GSX1400 Manual PART TWO

CHASSIS
CONTENTS
EXTERIOR PARTS ............................................................................ 6- 2

CONSTRUCTION........................................................................... 6- 2
REMOVAL ...................................................................................... 6- 3
REMOUNTING ............................................................................... 6- 4
FASTENER REMOVAL AND REINSTALLATION ......................... 6- 5
FRONT WHEEL ................................................................................. 6- 6
CONSTRUCTION........................................................................... 6- 6
REMOVAL ...................................................................................... 6- 7
INSPECTION AND DISASSEMBLY .............................................. 6- 7
REASSEMBLY AND REMOUNTING ............................................ 6- 9
FRONT FORK ................................................................................... 6-12
CONSTRUCTION........................................................................... 6-12
REMOVAL AND DISASSEMBLY .................................................. 6-13
INSPECTION ................................................................................. 6-16
REASSEMBLY AND REMOUNTING ............................................ 6-17
SUSPENSION SETTING ............................................................... 6-22
STEERING AND HANDLEBARS ..................................................... 6-23
CONSTRUCTION........................................................................... 6-23
INSPECTION AND DISASSEMBLY .............................................. 6-27
STEERING TENSION ADJUSTMENT .......................................... 6-31
REAR WHEEL ................................................................................... 6-32
CONSTRUCTION........................................................................... 6-32
REMOVAL ...................................................................................... 6-33
REAR SHOCK ABSORBER ............................................................. 6-40
CONSTRUCTION........................................................................... 6-40
REMOVAL ...................................................................................... 6-41
INSPECTION ................................................................................. 6-42
REAR SHOCK ABSORBER SCRAPPING PROCEDURE ........... 6-42
REMOUNTING ............................................................................... 6-42
SUSPENSION SETTING ............................................................... 6-43
REAR SWINGARM ........................................................................... 6-44
CONSTRUCTION........................................................................... 6-44
REMOVAL ...................................................................................... 6-45
REASSEMBLY ............................................................................... 6-47
REMOUNTING ............................................................................... 6-48
FINAL INSPECTION AND ADJUSTMENT ................................... 6-48
CHASSIS 6-1
FRONT BRAKE ................................................................................. 6-49

CONSTRUCTION........................................................................... 6-49
BRAKE PAD REPLACEMENT ...................................................... 6-50
BRAKE FLUID REPLACEMENT ................................................... 6-50
CALIPER REMOVAL AND DISASSEMBLY ................................. 6-51
CALIPER INSPECTION ................................................................ 6-52
CALIPER REASSEMBLY AND REMOUNTING ........................... 6-52
BRAKE DISC INSPECTION .......................................................... 6-53
MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-54
MASTER CYLINDER INSPECTION.............................................. 6-55
MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-55
REAR BRAKE ................................................................................... 6-57
CONSTRUCTION........................................................................... 6-57
BRAKE PAD REPLACEMENT ...................................................... 6-58
BRAKE FLUID REPLACEMENT ................................................... 6-58
CALIPER REMOVAL AND DISASSEMBLY .................................
CALIPER INSPECTION ................................................................
6-59
6-60
6
CALIPER REASSEMBLY AND REMOUNTING ........................... 6-60
MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-61
MASTER CYLINDER INSPECTION.............................................. 6-62
MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-62
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER .......... 6-64
CONSTRUCTION........................................................................... 6-64
CLUTCH FLUID REPLACEMENT ................................................. 6-65
CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY.. 6-65
CLUTCH RELEASE CYLINDER INSPECTION ............................ 6-66
CLUTCH RELEASE CYLINDER REASSEMBLY AND
REMOUNTING ............................................................................... 6-66
CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY ... 6-67
CLUTCH MASTER CYLINDER INSPECTION .............................. 6-68
CLUTCH MASTER CYLINDER REASSEMBLY AND
REMOUNTING ............................................................................... 6-69
TIRE AND WHEEL ............................................................................ 6-70
TIRE REMOVAL ............................................................................. 6-70
INSPECTION ................................................................................. 6-70
VALVE INSTALLATION ................................................................. 6-71
TIRE INSTALLATION .................................................................... 6-71
6-2 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
1 Seat
2 Seat support
3 Seat lock cable
4 Seat lock set
5 Pillion rider handle
6 Fastener
7 Seat tail cover
8 Frame cover (RH)
9 Frame cover (LH)
CHASSIS 6-3
REMOVAL
SEAT
• Remove the seat with the ignition key.
FRAM COVERS
• Remove the seat. (Above)
• Remove the frame cover mounting secrews (left and right sides).
• Remove the frame covers by pulling on the hooked parts.
: hooked part
PILLION RIDER HANDLE

• Remove the pillion rider handle by removing the pillion rider
handle mounting bolts.
SEAT TAIL COVER

• Remove the seat. (Above)
• Remove the pillion rider handle. (Above)
• Remove the seat tail cover mounting screws.
6-4 CHASSIS
• Remove the fasteners.(6-5)
• Disconnect the seat lock cable A.
• Disconnect the brake light/taillight lead wire coupler.

• Remove the seat tail cover.
REMOUNTING
• Remount the seat, frame covers, pillion rider handle and seat
tail cover in the reverse order of removal.
CHASSIS 6-5
FASTENER REMOVAL AND REINSTALLATION

FASTENER
REMOVAL
• Depress the head of fasteners center piece 1.
• Pull out the fastener.
INSTALLATION
• Let the center piece stick out toward the head so that the pawls
2 close.
• Insert the fastener into the installation hole.
NOTE:
To prevent the pawl 2 from damage, insert the fastener all the
way into the installation hole.
• Push in the head of center piece until it becomes flush with the
fastener outside face.
6-6 CHASSIS
FRONT WHEEL
CONSTRUCTION
1 Brake disc
2 Dust seal
3 Bearing
4 Spacer
5 Spacer nut
6 Front wheel
7 Tire valve
A Front axle
B Brake disc bolt (Front)
"
ITEM N. m kgf.m lb-ft
A 100 10.0 72.5
B 23 2.3 16.5
CHASSIS 6-7
REMOVAL
• Remove the brake calipers 1.

Do not operate the brake lever while removing the cali-
pers.
• Loosen two axle pinch bolts 2 on the right front fork leg.
• Loosen the front axle 3.
\ 09900-18740: Hexagon wrench 24 mm
• Raise the front wheel off the ground and support the motor-
cycle with a jack or a wooden block.

Do not work by using side stand. Do not support the
motorcycle with exhaust pipe. Make sure that the motor-
cycle is supported securely.
• Remove the front axle and the front wheel.

NOTE:
After removing the front wheel, fit the calipers temporarily to the
original positions.
• Loosen two axle pinch bolts on the left front fork leg and re-
move the spacer nut 4.
INSPECTION AND DISASSEMBLY

TIRE (6-70)
• Remove the brake disc.
BRAKE DISC (6-53)
6-8 CHASSIS
• Remove both dust seals by using the oil seal remover.

\ 09913-50121: Oil seal remover

Never reuse the removed dust seals.
FRONT AXLE
Using a dial gauge, check the front axle for runout and replace it
if the runout exceeds the limit.
\ 09900-20607: Dial gauge (1/100)
09900-20701: Magnetic stand
09900-21304: V-block set (100 mm)
Axle shaft runout
Service Limit: 0.25 mm (0.010 in)
WHEEL
Make sure that the wheel runout checked as shown does not
exceed the service limit. An excessive runout is usually due to
worn or loosened wheel bearings and can be reduced by replac-
ing the bearings. If bearing replacement fails to reduce the runout,
replace the wheel.
(Wheel inspection: 6-70)
Wheel runout
Service Limit (Axial and Radial): 2.0 mm (0.08 in)
WHEEL BEARING
Inspect the play of the wheel bearings by finger while they are in
the wheel. Rotate the inner race by finger to inspect for abnormal
noise and smooth rotation.
Replace the bearing in the following procedure if there is any-
thing unusual.
• Remove the wheel bearings by using the special tool.

\ 09921-20240: Bearing remover set

Never reuse the removed bearings.
CHASSIS 6-9
REASSEMBLY AND REMOUNTING

Reassemble and remount the front wheel in the reverse order of
removal and disassembly. Pay attention to the following points:
Left Right
25 N.m
(2.5 kgf.m, 18.0 lb-ft) 25 N.m
(2.5 kgf.m, 18.0 lb-ft)
23 N.m
(2.3 kgf.m, 16.5 lb-ft) 23 N.m
(2.3 kgf.m, 16.5 lb-ft)
100 N.m
(10.0 kgf.m, 72.5 lb-ft)
23 N.m 23 N.m
(2.3 kgf.m, 16.5 lb-ft) (2.3 kgf.m, 16.5 lb-ft)
6-10 CHASSIS
WHEEL BEARING
• Apply grease to the wheel bearings.
X 99000-25010: SUZUKI SUPER GREASE “A”
• First install the left wheel bearing, then install the right wheel
bearing and spacer by using the special tools.
\ 09941-34513: Bearing/Steering race installer set

The sealed cover of the bearing must face outside.
BRAKE DISC
Make sure that the brake disc is clean and free of any greasy
matter.
• Apply THREAD LOCK SUPER “1360” to the disc mounting bolts
and tighten them to the specified torque.
" Brake disc bolt (Front): 23 N.m (2.3 kgf.m, 16.5 lb-ft)
K 99000-32130: THREAD LOCK SUPER “1360”
CHASSIS 6-11
SPACER NUT
After touching the flange of spacer nut being contact with the left
front fork leg, tighten the two axle pinch bolts on the left front fork
leg to the specified torque.
" Front axle pinch bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
WHEEL
Install the front wheel with the front axle and hand-tighten the
front axle temporarily.
#
The directional arrow on the wheel should point to the
wheel rotation, when remounting the wheel.
BRAKE CALIPER
• Tighten the brake caliper mounting bolts to the specified torque.
" Front brake caliper mounting bolt: 25 N.m
(2.5 kgf.m, 18.0 lb-ft)
NOTE:
Push the pistons all the way into the caliper and remount the
calipers.
FRONT AXLE
• Tighten the front axle to the specified torque.
" Front axle: 100 N.m (10.0 kgf.m, 72.5 lb-ft)
NOTE:
Before tightening the two axle pinch bolts on the right front fork
leg, move the front fork up and down 4 or 5 times.
• Tighten two axle pinch bolts on the right front fork leg to the
specified torque.
" Front axle pinch bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
6-12 CHASSIS
FRONT FORK
CONSTRUCTION
1 O-ring
2 Washer
3 Spacer
4 Spring
5 Inner rod/damper rod (cartridge)
6 Inner tube
7 Slide metal
8 Protecter
9 Dust seal
0 Oil seal stopper ring
A Oil seal
B Oil seal retainer
C Guide metal
D Oil lock piece
E Outer tube
F Gasket
A Front fork cap bolt

B Inner rod lock nut
C Front axle pinch bolt
D Damper rod bolt
"
A 23 2.3 16.5
B 15 1.5 11.0
C 23 2.3 16.5
D 40 4.0 29.0
CHASSIS 6-13
REMOVAL AND DISASSEMBLY

• Remove the front wheel. (6-7)
• Disconnect the brake hoses.
• Remove the front fender and brake hose guides.
• Loosen the front fork upper clamp bolts 1.

NOTE:
Slightly loosen the front fork cap bolts 2 before loosening the
lower clamp bolts to facilitate later disassembly.
• Loosen the front fork lower clamp bolts.

NOTE:
Hold the front fork by the hand to prevent sliding out of the steer-
ing stem.
• Remove the protecter 3.

6-14 CHASSIS
• Loosen and remove the front fork cap bolt.
• Remove the spacer 1, washers 2 and spring 3.
• Remove the adjuster rod.
• Invert the fork and drain the fork oil out of the fork by stroking.
• Hold the fork inverted for a few minutes to drain oil.
• Remove the dust seal.

CHASSIS 6-15
• Remove the oil seal stopper ring.
• Remove the front axle pinch bolts.
• Remove the damper rod with the front fork assembling tool.
\ 09940-30250: Front fork assembling tool.

Do not disassemble the inner rod/damper rod (cartridge).
• Drain the fork oil out of inner rod / damper rod (cartridge) by
pumping the rod.
• Pull the inner tube out of the outer tube.

NOTE:
Be careful not to damage the inner tube.

The slide metals, oil seal and dust seal must be replaced
with the new ones when reassembling the front fork.
6-16 CHASSIS
• Remove the following parts.

1 Oil seal
2 Oil seal retainer
3 Guide metal
4 Slide metal
5 Oil lock piece
INSPECTION
INNER AND OUTER TUBES
• Inspect the inner tube outer surface and the outer tube inner
surface for scratches.
• If any defects are found, replace them with the new ones.
FORK SPRING
• Measure the fork spring free length.
• If it is shorter than the service limit, replace it with a new one.
Front fork spring free length
Service limit : 316.0 mm (12.44 in)
DAMPER ROD
• Move the inner rod by hand to examine it for smoothness.
• If any defects are found, replace the inner/damper rod (car-
tridge).
CHASSIS 6-17

Reassemble and remount the front fork in the reverse order of
removal and disassembly. Pay attension to the following points:
TUBE METALS AND SEALS
• Hold the inner tube vertically and clean the metal groove and
install the guide metal 1 by hand as shown.

Use special care to prevent damage to the “Teflon” coated
surface of the guide metal when mounting it.
• Install the oil lock piece A into the inner tube.
• Apply fork oil to the oil seal lip lightly before installing it.
• Assemble the following parts as shown.
1 Oil seal
2 Oil seal retainer
3 Guide metal
4 Dust seal
5 Oil seal stopper ring

* When installing the oil seal to outer tube, be careful
not to damage the oil seal lip.
* Do not use solvents for washing to prevent oil seal
damage.
* Apply fork oil to the Anti-friction metals and lip of the
oil seal.
* Make sure that the oil seal stopper ring 5 has been
fitted securely.
• Insert the inner tube into the outer tube and fit the oil seal and
dust seal with the special tool.
\ 09940-52861: Front fork oil seal installer
NOTE:
Stamped mark on the oil seal should face outside.
6-18 CHASSIS
DAMPER ROD BOLT

• Insert the inner rod/damper rod (cartridge) into the inner tube.
• Apply THREAD LOCK SUPER “1322” to the damper rod bolt
and tighten it to the specified torque with the special tool.
H 99000-32110: THREAD LOCK SUPER “1322”
\ 09940-30250: Front fork assembling tool
" Damper rod bolt: 40 N.m (4.0 kgf.m, 29.0 lb-ft)

Use a new damper rod bolt gasket to prevent oil leak-
age.
FORK OIL
• Place the front fork vertically without spring.
• Compress it fully.
• Pour the specified front fork oil into the front fork up to the top of
the inner rod.
• Move the inner rod slowly more than ten times until no more air
bubbles come out from the oil.
\ 09940-52841: Inner rod holder
NOTE:
Refill the front fork oil up to the top of the outer tube to find air
bubbles while bleeding air.
• Move the inner tube up and down several strokes until no more
bubbles come out from the oil.
• Keep the front fork vertically and leave it during 5 – 6 minutes.
NOTE:
* Always keep the oil level over the cartridge top end, or air may
enter the cartridge during this procedure.
* Take extream attention to pump out air completely.
CHASSIS 6-19
• Install the adjusting rod 1.
• Hold the front fork vertically and adjust the fork oil level with the
special tool.
NOTE:
When adjusting the fork oil level, remove the fork spring and com-
press the inner tube fully.
\ 09943-74111: Front fork oil level gauge
Fork oil level: 108.0 mm (4.25 in)
99000-99044-L01: SUZUKI FORK OIL L01
Capacity (each leg): 644.0 ml (21.76/22.68 US/lmp oz)
FORK SPRING
• Pull the inner rod up with the inner rod holder.
\ 09940-52841: Inner rod holder
• Install the fork spring.

NOTE:
The small end of the fork spring should be at the bottom of the
front fork.
6-20 CHASSIS
FRONT FORK CAP BOLT

• Install the washers 1 and spacer 2.
• Adjust the height A of the inner rod threads by turning the lock
nut 3 as shown.
A: 11 mm (0.43 in)
• Tighten the front fork cap bolt to seat at lock nut by hand tight-
ening.
• Hold the front fork cap bolt, tighten the lock nut.
" Inner rod lock nut : 15 N.m (1.5 kgf.m, lb-ft)
• Apply fork oil lightly to the O-ring.

Use a new O-ring to prevent oil leakage.
• Tighten the front fork cap bolt temporarily.
• Install the front fork protecter.

NOTE:
Fit the projection of the front fork protecter to the depression of
the front fork outer tube.
CHASSIS 6-21
• Fix the front fork to the front fork lower bracket temporarily as
shown.
• Tighten the front fork cap bolt to the specified torque.
" Front fork cap bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Align the top of the inner tube to the upper surface of the steer-
ing stem upper bracket.
• Tighten the front fork upper and lower clamp bolts.

" Front fork upper clamp bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
Front fork lower clamp bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Install the front fender and brake hose guides.

• Install the front wheel. (6-9)
• Install the front brake calipers.(6-52)
NOTE:
After install the brake calipers, front brake should be efficient by
pumping the front brake lever.
6-22 CHASSIS
SUSPENSION SETTING
After installing the front fork, adjust the spring pre-load and damp-
ing force as follows.
SPRING PRE-LOAD ADJUSTMENT
There are eight grooves on the spring adjuster. Position 1 pro-
vides the maximum spring pre-load and position 8 provides the
minimum spring pre-load.
STD position: 5
DAMPING FORCE ADJUSTMENT

Rebound damping force
Fully turn the damping force adjuster 1 clockwise. It is at stiffest
position and turn it out to standard setting position.
STD position: 8 clicks out from stiffest position
Compression damping force
Fully turn the damping force adjuster 2 clockwise. It is at stiffest
position and turn it out to standard setting position.
STD position: 7 clicks out from stiffest position
Rebound side
NOTE:
Make sure to check the 1st click position by last click sound when
turnning in the adjuster.
#
Unequal suspension adjustment can cause poor han-
dling and loss of stability. Adjust the right and left front
forks to the same settings.

Do not turn the adjust screws more than the given posi- Compression side
tion or the adjuster may be damaged.
CHASSIS 6-23
STEERING AND HANDLEBAR

CONSTRUCTION
1 Handlebars
2 Steering stem upper bracket
3 Dust seal
4 Bearing upper
5 Bearing lower
6 Steering stem lower bracket
7 Headlight housing bracket
8 Headlight housing stay
A Handlebar clamp bolt

B Steering stem head nut
C Handlebar holder nut
D Front fork upper clamp bolt
E Steering stem nut
F Front fork lower clamp bolt
"
A 23 2.3 16.5
B 65 6.5 47.0
C 45 4.5 32.5
D 23 2.3 16.5
E 45 4.5 32.5
F 23 2.3 16.5
6-24 CHASSIS

• Remove the front wheel. (6-7)
• Remove the front forks. (6-13)
• Remove the headlight.
• Disconnect all the lead wire couplers in the headlight housing.

• Remove the headlight housing bolts.
• Remove the brake hose joint mounting bolt.

• Remove the headlight housing.
• Remove the headlight housing brackets.
• Remove the speedometer.

CHASSIS 6-25
• Remove the rear view mirrors.
• Disconnect the front brake light switch lead wire coupler 1.

• Remove the front brake master cylinder along with brake hose
and calipers.
• Remove the right handlebar switch box 2 and throttle case 3.
• Remove the handlebar balancers.

NOTE:
The handlebar balancer mounting screws should be slightly loos-
ened.
• Disconnect the clutch switch lead wires 4.
• Remove the left handlebar switch box 5.

• Remove the clutch master cylinder.
6-26 CHASSIS
• Loosen the handlebar holder nuts.
• Remove the handlebar clamp bolt caps.

• Remove the handlebar by removing the handlebar clamp bolts.
• Remove the steering stem upper bracket by removing the steer-

ing stem head nut.
• Remove the steering stem nut with the steering stem nut wrench.
\ 09940-14911: Steering stem nut wrench
NOTE:
Hold the steering stem lower bracket to prevent it from falling.
• Remove the dust seal 1, the steering stem upper bearing 2.

• Remove the steering stem lower bracket.
CHASSIS 6-27
• Remove the ignition switch. (7-29)
• Remove the handlebar holder.

Inspect the removed parts for the following abnormalities.
* Handlebars distriction
* Race wear and brinelling
* Bearing wear or damage
* Abnormal bearing noise
* Distortion of the steering stem
If any abnormal points are found, replace defective parts with the
new ones.
• Remove the steering stem lower bearing inner race using a

chisel.

The removed bearing inner race and dust seal should be
replaced with the new ones.
• Drive out the steering stem upper and lower bearing races us-
ing the special tools.
\ 09941-54911: Bearing outer race remover
09941-74911: Steering bearing installer
6-28 CHASSIS

Reassemble and remount the steering stem in the reverse order
of removal and disassembly. Pay attention to the following points:
OUTER RACES
• Press in the upper and lower outer races using the special tool.
\ 09941-34513: Steering outer race installer
BEARINGS
• Press in the lower bearing using the special tool.
\ 09941-74911: Steering bearing installer
• Apply grease to the bearings and bearing races.

• Install the lower bearing to the steering stem lower bracket.
• Install the upper bearing, bearing inner race and dust seal.
X 99000-25010: SUZUKI SUPER SREASE “A”
STEERING STEM
• Tighten the steering stem nut to the specified torque with the
steering stem nut wrench.
\ 09940-14911: Steering stem nut wrench
" Steering stem nut: 45 N.m (4.5 kgf.m, 32.5 lb-ft)
• Turn the steering stem about five or six times to the left and
right so that the angular ball bearing will be seated properly.
• Loosen the steering stem nut by ¼ – ½ turn.
NOTE:
This adjustment will vary from motorcycle to motorcycle.
CHASSIS 6-29
• Install the ignition switch. (7-29)

• Install the handlebar holders to the steering stem upper bracket.
NOTE:
Tighten the handlebar holder nuts 1 lightly.
After installing handlebars, it should be tightend to the specified
torque.
• Install the steering stem upper bracket and tighten the steering
stem nut lightly.
• Install the front fork to the steering stem and tighten the lower
clamp bolts temporarily.
• Tighten the steering stem head nut to the specified toupue.

" Steering stem head nut: 65 N.m (6.5 kgf.m, 47.0 lb-ft)
FRONT FORK
• Remount the front forks. (6-17)
HANDLEBARS
• Set the punched mark to the mating surface of the handlebar
holder.
6-30 CHASSIS
• Set the punched mark on the handlebar clamp forward.

• Tighten the handlebar clamp bolts.
" Handlebar clamp bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Tighten the handlebar holder nuts to the specified torque.

" Handlebar holder nut: 45 N.m (4.5 kgf.m, 32.5 lb-ft)
HANDLEBAR SWITCH BOX

• Install the right handlebar switch box to the handlebars by en-
gaging the stopper 1 with the handlebar hole 2.
• Install the front brake master cylinder. (6-62)
(Brake hose routing: 8-22)
• Install the throttle cable case. (Throttle cable routing: 8-20)

• Apply the grease to the throttle cables and their holes.
X 99000-25010: SUZUKI SUPER SREASE “A”
• Squeeze the brake lever fully and check or adjust the clear-
ance (between the brake lever and throttle cable case) to pro-
vide more than 2 mm (0.08 in).
• Adjust the throttle cable play. (2-15)
CHASSIS 6-31
• Install the left handlebar switch box to the handlebars by en-

gaging the stopper 1 with the handlebars hole 2.
• Install the clutch master cylinder with the proper clutch hose
routing. (Clutch hose routing: 8-19)
• Install the handlebar barancers and the rear view mirrors.

• Install the speedometer, the headlight housing and the head-
light.
• Install the front wheel. (6-9)
• Adjust the headlight beam. (7-28)
STEERING TENSION ADJUSTMENT

Check the steering movement in the following procedure.
• By supporting the motorcycle with a jack, lift the front wheel
until it is off the floor by 20 – 30 mm (0.8 – 1.2 in).
• Check to make sure that the cables and wire harnesses are
properly routed.
• With the front wheel in the straight ahead state, hitch the spring
scale (special tool) on one handlebar grip end as shown in the
figure and read the graduation when the handlebar starts mov-
ing. Do the same on the other grip end.
Initial force: 200 – 500 grams
\ 09940-92720: Spring scale
• If the initial force read on the scale when the handlebar starts
turning is either too heavy or too light, adjust it till it satisfies the
specification.
1)First, loosen the front fork upper and lower clamp bolts, steer-
ing stem head nut and steering stem lock nut, and then adjust
the steering stem nut by loosening or tightening it.
2)Tighten the steering stem lock nut, stem head nut and front
fork upper and lower clamp bolts to the specified torque and
re-check the initial force with the spring scale according to the
previously described procedure.
3)If the initial force is found within the specified range, adjust-
ment has been completed.
NOTE:
Hold the front fork legs, move them back and forth and make sure
that the steering is not loose.
6-32 CHASSIS
REAR WHEEL
CONSTRUCTION
1 Rear axle
2 Caliper bracket
3 Brake disc
4 Collar
5 Bearing
6 Rear wheel
7 Tire valve
8 Damper
9 Spacer
0 Bearing
A Retainer
B Sproket mounting drum
C Rear sproket
D Bearing
E Dust seal
F Collar
G Washer
A Brake disc bolt (Rear)

B Rear sprocket nut
C Rear axle nut
"
A 23 2.3 16.5
B 102 10.2 74.0
C 100 10 72.5
CHASSIS 6-33
REMOVAL
• Loosen the rear axle nut 1.
• Raise the rear wheel off the ground and support the motor-
cycle with the center stand.
• Remove the axle nut and draw out the rear axle.

Do not operate the brake pedal while removing the rear
wheel.
• Remove the collar 2.

• Draw out the rear sprocket mounting drum 3 from the wheel
hub.
NOTE:
Before removing the rear sprocket mounting drum, slightly loosen
the rear sprocket nuts.
• Remove the rear sprocket mounting drum retainer 4.

• Separate the rear sprocket from its mounting drum by remov-
ing nuts.
• Remove the dust seal by using special tool.

\ 09913-50121: Oil seal remover

Never reuse the removed dust seal.
• Remove the brake disc.

6-34 CHASSIS

TIRE INSPECTION: 6-70
WHEEL INSPECTION: 6-7 and 6-70
REAR AXLE
Using a dial gauge, check the rear axle for runout.
If the runout exceeds the limit, replace the rear axle.
Axle shaft runout: Service Limit: 0.25 mm (0.010 in)
\ 09900-20607: Dial gauge (1/100 mm)
09900-21304: V-block set (100 mm)
WHEEL DAMPER
Inspect the dampers for wear and damage.
Replace the damper if there is anything unusual.
SPROCKET
Inspect the rear sprocket teeth for wear. If they are worn as shown,
replace the engine sprocket, rear sprocket and drive chain as a
set.
Normal wear Excessive wear
BEARING
Inspect the play of the wheel and sprocket mounting drum bear-
ings by hand while they are in the wheel and drum. Rotate the
inner race by hand to inspect for abnormal noise and smooth
rotation. Replace the bearing if there is anything unusual.
CHASSIS 6-35
• Remove the sprocket mounting drum bearing and wheel bear-

ings by using the special tool.
\ 09921-20240: Bearing remover set

The removed bearings must be replaced with the new
ones.
6-36 CHASSIS

Reassemble and remount the rear wheel in the reverse order of
removal and disassembly. Pay attention to the following points:
Left Right
100 N.m (10.0 kgf.m, 72.5 lb-ft)

23 N.m
102 N.m (10.2 kgf.m, 74.0 lb-ft) (2.3 kgf.m, 16.5 lb-ft)
26 N.m
2.6 kgf.m
( )
19.0 lb-ft
CHASSIS 6-37
BEARING
• Apply grease to the bearings before installing.
• Install the new bearing to the sprocket mounting drum using

the special tool.
\ 09924-84510: Bearing installer set
• First install the right wheel bearing, then install the left wheel
bearing and spacer using the special tool.
\ 09941-34513: Bearing/Steering race installer set

The sealed cover of the bearing must face outside.
Left Right Left Right
Spacer
Bearing Clearance
installer
6-38 CHASSIS
DUST SEAL
• Install the new dust seal using proper drift.
• Apply grease to the dust seal lip before assembling rear wheel.
BRAKE DISC
• Apply THREAD LOCK SUPER “1360” to the disc bolts and
tighten them to the specified torque.
NOTE:
Make sure that the brake disc is clean and free of any greasy
matter.

" Brake disc bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
REAR SPROCKET
• Tighten the sprocket mounting nuts to the specified torque.
" Rear sprocket nut: 102 N.m (10.2 kgf.m, 74.0 lb-ft)
NOTE:
Stamped mark on the sprocket should face outside.
• Apply grease to the rear sprocket mounting retainer.

• Install the rear sprocket mounting drum retainer.
• Apply grease to the contacting surface between the rear wheel
and the sprocket drum.
• Install the rear sprocket mounting drum.

• Install the collar.
CHASSIS 6-39
REAR AXLE
• Remount the rear wheel and rear axle, install the washer and
rear axle nut.
• Tighten the rear axle nut 1 to the specified torque.
• Adjust the chain slack after rear wheel installation. (2-17)
" Rear axle nut: 100 N.m (10.0 kgf.m, 72.5 lb-ft)
6-40 CHASSIS
REAR SHOCK ABSORBER

CONSTRUCTION
1 Hook
2 Washer
3 Rear shock absorber
4 Spacer
5 Rear shock absorber lower mounting bolt
6 Swingarm
A Rear shock absorber upper mounting bolt
B Rear shock absorber lower mounting nut
"
A 23 2.3 16.5
B 34 3.4 24.5
CHASSIS 6-41
REMOVAL
• Remove the left muffler. (3-4)
• Remove the rear shock absorber upper mounting bolt.
• Loosen the rear shock absorber lower mounting bolt.
• Dismount the rear shock absorber’s upper side from the frame.
• Remove the rear shock absorbers by removing the lower bolts.

6-42 CHASSIS
INSPECTION
Inspect the shock absorber body and bushing for damage and oil
leakage.
If any defects are found, replace the shock absorber with a new
one.

Do not attempt to disassemble the rear shock absorber
unit. It is unserviceable.
REAR SHOCK ABSORBER SCRAPPING

PROCEDURE
#
* Handle the rear shock absorber with caution since a
high pressure nitrogen gas is contained.
* Avoid incineration, exposure to high pressure or over-
hauling.
* In the case of scrapping the rear shock absorber,
evacuate gas in the following procedures. In the case
of scrapping the rear shock absorber, evacuate gas in
the following procedures.
REAR SHOCK ABSORBER GAS EVACUATION

• Remove the valve cover 1.
• Remove the valve cap 2, evacuate gas by depressing the valve.
#
Keep your face away from the valve hole.
REMOUNTING
Remount the rear shock absorbers in the reverse order of re-
moval. Pay attention to the following points:
• Install the rear shock absorber and tighten the rear shock ab-
sorber upper/lower mounting bolts and nuts.
" Rear shock absorber mounting lower bolt:
34 N.m (3.4 kgf.m, 24.5 lb-ft)
" Rear shock absober mounting upper bolt:
23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Install the left muffler. (3-10)
CHASSIS 6-43
SUSPENSION SETTING
After installing the rear suspension, adjust the spring pre-load
and damping force as follows.
SPRING PRE-LOAD ADJUSTMENT

Position “1” provides the softest spring pre-load.
Position “5” provides the stiffest spring pre-load.
STD position: “1.5”
STD position
Stiffest position Softest position

DAMPING FORCE ADJUSTMENT
The rebound and compression damping force can be individually
adjusted by turning the respective adjusters.
Compression side
Position “1” provides the softest rebound damping force.
Position “4” provides the stiffest rebound damping force.
STD position: Position “2”
Compression side
Rebound side
Position “ ” provides the softest rebound damping force.
Position “ ” provides the stiffest rebound damping force.
STD position: “ ”

Be sure that the damping adjusters are firmly located in
a detent, and not between positions.
#
Be sure to adjust the spring pre-load and damping force
on the both suspensions equally.
Rebound side
6-44 CHASSIS
REAR SWINGARM
CONSTRUCTION
1 Swingarm
2 Bearing
3 Spacer
4 Chain buffer
5 Dust seal
6 Washer
7 Bearing spacer
8 Pivot shaft
A Swingarm pivot nut
"
A 120 12.0 87.0
CHASSIS 6-45
REMOVAL
• Remove the rear wheel. (6-33)
• Remove the rear shock absorbers. (6-41)
• Remove the rear brake hose guide 1.
• Remove the touque link.

• Remove the rear brake hose union bolt at the rear brake cali-
per.

Completely wipe off any brake fluid adhering to any part
of motorcycle. The fluid reacts chemically with paint, plas-
tics, rubber materials and so on.
• Remove the pivot shaft cap.

• Remove the swingarm by removing the pivot shaft.
• Remove the chain case.

6-46 CHASSIS

DUST SEAL AND SPACER
• Remove the dust seals 1, washers 2 and spacers 3 from
swingarm.
• Inspect the spacers for any flaws or other damage. If any de-
fects are found, replace the spacers with the new ones.
CHAIN BUFFER
• Remove the chain buffer.
• Inspect the chain buffer for wear and damage. If any defects
are found, replace the chain buffer with a new one.
SWINGARM BEARING
Insert the spacer into bearing and check the play when moving
the spacer up and down.
If excessive play is noted, replace the bearing with a new one.
• Remove the swingarm bearing and spacer with the special tools.
\ 09941-64511: Bearing remover
09930-30102: Sliding shaft

Never reuse the removed bearings.
SWINGARM PIVOT SHAFT

Using a dial gauge, check the pivot shaft runout and replace it if
the runout exceeds the limit.
\ 09900-20607: Dial gauge (1/100 mm, 10 mm)
09900-21304: V-block (100 mm)
Swingarm pivot shaft runout:
Service limit: 0.3 mm (0.01 in)
CHASSIS 6-47
REASSEMBLY
Reassemble the swingarm in the reverse order of disassembly and removal.
Pay attention to the following points:
120 N.m
Left Right (12.0 kgf.m, 87.0 lb-ft)
Pivot shaft
Spacer
PIVOT THRUST CLEARANCE

* The cap (thrust shim) 1 is used for adjusting the pivot thrust
clearance A.
* Before tightening the pivot nut, measure the pivot thrust
clearance A by using the thickness gauge. If the clearance
exceeds 0.9 mm (0.035 in), the cap (thrust shim) 1 must
be installed at the right frame pivot boss 2 as shown.
SWINGARM BEARING
• Install the bearings and spacer into the swingarm pivot by us-
ing the special tool.
\ 09941-34513: Steering race installer
• Apply grease to the bearings and spacers and dust seals.

• Install the bearings, spacers, washers and dust seals.
• Install the chain buffer to the swingarm.
• Install the chain case to the swingarm.
6-48 CHASSIS
REMOUNTING
Remount the swingarm in the reverse order of disassembly and
removal, and pay attention to the following points:
SWINGARM
• Insert the swingarm pivot shaft and tighten it to the specified
torque.
" Swingarm pivot nut: 120 N.m (12.0 kgf.m, 87.0 lb-ft)
• Install the pivot shaft caps.
• Install the touque link.

" Touque link bolt/nut: 28 N.m (2.8 kgf.m, 20.5 lb-ft)
• Install the rear shock absorbers. (6-42)

• Install the rear brake hose guide.
• Install the rear wheel. (6-36)
• Install the rear brake hose with the proper brake hose routing.
(Rear brake hose routing:8-23)
" Brake hose union bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)

Bleed air from the brake system. (2-22)
FINAL INSPECTION AND ADJUSTMENT

After installing the rear suspension and wheel, the following ad-
justments are required before driving.
* Drive chain: 2-17
* Tire pressure: 6-72
* Chassis bolts and nuts: 2-25
CHASSIS 6-49
FRONT BRAKE
CONSTRUCTION
1 Diaphragm
2 Dust boot
3 Piston/cup set
4 Brake hose #1
5 Brake hose #2 (RH)
6 Brake hose #2 (LH)
7 Brake pad spring
8 Brake pad
9 O-ring
0 Piston seal
A Dust seal
B Piston
A Front brake master cylinder

mounting bolt
B Brake hose union bolt
C Pad mounting pin
D Air bleeder valve
E Brake caliper housing bolt
F Brake caliper mounting bolt
D
FW
"
A 10 1.0 7.3
B 23 2.3 16.5
C 16 1.6 11.5
D 8 0.8 5.7
E 21 2.1 15.0
D
F 25 2.5 18.0 FW
#
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid
left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. and
will damage then severly.
6-50 CHASSIS
BRAKE PAD REPLACEMENT

• Remove the pad spring 1.
• Remove the brake pads by removing the pad mounting pin 2.

* Do not operate the brake lever while dismounting the
pads.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
• Clean up the caliper especially around the caliper pistons.
• Install the new brake pads so the brake disc is positioned be-
tween the pads.
" Pad mounting pin: 16 N.m (1.6 kgf.m, 11.5 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever few times to
check for proper brake operation and then check the brake fluid
level.
BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-
bars straight.
• Remove the brake fluid reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with the new brake fluid.
• Connect a clear hose to the caliper air bleeder valve and insert
the other end of hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until old
brake fluid flows out of the bleeder system.
• Close the caliper air bleeder valve and disconnect a clear hose.
Fill the reservoir with the new fluid to the upper mark of the
reservoir.
O Specification and Classification: DOT 4

2-21)
Bleed air from the brake system. (
CHASSIS 6-51
CALIPER REMOVAL AND DISASSEMBLY

• Drain the brake fluid. (6-50)
• Remove the brake pads. (6-50)
• Disconnect the brake hoses by removing the brake hose union
bolts.
NOTE:
Place a rag underneath the union bolt on the brake caliper to
catch any spilt brake fluid.
• Remove the brake calipers by removing the caliper mounting
bolts.
NOTE:
Slightly loosen the caliper housing bolts before removing the cali-
per mounting bolts to facilitate later disassembly.

Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods of time.
#
Brake fluid, if it leaks, will interfere with safe running and
discolor painted surfaces. Check the brake hose and
hose joints for cracks and fluid leakage.
• Separate the caliper halves to remove the caliper housing bolts.
• Remove the O-ring.

Replace the O-ring with a new one.
• Place a rag over the pistons to prevent they from popping out
and then force out the pistons using compressed air.

Do not use high pressure air to prevent piston damage.
6-52 CHASSIS
• Remove the dust seals and piston seals.

Never reuse the removed dust seals and piston seals to
prevent fluid leakage.
CALIPER INSPECTION
BRAKE CALIPER
Inspect the brake caliper cylinder wall for nicks, scratches or other
damage.
BRAKE CALIPER PISTON

Inspect the brake caliper piston surface for any scratches or other
damage.
CALIPER REASSEMBLY AND REMOUNTING

Reassemble the caliper in the reverse order of removal and dis-
assembly. Pay attention to the following points:
• Wash the caliper bores and pistons with specified brake fluid.
Particularly wash the dust seal grooves and piston seal grooves.

* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or gaso-
line to wash them.
* Do not wipe the brake fluid off after washing the com-
ponents with a rag.
* When washing the components, use the specified
brake fluid. Never use different types of fluid or clean-
ing solvent such as gasoline, kerosine or the others.
* Replace the piston seals and dust seals with the new
ones when reassembly. Apply the brake fluid to both
seals when installing them.
PISTON SEAL
• Install the piston seals as shown in the illustration.
• Install the pistons to the caliper halves.
O-ring
• Install the new O-ring and reassemble caliper halves.

CHASSIS 6-53
• Tighten each bolt to the specified torque.

(Front brake hose routing: 8-22)
" Front brake caliper housing bolt 1:
21 N.m (2.1 kgf.m, 15.0 lb-ft)
Front brake caliper mounting bolt 2:
25 N.m (2.5 kgf.m, 18.0 lb-ft)
Front brake hose union bolt 3:
23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Install the brake pads. (6-50)
NOTE:
Before remounting the caliper, push the piston all the way into
the caliper.

* The seal washers should be replaced by the new ones
to prevent fluid leakage.
* Bleed air from the system after reassembling the cali-
per. (2-21)
BRAKE DISC INSPECTION

Visually check the brake disc for damage or cracks.
Measure the thickness with a micrometer.
Replace the disc if the thickness is less than the service limit or if
damage is found.
Front disc thickness: Service Limit: 4.5 mm (0.18 in)
\ 09900-20205: Micrometer (0–25 mm)
• Remove the brake calipers. (6-51)
Measure the runout with a dial gauge.
Replace the disc if the runout exceeds the service limit.
Front disc runout: Service Limit: 0.30 mm (0.012 in)
\ 09900-20607: Dial gauge (1/100 mm)
* Brake disc removal (6-7)
* Brake disc installation (6-9)
6-54 CHASSIS
MASTER CYLINDER REMOVAL AND

DISASSEMBLY
• Remove the rear view mirror.
• Disconnect the front brake light switch lead wire coupler 1.
• Place a rag underneath the union bolt on the master cylinder to

catch any spilt brake fluid. Remove the brake hose union bolt
and disconnect the brake hose.

Immediately and completely wipe off any brake fluid con-
tacting any part of the motorcycle. The fluid reacts chemi-
cally with paint, plastics and rubber materials, etc. and
will damage them severely.
• Remove the master cylinder by removing the master cylinder

mounting bolts.
• Remove the brake lever 2 and brake switch 3.
• Pull out the dust boot 4 and remove the circlip 5.

\ 09900-06108: Snap ring pliers
CHASSIS 6-55
• Remove the piston/secondary cup, primary cup and return

spring.
1 Piston
2 Secondary cup
3 Primary cup
4 Return spring
MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other dam-
age.
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust seal for wear or
damage.
MASTER CYLINDER REASSEMBLY AND

REMOUNTING
Reassemble the master cylinder in the reverse order of removal
and disassembly. Pay attention to the following points:

* Wash the master cylinder components with fresh brake
fluid before reassembly. Never use cleaning solvent or
gasoline to wash them.
* Do not wipe the components with a rag.
* Apply brake fluid to the cylinder bore and all the com-
ponent to be inserted into the bore.

6-56 CHASSIS
• Apply brake fluid to the piston and cups.

• Install the following parts to the master cylinder.
1 Dust boot
2 Circlip
3 Secondary cup
4 Piston
5 Primary cup
6 Return spring
\ 09900-06108: Snap ring plires
• When remounting the brake master cylinder onto the handle-

bar, align the master cylinder holder’s mating surface A with
punched mark B on the handlebars and tighten the upper clamp
bolt first as shown.
" Front brake master cylinder mounting bolt: 10 N.m
(1.0 kgf.m, 7.3 lb-ft)
• Tighten the union bolt.

(Brake hose routing: 8-22)

* Bleed air from the system after reassembling the mas-
ter cylinder. (2-21)
INSPECTION AFTER REASSEMBLY

• Front brake: 2-19
CHASSIS 6-57
REAR BRAKE
CONSTRUCTION
1 Brake hose
2 Diaphragm
3 Reservoir tank hose
4 Piston/cup set
5 Push rod
6 Dust boot
7 Piston seal
8 Dust seal
9 Piston
0 Pad shim
A Brake pad
B O-ring
C Brake pad spring
A Brake hose union bolt

B Rear brake master cylinder mounting
C Rear brake master cylinder rod lock nut
D Air bleeder valve
E Brake caliper mounting bolt
F Pad mounting pin
G Brake caliper housing bolt
"
A 23 2.3 16.5
B 10 1.0 7.3
C 18 1.8 13.0
D 8 0.8 5.7
E 26 2.6 19.0
F 17 1.7 12.5
G 37 3.7 27.0
#
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.

will damage them severly.
6-58 CHASSIS
BRAKE PAD REPLACEMENT

• Remove the pad mounting pin 1.
• Remove the brake pad spring 2.
• Remove the brake pads along with the pad shims.

* Do not operate the brake pedal while dismounting the
pads.
* Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
• Clean up the caliper especially around the caliper pistons.
• Install the new brake pads and shims 3 so the brake disc is
positioned between the pads.
" Pad mounting pin: 17 N.m (1.7 kgf.m, 12.5 lb-ft)
NOTE:
After replacing the brake pads, pump the brake pedal few times
to operate the brake correctly and then check the brake fluid level.
BRAKE FLUID REPLACEMENT

• Remove the right frame cover. (6-3)
• Remove the brake fluid reservoir cap.
• Replace the brake fluid in the same manner as the front brake.
(6-50)

2-22)
Bleed air from the brake system. (
CHASSIS 6-59
CALIPER REMOVAL AND DISASSEMBLY

• Remove the brake pads. (6-58)
• Disconnect the brake hose by removing the brake hose union
bolt.

Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods.
#
Brake fluid, if it leaks, will interfere with safe running and
discolor painted surfaces. Check the brake hose and
hose joints for cracks and fluid leakage.
• Remove torque link bolt 1 and the brake caliper mounting bolts
2.
NOTE:
Slightly loosen the caliper housing bolts 3 to facilitate later dis-
assembly before removing the caliper mounting bolts.
• Remove the caliper housing bolts 3.
• Separate the caliper halves.
• Remove the O-ring 4.

• Place a rag over the piston to prevent it from popping out and
then force out the pistons using compressed air.

• Remove the dust seals and piston seals.

Do not reuse the dust seals and piston seals to prevent
fluid leakage.
6-60 CHASSIS
CALIPER INSPECTION
CALIPER INSPECTION: 6-52
BRAKE DISC INSPECTION: 6-53
Service Limit
Rear disc thickness: 5.0 mm (0.20 in)
Rear disc runout: 0.30 mm (0.012 in)
CALIPER REASSEMBLY AND REMOUNTING

Reassemble and remount the caliper in the reverse order of re-
moval and disassembly. Pay attention to the following points:

* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or gaso-
line to wash them.
* Apply brake fluid to the caliper bore and piston to be
inserted into the bore.
PISTON SEAL
• Install the piston seals as shown in the right illustration.
• Install the pistons to the caliper halves.
O-ring
• Install the new O-ring 1 and reassemble caliper halves.

• Apply THREAD LOCK SUPER “1360” to the caliper housing

bolts and tighten them to the specified torque.
" Rear brake caliper housing bolt: 37 N.m
(3.7kgf.m, 27.0 lb-ft)
NOTE:
Completely clean up the thread of the caliper housing and hous-
ing bolts, before applying THREAD LOCK.
CHASSIS 6-61
• Install the caliper to the caliper bracket and tighten each bolt to
the specified torque.
" Rear brake caliper mounting bolt 1: 26 N.m
(2.6 N.m, 19.0 lb-ft)
Rear torque link nut 2: 34 N m (3.4 kgf.m, 24.5 lb-ft)
.
• Connect the rear brake hose to the rear brake caliper.

• Tighten the brake hose union bolt with the brake hose union
pipe touching to the stopper of caliper.
(Rear brake hose routing: 8-23)

* Bleed air from the system after reassembling the cali-
per. (2-22)
MASTER CYLINDER REMOVAL AND

DISASSEMBLY
• Remove the brake fluid reservoir tank mounting bolt 1.

catch spilled drops of brake fluid. Remove the union bolt 2 and
disconnect the brake hose.
• Disconnect the reservoir tank hose.

Immediately and completely wipe off any brake fluid con-
tacting any parts of the motorcycle. The fluid reacts
chemically with paint, plastic and rubber materials, etc.
and will damage them severely.
• Loosen the lock nut 3.

• Remove the master cylinder mounting bolts 4.
• Remove the master cylinder by turning the master cylinder rod
5.
6-62 CHASSIS
• Remove the reservoir cap and diaphragm.

• Remove the connector 6 by removing the circlip 7.
• Remove the O-ring 8.

• Pull out the dust seal 9, then remove the circlip 0 with the
special tool.
• Remove the push rod, piston/primary cup and spring.
MASTER CYLINDER INSPECTION

CYLINDER, PISTON AND CUP SET
Inspect the cylinder bore wall for any scratches or other damage.
Inspect the cup set and each rubber part for damage.
MASTER CYLINDER REASSEMBLY AND

REMOUNTING
Reassemble and remount the master cylinder in the reverse or-
der of removal and disassembly. Pay attention to the following
points:


CHASSIS 6-63
• Apply brake fluid to the piston/cup set.

• Install the following parts.
1 Piston/primary cup
2 Push rod
3 Circlip
4 Dust boot
• Apply the SUZUKI MOLY PASTE to the push rod.
Z 99000-25140: SUZUKI MOLY PASTE
• Install the master cylinder.

• Tighten the lock nut 2.
" Rear master cylinder mounting bolt 1:
10 N.m (1.0 kgf.m, 7.3 lb-ft)
Rear master cylinder rod lock nut 2:
18 N.m (1.8 kgf.m, 13.0 lb-ft)
• Connect the brake hose to the master cylinder.

(Rear brake hose routing: 8-23)
• Tighten the brake hose union bolt 3 to the specified torque.
" Brake hose union bolt 3: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
• Install the reservoir tank and reservoir tank hose.
(Rear brake hose routing : 8-23)

• Adjust the brake pedal height. (2-20)
INSPECTION AFTER REASSEMBLY

Rear brake: 2-19
6-64 CHASSIS
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER

CONSTRUCTION
1 Diaphragm
2 Push rod
3 Dust boot
4 Piston/cup set
5 Clutch hose
6 Clutch push rod
7 Piston
8 Piston cup
9 Spring
A Clutch master cylinder mounting bolt

B Clutch hose union bolt
C Air bleeder valve
"
A 10 1.0 7.3
B 23 2.3 16.5
C 8 0.8 5.7
#
* This clutch system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix

will damage them sererly.
CHASSIS 6-65
CLUTCH FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-
bars straight.
• Remove the engine sprocket cover. (3-6)
• Remove the master cylinder reservoir cap and diaphragm.
• Suck up the old clutch fluid as much as possible from the reser-
voir tank.
• Fill the reservoir with the new clutch fluid.
• Connect a clear hose to the clutch release cylinder air bleeder
valve and insert the other end of hose into a receptacle.
• Loosen the air bleeder valve and pump the clutch lever until old
clutch fluid flows out of the bleeder system.
• Close the clutch release cylinder air bleeder valve, and discon-
nect a clear hose. Fill the reservoir with fresh brake fluid to the
upper level.

2-17)
Bleed air in the clutch fluid system. (
• Install the engine sprocket cover. (3-9)
CLUTCH RELEASE CYLINDER REMOVAL AND

DISASSEMBLY
• Drain the clutch fluid. (above)
• Disconnect the clutch hose by removing the union bolt 1.
NOTE:
Completely wipe off any clutch fluid adhering to any part of mo-
torcycle.
The fluid reacts chemically with paint, plastics, rubber materials,
etc.
• Remove the air bleeder valve 2.
• Remove the clutch release cylinder housing 3.
• Remove the clutch release cylinder by removing the bolts 4
and screws 5.
6-66 CHASSIS
• Place a rag over the piston to prevent it from popping out. Force
out the piston by using compressed air.

CLUTCH RELEASE CYLINDER INSPECTION

Inspect the clutch release cylinder bore wall for nicks, scratches
or other damage. Inspect the oil seal for damage and wear. In-
spect the piston surface for any scratches or other damage.
CLUTCH RELEASE CYLINDER REASSEMBLY

AND REMOUNTING
Reassemble the clutch release cylinder in the reverse order of
disassembly and by taking the following steps:

* Wash the clutch cylinder components with fresh brake
* Apply brake fluid to the cylinder bore and piston to be
inserted into the bore.

1 Clutch release cylinder retainer
2 Piston
3 Piston cup
4 Spring
5 Air bleeder valve
6 Bleeder cap
7 Clutch ralease cylinder body
8 Push rod
• Apply grease to the clutch push rod 8.
CHASSIS 6-67
• Tighten each bolts to the specified torque.

" Clutch hose union bolt 1: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
Air bleeder valve 2: 8.0 N.m (0.8 kgf.m, 6.0 lb-ft)

* Bleed air from the system after reassembling the re-
2-17)
lease cylinder. (
CLUTCH MASTER CYLINDER REMOVAL AND

DISASSEMBLY
• Drain the clutch fluid. (6-65)
• Disconnect the clutch lever position switch lead wires.
catch spilled drops of brake fluid. Remove the union bolt and
disconnect the clutch hose from the master cylinder.

Completely wipe off any brake fluid adhering to any parts
of motorcycle. The fluid reacts chemically with paint, plas-
tics, rubber materials, etc. and will damage them severely.
• Remove the clutch master cylinder.

6-68 CHASSIS
• Remove the clutch lever 1 and clutch lever position switch.
• Remove the boot 2 and push rod 3.

• Remove the circlip 4 with snap ring pliers.
• Remove the piston/cup set

5 Secondary cup
6 Piston
7 Primary cup
8 Spring
CLUTCH MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other dam-
age.
Inspect the piston surface for any scratches or other damage.
Inspect the primary cup, secondary cup and dust seal for wear or
damage.
CHASSIS 6-69
CLUTCH MASTER CYLINDER REASSEMBLY

AND REMOUNTING
Reassemble the master cylinder in the reverse order of removal
and disassembly. Pay attention to the following points:

• Apply brake fluid to the piston/cup set and install them to the
clutch master cylinder.
1 Spring
2 Primary cup
3 Piston
4 Secondary cup
5 Stopper plate
6 Circlip
7 Dust boot
8 Push rod
• Apply SUZUKI MOLY PASTE to the push rod.

• Install the push rod and dust boot.
• When remounting the master cylinder on the handlebars, align

Upper
the master cylinder holder’s mating surface A with punched
mark B on the handlebars and tighten the upper clamp bolt
first as shown. Handlebars
" Clutch master cylinder mounting bolt: Master
cylinder
10 N.m (1.0 kgf.m, 7.3 lb-ft) holder
Clutch master cylinder union bolt: 23 N.m
(2.3 kgf.m, 16.5 lb-ft)
• Connect the clutch lever position switch lead wire.

6-70 CHASSIS
TIRE AND WHEEL

TIRE REMOVAL
The most critical factor of a tubeless tire is the seal between the
wheel rim and the tire bead. For this reason, it is recommended
to use a tire changer that can satisfy this sealing requirement
and can make the operation efficient as well as functional.
For operating procedures, refer to the instructions supplied by
the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection, mark
the tire with a chalk to indicate the tire position relative to the
valve position.
Even though the tire is refitted to the original position after repair-
ing puncture, the tire may have to be balanced again since such
a repair can cause imbalance.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following:
* Distortion and crack
* Any flaws and scratches at the bead seating area.
* Wheel rim runout (6-7)
TIRE
Tire must be checked for the following points:
* Nick and rupture on side wall
* Tire tread depth (2-22)
* Tread separation
* Abnormal, uneven wear on tread
* Surface damage on bead
* Localized tread wear due to skidding (Flat spot)
* Abnormal condition of inner liner
CHASSIS 6-71
VALVE
• Inspect the valve after the tire is removed from the rim. Replace
the valve with a new one if the seal rubber is peeling or has
damage.
• Inspect the valve core. If the seal has abnormal deformation,
replace the valve with a new one.
VALVE INSTALLATION
• Any dust or rust around the valve hole must be cleaned off.
Then install the valve in the rim. Seal
NOTE:
To properly install the valve into the valve hole, apply a special
tire lubricant or neutral soapy liquid to the valve.

Be careful not to damage the lip of valve.
Valve hole
TIRE INSTALLATION
• Apply tire lubricant to the tire bead. Wheel
• When installing the tire onto the wheel, observe the following
points.

Valve lip Valve
* Do not reuse the valve which has been once removed.
* Never use oil, grease or gasoline on the tire bead in
place of tire lubricant.
6-72 CHASSIS
• When installing the tire, the arrow 1 on the side wall should
point to the direction of wheel rotation.
• Align the chalk mark put on the tire at the time of removal with
the valve position.
• For installation procedure of tire onto the wheel, follow the in-
structions given by the tire changer manufacturer.
• Bounce the tire several times while rotating. This makes the tire
bead expand outward to contact the wheel, thereby facilitating
air inflation.
• Inflate the tire.
#
* Do not inflate the tire to more than 400 kPa (4.0kgf/
cm2). If inflated beyond this limit, the tire can burst and
possibly cause injury. Do not stand directly over the
tire while inflating.
* In the case of preset pressure air inflator, pay special
Rim line
care for the set pressure adjustment.
• In this condition, check the “rim line” cast on the tire side walls.
The line must be equidistant from the wheel rim all around. If
the distance between the rim line and wheel rim varies, this
indicates that the bead is not properly seated. If this is the case,
deflate the tire completely and unseat the bead for both sides.
Coat the bead with lubricant and fit the tire again.
• When the bead has been fitted properly, adjust the pressure to
specification.
• As necessary, adjust the tire balance.

Do not run with a repaired tire at a high speed.
Tire pressure
Solo riding:Front: 250 kPa (2.50 kgf/cm2, 36 psi)
Rear: 250 kPa (2.50 kgf/cm2, 36 psi)
Dual riding:Front: 250 kPa (2.50 kgf/cm2, 36 psi)
Rear: 290 kPa (2.90 kgf/cm2, 42 psi)
ELECTRICAL SYSTEM 7-1
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING ............................................................... 7- 2
LOCATION OF ELECTRICAL COMPONENTS ............................... 7- 4
CHARGING SYSTEM ....................................................................... 7- 6
TROUBLESHOOTING ................................................................... 7- 6
INSPECTION ................................................................................. 7- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION
INTERLOCK SYSTEM ...................................................................... 7-11
TROUBLESHOOTING ................................................................... 7-11
STARTER MOTOR REMOVAL AND DISASSEMBLY .................. 7-12
STARTER MOTOR INSPECTION ................................................. 7-13
STARTER MOTOR REASSEMBLY ............................................... 7-13
STARTER RELAY INSPECTION ................................................... 7-14
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ................................................................................. 7-15
IGNITION SYSTEM ...........................................................................
TROUBLESHOOTING ...................................................................
7-18
7-18
7
INSPECTION ................................................................................. 7-20
COMBINATION METER .................................................................... 7-23
INSPECTION ................................................................................. 7-24
LAMPS .............................................................................................. 7-28
RELAYS ............................................................................................. 7-29
SWITCHES ........................................................................................ 7-29
BATTERY ........................................................................................... 7-31
SPECIFICATIONS.......................................................................... 7-31
INITIAL CHARGING ...................................................................... 7-31
SERVICING .................................................................................... 7-32
RECHARGING OPERATION ......................................................... 7-33
7-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
• When connecting a connector, be sure to push it in until a click
is felt.
• Inspect the connector for corrosion, contamination and break-
age in its cover.
COUPLER
• With a lock type coupler, be sure to release the lock before
disconnecting it and push it in fully till the lock works when
connecting it.
• When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
• Inspect each terminal on the coupler for being loose or bent.
• Inspect each terminal for corrosion and contamination.
CLAMP
• Clamp the wire harness at such positions as indicated in “WIRE
HARNESS ROUTING”. (8-16 to 8-18)
• Bend the clamp properly so that the wire harness is clamped
securely.
• In clamping the wire harness, use care not to allow it to hang
down.
• Do not use wire or any other substitute for the band type clamp.
FUSE
• When a fuse blows, always investigate the cause, correct it
and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
SEMI-CONDUCTOR EQUIPPED PART

• Be careful not to drop the part with a semi-conductor built in
such as a ECM.
• When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
BATTERY
• The MF battery used in this motorcycle does not require main-
tenance (e.g., electrolyte level inspection, distilled water replen-
ishment).
• During normal charging, no hydrogen gas is produced. How-
ever, if the battery is overcharged, hydrogen gas may be pro-
duced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open
area.
• Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF bat-
tery with a conventional battery.
CONNECTING THE BATTERY

• When disconnecting terminals from the battery for disassem-
bly or servicing, be sure to disconnect the - battery lead wire,
first.
• When connecting the battery lead wires, be sure to connect
the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm wa-
ter over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the
battery terminals.
• Install the cover over the + battery terminal.
WIRING PROCEDURE
• Properly route the wire harness according to the “WIRE ROUT-
ING” section. (8-16 to 8-18)
USING THE MULTI CIRCUIT TESTER

• Properly use the multi circuit tester + and - probes. Improper
use can cause damage to the motorcycle and tester.
• If the voltage and current values are not known, begin measur-
ing in the highest range.
• When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF
position.

Before using the multi circuit tester, read its instruction
manual.
LOCATION OF ELECTRICAL COMPONENTS
1 ECM (Engine Control Module) 0 Secondary throttle position sensor (4-43)

2 Battery A CKP sensor
3 Fuel injector (4-46) B Oil pressure switch
4 Actuator (4-42) C Fan motor switch (5-10)
5 Intake air pressure sensor (4-33) D Starter motor
6 Cam position sensor (4-31) E Oil temp. sensor (5-11)
7 Fuel pump (4-50) F Intake air temp. sensor (4-38)
8 Fuel level gauge G Air pressure sensor (4-39)
9 Ignition coil (No. 2 & 3) H Tip over sensor (4-41)
1 Cooling fan 0 Generator

2 Ignition coil (No. 1 & 4) A Side-stand switch
3 Throttle position sensor B Gear position switch
4 Fuse box C Speedometer sensor
5 Side-stand/turn signal relay
6 Starter relay
7 Fuel pump relay
8 Regulator/rectifier
9 Mode selection switch coupler
CHARGING SYSTEM
Regulator / rectifier
Ig.switch
Generator
IC
Load
Battery
SCR
TROUBLESHOOTING
Battery runs down quickly.
Check accessories which use excessive Accessories • Remove accessories.

amounts of electricity. are installed
No accessories
Check the battery for current Current leaks • Short circuit of wire harness
leaks. (7-7) • Faulty electrical equipment
No current leaks
Measure the charging voltage

between the battery terminals. Correct • Faulty battery
(7-8) • Abnormal driving condition
Incorrect
Measure the continuity of

the generator coil. No continuity • Faulty generator coil or
(7-8) disconnected lead wires
Continuity
Continued on next page

Measure the generator no-load

voltage. (7-8) Incorrect • Faulty generator
Correct
Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier

(7-10)
Correct
Inspect wirings. Incorrect • Short circuit of wire harness

• Poor contact of couplers
Correct
• Faulty battery
Others
Battery overcharge • Faulty regulator/rectifier

• Faulty battery
• Poor contact of generator lead wire coupler
INSPECTION
BATTERY CURRENT LEAKAGE
• Remove the seat. (6-3)
• Remove the tray.
• Turn the ignition switch to the OFF position.
• Disconnect the battery - lead wire.
Measure the current between - battery terminal and the - bat-
tery lead wire using the multi circuit tester. If the reading exceeds
the specified value, leakage is evident.
\ 09900-25008: Multi circuit tester set
Battery current (leak): Under 3 mA
R Tester knob indication: Current (
, 20 mA)

DCmA
* Because the current leak might be large, turn the tester
to high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position
when measuring current. Battery
When checking to find the excessive current leakage, remove

the couplers and connectors, one by one, checking each part. + -
REGULATED VOLTAGE
• Start the engine and keep it running at 5 000 r/min. with lighting
switch turned ON (except for E-24) and dimmer switch turned
HI position.
Measure the DC voltage between the + and - battery terminals
using the multi circuit tester. If the voltage is not within the speci-
fied value, inspect the generator and regulator/rectifier. (7-8
and 7-10)
NOTE: Battery
- +
When making this test, be sure that the battery is in fully-charged
condition.
\ 09900-25008: Multi circuit tester set DCV
W Tester knob indication: Voltage (

)
Charging output (Regulated voltage):
14.0 – 15.5 V at 5 000 r/min.
GENERATOR COIL RESISTANCE

• Remove the engine sprocket outer cover.
• Disconnect the generator coupler.
Measure the resistance between the three lead wires.
If the resistance is not specified value, replace the stator with a
new one. Also, check that the generator core is insulated.
Ω)
V Tester knob indication: Resistance (Ω
Generator coil resistance: 0.2 – 1.0 Ω (Yellow – Yellow)
∞ Ω (Yellow – Ground)
NOTE:
When making above test, it is not necessary to remove the gen- Y
erator. Y
GENERATOR NO-LOAD PERFORMANCE Y
• Start the engine and keep it running at 5 000 r/min.
Using the multi circuit tester, measure the voltage between three
lead wires.
If the tester reads under the specified value, replace the genera-
tor with a new one.
W Tester knob indication: Voltage (∼
∼)
Y
Generator no-load performance:
More than 60 V at 5 000 r/min (When engine is cold) Y
Y
REGULATOR/RECTIFIER
• Remove the battery.
• Disconnect the seat lock cable 1 and brake light/taillight cou-

pler 2.
• Remove the pillion rider gripe 3 and seat tail cover 4.
• Disconnect the rear turn signal light couplers (right and left).
• Remove the rear fender mounting bolts.
• Move the rear fender backward.

• Remove the regulator/rectifier.
Measure the voltage between the terminals using the multi circuit
tester as indicated in the table below. If the voltage is not within
the specified value, replace the regulator/rectifier with a new one.
Tester knob indication: Diode test (>
>)
Unit: V
+ Probe of tester to:
A B C D E F
- Probe of tester to:
A 0.4 – 0.7 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6

B
C
D 0.3 – 0.6
E 0.3 – 0.6
F 0.3 – 0.6
More than 1.4 V (tester’s battery voltage)

NOTE:
If the tester reads under 1.4 V when the tester probes are not
connected, replace the battery of multi circuit tester.
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK

SYSTEM
Engine stop Ignition

switch switch
Fuse(30A)
To ECM and
O/W R
Ignition coil
Starter Y/G
motor O/B
Fuse Gear position
Battery
(15A) switch
Bl
Starter relay B/Y Starter
Clutch lever button Turn signal/ G
position switch side-stand relay
side-stand
B/W switch
TROUBLESHOOTING
Starter motor will not run.
The transmission is in neutral. Grasp the Check if the starter motor runs
clutch lever, turn on the ignition switch when its terminal is connected
with the engine stop switch in the “RUN” Clicks to the battery + terminal (Do
position and listen for a click from the not use thin “wire” because a
starter relay when the starter button is large amount of current flows)
pushed.
Runs Does not run
No click
• Faulty starter motor
• Faulty starter relay

• Loose or disconnected starter
Measure the starter relay voltage at the motor lead wire
starter relay connectors (between Y/G + No voltage • Faulty ignition switch
and B/Y -) when the starter button is • Faulty engine stop switch
pushed. • Faulty clutch lever position
switch
• Faulty gear position switch
• Faulty turn signal/side-stand
Voltage relay
• Faulty starter button
• Poor contact of connector
• Open circuit in wire harness
Check the starter relay.

Incorrect • Faulty starter relay
(7-14)
Correct
• Poor contact of the starter relay
The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any
position other than neutral, with the side-stand up.
Check the side-stand switch.

Incorrect • Faulty side-stand switch
(7-15)
Correct
• Open circuit in wire harness
• Poor contact of connector
Others
Engine does not turn though • Faulty starter clutch

the starter motor runs.
STARTER MOTOR REMOVAL AND

DISASSEMBLY
• Remove the oil hose connector 1 from the crankcase.
• Disconnect the starter motor lead wire 2.
• Remove the starter motor.
• Disassemble the starter motor as shown in the illustration.
1 O-ring
2 Housing end (inside)
3 Starter motor case
4 Armature
5 Brush holder and spring
6 Housing end (outside)
STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness in
the brush holder.
If any damages are found, replace the brush assembly with a
new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or un-
dercut A.
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand
paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw
blade.
ARMATURE COIL INSPECTION

Check for continuity between each segment and between each
segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continu-
ity between the segments and shaft, replace the armature with a
new one.
?)
= Tester knob indication: Continuity test (?
OIL SEAL INSPECTION

Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of disassem-
bly. Pay attention to the following points:
• Apply grease to the lip of the oil seal.
• Apply a small quantity of SUZUKI MOLY PASTE to the arma-

ture shaft.
• Apply a small quantity of THREAD LOCK SUPER “1322” to the

starter motor housing bolts.
• Apply SUZUKI SUPER GREASE “A” to the O-ring.
• Tighten the starter motor lead wire mounting nut.
STARTER RELAY INSPECTION

• Remove the left frame cover.
• Disconnect the battery - lead wire from the battery.
• Remove the starter relay cover.
• Disconnect the starter motor lead wire 1, battery lead wire 2
and starter relay coupler 3.
• Remove the starter relay 4.
Apply 12 V to A and B terminals and check for continuity be-
tween the positive and negative terminals using the multi circuit
tester. If the starter relay clicks and continuity is found, the relay
is ok.
= Tester knob indication: Continuity test (?
?)

Do not apply a battery voltage to the starter relay for more
than five seconds, since the relay coil may overheat and
damaged.
Measure the relay coil resistance between the terminals using

the multi circuit tester. If the resistance is not within the specified
value, replace the starter relay with a new one.
Ω)
Starter relay resistance: 3 – 5 Ω
SIDE STAND/IGNITION INTERLOCK SYSTEM

PARTS INSPECTION
Check the interlock system for proper operation. If the interlock
system does not operate properly, check each component for
damage or abnormalities. If any abnormality is found, replace the
component with a new one.
SIDE-STAND SWITCH
• Remove the left frame cover. ( 6-3)
• Disconnect the side-stand switch coupler and measure the
voltage between Green and Black/White lead wires.
>)
More than 1.4 V

(Tester's battery voltage)
NOTE:
If the tester reads under 1.4V when the tester probes are not
connected, replace its battery.
GEAR POSITION SWITCH

• Disconnect the gear position switch coupler and check the con-
tinuity between Blue and Black/White with the transmission in
“NEUTRAL”.

When disconnecting and connecting the gear position
switch coupler, make sure to turn OFF the ignition switch,
or electronic parts may get damaged.
• Connect the gear position switch coupler to the wiring harness.

• Turn the ignition switch to “ON” position and side-stand to up-
right position.
Measure the voltage between Pink and Black/White lead wires
using a multi circuit tester, when shifting the gearshift lever from
low to top.
)
Gear position switch voltage: More than 0.6V
(
* Low to top gear position
* Except neutral position )
(Pink – B/W)
NOTE:
* When connecting the multi circuit tester, install the copper wire
(O.D is below 0.5 mm) to the back side of the lead wire coupler
and connect the probes of tester to them.
* Use the copper wire, its outer diameter is below 0.5 mm, to
prevent the rubber of the water proof coupler from damage.
TURN SIGNAL/SIDE-STAND RELAY

The turn signal/side-stand relay is composed of the turn signal
relay, and the side-stand relay and diode.
• Remove the turn signal/side-stand relay.
SIDE-STAND RELAY INSPECTION

First check the insulation between D and E terminals with the
tester. Then apply 12V to terminals D and C (+ to D and -
to C) and check the continuity between D and E. If there is no
continuity, replace the turn signal/side-stand relay with a new one.
DIODE INSPECTION
Measure the voltage between the terminals using the multi circuit
tester. Refer to the following table.
Unit: V
More than 1.4 V

(Tester's battery voltage)

>)
NOTE:
If the multi circuit tester reads under 1.4V when the tester probes
are not connected, replace its battery.
IGNITION SYSTEM
Engine stop switch
ECM Side-
stand
Power source relay
circuit Ignition
coil Spark plug
CKP
sensor Fuse
1.4
Wave form
arrangement
Ignition
circuit
switch
CPU
2.3
Fuse
Wave form
arrangement
circuit Battery
Cam position
sensor
Throttle Engine Gear

position oil temp. position
sensor sensor switch
NOTE:
The ignition cut-off circuit is incorporated in this ECM to prevent over-running of engine. If engine rpm reaches
9 200 r/min., this circuit cuts off the ignition primary current for all spark plugs.

Under no load, the engine can run over 9 200 r/min, even if the ignition cut-off circuit is effective,
and it may cause engine damage. Do not run the engine without load over 9 200 r/min at anytime.
TROUBLESHOOTING
* Check that the transmission is in neutral and the
No spark or poor spark engine stop switch is in the “RUN” position. Grasp
the clutch lever. Check that the fuse is not blown
and the battery is fully-charged before diagnosing.
Check the ignition system couplers for
poor connections. Looseness • Poor connection of couplers
Correct

Measure the battery voltage between

input lead wires (O/W and B/W) at the
ECM with the ignition switch in the Incorrect • Faulty ignition switch
“ON” position. • Faulty turn signal/side-stand
relay
• Faulty engine stop switch
Correct • Broken wire harness or poor
connection of related circuit
couplers
Measure the ignition coil primary peak

voltage. (7-20) Correct Inspect the spark plugs.
NOTE: This inspection method is ( 2-5)
applicable only with the multi circuit
tester and the peak volt adaptor.
Correct Incorrect
Incorrect
• Faulty spark plug (-s)
• Poor connection of the

spark plug cap (-s)
Inspect the ignition coil (-s).
Incorrect • Faulty ignition coil (-s)
(7-21)
Correct
Measure the crankshaft position sensor

peak voltage and its resistance.
(7-21, -22) Incorrect • Faulty crankshaft position
NOTE: The crankshaft position sensor sensor
peak voltage inspection is applicable
only with the multi circuit tester and
peak volt adaptor.
Correct
• Faulty ECM
• Poor connection of ignition
couplers.
INSPECTION
IGNITION COIL PRIMARY PEAK VOLTAGE
• Remove the fuel tank. (4-48)
• Disconnect the four spark plug caps.
• Connect new four spark plugs to each spark plug cap and
ground them to the ignition coil brackets.
NOTE:
Make sure that all couplers and spark plugs are connected prop-
erly and the battery used is in fully-charged condition.
Measure the No. 1 & 4 and No. 2 & 3 ignition coils primary peak
voltage in the following procedure.
• Connect the multi circuit tester with peak voltage adaptor as
follows.
No. 1 & 4 ignition coil: + Probe: White/Blue
- Probe: Orange/White
No. 2 & 3 ignition coil: + Probe: Black
- Probe: Orange/White
NOTE:
Do not disconnect the ignition coil primary wire coupler.
Peak volt adaptor

Before using the multi circuit tester and peak volt adap- Ignition coil
(No. 1 & 4)
tor, be sure to refer to the appropriate instruction manual.
• Shift the transmission into the neutral and then turn the ignition
ECM New spark plugs
switch to the “ON” position.
Battery
• Pull the clutch lever.
• Press the starter button and allow the engine to crank for a few
seconds, and then measure the ignition coil primary peak volt-
age.
• Repeat the above procedure a few times and measure the high-
est ignition coil primary peak voltage.
W Tester knob indication: Voltage ()
Ignition coil primary peak voltage: More than 150 V
#
While testing, do not touch the tester probes and spark
plugs to prevent receiving an electric shock .
If the peak voltage is lower than the specified values, inspect the
ignition coil. (7-21)
IGNITION COIL RESISTANCE

• Disconnect the spark plug caps and coupler, and remove the
ignition coil.
Measure the ignition coil resistance in both the primary and sec-
ondary windings. If the resistance is not within the standard range,
replace the ignition coil with a new one.
V Tester knob indication: Resistance (Ω)
Ignition coil resistance
Primary : 2 – 4 Ω (+
+ tap – - tap)
Secondary : 25 – 40 kΩ Ω (Plug cap – Plug cap)
CKP SENSOR PEAK VOLTAGE

• Remove the seat. ( 6-3)
• Disconnect the ECM coupler.
NOTE:
Make sure that all of the couplers are connected properly and the
battery used is in fully-charged condition.
Measure the CKP sensor peak voltage in the following proce-
dures.
• Connect the multi circuit tester with peak volt adaptor as fol-
lows.
+ Probe: White lead wire
- Probe: Black/Brown lead wire

Before using the multi circuit tester and peak volt adap-
tor, be sure to refer to the appropriate instruction manual.
• Shift the transmission into the neutral, and then turn the igni-
tion switch to the “ON” position.
• Pull the clutch lever.
• Press the starter button and allow the engine to crank for a few
seconds, and then measure the CKP sensor peak voltage. ECM
CKP sensor coupler
• Repeat the above procedure a few times and measure the high- coupler
B/Br
G/W
est peak voltage.
W
) CKP sensor
Peak
CKP sensor peak voltage: More than 2.7 V volt
adaptor
If the peak voltage is lower than the specified values, check the
peak voltage at the CKP sensor lead wire coupler.
• Remove fuel tank. ( 4-48)

• Disconnect the CKP sensor lead wire coupler and connect the
multi circuit tester with the peak volt adaptor.
+ Probe: Yellow lead wire
- Probe: Blue lead wire
• Measure the CKP sensor peak voltage at the CKP sensor lead
wire coupler in the same manner as on the ECM coupler.
)
CKP sensor peak voltage: More than 2.7 V
If the peak voltage on the CKP sensor lead wire coupler is ok but
on the ECM coupler is out of specification, the wire harness must
be replaced. If both peak voltages are out of specification, the CKP sensor
coupler
CKP sensor must be replaced and re-checked. G
Bl
B
Y
CKP sensor
Peak
volt
adaptor
CKP SENSOR RESISTANCE

Measure the resistance between the lead wires and ground. If
CKP sensor
the resistance is not specified value, the CKP sensor must be coupler
replaced.
\ 09900-25008: Multi circuit tester set CKP sensor
Ω)
CKP sensor resistance : 130 – 210 Ω (Yellow – Blue)
: ∞ Ω (Green – Ground)
COMBINATION METER
• Remove the headlight. (6-24)
• Remove the headlight housing.
• Remove the combination meter.

When disconnecting and connecting the combination
meter coupler, make sure to turn OFF the ignition switch,
or electronic parts may get damaged.
• Disassemble the combination meter as follows.

Do not attempt to disassemble the combination meter unit 2.
1 Combination meter cover

2 Combination meter unit
3 Combination meter case
4 Combination meter bracket
INSPECTION
LED (LIGHT EMITTING DIODE)
Check that the LED lights immediately after turning the ignition switch on.
If the LED fails in operation, replace the combination meter unit with a new one after checking its wire
harness/coupler.
STEPPING MOTOR
Check that the pointer calibrates itself immediately after turning
the ignition switch on and stops at starting point.
If abnormal condition is found, replace the combination meter
unit with a new one after checking its wire harness/coupler.
NOTE:
The pointer may not return to the proper position even turning the ignition switch on under low temperature
condition. In that case, you can reset the pointer to the proper position by following the instruction below:
1) With the reset switch A pressed, turn the ignition switch on.
2) Release the function switch A, 3 to 5 seconds after turning the ignition switch on.
3) Press the function switch A twice (within 1 second). → Reset
* Complete the operation within 10 seconds after the ignition switch has been turned on.
Time Ignition switch Adjuster switch A

OFF PUSH
0 ON
•
•
3 sec
•
5 sec Release
•
• Push
•
• Push→Reset
10 sec
Pointer will return to the starting point right after the completion of the operation. In the case of the pointer not
returning to the proper position after doing above, replace the combination meter unit.
FUEL LEVEL METER

• Connect each resistor between the Yellow/Black and Black/
White lead wires at the wire harness.
• Turn the ignition switch “ON” position and wait for approx. 13
seconds.
Check the display of fuel meter as shown below, If any abnormal-
ity is found, replace the combination meter with a new one.
Main wiring
harness
To fuel level
gauge
Resistor
More than Less than

Resistance 76 – 82 Ω 62 – 70 Ω 47 – 56 Ω 31 – 42 Ω
90 Ω 27 Ω
Fuel level Flicker
meter E F E FE F E FE FE F
OIL PRESSURE INDICATOR

NOTE:
Before inspecting the oil pressure switch, check if the engine oil
level is enough. (2-13)
• Remove the CKP sensor cover.
• Disconnect the oil pressure switch lead wire from the oil pres-
sure switch.
• Turn the ignition switch “ON” position.
Check if the oil pressure indicator will light, when grounding the
lead wire.
To oil pressure
switch
FUEL LEVEL GAUGE INSPECTION

• Disconnect the hose 1.
• Remove the fuel level gauge 2.
Measure the resistance at each fuel level gauge float position. If

the resistance is incorrect, replace the fuel level gauge with a
new one.
Float position Resistance

A “F” (Full) 4 – 10 Ω
B “E” (Empty) 90 – 100 Ω
Remount the fuel level gauge in the reverse order of removal.

Pay attention to the following points.
• Apply grease to the O-ring.
Use a new O-ring to prevent fuel leakage.
• Lightly tighten the fuel level gauge mounting bolts in the as-
cending order of numbers, and then tighten them to the speci-
fied torque in the above manner.
" Fuel level gauge bolt: 10 N.m (1.0 kgf.m, 7.0 lb-ft)
SPEEDOMETER
If the speedometer, odometer or trip meter does not function prop-
erly, inspect the speedometer sensor and connection of couplers.
If the speedometer sensor and connection are all right, replace
the meter with a new one.
SPEEDOMETER SENSOR
• Remove the left frame cover. (6-3)
• Remove the engine sprocket cover.
• Disconnect speedometer sensor coupler.
• Remove the speedometer sensor 1 by removing its mounting
bolt.
• Connect 12V battery, 10 kΩ resistor and the multi circuit tester
as shown right illustration.
B/R: Black with Red tracer
B/W: Black with White tracer B B/R
B: Black
Speedometer sensor
)
• Under above condition, if a suitable screwdriver touching the

pick-up surface of the speedometer sensor is moved, the tester
reading voltage changes (0V→12V or 12V→0V). If the tester
reading voltage does not change, replace the speedometer sen-
sor with a new one.
NOTE:
The highest tester reading voltage (12V) while testing is same as
battery voltage.
LAMPS
HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT
HEADLIGHT
12 V 60/55 W ............ E-24
12 V 60/55 W + 5 W .. E-02, 19
Except E-24
BRAKE LIGHT/TAILLIGHT
12 V 21/5 W
TURN SIGNAL LIGHT

12 V 21 W

If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol or
soapy water to prevent early failure.
HEADLIGHT BEAM ADJUSTMENT

• Adjust the headlight beam, both vertical and horizontal.
A: Vertical adjuster
B: Horizontal adjuster
RELAYS
TURN SIGNAL/SIDE-STAND RELAY
The turn signal/side-stand relay is composed of the turn signal
relay, side-stand relay and diode.
INSPECTION
Before removing the turn signal/side-stand relay, check the op-
eration of the turn signal light.
If the turn signal light does not illuminate, inspect the bulb, turn
signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are OK, the
turn signal relay may be faulty; therefore, replace the turn signal/
side-stand relay with a new one.
NOTE:
* Make sure that the battery is fully charged.
* Refer to the page 7-17 for the side-stand relay and diode in-
spection.
STARTER RELAY
7-14
FUEL PUMP RELAY

4-47
SWITCHES
IGNITION SWITCH REMOVAL
• Remove the headlight housing. (6-24)
• Remove the ignition switch mounting bolts using the special
tools.
\ 09930-11920: Torx bit JT40H
09930-11940: Bit holder

When reusing the ignition switch bolt, clean thread and
apply the THREAD LOCK SUPER “1322”

Inspect each switch for continuity with a tester. If any STARTER BUTTON
abnormality is found, replace the respective switch Color
O/W Y/G
assemblies with new ones. Position
IGNITION SWITCH PUSH

(For E-24)
Color HORN BUTTON
R O O/Y B/W Color
Position
B/Bl B/W
ON Position
OFF
LOCK PUSH
FRONT BRAKE SWITCH
(For Others)
Color
Color B/R B
R O O/Y B/W Gr Br Position
Position
OFF
ON
ON
OFF
LOCK REAR BRAKE SWITCH
P Color
O/G W/B
Position
LIGHTING SWITCH OFF
(Except for E-24) ON
Color CLUTCH LEVER POSITION SWITCH
O/Bl Gr O/R Y/W
Position
Color
OFF ( ) Position
B/Y B/Y
S( ) OFF
ON ( ) ON
DIMMER SWITCH OIL PRESSURE SWITCH
Color Color
W Y Y/W G/Y Ground
Position Position
HI ( ) ON (engine
LO ( ) is stopped)
OFF (engine
TURN SIGNAL SWITCH is running)
Color NOTE:
Lg Lbl B
Position
Before inspecting the oil pressure switch, check if the
L
engine oil level is enough. ( 2-13)
PUSH
R WIRE COLOR
B : Black Lbl : Light blue R : Red
PASSING LIGHT SWITCH Br : Brown Lg : Light green Y : Yellow
(Except for E-24) Gr : Gray O : Orange W : White
B/Bl : Black with Blue tracer
Color B/W : Black with White tracer
O/R Y
Position B/Y : Black with Yellow tracer
B/R : Black with Red tracer
G/Y : Green with Yellow tracer
PUSH
O/B : Orange with Black tracer
O/Bl : Orange with Blue tracer
ENGINE STOP SWITCH O/G : Orange with Green tracer
Color O/R : Orange with Red tracer
O/B O/W
Position O/W : Orange with White tracer
OFF ( ) O/Y : Orange with Yellow tracer
W/B : White with Black tracer
RUN ( ) Y/G : Yellow with Green tracer
Y/W : Yellow with White tracer
BATTERY
SPECIFICATIONS
Type designation FTX14-BS
Capacity 12V, 43.2 kC (12 Ah)/10HR
INITIAL CHARGING
Filling electrolyte
• Remove the aluminum tape 1 sealing the battery electrolyte
filler holes.
• Remove the caps 2.

NOTE:
* After filling the electrolyte completely, use the removed cap 2
as the sealed caps of battery-filler holes.
* Do not remove or pierce the sealed areas 3 of the electrolyte
container.
• Insert the nozzles of the electrolyte container into the battery’s

electrolyte filler holes, holding the container firmly so that it does
not fall. Take precaution not to allow any of the fluid to spill.
• Make sure air bubbles are coming up each electrolyte container,

and leave in this position for about more than 20 minutes.
NOTE:
If no air bubbles are coming up from a filler port, tap the bottom of
the electrolyte container two or three times.
Never remove the container from the battery.
• After confirming that the electrolyte has entered the battery

completely, remove the electrolyte containers from the battery.
Wait for about 20 minutes.
• Insert the caps into the filler holes, pressing in firmly so that the
top of the caps do not protrude above the upper surface of the
battery’s top cover.

* Never use anything except the specified battery.
* Once install the caps to the battery; do not remove the
caps.
* Do not tap the caps with a hammer when installing
them.
CORRECT INCORRECT
• Using multi circuit tester, measure the battery voltage. The tester
should indicate more than 12.5 – 12.6V (DC) as shown in the
Fig. If the battery voltage is lower than the specification, charge
the battery with a battery charger. (Refer to the recharging op-
eration)

Do not remove the caps on the battery top while charg-
ing.
NOTE:
Initial charging for a new battery is recommended if two years
have elapsed since the date of manufacture.
SERVICING
Visually inspect the surface of the battery container. If any signs
of cracking or electrolyte leakage from the sides of the battery
have occurred, replace the battery with a new one. If the battery
terminals are found to be coated with rust or an acidic white pow-
dery substance, then this can be cleaned away with sandpaper.
RECHARGING OPERATION
• Using the multi circuit tester, check the battery voltage. If the
voltage reading is less than the 12.0V (DC), recharge the bat-
tery with a battery charger.

* When recharging the battery, remove the battery from
the motorcycle.
* Do not remove the caps on the battery top while re-
charging.
Recharging time: 1.4 A for 5 to 10 hours or 6 A for one hour

Be careful not to permit the charging current to exceed
6A at any time.
• After recharging, wait for more than 30 minutes and check the
battery voltage with a multi circuit tester.
• If the battery voltage is less than the 12.5V, recharge the bat-
tery again.
• If battery voltage is still less than 12.5V, after recharging, re-
place the battery with a new one.
• When the motorcycle is not used for a long period, check the
battery every 1 month to prevent the battery discharge.
SERVICING INFORMATION 8-1
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING ...................................................................... 8- 2
FI SYSTEM MALFUNCTION CODE AND
DEFECTIVE CONDITION .............................................................. 8- 2
ENGINE .......................................................................................... 8- 4
COOLING SYSTEM ....................................................................... 8- 9
CHASSIS........................................................................................ 8-10
BRAKES ........................................................................................ 8-11
ELECTRICAL ................................................................................. 8-12
BATTERY ....................................................................................... 8-13
WIRING DIAGRAM ........................................................................... 8-14
FI SYSTEM WIRING DIAGRAM........................................................ 8-15
WIRE HARNESS, CABLE AND HOSE ROUTING........................... 8-16
WIRE HARNESS ROUTING .......................................................... 8-16
HIGH-TENSION CORD ROUTING ................................................ 8-17
ENGINE ELECTRICAL PARTS SET-UP ....................................... 8-18
CLUTCH HOSE ROUTING ............................................................ 8-19
THROTTLE CABLE ROUTING .....................................................
FUEL PUMP/FUEL LEVEL GAUGE SET-UP ...............................
8-20
8-21
8
FRONT BRAKE HOSE ROUTING ................................................ 8-22
REAR BRAKE HOSE ROUTING .................................................. 8-23
SIDE-STAND SET-UP .................................................................... 8-24
CENTER STAND SET-UP .............................................................. 8-24
SEAT LOCK CABLE ROUTING AND
LUGGAGE HOOK SET-UP ............................................................ 8-25
BRAKE PEDAL SET-UP ................................................................ 8-25
FUEL HOSE ROUTING ................................................................. 8-26
FUEL TANK SET-UP ...................................................................... 8-27
THROTTLE BODY SET-UP ........................................................... 8-28
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING.......................... 8-29
SPECIAL TOOLS .............................................................................. 8-30
TIGHTENING TORQUE ..................................................................... 8-33
SERVICE DATA ................................................................................. 8-37
8-2 SERVICING INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
c00 NO FAULT –––––––––––
Camshaft position The signal does not reach ECM for more than 4 sec. after re-
sensor ceiving the starter signal.
c11 The camshaft position sensor wiring and mechanical parts.
(Camshaft position sensor, intake cam pin, wiring/coupler con-
nection)
Crankshaft position The signal does not reach ECM for more than 3 sec. after re-
sensor ceiving the starter signal.
c12
The crankshaft position sensor wiring and mechanical parts.
(Crankshaft position sensor, wiring/coupler connection)
Intake air pressure The sensor should produce following voltage.
sensor (0.20 V sensor voltage < 4.80 V)
c13
Without the above range, c13 is indicated.
Intake air pressure sensor, wiring/coupler connection.
Throttle position The sensor should produce following voltage.
sensor (0.20 V sensor voltage < 4.80 V)
c14
Throttle position sensor, wiring/coupler connection.
Engine oil The sensor voltage should be the following.
temperature sensor (0.26 V sensor voltage < 4.77 V)
c15
Engine oil temperature sensor, wiring/coupler connection.
Intake air The sensor voltage should be the following.
temperature sensor (0.17 V sensor voltage < 4.60 V)
c21
Intake air temperature sensor, wiring/coupler connection.
Atmospheric The sensor voltage should be the following.
pressure sensor (0.20 V sensor voltage < 4.80 V)
c22
Atm. pressure sensor, wiring/coupler connection.
Tip over sensor The sensor voltage should be less than the following for more
than 4 sec. after ignition switch turns ON.
c23 (Sensor voltage < 3.90 V)
Without the above value, c23 is indicated.
Tip over sensor, wiring/coupler connection.
Ignition signal Crankshaft position sensor (pick-up coil) signal is produced but
signal from ignition coil is interrupted continuous by two times or
c24 or c25 more. In this case, the code c24 or c25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery.
Secondary throttle When no actuator control signal is supplied from ECM or com-
valve actuator munication signal does not reach ECM or operation voltage does
c28
not reach STVA motor, c28 is indicated. STVA can not operate.
STVA lead wire/coupler.
Secondary throttle The sensor should produce following voltage.
position sensor (0.20 V sensor voltage < 4.80 V)
c29
Secondary throttle position sensor, wiring/coupler connection.
Gear position signal Gear position signal voltage should be higher than the following
for more than 4 seconds.
(Gear position sensor voltage > 0.60 V)
c31
Without the above value, c31 is indicated.
Gear position sensor, wiring/coupler connection. Gearshift cam
etc.
Fuel injector signal When fuel injection signal stops, the c32, c33, c34 or c35 is
c32, c33, c34 indicated.
or c35 Injector, wiring/coupler connection, power supply to the in-
jector.
Fuel pump relay When no signal is supplied from fuel pump relay, c41 is indicated.
c41 signal Fuel pump relay, connecting lead, power source to fuel pump
relay.
Ignition switch signal Ignition switch signal is not input in the ECM.
c42
Ignition switch, lead wire/coupler.
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start, Compression too low
or is hard to start. 1. Out of adjustment valve clearance. Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3. Mistiming valves. Adjust.
4. Excessively worn piston rings. Replace.
5. Worn-down cylinder bores. Replace.
6. Too slowly starter motor cranks. See electrical section.
7. Poor seating of spark plugs. Retighten.
Plugs not sparking
1. Fouled spark plugs. Clean.
2. Wet spark plugs. Clean and dry.
3. Defective ignition coil or plug cap. Replace.
4. Defective CKP sensor. Replace.
5. Defective ECM. Replace.
6. Open-circuited wiring connections. Repair or replace.
No fuel reaching intake manifold
1. Clogged fuel filter or fuel hose. Clean or replace.
2. Defective fuel pump. Replace.
3. Defective fuel pressure regulator. Replace.
4. Defective fuel injector. Replace.
5. Defective fuel pump relay. Replace.
7. Open-circuited wiring connections. Check and repair.
Incorrect fuel/air mixture
1. Out of adjustment throttle position sensor. Adjust.
4. Defective throttle position sensor. Replace.
5. Defective crankshaft position sensor. Replace.
6. Defective intake air pressure sensor. Replace.
7. Defective atmospheric pressure sensor. Replace.
9. Defective engine oil temp. sensor. Replace.
10. Defective intake air temp. sensor. Replace.

Engine idles poorly. 1. Out of adjustment valve clearance. Adjust.
2. Poor seating of valves. Replace or repair.
3. Defective valve guides. Replace.
4. Worn down camshaft. Replace.
5. Too wide spark plug gaps. Adjust or replace.
6. Defective ignition coil or plug cap. Replace.
11. Imbalanced throttle valve. Adjust.
12. Damaged or cracked vacuum hose. Replace.
Engine stalls easily. Incorrect fuel/air mixture
1. Defective intake air pressure sensor or circuit. Repair or replace.
2. Clogged fuel filter. Clean or replace.
Improperly working fuel injector
1. Defective fuel injector. Replace.
2. No injection signal from ECM. Repair or replace.
3. Open or short circuited wiring connection. Repair or replace.
4. Defective battery or low battery voltage. Replace or recharge.
Improperly working control circuit or sensors
5. Defective camshaft position sensor. Replace.
8. Defective fuel pump relay. Replace.
Improperly working engine internal parts
1. Fouled spark plugs. Clean.
2. Defective crankshaft position sensor or ECM. Replace.
3. Clogged fuel hose. Clean.
4. Out of adjustment tappet clearance. Adjust.

Noisy engine. Excessive valve chatter
1. Too large valve clearance. Adjust.
2. Weakened or broken valve springs. Replace.
3. Worn tappet or cam surface. Replace.
4. Worn and burnt camshaft journal. Replace.
Noise seems to come from piston
1. Worn down pistons or cylinders. Replace.
2. Fouled with carbon combustion chambers. Clean.
3. Worn piston pins or piston pin bore. Replace.
4. Worn piston rings or ring grooves. Replace.
Noise seems to come from timing chain
1. Stretched chain. Replace.
2. Worn sprockets. Replace.
3. Not working tension adjuster. Repair or replace.
Noise seems to come from clutch
1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of clutch plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
4. Worn clutch release bearing. Replace.
5. Weakened clutch dampers. Replace the primary
driven gear.
Noise seems to come from crankshaft
1. Due to wear rattling bearings. Replace.
2. Worn and burnt big-end bearings. Replace.
3. Worn and burnt journal bearings. Replace.
4. Too large thrust clearance. Replace thrust bearing.
Noise seems to come from balancer
1. Worn and burnt journal bearings. Replace.
Noise seems to come from transmission
1. Worn or rubbing gears. Replace.
2. Worn splines. Replace.
3. Worn or rubbing primary gears. Replace.
4. Worn bearings. Replace.
Engine runs poorly Defective engine internal/electrical parts
in high speed range. 1. Weakened valve springs. Replace.
2. Worn camshafts. Replace.
3. Valve timing out of adjustment. Adjust.
4. Too narrow spark plug gaps. Adjust.
5. Ignition not advanced sufficiently due to poorly Replace ECM.
working timing advance circuit.
6. Defective ignition coil. Replace.
9. Clogged air cleaner element. Clean.
10. Clogged fuel hose, resulting in inadequate fuel Clean and prime.
supply to injector.
13. Defective STP sensor or STV actuator Replace.

Engine runs poorly Defective air flow system
in high speed range. 1. Clogged air cleaner element. Clean or replace.
2. Defective throttle valve. Adjust or replace.
3. Defective secoundary throttle valve. Adjust or replace.
4. Sucking air from throttle body joint. Repair or replace.
6. Imbalancing throttle valve synchronization. Adjust.
Defective control circuit or sensor
1. Low fuel pressure. Repair or replace.
6. Defective gear position sensor. Replace.
11. Defective STP sensor and/or STV actuator. Replace.
Engine lacks power. Defective engine internal/electrical parts
1. Loss of valve clearance. Adjust.
2. Weakened valve springs. Replace.
3. Out of adjustment valve timing. Adjust.
4. Worn piston rings or cylinders. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plug. Clean or replace.
7. Incorrect spark plug. Adjust or replace.
8. Clogged injector. Clean.
10. Clogged air cleaner element. Clean.
11. Imbalancing throttle valve synchronization. Adjust.
12. Sucking air from throttle valve or vacuum hose. Retighten or replace.
13. Too much engine oil. Drain out excess oil.
14. Defective fuel pump or ECM. Replace.
15. Defective crankshaft position sensor and Replace.
ignition coil.
Defective control circuit or sensor
1. Low fuel pressure. Repair or replace.
6. Defective gear position sensor. Replace.
11. Defective STP sensor and/or STV actuator. Replace.

Engine overheats. Defective engine internal parts
1. Heavy carbon deposit on piston crowns. Clean.
2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Replace or clean.
4. Sucking air from intake pipes. Retighten or replace.
5. Use incorrect engine oil. Change.
6. Defective cooling system. See cooling section.
Lean fuel/air mixture
1. Short-circuited intake air pressure sensor/lead Repair or replace.
wire.
2. Short-circuited intake air temp. sensor/lead wire. Repair or replace.
3. Sucking air from intake pipe joint. Clean or replace.
4. Defective fuel injector. Repair or replace.
The other factors
1. Ignition timing is too advanced due to defective Replace.
timing advance system (engine coolant temp.
sensor, gear position sensor, crankshaft position
sensor and ECM.)
2. Drive chain is too tight. Adjust.
Dirty or heavy 1. Too much engine oil in the engine. Check with inspection
exhaust smoke. window drain out
excess oil.
2. Worn piston rings or cylinders. Replace.
3. Worn valve guides. Replace.
4. Scored or scuffed cylinder walls. Replace.
5. Worn valves stems. Replace.
6. Defective stem seal. Replace.
7. Worn oil ring side rails. Replace.
Slipping clutch. 1. Weakened clutch springs. Replace.
2. Worn or distorted pressure plate. Replace.
3. Distorted clutch plates or clutch plate. Replace.
Dragging clutch. 1. Some clutch spring weakened while others Replace.
are not.
2. Distorted pressure plate or clutch plate. Replace.
Transmission will 1. Broken gearshift cam. Replace.
not shift. 2. Distorted gearshift forks. Replace.
3. Worn gearshift pawl. Replace.
Transmission will 1. Broken return spring on shift shaft. Replace.
not shift back. 2. Rubbing or stickly shift shaft. Repair or replace.
3. Distorted or worn gearshift forks. Replace.
Transmission jumps 1. Worn shifting gears on driveshaft or Replace.
out of gear. countershaft.
2. Distorted or worn gearshift forks. Replace.
3. Weakened stopper spring on gearshift stopper. Replace.
4. Worn gearshift cam plate. Replace.
COOLING SYSTEM
Engine overheats. 1. Not enough engine oil. Add oil.
2. Clogged with dirt or trashes oil cooler core. Clean.
3. Faulty cooling fan. Repair or replace.
4. Defective cooling fan thermo-switch. Replace.
5. Clogged oil passage. Clean.
6. Air trapped in the cooling circuit. Bleed out air.
7. Defective oil pump. Replace.
8. Use incorrect oil. Replace.
9. Defective oil relief valve or oil pressure regulator. Replace.
Engine overcools. 1. Defective cooling fan thermo-switch. Replace.
2. Extremely cold weather. Put on the oil cooler
cover.
3. Defective oil relief valve or oil pressure regulator. Replace.
CHASSIS
Heavy steering. 1. Overtightened steering stem nut. Adjust.
2. Broken bearing in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Wobbly handlebars. 1. Loss of balance between right and left front forks. Adjust.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
4. Loose steering stem nut. Adjust.
5. Worn or incorrect tire or wrong tire pressure. Adjust or replace.
6. Worn bearing/race in steering stem. Replace.
Wobbly front wheel. 1. Distorted wheel rim. Replace.
2. Worn front wheel bearings. Replace.
3. Defective or incorrect tire.Replace.
4. Loose axle or axle pinch bolt. Retighten.
5. Incorrect front fork oil level. Adjust.
Front suspension 1. Weakened springs. Replace.
too soft. 2. Not enough fork oil. Replenish.
3. Wrong weight fork oil. Replace.
4. Improperly set front fork spring adjuster. Adjust.
5. Improperly set front fork damping force adjuster. Adjust.
Front suspension 1. Too viscous fork oil. Replace.
too stiff. 2. Too much fork oil. Drain excess oil.
3. Improperly set front fork spring adjuster. Adjust.
4. Improperly set front fork damping force adjuster. Adjust.
5. Bent front axle. Replace.
Noisy front 1. Not enough fork oil. Replenish.
suspension. 2. Loose bolts on suspension. Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Replace.
2. Worn rear wheel bearing or swingarm bearings. Replace.
3. Defective or incorrect tire.Replace.
4. Worn swingarm and rear suspension bearings. Replace.
5. Loose nuts or bolts on rear suspensions. Retighten.
Rear suspension 1. Weakened spring of shock absorber. Replace.
too soft. 2. Leakage oil or gas of shock absorber. Replace.
3. Improperly set rear spring pre-load adjuster. Adjust.
4. Improperly set damping force adjuster. Adjust.
Rear suspension 1. Bent shock absorber shaft. Replace.
too stiff. 2. Bent swingarm. Replace.
3. Worn swingarm and rear suspension bearings. Replace.
4. Improperly set rear spring pre-load adjuster. Adjust.
5. Improperly set damping force adjuster. Adjust.
Noisy rear 1. Loose nuts or bolts on rear suspension. Retighten.
suspension. 2. Worn swingarm and suspension bearings. Replace.
BRAKES
Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace.
power. 2. Worn pads. Replace.
3. Oil adhesion of engaging surface of pads/shoe. Clean disc and pads.
4. Worn disc. Replace.
5. Air in hydraulic system. Bleed air.
6. Not enough brake fluid in the reservoir. Replenish.
Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with
sandpaper.
2. Tilted pad. Modify pad fitting or
replace.
3. Damaged wheel bearing. Replace.
4. Loosen front-wheel axle or rear-wheel axle. Tighten to specified
torque.
5. Worn pads. Replace.
6. Foreign material in brake fluid. Replace brake fluid.
7. Clogged return port of master cylinder. Disassemble and
clean master cylinder.
Excessive brake 1. Air in hydraulic system. Bleed air.
lever stroke. 2. Insufficient brake fluid. Replenish fluid to spe-
cified level; bleed air.
3. Improper quality of brake fluid. Replace with correct
fluid.
Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified
fluid torque.
2. Cracked hose. Replace.
3. Worn piston and/or cup. Replace piston and/or
cup.
Brake drags. 1. Rusty part. Clean and lubricate.
2. Insufficient brake lever or brake pedal Lubricate.
pivot lubrication.
ELECTRICAL
No sparking or poor 1. Defective ignition coil or plug cap or camshaft Replace.

sparking. position sensor.
2. Defective spark plugs. Replace.
5. Defective tip over sensor. Replace.
6. Open-circuited wiring connections. Check and repair.
Spark plug soon 1. Mixture too rich. Inspect FI system.
become fouled with 2. Idling speed set too high. Adjust fast idle or
carbon. throttle stop screw.
3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean or replace.
5. Too cold spark plugs. Replace with hot type
plugs.
Spark plugs become 1. Worn piston rings. Replace.
fouled too soon. 2. Worn piston or cylinders. Replace.
3. Excessive clearance of valve stems in valve Replace.
guides.
4. Worn stem oil seal. Replace.
Spark plug electrod- 1. Too hot spark plugs. Replace with cold
es overheat or burn. type plugs.
2. Loose spark plugs. Retighten.
3. Too lean mixture. Inspect FI system.
Generator does not 1. Open or short lead wires, or loose lead Repair or replace or
charge. connections. retighten.
2. Shorted, grounded or open generator coils. Replace.
3. Shorted or punctured regulator/rectifiers. Replace.
Generator does 1. Lead wires tend to get shorted or open-circuited Repair or retighten.
charge, but charging or loosely connected at terminals.
rate is below the 2. Grounded or open-circuited stator coils or Replace.
specification. generator.
3. Defective regulator/rectifier. Replace.
4. Defective cell plates in the battery. Replace the battery.
Generator 1. Internal short-circuit in the battery. Replace the battery.
overcharges. 2. Damaged or defective regulator/rectifier. Replace.
3. Poorly grounded regulator/rectifier. Repair, replace, or
connect properly.
Unstable charging. 1. Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent shorting.
2. Internally shorted generator. Replace.
3. Defective regulator/rectifier. Replace.
Starter button is not 1. Run down battery. Repair or replace.
effective. 2. Defective switch contacts. Replace.
3. Not seating properly brushes on commutator in Repair or replace.
starter motor.
4. Defective starter relay/starter interlock switch. Replace.
5. Defective main fuse. Replace.
BATTERY
“Sulfation”, acidic 1. Cracked battery case. Replace the battery.
white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery.
stance or spots on a long time.
surface of cell plates.
Battery runs down 1. Not correct the charging system. Check the generator,
quickly. regulator/rectifier and
circuit connections
and make necessary
adjustments to obtain
specified charging
operation.
2. Cell plates have lost much of their active Replace the battery,
material as a result of overcharging. and correct the charg-
ing system.
3. Internal short-circuit in the battery. Replace the battery.
4. Too low battery voltage. Recharge the battery
fully.
5. Too old battery. Replace the battery.
Battery “sulfation”. 1. Incorrect charging rate. Replace the battery.

(When not in use batteries should be checked at
least once a month to avoid sulfation.)
2. The battery was left un used in a cold climate for too Replace the battery if
long. badly sulfated.
B
Br
Lg
B/W
B/W
B/W
W
B/W
B
Br
Lg
B/W
B/W
B/W
B/Bl
B
B/Bl B/G
B R
O/R
P/B
G/Y
Br/B
B/Bl B/Bl B/W
B/W B/W B
Lg Lg Lg
Lbl
Lb Lbl
Lb O/G
B B Y
O/R O Bl/B
W W/Bl
Y Y/Bl Gr
Y/W Y/W B/W
B/Y B/W Y/B
B/Y B/Y
R
O
O/Y Gr
B/W
Gr
B/R B/R Br
B/W B/W
O/L
Only for E-24
B B/R
Bl O/Bl O/G O/Bl O/R
Gr Gr
O O/R O/B
Y/W Y/W Y/W O/W
B/Br O/B O/B B/R
O/W O/W B/L
B/Br O/G B/R Y/G
G/B W/B B
R Y/G Y/G
Y B/R
R R/B
Bl R O/W
Y Y W/Bl
STP
B B/Br
R/B R/B
B/R B/R
SENSOR
Y Y
Gr/W Y/R Y/R
Y/R R R
P/B P/B
Gr/B Gr/Y Gr/Y
Y/R Gr/B Gr/B B
Gr/W Gr/W O/W
Gr/Y Gr/R Gr/R
Y/R B/Br B/Br
Y/B Y/B
Gr/R B/W B/W
Y/R R/W Y/R Y/R
W/Bl B/W B
Bl R Y/Bl
Y P/B Y
B B/Bl W
R
O/Y O/G
O W/B
O/G
O/Bl
Bl/B
Bl Y/B
O/W
G O/Y
O/Y Y/R
O/B
O/G
Lbl
Lb Br B
B/Br B/W
B/Bl
B/Br B/Br
G/Y
R
G/Y G/Y
Bl Y/Bl Dg
Y W B/Br
O/G O/R W/Bl

P P/B B
B/W B/W B/W
Br/B
Bl Bl Gr/W
P P Gr/B
B/W B/W Gr/Y
Gr/R
G G R
B/W B/W Bl/G
Y/W
B/W
B B Dg
B B O/W
B B G/B
G/Y
B B/Y
B P/B
B B/R
R Y/G
B/W R/B
B/W
Y/Bl
Bl/B
B/Y Y/R
Y/G
R W
R/W P
Y/B
O/Y
B/Br
B/W
B/W B/W B/Bl
B/G
Bl/W
W/R
Bl
Br
Bl/Y
Bl/R
Y
B/Br
Bl/W
Bl/B
B
Br
Lg
B/W
B/W
W/B
B/W
Bl/G
Bl/R
Bl/Y
R
Br
B
B
B
B
B/W
W/B
W/R
B/W
WIRING DIAGRAM

STARTER SIDE-STAND
FI SYSTEM WIRING DIAGRAM

BUTTON SIDE- SWITCH
STAND
RELAY BATTERY
ENGINE FUEL PUMP STARTER

IGNITION COIL RELAY RELAY
STOP
SWITCH MAIN
SWITCH
1&4 2&3 CLP FUEL
SWITCH PUMP
ECM IAPS
12 IG1 W/Bl
56 IG2 FI1
B
Gr/W
78 FI2FI3
Gr/B
Gr/Y
V F.RLY
FI4 Gr/R
W AT
Y/B
E +B
O/Y
H CLT
O/W
^ NT
B/Y
J MO+
Bl
L MO-
B/R
T N+
R/B
P N-
W
K STA
Y/Bl
B G+
Y/G
d STP
Y/W
R VM
Y
#4 #3 #2
I TP
Y/R
0 VCC
P/B
FI
D THA
R CMPS
Z THO #1
Dg
F PM
B/Bl
X E2
G/B
a DON
B/Br
4 TACO
Br STPS
[ TECH
Br/B
TPS
U GP
B/G
G PA
P
G/Y STV
STVA APS
]3 E01
TS W/R IATS
OY E02 B/W
B/W
C E03
E1
B/W
B/W
EOTS
EOTS
STARTER
MOTOR

SPS
IAPS : INTAKE AIR PRESSURE SENSOR
CMPS : CAMSHAFT POSITION SENSOR
TPS : THROTTLE POSITION SENSOR CKPS
STPS : SECONDARY THROTTLE GPS
POSITION SENSOR
STVA : SECONDARY THROTTLE
TIP OVER VALVE ACTUATOR
MODE SPEEDOMETER SENSOR GP FI : FUEL INJECTOR
SELECTION SWITCH IATS : INTAKE AIR TEMPERATURE SENSOR
SWITCH APS : ATMOSPHERIC PRESSURE SENSOR
EOTS : ENGINE OIL TEMPERATURE SENSOR
CKPS : CRANKSHAFT POSITION SENSOR
SPS : SPEEDOMETER SENSOR
GPS : GEAR POSITION SWITCH
WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING
Clamp
(After binding the
Clamp lead wires, cut the
(After binding the lead wires, projection of the clamp.)
cut the projection of the clamp.)
To the right horn
Clamp
Clamp
Clamp To the left horn Clamp
(After binding the lead wires, Fuel injector lead wires/wiring harness
Frame
Clamp
Clamp
To the fuel level gauge
Clamp Clamp
CMP sensor
Clamp
Frame
Wiring harness
Clamp
Rear fender
Air cleaner box
IAT sensor
AP sensor
Clamp
Regulator/Rectifier
Engine ground Clamp
Clamp
TO sensor Regulator/Rectifier
TO sensor Clamp
INSIDE OF THE HEADLIGHT HOUSING
HIGH-TENSION CORD ROUTING

ENGINE ELECTRICAL PARTS SET-UP
Grommet
25 N.m
(2.5 kgf.m, 18.0 lb-ft)
CMP sensor
Oil pressure switch
14 N.m
(1.4 kgf.m, 10 lb-ft)
8 N .m
(0.8 kgf.m, 5.7 lb-ft)
TP sensor lead wire

11 N.m
(1.1 kgf.m, 8 lb-ft)
Seconder throttle
valve actuator Clamp
Starter motor
lead wire
Gear position switch
lead wire
Generator 0˚ – 45˚
lead wire
Oil temp.
sensor
Starter
motor
wire
6 N.m
160 N.m (0.6 kgf.m, 4.3 lb-ft)
(16.0 kgf.m, 115.5 lb-ft)
10 N.m Clamp Engine ground

(1.0 kgf.m, 7.3 lb-ft) wire
Apply bond to
the groove of
the grommet. 10 N.m
(1.0 kgf.m, 7.3 lb-ft)
CLUTCH HOSE ROUTING
Approx. 21˚
Frame pipe
Approx. 21˚
Approx. 35˚
After touching the hose

union to the stopper,
tighten the union bolt.
Wiring harness
Clutch hose
Pass through the clutch hose

behind the ignition coil bracket.
Clamp
Approx. 14˚
Approx. 5˚
Approx. 21˚

THROTTLE CABLE ROUTING
More than 2 mm (0.08 in)
Squeeze the brake lever fully and check or

adjust the clearance between the lever and
throttle cable case to provide more than 2 mm (0.08 in).
The end of the clip face to the left side.
Pass through the throttle cables

under the PAIR valve. Pass through the
No. 2 throttle cables between
the front fork and front
brake hose.
No. 1
Clamp
Pass through the throttle cable No.2
over the throttle cable No.1.
FUEL PUMP/FUEL LEVEL GAUGE SET-UP
Fuel pump
1.6 3
5
4
2 Fuel tank drain hose
1.5 3
4 2
Fuel level gauge
* Tighten the bolts in ascending order of

numbers to the specified torque.
10 N.m (1.0 kgf.m, 7.3 lb-ft)
FRONT BRAKE HOSE ROUTING
Throttle cable
Brake hose
No. 1
Approx. 35˚

Approx.
21˚ Approx. 14˚
Approx. 28˚
Approx. 7˚
Approx. 35˚
Right brake
No. 2
Clamp
FWD
Approx. 14˚

Approx. 14˚
Approx. 7˚
Approx. 35˚
Clamp
Left brake
hose No. 2

REAR BRAKE HOSE ROUTING
The clamp ends

face to backward.
After touching the

hose union to the
stopper, tighten the
union bolt.
Clamp
Approx. 28˚
Pass through the brake hose inside the guide.
After touching the hose union

to the stopper, tighten the union bolt.
SIDE-STAND SET-UP
40 N.m
(4.0 kgf.m, 29 lb-ft)
50 N.m
(5.0 kgf.m, 36 lb-ft)
CENTER STAND SET-UP
To muffler
Cushion
SEAT LOCK CABLE ROUTING AND LUGGAGE HOOK SET-UP
BRAKE PEDAL SET-UP
Fix the circlip

securely.
Apply grease to the groove.

FUEL HOSE ROUTING

Fuel connecting hose
Clip
Clip
Fuel feed hose

Water drain hose
Fuel pump
Air cleaner box
Swingarm
Water drain hose
Fuel feed hose
Wiring harness
Water drain hose

Fuel pump
Fuel connecting hose
VIEW OF A
FUEL TANK SET-UP
Cushion rubber
Cushion rubber
Align the hole of the cushion with Before installing the cushion rubber,
the protrusion on the frame tube. apply adhesive agent to its bottom.
Hole
Cushion rubber Protrusion
Outside Inside
Face the clamp end to inside.

After binding the cushion rubber, cut the projection
of the clamp end to remain about 10 mm (0.4 in).
THROTTLE BODY SET-UP
VIEW OF A
VIEW OF B
A B
Crankcase
breather hose
Intake air temp. sensor

Engine oil temp. 18 N.m
sensor
(1.8 kgf.m, 13.0 lb-ft)
10 N.m
(1.0 kgf.m, 7.0 lb-ft)
Air cleaner water drain hose

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
PAIR hose (R)
PAIR valve vacuum hose

(To No.3 throttle body)
IAP sensor
PAIR cleaner hose

To air cleaner box
Matching mark (Yellow)
Throttle cable
IAP sensor vacuum hose
Matching mark (White)

PAIR hose (L)
: Face the clamp end to Left side.

: Face the clamp end to Down side.
Pass through the PAIR vacuum hose 10 N.m (1.0 kgf.m, 7.3 lb-ft)
under the throttle cables.
IAP sensor
PAIR valve
PAIR hose
PAIR cleaner hose
PAIR valve vacuum hose

(To No.3 throttle body)
SPECIAL TOOLS
09900-18740 09900-20101
09900-06104 09900-06107 09900-06108 Hexagon socket 09900-20102
Snap ring pliers Snap ring pliers Snap ring pliers (24 mm) Vernier calipers
09900-20202 09900-20203 09900-20204 09900-20205

Micrometer Micrometer Micrometer Micrometer 09900-20508
(25 – 50 mm) (50 – 75 mm) (75 – 100 mm) (0 – 25 mm) Cylinder gauge set
09900-20602 09900-20605 09900-20607 09900-20803

Dial gauge Dial calipers Dial gauge 09900-20701 09900-20806
(1/1000 mm, 1 mm) (1/100 mm, 10 – 34 mm) (1/100 mm, 10 mm) Magnetic stand Thickness gauge
09900-22301 09900-22401 (10 – 18 mm)

09900-20805 09900-21304 09900-22302 09900-22403 (18 – 35 mm) 09900-25008
Tire depth gauge V-block (100 mm) Plastigauge Small bore gauge Multi circuit tester set
09913-10750
Compression gauge 09913-50121 09913-70210 09915-40610 09915-64510
adapter Oil seal remover Bearing installer set Oil filter wrench Compression gauge
09915-74520 09915-74540 09915-77330 09916-14510

Oil pressure gauge Oil pressure gauge Meter 09916-10911 Valve spring
hose adaptor (for high pressure) Valve lapper set compressor
09916-14521 09916-20610 09916-20620 09916-20640

Valve spring compres- Valve seat cutter head Valve seat cutter Solid pilot 09916-21111
sor attachment (N-121) head (N-122) (N-100 -4.5) Valve seat cutter set
09916-74521
09916-33210 09916-43210 Piston ring holder set
Valve guide reamer 09916-34542 09916-34580 Valve guide remover/ 09916-74550
(4.5 mm) Reamer handle Valve guide reamer installer Band
09920-53740 09921-20240
09916-84511 09917-47010 Clutch sleeve hub 09921-20210 Bearing remover
Tweezers Vacuum pump gauge holder Bearing remover set
09924-84510
09923-73210 09923-74510 Bearing installer 09924-84521 09930-11920
Bearing remover Bearing remover set Bearing installer set Torx bit JT40H
09930-11940 09930-11960 09930-30102 09930-30450 09930-44530

Bit holder Torx wrench Sliding shaft Rotor remover Generator rotor holder
09940-14911 09940-30250 09940-40211 09940-40220

09930-82710 Steering stem nut Front fork assembling Fuel pressure gauge Fuel pressure gauge
Mode selection switch wrench tool adaptor hose attachment
09940-52841 09940-52861 09941-54911

Front fork inner rod Front fork oil seal 09940-92720 09941-34513 Bearing outer race
holder installer Spring scale Steering race installer remover
09941-74911 09943-74111 09944-60210

Bearing installer Fork oil level gauge Wheel bearing remover
NOTE:
When order the special tool, please confirm whether it is available or not.
TIGHTENING TORQUE
ENGINE
Exhaust pipe bolt 23 2.3 16.5
Exhaust pipe connecting bolt 20 2.0 14.5
Muffler connecting bolt 24 2.4 17.5
Muffler mounting bolt 23 2.3 16.5
Speed sensor rotor bolt 20 2.0 14.5
Engine sprocket nut 115 11.5 83.0
Cylinder head cover bolt (M:8) 20 2.0 14.5
(M:7) 14 1.4 10.0
Spark plug 11 1.1 8.0
Cam chain guide bolt 10 1.0 7.3
Camshaft journal holder bolt 10 1.0 7.3
Cam chain tension adjuster cap bolt 35 3.5 25.5
Cam chain tension adjuster mounting bolt 10 1.0 7.3
Cylinder head bolt/nut (M:10) (Initial) 25 2.5 18.0
(Final) 37 3.7 27.0
(M:6) 10 1.0 7.3
PAIR reed valve cover bolt 10 1.0 7.3
Clutch cover bolt 11 1.1 8.0
Clutch sleeve hub nut 90 9.0 65.0
Clutch spring set bolt 10 1.0 7.3
Starter clutch bolt 25 2.5 18.0
Generator cover bolt 11 1.1 8.0
Generator rotor bolt 160 16.0 115.5
Generator stator set bolt 10 1.0 7.3
Gearshift cam stopper bolt 10 1.0 7.3
Gearshift cam stopper plate bolt 10 1.0 7.3
Oil pressure switch 14 1.4 10.0
Crankcase bolt (M:6) 11 1.1 8.0
(M:8) 26 2.6 19.0
(M:9) (Initial) 18 1.8 13.0
(Final) 32 3.2 23.0
Oil drain plug 23 2.3 16.5
Cylinder nut 10 1.0 7.3
Cam sprocket bolt 25 2.5 18.0
Oil hose union bolt
(Crankcase – Cylinder head cover) 10 1.0 7.3
(Crankcase – Cylinder head) 20 2.0 14.5
CKP sensor rotor bolt 25 2.5 18.0
CKP sensor cover bolt 11 1.1 8.0
Oil gallery plug (Cylinder head cover) 14 1.4 10.0
(Cylinder head) 20 2.0 14.5
(Main gallery) 35 3.5 25.5
(Sub-gallery) 21 2.1 15.0
Oil check valve plug 35 3.5 25.5
Oil pipe bolt 10 1.0 7.3

Balancer lever bolt 10 1.0 7.3
Balancer cover bolt 10 1.0 7.3
Piston cooling oil jet bolt 10 1.0 7.3
Oil pump mounting bolt 10 1.0 7.3
Conrod bearing cap bolt (Initial) 21 2.1 15.5
(Final) 90° (¼ turn)
Bearing retainer screw 10 1.0 7.3
Breather cover bolt 10 1.0 7.3
Oil strainer bolt 10 1.0 7.3
Oil pan bolt 11 1.1 8.0
Oil cooler mounting bolt 10 1.0 7.3
Oil cooler hose union bolt 10 1.0 7.3
FI SYSTEM
Camshaft position sensor mounting bolt 8 0.8 5.7
Intake air temperature sensor 18 1.8 13.0
Fuel delivery pipe mounting screw 5.0 0.5 3.7
Fuel pump mounting bolt 10 1.0 7.3
Throttle body connecting bolt 5.0 0.5 3.7
Actuator motor cover nut 2.0 0.2 1.5
TPS and STPS mounting screw 3.5 0.35 2.5
CHASSIS
Steering stem head nut 65 6.5 47.0
Steering stem nut 45 4.5 32.5
Front fork upper clamp bolt 23 2.3 16.5
Front fork lower clamp bolt 23 2.3 16.5
Front fork cap bolt 23 2.3 16.5
Front fork inner rod lock nut 15 1.5 11.0
Front fork damper rod bolt 40 4.0 29.0
Front axle 100 10.0 72.5
Front axle pinch bolt 23 2.3 16.5
Handlebar holder nut 45 4.5 32.5
Handlebar clamp bolt 23 2.3 16.5
Front brake master cylinder mounting bolt 10 1.0 7.3
Front brake caliper mounting bolt 25 2.5 18.0
Front brake caliper housing bolt 21 2.1 15.0
Front brake pad mounting pin 16 1.6 11.5
Brake hose union bolt 23 2.3 16.5
Clutch master cylinder mounting bolt 10 1.0 7.3
Air bleeder valve 8.0 0.8 5.7
Brake disc bolt (Front) 23 2.3 16.5
Brake disc bolt (Rear) 23 2.3 16.5
Rear brake caliper mounting bolt 26 2.6 19.0
Rear brake caliper housing bolt 37 3.7 27.0
Rear brake pad mounting pin 17 1.7 12.5
Rear brake master cylinder mounting bolt 10 1.0 7.3
Rear brake master cylinder rod lock nut 18 1.8 13.0
Front footrest mounting bolt 26 2.6 19.0
Swingarm pivot nut 120 12.0 87.0
Torque link nut (Front) 28 2.8 20.5
Torque link nut (Rear) 34 3.4 24.5
Rear shock absorber mounting bolt (Upper) 23 2.3 16.5
Rear shock absorber mounting bolt/nut (Lower) 34 3.4 24.5
Rear axle nut 100 10.0 72.5
Rear sprocket nut 102 10.2 74.0
TIGHTENING TORQUE CHART

For other bolts and nuts listed previously, refer to this chart:
Bolt Diameter Conventional or “4” marked bolt “7” marked bolt
A (mm) N. m kgf.m lb-ft N. m kgf.m lb-ft
4 1.5 0.15 1.0 2.3 0.23 1.5
5 3 0.3 2.0 4.5 0.45 3.0
6 5.5 0.55 4.0 10 1.0 7.0
8 13 1.3 9.5 23 2.3 16.5
10 29 2.9 21.0 50 5.0 36.0
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 97.5
16 105 10.5 76.0 210 21.0 152.0
18 160 16.0 115.5 240 24.0 173.5
Conventional bolt “4” marked bolt “7” marked bolt

SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STD/SPEC. LIMIT
Valve diam. 28.5
IN. ———
(1.12)
25
EX. ———
(0.98)
Valve clearance (when cold) 0.10 – 0.20
IN. ———
(0.004 – 0.008)
0.20 – 0.30
EX. ———
(0.008 – 0.012)
Valve guide to valve stem 0.010 – 0.037
IN. ———
clearance (0.0004 – 0.0015)
0.030 – 0.057
EX. ———
(0.0012 – 0.0022)
Valve guide I.D. 4.500 – 4.512
IN. & EX. ———
(0.1772 – 0.1776)
Valve stem O.D. 4.475 – 4.490
IN. ———
(0.1762 – 0.1768)
4.455 – 4.470
EX. ———
(0.1754 – 0.1760)
Valve stem deflection 0.35
IN. & EX. ———
(0.014)
Valve stem runout 0.05
IN. & EX. ———
(0.002)
Valve head thickness 0.5
IN. & EX. ———
(0.02)
Valve seat width 0.9 – 1.1
IN. & EX. ———
(0.035 – 0.043)
Valve head radial runout 0.03
IN. & EX. ———
(0.001)
Valve spring free length 38.6
INNER ———
(1.52)
IN. & EX.
40.6
OUTER ———
(1.60)
Valve spring tension 4.9 – 5.9 kgf (10.8 – 13.0 lbs)
INNER ———
at length 29.9 mm (1.18 in)
IN. & EX.
13.6 – 15.6 kgf (30.0 – 34.4 lbs)
OUTER ———
CAMSHAFT + CYLINDER HEAD Unit: mm (in)

Cam height 35.28 – 35.33 34.98
IN.
(1.389 – 1.391) (1.377)
34.18 – 34.22 33.88
EX.
(1.346 – 1.347) (1.334)
Camshaft journal oil clearance 0.032 – 0.066 0.150
IN. & EX.
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. 24.012 – 24.025
IN. & EX. ———
(0.9454 – 0.9459)

Camshaft journal O.D. 23.959 – 23.980
IN. & EX. ———
(0.9433 – 0.9441)
Camshaft runout ——— 0.10
(0.004)
Cam chain pin (at arrow “3”) 24th pin ———
Cylinder head distortion ——— 0.20
(0.008)
CYLINDER + PISTON + PISTON RING Unit: mm (in)

Compression pressure 1 180 kPa 880 kPa
(11.8 kgf/cm2
168 psi ) (
8.8 kgf/cm2
125 psi )
Compression pressure 200 kPa
difference ———
(2 kgf/cm2
28 psi )
Piston to cylinder clearance 0.015 – 0.025 0.120
(0.0006 – 0.0010) (0.0047)
Cylinder bore 81.000 – 81.015 Nicks or
(3.1890 – 3.1896) Scratches
Piston diam. 80.980 – 80.995 80.880
(3.1881 – 3.1888) (3.1842)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion 0.20
———
(0.008)
Piston ring free end gap 9.5 7.6
1st N Approx.
(0.37) (0.30)
11.0 8.8
2nd 2N Approx.
(0.43) (0.35)
Piston ring end gap 0.08 – 0.20 0.50
1st N
(0.003 – 0.008) (0.020)
0.18 – 0.30 0.50
2nd 2N
(0.007 – 0.012) (0.020)
Piston ring to groove clearance 0.180
1st ———
(0.0071)
0.150
2nd ———
(0.0059)
Piston ring groove width 1.21 – 1.23
1st ———
(0.0476 – 0.0484)
1.01 – 1.03
2nd ———
(0.0398 – 0.0406)
2.01 – 2.03
Oil ———
(0.0791 – 0.0799)
Piston ring thickness 1.175 – 1.190
1st ———
(0.0463 – 0.0469)
0.970 – 0.990
2nd ———
(0.0382 – 0.0390)
Piston pin bore 18.002 – 18.008 18.030
(0.7087 – 0.7090) (0.7098)
Piston pin O.D. 17.996 – 18.000 17.980
(0.7085 – 0.7087) (0.7079)
CONROD + CRANKSHAFT Unit: mm (in)

Conrod small end I.D. 18.010 – 18.018 18.040
(0.7091 – 0.7094) (0.7102)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.012)
Conrod big end width 20.950 – 21.000
———
(0.8248 – 0.8268)
Crank pin width 21.100 – 21.150
———
(0.8307 – 0.8327)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000
———
(1.4951 – 1.4961)
Crankshaft journal oil clearance 0.016 – 0.040 0.080
(0.0006 – 0.0016) (0.0031)
Crankshaft journal O.D. 39.976 – 40.000
———
(1.5734 – 1.5748)
Crankshaft thrust bearing 2.425 – 2.450
Right side ———
thickness (0.0955 – 0.0965)
2.430 – 2.585
Left side ———
(0.0957 – 0.1018)
Crankshaft thrust clearance 0.055 – 0.110
———
(0.0022 – 0.0043)
Crankshaft runout 0.05
———
(0.002)
OIL PUMP
Oil pressure (at 60°C, 140°F) 300 – 600 kPa
(3.0 – 6.0 kgf/cm2, 43 – 85 psi) ———
at 3 000 r/min.
CLUTCH Unit: mm (in)

Drive plate thickness No. 1, 2 3.22 – 3.38 2.92
and 3 (0.127 – 0.133) (0.115)
Drive plate claw width No. 1, 2 13.7 – 13.8 12.9
and 3 (0.5394 – 0.5433) (0.5079)
Driven plate distortion 0.10
———
(0.004)
Clutch spring free length 28.96 27.6
(1.140) (1.087)
Clutch master cylinder bore 14.000 – 14.043
———
(0.5512 – 0.5529)
Clutch master cylinder piston 13.957 – 13.984
———
diam. (0.5495 – 0.5506)
Clutch release cylinder bore 35.700 – 35.762
———
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675
———
diam. (1.4035 – 1.4045)
Clutch fluid type Brake fluid DOT 4 ———
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

Primary reduction ratio 1.509 (83/55) ———
Final reduction ratio 2.277 (41/18) ———
Gear ratios Low 2.916 (35/12) ———
2nd 1.937 (31/16) ———
3rd 1.526 (29/19) ———
4th 1.285 (27/21) ———
5th 1.136 (25/22) ———
Top 1.000 (24/24) ———
Shift fork to groove clearance 0.10 – 0.30 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1
———
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9
———
(0.189 – 0.193)
Drive chain Type RKGB50GSVZ3 ———
Links 116 links ———
319.4
20-pitch length ———
(12.57)
Drive chain slack (on side-stand) 20 – 30
———
(0.79 – 1.18)
Gearshift lever height 30 – 40
———
(1.2 – 1.6)
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM STD/SPEC. NOTE
Injector resistance 12 – 18 Ω at 20°C (68°F)
Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec.
Fuel pressure regulator operating
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
set pressure
FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR

ITEM STD/SPEC. NOTE
CMP sensor output voltage More than 3.7 V
CKP sensor resistance 134 – 202 Ω
CKP sensor peak voltage More than 2.7 V
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.5 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
EOT sensor input voltage 4.5 – 5.5 V
EOT sensor resistance Approx. 61.3 kΩ at 20°C (68°F) W–W
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor resistance Terminal –
Approx. 2.6 kΩ at 20°C (68°F)
Terminal
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 4.0 V at 100 kPa (760 mmHg)
TO sensor resistance 60 – 64 kΩ
TO sensor voltage Approx. 3.8 V
GP switch voltage More than 0.6 V (From 1st to Top)
Injector voltage Battery voltage
Ignition coil primary peak voltage More than 150 V (When cranking)
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 0.8 kΩ
STP sensor output voltage Closed Approx. 0.8 V
STV actuator resistance Approx. 4.8 – 7.2 Ω
THROTTLE BODY
ITEM STD/SPEC.
Bore size 34 mm
I.D. No. 42F0
Idle r/min. 1 100 ± 100 r/min.
Fast idle r/min. 1 500 – 1 700 r/min. (When engine is cold)
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)
ELECTRICAL Unit: mm (in)

ITEM STD/SPEC. NOTE
Firing order 1. 2 . 4 . 3
Spark plug NGK: CR8EK
Type
DENSO: U24ETR
0.6 – 0.7
Gap
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
CKP sensor peak voltage More than 2.7 V : Y : Bl
Ignition coil resistance Terminal –
Primary 2–4Ω
Terminal
Plug cap –
Secondary 25 – 40 kΩ
Plug cap
Ignition coil primary peak voltage No.1&4 : W/Bl
: O/W
More than 150 V
No.2&3 :B
: O/W
Generator coil resistance 0.2 – 1.0 Ω
Generator no-load voltage
More than 60 V (AC) at 5 000 r/min.
(when engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Starter relay resistance 3–5Ω
GP switch voltage More than 0.6 V (From 1st to top without neutral)
Battery Type designation FTX14-BS
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size HI 10 A
Headlight
LO 10 A
Signal 15 A
Ignition 15 A
Meter 10 A
Fan 10 A
Main 30 A
WATTAGE
ITEM STD/SPEC.
Headlight HI 60 W
LO 55 W
Parking or position light 5 W (Except for E-24)
Brake light/Taillight 21/5 W × 2
Turn signal light 21 W × 4
Speedometer light LED
Tachometer light LED
Turn signal indicator light LED
High beam indicator light LED
Neutral indicator light LED
FI indicator light LED
Oil pressure indicator light LED
BRAKE + WHEEL Unit: mm (in)

Rear brake pedal height 35 – 45
———
(1.4 – 1.8)
Brake disc thickness 4.8 – 5.2 4.5
Front
(0.189 – 0.205) (0.177)
5.3 – 5.7 5.0
Rear
(0.209 – 0.224) (0.197)
Brake disc runout 0.30
———
(0.012)
Master cylinder bore 15.870 – 15.913
Front ———
(0.6248 – 0.6265)
12.700 – 12.743
Rear ———
(0.5000 – 0.5017)
Master cylinder piston diam. 15.827 – 15.854
Front ———
(0.6231 – 0.6242)
12.657 – 12.684
Rear ———
(0.4983 – 0.4994)
Brake caliper cylinder bore 24.000 – 24.076
Leading ———
(0.9449 – 0.9479)
Front
27.000 – 27.076
Trailing ———
(1.0630 – 1.0660)
38.180 – 38.230
Rear ———
(1.5031 – 1.5051)
Brake caliper piston diam. 23.925 – 23.975
Leading ———
(0.9419 – 0.9439)
Front
26.920 – 26.970
Trailing ———
(1.0598 – 1.0618)
38.115 – 38.148
Rear ———
(1.5006 – 1.5019)
Brake fluid type DOT 4 ———

Wheel rim runout 2.0
Axial ———
(0.08)
2.0
Radial ———
(0.08)
Wheel rim size Front 17 × MT 3.50, 17 M/C × MT 3.50 ———
Rear 17 × MT 6.00, 17 M/C × MT 6.00 ———
Wheel axle runout 0.25
Front ———
(0.010)
0.25
Rear ———
(0.010)
TIRE Unit: mm (in)

Cold inflation tire pressure 250 kPa
Front ———
(Solo riding) (2.50 kgf/cm2, 36 psi)
250 kPa
Rear ———
(2.50 kgf/cm2, 36 psi)
Cold inflation tire pressure 250 kPa
Front ———
(Dual riding) (2.50 kgf/cm2, 36 psi)
290 kPa
Rear ———
(2.90 kgf/cm2, 42 psi)
Tire size Front 120/70 ZR17 (58W), 120/70ZR17M/C (58 W) ———
Rear 190/50 ZR17 (73W), 190/50ZR17M/C (73 W) ———
Tire type Front BRIDGESTONE: BT020F F ———
Rear BRIDGESTONE: BT020R ———
Tire tread depth 1.6
Front ———
(Recommended depth) (0.06)
2.0
Rear ———
(0.08)
SUSPENSION Unit: mm (in)

Front fork stroke 130
———
(5.12)
Front fork spring free length 322.6 316
(12.70) (12.44)
Front fork oil level (without spring, 108
———
outer tube fully compressed) (4.25)
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil ———
Front fork oil capacity (each leg) 644 ml
———
(21.76/22.68 US/Imp oz)
Front fork spring adjuster 5th groove from top ———
Front fork damping force Rebound 8 clicks out from stiffest position ———
adjuster Compression 7 clicks out from stiffest position ———
Rear shock absorber spring
1.5 ———
adjuster
Rear shock absorber damping Rebound II ———
force adjuster Compression 2 ———

Rear wheel travel 123
———
(4.8)
Swingarm pivot shaft runout 0.3
———
(0.01)
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity including 22 L
reserve (5.8/4.8 US/lmp gal)
Engine oil type SAE 10W/40, API, SF or SG
Engine oil capacity 4 200 ml
Change
(4.4/3.7 US/lmp qt)
4 800 ml
Filter change
(5.1/4.2 US/lmp qt)
5 700 ml
Overhaul
(6.0/5.0 US/lmp qt)
GSX1400K3 (’03-MODEL) 9-1
GSX1400K3 (’03-MODEL)
This chapter describes service specifications, service data and servicing procedurers which dif-
fer from those of the GSX1400K2 (’02-MODEL).
NOTE:
* Any differences between the GSX1400K2 (’02-MODEL) and GSX1400K3 (’03-MODEL)
in specifications are cleary indicated with an asterisk (*) mark.
* Please refer to the capters 1 through 8 for details which are not given in this chapter.
CONTENTS
SPECIFICATIONS................................................................................ 9- 2
ENGINE ................................................................................................ 9- 3
GEARSHIFT CAM........................................................................ 9- 3
CHASSIS .............................................................................................. 9- 3
STEERING ................................................................................... 9- 3
WIRING DIAGRAM .............................................................................. 9- 4
WIRE HARNESS ROUTING ................................................................ 9- 5
SERVICE DATA ................................................................................... 9- 6
9
9-2 GSX1400K3 (’03-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................................... 2 160 mm (85.0 in)
Overall width........................................................................... 810 mm (31.9 in)
Overall height ......................................................................... 1 140 mm (44.9 in)
Wheelbase ............................................................................. 1 520 mm (59.8 in)
Ground clearance ................................................................... 130 mm ( 5.1 in)
Seat height ............................................................................. 790 mm (31.1 in)
Dry mass ................................................................................ 228 kg (502 lbs)
ENGINE
Type....................................................................................... Four-stroke, air-cooled with SACS, DOHC
Number of cylinders................................................................ 4
Bore ....................................................................................... 81.0 mm (3.189 in)
Stroke..................................................................................... 68.0 mm (2.677 in)
3
Piston displacement................................................................ 1 402 cm (85.5 cu. in)
Compression ratio................................................................... 9.5 : 1
Fuel system ..................................................................................... Fuel injection system
Air cleaner .............................................................................. Non-woven fabric element
Starter system ........................................................................ Electric
Lubrication system.................................................................. Wet sump
Idle speed............................................................................... 1 100 ± 100 r/min
DRIVE TRAIN
Clutch..................................................................................... Wet multi-plate type
Transmission .......................................................................... 6-speed constant mesh
Gearshift pattern..................................................................... 1-down, 5-up
Primary reduction ratio............................................................ 1.509 (83/55)
Gear ratios, Low .................................................................... 2.916 (35/12)
2nd..................................................................... 1.937 (31/16)
3rd ..................................................................... 1.526 (29/19)
4th ..................................................................... 1.285 (27/21)
5th .............................................................................. 1.136 (25/22)
Top .................................................................... 1.000 (24/24)
Secondary reduction ratio ....................................................... 2.277 (41/18)
Drive chain ............................................................................. RK GB50GSVZ3, 116 links
CHASSIS
Front suspension .................................................................... Telescopic, coil spring, oil damped
Rear suspension..................................................................... Swingarm, coil spring, oil damped
Front suspension stroke.......................................................... 130 mm (5.1 in)
Rear wheel travel.................................................................... 123 mm (4.7 in)
Caster .................................................................................... 26°
Trail ........................................................................................ 105 mm (4.1 in)
Steering angle ........................................................................ 37° (right and left)
Turning radius ........................................................................ 2.8 m (9.2 ft)
Front brake............................................................................. Disc brake, twin
Rear brake ............................................................................. Disc brake
Front tire size.......................................................................... 120/70-ZR17 M/C (58W), tube less
Rear tire size .......................................................................... 190/50-ZR17 M/C (73W), tube less
ELECTRICAL
Ignition type............................................................................ Electronic ignition (Transistorized)
Ignition timing ......................................................................... 7° B.T.D.C. at 1 100 r/min
Spark plug .............................................................................. NGK CR8EK or DENSO U24ETR
Battery.................................................................................... 12V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................... Three-phase A.C. generator
Main fuse................................................................................ 30A
Fuse....................................................................................... 10/10/15/15/10/10A
Headlight ................................................................................ 12V 60/55W (H4)
Position light ........................................................................... 12V 5W ….. Except E-24
Turn signal light ...................................................................... 12V 21W
Brake light/Taillight ................................................................. 12V 21/5W × 2
Speedometer light .................................................................. LED
Tachometer light..................................................................... LED
Turn signal indicator light ........................................................ LED
Neutral indicator light .............................................................. LED
High beam indicator light ........................................................ LED
Oil pressure indicator light....................................................... LED
Fuel injection warning light...................................................... LED
CAPACITIES
Fuel tank, including reserve.................................................... 22 L (5.8/4.8 US/Imp gal)
Engine oil, oil change............................................................. 4 200 ml (4.4/3.7 US/Imp qt)
with filter change .................................................. 4 800 ml (5.1/4.2 US/Imp qt)
overhaul ............................................................... 5 700 ml (6.0/5.0 US/Imp qt)
Front fork oil (each leg) ........................................................... 644 ml (21.8/22.7 US/Imp oz)
GSX1400K3 (’03-MODEL) 9-3
ENGINE
GEARSHIFT CAM
! Gearshift cam stopper plate bolt:
13 N·m (1.3 kgf-m, 9.5 lb-ft)
Gearshift
cam stopper
plate bolt
CHASSIS
STEERING
Steering stem bearings have been changed from ball type to
taper-roller type.
Taper-roller bearing
B
Br
Lg
B/W
B/W
B/W
W
B/W
B
Br
Lg
B/W
B/W
B/W
B/Bl
B
B/Bl B/G
B R
O/R
P/B
G/Y
Br/B
B/Bl B/Bl B/W
B/W B/W B
Lg Lg Lg
Lb
Lbl Lbl
Lb O/G
B B Y
O/R O Bl/B
W W/Bl
Y Y/Bl Gr
Y/W Y/W B/W
B/Y B/W Y/B
B/Y B/Y
R
O
O/Y Gr
B/W
Gr
B/R Br
B/W
O/L
Only for E-24
B B/R
Bl O/Bl O/G O/Bl O/R
Gr Gr
O O/R O/B
Y/W Y/W Y/W O/W
B/Br O/B O/B B/R
O/W O/W B/L
B/Br O/G B/R Y/G
G/B W/B B
R Y/G Y/G
Y B/R
R R/B
Bl R O/W
Y Y W/Bl
STP
B B/Br
R/B R/B
B/R B/R
SENSOR
Y Y
Gr/W Y/R Y/R
Y/R R R
P/B P/B
Gr/B Gr/Y Gr/Y
Y/R Gr/B Gr/B B
Gr/W Gr/W O/W
Gr/Y Gr/R Gr/R
Y/R B/Br B/Br
Y/B Y/B
Gr/R B/W B/W
Y/R R/W Y/R Y/R
W/Bl B/W B
Bl R Y/Bl
Y P/B Y
B B/Bl W
R
O/Y O/G
O W/B
O/G
O/Bl
Bl/B
Bl Y/B
O/W
G O/Y
O/Y Y/R
O/B
O/G
Lbl
Lb Br B
B/Br B/W
B/Bl
B/Br B/Br
G/Y
R
G/Y G/Y
Bl Y/Bl Dg
Y W B/Br
O/G O/R W/Bl

P P/B B
B/W B/W B/W
Br/B
Bl Bl Gr/W
P P Gr/B
B/W B/W Gr/Y
Gr/R
G G R
B/W B/W Bl/G
Y/W
B/W
B B Dg
B B O/W
B B G/B
G/Y
B B/Y
B P/B
B B/R
R Y/G
B/W R/B
B/W
Y/Bl
Bl/B
B/Y Y/R
Y/G
R W
R/W P
Y/B
O/Y
B/Br
B/W
B/W B/W B/Bl
B/G
Bl/W
W/R
Bl
Br
Bl/Y
Bl/R
Y
B/Br
Bl/W
Bl/B
B
Br
Lg
B/W
B/W
W/B
B/W
Bl/G
Bl/R
Bl/Y
R
Br
B
B
B
B
B/W
W/B
W/R
B/W
WIRING DIAGRAM
GSX1400K3 (’03-MODEL) 9-4

GSX1400K3 (’03-MODEL) 9-5
WIRE HARNESS ROUTING

Clamp Clamp
(After binding the lead wires, (After binding
cut the projection of the clamp.) the lead wires,
cut the projection
of the clamp.)
To the right horn
Clamp
Clamp
Clamp To the left horn
(After binding the lead wires, Clamp
cut the projection of the clamp.) Frame Fuel injector lead wires/wiring harness
Clamp Clamp
Main wiring harness

To the fuel level gauge Clamp
Clamp
CMP sensor
Clamp Clamp
Frame
Clamp
Wiring
harness
Rear fender
IAT sensor Air cleaner box
AP sensor
Clamp
Regulator/Rectifier
Engine ground
Clamp
Clamp
TO sensor
Regulator/Rectifier
Clamp
TO sensor
9-6 GSX1400K3 (’03-MODEL)
SERVICE DATA
Valve diam. IN. 28.5 —
(1.12)
EX. 25 —
(0.98)
Valve clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem IN. 0.010 – 0.037 —
clearance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve guide I.D. IN. & EX. 4.500 – 4.512 —
(0.1772 – 0.1776)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length INNER — 38.6
(IN. & EX.) (1.52)
OUTER — 40.6
(1.60)
Valve spring tension 49 – 59 N, 4.9 – 5.9 kgf
(IN. & EX.) INNER (10.8 – 13.0 lbs) —
136 – 156 N, 13.6 – 15.6 kgf
OUTER (30.0 – 34.4 lbs) —
GSX1400K3 (’03-MODEL) 9-7

Cam height IN. 35.28 – 35.33 34.98
(1.389 – 1.391) (1.377)
EX. 34.18 – 34.22 33.88
(1.346 – 1.347) (1.334)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —
(0.9454 – 0.9459)
Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —
(0.9433 – 0.9441)
Camshaft runout — 0.10
(0.004)
Cam chain pin (at arrow “3”) 24th pin —
Cylinder head distortion — 0.20
(0.008)

(11.8 kgf/cm2, 168 psi) (8.8 kgf/cm2, 125 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm2, 28 psi)
(0.0006 – 0.0010) (0.0047)
(3.1890 – 3.1896) Scratches
Piston diam. 80.980 – 80.995 80.880
(3.1881 – 3.1888) (3.1842)
Cylinder distortion — 0.20
(0.008)
Piston ring free end gap 1st N Approx. 9.5 (0.37) 7.6
(0.30)
2nd 2N Approx. 11.0 (0.43) 8.8
(0.35)
Piston ring end gap 1st N 0.08 – 0.20 0.50
(0.003 – 0.008) (0.020)
2nd 2N 0.18 – 0.30 0.50
(0.007 – 0.012) (0.020)
Piston ring to groove clearance 1st — 0.180
(0.0071)
2nd — 0.150
(0.0059)
Piston ring groove width 1st 1.21 – 1.23 —
(0.0476 – 0.0484)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.01 – 2.03 —
(0.0791 – 0.0799)
9-8 GSX1400K3 (’03-MODEL)

Piston ring thickness 1st 1.175 – 1.190 —
(0.0463 – 0.0469)
2nd 0.970 – 0.990 —
(0.0382 – 0.0390)
Piston pin bore 18.002 – 18.008 18.030
(0.7087 – 0.7090) (0.7098)
Piston pin O.D. 17.996 – 18.000 17.980
(0.7085 – 0.7087) (0.7079)

(0.7091 – 0.7094) (0.7102)
(0.004 – 0.008) (0.012)
Conrod big end width 20.950 – 21.000 —
(0.8248 – 0.8268)
Crank pin width 21.100 – 21.150 —
(0.8307 – 0.8327)
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000 —
(1.4951 – 1.4961)
(0.0006 – 0.0016) (0.0031)
Crankshaft journal O.D. 39.976 – 40.000 —
(1.5734 – 1.5748)
Crankshaft thrust bearing Right side 2.425 – 2.450 —
thickness (0.0955 – 0.0965)
Left side 2.430 – 2.585 —
(0.0957 – 0.1018)
Crankshaft thrust clearance 0.055 – 0.110 —
(0.0022 – 0.0043)
Crankshaft runout — 0.05
(0.002)
OIL PUMP
(3.0 – 6.0 kgf/cm2, 43 – 85 psi) —
at 3 000 r/min.
GSX1400K3 (’03-MODEL) 9-9

and 3 (0.127 – 0.133) (0.115)
and 3 (0.5394 – 0.5433) (0.5079)
Driven plate distortion — 0.10
(0.004)
(1.140) (1.087)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5512 – 0.5529)
Clutch master cylinder piston 13.957 – 13.984 —
diam. (0.5495 – 0.5506)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)
Clutch fluid type Brake fluid DOT 4 —
DRIVE TRAIN Unit: mm (in) Except ratio

Primary reduction ratio 1.509 (83/55) —
Final reduction ratio 2.277 (41/18) —
Gear ratios Low 2.916 (35/12) —
2nd 1.937 (31/16) —
3rd 1.526 (29/19) —
4th 1.285 (27/21) —
5th 1.136 (25/22) —
Top 1.000 (24/24) —
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type RKGB50GSVZ3 —
Links 116 links —
20-pitch — 319.4
length (12.57)
Drive chain slack (on side-stand) 20 – 30 —
(0.79 – 1.18)
Gearshift lever height 30 – 40 —
(1.2 – 1.6)

ITEM STD/SPEC. NOTE
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
set pressure
9-10 GSX1400K3 (’03-MODEL)

ITEM STD/SPEC. NOTE
CMP sensor peak voltage More than 3.7 V
IAT sensor resistance Approx. 2.6 kΩ at 20°C (68°F) Terminal –
Terminal
THROTTLE BODY
ITEM STD/SPEC.
Bore size 34 mm
I.D. No. 42F0
Idle r/min. 1 100 ± 100 r/min.
Fast idle r/min. 1 500 – 1 700 r/min. (When engine is cold)
(0.08 – 0.16 in)
GSX1400K3 (’03-MODEL) 9-11

ITEM STD/SPEC. NOTE
Firing order 1·2·4·3
Spark plug Type NGK: CR8EK
DENSO: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
CKP sensor peak voltage More than 2.7 V +: Y -: Bl
Ignition coil resistance Primary 2–4Ω Terminal –
Terminal
Secondary 25 – 40 kΩ Plug cap –
Plug cap
Ignition coil primary peak voltage No.1&4 +: W/Bl
-: O/W
More than 150 V
No.2&3 +: B
-: O/W
Generator no-load voltage More than 60 V (AC) at 5 000 r/min.
(When engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min.
Battery Type designa- FTX14-BS
tion
Fuze size HI 10 A
Headlight
LO 10 A
Signal 15 A
Ignition 15 A
Meter 10 A
Fan 10 A
Main 30 A
9-12 GSX1400K3 (’03-MODEL)
WATTAGE Unit: W
ITEM STD/SPEC.
Headlight HI 60 W
LO 55 W

Rear brake pedal height 35 – 45 —
(1.4 – 1.8)
Brake disc thickness Front 4.8 – 5.2 4.5
(0.189 – 0.205) (0.177)
Rear 5.3 – 5.7 5.0
(0.209 – 0.224) (0.197)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6265)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diam. Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Leading 24.000 – 24.076 —
(0.9449 – 0.9479)
Front
Trailing 27.000 – 27.076 —
(1.0630 – 1.0660)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston diam. Leading 23.925 – 23.975 —
(0.9419 – 0.9439)
Front
Trailing 26.920 – 26.970 —
(1.0598 – 1.0618)
Rear 38.115 – 38.148 —
(1.5006 – 1.5019)
Brake fluid type DOT 4 —
GSX1400K3 (’03-MODEL) 9-13

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel rim size Front 17 × MT 3.50, 17 M/C × MT 3.50 —
Rear 17 × MT 6.00, 17 M/C × MT 6.00 —
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
TIRE Unit: mm (in)

Cold inflation tire pressure Front 250 kPa —
(Solo riding) (2.50 kgf/cm2, 36 psi)
Rear 250 kPa —

(2.50 kgf/cm2, 36 psi)
(Dual riding) (2.50 kgf/cm2, 36 psi)
Rear 290 kPa —

(2.90 kgf/cm2, 42 psi)
Tire size Front 120/70 ZR17 (58W), 120/70ZR17M/C (58 W) —
Rear 190/50 ZR17 (73W), 190/50ZR17M/C (73 W) —
Tire type Front BRIDGESTONE: BT020F F —
Rear BRIDGESTONE: BT020R —
Tire tread depth Front — 1.6
Rear — 2.0
(0.08)
9-14 GSX1400K3 (’03-MODEL)

Front fork stroke 130 —
(5.12)
(12.70) (12.44)
Front fork oil level (without spring, 108 —
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil —
Front fork oil capacity (each leg) 644 ml —
(21.76/22.68 US/Imp oz)
Front fork spring adjuster 5th groove from top —
Front fork damping force Rebound 8 clicks out from stiffest position —
adjuster Compression 7 clicks out from stiffest position —
Rear shock absorber spring 1.5 —
adjuster
Rear shock absorber damping Rebound II —
force adjuster Compression 2 —
Rear wheel travel 123 —
(4.8)
Swingarm pivot shaft runout — 0.3
(0.01)
FUEL + OIL
ITEM STD/SPEC. NOTE
Engine oil type SAE 10W-40, API, SF or SG
Engine oil capacity Change 4 200 ml
(4.4/3.7 US/lmp qt)
Filter change 4 800 ml
(5.1/4.2 US/lmp qt)
Overhaul 5 700 ml
(6.0/5.0 US/lmp qt)
GSX1400K4 (’04-MODEL) 10-1
GSX1400K4 (’04-MODEL)
NOTE:
* Any differences between the GSX1400K3 (’03-MODEL) and GSX1400K4 (’04-MODEL)
in specifications are cleary indicated with an asterisk (*) mark.
CONTENTS
SPECIFICATIONS ............................................................................. 10- 2
SERVICE DATA ................................................................................ 10- 3
PERIODIC MAINTENANCE CHART ................................................ 10-12
WIRING DIAGRAM ........................................................................... 10-13
10
10-2 GSX1400K4 (’04-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 160 mm (85.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ...................................................................................... 1 140 mm (44.9 in)
Wheelbase .......................................................................................... 1 520 mm (59.8 in)
Ground clearance................................................................................ 130 mm (5.1 in)
Seat height .......................................................................................... 790 mm (31.1 in)
Dry mass............................................................................................. 228 kg (502 lbs).............. E-24
* 229 kg (504 lbs) ............. E-02, 19
ENGINE
Type..................................................................................................... Four-stroke, air-cooled with SACS, DOHC
Number of cylinders ............................................................................ 4
Bore .................................................................................................... 81.0 mm (3.189 in)
Stroke.................................................................................................. 68.0 mm (2.677 in)
Piston displacement ............................................................................ 1 402 cm3 (85.5 cu. in)
Compression ratio ............................................................................... 9.5 : 1
Fuel system......................................................................................... Fuel injection system
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 100 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio........................................................................ 1.509 (83/55)
Gear ratios, Low .............................................................................. 2.916 (35/12)
2nd ............................................................................... 1.937 (31/16)
3rd................................................................................ 1.526 (29/19)
4th ................................................................................ 1.285 (27/21)
5th ................................................................................ 1.136 (25/22)
Top ............................................................................... 1.000 (24/24)
Secondary reduction ratio ................................................................... 2.277 (41/18)
Drive chain .......................................................................................... RK GB50GSVZ3, 116 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm, coil spring, oil damped
Front suspension stroke ...................................................................... 130 mm (5.1 in)
Rear wheel travel ................................................................................ 123 mm (4.7 in)
Caster ................................................................................................. 26°
Trail...................................................................................................... 105 mm (4.1 in)
Steering angle ..................................................................................... 37° (right & left)
Turning radius ..................................................................................... 2.8 m (9.2 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17 M/C (58W), tubeless
Rear tire size ....................................................................................... 190/50ZR17 M/C (73W), tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 7° B.T.D.C. at 1 100 r/min
Spark plug ........................................................................................... NGK CR8EK or DENSO U24ETR
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 30 A
Fuse ....................................................................................................* 10/10/15/10/10/10 A
Headlight ............................................................................................. 12 V 60/55 W (H4)
Position light ........................................................................................ 12 V 5 W............................. Except E-24
Turn signal light ................................................................................... 12 V 21 W × 4
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
Speedometer light ............................................................................... LED
Tachometer light.................................................................................. LED
Turn signal indicator light .................................................................... LED
Neutral indicator light .......................................................................... LED
High beam indicator light .................................................................... LED
Oil pressure indicator light .................................................................. LED
Fuel injection warning light.................................................................. LED
CAPACITIES
Fuel tank, including reserve ................................................................ 22 L (5.8/4.8 US/Imp gal)
Engine oil, oil change .......................................................................... 4 200 ml (4.4/3.7 US/Imp qt)
with filter change ............................................................... 4 800 ml (5.1/4.2 US/Imp qt)
overhaul............................................................................. 5 700 ml (6.0/5.0 US/Imp qt)
GSX1400K4 (’04-MODEL) 10-3
SERVICE DATA
(1.12)
EX. 25 —
(0.98)
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem IN. 0.010 – 0.037 —
clearance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
(0.1772 – 0.1776)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
(0.014)
(0.002)
(0.02)
(0.035 – 0.043)
(0.001)
(IN. & EX.) (1.52)
OUTER — 40.6
(1.60)
Valve spring tension 49 – 59 N
(IN. & EX.) INNER (4.9 – 5.9 kgf, 10.8 – 13.0 lbs) —
136 – 156 N
OUTER (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
10-4 GSX1400K4 (’04-MODEL)

Cam height IN. 35.28 – 35.33 34.98
(1.389 – 1.391) (1.377)
EX. 34.18 – 34.22 33.88
(1.346 – 1.347) (1.334)
(0.0013 – 0.0026) (0.0059)
(0.9454 – 0.9459)
(0.9433 – 0.9441)
(0.004)
(0.008)

(2 kgf/cm2, 28 psi)
(0.0006 – 0.0010) (0.0047)
(3.1890 – 3.1896) Scratches
Piston diam. 80.980 – 80.995 80.880
(3.1881 – 3.1888) (3.1842)
(0.008)
(0.30)
2nd 2N Approx. 11.0 (0.43) 8.8
(0.35)
(0.003 – 0.008) (0.020)
2nd 2N 0.18 – 0.30 0.50
(0.007 – 0.012) (0.020)
(0.0071)
2nd — 0.150
(0.0059)
(0.0476 – 0.0484)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.01 – 2.03 —
(0.0791 – 0.0799)
GSX1400K4 (’04-MODEL) 10-5

(0.0463 – 0.0469)
2nd 0.970 – 0.990 —
(0.0382 – 0.0390)
Piston pin bore 18.002 – 18.008 18.030
(0.7087 – 0.7090) (0.7098)
Piston pin O.D. 17.996 – 18.000 17.980
(0.7085 – 0.7087) (0.7079)

(0.7091 – 0.7094) (0.7102)
(0.004 – 0.008) (0.012)
(0.8248 – 0.8268)
Crank pin width 21.100 – 21.150 —
(0.8307 – 0.8327)
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000 —
(1.4951 – 1.4961)
(0.0006 – 0.0016) (0.0031)
(1.5734 – 1.5748)
Crankshaft thrust bearing Right side 2.425 – 2.450 —
thickness (0.0955 – 0.0965)
Left side 2.430 – 2.585 —
(0.0957 – 0.1018)
(0.0022 – 0.0043)
(0.002)
OIL PUMP
(3.0 – 6.0 kgf/cm2 , 43 – 85 psi) —
at 3 000 r/min
10-6 GSX1400K4 (’04-MODEL)

and 3 (0.127 – 0.133) (0.115)
and 3 (0.5394 – 0.5433) (0.5079)
(0.004)
(1.140) (1.087)
(0.5512 – 0.5529)
Clutch master cylinder piston 13.957 – 13.984 —
diam. (0.5495 – 0.5506)
(1.4055 – 1.4079)
diam. (1.4035 – 1.4045)

2nd 1.937 (31/16) —
3rd 1.526 (29/19) —
4th 1.285 (27/21) —
5th 1.136 (25/22) —
Top 1.000 (24/24) —
(0.004 – 0.012) (0.020)
(0.197 – 0.201)
(0.189 – 0.193)
Links 116 links —
20-pitch — 319.4
length (12.57)
(0.79 – 1.18)
(1.2 – 1.6)

ITEM STD/SPEC. NOTE
set pressure
GSX1400K4 (’04-MODEL) 10-7

ITEM STD/SPEC. NOTE
IAT sensor resistance Approx. 2.6 kΩ at 20°C (68°F) Terminal –
Terminal
THROTTLE BODY
ITEM STD/SPEC.
Bore size 34 mm
I.D. No. 42F0
Idle r/min 1 100 ± 100 r/min
Fast idle r/min 1 500 – 1 700 r/min (When engine is cold)
(0.08 – 0.16 in)
10-8 GSX1400K4 (’04-MODEL)

ITEM STD/SPEC. NOTE
DENSO: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Terminal
Plug cap
-: O/W
More than 150 V
No.2&3 +: B
-: O/W
Generator no-load voltage More than 60 V (AC) at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Battery Type designa- FTX14-BS
tion
Fuse size HI 10 A
Headlight
LO 10 A
Signal 15 A
Ignition * 10 A
Fuel 10 A
Fan 10 A
Main 30 A
GSX1400K4 (’04-MODEL) 10-9
WATTAGE Unit: W
ITEM STD/SPEC.
Headlight HI 60 W
LO 55 W

(1.4 – 1.8)
(0.189 – 0.205) (0.177)
Rear 5.3 – 5.7 5.0
(0.209 – 0.224) (0.197)
(0.012)
(0.6248 – 0.6265)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
(0.6231 – 0.6242)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
(0.9449 – 0.9479)
Front
Trailing 27.000 – 27.076 —
(1.0630 – 1.0660)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
(0.9419 – 0.9439)
Front
Trailing 26.920 – 26.970 —
(1.0598 – 1.0618)
Rear 38.115 – 38.148 —
(1.5006 – 1.5019)
10-10 GSX1400K4 (’04-MODEL)

(0.08)
Radial — 2.0
(0.08)
Wheel rim size Front 17 M/C × MT 3.50 —
Rear 17 M/C × MT 6.00 —
(0.010)
Rear — 0.25
(0.010)
TIRE Unit: mm (in)

(Solo riding) (2.50 kgf/cm2 , 36 psi)
Rear 250 kPa —

(2.50 kgf/cm2 , 36 psi)
(Dual riding) (2.50 kgf/cm2 , 36 psi)
Rear 290 kPa —

(2.90 kgf/cm2 , 42 psi)
Tire size Front 120/70ZR17M/C (58 W) —
Rear 190/50ZR17M/C (73 W) —
Rear — 2.0
(0.08)
GSX1400K4 (’04-MODEL) 10-11

(5.12)
(12.70) (12.44)
(21.76/22.68 US/Imp oz)
Front fork damping force Rebound 8 clicks out from stiffest position —
adjuster Compression 7 clicks out from stiffest position —
adjuster
(4.8)
(0.01)
FUEL + OIL
ITEM STD/SPEC. NOTE
Engine oil type SAE 10W-40, API, SF or SG
(4.4/3.7 US/lmp qt)
(5.1/4.2 US/lmp qt)
Overhaul 5 700 ml
(6.0/5.0 US/lmp qt)
10-12 GSX1400K4 (’04-MODEL)
PERIODIC MAINTENANCE CHART

Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 2 12 24 36 48
Air cleaner element — I I R I
Spark plugs — I R I R
Valve clearance — — — — I
Engine oil R R R R R
Engine oil filter R — — R —
Fuel line — I I I I
Replace fuel hose every 4 years.
Idle speed I I I I I
Throttle valve synchronization — — I — I
PAIR (air supply) system — — I — I
Throttle cable play I I I I I
Clutch hose — I I I I
Replace every 4 years.
Clutch fluid — I I I I
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles)
Brakes I I I I I
Brake hoses — I I I I
Brake fluid — I I I I
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Exhaust pipe bolts and muffler bolt and nut T — T — T
Chassis bolts and nuts T T T T T
I = Inspect and adjust, clean, lubricate or replace as necessary
R= Replace
T= Tighten
WIRING DIAGRAM
SP : SPEEDOMETER LIGHT
TA : TACHOMETER LIGHT
N : NEUTRAL INDICATOR LIGHT
H : HIGH BEAM INDICATOR LIGHT
IGNITION SWITCH
HANDLEBAR SWITCH (R)
O : OIL PRESSURE INDICATOR LIGHT
R : TURN SIGNAL INDICATOR LIGHT (R) ON ENGINE IGNITION COIL FUEL
L : TURN SIGNAL INDICATOR LIGHT (L) OFF STOP FRONT BRAKE LEVEL FUEL TO
LOCK SWITCH LIGHT SWITCH GAUGE PUMP IAT
SENSOR SENSOR
SPEEDOMETER P
OFF OFF FUEL ECM
ON AP
HAZARD
RUN ON PUMP OFF
STARTER RELAY SENSOR
SWITCH BUTTON REAR BRAKE
LIGHTSWITCH
OFF
ON PUSH ON
OFF
Gr/W
Bl/W
W/Bl
Bl/W
Or/R
Gr/R
Gr/B
Or/R
Gr/R
Gr/R
B/Br
B/Br
B/Br
B/Br
Br/B
Or/Y
Gr/Y
B/Br
Bl/G
Bl/G
O/W
Bl/B
B/Bl
Bl/R
Bl/B
Bl/R
Y/Bl
B/W
W/R
Bl/Y
B/W
B/W
Bl/Y
W/R
B/W
Y/W
O/G
O/G
O/B
G/B
B/G
G/Y
G/Y
Y/G
B/R
O/Y
R/B
Y/B
Y/R
B/Y
Y/R
P/B
Y/B
Dg
Dg
Br
Br
Bl
W
R
R
P
Y
W/Bl
O/W
O/W
B/W
B/W
W/B
O/G
Y/B
Y/R
B/Br
Bl/B
O/W
B/Bl
B/W
B/W
O/G
B/G
O/B
G/Y
R/B
O/Y
B/R
Y/G
B/Y
Lbl
B
Lg
Lg
Gr
Gr
Br
O
O
R
B
P
Y
Br/B
Bl/B
O/W
B/W
B/W
B/W
W/B
O/G
O/G
O/G
O/G
B/G
O/R
O/B
G/Y
O/Y
Y/G
P/B
Y/B
Lbl
Lg
Lg
Br
O
R
B
Y
FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B
B/W B/W B/W B
HEADLIGHT
Y W/B W/B
B/W B/W B/W
W Br Br
Br Br
B/W B/W
LICENSE PLATE LIGHT
POSITION LIGHT
B B B B
B/W B/W B/W B
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)
W/Bl
B/Br
O/Bl
B/Bl
B/Bl
B/Bl
B/W
Y/Bl
B/W
B/W
B/W
Y/W
O/G
G/B
O/Y
Lbl
Lg
Br
O
O
B
B/Br
B/Bl
ON
Y/Bl
B/W
B/W
B/W
B/W
R/W
B/W
O/R
G/Y
Y/G
P/B
B/Y
Bl
W
B
B
B
B
B
B
R
B
B
B
B
B
P
B/Bl
B/W
Y/W
O/R
B/Y
B/Y
Lbl
OFF
Lg
W
B
Gr/W
W/Bl
Gr/B
Gr/R
Gr/Y
B/Br
O/Bl
Bl/B
R/W
Y/Bl
O/G
O/B
R/B
B/R
O/Y
O/Y
Y/R
P/B
Lbl
Br
Bl
W
G
R
R
Y
FAN MOTOR
SWITCH
B/W
HORN (L) HORN (R) IAP
B/W
B/W
B/W
O/G
G/Y
Bl
Bl
B
B
B
Y
P
Bl
B
SENSOR
CMP
Gr/W
Gr/B
Gr/R
Gr/Y
B/Br
R/B
B/R
Y/R
P/B
FREE REGULATOR/
SENSOR
R
Y
PUSH PUSH ON RECTIFIER

OFF 1: MAIN 30 A
HORN PASSING LIGHT CLUTCH FAN SPEED NEUTRAL
SWITCH SWITCH LEVER MOTOR SENSOR SWITCH STARTER STARTER BATTERY
GENERATOR MOTOR RELAY
L HI POSITION OIL
PUSH LO SWITCH PRESSURE
R
DIMMER SWITCH
OT FREE
TURN SIGNAL SWITCH
GSX1400K4 (’04-MODEL) 10-13

FUSE BOX PUSH
LIGHT SWITCH SENSOR
1. HEAD (HI) 10 A SIDE-STAND
HANDLEBAR SWITCH (L) 2. HEAD (LO) 10 A CKP SWITCH
3. METER 10 A SENSOR
4. IGNITION 10 A
5. SIGNAL 15 A
6. FAN 10 A
Gr/W
Gr/B
Gr/R
B/Br
Gr/Y
B/Br
B/R
R/B
Y/R
Y/R
Y/R
Y/R
P/B
R
R
Y
Bl
R
B
Y
Bl
B
Y
STP TP
SENSOR SENSOR
INJECTOR
STV ACTUATOR
GSX1400K5/UDK5 (’05-MODEL) 11-1
GSX1400K5/UDK5 (’05-MODEL)
NOTE:
* Any differences between the GSX1400K4 (’04-MODEL) and GSX1400K5/UDK5
(’05-MODEL) in specifications are cleary indicated with an asterisk (*) mark.
CONTENTS
SPECIFICATIONS ............................................................................. 11- 2
SERVICE DATA ................................................................................ 11- 3
IMMOBILIZER ................................................................................... 11-12
EXHAUST PIPE/MUFFLER INSTALLATION ................................... 11-14
CENTER STAND INSTALLATION ................................................... 11-15
WIRE HARNESS ROUTING ............................................................. 11-16
WIRING DIAGRAM ........................................................................... 11-17
11
11-2 GSX1400K5/UDK5 (’05-MODEL)
SPECIFICATIONS
IMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 160 mm (85.0 in)
Overall width ....................................................................................... 810 mm (31.9 in)
Overall height ...................................................................................... 1 140 mm (44.9 in)
Wheelbase .......................................................................................... 1 520 mm (59.8 in)
Ground clearance................................................................................ 130 mm (5.1 in)
Seat height .......................................................................................... 790 mm (31.1 in)
Dry mass.............................................................................................* 225 kg (496 lbs).................................... E-24
* 226 kg (498 lbs).................................... E-02, 19
ENGINE
Type..................................................................................................... Four-stroke, air-cooled with SACS, DOHC
Number of cylinders ............................................................................ 4
Bore .................................................................................................... 81.0 mm (3.189 in)
Stroke.................................................................................................. 68.0 mm (2.677 in)
Piston displacement ............................................................................ 1 402 cm3 (85.5 cu. in)
Compression ratio ............................................................................... 9.5 : 1
Fuel system......................................................................................... Fuel injection
Air cleaner ........................................................................................... Non-woven fabric element
Starter system..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 100 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 5-up
Primary reduction ratio........................................................................ 1.509 (83/55)
Gear ratios, Low .............................................................................. 2.916 (35/12)
2nd ............................................................................... 1.937 (31/16)
3rd................................................................................ 1.526 (29/19)
4th ................................................................................ 1.285 (27/21)
5th ................................................................................ 1.136 (25/22)
Top ............................................................................... 1.000 (24/24)
Secondary reduction ratio ................................................................... 2.277 (41/18)
Drive chain .......................................................................................... RK GB50GSVZ3, 116 links
CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Swingarm type, coil spring, oil damped
Front suspension stroke ...................................................................... 130 mm (5.1 in)
Rear wheel travel ................................................................................ 123 mm (4.7 in)
Caster ................................................................................................. 26°
Trail...................................................................................................... 105 mm (4.1 in)
Steering angle ..................................................................................... 37° (right and left)
Turning radius ..................................................................................... 2.8 m (9.2 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17 M/C (58W), tubeless
Rear tire size ....................................................................................... 190/50ZR17 M/C (73W), tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 7° B.T.D.C. at 1 100 r/min
Spark plug ........................................................................................... NGK CR8EK or DENSO U24ETR
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 30 A
Fuse .................................................................................................... 10/10/15/10/10/10 A
Headlight ............................................................................................. 12 V 60/55 W (H4)
Position light ........................................................................................ 12 V 5 W.................................................. Except E-24
Turn signal light ................................................................................... 12 V 21 W × 4
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
Speedometer light ............................................................................... LED
Tachometer light.................................................................................. LED
Turn signal indicator light .................................................................... LED
Neutral indicator light .......................................................................... LED
High beam indicator light .................................................................... LED
Oil pressure indicator light .................................................................. LED
Fuel injection warning light.................................................................. LED
* Immobilizer indicator light ................................................................. LED
CAPACITIES
Fuel tank, including reserve ................................................................ 22.0 L (5.8/4.8 US/Imp gal)
Engine oil, oil change ....................................................................... 4 200 ml (4.4/3.7 US/Imp qt)
with filter change............................................................. 4 800 ml (5.1/4.2 US/Imp qt)
overhaul .......................................................................... 5 700 ml (6.0/5.0 US/Imp qt)
These specifications are subject to change without notice.
GSX1400K5/UDK5 (’05-MODEL) 11-3
SERVICE DATA
(1.12)
EX. 25 —
(0.98)
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem clear- IN. 0.010 – 0.037 —
ance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
(0.1772 – 0.1776)
Valve stem O.D. IN. 4.475 – 4.490 —
(0.1762 – 0.1768)
EX. 4.455 – 4.470 —
(0.1754 – 0.1760)
(0.014)
(0.002)
(0.02)
(0.035 – 0.043)
(0.001)
(IN. & EX.) (1.52)
OUTER — 40.6
(1.60)
Valve spring tension 49 – 59 N
(IN. & EX.) INNER (4.9 – 5.9 kgf, 10.8 – 13.0 lbs) —
136 – 156 N
OUTER (13.6 – 15.6 kgf, 30.0 – 34.4 lbs) —
11-4 GSX1400K5/UDK5 (’05-MODEL)

Cam height IN. 35.28 – 35.33 34.98
(1.389 – 1.391) (1.377)
EX. 34.18 – 34.22 33.88
(1.346 – 1.347) (1.334)
(0.0013 – 0.0026) (0.0059)
(0.9454 – 0.9459)
(0.9433 – 0.9441)
(0.004)
(0.008)

(2 kgf/cm2, 28 psi)
(0.0006 – 0.0010) (0.0047)
(3.1890 – 3.1896) Scratches
Piston diam. 80.980 – 80.995 80.880
(3.1881 – 3.1888) (3.1842)
(0.008)
(0.30)
2nd 2N Approx. 11.0 (0.43) 8.8
(0.35)
(0.003 – 0.008) (0.020)
2nd 2N 0.18 – 0.30 0.50
(0.007 – 0.012) (0.020)
(0.0071)
2nd — 0.150
(0.0059)
(0.0476 – 0.0484)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.01 – 2.03 —
(0.0791 – 0.0799)
GSX1400K5/UDK5 (’05-MODEL) 11-5

(0.0463 – 0.0469)
2nd 0.970 – 0.990 —
(0.0382 – 0.0390)
Piston pin bore 18.002 – 18.008 18.030
(0.7087 – 0.7090) (0.7098)
Piston pin O.D. 17.996 – 18.000 17.980
(0.7085 – 0.7087) (0.7079)

(0.7091 – 0.7094) (0.7102)
(0.004 – 0.008) (0.012)
(0.8248 – 0.8268)
Crank pin width 21.100 – 21.150 —
(0.8307 – 0.8327)
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000 —
(1.4951 – 1.4961)
(0.0006 – 0.0016) (0.0031)
(1.5734 – 1.5748)
Crankshaft thrust bearing thickness Right side 2.425 – 2.450 —
(0.0955 – 0.0965)
Left side 2.430 – 2.585 —
(0.0957 – 0.1018)
(0.0022 – 0.0043)
(0.002)
OIL PUMP
Oil pressure (at 60 °C, 140 °F) 300 – 600 kPa
(3.0 – 6.0 kgf/cm2 , 43 – 85 psi) —
at 3 000 r/min
11-6 GSX1400K5/UDK5 (’05-MODEL)

and 3 (0.127 – 0.133) (0.115)
and 3 (0.5394 – 0.5433) (0.5079)
(0.004)
(1.140) (1.087)
(0.5512 – 0.5529)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5506)
(1.4055 – 1.4079)
diam. (1.4035 – 1.4045)

2nd 1.937 (31/16) —
3rd 1.526 (29/19) —
4th 1.285 (27/21) —
5th 1.136 (25/22) —
Top 1.000 (24/24) —
(0.004 – 0.012) (0.020)
(0.197 – 0.201)
(0.189 – 0.193)
Links 116 links —
20-pitch — 319.4
length (12.57)
(0.79 – 1.18)
(1.2 – 1.6)
GSX1400K5/UDK5 (’05-MODEL) 11-7

ITEM STD/SPEC. NOTE
Injector resistance 12 – 18 Ω at 20 °C (68 °F)
set pressure

ITEM STD/SPEC. NOTE
EOT sensor resistance Approx. 61.3 kΩ at 20 °C (68 °F) W–W
IAT sensor resistance Approx. 2.6 kΩ at 20 °C (68 °F) Terminal –
Terminal
THROTTLE BODY
ITEM STD/SPEC.
Bore size 34 mm
I.D. No. 42F0
Idle r/min 1 100 ± 100 r/min
Fast idle r/min 1 500 – 1 700 r/min (When engine is cold)
(0.08 – 0.16 in)
11-8 GSX1400K5/UDK5 (’05-MODEL)

ITEM STD/SPEC. NOTE
DENSO: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Terminal
Plug cap
-: O/W
More than 150 V
No.2&3 +: B
-: O/W
Generator no-load voltage More than 60 V (AC) at 5 000 r/min
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Battery Type FTX14-BS
designation
Fuse size HI 10 A
Headlight
LO 10 A
Signal 15 A
Ignition 10 A
Fuel 10 A
Fan 10 A
Main 30 A
GSX1400K5/UDK5 (’05-MODEL) 11-9
WATTAGE Unit: W
ITEM STD/SPEC.
Headlight HI 60 W
LO 55 W
* Immobilizer indicator light LED

(1.4 – 1.8)
(0.189 – 0.205) (0.177)
Rear 5.3 – 5.7 5.0
(0.209 – 0.224) (0.197)
(0.012)
(0.6248 – 0.6265)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
(0.6231 – 0.6242)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
(0.9449 – 0.9479)
Front
Trailing 27.000 – 27.076 —
(1.0630 – 1.0660)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
(0.9419 – 0.9439)
Front
Trailing 26.920 – 26.970 —
(1.0598 – 1.0618)
Rear 38.115 – 38.148 —
(1.5006 – 1.5019)
11-10 GSX1400K5/UDK5 (’05-MODEL)

(0.08)
Radial — 2.0
(0.08)
Wheel rim size Front 17 M/C × MT 3.50 —
Rear 17 M/C × MT 6.00 —
(0.010)
Rear — 0.25
(0.010)
TIRE Unit: mm (in)

(Solo riding) (2.50 kgf/cm2 , 36 psi)
Rear 250 kPa —

(2.50 kgf/cm2 , 36 psi)
(Dual riding) (2.50 kgf/cm2 , 36 psi)
Rear 290 kPa —

(2.90 kgf/cm2 , 42 psi)
Tire size Front 120/70ZR17M/C (58 W) —
Rear 190/50ZR17M/C (73 W) —
Rear — 2.0
(0.08)
GSX1400K5/UDK5 (’05-MODEL) 11-11

(5.12)
(12.70) (12.44)
(21.76/22.68 US/Imp oz)
Front fork damping force adjuster Rebound 8 clicks out from stiffest position —
Compression 7 clicks out from stiffest position —
adjuster
(4.8)
(0.01)
FUEL + OIL
ITEM STD/SPEC. NOTE
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
(4.4/3.7 US/lmp qt)
(5.1/4.2 US/lmp qt)
Overhaul 5 700 ml
(6.0/5.0 US/lmp qt)
11-12 GSX1400K5/UDK5 (’05-MODEL)
IMMOBILIZER
• The immobilizer, an anti-theft system, is installed as a standard equipment.
• The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through
the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start.
Immobi-antenna
Indicator light
Transponder Immobilizer
antenna
ECM
ID
GSX1400K5/UDK5 (’05-MODEL) 11-13
OPERATION
• When the ignition switch is turned ON with the engine stop switch in ON, the immobi-antenna and ECM
are powered ON.
The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison
between the key ID and ECM ID.
With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make com-
parison with its own ID, and if it matches, the engine is made ready to start.
Transponder
Immobi-antenna
R O
Ignition switch OFF
ON
ECM
Also, when the ignition switch is turned ON, the indicator light
Flashing Lighting
flashes as many as the number of IDs registered in ECM. There-
after, if the IDs are in agreement, the indicator light turns on for 2 registered Normal
two seconds to notify of completion in successful communica- 3 registered Normal
tion. 4 registered Normal
If the indicator light flashes fast, it notifies of communication Abnormal
error or disagreement of ID. Fast flashing
Approx. 1.6 sec. Approx. 2.0 sec.
NOTE:
If the indicator light flashes fast, turn the ignition switch OFF
Indicator light
then ON to make judgment again as there is possible misjudg-
ment due to environmental radio interference.
!
When the battery performance is lowered in winter
(low temperature), the system may at times makes a
re-judgment at the time of beginning the starter motor
operation. In this case, the indicator light operation
starts immediately after the starter operation.
11-14 GSX1400K5/UDK5 (’05-MODEL)
EXHAUST PIPE/MUFFLER INSTALLATION
23 N·m
(2.3 kgf-m, 16.5 lb-ft)
Use a new connector.

Use a new gasket.
Apply PERMATEX 1372.
24 N·m
23 N·m (2.4 kgf-m, 17.5 lb-ft)
(2.3 kgf-m, 16.5 lb-ft)
23 N·m
(2.3 kgf-m, 16.5 lb-ft)
20 N·m
(2.0 kgf-m, 14.4 lb-ft)
I.D. No. 4 Use a new connector.

I.D. No. 3
I.D. No. 1 Apply PERMATEX 1372.
I.D. No. 2
GSX1400K5/UDK5 (’05-MODEL) 11-15
CENTER STAND INSTALLATION

11-16 GSX1400K5/UDK5 (’05-MODEL)
WIRE HARNESS ROUTING

Clamp Clamp
(After binding the lead wires, (After binding the lead wires,
cut the projection of the clamp.) cut the projection of the clamp.)
To the right horn
Clamp
Clamp
To the left horn Frame Clamp
Clamp
(After binding the lead wires, Fuel injector lead wire/Wiring harness
Clutch hose Clamp
Clamp
Wiring harness
Clutch hose
To the fuel level gauge
Clamp
Wiring Clamp
harness CMP sensor
Clamp
Clamp
Frame
Air cleaner box
Clamp Wiring
harness
Rear fender
IAT sensor
AP sensor
Clamp Regulator/
Rectifier
Engine ground
TO sensor Clamp
TO sensor
Clamp Clamp
SP : SPEEDOMETER LIGHT
TA : TACHOMETER LIGHT
N : NEUTRAL INDICATOR LIGHT
HANDLEBAR SWITCH (R)
H : HIGH BEAM INDICATOR LIGHT
O : OIL PRESSURE INDICATOR LIGHT IGNITION SWITCH
R : TURN SIGNAL INDICATOR LIGHT (R) ON ENGINE IGNITION COIL FUEL
L : TURN SIGNAL INDICATOR LIGHT (L) OFF STOP FRONT BRAKE LEVEL FUEL TO
LOCK SWITCH LIGHT SWITCH GAUGE PUMP IAT
SENSOR SENSOR
SPEEDOMETER P FUEL ECM
OFF OFF
ON AP
RUN ON PUMP
HAZARD STARTER OFF
REAR BRAKE RELAY SENSOR
SWITCH BUTTON
B
LIGHT SWITCH
B/W
OFF
ON PUSH ON
OFF
Y/B
Y/R
B/W
B/W
P
Y
R
R
R
R
B
R
G
W
Bl
Br
Br
Dg
Dg
Y/B
Y/R
B/Y
Y/R
Y/B
P/B
R/Y
G/Y
G/Y
Y/G
B/R
R/B
B/G
O/B
G/B
O/G
O/G
Y/W
Y/Bl
B/W
W/R
Bl/Y
B/W
Bl/Y
W/R
B/W
O/W
Bl/B
Bl/R
Bl/B
Bl/R
B/W
Bl/G
B/Bl
Bl/G
R/Bl
B/Br
B/Br
B/Br
B/Br
Or/Y
Gr/Y
B/Br
Gr/R
Or/R
Or/R
Gr/R
Gr/R
Br/B
Bl/W
W/Bl
Bl/W
Gr/B
Gr/W
R
O
B
Br
Gy
Lg
Lbl
Y/B
Y/R
O/R
B/R
Y/G
O/B
O/G
Y/W
B/W
B/W
W/B
O/W
O/W
O/W
B/Bl
W/Bl
P
Y
R
B
O
Lg
B/Y
G/Y
R/B
B/G
O/G
B/W
Bl/B
B/Br
WIRING DIAGRAM
R
O
Br
O/G
B
O
Lg
Lbl
Y/G
O/B
O/G
Y/W
W/B
O/W
R
B
Lg
P/B
Y/B
G/Y
B/G
O/R
O/G
B/W
B/W
Bl/B
Br/B
FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B
B/W B/W B/W B
HEADLIGHT
Y W/B W/B
B/W B/W B/W
W Br Br
Br Br
B/W B/W
LICENSE PLATE LIGHT
POSITION LIGHT
B B B B
B/W B/W B/W B
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)
B
O
Lg
Lbl
B
B
B
B
R
B/Y
Y/W
B/W
Y/Bl
B/W
B/Bl
W/Bl
O/Y
G/B
Y/W
B/W
B/W
B/Bl
B/Bl
O/Bl
B/Br
G
R/Y
O/Y
ON
B/W
R/Bl
P
B
B
B
B
B
B
R
R
B
B
B
B
B
W
Bl
P/B
B/Y
G/Y
Y/G
O/R
OFF
Y/Bl
B/W
B/W
B/W
B/W
R/W
B/W
B/Bl
B/Br
B
W
Lg
Lbl
B/Y
B/Y
O/R
Y/W
B/W
B/Bl
Y
Y
R
R
O
G
W
Bl
Br
Lbl
FAN MOTOR
Y/R
P/B
R/B
B/R
O/Y
O/Y
O/B
O/G
R/W
Y/Bl
Bl/B
O/Bl
Gr/Y
B/Br
Gr/B
Gr/R
W/Bl
Gr/W
HORN (L) HORN (R) SWITCH
IAP
R
B
G
Y
P
B
B
B
Bl
B
G
Bl
Bl
B
B/W
Bl
G/Y
B/R
B/W
B/W
B/W
SENSOR
CMP
FREE REGULATOR/
Y
R
SENSOR
Y/R
P/B
R/B
B/R
ON
Gr/Y
B/Br
Gr/B
Gr/R
PUSH PUSH
Gr/W
OFF
RECTIFIER 1: MAIN 30 A
HORN PASSING LIGHT CLUTCH FAN IMMOBILIZER SPEED GP
SWITCH SWITCH LEVER MOTOR SENSOR SWITCH STARTER STARTER BATTERY
GENERATOR MOTOR RELAY
L HI POSITION OIL
PUSH LO SWITCH PRESSURE
R SWITCH
DIMMER FREE
TURN SIGNAL SWITCH OT PUSH
LIGHT SWITCH FUSE BOX SENSOR
SIDE-STAND
HANDLEBAR SWITCH (L) 1. HEAD (HI) 10 A CKP
2. HEAD (LO) 10 A
SWITCH
SENSOR
3. METER 10 A
4. IGNITION 10 A
5. SIGNAL 15 A
6. FAN 10 A
Y
R
R
Y/R
Y/R
Y/R
Y/R
P/B
B/R
R/B
B/Br
Gr/Y
B/Br
Gr/B
Gr/R
Gr/W
Y
Y
R
B
Bl
Y
B
Bl
STP TP
SENSOR SENSOR
INJECTOR
STV ACTUATOR
GSX1400K5/UDK5 (’05-MODEL) 11-17
Prepared by
2nd Ed. May, 2005

1st Ed. March, 2001
Part No. 99500-39222-01E
Printed in Japan
404
Printed in Japan
K2 K3 K4 K5

GSX1400 Manual PART TWO

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CHASSIS

EXTERIOR PARTS ............................................................................ 6- 2

FRONT BRAKE ................................................................................. 6-49

PILLION RIDER HANDLE

SEAT TAIL COVER

• Remove the fasteners.(6-5)

• Disconnect the seat lock cable A.

• Disconnect the brake light/taillight lead wire coupler.

FASTENER REMOVAL AND REINSTALLATION

• Remove the front axle and the front wheel.

INSPECTION AND DISASSEMBLY

• Remove both dust seals by using the oil seal remover.

• Remove the wheel bearings by using the special tool.

REASSEMBLY AND REMOUNTING

A Front fork cap bolt

REMOVAL AND DISASSEMBLY

• Loosen the front fork upper clamp bolts 1.

• Loosen the front fork lower clamp bolts.

• Remove the protecter 3.

• Loosen and remove the front fork cap bolt.

• Remove the spacer 1, washers 2 and spring 3.

• Remove the adjuster rod.

• Remove the dust seal.

• Remove the oil seal stopper ring.

• Remove the front axle pinch bolts.

• Pull the inner tube out of the outer tube.

• Remove the following parts.

REASSEMBLY AND REMOUNTING

• Install the oil lock piece A into the inner tube.

DAMPER ROD BOLT

• Install the adjusting rod 1.

• Install the fork spring.

FRONT FORK CAP BOLT

• Apply fork oil lightly to the O-ring.

• Install the front fork protecter.

• Tighten the front fork upper and lower clamp bolts.

• Install the front fender and brake hose guides.

DAMPING FORCE ADJUSTMENT

STEERING AND HANDLEBAR

A Handlebar clamp bolt

REMOVAL AND DISASSEMBLY

• Disconnect all the lead wire couplers in the headlight housing.

• Remove the brake hose joint mounting bolt.

• Remove the headlight housing brackets.

• Remove the speedometer.

• Remove the rear view mirrors.

• Disconnect the front brake light switch lead wire coupler 1.

• Remove the handlebar balancers.

• Disconnect the clutch switch lead wires 4.

• Remove the left handlebar switch box 5.

• Loosen the handlebar holder nuts.

• Remove the handlebar clamp bolt caps.

• Remove the steering stem upper bracket by removing the steer-

• Remove the dust seal 1, the steering stem upper bearing 2.

• Remove the ignition switch. (7-29)

• Remove the handlebar holder.

INSPECTION AND DISASSEMBLY

• Remove the steering stem lower bearing inner race using a

REASSEMBLY AND REMOUNTING

• Remove the fasteners.(6-5)

• Remove the ignition switch. (7-29)

• Install the ignition switch. (7-29)

• Install the throttle cable case. (Throttle cable routing: 8-20)

• Install the rear shock absorbers. (6-42)