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.

1-6 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.............................................................. 1,932 mm
Overall width .............................................................. 650 mm
Overall height ............................................................. 1,062 mm
Seat height ................................................................. 755 mm
Wheel base ................................................................ 1,230 mm
Ground clearance ...................................................... 153 mm
Dry mass .................................................................... 96 kg
ENGINE
Type ........................................................................... Four-stroke, air-cooled, SOHC
Number of cylinder ..................................................... 1
Bore ........................................................................... 53.5 mm
Stroke ......................................................................... 48.8 mm
Piston Displacement .................................................. 109.6 cm3
Compression ration .................................................... 9.6 : 1
Carburetor .................................................................. MIKUNI VM17
Air cleaner .................................................................. Paper
Starter system Electric starter & Kick starter
starter Lubrication system Wet sump
Valve clearance ......................................................... IN : 0.04-0.07 mm.
EX : 0.04-0.07 mm.
TRANSMISSION
Clutch ......................................................................... Wet shoe, automatic, centrifugal type
Transmission .............................................................. 4-speed constant mesh
Gearshift pattern ........................................................ All-down
Primary reduction ratio ............................................... 3.666 (77/21)
Final reduction ratio ................................................... 2.428 (34/14)
Gear ratios, Low ......................................................... 3.000 (33/11)
2nd ......................................................... 1.875 (30/16)
3rd .......................................................... 1.368 (26/19)
Top ......................................................... 1.052 (20/19)
Drive chain ................................................................. DIADO D.I.D 428, 98 links

GENERAL INFORMATION 1-7
CHASSIS
Frame ......................................................................... SSRF (SUZUKI SINGLE RECTANGULAR FRAME)
Front suspension ........................................................ Telescopic, coil spring, oil damped
Rear suspension ........................................................ Swing arm type, coil spring
Steering angle ............................................................ 45° (right & left)
Caster ......................................................................... 27°
Trail ............................................................................ 65 mm
Front brake ................................................................. Disc brake, hydraulically operated
Expanding, drum, brake.
Rear brake ................................................................. Internal expanding, drum brake
Front tire size ............................................................. 2.25 – 17 NR72 33L
Rear tire size .............................................................. 2.50 – 17 NR72 38L
Front fork stroke ......................................................... 90 mm
Rear wheel travel ....................................................... 79 mm
ELECTRICAL
Ignition type................................................................. DC-CDI
Spark plug .................................................................. ND: U20FS-U
NGK: C6HS
Batter .......................................................................... 12 V 5AH 10HR
Fuse ............................................................................ 10 A
Headlight ..................................................................... 12 V 35/35 W
Turn signal light........................................................... 12 V 10 W
Taillight/Brake light ..................................................... 12 V5/21W
Speedometer light ...................................................... 12 V 3 W
High beam indicator light ............................................ 12 V 1.7 W
Turn signal indicator light ........................................... 12 V 1.7 W
Neutral, gear position indicator light ........................... 12 V 1.7 W
CAPACITY
Fuel tank .................................................................... 4.2 L
Engine oil, oil change ................................................. 800 ml
with filter change ........................................................ 900 ml
overhaul ..................................................................... 1,000 ml
Front fork oil ............................................................... 70 ml
These specifications are subject to change without notice.

1-8 GENERAL INFORMATION

PERIODICAL MAINTENANCE 2-1
CONTENTS 2
PERIODICAL MAINTENANCE
PERIODICAL MAINTENANCE SCHEDULE ................................................. 2-2
PERIODIC MAINTENANCE CHART....................................................... 2-2
LUBRICATION POINTS .......................................................................... 2-3
MAINTENANCE AND TUNE-UP PROCEDURES ......................................... 2-4
BATTERY ................................................................................................ 2-4
EXHAUST PIPE BOLTS.......................................................................... 2-5
AIR CLEANER ........................................................................................ 2-5
VALVE CLEARANCE.............................................................................. 2-6
SPARK PLUG.......................................................................................... 2-8
ENGINE OIL ............................................................................................ 2-9
OIL FILTER.............................................................................................. 2-9
FUEL HOSE........................................................................................... 2-10
FUEL FILTER ........................................................................................ 2-10
CARBURETOR...................................................................................... 2-10
DRIVE CHAIN........................................................................................ 2-11
BRAKE .................................................................................................. 2-13
TIRE ....................................................................................................... 2-16
STEERING............................................................................................. 2-16
FRONT FORK........................................................................................ 2-17
REAR SUSPENSION ............................................................................ 2-17
CHASSIS BOLTS AND NUTS .............................................................. 2-18
COMPRESSION PRESSURE CHECK ........................................................ 2-20
OIL PRESSURE CHECK ............................................................................. 2-21
AUTOMATIC CLUTCH INSPECTION ......................................................... 2-22

2-2 PERIODIC MAINTENANCE
PERIODICAL MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary t keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers
and time for your convenience.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
NOTE:
I: Inspection and adjust, clean, Lubricate or replace as necessary
C: Clean R: Replace T: Tighten
Interval Km 1,000 4,000 8,000 12,000 16,000 20,000 24,000
Item Months 161218243036
Battery IIIIIII
Exhaust pipe bolts TTTTTTT
Air cleaner —CCRCCR
Valve clearance IIIIIII
Spark IIRIRIR
Engine oil RRRRRRR
Replace every 4,000 km
Engine oil filter R—R—R I R
Replace every 8,000 km
Fuel hose IIIIIII
Clutch IIIIIII
Fuel filter IIIIIII
Engine idle rpm (Carburetor) I I I I I I I
Throttle cable play (Carburetor) IIIIIII
Drive chain I I I I I I I
Brakes IIIIIII
Tires IIIIIII
Steering I I I I I I I
Cylinder head nut TTTTTTT
Suspension —— I — I — I
Chassis bolts and nuts TTTTTTT

PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
*Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
*Lubricate exposed parts which are subject to rust, with a rust preventative spry whenever the motorcycle
has been operated under wet or rainy condition.
SPEEDOMETER
GEARBOX
FRONT WHEEL
BEARING
AXLE SHAFT
FRONT BRAKE CAM
SPEEDOMETER
CABLE
SIDE STAND PIVOT
AND SPRING HOOK
CENTER STAND PIVOT
AND SPRING HOOK
DRIVE CHAIN
BRAKE LEVER
HOLDER
THROTTLE CABLE
STEERING STEM
BEARING
KICK STARTER LEVER
PIVOT
BRAKE PEDAL
PIVOT
REAR BRAKE CAM
REAR WHEEL
BEARING
AXLE SHAFT

2-4 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item of the Periodic Maintenance requirements.
BATTERY
•The battery must be removed to check the electrolyte level
and specific gravity.
•Open the seat.
•Remove battery - and + leads at the battery terminals.

•Remove battery from the frame.
• Check electrolyte for level and specific gravity. Add distilled
water, as necessary, to keep the surface of the electrolyte
above the LOWER. Level line but not above the UPPER.
Level line.
For checking specific gravity, use a hydrometer to determine the
charged condition.
09900-28403: Hydrometer
Battery type ….GM3-3B
Battery type …. YB5L-B
An S.G. reading of 1.22 [YB5L-B] 1.20 [GM 3-3B] (AT 20oC) or
under means that the battery needs recharging off the machine:
Take if off and charge it from a recharge. Charging the battery in
place can lead to failure of the regulator or rectifier.
•To install the battery, reverse the procedure cribbed above.
Inspect initially at 1,000 km (1 month) and Every
4,000 km (4 months) thereafter.
When removing the battery, disconnect the negative
cable first and then the positive cable.
Standard specific gravity 1.26 at 20 °C
Standard specific gravity 1.28 at 20 °C
Hydrometer

PERIODIC MAINTENANCE 2-5

•Make sure that the breather pipe is tightly secured and
undamaged, and is routed as shown in the photograph.
EXHAUST PIPE BOLTS
•Tighten the exhaust pipe clamp bolts and muffler mounting
bolts to the specified torque with a torque wrench.
Exhaust pipe nut: 1.1 kg-m
Muffler mounting bolt: 2.6 kg-m
AIR CLEANER
If the air cleaner is clogged with dust, intake resistance will be
increased with a resultant decrease in output and an increase
the fuel consumption. Check and clean the element in the
following manner.
•Loosen the 3 screw.
•Take off the air cleaner cover.
•Remove the element from the case.
When installing the battery lead wires fix the + Led
first and - lead last.
Tighten Initially at 1,000 km (1 month) and Inspect
Every 4,000 km (6 months) thereafter.
BATTERY
BATTERY BREATHER HOSE
Clean Every 4,000 km (6 months).

2-6 PERIODIC MAINTENANCE
•Loosen the four screw and remove the air cleaner cover.
•Remove the air cleaner element.
•Carefully use an air hose to blow the dust form the cleaner
element inside.
•Reinstall the cleaned or new cleaner element in the reverse
order of removal.


VALVE CLEARANCE
Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power. At
the distances indicated above, check and adjust the clearance to
the following specification.
Clean Every 4,000 km (6 months).
Valve clearance (When cold):
IN.: 0.04 - 0.07 mm
EX.: 0.04 - 0.07 mm
•Remove the center leg shield.
•Remove the leg shields, left and right.
•Remove the carburetor by loosening the screws
The procedure for adjusting the valve clearance is as follows:
NOTE:
*The piston must be at (TDC) on the compression stroke in order
to check the valve clearance or to adjust valve clearance.
*The clearance specification is for GOLD state.
Always use air pressure on the side of the steel sheet.
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air
cleaner is in good condition at all times. Life of the
engine depends largely on this component !
Inspect Initially at 1,000 km (1 month) and Every
4,000 km (6 months) thereafter.

PERIODIC MAINTENANCE 2-7
•Remove spark plug, valve inspection caps 1 and valve timing
inspection plug 2.
•Remove the magneto cover cap and rotate the magneto rotor
with box wrench to set the piston at (TDC) of the compression
stroke. (Rotate the rotor until the “T” line on the rotor is
aligned with the center of hole on the magneto cover.
•Insert the thickness gauge to the clearance between the valve
stem end and the adjusting screw on the rocker arm.
09900-20803: Thickness gauge
•If clearance is off the specification, bring it into the specified
range by using the special tool.
•Reinstall spark plug, valve inspection caps, valve timing
inspection plug and magneto cover cap.
09917-14910: Tappet adjust driver
NOTE:
*The clearance specification is for GOLD state
1
2
Rockerarm
Adjuster Screw
Valve clearance