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L4
December ’13 (TK) 21
99505-01134-01E
© COPYRIGHT SUZUKI MOTOR JAPAN
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol
and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:
Indicates a potential hazard that could result in death or serious injury.
Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment
damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
1
PREPARATION
WORKSHOP
A: Packed vehicle
B: Working space
SELF PROTECTION
CAUTION
Assembling the vehicle in poor working condi-
tion can be hazardous.
Place the packed vehicle on a level floor where
it is clean and spacious.
CAUTION
Assembling the vehicle without proper clothes
and protective gear can be hazardous. You can
be injured if you do not wear proper clothes
and protective gear.
Be sure to wear proper clothes and shoes for
assembling and wear protective glasses, mask
or gloves as necessary.
2
UNCRATING THE MOTORCYCLE
Cut the strap by using scissors.
A: Strap
Remove the carton.
A: Crate
CAUTION
Metal crates may have sharp edges and may
cause injury.
Wear proper protective clothes and gear.
3
Remove the strap.
Take out the front wheel assembly from the crate base.
A: Strap
B: Front wheel assembly
Remove the strap.
Take out the various component parts packaged from
the crate base.
A: Strap
B: Component parts
Remove the bolts of the bracket.
A: Bolt
4
Remove the bolts from the crate.
A: Bolt
Lift the steel frame to separate it from the base of the
crate.
Carefully remove the various component parts pack-
aged around the motorcycle.
A: Steel frame
B: Crate base
CAUTION
Careless steel frame separation can injure a
person.
Lift the steel frame with two persons.
Wear proper protective clothes and gear.
NOTE:
Be careful not to damage the motorcycle when
separating the steel frame.
5
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Windscreen 1
Stepped Allen screw 4 6 × 20 mm
Rubber cushion 4 OD:18.0 T:10.0
Rubber cap 4
B
Handlebars assembly 1
Clamp 2
Flange bolt 4 8 × 30 mm
Burring washer 4 OD:13.0 ID:8.5
Screw 1
5 × 45 mm
For right switch
Screw 2
5 × 25 mm
For left switch
Strap 2 L:140
C
Holder 2 For master cylinder
Flange bolt 4 6 × 22 mm
D
Handlebar balancer
weight
2 Right and Left
Screw 2 6 × 105 mm
Flange rubber cushion 2 L:34.0
Spacer 2 L:50.0
Washer 2
OD:16.0 ID:6.5
T:1.6
Rubber cushion 2 L:15.0
Spacer nut 2 6 mm
E Rear view mirror 2 Right and Left
Item Part Name Q’ty Remarks
F1
Front fender 1
Stepped Allen screw 6 6 × 16 mm
Clip 1
For front brake
hose
F2
Front fender 1
Stepped Allen screw 4 6 × 16 mm
Reflex reflector assembly 2 Right and Left
Clip 1
For front brake
hose
G Front wheel assembly 1
H
Front axle nut 1 24 mm
Front wheel spacer 1 Right
I Flange bolt 2
6 × 12 mm
For ABS sensor
assembly
J Case lock assembly 3
For side and rear
case
(Optional parts)
K Washer 2 OD:13.0 ID:6.5
L
Battery electrolyte
container
1
M Owner’s manual set 1
N Warning label set 7
For
E-21 CC selection
O Warning label set 4
For
E-21 CD selection
NOTE:
• The parts shown as Item J in the above table are on the tray under the seat.
• The parts shown as Item F2, N and O in the above table are supplied for limited specifications.
• Use washers of Item K for mounting the license plate.
• Please hand over the parts shown as Item J and M in the above table to your customer together with motor-
cycle.
G F1,F2 A B E C D
DC E
IH
6
The photograph shown indicates the parts dismounted
from the motorcycle in addition to the items shown in
the preceding page.
A: Front brake master cylinder
B: Throttle assembly
C: Clutch master cylinder
D: Left switch
E: Right switch
F: Front wheel ABS sensor assembly
G: Case lock assembly
A
A
A
BB
KK
EE
II
JJ
GG
CC
DD
F1
F1
F1
HH
N
N
OO
M
M
LL
F2
F2
F2
7
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 52.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
ASSEMBLY
LEFT RIGHT
REMOVING THE BRACKET
Remove the bolts to take off the front brake and clutch
master cylinder from the bracket.
A: Front brake master cylinder
B: Clutch master cylinder
C: Bolt
D: Bracket
Remove the bolts to take off the bracket from the han-
dlebar holder.
A: Bracket
B: Bolt
NOTE:
• Keep the position of front brake and clutch mas-
ter cylinder with its cap facing upwards until it is
installed.
• The bolts are not necessary to assemble the
motorcycle.
NOTE:
• Be careful not to damage the fuel tank.
• The bracket and bolts are not necessary to
assemble the motorcycle.
8
HANDLEBARS
Loosen the right switch retaining screws and throttle
housing retaining bolts.
Insert the right switch and throttle assembly onto the
handlebars.
A: Throttle assembly
B: Right switch
C: Handlebars
Install the handlebars assembly with the two clamps,
four bolts and washers.
A: Clamp
B: 8 × 30 mm flange bolt
C: Burring washer OD:13.0 mm ID:8.5 mm
D: Punch mark
E: Dot mark
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolt: 23 N·m (2.3 kgf-m)
A: 8 × 30 mm flange bolt
B: 8 × 30 mm flange bolt
NOTE:
• Install the burring washer in the direction as
shown in the illustration.
• Install each clamp with the punch mark facing
front.
• Align the dot mark on the handlebars with the
mating surface of the front side of left clamp.
NOTE:
• 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.
FRONT
9
A: Front brake hose
B: Throttle cables
C: Right switch wiring harness
D: Clutch hose
E: Left switch wiring harness
THROTTLE
Install the throttle assembly with two Allen bolts.
A: Throttle assembly
B: Allen bolt
C: Dot mark
RIGHT SWITCH
Insert the boss of right switch housing into the hole on
the handlebars.
Install the right switch assembly with the two screws.
A: Boss
B: Hole
C: 5 × 45 mm screw
NOTE:
• The line drawings on page 47, 48, 49, 50 and 51
show the proper routing of the control cables,
hose and wirings.
• Refer to them in addition to following the instruc-
tions carefully.
NOTE:
Align the dot mark on the handlebars with the mat-
ing surface of the throttle housing.
WARNING
Improper throttle installing can interfere with
smooth throttle grip operation. It can result in
an accident.
Check to ensure that the throttle operates
freely and closes automatically.
NOTICE
Pinching the lead wires in the parts can short or
break circuit.
Check the lead wire routing when assembling
the switch.
10
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
A: Holder
B: Front brake master cylinder
C: 6 × 22 mm flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
Tighten the front brake master cylinder mounting bolts
to the specified torque.
Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: 6 × 22 mm flange bolt
B: 6 × 22 mm flange bolt
C: Holder
D: Front brake master cylinder
E: Handlebars
Connect the lead wire coupler to the front brake light
switch.
A: Front brake light switch
B: Lead wire coupler
NOTE:
• Install the holder in position according to the
mark “UP”.
• Align the dot mark on the handlebars with the
master cylinder-to-holder fitting surface.
NOTE:
• First tighten the bolt A of the upper side with
specified torque and then tighten the bolt B of
the lower side.
• Make sure that the holder has no clearance at
the upper side.
11
LEFT SWITCH
Insert the boss of left switch housing into the hole on
the handlebars.
Install the left switch assembly with two screws.
A: Boss
B: Hole
C: 5 × 25 mm screw
CLUTCH MASTER CYLINDER
Install the clutch master cylinder onto the handlebars.
A: Holder
B: Clutch master cylinder
C: 6 × 22 mm flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
Tighten the clutch master cylinder mounting bolts to
the specified torque.
Clutch master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: 6 × 22 mm flange bolt
B: 6 × 22 mm flange bolt
C: Holder
D: Clutch master cylinder
E: Handlebars
NOTICE
Pinching the lead wires in the parts can short or
break circuit.
Check the lead wire routing when assembling
the switch.
NOTE:
• Install the holder in position according to the
mark “UP”.
• Align the dot mark on the handlebars with the
master cylinder-to-holder fitting surface.
NOTE:
• First tighten the bolt A of the upper side with
specified torque and then tighten the bolt B of
the lower side.
• Make sure that the holder has no clearance at
the upper side.
12
Connect the lead wires to the clutch lever position
switch.
A: Clutch lever position switch
B: Lead wire
RIGHT
CLAMP
Clamp the right switch wiring harness and front brake
hose union with strap.
A: Strap L:140 mm
B: Front brake hose union
C: Right switch wiring harness
LEFT
Clamp the left switch wiring harness and clutch hose
union with strap.
A: Strap L:140 mm
B: Clutch hose union
C: Left switch wiring harness
NOTE:
Cut off the excess strap as shown in the photo-
graph.
OUTSIDE
NOTE:
Cut off the excess strap as shown in the photo-
graph.
OUTSIDE
13
HANDLEBAR BALANCER
Assemble the handlebar balancer parts as shown.
A: Balancer weight
B: 6 × 105 mm screw
C: Flange rubber cushion L:34.0 mm
D: Spacer L:50.0 mm
E: Washer OD:16.0 mm ID:6.5 mm T:1.6 mm
F: Rubber cushion L:15.0 mm
G: 6 mm spacer nut
Tighten the screw a little.
Insert the balancer sub-assembly into the handlebar
end all the way.
Tighten the screw securely.
A: Balancer assembly
WARNING
Improper handlebar balancer fitting can inter-
fere with smooth throttle grip operation. It can
result in an accident.
Check to ensure that the throttle operates
freely and closes automatically.
14
TAKING OUT THE MOTORCYCLE
Bind a hoist band around the handlebar clamps as
shown in the photograph.
A: Hoist band
Remove the crate axle bracket from the crate base.
A: Crate axle bracket
B: Bolt
1. Lift the front of motorcycle by using a hoist.
2. Raise the rear of motorcycle.
3. Pull the crate base forward, then balance the
motorcycle.
NOTE:
Lift the motorcycle a little by using a hoist to pre-
vent the motorcycle from falling down.
NOTICE
Binding a hoist band to the handlebar or grips
can damage the motorcycle parts.
Be sure to bind a hoist band around the handle-
bar clamps.
NOTE:
The bracket and bolt are not necessary to assem-
ble the motorcycle.
15
FRONT FENDER
Install the front fender to the front fork legs.
A: Front fender
B: 6 × 16 mm stepped Allen screw
C: Front fork leg
(FOR LIMITED SPECIFICATIONS)
Install the front fender to the front fork legs.
A: Front fender
B: 6 × 16 mm stepped Allen screw
C: Front fork leg
D: Reflex reflector assembly
E: Reflex reflector stay
FRONT BRAKE HOSE
Install the brake hose to the brake hose guide with the
protector properly in place.
A: Hose guide
B: Brake hose
C: Protector
Fit the clip to the protector of brake hose.
Install the clip to the hole of front fender.
A: Clip
B: Brake hose
C: Protector
D: Hole
E: Front fender
NOTE:
When installing the reflex reflector assembly,
tighten the reflex reflector stay.
16
FRONT REAR
BRAKE DISC
To prevent brake squeaking and pad contamination,
carefully clean the front and rear brake disc plates with
alcohol or other non-petroleum based solvent.
This will remove the rust-preventive coating and dirt.
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 indi-
cate forward rotation of the wheel.
NOTE:
The ABS sensor side is right side.
WARNING
Installing the front wheel in the reverse direc-
tion can be hazardous. The tire for this motor-
cycle is directional. Therefore, the motorcycle
may have unusual handling if the wheel is
installed incorrectly.
Install the front wheel in the specified direction,
as indicated by the arrow on the sidewall of the
tire.
FRONT
FRONT
FRONT
17
Loosen the axle clamp bolts.
Remove the front axle from the fork legs.
A: Axle clamp bolt
B: Front axle
Mount the front wheel assembly properly.
A: Right fork leg
B: Left fork leg
C: Front wheel spacer (Right)
D: Front axle
E: Axle nut (24 mm flange nut)
Temporarily remove the right front brake caliper.
A: Brake caliper
B: Caliper mounting bolt
C: Pad
D: Supporter
NOTE:
• Put a suitable pad C to prevent the motorcycle
from being damaged.
• Do not remove the supporter inserted between
the brake pads until the brake caliper is installed.
18
LEFT
Remove the supporter from the brake pad of the left
front brake caliper.
A: Supporter
RIGHT LEFT
Attach the front wheel spacer to the front wheel hub.
Carefully insert the front brake disc plate between the
caliper brake pads.
A: Front wheel spacer
B: Oil seal (Lip)
C: Pads
D: Disc plate
Insert the front axle from the left side of fork leg and fix
the front wheel assembly to the front fork.
A: Front axle
B: Oil seal (Lip)
NOTE:
• When attaching the front wheel spacer, be care-
ful not to damage the oil seal lip.
• The flange side of the spacer faces the right fork
leg.
NOTICE
Forcing to install the front axle can damage the
motorcycle.
Align the shaft line of front forks and wheel.
Install the front axle by hand.
NOTE:
When installing the front axle, be careful not to
damage the oil seal lip.
19
Tighten the front axle nut to the specified torque while
holding the front axle.
Front axle nut: 100 N·m (10.0 kgf-m)
A: Axle nut
FRONT BRAKE CALIPER
Remove the supporter from the brake pad of the right
front brake caliper.
A: Supporter
B: Brake caliper (Right)
Set the front brake caliper so the brake disc plate is
inserted between two brake pads.
Install the front brake caliper.
A: Pads
B: Disc plate
C: Brake caliper (Right)
D: Caliper mounting bolt
RIGHT LEFT
Tighten the front brake caliper mounting bolts to the
specified torque.
Front brake caliper mounting bolt:
39 N·m (3.9 kgf-m)
A: Brake caliper
B: Caliper mounting bolt
NOTE:
Make sure that both the right and left caliper
mounting bolts are tightened with specified torque.
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