FOREWORD. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in vehicle damage.

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FOREWORD This vehicle has been designed and produced utilizing Suzuki s most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced.

1 FOREWORD This vehicle has been designed and produced utilizing Suzuki s most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this vehicle. Please review this set-up manual carefully before performing any work. Take special care to properly perform the required assembly and servicing marked by either a Warning or a Caution. Failure to follow the directions in either of these two (2) categories could lead to serious problems. and areas are denoted to emphasize certain areas and carry the following meanings: Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in vehicle damage. This set-up manual is based on a vehicle of standard specification. Some minor differences from this manual may be found in other specifications. K E August 06 Printed in Japan (TK) 28

A: Packed vehicle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather

2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed vehicle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates. UNCRATING THE VEHICLE Remove the carton. Metal crates may have sharp edges and may cause injury. A: Crate 1

discarded. A: Bolt B: Bracket C: Vinyl tube Remove the bolts from the crate.

Handling crates requires two operators. Be careful not to scratch the vehicle.

3 REAR Remove the bolts and brackets. NOTE: The brackets, bolts and vinyl tube are no longer needed and these may be discarded. A: Bolt B: Bracket C: Vinyl tube Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Handling crates requires two operators. Be careful not to scratch the vehicle. A: Steel frame B: Crate base Take out the front wheel assembly and various component parts packaged around from the crate. A: Front wheel assembly B: Component parts 2

4 LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q ty Remarks A Steering head cover 1 B Fuel tank vent hose 1 C Front grip 1 Flange bolt mm Front wheel assembly 2 Right and Left D Flange nut 8 10 mm Washer 8 OD:20.0 ID:10.5 E Pin 1 Adjuster nut 1 For rear brake cable Reflex reflector 2 Right and Left F Bracket 2 Flange nut 2 5 mm 3 For E-19 CG selection G Warning label set 2 For E-19 CH selection 3 For E-19 CI selection Item Part Name Q ty Remarks H Fuel label 1 I Battery electrolyte container 1 J Owner s manual 1 T L OD ID OD : Outside diameter (mm) ID : Inside diameter (mm) L T : Length (mm) : Thickness (mm) NOTE: The parts shown as Item F, G and H in the above table are supplied for limited markets. Parts listed above are installed respectively into the positions as follows. CF D A B E D F 3

5 A E B C D F G H I J The photograph shown indicates the parts dismounted from the model in addition to the items shown in the preceding page. A: Handlebar assembly B: Throttle cable C: Front brake cable D: Rear brake cable E: Tool set 4

A: Handlebar clamp bolt Align the dot mark on the handlebars with the mating surface of the front side of right clamp. Tighten the handlebar clamp bolts to the specified torque.

6 Before assembling the vehicle, thoroughly understand the Safety Check Out described on page 29. After completion of assembly, carefully check the vehicle referring to the Safety Check Out, then deliver the vehicle to the customer. ASSEMBLY HANDLEBARS Loosen the handlebar clamp bolts. A: Handlebar clamp bolt Align the dot mark on the handlebars with the mating surface of the front side of right clamp. Tighten the handlebar clamp bolts to the specified torque. Handlebar clamp bolt: 26 N m (2.6 kgf-m) FRONT NOTE: To install the handlebars correctly, first tighten the bolt A of the front side with specified torque and then tighten the bolt B of the rear side. Make sure that the clamp has no clearance at the front side as shown in the illustration. A: Flange bolt B: Flange bolt C: Dot mark D: Clamp (Upper) E: Clamp (Lower) 5

The line drawings on page 26, 27 and 28 show the proper routing of the

Refer to drawings in addition to following the instructions carefully.

Parking brake switch lead wire E: Rear brake cable THROTTLE CABLE Remove

Insert the inner cable end into the recess of throttle cable lever

A: Throttle case cover B: Screw C: Cable end D: Throttle cable lever Pull

7 The line drawings on page 26, 27 and 28 show the proper routing of the control cables and wiring. Refer to drawings in addition to following the instructions carefully. A: Front brake cable B: Throttle cable C: Left switch wiring harness D: Parking brake switch lead wire E: Rear brake cable THROTTLE CABLE Remove the screw to take off the throttle case cover. Insert the inner cable end into the recess of throttle cable lever correctly. A: Throttle case cover B: Screw C: Cable end D: Throttle cable lever Pull on the outer cable and insert the outer cable cap to the recess of throttle case correctly as shown. NOTE: Before installing the cable, grease the cable end. A: Throttle cable B: Outer cable cap C: Throttle case D: Recessed area Check the gasket at the correct position. Reinstall the throttle case cover. Check to ensure that the throttle operates freely and closes automatically. A: Gasket 6

REAR BRAKE CABLE Turn the brake cable adjuster and lock nut in as far as possible and align the slots.

insert it into the adjuster. NOTE: Before installing the cable, grease the cable end.

Insert the end of the brake cable into the pin hole.

8 REAR BRAKE CABLE Turn the brake cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess of brake lever, then pull on the outer cable housing and insert it into the adjuster. NOTE: Before installing the cable, grease the cable end. A: Brake cable B: Adjuster C: Lock nut D: Cable end Set the pin into the brake cam lever. Insert the end of the brake cable into the pin hole. Attach the adjuster nut on the end of the brake cable. Do not adjust at this time. Adjustment will be covered in the SERVICING section. A: Brake cam lever B: Pin C: Adjuster nut 7

FRONT BRAKE CABLE Pass the front brake cable through the hole of steering head cover.

cable housing and insert it into the adjuster. Do not adjust at this time.

NOTE: Set the right side brake cable to the lower side adjuster.

A: Brake cable B: Adjuster C: Lock nut D: Cable end E: Brake cable equalizer The procedure

9 FRONT BRAKE CABLE Pass the front brake cable through the hole of steering head cover. A: Front brake cable B: Steering head cover C: Hole Turn the brake cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess of brake cable equalizer, then pull on the outer cable housing and insert it into the adjuster. Do not adjust at this time. Adjustment will be covered in the SERVICING section. NOTE: Set the right side brake cable to the lower side adjuster. Before installing the cable, grease the cable end. A: Brake cable B: Adjuster C: Lock nut D: Cable end E: Brake cable equalizer The procedure to install the left brake cable is identical to that of the right. NOTE: Set the left side brake cable to the upper side adjuster. Before installing the cable, grease the cable end. A: Brake cable B: Adjuster C: Lock nut D: Cable end E: Brake cable equalizer 8

Remove the bolts holding the front part of the vehicle.

to prevent the damage to the bolt threads.

Lift the front of vehicle by using a hoist. 2. Raise the rear of vehicle. 3.

Be careful the hoist band has clearance at the cables, guide and wiring harness.

must be paid to the arrow of the rotational direction on the tire sidewall.

10 Remove the bolts holding the front part of the vehicle. Before removing bolts, lift the front of the vehicle a little by using a hoist to prevent the damage to the bolt threads. NOTE: The bolts are no longer needed and may be discarded. A: Bolt 1. Lift the front of vehicle by using a hoist. 2. Raise the rear of vehicle. 3. Pull the crate base forward, then balance the vehicle. Be careful the hoist band has clearance at the cables, guide and wiring harness. FRONT WHEEL When installing the front wheel onto the axle, special attention must be paid to the arrow of the rotational direction on the tire sidewall. When the tire is properly installed, the arrow must indicate forward rotation of the wheel. FRONT Carefully clean the front wheel hubs and drums with a cloth to remove all dust. 9

Properly position the wheel on the axle stud bolts.

facing outwards. Temporarily finger-tighten the wheel set nuts.

5 mm D: 10 mm flange nut (Wheel set nut) Remove the hoist used

Tighten the wheel set nuts to the specified torque.

5 kgf-m) A: 10 mm flange nut (Wheel set nut) STEERING HEAD

Fix the steering head cover by push down firmly.

11 Properly position the wheel on the axle stud bolts. NOTE: Be sure to install the front wheels with the air valves facing outwards. Temporarily finger-tighten the wheel set nuts. A: Stud bolt B: Air valve C: Washer OD:20.0 mm ID:10.5 mm D: 10 mm flange nut (Wheel set nut) Remove the hoist used to lift the vehicle and then place the vehicle in place. Tighten the wheel set nuts to the specified torque. Wheel set nut: 55 N m (5.5 kgf-m) A: 10 mm flange nut (Wheel set nut) STEERING HEAD COVER Align the recess of steering head cover on the handlebars. Fix the steering head cover by push down firmly. A: Steering head cover B: Handlebars C: Recess FRONT GRIP Install the front grip on the frame using four bolts. A: Front grip B: Frame C: 8 16 mm flange bolt 10

FRONT GRIP AND REFLEX REFLECTOR FRONT SIDE (FOR LIMITED MARKET) Install

A: Reflex reflector B: Bracket C: 5 mm flange nut Install the front grip

A: Front grip B: Frame C: 8 16 mm flange bolt D: Reflex reflector E:

12 FRONT GRIP AND REFLEX REFLECTOR FRONT SIDE (FOR LIMITED MARKET) Install the reflex reflector to the bracket. A: Reflex reflector B: Bracket C: 5 mm flange nut Install the front grip with four bolts together with the reflector assembly. A: Front grip B: Frame C: 8 16 mm flange bolt D: Reflex reflector E: Bracket F: Boss G: Mark (R and L) FUEL TANK VENT HOSE Install the fuel tank vent hose to the fuel tank cap. Insert the free end of fuel tank vent hose to the hole of steering head cover. Be sure not to bend or twist the hose when installing. A: Fuel tank vent hose B: Fuel tank cap C: Hole 11

TOUJOURS PORTER UN CASQUE ET DES VETEMENTS DE SECURITE APPROUVES NE JAMAIS UTILISER SUR DES ROUTES PUBLIQUES NE JAMAIS ACCEPTER DE PASSAGER NE JAMAIS CONDUIRE SOUS L'INFLUENCE DE STUPEFIANTS OU

13 TOUJOURS PORTER UN CASQUE ET DES VETEMENTS DE SECURITE APPROUVES NE JAMAIS UTILISER SUR DES ROUTES PUBLIQUES NE JAMAIS ACCEPTER DE PASSAGER NE JAMAIS CONDUIRE SOUS L'INFLUENCE DE STUPEFIANTS OU D'ALCOOL OWNER S MANUAL Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Store the owner s manual in place. A: Owner s manual WARNING LABEL (FOR E-19 MARKET) Select the appropriate language label for your country. AVERTISSEMENT L'utilisation incorrecte du VTT peut résulter en BLESSURES GRAVES ou MEME LA MORT NE JAMAIS conduire : sans avoir reçu une formation ou des directives adéquates au préalable à des vitesses excédant vos compétences ou les conditions de conduite sur les routes publiques - au risque de provoquer une collision avec une autre véhicule avec un passager - les passagers affectent l'équilibre et la manoeuvrabilité et augmentent le risque de perte de contrôle TOUJOURS : utiliser des techniques de conduite acceptées pour éviter le renversement du véhicule sur collines, terrains accidentés et dans les virages éviter les chaussées pavées - au risque d'affecter gravement la manoeuvrabilité et le contrôle. REPERER ET LIRE LE MANUEL DU PROPRIETAIRE SE CONFORMER A TOUS LES AVERTISSEMENTS ET DIRECTIVES AVERTISSEMENT NE JAMAIS accepter de passager Les passagers risquent de causer une perte de contrôle, résultant en BLESSURES GRAVES ou MÉME LA MORT AVERTISSEMENT Une mauvaise pression des pneus ou une surcharge peut entraîner une perte de contrôle. Une perte de contrôle peut entraîner des accidents graves ou mortels. Garder TOUJOURS une pression des pneus appropriée selon le tableau indiqué cidessous. NE JAMAIS dépasser la capacité de charge du véhicule qui est de 90 kg (198 lbs). PRESSION DU PNEU A FROID AVANT : ARRIÈRE : CHARGE 22,5 kpa, 0,225 kgf/cm 2, 3,3 psi 20 kpa, 0,20 kgf/cm 2, 2,9 psi Jusqu à 90 kg (198 lbs) AVERTISSEMENT MOINS DE 12 ANS L'utilisation de ce VTT par des enfants de moins de 12 ans augmente le risque de subir des accidents graves ou mortels. Les enfants de moins de 16 ans doivent être surveillés par des adultes. NE JAMAIS permettre aux enfants de moins de 12 ans de conduire ce VTT. NOTE: For E-19 CG selection: German, Spanish, Portuguese For E-19 CH selection: French, Dutch For E-19 CI selection: Swedish, Finnish, Danish DIMENSION AVANT AT : DU PNEU ARRIÈRE AT

C: Warning label (Age 12) D: Front fender (Right) E: Rear fender

14 FRONT Stick the label selected for your country. A: Warning label (General warning) B: Warning label (Tire information) C: Warning label (Age 12) D: Front fender (Right) E: Rear fender (Right) FUEL LABEL (FOR LIMITED MARKET) Stick the label on the fuel tank. A: Fuel tank B: Fuel label 13

SERVICING BATTERY The battery is located under the seat. Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Unhook the clamp to take off the CDI wiring harness.

15 SERVICING BATTERY The battery is located under the seat. Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Unhook the clamp to take off the CDI wiring harness. Remove the rubber band. Remove the battery from the vehicle. A: Clamp B: Rubber band Filling electrolyte Remove the aluminium tape sealing the battery electrolyte filler holes. A: Aluminium tape B: Electrolyte filler hole 14

16 Remove the caps from the electrolyte container. NOTE: Use the removed caps as the sealed caps of battery filler holes. Do not remove or pierce the sealed areas of the electrolyte container. A: Caps B: Sealed area With just enough force to break the nozzle seal of electrolyte container, push each nozzle of the electrolyte container into the battery s electrolyte filler ports and hold the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. A: Electrolyte containers Make sure air bubbles are coming up in each electrolyte container, and leave in this position for about 20 minutes. A: Air bubbles NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the container two or three times. Never remove the container from the battery. 15

17 After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes. Insert the caps into the filler holes, pressing in firmly so that the top of the each caps does not protrude above the upper surface of the battery s top cover. A: Caps Never use anything except the specified battery electrolyte. Once the sealing cap has been installed in the battery, do not remove the sealing cap. Charge the battery with a battery charger. For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life. Do not remove the cap during charging. Position the battery with the cap facing upward during charging. After charging the battery, install the battery in the vehicle as follows. When attaching the wiring harness battery leads to the battery terminals, observe the correct polarity. NOTE: The terminal bolts and nuts are attached to the battery. 16

Check the rubber cushions are installed in the correct position before installing the battery.

First connect the + lead to the + positive terminal of the battery. 3. Cover + terminal with rubber boot. 4.

Clamp the wiring harness. A: + lead B: - lead C: Rubber boot D: Rubber band E: Clamp Reinstall the seat.

18 Check the rubber cushions are installed in the correct position before installing the battery. A: Rubber cushion 1. Set the battery to the box. 2. First connect the + lead to the + positive terminal of the battery. 3. Cover + terminal with rubber boot. 4. Connect the - lead to the - negative terminal of the battery. 5. Fix the battery with rubber band. 6. Clamp the wiring harness. A: + lead B: - lead C: Rubber boot D: Rubber band E: Clamp Reinstall the seat. Insert the seat hook into the seat hook retainer and pass the seat lock lever through the hole of the rear fender. Push down the seat firmly. A: Seat assembly B: Hook C: Hook retainer D: Seat lock lever E: Hole 17

THROTTLE CABLE Check the throttle cable play at the throttle lever end. Throttle cable play: 3.0 5.

Loosen the throttle cable adjuster lock nut A. 3. Turn the adjuster B in or out until the correct play. 4.

19 THROTTLE CABLE Check the throttle cable play at the throttle lever end. Throttle cable play: mm mm If adjustment is necessary, carry out the procedure below: 1. Remove the steering head cover. 2. Loosen the throttle cable adjuster lock nut A. 3. Turn the adjuster B in or out until the correct play. 4. Tighten the lock nut A while holding the adjuster B. Place the rubber boot C. 5. Reinstall the steering head cover. After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically. 18

Front brake lever play: 3 7 mm 3 7 mm Least 5 mm If adjustment is necessary, carry out the procedure below: 1. Place the vehicle on a level surface.

20 FRONT BRAKE Check the brake lever play. The brake lever play A measured at the lever holder when the lever is squeezed, and the brake cable holder B is in the straight up position as shown in the photograph. Front brake lever play: 3 7 mm 3 7 mm Least 5 mm If adjustment is necessary, carry out the procedure below: 1. Place the vehicle on a level surface. Lift the front end of the vehicle and place a solid object, such as a wooden block, securely under the frame. 2. Loosen the lock nuts E and turn the upper and lower cable adjusters D equally until the brake lever play A measured at the lever holder is 3 7 mm when the lever is squeezed. Make sure that at least 5 mm of the adjuster threads are inserted in the lever holder C, as shown in the photograph. Tighten the lock nuts E. If the cable adjusters D do not provide enough adjustment, turn the left and right brake cable adjusters F equally to obtain the specified play. 3. Turn the upper or lower cable adjuster so that when the brake lever is fully squeezed the cable holder is in the straight up position. This adjustment is important for smooth braking, and to help prevent uneven wear of the brake shoes on the left and right wheels. Check the brake lever play again, and repeat step (2) if necessary. 4. Release the front brake lever and turn the front wheels by hand to make sure the brakes don t drag. If either brake drags, the brake lever play should be increased slightly. Repeat steps (2) and (3). 19

DRIVE CHAIN Check the drive chain slack through the inspection window. Drive chain slack: 15 25 mm If it is too tight or too loose, follow these procedures. 1. Remove the bolt to take off the chain case cover.

Adjust the slack in the drive chain by turning the right and left chain adjuster nuts C equally. 4. When proper slack is obtained, tighten the bolts A and B. 5.

0 kgf-m) Chain adjuster nut C: 15 N m (1.

21 DRIVE CHAIN Check the drive chain slack through the inspection window. Drive chain slack: mm If it is too tight or too loose, follow these procedures. 1. Remove the bolt to take off the chain case cover. A: Chain case cover B: Bolt C: Hook D: Inspection window 2. Loosen the rear axle housing bolts A and B. 3. Adjust the slack in the drive chain by turning the right and left chain adjuster nuts C equally. 4. When proper slack is obtained, tighten the bolts A and B. 5. Tighten the adjusting nuts C. 6. Reinstall the chain case cover. Rear axle housing bolt A: 94 N m (9.4 kgf-m) Rear axle housing bolt B: 110 N m (11.0 kgf-m) Chain adjuster nut C: 15 N m (1.5 kgf-m) mm Make sure that the rear sprocket is properly aligned with the engine sprocket by sighting down along the chain from the rear end of the vehicle. Verify that the master link clip is installed properly. The opening of the master link clip faces away from the direction of travel. A: Direction of travel B: Master link clip 20

REAR/PARKING BRAKE Check the brake lever play. The brake lever play measured at the lever holder when the lever is squeezed.

Turning the adjusting nut D clockwise will decrease the brake lever play. Minor adjustments can now be made with the brake lever adjuster A.

Set the parking brake by squeezing the brake lever and set the stopper C. 4. Check that the rear wheels are locked by trying to move the vehicle back and forth.

22 REAR/PARKING BRAKE Check the brake lever play. The brake lever play measured at the lever holder when the lever is squeezed. Rear brake lever play: 3 5 mm 3 5 mm If adjustment is necessary, carry out the procedure below: 1. To adjust the brake lever play, turn the adjusting nut D. Turning the adjusting nut D clockwise will decrease the brake lever play. Minor adjustments can now be made with the brake lever adjuster A. Tighten the lock nut B. 2. After adjusting the play, check that the rear wheels roll freely with the brake disengaged and the rear wheels off the ground. 3. Set the parking brake by squeezing the brake lever and set the stopper C. 4. Check that the rear wheels are locked by trying to move the vehicle back and forth. 5. Readjust the rear brake lever adjusting nut D if the rear wheels could not roll freely in step 2, or if the rear wheels did not lock in step 4. Setting the parking brake, check that the wheel is locked securely. 21

F L ENGINE OIL This vehicle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Check the engine oil level with the engine oil dipstick. 1.

The engine oil dipstick comes out together with the oil filler plug. Wipe the oil from the dipstick with a clean rag. 4.

23 F L ENGINE OIL This vehicle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Check the engine oil level with the engine oil dipstick. 1. Place the vehicle on level ground. 2. Start the engine and allow it to run for a few minutes at idling speed. Stop the engine and wait about three minutes. 3. Remove the oil filler plug. The engine oil dipstick comes out together with the oil filler plug. Wipe the oil from the dipstick with a clean rag. 4. Reinsert the dipstick until the threads touch the filler neck, but do not screw the plug in. 5. Draw out the dipstick and check the oil level. The level found on the dipstick should be between L (Low) and F (Full) line. 6. If the oil level is below the L line, add fresh oil from the filler hole until the oil level reaches to F line. If the level is above the F line, drain oil to F line. 7. Reinstall the drain plug and engine oil filler plug. Tighten them securely. Oil drain plug: 18 N m (1.8 kgf-m) A: Engine oil filler plug B: Engine oil dipstick SAE API JASO 10W-40 SF or SG 10W-40 SH or SJ MA Engine oil Oil quality is a major contributor to your engine s performance and life. Always select good quality engine oil. Use SF/SG or SH/SJ in API (American Petroleum Institute) classification, with MA in JASO. API: American Petroleum Institute JASO: Japanese Automobile Standards Organization 22

24 ENGINE OIL VISCOSITY RATING SELECTION CHART 20W W W - 50 ENGINE OIL 10W W W W - 30 C TEMP. F SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart. NOTE: If the vehicle is used in very cold weather (below 10 C (14 F)), use SAE 5W-30 for good engine starting and smooth operation. JASO T903 The JASO T903 standard is an index to select engine oils for 4-stroke motorcycle and ATV engines. Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil. JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission. There are two classes, MA and MB. The oil container has following classification for confirming the standard. A: Code number of oil sales company B: Oil classification ENERGY API SERVICE SJ SAE 10W-40 CONSERVING API SERVICE SJ SAE 10W-40 Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils. Some engine oils which is API SH or greater has ENERGY CONSERVING indication in API classification doughnut mark. These oils can affect engine life and clutch performance. Not recommended Recommended 23

TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires. The pressure should be as shown. COLD INFLATION TIRE PRESSURE TIRE PRESSURE FRONT 22.5 kpa 0.

NOTE: The engine idle should be adjusted with engine warmed up.

25 TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires. The pressure should be as shown. COLD INFLATION TIRE PRESSURE TIRE PRESSURE FRONT 22.5 kpa kgf/cm psi REAR 20 kpa 0.20 kgf/cm psi IDLE SPEED ADJUSTMENT After completing all of the servicing procedures, adjust the engine idle speed by turning the throttle stop screw. NOTE: The engine idle should be adjusted with engine warmed up. Engine idle speed: r/min A: Throttle stop screw TRANSMISSION OIL Transmission oil is factory filled requiring no maintenance. Test ride the vehicle checking all mechanical functions. Tighten all nuts, bolts, and miscellaneous mounting parts to the proper torque specs. Confirm that all cables and wiring harnesses are connected and routed correctly. 24

TIGHTENING TORQUE Item Part Name N m kgf-m STEERING, FRONT SUSPENSION AND FRONT BRAKE A Handlebar set bolt 26 2.6 B Front wheel nut 55 5.5 C Front axle nut 65 6.

5 H Rear shock absorber bolt (Upper) 29 2.9 I Rear brake cam lever nut 7.7 0.77 OTHERS J Front footrest bolt 55 5.5 K Rear swingarm pivot nut 130 13.0 L Rear axle housing bolt (Upper) 94 9.

26 TIGHTENING TORQUE Item Part Name N m kgf-m STEERING, FRONT SUSPENSION AND FRONT BRAKE A Handlebar set bolt B Front wheel nut C Front axle nut D Front shock absorber bolt (Upper and Lower) E Front brake cam lever nut Item Part Name N m kgf-m REAR SUSPENSION AND REAR BRAKE F Rear wheel nut G Rear axle nut H Rear shock absorber bolt (Upper) I Rear brake cam lever nut OTHERS J Front footrest bolt K Rear swingarm pivot nut L Rear axle housing bolt (Upper) M Rear axle housing bolt (Lower) For other bolts and nuts not listed, refer to this chart. Bolt Diameter (mm) Conventional or 4 marked bolt 7 marked bolt N m kgf-m N m kgf-m Conventional bolt D D 4 marked bolt 7 marked bolt D D A E H L I F G K J C B M 25

27 HARNESS ROUTING Rear brake cable Clamp CDI unit Wiring harness Handlebar switch lead wire (L) Rear brake switch lead wire Battery Clamp Starter relay Starter motor lead wire Battery - terminal Battery + terminal Generator lead wire Clamp Wiring harness Handlebar switch lead wire (L) Rear brake switch lead wire Starter motor Forward Wiring harness, battery + and - lead wire through downside of the frame. Clamp Handlebar switch lead wire (L) Clamp Breather hose Air bent hose Wiring harness Clamp Wiring harness Starter motor lead wire Generator lead wire Battery - lead wire Clamp Wiring harness Battery - lead wire Battery + lead wire Regulator/Rectifier lead wire Rear brake switch lead wire Ignition switch Breather hose Wiring harness Clamp Clamp Battery - lead wire Battery + lead wire Ignition coil Generator lead wire Battery - lead wire Regulator/Rectifier lead wire Frame Clamp Clamp Wiring harness Clamp the wiring harness inside of the frame. 26

28 CABLE ROUTING Clamp Rear brake cable Front brake cable (R) Throttle cable Pass the rear brake cable through downside of the frame. Rear brake cable Front brake cable (L) Pass the brake cable through downside of the frame. Front brake cable (L) Front brake cable (R) Throttle cable Rear brake cable Front brake cable (R) Align the clearance. Front brake cable (R) Front brake cable (L) Rear brake cable Front brake cable (L) Throttle cable Front brake cable (R) Pass the throttle cable through inside of the rear brake cable. Pass the front brake cable through outside of the rear brake cable. Front brake cable (L) 27

Clamp Throttle cable Bracket Front brake cable Fix the boot of the front brake cable. Adjuster nut Front brake cable (L) Pass the rear brake cable through outside of the rear belt cooling duct.

29 Clamp Throttle cable Bracket Front brake cable Fix the boot of the front brake cable. Adjuster nut Front brake cable (L) Pass the rear brake cable through outside of the rear belt cooling duct. Rear brake cable Front brake cable (R) Wiring harness Pass the rear brake cable through inside of the rear fender. Wiring harness Throttle cable Rear brake cable Throttle cable Pass the rear brake cable through underside of the frame. Front brake cable (L) Front brake cable (R) Rear brake cable Clamp Mounting plate Cable protector Adjuster nut Rear brake cable 28

30 SAFETY CHECK OUT After completion of the setting-up the vehicle all the following items should be doublechecked to confirm that the operation and function of the vehicle are satisfactory. Now, setting-up the vehicle and pre-delivery inspection have been completed and the vehicle can be passed to the customer. ENGINE AND TRANSMISSION ITEM MEASURE SPECIFICATIONS Engine oil Check/Refill 950 ml Fuel tank Drain/Fill 6.0 L Throttle cable Check/Adjust mm Idle r/min Check/Adjust r/min Exhaust system Leakage Fuel system connection Circlip/Leakage Transmission oil Check/Leakage 90 ml CHASSIS ITEM MEASURE SPECIFICATIONS Front brake lever Check/Adjust mm Rear/Parking brake lever Check/Adjust mm Drive chain Lubricate/Check/ Adjust mm Oiling points All necessary points Battery Filling electrolyte Wiring and cable Routing/Operation Wiring connectors Clean/Tight Suspensions Operation Tighten all nuts and bolts Cotter pins and circlip Paint and chrome Warning label (For E-19 market) Torque those listed in this manual Fasteners/Check Inspect/ Wash and polish Select/Stick Appropriate language COLD INFLATION TIRE PRESSURE TIRE PRESSURE FRONT 22.5 kpa kgf/cm psi ITEM Switch Operations Ignition switch Engine stop switch Brake switch Starter button Parking brake switch Engine ELECTRICALS REAR 20 kpa 0.20 kgf/cm psi CHECK FOR Operation ROAD TEST INSPECTION ITEM Transmission Drive chain Brake Steering Suspension Control cables Leakage Rear/Parking brake lever CHECK FOR Starting/Acceleration /Smoothness/Noise Operation/Noise Operation/Noise Front/Rear, Operation/Noise Stability Operation Operation/Proper return Fuel/Oil/Exhaust Operation 29

Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage.

Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. FOREWORD This motorcycle has been designed and produced utilizing Suzuki s most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced. This