2009 Suzuki C50 Owners Manual

01.01.2020

2009 Suzuki C50 Owners Manual 3,0/5 9387 reviews

2009 Suzuki C50 Service Manual
2009 Suzuki C50 Owners Manual

Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.

Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6.

Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

Incoming search terms:. Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1.

Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5.

Spacer (3) (keep) 6. Torx screw (5) (replace) 7.

Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13.

Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced.

Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual.

Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7.

Front Wheel 2. See Figure 2.

Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws.

Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover.

After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99.

After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first.

Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1.

Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual.

Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring.

Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1.

O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in.

(112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual.

NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer.

Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:. Remove existing front wheel assembly.

Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual.

For FLSTC and FLSTN Models: Discard moon-style hub cap.J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. See Figure 2.

Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09:.

The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07:. Install the wheel so that the hub markings are on the left side of the motorcycle.

The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition.

Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2).

Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3).

The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07:. The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation.

These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub.

Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required.

Refer to FRONT WHEEL in Service Manual. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork.

All other models: Install wheel spacers previously removed. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual Incoming search terms:.

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. The section titles are listed in the GROUP INDEX. Holding the manual as shown at the right will allow you to find the first page of the section easily. The contents are listed on the first page of each section to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40. If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart. BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only.

Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Incoming search terms:.

INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. On the fairing cap, remove the inner left side hole plug.

See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch.

If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead.

Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector 105B 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual.

Install the new left-hand control switch assembly (3) from the kit. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference.

Interference with steering could result in loss of vehicle control and death or serious injury. (00371a). Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops. Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse. INSTALLATION 1. Remove existing front wheel assembly.

Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual.

For FLSTC and FLSTN Models: Discard moon-style hub cap. Or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. See Figure 2. Install valve stem assembly (L) on wheel.

Refer to TIRES in service manual. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08. For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle.

For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side.

For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08:. Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side. For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing.

Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit. Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual.

For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to verify that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush.

Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant. REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.

Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. Remove primary chaincase according to the instructions in the Service Manual. See Figure 2.

Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. Remove the two T-27 TORX screws (2). Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. Disassemble connector 46B (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual.

NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. Pull wires through crankcase hole.

INSTALLATION 1. Insert wires through crankcase hole. See Figure 1. Push rubber grommet (B) through crankcase hole.

If necessary, apply the same lubricant used during removal. Insert wires into connector 46B (A). Mate connector 46. See VOLTAGE REGULATOR in Service Manual. Is03776 Figure 1. Voltage Regulator 5.

See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). Install the rotor (1) on the sprocket shaft. Apply Loctite Threadlocker 262 (red) to sprocket nut threads.

Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). Install primary chaincase according to the instructions in the Service Manual. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. Connect negative battery cable.

See BATTERY MAINTENANCE in Service Manual Incoming search terms:. Removal of Original Transmission 1. Position motorcycle on a suitable lift. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first.

If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps. Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover.

Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly.

Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation.

Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch. Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation Incoming search terms:.

REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. Refer to the service manual and follow the instructions given to remove the main fuse. Remove the outer fairing. See the service manual.

Remove the fairing cap. See the service manual.

FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual.

If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T.

4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention.

Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth.

Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splashes of DOT 4 brake fluid. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual. NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box.

See the service manual. The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. Pull the radio or storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully.

Damage to seating surfaces can cause leakage. Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual.

Remove the front brake line assembly. NOTES Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available. Remove the front brake master cylinder and clutch lever assemblies from the handlebar. Disconnect the clutch cable from the clutch lever. See the service manual.

Incoming search terms:.

Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.

Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted.

Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2.

Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box.

(Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:.

The author of this manual has the conviction that the only way in which a meaningful and easy to follow text can be written is first to do the work himself, under conditions similar to those found in the average household. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner. Unless specially mentioned, and therefore considered essential, Honda service tools have not been used. There is invariably some alternative means of slackening or removing some vital component when service tools are not available and isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections.

Within the Sections are numbered paragraphs. In consequence, cross reference throughout this manual is both straightforward and logical.

When a reference is made ‘See Section 5.12′ it means Section 5, paragraph 12 in the same Chapter. If another Chapter were meant, the text would read ‘See Chapter 2, Section 5.12′. All photographs are captioned with a Section/paragraph number to which they refer and are always relevant to the Chapter text adjacent. Figure numbers (usually line illustrations) appear in numerical order, within a given Chapter.

1.1 therefore refers o the first figure in Chapter 1. Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity. We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us. No liability can be ccepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information give Incoming search terms:. Remove seat, right and left side covers, and fuel tank. Remove airbox.

We highly recommend you consult the factory service manual for proper removal of airbox. Route wiring harness as shown in the picture. Unplug stock wiring harness from injectors and plug in the connectors from Fuelpak as shown. Unplug the TPS connector (grey) and attach T-tap connectors to the two outside wires. Route Fuelpak green wire to T-tap on the factory black wire with brown stripe. Routh the Fuelpak violet wire to T-tap on the factory pink wire with black stripe as shown (Fig 3) 7.

Reattach the TPS connector. Route red wire to the front of engine and down to the horn. Disconnect the two position connector from horn and snip connector in half so you have two one-wire connections. Reattach factory grey wire to horn. Attach Fuelpak red wire to the other horn connection. Plug the factory horn orange wire to the male connection on the Fuelpak red wire.

Route black wire to battery negative connection as shown. Attach Fuelpak to Fuelpak harness and mount to bracket under the left side cover as shown. Before reassembling the bike, make sure handlebar switch is in the engine-not-running position and turn the key on.

Fuelpak should light up. Sound the horn.

If Fuelpak turns off when the horn is sounded, recheck the red wire connection on the horn and that it is connected to the orange wire from the factory harness. Follow the service manual to reinstall the airbox and gas tank.

Incoming search terms:. HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1.

The text of this manual is divided into sections. The section titles are listed in the GROUP INDEX.

Holding the manual as shown at the right will allow you to find the first page of the section easily. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification.

The recommended viscosity is SAE 1 OW-40. If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart.

BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Incoming search terms:.

Remove the (2) Bolts at the top of the stock air cleaner to the left and right of the oval rubber hose coming from under the fuel tank. Loosen the hose clamp at the base of the oval rubber hose on the top of the air cleaner. A male barb protrudes from the rear of the air cleaner that inserts into a rubber grommet mounted to the cylinders. Pull the air cleaner away from the cylinders firmly and you will feel the barb release.

Now pull the upper section of the air cleaner downward to remove it from the oval snorkel tube from under the fuel tank. Now you can reach to the rear of the box and unplug the electrical lead for the Air Sensor” which sits just about in the middle of the rear of the air cleaner.

Now remove the breather hose at bottom of the air cleaner. Set the air cleaner aside and turn it over to access the back. Remove the single bolt that secures the Air Sensor” (This sensor will be installed into the Aluminum Manifold of your new BAK assembly later) 6. Remove the lower mounting arm assembly from the cylinders. (You will not reuse this).

Using the (2) Dome head m6 x 15mm screws install the (2) #1 Arms to the rear (the side without the groove) of the backing plate, the shiny/chrome side of the arms should face outward. The smaller of the two holes in each arm is the one you place the screws through.

Use the m6 Flange Nuts to secure the bolts at the rear of backing plate. Snug these up but do not tighten fully. Incoming search terms:. Always make a pre-ride inspection before you start the engine. You may prevent an accident or equipment damage. 2 Many accidents involve inexperienced riders. Most countries require a special riding test or license.

Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. 3 Many car/motorcycle accidents happen because the car driver does not “ see the motorcyclist. Make yourself conspicuous to help avoid the accident that is not your fault:. Wear bright or reflective clothing. Don’t drive in another motorist’s “blind spot” 4 Obey all national, and local laws and regulations Excessive speed is a factor in many accidents.

Obey the speed limits am NEVER travel faster than conditions warrant. Signal before you make a turn or lane change. Your size and manoeuvrability can surprise other motorists.5 Don’t let other motorists surprise you. Use extra caution at intersections, parking entrances and exits and driveways. 6 Keep both hands on the handlebars and both feet on the footrests while riding. A passenger should hold onto the motorcycle or the rider with both hands, and keep both feet on the passenger footrests. PROTECTIVE APPAREL 1 Most motorcycle accidents fatalities are due to head impact.

ALWAYS wear a helmet. You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection.

The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. 3 Do not wear loose clothing which could catch on the control levers, footrests, or wheels.

Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5.

Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8.

Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14.

Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced.

See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. Install the new wheel to the rear fork.

Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions.

Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual.

Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover.

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual.

Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual.

Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual.

Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques.

Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in.

(107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces.

See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). See Figure 1 and Table 1.

Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:. In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later. Front wheel removal: Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution: there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. Goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine.

Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal Incoming search terms:. INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation.

Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. Or FXSTD: Discard tapered spacer. NOTE Install short valve stem (43157-83A) included in the installation kit. Discard all other valve stems. See Figure 2.

Install valve stem assembly (L) on wheel. Refer to TIRES in service manual.

Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The side with the machined groove on the hub face is the primary bearing side for all kits except Kits 41681-07 and 40818-08.

For Kit 41681-07: Install the wheel so that the hub markings are on the left side and the machined groove is on the right side of the motorcycle. For 2006 and later FXDWG Models: When correctly installed, the tire will be 0.08-0.2 in (2-5 mm) off of center, compared to the fender. For 2007 and later FX Softail and 2008 and later FXDWG Models: The left side of the wheel is the primary bearing side. For 2006 and earlier FX Softail and 2007 and earlier FXDWG Models: The right side of the wheel is the primary bearing side. For Kit 40818-08:. Proper installation of this kit requires the separate purchase of two floating brake discs (44343-01 for 2004 – 2007 models and 44553-06A (stock) or 41500012 (polished) for 2008 and later models) and a tire (43371-07 on 2004-2008 models and 44026-09A on 2009-later models). The left side of the wheel has machined DOT markings to identify it as the primary bearing side.

2009 Suzuki C50 Service Manual

For 2008 and later Touring: Install bearing shim (43903- 08) under the primary bearing. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Install wheel kit and right hand wheel spacer provided in installation kit.

Refer to FRONT WHEEL in service manual. For FXSTD Models: Install wheel kit, stock wheel spacer and right side wheel spacer provided in installation kit in place of the tapered spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install wheel kit, stock wheel spacers and spacer provided in installation kit between the left side wheel spacer and the left fork. For all other models: Install previously removed wheel spacers. Refer to FRONT WHEEL in service manual.