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DL650AOWNER’S MANUAL

99011-27G62-03A

DL

650A

Part No. 99011-27G62-03AJuly, 2008 ENTK

5 mm5 mmNo.646 DL650A 99011-27G62-03A 2/1No.646 DL650A 99011-27G62-03A 2/1 DIC184(TDP006) DIC157

This owner’s manual containsimportant safety information.Please read it carefully.

WARNINGFailure to follow these safetyprecautions may increase yourrisk of injury:

Wear a helmet, eye protec-tion, and bright protectiveclothing.Don’t ride after consumingalcohol or other drugs.Slow down on slippery sur-faces, unfamiliar terrain, orwhen visibility is reduced.Read owner’s manual care-fully.

K9 Printed in Japan300 TAKATSUKA, MINAMI, HAMAMATSU, JAPAN

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5 mmNo.646 DL650A 99011-27G62-03A 2/1 Black

California Proposition 65 Warning

WARNINGEngine exhaust, some of its constituents, and certain product com-ponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

IMPORTANT

WARNING/CAUTION/NOTEPlease read this manual and fol-low its instructions carefully. Toemphasize special information,the symbol and the wordsWARNING, CAUTION and NOTEhave special meanings. Pay spe-cial attention to the messageshighlighted by these signal words:

NOTE: Indicates special informa-tion to make maintenance easieror instructions clearer.

WARNINGs and CAUTIONs arearranged like this:

FOREWORD

Motorcycling is one of the mostexhilarating sports and to ensureyour riding enjoyment, you shouldbecome thoroughly familiar withthe information presented in thisOwner’s Manual before riding themotorcycle.

The proper care and maintenancethat your motorcycle requires isoutlined in this manual. By follow-ing these instructions explicitlyyou will ensure a long trouble-freeoperating life for your motorcycle.This motorcycle also conforms tothe U.S Environmental ProtectionAgency emission regulationswhich apply to new motorcycles.The proper adjustment of enginecomponents is necessary for thismotorcycle to comply with theEPA regulations. Therefore,please follow the maintenanceinstructions closely to ensureemission compliance. Your Suzukidealer has experienced techni-cians that are trained to provideyour machine with the best possi-ble service with the right tools andequipment.

WARNINGIndicates a potential hazardthat could result in death orinjury.

CAUTIONIndicates a potential hazardthat could result in motorcycledamage.

WARNING-or-CAUTIONThe first part will describe aPOTENTIAL HAZARD andWHAT CAN HAPPEN if youignore the WARNING or CAU-TION.

The second part will describeHOW TO AVOID THE HAZARD.

All information, illustrations andspecifications contained in thismanual are based on the latestproduct information available atthe time of publication. Due toimprovements or other changes,there may be some discrepan-cies between information in thismanual and your motorcycle.Suzuki reserves the right to makeproduction changes at any time,without notice and without incur-ring any obligation to make thesame or similar changes to vehi-cles previously built or sold.

Suzuki Motor Corporationbelieves in conservation and pro-tection of Earth’s naturalresources. To that end, weencourage every vehicle owner torecycle, trade in, or properly dis-pose of, as appropriate, usedmotor oil, coolant, and other flu-ids, batteries and tires.

© COPYRIGHT SUZUKI MOTORCORPORATION 2008

TABLE OF CONTENTS

1

2

3

4

5

6

7

8

9

10

THE SPORT OF MOTORCYCLING

FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS

CONTROLS, EQUIPMENT AND ADJUSTMENTS

BREAK-IN AND INSPECTION BEFORE RIDING

RIDING TIPS

ACCESSORY USE AND MOTORCYCLE LOADING

INSPECTION AND MAINTENANCE

TROUBLESHOOTING

STORAGE PROCEDURE AND MOTORCYCLE CLEANING

CONSUMER INFORMATION

SPECIFICATIONS

INDEX

1-1

1


MOST ACCIDENTS CAN BE AVOIDED ............................................................. 1-2IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE ..................................................................... 1-2IF A COLLISION IS IMMINENT, DO SOMETHING! ........................................... 1-3SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......................................... 1-3KNOW YOUR LIMITS .......................................................................................... 1-4BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS ........................ 1-4PRACTICE AWAY FROM TRAFFIC ................................................................... 1-4INSPECTION BEFORE RIDING .......................................................................... 1-5ACCESSORIES AND LOADING ......................................................................... 1-5CARRYING A PASSENGER ............................................................................... 1-5MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA) ..................................................................................... 1-6BE STREET SMART ........................................................................................... 1-6CONCLUSION ..................................................................................................... 1-6

1-2


Your motorcycle and this owner’smanual have been designed bypeople like you who enjoy motor-cycling. People become motorcy-clists for many reasons. Forstarters, street riding is fun andinvigorating. But no matter whyyou became a motorcyclist, orhow experienced you are, you willeventually face some challengingsituations.

In preparing for these challenges,you will be fine-tuning your coordi-nation, concentration, and atti-tude. Learning the skills andstrategies associated with motor-cycling is the basis for safely par-ticipating in this sport. Manymotorcyclists find that as theybecome better riders, they alsoget more enjoyment from the free-dom unique to motorcycling.

Please remember:

MOST ACCIDENTS CAN BE AVOIDEDThe most common type of motor-cycle accident in the U.S. occurswhen a car traveling towards amotorcycle turns left in front of themotorcycle. Is that because otherdrivers are out to get motorcy-clists? No. Other drivers simplydon’t always notice motorcyclists.

Ride defensively. Wise motorcy-clists use a strategy of assumingthey are invisible to other drivers,even in broad daylight. Pay care-ful attention to other motorists,especially at intersections,because they may not be payingattention to you. Select a laneposition that gives you the bestview of others, and other motor-ists the best view of you. Wearbright, reflective clothing. Putreflective strips on your helmet.

IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDEMost accidents occur within a fewmiles of home, and almost halfoccur at speeds of less than 30mph. So even if you’re just goingon a quick errand, be prepared –strap on your helmet before youtake off.

Helmets do not reduce essentialvision or hearing. Generally, hel-mets do not cause or intensifyinjury if you crash. Helmets simplyhelp your skull protect your intelli-gence, your memory, your per-sonality, and your life.

Your eyesight is equally valuable.Wearing suitable eye protectioncan help keep your visionunblurred by the wind and saveyour eyes from airborne hazardslike bugs, dirt, or pebbles kickedup by tires.

1-3

IF A COLLISION IS IMMINENT, DO SOMETHING!Many riders fear locking up theirbrakes or haven’t learned toswerve to avoid an accident.Many inexperienced riders (andtoo many seasoned riders) useonly their rear brake in an emer-gency, resulting in unnecessaryimpacts in some cases andunnecessarily high impact speedsin other cases. Your rear brakecan only provide about 30% ofyour motorcycle’s potential stop-ping power. The front and rearbrakes can and should be usedtogether to maximize brakingeffectiveness.

Experienced motorcyclists learnto “cover” the front brake lever bylightly resting a couple of fingersover the lever when riding in trafficand near intersections to givetheir reaction time a head start.

Emergency stopping and swerv-ing are techniques that youshould practice and master beforeyou find yourself in an emergencysituation. The best place to prac-tice such techniques is in a con-trolled environment such as theMotorcycle Safety Foundation’s(MSF) rider training courses. TheMSF’s Motorcycle Rider Courses(fundamental techniques) andExperienced Rider Courses(advanced strategies) presenthands-on instruction of the basicprinciples of motorcycling and avariety of accident-avoidance

maneuvers. Even a seasonedmotorcyclist can improve his orher riding skills, and pick up a fewnew skills, through these courses.Some insurance companies evenoffer discounts to course gradu-ates.

SPECIAL SITUATIONS REQUIRE SPECIAL CAREOf course, there are some timeswhen full-force braking is not thecorrect technique. When the roadsurface is wet, loose, or rough,you should brake with care. Whenyou’re leaned over in a corner,avoid braking. Straighten upbefore braking. Better yet, slowdown before entering a corner.

In these situations, the tractionavailable between your tires andthe road surface is limited. Over-braking when traction is limitedwill cause your tires to skid, possi-bly resulting in loss of directionalcontrol or causing you and yourmotorcycle to fall over.

1-4

KNOW YOUR LIMITSAlways ride within the boundariesof your own skills. Knowing theselimits and staying within them willhelp you avoid accidents.

A major cause of accidents involv-ing only a motorcycle (and nocars) is going too fast through aturn. Before entering a turn, selectan appropriately low corneringspeed. Even on straight roads,ride at a speed that is appropriatefor the traffic, visibility and roadconditions, your motorcycle, andyour experience.

Riding a motorcycle safelyrequires that your mental andphysical skills are fully part of theexperience. You should notattempt to operate a motor vehi-cle, especially one with twowheels, if you are tired or underthe influence of alcohol or otherdrugs. Alcohol, illegal drugs, andeven some prescription and over-the-counter drugs can causedrowsiness, loss of coordination,loss of balance, and especiallythe loss of good judgment. If youare tired or under the influence ofalcohol or other drugs, PLEASEDO NOT RIDE your motorcycle.

BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYSRiding on bad weather days,especially wet ones, requiresextra caution. Braking distancesincrease on a rainy day. Stay offthe painted surface marks, man-hole covers, and greasy-appear-ing areas, as they can beespecially slippery. Use extra cau-tion at railway crossings and onmetal gratings and bridges. Whenit starts to rain, any oil or greaseon the road rises to the surface ofthe water. Pull over and wait a fewminutes until this oil film iswashed away before riding.Whenever in doubt about roadconditions, slow down !

PRACTICE AWAY FROM TRAFFICYour riding skill and your mechan-ical knowledge form the founda-tion for safe riding practices. Wesuggest that you practice ridingyour motorcycle in a non-trafficsituation until you are thoroughlyfamiliar with your machine and itscontrols. Again, consider takingone of the MSF’s Rider Courses.Even experts will be pleased withthe caliber of the information pre-sented in these courses. As theMSF says: “The more you know,the better it gets !”

1-5

INSPECTION BEFORE RIDINGReview the instructions in the“INSPECTION BEFORE RIDING”section of this manual. Perform anentire pre-ride inspection beforeyou head out on the road. Spend-ing a few minutes preparing yourmachine for a ride can help pre-vent accidents due to mechanicalfailure or costly, inconvenientbreakdowns far from home.

ACCESSORIES AND LOADINGThe accessories you use withyour motorcycle and the mannerin which you load your gear ontothe bike might create hazards.Aerodynamics, handling, balance,and cornering clearance can suf-fer, and the suspension and tirescan be overloaded. Read the“ACCESSORY USE ANDMOTORCYCLE LOADING” sec-tion.

CARRYING A PASSENGERCarrying a passenger, when donecorrectly, is a great way to sharethe joy of motorcycling. You willhave to alter your riding stylesomewhat since the extra weightof a passenger will affect handlingand braking. You may also needto adjust tire pressures and sus-pension; please refer to the TirePressure and Loading sectionand the Suspension section formore details.

A passenger needs the same pro-tection that you do, including ahelmet and proper clothing. Thepassenger should not wear longshoe laces or loose pants thatcould get caught in the wheel orthe chain. Passengers must betall enough that their feet reachthe footrests.

1-6

MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA)This special handbook, suppliedwith your owner’s manual, con-tains a variety of safety tips, help-ful hints, and practice exercises.This manual can increase yourriding enjoyment and safety. Youshould read it thoroughly.

BE STREET SMARTAlways heed speed limits, locallaws, and the basic rules of theroad. Set a good example for oth-ers by demonstrating a courteousattitude and a responsible ridingstyle.

CONCLUSIONTraffic, road and weather condi-tions vary. Other motorists’actions are unpredictable. Yourmotorcycle’s condition canchange. These factors can bestbe dealt with by giving every rideyour full attention.

Circumstances beyond your con-trol could lead to an accident. Youneed to prepare for the unex-pected by wearing a helmet andother protective gear, and learn-ing emergency braking andswerving techniques to minimizethe damage to you and yourmachine.

The best way to learn basic ridingskills and evasive maneuvers orrefresh your own riding skills is totake one of the courses offered bythe Motorcycle Safety Foundation.Your Suzuki dealer can help youlocate the fundamental oradvanced riding skills coursenearest you, or owners in the USAcan call toll-free 1-800-446-9227.

Good riding on your new Suzuki !

2-1

2


FUEL .................................................................................................................... 2-2ENGINE OIL ......................................................................................................... 2-3ENGINE COOLANT SOLUTION ......................................................................... 2-5

2-2


FUELYour motorcycle requires regularunleaded gasoline with a mini-mum pump octane rating of 87((R+M)/2 method). In some areas,the only fuels that are availableare oxygenated fuels.

Oxygenated fuels which meet theminimum octane requirement andthe requirements described belowmay be used in your motorcyclewithout jeopardizing the NewVehicle Limited Warranty or theEmission Control System War-ranty.

NOTE: Oxygenated fuels arefuels which contain oxygen-carry-ing additives such as MTBE oralcohol.

Gasoline Containing MTBEUnleaded gasoline containingMTBE (Methyl Tertiary ButylEther) may be used in your motor-cycle if the MTBE content is notgreater than 15%. This oxygen-ated fuel does not contain alco-hol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline andethanol (grain alcohol), alsoknown as “GASOHOL”, may beused in your vehicle if the ethanolcontent is not greater than 10%.

Gasoline/Methanol BlendsFuels containing 5% or less meth-anol (wood alcohol) may be suit-able for use in your motorcycle ifthey contain co-solvents and cor-rosion inhibitors.

DO NOT USE fuels containingmore than 5% methanol underany circumstances. Fuel systemdamage or motorcycle perfor-mance problems resulting fromthe use of such fuels are not theresponsibility of Suzuki and maynot be covered under the NewVehicle Limited Warranty or theEmission Control System War-ranty.

Fuel Pump LabelingIn some states, pumps that dis-pense oxygenated fuels arerequired to be labeled for the typeand percentage of oxygen, andwhether important additives arepresent. Such labels may provideenough information for you todetermine if a particular blend offuel meets the requirements listedabove. In other states, pumpsmay not be clearly labeled as tothe content or type of oxygen andadditives. If you are not sure thatthe fuel you intend to use meetsthese requirements, check withthe service station operator or thefuel supplier.

2-3

NOTE: • To help minimize air pollution,

Suzuki recommends that youuse oxygenated fuels.

• Be sure that any oxygenatedfuel you use has octane rat-ings of at least 87 pumpoctane ((R+M)/2 method).

• If you are not satisfied with thedriveability or fuel economy ofyour motorcycle when you areusing an oxygenated fuel, or ifengine pinging is experi-enced, substitute anotherbrand as there are differencesbetween brands.

ENGINE OILOil quality is a major contributor toyour engine’s performance andlife. Always select good qualityengine oil. Suzuki recommendsthe use of SUZUKI PERFOR-MANCE 4 MOTOR OIL or equiva-lent engine oil. Use oil with an API(American Petroleum Institute)classification of SF/SG or SH/SJ,or with a JASO classification ofMA.

API: American Petroleum InstituteJASO: Japanese AutomobileStandards Organization

SAE Engine Oil ViscositySuzuki recommends the use ofSAE 10W-40 engine oil. If SAE10W-40 engine oil is not available,select an alternative according tothe following chart.

CAUTIONSpilled gasoline containingalcohol can harm your motor-cycle. Alcohol can damagepainted surfaces.

Be careful not to spill any fuelwhen filling the fuel tank. Wipespilled gasoline up immedi-ately.

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

2-4

JASO T903The JASO T903 standard is anindex to select engine oils for 4-stroke motorcycle and ATVengines. Motorcycle and ATVengines lubricate clutch andtransmission gears with engineoil. JASO T903 specifies perfor-mance requirements for motorcy-cle and ATV clutches andtransmissions.

There are two classes, MA andMB. The oil container shows theclassification as follows.

1 Code number of oil sales company2 Oil classification

Energy ConservingSuzuki does not recommend theuse of “ENERGY CONSERVING”oils. Some engine oils which havean API classification of SH orhigher have an “ENERGY CON-SERVING” indication in the APIclassification doughnut mark.These oils can affect engine lifeand clutch performance.

Not recommended Recommended

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

API SERVICE SJ

SAE10W-40

2-5

ENGINE COOLANT SOLUTIONUse engine coolant that is com-patible with an aluminum radiator,mixed with distilled water at a50:50 mixture ratio for enginecoolant solution. An engine cool-ant mixture other than 50:50 canaffect cooling efficiency or rustinhibiting performance.

Engine CoolantEngine coolant should be used atall times in your motorcycle’s radi-ator, even if the temperature inyour area does not go down to thefreezing point. Engine coolantacts as a rust inhibitor and waterpump lubricant as well as an anti-freeze solution.

Water for MixingUse distilled water only. Waterother than distilled water can cor-rode and clog the aluminum radia-tor.

Required amount of engine cool-ant/water solution capacity (total):1900 ml (2.0 US qt)

WARNINGEngine coolant is harmful orfatal if swallowed or inhaled.

Do not drink antifreeze or cool-ant solution. If swallowed, donot induce vomiting. Immedi-ately contact a poison controlcenter or a physician. Avoidinhaling mist or hot vapors; ifinhaled, remove to fresh air. Ifcoolant gets in eyes, flush eyeswith water and seek medicalattention. Wash thoroughlyafter handling. Solution can bepoisonous to animals. Keepout of the reach of children andanimals.

CAUTIONSpilled engine coolant candamage painted surfaces.

Do not spill any fluid when fill-ing the radiator. Wipe spilledengine coolant up immediately.

Engine coolant 950 ml(1.0 US qt)

Water 950 ml(1.0 US qt)

3-1

3


LOCATION OF PARTS ....................................................................................... 3-2KEY ...................................................................................................................... 3-5IGNITION SWITCH .............................................................................................. 3-5INSTRUMENT PANEL ......................................................................................... 3-7LEFT HANDLEBAR ........................................................................................... 3-14RIGHT HANDLEBAR ........................................................................................ 3-15FUEL TANK CAP .............................................................................................. 3-18GEARSHIFT LEVER .......................................................................................... 3-19REAR BRAKE PEDAL ...................................................................................... 3-19SEAT LOCK ....................................................................................................... 3-20HELMET HOLDER ............................................................................................ 3-20SIDE STAND ...................................................................................................... 3-21SUSPENSION ADJUSTMENT .......................................................................... 3-22WINDSHIELD HEIGHT ADJUSTMENT ............................................................ 3-24

3-2


LOCATION OF PARTS

1Clutch lever2Left handlebar switches3 Ignition switch4Speedometer5 Indicator lights6Tachometer7Front brake fluid reservoir8Right handlebar switches9Throttle grip0Front brake leverAFuel tank cap

3-3

BToolsCGearshift leverDSide standESeat lock

3-4

FRear brake pedal

3-5

KEY

Two keys come with this motorcy-cle. Keep the spare key in a safeplace. An identifying number isstamped on the plate. Use thisnumber when making a replace-ment key.

Please write down your key num-ber in the box provided for yourfuture reference.

IGNITION SWITCH

The ignition switch has 4 posi-tions.

“OFF” positionAll electrical circuits are off. Theengine will not start. The key canbe removed.

“ON” positionThe ignition circuit is completedand the engine can run. Theheadlight and taillight will auto-matically turn on. The key cannotbe removed in this position.

NOTE: Start the engine promptlyafter turning the key to the “ON”position, or the battery will losepower due to consumption by theheadlight and taillight.

“LOCK” positionAll electrical circuits are off. Thekey can be removed and thesteering will be locked. Turn thesteering all the way to the left andpush down the key and turn it tothe “LOCK” position.

Key No.

ON

OFF

LO

C

KP IGNIT

ION

PU

SH

3-6

“P” (PARKING) positionThe taillight will come on toincrease visibility for temporaryroad side parking at night. Thekey can be removed and thesteering will be locked.

The key hole can be covered byturning the lid.

Align the lid hole position with thekey hole position when insertingthe key.

WARNINGTurning the ignition switch tothe “P” (PARKING) or “LOCK”position while the motorcycleis moving can be hazardous.Moving the motorcycle whilethe steering is locked can behazardous. You could lose yourbalance and fall, or you coulddrop the motorcycle.

Stop the motorcycle and placeit on the side stand before lock-ing the steering. Never attemptto move the motorcycle whenthe steering is locked.

ON

OFF

LO

C

KP IGNIT

ION

PU

SH

3-7

INSTRUMENT PANEL

When the ignition switch is turnedto the “ON” position, the speed-ometer and tachometer needlesmoves to the full scale positionand return to the home position.LCD displays all segments for 3seconds when the ignition switchis turned to the “ON” position toconfirm display function.

If the speedometer and tachome-ter needle does not point to zero,follow the procedure below toreset the speedometer andtachometer.

1. Press the ADJ button B andturn on the ignition switch.

2. Press and hold the ADJ buttonB for 3 – 5 seconds.

3. Release the ADJ button. Pressthe ADJ button twice within 1second.

NOTE: Reset procedure, fromstep 1 to step 3, should be per-formed within 10 seconds.

Speedometer 1The speedometer indicates theroad speed in miles per hour and/or kilometers per hour.

Turn Signal Indicator Light “” 2When the turn signals are beingoperated either to the right or tothe left, the indicator will flash atthe same time.

NOTE: If a turn signal light is notoperating properly due to bulb fila-ment or circuit failure, the indica-tor light flickers more quickly tonotify the rider of the existence ofa trouble.

High Beam Indicator Light “” 3This blue indicator light will be litwhen the headlight high beam isturned on.

Neutral Indicator Light “N” 4The green light will come on whenthe transmission is in neutral. Thelight will go out when you shift intoany gear other than neutral.

Tachometer 5The tachometer indicates theengine speed in revolutions perminute (r/min).

3-8

Fuel Injection System Indicator “FI”/Clock 6

If the fuel injection system fails,the red indicator light 7 comes onand the display 6 indicates “FI” infollowing two modes;

A. The display 6 indicates “FI”and the clock alternately, andthe red indicator light 7comes on and remains lit.

B. The display 6 indicates “FI”continuously and the red indi-cator light 7 blinks.

The engine may continue to run inmode A, but mostly the engine willnot run in mode B.

NOTE: If the display indicates “FI”and the clock alternately, and thered indicator light comes on andremains lit, keep the engine run-ning and bring your motorcycle toan authorized Suzuki dealer. If theengine stalls, try restarting theengine after turning the ignitionswitch off and on.

CAUTIONRiding the motorcycle with thedisplay indicating a problem ofthe fuel injection system andwith the indicator light lit candamage the engine and trans-mission.

Whenever the red indicatorlight is lit and the display indi-cates “FI”, have your autho-rized Suzuki dealer or aqualified mechanic inspect thefuel injection system as soonas possible.

3-9

When the display 6 indicates“CHEC”, check following items;• Make sure that the engine stop

switch is in the “” position.• Make sure that the transmis-

sion is in neutral or the sidestand is fully up.

If the display still indicates“CHEC” after checking the aboveitems, inspect the ignition fuseand the connection of the leadwire couplers.

NOTE: The coolant temperaturemeter indicates “H” when the dis-play shows “CHEC”.

Clock

The clock has a 12-hour display.Follow the procedure below toadjust the clock.

1. Push the buttons, SEL 0 andADJ B, simultaneously for 2seconds until the minute dis-play blinks.

2. Adjust the minute display bypushing the “ADJ” button B.

NOTE: When the “ADJ” button Bis held in the display advancescontinuously.

3. Push the “SEL” button 0 tohighlight the hour display.

4. Adjust the hour display bypushing the “ADJ” button B.

5. Push the “SEL” button 0 toreturn to the clock mode.

3-10

Oil Pressure Indicator Light “” 7With the ignition switch in the“ON” position but the engine is notstarted, the symbol “” in thedisplay and the indicator light 7comes on. As soon as the engineis started, the symbol “” andthe indicator light should go out.

When the engine oil pressuredrops under the normal operatingrange, the symbol “” in thedisplay appears and the indicatorlight 7 comes on.

ABS Indicator Light “” 8This indicator normally comes onwhen the ignition switch is turned“ON” and goes off after the motor-cycle speed exceeds 5 km/h (3mph).

If there is a problem with the ABS(Anti-lock Brake System), thisindicator light blinks or comes on.The ABS does not operate whenthe ABS indicator light is on orblinking and the brake system willwork as normal brakes.

CAUTIONRiding the motorcycle whenthe symbol “” appears andthe indicator light lit can dam-age the engine and transmis-sion.

Whenever the symbol “”appears and the indicatorlights up, indicating low oilpressure, stop the engineimmediately. Check the oil leveland make sure the properamount of oil is in the engine. Ifthe light still does not go out,have your authorized Suzukidealer or a qualified mechanictroubleshoot your motorcycle.

3-11

NOTE: If the ABS indicator lightgoes off before starting the motor-cycle, check the ABS indicatorlight function by turning off and onthe ignition switch. The ABS indi-cator light can go off if the engineis revved at high speed beforestarting the motorcycle. If the ABSindicator light does not come onwhen the ignition switch is turnedon, you should have the systemchecked by an authorizedSUZUKI dealer as soon as possi-ble.

Fuel Meter “” 9The fuel meter indicates theamount of fuel remaining in thefuel tank. The fuel meter displaysall 5 segments when the fuel tankis full. The mark flickers when thefuel level drops below 4.5 L (4.8US qt). The mark and segmentflicker when the fuel drops below3.0 L (3.2 US qt).

NOTE: The fuel meter will notindicate correctly when the motor-cycle is placed with the sidestand.

WARNINGRiding the motorcycle with theABS indicator light on can behazardous.

If the ABS indicator light blinksor comes on while riding, stopthe motorcycle in a safe placeand turn off the ignition switch.Turn the ignition switch “ON”after a while and check if theindicator light comes on.• If the indicator light goes off

a after starting to ride, theABS will be functioning.

• If it does not go off afterstarting to ride, ABS is notfunctioning, and the brakesprovide normal stopping abil-ity. You should have the sys-tem checked by anauthorized SUZUKI dealer assoon as possible.

Fuel tank

Fuel gauge

Approximately3.0 L

FullApproximately

4.5 L

Mark

Flicker Flicker

Flicker

3-12

Odometer/Trip Meter AThis display has 3 functions;odometer and two trip meters.When the ignition switch is turnedto the “ON” position, the displayindicates the test pattern shownbelow for 3 seconds. Then thedisplay changes to odometer ortrip meter, according to what wasselected before turning the igni-tion switch off.

OdometerThe odometer registers the totaldistance that the motorcycle hasbeen ridden.

Trip MeterThe two trip meters are resettableodometers. They can register twokinds of distance at the sametime. For instance, trip meter 1can register the trip distance andtrip meter 2 can register the dis-tance between fuel stops.

To change the display, push the“SEL” button 0. The displaychanges in the order below.

Odometer

Trip meter 1

Trip meter 2

3-13

To reset the trip meter to zero,push the “ADJ” button B for twoseconds while the display indi-cates the trip meter 1 or 2 youwant to reset.

Coolant Temperature Meter “” C

The coolant temperature meterindicates engine coolant tempera-ture. When the coolant tempera-ture becomes high, the mark Aand indicator light 7 come on.

WARNINGOperating the display whileriding can be hazardous.Removing a hand from the han-dlebars can reduce your abilityto control the motorcycle.

Always keep both hands on thehandlebars while riding.

CAUTIONRunning the engine with hightemperature engine coolantcan cause serious engine dam-age. If the mark and indicatorlight come on, stop the engineto let it cool.

Do not run the engine until themark and indicator light go off.

3-14

LEFT HANDLEBAR

Clutch Lever 1The clutch lever is used for disen-gaging the drive to the rear wheelwhen starting the engine or shift-ing transmission gears. Squeez-ing the lever disengages theclutch.

Headlight Flasher Switch 2Press the switch to flash theheadlight. The headlight highbeam will be lit when the dimmerswitch is in “” position.

Dimmer Switch 3“” positionThe headlight low beam and tail-light turn on.

“” positionThe headlight high beam and tail-light turn on. The high beam indi-cator light also turns on.

Hazard Warning Switch “” 4All four turn signal lights and indi-cators will flash simultaneouslywhen the switch is turned on withthe ignition switch in the “ON” or“P” position. Use the hazardwarning lights to warn other trafficduring emergency parking orwhen your vehicle could other-wise become a traffic hazard.

CAUTIONHolding the dimmer switchbetween “” and “” posi-tion will light both “” and“” headlight beam. Thisoperation can damage themotorcycle.

Use the dimmer switch only at“” or “” position.

CAUTIONSticking some tape or placingobjects in front of the headlightcan damage the headlight.

Do not stick any tapes to theheadlight. Do not place objectsin front of the headlight.

3-15

Turn Signal Switch “” 5Moving the switch to the “”position will flash the left turn sig-nals. Moving the switch to the “”position will flash the right turnsignals. The indicator light willalso flash intermittently. To cancelturn signal operation, push theswitch in.

Horn Button “” 6Press the button to sound thehorn.

RIGHT HANDLEBAR

Engine Stop Switch 1“” positionThe ignition circuit is off. Theengine cannot start or run.

“” positionThe ignition circuit is on and theengine can run.

Front Brake Lever 2Apply the front brake by squeez-ing the front brake lever towardsthe grip. The brake light will comeon when the lever is squeezed.

WARNINGFailure to use the turn signals,and failure to turn off the turnsignals can be hazardous.Other drivers may misjudgeyour course and this mayresult in an accident.

Always use the turn signalswhen you intend to changelanes or make a turn. Be sureto turn off the turn signals aftercompleting the turn or lanechange.

3-16

Electric Starter Button “” 3Use this button to operate thestarter motor. With the ignitionswitch in the “ON” position, theengine stop switch in the “”position, and the transmission inneutral, pull in the clutch lever andpush the electric starter button tostart the engine.

NOTE: This motorcycle has astarter interlock system for theignition and starter circuit. Theengine can only be started if:• The transmission is in neutral

and the clutch is disengaged,or

• The transmission is in gear,the side stand is fully up, andthe clutch is disengaged.

NOTE: The headlight will go offwhen the electric starter button ispushed.

Throttle Grip 4Engine speed is controlled by theposition of the throttle grip. Turn ittoward you to increase enginespeed. Turn it away from you todecrease engine speed.

CAUTIONTo prevent electrical systemdamage, do not operate thestarter longer than five sec-onds at a time.

If the engine does not startafter several attempts, checkthe fuel supply and ignitionsystem. Refer to the TROUBLE-SHOOTING section in this man-ual.

3-17

Front Brake Lever Adjustment

The distance between the throttlegrip and the front brake lever isadjustable to 5 positions. Tochange the position, push thebrake lever forward and turn theadjuster to the desired position.Be sure the adjuster stops in theproper position; a projection of thebrake lever holder should fit intothe depression of the adjuster.This motorcycle is delivered fromthe factory with its adjuster set onposition 3.

WARNINGAdjusting the front brake leverposition while riding can behazardous. Removing a handfrom the handlebars canreduce your ability to controlthe motorcycle.

Always keep both hands on thehandlebars while riding.

3-18

FUEL TANK CAP

To open the fuel tank cap, insertthe ignition key into the lock andturn it clockwise. With the keyinserted, lift up the cap. To closethe cap, push the cap down firmlywith the key in the cap lock.

1Fuel level2Filler neck

WARNINGOverfilling the fuel tank cancause the fuel to overflowwhen it expands due to heatfrom the engine or the sun.Spilled fuel can catch on fire.

Never fill the fuel above thebottom of the filler neck.

WARNINGFuel and fuel vapor are highlyflammable and toxic. You canbe burned or poisoned whenrefueling.

• Stop the engine and keepflames, sparks and heatsources away.

• Refuel only outdoors or in awell ventilated area.

• Do not smoke.• Wipe up spills immediately.• Avoid breathing fuel vapor.• Keep children and pets away.

3-19

GEARSHIFT LEVER

This motorcycle has a 6-speedtransmission which operates asshown. To shift properly, squeezethe clutch lever and close thethrottle at the same time youoperate the gearshift lever. Lift thegearshift lever to upshift anddepress the lever to downshift.Neutral is located between 1stand 2nd gear. When neutral isdesired, depress or lift the leverhalfway between 1st and 2ndgear.

NOTE: When the transmission isin neutral the green indicator lighton the instrument panel will be lit.However, even though the light isilluminated, cautiously and slowlyrelease the clutch lever to makesure that the transmission is posi-tively in neutral.

Reduce the motorcycle speedbefore down-shifting. When down-shifting, the engine speed shouldbe increased before the clutch isengaged. This will prevent unnec-essary wear on the drive traincomponents and the rear tire.

REAR BRAKE PEDAL

Pressing the rear brake pedal willapply the rear brake. The brakelight will come on when the rearbrake is operated.

3-20

SEAT LOCK

To remove the seat, insert theignition key into the lock and turnit clockwise. Raise the rear end ofthe seat and slide it backward.

To reinstall the seat, slide the seathooks into the seat hook retainersand push down firmly until theseat snaps into the locked posi-tion.

A small and light article such asrain gear or a windbreaker can beplaced under the seat.

Loading limit: 2 kg (4.5 lbs)

HELMET HOLDER

Use helmet holder wire as shownto hook the helmet.

WARNINGFailure to install the seat prop-erly could allow the seat tomove and cause loss of ridercontrol.

Latch the seat securely in itsproper position.

WARNINGRiding with a helmet fastenedto the helmet holder can inter-fere with rider control.

Never carry a helmet fastenedto a helmet holder. Fix the hel-met securely atop the seat ifyou must carry it.

3-21

SIDE STAND

An interlock system is provided tocut off the ignition circuit when theside stand is down and the trans-mission is in any gear other thanneutral.

The side stand/ignition interlocksystem works as follows:• If the side stand is down and

the transmission is in gear, theengine cannot be started.

• If the engine is running and thetransmission is shifted intogear with the side stand down,the engine will stop running.

• If the engine is running and theside stand is put down with thetransmission in gear, theengine will stop running.

WARNINGRiding with the side standincompletely retracted canresult in an accident when youturn left.

• Check operation of the sidestand/ignition interlock sys-tem before riding.

• Always retract the side standcompletely before startingoff.

CAUTIONPark the motorcycle on firm,level ground to help prevent itfrom falling over.

If you must park on an incline,put the front of the motorcy-cle toward uphill and put thetransmission into 1st gear toreduce the possibility of rollingoff the side stand.

3-22

SUSPENSION ADJUSTMENTThe standard settings for bothfront and rear suspensions areselected to meet various ridingconditions such as low to highmotorcycle speed and light toheavy load on the motorcycle.The suspension settings can beadjusted to fine-tune then accord-ing your preference.

FRONT SUSPENSIONSpring Pre-load Adjustment

To change the spring pre-load,turn the adjuster 1 clockwise orcounterclockwise. Turning theadjuster clockwise will increasethe spring pre-load. Turning theadjuster counterclockwise willdecrease the spring pre-load.There are 5 grooved lines on theside of the adjuster 1 for refer-ence. Position 5 provides the min-imum spring pre-load and position0 provides the maximum pre-load.This motorcycle is delivered fromthe factory with its adjuster set onposition 3.

A Position 0B Position 3C Position 5

WARNINGUnequal suspension adjust-ment can cause poor handlingand loss of stability.

Adjust the right and left frontforks to the same settings.

01

23

45

01

23

0

3-23

REAR SUSPENSIONSpring Pre-load Adjustment

To adjust the rear suspensionspring pre-load, turn the adjuster1. Turning the adjuster clockwisewill stiffen the spring pre-load andturning it counterclockwise willsoften the spring pre-load. Posi-tion 0 provides the softest springpre-load and position 5 providesthe stiffest. This motorcycle isdelivered from the factory with itsadjuster set on position 2.

Damping Force Adjustment

The rebound damping forceadjuster 2 is located at the bot-tom of the rear suspensiondamper unit. To adjust the damp-ing force, set the adjuster to thestandard setting first and thenadjust it to the desired position. Toset the damping force adjuster tothe standard position:

1. Turn the adjuster clockwiseuntil it stops.

2. Turn the adjuster counterclock-wise 1 turn.

Turn the adjuster clockwise tostiffen the damping force and turnit counterclockwise to soften thedamping force.

012345

S H

3-24

WINDSHIELD HEIGHT ADJUSTMENTThe windshield height can beadjusted in 3 positions. To changewindshield height, follow the pro-cedure below.

1. Remove the screws andplates.

2. Remove the screws and wind-shield.

3. Remove the 4 bolts.4. Move the windshield up and

down to desired windshieldheight.

5. Reinstall the windshield in thereverse order of the removal.

4-1

4


INSPECTION BEFORE RIDING .......................................................................... 4-3

4-2


The first 800 km (500 miles) is themost important in the life of yourmotorcycle. Proper operation dur-ing this break-in period will helpassure maximum life and perfor-mance from your new motorcycle.The following guidelines explainproper break-in procedures.

Maximum Engine Speed RecommendationThe table below shows the maxi-mum engine speed recommenda-tion during the break-in period.

Vary the Engine SpeedVary the engine speed during thebreak-in period. This allows theparts to “load” (aiding the matingprocess) and then “unload”(allowing the parts to cool).Although it is essential to placesome stress on the engine com-ponents during break-in, you mustbe careful not to load the enginetoo much.

Breaking in the New TiresNew tires need proper break-in toassure maximum performance,just as the engine does. Wear inthe tread surface by graduallyincreasing your cornering leanangles over the first 160 km (100miles) before attempting maxi-mum performance. Avoid hardacceleration, hard cornering, andhard braking for the first 160 km(100 miles).

Allow the Engine Oil to Circulate before RidingAllow enough idling time afterwarm or cold engine start-upbefore revving the engine or plac-ing the transmission in gear. Thisallows time for the lubricating oilto reach all critical engine compo-nents.

Initial 800 km (500 miles) Below 5000 r/min

Up to 1600 km (1000 miles) Below 7500 r/min

Over 1600 km (1000 miles) Below 10500 r/min

WARNINGFailure to perform break-in ofthe tires could cause tire slipand loss of control.

Use extra care when riding onnew tires. Perform properbreak-in of the tires asdescribed in this section andavoid hard acceleration, hardcornering, and hard braking forthe first 160 km (100 miles).

4-3

Observe Your Initial and Most Critical ServiceThe initial service (break-in main-tenance) is the most importantservice your motorcycle willreceive. During break-in opera-tion, all of the engine componentswill have mated together andseated. Maintenance required aspart of the initial service includescorrection of all adjustments,tightening of all fasteners andreplacement of dirty oil. Timelyperformance of this service willhelp make sure you get the longerservice life and the best perfor-mance from the engine.

INSPECTION BEFORE RIDING

WARNINGFailure to inspect and maintainyour motorcycle properlyincreases the chance of anaccident or equipment dam-age.

Always perform a pre-rideinspection before each ride.Refer to the table on page 4-4for check items. For furtherdetails, refer to the INSPEC-TION AND MAINTENANCE sec-tion.

WARNINGUsing worn, improperlyinflated, or incorrect tires willreduce stability and can causean accident.

Follow all instructions in theTIRES section in this owner’smanual.

4-4

Check the condition of the motor-cycle to help make sure that youdo not have mechanical problemsor get stranded somewhere whenyou ride. Before riding the motor-cycle, be sure to check the follow-ing items. Be sure yourmotorcycle is in good condition forthe personal safety of the rider,passenger and protection of themotorcycle.

WARNINGChecking maintenance itemswhen the engine is running canbe hazardous. You could beseverely injured if your handsor clothing get caught in mov-ing parts.

Shut the engine off when per-forming maintenance checks,except when checking theengine stop switch and throt-tle.

WHAT TO CHECK CHECK FOR

Steering • Smoothness• No restriction of movement• No play or looseness

Brakes • Proper pedal and lever operation

• Correct fluid level• No fluid leakage• No “sponginess”• Proper pedal and lever

play• Brake pad wear

Tires • Proper pressure• Enough tread depth• No cracks, rips, or other

damage

Fuel tank Tank cap locked securely

Lighting Proper operation of all lights – Headlight, Taillight, Brake light, Instrument lights, Turn signals

Indicator lights

Proper operation of all indicators – Coolant temperature, Oil pressure, High beam, Neutral, Turn signal , FI, ABS

Engine stop switch

Proper operation

Horn Correct function

Engine oil Correct level

Cooling system

• Proper engine coolant level

• No leaks or damage

Throttle • Proper play• Smooth response• Quick return to idle

position

Gearshift lever

• No damage• Smooth operation

Clutch • Correct fluid level• No fluid leakage• No “sponginess”• Proper lever play• Smooth and progressive

action

Drive chain • Proper tension• Adequate lubrication• No excessive wear or

damage

Side stand/Ignition interlock system

Proper operation

General condition

• Bolts and nuts tightness• No rattle from any parts of

machine with the engine running

• No visible evidence of damage

5

5-1

RIDING TIPS

STARTING THE ENGINE .................................................................................... 5-2STARTING OFF AND SHIFTING ........................................................................ 5-3USING THE TRANSMISSION ............................................................................. 5-4RIDING ON HILLS ............................................................................................... 5-5STOPPING AND PARKING ................................................................................ 5-5CARRYING A PASSENGER ............................................................................... 5-8

5-2

RIDING TIPS

STARTING THE ENGINEBefore attempting to start theengine, make sure:1. The transmission is in neutral.2. The engine stop switch is in

the “” position.

NOTE: This motorcycle has inter-lock switches for the ignition cir-cuit and the starter circuit. Theengine can only be started if:• The transmission is in neutral

and the clutch is disengaged,or

• The transmission is in gear,the side stand is fully up, andthe clutch is disengaged.

3. Close the throttle completelyand push the electric starterbutton.

NOTE: Open the throttle 1/8 andpush the electric starter buttonwhen the engine is hard to start.

WARNINGRunning the engine indoors orin a garage can be hazardous.Exhaust gas contains carbonmonoxide, a gas that is color-less and odorless and cancause death or severe injury.

Only run the engine outdoorswhere there is fresh air.

CAUTIONRunning the engine too longwithout riding may cause theengine to overheat. Overheat-ing can result in damage tointernal engine componentsand discoloration of exhaustpipes.

Shut the engine off if you can-not begin your ride promptly.

5-3

STARTING OFF AND SHIFTING

Make sure that the side stand is inthe fully up position. Squeeze theclutch lever and pause momen-tarily. Engage first gear bydepressing the gearshift leverdownward. Turn the throttle griptoward you and at the same timerelease the clutch lever gently andsmoothly. As the clutch engages,the motorcycle will start movingforward. To shift to the next highergear, accelerate gently, then closethe throttle and squeeze theclutch lever simultaneously. Liftthe gear shift lever upward toselect the next gear and releasethe clutch lever as you open thethrottle again. Select higher gearsin this manner until top gear isreached.

NOTE: This motorcycle has a sidestand/ignition interlock switch. Ifyou shift the transmission intogear when the side stand is down,the engine will stop running.

WARNINGRiding this motorcycle atexcessive speed increasesyour chances of losing controlof the motorcycle. This mayresult in an accident.

Always ride within the limits ofyour skills, your motorcycle,and the riding conditions.

WARNINGRemoving your hands from thehandlebars or feet from thefootrests during operation canbe hazardous. If you removeeven one hand or foot from themotorcycle, you can reduceyour ability to control themotorcycle.

Always keep both hands on thehandlebars and both feet onthe footrests of your motorcy-cle during operation.

WARNINGSudden side winds, which canoccur when being passed bylarger vehicles, at tunnel exitsor in hilly areas, can upset yourcontrol.

Reduce your speed and bealert to side winds.

5-4

USING THE TRANSMISSIONThe transmission is provided tokeep the engine operatingsmoothly in its normal operatingspeed range. The gear ratioshave been carefully chosen tomeet the characteristics of theengine. The rider should alwaysselect the most suitable gear forthe prevailing conditions. Neverslip the clutch to control roadspeed, but rather downshift toallow the engine to run within itsnormal operational range. Thetable below shows the approxi-mate speed range for each gear.

Shifting up schedule

Shifting down schedule

Disengage the clutch when themotorcycle speed drops below 20km/h (12 miles/h).

Gear position km/h miles/h

1st → 2nd 20 12

2nd → 3rd 30 19

3rd → 4th 40 25

4th → 5th 50 31

5th → 6th 60 37

Gear position km/h miles/h

6th → 5th 50 31

5th → 4th 40 25

4th → 3rd 30 19

WARNINGDownshifting when enginespeed is too high can:• cause the rear wheel to skid

and lose traction due toincreased engine braking,resulting in an accident; or

• force the engine to overrev inthe lower gear, resulting inengine damage.

Reduce speed before down-shifting.

WARNINGDownshifting while the motor-cycle is leaned over in a cornermay cause rear wheel skid andloss of control.

Reduce your speed and down-shift before entering a corner.

CAUTIONRevving the engine into the redzone can cause severe enginedamage.

Never allow the engine to revinto the red zone in any gear.

5-5

RIDING ON HILLS• When climbing steep hills, the

motorcycle may begin to slowdown and show lack of power.At this point you should shift toa lower gear so that the enginewill again be operating in itsnormal power range. Shift rap-idly to prevent the motorcyclefrom losing momentum.

• When riding down a steep hill,the engine may be used forbraking by shifting to a lowergear.

• Be careful, however, not toallow the engine to overrev.

STOPPING AND PARKINGAnti-lock Brake System (ABS)This model is equipped with anAnti-lock Brake System (ABS)designed to help prevent wheellock up during hard braking orduring braking on slippery sur-faces while riding in a straight line.

The ABS will operate whenever itsences that the wheels are lock-ing up. You may feel the brakelever pulsates lightly while theABS is operating.

Even though ABS helps preventwheel lock-up, you must still becareful when braking in curves.Hard braking while turning couldcause wheel skidding and loss ofcontrol, whether or not yourmotorcycle is equipped with ABS.Having ABS does not mean youcan take unnecessary risks. ABSwill not compensate for poor judg-ment, incorrect braking tech-niques, or the need to slow downover bad roads or in poor weatherconditions.

5-6

You must still ride sensibly andalertly.

On regular paved roads, someriders may be able to obtainslightly shorter stopping distanceswith conventional brake systemsthan with ABS.

NOTE: In some situations, amotorcycle with ABS may requirea longer stopping distance to stopon loose or uneven surfaces thanan equivalent motorcycle withoutABS.

WARNINGInexperienced riders tend tounderutilize the front brake.This can cause excessive stop-ping distance and lead to a col-lision. Using only the front orrear brake can cause skiddingand loss of control.

Apply both brakes evenly andat the same time.

WARNINGBraking while turning themotorcycle can be hazardous,whether or not your motorcycleis equipped with ABS. ABS cannot control wheel’s side-slipsthat occur when you brakehard while turning and theside-slips could cause loss ofcontrol.

Slow down sufficiently in astraight line before you beginto turn and avoid braking whileturning except slight braking.

WARNINGFailure to use good judgmentwith ABS can be hazardous.ABS cannot make up for badroad conditions, bad judge-ment, or improper operation ofthe brakes.

Remember that ABS will notcompensate for poor judg-ment, incorrect braking tech-niques, or the need to slowdown over bad roads or in poorweather conditions. Use goodjudgment and do not ride fasterthan conditions will safelyallow.

5-7

How the ABS WorksABS works by electronically con-trolling braking pressure. A com-puter monitors wheel rotationspeed. If the computer detectsthat a braked wheel has slowedsuddenly, indicating a skidding sit-uation, the computer will reducebraking pressure to prevent thatwheel from locking up. ABS worksautomatically, so you do not needany special braking technique.Just apply the front and rearbrakes, as forcefully as necessaryfor the situation, without pumpingeither one. It is normal for thebrake lever/pedal to pulsate whilethe ABS is operating.

Non-recommended tires canaffect wheel speed and may con-fuse the computer.

ABS does not work at very lowspeed, less than 10 km/h (6 mph),and does not work with the dis-charged battery.

Stopping and Parking1. Turn the throttle grip away from

you to close the throttle com-pletely.

2. Apply the front and rear brakesevenly and at the same time.

3. Downshift through the gearsas motorcycle speeddecreases.

4. Select neutral with the clutchlever squeezed towards thegrip (disengaged position) justbefore the motorcycle stops.The neutral position can beconfirmed by observing theneutral indicator light.

WARNINGInexperienced riders tend tounderutilize the front brake.This can cause excessive stop-ping distance and lead to a col-lision. Using only the front orrear brake can cause skiddingand loss of control.

Apply both brakes evenly andat the same time.

WARNINGHard braking while turning maycause wheel skid and loss ofcontrol.

Brake before you begin to turn.

WARNINGHard braking on wet, loose,rough, or other slippery sur-faces can cause wheel skidand loss of control.

Brake lightly and with care onslippery or irregular surfaces.

5-8

5. Park the motorcycle on a firm,flat surface where it will not fallover.

6. Turn the ignition switch to the“OFF” position.

7. Turn the handlebars all theway to the left and lock thesteering for security.

8. Remove the ignition key.

NOTE: If an optional anti-theftlock such as U-shape lock, brakedisk lock and chain is used toavoid theft, be sure to removeanti-theft lock before moving themotorcycle.

CARRYING A PASSENGERBefore you invite someone to be apassenger on your motorcycle,you need to be thoroughly familiarwith motorcycle operation. Adjusttire pressures and suspensionaccording to the Tire Pressureand Loading section and the Sus-pension section of this manual.

The passenger should alwayshold onto your waist or hips, oronto the seat strap or grab bar, asequipped. Ask your passengernot to make any sudden move-ments. When you lean goingaround a corner, the passengershould lean with you. The passen-ger should always keep his or herfeet on the footrests, even whenyou are stopped at a light.

To help prevent burn injuries,warn your passenger not to con-tact the muffler when mounting ordismounting your motorcycle.

WARNINGFollowing another vehicle tooclosely can lead to a collision.As vehicle speeds increase,stopping distance increasesprogressively.

Be sure you have a safe stop-ping distance between you andthe vehicle in front of you.

WARNINGA hot muffler can burn you. Themuffler will be hot enough toburn you for some time afterstopping the engine.

Park the motorcycle wherepedestrians or children are notlikely to touch the muffler.

6-1

6


ACCESSORY USE .............................................................................................. 6-2ACCESSORY INSTALLATION GUIDELINE ....................................................... 6-2LOADING LIMIT .................................................................................................. 6-3LOADING GUIDELINES ...................................................................................... 6-4MODIFICATION ................................................................................................... 6-4

6-2


ACCESSORY USEThe addition of unsuitable acces-sories can lead to unsafe operat-ing conditions. It is not possiblefor Suzuki to test each accessoryon the market or combinations ofall the available accessories; how-ever, your dealer can assist you inselecting quality accessories andinstalling them correctly. Useextreme caution when selectingand installing the accessories onyour motorcycle and consult yourSuzuki dealer if you have anyquestions.

ACCESSORY INSTALLATION GUIDELINE• Install aerodynamic affecting

accessories, such as a fairing,windshield, backrests, saddle-bags, and travel trunks, as lowas possible, as close to themotorcycle and as near to thecenter of gravity as is feasible.Check that the mountingbrackets and other attach-ment hardware are rigidlymounted.

• Inspect for proper groundclearance and bank angle.Inspect that the accessorydoes not interfere with theoperation of the suspension,steering or other control oper-ations.

• Accessories fitted to the han-dlebars or the front fork areacan create serious stabilityproblems. The extra weight willcause the motorcycle to beless responsive to your steer-ing control. The weight mayalso cause oscillations in thefront end and lead to instabilityproblems. Accessories addedto the handlebars or front forkof the machine should be aslight as possible and kept to aminimum.

• Certain accessories displacethe rider from his or her normalriding position. This limits thefreedom of movement of therider and may limit control abil-ity.

WARNINGImproper accessory installa-tion can make your motorcycleunsafe and can lead to an acci-dent.

Use Suzuki genuine accesso-ries or equivalent, designedand tested for your motorcycle.Follow the guidelines in thissection.

6-3

• Additional electrical accesso-ries may overload the existingelectrical system. Severe over-loads may damage the wiringharness or create a hazardoussituation due to the loss ofelectrical power during theoperation of the motorcycle.

• Do not pull a trailer or sidecar.This motorcycle is notdesigned to pull a trailer orsidecar.

LOADING LIMIT

• Never exceed the GVWR(Gross Vehicle Weight Rating)of this motorcycle. The GVWRis the combined weight of themachine, accessories, pay-load, rider and passenger.When selecting your accesso-ries, keep in mind the weight ofthe riders as well as the weightof the accessories. The addi-tional weight of the accesso-ries may not only create anunsafe riding condition butmay also affect the steeringease.

GVWR: 420 kg (926 lbs) at thetire pressure (cold)Front: 225 kPa

(2.25 kgf/cm2, 33 psi) Rear: 280 kPa

(2.80 kgf/cm2, 41 psi)

WARNINGOverloading or improper load-ing can cause loss of motorcy-cle control and this may resultin an accident.

Follow loading limits and load-ing guidelines in this manual.

6-4

LOADING GUIDELINESThis motorcycle is primarilyintended to carry small itemswhen you are not riding with apassenger. Follow the guidelinesbelow to carry a passenger orcargo:• Balance the load between the

left and right side of the motor-cycle and fasten it securely.

• Keep cargo weight low andclose to the center of themotorcycle as possible.

• Do not attach large or heavyitems to the handlebars, frontforks or rear fender.

• Do not install a luggage carrieror a luggage box protrudingover the tail end of the motor-cycle.

• Do not carry any items thatprotrude over the tail end ofthe motorcycle.

• Check that both tires are prop-erly inflated to the specifiedtire pressure for your loadingconditions. Refer to page 7-34.

• Improperly loading your motor-cycle can reduce your ability tobalance and steer the motor-cycle. You should ride atreduced speeds, less than 130km/h (80 mph), when you arecarrying cargo or have addedaccessories.

• Adjust suspension setting asnecessary.

MODIFICATIONModification of the motorcycle, orremoval of original equipmentmay render the vehicle unsafe orillegal. Obey all applicable equip-ment regulations in your area.

The frame of this motorcycle ismade of an aluminum alloy.Therefore, never make any modi-fications such as drilling or weld-ing to the frame as it weakens theframe significantly. This couldresult in an unsafe vehicle operat-ing condition and subsequentaccident. Suzuki will not beresponsible in any way for per-sonal injury or damage to themotorcycle caused by frame mod-ifications.

Bolt-on-accessories that do notmodify the frame in any way maybe installed, provided that theGVWR is not exceeded.

WARNINGModification to an aluminumalloy frame, such as drilling orwelding, weakens the frame.This could result in an unsafeoperating condition and maylead to an accident.

Never make any modificationsto the frame.

7-1

7


NOTICE ................................................................................................................ 7-2MAINTENANCE SCHEDULE .............................................................................. 7-2TOOLS ................................................................................................................. 7-5FUEL TANK LIFT ................................................................................................ 7-5LUBRICATION POINTS ...................................................................................... 7-7BATTERY ............................................................................................................ 7-8AIR CLEANER ..................................................................................................... 7-9SPARK PLUG .................................................................................................... 7-12ENGINE OIL ....................................................................................................... 7-16ENGINE IDLE SPEED INSPECTION ................................................................ 7-20THROTTLE CABLE PLAY ................................................................................ 7-21FUEL HOSES .................................................................................................... 7-22ENGINE COOLANT ........................................................................................... 7-22DRIVE CHAIN .................................................................................................... 7-24CLUTCH ............................................................................................................. 7-28BRAKES ............................................................................................................ 7-29TIRES ................................................................................................................. 7-33SIDE STAND/IGNITION INTERLOCK SYSTEM ............................................... 7-36FRONT WHEEL REMOVAL .............................................................................. 7-37REAR WHEEL REMOVAL ................................................................................ 7-40LIGHT BULB REPLACEMENT ......................................................................... 7-42FUSES ............................................................................................................... 7-44

7-2


NOTICE

MAINTENANCE SCHEDULEIt is very important to inspect andmaintain your motorcycle regu-larly. Follow the guidelines in thechart. The intervals between peri-odic services in kilometers, milesand months are shown. At theend of each interval, be sure toperform the maintenance listed.

MAINTENANCE, REPLACE-MENT OR REPAIR OF THEEMISSION CONTROLDEVICES AND SYSTEMSMAY BE PERFORMED BYANY MOTORCYCLE REPAIRESTABLISHMENT OR INDI-VIDUAL USING ANY MOTOR-CYCLE PART WHICH HASBEEN CERTIFIED UNDERTHE PROVISIONS IN THECLEAN AIR ACT Sec. 207(a)(2).

WARNINGImproper maintenance or fail-ure to perform recommendedmaintenance increases thechance of an accident ormotorcycle damage.

Always follow the inspectionand maintenance recommen-dations and schedules in thisowner’s manual. Ask yourSUZUKI dealer or a qualifiedmechanic to do the mainte-nance items marked with anasterisk (*). You may performthe unmarked maintenanceitems by referring to theinstructions in this section, ifyou have mechanical experi-ence. If you are not sure how todo any of the jobs, have yourSUZUKI dealer or a qualifiedmechanic do them.

7-3

NOTE: The MAINTENANCECHART specifies the minimumrequirements for maintenance. Ifyou use your motorcycle undersevere conditions, perform main-tenance more often than shown inthe chart. If you have any ques-tions regarding maintenanceintervals, consult your SUZUKIdealer or a qualified mechanic.

WARNINGRunning the engine indoors orin a garage can be hazardous.Exhaust gas contains carbonmonoxide, a gas that is color-less and odorless and cancause death or severe injury.

Only run the engine outdoorswhere there is fresh air.

CAUTIONUsing poor quality replacementparts can cause your motorcy-cle to wear more quickly andmay shorten its useful life.

Use only genuine Suzukireplacement parts or theirequivalent.

7-4

MAINTENANCE CHARTInterval: This interval should be judged by odometer reading or numberof months, whichever comes first.

NOTE: I= Inspect and clean, adjust, replace or lubricate as necessary,R= Replace, T= Tighten

NOTE: (California model only) and (CA. only) means that the items orthe maintenance interval is to be applied only for the California model.

Interval km 1000 6000 12000 18000 24000

miles 600 4000 7500 11000 14500

Element months 2 12 24 36 48

Air cleaner element – I I R I

* Exhaust pipe bolts and muffler bolts T T T T T

* Valve clearance – – – – I

Spark plugs – I R I R

Fuel hose– I I I I

*Replace every 4 years

Engine oil R R R R R

Engine oil filter R – – R –

Throttle cable play I I I I I

* Throttle valve synchronization I(CA. only) – I – I

* Evaporative emission control system (California model only)

– – I – I

Replace vaper hose every 4 years

* PAIR (air supply) system – – I – I

* Engine coolant Replace every 2 years

Radiator hose– I I I I

Replace every 4 years

Clutch – I I I I

Drive chainI I I I I

Clean and lubricate every 1000 km (600 miles)

* Brakes I I I I I

Brake hose– 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

* Chassis bolts and nuts T T T T T

7-5

TOOLS

A tool kit is provided with yourmotorcycle. It is located under theseat.

FUEL TANK LIFT1. Place the motorcycle on the

side stand.2. Remove the seat.

3. Remove the bolt 1 and hooks2. Remove the covers.

4. Remove the fasteners 3 andbolts 4.

7-6

5. Remove the bolts 5.

6. Remove the bolt 6. Removethe prop 7.

7. Raise the covers with hand toseparate the covers.

8. Support the fuel tank with theprop 7.

7-7

LUBRICATION POINTSProper lubrication is important forsafe, smooth operation and a longlife for your motorcycle. Be surethat all lubrication is performedduring periodic maintenance onthe motorcycle. Increase fre-quency when you use your motor-cycle in severe conditions.

.... Motor oil ....Grease

1....Clutch lever holder2....Side stand pivot and spring

hook3....Drive chain4.... Throttle cable and brake

lever holder5....Brake pedal pivot and

footrest pivot

CAUTIONLubricating switches can dam-age the switches.

Do not apply grease and oil tothe switches.

7-8

BATTERYThe battery is located under theseat. This battery is a sealed typebattery and requires no mainte-nance. Have your dealer checkthe battery’s state of charge peri-odically. The standard chargingrate in 1.2A × 5 – 10 hours andthe maximum rate is 5A × 1 hour.

WARNINGBattery posts, terminals, andrelated accessories containlead and lead compounds.

Wash hands after handling.

WARNINGHydrogen gas produced by bat-teries can explode if exposedto flames or sparks.

Keep flames and sparks awayfrom the battery. Never smokewhen working near the battery.

CAUTIONExceeding the maximumcharging rate for the batterycan shorten its life.

Never exceed the maximumcharging rate.

CAUTIONReversing the battery leadwires can damage the chargingsystem and the battery.

The red lead must go to thepositive (+) terminal and theblack (or black with whitetracer) lead must go to the neg-ative (–) terminal.

7-9

AIR CLEANERThe air cleaner element must bekept clean to provide good enginepower and gas mileage. If you useyour motorcycle under normallow-stress conditions, you shouldservice the air cleaner at the inter-vals specified. If you ride in dusty,wet, or muddy conditions, you willneed to inspect the air cleanerelement much more frequently.Use the following procedure toremove the element and inspectit.

WARNINGOperating the engine withoutthe air cleaner element in placecould allow a flame to spit backfrom the engine to the aircleaner, or could allow dirt toenter the engine. This couldcause a fire or severe enginedamage.

Never run the engine withoutthe air cleaner element prop-erly installed.

CAUTIONClean or replace the air cleanerelement frequently if the motor-cycle is used in dusty, wet ormuddy conditions. The aircleaner element will clog underthese conditions, and this maycause engine damage, poorperformance, and poor fueleconomy.

Clean the air cleaner case andelement immediately if watergets in the air cleaner box.

7-10

Air Cleaner Element Removal1. Lift the fuel tank by referring to

the FUEL TANK LIFT section.

2. Disconnect the fuel hose 1and coupler 2.

3. Disconnect the hose 3.

4. Remove the nut 4 and bolt.5. Remove the fuel tank.

6. Remove the screws.7. Pull up the air cleaner cover

5.

8. Remove the air cleaner ele-ment 6.

7-11

Air Cleaner Element Cleaning

Carefully use an air hose to blowthe dust from the air cleaner ele-ment.

NOTE: Always apply air pressureto the mesh side of the air cleanerelement only. If you apply air pres-sure to the fabric side, dirt will beforced into the pores of the ele-ment, restricting the air flowthrough the element.

InstallationReinstall the air cleaner elementin the reverse order of theremoval.

CAUTIONA torn air cleaner element willallow dirt to enter the engineand can damage the engine.

Carefully examine the aircleaner element for tears dur-ing cleaning. Replace it with anew one if it is torn.

CAUTIONFailure to position the aircleaner element properly canallow dirt to bypass the aircleaner element. This willcause engine damage.

Be sure to properly install theair cleaner element.

7-12

SPARK PLUGYour motorcycle comes equippedwith NGK CR8E or DENSOU24ESR-N spark plugs. To deter-mine if the standard spark plug isright for your usage, check thecolor of the plug’s porcelain cen-ter electrode insulator after motor-cycle operation. A light browncolor indicates that the plug is cor-rect. A white or dark insulator indi-cates that the engine may needadjustment, or another plug typemay be needed. Consult yourSuzuki dealer or a qualifiedmechanic if your plug insulator isnot a light brown color.

Plug Replacement Guide

NOTE: If the above-named plugsare not available, consult yourSuzuki dealer.

NOTE: This motorcycle usesresistor-type spark plug to avoidjamming electronic parts.Improper spark plug selectionmay cause electronic interfer-ence with your motorcycles’ igni-tion system, resulting inmotorcycle performance prob-lems. Use only the recommendedspark plugs.

CAUTIONAn improper spark plug mayhave an incorrect fit or heatrange for your engine. Thismay cause severe engine dam-age which will not be coveredunder warranty.

Use one of the spark plugslisted below or a equivalent.Consult your Suzuki dealer or aqualified mechanic if you arenot sure which spark plug iscorrect for your type of usage.

NGK DENSO REMARKS

CR7E U22ESR-N

If the standard plug’s insulator is dark, replace with this plug.

CR8E U24ESR-N Standard

CR9E U27ESR-N

If the standard plug’s insulator is white, replace with this plug.

7-13

SPARK PLUG REMOVALTo remove the spark plugs, followthe procedure below:

Front Side

1. Remove the bolts 1.

2. Remove the fasteners.

3. Remove the screws 2.

4. Remove the radiator mountingbolt 3 and 4.

5. Release the hook 5 and slidethe radiator forward.

7-14

6. Pull off the spark plug cap.7. Remove the spark plugs with a

spark plug wrench.

NOTE: Be careful not to damagethe radiator fins.

Rear Side1. Lift the fuel tank by referring to


2. Remove the spark plugs with aspark plug wrench.

NOTE: Pry up the spark plug capwith a screwdriver or a bar if it ishard to remove by hand. Do notpull the spark plug cord.

WARNINGA hot radiator and hot enginecan burn you.

Wait until the radiator andengine are cool enough totouch with bare hands beforestarting this work.

CAUTIONDirt can damage your engine ifit enters an open spark plughole.

Cover the spark plug holewhenever spark plug isremoved.

7-15

Spark Plug Cleaning

To maintain a hot, strong spark,keep the plugs free from carbon.Adjust the gap to 0.7 – 0.8 mm(0.028 – 0.031 in) for good igni-tion. Use a thickness (feeler)gauge to check the gap.

InstallationTo install a spark plug, turn it in asfar as possible with your fingers,then tighten it with a wrench.

Carefully turn the spark plug byhand into the threads until it is fin-ger tight. If the spark plug is new,tighten it with a wrench about 1/2turn past finger tight. If you arereusing the old spark plug, tightenit with a wrench about 1/8 turnpast finger tight.

0.7 – 0.8 mm(0.028 – 0.031 in)

CAUTIONA crossthreaded or overtight-ened spark plug will damagethe aluminum threads of thecylinder head.

Follow the procedure below totighten the spark plug properly.

7-16

ENGINE OILEngine life depends on oil amountand quality. Daily oil level checksand periodic changes are two ofthe most important maintenanceitems to be performed.

Engine Oil Level CheckCheck the engine oil level as fol-lows:1. Place the motorcycle on level

ground on the side stand.2. Start the engine and allow it to

idle for a few minutes.3. Stop the engine and wait for

three minutes.

4. Hold the motorcycle verticallyand check the oil level throughthe oil level inspection windowon the right side of the engine.The engine oil level should bebetween “L” (low) and “F” (full)lines.

CAUTIONThe engine oil level must bebetween the “L” (Low) line and“F” (Full) line, or engine dam-age may occur.

Inspect the oil level, throughthe inspection window, with themotorcycle held vertically onlevel ground before each use ofthe motorcycle.

7-17

Engine Oil and Filter ChangeChange the engine oil and oil filterat the scheduled times. Theengine should always be warmwhen the oil is changed so the oilwill drain easily. The procedure isas follows:

1. Place the motorcycle on theside stand.

2. Remove the oil filler cap 1.

3. Remove the drain plug 2 fromthe bottom of the engine anddrain the engine oil into a drainpan.

NOTE: Recycle or properly dis-pose of used oil.

WARNINGEngine oil and exhaust pipescan be hot enough to burn you.

Wait until the oil drain plug andexhaust pipes are cool enoughto touch with bare handsbefore draining oil.

WARNINGNew and used oil can be haz-ardous. Children and pets maybe harmed by swallowing newor used oil. Repeated, pro-longed contact with usedengine oil may cause skin can-cer. Brief contact with used oilmay irritate skin.

• Keep new and used oil awayfrom children and pets.

• Wear a long-sleeve shirt andwaterproof gloves.

• Wash with soap if oil con-tacts your skin.

7-18

4. Reinstall the drain plug andgasket. Tighten the plugsecurely with a wrench.

Oil filter wrench(Part No. 09915-40620)

5. Turn the oil filter 3 counter-clockwise with a Suzuki “captype” oil filter wrench or a“strap type” filter wrench of theproper size.

6. Wipe off the mounting surface4 on the engine where thenew filter will be seated with aclean rag.

7. Smear a little engine oilaround the rubber gasket 5 ofthe new oil filter.

8. Screw on the new filter byhand until the filter gasket con-tacts the mounting surface(small resistance will be felt).

7-19

NOTE: To tighten the oil filterproperly, it is important to accu-rately identify the position atwhich the filter gasket first con-tacts the mounting surface.

9. Mark the top dead center posi-tion on the “cap type” filterwrench or on the oil filter. Usean oil filter wrench to tightenthe filter 2 turns or to specifiedtorque.

Oil filter tightening torque:20 N·m (2.0 kgf-m, 14.5 lbf-ft)

CAUTIONUsing an oil filter with thewrong design or thread specifi-cations can cause oil leaks orengine damage.

Use a genuine SUZUKI oil filteror an equivalent filter designedfor your motorcycle.

Mark top dead center

Oil filter wrench

In the position at which the filtergasket first contactsthe mountingsurface.

Tighten the filter 2 turns or to specified torque.

7-20

10.Reinstall the drain plug andtighten it securely. Pour about2700 ml (2.9 US qt) of thespecified engine oil in the fillerhole. (See FUEL, ENGINE OILAND COOLANT RECOM-MENDATIONS section.)

NOTE: About 2300 ml (2.4 US qt)of oil will be required when chang-ing oil only.

11.Reinstall the oil filler cap.12.Start the engine (while the

motorcycle is outside on levelground) and allow it to idle fora few minutes.

13.Turn the engine off and wait forthree minutes. Recheck the oillevel on the engine oil inspec-tion window. The engine oillevel should be at the “F” (full)mark. If it is lower than the “L”mark, add oil until it reachesthe “F” mark. Inspect the areaaround the drain plug and oilfilter for leaks.

ENGINE IDLE SPEED INSPECTIONInspect the engine idle speed.The engine idle speed should be1200 – 1400 r/min when theengine is warm.

NOTE: If the engine idle speed isnot within the specified range, askyour Suzuki dealer or a qualifiedmechanic to inspect and repairthe motorcycle.

CAUTIONEngine damage may occur ifyou use oil that does not meetSuzuki’s specifications.

Use the oil specified in theFUEL, ENGINE OIL AND COOL-ANT RECOMMENDATIONS sec-tion.

7-21

THROTTLE CABLE PLAY

This motorcycle has a twin throttlecable system. Cable A is for pull-ing and cable B is for returning.

To adjust the cable play:1. Loosen the lock nut 1.2. Turn in the adjuster 2 fully.3. Loosen the lock nut 3.4. Turn the adjuster 4 so that the

throttle grip has 2.0 – 4.0 mm(0.08 – 0.16 in) play.

5. Tighten the lock nut 3.6. While holding the throttle grip

at the closed position, turn outthe adjuster 2 to feel resis-tance.

7. Tighten the lock nut 1.

2.0–4.0 mm(0.08–0.16 in)

WARNINGInadequate throttle cable playcan cause engine speed to risesuddenly when you turn thehandlebar. This can lead toloss of rider control.

Adjust the throttle cable playso that engine idle speed doesnot rise due to handlebarmovement.

7-22

FUEL HOSES

Inspect the fuel hose for damageand fuel leakage. If any defectsare found, the fuel hose must bereplaced.

ENGINE COOLANT

COOLANT LEVEL

Remove the seat to check thecoolant level. The engine coolantsolution should be between the“F” (FULL) and the “L” (low) levellines on the engine coolant reser-voir. If the level is lower than the“L” (low) level line, bring it up tothe “F” (full) level by adding a50:50 mixture of distilled waterand engine coolant.

L

F

7-23

To add mixed coolant:1. Lift the fuel tank by referring to


2. Remove the filler cap and addmixed coolant through the fillerhole.

NOTE: Adding only water willdilute the engine coolant andreduce its effectiveness. Add a50:50 mixture of engine coolantand water.

WARNINGEngine coolant is harmful orfatal if swallowed or inhaled.

Do not drink antifreeze or cool-ant solution. If swallowed, donot induce vomiting. Immedi-ately contact a poison controlcenter or a physician. Avoidinhaling mist or hot vapors; ifinhaled, remove to fresh air. Ifcoolant gets in eyes, flush eyeswith water and seek medicalattention. Wash thoroughlyafter handling. Solution can bepoisonous to animals. Keepout of the reach of children andanimals.

7-24

DRIVE CHAINThis motorcycle has an endlessdrive chain constructed from spe-cial materials. It does not use amaster link. The drive chain hasspecial “O” rings that permanentlykeep grease inside. We recom-mend that you take your motorcy-cle to an authorized Suzuki dealerif the drive chain needs to bereplaced.

The condition and adjustment ofthe drive chain should be checkedbefore each use of the motorcy-cle. Always follow the guidelinesbelow for inspecting and servicingthe chain.

Inspecting the Drive ChainWhen inspecting the chain, lookfor the following:• Loose pins• Damaged rollers• Dry or rusted links• Kinked or binding links• Excessive wear• Improper chain adjustment

Damage to the drive chain meansthat the sprockets may also bedamaged. Inspect the sprocketsfor the following:

• Excessively worn teeth• Broken or damaged teeth• Loose sprocket mounting nuts

If you find any of these problemswith your sprocket, consult yourSuzuki dealer.

WARNINGRiding with the chain in poorcondition or improperlyadjusted can lead to an acci-dent.

Inspect, adjust, and maintainthe chain properly before eachride, according to this section.

Good Worn

7-25

Drive Chain Cleaning and OilingClean and oil the chain as follows:1. Wash the chain with kerosene.

Kerosene will lubricate andclean the chain.

WARNINGImproperly installing a replace-ment chain, or using a joint-cliptype chain, can be hazardous.An incompletely riveted masterlink, or a joint-clip type masterlink, may come apart andcause an accident or severeengine damage.

Do not use a joint-clip typechain. Chain replacementrequires a special riveting tooland a high-quality, non-joint-clip type chain. Ask an autho-rized SUZUKI dealer or a quali-fied mechanic to perform thiswork.

WARNINGKerosene can be hazardous.Kerosene is flammable. Chil-dren or pets may be harmedfrom contact with kerosene.

Keep flames and smokingmaterials away from kerosene.Keep children and pets awayfrom kerosene. If swallowed,do not induce vomiting. Callphysician immediately. Dis-pose of used kerosene prop-erly.

CAUTIONCleaning the chain with gaso-line or commercial cleaningsolvents can damage O-ringsand ruin the chain.

Clean the drive chain with kero-sene only.

7-26

2. Allow the chain to dry, thenlubricate the links with Suzukichain lube or an equivalentchain lubricant.

Drive Chain Adjustment

Inspect the drive chain slackbefore each use of the motorcy-cle. Place the motorcycle on theside stand. The drive chain shouldbe adjusted for 20 – 30 mm (0.8 –1.2 in) of slack, as shown.

CAUTIONSome drive chain lubricantscontain solvents and additiveswhich could damage the “O”rings in your chain.

Use Suzuki chain lube or anequivalent chain lubricant thatis specifically intended for usewith “O” ring chains.

WARNINGToo much chain slack cancause the chain to come off thesprockets, resulting in an acci-dent or serious damage to themotorcycle.

Inspect and adjust the drivechain slack before each use.

20 – 30 mm(0.8 – 1.2 in)

7-27

To adjust the drive chain, followthe procedure below:


2. Loosen the axle nut 1.3. Turn the right and left adjuster

bolts 2 until the chain has 20– 30 mm (0.8 – 1.2 in) of slackhalfway between the enginesprocket and rear sprocket.

4. At the same time that thechain is being adjusted, therear sprocket must be kept inperfect alignment with the frontsprocket. To assist you in per-forming this procedure, thereare reference marks 3 on theswingarm and each chainadjuster which are to bealigned with each other and tobe used as a reference fromone side to the other.

5. Tighten the axle nut 1securely.

6. Recheck the chain slack aftertightening and readjust if nec-essary.

Rear axle nut tightening torque:100 N·m (10.0 kgf-m, 72.5 lbf-ft)


Wait until the muffler cools toavoid burns.

7-28

CLUTCH

At each maintenance interval,adjust the clutch cable play withthe clutch cable adjuster. Thecable play should be 10 – 15 mm(0.4 – 0.6 in) as measured at theclutch lever end before the clutchbegins to disengage. If you findthe play of clutch incorrect, adjustit in the following way:

1. Loosen the lock nut 1.2. Turn the clutch lever adjuster

2 clockwise as far as it will go.

3. Remove the bolts and sprocketcover.

4. Loosen the cable adjuster locknuts 3, and turn cableadjuster 4 to obtain approxi-mately 10 – 15 mm (0.4 – 0.6in) of free play at the clutchlever end as indicated.

5. Minor adjustment can now bemade with the adjuster 2.

6. Tighten the lock nuts, 1 and3, after finishing adjustment.

NOTE: Any maintenance of theclutch other than the clutch cableplay should be performed by yourSuzuki dealer.

10 – 15 mm(0.4 – 0.6 in)

7-29

BRAKESThis motorcycle has front andrear disk brakes.

NOTE: Operating in mud, water,sand or other extreme conditionscan cause accelerated brakewear. If you operate your motorcy-cle under these conditions, thebrakes must be inspected moreoften than recommended in theMAINTENANCE SCHEDULE.

Brake Fluid

Check the brake fluid level in boththe front and rear brake fluid res-ervoirs. Inspect for brake padwear and leaks.

WARNINGFailure to inspect and properlymaintain the brakes increasesyour chance of having an acci-dent.

Inspect the brake systembefore each use according tothe INSPECTION BEFORERIDING section. Follow theMAINTENANCE SCHEDULEsection to maintain your brakesystem.

UPPER

LOWER

7-30

WARNINGBrake fluid is harmful or fatal ifswallowed, and harmful if itcomes in contact with skin oreyes.

If swallowed, do not inducevomiting. Immediately contacta poison control center or aphysician. If brake fluid gets ineyes, flush eyes with water andseek medical attention. Washthoroughly after handling.Solution can be poisonous toanimals. Keep out of the reachof children and animals.

WARNINGFailure to keep the brake fluidreservoir full with proper brakefluid can be hazardous. Thebrakes may not work correctlywithout the proper amount andtype of brake fluid. This couldlead to an accident.

Inspect the brake fluid levelbefore each use. Use onlyDOT4 brake fluid from a sealedcontainer. Never use or mixwith different types of brakefluid. If there is frequent loss offluid, take your motorcycle to aSUZUKI dealer or a qualifiedmechanic for inspection.

CAUTIONSpilled brake fluid can damagepainted surfaces and plasticparts.

Avoid spilling any fluid whenfilling the reservoir. Wipe upspills immediately.

7-31

Brake Pads

FRONT

REAR

Inspect the front and rear brakepads to see if they are worn downto the grooved wear limit line 1. If a front or rear pad is worn to thegrooved limit line both front orboth rear pads must be replacedwith new ones by your authorizedSuzuki dealer or qualified service

mechanic. After replacing eitherthe front or rear brake pads, thebrake lever or pedal must bepumped several times. This willextend the pads to their properposition.

NOTE: Do not squeeze/depressthe brake lever/pedal when thepads are not in their positions. It isdifficult to push the pistons backinto position.

WARNINGRiding with worn brake padswill reduce braking perfor-mance and will increase yourchance of having an accident.

Inspect brake pad wear beforeeach use. Ask your SUZUKIdealer or a qualified mechanicto replace brake pads if anypad is worn to the limit.

WARNINGFailure to extend brake padsafter repair or replacement cancause poor braking perfor-mance and may result in anaccident.

Before riding, “pump” thebrake lever/pedal repeatedlyuntil brake pads are pressedagainst the brake disks andproper lever/pedal stroke andfirm feel are restored.

7-32

Rear Brake AdjustmentThe rear brake pedal must beadjusted to set the clearancebetween the pedal and the foot-rest. Adjust the brake pedal as fol-lows:

1. Loosen the lock nut 1, andturn the push rod 2 to locatethe pedal 15 – 25 mm (0.6 –1.0 in) below the top face ofthe foot rest.

2. Retighten the lock nut 1 tolock the push rod 2 in theproper position.

Rear Brake Light Switch

To adjust the brake light switch,hold the switch body and turn theadjuster so that the brake light willcome on just before a pressurerise is felt when the brake pedal isdepressed.

WARNINGReplacing only one or the twobrake pads can result inuneven braking action.

Replace both pads together.

15 – 25 mm(0.6 – 1.0 in)

CAUTIONAn incorrectly adjusted brakepedal may force brake pads torub against the disk at alltimes, causing damage to thepads and disk.

Follow the steps in this sectionto adjust the brake pedal prop-erly.

7-33

TIRES

WARNINGFailure to follow these warn-ings may result in an accidentdue to tire failure. The tires onyour motorcycle form the cru-cial link between your motorcy-cle and the road.

Follow these instructions:• Check tire condition and

pressure, and adjust pres-sure before each ride.

• Avoid overloading yourmotorcycle.

• Replace a tire when worn tothe specified limit, or if youfind damage such as cuts orcracks.

• Always use the size and typeof tires specified in thisowner’s manual.

• Balance the wheel after tireinstallation.

• Read this section of theowner’s manual carefully.

WARNINGFailure to perform break-in ofthe tires could cause tire slipand loss of control.

Use extra care when riding onnew tires. Perform properbreak-in of the tires referring tothe BREAK-IN section andavoid hard acceleration, hardcornering, and hard braking forthe first 160 km (100 miles).

7-34

Tire Pressure and LoadingProper tire pressure and propertire loading are important factors.Overloading your tires can lead totire failure and loss of motorcyclecontrol.

Check tire pressure each daybefore you ride, and adjust tirepressure according to the tablebelow. Tire pressure should onlybe checked and adjusted beforeriding, since riding will heat up thetires and lead to higher inflationpressure readings.

Under-inflated tires make smoothcornering difficult, and can resultin rapid tire wear. Over-inflatedtires cause a smaller amount oftire to be in contact with the road,which can contribute to skiddingand loss of control.

NOTE: When you detect drops intire pressure, check the tire fornails or other punctures, or adamaged wheel rim. Tubelesstires sometimes lose pressuregradually when punctured.

Tire Condition and TypeTire condition and tire type affectmotorcycle performance. Cuts orcracks in the tires can lead to tirefailure and loss of motorcycle con-trol. Worn tires are susceptible topuncture failures and subsequentloss of motorcycle control. Tirewear also affects the tire profile,changing motorcycle handlingcharacteristics.

Check the condition of your tireseach day before you ride. Replacetires if tires show visual evidenceof damage, such as cracks orcuts, or if tread depth is less than1.6 mm (0.06 in) front, 2.0 mm(0.08 in) rear.

LOAD SOLO RIDING

DUAL RIDINGTIRE

FRONT225 kPa

2.25 kgf/cm2

33 psi

225 kPa2.25 kgf/cm2

33 psi

REAR250 kPa

2.50 kgf/cm2

36 psi

280 kPa2.80 kgf/cm2

41 psi

7-35

NOTE: The “ ” mark indicatesthe place where the wear bars aremolded into the tire. When thewear bars contact the road, it indi-cates that the tire wear limit hasbeen reached.

Whenever you replace a tire, usea tire of the size and type listedbelow. If you use a different sizeor type of tire, motorcycle han-dling may be adversely affected,possibly resulting in loss of motor-cycle control.

Always balance the wheel afterrepairing a puncture or replacingthe tire. Proper wheel balance isimportant to avoid variable wheel-to-road contact, and to avoiduneven tire wear.

FRONT REAR

SIZE 110/80 R19 M/C 59H

150/70 R17 M/C 69H

TYPE BRIDGESTONE TW101J

BRIDGESTONE TW152F

WARNINGAn improperly repaired,installed, or balanced tire cancause loss of control orshorten tire life.

• Ask your SUZUKI dealer or aqualified mechanic to per-form tire repair, replacement,and balancing becauseproper tools and experienceare required.

• Install tires according to therotation direction shown byarrows on the sidewall ofeach tire.

7-36

SIDE STAND/IGNITION INTERLOCK SYSTEM

Check the side stand/ignitioninterlock system for proper opera-tion as follows:1. Sit on the motorcycle in the

normal riding position, with theside stand up.

2. Shift into first gear, hold theclutch in, and start the engine.

3. While continuing to hold theclutch in, move the side standto the down position.

If the engine stops running whenthe side stand is moved to thedown position, then the sidestand/ignition interlock system isworking properly. If the enginecontinues to run with the sidestand down and the transmissionin gear, then the side stand/igni-tion interlock system is not work-ing properly. Have yourmotorcycle inspected by anauthorized Suzuki dealer or someother qualified service mechanic.

WARNINGFailure to follow these instruc-tions about tubeless tires mayresult in an accident due to tirefailure. Tubeless tires requiredifferent service proceduresthan tube tires.

• Tubeless tires require an air-tight seal between the tirebead and wheel rim. Specialtire irons and rim protectors ora specialized tire mountingmachine must be used forremoving and installing tiresto prevent tire or rim damagewhich could result in an airleak.

• Repair punctures in tubelesstires by removing the tire andapplying an internal patch.

• Do not use an external repairplug to repair a puncture sincethe plug may work loose as aresult of the cornering forcesexperienced by a motorcycletire.

• After repairing a tire, do notexceed 80 km/h (50 mph) forthe first 24 hours, 130 km/h (80mph) thereafter. This is toavoid excessive heat build-upwhich could result in a tirerepair failure and tire deflation.

• Replace the tire if it is punc-tured in the sidewall area, or ifa puncture in the tread area islarger than 6 mm (3/16 in).These punctures cannot berepaired adequately.

7-37

FRONT WHEEL REMOVAL1. Place the motorcycle on the

side stand.

2. Remove both brake calipersfrom the front forks by remov-ing two mounting bolts 1 oneach of the caliper.

NOTE: Never squeeze the frontbrake lever with the caliperremoved. It is very difficult to forcethe pads back into the caliperassembly and brake fluid leakagemay result.

WARNINGIf the side stand/ignition inter-lock system is not workingproperly, it is possible to ridethe motorcycle with the sidestand in the down position.This may interfere with ridercontrol during a left turn.

Check the side stand/ignitioninterlock system for properoperation before riding. Checkthat the side stand is returnedto its full up position beforestarting off.

7-38

3. Remove the front wheel speedsensor by removing themounting bolt 2.

4. Loosen the axle holder bolt 3on the right front fork.

5. Loosen the axle 4 tempo-rarily.

NOTE: A special tool is necessaryto loosen the shaft 4. The specialtool is available at Suzuki dealer.

6. Place an accessory servicestand or equivalent under theswingarm to help stabilize therear end.

7. Carefully position a jack underthe engine and raise the jackuntil the front wheel is slightlyoff the ground.

8. Turn the axle counterclockwiseand draw it out.

9. Remove the front wheel speedsensor bracket 5.

10.Slide the front wheel forward.11.To reinstall the wheel assem-

bly, reverse the sequencedescribed above.

12.After installing the wheel,apply the front brake severaltimes to restore the properlever stroke.CAUTION

Improper jacking may causedamage to the fairing or oil fil-ter.

Do not apply the jack head tothe fairing lower part or the oilfilter when jacking up themotorcycle.

7-39

Front axle tightening torque: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)

Front axle holder bolt tightening torque: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Front brake caliper mounting bolt tightening torque: 39 N·m (3.9 kgf-m, 28.0 lbf-ft)

NOTE: Be careful not to damagethe oil seal when installing thefront wheel.

WARNINGFailure to extend brake padsafter installing the wheel cancause poor braking perfor-mance and may result in anaccident.

Before riding, “pump” thebrake repeatedly until thebrake pads are pressed againstthe brake disks and properlever stroke and firm feel arerestored. Also check that thewheel rotates freely.

WARNINGInstalling the front wheel in thereverse direction can be haz-ardous. The tire for this motor-cycle is directional. Therefore,the motorcycle may haveunusual handling if the wheelis installed incorrectly.

Install the front wheel in thespecified direction, as indi-cated by the arrow on the side-wall of the tire.

WARNINGFailure to torque bolts and nutsproperly could lead to an acci-dent.

Torque bolts and nuts to theproper specifications. If youare not sure of the proper pro-cedure, have your authorizedSUZUKI dealer or a qualifiedmechanic do this.

7-40

REAR WHEEL REMOVAL


2. Remove the axle nut 1.3. Place an accessory service

stand or equivalent under theswingarm to lift the rear wheelslightly off the ground.

4. Loosen the right and left chainadjusting bolts 2.

5. Remove the rear wheel speedsensor by removing themounting bolt.

6. Draw out the axle shaft.

7. With the wheel moved forward,remove the chain from thesprocket.

8. Pull the rear wheel assemblyrearward.


Wait until the muffler cools toavoid burns.

7-41

NOTE: Never depress the rearbrake pedal with the rear wheelremoved. It is very difficult to forcethe pads back into the caliperassembly.

9. To replace the wheel, reversethe complete sequence listed.

10.After installing the wheel,apply the brake several timesand then check that the wheelrotates freely.

Rear axle nut tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft)

WARNINGFailure to adjust the drive chainand failure to torque bolts andnuts properly could lead to anaccident.

• Adjust the drive chain asdescribed in DRIVE CHAINADJUSTMENT section afterinstalling the rear wheel.

• Torque bolts and nuts to theproper specifications. If youare not sure of the properprocedure, have your autho-rized SUZUKI dealer or aqualified mechanic do this.

WARNINGFailure to extend brake padsafter installing the wheel cancause poor braking perfor-mance and may result in anaccident.

Before riding, “pump” thebrake repeatedly until brakepads are pressed against thebrake disks and proper pedalstroke and firm feel arerestored. Also check that thewheel rotates freely.

7-42

LIGHT BULB REPLACEMENTThe wattage rating of each bulb isshown in the following chart.When replacing a burned outbulb, always use the same watt-age rating.

Headlight

1. Disconnect the socket 1 fromthe headlight and remove therubber cap 2.

2. Unhook the bulb holder spring3 and pull out the bulb 4.

CAUTIONUsing a light bulb with thewrong wattage rating cancause electrical system dam-age or shorten bulb life.

Always use the specified lightbulb.

Headlight 12V 60/55W × 2 (H4)

Turn signal light 12V 21W

Brake light/Taillight 12V 21/5W × 2

License plate light 12V 5W

CAUTIONOil from your skin may damagethe headlight bulb or shortenits life.

Grasp the new bulb with aclean cloth.

7-43

Headlight Beam AdjustmentThe headlight beam can beadjusted both horizontally andvertically if necessary.

To adjust the beam horizontally:Turn the adjuster 1 clockwise orcounterclockwise.

To adjust the beam vertically:Turn the adjuster 2 clockwise orcounterclockwise.

NOTE: To adjust the headlightbeam, adjust the beam horizon-tally first, then adjust vertically.

Turn Signal LightTo replace the turn signal lightbulb, follow these directions.

1. Remove the screw and take offthe lens.

2. Push in on the bulb, turn it tothe left, and pull it out.

CAUTIONOvertightening the screwswhen reinstalling the lens maycause the lens to crack.

Tighten the screws only untilthey are snug.

7-44

Brake Light/TaillightTo change the brake light/taillightbulb, perform the following steps:

1. Turn the socket 1 counter-clockwise and remove it.

2. Push in the bulb, turn it to theleft and pull it off.

FUSES

The main fuse is located underthe seat. One 30A spare fuse islocated in the fuse box.

The fuses are located under theseat. Two spare fuses (one 10Aand one 15A) are provided in thefuse box.

7-45

The ABS fuse is located under theseat. Two spare fuses (one 40Aand one 25A) are provided in thefuse box.

The fuses are designed to openwhen an overload exists in indi-vidual electrical system circuits. Ifany electrical system fails to oper-ate, then the fuses must bechecked.

FUSE LIST• 30A MAIN fuse protects the

horn, indicator lights, turn sig-nal lights, brake lights andlicense light.

• 15A HEAD-HI fuse protectsthe headlight high beam andhigh beam indicator light.

• 15A HEAD-LO fuse protectsthe headlight low beam.

• 10A FUEL fuse protects theISC, ECU, instrument panellights, fuel pump and injectors.

• 10A IGNITION fuse protectsthe ECU, PAIR solenoid, fuelpump relay, starter relay andignition coils.

• 15A SIGNAL fuse protects theturn signal lights, brake/tail-light, license light, instrumentpanel lights and indicatorlights.

• 15A FAN fuse protects thecooling fan motor.

• 40A ABS MOT fuse protectsABS system.

• 25A ABS VALVE fuse protectsABS system.

CAUTIONInstalling a fuse of incorrectrating or using aluminum foil orwire instead of a fuse may seri-ously damage the electricalsystem.

Always replace a blown fusewith a fuse of the same typeand rating. If the new fuseblows in a short time, consultyour Suzuki dealer or a quali-fied mechanic immediately.

- 40

--

25 -

8-1

8

TROUBLESHOOTING

FUEL SYSTEM CHECK ...................................................................................... 8-2IGNITION SYSTEM CHECK ................................................................................ 8-3

8-2

TROUBLESHOOTING

This troubleshooting guide is pro-vided to help you find the cause ofsome common complaints.

COMPLAINT: Engine is hard tostart or does not start at all.

FUEL SYSTEM CHECKIf the meter indicates “FI”, show-ing signs of trouble in the fuelinjection system, take yourmachine to an authorized Suzukidealer. Refer to the “INSTRU-MENT PANEL” section for anexplanation of the fuel injectionsystem indicator. If the meterdoes not indicate “FI”, make surethere is enough fuel in the fueltank. If the meter does not indi-cate “FI” and there is enough fuel,the ignition system should bechecked.

CAUTIONFailure to troubleshoot a prob-lem correctly can damage yourmotorcycle. Improper repairsor adjustments may damagethe motorcycle instead of fixingit. Such damage may not becovered under warranty.

If you are not sure about theproper action, consult yourSuzuki dealer about the prob-lem.

8-3

IGNITION SYSTEM CHECK1. Remove the spark plugs and

reattach them to the sparkplug leads.

2. Put the engine stop switch inthe “” position and the igni-tion switch in the “ON” posi-tion. While holding a sparkplug with its base firmlyagainst the engine, push theelectric starter button. If theignition system is operatingproperly, a blue spark shouldjump across the spark pluggap.

3. If there is no spark, clean thespark plug. Replace it if neces-sary. Retry the above proce-dure with the cleaned sparkplug or new one.

4. If there is still no spark, takeyour motorcycle to an autho-rized Suzuki dealer.

COMPLAINT: Engine Stalls1. Make sure there is enough fuel

in the fuel tank.2. If the coolant temperature

meter indicates “FI”, showingsigns of trouble in the fuelinjection system, take yourmachine to an authorizedSuzuki dealer. Refer to the“INSTRUMENT PANEL” sec-tion for an explanation of thefuel injection system indicator.

3. Check the ignition system forintermittent spark.

4. Check the idle speed. The cor-rect idle speed is 1200 – 1400r/min.

WARNINGPerforming the spark testimproperly can cause a highvoltage electrical shock or anexplosion.

Avoid performing this check ifyou are not familiar with thisprocedure, or if you have aheart condition or wear a pace-maker. Keep the spark plugaway from the spark plug holeduring this test.

9-1

9


STORAGE PROCEDURE .................................................................................... 9-2PROCEDURE FOR RETURNING TO SERVICE ................................................. 9-3CORROSION PREVENTION ............................................................................... 9-3MOTORCYCLE CLEANING ................................................................................ 9-4INSPECTION AFTER CLEANING ....................................................................... 9-6

9-2


STORAGE PROCEDUREIf your motorcycle is to be leftunused for an extended period oftime, it needs special servicingrequiring appropriate materials,equipment and skill. For this rea-son, Suzuki recommends that youtrust this maintenance work toyour Suzuki dealer. If you wish toservice the machine for storageyourself, follow the general guide-lines below:

MOTORCYCLEClean the entire motorcycle.Place the motorcycle on the sidestand on a firm, flat surface whereit will not fall over. Turn the han-dlebars all the way to the left andlock the steering, and remove theignition key.

FUEL1. Fill the fuel tank to the top with

fuel mixed with the amount ofgasoline stabilizer recom-mended by the stabilizer man-ufacturer.

2. Run the engine for a few min-utes until the stabilized gaso-line fills the fuel injectionsystem.

ENGINE1. Pour one tablespoon of motor

oil into each spark plug hole.Reinstall the spark plugs andcrank the engine a few times.

2. Drain the engine oil thoroughlyand refill the crankcase withfresh engine oil all the way upto the filler hole.

3. Cover the air cleaner intakeand the muffler outlet with oilyrags to prevent humidity fromentering.

BATTERY1. Remove the battery from the

motorcycle.2. Clean the outside of the bat-

tery with mild soap andremove corrosion from the ter-minals and wiring harness.

3. Store the battery in a roomabove freezing.

TIRESInflate tires to the normal pres-sure.

EXTERNAL• Spray all vinyl and rubber

parts with rubber protectant.• Spray unpainted surfaces with

rust preventative.• Coat painted surfaces with car

wax.

9-3

MAINTENANCE DURING STORAGEOnce a month, recharge the bat-tery. The standard charging rate is1.2A × 5 – 10 hours.

PROCEDURE FOR RETURNING TO SERVICE1. Clean the entire motorcycle.2. Remove the oily rags from the

air cleaner intake and muffleroutlet.

3. Drain all the engine oil. Installa new oil filter and fill theengine with fresh oil as out-lined in this manual.

4. Remove the spark plugs. Turnthe engine a few times. Rein-stall the spark plugs.

5. Reinstall the battery.6. Make sure that the motorcycle

is properly lubricated.7. Perform the INSPECTION

BEFORE RIDING as listed inthis manual.

8. Start the motorcycle as out-lined in this manual.

CORROSION PREVENTIONIt is important to take good care ofyour motorcycle to protect it fromcorrosion and keep it looking newfor years to come.

Important Information About CorrosionCommon causes of corrosion• Accumulation of road salt, dirt,

moisture, or chemicals in hard-to-reach areas.

• Chipping, scratches, and anydamage to treated or paintedmetal surfaces resulting fromminor accidents or impactsfrom stones and gravel.

Road salt, sea air, industrial pollu-tion, and high humidity will all con-tribute to corrosion.

How to Help Prevent Corrosion• Wash your motorcycle fre-

quently, at least once a month.Keep your motorcycle as cleanand dry as possible.

• Remove foreign materialdeposits. Foreign materialsuch as road salt, chemicals,road oil or tar, tree sap, birddroppings and industrial fall-out may damage your motor-cycle’s finish. Remove thesetypes of deposits as soon aspossible. If these deposits aredifficult to wash off, an addi-tional cleaner may be required.Follow the manufacturer’sdirections when using thesespecial cleaners.

9-4

• Repair finish damage as soonas possible. Carefully exam-ine your motorcycle for dam-age to the painted surfaces.Should you find any chips orscratches in the paint, touchthem up immediately to pre-vent corrosion from starting. Ifthe chips or scratches havegone through to the baremetal, have a Suzuki dealermake the repair.

• Store your motorcycle in a dry,well-ventilated area. If youoften wash your motorcycle inthe garage or if you frequentlypark it inside when wet, yourgarage may be damp. Thehigh humidity may cause oraccelerate corrosion. A wetmotorcycle may corrode evenin a heated garage if the venti-lation is poor.

• Cover your motorcycle. Expo-sure to mid-day sun can causethe colors in paint, plasticparts, and instrument faces tofade. Covering your motorcy-cle with a high-quality, “breath-able” motorcycle cover canhelp protect the finish from theharmful UV rays in sunlight,and can reduce the amount ofdust and air pollution reachingthe surface. Your Suzukidealer can help you select theright cover for your motorcycle.

MOTORCYCLE CLEANINGWashing the MotorcycleWhen washing the motorcycle,follow the instructions below:1. Remove dirt and mud from the

motorcycle with running water.You may use a soft sponge orbrush. Do not use hard materi-als which can scratch thepaint.

2. Wash the entire motorcyclewith mild detergent or carwash soap using a sponge orsoft cloth. The sponge or clothshould be frequently soaked inthe soap solution.

NOTE: Avoid spraying or allowingwater to flow over the followingplaces:• Ignition switch• Spark plugs• Fuel tank cap• Fuel injection system• Brake master cylinders

CAUTIONRadiator fins can be damagedby spraying high pressurewater on them.

Do not spray high pressurewater on the radiator fins.

9-5

3. Once the dirt has been com-pletely removed, rinse off thedetergent with running water.

4. After rinsing, wipe off themotorcycle with a wet chamoisor cloth and allow it to dry inthe shade.

5. Check carefully for damage topainted surfaces. If there isany damage, obtain “touch-up”paint and “touch-up” the dam-age.

Windshield CleaningClean the windshield with a softcloth and warm water with a milddetergent. If scratched, polishwith a commercially availableplastic polish. Replace the wind-shield if it becomes scratched ordiscolored so as to obstruct view.When replacing the windshield,use a Suzuki replacement wind-shield.

CAUTIONHigh pressure washers andparts cleaner can damage yourmotorcycle.

Do not use high pressurewashers to clean your motorcy-cle. Do not use parts cleaner tothrottle body and fuel injectionsensors.

CAUTIONCleaning with any alkaline orstrong acid cleaner gasoline,brake fluid, or any other sol-vent will damage the motorcy-cle parts.

Clean only with soft cloth andwarm water with mild deter-gent.

9-6

Waxing the MotorcycleAfter washing the motorcycle,waxing is recommended to furtherprotect and beautify the paint.Observe the precautions speci-fied by the wax manufacturer.

Special Care for Matte Finish Paint• Do not use polishing com-

pounds or waxes that containpolishing compounds on sur-faces which have a matte fin-ish. The use of polishingcompounds will change theappearance of the matte finish.

• Solid type waxes may be diffi-cult to remove from surfaceswith a matte finish.

• Excessive rubbing or polish-ing of a surface with a mattefinish will change its appear-ance.

INSPECTION AFTER CLEANINGFor extended life of your motorcy-cle, lubricate according to “GEN-ERAL LUBRICATION” section.

Follow the procedures in the“INSPECTION BEFORE RIDING”section to check your motorcyclefor any problems that may havearisen during your last ride.

WARNINGWet brakes can cause poorbraking performance and maylead to an accident.

Avoid a possible accident byexpecting longer stopping dis-tances after washing yourmotorcycle. Apply brakes sev-eral times to let heat dry thebrake pads or shoes.

10

10-1


EMISSION CONTROL WARRANTY ................................................................. 10-2REPORTING SAFETY DEFECTS ..................................................................... 10-2TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...................... 10-3ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION .................. 10-4SERIAL NUMBER LOCATION .......................................................................... 10-5LOCATION OF LABELS ................................................................................... 10-6

10-2


EMISSION CONTROL WARRANTYSuzuki Motor Corporation war-rants to the ultimate purchaserand each subsequent purchaserthat this vehicle is designed, built,and equipped so as to conform atthe time of sale with all U.S. emis-sion standards applicable at thetime of manufacture, and that it isfree from defects in materials andworkmanship which would causeit not to meet these standardswithin its useful life. Useful life isdefined for each class of motorcy-cle as 5 years or the correspond-ing number of kilometers (miles)shown in the chart below, which-ever occurs first.

Failures, other than those result-ing from defects in material orworkmanship, which arise solelyas a result of owner abuse and/orlack of proper maintenance arenot covered by the warranty.

REPORTING SAFETY DEFECTSIf you believe that your vehiclehas a defect which could cause acrash or could cause injury ordeath, you should immediatelyinform the National Highway Traf-fic Safety Administration (NHTSA)in addition to notifying AmericanSuzuki Motor Corp.

If NHTSA receives similar com-plaints, it may open an investiga-tion, and if it finds that a safetydefect exists in a group of vehi-cles, it may order a recall andremedy campaign. However,NHTSA cannot become involvedin individual problems betweenyou, your dealer, or AmericanSuzuki Motor Corp.

To contact NHTSA, you mayeither call the Vehicle Safety HotLine toll-free 1-888-327-4236(TTY: 1-800-424-9153); go tohttp://www.safercar.gov; or writeto: Administrator, NHTSA, 400Seventh Street, SW., WashingtonDC 20590. You can also obtainother information about motorvehicle safety from http://www.NHTSA.gov.

Vehicle class

Engine displacement

Useful Life Distance

Class I 50 to 169 cc 12000 km(7456 miles)

Class II 170 to 279 cc 18000 km(11185 miles)

Class III 280 cc and over

30000 km(18641 miles)

10-3

To contact American Suzuki, own-ers in the continental UnitedStates can call toll-free 1-800-444-5077, or write to: AmericanSuzuki Motor Corporation Motor-cycle Customer Service P.O. Box1100, Brea, CA 92822-1100.

For owners outside the continen-tal United States, please refer tothe distributor’s address listed onyour Warranty Information bro-chure.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITEDFederal law prohibits the followingacts or the causing thereof;1. The removal or rendering inop-

erative by any person otherthan for purposes of mainte-nance, repair, or replacement,of any device or element ofdesign incorporated into anynew vehicle for the purpose ofnoise control prior to its sale ordelivery to the ultimate pur-chaser or while it is in use, or

2. The use of the vehicle aftersuch device or element ofdesign has been removed orrendered inoperative by anyperson.

10-4

Among those acts presumed toconstitute tampering are the actslisted below:• Removing or puncturing the

muffler, baffles, header pipes,screen type spark arrester (ifequipped) or any other compo-nent which conducts exhaustgases.

• Replacing the exhaust systemor muffler with a system ormuffler not marked with thesame model specific code asthe code listed on the Motorcy-cle Noise Emission ControlInformation label, and certifiedto appropriate EPA noise stan-dards.

• Removing or puncturing the aircleaner case, air cleanercover, baffles, or any othercomponent which conductsintake air.

Whenever replacing parts on yourmotorcycle, Suzuki recommendsthat you use genuine Suzukireplacement parts or their equiva-lent.

ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATIONYour motorcycle is equipped withon-board computer systemswhich monitor and control severalaspects of motorcycle perfor-mance, including the following:• Emission-related components

and engine parameters suchas engine speed and throttleposition are monitored to pro-vide emission control and toprovide optimum fuel econ-omy. Your motorcycle also hasan on-board diagnostic systemwhich monitors and recordsinformation about emission-related malfunctions.

• If your motorcycle is equippedwith antilock brakes, condi-tions such as motorcyclespeed and brake performanceare monitored, so that the ABSsystem can provide effectiveantilock braking.

10-5

Some information may be storedby the on-board computer whenmalfunctions occur. This storedinformation can assist techni-cians in repairing the motorcycle.To read the stored information,special equipment is needed andaccess to the motorcycle or stor-age device is required. In addi-tion, once SUZUKI collects orreceives data, SUZUKI may usethe data for research conductedby SUZUKI, make the data avail-able for outside research if needis shown and confidentiality isassured, or make summary datawhich does not identify specificmotorcycles available for outsideresearch.

Others, such as law enforcementpersonnel, may have access tothe special equipment that canread the information if they haveaccess to the motorcycle or stor-age device.

SERIAL NUMBER LOCATIONYou need to know the frame andengine serial numbers to get titledocuments for your motorcycle.You also need these numbers tohelp your dealer when you orderparts.

The frame number 1 is stampedon the steering head as shown inthe illustration. The engine serialnumber 2 is stamped on the rightside of the crankcase assembly.

Write down the serial numbershere for your future reference.

Frame No.:

Engine No.:

10-6

LOCATION OF LABELSRead and follow all of the warn-ings labeled on your motorcycle.Make sure you understand all ofthe labels. Keep the labels onyour motorcycle. Do not removethem for any reason.

1

2

3

WARNINGDo not carry any objects in the space behind the fairing or on the fairing support bars.Objects placed in these area can interfere with steering and can cause loss of control.

WARNING• Keep windshield clean at all times.• Clean only with a soft cloth and warm

water with a mild detergent.• Minor scratches may be removed by

polishing with a commercially available plastic polish. Make sure the plastic polish does not contain an abrasive compound, as it may cause permanent scratches.

• Replace windshield if it becomes scratched or discolored so as to interfere with view.

• Avoid using any alkaline or strong acid cleaner, gasoline, brake fluid, or any other solvent.

• When replacing windshield, use Suzuki replacement windshield.

WARNINGFailure to follow these safetyprecautions may increase your riskof injury:

• Wear a helmet, eye protection, and bright protective clothing.

• Don’t ride after consuming alcohol or other drugs.

• Slow down on slippery surfaces,unfamiliar terrain, or when visibilityis reduced.

• Read owner’s manual carefully.

10-7

4

5

6

7

WARNINGNever make any modifications to the aluminum alloy frame, such as drilling or welding. Such modifications will weaken the frame and may lead to an accident.

The owner’s manual contains important safety information and instructions which should be read carefully before operating the vehicle.If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance.

MAXIMUM LOAD : 10 kg (22 lbs)

WARNING

BRIDGESTONE

kgf/cm2

TYPE

kPa psi

TIRE SIZE

FRONT REAR

110/80R19M/C 59H 150/70R17M/C 69H

TW101 J TW152 F

SOLO RIDING DUAL RIDING

FRONTREAR

COLD TIREPRESSURE

225250

2.252.50

3336

WARNINGCheck tire condition,wear, and cold tirepressure before each ride.Replace only with TUBELESS tires of listed size and type.Read Owner’s manual formore information.

•

•

•

kgf/cm2kPa psi225280

2.252.80

3341

SPECIFICATIONS

DIMENSIONS AND CURB MASSOverall length ..................................................2290 mm (90.2 in)Overall width.................................................... 840 mm (33.1 in)Overall height ..................................................1390 mm (54.7 in) ... Low windshield position (STD)

1420 mm (55.9 in) ... Middle windshield position 1450 mm (57.1 in) ... High windshield position

Wheelbase ......................................................1555 mm (61.2 in)Ground clearance............................................ 165 mm (6.5 in)Seat height ...................................................... 820 mm (32.3 in)Curb mass ....................................................... 220 kg (485 lbs)

ENGINEType.................................................................4-stroke, Liquid-cooled, DOHC,

90° degree V-twinNumber of cylinders ........................................2Bore.................................................................81.0 mm (3.189 in)Stroke ..............................................................62.6 mm (2.465 in)Displacement...................................................645 cm3 (39.4 cu. in)Compression ratio ...........................................11.5 : 1Fuel system.....................................................Fuel injection systemAir cleaner .......................................................Non-woven fabric elementStarter system .................................................ElectricLubrication system ..........................................Wet sump

DRIVE TRAINClutch ..............................................................Wet multi-plate typeTransmission ...................................................6-speed constant meshGearshift pattern .............................................1-down, 5-upPrimary reduction ratio ....................................2.088 (71/34)Gear ratios,Low...............................................2.461 (32/13)

2nd ...............................................1.777 (32/18)3rd ................................................1.380 (29/21)4th ................................................1.125 (27/24)5th ................................................0.961 (25/26)Top................................................0.851 (23/27)

Final reduction ratio.........................................3.133 (47/15)Drive chain ......................................................DID525V8, 118 links

CHASSISFront suspension .............................................Telescopic, coil spring, oil dampedRear suspension .............................................Link type, coil spring, oil dampedFront fork stroke ..............................................150 mm (5.9 in)Rear wheel travel.............................................150 mm (5.9 in)Caster..............................................................26°Trail ..................................................................110 mm (4.33 in)Steering angle .................................................40° (right and left)Turning radius..................................................2.6 m (8.5 ft)Front brake ......................................................Disk brake, twinRear brake.......................................................Disk brakeFront tire size...................................................110/80 R19 M/C 59H, tubelessRear tire size ...................................................150/70 R17 M/C 69H, tubeless

ELECTRICALIgnition type .....................................................Electronic ignition (Transistorized)Spark plug .......................................................NGK CR8E or DENSO U24ESR-NBattery.............................................................12V 36.0 kC(10 Ah)/10 HRGenerator ........................................................Three-phase A.C. generatorMain fuse.........................................................30AFuse ................................................................15/15/10/10/15/15AABS fuse .........................................................40/25AHeadlight .........................................................12V 60/55W × 2 (H4)Brake light/Taillight...........................................12V 21/5W × 2License plate light............................................12V 5WTurn signal light ...............................................12V 21WSpeedometer light ...........................................LEDTachometer light ..............................................LEDTurn signal indicator light.................................LEDNeutral indicator light.......................................LEDHigh beam indicator light.................................LEDOil pressure/Coolant temperature/Fuel injection indicator light ............................LEDABS indicator light ...........................................LED

CAPACITIESFuel tank, including reserve ............................ 22.0 L (5.8 US gal)Engine oil, oil change ......................................2300 ml (2.4 US qt)

With filter change ...........................2700 ml (2.9 US qt)Engine coolant................................................. 1.9 L (2.0 US qt)

INDEX

AACCESSORIES AND LOADING ............................... 1-5ACCESSORY INSTALLATION GUIDELINE............................ 6-2ACCESSORY USE ................ 6-2AIR CLEANER ....................... 7-9

BBATTERY............................... 7-8BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS................... 1-4BE STREET SMART.............. 1-6BRAKES............................... 7-29

CCARRYING A PASSENGER...................1-5,5-8CLUTCH............................... 7-28CONCLUSION ....................... 1-6CORROSION PREVENTION........................ 9-3

DDRIVE CHAIN ...................... 7-24

EEMISSION CONTROL WARRANTY .........................10-2ENGINE COOLANT .............7-22ENGINE COOLANT SOLUTION .............................2-5ENGINE IDLE SPEED INSPECTION........................7-20ENGINE OIL .................. 2-3,7-16

FFRONT WHEEL REMOVAL ............................7-37FUEL ......................................2-2FUEL HOSES.......................7-22FUEL SYSTEM CHECK .........8-2FUEL TANK CAP .................3-18FUEL TANK LIFT ...................7-5FUSES..................................7-44

GGEARSHIFT LEVER ............3-19

HHELMET HOLDER ...............3-20

IIF A COLLISION IS IMMINENT, DO SOMETHING! .................. 1-3IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE ....... 1-2IGNITION SWITCH ................ 3-5IGNITION SYSTEM CHECK................................... 8-3INSPECTION AFTER CLEANING............................. 9-6INSPECTION BEFORE RIDING.............................1-5,4-3INSTRUMENT PANEL........... 3-7

KKEY ........................................ 3-5KNOW YOUR LIMITS ............ 1-4

LLEFT HANDLEBAR.............. 3-14LOADING GUIDELINES ........ 6-4LOADING LIMIT ..................... 6-3LOCATION OF LABEL......... 10-6LOCATION OF PARTS.......... 3-2LUBRICATION POINTS......... 7-7

MMAINTENANCE SCHEDULE ............................7-2MODIFICATION .....................6-4MOST ACCIDENTS CAN BE AVOIDED ...............................1-2MOTORCYCLE CLEANING .............................9-4MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA) .......1-6

NNOTICE ..................................7-2

OON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....................10-4

PPRACTICE AWAY FROM TRAFFIC ................................1-4PROCEDURE FOR RETURNING TO SERVICE..........................9-3

RREAR BRAKE PEDAL ......... 3-19REAR WHEEL REMOVAL............................ 7-40REPORTING SAFETY DEFECTS............................. 10-2RIDING ON HILLS ................. 5-5RIGHT HANDLEBAR ........... 3-15

SSEAT LOCK ......................... 3-20SERIAL NUMBER LOCATION........................... 10-5SIDE STAND........................ 3-21SIDE STAND/IGNITION INTERLOCK SYSTEM......... 7-36SPARK PLUG ...................... 7-12SPECIAL SITUATIONS REQUIRE SPECIAL CARE ..................................... 1-3STARTING OFF AND SHIFTING............................... 5-3STARTING THE ENGINE.................................. 5-2STOPPING AND PARKING ............................... 5-5STORAGE PROCEDURE ........................ 9-2SUSPENSION ADJUSTMENT ..................... 3-22

TTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED........................10-3THROTTLE CABLE PLAY ....................................7-21TIRES ...................................7-33TOOLS ...................................7-5

UUSING THE TRANSMISSION ....................5-4

WWINDSHIELD HEIGHT ADJUSTMENT .....................3-24

Total page: 124

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1st cover4th cover

Top

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DL650AOWNER’S MANUAL

99011-27G62-03A

DL

650A

Part No. 99011-27G62-03AJuly, 2008 ENTK

5 mm5 mmNo.646 DL650A 99011-27G62-03A 2/1No.646 DL650A 99011-27G62-03A 2/1 DIC184(TDP006) DIC157

This owner’s manual containsimportant safety information.Please read it carefully.

WARNINGFailure to follow these safetyprecautions may increase yourrisk of injury:

Wear a helmet, eye protec-tion, and bright protectiveclothing.Don’t ride after consumingalcohol or other drugs.Slow down on slippery sur-faces, unfamiliar terrain, orwhen visibility is reduced.Read owner’s manual care-fully.

K9 Printed in Japan300 TAKATSUKA, MINAMI, HAMAMATSU, JAPAN

california proposition 65 warning this manual should be ... · top 2nd cover 3rd cover no.646...

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