Valve + guide
Unit: mm (in)
| ITEM | STANDARD | LIMIT | |
| Valve diam. | IN. | 31 (1-2) | — |
| EX. | 25.5 (1.0) | — | |
| Valve clearance (when cold) | IN. | 0.10-0.20 (0.004 - 0.008) | — |
| EX. | 0.20 - 0.30 (0.008-0.012) | — | |
| Valve guide to valve stem clearance | IN. | 0.020 - 0.047 (0.0008-0.0019) | — |
| EX. | 0.030 - 0.057 (0.0012 - 0.0022) | — | |
| Valve guide I.D. | IN. & EX. | 4.500 - 4.512 (0.1772 - 0.1776) | — |
| Valve stem O.D. | IN. | 4.465 - 4.480 (0.1758-0.1764) | — |
| EX. | 4.455 - 4.470 (0.1754-0.1760) | — | |
| Valve stem deflection | IN. & EX. | — | 0.35 (0.014) |
| Valve stem runout | IN. & EX. | — | 0.05 (0.002) |
| Valve head thickness | IN. & EX. | — | 0.5 (0.02) |
| Valve seat width | IN. & EX. | 0.9- 1.1 (0.035 - 0.043) | — |
| Valve head radial runout | IN. & EX. | — | 0.03 (0.001) |
| Valve spring free length (IN. & EX.) | INNER | — | 36.8 (1-45) |
| OUTER | — | 39.8 (1-57) | |
| Valve spring tension (IN. &EX.) | INNER | 4.2 - 4.8 kgf (9.26- 10.58 lbs) at length 29.9 mm (1.18 in) | — |
| OUTER | 17.0-19.6 kgf (37.48-43.21 lbs) at length 33.4 mm (1.31 in) | — | |
Camshaft + cylinder head
Unit: mm (in)
| ITEM | STANDARD | LIMIT | |
| Cam height | IN. | 35.48 - 35.53 (1.3968- 1.3988) | 35.18 (1.3850) |
| EX. | 33.48 - 33.53 (1.3181 - 1.3201) | 33.18 (1.3063) | |
| Camshaft journal oil clearance | IN. & EX. | 0.032 - 0.066 (0.0013-0.0026) | 0.150 (0.0059) |
| Camshaft journal holder I.D. | IN. & EX. | 22.012 - 22.025 (0.8666 - 0.8671) | — |
| Camshaft journal O.D. | IN. & EX. | 21.959 - 21.980 (0.8645 - 0.8654) | — |
| Camshaft runout | IN. & EX. | — | 0.10 (0.004) |
| Cam chain pin (at arrow "3") | 16th pin | — | |
| Cylinder head distortion | — | 0.05 (0.002) | |
Cylinder + piston + piston ring
Unit: mm (in)
| ITEM | STANDARD | LIMIT | |
| Compression pressure | 1300 - 1700 kPa (13-17 kgf/cm² / 185 - 242 psi) | 1100 kPa (11 kgf/cm² / 156 psi) | |
| Compression pressure difference | — | 200 kPa (2 kgf/cm² / 28 psi) | |
| Piston to cylinder clearance | 0.055 - 0.065 (0.0022 - 0.0026) | 0.120 (0.0047) | |
| Cylinder bore | 81.000 - 81.015 (3.1890 - 3.1896) | Nicks or Scratches | |
| Piston diam. | 80.950 - 80.955 (3.1870 - 3.1872) Measure at 20 mm (0.79 in) from the skirt end. | 80.88 (3.184) | |
| Cylinder distortion | — | 0.05 (0.002) | |
| Piston ring free end gap | 1st | Approx. 9.5 (0.37) | 7.6 (0.30) |
| 2nd | Approx. 11 (0.43) | 8.8 (0.35) | |
| Piston ring end gap | 1st | 0.20 - 0.35 (0.008 - 0.014) | 0.70 (0.028) |
| 2nd | 0.20 - 0.35 (0.008-0.0014) | 0.70 (0.028) | |
| Piston ring to groove clearance | 1st | — | 0.180 (0.0071) |
| 2nd | — | 0.150 (0.0059) | |
| Piston ring groove width | 1st | 1.21 - 1.23 (0.0476 - 0.0484) | — |
| 2nd | 1.01 - 1.03 (0.0398 - 0.0406) | — | |
| Oil | 2.01 - 2.03 (0.0791 - 0.0799) | — | |
| Piston ring thickness | 1st | 1.17 - 1.19 (0.0461 - 0.0469) | — |
| 2nd | 0.97 - 0.99 (0.0382 - 0.0390) | — | |
| Piston pin bore | 20.002 - 20.008 (0.7875 - 0.7877) | 20.030 (0.7886) | |
| Piston pin O.D. | 19.992 - 20.000 (0.7871 - 0.7874) | 19.98 (0.7866) | |
Conrod + crankshaft
Unit: mm (in)
| ITEM | STANDARD | LIMIT |
| Conrod small end LD. | 20.010 - 20.018 (0.7878 - 0.7881) | 20.040 (0.7890) |
| Conrod big end side clearance | 0.170 - 0.320 (0.0067 - 0.0126) | 0.5 (0.02) |
| Conrod big end width | 20.95 - 21.00 (0.825 - 0.827) | — |
| Crank pin width | 42.17 - 42.22 (1.660 - 1.662) | — |
| Conrod big end oil clearance | 0.032 - 0.056 (0.0013 - 0.0022) | 0.080 (0.0031) |
| Crank pin O.D. | 37.976 - 38.000 (1.4951 - 1.4960) | — |
| Crankshaft journal oil clearance | 0.002 - 0.029 (0.0001 - 0.0011) | 0.080 (0.0031) |
| Crankshaft journal O.D. | 41.985 - 42.000 (1.6529 - 1.6535) | — |
| Crankshaft runout | — | 0.05 (0.002) |
Oil pump
| ITEM | STANDARD | LIMIT |
| Oil pressure (at 60°C, 140°F) | Above 100 kPa (1.0 kgf/cm², 14 psi) Below 400 kPa (4.0 kgf/cm², 57 psi) at 3 000 r/min. | — |
Clutch
Unit: mm (in)
| ITEM | STANDARD | LIMIT | |
| Clutch cable play | 10-15 (0.4-0.6) | — | |
| Clutch release screw | 1/4 turns back | — | |
| Drive plate thickness | No.1 & No.2 | 2.92-3.08 (0.115-0.121) | 2.62 (0.103) |
| Drive plate claw width | No.1 & No.2 | 13.7-13.8 (0.539-0.543) | 12.9 (0.507) |
| Driven plate distortion | — | 0.10 (0.004) | |
| Clutch spring free length | 53.1 (2.09) | 50.5 (1-99) | |
Transmission + drive chain
Unit: mm (in) Except ratio
| ITEM | STANDARD | LIMIT | ||
| Primary reduction ratio | 2.088 (71/34) | — | ||
| Final reduction ratio | 3.133 (47/15) | — | ||
| Gear ratios | Low | 2.461 (32/13) | — | |
| 2nd | 1.777 (32/18) | — | ||
| 3rd | 1.380 (29/21) | — | ||
| 4th | 1.125 (27/24) | — | ||
| 5th | 0.961 (25/26) | — | ||
| Top | 0.851 (23/27) | — | ||
| Shift fork to groove clearance | 0.1-0.3 (0.004-0.012) | 0.50 (0.020) | ||
| Shift fork groove width | 5.5-5.6 (0.217-0.220) | — | ||
| Shift fork thickness | 5.3-5.4 (0.209-0.213) | — | ||
| Drive chain | Type | DID525V8 | — | |
| Links | 116 links | — | ||
| 20-pitch length | — | 319.4 (12.57) | ||
| Drive chain slack (on side-stand) | 20-30 (0.79-1.18) | — | ||
| Gearshift lever height | 25 (0.98) | — | ||
Thermostat + radiator + fan + coolant
| ITEM | STANDARD | NOTE | |
| Thermostat valve opening temperature | Approx. 88°C (190°F) | — | |
| Thermostat valve lift | Over 8.0 mm (0.31 in) at 100°C (212°F) | — | |
| ECT sensor resistance | 20°C (68°F) | Approx. 2.45 kΩ | — |
| 40°C (104°F) | Approx. 1.148 kΩ | — | |
| 60°C (140°F) | Approx. 0.587 kΩ | — | |
| 80°C (176°F) | Approx. 0.322 kΩ | — | |
| Radiator cap valve opening pressure | 95-125 kPa (0.95-1.25 kgf/cm², 13.5-17.8 psi) | — | |
| Cooling fan thermo-switch operating temperature | OFF→ON | Approx. 98°C (208°F) | — |
| ON→OFF | Approx. 92°C (198°F) | — | |
| Engine coolant type | Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. | — | |
| Engine coolant including reserve | Reserve tank side | Approx. 250 ml (0.53/0.44 US/Imp qt) | — |
| Engine side | Approx. 1650 ml (3.49/2.90 US/Imp qt) | — | |
Injector + fuel pump + fuel pressure regulator
| ITEM | SPECIFICATION | NOTE |
| Injector resistance | 11-13 Ω at 20°C (68°F) | |
| Fuel pump discharge amount | MIN. 168 ml (5.7/5.9 US/Imp oz) for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi) | |
| Fuel pressure regulator operating set pressure | Approx. 300 kPa (3.0 kgf/cm², 43 psi) |
Fl sensors+ secondary throttle valve actuator
| ITEM | SPECIFICATION | NOTE | |
| CKP sensor resistance | 130-240 Ω | W-G | |
| CKP sensor peak voltage | 3.7 V (When cranking) and more | ||
| IAP sensor input voltage | 4.5-5.5 V | ||
| IAP sensor output voltage | Approx. 2.7 V at idle speed | (+) G/B - (-) B/Br | |
| TP sensor input voltage | 4.5-5.5 V | ||
| TP sensor resistance | Closed | Approx. 1.12 kΩ | |
| Opened | Approx. 4.26 kΩ | ||
| TP sensor output voltage | Closed | Approx. 1.12 V | (+) P/W - (-) B/Br |
| Opened | Approx. 4.26 V | ||
| ECT sensor input voltage | 4.5-5.5 V | ||
| ECT sensor resistance | Approx. 2.45 kΩ at 20°C (68°F) | ||
| IAT sensor input voltage | 4.5-5.5 V | ||
| IAT sensor resistance | Approx. 2.45 kΩ at 20°C (68°F) | ||
| TO sensor resistance | 19.1 - 19.7 kΩ | ||
| TO sensor voltage | Normal | 0.4-1.4 V | (+) Br/W - (-) B/Br |
| Leaning 65° | 3.7-4.4 V | ||
| GP switch voltage | 1.0 V and more (From 1 st to Top) | ||
| Injector voltage | Battery voltage | ||
| STP sensor input voltage | 4.5-5.5 V | ||
| STP sensor resistance | Closed | Approx. 0.58 kΩ | Y- B |
| Opened | Approx. 4.38 kΩ | ||
| STP sensor output voltage | Closed | Approx. 0.58 V | (+) Y - (-) B/Br |
| Opened | Approx. 4.40 V | ||
| STV actuator resistance | 7-14Ω | ||
| PAIR solenoid valve resistance | 20-24 kΩ at 20°C (68°F) | ||
Throttle body
| ITEM | SPECIFICATION |
| I.D. No. | 27 GO (Others), 27 G1 (For E-33) |
| Bore size | 39 mm |
| Fast idle r/min. | 1800 - 2400 r/min at 25°C (77°F) |
| Idle r/min. | 1300±100 r/min/Warmed engine |
| Throttle cable play | 2.0-4.0 mm (0.08-0.16 in) |
Electrical
Unit: mm (in)
| ITEM | SPECIFICATION | Note | ||
| Firing order | 1.2 | |||
| Spark plug | Type | NGK: CR8E DENSO: U24ESR-N | ||
| Gap | 0.7-0.8 mm (0.028-0.031 in) | |||
| Spark performance | Over 8 mm (0.3 in) at 1 atm. | |||
| CKP sensor resistance | 130-240 Ω | W-G | ||
| Ignition coil resistance | Primary | 2-5 Ω | (+) tap - (-) tap | |
| Secondary | 24-37 kΩ | (+) tap - Plug cap | ||
| CKP sensor peak voltage | 3.7 V and more | When cranking | ||
| Ignition coil primary peak voltage | 150 V and more | |||
| Generator coil resistance | 0.2-0.7 Ω | |||
| Generator Max. output | Approx. 375 W at 5 000 r/min | |||
| Generator no-load voltage (When cold) | 60 V (AC) and more at 5 000 r/min. | |||
| Regulated voltage | 14.0-15.5 Vat 5000 r/min. | |||
| Starter relay resistance | 3-6 Ω | |||
| Battery | Type designation | YTX12-BS | ||
| Capacity | 12 V 36.0 kC (10 Ah)/10 HR | |||
| Fuse size | Headlight HI | 15 A | ||
| Headlight LO | 15 A | |||
| Fuel | 10 A | |||
| Ignition | 10 A | |||
| Fan motor | 15 A | |||
| Signal | 15 A | |||
| Main | 30 A | |||
Wattage
Unit: w
| ITEM | SPECIFICATION | |
| E-03, 24, 28, 33 | Others | |
| Headlight | 12 V 60/55 Wx2(H4) | ← |
| Position/Parking light | 12 V5 Wx2 | |
| Brake light/Taillight | 12 V21/5 Wx2 | ← |
| Turn signal light | 12 V 21 W | ← |
| License light | 12 V 5 W | ← |
| Speedometer light | LED | ← |
| Turn signal indicator light | LED | ← |
| High beam indicator light | LED | ← |
| Neutral indicator light | LED | ← |
| Oil pressure/Coolant temp./Fuel injection warning | LED | ← |
Brake + wheel
Unit: mm (in)
| ITEM | STANDARD | LIMIT | |
| Rear brake pedal height | 15-25 (0.59-0.98) | — | |
| Brake disc thickness | Front | 5 (0.20) | 4.5 (0.18) |
| Rear | 5 (0.20) | 4.5 (0.18) | |
| Brake disc runout | — | 0.3 (0.012) | |
| Master cylinder bore | Front | 15.870- 15.913 (0.6248 - 0.6265) | — |
| Rear | 14.000- 14.043 (0.5512-0.5529) | — | |
| Master cylinder piston diam. | Front | 15.827- 15.854 (0.6231 -0.6242) | — |
| Rear | 13.957- 13.984 (0.5495 - 0.5506) | — | |
| Brake caliper cylinder bore | Front | 30.230 - 30.306 (1.1902- 1.1931) | — |
| Rear | 38.180-38.256 (1.5031 - 1.5061) | — | |
| Brake caliper piston diam. | Front | 30.150-30.200 (1.1870- 1.1890) | — |
| Rear | 38.098-38.148 (1.4999- 1.5019) | — | |
| Brake fluid type | DOT 4 | ||
| Wheel rim runout | Axial | — | 2.0 (0.08) |
| Radial | — | 2.0 (0.08) | |
| Wheel rim size | Front | 19 M/C x MT2.50 | — |
| Rear | 17 M/C x MT4.00 | — | |
| Wheel axle runout | Front | — | 0.25 (0.010) |
| Rear | — | 0.25 (0.010) | |
Tire
| ITEM | STD/SPEC. | LIMIT | |
| Cold inflation tire pressure (Solo riding) | Front | 225 kPa (2.25 kgf/cm², 33 psi) | — |
| Rear | 250 kPa (2.50 kgf/cm², 36 psi) | — | |
| Cold inflation tire pressure (Dual riding) | Front | 225 kPa (2.25 kgf/cm², 33 psi) | — |
| Rear | 280 kPa (2.80 kgf/cm², 41 psi) | — | |
| Tire size | Front | 110/80 R19 М/С (59 H) | — |
| Rear | 150/70 R17 М/С (69 H) | — | |
| Tire type | Front | BRIDGESTONE: TW101 F | — |
| Rear | BRIDGESTONE: TW152 F | — | |
| Tire tread depth | Front | — | 1.6 (0.06) |
| Rear | — | 2.0 (0.08) | |
Suspension
Unit: mm (in)
| ITEM | STD/SPEC. | LIMIT | |
| Front fork stroke | 150 (5.9) | — | |
| Front fork spring free length | 444.1 (17.5) | 435 (17.1) | |
| Front fork oil level (without spring, outer tube fully compressed) | 143 (5.63) | — | |
| Front fork spring adjuster | 3 groove from Top/Spring adjuster height 9 mm (0.35 in) | — | |
| Front fork oil type | SUZUKI FORK OIL SS-08 or equivalent fork oil | — | |
| Front fork oil capacity (each leg) | 524 ml (17.7/18.5 US/Imp oz) | — | |
| Rear shock absorber spring adjuster | 2 groove from bottom | — | |
| Rear shock absorber damping force adjuster | Rebound | 1 turn back from stiffest position | E-02, 19, 24 |
| 1½ turns back from stiffest position | E-03, 28, 33 | ||
| Rear wheel travel | 150 mm (5.9 in) | — | |
| Swingarm pivot shaft runout | — | 0.3 (0.01) | |
Fuel + oil
| ITEM | STD/SPEC. | NOTE | |
| Fuel type | Use only unleaded gasoline of at least 87 pump octane (R+M)/2 or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. | E-03, 28, 33 | |
| Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. | Others | ||
| Fuel tank capacity | 22 L (5.8/4.8 US/Imp gal) | ||
| Engine oil type | SAE 10 W - 40, API SF or SG | ||
| Engine oil capacity | Change | 2 300 ml (2.4/2.0 US/Imp qt) | |
| Filter change | 2 700 ml (2.9/2.4 US/Imp qt) | ||
| Overhaul | 3 100 ml (3.3/2.7 US/Imp qt) | ||