Top
2nd cover 3rd cover
California Proposition 65 Warning WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your hands frequently when servicing your vehicle. For more information go to www.P65Warnings.ca.gov/ passenger-vehicle.
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.
DL1000A/XA (99011-31J53-03A) 7 mm 4/1 Black IMPORTANT FOREWORD
WARNING/CAUTION/ Motorcycling is one of the most NOTICE/NOTE exhilarating sports and to ensure Please read this manual and fol- your riding enjoyment, you should low its instructions carefully. To become thoroughly familiar with emphasize special information, the information presented in this the symbol and the words Owner’s Manual before riding the WARNING, CAUTION, NOTICE motorcycle. and NOTE have special mean- ings. Pay particular attention to The proper care and maintenance messages highlighted by these that your motorcycle requires is signal words: outlined in this manual. By follow- ing these instructions explicitly, you will ensure a long trouble-free WARNING operating life for your motorcycle. Indicates a potential hazard This motorcycle also conforms to that could result in death or the U.S. Environmental Protection Agency emission regulations serious injury. which apply to new motorcycles. The proper adjustment of engine CAUTION components is necessary for this motorcycle to comply with the Indicates a potential hazard EPA regulations. Therefore, that could result in minor or please follow the maintenance moderate injury. instructions closely to ensure emission compliance. Your Suzuki dealer has experienced techni- NOTICE cians that are trained to provide Indicates a potential hazard your machine with the best possi- that could result in vehicle or ble service with the right tools and equipment damage. equipment.
NOTE: Indicates special informa- tion to make maintenance easier or instructions clearer. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepan- cies between information in this manual and your motorcycle. Suzuki reserves the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehi- cles previously built or sold.
Suzuki Motor Corporation believes in conservation and pro- tection of Earth’s natural resources. To that end, we encourage every vehicle owner to recycle, trade in, or properly dis- pose of, as appropriate, used motor oil, coolant, and other flu- ids, batteries and tires. TABLE OF CONTENTS
THE SPORT OF MOTORCYCLING 1
FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS 2
CONTROLS, EQUIPMENT AND ADJUSTMENTS 3
BREAK-IN AND INSPECTION BEFORE RIDING 4
RIDING TIPS 5
ACCESSORY USE AND MOTORCYCLE LOADING 6
INSPECTION AND MAINTENANCE 7
TROUBLESHOOTING 8
STORAGE PROCEDURE AND MOTORCYCLE CLEANING 9
CONSUMER INFORMATION 10
SPECIFICATIONS
INDEX
1 THE SPORT OF MOTORCYCLING
MOST ACCIDENTS CAN BE AVOIDED ...... 1-2 IF YOU DON’T HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE ...... 1-2 IF A COLLISION IS IMMINENT, DO SOMETHING! ...... 1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE ...... 1-4 KNOW YOUR LIMITS ...... 1-4 BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS ...... 1-4 PRACTICE AWAY FROM TRAFFIC ...... 1-5 INSPECTION BEFORE RIDING ...... 1-5 ACCESSORIES AND LOADING ...... 1-5 CARRYING A PASSENGER ...... 1-5 MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA) ...... 1-5 BE STREET SMART ...... 1-6 LABELS ...... 1-6 CONCLUSION ...... 1-6
1-1 THE SPORT OF Ride defensively. Wise motorcy- MOTORCYCLING clists use a strategy of assuming they are invisible to other drivers, even in broad daylight. Pay care- Your motorcycle and this owner’s ful attention to other motorists, manual have been designed by especially at intersections, people like you who enjoy motor- because they may not be paying cycling. People become motorcy- attention to you. Select a lane clists for many reasons. For position that gives you the best starters, street riding is fun and view of others, and other motor- invigorating. But no matter why ists the best view of you. Wear you became a motorcyclist, or bright, reflective clothing. Put how experienced you are, you will reflective strips on your helmet. eventually face some challenging situations.
In preparing for these challenges, IF YOU DON’T HAVE A HELMET, you will be fine-tuning your coordi- BUY A HELMET AND WEAR IT nation, concentration, and atti- EVERY TIME YOU RIDE tude. Learning the skills and Most accidents occur within a few strategies associated with motor- miles of home, and almost half cycling is the basis for safely par- occur at speeds of less than 30 ticipating in this sport. Many mph. So even if you’re just going motorcyclists find that as they on a quick errand, be prepared – become better riders, they also strap on your helmet before you get more enjoyment from the free- take off. dom unique to motorcycling. Helmets do not reduce essential Please remember: vision or hearing. Generally, hel- mets do not cause or intensify injury if you crash. Helmets simply MOST ACCIDENTS CAN BE help your skull protect your intelli- AVOIDED gence, your memory, your per- The most common type of motor- sonality, and your life. cycle accident in the U.S. occurs when a car traveling towards a Your eyesight is equally valuable. motorcycle turns left in front of the Wearing suitable eye protection motorcycle. Is that because other can help keep your vision drivers are out to get motorcy- unblurred by the wind and save clists? No. Other drivers simply your eyes from airborne hazards don’t always notice motorcyclists. like bugs, dirt, or pebbles kicked up by tires.
1-2 IF A COLLISION IS IMMINENT, Emergency stopping and swerv- DO SOMETHING! ing are techniques that you Many riders fear locking up their should practice and master before brakes or haven’t learned to you find yourself in an emergency swerve to avoid an accident. situation. The best place to prac- Many inexperienced riders (and tice such techniques is in a con- too many seasoned riders) use trolled environment such as the only their rear brake in an emer- Motorcycle Safety Foundation’s gency, resulting in unnecessary (MSF) rider training courses. The impacts in some cases and MSF’s Motorcycle Rider Courses unnecessarily high impact speeds (fundamental techniques) and in other cases. Your rear brake Experienced Rider Courses can only provide about 30% of (advanced strategies) present your motorcycle’s potential stop- hands-on instruction of the basic ping power. The front and rear principles of motorcycling and a brakes can and should be used variety of accident-avoidance together to maximize braking maneuvers. Even a seasoned effectiveness. motorcyclist can improve his or her riding skills, and pick up a few Experienced motorcyclists learn new skills, through these courses. to “cover” the front brake lever by Some insurance companies even lightly resting a couple of fingers offer discounts to course gradu- over the lever when riding in traffic ates. and near intersections to give their reaction time a head start.
1-3 SPECIAL SITUATIONS REQUIRE Riding a motorcycle safely SPECIAL CARE requires that your mental and Of course, there are some times physical skills are fully part of the when full-force braking is not the experience. You should not correct technique. When the road attempt to operate a motor vehi- surface is wet, loose, or rough, cle, especially one with two you should brake with care. When wheels, if you are tired or under you’re leaned over in a corner, the influence of alcohol or other avoid braking. Straighten up drugs. Alcohol, illegal drugs, and before braking. Better yet, slow even some prescription and over- down before entering the corner. the-counter drugs can cause drowsiness, loss of coordination, In these situations, the traction loss of balance, and especially available between your tires and the loss of good judgment. If you the road surface is limited. Over- are tired or under the influence of braking when traction is limited alcohol or other drugs, PLEASE will cause your tires to skid, possi- DO NOT RIDE your motorcycle. bly resulting in loss of directional control or causing you and your motorcycle to fall over. BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days, KNOW YOUR LIMITS especially wet ones, requires Always ride within the boundaries extra caution. Braking distances of your own skills. Knowing these increase on a rainy day. Stay off limits and staying within them will the painted surface marks, man- help you avoid accidents. hole covers, and greasy-appear- ing areas, as they can be A major cause of accidents involv- especially slippery. Use extra cau- ing only a motorcycle (and no tion at railway crossings and on cars) is going too fast through a metal gratings and bridges. When turn. Before entering a turn, select it starts to rain, any oil or grease an appropriately low cornering on the road rises to the surface of speed. Even on straight roads, the water. Pull over and wait a few ride at a speed that is appropriate minutes until this oil film is for the traffic, visibility and road washed away before riding. conditions, your motorcycle, and Whenever in doubt about road your experience. conditions, slow down !
1-4 PRACTICE AWAY FROM CARRYING A PASSENGER TRAFFIC Carrying a passenger, when done Your riding skill and your mechan- correctly, is a great way to share ical knowledge form the founda- the joy of motorcycling. You will tion for safe riding practices. We have to alter your riding style suggest that you practice riding somewhat since the extra weight your motorcycle in a non-traffic of a passenger will affect handling situation until you are thoroughly and braking. You may also need familiar with your machine and its to adjust tire pressures and sus- controls. Again, consider taking pension; please refer to the Tire one of the MSF’s Rider Courses. Pressure and Loading section Even experts will be pleased with and the Suspension section for the caliber of the information pre- more details. sented in these courses. As the MSF says: “The more you know, A passenger needs the same pro- the better it gets !” tection that you do, including a helmet and proper clothing. The INSPECTION BEFORE RIDING passenger should not wear long Review the instructions in the shoe laces or loose pants that “INSPECTION BEFORE RIDING” could get caught in the wheel or section of this manual. Perform an the chain. Passengers must be entire pre-ride inspection before tall enough that their feet reach you head out on the road. Spend- the footrests. ing a few minutes preparing your machine for a ride can help pre- vent accidents due to mechanical MOTORCYCLE SAFETY failure or costly, inconvenient FOUNDATION’S “RIDING TIPS breakdowns far from home. AND PRACTICE GUIDE” HANDBOOK ACCESSORIES AND LOADING (FOR OWNERS IN USA) The accessories you use with This special handbook, supplied your motorcycle and the manner with your owner’s manual, con- in which you load your gear onto tains a variety of safety tips, help- the bike might create hazards. ful hints, and practice exercises. Aerodynamics, handling, balance, This manual can increase your and cornering clearance can suf- riding enjoyment and safety. You fer, and the suspension and tires should read it thoroughly. can be overloaded. Read the “ACCESSORY USE AND MOTORCYCLE LOADING” sec- tion.
1-5 BE STREET SMART CONCLUSION Always heed speed limits, local Traffic, road and weather condi- laws, and the basic rules of the tions vary. Other motorists’ road. Set a good example for oth- actions are unpredictable. Your ers by demonstrating a courteous motorcycle’s condition can attitude and a responsible riding change. These factors can best style. be dealt with by giving every ride your full attention. LABELS Read and follow all the labels on Circumstances beyond your con- the motorcycle. Make sure you trol could lead to an accident. You understand all of the labels. Do need to prepare for the unex- not remove any labels from the pected by wearing a helmet and motorcycle. other protective gear, and learn- ing emergency braking and swerving techniques to minimize the damage to you and your machine.
The best way to learn basic riding skills and evasive maneuvers or refresh your own riding skills is to take one of the courses offered by the Motorcycle Safety Foundation. Your Suzuki dealer can help you locate the fundamental or advanced riding skills course nearest you, or owners in the USA can call toll-free 1-800-446-9227.
Good riding on your new Suzuki !
1-6 FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS 2
FUEL ...... 2-2 ENGINE OIL ...... 2-4 ENGINE COOLANT SOLUTION ...... 2-5
2-1 FUEL, ENGINE OIL Oxygenated fuels which meet the AND COOLANT minimum octane requirement and the requirements described below RECOMMENDATIONS may be used in your motorcycle without jeopardizing the New FUEL Vehicle Limited Warranty or the Your motorcycle requires pre- Emission Control System War- mium unleaded gasoline with a ranty. minimum pump octane rating of 90 ((R+M)/2 method). In some NOTE: Oxygenated fuels are areas, the only fuels that are fuels which contain oxygen-carry- available are oxygenated fuels. ing additives such as alcohol.
NOTE: Gasoline/Ethanol Blends • The DL1000A/XA engine is Blends of unleaded gasoline and designed to use premium ethanol (grain alcohol), also unleaded gasoline only. Use known as GASOHOL, are com- premium unleaded gasoline mercially available in some areas. under all riding conditions. Blends of this type may be used in • If the engine develops some your motorcycle if they are no trouble like lack of acceleration more than 10% ethanol ( ). Make or insufficient power, the cause sure this gasoline-ethanol blend may be due to the fuel the has octane ratings no lower than motorcycle uses. In such case, those recommended for gasoline. try changing to a different gas station. If the situation is not improved by changing, consult your Suzuki dealer.
2-2 Fuel Pump Labeling In some states, pumps that dis- NOTICE pense oxygenated fuels are required to be labeled for the type Spilled gasoline containing and percentage of oxygenate, and alcohol can damage the whether important additives are painted surfaces of your present. Such labels may provide motorcycle. enough information for you to determine if a particular blend of Be careful not to spill any fuel fuel meets the requirements listed when filling the fuel tank. Wipe above. In other states, pumps spilled gasoline up immedi- may not be clearly labeled as to ately. the content or type of oxygen and additives. If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel supplier.
NOTE: • To help minimize air pollution, Suzuki recommends that you use oxygenated fuels. • Be sure that any oxygenated fuel you use has octane rat- ings of at least 90 pump octane ((R+M)/2 method). • If you are not satisfied with the drivability or fuel economy of your motorcycle when you are using an oxygenated fuel, or if engine pinging is experi- enced, substitute another brand as there are differences between brands.
2-3 ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of Suzuki recommends the use of SUZUKI PERFORMANCE 4 SAE 10W-40 engine oil. If SAE MOTOR OIL or equivalent engine 10W-40 engine oil is not available, oil. If SUZUKI PERFORMANCE 4 select an alternative according to MOTOR OIL is not available, the following chart. select a proper engine oil accord- ing to the following guideline. Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use oil with an API (American Petroleum Institute) classification of SG, SH, SJ or SL with a JASO classification of MA.
SAE API JASO SG, SH, SJ JASO T903 10W-40 MA or SL The JASO T903 standard is an index to select engine oils for 4- API: American Petroleum Institute stroke motorcycle and ATV JASO: Japanese Automobile engines. Motorcycle and ATV Standards Organization engines lubricate clutch and transmission gears with engine NOTE: SUZUKI highly recom- oil. JASO T903 specifies perfor- mends the use of ECSTAR brand mance requirements for motorcy- engine oil. ECSTAR has been cle and ATV clutches and specially formulated for your transmissions. SUZUKI product and contributes to the desired motorcycle perfor- There are two classes, MA and mance and ideal riding experi- MB. The oil container shows the ence. classification as follows.
1 Code number of oil sales company 2 Oil classification
2-4 Energy Conserving ENGINE COOLANT SOLUTION Suzuki does not recommend the Use “SUZUKI SUPER LONG use of “ENERGY CONSERVING” LIFE COOLANT” or “SUZUKI or “RESOURCE CONSERVING” LONG LIFE COOLANT”. If oils. Some engine oils which have “SUZUKI SUPER LONG LIFE an API classification of SH, SJ or COOLANT” and “SUZUKI LONG SL have an “ENERGY CON- LIFE COOLANT” are not avail- SERVING” indication in the API able, use a glycol-based anti- classification donut mark. These freeze compatible with an oils can affect engine life and aluminum radiator mixed with dis- clutch performance. tilled water only at the ratio of 50:50. API SG, SH, SJ or SL
ERVIC I S E WARNING P S A J SAE Engine coolant is harmful or 10W-40 fatal if swallowed or inhaled. Solution can be poisonous to Recommended animals. Do not drink antifreeze or cool- API SH, SJ or SL ant solution. If swallowed, do not induce vomiting. Immedi- ERVIC I S E P S ately contact a poison control A J SAE center or a physician. Avoid
E
N 10W-40 G E N inhaling mist or hot vapors; if I R V G R Y CONSE inhaled, remove to fresh air. If coolant gets in eyes, flush eyes Not recommended with water and seek medical attention. Wash thoroughly after handling. Keep out of the reach of children and animals.
2-5 SUZUKI LONG LIFE COOLANT NOTICE (Green) Spilled engine coolant can Water for Mixing damage the painted surfaces of Use distilled water only. Water your motorcycle. other than distilled water can cor- rode and clog the aluminum radia- Be careful not to spill any fluid tor. when filling the radiator. Wipe spilled engine coolant up Required amount of engine cool- immediately. ant/water solution capacity (total): 2130 ml (2.3 US qt)
NOTE: SUZUKI highly recom- 1065 ml Engine coolant mends the use of ECSTAR brand (1.1 US qt) coolant. ECSTAR has been spe- 1065 ml Water cially formulated for your SUZUKI (1.1 US qt) product and contributes to the desired motorcycle performance NOTE: This 50% mixture will and ideal riding experience. protect the cooling system from freezing at temperatures above ENGINE COOLANT –31°C (–24°F). If the motorcycle Engine coolant performs as a rust is to be exposed to temperature inhibitor and water pump lubricant below –31°C (–24°F), this mix- as well as an anti-freeze solution. ing ratio should be increased up Therefore Engine coolant should to 55% (–40°C/–40°F) or 60% be used at all times even though (–55°C/–67°F) coolant. The mix- the atmospheric temperature in ing ratio should not exceed 60% your area does not go down to the coolant. freezing point.
SUZUKI SUPER LONG LIFE COOLANT (Blue) “SUZUKI SUPER LONG LIFE COOLANT” is pre-mixed to the proper ratio. Add only “SUZUKI SUPER LONG LIFE COOLANT” if coolant level drops. It is not nec- essary to dilute “SUZUKI SUPER LONG LIFE COOLANT” when replacing coolant.
2-6 CONTROLS, EQUIPMENT AND ADJUSTMENTS
LOCATION OF PARTS ...... 3-2 3 KEY ...... 3-5 IGNITION SWITCH ...... 3-5 INSTRUMENT PANEL ...... 3-8 LEFT HANDLEBAR ...... 3-22 RIGHT HANDLEBAR ...... 3-27 FUEL TANK CAP ...... 3-30 GEARSHIFT LEVER ...... 3-31 REAR BRAKE PEDAL ...... 3-31 SEAT LOCK ...... 3-32 SIDE STAND ...... 3-33 SUSPENSION ADJUSTMENT ...... 3-34 WINDSHIELD ...... 3-37 OUTPUT TERMINAL ...... 3-39
3-1 CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS
1000 r/min
mph km/h
GEAR
H TRIP 12 TC 0 AIR OFF 1 2 C RANGEV MPG AVG12 km/L/100km EF
1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Brake lever 8 Ignition switch 9 Fuel tank cap 0 Output terminal
3-2 DL1000A
A Air cleaner B Air cleaner drain plug C Battery D Fuses E Tools F Spark plugs G Gearshift lever H Side stand I Footrests J Seat lock K Passenger footrests DL1000XA
3-3 DL1000A
L Rear brake fluid reservoir M Engine coolant reservoir N Engine oil filler cap O Rear brake pedal P Engine oil drain plug Q Engine oil inspection window R Engine oil filter
DL1000XA
3-4 KEY IGNITION SWITCH
Two keys come with this motorcy- The ignition switch has 4 posi- cle. Keep the spare key in a safe tions: place. “OFF” Position All electrical circuits are off. The engine will not start. The key can be removed.
“ON” Position The ignition circuit is completed and the engine can run. The headlight, position light, taillight and license plate light will auto- matically turn on. The key cannot be removed in this position.
NOTE: Start the engine promptly after turning the key to the “ON” position, or the battery will lose power due to consumption by the headlight and taillight.
“LOCK” position All electrical circuits are off. The key can be removed and the steering will be locked. Turn the steering all the way to the left and push down the key and turn it to the “LOCK” position.
3-5 WARNING Turning the ignition switch to the “P” (PARKING) or “LOCK” position while the motorcycle is moving can be hazardous. Moving the motorcycle while the steering is locked can be hazardous. You could lose your balance and fall, or you could “P” (Parking) Position drop the motorcycle. The taillight will come on to increase visibility for temporary Stop the motorcycle and place roadside parking at night. The key it on the side stand before lock- can be removed and the steering ing the steering. Never attempt will be locked. to move the motorcycle when the steering is locked.
3-6 WARNING If the motorcycle falls down due to a slip or collision, unex- pected damage to the motorcy- ON OFFFF
H
cle could cause the engine to S
U
P
L keep running, which could O C K result in a fire, or could result P in injury from moving parts IGNITION such as the rear wheel.
If the motorcycle falls down, turn the ignition switch off ON OFF
H
immediately. Ask your autho- S
U
P
rized Suzuki dealer to inspect L O C the motorcycle for unseen K damage. P IGNITION
In order to align the lid with the keyhole, the same procedure is used.
A lid 2 is provided for the key cyl- inder 1 to prevent tampering. Turning the lid position covers the keyhole 3, to prevent any alien substance entering the keyhole. To turn the lid, insert the tip of the key slightly into the lid and turn it.
3-7 INSTRUMENT PANEL WARNING Changing the display while riding can be hazardous. 10 11 12 9 8 1000 r/min Removing a hand from the han- 7
6 mph dlebars can reduce your ability km/h
5 GEAR ADJ 4 to control the motorcycle. H TRIP 3 12 2 TC 10 AIR OFF 1 2 C RANGE V MPG AVG12 km/L/100km EF Never change the display while riding. Keep both hands on the handlebars.
The malfunction indicator light 6, Turn Signal Indicator Light 2 freeze indicator light B, engine “” coolant temperature indicator When the turn signals are being light/oil pressure indicator light 4, operated either to the right or to ABS indicator light D, traction the left, the indicator light will blink control indicator light 5, LCD’s intermittently. and tachometer needle work as follows to confirm their function NOTE: If a turn signal light is not when the ignition switch is turned operating properly due to bulb fila- to the “ON” position. ment or circuit failure, the indica- tor light blinks more quickly to • The malfunction indicator light notify the rider of the existence of 6 and freeze indicator light B a problem. come on for 2 seconds. • The tachometer needle moves to the full scale position and returns to the home position. • All LCD segments appear and then show the normal display.
3-8 Tachometer 3 The tachometer indicates the NOTICE engine speed in revolutions per minute (r/min). After starting the engine, open- ing the throttle or running the If the tachometer needle does not motorcycle with the oil pres- point to zero, follow the procedure sure indicator light turned on, below to reset the tachometer. may adversely affect the engine. 1. Press and hold the ADJ button 1 and turn on the ignition Make sure that the oil pressure switch. indicator light has turned off 2. Hold the ADJ button 1 for 4 before operating the throttle or seconds. running the motorcycle. Oil Pressure Indicator Light “” 4 NOTICE When the ignition switch is in the “ON” position but the engine has Riding the motorcycle with the not been started, the indicator oil pressure indicator light lit “” 7 in the display and the can damage the engine and indicator light 4 comes on. As transmission. soon as the engine is started, the indicator “” 7 and the indica- If the oil pressure indicator tor light 4 should go out. light comes on, indicating low oil pressure, stop the engine When the engine oil pressure drops under the normal operating immediately. Check the oil level range, the indicator “” 7 in and add oil if necessary. If the display appears and the indi- there is a proper amount of oil cator light 4 comes on. and the light still does not go out, have your authorized Suzuki dealer or a qualified mechanic inspect your motor- cycle.
3-9 WARNING Riding the motorcycle with the 10 11 12 9 8 1000 r/min traction control system turned 7
6 mph on and the traction control indi- km/h
5 GEAR ADJ 4 cator light lit can be hazardous. H TRIP 3 12 2 TC 10 AIR OFF 1 2 C RANGE V MPG AVG12 km/L/100km EF If the traction control indicator light comes on while riding, stop the motorcycle in a safe place and turn off the ignition Traction Control Indicator Light switch. Turn the ignition switch “TC” 5 “ON” after a while and check When the traction control system whether the indicator light is turned off, the traction control comes on. indicator light remains lit. • If the indicator light goes off after starting to ride, the trac- When the traction control system tion control system will be is set to Mode 1 or Mode 2, the functioning. traction control indicator light indi- • If it does not go off after cates as follows. starting to ride, the traction • The indicator comes on when control system is not func- the ignition switch is turned tioning. You should have the “ON” and goes off after the system checked by an autho- motorcycle speed exceeds 5 rized Suzuki dealer as soon km/h (3 mph). as possible. • The indicator comes on and remains on when the traction NOTE: For more detailed informa- control system is not working tion on the traction control sys- due to a system malfunction. tem, see page 3-24. • The indicator blinks when the traction control system senses rear wheel spin and is control- ling engine power output. • The indicator remains off when the traction control system is monitoring the traction of the rear wheel during acceleration.
3-10 Malfunction Indicator Light “” 6 NOTICE The malfunction indicator light comes on to indicate a problem with the fuel injection system. If the fuel injection system fails, Riding the motorcycle with the the malfunction indicator light 6 malfunction indicator light lit comes on and the display indi- can damage the engine and cates “FI” in the odometer display transmission. area in the following two modes; If the display indicates “FI” and A. The display J in the odometer the malfunction indicator light display area alternately indi- comes on, have your autho- cates “FI” and the odometer/ rized Suzuki dealer or a quali- trip meter reading, and the fied mechanic inspect the fuel 6 malfunction indicator light injection system as soon as comes on and remains lit. B. The display J in the odometer possible. display area indicates “FI” con- tinuously and the malfunction NOTE: indicator light 6 blinks while • If the display indicates “FI” and cranking the engine. the odometer/trip meter read- ing alternately, and the mal- The engine may continue to run in function indicator light comes mode A, but the engine will not on and remains lit, keep the run in mode B. engine running and bring your motorcycle to an authorized Suzuki dealer. If the engine stalls, try restarting the engine after turning the ignition switch off and on. • If the display indicates “FI” continuously and the malfunc- tion indicator light blinks, the engine will not start.
3-11 Gear Position Indicator 8 The gear position indicator indi- cates gear position. This indica-
10 11 12 tor displays “N” when the 9 8 1000 r/min transmission is in neutral. 7
6 mph km/h
5 GEAR ADJ 4 NOTE: When the display indi- H TRIP 3 12 2 TC 10 OFF AIR cates “CHEC” in the odometer 1 2 C RANGE V MPG AVG12 km/L/100km EF display area, the gear position indicator does not indicate a num- ber but indicates “–”.
Speedometer 9 The speedometer indicates the road speed in kilometers per hour or miles per hour. When the display indicates “CHEC” in the odometer display area, check the following items; km/h mph • Make sure that the engine stop switch is in the “” position. NOTE: • Make sure that the transmis- • Set the meter J to odometer, sion is in neutral or the side then press and hold the ADJ stand is fully up. button 1 for 2 seconds to switch between km/h and mph. If the display still indicates At the same time, the odome- “CHEC” after checking the above ter will be changed between items, inspect the ignition fuse km and mile. and the connection of the lead • Select km/h or mph, as appro- wire couplers. priate, to comply with traffic regulations. • Check km/h and mph display after adjusting the instrument panel display.
3-12 Thermometer 0 Neutral Indicator Light “N” A The green light will come on when
AIR the transmission is in neutral. The light will go out when you shift into any gear other than neutral. The thermometer shows the ambient air temperature, when Freeze Indicator Light “ ” B the ignition switch is in the “ON” The freeze indicator light B starts position. blinking when the ambient tem- perature falls below 3°C (38°F). The thermometer display will be The freeze indicator light keeps changed between °C and °F flashing for 30 seconds and then according to the speedometer remains lit until the ambient tem- setting when the ADJ button 1 is perature rises above 5°C (41°F). pressed and held for 2 seconds. Display 0 shows the thermome- ter reading and blinks for 30 sec- Speedometer Thermometer onds when the ambient mph °F temperature falls below 3°C km/h °C (38°F).
NOTE: High Beam Indicator Light “” • The thermometer will not indi- C cate the actual ambient air This blue indicator light will be lit temperature when riding at low when the headlight high beam is speed or when stopped. turned on. • The thermometer displays “Lo” when the ambient air tempera- ture is below –10°C (14°F). The thermometer displays “HI” when the ambient air tempera- ture is above 50°C (122°F).
3-13 WARNING Riding the motorcycle with the 10 11 12 9 8 1000 r/min ABS indicator light on can be 7
6 mph hazardous. km/h
5 GEAR ADJ 4 H TRIP 3 12 2 TC 10 AIR OFF 1 If the ABS indicator light blinks 2 C RANGE V MPG AVG12 km/L/100km EF or comes on while riding, stop the motorcycle in a safe place and turn off the ignition switch. Turn the ignition switch “ON” ABS Indicator Light “” D after a while and check if the This indicator normally comes on indicator light comes on. when the ignition switch is turned • If the indicator light goes off “ON” and goes off after the motor- after starting to ride, the ABS cycle speed exceeds 5 km/h (3 will be functioning. mph). • If it does not go off after starting to ride, ABS is not If there is a problem with the ABS functioning. You should have (Anti-lock Brake System), this the system checked by an indicator light blinks or comes on. authorized Suzuki dealer as The ABS does not operate when soon as possible. the ABS indicator light is on or blinking.
NOTE: If the ABS indicator light goes off after you start the motor- cycle but before you begin riding, check the ABS indicator light function by turning off and on the ignition switch. The ABS indicator light can go off if the engine is revved at high speed before you begin riding. If the ABS indicator light does not come on when the ignition switch is turned on, you should have the system checked by an authorized Suzuki dealer as soon as possible.
3-14 Engine Coolant Temperature Fuel Level Indicator “” F Indicator “” E The fuel level indicator indicates The coolant temperature is dis- the amount of fuel remaining in played by an LCD segment tem- the fuel tank. The fuel level indica- perature indicator E, water tor displays all 6 segments when temperature indicator 7, and indi- the fuel tank is full. The mark cator light 4. blinks when the fuel level drops below 4.5 L (4.8 US qt). The mark When the coolant temperature and segment blink when the fuel exceeds 116°C (241°F), all six drops below 1.5 L (1.6 US qt). LCD segments turn on. When the coolant temperature comes to Approximately Approximately Fuel tank Full 120°C (248°F), the indicator light 1.5 L 4.5 L 4 turns on. If all six LCD seg- Blink ments for the temperature indica- Segment tor E turn on, stop the engine, Blink Blink wait until the engine is cooled, mark and check the coolant level. NOTICE NOTE: • The fuel level indicator will not Riding the motorcycle with the indicate correctly when the engine coolant temperature motorcycle is placed on the indicator light lit can cause side stand. Turn the ignition serious engine damage due to switch to the “ON” position overheating. when the motorcycle is held upright. If the engine coolant tempera- • If the fuel mark blinks, fill the ture indicator light comes on, fuel tank immediately. Also, the last segment of the fuel level stop the engine to let it cool. indicator blinks when the fuel Do not run the engine until the tank is almost empty. engine coolant temperature indicator light goes off.
3-15 • km/L to L/100km
“km/L” mode
10 11 12 9 8 1000 r/min 7
6 mph km/h
5 GEAR ADJ 4 H TRIP 3 12 2 TC 10 AIR OFF 1 2 C RANGE V MPG AVG12 km/L/100km EF “L/100 km” mode
Set the meter G to instantaneous fuel consumption meter or aver- Instantaneous Fuel age fuel consumption, then press Consumption Meter/ and hold the MODE switch Average Fuel Consumption Meter/ (Down) for 2 seconds to change Driving Range Meter/ “km/L” mode to “L/100 km” mode. Voltmeter G • MPG to km/L (L/100km) The display has 4 functions; instantaneous fuel consumption “MPG” mode meter, average fuel consumption meter, driving range meter and voltmeter. When the ignition switch is turned to the “ON” posi- tion, the test pattern shown below MPG US is displayed for 2 seconds. The display is memorized when the “km/L” mode ignition switch is turned off and the memorized display appears Set the meter J to odometer, when the ignition switch is turned then press and hold the ADJ but- on again. ton 1 for 2 seconds to change “MPG” mode to “km/L (L/100 km)” mode. At the same time, the odometer will be change between mile and km.
3-16 To change the display, push the Instantaneous fuel left handlebar MODE switch consumption meter (Down). The display changes in The instantaneous fuel consump- the order below. tion meter displays the fuel con- sumption value only when the motorcycle is moving. However, km/L when the motorcycle is stopping, Instantaneous fuel the fuel consumption meter dis- consumption plays “--.-”. This meter ranges from 0.1 to 50.0 (km/L, L/100 km) or from 0.1 to 99.9 (MPG US).
AVG 1 km/L NOTE: The display shows esti- Trip meter 1 or 2 mated values. Indications may not average fuel consumption be the same as actual values.
RANGE km Driving range
V Volt
3-17 Driving range meter The driving range meter displays estimated driving range (distance)
10 11 12 based on the remaining fuel 9 8 1000 r/min within the range from 1 to 999 km 7
6 mph km/h (mile). The driving range is recal- 5 GEAR ADJ 4 culated when you refuel, but the H TRIP 3 12 2 TC 10 OFF AIR indication may not change when 1 2 C RANGE V MPG AVG12 km/L/100km EF only a small amount of fuel is added.
The driving range will not be recalculated when the motorcycle Average fuel consumption is placed on the side stand. meter Check the estimated driving The average fuel consumption range (distance) when the side meter displays average fuel con- stand is retracted. When the bat- sumption ratio or trip 1 and trip 2. tery is disconnected, the driving The average fuel consumption range meter will be reset. when meter ranges from 0.1 to 99.9 this happens, the meter indicates (km/L, MPG US) or from 2.0 to “---” until the motorcycle is ridden 99.9 (L/100 km). The Average fuel for a certain distance. consumption meter indicates “--.-” when the trip meter indicates 0.0. NOTE: For resetting the fuel consumption • The driving range (distance) is meter, reset the trip meter. an estimated value. The indi- cation may not be the same as NOTE: The display shows esti- the actual driving distance. mated values. Indications may not • The meter does not use the be the same as actual values. average fuel consumption value to calculate driving range (distance) and the cal- culation result may not be the same as indicated by the aver- age fuel consumption meter. • To avoid running out of gaso- line, you should not continue ride the motorcycle until the estimated driving range drops to 1.
3-18 Voltmeter Clock I The voltmeter displays the battery voltage within the range of 10.0 to 16.0V. Time is shown when the ignition Traction Control System switch is in the “ON” position. The H indicator clock has a 12-hour display. Fol- The setting of the traction control low the procedure below to adjust system is indicated by OFF, 1 or the clock. 2. Press and hold the left handlebar MODE switch (Up or Down) and TC the ADJ button 1 simultaneously OFF for 2 seconds until the clock dis- 1 play blinks when adjusting clock. 2 1. Push the left handlebar MODE switch (Up or Down) to adjust NOTE: For more detailed informa- the hour display. tion on the traction control sys- 2. Push the ADJ button 1 to tem, see page 3-24. adjust the minute display. 3. Press and hold the left handle- bar MODE switch (Up or Down) and the ADJ button 1 simultaneously for 2 seconds to return to the clock mode.
NOTE: • When the switch or button is pressed and held, the display will increase continuously. • The clock can be adjusted when the ignition switch is in the “ON” position. • This clock is powered by the battery of the motorcycle. If your motorcycle is to be left unused for more than two months, remove the battery from the motorcycle.
3-19 NOTE: • Set the meter to odometer, then press and hold the ADJ
10 11 12 button 1 for 2 seconds to 9 8 1000 r/min switch between km and mile. At 7
6 mph km/h this time, speedometer will be 5 GEAR ADJ 4 changed between km/h and H TRIP 3 12 2 TC 10 OFF AIR mph and the instantaneous fuel 1 2 C RANGE V MPG AVG12 km/L/100km EF consumption meter will be changed between km/L (L/100 km) and MPG US. • Select km/h or mph, as appro- priate, to comply with traffic Odometer/Trip Meter/Instrument regulations. Panel Light Brightness J • Check the km/h and mph dis- The display has 4 functions; play after adjusting the instru- odometer, two trip meters and ment panel display. instrument panel light brightness. When the ignition switch is turned To change the display, push the to the “ON” position, the test pat- left handlebar MODE switch (Up). tern shown below is displayed for The display changes in the order 2 seconds. After the test pattern is below. displayed, the display will show the function that was displayed the last time that the ignition switch was turned off. Odometer
TRIP 1 Trip meter 1
TRIP 2 Trip meter 2
Instrument panel light brightness
3-20 Odometer Instrument panel light The odometer registers the total brightness distance that the motorcycle has Set the meter to instrument panel been ridden. The odometer light brightness. Pushing the ADJ ranges from 0 to 999999 km or button 1 will change the instru- from 0 to 624999 miles. ment panel light brightness in 6 steps. The brightness indicator NOTE: The odometer display indicates brightness from “” locks at 999999 km or 624999 (min) to “” (max). miles when the total distance exceeds 999999 km or 624999 miles. WARNING Changing the display while Trip meters riding can be hazardous. The two trip meters are resettable Removing a hand from the han- odometers. They can register two dlebars can reduce your ability kinds of distances at the same to control the motorcycle. time. For instance, trip meter 1 can register the trip distance and trip meter 2 can register the dis- Never change the display while tance between fuel stops. riding. Keep both hands on the handlebars. To reset a meter to zero, press and hold the ADJ button 1 or MODE switch (Up) for 2 seconds while the display indicates the trip meter 1, or 2, you want to reset. When you reset the trip meter 1 or 2, the fuel consumption meter will also be reset.
NOTE: When the trip meter exceeds 9999.9, the trip meter will return to 0.0 and start counting again.
3-21
LEFT HANDLEBAR Clutch Lever Adjustment
SS A P
The distance between the grip
PASS and the clutch lever is adjustable to 4 positions. To change the posi- MODE SEL tion, push the clutch lever forward and turn the adjuster to the desired position. When changing the clutch lever position, always be sure the adjuster stops in the proper position; a projection of the Clutch Lever 1 clutch lever pivot should fit into The clutch lever is used for disen- the depression of the adjuster. gaging the drive to the rear wheel This motorcycle is delivered from when starting the engine or shift- the factory with its adjuster set on ing transmission gears. Squeez- position 2. ing the lever disengages the clutch. WARNING Adjusting the clutch lever posi- tion while riding can be hazard- ous. Removing a hand from the handlebars can reduce your ability to control the motorcy- cle.
Never adjust the clutch lever position while riding. Keep both hands on the handlebars.
3-22 Dimmer Switch 2 Mode Switch 3 “” position Use the MODE SWITCH to change The headlight low beam and tail- the speedometer display setting light turn on. and traction control system setting. Refer to the INSTRUMENT PANEL “” position and TRACTION CONTROL SYS- Push the dimmer switch forward, TEM section for detail. the headlight low beam, high beam and taillight turn on. The NOTE: For more detailed informa- high beam indicator light also tion on the traction control sys- turns on. tem, see page 3-24.
Headlight flasher switch Horn Switch “” 4 Press the switch to flash the Press the switch to sound the headlight. horn. NOTICE Turn Signal Light Switch “” 5 Sticking tape or placing Moving the switch to the “” posi- objects in front of the headlight tion will flash the left turn signals. can obstruct headlight heat Moving the switch to the “” posi- radiation. This can result in tion will flash the right turn signals. headlight damage. The indicator light will also flash intermittently. To cancel turn signal operation, push the switch in. Do not stick tape on the head- light or place objects in front of the headlight. WARNING Failure to use the turn signals, NOTICE and failure to turn off the turn signals can be hazardous. Do not put objects in front of Other drivers may misjudge the headlight or taillight when your course and this may they are on, and do not cover result in an accident. with clothes when the motorcy- cle is stopped. Always use the turn signals when you intend to change This may cause melting of the lanes or make a turn. Be sure lens or damage to the object by to turn off the turn signals after the heat from the lens. completing the turn or lane change.
3-23 WARNING
Relying too much on the trac-
SS A P tion control system can be haz- ardous.
The traction control system cannot provide control to limit rear wheel spin under certain PASS conditions. The system cannot
MODE SEL control rear wheel spin result- ing from high speed cornering, excessive bank angle, braking operation or engine braking effect. Be sure to operate the motorcycle at an appropriate Traction Control System Switch speed according to your riding 6 skill, and weather and road conditions. Traction Control System When the traction control system senses rear wheel spin during WARNING acceleration, it automatically con- Replacing the tires with other trols engine power output to than the specified tires can be restore the gripping power of the hazardous. rear tire. The traction control sys- tem indicator light blinks when the traction control system is control- When replacing tires, be sure ling engine power output. to mount the specified tires. If tires other than the specified size or type are mounted on the motorcycle, the traction control system will not be able to control engine power output properly.
3-24 NOTE: The traction control system can • When the traction control sys- be set to OFF, Mode 1 or Mode 2. tem is controlling engine power output, the engine
Confirm that the traction con- trol system is in the intended mode before operating the motorcycle.
3-25 Mode setting 1. Press the traction control sys-
tem switch 6 for mode selec-
SS tion. A P
TC TC OFF OFF 1 1 2 2
PASS 2. Press the Mode switch (UP,
MODE SEL DOWN) 3 and change the indication on the traction con- trol system display in the meter cluster to the desired mode. The display changes in the order below.
TC OFF 1 2
TC OFF 1 2
TC OFF 1 2
3. Press the traction control sys- tem switch 6 to cancel the mode selection. The traction control system display in the meter cluster returns to the normal display mode.
3-26 NOTE: RIGHT HANDLEBAR • Be sure to keep the throttle fully closed when changing the mode. If the change of mode is not possible because the throt- tle is not fully closed, a seg- ment of the selected mode on the traction control system dis- play blinks. • The setting is retained in the memory even when the igni- tion switch is turned off. • The setting of the traction con- Engine Stop Switch 1 trol system is retained in the “” position memory even when the bat- The ignition circuit is off. The tery becomes fully discharged engine cannot start or run. or is disconnected and removed from the motorcycle. “” position The ignition circuit is on and the engine can run.
Brake Lever 2 The front and rear brakes are simultaneously applied by squeezing the brake lever gently toward the throttle grip. This motorcycle is equipped with a disk brake system and excessive pressure is not required to slow the machine down properly. The brake light will be lit when the lever is squeezed inward.
When the brake lever is com- pressed and the ABS is activated, braking control is applied sepa- rately and independently to the front and rear wheels. For ABS, refer to page 5-7.
3-27 WARNING Adjusting the brake lever posi- tion while riding can be hazard- ous. Removing a hand from the handlebars can reduce your ability to control the motorcy- cle.
Never adjust the brake lever Brake Lever Adjustment position while riding. Keep both hands on the handlebars.
Electric Starter Switch “” 3 This switch is used for operating the starter motor. With the ignition switch in the “ON” position, the engine stop switch in “ ” and the The distance between the throttle transmission in neutral, squeeze grip and the brake lever is adjust- the clutch lever and push the elec- able to 5 positions. tric starter switch to start the To change the position, push the engine. brake lever forward and turn the adjuster to the desired position. NOTE: This motorcycle is When changing the brake lever equipped with an interlock system position, always be sure the for the ignition circuit and the adjuster stops in the proper posi- starter circuit. The engine can tion; a projection of the brake only be started if: lever pivot should fit into the • The transmission is in neutral depression of the adjuster. This and the clutch is disengaged, motorcycle is delivered from the or factory with its adjuster set on • The transmission is in gear, position 3. the side stand is fully up and the clutch is disengaged.
NOTE: The headlight will go off when the electric starter switch is pushed.
3-28 Throttle Grip 4 NOTICE Engine speed is controlled by the position of the throttle grip. Twist it Engaging the starter motor for toward you to increase engine more than five seconds at a speed. Turn it away from you to time can damage the starter decrease engine speed. motor and wiring harness from overheating. Hazard Warning Switch “” 5 All four turn signal lights and indi- Do not engage the starter cators will flash simultaneously motor for more than five sec- when the switch is turned on with onds at a time. If the engine the ignition switch in the “ON” or does not start after several “P” position. Use the hazard warning lights to warn other traffic attempts, check the fuel supply during emergency parking or and ignition system. Refer to when your vehicle could other- the TROUBLESHOOTING sec- wise become a traffic hazard. tion in this manual.
NOTICE Check if the engine is under the following conditions. If the engine is started under the conditions other than those mentioned, the serious engine damage may result. If these conditions are not indicated on the indicator, consult your Suzuki dealer for checking.
• When the neutral indicator light comes on, the gear position indicator should indicate “N” (Neutral). • When the neutral indicator light goes off, the gear posi- tion indicator should indicate either “1”, “2”, “3”, “4”, “5” or “6”.
3-29 FUEL TANK CAP
1 Fuel level 2 Filler neck
WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire.
Stop adding fuel when the fuel To open the fuel tank cap, insert level reaches the bottom of the the ignition key into the lock and filler neck. turn it clockwise. With the key inserted, lift up with the key and open the fuel tank cap. To close WARNING the fuel tank cap, push the cap down firmly with the key in the cap Failure to follow safety precau- lock. tions when refueling could result in a fire or cause you to Use fresh gasoline when filling up breathe toxic fumes. the fuel tank. Do not use bad gas- oline which is contaminated with Refuel in a well ventilated area. dirt, dust, water or other liquid. Be Make sure the engine is off and careful that dirt, dust or water avoid spilling fuel on a hot does not enter the fuel tank when engine. Do not smoke, and make refueling. sure there are no open flames or sparks in the area. Avoid breath- ing gasoline vapors. Keep chil- dren and pets away when you refuel the motorcycle.
3-30 GEARSHIFT LEVER REAR BRAKE PEDAL
5 4 3 2
This motorcycle has a 6-speed Depressing the rear brake pedal transmission which operates as will apply the rear disk brake. The shown. To shift properly, squeeze brake light will be lit when the rear the clutch lever and close the brake is operated. throttle at the same time you operate the gearshift lever. Lift the gearshift lever to upshift and depress the lever to downshift. Neutral is located between 1st and 2nd gear. When neutral is desired, depress or lift the lever halfway between 1st and 2nd gear.
NOTE: When the transmission is in neutral, the green indicator light on the instrument panel will be lit. However, even though the light is illuminated, cautiously and slowly release the clutch lever to make sure that the transmission is posi- tively in neutral.
Reduce the motorcycle speed before down-shifting. When down- shifting, the engine speed should be increased before the clutch is engaged. This will prevent unnec- essary wear on the drive train components and the rear tire.
3-31 SEAT LOCK
To remove the seat, insert the ignition key into the lock and turn To reinstall the seat, slide the seat it clockwise. Raise the rear end of hooks into the seat hook retainers the seat and slide it backward. and push down firmly until the seat snaps into the locked posi- tion. WARNING Failure to install the seat prop- erly could allow the seat to move and cause loss of rider control.
Latch the seat securely in its proper position.
3-32 SIDE STAND WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left.
Check operation of the side stand/ignition interlock sys- tem before riding. Always An interlock system is provided to retract the side stand com- cut off the ignition circuit when the pletely before starting off. side stand is down and the trans- mission is in any gear other than neutral. NOTICE If you do not take proper pre- The side stand/ignition interlock system works as follows: cautions when parking, the • If the side stand is down and motorcycle can fall over. the transmission is in gear, the engine can not be started. Park the motorcycle on firm, • If the engine is running and the level ground whenever possi- transmission is shifted into ble. If you must park on an gear with the side stand down, incline, aim the front of the the engine will stop running. motorcycle uphill and put the • If the engine is running and the transmission into 1st gear to side stand is put down with the reduce the possibility of rolling transmission in gear, the off the side stand. engine will stop running.
3-33 SUSPENSION ADJUSTMENT There are 5 grooved lines on the The standard settings for both side of the adjuster 1 for refer- front and rear suspensions are ence. Position 5 provides the min- selected to meet various riding imum spring pre-load and position conditions such as low to high 0 provides the maximum pre-load. motorcycle speed and light to This motorcycle is delivered from heavy load on the motorcycle. the factory with its adjuster set on The suspension settings can be position 4. adjusted and fine-tuned according to your preference. NOTICE Turning adjusters by force can damage the suspensions.
Do not turn adjusters beyond their natural limits.
FRONT SUSPENSION Spring Pre-load Adjustment
A Position 0 B Position 4 C Position 5 WARNING To change the spring pre-load, turn the adjuster 1 clockwise or Unequal suspension adjust- counterclockwise. Turning the ment can cause poor handling adjuster clockwise will increase and instability. the spring pre-load. Turning the adjuster counterclockwise will Adjust the right and left front decrease the spring pre-load. forks to the same setting.
3-34 Damping Force Adjustment The rebound and compression damping force can be individually adjusted by turning the respective adjusters. The rebound damping force adjuster 2 is located at the top of the front suspension. The compression damping force adjusters 3 are located at the bottom of the front suspension. To set the compression damping To adjust the damping force, set force adjuster to the standard the adjuster to the standard set- position, turn the adjuster clock- ting first and then adjust the wise until it stops and then turn it adjuster to the desired position. counterclockwise 8 clicks.
Turn the adjuster clockwise from the standard position to stiffen the damping force. Turn the adjuster counterclockwise to soften the damping force. The damping force should be adjusted gradu- ally, 1 click at a time, to fine-tune the suspension.
To set the rebound damping force NOTE: Do not loosen the adjuster adjuster to the standard position, base 4, or front fork oil will ooze turn the adjuster clockwise until it through the adjuster base. stops and then turn it counter- clockwise 8 clicks. WARNING Turn the adjuster clockwise from Unequal suspension adjust- the standard position to stiffen the ment can cause poor handling damping force. Turn the adjuster and instability. counterclockwise to soften the damping force. The damping Adjust the right and left front force should be adjusted gradu- forks to the same setting. ally, 1 click at a time, to fine-tune the suspension.
3-35 REAR SUSPENSION Rear Suspension Label Spring Pre-load Adjustment WARNING
S H This unit contains high-pres- sure nitrogen gas. Mishandling can cause explo- sion. To adjust the rear suspension spring pre-load, turn the adjuster • Keep away from fire and heat. 1. • Read owner’s manual for As you turn the adjuster, you will more information. notice the clicks. Count the num- ber of clicks from the softest posi- NOTE: Ask your Suzuki dealer to tion. Turning the adjuster dispose of the rear suspension clockwise will stiffen the spring unit. pre-load and turning it counter- clockwise will soften the spring preload. The spring pre-load is set on 11 clicks position from the softest position at the factory.
3-36 Damping Force Adjustment WINDSHIELD Height Adjustment The windshield height can be adjusted to 3 positions. To change the windshield height, follow the procedure below.
The rebound damping force adjuster 2 is located at the bot- tom of the rear suspension damper unit. To adjust the damp- ing force, set the adjuster to the standard setting first and then adjust it to the desired position.
To set the rebound damping force adjuster to the standard position, turn the adjuster clockwise until it stops and then turn it counter- clockwise 1-1/4 turn. 1. Remove the caps 1 and bolts 2 and then remove the wind- Turn the adjuster clockwise from shield 3. the standard position to stiffen the damping force. Turn the adjuster counterclockwise to soften the damping force. The damping force should be adjusted gradu- ally, 1/8 turn at a time, to fine-tune the suspension.
2. Move the windshield up or down to the desired windshield position. 3. Reinstall the windshield in the reverse order of removal.
3-37 Angle Adjustment The windshield angle is adjust- WARNING able to 3 positions by tilting it frontward. Moving the motorcycle with its You can release the windshield windshield interfering with the from the tilted position and return rear view mirror can be hazard- it to the original position by tilting it ous. You could lose your bal- forward from the third position. ance and fall.
After adjusting the windshield 3 2 1 height and the rear view mirror position, turn the handlebar right and left to check that the windshield does not interfere with the rear view mirror. If the rear view mirror touches the windshield, adjust the rear view mirror position. Also check if the windshield is firmly and securely fixed.
NOTE: After adjusting the wind- shield angle, check that the locks are fixed in the same positions at both right and left sides. WARNING Changing the angle of the windshield while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the motorcycle.
Never change the angle of the windshield while riding. Keep both hands on the handlebars.
3-38 OUTPUT TERMINAL WARNING When using the output termi- nal, if its electrical devices are not properly installed and con- nected, they may interfere with movement of the handlebars, causing loss of control or causing the devices to fall off.
The DL1000A/XA has an output Before riding, turn the handle- terminal for attaching 12V electri- bars to the right and to the left cal accessories. Total electrical to make it sure that there is no accessory wattage should be less interference with handlebar than 36W. Check electrical acces- movement or secure installa- sory voltage and wattage before tion of the devices. attaching accessories to the out- put terminal. NOTICE WARNING Using improper electrical accessories can damage your If you insert a long socket into motorcycle. Exceeding 36W or the output terminal, it may using other than 12V accesso- interfere with the handlebars ries can seriously damage the and disturb safe riding or mov- electrical system and accesso- ing the motorcycle, and you ries. could lose your balance and
fall. Check voltage and wattage before connecting electrical After inserting the socket into accessories. the output terminal, turn the handlebars right and left to check that the inserted socket does not interfere with the han- dlebars.
3-39
BREAK-IN AND INSPECTION BEFORE RIDING
BREAK-IN ...... 4-2 INSPECTION BEFORE RIDING ...... 4-3
4
4-1 BREAK-IN AND Breaking in the New Tires INSPECTION BEFORE New tires need proper break-in to assure maximum performance, RIDING just as the engine does. Wear in the tread surface by gradually BREAK-IN increasing your cornering lean The first 800 km (500 miles) is the angles over the first 160 km (100 most important in the life of your miles) before attempting maxi- motorcycle. Proper operation dur- mum performance. Avoid hard ing this break-in period will help acceleration, hard cornering, and assure maximum life and perfor- hard braking for the first 160 km mance from your new motorcycle. (100 miles). The following guidelines explain proper break-in procedures. WARNING Maximum Engine Speed Failure to perform break-in of Recommendation the tires could cause tire slip This table shows the maximum and loss of control. engine speed recommendation during the break-in period. Use extra care when riding on
Initial 800 km Below new tires. Perform proper (500 miles) 4500 r/min break-in of the tires as Up to 1600 km Below described in this section and (1000 miles) 6500 r/min avoid hard acceleration, hard Over 1600 km Below cornering, and hard braking for (1000 miles) 9250 r/min the first 160 km (100 miles). Vary the Engine Speed Vary the engine speed during the break-in period. This allows the parts to “load” (aiding the mating process) and then “unload” (allowing the parts to cool). Although it is essential to place some stress on the engine com- ponents during break-in, you must be careful not to load the engine too much.
4-2 Allow the Engine Oil to INSPECTION BEFORE RIDING Circulate before Riding Allow sufficient idling time after WARNING warm or cold engine start up before revving the engine or plac- Failure to inspect your motor- ing the transmission in gear. This cycle before riding and to prop- allows time for the lubricating oil erly maintain your motorcycle to reach all critical engine compo- increases the chances of an nents. accident or equipment dam- age. Observe Your Initial and Most Critical Service Always inspect your motorcy- The initial service (break-in main- tenance) is the most important cle each time you use it to service your motorcycle will make sure it is in safe operat- receive. During break-in opera- ing condition. Refer to the tion, all of the engine components INSPECTION AND MAINTE- will have mated together and NANCE section in this owner’s seated. Maintenance required as manual. part of the initial service includes correction of all adjustments, tightening of all fasteners and WARNING replacement of dirty oil. Timely If you operate this motorcycle performance of this service will with improper tires or improper help make sure you get a longer or uneven tire pressure, you service life and the best perfor- mance from the engine. may lose control of the motor- cycle. This will increase your NOTE: The 1000 km (600 miles) risk of an accident. service should be performed as outlined in the INSPECTION AND Always use tires of the size and MAINTENANCE section of this type specified in this owner’s Owner’s Manual. Pay particular manual. Always maintain attention to the CAUTION and proper tire pressure as WARNING messages in that sec- described in the INSPECTION tion. AND MAINTENANCE section.
4-3 Check the condition of the motor- Clutch • Correct fluid level cycle to help make sure that you ( 3-22, • No fluid leakage 7-33) • No “sponginess” do not have mechanical problems • Smooth and progressive or get stranded somewhere when action you ride. Before riding the motor- Brakes • Proper pedal and lever cycle, be sure to check the follow- ( 3-28, operation ing items. Be sure your 3-31, 7-34) • Fluid level in the reservoir to be above “LOWER” line motorcycle is in good condition for • Correct pedal play the personal safety of the rider, • No “sponginess” • No fluid leakage passenger and protection of the • Brake pads not worn down motorcycle. to the limit line Suspension Smooth movement WARNING ( 3-34) Fuel Enough fuel for the planned Checking maintenance items ( 3-15) distance of operation when the engine is running can Drive chain • Correct tension or slack ( 7-30) • Adequate lubrication be hazardous. You could be • No excessive wear or severely injured if your hands damage or clothing get caught in mov- Tires • Correct pressure ing engine parts. ( 7-39) • Adequate tread depth • No cracks or cuts Engine oil Correct level Shut the engine off when per- ( 7-22) forming maintenance checks, Cooling • Proper coolant level except when checking the system • No coolant leakage lights, engine stop switch, and ( 7-28) throttle. Lighting Operation of all lights and ( 3-5, indicators 3-8, 3-22) NOTE: Check switch operation Horn Correct function before riding when ambient tem- ( 3-23) perature is below zero. Engine stop Correct function switch WHAT TO CHECK FOR: ( 3-27) CHECK Side stand/ Proper operation Steering • Smoothness Ignition • No restriction of movement interlock • No play or looseness switch Throttle • Correct play in the throttle ( 7-44) ( 7-27) cable Windshield Good visibility • Smooth operation and ( 3-37, positive return of the 9-6) throttle grip to the closed position Spoke •Spoke tension wheels • Check for damage (DL1000XA) ( 7-43)
4-4 RIDING TIPS
STARTING THE ENGINE ...... 5-2 STARTING OFF AND SHIFTING ...... 5-4 USING THE TRANSMISSION ...... 5-5 RIDING ON HILLS ...... 5-6 STOPPING AND PARKING ...... 5-7 CARRYING A PASSENGER ...... 5-11 5
5-1 RIDING TIPS NOTICE STARTING THE ENGINE Check if the engine is under Before attempting to start the the following conditions. If the engine, make sure: engine is started under the 1. The transmission is in neutral. conditions other than those 2. The engine stop switch is in mentioned, the serious engine the “” position. damage may result. If these NOTE: This motorcycle has an conditions are not indicated on interlock system for the ignition the indicator, consult your circuit and the starter circuit. Suzuki dealer for checking. The engine can only be started if: • The transmission is in neutral • When the neutral indicator and the clutch is disengaged, light comes on, the gear or position indicator should • The transmission is in gear, indicate “N” (Neutral). the side stand is fully up and • When the neutral indicator the clutch is disengaged. light goes off, the gear posi- tion indicator should indicate 3. Close the throttle completely either “1”, “2”, “3”, “4”, “5” and push the electric starter or “6”. switch.
NOTE: Open the throttle 1/8 and push the electric starter switch when the engine is hard to start.
NOTE: The fuel supply system stops the engine when the motor- cycle is overturned. Turn off the ignition switch before restarting the engine.
5-2 WARNING NOTICE Exhaust gas contains carbon Running the engine too long monoxide, a dangerous gas without riding may cause the that is difficult to detect engine to overheat. Overheat- because it is colorless and ing can result in damage to odorless. Breathing carbon internal engine components monoxide can cause death or and discoloration of exhaust severe injury. pipes. Never start the engine or let it Shut the engine off if you can- run indoors or where there is not begin your ride promptly. little or no ventilation.
NOTICE After starting the engine, open- ing the throttle or running the motorcycle with the oil pres- sure indicator light turned on, may adversely affect the engine.
Make sure that the oil pressure indicator light has turned off before operating the throttle or running the motorcycle.
5-3 STARTING OFF AND SHIFTING WARNING WARNING Sudden side winds, which can occur when being passed by Riding at excessive speeds larger vehicles, at tunnel exits increases your chances of los- or in hilly areas, can cause you ing control of the motorcycle, to lose control of the motorcy- which can result in an acci- cle. dent. Reduce your speed and be Always ride at a speed that is alert to the possibility of sud- proper for the terrain, visibility den side winds. and operating conditions, and your skills and experience. Make sure that the side stand is in the fully up position. Squeeze the WARNING clutch lever and pause momen- tarily. Engage first gear by If you remove even one hand or depressing the gear shift lever foot from the motorcycle, you downward. Turn the throttle grip can reduce your ability to con- toward you and at the same time trol the motorcycle. This could release the clutch lever gently and cause you to lose your balance smoothly. As the clutch engages, and fall off the motorcycle. If the motorcycle will start moving you remove a foot from a foot- forward. To shift to the next higher rest, your foot or leg may come gear, accelerate gently, then close in contact with the rear wheel. the throttle and squeeze the This could injure you or cause clutch lever simultaneously. Lift an accident. the gear shift lever upward to select the next gear and, release Always keep both hands on the the clutch lever as you open the handlebars and both feet on throttle again. Select higher gears the footrests of your motorcy- in this manner until top gear is cle during operation. reached.
NOTE: This motorcycle has a side stand/ignition interlock system. If you shift the transmission into gear when the side stand is down, the engine will stop running.
5-4 USING THE TRANSMISSION The transmission is provided to WARNING keep the engine operating Downshifting when engine smoothly in its normal operating speed is too high can: speed range. The gear ratios • cause the rear wheel to skid have been carefully chosen to and lose traction due to meet the characteristics of the increased engine braking, engine. The rider should always resulting in an accident; or select the most suitable gear for • force the engine to overrev in the prevailing conditions. Never the lower gear, resulting in slip the clutch to control road engine damage. speed, but rather downshift to allow the engine to run within its Reduce speed before down- normal operational range. The shifting. table below shows the approxi- mate speed range for each gear. WARNING Shifting up schedule Downshifting while the motor- Gear position km/h mph cycle is leaned over in a corner 1st → 2nd 17 11 may cause rear wheel skid and 2nd → 3rd 39 24 loss of control. 3rd → 4th 53 33 → Reduce your speed and down- 4th 5th 70 43 shift before entering a corner. 5th → 6th 82 51
Shifting down schedule NOTICE Gear position km/h mph Revving the engine into the red 6th → 5th 73 45 zone can cause severe engine 5th → 4th 57 35 damage. → 4th 3rd 41 25 Never allow the engine to rev into the red zone in any gear. Disengage the clutch when the motorcycle speed drops below 19 km/h (12 mph).
5-5 RIDING ON HILLS NOTICE • When climbing steep hills, the Improper gearshift lever opera- motorcycle may begin to slow tion can damage the transmis- down and show lack of power. sion. At this point, you should shift to a lower gear so that the • Do not rest your foot on the engine will again be operating gearshift lever. in its normal power range. • Do not use force to shift Shift rapidly to prevent the gears. motorcycle from losing momentum. • When descending a long, steep slope, use the engine compression to assist the brakes by shifting to a lower gear. Continuous brake appli- cation can overheat the brakes and reduce their effectiveness. • Be careful, however, not to allow the engine to overrev.
5-6 STOPPING AND PARKING The ABS will operate whenever it Anti-lock Brake System (ABS) senses that the wheels are lock- This model is equipped with ing up. You may feel the brake Antilock Braking System (ABS) lever and/or the brake pedal pul- that incorporates inertial mea- sate lightly while the ABS is oper- surement unit for the purpose of ating. preventing wheel locks caused by hard braking or slippery road sur- Even though ABS helps prevent face during running. It also acts to wheel lock-up, you must still be prevent rear wheel from lifting in careful when braking in curves. the case of harsh front braking. Hard braking while turning could cause wheel skidding and loss of Motion Track Brake System control, whether or not your This model is equipped with a motorcycle is equipped with ABS. system called the “Motion Track Having ABS does not mean you Brake System”. This performs the can take unnecessary risks. ABS ABS control of braking, appropri- will not compensate for poor judg- ately according to the motorcycle ment, incorrect braking tech- bank angle while the motorcycle niques, or not slowing down over is cornering. This system pre- bad roads or in poor weather con- vents the wheel locking, within a ditions. certain range, if excessive or quick braking is applied. This sup- You must still ride sensibly and ports the rider's ability to follow alertly. the line as he intends. When the brake lever is compressed, both On regular paved roads, some front brake and rear brake are riders may be able to obtain applied. slightly shorter stopping distances with conventional brake systems NOTE: When the brake pedal is than with ABS. operated, only the rear brake is applied. NOTE: In some situations, a motorcycle with ABS may require a longer stopping distance to stop on loose or uneven surfaces than an equivalent motorcycle without ABS.
5-7 WARNING WARNING Inexperienced riders tend to Failure to use good judgment underutilize the front brake. with ABS can be hazardous. This can cause excessive stop- ABS cannot make up for bad ping distance and lead to a col- road conditions, bad judge- lision. Using only the brake ment, or improper operation of lever or brake pedal can cause the brakes. skidding and loss of control. Remember that ABS will not compensate for poor judg- Apply both brakes evenly and ment, incorrect braking tech- at the same time. niques, or the need to slow down over bad roads or in poor WARNING weather conditions. Use good judgment and do not ride faster Braking while turning the than conditions will safely motorcycle can be hazardous, allow. whether or not your motorcycle is equipped with ABS. The “Motion Track Brake System” manages ABS control of brak- ing appropriate for the motor- cycle bank angle while the motorcycle is cornering. How- ever, ABS does not control the motorcycle slipping sideways exceeding the physical limit, which might be present under heavy braking while the motor- cycle is turning. In such a case, motorcycle control might be lost.
Slow down sufficiently in a straight line before you begin to turn and avoid other than slight braking while turning.
5-8 How the ABS Works STOPPING AND PARKING ABS works by electronically con- 1. Turn the throttle grip away from trolling braking pressure. A com- you to close the throttle com- puter monitors wheel rotation pletely. speed and motorcycle attitude. If 2. Squeeze the brake lever and the computer detects that a press the brake pedal evenly and braked wheel has slowed sud- at the same time. denly, indicating a skidding situa- 3. Downshift through the gears tion, the computer will reduce as motorcycle speed braking pressure to prevent that decreases. wheel from locking up. ABS works 4. Select neutral with the clutch automatically, so you do not need lever squeezed toward the grip any special braking technique. (disengaged position) when Just apply the front and rear the motorcycle is almost com- brakes, as forcefully as necessary pletely stopped. The neutral for the situation, without pumping position can be confirmed by either one. It is normal for the observing the neutral indicator brake lever/pedal to pulsate while light. the ABS is operating. WARNING Non-recommended tires can affect wheel speed and may con- Inexperienced riders tend to fuse the computer. underutilize the front brake. This can cause excessive stop- ABS does not work at very low ping distance and lead to a col- speed, less than 8 km/h (5 mph), lision. Using only the brake and does not work with a dis- lever or brake pedal can cause charged battery. skidding and loss of control.
Apply both brakes evenly and at the same time.
WARNING Hard braking while turning may cause wheel skid and loss of control.
Brake before you begin to turn.
5-9 5. Park the motorcycle on a firm, WARNING flat surface where it will not fall over. Hard braking on wet, loose, rough, or other slippery sur- faces can cause wheel skid CAUTION and loss of control. A hot muffler can cause severe burns. The muffler will be hot Brake lightly and with care on enough to cause burns for slippery or irregular surfaces. some time after stopping the engine. WARNING Park the motorcycle where Following another vehicle too pedestrians or children are not closely can lead to a collision. likely to touch the muffler. As vehicle speeds increase, stopping distance increases NOTE: If the motorcycle is to be progressively. parked on the side stand on a slight slope, the front end of the Always maintain a safe stop- motorcycle should face “up” the ping distance between you and incline to avoid rolling forward off the vehicle in front of you. the side stand. You may leave the motorcycle in 1st gear to help pre- NOTICE vent it from rolling off the side stand. Shift to neutral before start- Holding the motorcycle ing the engine. stopped with throttle and clutch lever operation on 6. Turn the ignition switch to the inclines can damage the motor- “OFF” position. cycle’s clutch. 7. Turn the handlebars all the way to the left and lock the Use the brakes when stopping steering for security. the motorcycle on inclines. 8. Remove the ignition key.
NOTE: If an optional anti-theft lock such as an U-shape lock, brake disk lock or chain is used to avoid theft, be sure to remove the anti-theft lock before moving the motorcycle.
5-10 CARRYING A PASSENGER Before you invite someone to be a passenger on your motorcycle, you need to be thoroughly familiar with motorcycle operation. Adjust tire pressures and suspension according to the Tire Pressure and Loading section and the Sus- pension section of this manual.
The passenger should always hold onto your waist or hips, or onto the seat strap or grab bar, as equipped. Ask your passenger not to make any sudden move- ments. When you lean going around a corner, the passenger should lean with you. The passen- ger should always keep his or her feet on the footrests, even when you are stopped at a light.
To help prevent burn injuries, warn your passenger not to con- tact the muffler when mounting or dismounting your motorcycle.
5-11
ACCESSORY USE AND MOTORCYCLE LOADING
ACCESSORY USE ...... 6-2 ACCESSORY INSTALLATION GUIDELINES ...... 6-2 LOADING LIMIT ...... 6-3 LOADING GUIDELINES ...... 6-4 MODIFICATION ...... 6-5
6
6-1 ACCESSORY USE AND ACCESSORY INSTALLATION MOTORCYCLE LOADING GUIDELINES • Install aerodynamic-affecting ACCESSORY USE accessories, such as a fairing, The addition of unsuitable acces- windshield, backrests, saddle- sories can lead to unsafe operat- bags, and travel trunks, as low ing conditions. It is not possible as possible, as close to the for Suzuki to test each accessory motorcycle and as near the on the market or combinations of center of gravity as is feasible. all the available accessories; how- Check that the mounting brack- ever, your dealer can assist you in ets and other attachment hard- selecting quality accessories and ware are rigidly mounted. installing them correctly. Use • Inspect for proper ground clear- extreme caution when selecting ance and bank angle. Inspect and installing the accessories on that the accessory does not your motorcycle and consult your interfere with the operation of Suzuki dealer if you have any the suspension, steering or questions. other control operations. • Accessories fitted to the han- dlebars or the front fork area WARNING can create serious stability Improper installation of acces- problems. This extra weight will sories or modification of the cause the motorcycle to be less responsive to your steering motorcycle may cause control. The weight may also changes in handling which cause oscillations in the front could lead to an accident. end and lead to instability prob- lems. Accessories added to the Never use improper accesso- handlebars or front fork of the ries, and make sure that any machine should be as light as accessories that are used are possible and kept to a mini- properly installed. All parts and mum. accessories added to the motorcycle should be genuine Suzuki parts or their equivalent designed for use on this motor- cycle. Install and use them according to their instructions. If you have any questions, con- tact your Suzuki dealer.
6-2 • Certain accessories displace LOADING LIMIT the rider from his or her normal riding position. This limits the freedom of movement of the WARNING rider and may limit control abil- Overloading or improper load- ity. ing can cause loss of motorcy- • Additional electrical accesso- cle control and an accident. ries may overload the existing electrical system. Severe over- loads may damage the wiring Follow loading limits and load- harness or create a hazardous ing guidelines in this manual. situation due to the loss of elec- trical power during the opera- • Never exceed the GVWR tion of the motorcycle. (Gross Vehicle Weight Rating) • Do not pull a trailer or sidecar. of this motorcycle. The GVWR This motorcycle is not designed is the combined weight of the to pull a trailer or sidecar. machine, accessories, payload, rider and passenger. When selecting your accessories, keep in mind the weight of the rider as well as the weight of the accessories. The addi- tional weight of the accessories may not only create an unsafe riding condition but may also affect the steering ease.
GVWR: 440 kg (970 lbs) at the tire pressure (cold) Front: 250 kPa (2.50 kgf/cm2, 36 psi) Rear: 290 kPa (2.90 kgf/cm2, 42 psi)
6-3 LOADING GUIDELINES This motorcycle is primarily WARNING intended to carry small items Placing objects in the space when you are not riding with a passenger. Follow the loading behind the fairing can interfere guidelines below: with steering and can cause • Balance the load between the loss of control. left and right side of the motor- cycle and fasten it securely. Do not carry any objects in the • Keep cargo weight low and as space behind the fairing. close to the center of the motorcycle as possible. • Do not attach large or heavy items to the handlebars, front forks or rear fender. • Do not install a luggage carrier or a luggage box protruding over the tail end of the motor- cycle. • Do not carry any items that protrude over the tail end of the motorcycle. • Check that both tires are prop- erly inflated to the specified tire pressure for your loading conditions. Refer to page 7-40. • Improperly loading your motor- cycle can reduce your ability to balance and steer the motor- cycle. You should ride at reduced speeds, less than 130 km/h (80 mph), when you are carrying cargo or have added accessories. • Adjust suspension setting as necessary.
6-4 MODIFICATION The frame of this motorcycle is Modification of the vehicle or made of an aluminum alloy. removal of original equipment Therefore, never make any modi- may render the vehicle unsafe or fications such as drilling or weld- illegal. Obey all applicable regula- ing to the frame as it weakens the tions in your area including federal frame significantly. This could and state regulations regarding result in an unsafe vehicle operat- environmental protection. ing condition and subsequent Suzuki’s limited warranties may accident. Suzuki will not be not cover damage caused by responsible in any way for per- modifications that would change sonal injury or damage to the the original vehicle specifications motorcycle caused by frame mod- including, without limitation, modi- ifications. fications of any emission-related parts such as the carburetor(s), Bolt-on-accessories that do not fuel injection system components, modify the frame in any way may the engine control module, air be installed, provided that you do suction system components, the not exceed the loading limit catalytic converter (if equipped), described in this section. evaporative emission control sys- tem components (such as the car- WARNING bon canister, fuel tank, fuel hoses and vapor hoses), etc. Modification to an aluminum It is strictly prohibited to mod- alloy frame, such as drilling or ify a vehicle by installing parts welding, weakens the frame. that can affect emissions con- This could result in an unsafe trol, except in accordance with operating condition and may very specific U.S. Environmen- lead to an accident. tal Protection Agency and Cali- fornia Air Resources Board Never make any modifications regulations. to the frame.
6-5
INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE ...... 7-2 TOOLS ...... 7-5 FUEL TANK LIFT ...... 7-5 FUEL TANK REMOVAL ...... 7-9 LUBRICATION POINTS ...... 7-10 BATTERY ...... 7-11 AIR CLEANER ...... 7-14 SPARK PLUGS ...... 7-16 FUEL HOSE ...... 7-21 ENGINE OIL ...... 7-22 ENGINE IDLE SPEED INSPECTION ...... 7-27 THROTTLE CABLE PLAY ...... 7-27 ENGINE COOLANT ...... 7-28 7 DRIVE CHAIN ...... 7-30 CLUTCH ...... 7-33 BRAKES ...... 7-34 TIRES ...... 7-39 SPOKE WHEELS (DL1000XA) ...... 7-43 SIDE STAND/IGNITION INTERLOCK SYSTEM ...... 7-44 FRONT WHEEL REMOVAL ...... 7-45 REAR WHEEL REMOVAL ...... 7-47 LIGHT BULB REPLACEMENT ...... 7-50 FUSES ...... 7-55 BRAKE LEVER FITTING ...... 7-56 CLUTCH LEVER FITTING ...... 7-57 CATALYTIC CONVERTER ...... 7-57
7-1 INSPECTION AND MAINTENANCE SCHEDULE MAINTENANCE It is very important to inspect and maintain your motorcycle regu- larly. Follow the guidelines in the MAINTENANCE, REPLACE- chart. The intervals between peri- MENT OR REPAIR OF THE odic services in kilometers, miles EMISSION CONTROL and months are shown. At the DEVICES AND SYSTEMS MAY end of each interval, be sure to BE PERFORMED BY ANY perform the maintenance listed. MOTORCYCLE REPAIR ESTABLISHMENT OR INDI- VIDUAL USING ANY MOTOR- WARNING CYCLE PART WHICH HAS Improper maintenance or fail- BEEN CERTIFIED UNDER THE ure to perform recommended PROVISIONS IN THE CLEAN maintenance can lead to an AIR ACT Sec. 207 (a)(2). accident.
Keep your motorcycle in good condition. Ask your Suzuki dealer or a qualified mechanic to perform the maintenance items marked with an asterisk (*). You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, ask your Suzuki dealer to do the maintenance.
7-2 WARNING NOTICE Exhaust gas contains carbon Poorly-made replacement parts monoxide, a dangerous gas can cause your motorcycle to that is difficult to detect wear more quickly and may because it is colorless and shorten its useful life. odorless. Breathing carbon monoxide can cause death or When replacing parts on your severe injury. motorcycle, use only genuine Suzuki replacement parts or Never start the engine or let it their equivalent. run indoors or where there is little or no ventilation. NOTE: The MAINTENANCE CHART specifies the minimum requirements for maintenance. If NOTICE you use your motorcycle under Servicing electric parts with severe conditions, perform main- the ignition switch in the “ON” tenance more often than shown in position can damage the elec- the chart. If you have any ques- tric parts when the electric cir- tions regarding maintenance intervals, consult your Suzuki cuit is shorted. dealer or a qualified mechanic. Turn off the ignition switch before servicing the electric parts to avoid short-circuit damage.
7-3 MAINTENANCE CHART Interval: This interval should be judged by number of months or odom- eter reading, whichever comes first. Intervalmonths212243648 km 1000 6000 12000 18000 24000 Element miles 600 4000 7500 11000 14500 Air cleaner element ( 7-14) – I I R I * Exhaust pipe bolts and muffler bolts T – T – T * Exhaust control valve I – I – I *Valve clearance –––– I Spark plugs ( 7-16) – I R I R Fuel hose ( 7-21) – I I I I * Evaporative emission control system –– I – I (California model only) Engine oil ( 7-22) RRRRR Engine oil filter ( 7-22) R – – R – Idle speed ( 7-27) I I I I I Throttle cable play ( 7-27) I I I I I * Throttle valve synchronization I (CA. only) –I–I “SUZUKI SUPER LONG Replace every 4 years or 48000 km (29000 miles) LIFE COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) or an ( 7-28) engine coolant other than ––R–R “SUZUKI SUPER LONG LIFE COOLANT” (Blue) Radiator hose ( 7-29) –IIII –IIII Clutch hose ( 7-34) *Replace every 4 years –IIII Clutch fluid ( 7-33) *Replace every 2 years IIIII Drive chain ( 7-30) Clean and lubricate every 1000 km (600 miles) *Brakes ( 7-34) IIIII –IIII Brake hose ( 7-35) *Replace every 4 years –IIII Brake fluid ( 7-35) *Replace every 2 years Tires ( 7-39) – I I I I *Steering I–I–I * Front forks ( 3-34) – – I – I * Rear suspension ( 3-36) – – I – I *Chassis bolts and nuts TTTTT Lubrication Lubricate every 1000 km (600 miles) * Spoke wheels (DL1000XA) ( 7-43)IIIII 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 or the maintenance interval is to be applied only for the California model.
7-4 TOOLS FUEL TANK LIFT 1. Place the motorcycle on the side stand. 2. Remove the seat by referring to the SEAT LOCK section.
A tool kit is supplied and located under the seat.
3. Remove the right and left bolts. Unhook the hooks and remove the right and left side covers 1.
7-5 4. Remove the bolts. Pull the 5. Remove the bolts and fasten- right and left side frame covers ers. 2.
6. Unhook the hooks and remove the front tank cover 3. Covers have hooks at the circled places.
7-6 8. Slide the right and left fuel tank side covers 4 forward to slip off the hook. Remove the right 7. Remove the right and left fuel and left fuel tank side covers tank side covers bolts. 4. Remove the wiring harness clamp.
7-7 10.Support the fuel tank with the prop 5.
9. Remove the bolt. Remove the prop 5 and two cushions 6.
7-8 FUEL TANK REMOVAL Lift the fuel tank by referring to the FUEL TANK LIFT section.
1. Remove the bolt.
2. Disconnect the hoses and coupler. 3. Pull the retainer 1. 4. Disconnect the fuel feed hose joint 2 from fuel pipe. 5. Remove the fuel tank.
7-9 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motor- cycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet it in the rain or after washing it. Major lubrication points are indicated below. NOTICE Lubricating electrical switches can damage the switches.
Do not apply grease or oil to electrical switches.
.... Grease D .... Drive chain lubricant
1... Clutch lever pivot 2... Gearshift lever pivot and footrest pivot 3... Side stand pivot and spring hook 4... Drive chain 5... Brake lever pivot 6... Brake pedal pivot and footrest pivot
7-10 BATTERY The battery is a sealed type bat- WARNING tery and requires no maintenance Batteries produce flammable of fluid level and gravity. But have your dealer check the charging hydrogen gas which can condition of the battery periodi- explode if exposed to flames or cally. sparks.
The standard charging rate is Keep flames and sparks away 1.1A × 5 to 10 hours and the max- from the battery. Never smoke imum rate is 5.5A × 1 hour. Never when working near the battery. exceed the maximum charging rate. WARNING WARNING Wiping the battery with a dry cloth can cause a static elec- Battery posts, terminals, and tricity spark, which can start a related accessories contain fire. lead and lead compounds. Lead is harmful to your health Wipe the battery with a damp if it gets into your blood cloth to avoid static electricity stream. build up. Wash hands after handling any parts containing lead. NOTICE Exceeding the maximum WARNING charging rate for the battery can shorten its life. Diluted sulfuric acid from the battery can cause blindness or Never exceed the maximum severe burns. charging rate for the battery. When working near the battery, use proper eye protection and gloves. Flush eyes or body with ample water and get medi- cal care immediately if you suf- fer injury. Keep batteries out of reach of children.
7-11 Battery Removal To install the battery: To remove the battery, follow the 1. Install the battery in the procedure below: reverse order of removal. 1. Place the motorcycle on the 2. Connect the battery terminals side stand. securely. 2. Remove the seat by referring to the SEAT LOCK section. WARNING Batteries contain toxic sub- stances including sulfuric acid and lead. They could cause injury to humans or could dam- age the environment. An used battery must be dis- posed of or recycled according to local law and must not be discarded with ordinary house- hold waste. Make sure not to tip over the battery when you remove it from the vehicle. Oth- erwise, sulfuric acid could run out and you might be injured.
NOTICE Reversing the battery lead 3. Disconnect the negative (–) wires can damage the charging terminal 1. system and the battery. 4. Remove the cap. Disconnect the positive (+) terminal 2. Always attach the red lead to the 5. Remove the bolt 3. Pull off (+) positive terminal and the the battery holder hooks. Bat- black (or black with white tracer) tery holders have hook at the lead to the (–) negative terminal. circled places. Remove the battery holder 4. 6. Remove the battery 5.
7-12 NOTE: By ensuring the used battery is • Select the same type MF bat- disposed of or recycled correctly, tery when replacing the battery. you will help prevent potential • Recharge the battery once a negative consequences for the month if the motorcycle is not environment and human health, used for a long time. which could otherwise be caused by inappropriate waste handling of the battery. The recycling of materials will help to conserve natural resources. For more detailed information about dispos- ing or recycling of the used bat- tery, consult your Suzuki dealer. Pb
The crossed-out wheeled bin symbol A located on the battery label indicates that an used bat- tery should be collected sepa- rately from ordinary household waste. The chemical symbol of “Pb” B indicates the battery contains more than 0.004% lead.
7-13 AIR CLEANER The air cleaner element must be NOTICE kept clean to provide good engine Failure to inspect the air power and gas mileage. If you use your motorcycle under normal cleaner element frequently if low-stress conditions, you should the vehicle is used in dusty, service the air cleaner at the inter- wet, or muddy conditions can vals specified. If you ride in dusty, damage your motorcycle. The wet, or muddy conditions, you will air cleaner element can need to inspect the air cleaner become clogged under these element much more frequently. conditions, and engine damage Use the following procedure to may result. remove the element and inspect it. Always inspect the air cleaner element after riding in severe WARNING conditions. Replace the ele- Operating the engine without ment as necessary. If water the air cleaner element in place gets in the air cleaner case, can be hazardous. A flame can immediately clean the element spit back from the engine to and the inside of the case. the air intake box without the air cleaner element to stop it. Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner element.
Never run the engine without the air cleaner element in place.
7-14 Air Cleaner Element Removal Installation 1. Remove the fuel tank by refer- Reinstall the cleaned element or ring to the FUEL TANK new air cleaner element in REMOVAL section. reverse order of removal. Be absolutely sure that the element is securely in position and is seal- ing properly. NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine.
2. Remove the screws. Replace the air cleaner element 3. Pull up the air cleaner cap 1. with a new one if it is torn. Carefully examine the air cleaner element for tears dur- ing cleaning.
NOTICE Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element. This will 4. Remove the air cleaner ele- ment 2. cause engine damage. 5. Inspect the air cleaner element condition. Replace the air Be sure to properly install the cleaner element periodically. air cleaner element.
NOTE: Be careful not to spray NOTICE water on the air cleaner box when Compressed air can damage cleaning the motorcycle. the air cleaner element. Reinstall the fuel tank. Do not blow the air cleaner ele- ment with compressed air. NOTE: Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank.
7-15 Air Cleaner Drain Plug SPARK PLUGS Your motorcycle comes equipped with NGK LMAR8BI-9 spark plugs. To determine if the stan- dard spark plug is right for your usage, check the color of the plug’s porcelain center electrode insulator after motorcycle opera- tion. A light brown color indicates that the plug is correct. A white or dark insulator indicates that the Remove the plug and drain water engine may need adjustment, or and oil at the periodic mainte- another plug type may be needed. nance interval. The air cleaner Consult your Suzuki dealer or a drain plug is located beneath the qualified mechanic if your plug air cleaner box. insulator is not a light brown color. NOTICE An improper spark plug may have an incorrect fit or inappro- priate heat range for your engine. This may cause severe engine damage which may not be covered under warranty.
Use one of the spark plugs listed or their equivalent. Con- sult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage.
7-16 Plug Replacement Guide SPARK PLUG REMOVAL To remove the spark plugs, follow NGK REMARKS the procedure below: LMAR8BI-9 Standard CAUTION NOTE: If the above-named plugs are not available, consult your A hot radiator and hot engine Suzuki dealer. can burn you.
NOTE: This motorcycle uses a Wait until the radiator and resistor-type spark plug to avoid engine are cool enough to jamming electronic parts. touch with bare hands before Improper spark plug selection starting this work. may cause electronic interfer- ence with your motorcycle’s igni- tion system, resulting in NOTICE motorcycle performance prob- lems. Use only the recommended Dirt can damage the moving spark plugs. engine parts of your motorcy- cle if it enters an open spark plug hole.
Cover the spark plug hole while the spark plug is out of the hole.
7-17 Front Side
3. Pull off the spark plug cap. RIGHT 4. Remove the spark plugs with a spark plug wrench.
NOTE: Be careful not to damage the radiator fins.
LEFT 1. Remove the bolts and pull off the right and left side fairing 1 from the radiator.
2. Remove the radiator mounting bolt 2 and slide the radiator forward.
NOTE: Do not extract the radiator hose.
7-18 Rear Side NOTE: Pry up the spark plug cap 1. Lift the fuel tank by referring to with a screwdriver or a bar if it is the FUEL TANK LIFT section. hard to remove by hand. Do not pull the spark plug cord.
2. Remove the reservoir tank mounting bolts and move the reservoir tank forward.
3. Pull off the spark plug caps. 4. Remove the spark plugs with a spark plug wrench.
7-19 Spark Plug Inspection Installation To install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench. NOTICE Improper installation of the spark plug can damage your motorcycle. An overly-tight or cross-threaded spark plug will Measure the spark plug gap A damage the aluminum threads with a wire type feeler gauge. The of the cylinder head. standard spark plug gap is 0.8 – 0.9 mm (0.031 – 0.035 in). If the Carefully turn the spark plug by measured spark plug gap is out of hand into the threads. If the standard range, replace the spark spark plug is new, tighten it plug with a new one. with a wrench about 1/2 turn past finger tight. If you are reusing the old spark plug, tighten it with a wrench about 1/8 turn past finger tight.
NOTICE Dirt can damage the moving engine parts of your motorcy- cle if it enters an open spark plug hole.
Cover the spark plug hole while the spark plug is out of the hole.
7-20 FUEL HOSE
NOTE: When installing the spark plug caps, point the arrow marks Inspect the fuel hose for damage on the spark plug caps to the and fuel leakage. If any defects exhaust side. are found, the fuel hose must be replaced.
NOTE: Push the spark plug caps all the way on so that there is a tight seal.
Remount the radiators and tighten the mounting bolts securely.
Reinstall the fuel tank.
NOTE: Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank.
7-21 ENGINE OIL Engine life depends on oil amount NOTICE and quality. Daily oil level checks Operating the motorcycle with and periodic changes are two of the most important maintenance too little or too much oil can items to be performed. damage the engine.
Engine Oil Level Check Place the motorcycle on level Check the engine oil level as fol- ground. Check the oil level with lows: the engine oil inspection win- 1. Place the motorcycle on level dow before each use of the ground on the side stand. vehicle. Be sure the engine oil 2. Start the engine and allow it to level is always above the “L” idle for three minutes. (low) line and not higher than 3. Stop the engine and wait for the “F” (full) line. three minutes. Engine Oil and Filter Change Change the engine oil and oil filter at the scheduled time. The engine should always be warm when the oil is changed so the oil will drain easily. The procedure is as fol- lows:
1. Place the motorcycle on the side stand. 4. Hold the motorcycle vertically and check the oil level through the oil level inspection window on the right side of the engine. The engine oil level should be between “L” (low) and “F” (full) lines.
2. Remove the oil filler cap 1.
7-22 WARNING Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with oil may irritate skin. 3. Remove the drain plug 2 and gasket 3 from the bottom of Keep new and used oil and the engine and drain the used oil filters away from chil- engine oil into a drain pan. dren and pets. To minimize your exposure to used oil, wear CAUTION a long-sleeve shirt and mois- Hot engine oil and exhaust ture-proof gloves (such as pipes can burn you. dishwashing gloves) when changing oil. If oil contacts Wait until the oil drain plug and your skin, wash thoroughly exhaust pipes are cool enough with soap and water. Launder to touch with bare hands any clothing or rags if wet with before draining oil. oil. Recycle or properly dis- pose of used oil and filters.
NOTICE Turning the engine while drain- ing the engine oil will cause oil film shortage and adversely affect the engine.
Do not use the electric starter switch during engine oil replacement work.
7-23 NOTE: • Recycle or properly dispose of used oil. • Before starting the work, check that there is not any dust, mud, or foreign object inside the oil jug or on the oil filter mounting surface.
5. Turn the oil filter 5 counter- clockwise with a Suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size.
4. Remove the right and left bolts and remove the under cowl- ings 4.
6. Wipe off the mounting sur- face 6 on the engine where the new filter will be seated with a clean rag.
Available from Suzuki dealer Oil filter wrench (Part No. 09915-40620)
7-24 Mark top dead center
Oil filter wrench
In the position at 7. Smear a little engine oil which the filter gasket first contacts around the rubber gasket 7 of the mounting the new oil filter. surface. 8. Screw the new filter by hand until the filter gasket contacts the mounting surface (a small resistance will be felt). NOTICE Tighten the filter 2 turns or Failure to use an oil filter with to specified torque. the correct design and thread specifications can damage 9. Mark the top dead center posi- your motorcycle’s engine. tion on the “cap type” filter wrench or on the oil filter. Use Be sure to use a genuine an oil filter wrench to tighten Suzuki oil filter or an equiva- the filter 2 turns or to specified lent one designed for your torque. motorcycle. Oil filter tightening torque: NOTE: To tighten the oil filter 20 N·m (2.0 kgf-m, 14.5 lbf-ft) properly, it is important to accu- rately identify the position at which the filter gasket first con- tacts the mounting surface.
7-25 10.Replace the drain plug gasket 11.Start the engine (while the with a new one. Reinstall the motorcycle is outside on level drain plug and gasket. Tighten ground) and allow it to idle for the plug securely with a torque three minutes. wrench. Pour about 3100 ml 12.Turn the engine off and wait (3.3 US qt) of the specified approximately three minutes. engine oil in the filler hole. Recheck the oil level on the (See FUEL, ENGINE OIL AND engine oil inspection window COOLANT RECOMMENDA- while holding the motorcycle TIONS section.) vertically. If it is lower than the “L” line, add oil until the oil level Drain plug tightening torque: is between the “L” line and the 23 N·m (2.3 kgf-m, 17 lbf-ft) “F” line. Inspect the area around the drain plug and oil NOTE: About 2700 ml (2.9 US qt) filter for leaks. of oil will be required when chang- ing oil only. NOTE: If you do not have a proper oil filter wrench, have your Suzuki NOTICE dealer perform this service. Engine damage may occur if you use oil that does not meet Suzuki’s specifications.
Be sure to use the oil specified in the FUEL, ENGINE OIL AND COOLANT RECOMMENDA- TIONS section.
7-26 ENGINE IDLE SPEED THROTTLE CABLE PLAY INSPECTION Inspect the engine idle speed. The engine idle speed should be 1200 – 1400 r/min when the engine is warm.
NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle.
2.0 – 4.0 mm (0.08 – 0.16 in)
To adjust the cable play: 1. Remove the boot 1. 2. Loosen the lock nut 2. 3. Turn the adjuster 3 so that the throttle grip has 2.0 – 4.0 mm (0.08 – 0.16 in) play. 4. Tighten the lock nut 2. 5. Reinstall the boot 1. WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of control and an accident.
Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement.
7-27 Throttle Cable Boots ENGINE COOLANT
Coolant Level
boots
The throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the boots when wash- ing. Wipe off dirt from the boots with a wet cloth when the boots are dirty. Remove the seat to check the coolant level. The engine coolant solution should be between the “F” (FULL) and the “L” (LOW) level lines on the engine coolant reser- voir. If the level is lower than the “L” level line, bring it up to the “F” level by adding specified engine coolant.
NOTE: • Check the coolant level when the engine is cold. • If the engine coolant reservoir is empty, check the radiator coolant level.
7-28 To add specified engine coolant: 1. Lift the fuel tank by referring to WARNING the FUEL TANK LIFT section. Engine coolant is harmful or fatal if swallowed or inhaled. Solution can be poisonous to animals.
Do not drink antifreeze or cool- ant solution. If swallowed, do not induce vomiting. Immedi- ately contact a poison control center or a physician. Avoid 2. Remove the filler cap and add inhaling mist or hot vapors; if specified engine coolant inhaled, remove to fresh air. If through the filler hole until it coolant gets in eyes, flush eyes reaches the “F” line. Refer to with water and seek medical the FUEL, ENGINE OIL AND attention. Wash thoroughly COOLANT RECOMMENDA- after handling. Keep out of the TIONS section. reach of children and animals. NOTE: When installing the filler cap, point the arrow marks on the NOTE: Adding only water will cap to the hose direction. dilute the engine coolant and reduce its effectiveness. Add specified engine coolant.
Changing The Coolant Change the coolant periodically.
NOTE: About 2130 ml (2.3 US qt) of coolant will required when fill- ing the radiator and reservoir tank.
Radiator Hose Inspection Inspect the radiator hoses for cracks, damage or engine coolant leakage. If any defects are found, ask your Suzuki dealer to replace the radiator hose with a new one.
7-29 DRIVE CHAIN Inspecting the Drive Chain This motorcycle has an endless When inspecting the chain, look drive chain constructed from spe- for the following: cial materials. It does not use a • Loose pins master link. The drive chain has • Damaged rollers special “O” rings that permanently • Dry or rusted links keep grease inside. We recom- • Kinked or binding links mend that you take your motorcy- • Excessive wear cle to an authorized Suzuki dealer • Improper chain adjustment if the drive chain needs to be replaced. Damage to the drive chain means that the sprockets may also be The condition and adjustment of damaged. Inspect the sprockets the drive chain should be checked for the following: before each use of the motorcy- Good Worn cle. Always follow the guidelines below for inspecting and servicing the chain. WARNING Riding with the chain in poor condition or improperly • Excessively worn teeth adjusted can lead to an acci- • Broken or damaged teeth dent. • Loose sprocket mounting nuts
Inspect, adjust, and maintain If you find any of these problems the chain properly before each with your sprocket, consult your ride, according to the instruc- Suzuki dealer. tions in this section.
7-30 Drive Chain Cleaning and WARNING Oiling 1. Remove dirt and dust from the Improperly installing a replace- drive chain. Be careful not to ment chain, or using a joint-clip damage the seal ring. type chain, can be hazardous. 2. Clean the drive chain with a An incompletely riveted master sealed drive chain cleaner, or link, or a joint-clip type master water and neutral detergent. link, may come apart and cause an accident or severe NOTICE engine damage. Cleaning the drive chain Do not use a joint-clip type improperly can damage seal chain. Chain replacement rings and ruin the drive chain. requires a special riveting tool and a high-quality, non-joint- • Do not use a volatile solvent clip type chain. Ask an autho- such as paint thinner, kero- sene and gasoline. rized Suzuki dealer or a quali- • Do not use a high pressure fied mechanic to perform this cleaner to clean the drive work. chain. • Do not use a wire brush to clean the drive chain.
3. Use a soft brush to clean the drive chain. Be careful not to damage the seal ring even though using a soft brush. 4. Wipe off water and neutral detergent. 5. Lubricate with a motorcycle sealed drive chain lubricant or high viscosity oil (#80 – 90).
7-31 Drive Chain Adjustment NOTICE Some drive chain lubricant contains solvents and addi- tives which could damage the seal rings in the drive chain. 20 – 30 mm Use sealed drive chain lubri- (0.8 – 1.2 in) cant which is specifically Inspect the drive chain slack intended for use with sealed before each use of the motorcycle. drive chains. Place the motorcycle on the side stand. The drive chain should be 6. Lubricate both front and back adjusted for 20 – 30 mm (0.8 – plates of the drive chain. 1.2 in) of slack, as shown. 7. Wipe off excess lubricant after lubricating all around the drive WARNING chain. Too much chain slack can cause the chain to come off the sprockets, resulting in an acci- dent or serious damage to the motorcycle.
Inspect and adjust the drive chain slack before each use.
To adjust the drive chain, follow the procedure below: CAUTION A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.
Wait until the muffler cools before adjusting the drive chain.
7-32 1. Place the motorcycle on the CLUTCH side stand.
The clutch release mechanism of 2. Loosen the axle nut 1. this motorcycle is operated by 3. Loosen the right and left lock hydraulic pressure. There is no nuts 2. adjustment needed on the clutch 4. Turn the right and left adjuster release system because the sys- bolts 3 until the chain has 20 tem is self adjusting. However, – 30 mm (0.8 – 1.2 in) of slack inspect the following each time halfway between the engine before driving to make sure that sprocket and rear sprocket. At the system is in good condition the same time that the chain is and functioning properly. being adjusted, the rear • Fluid level in the reservoir to sprocket must be kept in per- be above “LOWER” line. fect alignment with the front • No fluid leakage. sprocket. To assist you in per- • Smooth and sure action of forming this procedure, there clutch lever. are reference marks 4 on the swingarm and each chain adjuster which are to be WARNING aligned with each other and to The use of any fluid except be used as a reference from DOT4 fluid from a sealed con- one side to the other. tainer can damage the clutch 5. Tighten the right and left lock system and lead to an acci- nut 2. 6. Tighten the axle nut 1 dent. securely. 7. Recheck the chain slack after Clean filler cap before remov- tightening and readjust if nec- ing. Use only DOT4 fluid from a essary. sealed container. Never use or mix with different types of Rear axle nut tightening torque: fluid. 100 N·m (10.0 kgf-m, 72.5 lbf-ft)
7-33 BRAKES WARNING This motorcycle utilizes front and Fluid is harmful or fatal if swal- rear disk brakes. Proper operation of brake systems is vital to safe lowed, and harmful if it comes riding. Be sure to perform the in contact with skin or eyes. brake inspection as scheduled. Solution can be poisonous to animals. WARNING If fluid is swallowed, do not Failure to properly inspect and induce vomiting. Immediately maintain your motorcycle’s contact a poison control center brake systems can increase or a physician. If fluid gets in your chance of having an acci- eyes, flush eyes with water and dent. seek medical attention. Wash thoroughly after handling. Be sure to inspect the brakes Keep out of the reach of chil- before each use according to dren and animals. the INSPECTION BEFORE RIDING section. Always main- tain your brakes according to NOTICE the MAINTENANCE SCHED- Spilled fluid can damage ULE. painted surfaces and plastic parts. NOTE: Operating in mud, water, sand or other extreme conditions Be careful not to spill any fluid can cause accelerated brake when filling the fluid reservoir. wear. If you operate your motorcy- Wipe spilled fluid up immedi- cle under these conditions, the ately. brakes must be inspected more often than recommended in the MAINTENANCE SCHEDULE. Clutch Hose Inspection Inspect the clutch hoses and hose joints for cracks or clutch fluid leakage. If any defects are found, ask your Suzuki dealer to replace the clutch hose with a new one.
7-34 Brake Hose Inspection Inspect the brake hoses and hose WARNING joints for cracks, damage or brake fluid leakage. If any defects are Brake fluid will gradually found, ask your Suzuki dealer to absorb moisture through the replace the brake hose with a new brake hoses. Brake fluid with one. high water content lowers the boiling point and can cause Brake Fluid brake system (including ABS) malfunction due to corrosion of brake components. Boiling brake fluid or brake system (including ABS) malfunction could result in an accident.
Replace the brake fluid every two years to maintain braking performance. FRONT WARNING The use of any fluid except DOT4 brake fluid from a sealed container can damage the brake system and lead to an accident.
Clean filler cap before remov- REAR ing. Use only DOT4 brake fluid from a sealed container. Never Check the brake fluid level in both use or mix with different types the front and rear brake fluid res- of brake fluid. ervoirs. If the level in either reser- voir is below the lower mark, inspect for brake pad wear and leaks.
7-35 Brake Pads WARNING Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. Solution can be poison- ous to animals.
If brake fluid is swallowed, do not induce vomiting. Immedi- ately contact a poison control center or a physician. If brake fluid gets in eyes, flush eyes with water and seek medical attention. Wash thoroughly after handling. Keep out of the reach of children and animals.
NOTICE FRONT Spilled brake fluid can damage painted surfaces and plastic parts.
Be careful not to spill any fluid when filling the brake fluid res- ervoir. Wipe spilled fluid up immediately.
NOTE: SUZUKI highly recom- mends the use of ECSTAR brand brake fluid. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired motorcycle perfor- mance and ideal riding experi- ence. REAR
7-36 Inspect the front and rear brake pads by noting whether or not the WARNING friction pads are worn down to the grooved wear limit line 1. If a If you ride this motorcycle after front or rear pad is worn to the brake system repair or brake grooved wear limit line both front pad replacement without or both rear pads must be pumping the brake lever/pedal, replaced with new ones by your you may get poor braking per- authorized Suzuki dealer or quali- formance which could result in fied service mechanic. an accident.
NOTE: After replacing either the After brake system repair or front or rear brake pads, the brake brake pad replacement, pump lever or pedal must be pumped several times. This will extend the the brake lever/pedal several pads to their proper position. times until brake pads are pressed against the brake disks and proper lever/pedal WARNING stroke and firm feel are Failure to inspect and maintain restored. the brake pads and replace them when recommended can NOTE: Do not squeeze/depress increase your chance of having the brake lever/pedal when the an accident. pads are not in their positions. It is difficult to push the pistons back If you need to replace brake and brake fluid leakage may pads, have your Suzuki dealer result. do this work. Inspect and main- tain the brake pads as recom- WARNING mended. Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an accident.
Always replace both pads together.
7-37 Rear Brake Pedal Adjustment The rear brake pedal position NOTICE must be properly adjusted at all times or the disk brake pads will An incorrectly adjusted brake rub against the disk causing dam- pedal may force brake pads to age to the pads and to the disk continuously rub against the surface. Adjust the brake pedal disk, causing damage to the position in the following manner: pads and disk.
Follow the steps in this section to adjust the brake pedal prop- erly.
20 – 30 mm (0.8 – 1.2 in)
1. Loosen the lock nut 1, and rotate the push rod 2 to locate the pedal 20 – 30 mm (0.8 – 1.2 in) below the top face of the footrest. 2. Retighten the lock nut 1 to secure the push rod 2 in the proper position. 3. Check the boot for deformation by torsion, and if deformed, correct the boot form by rotat- ing it back.
7-38 Rear Brake Light Switch TIRES WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road. Failure to take the precautions below may result in an accident due to tire failure.
• Check tire condition and To adjust the brake light switch, pressure before each ride, hold the switch body and turn the and adjust pressure if neces- adjuster so that the brake light will sary. come on just before a pressure • Avoid overloading your rise is felt when the brake pedal is motorcycle. depressed. • Replace a tire when worn to the specified limit, or if you find damage such as cuts or cracks. • Always use the size and type of tires specified in this owner’s manual. • Balance the wheel after tire installation. • Read this section of the owner’s manual carefully.
7-39 Tire Pressure and Loading WARNING Proper tire pressure and proper tire loading are important factors. Failure to perform break-in of Overloading your tires can lead to the tires could cause tire slip tire failure and loss of motorcycle and loss of control, which control. could result in an accident. Check tire pressure each day Use extra care when riding on before you ride, and adjust tire new tires. Perform proper pressure and be sure the pres- break-in of the tires referring to sure according to the table below. the BREAK-IN section of this Tire pressure should only be manual and avoid hard acceler- checked and adjusted before riding, since riding will heat up the ation, hard cornering, and hard tires and lead to higher inflation braking for the first 100 miles pressure readings. (160 km). Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear. Over-inflated tires cause smaller amount of tire to be in contact with the road, which can contribute to skidding and loss of control.
NOTE: When you detect drops in tire pressure, check the tire for nails or other punctures, or a damaged wheel rim. Tubeless tires sometimes lose pressure gradually when punctured.
LOAD SOLO DUAL TIRE RIDING RIDING 250 kPa 250 kPa FRONT 2.50 kgf/cm2 2.50 kgf/cm2 36 psi 36 psi 290 kPa 290 kPa REAR 2.90 kgf/cm2 2.90 kgf/cm2 42 psi 42 psi
7-40 Tire Condition and Type Tire condition and tire type affect motorcycle performance. Cuts or cracks in the tires can lead to tire failure and loss of vehicle control. Worn tires are susceptible to puncture failures and subsequent loss of vehicle control. Tire wear also affects the tire profile, chang- ing vehicle handling characteris- tics. NOTE: The “ ” mark indicates the place where the wear bars are molded into the tire. When the wear bars contact the road, it indi- cates that the tire wear limit has been reached.
When you replace a tire, use a tire of the size and type listed below. If you use a different size or type of tire, motorcycle handling may be Check the condition of your tires adversely affected, possibly each day before you ride. Replace resulting in loss of motorcycle tires if tires show visual evidence control. of damage, such as cracks or FRONT REAR cuts, or if tread depth is less than 110/80R19M/C 150/70R17M/C SIZE 1.6 mm (0.06 in) front, 2.0 mm 59V 69V (0.08 in) rear. BRIDGESTONE BRIDGESTONE TYPE BW-501 BW-502 RADIAL J RADIAL J
Always balance the wheel after repairing a puncture or replacing the tire. Proper wheel balance is important to avoid variable wheel- to-road contact, and to avoid uneven tire wear.
7-41 WARNING WARNING An improperly repaired, Failure to follow the instruc- installed, or balanced tire can tions below for tubeless tires cause loss of control and an may result in an accident due accident, or can wear out to tire failure. Tubeless tires sooner. require different service proce- dures than tube tires. • Ask your Suzuki dealer or a qualified mechanic to per- • Tubeless tires require an air- form tire repair, replacement, tight seal between the tire bead and balancing because and wheel rim. Special tire irons proper tools and experience and rim protectors or a special- are required. ized tire mounting machine • Install tires according to the must be used for removing and rotation direction shown by installing tires to prevent tire or arrows on the sidewall of rim damage which could result each tire. in an air leak. • Repair punctures in tubeless tires by removing the tire and applying an internal patch. • Do not use an external repair plug to repair a puncture since the plug may work loose as a result of the cor- nering forces experienced by a motorcycle tire. • After repairing a tire, do not exceed 80 km/h (50 mph) for the first 24 hours, and do not exceed 130 km/h (80 mph) thereafter. This is to avoid excessive heat build-up which could result in a tire repair failure and tire deflation. • Replace the tire if it is punc- tured in the sidewall area, or if a puncture in the tread area is larger than 6 mm (3/16 in). These punctures cannot be repaired adequately.
7-42 SPOKE WHEELS (DL1000XA) Spoke Inspection
Wheel Rim Inspection
Check the tension of spokes to verify the tightness of the spoke Check to see if there is any dam- nipples. The tension can be age like crack, distortion or bend checked by hitting the spokes with in the wheel rim. a small metal bar. If the spoke nip- ple is loose, its sound will be dull.
WARNING To tighten the spoke nipples prop- Damaged rims can allow air to erly, tighten them equally to the leak, resulting in reduced run- specified torque. Loosened and ning stability which can lead to overtightened spoke nipples may accidents. cause unequal tension of spokes and may result in distortion of the wheel rim. Contact your Suzuki If any damage is found, replace dealer for this service to be per- the rim. Do not reuse the dam- formed. aged rim by repairing or cor- recting it.
7-43 SIDE STAND/IGNITION INTERLOCK SYSTEM WARNING If the side stand/ignition inter- lock system is not working properly, it is possible to ride the motorcycle with the side stand in the down position. This may interfere with rider control during a left turn and could cause an accident.
Check the side stand/ignition Check the side stand/ignition interlock system for proper opera- interlock system for proper tion as follows: operation before riding. Check 1. Sit on the motorcycle in the that the side stand is returned normal riding position, with the to its full up position before side stand up. starting off. 2. Shift into first gear, hold the clutch in, and start the engine. 3. While continuing to hold the clutch in, move the side stand to the down position.
If the engine stops running when the side stand is moved to the down position, then the side stand/ignition interlock switch is working properly. If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- ing properly. If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- ing properly. Have your motorcycle inspected by an authorized Suzuki dealer or some other qualified service mechanic.
7-44 FRONT WHEEL REMOVAL 1. Place the motorcycle on the side stand.
4. Remove the axle nut 2. 5. Loosen the axle holder bolts 3 on the right and left front fork. 2. Remove the front wheel speed 6. Loosen the axle shaft 4 tem- sensor by removing the porarily. mounting bolt. NOTE: A special tool is necessary to loosen the shaft 4. The special tool is available at a Suzuki dealer.
7. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end. 8. Carefully position a jack under the engine and raise the jack 3. Remove both brake calipers until the front wheel is slightly from the front forks by remov- off the ground. ing two mounting bolts 1 on each of the calipers. NOTICE NOTE: Never squeeze the brake Improper jacking may cause lever with the caliper removed. It damage to the fairing or oil fil- is very difficult to force the pads ter. back into the caliper assembly and brake fluid leakage may Do not place the jack under the result. lower part of the fairing or the oil filter when jacking up the motorcycle.
7-45 WARNING Failure to extend brake pads after installing the wheel can cause poor braking perfor- mance and may result in an accident.
Before riding, “pump” the 9. Turn the axle shaft counter- brake lever repeatedly until the clockwise and draw it out. brake pads are pressed against the brake disks and proper lever stroke and firm feel are restored. Also check that the wheel rotates freely.
WARNING Installing the front wheel in the reverse direction can be haz- 10.Slide the front wheel forward. ardous. The tire for this motor- 11.To reinstall the wheel assem- cycle is directional. Therefore, bly, reverse the sequence the motorcycle may have described above. unusual handling if the wheel 12.After installing the wheel, is installed incorrectly. apply the front brake several times to restore the proper Install the front wheel so that lever stroke. the tire rotates in the specified direction, as indicated by the arrow on the sidewall of the tire.
7-46 REAR WHEEL REMOVAL WARNING If the bolts and nuts are not CAUTION properly tightened, the wheel A hot muffler can burn you. can come off, causing an acci- dent. Wait until the muffler cools before removing the axle nut. Be sure to tighten the bolts and nuts to the specified torque. If you do not have a torque NOTICE wrench or do not know how to Removing the rear wheel with- use one, ask your authorized out use of an accessory stand Suzuki dealer to check the can result in your motorcycle bolts and nuts. falling over and being dam- aged. Front axle tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft) Do not attempt roadside removal of the rear wheel. Only Front axle holder bolt tightening torque: remove the rear wheel at a 23 N·m (2.3 kgf-m, 16.5 lbf-ft) properly equipped servicing facility using an accessory ser- Front brake caliper mounting bolt vice stand. tightening torque: 39 N·m (3.9 kgf-m, 28.0 lbf-ft)
NOTE: Be careful not to damage the oil seal when installing the front wheel.
7-47 1. Place the motorcycle on the side stand.
6. Draw out the axle shaft.
2. Remove the rear wheel speed sensor by removing the mounting bolt.
7. With the wheel moved forward, remove the chain from the sprocket.
3. Remove the axle nut 1. 4. Place an accessory service stand or an equivalent stand under the swingarm to lift the rear wheel slightly off the ground. 5. Loosen the right and left lock nuts 2. Turn the right and left chain adjuster bolts 3 clock- wise. 8. Remove the rear brake caliper assembly 4.
7-48 WARNING Failure to adjust the drive chain and failure to torque bolts and nuts properly could lead to an accident.
• After installing the rear wheel, adjust the drive chain 9. Pull the rear wheel assembly as described in the DRIVE rearward. CHAIN ADJUSTMENT sec- tion. NOTE: Never depress the rear • Torque bolts and nuts to the brake pedal with the rear wheel proper specifications. If you removed. It is very difficult to force are not sure of the proper the pads back into the caliper procedure, have your autho- assembly. rized Suzuki dealer or a qual- ified mechanic do this. 10.To replace the wheel, reverse the complete sequence listed Rear axle nut tightening torque: above. 100 N·m (10.0 kgf-m, 72.5 lbf-ft) 11.Adjust the drive chain slack. 12.After installing the wheel, apply the brake several times WARNING and then check that the wheel Failure to extend brake pads rotates freely. after installing the wheel can cause poor braking perfor- mance and may result in an accident.
Before riding, “pump” the brake pedal repeatedly until brake pads are pressed against the brake disks and proper pedal stroke and firm feel are restored. Also check that the wheel rotates freely.
7-49 LIGHT BULB REPLACEMENT Headlight/Position light The wattage rating of each bulb is To replace the headlight bulb and shown in the following chart. position light bulb, perform the fol- When replacing a burned out lowing step: bulb, always use the same watt- age rating. To remove the instrument panel assembly: NOTICE Failure to use a light bulb with the correct wattage rating can overload the electrical system of your motorcycle or cause the bulb to burn out sooner.
Use only the light bulbs shown in the chart as replacement bulbs.
12V 65W H9 ...... High beam Headlight 12V 55W H7 ...... Low beam Position light 12V 5W 1. Remove the bolts and fasten- ers. Turn signal light 12V 21W License plate light 12V 5W
2. Unhook the hooks.
7-50 Headlight
High beam bulb
3. Move the instrument panel to the arrowed direction. 4. Disconnect the meter coupler. 1. Disconnect the coupler 1. Turn the socket 2 counter- clockwise and remove it.
5. Disconnect the power source coupler. Remove the instru- ment panel assembly. 6. To install the instrument panel 2. Pull off the bulb 3 from the assembly, reverse the com- socket. plete sequence listed. NOTICE The headlight bulb’s life may be shortened by oil from your fingers if you touch it.
When replacing the headlight bulb, be careful not to touch the glass. Grasp the new bulb with a clean cloth.
7-51 Low beam bulb Position Light
1. Turn the cap 1 counterclock- 1. Turn the socket 1 counter- wise and remove it. clockwise and remove it.
2. Pull off the bulb 2 from the socket. 2. Disconnect the socket 2. Unhook the bulb holder spring 3 and pull out the bulb 4. NOTICE The headlight bulb’s life may be shortened by oil from your fingers if you touch it.
When replacing the headlight bulb, be careful not to touch the glass. Grasp the new bulb with a clean cloth.
7-52 Headlight Beam Adjustment Turn Signal Light The headlight beam can be To replace the turn signal light adjusted both right and left or up bulb, follow these directions. and down if necessary.
High Beam
1. Remove the screw and take off the lens.
Low Beam
2. Push in on the bulb, twisting it to the left, and pull it out. To adjust the beam up and down: NOTICE Turn the adjuster 1 clockwise or counterclockwise. Overtightening the screws when reinstalling the lens may To adjust the beam right and cause the lens to crack. left: Turn the adjuster 2 clockwise or Tighten the screws only until counterclockwise. they are snug.
NOTE: To adjust the headlight beam, adjust the beam right and left first, then adjust up and down.
7-53 License Plate Light To replace the license plate light bulb, follow the procedure steps:
3. Push in on the bulb, twisting it to the left, and pull it out. 4. To fit the replacement bulb, 1. Remove the nuts 1. push it in and twist it to the right while pushing.
2. Remove the screws 2 and take off the cover with the lens 3.
7-54 FUSES If something electrical on your motorcycle stops working, the first thing you should check for is a blown fuse. The electrical circuits on the motorcycle are protected from overload by fuses in the cir- cuits.
If a blown fuse is found, then the electrical problem must be The main fuse is located under inspected and repaired before the seat. One 30A spare fuse is replacing the blown fuse with a located in the starter relay box. new fuse. Consult your Suzuki dealer for the electrical system check and repair. WARNING Replacing a fuse with a fuse that has an incorrect amperage rating or substitute, e.g. alumi- num foil or wire, may cause serious damage to the electri- The fuses are located under the cal system and possibly fire. seat. Four spare fuses (one 10A, Always replace a blown fuse one 15A, one 3A and one 25A) with a fuse of the same amper- are provided inside the fuse box age rating. cap.
If the new fuse blows in a short time, the electrical problem may not be fixed. Have your motorcycle inspected immedi- ately by your Suzuki dealer.
7-55 FUSE LIST BRAKE LEVER FITTING • 30A MAIN fuse protects all electrical circuits. • 15A HEAD-HI fuse protects the headlight high beam and speedometer. • 15A HEAD-LO fuse protects the headlight low beam. • 10A FUEL fuse protects the solenoid, fuel pump relay, speedometer, fuel pump and injectors. • 10A IGNITION fuse protects the ECM, oxygen sensor, sole- noid, side stand relay, starter relay and ignition coils. • 15A SIGNAL fuse protects the turn signal lights, brake/tail- light, license light, position light and speedometer. • 15A FAN fuse protects the cooling fan relay and cooling fan motor. • 25A ABS MOT fuse protects Align the dot mark on the handle- ABS system. bar with the mating surface of the • 15A ABS VALVE fuse protects lever holder A. ABS system. • 3A P-SOURCE fuse protects the POWER SOURCE.
7-56 CLUTCH LEVER FITTING CATALYTIC CONVERTER The purpose of the catalytic con- verter is to minimize the amount of harmful pollutants in your motorcycle’s exhaust. Use of leaded fuel in motorcycles equipped with catalytic converters is prohibited because lead deacti- vates the pollutant-reducing com- ponents of the catalyst system.
The converter is designed to last the life of the motorcycle under normal usage and when unleaded fuel is used. Not special mainte- nance is required on the con- verter. However, it is very important to keep the engine properly tuned. Engine misfiring, which can result from an improp- erly tuned engine, may cause overheating of the catalyst. This Align the dot mark on the handle- may result in permanent heat bar with the mating surface of the damage to the catalyst and other lever holder A. motorcycle components.
7-57 NOTICE WARNING Improper motorcycle opera- If you park or operate the tion can cause catalyst or other motorcycle in areas where motorcycle damage. there are combustible materi- als such as dry grass or leaves, To avoid damage to the catalyst these materials may come in or other related components, contact with the catalytic con- you should take the following verter or other hot exhaust precautions: components. This can cause a • Maintain the engine in the fire. proper operating condition. • In the event of an engine mal- Avoid parking or operating function, particularly one your vehicle in areas with any involving engine misfire or combustible materials. other apparent performance loss, stop riding the motorcy- cle and turn off the engine and have the motorcycle ser- viced promptly. • Do not shut off the engine or interrupt the ignition when the transmission is in gear and the motorcycle is in motion. • Do not try to start the engine by pushing the motorcycle or by coasting down a hill. • Do not idle the engine with any spark plug wires discon- nected or removed, such as during diagnostic testing. • Do not idle the vehicle for prolonged periods if idling seems rough or there are other malfunctions. • Do not allow the fuel tank to get near the empty level.
7-58 TROUBLESHOOTING
FUEL SYSTEM CHECK ...... 8-2 IGNITION SYSTEM CHECK ...... 8-3
8
8-1 TROUBLESHOOTING COMPLAINT: Engine is hard to start or does not start at all. This troubleshooting guide is pro- vided to help you find the cause of FUEL SYSTEM CHECK some common complaints. If the odometer displays “FI” and malfunction indicator light comes on, trouble in the fuel injection NOTICE system, take your machine to an Improper repairs or adjust- authorized Suzuki dealer. Refer to ments may damage the motor- the “INSTRUMENT PANEL” sec- cycle instead of fixing it. Such tion for an explanation of the mal- damage may not be covered function indicator light. under warranty.
If you are not sure about the proper action, consult your Suzuki dealer about the prob- lem.
8-2 IGNITION SYSTEM CHECK 1. Remove the all spark plug WARNING caps. Performing the spark test 2. Remove the spark plugs and reattach them to the spark improperly can be hazardous. plug caps. You could get a high voltage 3. Put the engine stop switch in electrical shock if you are not the “” position and the igni- familiar with this procedure. tion switch in the “ON” posi- tion. While holding a spark Do not perform this check if plug with its base firmly you are not familiar with the against the engine, push the procedure. Do not point the electric starter switch. If the spark plug near the spark plug ignition system is operating hole during this test. Do not properly, a blue spark should perform this test if you have a jump across the spark plug gap. heart condition or wear a pace- 4. If there is no spark, clean the maker. spark plug. Replace it if neces- sary. Retry the above proce- COMPLAINT: Engine Stalls dure with the cleaned spark 1. Make sure there is enough fuel plug or a new one. in the fuel tank. 5. If there is still no spark, take 2. If the odometer displays “FI” your motorcycle to an autho- and malfunction indicator light rized Suzuki dealer. comes on, trouble in the fuel injection system, take your machine to an authorized Suzuki dealer. Refer to the “INSTRUMENT PANEL” sec- tion for an explanation of the malfunction indicator light. 3. Check the ignition system for intermittent spark. 4. Check the idle speed. The cor- rect idle speed is 1200 – 1400 r/min.
8-3
STORAGE PROCEDURE AND MOTORCYCLE CLEANING
STORAGE PROCEDURE ...... 9-2 PROCEDURE FOR RETURNING TO SERVICE ...... 9-3 CORROSION PREVENTION ...... 9-3 MOTORCYCLE CLEANING ...... 9-4 INSPECTION AFTER CLEANING ...... 9-7
9
9-1 STORAGE PROCEDURE ENGINE AND MOTORCYCLE 1. Pour one tablespoon of motor oil into each spark plug hole. CLEANING Reinstall the spark plugs and crank the engine a few times. STORAGE PROCEDURE 2. Drain the engine oil thoroughly If the motorcycle is to be left and refill the crankcase with unused for an extended period of fresh engine oil all the way up time, it needs special servicing to the filler hole. requiring appropriate materials, 3. Cover the air cleaner intake equipment and skill. For this rea- and the muffler outlet with oily son, Suzuki recommends that you rags to prevent humidity from trust this maintenance work to entering. your Suzuki dealer. If you wish to service the machine for storage BATTERY yourself, follow the general guide- 1. Remove the battery from the lines below: motorcycle by referring to the BATTERY section. MOTORCYCLE 2. Clean the outside of the bat- Clean the entire motorcycle. tery with a mild soap and Place the motorcycle on the side remove any corrosion from the stand on a firm, flat surface where terminals and wiring harness. it will not fall over. Turn the han- 3. Store the battery in a room dlebars all the way to the left and above freezing. lock the steering, and remove the ignition key. TIRES Inflate the tires to the normal FUEL pressure. 1. Fill the fuel tank to the top with EXTERNAL fuel mixed with the amount of • Spray all vinyl and rubber gasoline stabilizer recom- parts with rubber protectant. mended by the stabilizer man- • Spray the unpainted surfaces ufacturer. with rust preventative. 2. Run the engine for a few min- • Coat the painted surfaces with utes until the stabilized gaso- car wax. line fills the fuel injection system. PROCEDURE DURING STORAGE Once a month, recharge the bat- tery with a specified charging rate (Ampere). Standard charging rate is 1.1A × 5 to 10 hours.
9-2 PROCEDURE FOR RETURNING CORROSION PREVENTION TO SERVICE It is important to take good care of 1. Clean the entire motorcycle. your motorcycle to protect it from 2. Remove the oily rags from the corrosion and keep it looking new air cleaner intake and muffler for years to come. outlet. 3. Drain all the engine oil. Install Important Information About a new oil filter and fill the Corrosion engine with fresh oil as out- Common causes of corrosion lined in this manual. • Accumulation of road salt, dirt, 4. Remove the spark plugs. Turn moisture, or chemicals in hard- the engine a few times. Rein- to-reach areas. stall the spark plugs. • Chipping, scratches, and any 5. Reinstall the battery by refer- damage to treated or painted ring to the BATTERY section. metal surfaces resulting from 6. Make sure that the motorcycle minor accidents or impacts is properly lubricated. from stones and gravel. 7. Perform the INSPECTION BEFORE RIDING as listed in Road salt, sea air, industrial pollu- this manual. tion, and high humidity will all con- 8. Start the motorcycle as out- tribute to corrosion. lined in this manual. How to Help Prevent Corrosion • Wash your motorcycle fre- quently, at least once a month. Keep your motorcycle as clean and dry as possible. • Remove foreign material deposits. Foreign material such as road salt, chemicals, road oil or tar, tree sap, bird droppings and industrial fall- out may damage your motor- cycle’s finish. Remove these types of deposits as soon as possible. If these deposits are difficult to wash off, an addi- tional cleaner may be required. Follow the manufacturer’s directions when using these special cleaners.
9-3 • Repair finish damage as soon MOTORCYCLE CLEANING as possible. Carefully exam- ine your motorcycle for dam- WASHING THE MOTORCYCLE age to the painted surfaces. When washing the motorcycle, Should you find any chips or follow the instructions below: scratches in the paint, touch 1. Remove dirt and mud from the them up immediately to pre- motorcycle with cool running vent corrosion from starting. If water. You may use a soft the chips or scratches have sponge or brush. Do not use gone through to the bare hard materials which can metal, have a Suzuki dealer scratch the paint. make the repair. 2. Wash the entire motorcycle • Store your motorcycle in a dry, with a mild detergent or car well-ventilated area. If you wash soap using a sponge or often wash your motorcycle in soft cloth. The sponge or cloth the garage or if you frequently should be frequently soaked in park it inside when wet, your the soap solution. garage may be damp. The high humidity may cause or NOTE: Clean the motorcycle with accelerate corrosion. A wet cool water immediately after motorcycle may corrode even riding on road salt or riding along in a heated garage if the venti- the coast. Be sure to use cool lation is poor. water because warm water can • Cover your motorcycle. Expo- hasten corrosion. sure to mid-day sun can cause the colors in paint, plastic NOTE: Avoid spraying or allowing parts, and instrument faces to water to flow over the following fade. Covering your motorcy- places: cle with a high-quality, “breath- • Ignition switch able” motorcycle cover can • Spark plugs help protect the finish from the • Fuel tank cap harmful UV rays in sunlight, • Fuel injection system and can reduce the amount of • Brake master cylinders dust and air pollution reaching • Clutch master cylinder the surface. Your Suzuki • Throttle cable boots dealer can help you select the right cover for your motorcycle.
9-4 NOTE: The headlight lens can be NOTICE fogged after washing the motorcy- cle or riding in the rain. Headlight High pressure washers such as fogging will be cleared gradually those found at coin-operated when the headlight is turned on. car washes have enough pres- When clearing the headlight lens sure to damage the parts of fogging, run the engine to avoid your motorcycle. It may cause battery discharge. rust, corrosion and increase wear. Parts cleaner can also NOTICE damage motorcycle parts. Cleaning your motorcycle with Do not use high pressure any alkaline or strong acid washers to clean your motorcy- cleaner, gasoline, brake fluid, cle. Do not use parts cleaner or any other solvent will dam- on throttle body and fuel injec- age the motorcycle parts. tion sensors. Clean only with soft cloth and warm water with mild deter- 3. Once the dirt has been com- pletely removed, rinse off the gent. detergent with running water. 4. After rinsing, wipe off the motorcycle with a wet chamois or cloth and allow it to dry in the shade. 5. Check carefully for damage to painted surfaces. If there is any damage, obtain “touch-up” paint and “touch-up” the dam- age following the procedure below: a. Clean all damaged spots and allow them to dry. b. Stir the paint and “touch- up” the damaged spots lightly with a small brush. c. Allow the paint to dry com- pletely.
9-5 WINDSHIELD CLEANING WAXING THE MOTORCYCLE Clean the windshield with a soft After washing the motorcycle, cloth and warm water with a mild waxing and polishing are recom- detergent. If scratched, polish mended to further protect and with a commercially available beautify the paint. plastic polish. Replace the wind- • Only use waxes and polishes shield if it becomes scratched or of good quality. discolored so as to obstruct view. • When using waxes and pol- When replacing the windshield, ishes, observe the precautions use a Suzuki replacement wind- specified by the manufactur- shield. ers.
SPEEDOMETER DISPLAY SPECIAL CARE FOR MATTE CLEANING FINISH PAINT When the speedometer display is Do not use polishing compounds to be cleaned, wipe gently using a or waxes that contain polishing moist cloth. compounds on surfaces which have a matte finish. The use of NOTICE polishing compounds will change the appearance of the matte fin- When the speedometer display ish. is wiped or rubbed aggres- sively using a dry cloth, the Solid type waxes may be difficult display might be scratched. to remove from surfaces with a matte finish. Use a moist soft cloth. Friction while riding, excessive rubbing or polishing of a surface with a matte finish will change its appearance.
9-6 INSPECTION AFTER CLEANING For extended life of your motorcy- cle, lubricate it according to the “LUBRICATION POINTS” section. WARNING Operating the motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes. This could lead to an accident.
Test your brakes after washing the motorcycle, while riding at slow speed. If necessary, apply the brakes several times to let friction dry out the linings.
Follow the procedures in the “INSPECTION BEFORE RIDING” section to check your motorcycle for any problems that may have arisen during your last ride.
9-7
CONSUMER INFORMATION
WARRANTIES ...... 10-2 EMISSION CONTROL SYSTEMS ...... 10-3 REPORTING SAFETY DEFECTS ...... 10-4 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-5 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ...... 10-6 SERIAL NUMBER LOCATION ...... 10-7 LOCATION OF LABELS ...... 10-8
10
10-1 CONSUMER Suzuki limited warranties and the INFORMATION Federal and California Emission Control System Limited Warranty may not cover damage caused by WARRANTIES modifications that would change The warranties for your motorcy- the original vehicle specifications cle are explained in a separate including, without limitation, modi- warranty policy booklet given to fications of any emission-related you at the time of sale. Please parts such as the carburetor(s), read this booklet carefully so you fuel injection system components, can understand your rights and the engine control module, air responsibilities. The following suction system components, the warranties are provided with your catalytic converter (if equipped), motorcycle: evaporative emission control sys- • On-Road Motorcycle Limited tem components, etc. Warranty • Motorcycle Federal Emission Control System Limited War- ranty • California Emission Control System Limited Warranty (Applies ONLY to Suzuki street-legal emission-con- trolled motorcycles certified for sale and registered in Califor- nia.)
10-2 EMISSION CONTROL SYSTEMS Servicing Requirements Your vehicle is subject to U.S. It is essential to have your vehicle Environmental Protection Agency serviced according to the mainte- (EPA) and California Air nance schedule in this manual to Resources Board (CARB) emis- maintain good emission perfor- sion regulations. mance and to preserve your emis- sion warranty coverage. If parts These regulations set specific replacement is necessary, replace standards for exhaust emission the parts with Genuine Suzuki output levels and fuel permeation parts or their equivalent. Installing emissions, as well as particular improper replacement parts or servicing requirements. performing improper adjustments can cause your vehicle to exceed Evaporative Emission Control emission level limits. Tampering System (if equipped) with emission-related compo- The evaporative emission control nents in a manner which defeats system of your vehicle consists of or reduces the effectiveness of the carbon canister, fuel tank, fuel these components is prohibited hoses, and fuel vapor hoses. by federal and California law. These parts incorporate technolo- gies to control fuel evaporative emissions.
10-3 REPORTING SAFETY To contact Suzuki Motor of Amer- DEFECTS ica, Inc., owners in the continental If you believe that your vehicle United States can call toll-free 1- has a defect which could cause a 800-444-5077, or write to: Suzuki crash or could cause injury or Motor of America, Inc. Motorcy- death, you should immediately cle Customer Service P.O. Box inform the National Highway Traf- 1100, Brea, CA 92822-1100. fic Safety Administration (NHTSA) in addition to notifying Suzuki For owners outside the continen- Motor of America, Inc. tal United States, please refer to the distributor’s address listed on If NHTSA receives similar com- your Warranty Information bro- plaints, it may open an investiga- chure. tion, and if it finds that a safety defect exists in a group of vehi- cles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Suzuki Motor of America, Inc.
To contact NHTSA, you may either call the Vehicle Safety Hot Line toll-free 1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to: Administrator, NHTSA, 1200 New Jersey Ave., S.E., Washing- ton DC 20590. You can also obtain other information about motor vehicle safety from http:// www.safercar.gov.
10-4 TAMPERING WITH NOISE • Removing or puncturing the air CONTROL SYSTEM cleaner case, air cleaner PROHIBITED cover, baffles, or any other component which conducts Federal law prohibits the following intake air. acts or the causing thereof; 1. The removal or rendering inop- Whenever replacing parts on your erative by any person other motorcycle, Suzuki recommends than for purposes of mainte- that you use genuine Suzuki nance, repair, or replacement, replacement parts or their equiva- of any device or element of lent. design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur- chaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below: • Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other compo- nent which conducts exhaust gases. • Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcy- cle Noise Emission Control Information label, and certified to appropriate EPA noise stan- dards.
10-5 ON-BOARD MOTORCYCLE Some information may be stored COMPUTER DATA by the on-board computer when INFORMATION malfunctions occur. This stored information can assist techni- Your motorcycle is equipped with cians in repairing the motorcycle. on-board computer systems To read the stored information, which monitor and control several special equipment is needed and aspects of motorcycle perfor- access to the motorcycle or stor- mance, including the following: age device is required. In addi- • Emission-related components tion, once Suzuki collects or and engine parameters such receives data, Suzuki may use as engine speed and throttle the data for research conducted position are monitored to pro- by Suzuki, make the data avail- vide emission control and to able for outside research if need provide optimum fuel econ- is shown and confidentiality is omy. Your motorcycle also has assured, or make summary data an on-board diagnostic system which does not identify specific which monitors and records motorcycles available for outside information about emission- research. related malfunctions. • If your motorcycle is equipped Others, such as law enforcement with antilock brakes, condi- personnel, may have access to tions such as motorcycle the special equipment that can speed and brake performance read the information if they have are monitored, so that the ABS access to the motorcycle or stor- system can provide effective age device. antilock braking.
10-6 SERIAL NUMBER LOCATION Write down the serial numbers You need to know the frame and here for your future reference. engine serial numbers to get title documents for your motorcycle. Frame No.: You also need these numbers to help your dealer when you order Engine No.: parts.
The frame number 1 is stamped on the steering head as shown in the illustration. The engine serial number 2 is stamped on the crankcase assembly.
10-7 LOCATION OF LABELS Read and follow all of the warnings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcy- cle. Do not remove them for any reason.
1
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.
2
3
COLD TIRE SOLO RIDING DUAL RIDING PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi FRONT 250 2.50 36 250 2.50 36 REAR 290 2.90 42 290 2.90 42 FRONT REAR TIRE SIZE 110/80R19M/C 59V 150/70R17M/C 69V TYPE BRIDGESTONE BW-501 RADIAL J BW-502 RADIAL J
10-8 4
WARNING Never exceed the max imum loading capacity. Exceeding maximum loading capacity can cause loss of control. Maximum loading capacity 10 kg (22 lbs) (Rear carrier)
5
VEHICLE EMISSION CONTROL INFORMATION SUZUKI MOTOR CORPORATION DISPLACEMENT :645 cc ENGINE FAMILY :ESKXC.645VC1 PERMEATION FAMILY : ESKXPMETAL01 EXHAUST EMISSION CONTROL SYSTEM : SFI / TWC / HO2S ENGINE TUNE-UP SPECIFICATIONS : ALL ADJUSTMENTS ARE TO BE PERFORMED WITH TRANSMISSION IN NEUTRAL VALVE LASH :IN 0.10 - 0.20mm, EX 0.20 - 0.30mm FUEL : UNLEADED GASOLINE, 87 PUMP MIN IDLE SPEED : ELECTRONICALLY CONTROLLED IDLE SPEED 1,300 RPM NON-ADJUSTABLE ENGINE OIL : API SF / SG OR API SH / SJ WITH JASO MA, AND VISCOSITY RATING OF SAE 10W-40 REFER TO YOUR OWNER'S MANUAL FOR ADDITIONAL MAINTENANCE INSTRUCTIONS THIS VEHICLE CONFORMS TO U . S . EPA REGULATIONS APPLICABLE TO 2014 MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO 0.8 HC + NOx ENGINE FAMILY EXHAUST EMISSION STANDARD
5 California
VEHICLE EMISSION CONTROL INFORMATION SUZUKI MOTOR CORPORATION DISPLACEMENT :645 cc ENGINE FAMILY :ESKXC.645VC1 EVAP FAMILY : ESKXU0018YTJ PERMEATION FAMILY :ESKXPMETAL01 EXHAUST EMISSION CONTROL SYSTEM : SFI / TWC / HO2S ENGINE TUNE-UP SPECIFICATIONS : ALL ADJUSTMENTS ARE TO BE PERFORMED WITH TRANSMISSION IN NEUTRAL VALVE LASH : IN 0.10 - 0.20mm, EX 0.20 - 0.30mmFUEL : UNLEADED GASOLINE, 87 PUMP MIN IDLE SPEED : ELECTRONICALLY CONTROLLED IDLE SPEED 1,300 RPM NON-ADJUSTABLE ENGINE OIL : API SF / SG OR API SH / SJ WITH JASO MA, AND VISCOSITY RATING OF SAE 10W-40 REFER TO YOUR OWNER'S MANUAL FOR ADDITIONAL MAINTENANCE INSTRUCTIONS THIS VEHICLE CONFORMS TO U . S . EPA AND CALIFORNIA REGULATIONS APPLICABLE TO 2014 MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO 0.8 (EPA) AND 0.8 (CALIFORNIA) g/km HC + NOx ENGINE FAMILY EXHAUST EMISSION STANDARDS
6
WARNING AVERTISSEMENT
This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. • Keep away from fire and heat. • Read owner’s manual for more information. L’amortisseur contient de l’azote sous haute pression. Toute mauvaise manipulation peut causer une explosion. • Tenir à l’écart du feu et de la chaleur. • Lire le manuel du propriétaire pour plus d’informations.
10-9 SPECIFICATIONS
DIMENSIONS AND CURB MASS Overall length ...... 2280 mm (89.8 in) Overall width...... 930 mm (36.6 in) Overall height ...... 1470 mm (57.9 in) Wheelbase ...... 1555 mm (61.2 in) Ground clearance...... 165 mm (6.5 in) Curb mass ...... 232 kg (511 lbs) ... DL1000A 233 kg (514 lbs) ... DL1000XA
ENGINE Type...... 4-stroke, liquid-cooled, DOHC, 90-degree V-twin Number of cylinders ...... 2 Bore...... 100.0 mm (3.937 in) Stroke ...... 66.0 mm (2.598 in) Displacement...... 1037 cm3 (63.3 cu. in) Compression ratio ...... 11.3 : 1 Fuel system ...... Fuel injection system Air cleaner ...... Paper element Starter system ...... Electric Lubrication system ...... Wet sump
DRIVE TRAIN Clutch ...... Wet multi-plate type Transmission ...... 6-speed constant mesh Gearshift pattern ...... 1-down, 5-up Primary reduction ratio ...... 1.838 (57/31) Gear ratios, Low...... 3.000 (36/12) 2nd ...... 1.933 (29/15) 3rd ...... 1.500 (27/18) 4th ...... 1.227 (27/22) 5th ...... 1.086 (25/23) Top...... 1.000 (24/24) Final reduction ratio...... 2.411 (41/17) Drive chain ...... RK525SMOZ8, 116 links
CHASSIS Front suspension...... Telescopic, coil spring, oil damped Rear suspension ...... Link type, coil spring, oil damped Front fork stroke ...... 160 mm (6.3 in) Rear wheel travel...... 160 mm (6.3 in) Caster...... 25° 30’ Trail...... 109 mm (4.29 in) Steering angle ...... 36° (right and left) Turning radius...... 2.9 m (9.5 ft) Front brake ...... Disk brake, twin Rear brake...... Disk brake Front tire size...... 110/80R19M/C 59V, tubeless Rear tire size ...... 150/70R17M/C 69V, tubeless ELECTRICAL Ignition type ...... Electronic ignition (Transistorized) Spark plug ...... NGK LMAR8BI-9 Battery...... 12V 40.3 kC(11.2 Ah)/10 HR Generator ...... Three-phase A.C. generator Main fuse...... 30A Fuse ...... 15/15/15/15/10/10/3A ABS fuse ...... 25/15A Headlight high beam ...... 12V 65W H9 Headlight low beam...... 12V 55W H7 Position light ...... 12V 5W Brake light/Taillight...... LED License plate light...... 12V 5W Turn signal light ...... 12V 21W Speedometer light ...... LED Turn signal indicator light...... LED Neutral indicator light...... LED High beam indicator light...... LED Oil pressure/Coolant temperature indicator light ...... LED Malfunction indicator light...... LED Freeze indicator light ...... LED ABS indicator light ...... LED Traction control system indicator light ...... LED
CAPACITIES Fuel tank...... 20.0 L (5.3 US gal) Engine oil, oil change ...... 2700 ml (2.9 US qt) With filter change...... 3100 ml (3.3 US qt) Engine coolant...... 2130 ml (2.3 US qt) INDEX
A D ACCESSORIES AND DRIVE CHAIN ...... 7-30 LOADING ...... 1-5 ACCESSORY INSTALLATION E GUIDELINES...... 6-2 EMISSION CONTROL ACCESSORY USE ...... 6-2 SYSTEMS ...... 10-3 AIR CLEANER ...... 7-14 ENGINE COOLANT ...... 7-28 ENGINE COOLANT B SOLUTION ...... 2-5 BATTERY...... 7-11 ENGINE IDLE SPEED BE EXTRA SAFETY- INSPECTION...... 7-27 CONSCIOUS ON BAD ENGINE OIL ...... 2-4,7-22 WEATHER DAYS...... 1-4 BE STREET SMART...... 1-6 F BRAKE LEVER FITTING ..... 7-56 FRONT WHEEL BRAKES...... 7-34 REMOVAL ...... 7-45 BREAK-IN ...... 4-2 FUEL ...... 2-2,3-30 FUEL HOSE ...... 7-21 C FUEL SYSTEM CHECK ...... 8-2 CARRYING A FUEL TANK CAP ...... 3-30 PASSENGER...... 1-5,5-11 FUEL TANK LIFT ...... 7-5 CATALYTIC FUEL TANK REMOVAL ...... 7-9 CONVERTER...... 7-57 FUSES...... 7-55 CLUTCH...... 7-33 CLUTCH LEVER G FITTING ...... 7-57 GEARSHIFT LEVER ...... 3-31 CONCLUSION ...... 1-6 CORROSION PREVENTION...... 9-3 I M IF A COLLISION IS IMMINENT, MAINTENANCE DO SOMETHING! ...... 1-3 SCHEDULE ...... 7-2 IF YOU DON’T HAVE A HELMET, MODIFICATION ...... 6-5 BUY A HELMET, AND WEAR IT MOST ACCIDENTS CAN BE EVERY TIME YOU RIDE ...... 1-2 AVOIDED ...... 1-2 IGNITION SWITCH ...... 3-5 MOTORCYCLE IGNITION SYSTEM CLEANING ...... 9-4 CHECK...... 8-3 MOTORCYCLE SAFETY INSPECTION AFTER FOUNDATION’S CLEANING...... 9-7 “RIDING TIPS AND PRACTICE INSPECTION BEFORE GUIDE” HANDBOOK RIDING...... 1-5,4-3 (FOR OWNERS IN USA) ...... 1-5 INSTRUMENT PANEL...... 3-8 O K ON-BOARD VEHICLE KEY ...... 3-5 COMPUTER DATA KNOW YOUR LIMITS ...... 1-4 INFORMATION ...... 10-6 OUTPUT TERMINAL...... 3-39 L LABELS...... 1-6 P LEFT HANDLEBAR...... 3-22 PRACTICE AWAY FROM LIGHT BULB TRAFFIC ...... 1-5 REPLACEMENT ...... 7-50 PROCEDURE FOR RETURNING LOADING GUIDELINES ...... 6-4 TO SERVICE...... 9-3 LOADING LIMIT...... 6-3 LOCATION OF LABELS ...... 10-8 LOCATION OF PARTS...... 3-2 LUBRICATION POINTS...... 7-10
R T REAR BRAKE PEDAL ...... 3-31 TAMPERING WITH NOISE REAR WHEEL CONTROL SYSTEM REMOVAL...... 7-47 PROHIBITED...... 10-5 REPORTING SAFETY THROTTLE CABLE DEFECTS...... 10-4 PLAY ...... 7-27 RIDING ON HILLS ...... 5-6 TIRES ...... 7-39 RIGHT HANDLEBAR ...... 3-27 TOOLS ...... 7-5 S U SEAT LOCK ...... 3-32 USING THE SERIAL NUMBER TRANSMISSION ...... 5-5 LOCATION...... 10-7 SIDE STAND...... 3-33 W SIDE STAND/IGNITION WARRANTIES...... 10-2 INTERLOCK SYSTEM...... 7-44 WINDSHIELD ...... 3-37 SPARK PLUGS...... 7-16 SPECIAL SITUATIONS REQUIRE SPECIAL CARE ...... 1-4 SPOKE WHEELS (DL1000XA)...... 7-43 STARTING OFF AND SHIFTING...... 5-4 STARTING THE ENGINE ...... 5-2 STOPPING AND PARKING ...... 5-7 STORAGE PROCEDURE...... 9-2 SUSPENSION ADJUSTMENT ...... 3-34
Total page: 164