Suzuki FD 110 XCS User manual

FD110
FD110 
 

GROUP INDEX
GENERAL INFORMATION 1
PERIODICAL MAINTENANCE 2
ENGINE 3
FUEL AND LUBRICATION SYSTEM
4
CHASSIS 5
ELECTRICAL SYSTEM
6
SERVICING INFORMATION 7
COOLING AND LUBRICATION SYSTEM
8
CHASSIS 9
ELECTRICAL SYSTEM 10
SERVICING INFORMATION 11
EMISSION CONTROL INFORMATION
12
VZR1800K7 (’07-MODEL) 13
VZR1800ZK7 (’07-MODEL) 14
VZR1800NK8 (’08-MODEL) 15
VZR1800K8 (’08-MODEL) 16
VZR1800ZK8/ZK9 (’08, ’09-MODEL)
17
VZR1800K9/NK9 (’09-MODEL) 18
VZR1800/ZL0/ZL1 (’10, ’11-MODEL)
19
VZR1800/ZL2 (’12-MODEL)
20
WIRING DIAGRAM
21
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.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2012
*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
1
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.