Covered Systems:
Engine Mechanical, Engine Control System, Cooling System, Fuel System, Ignition System, Starting System, Charging System, Lubrication System, Exhaust System, Clutch System, Transmission System, Drive Shaft, Frame, Suspension System (Front & Rear), Brake System (Front & Rear), Wheels & Tires, Electrical System, Lighting System, Instruments & Controls, Bodywork
Type:
Workshop Service Repair Manual
Engine:
Complete disassembly, assembly, inspection, troubleshooting, and repair of the engine. Includes cylinder head, cylinder block, crankshaft, pistons, connecting rods, valves, timing system, oil pump, cooling system, and lubrication system.
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel filter, fuel tank, and evaporative emission control system (charcoal canister).
Cooling System:
Radiator, cooling fan, water pump, thermostat, coolant hoses, and coolant specifications.
Ignition System:
Ignition coils, spark plugs, ECU control, and troubleshooting of ignition faults.
Transmission:
Clutch system (operation, maintenance, components), gearbox (internal components, shifting mechanism, lubrication), and drive shaft.
Brakes:
Front and rear brake systems, including master cylinders, calipers, brake pads, brake discs, brake lines, brake fluid specifications, bleeding procedures, and troubleshooting.
Suspension:
Front telescopic forks (disassembly, assembly, oil levels, adjustments) and rear monoshock suspension (shock absorber, linkage, adjustments).
Electrical System:
Complete electrical system diagnosis and repair, including battery, starter motor, alternator, wiring harnesses, fuses, relays, lighting (headlight, taillight, indicators), combination meter, horn, and ECU.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, handlebars, instruments, and other exterior components.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustments, brake adjustments, tire pressure checks, and general upkeep.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon problems across all vehicle systems, including fault codes.
Repair:
Detailed, step-by-step instructions for repairing and rebuilding all major mechanical and electrical components.
Inspection:
Component inspection procedures with specific tolerances and specifications for wear and damage.
Wiring Diagrams:
Comprehensive electrical wiring diagrams with component identification and circuit tracing information.
Depth:
Comprehensive coverage suitable for both DIY enthusiasts and professional mechanics, detailing everything from routine maintenance to complete engine rebuilds and electrical system diagnostics.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 16-valve, Inline-four
Bore X Stroke:
65.0 mm x 45.2 mm
Compression Ratio:
12.5:1
Horsepower:
Approx. 98 HP @ 12,000 rpm (claimed)
Torque:
Approx. 6.2 kgf·m (60.8 Nm; 44.8 lb·ft) @ 10,000 rpm (claimed)
Fuel Delivery:
Fuel Injection, SDTV (Suzuki Dual Throttle Valve)
Fuel Type:
Unleaded gasoline, minimum 95 octane
Oil Type:
Suzuki Genuine 4-stroke Motorcycle Oil (API SG, SF, SE, SH, SJ) or equivalent SAE 10W-40, 15W-40, 10W-30, 20W-40, 20W-50.
Coolant Type:
Suzuki Super Coolant or equivalent ethylene glycol-based antifreeze with demineralized water (50:50 mixture).
Oil Change:
Every 6,000 km or 6 months, whichever comes first.
Oil Filter Change:
Every 12,000 km or 12 months.
Spark Plug Replacement:
Refer to manual for specific intervals, typically around 12,000-24,000 km depending on plug type.
Valve Clearance Check:
Refer to manual, typically around 24,000 km.
Common Problems:
While generally reliable, potential issues could include normal wear and tear on clutch components, occasional electrical gremlins if not maintained, and common chain/sprocket wear. The manual would detail specific diagnostics for these.