Cooling system. Inspect at initial 1000 km (600 miles or 2 months) and every 12000 km (7500 miles or 24 months).

Inspect at initial 1000 km (600 miles or 2 months) and every 12000 km (7500 miles or 24 months).

Change coolant every 2 years. Replace radiator hoses every 4 years.

• Keep the motorcycle upright.

• Check the coolant level by observing the upper and lower limit line on the coolar: it reservoir.

• If the level is below mark " F ", add coolant to the upper line from the coolant reservoir filler.

• Remove the seat, air cleaner covers and fuel tank. (R efer to pages 1-12 and 4-2.)

• R emove the radiator cap CD and drain plug @, and drain

coolant.

WARNING:

* Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.

* Coolant may be harmful if swallowed or if it comes in

• F lush the radiator with fresh water if necessary.

• Tighten the drain plug @ securely.

• Pour the specified coolant up to the radiator inlet.

Tightening torque

Coolant drain plug: 10 - 12 N-m

NOTE:

For coolant information, refer to page 54.

• Close the radiator cap CD securely.

• After warming up and cooling down the engine, add the specified coolant up to the coolant reservoir.

CAUTION:

Repeat above procedure several times and make sure that the radiator is filled with coolant up to the coolant reservoir.

Coolant capacity: 1900 ml (2.0/1.7 US/Imp qt)

Inspect at initial 1000 km (600 miles or 2 months) and ra....

every 6000 km (4000 miles or 12 months). '" 'i! l'lll/

• Loosen the lock nut CD and turn in the adjuster @ all the way into the clutch lever holder.

•

in place to introduces some play in the clutch lever.

• R emove the clutch release cover.

• Loosen the lock nut ® and back the adjusting screw ® out two or three rotations.

• Slowly turn the adjusting screw in until it begins to meet high resistance to turning.

F rom this position, back it out 1/4 -1/2 rotation and secure the lock nut ®.

•

• Lock the adjuster ® using lock nut CD.

Inspect at initially 1000 km (600 miles or 2 months) and every 6000 km (4000 miles or 12 months).

Clean and lubricate every 1000 km (600 miles).

V isually check the drive chain for the listed below possible defects. (Support the motorcycle by center stand, and turn the rear wheel slowly by hand with the transmission shifted to Neutral.)

* Loose pins

* Damaged rollers

* Dry or rusted links

* Kinked or binding links

* Excessive wear

* Improper chain adjustment

* Missing 0-ring seals

If any defects are found, the drive chain must be replaced.

CHECKING

• Remove the cotter pin. (For E-03, 28 and 33 models.)

• Loosen the ax le nut CD.

• Tense the drive chain fully by tightening the chain adjust­ ing nuts ®, left and right.

E-03: U.S.A.

E-28: Canada

E-33: California (U.S.A.)

• Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance ex­ ceeds following limit, the chain must be replaced.

Service Limit: 319.4 mm (12.57 in)

ADJUSTI NG

•

Place on side stand for accurate adjustment.

• After adjusting the drive chain slack, tighten the axle nut CD

securely.

• Tighten the chain adjusting nuts securely.

CLEANING AND LUBRICATING

• Wash the chain with kerosene. If the chain tends to rust faster, the intervals must be shortened.

CAUTION:

• After washing and drying the chain, oil it with a heavy­ weight motor oil.

CAUTION:

* Do not use any oil sold commercially as " drive chain oil".

Such oil can damage the " O" rings (or seals).

* The standard drive chain is D.l.D. 525V9 - 114 links or R K525SMOZ2 - 114 links. SUZUKI recommends that the above-mentioned standard drive chain be used for the re­ placement.

Inspect system at initial 1000 km (600 miles or 2 months) and every 6000 km (4000 miles or 12 months).

Replace hoses every 4 years. Change fluid every 2 years.

BRAKE FLUID LEVEL

•

• Check the brake fluid level by observing the lower limit lines on the brake fluid reservoirs.

• When the level is below the lower limit line, replenish with brake fluid that meets the following specification.

Specification and Classification: DOT4

99000-23110: SUZUKI BRAKE FLUID DOT3 & DOT4 WARNING:

The brake syst m of this motorcycle is filled with a glycol­ based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods.

WARNING:

Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

The extent of brake pad wear can be checked by observing the grooved limit line CD marked on the pad. When the wear

exceeds the grooved limit line, replace the pads with new ones. (R efer to pages 7-6 and 7-21.)

CAUTION:

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

• Loosen the lock nut CD and rotate the push rod ® to locate brake pedal 40 - 50 mm (1.6 - 2.0 in) below the top face of the footrest.

• R etighten the lock nut CD to secure the push rod ® in the

proper position.

Brake pedal height ®: 40 - 50 mm (1.6 - 2.0 in)

Adjust both brake light switches, front and rear, so that the brake light will come on just before a pressure is felt when the brake lever is squeezed, or the brake pedal is depressed.

AIR BLEEDING THE BRAK E FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by " sponginess" of the brake level/pedal and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

• Fill up the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap.

• Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle.

•

NOTE:

Replenish the brake fluid in the reservoir as necessar y while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir.

• Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the upper end of the inspection window.

CAUTION:

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.

Tightening torque

Air bleeder valve: 6 - 9 N·m

(0.6 - 0.9 kg-m, 4.5 - 6.5 lb-ft)

Inspect at initially 1000 km (600 miles or 2 months) and every 6000 km (4000 miles or 12 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specifi­ cation.

Tire tread depth limit Front: 1.6 mm (0.06 in) Rear: 2.0 mm (0.08 in)

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be ad­ versely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result.

Cold inflation tire pressure is as follows.

The standard tire fitted on th is motorcycle is 110/70-17 54H (DUNLOP K505FL) for front and 150/70-17 69H (DUNLOP

K505J) for rear. The use of tires other than the those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire.

Inspect at initially 1000 km (600 miles or 2 months) and every 6000 km (4000 miles or 12 months).

Taper roller type bearings are used on the steering system for better handling.

Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability.

Check that there is no play in the front fork assembly by sup­ porting the machine so that the front wheel is off the ground, with the wheel straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as described in page 7-19 of this manual.