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1986-93 Suzuki RM125 ESL450 Ignition/Lighting StatorFitting Instructions

Read these instructions completely
Step 1:Take the ignition cover off. Are The Replacement Parts Similar? Compare the replacement part to the original. The replacement part should match, including the mounting hole locations. If not: Double check the application listing with your bike.
Step 2: Remove the flywheel using a proper puller. Remove the baseplate with the original stator. Disconnect the wires from the wiring loom.
Step 3: Remove existing stator coil off the baseplate and cut the wires close to the coil. Replace it with the new unit and feed the new leads though the holes in the baseplate.
Step 4: Screw the unit tight in position, as shown in the diagram, and make sure you use locking compound on the screws. TIGHTEN THE SCREWS SECURELY! Ignition Connections Suzuki RM: Connect the new BLACK lead to the original RED/ WHITE wire. Connect the new BLUE lead to the original BLACK/ RED wire. Honda CR: Connect the new BLACK lead to the original WHITE wire. Connect the new BLUE lead to the original RED wire. Yamaha YZ: Connect the new BLACK lead to the original BROWN wire. Connect the new BLUE lead to the original RED wire.
Step 5: Make sure the connections you make are good ones. Preferably you should crimp the wires using a high quality crimps. Otherwise use solder, but be aware that solder doesn’t work very well on older wiring. Lighting Connection Single YELLOW lighting output can be connected up straight to the lighting circuit. However it is better to use a 12V-AC regulator (ERG-200) parallel in circuit. The ground tag for the lighting coil can be hooked up under the base plate fitting screw. Take a look at our universal instructions for lighting coils for wiring details.
Step 6: On all applications, ensure the wires CANNOT TOUCH THE FLYWHEEL.

Troubleshooting
Engine will not start: Sometimes the source coil wires are reversed. Swap the connections, resolder the wires and the engine should start. If the engine still does not start, and before calling technical support at ElectroSport, preform a few basic tests: 1) Re-check the connections. Make sure you carefully solder the connections. Twisting wires together or taping wires will cause engine inoperability. 2) Check the engine for spark and 3) Is fresh fuel in the gas tank? If you still cannot get the engine to start, have all your testing information ready for a technician prior to calling.

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Honda/Kawasaki/Suzuki/Yamaha Electronic Jet Kit Instructions

INSTALLATION
1. Before installing the TFI you must first disconnect the negative lead from the battery.
2. Determine a location for the TFI unit. Suggested locations are as follows: Under the seat, behind a side cover or tail section.
3. The TFI comes with a harness with injector connectors that match the factory injector connectors.
4. Locate the factory fuel injectors (see owners manual if you are not sure)*.

5. Disconnect the factory injector connectors from the fuel injectors and replace with the TFI injector connectors from the TFI unit, basically unhook the factory injector connector and plug the matching TFI connector (female) to the injector and then connect the factory injector connector to the TFI connector that simulates the injector (male). There is no order to hook up the TFI harness to the factory harness just make sure the original factory connector goes to its’ original cylinder. It is a good idea to make sure there is a little slack in the harness to prevent engine vibration from damaging/breaking a wire on the connectors.
6. Be sure to check the wires are not in direct contact with any sharp edges, exhaust and/or other objects that could result in long term wearing and/or damage.
7. Connect the TFI ground lead to the negative terminal of the battery along with the factory ground lead.
8. With the rubber plug removed from the TFI, turn the motorcycle key switch to the “ON” position. As the bikes electrical system goes through initial start up mode you may see LED’s flashing on the TFI.
9. Start the motorcycle. The TFI is programmed “not” to add fuel at idle. This “may” cause all the LED’s to flash at idle, this is normal. Some models “may” have a solid green LED at idle, this is also normal. If just the green or red LED’s flash after startup or no LED’s are visible or bike doesn’t start, please confirm/retry all connections.

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240 Suzuki Hayabusa Swingarm Installation Instructions

Notes on fitting wide wheel and tire
• An advanced degree of mechanical skill is required to properly install this kit. If after reading these instructions you have any doubts, we strongly recommend that you have a professional install it for you. If you install the kit yourself, we recommend that you also use the applicable shop manual for your motorcycle. This kit involves significant alterations of your motorcycle and may void your factory warranty.
• Whenever installing wheels and tires that are wider than original equipment, please ensure that there will be sufficient clearance throughout the suspension range in the frame, swingarm, fender and that there is no interference with the belt, chain , brake caliper, or exhaust system.
• Motorcycles can be dangerous if not properly maintained and ridden safely. RC Components has no control over the usage of any of its parts. RC Components expects its customers to exercise good judgment as to the proper selection, installation, use, and maintenance of any parts. RC Components assumes no responsibility for damage or injury of any kind because of the misuse or improper application of any parts in any way by any person. RC Components expects the end user to exercise good judgment.
• Before installing this kit, read through these directions completely. This will familiarize you with the way in which the parts fit together and the tools needed to complete the job.
• Before performing any installation steps, disconnect the motorcycle’s battery to eliminate any possibility of electrical damage or personal injury due to a short circuit.

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Suzuki Hayabusa Gear position indicator Geartronics GPI-4 Fitting instructions

The gear indicator comes configured for use with the OEM Suzuki gear position sensor, and is fitted with standard connectors to plug directly into the Suzuki wiring harness. The unit also features the so-called ‘TRE’ modification, which is designed to defeat the gear dependent mapping strategy of the Suzuki ECU. Please refer to the bottom of this document for a description of the TRE function.

Installation
A reasonably competent amateur mechanic, using only basic hand tools, should be capable of fitting the Geartronics indicator in less than 1 hour.
Step 1.
Remove the screw at each side of the seat and remove the riders seat. Remove the 2 screws in front of the fuel tank. Lift the front of the tank and support at approximately 45° to gain access behind the engine.
Step 2.
Remove all screws securing the left hand lower fairing and carefully remove the panel to expose the bike frame. Note that there are 2 different sizes of screws! Remove the single screw & clip securing the insert panel located to the left of the instrument cluster. The centre of the clip should be pushed in, allowing the outer part to be pulled out.
Step 3.
Locate the gear position sensor connectors with reference to the photo below.

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Suzuki Swift S Manual Road Test

The original Suzuki Swift was launched in Australia in 1984, and with a zippy 1.3 litre engine, good build quality and attractive pricing, soon became a favourite with consumers. Owners that have kept Swift’s long term have also been rewarded with class leading reliability, and there plenty of originals still on the road today.

The new model was previewed at the Sydney Motor Show, in 2004 and released in February 2005. Developed in Europe, Suzuki believe the new Swift will have wide international appeal., it’s available as a five door in Australia, with a 1.5 litre engine with a choice of either manual or automatic transmission It replaces the Suzuki Ignis in the Suzuki model line up.

ERGONOMICS
Sitting behind the wheel for the first time the driving position feels quite high, the nose of the Swift drops away sharply from the front screen, so the high position helps in parking. Dash design is simple and straight forward, a large speedometer is in the centre of the dash with the tacho positioned to its left. Two smaller dials for fuel and temperature are either side, all the instruments are easy to read. Audio controls are in the leather bound steering wheel, the main controls for the audio system and air-conditioning are positioned centrally in the dash and are easy to use and operate first up. The clutch pedal sits higher in relationship to the brake pedal and as well the clutch take up is towards the end of its travel, making it awkward to operate.

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Suzuki 03-04 GSX-R1000 TiForce exhaust system

Thank you for selecting and purchasing a TiForce exhaust system for your ’ 03-‘04 GSX-R1000. TiForce is the world’s finest titanium exhaust system available today. Please read the following instructions and materials to fully familiarize you with new exhaust system before getting started.

Before Installation
Make sure to detach the connector of the exhaust device
Coat joints on all parts with liquid gasket
Check all accessories have been included
Detach the battery for your safety
For detach and attaching the parts, please refer the service manual
1. Detach the seat, battery, under cowling, tail winker and passenger foot peg.
2. Use standard rod to lift the fuel tank and detach the connector of the exhaust devise servomotor.
(Failure to detach the connector and turn on the main switch, serious damage may occur to the servomotor.)(*See Photo. 1) Detach the standard silencer and wire for the device.
3. Release the coolant and detach the oil cooler.
Detach the standard exhaust pipes after free the oil cooler.
4. Attach an enclosed exhaust pipe to the engine and tighten enough to keep from slipping out of place. (Cylinder number is 1,2,3 and 4 from the engine right side)
*Suggest using new gasket in order to prevent leaking the exhaust.
*Use the standard flange nut and tighten by hand.
5. Attach the joint pipe followed by the tail pipe. Jiggle it and attach the springs.
*Make sure to push into the joint pipe from the right body side to the oil pan. Failure to push into the joint pipe may touch the under cowling.
6. Attach the enclosed silencer stay using by Collar A and Bolt (M8-50mm) to the position of the passengers foot peg of the silencer side. (See Fig. 1)
*For the passenger foot peg users, use collar B and Bolt (M8-110mm).
7. Push silencer into the tail pipe, put the springs, silencer rubber band, band and silencer stay. (Make sure to use rubbered springs to the upper side of the silencer joint.) (M6 x 20mm x 2, M6 nut x 2, M6 washer x 4) (See Fig. 2)
8. Attach the silencer stay enough to keep from loosening using the enclosed bolt (M8-20mm), M8 nut and washer to the silencer stay B assembled in step 6. (See Fig. 1)
9. Check the exhaust pipe, joint pipe and tail pipe not to contact to any one another in any way. And tighten all.
10. Reinstall the battery, radiator and oil cooler. Put coolant and leak the air. (For leaking the air, please refer the service manual.)
11. Check all bots and nuts are tight; start the engine and check for exhaust leak.
12. Attached the enclosed winker to the seat cowling. (Wire by the electronic tap.)
13. Put the heat-resistant tape on both of the closest place to the front pipe #1 (where is the pipe bulge outside) and the joint pipe of the under cowling back side in order to prevent melting the cowling from the pipe heat. (*See Photos.4 and 5)

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Suzuki introduces an all new lightweight 25PS (18.4kW) Four-Stroke Outboard

Suzuki engineers have designed an all-new light weight 25PS (18.4kW) 4-stroke outboard that weighs just 69kg (152lbs.)*. Its lighter weight and economical operation make it ideal for boaters and fishermen who need a powerful compact outboard. In addition, this new 4-stroke fully complies with 2006 EPA and forthcoming EURO 1 standards (EU Directive 2003/44/EC), and carries the California Air Resources Board (CARB) 3-star Ultra-Low emissions rating.

V-Twin Powerhead
This new 25PS (18.4kW) model is the first Suzuki 4-stroke outboard to feature a V-Twin powerhead. The 70º v-bank angle is wide enough to minimize vibration without the use of a counterbalance system, and narrow enough to provide a compact profile on the transom.

The V-twin layout also moves the center of gravity forward, compared to an inline powerhead. This allows for better balance on the transom, and makes the engine easier to tilt. Since engines in this category typically are tilted by hand, a little bit of help is a big advantage. Twin cylinders, each displacing 269cm 3 (total displacement is 538cm 3) combined with 2 overhead valves per cylinder, produce maximum power at 5,000 rpm. The engine uses a single carburetor for easy maintenance and lighter weight. Aluminum block and aluminum connecting rods contribute to the lightweight design.

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SUZUKI INTRUDER 1500 LC REMOVAL & INSTALLATION OF BOTH WHEELS

The following is the experience I gained in removing my wheels to have new tires fitted on Jan/Feb 2004, I must point out, that I will not be resposible for any accidents to any person/persons, or damage to equipment or property by using my suggestions. Note : The Intruder 1500 LC is a very heavy motorcycle, & all precautions must be taken to do this job safely, by using proper load tested restrainers, proper lifting equipment & the proper tools. A lot of my success was gained by Wes’s guide at :- http://www.intruder1500.com/reartire.shtml

I used my motorcycle bike lift to take the total weight of the bike to a height approx. 22″ from the tip of the fender to the floor, this height may need to be increased later depending on the size of the tires on the wheels to be installed. I then removed the windshield in order to provide access to the triple tree area for installation of the two front safety straps to my storage shed roof trusses, which have been reinforced to take the weight, just in case things go wrong.

I had a total of (7) adjustable load tested nylon straps securing the bike while lifting it to this height, (4) straps were used to hold bike from the roof truss of my storage shed, (2) were secured near the triple tree area to take the weight of the front end, just in case something terrible should occur, these straps will have to be tightened as bike is jacked up.

The other (2) straps secured on the frame tube section below the driver seat (Driver Seat has to be removed for this) these straps will also have to be tightened as the bike is being jacked up.

I used (2) more straps to secure the handlebars from swinging during the lifting, caution: as these are attached to to base of the bike lift, they have to be constantly slackened off until the working height is achieved, otherwise damage to the handlebars can occur. Another strap was put across the frame & secured also to the bike lift caution : this also requires slackening during lifting until desired working height is achieved, this strap will reduce the probability of the bike sliding left or right or tipping during work on the bike.

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SUZUKI 800 VOLUSIA Adaptor Kit Installation Instructions

Congratulations on your purchase of the SUZUKI 800 VOLUSIA Adaptor Kit. We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should be installed on bikes with After Market Exhaust Pipes only and jetted, (not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Suzuki service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well- ventilated area and clean up any spills immediately. Check for leaks before riding.

1) Remove Seat – 6mm allen head
2) Remove Dash 1 - 3mm allen and 2 - 4mm allen heads.
3) Remove Tank 1 - 12mm socket at the rear of the tank.
4) Remove the chrome cosmetic cover on the left side of the bike – 2 8mm socket heads. Disconnect the 2 vacuum lines from the tank and fuel line.
5) Pop the idle adjustment out of the bracket and lift at the rear of the tank. Unplug the one white electrical plug.
6) Remove the stock air box 2 – 4mm allen heads at the top of the air box. Loosen the hose clamp and pull out from the bottom of the air box and remove.
7) Remove the stock air box hanger bracket 3 – 10mm bolts.
8 )Jetting can now be done.
9) Plug the pair valve hose with the supplied red plug – It is the large 5/8 hose going to the vacuum canister on the left hand side of the bike.
10) Place the provided O-Ring in the grove at the top oval opening.

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SUZUKI TIS 2 Web User Guide

The Techline Information System (TIS 2 Web) User’s Guide provides a comprehensive overview of TIS 2 Web software including Tech2 View, Software Download, Snapshot Upload / Display and Service Programming System (SPS). This TIS2 Web software is available from the Web site (TIS 2 Web) provided by GM Service and Parts Operations via Suzuki Service Protocol Site (http://portal.suzukibitstop.com). ASMC (American Suzuki Motor Corporation) and its affiliated dealers only can obtain it from Suzuki Pit Stop (http://www.suzukipitstop.com) as well.

Everything contained in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in any retrieval system, or transmitted in any form by any means, including but not limited to electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Suzuki Motor Corporation. This includes all text, tables, illustrations, and charts.

To obtain assistance with the TIS 2 Web application distributors and dealers should use the following process based on their location.

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Suzuki MightyBoy history

Suzuki Have a long history of producing small motor vehicles. It all started in 1955 with the Suzulight series of Kei class cars. The Suzulight looked similar to a Moris / Leyland Mini-minor, only the performance was nowhere near as good, considering it was fitted with a 359cc 2-stroke, Air cooled engine.

Now, getting to the inception of the MightyBoy takes us to the late 70’s, and the introduction of the Suzuki Fronte 2nd generation 2-door fastback coupe.

The engine fitted to these vehicles was an in-line, 3 cylinder 543cc, OHC, water cooled engine, transversely mounted, driving the front wheels through a 4 speed manual or 2 speed automatic gearbox. In 1983, a turbo was added to this engine.

1983 brings us to the year the first model Suzuki MightyBoy was released in Japan. Based on the principles and regulations of the Japanese keijidōsha class of vehicles, the MightyBoy is a coupe utility variation of the 2nd generation, 2-door fastback Suzuki Cervo. Released in 1983, it was equipped with an 534 cc SOHC 3 cylinder transverse-mounted engine (F5A), however unlike its cousin the Cervo, no turbo was available. Driving the front wheels through a 4-speed manual or optional 2-speed automatic gearbox, the F5A motor delivered 19 kW of power at the flywheel.

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Suzuki VZR 1800 Services Manual Corrections - Valve Spring Specifications and Cluth Washer

This bulletin contains service manual correction information for the VZR1800. Please change the valve spring specifications in your dealership service manual based upon the information provided below. Insert a copy of each of the attached pages with clutch washer information into your dealership service manual at the appropriate page.

REAR CAM CHAIN TENSION ADJUSTER
• Unlock the ratchet / and insert the special tool. y 09917-62430: Chain tensioner lock tool
• Remove the rear cam chain tensioner No. 1 assy 0.
• Remove the cam chain guide No. 1 1 and rear cam chain tension adjuster No. 1 2.

REAR CAM CHAIN IDLER SPROCKET
• Remove the idler shaft /.
• Disengage the cam chain No. 1 0 from the rear cam chain idler sprocket 1

Get pdf Suzuki VZR 1800 Services Manual Corrections - Valve Spring Specifications and Cluth Washer

Suzuki CAT1 User Guide

The Suzuki CAT1 consists of the following main components;
• Installed CAT1 main unit
• 2 x remote transmitters
• Installed protecting switch
• Installed system fuse and spare fuse
• LED system indicator

Be sure that you know:
1. Where the system fuse is, and where the spare fuse is located. If the fuse fails, the system will not allow the motorcycle to start.
2. Set your PIN override. This will enable you to disarm the system and still start your motorcycle if the remote transmitter is lost or does not function (see Section 16).

The CAT1 will monitor;
1. The motorcycle battery and associated motorcycle wiring. If the battery is disconnected or the ignition is switched on the alarm will trigger. The CAT1 also monitors the state of the motorcycle battery for ‘sleep’ purposes.
2. The ignition circuit. If the ignition is switched on while the CAT1 is protecting the system it will trigger an alarm. Also, the CAT1 Uses the ignition to enter diagnostic and service mode.
3. Nudge and movement, with a liquid filled, state-of-the-art sensor.
4. An anti-tamper switch will cause the alarm to trigger if an attempt is made to gain unauthorised access to the CAT1 system.

The CAT1 also;
1. Has a ‘fully armed’ mode (see section 1)
2. Has a ‘Convenience’ mode (see section 2)
3. Has a service/valet mode (see section 3)
4. Has a diagnostic mode (see section 4)
5. Has 14 different siren tones (see section 5)
6. Can have the audible warning of arming/disarming removed (see section 6)
7. Can activate all four indicators in a Hazard warning mode (see section 7)
8. Can be programmed to arm in ‘Full’ mode (without movement/nudge sensing) (see section 1)
9. Can be programmed to have the nudge sensing removed
10. Can be programmed to act as an indicator or warning system when riding the motorcycle (see section 9)
11. Will tell you if it senses excess voltage when the engine is running (see section 10)
12. Will tell you if the remote transmitter batteries are becoming discharged (see section 11)
13. Has a useful torch in the remote transmitter (see section 12)
14. Has an ignition key conversion feature in the remote transmitter (see section 13)
15. Will tell you if the alarm has triggered in your absence (see section 14)
16. Has a user-selectable PIN override number (see section 16)

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1980 Suzuki GS850GT Stator Replacement

Let’s begin by disconnecting the positive terminal of the battery (or removing the battery altogether) and draining the oil. I happened to need an oil/filter change at the same time I was replacing my stator so the timing worked nicely. Some riders will just lean their bikes to the right, against something stable, so that when the left crankcase cover is removed no oil will drain out. Here is the left crankcase cover gasket. I’m holding it upside down, sorry. This is part number 477686-001.

(Before we go much farther, let me apologize for the filthy condition of my bike. I’ve been a little neglectful lately. But now that she’s running better I’ll get her cleaned up.) Moving on…

Remove the left crankcase cover bolts (below). My bike still has the original phillips head bolts. They need a few taps from my impact driver to loosen them up. If I would’ve planned ahead they would be replaced with new hex head bolts. But alas, that will have to wait. In the picture below, the cover is loose and hanging. At this point you may wish to just cut the stator wires but I chose to pull everything out intact.

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Suzuki VZR1800 Supplemental Service Manual Information

This bulletin contains additional technical and service information for the VZR1800K7. Please place a copy of this bulletin with your dealership’s VZR1800 Service Manual.

SUBJECT: SUPPLEMENTAL SERVICE MANUAL INFORMATION
MODEL: VZR1800K7
REFERENCE: VZR1800 SERVICE MANUAL (P/N 99500-39290-03E)

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SUZUKI / GSX-R600/750 / 2006-2007 Carbon Fiber / Aluminum 6061 Installation Instructions

1 After bike is cool make sure the bike is secured before beginning the installation.
2 Remove the right side lower fairing bolts and pull the fairing out from the push pin/rubber connector.
3 Fully loosen the muffler clamp from the header collector.
4 Remove the 3 muffler mounting bolts (2 on the right side, 1 on the left side).
5 Carefully remove the stock muffler and place in a safe location.
6 Apply a small amount of high temperature silicone (such as Permatex Ultra Black) to the inside of the exhaust inlet. Attach the LOR exhaust canister to the slip-on tube adapter with the spring tabs aligned (make sure your hands are protected with a pair of gloves in case the tubes slip). You may have to squeeze the mid- pipe adapter tube to fit into the exhaust inlet as the mandrel bends may become slightly out of round due to a cut near the bend (the tube will take form once connected). Slide the canister all the way until the slip-on adapter seats fully against the exhaust inlet. Wipe off any excess silicone. Place each spring over the exhaust side spring tabs and use the spring tool to pull the springs over the adapter spring tabs. Both springs must be secured for proper installation.
7 Apply a small amount of high temperature silicone sealer (such as Permatex Ultra Black) to the inside (inlet side) of the slip-on adapter. Slide the low profile barrel clamp over the LevelOne Adapter pipe. Slide the slip-on adapter pipe over the stock header collector. Do not fully tighten the barrel clamp.
8 Place the round canister clamp with the rubber gasket over the rear of the exhaust and slide to the angle bracket clamp location (Follow the instructions for the hanger conversion located at the end of this manual). Follow the clamp setup (shown in figure 1a or 2a) based on your sleeve type. Do not fully tighten as you will need to adjust the system for a perfect fit.

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Suzuki LTR 450 Fuelpak Fuel Management System

Fuelpak maps for the LTR450 were created with a White Brothers Power Pro performance module installed. The included Power Pro unit must be used in conjunction with the Fuelpak for proper function. Failure to do so will result in poor performance and may cause engine damage.

1. Be sure that key is in the off position, then remove seat.
2. Referring to figure 1, remove (4) push pins and (1) 10mm bolt. Repeat for opposite side. Push pins that are accessible from the back can be popped out by pushing on the pin from the back side. Push pins with flanged pin heads can be gently pried up with a slotted screwdriver.
3. Remove fuel cap and tank cover. Reinstall fuel cap.
4. Clean Fuelpak mounting location with alcohol and allow to dry. Referring to figure 2, mount Fuelpak as shown with supplied Velcro. Route harness as shown, between airbox and subframe, and underneath subframe cross brace.Gently pull up and out on subframe side cover and attach harness to subframe with included zip ties. Ensure that harness is not running over black rubber strip behind airbox.
5. Remove TPS plug and install TPS T-tap to yellow wire as shown in figure 3. It may be helpful to use a slotted screwdriver to gently disengage the TPS plug lock tab. Plug purple wire into T-tap (use dielectric grease). Reinstall TPS plug.
6. Route ground wire to the left of the throttle body and in front of the fuel pump. Referring to figure 4, remove (1) 8mm bolt on fuel hose bracket, add Fuelpak ground terminal, and reinstall.

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Suzuki FOUR-STROKE / Electronic Fuel Injection

The engine is designed from the ground up, specifically for outboard use, by Suzuki engineers who draw on decades of knowledge gained through the manufacture of not only outboards, but also technologically-advanced motorcycles and automobiles.The product of their labors is an all-new 3.6-liter DOHC, 24-valve V6 engine that holds some of our most advanced and innovative ideas to date. Upon its base we have created three configurations, each of which is designed to deliver the ultimate in power and performance.

The flagship DF250 is the industry’s first 250PS (184kW) V6 four-stroke outboard and Suzuki’s most powerful outboard built to date. Its 3614cm displacement is of course, our largest to date, and the largest to date in the industry as well. Producing 69PS (51kW) per liter it holds the greatest power to displacement ratio and the greatest power to weight ratio the industry has ever seen in the four-stroke category. It is also the lightest outboard motor in its class. Delivering 225PS (165kW) of power in the DF225 and 200PS (147kW) in the DF200, the engine provides both of these outboards with the largest displacement in their respective categories while its narrow profile makes them, like the DF250, the lightest and most compact outboards in their class.

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SUZUKI SV1000S Service Manual

This manual contains an introductory description on the SUZUKI SV1000S and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included.

Read the GENERL INFORMTION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service .

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

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2000-LATER Suzuki DRZ400/400S INSTRUCTION SUPPLEMENT

Removing stock carburetor and cables
1. Remove seat and gas tank. Make sure fuel petcock is in “off” position.
2. Remove throttle cables and throttle housing.
3. Remove voltage regulator from left side of frame to allow carb to come out.
4. Remove stock carburetor.
5. Unplug TPS (throttle position sensor) and tape end off coming from bike.
6. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
7. Remove engine breather lines along with plastic canister on right side of bike.

Installing the Edelbrock Carburetor and Throttle Cables
1. Install the provided throttle cables into throttle housing supplied in kit and place onto clean handle bar.
2. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or sharp cutters. This should be done with the rag left in the manifold. Be very careful not to damage the manifold or your hands while doing this!!
3. Install new manifold or air boot at this time to manufacturers recommendations. NOTE: If installing onto an “S” model, you will need to reuse one of the clamps off of the stock manifold. You will reuse the clamp that holds the manifold to the head.
4. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap.
5. Install provided fuel line onto fuel inlet banjo and secure with pinch clamp.
6. If installing carb onto an “S” model, remove vacuum cap and install stock vacuum line to operate petcock. See figure 2. If vacuum line is not installed, the petcock will have too be run in the “PRIME” position.

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