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Repair motorcycles Suzuki DR-Z
Suzuki DRZ-250 (1996-2007)
Information for owner

How to use the manual
Symbols for instructions and other information
Precautions and Notes
General precautions
Motorcycle appearance
Serial Number Location
Fuel Use Recommendations
Motor oil and other fluids
Motorcycle Break-in Procedure
Information signs
Special tools and devices
Tightening torque
Break-in procedure for motorcycle DR-Z250K1 (E-24)
Motorcycle instrument panel DR-Z250K1 (E-24)

Technical characteristics

Motorcycle Specifications
Motorcycle Service Data
Motorcycle Specifications DR-Z250K1 (E-24)
Service data for motorcycle DR-Z250K1 (E-24)
Motorcycle Specifications DR-Z250K1 (2002)
Service data for motorcycle DR-Z250K1 (2002)
Motorcycle Specifications DR-Z250K3/K4/K5 (2003-2005)
Service data for motorcycle DR-Z250K3/K4/K5 (2003-2005)
Motorcycle DR-Z250K3/K4/K5 (2003-2005) Information Labels
Motorcycle Specifications DR-Z250K6/K7 (2006-2007)
Service data for motorcycle DR-Z250K6/K7 (2006-2007)
Motorcycle Specifications DR-Z250K9 (2009)

Maintenance

Periodic Maintenance Schedule
Air filter
Exhaust system fasteners
Checking valve clearances
Adjusting valve clearances
Spark plug
Removal carbon deposits from a flame arrester
Fuel lines
Engine oil and filter
Checking oil lines
Adjusting the throttle cable
Idle speed adjustment
Clutch free play
Checking and adjusting the chain
Cleaning and lubricating the chain
Brake pads
Brake foot position
Brake fluid level
Bleeding the brake system
Free play of the brake lever
Checking brake hoses
Tire tread condition
Tire pressure
Checking the spokes
Steering and suspension
Fasteners
Main lubrication points
Checking engine compression
Checking oil pressure
Maintenance Schedule DR-Z250K1 (E-24)

Troubleshooting

Engine Troubleshooting
Carburetor Troubleshooting
Troubleshooting the chassis
Troubleshooting the brake system
Troubleshooting electrical equipment
Troubleshooting the Battery
Engine and systems

Engine repair

Removal engine components without removing the engine from the motorcycle
Removal the engine
Engine installation
Disassembling the engine
Checking and servicing the camshaft/cylinder head
Checking and servicing cylinders
Checking and servicing the piston and rings
Checking and servicing the connecting rod
Crankshaft journal runout
Inspection of the balance shaft
Oil pan filter
Engine assembly
Block diagram of the engine lubrication system
Oil radiator

Fuel system

Removal the gas tank
Removal the fuel tap and filter
Checking the fuel line
Carburetor device (E-03, E-28)
Carburetor device (E-33)
Carburetor Specifications
Location of identification number
Removal the carburetor
Disassembling the carburetor (E-03, E-28)
Cleaning the carburetor (E-03, E-28)
Checking the carburetor (E-03, E-28)
Assembly and installation of the carburetor (E-03, E-28)
Disassembling the carburetor (E-33)
Cleaning the carburetor (E-33)
Checking the carburetor (E-33)
Assembly and installation of the carburetor (E-33)

Transmission

Clutch — Inspection and Maintenance
Transmission — design description
Shift Fork — Groove Clearance
Checking transmission bearings
Transmission assembly
Running gear and frame

Frame and hinged elements

Headlight fairing
Frame Trim and Saddle
Motorcycle Wiring
Motorcycle Cable Routing
Carburetor Air Hose Wiring
Front Brake Hose Routing
Rear Brake Hose Routing
Installing the side stand spring
Wiring, cables and flexible hoses DR-Z250K1 (E-24)
Wiring, cables and flexible hoses DR-Z250K3/K4/K5 (2003-2005)

Wheels and tires

Front wheel — design description
Front wheel — removal
Odometer reducer — check
Hub seal — check
Front wheel — check
Wheel bearings — check
Front axle — check
Brake disc — check
Front wheel — assembly and installation
Rear wheel — design description
Rear wheel — removal
Rear wheel — defect detection and disassembly
Rear wheel — assembly and installation

Brake system

Front brake system — design description
Front brake system — precautions
Replacing the front brake pads
Replacing brake fluid in front brakes
Removal and disassembling the front brake caliper
Front brake caliper defect detection
Assembly and installation of the front brake caliper
Front brake disc defect detection
Master Brake Cylinder (Front) — Removal and Disassembly
Defect detection of the main brake cylinder (front)
Master Brake Cylinder (Front) — Assembly and Installation
Rear brake system — design description
Rear brake system — precautions
Replacing rear brake pads
Replacing brake fluid in rear brakes
Rear Brake Caliper — Removal and Disassembly
Rear Brake Caliper — Assembly and Installation
Master Brake Cylinder (Rear) — Removal and Disassembly
Master Brake Cylinder (Rear) — Assembly and Installation

Front suspension and handlebar

Front fork — design description
Front fork — removal and disassembly
Front fork — defects
Front fork — assembly and installation
Suspension adjustment
Steering wheel — design description
Steering wheel — dismantling and disassembly
Steering wheel — defects
Steering wheel — assembly and installation

Rear suspension

Rear swingarm and suspension — design description
Rear Swingarm and Suspension — Removal
Defect detection and disassembly of the pendulum bushing
Pendulum bearing — defect detection
Pendulum — defect detection
Needle bearings of the lever — defect detection
Rear shock absorber — defect list
Pendulum axis — troubleshooting
Rear swingarm and suspension — assembly and installation
Rear suspension adjustment
Shock absorber disposal
Electric equipment

Equipment and devices

Important points during maintenance
Location of electrical components
Removal the odometer
Headlight and taillight
Starter relay
Ringing the switches
Battery — Specifications and Maintenance
Motorcycle Electrical Wiring Diagram
Motorcycle headlight and lamps DR-Z250K1 (E-24)
Testing motorcycle switches DR-Z250K1 (E-24)
Motorcycle Electrical Diagram DR-Z250K1 (E-24)

Starting and charging system

Maintenance of the generator stator and winding
Starter overrunning clutch
Battery charging system
Battery leakage current — check
Voltage Regulator — Check
Generator winding resistance
Generator performance without load
Regulator/Rectifier — Check
Starter — diagram and troubleshooting
Removal and disassembling the starter
Inspection of the starter
Assembling the starter
Inspection of the starter relay
Ignition System — Schematic and Troubleshooting
Peak voltage on the primary winding of the ignition coil
Ignition coil resistance
Peak voltage on the sensor winding and signal winding
Starter and ignition system locks DR-Z250K1 (E-24)
Starting system lock DR-Z250K1 (E-24)

Repair motorcycles Suzuki V-Strom
Suzuki DL 650 (1 generation, 2004-2011)
Information for owner

Introduction to manual

Component parts and work to be done
Symbols indicating instructions for servicing
Abbreviations used in this manual
SAE-to-former Suzuki term
Wire color codes
Warning/caution/note
Serial number location
Fuel, oil and engine coolant recommendation
Break-in procedures
Cylinder identification
Information labels
Specifications of motorcycle
Country and area codes
Special tools for motorcycle repair
Tightening torques of fastening elements
Service data of motorcycle

Maintenance

Periodic maintenance schedule
Lubrication points
Air cleaner
Spark plug
Valve clearance
Fuel line inspection
Engine oil and oil filter
Engine idle speed
Throttle cable play adjustment
Throttle valve synchronization
Evaporative emission control system (E-33 only)
PAIR (air supply) system
Clutch adjustment
Cooling system servicing
Drive chain servicing — checking and adjusting
Brake system servicing
Tire tread condition
Steering system servicing
Front fork servicing
Rear suspension servicing
Exhaust pipe bolt
Chassis bolt and nut
Compression pressure check
Oil pressure check

Troubleshooting

Malfunction code and defective condition
Engine diagnosis and troubleshooting
Transmission diagnosis and troubleshooting
Radiator (cooling system) diagnosis and troubleshooting
Chassis diagnosis and troubleshooting
Brakes diagnosis and troubleshooting
Electrical system diagnosis and troubleshooting
Battery diagnosis and troubleshooting
Engine and systems

Engine repair

Engine components removable with the engine in place
Engine removal
Engine installation
Engine top side disassembly
Engine bottom side disassembly
Cylinder head cover — disassembly and assembly
Camshaft/camshaft journal — disassembly and assembly
Cylinder head — disassembly and assembly
Cylinder — disassembly and assembly
Piston and piston ring — disassembly and assembly
Conrod and crankshaft — disassembly and assembly
Crankcase — disassembly and assembly
Crankshaft journal bearing — inspection
Crankcase bearing and oil seal — removal, installation and inspection
Starter clutch — disassembly and assembly
Generator and signal generator — inspection
Oil pump inspection
Engine bottom side reassembly
Engine top side reassembly

Fuel injection

Fuel system

Fuel delivery system — construction
Fuel pump — construction
Fuel pressure regulator — construction
Fuel injector — construction
Fuel pump control system — construction
Fuel tank lift-up
Fuel tank — removal and installation
Fuel pressure inspection
Fuel pump inspection
Fuel pump relay inspection
Fuel pump and fuel filter removal
Fuel mesh filter inspection and cleaning
Fuel pump and fuel mesh filter installation
Throttle body and STV actuator construction
Air cleaner and throttle body removal
Throttle body disassembly
Throttle body cleaning
Throttle body inspection
Throttle body reassembly
STV synchronization
Throttle body installation
STP sensor adjustment
TP sensor adjustment
Fast idle inspection
Fast idle adjustment
Throttle valve synchronization

Cooling and lube system

Engine coolant
Cooling circuit inspection
Radiator — removal and installation
Radiator cap inspection
Water hose inspection
Cooling fans — removal and installation
Cooling fan thermo-switch — removal and installation
ECT sensor — removal and installation
Thermostat case assembly — removal and installation
Water pump — removal and installation
Oil cooler — removal and installation
Engine lubrication flow chart
Engine lubrication circuit

Transmission

Clutch — disassembly and assembly
Primary driven gear assembly
Gearshift shaft/gearshift arm — disassembly and inspection
Transmission countershaft disassembly
Transmission driveshaft disassembly
Transmission inspection
Transmission reassembly
Clutch release inspection
Drive chain cutting
Drive chain connecting
Running gear and frame

Frame and hinged elements

Exterior parts construction
Seat — removal and installation
Fuel tank side cover
Motorcycle trunk — removal and installation
Frame cover — removal and installation
Rear fender — removal and installation
Cowling and cowling brace
Exterior parts installation
Battery cushion installation
Side-stand set-up
Brake pedal/footrest set-up
Engine cap installation
Footrest set-up

Front suspension and handlebar

Front fork construction
Front fork — removal and disassembly
Front fork — inspection
Front fork — reassembly and remounting
Spring pre-load adjustment
Steering and handlebar construction
Handlebars — removal and installation
Steering stem — removal and installation
Steering and handlebar — inspection and disassembly
Steering and handlebar — reassembly and remounting
Steering tension adjustment
Handlebar balancer installation

Rear suspension

Rear shock absorber construction
Rear shock absorber — removal
Rear shock absorber — inspection
Rear shock absorber disposal
Rear shock absorber — remounting
Spring pre-load adjustment
Damping force adjustment
Rear swingarm construction
Rear swingarm — removal
Rear swingarm — inspection and disassembly
Rear swingarm — reassembly
Rear swingarm — remounting
Rear swingarm — final inspection and adjustment

Brake system

Front brake construction
Front brake pad replacement
Front brake fluid replacement
Front brake caliper — removal and disassembly
Front brake caliper — inspection
Front brake caliper — reassembly and remounting
Front brake disc — inspection
Front master cylinder — removal and disassembly
Front master cylinder — inspection
Front master cylinder — reassembly and remounting
Rear brake construction
Rear brake pad replacement
Rear brake fluid replacement
Rear caliper — removal and disassembly
Rear caliper — inspection
Rear brake disc — inspection
Rear caliper reassembly and remounting
Rear master cylinder — removal and disassembly
Rear master cylinder — inspection
Rear master cylinder — reassembly and remounting

Wheels and tires

Front wheel construction
Front wheel — removal
Front wheel — inspection and disassembly
Front wheel — reassembly and remounting
Rear wheel construction
Rear wheel — removal
Rear wheel — inspection and disassembly
Rear wheel — reassembly and remounting
Tire and wheel — inspection

Wires and hose routing

Wlre harness routing
Heated oxygen sensor (HO2S) wire routing (for E-02, 19)
Engine electrical parts set-up
Speed sensor lead wire routing
Throttle cable routing
Clutch cable routing
Throttle body installation/hose routing
Cooling system hose routing
Front brake hose routing
Rear brake hose routing
Fuel tank drain hose routing
Fuel tank installation
Pair (air supply) system hose routing
Seat lock cable routing
Head lamp set-up
Absorber hose routing
Electric equipment

Equipment and devices

Cautions in servicing
Location of electrical components
Side-stand/ignition interlock system parts — inspection
Combination meter — removal and disassembly
Combination meter — inspection
Engine coolant temperature meter inspection
Fuel level gauge inspection
Fuel level meter inspection
Oil pressure indicator inspection
Speedometer and speed sensor
Headlight, brake light/taillight and turn signal light
Turn signal/side-stand relay — inspection
Ignition switch — removal
Ignition switch — inspection

Starting and charging system

Charging system trouble shooting
Battery inspection
Starter system and side-stand/ignition interlock troubleshooting
Starter motor — removal and disassembly
Starter motor — inspection
Starter motor — reassembly
Starter relay — inspection
Ignition system troubleshooting
Ignition system — inspection
Battery specifications
Battery initial charging
Battery recharging operation

Electrical circuits

Fuel injection system wiring diagram
Charging system circuit
Starter system and side-stand/ignition interlock circuit
Ignition system circuit
Electrical schematic of motorcycle (except UK & EU models)
Electrical schematic of motorcycle (only UK & EU models)
Suzuki DL 1000 K2-K9 (2002-2012)
Information for owner

Introduction to manual

Component parts and work to be done
Abbreviations used in this manual
SAE-to-former Suzuki term
Warning/caution/note of general information
General precautions
Motorcycle appearance
Serial number location
Fuel, oil and engine coolant recommendation
Break-in procedures
Cylinder identification
Information labels
Specifications of motorcycle
Country and area codes
Special tools

Maintenance

Periodic maintenance schedule
Maintenance and tune-up procedures
Spark plug
Tappet clearance
Fuel hose
Engine oil and oil filter
Engine idle speed
Throttle cable play
Clutch hose and clutch fluid
Cooling system
Drive chain — checking and adjusting
Brake hose and brake fluid
Tire tread condition and pressure
Inspect steering
Front fork
Rear suspension
Exhaust pipe bolt
Chassis bolt and nut
Compression pressure check
Compression test procedure
Oil pressure check
Oil pressure test procedure

Troubleshooting

Fl system malfunction code and defective condition
Troubleshooting — engine
Troubleshooting — radiator (cooling system)
Troubleshooting — chassis
Troubleshooting — brakes
Troubleshooting — electrical
Troubleshooting — battery

Technical characteristics (K2)

Tightening torque engine
Fl system parts tightening torque
Chassis tightening torque
Tightening torque chart
Service data valve + guide
Camshaft + cylinder head specifications
Cylinder + piston + piston ring specifications
Conrod + crankshaft specifications
Oil pump specifications
Clutch specifications
Thermostat + radiator + fan specifications
Drive train specifications
Injector + fuel pump + fuel pressure regulator specifications
FI-sensors specifications
Throttle body specifications
Electrical specifications
Wattage specifications
Brake + wheel specifications
Suspension specifications
Tire pressure specifications
Fuel + oil + engine coolant specifications
Emission control systems
Pair (air supply) system inspection hoses
Pair (air supply) system hose routing
Evaporative emission control system inspection (Only for E-33)
Canister hose routing (Only for E-33)

Technical characteristics (K3)

Specifications of DL1000K3 (2003 model)
Service data — valve + guide
Service data — camshaft + cylinder head
Service data — cylinder + piston + piston ring
Service data — conrod + crankshaft
Service data — oil pump
Service data — clutch
Service data — thermostat + radiator + fan
Service data — drive train
Service data — injector + fuel pump + fuel pressure regurator
Service data — FI-sensors
Service data — throttle body
Service data — electrical
Service data — wattage
Service data — brake + wheel
Service data — suspension
Service data — tire pressure
Service data — fuel + oil + engine coolant
Front fork — construction
Regulator/rectifier inspection

Technical characteristics (K4)

Specifications of motorcycle
Service data — valve + guide
Service data — camshaft + cylinder head
Service data — cylinder + piston + piston ring
Service data — conrod + crankshaft
Service data — oil pump
Service data — clutch
Service data — thermostat + radiator + fan
Service data — drive train
Service data — FI-sensors
Service data — throttle body
Service data — electrical
Service data — wattage
Service data — brake + wheel
Service data — suspension
Service data — tire pressure
Service data — fuel + oil + engine coolant
Special tool
Periodic maintenance chart
Engine installation
Fl system
Combination meter — removal and disassembly and inspection
Wire harness routing
Cowling setup

Technical characteristics (K5)

Specifications of motorcycle
Service data — valve + guide
Service data — camshaft + cylinder head
Service data — cylinder + piston + piston ring
Service data — conrod + crankshaft
Service data — oil pump
Service data — clutch
Service data — thermostat + radiator + fan
Service data — drive train
Service data — injector + fuel pump + fuel pressure regurator
Service data — FI-sensors
Service data — throttle body
Service data — electrical
Service data — wattage
Service data — brake + wheel
Service data — suspension
Service data — tire pressure
Service data — fuel + oil + engine coolant
Cooling system hose routing

Technical characteristics (K6-K8)

Specifications of motorcycle
Service data — valve + guide
Service data — camshaft + cylinder head
Service data — cylinder + piston + piston ring
Service data — conrod + crankshaft
Service data — oil pump
Service data — clutch
Service data — thermostat + radiator + fan
Service data — drive train
Service data — injector + fuel pump + fuel pressure regurator
Service data — FI-sensors
Service data — throttle body
Service data — electrical
Service data — wattage
Service data — brake + wheel
Service data — suspension
Service data — tire pressure
Service data — fuel + oil + engine coolant
Specifications 2009 models
Engine and systems

Engine repair

Cooling and lube system

Engine coolant
Cooling circuit
Radiator — removal and installation
Radiator reservoir tank — removal and installation
Radiator cap — inspection
Water hose — inspection
Cooling fan — removal, installation and inspection
Cooling fan thermo-switch — removal, installation and inspection
Engine coolant temperature sensor — removal, installation and inspection
Thermostat — removal and inspection
Water pump — removal and disassembly
Oil cooler — removal and installation
Engine lubrication flow chart
Engine lubrication circuit

Fuel system

Transmission

Clutch — inspection
Transmission — construction
Transmission — disassembly
Transmission — reassembly
Gearshift fork
Primary drive gear
Gearshift — disassembly and assembly
Crankcase of transmission
Crankcase-crankshaft bearing
Clutch cover
Gearshift cover
Engine reassembly — gearshift
Engine reassembly — primary drive gear
Engine reassembly — cam drive idle gear/sprocket
Engine reassembly — gear position switch
Engine reassembly — clutch
Engine reassembly — clutch cover
Running gear and frame

Frame and hinged elements

Front suspension and handlebar

Front fork — construction
Front fork — removal and disassembly
Front fork — inspection
Front fork — reassembly and remounting
Steering and handlebar — construction
Steering and handlebar — removal
Steering and handlebar — inspection and disassembly
Steering and handlebar — reassembly and remounting
Steering and handlebar — steering tension adjustment

Rear suspension

Rear shock absorber — construction
Rear shock absorber — removal
Rear shock absorber — inspection
Rear shock absorber — rear shock absorber disposal
Rear shock absorber — remounting
Rear shock absorber — suspension setting
Rear swingarm — construction
Rear swingarm — removal
Rear swingarm — inspection and disassembly
Rear swingarm — reassembly
Rear swingarm — remounting
Rear swingarm — final inspection and adjustment

Brake system

Front brake — construction
Front brake — brake pad replacement
Front brake — brake fluid replacement
Front brake — caliper removal and disassembly
Front brake — caliper inspection
Front brake — caliper reassembly and remounting
Front brake — brake disc inspection
Front brake — master cylinder removal and disassembly
Front brake — master cylinder inspection
Front brake — master cylinder reassembly and remounting
Rear brake — construction
Rear brake — brake pad replacement
Rear brake — brake fluid replacement
Rear brake — caliper removal and disassembly
Rear brake — caliper inspection
Rear brake — brake disc inspection
Rear brake — caliper reassembly and remounting
Rear brake — master cylinder removal and disassembly
Rear brake — master cylinder inspection
Rear brake — master cylinder reassembly and remounting

Wheels and tires

Front wheel — construction
Front wheel — removal
Front wheel — inspection and disassembly
Front wheel — reassembly and remounting
Rear wheel — construction
Rear wheel — removal
Rear wheel — inspection and disassembly
Rear wheel — reassembly and remounting
Tire and wheel — tire removal
Tire and wheel — inspection
Tire and wheel — valve installation
Tire and wheel — tire installation

Wires and hose routing

Wire harness routing
Engine electrical parts set-up
High-tension cord routing
Throttle cable routing
Throttle body installation/hose routing
Crankcase breather hose routing
Clutch hose routing
Cooling system hose routing
Front brake hose routing
Rear brake hose routing
Fuel tank drain hose routing
Fuel tank installation
Pair (air supply) system hose routing
Seat lock cable routing
Side-stand set-up
Brake pedal/footrest set-up
Footrest set-up
Handlebar balancer installation
Electric equipment

Equipment and devices

Cautions in servicing
Location of electrical components
Side-stand/ignition interlock system parts inspection
Ignition system — troubleshooting
Ignition system — inspection
Combination meter — removal and disassembly
Combination meter — inspection
Engine coolant temperature meter and indicator
Lamps — headlight, brake light, tail light and turn signal light
Relays — turn signal/side-stand relay
Relays — switches
Wiring diagram

Starting and charging system

Charging system — inspection and troubleshooting
Starter system and side-stand/ignition interlock system
Starter motor removal and disassembly
Starter motor inspection
Starter motor reassembly
Starter relay inspection
Battery — specifications
Battery — initial charging
Battery — servicing and recharging operation
Injector + fuel pump + fuel pressure regurator
Suzuki DL 1000A/XA (2014-2019)
Information for owner

Introduction to manual

Precautions — introduction to manual
Precautions for Electrical Circuit Service
Short circuit check (Wire harness to ground)
Precautions for Circuit Tester
Precautions for SDS-II
Precautions for Identification
Warning/caution/notice/note
Applicable Model/VIN
List of abbreviations
SAE-to-Former SUZUKI Term
Table of symbols
Wire Color Symbols
Vehicle Side View
Vehicle Identification Number
Country and Area Codes
Warning, Caution and Information Labels Location
Electrical Components Location
Precautions for Maintenance
Scheduled Maintenance
Repair Instructions*
Chassis Bolte and Nuts Inspection
Lubrication Points

Technical characteristics

Dimensions and curb mass
General motorcycle specifications
Engine general information and diagnosis
Emission Control Devices
Engine Electrical Devices
Engine Mechanical
Engine Lubrication System
Engine Cooling System
Fuel System
Ignition System
Starting System
Charging System
Exhaust System
Front Suspension
Rear Suspension
Wheels and Tires
Drive Chain/Drive Train/Drive Shaft
Brake Control System and Diagnosis
Front Brakes Specification
Rear Brakes Specification
ABS Specification
Manual Transmission Specification
Clutch Specification
Steering/Handlebar
Wiring Systems
Lighting Systems
Combination Meter/Fuel Meter/Hom
Fasteners Information
Fastener Strength Identification
Standard Tightening Torques
Tightening torque chart
Special Tools and Equipment
Special Tool
Engine and systems

Engine diagnostics L4-L6

Precautions for Engine, for DTC Trouble Shooting*
General Description
Compensation of Injection Time (Volume)
Injection Stop Control
Traction Control System Description*
Self-Diagnosis Function
Schematic and Routing Diagram
Component Location
Diagnostic Information and Procedures*
DTC Check with Mode Select Switch*
DTC Check with SDS*
DTC Clearance with SDS*
Monitoring Failure Detection Data with SDS*
DTC detecting condition*
Fail-Safe Function Table
FI System Troubleshooting*
DTC P0105-h/P0105-l (C17)*
DTC P0110-h/P0110-l (C21)*
DTC P0115-h/P0115-l (C15)*
DTC P0120-h/0120-I (C14)*
DTC p0130 (C64)*
DTC p0135 (C64)*
DTC p0156 (C44)*
DTC p0201 (C32)*
DTC p0202 (C33)*
DTC P0230-h/P0230-I (C41)*
DTC p0335 (С12)*
DTC p0351 (C24)*
DTC p0352 (C25)*
DTC p0353 (C26)*
DTC p0354 (C27)*
DTC P0443 (C62) (If Equipped)*
DTC p0480 (C60)*
DTC p0500 (C16)*
DTC p0506 (C65)*
DTC p0507 (C65)*
DTC p0705 (C31)*
DTC p1500 (C91)*
DTC p1650 (C42)*
DTC P1651-H/P1651-l (C23)*
DTC P1654-H/P1654-l (C29)*
DTC p1655 (C28)*
DTC P1656 (C49) (If Equipped)*
DTC P1657-H/P1657-l (C46)*
DTC p1658 (C46)*
DTC P1750-H/P1750-l (C13)*
DTC p2505 (C41)*
Special Tools and Equipment*

Engine diagnostics L8

Precautions, General Description*
Self-Diagnosis Function*
Comparison Table of DTC Name*
FI System — Schematic and Routing Diagram*
FI System — Component Location*
DTC Clearance*
DTC Table
Fail-Safe Function Table*
DTC P0030 (C64)/P0050 (c44)*
DTC P0105/P0106/P0107 (c17)*
DTC P0110/P0112 (c21)*
DTC P0115/P0117 (c15)*
DTC P0120/P0123 (c14)*
DTC P0130 (C64)/P0150 (c44)*
DTC P0170 (c45)*
DTC P0201 (C32)/P0202 (c33)*
DTC P0220/P0223 (c29)*
DTC P0231/P0232 (c41)*
DTC P0335 (c12)*
DTC P0351 (C4)/P0352 (C25)/P0353 (C26)/P0354 (c27)*
DTC P0418 (c49)*
DTC P0443 (c62)*
DTC P0480 (c60)*
DTC P0500 (C16)/P2158 (c91)*
DTC P0506/P0507 (c65)*
DTC P0914 (c31)*
DTC P1100/P1101/P1102 (c13)*
DTC P1400/P1401 (c46)*
DTC P1403 (c46)*
DTC P1610 (c42)*
DTC P1700/P1702 (c23)*
DTC P2100 (c28)*
DTC P2505 (c41)*
Special Tools and Equipment*
PAIR Reed Valve Removal and Installation (If Equipped)*

Engine repair

Control system

Engine Electrical Devices*
Throttle Cable Routing Diagram
Throttle Cable Play On-vehicle Inspection and Adjustment
Throttle Body Assembly Removal and Installation*
Throttle Body Disassembly and Reassembly*
Throttle Body Inspection and Cleaning*
Throttle Valve Synchronization*
ISC Valve (Secondary Throttle Valve Interlinked) Inspection*
ECM Removal and Installation*
IAP Sensor Inspection, Removal and Installation*
IAT Sensor Inspection, Removal and Installation*
ECT Sensor Inspection, Removal and Installation*
TP Sensor Inspection, Adjustment, Removal and Installation *
HO2 Sensor Inspection, Removal and Installation*
Long Term Fuel Trim Reset (If Equipped)*
CKP Sensor, Wheel speed Sensor, GP Switch*
TO Sensor inspection, removal and installation*
Traction Control System Select Switch/Mode Switch Inspection*
Emission control tightening torque specifications*****
Recommended Service Material*

Lubrication system

Precautions for Engine Oil and Schematic and Routing Diagram*
Oil Pressure Check*
Engine Oil Inspection, Replacement*
Oil Filter Replacement*
Oil Strainer Inspection and Cleaning/Oil Pressure Regulator Removal and Installation*
Oil Pressure Regulator Inspection/Oil Pressure Switch Removal and Installation*
Oil Jet/Piston Cooling Nozzle Removal and Installation*
Oil Jet/Piston Cooling Nozzle Inspection*
Oil Pump Removal, Inspection and Installation*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Engine Lubrication System*
Water Hose Routing Diagram

Cooling system

Precautions for Engine Cooling System*
Engine Cooling Symptom Diagnosis*
Engine Coolant Level Inspection*
Air Bleeding of Engine Cooling System*
Engine Cooling System Inspection*
Radiator Cap Inspection*
Cooling Fan On-Vehicle Inspection*
Radiator Hose Inspection*
Radiator/Cooling Fan Motor Removal and Installation*
Radiator Inspection and Cleaning*
Radiator Reservoir Tank Inspection, Removal and Installation*
Water Hose Inspection, Removal and Installation*
Cooling Fan Relay Inspection*
Thermostat Removal and Installation*
Thermostat Inspection*
Water Pump Assembly Components
Water Pump Disassembly and Reassembly*
Water Pump Related Parts Inspection*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Engine Cooling System*

Fuel system

Precautions for Fuel System
Fuel System Description
Fuel System Diagnosis*
Fuel Tank Water Drain Hose and Breather Hose Routing Diagram
Fuel Feed Hose Disconnection and Reconnection
Fuel Pressure Inspection*
Fuel Discharge Amount Inspection*
Fuel Hose Inspection*
Fuel Tank Construction
Fuel Tank Molding Construction
Fuel Tank Cap Removal and Installation
Fuel Tank Removal and Installation*
Fuel Pump Components
Fuel Pump On-Vehicle Inspection, Removal, Installation*
Fuel Pump Disassembly and Reassembly*
Fuel Mesh Filter Inspection and Fuel Level Gauge Inspection*
Fuel Pump Relay Inspection*
Fuel Feed Hose Removal and Installation*
Fuel Injector/Fuel Delivery Pipe Removal and Installation*
Fuel Injector Inspection and Cleaning*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Fuel system*

Ignition system

Immobilizer Description (If Equipped)*
Ignition System Diagram
Ignition System Symptom Diagnosis*
No Spark or Poor Spark*
Ignition Coil Construction
Spark Plug Removal and Installation*
Spark Plug Inspection*
Ignition Coil Inspection, Removal and Installation*
Ignition Coil Primary Peak Voltage*
Ignition Coil Resistance*
Engine Stop Switch Inspection*
Ignition Switch Inspection, Removal and Installation*
Immobilizer Antenna Removal and Installation (If Equipped)*
Tightening Torque Specifications*
Recommended Service Material
Special Tool — Ignition system*
Starter Motor Assembly Removal and Installation, Disassembly and Reassembly*

Starting and charging system

Starting System Diagram*
Starting System Symptom Diagnosis*
Starter Motor Will Not Run*
Starter Motor Runs But Does Not Crank the Engine*
Starter Motor Components
Starter Motor Inspection*
Starter Relay Removal, Inspection and Installation*
Side-stand Relay Removal and Installation*
Starter Sub Relay Inspection (If Equipped)*
Side-stand/Ignition Interlock System Parts Inspection*
Starter Torque Limiter/Starter Clutch Removal and Installation*
Starter Torque Limiter Inspection*
Starter Clutch Inspection*
Starter Button*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Starting System*
Charging System Diagram*
Charging System Symptom Diagnosis*
Battery Runs Down Quickly*
Battery Current Leakage Inspection*
Regulated Voltage Inspection*
Generator Inspection*
Generator Removal*
Generator Installation*
Regulator/Rectifier Inspection*
Battery Charging*
Battery Removal and Installation*
Battery Visual Inspection*
Tightening Torque Specifications — Charging System*
Special Tool — Charging System*
Exhaust Pipe/Muffler Installation*

Exhaust system

Precautions for Exhaust System and Exhaust Control System Description*
Exhaust Control System Operation
Exhaust Control System Construction
Exhaust System Components
Exhaust Control Valve Inspection*
EXCVA/EXCV Cable Removal and Installation*
EXCVA Inspection*
EXCVA Adjustment*
Exhaust Pipe/Muffler Removal*
Exhaust System Inspection
Tightening Torque Specifications*

Emission control

Fuel Injection System Description*
Crankcase Emission Control System Description
Noise Emission Control System Description*
Evaporative Emission Control System Diagram (If Equipped)
PAIR System Hose Routing Diagram (If Equipped)
EVAP Canister Hose Routing Diagram (If Equipped)
PAIR Control Solenoid Valve Removal and Installation (If Equipped)*
PAIR System Inspection (If Equipped)*
PAIR Hose Removal and Installation (If Equipped)*
EVAP Control System Removal and Installation (If Equipped)*
EVAP Control System Inspection (If Equipped)*
Tightening Torque Specifications*
Special Tools and Equipment*
STP Sensor Inspection, Adjustment, Removal and Installation*

Transmission

Precautions for Driveline/Axle*
Drive Chain and Sprocket Symptom Diagnosis*
Drive Chain Related Components
Drive Cham Inspection and Adjustment, Cleaning and Lubricating*
Engine Sprocket Removal and Installation*
Rear Sprocket Removal and Installation*
Rear Sprocket Mounting Drum Assembly Removal and Installation*
Rear Sprocket Mounting Drum/Sprocket Inspection*
Rear Sprocket Mounting Drum Dust Seal/Bearing Removal and Installation*
Drive Chain Replacement*
Tightening Torque Specifications — Drive Chain/Drive Train/Drive Shaft*
Recommended Service Material*
Special Tool — Drive Chain/Drive Train/Drive Shaft*
Running gear and frame

Front suspension

Precautions for Suspension*
Suspension and Wheel Symptom Diagnosis*
Front Fork Components
Front Fork On-Vehicle Inspection*
Front Fork Assembly Removal and Installation*
Front Fork Disassembly and Reassembly*
Front Fork Inspection*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Front Suspension*

Rear suspension

Rear Suspension Components
Rear Suspension On-vehicle Inspection*
Rear Shock Absorber Adjustment, Removal and Installation*
Rear Shock Absorber Inspection*
Rear Shock Absorber Bearing Removal and Installation*
Rear Shock Absorber Disposal*
Cushion Lever Removal, Inspection and Installation*
Cushion Rod Removal, Inspection and Installation*
Cushion Rod Bearing Removal and Installation*
Swingarm Removal and Installation*
Swingarm Inspection*
Swingarm Bearing Removal and Installation*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Rear Suspension*

Wheels and tires

Precautions for Wheel and Tire*
Front Wheel Components
Front Wheel Assembly, Spoke Construction (DL1000XA)
Front Wheel Assembly Removal and Installation*
Front Wheel Dust Seal/Front Wheel Bearing Removal and Installation*
Rear Wheel Components
Rear Wheel Assembly, Spoke Construction (DL1000XA)
Rear Wheel Assembly Removal and Installation*
Rear Wheel Dust Seal/Rear Wheel Bearing Removal and Installation*
Wheel/Wheel Axle Inspection*
Rear Wheel Damper Removal, Inspection and Installation*
Tire Inspection and Cleaning*
Tire Removal and Installation*
Wheel Rim/Air Valve Inspection and Cleaning*
Air Valve Removal and Installation*
Wheel Balance Check and Adjustment*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Wheels and Tires*
Front Brake Hose Routing Diagram

Brake system

Precautions for Brake System and Brake Fluid Information*
Brake Symptom Diagnosis*
Rear Brake Hose Routing Diagram
Front Brake Light Switch Inspection*
Rear Brake Light Switch Inspection and Adjustment*
Brake Fluid Level Check
Brake Hose Inspection*
Brake Pedal Height Inspection and Adjustment*
Air Bleeding from Brake Line*
Brake Fluid Replacement*
Front Brake Hose Removal and Installation*
Rear Brake Hose Removal and Installation*
Front Brake Master Cylinder Assembly/Brake Lever Components
Front Brake Master Cylinder Assembly Removal and Installation*
Front Brake Master Cylinder Assembly/Brake Lever Disassembly and Reassembly*
Front Brake Master Cylinder Parts Inspection*
Rear Brake Master Cylinder Assembly Components
Rear Brake Master Cylinder Assembly Removal and Installation*
Rear Brake Master Cylinder Disassembly and Assembly*
Rear Brake Master Cylinder Parts Inspection*
Tightening Torque Specifications*
Recommended Service Material*
Special Tool — Brake Control System and Diagnosis*
Front Brake Components
Front Brake Pad Inspection*
Front Brake Caliper Removal and Installation*
Front Brake Caliper Disassembly and Reassembly*
Front Brake Caliper Parts Inspection*
Front Brake Disc Removal and Installation*
Front Brake Disc Inspection*
Front Brake Tightening Torque Specifications*
Front Brake Recommended Service Material*
Front Brake Special Tool*
Rear Brake Components
Rear Brake Pad Inspection and Replacement*
Rear Brake Caliper Removal and Installation*
Rear Brake Caliper Disassembly and Reassembly*
Rear Brake Caliper Parts Inspection*
Rear Brake Disc Removal, Inspection and Installation*
Rear Brakes Tightening Torque Specifications*
Rear Brakes Recommended Service Material*
Rear Brakes Special Tool*

ABS (anti-lock brake system)

Introduction to manual

Component parts and work to be done
Abbreviations used in this manual
Warning/caution/note of general information
General precautions
Left and right side of motorcycle
Serial number location
Fuel, oil and engine coolant recommendation fuel (for USA and Canada)
Break-in procedures
Cylinder identification
Information labels
Specifications dimensions and dry mass
Special tools

Technical characteristics

Tightening torque of engine
Tightening of driveline/axle
Tightening of FI system and intake air system
Tightening of cooling system
Tightening of chassis
Tightening torque chart
Service data of valve and guide
Service data of camshaft and cylinder head
Service data of cylinder, piston and piston ring
Service data of conrod and crankshaft
Service data of oil pump
Service data of clutch
Service data of thermostat, radiator, fan and coolant
Service data of drive train
Service data of driveline/axle
Service data of injector, fuel pump and fuel pressure regulator
Service data of FI-sensors
Service data of throttle body
Service data of electrical
Service data of wattage
Service data of brake and wheel
Service data of suspension
Service data of tire pressure
Service data of fuel and oil

Maintenance

Periodic maintenance schedule
Air cleaner
Exhaust pipe bolts and muffler bolts
Exhaust control valve
Valve clearance
Spark plug
Fuel line
Evaporative emission control system (E-33 only)
Engine oil and oil filter
Final gear oil
Throttle cable play
Pair (air supply) system
Throttle valve synchronization
Cooling system
Clutch cable play
Brake of periodic maintenance
Tires of periodic maintenance
Steering of periodic maintenance
Front fork
Rear suspension
Chassis bolts and nuts
Compression pressure check
Oil pressure check
SDS check

Troubleshooting

Troubleshooting of motorcycle
Troubleshooting of engine
Troubleshooting of radiator (cooling system)
Troubleshooting of chassis
Troubleshooting of shaft drive
Troubleshooting of brakes
Troubleshooting of electrical
Troubleshooting of battery
Engine and systems

Engine repair

Engine components removable with engine in place
Engine removal and installation engine removal
Engine disassembly
Engine components inspection and service
Cylinder head cover — installation, disassembly and inspection
Camshaft wear and runout
Cam chain tension adjuster
Cylinder head and valve
Cylinder repair
Piston and piston ring
Starter clutch — disassembly
Starter torque limiter
Generator cover
Crankcase — removal and installation
Balancer driven gear
Crankshaft and conrod — installation
Crankshaft journal and thrust bearing — installation and inspection
Engine reassembly
Balancer shaft
Front cam chain tension adjuster
Generator — reassembly
Rear cam chain drive sprocket
Starter torque limiter/starter idle gear
Rear cam chain idler sprocket
Piston ring — reassembly
Cylinder — reassembly
Front camshafts
Rear camshafts
Front cam chain tension adjuster of engine reassembly
Front and rear cylinder head cover
Installing generator cover
Intake pipe
Starter motor

Cooling and lube system

Oil pump — removal, installation, disassembly and inspection
Oil pressure regulator
Oil strainer
Water pump
Oil pressure switch
Thermostat — reassembly
Engine coolant
Cooling circuit
Radiator and water hose
Cooling fan — inspection
ECT sensor — removal, installation and inspection
Removal, inspection and installation thermostat
Removal and disassembly water pump
Engine lubrication system chart
Cooling system hose routing

Fuel and exhaust systems

Fuel delivery system
Fuel tank and fuel pump
Throttle body construction
Air cleaner box removal
Throttle body disassembly, cleaning and inspection
ISC valve inspection, removal and installation
Throttle body reassembly
Air cleaner chamber and throttle body installation
STP sensor adjustment
Fuel injector removal, inspection and installation
Throttle valve synchronization
Throttle position sensor (TPS) setting
EXCVA (exhaust control valve actuator) and EXCV (exhaust control valve)
Exhaust pipe and muffler removal
Throttle body hose routing
Pair (air supply) system hose routing (for Е-03, 28, 33)
Pair (air supply) system hose routing (for the others)
Fuel tank installation

Fuel injection

Emission control

Fuel injection system
Crankcase emission control system
Exhaust emission control system (pair system)
Noise emission control system
Pair (air supply) system and emission control system inspection
Pair (air supply) system hose routing (for Е-03, 28, 33)
Pair (air supply) system hose routing (for the others)
Heated oxgen sensor (ho2s) inspection (for Е-02, 19, 24)

Transmission

Clutch repair
Gearshift cover — disassembly
Clutch release camshaft — disassembly
Gearshift shaft/gearshift arm reassembly
Transmission — construction and reassembly
Transmission installation
Gear position switch
Gearshift — reassembly
Secondary drive gear
Gearshift cover — reassembly
Secondary driven gear
Clutch — reassembly
Clutch cover
Secondary bevel gears — removal, disassembly and inspection
Final bevel gears — inspection
Running gear and frame

Frame and hinged elements

Exterior parts — installation
Cable routing
Frame head cover and radiator cover installation
Frame head cover cushion installation
Radiator upper cover cushion installation
Left frame covers installation
Right frame covers installation
Headlight cover installation
Side-stand installation
Rear turn signal light, license light wire routing
Seat lock cable routing
License light and license plate installation
Brake light/taillight installation

Front suspension and handlebar

Front fork construction
Removal and disassembly front fork
Inspection front fork
Reassembly front fork
Installation front fork
Steering construction
Steering removal
Inspection and disassembly steering
Reassembly steering
Installation steering
Steering tension adjustment
Construction, removal and installation handlebars

Rear suspension

Rear suspension construction
Removal rear suspension
Inspection and disassembly rear suspension
Rear shock absorber disposal
Reassembly rear suspension
Installation rear suspension

Brake system

Front brake construction
Brake pad replacement of front brake
Brake fluid replacement of front brake
Front caliper removal
Front caliper disassembly
Front caliper inspection
Front caliper reassembly
Front caliper installation
Front brake disc inspection
Front master cylinder removal and disassembly
Front master cylinder inspection
Front master cylinder reassembly
Front master cylinder installation
Rear brake construction
Brake pad replacement of rear brake
Brake fluid replacement of rear brake
Caliper removal of rear brake
Caliper disassembly of rear brake
Caliper inspection of rear brake
Caliper reassembly of rear brake
Caliper installation of rear brake
Master cylinder removal of rear brake
Master cylinder disassembly of rear brake
Master cylinder inspection of rear brake
Master cylinder reassembly of rear brake
Master cylinder installation of rear brake
Front brake hose routing
Rear brake hose routing

Wheels and tires

Front wheel — removal
Rear wheel construction
Removal rear wheel
Disassembly rear wheel
Inspection and disassembly rear wheel
Reassembly and installation rear wheel
Tire and wheel — removal and installation
Electric equipment

Equipment and devices

Cautions in servicing
Location of electrical components
Speedometer and tachometer
Lamps — inspection and adjustment
Relays of electrical system — inspection
Wiring harness routing
Engine electrical parts lead wire routing
Wiring diagram

Starting and charging system

Charging system
Starter system and side-stand/ignition interlock system
Ignition system
Battery — charging and servicing
Ignition coil installation

Repair manuals for:

Aprilia BMW Ducati Harley Honda Kawasaki Suzuki Triumph Yamaha