MOTORCYCLEDATE: PAGE:

Nov. 2, 2004 1 OF 20

SUBJECT:

APPLICABLE MODEL:

SERVICE INFORMATION AN400/SK5 E-02: JS1BW111200100318 E-19: JS1BW111100125819 E-03, 28, 33, 54: JS1BW111450100001 E-02, 03, 19, 28, 33, 54

EFFECTIVE ENGINE OR FRAME NO.:

REFERENCE:

This bulletin is to inform you of the service information for AN400/SK5 models. Please use the following service manual along with the information contained in this bulletin for proper servicing. AN400 SERVICE MANUAL (BOOK): 99500-34081-01E 99500-34081-01F 99500-34080-01G 99500-34081-01B 99500-34080-01S 99500-34081-03E

AN400 SERVICE MANUAL (CD-ROM): 99560-43083-01E We hope that this information will be useful in your service activities.

CONTENTSPAGE SPECIFICATIONS..................................................................................... 2 SERVICE DATA ........................................................................................ 3 CRANK BALANCER GEARS................................................................... 11 IMMOBILIZER ........................................................................................... 12 SEAT LOCK CABLE ROUTING ............................................................... 14 EXHAUST PIPE/MUFFLER MOUNTING.................................................. 15 WIRING HARNESS ROUTING ................................................................. 16 WIRING DIAGRAM ................................................................................... 19

NOTE: Asterisk mark (*) indicates the new K5-model specifications.

SPECIFICATIONSDIMENSIONS AND DRY MASS Overall length ...................................................................................... 2 260 mm (89.0 in) Overall width........................................................................................ 760 mm (29.9 in) Overall height ...................................................................................... 1 375 mm (54.1 in) Wheelbase .......................................................................................... 1 590 mm (62.6 in) Ground clearance................................................................................ 125 mm (4.9 in) Seat height .......................................................................................... 695 mm (27.4 in) Dry mass ............................................................................................. 184 kg (405 lbs) ENGINE Type..................................................................................................... Number of cylinders ............................................................................ Bore..................................................................................................... Stroke .................................................................................................. Displacement ...................................................................................... Compression ratio ............................................................................... Fuel system ......................................................................................... Air cleaner ........................................................................................... Starter system ..................................................................................... Lubrication system .............................................................................. Idle speed............................................................................................ DRIVE TRAIN Clutch .................................................................................................. Gearshift pattern ................................................................................. Final reduction ratio............................................................................. Gear ratio ............................................................................................ Drive system........................................................................................ CHASSIS Front suspension................................................................................. Rear suspension ................................................................................. Front fork stroke .................................................................................. Rear wheel travel ................................................................................ Caster.................................................................................................. Trail...................................................................................................... Steering angle ..................................................................................... Turning radius...................................................................................... Front brake .......................................................................................... Rear brake........................................................................................... Front tire size....................................................................................... Rear tire size ....................................................................................... ELECTRICAL Ignition type ......................................................................................... Ignition timing ...................................................................................... Spark plug ........................................................................................... Battery................................................................................................. Generator ............................................................................................ Main fuse............................................................................................. Fuse .................................................................................................... Headlight ............................................................................................. Position/parking light ........................................................................... Brake light/Tail light ............................................................................. Licence plate light ............................................................................... Trunk light ............................................................................................ Turn signal light ................................................................................... Speedometer/Tachometer light ........................................................... Coolant temperature gauge light ......................................................... Fuel level gauge light .......................................................................... Turn signal indicator light..................................................................... High beam indicator light..................................................................... Brake lock indicator light ..................................................................... Oil change indicator light ..................................................................... Fuel injection warning light.................................................................. * Immobilizer indicator light .................................................................

4-stroke, liquid-cooled, OHC 1 83.0 mm (3.268 in) 71.2 mm (2.803 in) 385 cm3 (23.5 cu. in) 10.2 : 1 Fuel injection Polyurethane foam element Electric Wet sump 1 400 100 r/min

Dry shoe, automatic, centrifugal type Automatic 6.168 (31/14 39/14) 2.203 0.854 (Variable change) V-belt drive

Telescopic, coil spring, oil damped Link type, coil spring, oil damped 100 mm (3.9 in) 100 mm (3.9 in) 27 106 mm (4.2 in) 40 (right and left) 2.8 m (9.2 ft) Disc brake Disc brake 110/90-13 M/C 55P, tubeless 130/70-13 M/C 63P, tubeless

Electronic ignition (Transistorized) 10 B.T.D.C. at 1 400 r/min NGK CR7E or DENSO U22ESR-N 12 V 36.0 kC (10 Ah)/10 HR Three-phase A.C. generator 30 A 10/10/10/10/15/10 A 12 V 35/35 W 12 V 5 W ................................... E-02, 19, 37, 54 12 V 21/5 W 2 12 V 5 W 12 V 5 W 12 V 21 W 12 V 1.7 W 12 V 1.7 W 12 V 1.7 W 12 V 1.7 W 2 12 V 1.7 W 12 V 1.7 W 12 V 1.7 W 12 V 1.7 W LED ........................................... E-02, 19, 54

CAPACITIES Fuel tank including reserve ................................................................. 13.0 L (3.4/2.9 US/Imp gal) Engine oil oil change......................................................................... 1 900 ml (2.0/1.7 US/Imp qt) with filter change .............................................................. 2 000 ml (2.1/1.8 US/Imp qt) overhaul............................................................................ 2 300 ml (2.4/2.0 US/Imp qt) Final gear oil, oil change ................................................................... 190 ml (6.4/6.7 US/Imp oz) overhaul ...................................................................... 200 ml (6.8/7.0 US/Imp oz) Coolant ................................................................................................ 1.3 L (1.4/1.1 US/Imp qt)

2

SERVICE DATAVALVE + VALVE GUIDEITEM Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. Valve guide I.D. Valve stem O.D. IN. & EX. IN. EX. Valve stem deflection Valve stem runout Valve head thickness Valve stem end length Valve seat width Valve head radial runout Valve spring free length Valve spring tension IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. STANDARD 30.6 (1.20) 27.0 (1.06) 0.08 0.13 (0.003 0.005) 0.17 0.22 (0.007 0.009) 0.10 0.37 (0.004 0.015) 0.30 0.57 (0.012 0.022) 5.000 5.012 (0.1969 0.1973) 4.975 4.990 (0.1959 0.1965) 4.955 4.970 (0.1951 0.1957) 0.9 1.1 (0.035 0.043) 182 210 N (18.2 21.0 kgf, 40.1 46.3 lbs) at length 31.5 mm (1.24 in) Unit: mm (in) LIMIT 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 1.7 (0.07) 0.03 (0.001) 38.8 (1.53)

3

CAMSHAFT + CYLINDER HEADITEM Cam height IN. EX. Camshaft journal oil clearance 22 17.5 Camshaft journal holder I.D. 22 17.5 Camshaft journal O.D. 22 17.5 Camshaft runout Rocker arm shaft I.D. Rocker arm shaft O.D. Cylinder head distortion IN. & EX. IN. & EX. STANDARD 33.430 33.477 (1.316 1.318) 33.300 33.347 (1.311 1.313) 0.032 0.066 (0.001 0.003) 0.028 0.059 (0.001 0.002) 22.012 22.025 (0.8666 0.8671) 17.512 17.525 (0.689 0.690) 21.959 21.980 (0.8645 0.8654) 17.466 17.484 (0.6876 0.6883) 12.000 12.018 (0.472 0.473) 11.973 11.984 (0.471 0.472)

Unit: mm (in) LIMIT 33.130 (1.304) 33.000 (1.299) 0.15 (0.006) 0.15 (0.006) 0.10 (0.004) 0.05 (0.002) Unit: mm (in) LIMIT 616 kPa (6.16 kgf/cm, 88 psi) 0.120 (0.005) 83.085 (3.271) 82.880 (3.263) 0.05 (0.002) 9.0 (0.35) 6.2 (0.24) 0.70 (0.03) 1.0 (0.04) 0.18 (0.007) 0.15 (0.006)

CYLINDER + PISTON + PISTON RINGITEM Compression pressure Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Piston ring free end gap 1st 2nd Piston ring end gap 1st 2nd Piston ring to groove clearance 1st 2nd R R STANDARD 860 900 kPa (8.6 9.0 kgf/cm, 122 128 psi) 0.045 0.055 (0.0018 0.0022) 83.000 83.015 (3.2677 3.2683) 82.950 82.965 (3.2657 3.2663) Measure at 15 mm (0.6 in) from the skirtend. Approx. 11.3 (0.44) Approx. 7.7 (0.30) 0.20 0.35 (0.008 0.014) 0.35 0.50 (0.014 0.020)

4

ITEM Piston ring groove width

1st 2nd Oil

Piston ring thickness

1st 2nd

Piston pin bore Piston pin O.D.

STANDARD 1.01 1.03 (0.0398 0.0406) 1.01 1.03 (0.0398 0.0406) 2.01 2.03 (0.0791 0.0799) 0.97 0.99 (0.0382 0.0390) 0.97 0.99 (0.0382 0.0390) 20.002 20.008 (0.7874 0.7877) 19.992 20.000 (0.7871 0.7874)

LIMIT 20.030 (0.789) 19.980 (0.787) Unit: mm (in) LIMIT 20.040 (0.789) 3.0 (0.12) 1.0 (0.04) 0.08 (0.003)

CONROD + CRANKSHAFTITEM Conrod small end I.D. Conrod deflection Conrod big end side clearance Conrod big end width Width between crankshaft webs Crankshaft runout STANDARD 20.006 20.014 (0.7876 0.7880) 0.10 0.75 (0.004 0.030) 21.95 22.00 (0.864 0.866) 59.9 60.1 (2.358 2.366)

OIL PUMPITEM Oil pressure (at 60 C, 140 F) STANDARD Above 80 kPa (0.8 kgf/cm, 11 psi) Below 160 kPa (1.6 kgf/cm, 23 psi) at 3 000 r/min LIMIT

CLUTCHITEM Clutch wheel I.D. Clutch shoe thickness Engagement r/min Lock-up r/min STANDARD 150.0 150.2 (5.906 5.913) 3.0 (0.12) 2 300 2 900 rpm 3 500 4 500 rpm

Unit: mm (in) LIMIT 150.5 (5.925) 2.0 (0.08)

5

TRANSMISSIONITEM Reduction ratio Final reduction ratio Drive V-belt width Movable driven face spring free length Movable drive face roller O.D. Drive/Driven face wear STANDARD 2.203 0.854 (Variable change) 6.168 (31/14 39/14) 21.85 (0.86) 125 (4.92) 23.72 23.88 (0.93 0.94)

Unit: mm (in) Except ratio LIMIT 20.85 (0.82) 118.7 (4.67) 0.4 (0.02)

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATORITEM Injector resistance Fuel pump discharge amount Fuel pressure regulator operating set pressure SPECIFICATION 10 18 at 20 C (68 F) 35 ml and more For 10 sec, at 300 kPa (3.0 kgf/cm, 43 psi) Approx. 300 kPa (3.0 kgf/cm, 43 psi) NOTE

FI SENSORSITEM CKP sensor resistance CKP sensor peak voltage IAP sensor input voltage IAP sensor output voltage TP sensor input voltage TP sensor resistance TP sensor output voltage ECT sensor input voltage ECT sensor resistance IAT sensor input voltage IAT sensor resistance TO sensor resistance TO sensor output voltage Injector voltage Ignition coil primary peak voltage PAIR solenoid valve resistance HO2 sensor resistance HO2 sensor output voltage SPECIFICATION 180 280 4.5 V and more (When cranking) 4.5 5.5 V Approx. 2.6 V at idle speed 4.5 5.5 V Closed Approx. 0.6 k Opened Approx. 3.8 k Closed Approx. 0.6 V Opened Approx. 3.8 V 4.5 5.5 V Approx. 1.14 k at 40 C (104 F) 4.5 5.5 V Approx. 1.14 k at 40 C (104 F) 19.1 19.7 k Normal 1.3 V and less Leaning 3.8 V and more Battery voltage 150 V and more (when cranking) 20 24 at 20 C (68 F) 11.5 14.5 at 23 C (73.4 F) Idle speed 0.3 V and less 3 000 r/min 0.7 V and more NOTE +: G, -: BI

+: W -: Ground

6

THROTTLE BODYITEM I.D. No. Bore size Fast idle r/min Idle r/min Idle air screw opening IAC valve resistance Throttle cable play SPECIFICATION E-02, 03, 19, 28, 54 15G0 37.2 mm (1.46 in) 1 600 2 000 r/min 1 400 100 r/min 2 turns out Approx. 3 9 at 20 24 C (68 75 F) 2.0 4.0 mm (0.08 0.16 in) E-33 15G1

THERMOSTAT + RADIATOR + FAN + COOLANTITEM Thermostat valve opening temperature Thermostat valve lift Engine coolant temperature sensor resistance STANDARD/SPECIFICATION Approx. 82 C (180 F) 1.5 Over 3.0 mm at 95 C (203 F) 20 C (68 F) 40 C (104 F) 80 C (176 F) 100 C (212 F) Approx. 2.58 k Approx. 1.14 k Approx. 0.28 k Approx. 0.16 k LIMIT Unit: mm (in) NOTE

Radiator cap valve opening pressure Cooling fan thermo-switch operating temperature Engine coolant type

Engine coolant including reserve

107.9 137.3 kPa (1.1 1.4 kgf/cm, 16 20 psi) ON 93 103 C (199 217 F) OFF 87 97 C (189 207 F) Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Reserve Approx. 250 ml (8.5/8.8 US/Imp oz) tank side Engine Approx. 1 300 ml (43.9/45.8 US/Imp oz) side

ELECTRICALITEM Spark plug STANDARD/SPECIFICATION NGK: CR7E Type DENSO: U22ESR-N 0.7 0.8 Gap (0.28 0.03 in) 8.0 mm (0.31 in) and over at 1 atm. 180 288 4.5 V and more Primary Secondary 35 17 30 k 150 and more

Spark performance CKP sensor resistance CKP sensor peak voltage Ignition coil resistance Ignition coil primary peak voltage

G BI +: G/W -: BI

+: W -: Ground

7

ITEM Generator coil resistance Generator no-load voltage (When cold) Generator Max. output Regulated voltage Starter relay resistance Battery

STANDARD/SPECIFICATION Charging 0.2 0.6 55 V and more at 5 000 r/min Approx. 375 W at 5 000 r/min 14.0 15.5 V at 5 000 r/min 36 Type FT12A-BS designation Capasity 12 V 36 kC (10 Ah) /10 HR HI 10 A Headlight LO 10 A Meter 10 A Ignition 10 A Turn signal 15 A Power source 10 A Main 30 A

NOTE YY

Fuse size

WATTAGEITEM Headlight Parking or position light Brake light/Taillight Turn signal light License light Instrument panel light Oil change indicator light FI indicator light Brake-lock indicator light High beam indicator light Turn signal indicator light Trunk light * Immobilizer indicator light HI LO STANDARD/SPECIFICATION E-02, 19, 54 E-03, 28, 33 35 2 35 2 5 21/5 2 21 4 5 1.7 3 1.7 1.7 1.7 1.7 1.7 2 5 LED

Unit: W

8

BRAKE + WHEELITEM Brake disc thickness Front Rear Brake disc runout Master cylinder bore Front Rear Master cylinder piston diameter Front Rear Brake caliper cylinder bore Front Rear Brake caliper piston diameter Front Rear Wheel rim runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front Rear STANDARD 4.5 0.2 (0.18 0.008) 5.5 0.2 (0.22 0.008) 11.000 11.043 (0.433 0.435) 14.000 14.043 (0.551 0.553) 10.957 10.984 (0.431 0.432) 13.957 13.984 (0.549 0.551) 33.960 34.010/22.650 22.700 (1.337 1.339/0.892 0.894) 25.400 25.450 (1.000 1.002) 33.878 33.928/22.568 22.618 (1.334 1.336/0.889 0.890) 25.318 25.368 (0.997 0.999) 13M/C MT3.00 13M/C MT3.50

Unit: mm (in) LIMIT 4.0 (0.16) 4.5 (0.18) 0.30 (0.01) 2.0 (0.08) 2.0 (0.08) 0.25 (0.01) 0.25 (0.01) Unit: mm (in) LIMIT 324 (12.76)

SUSPENSIONITEM Front fork stroke Front fork spring free length Front fork oil type Front fork oil capacily (each leg) Front fork oil level Rear wheel travel Rear shock absorber spring adjuster STANDARD 100 (3.94) 330.4 (13.01) SUZUKI FORK OIL G-10 (#10) 284 ml 96 (3.78) 100 (3.94) 4 and 1/2 turns out Standard from softest position (9 clicks) Range 17 turns (34 clicks)

9

TIREITEM Cold inflation tire pressure Solo riding Front Rear Front Rear Front Rear Front Rear Front Rear STANDARD 175 kPa (1.75 kgf/cm, 25 psi) 200 kPa (2.00 kgf/cm, 28 psi) 175 kPa (1.75 kgf/cm, 25 psi) 280 kPa (2.80 kgf/cm, 40 psi) 110/90-13 M/C 55P 130/70-13 M/C 63P BRIDGESTONE HOOP B03G BRIDGESTONE HOOP B02G LIMIT 1.6 mm (0.06 in) 2.0 mm (0.08 in)

Dual riding Tire size Tire type Tire tread depth (Recommended depth)

FUEL + OILITEM Fuel type Fuel tank capacity SPECIFICATION Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. Including 13.0 L reserve (3.4/2.9 US/Imp gal) Fuel meter Approx. 3.0 L (3.2/2.6 US/Imp qt) red zone SAE 10W-40, API SF or SG 1.9 L Oil change (2.0/1.7 US/Imp qt) Filter 2.0 L change (2.1/1.8 US/Imp qt) 2.3 L Overhaul (2.4/2.0 US/Imp qt) 190 ml Oil change (6.4/6.7 US/Imp oz) 200 ml Overhaul (6.8/7.0 US/Imp oz) NOTE

Engine oil type Engine oil capacity

Final gear oil capacity

10

CRANK BALANCER GEARSK4-model

Snap ring Washer ! Spring washer " Washer # Balancer driven scissors gear No. 2 $ Balancer driven gear No. 1 (P/No. 12666-14F00) % Spring (P/No. 09440-07064) & Washer ' Nut

K5-model

Snap ring (Unchanged) Washer (Unchanged) ! Balancer driven scissors gear No. 2 (Unchanged) " Balancer driven gear No. 1 (P/No. 12666-14F10) # Spring (P/No. 09440-07077) $ Washer (Unchanged) % Nut (Unchanged) 11

IMMOBILIZER The immobilizer, an anti-theft system, is installed as a standard equipment. The immobilizer verifies that the key ID agrees with ECM ID by means of radio communication through the immobilizer antenna. When the ID agreement is verified, the system makes the engine ready to start.

Immobi-antenna

Indicator light

Transponder

Immobilizer antenna

Indicator light

ID

ECM

12

Operation When the ignition switch is turned ON with the engine stop switch in ON and the side stand in up position, the immobi-antenna and ECM are powered ON. The ECM transmits a signal to the transponder through the immobi-antenna in order to make comparison between the key ID and ECM ID. With the signal received, the transponder transmits the key ID signal to ECM so that ECM can make comparison with its own ID, and if it matches, the engine is made ready to start.

Transponder Immobi-antenna

Ignition switch ECM

Also, when the ignition switch is turned ON, the indicator light flashes as many as the number of IDs registered in ECM. Thereafter, if the IDs are in agreement, the indicator light turns on for two seconds to notify of completion in successful communication. If the indicator light flashes fast, it notifies of communication error or disagreement of ID.

Flashing2 registered 3 registered 4 registered

LightingNormal Normal NormalAbnormal

Fast flashingApprox. 1.6 sec. Approx. 2.0 sec.

NOTE: If the indicator light flashes fast, turn the ignition switch OFF then ON to make judgment again as there is possible misjudgment due to environmental radio interference. When the battery performance is lowered in winter (low temperature), the system may at times makes a re-judgment at the time of beginning the starter motor operation. In this case, the indicator light operation starts immediately after the starter operation.

Indicator light

13

Seat lock

To ignition switch

SEAT LOCK CABLE ROUTING

Water hose

14 Clamp Clamp Clamp

Clamp

Pass through the seat lock cable to the right side of the water hose.

Face the arrow mark to the top.

23 Nm (2.3 kgf-m, 16.5 lb-ft)

EXHAUST PIPE/MUFFLER MOUNTING

15

(

30 Nm 3.0 kgf-m 21.5 lb-ft

)

(

29 Nm 2.9 kgf-m 21.0 lb-ft

)

23 Nm (2.3 kgf-m, 16.5 lb-ft)

WIRING HARNESS ROUTING

16

17

Only for AN400S

Clamp

Clamp

Clamp

18

B O/R

Y/W B/Y B/Y

B Y/W W/Bl Y/Bl Y/W

B B B B B Y/B O Y/W O/G W/B

B/W B/Lg R/B Y B G R Y/Bl B/W G/Y O/Y

W Gr B W

B B

B/W Y/W

WIRING DIAGRAM (For E-02, 19, 54)

19 B/W B/W

(L)

O/G

O/Bl

O/G V

Gr P

O/R Y/W B/R B/Bl

1. HEAD HI 2. HEAD LO 3. METER 4. IGNITION 5. SIGNAL 6. P-SOURCE 10 A 10 A 10 A 10 A 15 A 10 A Gr Gr Gr Dg B/Br Dg B/Br B B/Br Y/W G/Y Br/B B/Br B/Bl B/G Y/R O/Bl B

HI : HIGH BEAM INDICATOR LIGHT OI : OIL CHAGE INDICATOR LIGHT FI : FI INDICATOR LIGHT BRK : BRAKE LOCK INDICATOR LIGHT TR : TURN SIGNAL INDICATOR LIGHT (R) TL : TURN SIGNAL INDICATOR LIGHT (L )

SPEEDO METER SIDE-STAND SWITCH

BRAKE-LOCK SWITCH R/B

TRUNK BOX SWITCH

Gr

WIRING DIAGRAM (For E-03, 28, 33)

O/G B/W

1. HEAD HI 2. HEAD LO 3. METER 4. IGNITION 5. SIGNAL 6. P-SOURCE

10 A 10 A 10 A 10 A 15 A 10 A

B/W Y/W

20

Gr

Gr