Suzuki FD 110 XCS User manual

FD110

FD110 

 

GROUP INDEX

GENERAL INFORMATION 1

PERIODICAL MAINTENANCE 2

ENGINE 3

FUEL AND LUBRICATION SYSTEM

CHASSIS 5

ELECTRICAL SYSTEM

SERVICING INFORMATION 7

COOLING AND LUBRICATION SYSTEM

CHASSIS 9

ELECTRICAL SYSTEM 10

SERVICING INFORMATION 11

EMISSION CONTROL INFORMATION

VZR1800K7 (’07-MODEL) 13

VZR1800ZK7 (’07-MODEL) 14

VZR1800NK8 (’08-MODEL) 15

VZR1800K8 (’08-MODEL) 16

VZR1800ZK8/ZK9 (’08, ’09-MODEL)

VZR1800K9/NK9 (’09-MODEL) 18

VZR1800/ZL0/ZL1 (’10, ’11-MODEL)

VZR1800/ZL2 (’12-MODEL)

WIRING DIAGRAM

FOREWORD

This manual contains an introductory description On

SUZUKI FD 110 and procedures for Its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included. Read GENERAL INFORMATION sec-

tion to Familiarize yourself with outline of the vehicle

and MAINTENANCE and other sections to use as a

guide for proper inspection and service. This man-

ual will help you now the vehicle better so that you

can assure your customers of your optimum and

quick service.



*This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation.

If modifications have been made since then,

differences may exist between the content of

this manual and the actual motorcycle.

*IIIustrations 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 motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

Without the proper tools and equipment

may not be able to properly perform the

service described I this manual. Improper

repair may result I injury to the mechanic

and may render the motorcycle unsafe for

the rider and passenger.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR :

1. The text of this manual is divided into sections.

2. As the title of these sections are listed on the previous page

as GROUP INDEX, select the section where what you are

looking for belong.

3. Holding the manual as shown as the right will allow

4. On the first page of each section, its contents are listed. Find

the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, its exploded view provided with work instruction and other service

information such as the tightening torque, lubricating and locking agent points.

Example:

LEFT RIGHT

22.0-35.0 N-m

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing and meaning associated with them respectively.

SYMBOL DEFINITION SYMBOL DEFINITION

Torq u e c o ntr o l r e qui r ed.

Data beside it indicates

Specified torque.

Apply THREAD LOCK SUPER “1303”

99000-32030

Apply oil, Use engine oil unless

otherwise specified.

Apply THREAD LOCK “1342”

99000-32050

Apply SUZUKI SUPER GREASE “A”

99000-25010 Apply or use brake fluid.

Apply SUZUKI SILICONE GREASE.

99000-25100 Measure in voltage range.

Apply SUZUKI MOLY PASTE.

99000-25140 Measure in resistance range.

Apply SUZUKI BOND “1215”

99000-31110 Measure in current range.

Apply THREAD LOCK SUPER “1322”

99000-31110 Use special tool.

Apply THREAD LOCK SUPER “1360”

99000-32130

Use fork oil.

99000-99044-10G

GENERAL INFORMATION

1-1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE........................................................................... 1-2

GENERAL PRECAUTIONS ............................................................................ 1-2

SUZUKI FD 110 XC / XCS / XCD / XCSD....................................................... 1-4

SERIAL NUMBER LOCATION ....................................................................... 1-4

FUEL AND OIL RECOMMENDATIONS .................................................. 1-4

FUEL ..................................................................................................... 1-4

ENGINE OIL.......................................................................................... 1-5

FRONT FORK OIL ................................................................................ 1-5

BREAK-IN PROCEDURES............................................................................. 1-5

SPECIFICATIONS........................................................................................... 1-6

1-2

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.



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



Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS



*Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the vehicle.

*When 2 or more persons work together, pay attention to the safety of each other.

*When it is necessary to run the engine indoors, make sure that exhaust gas is forced

outdoors.

*When working with toxic or the flammable materials, make sure that the area you work in is

well ventilated and that you follow all of the material manufacturer’s instructions.

*Never use getting burned, do not touch the engine, engine oil or exhaust system during or for

a while after engine operation.

*After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the

system for leaks.

GENERAL INFORMATION

1-3



*If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their

equivalent.

*When removing arts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

*Be sure to use special tools when instructed.

*Make sure that all parts used in reassembly are clean, and also lubricated when specified.

*When use of a certain type of lubricant, bond, or sealant is specified be sure to sue the

specified type.

*When removing the battery, disconnect the negative cable first and then positive cable. When

reconnecting the battery, connect the positive cablefirst and then negative cable, and replace

the terminal cover on the positive terminal.

*When performing service to electrical arts, if the service procedures not require use of battery

power, disconnect the negative cable of the battery.

*Tighten cylinder head case bolts and nuts, beginning with larger diameter and ending with

smaller diameter, from inside to outside diagonally, to the specified tightening torque.

*Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, cir-

clips and certain other parts as specified, be sure to replace them with new ones. Also, before

installing these new parts, be sure to remove any left over material from the mating surfaces.

*Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

*Do not use self-locking nuts a few times over.

*Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease

or oil if a thread is smeared with them.

*After reassembly, check parts for tightness and operation.

* To protect environment, do not unlawfully dispose of used motor oil and other fluids:

batteries, and tires.

*To protect Earth’s natural resources, properly dispose of used vehicles and parts.

1-4

GENERAL INFORMATION

SUZUKI FD 110 XB517QD/XB517QSC

• Difference between illustrations and actual motorcycles depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the left side of the steering

head tube. The engine serial number is located on the upper right side of the crankcase. These numbers are

required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATIONS

FUEL

Gasoline used should be graded 91 (Research Method)_ or higher. An unleaded gasoline type is recom-

mended.

GENERAL INFORMATION

1-5

ENGINE OIL

Be sure the engine oil you use comes under API classification of

SF or SG and that its viscosity rating is SAE 40. If an SAE 40

motor oil is not available, select an alternate according to the right

chart

BRAKE FLUID

Specification and classification: DOT 4



FRONT FORK OIL

Use fork oil # 10.

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very

high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine

to maximum stresses. The future performance and reliability of the engine depends on the care and restraint

exercised during its early life. The general rules are as follows.

•Keep to this break-in throttle position. Initial 500 km: less than ½ throttle Up to 1,600 km: Less than ¾

throttle

•Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation

for short periods of time.

Since the brake system of this motorcycle is filled with a glycol-based brake fluidby the manu-

facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based

fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long

period.

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