

INTERVAL: km 1 000 6 000 12 000 18 000 24 000

T H I S I N T E R V A L S H O U L D BE J U D G E D
miles 600 4 000 7 500 11 000 15 0 0 0
BY O D O M E T E R R E A D I N G OR
M O N T H S W H I C H E V E R COMES FIRST months 2 12 24 36 48
Battery - 1 1 1 1
A i r cleaner element Clean every 6 000 km (4 000 miles).
Spark plug
- 1 R 1 R
Engine oil and oil filter R R R R R
Engine idle speed 1 1 1 1 1
A u t o m a t i c de-compression cable 1 1 1 1 1
1 1 1 1 1
Fuel line
Replace every four years.
1 1 1 1 1
Vapor hose (California model only)
Replace every four years.
1 1 1 1 1
Clutch hose
Replace every four years.
1 1 1 1 1
Clutch f l u i d
Replace every t w o years.
Final gear o i l R
- 1
- 1
Brake 1 1 1 1 1
1 1 1 1 1
Brake hose
Replace every four years.
Brake f l u i d Replace every t w o years.
Tire 1 1 1 1 1
Steering 1 1 1 1 1
Front f o r k - - 1 - 1
Chassis bolts and nuts T T T T T

NOTE: T= Tighten, I = Inspect, R = Replace

 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2

MAINTENANCE AND TUNE-UP P R O C E D U R E S

This section describes the servicing procedures for

each items of the periodic maintenance require-
ments.

BATTERY
Inspect every 6 000 k m (4 000 miles).

CAUTION:
The battery voltage should be checked after
removing the battery f r o m the machine to
avoid making a short circuit between the
machine and the probe of the tester.

• Remove the battery cover by loosening t w o

screws ® ,
• Remove the battery 0 terminal screw (2)
to disconnect the © lead wire.

CAUTION:
When disconnecting the battery terminals,
be sure t o remove the 0 (negative) terminal
first, then remove the ® (positive) terminal.
When connecting the battery terminals,
be sure t o connect the ® (positive) terminal
first, then the 0 (negative) terminal.

• Remove the battery ® terminal screw ( 3 ) .

• Loosen t w o bolts ® to open the battery
case b o t t o m plate and remove the battery.
2-3 PERIODIC MAINTENANCE A N D TUNE-UP PROCEDURES

• Check the battery voltage w i t h the S U Z U K I

pocket tester. If the voltage reading is below
12.0V, this battery needs recharging.

Battery voltage Above 12.0 V

CAUTION:
Never charge a battery while still in the
machine as damage may result to the battery
or regulator/rectifier.

NOTE:
Read the E L E C T R I C A L SYSTEM section t o
keep excellent operational condition at all
times.

AIR C L E A N E R
Clean every 6 000 k m (4 000 miles).

• Remove the seats and right frame cover. (Refer

t o page 3-3.)
• Remove the fuel tank bracket and the frame
head covers. (Refer to page 3-6.)
• Remove the air cleaner cover and take o f f the
f r o n t element ® .
• Remove the cover and take o f f the rear element
(D.

• Fill a washing pan of a proper size w i t h non-

flammable cleaning solvent. Immerse the
element in the solvent and wash it clean.
• Squeeze the solvent off the washed element by
pressing it between the palms of both hands.
Do not twist and wring the element or it w i l l
develop tears.
• Immerse the element in a pool of motor oil
and squeeze the oil f r o m the element t o make it
slightly wet w i t h the o i l .
 PERIODIC M A I N T E N A N C E A N D TUNE-UP PROCEDURES 2-4

CAUTION:
Before and during the cleaning operation,
carefully examine the element for any tears in
the material. A torn element must be replaced
w i t h a new one.

Reinstall the cleaned element in reverse order

of removal. Be absolutely sure that the element
is securely in position and is sealing properly.

CAUTION:
If driving under dusty conditions, the air
cleaner element must be cleaned more
frequently than it is w i t h periodic mainte-
nance. N E V E R OPERATE T H E ENGINE Cleaning
solvent
W I T H O U T T H E E L E M E N T IN POSITION.
Operating the engine w i t h o u t the air cleaner
element w i l l increase engine wear. Always
be sure that the air cleaner element is in
excellent operational condition at all times. Motor oi

S P A R K PLUG
Clean every 6 000 k m (4 000 miles) and
replace every 12 000 k m (7 500 miles).

• Remove the covers ® by loosening the bolts (2).

The plug gap should be adjusted to 0.8 - 0.9 mm

using a thickness gauge (special t o o l ) . When carbon
is deposited on the spark plug, remove the carbon
w i t h a spark plug cleaning machine or carefully
using t o o l w i t h a pointed end. If electrodes are
extremely w o r n or burnt, replace the plug. Also
replace the plug if it has a broken insulator,
damaged thread, etc.

09930-13210 Socket wrench

09930-14530 Universal joint

09914-24510 T handle

09900-20804 Thickness gauge

2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

NGK DP8EA-9 or NIPPON DENSO X24EP-U9

listed in the table should be used as the standard
plug. If the plugs need t o be replaced, it is recom-
mended that the standard plugs listed in the table
be selected. However, the heat range of the plug
should be selected to meet the requirements
of speed, actual load, fuel, etc. Remove the
plugs and inspect the insulators. Proper heat range
would be indicated if all insulators were light
brown in color. If they are blackened by carbon,
they should be replaced by a hot type NGK
DP7EA-9 or NIPPON DENSO X22EP-U9 and if
braked w h i t e , by a cold type NGK DP9EA-9 or
NIPPON DENSO X27EP-U9.

NOTE:
To check the spark plugs, first make sure that
the fuel tank contains unleaded gasoline, and
after a test ride, if the plugs are either sooty
w i t h carbon or burnt white, replace them
altogether.
0.8 - 0.9 mm
(0.031 - 0.035 in)

NOTE:
Confirm the thread size and reach when
replacing the plug. If the reach is too short,
carbon w i l l be deposited on the screw portion
of the plug hole and engine damage may
result. If the reach is too long, the plug
w i l l h i t the piston head causing the severe
damage.

0.8 - 0.9 mm
Spark plug gap
(0.031 - 0 . 0 3 5 in)

NIPPON
NGK REMARKS
DENSO
DP7EA-9 X22EP-U9 Hot type

DP8EA-9 X24EP-U9 Standard

DP9EA-9 X27EP-U9 Cold type
 PERIODIC M A I N T E N A N C E A N D TUNE-UP PROCEDURES 2-6

ENGINE OIL AND OIL FILTER

Replace initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).

The oil should be changed while the engine is hot.

Oil filter replacement at the above intervals should
be done together w i t h engine oil change.
• Keep the motorcycle upright.
• Place an oil pan below the engine and drain the
oil by removing the drain plug ® and filler cap
®. - . .-I
• Remove the oil filter ® .
• A p p l y engine oil lightly to the gasket of the new
filter before installation.

CAUTION:
Use S U Z U K I motorcycle genuine oil filter
only, since the other makes filters and
after-market parts may differ in thread
specifications (thread diameter and pitch),
filtering performance and durability, which
could cause engine damage or oil leakage.
Suzuki automobile genuine oil filter is also
not usable f o r the motorcycle.

Install the new filter turning it by hand until

you feel the filter gasket contacts the mounting
surface. Then tighten 2 turns using the oil
filter wrench.

09915-40611 Oil filter wrench

Fit drain plug ® securely, and install fresh oil

through the filler. The engine will hold about
4.3 L (4.5 U S q t ) of oil.
Use API classification of SE or SF oil w i t h
SAE 10W/40 viscosity.
Start up the engine and allow it to run for
a few minutes at idling speed.
Check for oil leakage around the oil filter.
T u r n off the engine and wait about one minute,
then check the oil level by the dipstick. If the
level is below " F " line, supply oil until it reaches
the " F " line.

Tighten the filter 2 turns after contacting with the

mounting surface.
2-7 PERIODIC M A I N T E N A N C E A N D TUNE-UP PROCEDURES

NOTE: NECESSARY A M O U N T OF ENGINE O I L

The oil level inspection should be performed Oil change 3.7 L (3.9 U S q t )
under the f o l l o w i n g conditions:
Filter change 4.3 L (4.5 U S q t )
* The motorcycle is supported vertically on a
level ground. Overhau engine 5.0 L (5.3 US qt)
* The oil filler cap threads are not run in but
touching the filler hole upper edge.

CAUTION: _ p;
Never operate the motorcycle if the engine
oil level is below the " L " ( L o w ) line in the
— .-.^^^^^^im :- :
engine oil dipstick. Never f i l l the engine
oil above the " F " (Full) line

CARBURETOR
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 0 0 0 miles).

ENGINE I D L E SPEED

NOTE:
Make this adjustment when the engine is hot.

THROTTLE CABLE PLAY

• Loosen the lock nut ® and t u r n the adjuster
(D to adjust the cable play. (Refer to page
5-21 for balancing t w o carburetors.)

0.5 - 1.0 mm
Throttle cable play
(0.02 - 0.04 in)
 PERIODIC M A I N T E N A N C E A N D TUNE-UP PROCEDURES 2-8

AUTOMATIC DE-COMPRESSION
CABLE
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).

Incorrect adjustment of the cable slack may

result in starting difficulties or engine damage.
Check the cable slacks and if necessary, adjust as
follows:

• Remove the engine side covers.

• Loosen the lock nuts ® and locate the end of
the outer tube (2) to make the cable (3) have an
enough free play.
• Loosen the lock nuts ® and locate the end of
the outer tube (5) so t h a t t h e clearance ®
between the lever (6) and the stopper (7) is
1.5 - 2.5 mm (0.06 - 0.10 in), keeping the
plunger ® of the decompression solenoid at the
top end.
• Tighten the lock nuts ® .
• Holding the above clearance, locate the tube end
@ so t h a t t h e clearence ® is 1.0 — 2.0 mm
(0.04 - 0.08 in).
• Tighten the lock nuts ® .

O
2-9 PERIODIC MAINTENANCE A N D TUNE-UP PROCEDURES

F U E L LINE AND VAPOR HOSE

Inspect initially at 1 000 k m (600 miles)
and every 6 000 k m (4 000 miles).
Replace every four years.

Inspect the fuel line and vapor hose (California

model only) f o r damage and fuel leakage. If any
defects are f o u n d , the fuel line must be replaced.

CLUTCH
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).
Replace f l u i d every t w o years.
Replace hoses every four years.

CLUTCH FLUID LEVEL

• Keep the motorcycle upright and place the
handlebars straight.
• Check the clutch fluid level in the reservoir.
• If the level is found to be lower than the lower
mark, replenish with BRAKE FLUID that
meets the following specification.

Specification and
DOT 3 or DOT 4
classification

B L E E D I N G A I R FROM T H E C L U T C H F L U I D
CIRCUIT
The clutch f l u i d circuit may be purged of air in the
following manner.
• Fill up the master cylinder reservoir to the
upper end of the inspection window. Replace
the reservoir cap to prevent entry of dirt.
• Remove the secondary gear case cover.
• Set the vacuum pump gauge (T) and the recep-
tacle (2) as shown in the picture.

09917-47910 Vacuum pump gauge

 PERIODIC M A I N T E N A N C E AND TUNE-UP PROCEDURES 2-10

• Squeeze and release the clutch lever several

times in rapid succession, and at the same time
pump the vacuum pump gauge several times. A t
the last squeezing of the clutch lever, squeeze
it fully without releasing it and loosen the
bleeder valve (3) by turning it a quarter of a
turn so that the fluid runs into the receptacle.
Then close the bleeder valve.
• Repeat this process until the fluid flowing into
the receptacle no longer contains air bubbles.
• Close the bleeder valve, and disconnect the pipe.
Fill the reservoir to the upper end of the inspec-
tion window.
NOTE:
6 - 9 N-m Replenish the clutch fluid reservoir as neces-
Bleeder valve
/ 0.6 - 0.9 kg-m \ sary while bleeding the clutch system.
tightening torque
\4.5-6.5lb-ft / Make sure that there is always some f l u i d
visible in the reservoir.
WARNING:
The clutch system of this motorcycle is
CAUTION:
filled w i t h a glycol-based brake fluid. Do not
Handle the brake fluid w i t h care: the fluid
use or mix different types of fluid such as
reacts chemically w i t h paint, plastics, rubber
silicone-based and petroleum-based. Do not
materials, etc.
use any brake fluid taken f r o m old, used or
unsealed containers. Never re-use the brake
fluid left over f r o m the last servicing and
stored for long periods.

FINAL GEAR OIL

Replace initially at 1 000 k m (600 miles) and
inspect every 12 000 km (7 500 miles).

To change the final gear o i l , locate the motorcycle

on level ground, keep it upright and carry out the
following steps. Use SAE # 90 hypoid gear o i l .
• Drain oil by removing filler cap ® and drain
plug (2).
• Refit drain plug (D and pour the specified oil in
through the filler hole until it runs out f r o m the
filler hole.
• Refit filler cap (T).

NOTE:
The amount of oil to be replaced is 200 —
220 ml (6.8 - 7.4 US oz).
2-n PERIODIC MAINTENANCE A N D TUNE-UP PROCEDURES

BRAKE
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).
Replace f l u i d every t w o years.
Replace hoses every four years.

B R A K E PADS
Wearing condition of brake pads can be checked by
observing the limit line ® marked on the pad.
When the wear exceeds the limit line, replace the
pads w i t h new ones. (Refer to page 8-6 and 8-26.)

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the
handlebars straight.
• Remove the rear brake reservoir cover.
• Check the brake fluid level in the reservoir.
• If the level is found t o be lower than the lower
mark, replenish w i t h brake fluid that meets the
following specification.

Specification
DOT 3 or DOT 4
and classification

WARNING:
The brake system of this motorcycle is filled
w i t h a glycol-based brake f l u i d . Do not use
or mix different types of fluid such as silicone-
based and petroleum-based f l u i d for refilling
the system, otherwise serious damage w i l l be
caused. Do not use any brake fluid taken
from old or used or unsealed containers.
Never re-use the brake fluid left over f r o m the
last servicing and stored for long periods.

WARNING:
Brake f l u i d , if it leaks, w i l l interfere w i t h safe
running and discolor painted surfaces.
Check the brake hoses for cracks and hose
j o i n t f o r leakage before riding.
 PERIODIC M A I N T E N A N C E AND TUNE-UP PROCEDURES 2-12

B L E E D I N G A I R FROM T H E B R A K E F L U I D
CIRCUIT
A i r trapped in the fluid circuit acts like a cushion
to absorb a large proportion of the pressure de-
veloped by the master cylinder and thus interferes
w i t h the full braking performance of the brake
caliper. The presence of air is indicated by "spongi-
ness" of the brake lever and also by lack of braking
force. Considering the danger to which such
trapped air exposes the machine and rider, it is
essential that, after remounting the brake and
restoring the brake system to the normal c o n d i t i o n ,
the brake fluid circuit be purged of air in the
following manner:

• Fill up the master cylinder reservoir to the upper

end of the inspection w i n d o w (for f r o n t brake)
or upper line (for rear brake). Replace the
reservoir cap t o prevent entry of dirt.
• Attach a pipe to the caliper bleeder valve, and
insert the free end of the pipe into a receptacle.
• Squeeze and release the brake lever several times
in rapid succession, and squeeze the lever f u l l y
w i t h o u t releasing it. Loosen the bleeder valve
by turning it a quarter of a t u r n so that the
brake fluid runs into the receptacle; this w i l l
CAUTION:
remove the tension of the brake lever causing it
Handle the brake fluid w i t h care: the fluid
to touch the handlebars grip. Then, close the
reacts chemically w i t h paint, plastics, rubber
valve, pump and squeeze the lever, and open the
materials, etc.
valve. Repeat this process until the fluid f l o w i n g
into the receptacle no longer contains air bub-
• The only difference between bleeding the f r o n t
bles.
and rear brakes is that the rear master cylinder is
• Close the bleeder valve, and disconnect the pipe.
actuated by a pedal.
Fill the reservoir to the upper end of the inspec-
tion window (for f r o n t brake) or upper line
(for rear brake).

6 - 9 N-m
Bleeder valve
/ 0.6 - 0.9 kg-m \
tightening torque
V 4.5 - 6.5 Ib-ft /

NOTE:
Replenish the brake f l u i d reservoir as neces-
sary while bleeding the brake system.
Make sure that there is always some f l u i d
visible in the reservoir.
2-13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

BRAKE PEDAL HEIGHT

Turn the pedal height adjuster ® so that the brake
pedal is located 22 mm (0.87 in) above the t o p
face of the footrest.

Brake pedal height 22 m m (0.87 in)

B R A K E L I G H T SWITCHES
Adjust both brake light switches @ and ( 3 ) , f r o n t
and rear, so that the brake light comes on just
before a pressure is felt when the brake lever is
squeezed, or the brake pedal is depressed.

TIRE
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).

TIRE TREAD CONDITION

Operating the motorcycle w i t h excessively w o r n
tires w i l l decrease riding stability and consequently
invite a dangerous situation. It is highly recom-
mended t o replace the tire when the remaining
depth of tire tread reaches the following specifi-
cations.

Tire tread depth limit

FRONT REAR

1.6 mm (0.06 in) 2.0 m m (0.08 in)

 PERIODIC M A I N T E N A N C E A N D TUNE-UP PROCEDURES 2-14

T I R E PRESSURE Cold inflation tire pressure is as follows.

If the tire pressure is too high or t o o low, steering
FRONT REAR
will be adversely affected and tire wear increased.
Therefore, maintain the correct tire pressure for kPa kg/cnn^ psi kPa kg/cnn^ psi
good roadability or shorter tire life w i l l result. Solo riding 200 2.00 29 200 2.00 29
Dual riding 200 2.00 29 225 2.25 33
CAUTION:
The standard tire fitted on this motorcycle is
110/90-19 6 2 H for f r o n t and 170/80-15 77H
for rear. The use of a tire other than the
standard may causes instability. It is highly
recommended t o use a S U Z U K I genuine tire.

STEERING
Inspect initially at 1 000 k m (600 miles) and
every 6 000 k m (4 000 miles).

Taper roller type bearings are applied on the steer-

ing system for better handling.
Steering should be adjusted properly for smooth
manipulation of handlebars and safe running.
Too stiff steering prevents smooth manipulation of
handlebars and too loose steering will cause poor
stability.
Check that there is no play in the f r o n t fork
assembly by supporting the machine so that the
f r o n t wheel is o f f the ground, w i t h wheel straight
ahead, grasp lower fork tubes near the axle and
pull forward. If play is f o u n d , perform steering
bearing adjustment as described in page 8-23 of
this manual.

FRONT FORK
Inspect every 12 000 k m (7 500 miles).

Inspect the f r o n t fork oil leakage, scoring and

scratches on the outer surface of the inner tube
and replace the defective parts, if necessary.
(Refer to page 8-12.)
2-15 PERIODIC MAINTENANCE A N D TUNE-UP PROCEDURES

C H A S S I S B O L T S AND NUTS

Tighten initially at 1 000 k m (600 miles) and

every 6 000 k m (4 000 miles).

The nuts and bolts listed below are important safety parts. They must be retightened periodically to the
specified torque w i t h a torque wrench. (Refer to page 2-16 for the location of the following nuts and
bolts on the motorcycle.)

Item N-m kg-m Ib-ft

® Steering stem head nut 80- 100 8 . 0 - 10.0 5 8 . 0 - 72.5

® Handlebar mounting bolt 15-25 1.5 - 2.5 11.0- 18.0

® Clutch master cylinder mounting bolt 5-8 0.5 - 0.8 3.5 - 6.0

® Front brake master cylinder mounting bolt 5-8 0.5 - 0.8 3.5 - 6.0

® Front f o r k cap bolt 45-55 4.5-5.5 32.5 - 39.8

® Handlebar holder nut 80- 100 8.0 - 10.0 5 8 . 0 - 72.5

® Front fork lower clamp bolt 25-40 2.5-4.0 18.0-29.0

® Front axle 36-52 3.6 - 5.2 26.0 - 37.5

® Front axle clamp bolt 15 - 25 1.5 - 2.5 11.0- 18.0

Front wheel hub flange bolt 20-30 2.0-3.0 14.5-21.5

Front brake caliper housing bolt 15-20 1.5-2.0 11.0- 14.5

Front brake caliper mounting bolt 25-40 2.5-4.0 18.0-29.0

® Brake hose union bolt (10 mm) 20-25 2.0-2.5 14.5 - 18.0

Brake hose union bolt (14 mm) 30-35 3.0-3.5 21.5-25.3

® A i r bleeder valve 6 - 9 0.6 - 0.9 4.5-6.5

Brake disc bolt 15-25 1.5-2.5 11.0- 18.0

® Spoke nipple 4 - 5 0.4 - 0.5 3.0-3.5

® Clutch hose union bolt 20 - 25 2.0-2.5 14.5- 18.0

® Rear brake master cylinder mounting bolt 15-25 1.5 - 2.5 11.0- 18.0

® Brake pedal boss bolt 6-10 0.6 - 1.0 4.5-7.2

@ Footrest mounting bolt 15-25 1.5 - 2.5 11.0- 18.0

® Swingarm pivot nut 50-80 5.0 - 8.0 36.0 - 58.0

® Rear shock absorber upper mounting nut 20-30 2.0-3.0 14.5-21.5

® Rear shock absorber lower mounting bolt 20 - 3 0 2.0-3.0 14.5-21.5

® Rear axle nut 60-96 6.0-9.6 43.5 - 69.5

® Rear brake caliper housing bolt 15^20 1.5-2.0 11.0- 14.5

® Rear brake caliper m o u n t i n g bolt 25 - 40 2.5-4.0 18.0 - 29.0

® Rear torque link nut 40-60 4.0 - 6.0 29.0 - 43.4

PERIODIC M A I N T E N A N C E AND TUNE-UP PROCEDURES 2-16
2-17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle
and also for safe riding. It is a good practice t o oil the machine after a long rough ride and after getting it
wet in the rain or after washing it. Major oiling points are indicated below.

NOTE:
Before lubricating each part, clean off any rusty spots and wipe o f f any grease, o i l , d i r t or grime.

. . Motor oil
. . Grease

Clutch lever holderH-

Side stand p i v o t g HGearshifting link pivots

H T h r o t t l e grip

a Throttle cable
De-compression cableC;}
H B r a k e lever holder

Brake link p i v o t s H
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