Engine Mechanical:
Complete overhaul, inspection, and assembly of the 4-cylinder engine block, crankshaft, pistons, connecting rods, cylinder head, valves, camshafts, timing system, and lubrication system.
Fuel System:
Detailed coverage of the electronic fuel injection (EFI) system, throttle bodies, fuel pump, fuel pressure regulator, injectors, and fuel tank.
Ignition System:
Information on ignition coils, spark plugs, ECU control, and timing.
Cooling System:
Radiator, cooling fan, water pump, thermostat, hoses, and coolant specifications.
Transmission And Drivetrain:
Clutch operation, gearbox disassembly, inspection, and reassembly; final drive inspection.
Suspension System:
Front telescopic forks (including damping and spring preload adjustments), rear monoshock absorber, linkage system, and wheel bearing service.
Brake System:
Front and rear disc brakes, hydraulic system, brake fluid specifications, caliper servicing, master cylinder overhaul, and pad replacement.
Electrical System:
Battery, charging system (stator, rectifier/regulator), starter motor, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays, and instrument panel.
Chassis And Frame:
Frame inspection, steering head bearing service, and swingarm maintenance.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, and minor body component servicing.
Maintenance:
Routine checks, fluid changes (oil, coolant, brake fluid), filter replacements, chain adjustment and lubrication, spark plug service, and general inspection procedures.
Troubleshooting:
Diagnostic procedures for common problems related to starting, running, electrical systems, and performance issues. Includes symptom-based troubleshooting charts.
Repair And Overhaul:
Detailed step-by-step instructions for dismantling, inspecting, repairing, and reassembling major mechanical and electrical components.
Specifications And Measurements:
Torque specifications for all fasteners, critical clearances (e.g., valve lash, piston ring gap), bore and stroke dimensions, and electrical system values.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for the entire motorcycle, color-coded for clarity.
Depth Level:
Comprehensive (from basic maintenance to full engine rebuild)
Target Audience:
Professional motorcycle technicians and advanced DIY enthusiasts.
Engine Type:
Inline-Four, liquid-cooled, DOHC, 16 valves
Bore X Stroke:
67.0 mm x 42.5 mm
Compression Ratio:
12.8:1
Horsepower:
Approx. 120-125 hp (at crankshaft, may vary by region/tuning)
Torque:
Approx. 68-70 Nm (at crankshaft, may vary by region/tuning)
Fuel Delivery:
Fuel Injection with Dual Throttle Valve (SDTV) system
Fuel Type:
Unleaded Premium Gasoline
Oil Type:
API SG, SH, SJ, SL grade, SAE 10W-40 or 10W-50 (refer to manual for specific recommendations)
Oil Capacity:
Approx. 3.4 L (with filter change)
Crash Test Ratings:
N/A (Motorcycle specific safety ratings not typically provided in the same way as cars)
Braking System:
Dual 310 mm petal discs with radial-mount monobloc calipers (front), Single 220 mm petal disc with single-piston caliper (rear).
Suspension Adjustability:
Adjustable front forks (preload, compression, rebound) and rear shock (preload, rebound).
Lighting:
Multi-reflector halogen headlight, LED taillight.
Tires:
Sport-oriented radial tires. Front: 120/70ZR17 M/C (58W), Rear: 180/55ZR17 M/C (73W).
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning Inspection:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 24,000 km (15,000 miles).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain.
Brake Fluid Replacement:
Every 2 years or as needed.
Coolant Replacement:
Every 3 years or as needed.
Valve Lash Inspection:
Every 24,000 km (15,000 miles).
Engine Oil:
SAE 10W-40 or 10W-50 API SG, SH, SJ, SL (Suzuki brand recommended)
Coolant:
Suzuki Super Long Life Coolant or equivalent ethylene glycol-based coolant (50% mixture with distilled water).
Common Issues:
Occasional issues might include regulator/rectifier failure (common across many Japanese bikes of this era), potential stator issues, and normal wear-and-tear on clutch plates and suspension components with high mileage.
