Suzuki DR650SE Service Manual
The Suzuki DR650SE is a powerful and reliable motorcycle designed for both on and off-road adventures. This manual provides detailed instructions for inspection, service, and overhaul of its components. It includes information on periodic maintenance, engine specifications, fuel and lubrication systems, electrical systems, and emission control. Familiarize yourself with the general information to understand the motorcycle's layout, and use the maintenance sections as a guide for proper service.
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IMPORTANT NOTICE ! If this manual was not purchased from manualcd then you will be missing important pages and also have some features locked. To insure you have the complete manual only buy from manualcd If this manual was not purchased from manualcd please contact us and we will inform you of what pages are missing and which features are locked. [email protected] SUZUKI DR650SE SERVICE MANUAL FOREWORD This manual contains an introductory description on SUZUKI DR650SE and procedures for its in- spection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle bet- ter so that you can assure your customers of your optimum and quick service. * This manual has been prepared on the ba- sis of the latest specification at the time of publication. If modification has been made since then, difference may exist between the content of this manual and the actual vehicle. * lllustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehi- cle exactly in detall. * This manual is intended for those who have enough knowledge and skills for ser- vicing SUZUKI vehicles. Without such knowledge and skills, you should not at- tempt servicing by relying on this manu- al only. Instead, please contact your nearby authorized SUZUKI motorcycle dealer. IMPORTANT All street-legal Suzuki motorcycles with engine displacement of bOcc or greater are subject to Environmental Protection agency emission regut- lations. These regulations set specific standards for exhaust emission output levels as well as par- ticular servicing requirements. This manual in- cludes specific information required to properly inspect and service DR650SE in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is per- formed. Further information concerning the EPA emission regulations and U.S. Suzuki's emission control program can be found in the U.S. SUZUKI EMIS- SION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION DR650SEV/W/X/Y (°97/98/99/00-MODEL) DR650SEK1 ('01-MODEL) 1 Q SOON SUZUKI MOTOR CORPORATION Motorcycle Service Department 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 previ- ous page as GROUP INDEX, select the section where what you are looking for belong. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 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 is provided with work instruction and other service information such as the tightening torque, lubricating points and locking agent points. Example: Front wheel 00000 @ (1) O-ring (2) Housing end (inside) (3) Washer set @ O-ring (2 pcs) (5) Starter motor case (6) Armature (7) Washer set Brush holder (9) Brush spring Housing end (outside) SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK SUPER “1503”. (99000-32030) Apply oil. Use engine oil unless otherwise specified. Use fork oil. (99000-99044-10G) Apply SUZUKI SUPER GREASE ATE (99000-25030) Apply or use brake fluid. Apply SUZUKI SILICONE GREASE. (99000-25100) e AA Measure in voltage range. Ss Apply SUZUKI MOLY PASTE. Measure in resistance range. (99000-25140) Apply SUZUKI BOND “1207B7”. | Measure in current range. 207 (99104-31140) ILA Apply THREAD LOCK “1342”. — Use special tool. (99000-32050) TOOL bhi domo Apply THREAD LOCK SUPER 1360”. (99000-32130) GENERAL INFORMATION CONTENTS WARNING/CAUTION NOTE emo 00 AS 1- 1 GENERAL PRECAUTIONS ---<""<"<"<<0000mm mme mc crc renrane rence nan cr nana naar anne n neue 1- 1 SUZUKI DR650SET (°96-MODEL) ------<----<<-<--................………rrrrennes 1- 3 SERIAL NUMBER LOCATION. ========00r0000000:0:007000 00000 DAD 1- 3 FUEL AND OIL RECOMMENDATION ----------========v====r000rer0cereeaeeeeoa 1- 3 FUEL O ; 3 ENCINE ÓN, ===—nmz—0onvcmomanannnca en street 1- 4 BRAKE ELUID: ========0n20a0uamenaa a en amis vs sass suas ss ssa sans 1- 4 ÉRONT FORK OIL wise ee anne ennemie DA 1- 4 BREAK-IN PROCEDURES --<<<<<<<<<-<<<<<<<<<+++srscrerana uen nana nana na ana na na ana n 1- 4 INFORMATION LABELS veoemennenncenseeseecnnsenannÜnäna anses 1- 5 SPECIFICOR TION S emasmenmenmen nee ae ee re EEE 1- 7 COUNTRY OR AREA ---->-------<-----<-".<<<<<+0<rrrrrnenranantnea nan ea a an sara nacre 1- 9 1-1 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 atten- tion to the messages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. | À CAUTION | 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 WARNINGS 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 ex- perienced 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 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 gasoline as a cleaning solvent. * To avoid 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 1-2 A CAUTION | * |f parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. e Be sure to use special tools when instructed. e 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 use the specified type. * When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures not require use of bat- tery power, disconnect the negative cable the battery. * Tighten cylinder head and 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, be- fore 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 larg- er 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. e Do not use self-locking nuts a few times over. * Use a torque wrench to tighten fastners 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: batter- ies, and tires. * To protect Earth's natural resouces, properly dispose of used vehicles and parts. 1-3 GENERAL INFORMATION SUZUKI DR650SET ('96-MODEL) RIGHT SIDE LEFT SIDE *Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) (1) is stamped on the right side of the steering head pipe. The engine serial number (2) is located on the left side of the crankcase. FUEL AND OIL RECOMMENDATION FUEL (For U.S.A. model) 1. Use only unleaded gasoline of at least 87 pump octane ( rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above. FUEL (For Canadian model) Use only unleaded gasoline of at least 87 pump octane by the research method. FUEL (For the other models) Gasoline used should be graded 85—95 octane (Research Method) or higher. An unleaded gasoline type is recommended. R+M 5 ) method or 91 octane or higher ¿REM 5 ) method or 91 octane or higher rated GENERAL INFORMATION 1-4 ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE | | | | | | 4 MOTOR OIL or an oil which is rated SE, SF or SG under 20W-50 the API (American Petroleum Institute) classification system. MULTIGRADE ERY 10 15W-50 The viscosity rating is SAE 10W/40. If an SAE 10W/40 mo- PAR EL la oA tor oil is not available, select an alternate according to the right chart. TEMP E | 30-20-10 0 16 20 30 40 | °F | -22 -4 14 32 50 68 86 104 ENGINE OIL (For the other models) Make sure that the engine oil you use comes under API clas- sification of SE, SF or SG and that its viscosity rating is SAE 10W/40. If an SAE 10W/40 motor oil is not available, select an alternate 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 manufac- turer, 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 # 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 sub- jecting the engine to maximum stresses. The future performance and reliability of the engine de- pends on the care and restraint exercised during its early life. The general rules are as follows. e Keep to these break-in procedures: Initial 800 km ( 500 miles): Less than 1/2 throttle Up to 1 600 km (1 000 miles): Less than 3/4 throttle * Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. * Do not maintain constant engine speed for an extended time period during any portion of the break- in. Try to vary the throttle position. 1-5 GENERAL INFORMATION INFORMATION LABELS |.D. plate Safety label (For E-03, 28, 33) (For E-28) LH VIEW Manufacturer plate (For European markets) Engine starting label Right knuckle cover Warning safety label Engine idle speed label Brake approval label (For E-02, 21, 22, 34, 53) Regulation approval label (For European markets) RH VIEW Starter motor Seat VIEW LH Fuel tank Vacuum hose routing diagram label (For E-33) Rear fender Manual notice label GENERAL INFORMATION 1-6 Fuel tank Noise information label (For E-21, 24, 34, 53) |.D. label RH VIEW Tire air pressure label 7 Swingarm pivot \ Swingarm 1-7 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............eeeeeerersirererreorereece a A. 2 345 mm (92.3 in) ..... E18, 22 2 325 mm (91.5 in) ..... E18, 22 (Low seat) 2 255 mm (88.8 in) ..... Others 2 235 mm (88.0 in) ..... Others (Low seat) Overall dtl conaan nes 865 mm (34.1 in) Overall Melglttu==== Rar esp 1 205 mm (47.4 in) 1 165 mm (45.9 in) ..... (Low seat) Wheelbase............eeeeee£sscsircorieceeeeeeeererecc 1 490 mm (58.7 in) 1475 mm (58.1 in) ..... (Low seat) Ground clearance..….….….......…..…..essssssansanennu00 265 mm (10.4 in) 225 mm ( 8.9 in) (Low seat) Seat helahif ue aa EE 885 mm (34.8 in) 845 mm (33 in) ..... (Low seat) Dry: TITS hno SE Ga 147 kg (324 lbs) ENGINE ТОВ N БОРН Four-stroke, air-cooled, with SACS, OHC Valve clearance (IN) ..........eeeeenereceecrececrree 0.08—0.13 mm (0.003—0.005 in) (EN) ueno o 0.17—0.22 mm (0.007 —0.009 in) Number oF eYINAEers..c wmv 1 BONE .........eeecccsrrecorecorercossoseoaaer er eee eeoo ere 100 mm (3.937 in) Stroke ...........eeeoñrecccaearereereeerconereoreece nec ec Ns 82 mm (3.228 in) Piston displacement...............—..e.ermeevereeerereno. 644 cm? (39.3 cu. in) Compression ral: ==. ETES 9.5 : 1 CEO N BST40, single BUT BBE vows sm sims vi seis Polyurethane foam element Starter system ..…...........rrrrrsraa annee nn a anne nee Electric Lubrication system..….…..........….….…rrrsrcc can sans Wet sump TRANSMISSION CIUTEN resta TETE ET TE Wet multi-plate type Transmission b-speed constant mesh Gearshift pattern ….….……….…..........ssseeserrennnens 1-down, 4-up Primary reduction ratio .............e...reevvccercccóo 2.178 (61/28) Gear ratios, LOW...........eerresevrrvrreaoreecerecec 2.416 (29/12) ИК SN 1.625 (26/16) BE area e enn 1:238 (26/21) TT 1.000 (21/21) TOP viaria 0.826 (19/23) Final reduction ratio... 2.800 (42/15) ..... EO3,28,33 2.733 (41/15) Others Drive chain ..............eerrrccerricecen e eee ee e AD DID525 V9, 110 links CHASSIS Front suspension ...........eeeeceeaaarrreaaaraee Rear Suspension ........w..—.eeesrresssrrercacoreeemeece. Turn a sh on ms oe se a 2 Front: brake cusses senses Rear brake ............eeeoreeccccceoecoserececsrereoece ee, Front tire SIZe...........e.._._r_eeeeerecsorereerrrrre ce END. Rear tire [email protected] ana naa anna nan nana ana nu une ELECTRICAL lgnition TYPE vices Ignition timing ............. Spark plug .............e.... Battery .......... — e eeecsccora Generator ............—.—.—.... Meade ree. Parking or city light...... Turn signal light .......... Tail/brake light ............ License plate light........ Speedometer light........ Neutral indicator light... EAT High beam indicator lghU-==-===> as Turn signal: indicator Hght esse rer so CAPACITIES Fuel tank, including reserve ...............ee..eev... reserve ......... Engine oil, oil change... @ ® CA A CN 8 with filter change................eeoeee. overhaul...... GENERAL INFORMATION 1-8 Telescopic, coil spring, oil damped Link type, coil spring, gas/oil damped, spring pre-load fully adjustable, compression damping force adjustable 260 mm (10.2 in) 220 mm ( 8.7 in) ..... (Low seat) 260 mm (10.2 in) 220 тт ( 8.7 in) ..... (Low seat) 43° 28” 30 111 mm (4.37 in) 2.5 m (8.2 ft) Disc brake Disc brake 90/90-21 545, tube type 120/90-17 64S, tube type Electronic ignition (CDI) 10° B.T.D.C. at 1 500 rpm NGK CR10E or NIPPONDENSO U31ESR-N 12V 28.8 kC (8 Ah)/10 HR Three-phase A.C. generator 30/10/10A 12V 60/55W 12V 4W ..... except EO3, 24, 28, 33 12V 21W 12V 5/21W 12V 5W 12V 3W 12V 2W 12V 2W 12V 2W 12.0 L (3.2/2.6 US/Imp gal) ..... E33 13.0 L (3.4/2.9 US/Imp gal) ..... Others 3.0 L (0.8/0.7 US/Imp gal) 2 300 ml (2.4/2.0 US/Imp qt) 2 400 ml (2.5/2.1 US/Imp qt) 2 600 ml (2.7/2.3 US/Imp qt) 565 ml (19.1/19.9 US/Imp oz) 563 ml (19.0/19.8 US/Imp oz) ..... (Low seat) 1-9 GENERAL INFORMATION COUNTRY OR AREA The series of symbols on the left stand for the countries or area on the right. SYMBOL COUNTRY or AREA E-02 E-03 E-04 E-15 E-16 E-17 E-18 E-21 E-22 E-24 E-25 E-28 E-33 E-34 37 E-39 E-53 U.K. U.S.A. France Finland Norway Sweden Switzerland Belgium Germany Australia Netherlands Canada California (U.S.A.) Italy Brazil Austria Spain E-21 and 53 countries are included in E-34. (E: 5 and 16 countries are included in ca.) E-39 country is included in E-18. PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE :----=--========v===0r0r0s00eaeaernenanas 2- 1 PERIODIC MAINTENANCE CHART -------=-====0=e=e000reserereererenerererees 2- 1 LUBRICATION POINTS :«svvsvivsorvisniimsmisisiss sine is sass sos sass ans 2. 2 MAINTENANCE AND TUNE-UP PROCEDURES ----=-=====--..=eem22==..... 2- 3 VALVE CLEARANCE ----<"<"<<<<<<<<<<<rrrreronsenensensrsan ana nan ae nan an den a ne nan 2- 3 PARC BPEUIGS: vos swswmmcovssnimimmrsnssnesn ons asd sass ys does sa sesso dives 2. 4 AIR CLEANER ELEMENT =====>v===001 20500 AENA AAA 2. 5 CARBURETOR: EEE EL 2- 6 FUEL LINE --<-<<<<<<<<<<<<.+ccarecensancana era na are na ne aan nana ana nana ana nana na ae annee D 7 FUEL VALVE STRAINER ie DEE 2- 7 COUT CIS venant ae TE A EEE 2- 7 ENGINE OIL AND OIL FILTER ----..............0..0.00000000000miiner e AA 2- 8 DRIVE CHAIMN E 2; 9 BRAKES viveconemenenneennennne otage NeEE 2-10 TIRES conor sts ems so rs EE EE ER ERA AU 2.12 SPARK ARRESTER -+-"<"<<…<<<<<<<…<.rrecrrsarrennenennanen ana ne nan na nan annee nee 2-13 BTEERINIG: «»ssusewsscsssrsossisrnesssusossrisssssicns os sessions sis emis a 9dr wa i's 2-13 FRONT FORKS 2252 mn nee Eee ET 2-14 REAR SUSPENSION --<"<<<<<<<<<<.<....…..++<rrrereranaanaannansa nana ne a naar aa annee 2-14 EXHAUST PIPE AND MUFFLER BOLTS ----============0caaararaneanenaneoo 2-14 CHASSIS BOLTS AND NUTS --...........ce22100000000ir0iici en ee A 2-15 COMPRESSION PRESSURE CHECK <-<"<""<"…<<0<00mc mc cr rrc nr renn ren nana nanas 2-17 2-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle. The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART INTERVAL: km 1 000 | 6 000 [12 000 | 18 000 | 24 000 PP DOMETER READING OR GED | miles 600 | 4000 | 7 500 | 11 000 | 15 000 MONTHS WHICHEVER COMES FIRST | months 2 12 24 36 48 Valve clearance | — | — | Spark plugs — | В | В Air cleaner element Clean every 3 000 km (2 000 miles). Carburetor idle rpm | | | | | Fuel line | | | | | (ЕМАР hose ... California model only) Replace every 4 years. Fuel valve strainer — — C — C Clutch | | | | | Engine oil R R R R R Engine oil filter R — R R | | | | | Drive ела Clean and lubricate every 1 000 km (600 miles). Brakes | | | | | — | | | | Brake hase Replace every 4 years. — | | | | Brake fluid a every LL Tires - | 1 | 1 | 1 | Spark arrester Clean every 6 000 km (4 000 miles). (For Canada and U.S.A.) Steering | — | — | Front forks — — | — | Rear suspension — — | — | Exhaust pipe and muffler bolts T — T — T Chassis bolts and nuts T T T T T NOTE: |: Inspection and adjust, clean, lubricate or replace as necessary. R: Replace T: Tighten C: Clean PERIODIC MAINTENANCE 2-2 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. Clutch lever holder and clutch cable su q LA MEM Side-stand pivot = and spring hook Drive chain Ff Throttle cable “Ef Brake lever holder ACH Brake pedal pivot NOTE: * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions. If the spray is unavailable, use either motor oil or grease. * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. 2-3 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. VALVE CLEARANCE Inspect Initially at 1 000 km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) thereafter. The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjust- ed, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is dis- turbed by removing it for servicing. Valve clearance (when cold): IN.: 0.08—0.13 mm (0.003—0.005 in) EX.: 0.17-0.22 mm (0.007 —0.009 in) NOTE: Valve clearance is to be checked when the engine is cold. Both intake and exhaust valves must be checked and ad- justed when the piston is at Top — Dead — Center (TDC) on the compression stroke. e Remove the frame covers, seat and fuel tank. e Remove the spark plug and valve inspection caps, intake and exhaust. e Remove the valve timing inspection plug and magneto cover cap. * Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke. (Turn the crankshaft until the “T” line (1) on the magneto rotor is aligned with the center of hole on the magneto cover.) e Insert the thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm. 09900-20803: Thickness gauge 09917-14910: Valve clearance adjusting driver * |f clearance is out of the specification, bring it into the specified range. e Securely tighten the lock nut after adjustment is com- pleted. | А CAUTION | Both right and left valve clearances, should be as closely set as possible. * Reinstall the spark plug, valve inspection caps, valve tim- Ing inspection plug and magneto cover cap. PERIODIC MAINTENANCE 2-4 SPARK PLUGS Inspect Every 6 000 km (4 000 miles, 12 months) and Replace Every 12 000 km (7 500 miles, 24 months). * Remove the spark plugs. 09930-10121: Spark plug socket wrench set Standard Hot type NGK CR10E CR9E ND U31ESR-N U27ESR-N CARBON DEPOSIT Check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. SPARK PLUG GAP Measure the plug gap with a thickness gauge if it is correct. If not, adjust it to the following gap. Standard Spark plug gap 0.7—0.8 mm (0.028—0.031 in) 09900-20803: Thickness gauge | | с ) ELECTRODE'S CONDITION Check to see the worn or burnt condition of the electrodes. e НН e Y ———ZZ£ -Ñ — — =£ If it is extremely worn or burnt, replace the plug. And also — replace the plug if it has a broken insulator, damaged thread, ho in) etc. | A CAUTION | Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result. Aia A Me A de 2-5 PERIODIC MAINTENANCE AIR CLEANER ELEMENT Clean Every 3 000 km (2 000 miles). If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. * Remove the left frame cover. * Remove the air cleaner case cover by removing screws (1). * Remove the air cleaner element by removing its support screw (2). e Remove the polyurethane foam element (3) from the ele- ment frame (4). * Fill a washing pan of a proper size with non-flammable cleaning solvent. Immerse the element in the cleaning sol- vent and wash it clean. * Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands. e Immerse the element in motor oil, and squeeze the oil out of the element leaving it slightly wet with oil. NOTE: Do not twist or wring the element because it will tear or the individual cells of the element will be damaged. A CAUTION | Inspect the element carefully for rips, torn seams, etc. If any damage is noted, replace the element. ¢ Reinstall the cleaned or new cleaner element in the reverse order of removal. * When installing the air cleaner element in the cleaner case, make sure that the “UP” mark comes upward. A CAUTION | If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to acceler- ate engine wear is to use the engine without the ele- ment 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! Non-flammable cleaning solvent $ NOTE: When you clean the air cleaner element, drain water from the air cleaner drain hose by removing the drain plug. PERIODIC MAINTENANCE 2-6 CARBURETOR Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. THROTTLE CABLE ADJUSTMENT A twin throttle cable system is used in this motorcycle. Ca- ble (1) is for pulling and cable 2) is for returning. To adjust the cable play, adjust the returning cable first and then ad- just the pulling cable. Returning cable play The returning cable should be adjusted to have a thread length @ of 3—4 mm (0.12—0.16 in) as shown in the Fig. If the adjustment is necessary, adjust the thread length in the following way: * Loosen the lock nuts (3). * Move the adjuster (4) to obtain the thread length 4) of 3—4 mm (0.12—0.16 in). e Tighten the lock nuts (3) securely. Pulling cable play The pulling cable should be adjusted to have a cable play ® of 0.5—1.0 mm (0.02—0.04 in) as shown in the Fig. If the adjustment is necessary, adjust the cable play in the fol- lowing way: * Turn the handlebar all the way to the left. * Loosen the lock nuts ((5), (©). * Turn the adjuster (7) or move the adjuster (8) to obtain the cable play Bof 0.5—1.0 mm (0.02—0.04 in). * Tighten the lock nuts ((5), (6)) securely. A WARNING After the adjustment is completed, check that handle- bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automat- ically. IDLE RPM ADJUSTMENT NOTE: Make this adjustment when the engine is warm. *e Connect a tachometer. 09900-26006: Tachometer * Start up the engine and set its speed at anywhere between 1 400 and 1 600 r/min by turning the throttle stop screw (1). e Turn in or out the pilot screw within 1/2 turn from the standard setting, and set it when the engine speed is at the highest possible level. e After previous adjustment, recheck the idling speed and adjust to between 1 400 and 1 600 r/min with throttle stop screw If necessary. Engine idle speed: 1500+ 50 r/min ... for Switzerland 1 500 + 100 r/min ... for the Others 2-7 PERIODIC MAINTENANCE FUEL LINE (EVAP HOSE ... California model only) и Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. Replace Every 4 years. FUEL VALVE STRAINER Clean Every 12 000 km (7 500 miles, 24 months). Refer to page 4-2 for removal procedure. CLUTCH Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. * Loosen the lock nut (1) and turn the clutch cable adjuster (2) fully in. e Loosen the lock nut (3) and turn the clutch cable adjuster (4) to provide the specified clutch lever play @. Clutch lever play A): 10—15 mm (0.4—0.6 in) e Tighten the lock nuts ((1) and (3) while holding the ad- justers (2) and (2) in positions. NOTE: Minor adjustment can be made by the adjuster (2) after loosening the lock nut (1). At the same intervals, lubricate the clutch cable with motor oil ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace (Change) Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace Initially at 1 000 km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) thereafter. Oil should be changed while the engine is warm. Qil filter replacement at the above intervals should be done together with engine oil change. * Keep the motorcycle upright, supported by jack or woo- den block. * Place an oil pan below the engine and remove the engine oil drain plug (1) and oil filler cap (2) to drain engine oil. * Remove the oil filter cap by removing the three bolts (3). * Remove the oil filter (4) and install the new one. * Install the oil filter cap and tighten the bolts (3) securely. NOTE: Before installing the oil filter and oil filter cap, check to be sure that the spring (5) and new O-rings (6) and (7)) are in- stalled correctly and apply engine oil lightly to the new O- ring (6). * Tighten the oil drain plug (1) securely, and pour fresh oil through the oil filler. The engine will hold about 2 300 ml of oil. Use an API classification of SE, SF or SG oil with SAE 10W/40 viscosity. [®] Drain plug: 24 N-m (2.4 kg-m, 17.5 Ib-ft) * Install the oil filler cap 2). e Start up the engine and allow it to run for several minutes at idling speed. * Turn off the engine and walt about one minute, then check the oil level through the inspection window (8). If the lev- el is below mark ‘’F’’, add oil to the level. NECESSARY AMOUNT OF ENGINE OIL Oil change : 2 300 ml (2.4/2.0 US/Imp qt) Filter change : 2 400 ml (2.5/2.1 US/Imp qt) Overhaul engine: 2 600 ml (2.7/2.3 US/Imp qt) PERIODIC MAINTENANCE 2-8 2-9 PERIODIC MAINTENANCE DRIVE CHAIN Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. Clean and Lubricate Every 1 000 km (600 miles). Visually check the drive chain for the possible defects list- ed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the trans- mission shifted to Neutral.) * Loose pins * Excessive wear * Damaged rollers * Improper chain adjustment * Dry or rusted links * Missing O-ring seals * Kinked or binding links If any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set. CHECKING e Remove the axle cotter pin (Canada and U.S.A). e Loosen the axle nut (1) . e¢ Tense the drive chain fully by turning both chain adjusters (2). e Count out 21 pins (20 pitches) on the chain and meas- ure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Service Limit Drive chain 20-pitch length 319.4 mm ; 123 19 20 21 (12.6 in) À oYo oYo ole xo oXo ojo oYo oXo olo eX ADJUSTING =} — be e Turn both chain adjusters (2) until the chain has 30—45 CT o mm (1.2— 1.8 in) of slack in the middle between engine \ and rear sprockets. The number on both chain adjusters must be at the same number on the scale to ensure that the front and rear wheels are correctly aligned. * Place the motorcycle on its side-stand for accurate ad- justment. e After adjusting the drive chain, tighten the axle nut (1) to the specified torque. W Rear axle nut: 100 N-m (10.0 kg-m, 72.5 Ib-ft) (with cotter pin) Rear axle nut: 110 N-m (11.0 kg-m, 79.5 Ib-ft) (Self-locking) PERIODIC MAINTENANCE 2-10 CLEANING AND LUBRICATING e \Wash the chain with kerosene. If the chain tends to rust quickly, the intervals must be shortened. | À CAUTION | Do not use trichlene, gasoline or any similar fluids: These fluids have too great a dissolving power for this chain and, what is more important, they can damage the “O “-rings (or seals) confining the grease in the bush to pin clearance. Remember, high durability comes from the presence of grease in that clearance. * After washing and drying the chain, oil it with a heavy- weight motor oil. A CAUTION | * Do not use any oil sold commercially as ‘“drive chain oil”. Such oil can damage the “O” -rings (or seals). * The standard drive chain is D.I.D. 525 Vs, 110 links. SUZUKI recommends that this standard drive chain should be used for the replacement. BRAKES (BRAKE) Inspect Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect Every 6 000 km (4 000 miles, 12 months). Replace hoses Every 4 years. Replace fluid Every 2 years. BRAKE FLUID LEVEL * Keep the motorcycle upright and place the handlebars straight. e Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. * When the level is below the lower limit line, replenish with brake fluid that meets the following specification. Specification and Classification: DOT 4 A WARNING The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum- based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period. A WARNING Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. 2-11 PERIODIC MAINTENANCE BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line (1) on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (Refer to pages 5-7 and 5-34.) A CAUTION | Replace the brake pad as a set, otherwise braking per- formance will be adversely affected. BRAKE PEDAL HEIGHT e Loosen the lock nut (3) and rotate the push rod (4) to lo- cate brake pedal 5 mm below the top face of the footrest. e Retighten the lock nut (3) to secure the push rod (4) in the proper position. Brake pedal height 4): 5 mm (0.2 in) AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by ‘’sponginess’’ of the brake lever and also by lack of brak- ing force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after re- mounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner: e Fill up the master cylinder reservoir to the “UPPER” line. Replace the reservoir cap to prevent entry of dirt. * Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. (8) Air bleeder valve: 8 N-m (0.8 kg-m, 6.0 Ib-ft) * Front brake: Bleed the air from the air bleeder valve. * Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer con- tains air bubbles. NOTE: Replenish the brake fluid in the reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir. * Close the bleeder valve, and disconnect the pipe. Fill the reservoir with brake fluid to the “UPPER” end of the in- spection window. A CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. * The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. TIRES PERIODIC MAINTENANCE 2-12 Inspect Every 6 000 km (4 000 miles, 12 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a danger- ous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. Tire tread depth limit: FRONT & REAR 3.0 mm (0.12 in) 2-13 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, main- tain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows. COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE | kPa |kg/cm?| psi | kPa |kg/cm?| psi FRONT 150 | 1.50 | 22 175 | 1.75 | 25 REAR 175 | 1.75 | 25 200 | 2.00 | 29 | À CAUTION The standard tire fitted on this motorcycle is 90/90-21 54S for front and 120/90-17 64S for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. SPARK ARRESTER (For U.S.A. and CANADA) Clean Every 6 000 km (4 000 miles). If the muffler is clogged with carbon particles, exhaust resistance will be increased with a resultant decrease in pow- er output. e* Remove the drain plugs. e Start the engine and rev it to blow out the accumulated carbon particles. * Turn off the engine and wait until the muffler cools, then replace the drain plugs and tighten them securely. STEERING Inspect Initially at 1 000 km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) thereafter. Taper roller type bearings are used on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, perform steering bearing ad- justment as described in page 5-20 of this manual. FRONT FORKS Inspect Every 12 000 km (7 500 miles, 24 months). Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defec- tive parts, if necessary. (Refer to page 5-14.) REAR SUSPENSION Inspect Every 12 000 km (7 500 miles, 24 months). Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm assembly. EXHAUST PIPE AND MUFFLER BOLTS Tighten Initially at 1 000 km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) thereafter. * Remove the right frame cover. * Tighten the exhaust pipe bolts (1), muffler connection bolt (2) and muffler bolts (3) to the specified torque. W Exhaust pipe bolt/Muffler connection bolt/ Muffler bolt: 26 N-m (2.6 kg-m, 19.0 Ib-ft) PERIODIC MAINTENANCE 2-14 2-15 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten Initially at 1 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-16 for the locations of the following nuts and bolts on the motorcycle.) Item N-m kg-m Ib-ft (1) Steering stem head nut 90 9.0 65.0 (2) Front fork upper clamp bolt 29 2.9 21.0 (3) Front fork lower clamp bolt 26 2.6 19.0 (4) Front fork cap bolt 23 2.3 16.5 (5) Front axle 65 6.5 47.0 (6) Front axle holder nut 10 1.0 7:0 (7) Handlebars clamp bolt 23 2.3 16.5 Front brake master cylinder mounting bolt 10 1.0 7.0 (9) Front brake caliper mounting bolt 26 2.6 19.0 Front brake caliper pad mounting bolt 18 1.8 15:0 (1D Brake hose union bolt (Front & Rear) 23 2.3 16.5 (2 Air bleeder valve (Front & Rear) 8 0.8 6.0 (13 Brake disc bolt (Front & Rear) 23 2.3 16.5 Rear brake caliper pad mounting bolt 18 1.8 13.0 (5) Rear brake master cylinder mounting bolt 10 1.0 7.0 Rear brake master cylinder rod lock nut 18 1.8 13.0 (7) Front footrest bracket mounting bolt 39 3.9 28.0 Rear footrest bracket mounting bolt 23 2.3 16.5 Swingarm pivot nut 77 " 55.5 oar Shock absorber mounting bolt 55 ББ 40.0 @i) Rear cushion lever/rod mounting nut 100 10.0 72.5 @) Rear cushion lever mounting bolt 80 8.0 58.0 @) Rear axle nut (with cotter pin) 100 10.0 72.5 Rear axle nut (Self-locking) 110 11.0 79.5 25 Rear sprocket nut/bolt 27 2.7 19.5 PERIODIC MAINTENANCE 2-16 2-17 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each main- tenance service. COMPRESSION PRESSURE SPECIFICATION Standard 850 kPa Approx. (> "уч 120 psi Low compression pressure can indicate any of the following conditions: * Excessively worn cylinder wall * Worn-down piston or piston rings * Piston rings stuck in grooves * Poor seating of valves * Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE: * Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. * Have the engine warmed up by idling before testing. * Be sure that the battery used is in fully-charged condition. Remove the parts concerned and test the compression pres- sure in the following manner. * Remove the spark plug. * Fit the compression gauge in the plug hole, while taking care that the connection tight. e Keep the throttle grip in full-open position. ¢ While cranking the engine a few seconds with the start- er, and record the maximum gauge reading as the com- pression of that cylinder. Tool] 09915-64510: Compression gauge 09915-63310: Adaptor PERIODIC MAINTENANCE 2-18 OIL PRESSURE CHECK Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 30 kPa (0.3 kg/cm?, 4.3 psi) ; ; 5 о Below 70 kPa (0.7 kg/cm?, 10 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE * Oil leakage from the oil passage way * Damaged O-ring * Defective oil pump * Combination of above items HIGH OIL PRESSURE * Used a engine oil which is too high viscosity * Clogged oil passage way * Combination of above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner. e Remove the oil pressure inspection plug. e Install the oil pressure gauge in the position shown in the figure. e Warm up the engine as follows: Summer 10 min. at 2 000 r/min. Winter 20 min. at 2 000 r/min. e After warming up, increase the engine speed to 3 000 r/min. (with the engine tachometer), and read the oil pres- sure gauge. =) 09915-74510: Oil pressure gauge 09900-26006: Tachometer ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IKE PLA CE samosas oy es ey ps As EEE aaa Ke 3. 1 ENGINE REMOVAL AND REINSTALLATION ---------====———wene2nenenene—. 3- 2 ENCINE REMOVAJ, ====—.— 0... en oss vss eam sms sss 3- 2 ENGINE REINSTALLATION creuses ane ae as ce 3- 6 ENGINE DISASSEMBLY comme svi itis misses CARRIERE 3- 9 ENGINE COMPONENTS INSPECTION AND SERVICE ----=-=-===.=.....- 3-17 CYLINDER HEAD COVER -----------.---.......000000rveriiriceoi ei o ne e 3-17 ROCKER ARM ===... ——— a NES UE 3-18 CYLINDER HEAD ====200nua naaa IA IED Ns 3-19 VAL VE Gere rennen EEE 3-20 CAMSHAFT/AUTOMATIC DE-COMP. ASSEMBLY ee 3-25 CYLINDER aie annee aie sa a à a ae NA S08 2-97 PISTON creme Er ES Fa Eo EE SN EE ER La ER A es 3-27 PISTON BRINC :=::2===v=2202:002: 60.2 00ince nea enprne eee aa ANA 3-28 CONROD MO 3-29 CRANK SHAEFT emmm uN ENEE ЛаН 3-30 BALANCERSHAFT AND GEAR -----=====<===rerereraaaarrrararereoeeaeeoeeeecene 3-31 ELUTECES vos sims vp sy ED NIE ii. 2.32 STARTER CLUTCH ---"<<<<<<<<<<><<cersecrrrseranan nana ana nana na na nanas nana nan nee 3-34 TRANSMISSION ----..................0.00.00000000000ri0iii ri cer e ree er na neue 3-36 OE NOZZLE AND DIL JET ivresse ea ge aa ANNE 3-40 CRANKCASE BEARINGS: urine scien aves sas oro yas 3-40 0718 710 y 7 - MES 3-41 6] 11-1:7:050)- MES 3-41 ENGINE BEASSEMBLY ========0===00=0000=0000menan us via coy 3-42 3-1 ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE CENTER Refet to page Cam drive chain tensioner ................... 3- 9 and 57 Cylinder head gover ve 3-10 and 56 Camshaft/auto-decompression ............. 3-10 and 55 Cylinder head .............eeeeevvesriii0a0 00 em 3-10 and 54 Cylinder ooo rare nan eee 3-11 and 54 PiStON ee DD. 3-11 and 53 otarter MULON ¡cm armen sa Sey 3-11 and 52 Cam drive CNAINT arrete 3-14 and 48 ENGINE LEFT SIDE Refer to page Engine sprocket are 3- 5 and Generator cover ..….….…....……………..……. . 3- 9 and Starter torque limiter ............... 3-11 and Starter idle gear ..................... 3-11 and Generator rotor .........._.eeeereesve 3-11 and Starter СМИ cuac Eras 3-34 and Starter qedl rarement 3-12 and Gearshift shaft ....................... 3-13 and Gearshift cam pawl and cam driven gear ..........eeee.eesererrececo 3-13 and 7 52 52 52 51 35 51 47 46 ENGINE RIGHT SIDE Refer to page CUECA COVE soccer 3-13 and 50 Clutch eee 3-13 and 49 Primary driven gear ................. 3-14 and 49 Primary drive gear .................. 3-14 and 48 Oil pump driven gear ............... 3-14 and 48 Oil pump assembly ................. 3-14 and 48 Neutral position indicator SWItCh iii 3-14 and 47 Oil filter ee 3-41 ENGINE 3-2 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained in the following steps: e Remove the oil drain plug (1) to drain out engine oil. ® Remove the frame covers. (Refer to page 5-1.) * Remove the seat. (Refer to page 5-1.) Remove the battery holder plate (2). e Disconnect the battery © lead wire (3) from the battery terminal. e Remove the fuel tank. (Refer to page 4-3.) * Remove the oil cooler hose mounting bolts. ® Remove the oil cooler holder with cooler by removing the mounting bolts. 3-3 ENGINE e Remove the exhaust pipe bolts. * Remove the exhaust pipe by loosening the connection bolt. e Disconnect the pick-up coil/power source coil lead wire coupler (1). ¢ Disconnect the generator coil and neutral position indi- cator switch lead wires. e Disconnect the spark plug caps. ENGINE 3-4 e Disconnect the throttle cables and starter (choke) cable. e Disconnect the air vent hose. ® Remove the carburetor by loosening the mounting clamp screws. e Disconnect the clutch cable by removing the cable lever. e Disconnect the starter motor lead wire (1) and crankcase breather hose (2). e Remove the left front footrest (3). Remove the engine sprocket cover 4) and gearshift lever (5) 3-5 ENGINE * Remove the engine sprocket bolts while depressing the rear brake pedal. e Remove the engine sprocket. NOTE: If it is difficult to remove the engine sprocket, loosen the rear axle nut and then adjust the chain adjusters to provide additional chain slack. e Remove the engine ground wire and lead wire clamp. * Remove the engine mounting nuts, bolts, spacers and brackets. * Remove the engine through the left side of the frame. ENGINE 3-6 ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. e Insert the two long bolts from left side. Install the brackets, spacers, bolts and nuts properly, as shown in the following illustration. NOTE: The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts and tighten them to the specified torque. [9] LENGTH ITEM N-m kg-m Ib-ft Bolt (1) 53 mm (2.1 in) O 40 4.0 29.0 Bolt ©) 100 mm (3.9 in) BOB 65 6.5 47.0 Bolt (3) 235 mm (9.3 in) DO 40 4.0 29.0 Bolt @ 235 mm (9.3 in) B 23 2.3 16.5 Bolt (5) 130 mm (5.1 in) Spacer (6) 27 mm (1.1 in) Spacer (7) 65 mm (2.6 in) 3-7 ENGINE * Apply THREAD LOCK SUPER “1303” to the engine sprocket mounting bolts and tighten them to the speci- fied torque. 99000-32030: THREAD LOCK SUPER “1303” W Engine sprocket bolt: 6 N-m (0.6 kg-m, 4.5 Ib-ft) * Install the oil cooler hoses to the clutch cover and cylinder head correctly. A CAUTION | Replace the O-rings (1) with new one to prevent oil leakage. * Tighten the oil cooler hose securing bolts to the speci- fied torque. [®] oil cooler hose bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) e Tighten the front footrest bolts to the specified torque. [®] Front footrest bolt: 39 N-m (3.9 kg-m, 28.0 Ib-ft) * After remounting the engine, route the wiring harness- es, cables and hoses properly by referring to the sections, for wire routing, cable routing and hose routing. (Refer to pages 7-12 through 7-18.) ENGINE 3-8 e Adjust the following items to the specification. * Throttle cable play ................. (Refer to page 2-6.) * ding adjustment «==... (Refer to page 2-6.) * Clutch cable play ................... (Refer to page 2-7.) * Drive chain slack ..............e..... (Refer to page 2-9.) e Pour 2.6L {2.7/2.3 US/Imp qt) of engine oil SAE 10W/40 graded SE, SF or SG into the engine after overhauling engine. * Start up the engine and allow it run for several minutes at idle speed. About five minutes after stopping engine, check oil level. If the level is below the ‘’F’” mark, add oil until the level reaches the ‘’F’’ mark. Change 2 300 ml (2.4/2.0 US/Imp qt) Filter change 2 400 ml (2.5/2.1 US/Imp qt) Overhaul 2 600 ml (2.7/2.3 US/Imp qt) 3-9 ENGINE ENGINE DISASSEMBLY * Remove the oil pipe by removing the mounting bolts. * Remove the cam drive chain tensioner by removing the bolts. * Remove the two spark plugs. * Remove the generator cover by removing the bolts. NOTE: When removing the cylinder head cover, the piston must be at top dead center on the compression stroke. Align “TOP” line (1) on the generator rotor with index mark (2) on the crankcase. e Remove the valve inspection caps (Intake and Exhaust) by removing the bolts. * Loosen the cylinder head cover bolts in the ascending ord- er numbers and remove the cylinder head cover. e Flatten the lock washer and remove the camshaft sprocket bolts. ¢ Remove the sprocket and camshaft/auto-decompression assembly. NOTE: The cam chain tensioner bolt (0) is to be removed only when disassembling the engine. A CAUTION | Do not drop camshaft drive chain, pin, C-ring or sprock- et into the crankcase. ¢ Remove the cylinder head by removing the bolts and nuts diagonally. NOTE: If it is difficult to remove the cylinder head, gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer. Be careful not to break the fins. ENGINE 3-10 3-11 ENGINE * Remove the cylinder by removing the nuts. A CAUTION If tapping with a plastic hammer is necessary, do not break the fins. * Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into crankcase. Remove the piston pin circlips with a long-nose pliers. * Remove the piston by removing the piston pin. * Remove the clutch cable holder and starter motor. * Remove the starter torque limiter (1) and starter idle gear (2) with shaft. e Loosen the generator rotor bolt with the 36 mm offset wrench. NOTE: Do not remove the generator rotor bolt after loosening the bolt. The generator rotor bolt 1s used in conjunction with the rotor remover, when removing the generator rotor. * Remove the generator rotor with the special tool. 09930-33720: Rotor remover * Remove the key (1). * Remove the starter gear (2). * Remove the thrust washer (3). e Remove the ring nut with the special tools, then remove the spacer. 09917-23711: Ring nut socket wrench 09910-20116: Conrod holder * Remove the crankcase oil separator (4) by removing the screws. * Remove the spacer (5). * Remove the gearshift cover by removing the bolts. ENGINE 3-12 3-13 ENGINE e Extract the gearshift shaft (1) and remove the cam driven gear (2) by removing the screws (3). NOTE: When removing the cam driven gear, do not lose gearshift pawl 4), pin (8) and spring (©). ® Remove the clutch cover by removing the bolts. e Remove the clutch pressure plate by removing the bolts diagonally. e Remove the clutch drive and driven plates. ® Flatten the lock washer and remove the clutch sleeve hub nut with the special tool. 09920-53740: Clutch sleeve hub holder * Remove the thrust washer (1) and primary driven gear as- sembly. e Remove the thrust washer (2). * Remove the primary drive gear nut with the special tool. 09910-20116: Conrod holder | À CAUTION | This nut has left-hand thread nut. * Remove the cam drive chain (3) and key (4). * Remove the idle gear and oil pump driven gear by remov- ing the circlips. 09900-06107: Snap ring pliers * Remove the oil pump by removing the mounting screws. * Remove the breather cover. * Remove the neutral position indicator switch. NOTE: Do not loose the switch contact (5) and spring (6). ENGINE 3-14 3-15 ENGINE * Remove the crancase securing bolts. e Separate the crankcase into 2 parts, right and left with the crankcase separating tools. 09920-13120: Crankcase separating tool 09910-33210: Crankshaft installer attachment NOTE: Fit the crankcase separating tool, so that the tool plate is parallel with the end face of the crankcase. A CAUTION The crankshaft and transmission components must re- main in the right crankcase half. This is necessary be- cause the gearshift cam stopper is mounted on the right crankcase half and will be damaged if the transmission components remain in the left half. e Remove the gearshift cam stopper. e Remove the gearshift fork shafts and gearshift forks. e Remove the gearshift cam. * Remove the driveshaft assembly and countershaft as- sembly. ENGINE 3-16 * Align the punched marks on the balancer drive gear and driven gear. e Remove the balancershaft assembly. e Remove the crankshaft from the crankcase by using a crankshaft remover. 09920-13120: Crankshaft remover (Crankcase separating tool) e Remove the oil sump filter cover (1) by removing the bolts. e Remove the oil sump filter (2). 3-17 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD COVER SERVICE | À CAUTION | Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as ‘‘Ex- haust’’, “Inlet”, so that each will be restored to the original location during assembly. * Remove the intake and exhaust rocker arm shaft set bolts. * Remove the intake and exhaust rocker arm shafts with a 6 mm bolt. CYLINDER HEAD COVER DISTORTION After removing sealant from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge. Service Limit: 0.05 mm (0.002 in) If the distortion exceeds the limit, replace the cylinder head cover. ROCKER ARM SHAFT O.D. Measure the diameter of rocker arm shaft with a micrometer. Standard: 11.973— 11.984 mm (0.4714—0.4718 in) 09900-20205: Micrometer (0—25 mm) ROCKER ARM 1.D. When checking the rocker arm, the inside diameter of the rocker arm and wear of the camshaft contacting surface should be checked. Standard: 12.000—12.018 mm (0.4724 —0.4731 in) 09900-20605: Dial calipers ROCKER ARM AND SHAFT REASSEMBLY * Apply SUZUKI MOLY PASTE to the rocker arm shafts. АМН 99000-25140: SUZUKI MOLY PASTE * Install the rocker arms and shafts as shown in the illus- tration. * Tighten the rocker arm shaft set bolts (1) to the specified torque. [V)Set bolt 1): 28 N-m (2.8 kg-m, 20.0 Ib-ft) NOTE: Use new gasket on the set bolts (1). ENGINE 3-18 3-19 ENGINE CYLINDER HEAD SERVICE * Remove the cam chain tensioner by removing the bolt. e Compress the springs with the special tools. e Remove the valve cotters from the valve stem. 09916-14510: Valve spring compressor 09916-14910: Valve spring compressor attachment 09916-84511: Tweezers e Remove the valve spring retainer, inner spring and outer spring. * Remove the vlave stem from the other side. * Remove the oil seal with a long-nose pliers. * Remove the spring seat. NOTE: Removal of the valves completes ordinary disassembling Work. If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing. CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasketed surface of the cylinder head for distor- tion with a straightedge and thickness gauge, taking a clear- ance reading at several places as indicated. If the largest reading at any position of the straightege exceeds the limit, replace the cylinder head. Service Limit: 0.05 mm (0.002 in) VALVE FACE WEAR Measure the thickness (T) and, if the thickness is found to have been reduced to the limit, replace the valve. NOTE: Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. Service Limit: 0.5 mm (0.02 in) VALVE STEM RUNOUT Support the valve with “V”” blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. Service Limit: 0.05 mm (0.002 in) =) 09900-20701: Megnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block (100 mm) VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head, and measure the valve head radial runout. If it measures more than limit, replace the valve. Service Limit: 0.03 mm (0.001 in) VALVE STEM DEFLECTION Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the deflection in two directions, ‘X"’ and “Y” per- pendicular to each other, by positioning the dial gauge as shown. If the deflection measured exceeds the limit speci- fied below, then determine whether the valve or the guide should be replaced with a new one. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand Service Limit Intake and exhaust valves: 0.35 mm (0.014 in) ENGINE 3-20 3-21 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, when measured with a micrometer, where the clearance is found to be in excess of the limit indicated, replace the valve; if the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the clearance. 09900-20205: Micrometer (0—25 mm) Standard IN. : 5.475—5.490 mm (0.2156—0.2161 in) EX.: 5.455 —5.470 mm (0.2148—0.2154 in) VALVE GUIDE SERVICING e Remove the valve guide toward the camshaft side with the valve guide remover. 09916-44910: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement part. (Part No.11115-32E70.) e Re-finish the valve guide holes in cylinder head with the reamer (1) and handle (>). 09916-34580: Valve guide reamer 09916-34541: Reamer handle * Fit a ring to each vlave guide. Be sure to use new rings and valve guides. * Oil the stem hole, too, of each valve guide and drive the guide into the guide hole with the valve guide installer. 09916-44910: Valve guide remover/installer A CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head. e After fitting the valve guides, re-finish their guiding bores with the reamer (3) and handle (2). Be sure to clean and oil the guides after reaming. 09916-34550: Valve guide reamer 09916-34541: Reamer handle ENGINE 3-22 VALVE SEAT WIDTH * Coat the valve seat uniformly with Prussian blue. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lap- per to hold the valve head. ¢ The ring-like dye impression left on the valve face must be continuous-without any break. In addition, the width of the dye ring, which is the visualized seat “width”, must be within the specification. Standard Valve seat width W: 0.9—1.1 mm (0.035—0.043 in) If either requirement is not met, correct the seat by servic- Ing it as follows. VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are machined to two different angles. (The seat contact surface is cut 45°.) INTAKE EXHAUST 45° N-615 N-615 15° N-615 N-121 (For U.S.A.) Valve seat cutter (N-615) Valve seat cutter (N-121) Solid pilot (N-140-7.0) (For the Others) 09916-24900: Valve seat cutter set 09916-20610: Valve seat cutter (N-121) 09916-24210: Valve seat cutter (N-615) (N-140-7.0) : Solid pilot NOTE: The vlave seat contact area must be inspected after each cut. e Insert the solid pilot with a slight rotation, seat the pilot snugly. Install the 45° cutter and T-handle. * Using the 45” cutter, descale and clean up the seat with one or two turns. * Inspect the seat by the previously described seat width measurement procedure. If the seat is pitted or burned, additional seat conditioning with the 45° cutter is re- quired. NOTE: Cut the minimum amount necessary from the seat to pre- vent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle. Valve seat 3-23 ENGINE If the contact area is too high on the valve, or if it is too wide, use the 15° cutter to lower and narrow the contact area. If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. * After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up and burrs caused by the previous cutting operations. | À CAUTION | DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation. Contact area too high and too wide on face of valve W Contact area too low and too narrow on face of valve * Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. A WARNING Always use extreme caution when handling gasoline. NOTE: After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (Refer to page 2-3.) VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pit- ting or wear of the stem end face are present, the valve stem end should be resurfaced, providing that the length (1) will not be reduced to less than 2.7 mm (0.11 in). If this length becomes less than 2.7 mm (0.11 in), the valve should be replaced. After installing a valve whose stem end has been ground off as above, check to ensure that the face (2) of the valve stem end is above the cotters (3). VALVE SPRING The force of the coil spring keeps the valve seat tight. Weakened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. Check the springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit, or if the force required to compress the spring does not fall within the range specified, replace both inner and outer springs as a set. 09900-20102: Vernier calipers Valve spring free length Service Limit INNER : 34.4 mm (1.35 in) OUTER: 38.1 mm (1.50 in) Valve spring tension Standard INNER : 5.9—6.7 kg/27.5 mm (13.0— 14.8 Ibs/1.1 in) OUTER : 13.8— 15.8 kg/31.0 mm (30.4 — 34.8 Ibs/1.2 in) VALVE AND VALVE SPRING REASSEMBLY e Install the valve spring seat (1). Be careful not to confuse the lower seat with the spring retainer 2). e Lubricate each seal with oil, and fit the seals onto each guide. A CAUTION | ENGINE 3-24 5.9—6.7 kg + 27.5 mM eden Do not reuse the oil seals. 3-25 ENGINE e Insert the valves, with their stems coated with (SUZUKI MOLY PASTE) all around and along the full stem length without any break. Similarly oil the lip of the stem seal. WH 99000-25140: SUZUKI MOLY PASTE | A CAUTION | When inserting each valve, take care not to damage the lip of the stem seal. e Install the valve springs, making sure that the close-pitch end (1) of each spring goes in first to rest on the head. The coil pitch of both inner and outer springs vary: the pitch decreases from top to bottom, as shown in the il- lustration. * Put on the valve spring retainer, and using the valve lifter, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter 2) to wedge in between retainer and stem. Be sure that the rounded lip (3) of the cotter fits snugly into the groove (4) in the stem end. (22) 09916-14510: Valve spring compressor 09916-14910: Valve spring compressor attachment 09916-84511: Tweezers A CAUTION | Be sure to locate each spring and valve to their origi- nal positions. CAMSHAFT/AUTOMATIC DE-COMP. ASSEMBLY | A CAUTION Do not attempt to disassemble the camshaft/automatic de-comp. assembly. It is not serviceable. AUTOMATIC DE-COMP. Move the automatic de-comp. weight by hand to inspect If operating smoothly. If it does not smoothly must be replaced with a new cam- shaft/automatic de-comp. assembly. CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power. Any of these malconditions could be caused by a worn camshaft. CAMSHAFT CAM WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and ex- haust cams in terms of cam height Á), which is to be meas- ured with micrometer. Replace the camshaft if found it worn down to the limit. 09900-20202: Micrometer (25—50 mm) Cam height E) Intake cam : 33.410 mm (1.3154 in) Exhaust cam: 33.400 mm (1.3150 in) CAMSHAFT JOURNAL WEAR Determine whether each journal is worn down to the limit or not by measuring camshaft journal oil clearance with the camshaft installed. Use plastigauge to read the clearance, which is specified as follows: Service Limit Camshaft journal oil clearance Service Limit: 0.150 mm (0.0059 in) ¢ Tighten the cylinder head cover bolts evenly and diagonal- ly to the specified torque. © Cylinder head cover bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) 09900-22301: Plastigauge NOTE: To properly measure the oil clearance with plasti-gauge, all gasket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND No. 1207B until after the oil clearance has been determined. ENGINE 3-26 3-27 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clearance is incorrect. 09900-20205: Micrometer (0—25 mm) Camshaft journal O.D.: 21.959—21.980 mm (Right & Center) (0.8645 —0.8654 т) Camshaft journal O.D.: 17.466 — 17.484 mm (Left) (0.6877 —0.6883 in) CAMSHAFT RUNOUT Measure the runout with a dial gauge. Replace the camshaft If the runout exceeds the limit. Service Limit: 0.10 mm (0.004 in) 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance read- ing at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. Service Limit: 0.05 mm (0.002 in) CYLINDER BORE Inspect the cylinder wall for nicks, scratches or other damage. 09900-20508: Cylinder bore gauge set 09900-20513: Gauge rod Standard: 100.000 — 100.015 mm (3.9370—3.9376 т) PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place 21 mm (0.8 in) from the skirt end as shown in Fig. If the measurement is less than the limit, replace the piston. 09900-20204: Micrometer (75—100 mm) Service Limit: 99.880 mm (3.9323 in) ENGINE 3-28 PISTON —-CYLINDER CLEARANCE As a result of the previous measurement, if the piston to cylinder clearance exceeds the limit, replace both cylinder and piston. Service Limit: 0.120 mm (0.0047 in) PISTON RING—GROOVE CLEARANCE Using a thickness gauge, measure the side clearance of the 1st and 2nd rings. If any of the clearances exceeds the limit, replace both piston and piston rings. 09900-20803: Thickness gauge 09900-20205: Micrometer (0—25 mm) Piston ring—groove clearance Service Limit 1st : 0.180 mm (0.0071 in) 2nd: 0.150 mm (0.0059 in) Piston ring groove width Standard 1st : 1.23—1.25 mm (0.048 — 0.049 in) 2nd: 1.21—1.23 mm (0.047 — 0.048 in) Oil : 2.81 — 2.83 mm (0.110—0.111 in) Piston ring thickness Standard 1st : 1.170—1.190 mm (0.0461 —0.469 in) 2nd: 1.150— 1.170 mm (0.0453—0.0461 in) NOTE: Using a soft-metal scraper, decarbon the crown of the piston. Clean the ring grooves similarly. PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring. 09900-20102: Vernier calipers Piston ring free end gap Service Limit 1st : 10.8 mm (0.43 in) 2nd: 9.1 mm (0.36 in) 09900-20803: Thickness gauge Piston ring end gap Service Limit 1st: 0.50 mm (0.020 in) 2nd: 1.00 mm (0.039 in) 3-29 ENGINE PISTON PIN AND PIN BORE Using a caliper gauge, measure the piston pin bore inside diameter, and using a micrometer measure the piston pin outside diameter. If the difference between these two meas- urements is more than the limits, replace both piston and piston pin. 09900-20605: Dial calipers 09900-20205: Micrometer (0—25 mm) Piston pin bore Service Limit: 23.030 mm (0.9067 in) Piston pin O.D. Service Limit: 22.980 mm (0.9047 in) CONROD SMALL END 1.D. Using a caliper gauge, measure the conrod small end inside diameter. 09900-20605: Dial calipers Service Limit: 23.040 mm (0.9071 in) If the conrod small end bore inside diameter exceeds the limit, replace conrod. CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod’s big end. 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block Service Limit: 3.0 mm (0.12 in) Push the big end of the conrod to one side and measure the side clearance with a thickness gauge. 09900-20803: Thickness gauge Service Limit: 1.00 mm (0.039 in) Where the limit is exceeded, replace crankshaft assembly or reduce the deflection and the side clearance to within the limit by replacing the worn parts—conrod, big end bearing and crank pin etc. CRANKSHAFT RUNOUT Support the crankshaft with “V”” blocks as shown, with the two end journals resting on the blocks. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Correct or replace the crankshaft if the runout is greater than the limit. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block (100 mm) Service Limit: 0.05 mm (0.002 in) ENGINE 3-30 3-31 ENGINE BALANCERSHAFT AND GEAR D e (1) Balancershaft (2) Key (3) Inner race (4) Spring (6 pcs) (5) Pin (3 pcs) (6) Driven gear (7) Washer Washer © Circlip DISASSEMBLY * Remove the circlip (1) and washers (@), ©). e Remove the balancer driven gear. e Remove the 6 springs and 3 pins. Inspect the crank balancershaft wear or damage. REASSEMBLY ¢ When installing the inner race, align the pin with groove of inner race. * When installing the balancer driven gear, align the two punched marks as shown in photo. * When installing the 6 springs (1) and 3 pins (2), set the pins (2) to the triangle position as shown in photo. CLUTCH DRIVE PLATE Measure the thickness of each drive plate with vernier calipers. Replace drive plates found to have worn down to the limit. 09900-20102: Vernier calipers Standard Thickness No.1 & No.2: 2.9—3.1 mm (0.11—0.12 in) Service Limit Thickness No.1 & No.2: 2.6 mm (0.10 in) ENGINE 3-32 Measuring thickness 3-33 ENGINE CLUTCH DRIVEN PLATE Measure each driven plate for distortion with a thickness gauge. Replace driven plates which exceed the limit. 09900-20803: Thickness gauge Service Limit: 0.1 mm (0.004 in) CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with a vernier calipers, and determine the elastic strength of each. Replace any spring not within the limit. 09900-20102: Vernier calipers Service Limit: 33.0 mm (1.30 in) CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality, particular- ly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing. CLUTCH RELEASE PINION AND RACK Rotate the clutch release pinion by hand to inspect for a smooth roration. If a large resistance is felt to rotation, in- spect the pinion and rack for damage or wear. If the defect is found, replace them as a set. Measuring distortion ENGINE 3-34 STARTER CLUTCH (1) Starter clutch (2) Bearing (3) Starter idle gear (4) Idle gear shaft (5) Starter torque limiter © ITEM N-m kg-m a 25 2:5 18.0 DISASSEMBLY * Remove the starter clutch gear. e Remove the 3 bolts with a 6 mm hexagon wrench and 36 mm offset wrench. с ; 3-35 ENGINE STARTER CLUTCH Inspcet the stater clutch wear or damage. REASSEMBLY * Apply THREAD LOCK SUPER “1303” to the bolts and tighten them to the specified torque. 99000-32030: THREAD LOCK SUPER “1303” [VW] Bolt: 25 N-m (2.5 kg-m, 18.0 Ib-ft) Check that the rotor (1) turns in the direction of the arrow mark (2) on the rotor while holding the starter gear, and that the rotor never turns in the opposite direction of the arrow mark. STARTER TORQUE LIMITER | À CAUTION Do not attempt to disassemble the starter toque limiter. It is not serviceable. Check the slip torque with the special tools. Slip torque: 42—64 N°'m (4.2—6.4 kg-m, 30.5—46.5 Ib-ft) 09930-73110: Starter torque limiter holder 09930-73120: Starter torque limiter socket Set the starter torque limiter to the special tools and vise as shown in the photograph. If the slip torque is not within the specification, replace the starter torque limiter with a new one. ENGINE 3-36 TRANSMISSION ¢ Disassemble the transmission gears as shown in the illustration. (1) Low driven gear (2) Top driven gear (3) 3rd driven gear (4) 4th driven gear (& 2nd driven gear (6) Driveshaft (7) Countershaft/Low drive gear Top drive gear (9) 3rd drive gear 4th drive gear A 2nd drive gear 2ND DRIVE GEAR DISASSEMBL Y * Remove the 2nd drive gear by using the gear puller and appropriate attachment. 09913-60910: Gear puller 3-37 ENGINE SHIFT FORK— GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shift- ing action. Shift fork-Groove clearance Standard: 0.10-0.30 mm (0.004—0.012 in) Service Limit: 0.50 mm (0.020 in) If the clearance checked is noted to exceed the limit speci- fied, replace the fork or its gear, or both. 09900-20803: Thickness gauge 09900-20102: Vernier calipers Shift fork groove width Standard: 5.0—5.1 mm (0.197—0.200 in) Shift fork thickness Standard: 4.8—4.9 mm (0.189-—0.193 in) Checking thickness REASSEMBLY Assemble the countershaft and driveshaft, in the reverse order of disassembly. Pay attention to following points: NOTE: Before installing the gears, lightly coat moly paste or engine oil to the driveshaft and countershaft. JAW 99000-25140: SUZUKI MOLY PASTE e \When installing a new circlip, pay attention to the direc- tion of the circlip. Fit it to the side where the thrust is as shown in the illustration. A CAUTION | * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded, and a new cir- clip must be installed. *¥ When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. * After installing a circlip, always insure that it is com- pletely seated in its groove and securely fitted. 2ND DRIVE GEAR e Press-fit 2nd drive gear (1) onto the countershaft. NOTE: Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK SUPER “1303”. 99000-32030: THREAD LOCK SUPER 1303” NOTE: Take care not to smear 4th drive gear with THREAD LOCK SUPER “1303”. NOTE: * After mounting the 2nd drive gear, check that 4th drive gear spins smoothly by moving it with your fingers. * This procedure may be performed only twice before shaft replacement is required. 3RD DRIVEN GEAR BUSHING e When installing the gear bushing onto the driveshaft, align the oil hole (2) of the shaft with the bushing oil hole (3. ENGINE 3-38 — > Thrust Sharp edge © _ MEME ILE, WI DO 3-39 ENGINE NOTE: In reassembling the transmission, attention must be given to the locations and positions of washers and circlips. The cross sectional view given here will serve as a reference for correctly mounting the gears, washers and circlips. {0 ENGINE 3-40 OIL NOZZLE AND OIL JET REMOVAL e Remove the oil nozzle (1) and oil jet (2) of the right crankcase. | À CAUTION The removed oil jet (2) should be replaced with a new one. INSPECTION Check the oil nozzle for any damage or clogging. REASSEMBLY e Install the new oil jet (2) as shown in the illustration. e Install the oil nozzle (1). * Apply THREAD LOCK SUPER “1303” to the bolt and tighten to the specified torque. 99000-32030: THREAD LOCK SUPER 1303” (8) Bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) CRANKCASE BEARINGS Inspect the play of the crankcase bearings by hand while _ they are in the left and right crankcase. Rotate each crank- IO H— Play Play i case bearing inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. NOTE: a When reassembling the bearing retainer (4), apply a small quantity of THREAD LOCK “1342” to the bearing retainer screws and bolts. 3-41 ENGINE OIL FILTER e Remove the oil filter cap. * Remove the oil filter (1). e Install the new oil filter. NOTE: Before installing the oil filter and oil filter cap, check to be sure that the spring (2) and new O-rings (3) and (4)) are in- stalled correctly. GENERATOR * Remove the generator coil. * Remove the bearing by removing the circlip. ENGINE 3-42 ENGINE REASSEMBLY The engine is reassembled by carrying out the steps of dis- assembly in the reverse order, but there are a number of steps that demand special descriptions or precautionary measures. NOTE: Apply engine oil to each running and sliding part before reas- sembling. OIL SEALS e Fit the respective oil seals to the crankcase, clutch cover and gearshift cover. * Apply SUZUKI SUPER GREASE “A” to the lip of oil seals. JAM 99000-32030: SUZUKI SUPER GREASE "A" A CAUTION | Replace the oil seals with new ones every disassem- bly to prevent oil leakage. 3-43 ENGINE CRANKSHAFT (1) Crankshaft (R) (2) Conrod (3) Crank pin (4) Crankshaft (||) (6) Crankshaft bearing nut (6) Balancer drive gear (7) Primary drive gear kg-m Ib-ft 8.0 58.0 10.0 72.5 * Decide the width between the webs referring to the figure below when rebuilding the crankshaft. STD width between webs: 71.0+0.1 mm (2.795 + 0.004 in) 71.0+ 0.1 mm . ; : _— When mounting the crankshaft in the crankcase, it is (2.795 +0.004 in} necessary to pull its right end into the crankcase. (2) 09910-32812: Crankshaft installer 09910-32830: Attachment 09910-32860: Attachment | À CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft align- ment accuracy will be affected. ENGINE 3-44 BALANCERSHAFT * When installing the balancershaft, align the punched marks ((1), (2)) оп the balancer drive gear and driven gear. GEARSHIFT MECHANISM (1) Gearshift arm stopper (2) Gearshift shaft (3) Gearshift lever (4) Cam stopper plate (6) Cam stopper (8) Cam stopper bolt (7) Gearshift cam Gearshift fork No.1 (9) Gearshift fork No.2 Gearshift fork No.3 AD) Pawl lifter Ib-ft (2 Cam guide (3 Cam driven gear 13.5 3-45 ENGINE e After installing the countershaft assembly and driveshaft assembly into the right crankcase, fit the gearshift forks (1), 2) and (3) into the gearshift fork grooves. (1) For Top driven gear (No.1) (2) For 4th driven gear (No.2) (3) For 3rd drive gear (No.3) NOTE: Three kinds of gearshift forks, (1), 2) and (3) are used. They resemble each other very closely in external appearance and configuration. Carefully examine the illustration for correct installing posi- tions and directions. e Position the gearshift cam as shown in photo so that the gearshift fork shafts can be installed easily. NOTE: When replacing the gearshift cam stopper bolt (4), apply a small quantity of THREAD LOCK 1342" to the threaded part of the bolt. 99000-32050: THREAD LOCK 1342” * Hook the gearshift cam stopper spring. CRANKCASE When reassembling the crankcase pay attention to the fol- lowing points: * Remove sealant material on the mating surfaces of right and left halves of crankcase and thoroughly remove oil stains. e Apply SUZUKI BOND NO.1207B uniformly to the mating surface of the left half of the crankcase, and assemble the cases within few minutes. 99104-31140: SUZUKI BOND NO.1207B e Fit the dowel pins (1) on the right half as shown in photo. * Apply engine oil to conrod big end of the crankshaft and all parts of the transmission gears. e After the crankcase bolts have been tightened, check if driveshaft and countershaft rotate smoothly. [BV] crankcase bolt: 11 N-m (1.1 kg-m, 8.0 Ib-ft) e |f alarge resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer. CAM DRIVEN GEAR * Install the gearshift pawls into the cam driven gear. The large shoulder (A) must face to the outside as shown in the illustration. * When installing the cam guide 2) and paw! lifter (3), ap- ply a small quantity of THREAD LOCK “1342” to the securing screws (4). «£5 99000-32050: THREAD LOCK “1342” ENGINE 3-46 3-47 ENGINE GEARSHIFT SHAFT * Fit a spring to the gearshift shaft correctly. e Install the gearshift shaft. Match the center teeth of the gear on the gearshift shaft with the center teeth on the cam driven gear as shown. NOTE: When replacing the gearshift arm stopper (1), apply a small quantity of THREAD LOCK SUPER “1303” to its threaded part and tighten it to the specified torque. (See page 7-24.) 99000-32030: THREAD LOCK SUPER “1303” * Fit the dowel pins (2) and new gasket. e Fit the gearshift cover and tighten the bolts diagonally. NOTE: After the gearshift cover and gearshift lever have been fit- ted, confirm that gear change is normal while turning the countershaft and driveshaft. If gear change is not obtained, it means that assembly of gears or installation of gearshift fork is incorrect. If this is the case, disassemble and trace the mistake. NEUTRAL POSITION INDICATOR SWITCH e Install the neutral position indicator switch spring (3) and switch contact (9). e Install the neutral position indicator switch with two screws. e Install the breather cover. ENGINE 3-48 OIL PUMP * Before mounting oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft. * Apply a small quantity of THREAD LOCK 1342” to the oil pump mounting screws. 99000-32050: THREAD LOCK “1342” * Tighten the oil pump mounting screws. e Fix the oil pump driven gear with the circlip. NOTE: After installing the oil pump driven gear, rotate the pump gear by hand to see if it turns smoothly. * Fix the idle gear with the circlip. CAM DRIVE CHAIN AND PRIMARY DRIVE GEAR e Engage the cam drive chain. e Fit the key (1) in the key slot on the crankshaft, then in- stall the primary drive gear and nut. ® Tighten the primary drive gear nut to the specified tor- que with the special tool. 09910-20116: Conrod holder [7] Primary drive gear nut: 100 N-m (10.0 kg-m, 72.5 Ib-ft) NOTE: This nut has left-hand thread nut. 3-49 ENGINE CLUTCH (1) Clutch release arm (2) Clutch release pinion (3) Clutch release rack (4) Clutch pressure plate (5) Clutch sleeve hub (6) Washer seat (7) Concaved washer Clutch driven plate No.2 (Thicker plate, 1 pc) (9) Stopper ring Clutch drive plate No.2 (1 pc) (1 Clutch driven plate No.1 (7 pcs) (19 Clutch drive plate No.1 (7 pcs) (3 Primary driven gear ass'y N © @ ER ® ® NOTE: kg-m Ib-ft Check to be sure that concaved washer (7) a 10 1.0 7.0 is properly installed. 50 5.0 36.0 e Install the thrust washer (1. e Install the spacer with primary driven gear assembly. NOTE: When inserting the spacer into the primary driven gear, ap- ply engine oil to both inside and outside of the spacer. e Install the thrust washer (2). e Install the clutch sleeve hub and lock washer (3. NOTE: When installing the lock washer (3), align the slit (4) of lock washer with the rib of clutch sleeve hub. e Tighten the clutch sleeve hub nut to the specified torque with the special tool. 09920-53740: Clutch sleeve hub holder (8) Clutch sleeve hub nut: 50 N'-m (5.0 kg-m, 36.0 Ib-ft) o After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the lock washer. o Install the clutch drive plates and driven plates one by one. e Install the clutch pressure plate. e Tighten the clutch spring mounting bolts diagonally to the specified torque with the special tool. 09910-20116: Conrod holder W Clutch spring mounting bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) e Fit the dowel pins. A CAUTION | Use a new gasket to prevent oil leakage. * Engage the teeth of clutch release rack with those of pin- ion gear at the clutch cover side, and replace clutch cover. Make sure that the rack and pinion gear engage positive- ly. To install the cover, tap lightly with plastic hammer, and tighten the bolts. (1): Gasket ENGINE 3-50 3-b1 ENGINE STARTER CLUTCH AND GENERATOR Install the crankcase oil separator and spacer (1). * Tighten the ring nut to the specified torque with the spe- cial tools. 09917-23711: Ring nut socket wrench 09910-20116: Conrod holder (9) Ring nut: 80 N-m (8.0 kg-m, 58.0 Ib-ft) e Install the starter gear and thrust washer. e Degrease the tapered portion of the generator rotor and also the crankshaft. * Fil the key (2) in the key slot on the crankshaft, then in- stall the generator rotor. * Apply a small quantity of THREAD LOCK SUPER “1303” to the threaded part of rotor bolt. 99000-32030: THEAD LOCK SUPER “1303” ¢ Tighten the generator rotor bolt to the specified torque with the 36 mm off-set wrench. [®) Generator rotor bolt: 160 N-m (16.0 kg-m, 115.5 Ib-ft) ® Install the starter torque limiter and idle gear. e Install the starter motor. * Fit the dowel pin and install the new gasket. o Install the generator cover. OIL RING Install the spacer (1) into the oil ring groove first. Then in- stall both side rails (2), one on each side of the spacer. The spacer and side rails do not have a specific top or bottom when they are new. When reassembling used parts, install them in their original place and direction. ENGINE 3-52 TR rin ei) HE INCORRECT NARA CORRECT 7% 3-b3 ENGINE TOP RING AND 2ND RING Top and 2nd rings differ in the shape of the ring face. Top and 2nd rings have a letter ““R”” or “RN” marked on the side. Be sure to bring the marked side to top when fitting them to the piston. * Position the gaps of the three rings as shown. Before in- serting piston into the cylinder, check that the gaps are so located. e 2nd ring e Lower side rail * Upper side rail * Top ring IN. * Spacer * Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase. * Rub a small quantity of SUZUKI MOLY PASTE onto the piston pin. AH 99000-25140: SUZUKI MOLY PASTE * When fitting the piston, turn arrow mark (1) on the piston head to exhaust side. * Fit the piston pin circlips with long-nose pliers. A CAUTION | Use new piston pin circlip to prevent circlip failure which will occur with a bent one. e Fit the dowel pins (2) to the crankcase and attach a new gasket. | A CAUTION | Use a new gasket to prevent oil leakage. * Hold each piston ring with properly position, and insert the piston into the cylinder. NOTE: When mounting the cylinder, keep the camshaft drive chain (1) taut. The camshaft drive chain must not be caught be- tween cam drive chain sprocket and crankcase when crank- shaft is rotated. e Install the cam chain guide. NOTE: There is a holder for the bottom end of the cam chain guide cast in the crankcase. Be sure that the cam chain guide (2) is inserted properly. e Temporarily tighten the cylinder base nuts. e Fit the dowel pins (3) to the cylinder and attach a new gasket. | A CAUTION | Use a new cylinder head gasket to prevent oil leakage. Do not use the old gasket. * Place the cylinder head on the cylinder. e Cylinder head bolts and new gaskets must be fitted in the correct position, as shown in the photograph. A): 200 mm bolt $): 190 mm bolt © : 180 mm bolt NOTE: Apply engine oil to the new gaskets before installing. e Fasten the cylinder head by tightening the bolts and nuts diagonally. Tighten each bolt and nut to the specified torque. © Cylinder head bolt: 38 N-m (3.8 kg-m, 27.5 Ib-ft) Cylinder head nut: 25 N-m (2.5 kg-m, 18.0 Ib-ft) ENGINE 3-54 3-b5 ENGINE e After tightening the cylinder head bolts and nuts, tight- en the cylinder base nut to the specified torque. [®] cylinder base nut: 10 N-m (1.0 kg-m, 7.0 Ib-ft) CAMSHAFT e Turn the crankshaft counterclockwise with the box wrench and align ““T"" line (1) on the generator rotor with the center of hole on the generator cover keeping the cam- shaft drive chain pulled upward. A CAUTION | If crankshaft is turned without drawing the camshaft drive chain upward, the chain will be caught between crankcase and cam chain drive sprocket. e Install the C-ring (2) into the ring groove of the cylinder head. NOTE: Apply grease on the cam sprocket locating pin and install the pin into the camshaft. e Engage the chain on the cam sprocket with the locating pin hole (3) at two o'clock position. NOTE: Do not rotate the generator rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket. When installing the camshaft into the cam sprocket, pay attention not to dislodge the locating pin or it may fall into the crankcase. e Align the engraved line mark (4) on the camshaft so it is parallel with the surface of the cylinder head. ENGINE 3-56 e Fit the lock washer so that it is covering the locating pin. * Apply THREAD LOCK SUPER 1303” to the cam sprock- et bolts and tighten them to the specified torque. [9] cam sprocket bolt: 15 N-m (1.5 kg-m, 11.0 Ib-ft) 99000-32030: THREAD LOCK SUPER “1303” * Bend up the washer tongue positively to lock the bolts. * Apply SUZUKI MOLY PASTE to the camshaft journals and cam faces. AH 99000-25140: SUZUKI MOLY PASTE e Thoroughly wipe off oil from the fitting surfaces of cylinder head and cover. e Fit the dowel pins (1) and camshaft end cap 2) to the cylinder head side. * Apply SUZUKI BOND NO. 12078 uniformly to the mating = surface of the cylinder head cover, and install the cylinder - SITE x head cover within few minutes. D} | _ о) (ol JO О (2078) 99104-31140: SUZUKI BOND NO. 1207B O O O e) ES OD ‘ЛО * Fit the two gaskets (3) to the head cover bolts correctly 17 as shown in Fig. E A CAUTION | Use a new gasket to prevent oil leakage. NOTE: When tightening the cylinder head cover bolts, the piston must be at top dead center on the compression stroke. 3-57 ENGINE e Lightly tighten the cylinder head cover bolts sequentially in the ascending order of numbers, and then if everything is satisfactory, tighten securely with a torque wrench to the specified torque. [®] cylinder head cover bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) e¢ Turn the slotted end of the chain tensioner adjuster to lock it with a screwdriver in the clockwise direction. e Install the chain tensioner adjuster on the cylinder. [7] Cam chain tensioner adjuster mounting bolt (1): 10 N-m (1.0 kg-m, 7.0 Ib-ft) e Turn back and pull out the screwdriver from the chain ten- sioner adjuster. As the cylinder turns, the tensioner rod is advanced under spring force and pushes the tensioner against the cam drive chain. NOTE: The cam drive chain tensioner adjuster is maintained at the proper tension by an automatically adjusted tensioner. Be- fore installing the cam drive chain tensioner adjuster, inspect the smooth movement. e Tighten the tensioner adjuster cap bolt (2). [®] Bolt O): 6 N-m (0.6 kg-m, 4.5 Ib-ft) e Install the oil pipe and tighten the union bolt to the speci- fied torque. [1] oil pipe union bolt E): 23 N-m (2.3 kg-m, 16.5 Ib-ft) (4): 20 N-m (2.0 kg-m, 14.5 Ib-ft) IMPORTANT NOTICE ! If this manual was not purchased from manualcd then you will be missing important pages and also have some features locked. To insure you have the complete manual only buy from manualcd If this manual was not purchased from manualcd please contact us and we will inform you of what pages are missing and which features are locked. [email protected] FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SYSTEM ncormenmenmnennennen ais meta izan r samme sms 4- 1 FUEL VOL LE recovsemenasesennmnenteannnen en sss sess sss om 50 sa a IA 4- 2 FUEL TANK ete ease ene aeeeeas 4- 3 Nl Am nes 4- 4 CONSTRUCTION ---<-<-<-<-<<<<<<rrrrnrrrnensaansanaanana an canne nana nana neue 4- 4 SPECIEICATIONS ucraniana ao EEE 4- 5 I.D. NO. LOCATION +44 ERREREERREREERKRKERERREREER EEK EEER KEG 4- 6 SLOW CVOT EN) rome me en man NA 4- 7 MANU SYSTEM svn es ase om 96505 tasses 4- 8 STARTER EVSTENM :=======220000 marea MANTA 4- 9 FLOAT BY STEVE wswseswesscssuswmssioassscassensessssscesissessssss sissies sossaress ri sep ois sns sis 4- 9 REMOVAL ER EREEERKKEERRKRERRRERERERERERERKERKRRKEREREKERERERKERERETG 4-10 DISAGSENMBLY. w+vvvvwisuwwmisipavsmws sions sams ss vais sss ove smi sais 4-10 CARBURETOR CLEANING «4400000 KK ERR ER KKE RER EK ER 4-11 IMSPECTION. SGG GENE 4-13 NEEDLE VALVE INSPECTION ccomesemncecenmennmsnenmenmennnnnnennnnennnnnnnn 4-13 FLOAT HEIGHT ADJUSTINENT scene men pe ame pare 4-13 THROTTLE POSITION SWITCH —eremenenuenmnnann en an enan mean ennemies 4-13 REASSEMBLY AND REMOUNTING -----================e=2v0rererverereneeees 4-14 LUBRICATION SYSTEM AND COOLING SYSTEM ------=-==============-- 4-14 ENGINE LUBRICATION/CYLINDER HEAD COOLING SYSTEM CHABT mme nn ane peine eee 4-15 OIL COOLER EE nana ea nan en ana nan na nana nan 4-17 4-1 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM When turning starter motor, negative pressure is generated in the combustion chamber. This nega- tive pressure works on the diaphragm of fuel valve through passage way provided in the carburetor main bore and vacuum hose, and diaphragm builds up a negative pressure which is higher than the spring pressure. Valve in the fuel valve is forced to open due to diaphragm operation, and thus al- lows fuel to flow into carburetor float chamber. Fuel tank + Fuel valve Vacuum hose Fuel hose Vacuum > Fuel cre © © FUEL VALVE FUEL VALVE MECHANISM FUEL AND LUBRICATION 4-2 A valve is provided at the end of the fuel valve lever and can switch over to “ON”, “PRI” and “RES”. “PRI” position Fuel “ON” position “RES” position FUEL VALVE/FUEL FILTER REMOVAL * Remove the frame cover and seat. (Refer to pages 5-1 and 2.) * Remove the fuel tank. (Refer to page 4-3.) * Remove the fuel valve by removing the mounting bolts. A WARNING Gasoline is very explosive. Extreme care must be taken. Gaskets and O-ring must be replaced with new ones to prevent fuel leakage. 4-3 FUEL AND LUBRICATION SYSTEM INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. FUEL TANK FUEL TANK REMOVAL e Remove the frame cover and seat. (Refer to pages 5-1 and 2.) e Turn the fuel valve to “ON” position. * Remove the fuel tank mounting bolts (1). o Slide the fuel tank backward and lift up it after discon- necting the fuel hose 2) and vacuum hose (3). * Remove the fuel tank. Gasoline is very explosive. Extreme care must be taken. FUEL AND LUBRICATION 4-4 CARBURETOR CONSTRUCTION + — on em i a ® © | (1) Top cap (2) Spring (3) Spring seat (4) E-ring (5) Washer (6) Jet needie (7) O-ring Diaphragm (9) Piston valve Needle jet (D Main jet (2 Pilot jet (3 Main air jet Starter plunger (5 Pilot screw O-ring (7 O-ring Float Throttle stop screw O-ring @) Drain screw 4-5 FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION E-02,04,34 E-37 E-17,22,24 U-type E-22 Carburetor type RL] Pa E. Lt. Bore size 40 mm = — — |.D. No. 32E0 32E8 32E3 32E4 Idle r/min. 1 500 + 100 _ _ - r/min Float height 14.7+1.0 mm — _ _ (0.58 + 0.04 in) Main jet (M.J.) # 140 ce = ” Jet needle (J.N.) 6F19-3rd + — &— Needle jet (№...) Y-5 € = = Throttle valve (Th.V.) #95 = “ — Pilot jet (P.J.) # 42.5 — € — Starter jet (G.S.) #40 = + € Pilot screw (P.S.) PRE-SET — PRE-SET PRE-SET (1% turns back) (1.0 turn back) (178 turns back) Throttle cable play 0.5—1.0 mm - _ _ (pulling cable) (0.02— 0.04 in) Starter cable play 0.5—1.0 mm de. 7 Be (0.02—0.04 in) COUNTRY OR AREA E-02 : U.K. E-24 : Australia E-03 : U.S.A. E-28 : Canada E-04 : France E-33 : California (U.S.A.) E-17 : Sweden E-34 : Italy E-18 : Switzerland E-37 : Brazil E-22 : Germany FUEL AND LUBRICATION 4-6 SPECIFICATION НЕМ E-03 E-33 E-28 E-18 Carburetor type MIKUNI i _ _ BST40SS Bore size 40 mm — < = |.D. No. 32E1 32E6 32E5 32E2 Idle r/min. 1 500 + 100 _ _ 1 500+ 50 r/min r/min Float height 14.7+ 1.0 mm - "E i (0.58 + 0.04 in) Main jet (M.J.) #140 + # 140 # 137.5 Jet needle (J.N.) 6F23 + 6F19-3rd 6H21-4th Needle jet (N.J.) Y-5M E Y-5 — Throttle valve (Th.V.) # 9b — — € Pilot jet (P.J.) 40.5 “ # 42.5 <= Starter jet (4.5) #40 — + — Pilot screw (P.S.) ” PRE-SET PRE-SET PRE-SET (1% turns back)|(1.0 turn back) Throttle cable play 0.5—1.0 mm — i = (pulling cable) (0.02—0.04 in) Starter cable play 0.5— 1.0 mm _ i. а. (0.02—0.04 in) 1.D. NO. LOCATION Each carburetor has I.D. Number (1) printed on the carbure- tor body according to its specification. 4-7 FUEL AND LUBRICATION SYSTEM SLOW SYSTEM This system supplies fuel during engine operation with throttle valve (1) closed or slight opened. The fuel from float chamber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4) . This mixture, rich with fuel, then goes up through pilot passage to pilot screw (5) . A part of the mixture is discharged into the main bore out of bypass ports (6) . The remainder of mixture is metered by pilot screw (6) and sprayed out into the main bore through pilot outlet (7) . efes MN Fuel/Air mixture a Fuel FUEL AND LUBRICATION 4-8 MAIN SYSTEM As throttle valve (1) is opened, engine speed rises, and this increases negative pressure in the ventu- ri A. Consequently the piston valve (2) moves upward. Meanwhile, the fuel in float chamber (3) is metered by main jet (4) , and the metered fuel enters nee- dle jet 6) , in which it mixes with the air admitted through main air jet (6) to form an emulsion. The emulsified fuel then passes through the clearance between needle jet (5) and jet needle (7) , and is discharged into the venturi @), in which it meets main air stream being drawn by the engine. Mixture proportioning is accomplished in needle jet (5) ; the clearance through which the emulsified fuel must flow in large or small, depending ultimately on throttle position. © SE: 3 ele Г nie "o ly ! Fuel/Air mixture $m 4-9 FUEL AND LUBRICATION SYSTEM STARTER SYSTEM Pulling the starter cable (1) , fuel is drawn into the starter circuit from the float chamber 2). Starter jets ((3), (4)) meters this fuel, which then flows into fuel pipe 6) and mixes with the air com- ing from the float chamber. The mixture, rich in fuel content, reaches starter plunger (6) and mixes again with the air coming through a passage extending from behind the diaphragm. The two successive mixings of fuel with air are such that proper fuel/air mixture for starting is produced when the mixture is sprayed out through starter outlet port (7) into the main bore. 2 DIR 5 EZ Ё e Ke ZZ ARE A y I~ _ - © << Air Fuel/Air mixture \ + «еле Fuel FLOAT SYSTEM — Floats (1) and needle valve @) are associated with the same fr \ mechanism, so that, as the floats (1) move up and down, ed L the needle valve (2) too moves likewise. f | | When fuel level is up in float chamber (3) , floats (1) are up UT ? and needle valve (2) remains pushed up against valve seat. 7 Under this condition, no fuel enters the float chamber (3) . ML $ As the fuel level falls, floats (1) go down and needle valve as (2) unseats itself to admit fuel into the chamber 3) . | E In this manner, needle valve (2) admits and shuts off fuel alternately to maintain a practically constant fuel level in- side the float chamber (3) . 7 Z À EE г a т я Ld — E EH A ОЧ === "TA, E Hh TA | | || LUN < | "эй % FUEL AND LUBRICATION 4-10 REMOVAL Refer to page 3-4. DISASSEMBLY NOTE: Before disassembly, prepare a clean and well lit work place where carburetor components can be layed out neatly and won't get lost. * Remove the carburetor top cap (1). LA CAUTION Do not blow the carburetor body with compressed air, before removing the diaphragm. It may cause a damage to the diaphragm. * Remove the piston valve return spring 2) and piston valve with diaphragm (3). * Remove the jet needle (4) out of the piston valve. * Remove the float chamber body (5). 4-11 FUEL AND LUBRICATION SYSTEM * Remove the float assembly (1) and needle valve (2). A CAUTION | Do not use a wire for cleaning the valve seat. e Remove the main jet @), pilot jet @ and pilot screw ©) (Refer to PILOT SCREW REMOVAL of page 4-12 for E-03, 18 and 33 models). A CAUTION | Do not use a wire for cleaning of passage and jets. NOTE: Before removing the pilot screw (5), slowly turn the pilot screw in clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after removing. * Remove the main air jet (6). | A CAUTION | Do not use a wire for cleaning of jet. CARBURETOR CLEANING Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be han- dled carefully. Always follow the chemical manufac- turer's instructions on proper use, handling and strage. NOTE: Remove the pilot screw as described next page before cleaning. HE heno SESE nih col pacs EEE) pres cast * Clean all jets with a spray-type carburetor cleaner and blow dry with compressed air. e Clean all circuits of the carburetor thoroughly - not just the perceived problem area. Clean the circuits in the car- buretor body with a spray-type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish. Blow the body dry with compressed air. A CAUTION Do not use wire to clean jets or passageways. Wire can damage jets and passageways. If the components can- not be cleaned with a spray cleaner it may be neces- sary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer's in- structions for proper use and cleaning of the carbure- tor components. e After cleaning, reassemble the carburetor with new seals and gaskets. Reinstall the pilot screw to the original fac- tory setting with a new O-ring seal. e Install a new cap over the pilot screw opening. (for E-03,18,33 models) PILOT SCREW REMOVAL (FOR E-03,18 AND 33 MODELS) Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be removed before cleaning. ® Use a 1/8” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. * Thread a self-tapping sheet metal screw into the plug. Pull on the screw head with pliers to remove the plug. Care- fully clean any metal shavings from the area. e Slowly turn the pilot screw in clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after cleaning. e Remove the pilot screw with the spring, washer, and O-ring. e After cleaning reinstall the pilot screw to the original set- ting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly. e Install new plug by tapping it into place with a punch. FUEL AND LUBRICATION 4-12 Drill-stop— Pilot screw” | Plug | Carburetor body 4-13 FUEL AND LUBRICATION SYSTEM INSPECTION Check the following items for any damage. * Pilot jet * Needle valve * Main jet * Starter jet * Main air jet * Gasket and O-ring * Pilot air jet * Throttle shaft oil seal * Needle jet air bleeding hole * Diaphragm * Float * Pilot outlet and by-pass holes NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle, the gasoline will continue flowing and cause it to overflow. If the seat and needle are worn beyond the per- missible limits, similar trouble will occur. Conversely, if the needle sticks, the gasoline will not flow into the float cham- ber. Clean the float chamber and float parts with gasoline. If the needle is worn as shown in the illustration, replace it together with a valve seat. Clean the fuel passage of the CORRECT INCORRECT mixing chamber with compressed air. FLOAT HEIGHT ADJUSTMENT To check the float height, invert the carburetor body, with the float arm kept free, measure the height (À while float arm is just in contact with needle valve by using calipers. Bend the tongue as necessary to bring the height (À to this value. ham Lam A RE > 4: su ae Smad haga EEE TR NDS Float height (4): 14.7 + 1.0 тт (0.58 + 0.04 т) 09900-20102: Vernier calipers THROTTLE POSITION SWITCH (Except for E-03,18,24,28 and 33 models) * Remove the fuel tank. (Refer to page 4-3.) Inspect the throttle position switch for continuity with pock- et tester. If any abnormality is found, replace the respec- tive switch assemblies with new ones. =) 09900-25002: Pocket tester US) Tester knob indication: X 1 range Color Position B B ON (full-throttle) O O OFF B: Black NOTE: When making above test, it is not necessary to start the engine. FUEL AND LUBRICATION 4-14 REASSEMBLY AND REMOUNTING IE Ges Reassemble and remount the carburetor assembly in the i: reverse order of removal and disassembly. e When installing the carburetor top cap, align the vacuum ports (1), 2). * After remounting the carburetor, the following adjust- ments are necessary. * Engine Idle TAN! sae es Page 2-6 * Throttle cable play ¡:=::5=0.:.0::5065: 00600. ees Page 2-6 LUBRICATION SYSTEM AND COOLING SYSTEM OIL PRESSURE Refer to page 2-18. OIL FILTER Refer to page 2-8. OIL SUMP FILTER Refer to page 3-16. NOTE: When separating the crankcase, wash the oil sump filter with cleaning solvent, and then blow compressed air through it to dry off solvent. 4-15 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION/CYLINDER HEAD COOLING SYSTEM CHART _ | CAMSHAFT PARIS TREN ”| RIGHT-SIDE JOURNAL y INTAKE ROCKER CAM CHAIN ARM SHAFT |< COVER LEFT:SIDE <| COVER RIGHT-SIDE [| OIL HOSE AND CAM AND ROCKER ARM SPROCKET AMAT, A ros i 20 di INTAKE AND [JJ OIL COOLER AON EXHAUST в A Y GAM FACE CYLINDER A HEAD dk COOLING 404 — CYLINDER A WALL PISTON JA CYLINDER HEAD ; i YET deL | CONROD MA “A AA us 44 VV) CONROD BIG | | STARTER CYLINDER NOZZLE END BEARING CLUTCH i A A il Л AN ЙА diN Jb AN ды ¿AN CRANKSHAFT у OIL JET RIGHT-SIDE OIL HOSE OIL PIPE A A A A у BY-PASS q OIL FILTER COUNTERSHAFT i LEFT-SIDE Ea BEARING Y OIL PUMP DRIVESHAFT у A LEFT-SIDE BEARING OIL JET y OIL SUMP FILTER DRIVESHAFT COUNTERSHAFT k AND GEARS AND GEARS i A ' ys PRIMARY DRIVEN GEAR AND CLUTCH PLATES i) ¿AL EE e E OIL PAN 7 = —~ FUEL AND LUBRICATION 4-16 <5 h "= КС = | bal, SE A. | à JL) 0) À fe; e E 5 Eu i НЛО > E E ¡MELILLA HE 4-17 FUEL AND LUBRICATION SYSTEM OIL COOLER [9] (1) Oil cooler (2) O-ring (3) Oil cooler hose (To cylinder head) (4) Oil cooler hose (From clutch cover) (5) Oil cooler cover (6) Oil cooler guard ITEM N-m A) 10 REMOVAL * Drain engine oil. (Refer to page 3-1.) * Remove the oil cooler hose mounting bolts. * Remove the oil cooler holder with cooler by removing its mounting bolts. CHASSIS CONTENTS FRAME COVER AND SEAT "Fes EE RENE Se sae EEE EEE EEE Eee nse. 5. 7 FRONT WHEEL Я й Rm EER ER TR AA 5- 2 RE MO VA L LINA IAN ES SES STE NES EE TE EE ES aa 5 5 2 INSPECTION AND DISASSEMBLY ++++4444444444444 5- 3 REASSEMBLY AND REMOUNTING +++++++444444444040 5- 4 FRONT BRAKE EEE en 5- 6 BRAKE PAD REPLACEMENT ---........ee..ve0ssrvccriiiioo nene e eee ee 5- 7 BRAKE FLUID REPLACEMENT ++++4+444444444444 5- 7 CALIPER REMOVAL AND DISASSEMBLY ++44444444444440 5- 8 CALIPER INSPECTION ====emo—=.n—0=ooxconcannco na 0 ena 5- 9 CALIPER REASSEMBLY AND REMOUNTING ---------=--=-==--==-... 5- 9 BRAKE DISC INSPECTION SEE UU ay ua 5- 10 MASTER CYLINDER REMOVAL AND DISASSEMBLY --------.---.--- 5-11 MASTER CYLINDER INSPECTION +++ cena nae encens 5-12 MASTER CYLINDER REASSEMBLY AND REMOUNTING ----------- 5-13 FRONT FORK OA, 0 CE AE DE SC 5- 14 REMOVAL AND DISASSEMBLY -------=--=--=-==.020000000000000 5-14 INSPECTION: ===. TEA EA 5-16 REASSEMBLY AND REMOUNTING ++++++44444444444 ransen ne cnce0e 5-17 STEERING covers a ker oc 5-20 REMOVAL AND DISASSEMBLY +++++444444444444 canne nsa aan sacnnees 5-20 INSPECTION --<<--<--<-<"<<<<<<0rrrrrnaransaaranenrenananara nan nana na aan anna nana nan e nee 5-95 REASSEMBLY AND REMOUNTING ++++++-444444 cu00e 5-25 REAR WHEEJ, ===... —. ¡(no ssa eves 5-27 REMOVAL ======n=ovovoovsonmn nan aaa NENA Nao 5-27 INSPECTION AND DISASSEMBLY +44 canne ns n sans cnnes 5-29 REASSEMBLY AND REMOUNTING =.<<."<.<<<<<<<recrnrncsenansacsan scene 5-31 REAR BRAKE --<.<<<-<<--<<-<<0rrrrrrrrarnanasenanen ren ana nana nana nana ner ana nana anne 5-33 BRAKE PAD REPLACEMENT --<--<…<<...rerrrsserena rene ra nan nee 5-34 BRAKE FLUID REPLACEMENT +=====0==cco..ñ=000000000 00000000 INIA 5-34 CALIPER REMOVAL AND DISASSEMBLY --------==-=--=..=.00000.. 5-35 CALIPER AND DISC INSPECTION ----------===.2200000000000es 5-36 CALIPER REASSEMBLY AND REMOUNTING =... 5-36 MASTER CYLINDER REMOVAL AND DISASSEMBLY -------.--.----- 5-37 MASTER CYLINDER INSPECTION +++ 5-38 MASTER CYLINDER REASSEMBLY AND REMOUNTING ----------- 5-38 REAR SWINGARM AND SUSPENSION +++ 5-39 REMOVAL, re er overs dain vs ives sian 5-40 INSPECTION AND DISASSEMBLY --------=--=..=.20000000000000s 5-42 REASSEMBLY AND REMOUNTING ----------=--=====220000000s 5-44 REASSEMBLING INFORMATION ++++4+44444444444 5-45 FINAL INSPECTION AND ADJUSTMENT ++++4444444444444 5-46 LOWERING THE SEAT HEIGHT =====w========.0.0. 0.00 ANA 5.47 OPTIONAL PARTS SUPPLY tere miss vesimassns sss seuss ssi 5.47 SPECIAL TOOLS, —>ericermessecsçenenes eee qe re Re Tor iam 5-47 FRONT FORK iranienne en sii ern ems sms anses 5.48 REAR SHOCK ABSORBER fF aE Erne EE EE EE EE SEE Esa E wees EEE sean ena 5-53 SIDE STAND ---<<-<<<"<<000meccmcccrnrrrenrranrananaeran era nna ananas n anna na nan nana 5-56 M 11) een mare score mts ams ss aia ses Gags 5-57 5-1 CHASSIS FRAME COVER AND SEAT REMOVAL AND REMOUNTING * Remove the right and left frame covers by removing the mounting screws. ¢ Remove the seat by removing the mounting bolts. * Remount the seat and frame covers. CHASSIS 5-2 FRONT WHEEL (1) Axle holder (2) Speedometer gearbox (3) Bearing (R) (4) Spacer (5) Bearing (L) (6) Dust seal (7) Spacer Disc ITEM | N-m | kg-m (A) 65 6.5 10 1.0 © 4.5 | 0.45 D 23 2.3 REMOVAL e Loosen the front axle holder nuts (1) and axle shaft (2). e Carefully position a jack under the chassis tubes and raise until the front wheel is slightly off the ground. * Remove the front wheel by removing the front axle. NOTE: Do not operate the brake lever while dismounting the front wheel. e Remove the disc by removing the mounting bolts. 5-3 CHASSIS INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the play of bearing inner ring by hand while mount- ed in the wheel. Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly. Replace the bearing if there is anything unusual. * Remove the dust seal. * Drive out the both bearing with the special tool in the fol- lowing procedures. 09941-50111: Bearing remover e Insert the adapter into the bearing. * After inserting the wedge bar from the opposite side, lock the wedge bar in the slit of the adapter. * Drive out the bearing by knocking the wedge bar. A CAUTION | Play Play E The removed bearing should be replaced with new ones. FRONT AXLE Check the front axle runout with a dial gauge and replace it if the runout exceeds the limit. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: ‘’V’’ block set Service Limit: 0.25 mm (0.010 in) WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown. An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel. Service Limit : 2.0 mm (0.08 in) (Axial and Radial) SPOKE NIPPLE Check to be sure that all nipples are tight, and retighten them as necessary. [1 spoke nipple: 4.5 N-m (0.45 kg-m, 3.0 Ib-ft) TIRE (Refer to page 2-12.) REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly, and also carry out the follow- ing steps: WHEEL BEARING e Apply grease to the bearings. ACH 99000-25030: SUZUKI SUPER GREASE “A” e Install the wheel bearings with the special tools. 09924-84510: Bearing installer 09924-84521: Bearing installer NOTE: First install the wheel bearing for left side. CHASSIS 5-4 7 =} j À LE) / \/ A Bearing (L) < | Lo L Clearance 5-5 CHASSIS BRAKE DISC * Make sure that the brake disc is clean and free of any greasy matter. Apply THREAD LOCK SUPER 1360” to the disc mounting bolts and tighten them to the speci- fied torque. «23 99000-32130: THREAD LOCK SUPER 1360” [®] Disc bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) Align the drive lugs (1) to the recesses (2) of the wheel hub. * Before tightening the front axle, position the stopper (3) of speedometer gearbox against stopper (4). e Tighten the front axle to the specified torque and then move the front fork up and down. ¢ Tighten the axle holder nuts to the specified torque. NOTE: When tightening the axle holder nuts, first tighten the up- per nuts. [®] Front axle: 65 №т (6.5 kg-m, 47.0 Ib-ft) Axle holder nut: 10 N-m (1.0 kg-m, 7.0 Ib-ft) FRONT BRAKE CHASSIS 5-6 (1) Piston/cup set (2) Brake hose (3) Pad (4) Piston set © ITEM | N-m | kg-m | Ib-ft ® | 10 | 1.0 | 7.0 23 | 2.3 | 16.5 © | 18 | 1.8 | 13.0 © | 2.5 | 0.25 | 1.8 © 8 0.8 | 6.0 ® | 23 | 2.3 | 16.5 © | 13 | 1.3 | 9.5 ® | 26 | 26 | 19.0 A WARNING * * * * * This brake systemis filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods. When storing the brake fluid, seal the container completely and keep away from children. When replenishing brake fluid, take care not to get dust into fluid. When washing brake components, use fresh brake fluid. Never use cleaning solvent. A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent. A CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics rubber materials etc. 5-7 CHASSIS BRAKE PAD REPLACEMENT e Remove the plug (1). * Remove the brake pads by removing the mounting pin 2). A CAUTION | * Do not operate the brake lever while dismounting the pads. * Replace the brake pad as a set, otherwise braking performance will be adversely affected. e Install the new pads. A WARNING Make sure that the pads are properly engaged with the guide plates as shown in photo. * Tighten the pad mounting pin (2) and plug (1) to the speci- fied torque. (9) Pad mounting pin: 18 N-m (1.8 kg-m, 13.0 Ib-ft) Plug: 2.5 N-m (0.25 kg-m, 1.8 Ib-ft) NOTE: After replacing the brake pads, pump with the brake lever few times to operate the brake correctly and then check the brake fluid level. BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the han- dlebars straight. *e Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with fresh brake fluid. Specification and classification: DOT 4 e Connect a clear hose (3) to the air bleeder valve (4), and insert the free end of hose into a receptacle. e Loosen the bleeder valve and pump the brake lever until no more old brake fluid flows out of the bleeder valve. e Close the air bleeder valve, and disconnect a clear hose. Fill the reservoir with fresh brake fluid to the upper end of the inspection window. | À CAUTION | Bleed air in the brake fluid circuit. (Refer to page 2-11.) CALIPER REMOVAL AND DISASSEMBLY ® Disconnect the brake hose by removing the union bolt and catch the brake fluid in a suitable receptacle. * Remove the caliper by removing the mounting bolts. A CAUTION Never reuse the brake fluid left over from previous ser- vicing and stored for long periods. Brake fluid, if it leaks, will interfere with safe running and descolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage. * Remove the brake pad. (Refer to page 5-7.) * Remove the caliper holder (1) and spring 2). * Place a rag over the piston to prevent its popping out and push out the pistons with an air gun. A CAUTION | Do not use high pressure air to prevent piston damage. e Remove the dust seals and piston seals. | А CAUTION Do not reuse the remored seals to prevent fluid leakage. CHASSIS 5-8 5-9 CHASSIS CALIPER INSPECTION Inspect the caliper cylinder wall for nicks, scratches or other damage. Inspect the piston surface for any scratches or other damage. CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: e Wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves. d Specification and classification: DOT 4 | À CAUTION * Wash the caliper components with fresh brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components. * When washing the components, use the specified brake fluid. Never use different types of fluid or clean- ing solvent such as gasoline, kerosine or the others. * Replace the piston seals and dust seals with new ones when reassembly. Apply the brake fluid to both seals when installing them. e Apply SUZUKI SILICONE GREASE to the caliper axles. EH 99000-25100: SUZUKI SILICONE GREASE CHASSIS 5-10 e Tighten each bolt to the specified torque. [¥] caliper mounting bolt 1): 26 N-m (2.6 kg-m, 19.0 Ib-ft) Pad mounting pin 2: 18 N-m (1.8 kg-m, 13.0 Ib-ft) Plug O: 2.5 Nm (0.25 kg-m, 1.8 Ib-ft) Brake hose union bolt (3): 23 N-m (2.3 kg-m, 16.5 Ib-ft) Air bleeder valve (5): 8 N-m (0.8 kg-m, 6.0 Ib-ft) NOTE: Before remounting the caliper, push the piston all the way into the caliper. A CAUTION | Bleed air from the system after reassembling the caliper. (Refer to page 2-11.) BRAKE DISC INSPECTION * Remove the front and rear wheels. (Refer to pages 5-2 and 5-27.) Visually check the brake disc for damage or cracks. Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. 09900-20205: Micrometer (0—25 mm) Service Limit Front disc: 3.5 mm (0.14 in) Rear disc : 4.0 mm (0.16 in) Measure the runout with a dial gauge. Replace the disc if the runout exceeds the service limit. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand Service Limit Front and Rear disc: 0.3 mm (0.012 in) * Remove the disc. (Refer to pages 5-3 and 5-29.) e Install the disc. (Refer to pages 5-5 and 5-32.) 5-11 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY e Remove the brake lever cover and rear view mirror. ¢ Remove the brake lever. e Disconnect the front brake switch lead wires. ® Расе а гад underneath the union bolt on the master cylinder to catch any spilled drops of brake fluid. Remove the union bolt and disconnect the brake hose/master cylinder joint. A CAUTION | Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely. * Remove the master cylinder assembly. e Remove the front brake switch. CHASSIS 5-12 * Remove the reservoir cap and diaphragm. * Drain brake fluid. * Remove the dust boot. * Remove the circlip with the special tool. 09900-06108: Snap ring pliers * Remove the piston/secondary cup, primary cup and spring. i mm 3 be MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage. 5-13 CHASSIS MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: | A CAUTION | * Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning sol- vent or gasoline to wash them. * Do not wipe the components with a rag. * Apply brake fluid to the cylinder bore and all the com- ponent to be inserted into the bore. Specification and classification: DOT 4 * When remounting the master cylinder on the handlebars, align the master cylinder holder's lower mating surface (1) with punched mark () on the handlebars and tighten the upper clamp bolt first as shown. W Master cylinder mounting bolt: 10 N-m (1.0 kg-m, 7.0 Ib-ft) | A CAUTION Bleed air from the system after reassembling master cylinder. (Refer to page 2-11.) Handlebars Upper clamp bolt UP” mark Master cylinder ЧЕ Clearance CHASSIS 5-14 FRONT FORK —e S SS = —6S ; (2)— — © / / os [| J / / SH & ——Oo = © S&S 0 = Sh S— O > oa | —oe (4) 1 / D—@ (1) Spacer 13) (2) Washer = Soma | amper ro B (5) Spring =) 2 Inner tube Inner tube metal Boot В Stopper a © [7] an Oil seal B ITEM | N-m | kg-m | Ib-ft 2 autor «bre metal A 23 2.3 16.5 AM lock pes 30 3.0 | 21.5 me Ste slr © 10 1.0 7.0 REMOVAL AND DISASSEMBLY * Remove the front wheel. (Refer to page 5-2.) * Remove the front brake caliper. (Refer to page 5-8.) * Remove the front brake hose clamp bolt (1). * Remove the speedometer cable guide bolt (2). 5-15 CHASSIS e Slightly loosen the front fork cap bolt (1) after loosening the front fork upper clamp bolt 2) to facilitate later disas- sembly. e Remove the front fork by loosening the lower clamp bolts @. * Remove the front fork cap bolt (1), spacer (4), washer (5) and spring (6). e Invert the fork and stroke it several times to drain fork oil. *e Hold the fork inverted for a few minutes to drain fork oil. * Remove the damper rod bolt with a 8 mm hexagon wrench and special tools. 09940-34520: ‘’T’’ handle 09940-34592: Attachment “'G"’ * Remove the damper rod with spring. PEL 11 EE HE nadie | sd * Remove the boot by loosening the clamp screws. * Remove the dust seal stopper ring. * Separate the inner tube from the outer tube. | À CAUTION CHASSIS 5-16 * The removed dust seal and oil seal should be replaced. * When separating the inner tube from the outer tube, both anti-friction metals may be damaged and must be replaced with new ones. INSPECTION FORK SPRING Measure the fork spring free length. If it is shorter than serv- ice limit, replace it. Service Limit: 548 mm (21.6 in) INNER TUBE AND OUTER TUBE Inspect the inner tube sliding surface for any scuffing and check for bend. Inspect the outer tube sliding surface for any scuffing. ODA УМО ОМОУОООЛЫОНВОООООООЛООНОЛЬОН 5-17 CHASSIS DAMPER ROD RING Inspect the damper rod ring for wear or damage. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly, and also carry out the follow- ing steps: INNER TUBE METAL e Install the metal by hand as shown in the illustration. A CAUTION | Use special care to prevent damage to the ‘Teflon’ coated surface of the Anti-friction metal when mount- ing it. OUTER TUBE METAL, OIL SEAL AND DUST SEAL * Clean the metal groove of outer tube and metal outer surface. e Apply grease to the lip of new oil seal (3). JAH 99000-25030: SUZUKI SUPER GREASE A” e Install the outer tube metal (1), oil seal retainer (2), oil seal (3) and dust seal (4). 09940-52860: Front fork oil seal installer A CAUTION | Use special care to prevent damage to the ‘’Teflon’’ coated surface of the Anti-friction metal when mount- Ing it. e Install the dust seal stopper ring (5). A CAUTION | Make sure that the oil seal stopper ring fitted securely. SDS UNE SX DAMPER ROD BOLT Apply THREAD LOCK 1342” to the damper rod bolt and tighten it to the specified torque with the special tools and 8-mm hexagon wrench. 99000-32050: THREAD LOCK “1342” 09940-34520: ‘’T’’ handle 09940-34592: Attachment ‘’G”’ (#] Damper rod boit: 30 N-m (3.0 kg-m, 21.5 Ib-ft) FORK OIL e For the fork oil, be sure to use a front fork oil whose vis- cosity rating meets specifications below. Fork oil type: Fork oil # 10 Fork oil capacity: 565 ml (19.1/19.9 US/Imp oz) * Hold the front fork vertical and adjust the fork oil level with the special tool. NOTE: When adjusting oil level, remove the fork spring and com- press the inner tube fully. 09943-74111: Fork oil level gauge Oil level: 164 mm (6.5 in) FORK SPRING o Install the fork spring close pitch side up. CHASSIS 5-18 THREAD LOCK “1342” TOOL 5-19 CHASSIS FRONT FORK REMOUNTING e Align the top surface (1) of the inner tube to the top sur- face (2) of the steering stem upper bracket. * Tighten each bolt to the specified torque. [9] Front fork cap bolt E): 23 N-m (2.3 kg-m, 16.5 Ib-ft) Upper clamp bolt (4): 29 N-m (2.9 kg-m, 21.0 Ib-ft) Lower clamp bolt (5): 26 N-m (2.6 kg-m, 19.0 Ib-ft) CHASSIS 5-20 STEERING (1) Handlebar clamp (2) Handlebar holder ® Cap (4) Damper (Upper) (A) (5) Steering stem upper bracket (6) Damper (Lower) (7) Steering stem nut Bearing (Upper) (9) Bearing (Lower) Steering stem lower bracket _ (0 a ed > (a J Ta = (9) [*) > и VS ITEM | N-m | kg-m | Ib-ft 23 23 16.5 90 9.0 | 65.0 18.0 23 2.9 | 21.0 26 2.6 19.0 > e ) REMOVAL AND DISASSEMBLY ® Remove the front wheel. (Refer to page 5-2.) * Remove the front fork. (Refer to page 5-14.) * Remove the speedometer cable clamp and the front fender. 696818 от N с 5-21 CHASSIS e Remove the headlight cover by removing the three Screws. * Remove the lead wire cover (1). e¢ Disconnect each lead wire coupler. * Remove the headlight bracket with headlight by remov- ing the four bolts. e Remove the front brake master cylinder with brake hose. * Remove the left turn signal light. CHASSIS 5-22 e Unlock the clamps. * Remove the right turn signal light. * Remove the headlight bracket holders. * Remove the speedometer cable (1). e Remove the speedometer by removing the nuts. * Remove the throttle grip case screws. * Disconnect the throttle cables. * Remove the left handlebar switch case screws. e Disconnect the starter cable. 5-23 CHASSIS e Remove the clutch lever cover. ¢ Remove the clutch cable (1). * Remove the indicator light panel (2). e Remove the ignition switch mounting bolts with the spe- cial tools. 09930-11920: Torx bit JT40H 09930-11940: Bit holder e Remove the handlebars by removing the four mounting bolts. e Remove the handlebar holder by removing the mounting nuts. * Remove the steering stem upper bracket by removing the stem head nut. ® Loosen the steering stem nut with the special tools. 09940-14911: Steering stem nut socket wrench 09940-14960: Steering stem nut socket * Remove the steering stem lower bracket. NOTE: Hold the steering stem lower bracket by hand to prevent it from falling. * Remove the upper bearing. * Remove the steering stem lower bearing with a chisel. | À CAUTION | The removed bearing should be replaced with a new one. * Remove the steering stem bearing races, upper and low- er with the special tools. 09941-54911: Steering race remover 09941-74910: Steering bearing remover and installer CHASSIS 5-24 5-25 CHASSIS INSPECTION Inspect the removed parts for the following abnormalities. * Handlebars distortion * Handlebar clamp wear * Race wear and brinelling * Abnormal noise of bearing * Distortion of steering stem Inspect the play of dampers by hands while fixing it in the steering stem upper bracket. If the play can be found, replace the dampers. REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the fol- lowing points: BEARING RACES * Press in the upper and lower bearing races with the spe- cial tool. 09941-34513: Steering outer race installer BEARING * Press in the lower bearing with the special tool. 09925-18010: Steering bearing installer ® Apply grease to the upper and lower bearings. MAH 99000-25030: SUZUKI SUPER GREASE “A” STEM NUT * Tighten the steering stem nut to 45 Nm (4.5 kg-m, 32.5 Ib-ft) with the special tools. 09940-14911: Steering stem nut wrench 09940-14960: Steering stem nut socket e Turn the steering stem bracket about five or six times to the left and right until it locks in position so that the taper roller bearing will be seated properly. * Turn back the stem nut by 1/4— 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle. * Tighten the steering stem nut to the specified torque. [BV] Steering stem head nut: 90 N-m (9.0 kg-m, 65.0 Ib-ft) NOTE: Before tightening the steering stem nut, install the front fork temporarily. * Tighten the handlebar holder nuts to the specified torque. [®] Handlebar holder nut: 25 N-m (2.5 kg-m, 18.0 Ib-ft) NOTE: Before tighten the handlebar holder nuts, install the handle- bars temporarily. HANDLEBARS * Set the handlebars to match its punched mark to the mat- ing face of the holder. * Secure the each handlebar clamp in such a way that the clearances (A) ahead and behind of the handlebars are equalized. [9] Handlebar clamp bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) A CAUTION | CHASSIS 5-26 1/4— 1/2 turn After performing the adjustment and installing the steer- ing stem upper bracket, “rock” the front wheel assem- bly forward and back to ensure that there is no play and that the procedure was accomplished correctly. Fi- nally check to be sure that the steering stem moves freely from left to right with own weight. If play or stiff- ness is noticeable, re-adjust the steering stem nut. 5-27 CHASSIS REAR WHEEL OH 7 y =( \ № ` Fonei Ko © (1) Chain adjuster (2) Disc (3) Dust seal (4) Bearing (5) Spacer (6) Damper (7) Sprocket drum Rear sprocket (9) Spacer Bearing (1) Dust seal (2 Spacer (3 Rear axle Cotter pin (For Canada and U.S.A.) AN J EY HA VE N-m | kg-m | Ib-ft *100 | * 10.0 | *72.5 110 | 11.0| 79.5 ® | 45 | 0.45 | 3.0 © | 23 | 2.3 | 16.5 © | 27 | 2.7 | 19.5 NOTE: Asterisk mark (*) indicates the Canada and U.S.A. models. REMOVAL * Remove the cotter pin. (For Canada and U.S.A.) ®* | oosen the axle nut. * Support the motorcycle with a jack. * Remove the axle nut and axle. * Remove the rear wheel by disengaging the drive chain. | À CAUTION Do not operate the brake pedal while dismounting the rear wheel. e Remove the rear sprocket mounting drum from the wheel. e Remove the cushions. e Remove the spacer (1). e Remove the rear sprocket by removing the mounting nuts and bolts. * Remove the dust seal with the special tool. 09913-50121: Dust seal remover CHASSIS 5-28 5-29 CHASSIS * Remove the brake disc by removing the mounting bolts. INSPECTION AND DISASSEMBLY TIRE ices .. Refer to page 2-12. REAR WHEEL ............eeeeeenernacaanaco Refer to page 5-10. WHEEL BEARING AND SPROCKET DRUM BEARING Inspect the play of bearing inner ring by hand while mount- ed in the wheel or sprocket drum. Rotate the inner ring by hand to inspect any abnormal noise occurs or rotating smoothly. Replace the bearing if there is anything unusual. Remove the both bearing with the special tool in the follow- Ing procedures. * Insert the adapter into the bearing. 09941-50111: Bearing remover * After inserting the wedge bar from the opposit side, lock the wedge bar in the slit of the adapter. e Drive out the bearing by hammering the wedge bar. | А CAUTION | Play fp Play The removed bearings should be replaced with new ones. CHASSIS 5-30 * Remove the sprocket drum bearing with the special tool. 09913-75830: Bearing remover | À CAUTION | The removed bearing should be replaced with a new one. REAR AXLE Using a dial gauge, check the rear axle for runout. If the runout exceeds the limit, replace the rear axle. 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: ‘’V’’ block set Service Limit: 0.25 mm (0.010 in) REAR SPROCKET Inspect the sprocket teeth for wear. If they are worn as il- lustrated, replace the sprocket and drive chain. REAR SPROCKET DAMPER Inspect the dampers for wear and damage. If any defects are found, replace the dampers as a set. Normal wear Excessive wear 5-31 CHASSIS REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel in the reverse ord- er of removal and disassembly. Pay attention to the follow- Ing points: WHEEL BEARING * Apply grease to the bearings. AM 99000-25030: SUZUKI SUPER GREASE “A” o Install the wheel bearings with the special tools. 09924-84510: Bearing installer 09924-84521: Bearing installer NOTE: First install the bearing for right side. Seal side of bearing goes toward outside. Bearing (R) Bearing (L) J анна rr | — — ea — —— Clearance * |nstall the rear sprocket drum bearing by using a bearing installer. 09913-75810: Bearing installer NOTE: Seal side of bearing goes toward outside. CHASSIS 5-32 BRAKE DISC * Apply THREAD LOCK SUPER “1360” to the disc bolts and tighten them to the specified torque. NOTE: Make sure that the brake disc is clean and free of any greasy matter. 99000-32130: THREAD LOCK SUPER “1360” [1] Disc bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) SPROCKET * Tighten the sprocket nuts to the specified torque. [®] Sprocket nut: 27 N-m (2.7 kg-m, 19.5 Ib-ft) NOTE: Face the stamped mark on the sprocket to outside. REAR AXLE NUT ¢ Adjust the chain slack after rear wheel installation. (Refer to page 2-9.) e Tighten the axle nut to the specified torque. [¥) Axle nut: 100 N-m (10.0 kg-m, 72.5 Ib-ft) ... For Canada and U.S.A. : 110 №т (11.0 kg-m, 79.5 Ib-ft) ... Рог the others 5-33 CHASSIS REAR BRAKE ITEM | Nom | kg-m | lb-ft 18 1.8 13.0 8 0.8 6.0 23 2.3 16.5 13 1.3 9.6 10 1.0 7.0 23 2:3 16.5 ОЭ О ООО 18 1.8 13.0 (1) Piston (2) Pad (3) Insulator (4) Shim (5) Caliper holder (6) Reservoir tank (7) Reservoir tank hose Brake hose (9) Piston/cup set A WARNING * * * * * * This brake systemiis filled with a ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for long periods. When storing the brake fluid, seal the container completely and keep away from children. When replenishing brake fluid, take care not to get dust into fluid. When washing brake components, use fresh brake fluid. Never use cleaning solvent. A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent. | À CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. BRAKE PAD REPLACEMENT * Remove the brake pad mounting pins (1). * Remove the inside pad first. * Slide the caliper housing to outside then remove the pad O. | À CAUTION | * Do not operate the brake pedal while dismounting the pads. * Replace the brake pad as a set, otherwise braking performance will be adversely affected. o Install the new pads correclty. * Tighten the pad mounting pin (1) to the specified torque. (9) Pad mounting pin: 18 N-m (1.8 kg-m, 13.0 Ib-ft) NOTE: After replacing the brake pads, pump with brake pedal few times to operate the brake correctly and then check the brake fluid level. BRAKE FLUID REPLACEMENT * Remove the reservoir tank mounting bolt. * Replace brake fluid in the same manner of the front brake. (Refer to page 5-7.) Specification and classification: DOT 4 Á CAUTION Bleed air in the brake fluid circuit. (Refer to page 2-11.) CHASSIS 5-34 5-35 CHASSIS CALIPER REMOVAL AND DISASSEMBLY * Remove the rear wheel. (Refer to page 5-27.) * Place a rag underneath the union bolt on the brake caliper to catch any spilled drops of brake fluid. e Remove the union bolt and catch brake fluid in a suitable receptacle. A CAUTION | Never reuse the brake fluid left over from previous ser- vicing and stored for long periods. A WARNING Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. ® Remove the caliper with caliper holder. * Remove the caliper holder (1). e Remove the pads. (Refer to page 5-34.) * Place a rag over the piston to prevent popping up. Force out the piston with an air gun. A CAUTION | Do not use high pressure air to prevent piston damage. * Remove the dust seal and piston seal. | А CAUTION | Do not reuse the removed seals to prevent fluid leakage. Ш CALIPER AND DISC INSPECTION Inspect the caliper cylinder bore wall for nicks, scratches or other damage. Inspect the pistons for damage and wear. DISC erereere RR 0 0000 Refer to page 5-10. CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and disassembly. Pay attention to the following points: A CAUTION | CHASSIS 5-36 * Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. * Apply brake fluid to the caliper bore and piston to be inserted into the bore. Specification and classification: DOT 4 e Tighten the brake hose union bolt to the specified torque. [®] Brake hose union bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) | À CAUTION | Bleed air from the system after reassembling the caliper. (Refer to page 2-11.) 5-37 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY e Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. e Loosen the rear brake rod lock nut (1). * Remove the master cylinder mounting bolts (2). *e Disconnect the brake rod by rotating brake rod (3). * Disconnect the brake hose (4). * Remove the reservoir tank by removing the mounting bolt (5). e Remove the connector by removing the circlip (6). 09900-06108: Snap ring pliers * Remove the O-ring (7). | À CAUTION The removed O-ring should be replaced with a new one. * Remove the dust boot. * Remove the circlip with the special tool. 09900-06108: Snap ring pliers * Remove the rod, piston, primary cup and spring. CHASSIS 5-38 MASTER CYLINDER INSPECTION Inspect the cylinder bore wall for any scratches or other a Inspect the piston surface for scratches or other damage. Inspect the primary cup for damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the fol- lowing points: A CAUTION * Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning sol- vent or gasoline to wash them. * Apply brake fluid to the cylinder bore and all the in- ternals to be inserted into the bore. Specification and classification: DOT 4 MASTER CYLINDER e Tighten the bolts and nut to the specified torque. © Master cylinder mounting bolt (1) : 10 N-m (1.0 kg-m, 7.0 Ib-ft) Master cylinder rod lock nut (2) : 18 N-m (1.8 kg-m, 13.0 Ib-ft) Brake hose Union bolt (3): 23 N-.m (2.3 kg-m, 16.5 Ib-ft) A CAUTION | * Bleed air from the system after reassembling master cylinder. (Refer to page 2-11.) * Adjust the brake pedal height. (Refer to page 2-11.) 5-39 CHASSIS REAR SWINGARM AND SUSPENSION ITEM | N-m | kg-m | lb-ft (A) 55 5.5 | 40.0 B 100 | 10.0 | 72.5 © 100 | 10.0 | 72.5 D 80 8.0 | 58.0 © 77 Ed 55.5 (1) Shock absorber (2) Cushion rod (3) Cushion lever (4) Swingarm (5) Chain guide (6) Chain buffer (7) Rear axle Chain cover CHASSIS 5-40 REMOVAL * Remove the frame covers and seat. (Refer to page 5-1.) * Remove the rear wheel. (Refer to page 5-27.) Loosen the carburetor clamp screw (1). Disconnect the crankcase breather hose 2). * Remove the air cleaner by removing the mounting bolts (3). * Disconnect the brake hose from the hose guides. * Remove the drive chain cover and guide. * Remove the rear shock absorber lower mounting bolt (4). * Remove the cushion lever mounting nut (6) and bolt. 5-41 CHASSIS e Remove the rear swingarm pivot nut after removing the caps. ¢ Remove the rear swingarm by removing the pivot shaft. e Remove the rear shock absorber. e Remove the cushion rods with cushion lever. e Remove the drive chain buffer. e Remove the brake hose guides and mud guard. e Remove the cushion rods. * Remove the swingarm dust seals and spacers. se Remove the cushion lever dust seals and spacers. INSPECTION AND DISASSEMBLY SWINGARM Inspect the swingarm for wear or damage. Inspect the spacer for any flaws or other damage. Insert the spacer into the bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. e Draw out the swingarm bearings and spacer with the spe- cial tools. =) 09923-74510: Bearing remover 09930-30102: Sliding shaft A CAUTION | CHASSIS 5-42 The romoved bearings should be replaced with new ones. 5-43 CHASSIS CUSHION LEVER Inspect the spacer for any flaws or other damage. Insert the spacer into the bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with new ones. * Draw out the bearing with the special tools and appropri- ate tool. 09923-73210: Bearing remover 09930-30102: Sliding shaft A CAUTION | The removed bearing should be replaced with new ones. SHOCK ABSORBER Inspect the shock absorber for oil leakage or other damage. If any defects are found, replace the shock absorber with new a one. SWINGARM PIVOT SHAFT Using a dial gauge, check the pivot shaft runout and replace it if the runout exceeds the limit. 09900-20606: Dial gauge 09900-20701: Magnetic stand 09900-21304: V-block Service Limit: 0.3 mm (0.01 in) REASSEMBLY AND REMOUNTING Reassemble and remount the rear swingarm and suspension In the reverse order of removal and disassembly. Pay atten- tion to the following points: SWINGARM BEARING e Install the new bearing with the special tool. 09941-34513: Bearing installer NOTE: When installing the bearing, punch-marked side of bearing faces outside. CUSHION LEVER BEARING e Install the new bearing with the special tool. 09924-84521: Bearing installer NOTE: When installing the bearing, punch-mark side of bearing faces outside. e Remount the rear suspension. (Refer to page 5-45.) CHASSIS 5-44 5-45 CHASSIS REASSEMBLING INFORMATION Left Sp mm) Right ITEM | N-m | kg-m | Ib-ft Aa 55 5.5 | 40.0 B) 55 5.5 | 40.0 © | 100 | 10.0 | 72.5 D 80 8.0 | 58.0 Œ | 100 | 10.0 | 72.5 © 77 7.7 | 55.5 CHASSIS 5-46 FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and wheel, the follow- ing adjustments are required before driving. * Drive Cha HR e e Page 2- 9. * Rear brake pedal height .............e.eee.ee..... Page 2-11. * Tire Pressure EN Page 2-13. SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT Spring pre-load is adjustable by changing the spring adjuster ring position after removing the shock absorber. Turning the spring adjuster ring counterclockwise or clockwise as viewed from for increase or decrease the spring pre-load after loosening the adjuster lock ring. The standard set length is 247.5 mm. After adjusting the pre-load, tighten the spring adjuster lock ring securely. 09910-60611: Universal clamp wrench | À CAUTION | Do not set the spring to the length less than 238.5 mm (9.4 in). SPRING SETTING TABLE Spring pre-set length Softest 253.5 mm (10.0 in) Standard 247.5 mm (9.7 in) Stiffest 238.5 mm (9.4 in) SHOCK ABSORBER DAMPING FORCE ADJUSTMENT Fully turn the damping force adjuster clockwise. It is at stiffest position and turn it out to the standard setting po- sition. STD position: 8 clicks turns out 5-47 CHASSIS LOWERING THE SEAT HEIGHT The seat height can be lowered 40 mm by changing the lo- cation of the inner parts of the front fork and rear shock ab- sorber and replace the optional side stand. OPTIONAL PARTS SUPPLY Part No. Part Name PCS Note Non Side stand @) (Silver painting) 1 For E-03 09248-10006 | Plug 1 E-24 42300-32820 | 62184-32E00 | Plate 1 E-28 68380-32E10 | Label set 1 E Non Side stand (6) (Silver painting) 1 09248-10006 | Plug 1 42300-32810 62184-32E00 Plate 1 For the others 68380-32E00 | Label set 1 NOTE: Side stand length @) is defferent from B)in the above chart. SPECIAL TOOLS ee 7 This special tool is used for loosening and tight- ening the front fork damper rod bolt. 09940-34520: ‘’T’’” handle This special tool is used with tool (09940-34520) for loosening and tightening the front fork damper rod bolt. 09940-34592: Attachment “‘G"’ This special tool is used for adjusting the front fork oil level. 09943-74111: Front fork oil level gauge og J К This special tool is used for loosening and tight- ening the rear shock absorber ring. 09910-60611: Universal clamp wrench FRONT FORK CHASSIS 5-48 Iran Ц 7 Standard spacer (1) position Changed spacer (1) position (1) Spacer (2) Washer (3) Spring (4) Damper (5) Spring (6) Gasket (7) Speedometer gearbox Front wheel (9) Spacer Front brake caliper (5) ITEM N-m kg-m Ib-ft a 23 2.3 16.5 30 3.0 21.5 © 65 6.5 47.0 О 10 1.0 7.0 © 26 2.6 19.0 5-49 CHASSIS REMOVAL AND DISASSEMBLY * Loosen the front axle holder nuts (1) and axle (>). e Carefully position a jack under the chassis tubes and raise until the front wheel is slightly off the ground. * Remove the front wheel by removing the axle. * Remove the front brake caliper mounting bolts (3). Remove the front brake hose clamp bolt (4) and speedom- eter cable guide bolt (5). e Slightly loosen the front fork cap bolt (6) after loosening the front fork upper clamp bolt (7) to facilitate later disas- sembly. * Remove the front fork by loosening the lower clamp bolts (8). * Remove the other side front fork the same way. * Remove the front fork cap bolt (6), spacer (9), washer and spring (7). * Invert the front fork and stroke it several times to drain fork oil. CHASSIS 5-50 * Remove the damper rod bolt with a 8 mm hexagon wrench and special tools. 09940-34520: ‘’T’’ handle 09940-34592: Attachment ‘G’’ * Remove the damper rod (1) with spring O). REASSEMBLY AND REMOUNTING . Reassemble and remount the front fork and front wheel in à the reverse order of removal and disassembly. Pay atten- tion to the following points: e Install the removed spacer (3) and spring @) to the damp- er rod as shown in the photo. * Insert the damper rod assembly to the inner tube with the special tool. 09940-34520: ‘’T’’ handle 09940-34592: Attachment “‘G’’ @ (3) — * Apply THREAD LOCK “1342” to the damper rod bolt. 99000-32050: THREAD LOCK ‘‘1342”’ Q A CAUTION | ; | Г Use a new gasket (4) to prevent oil leakage. THREAD LOCK 1342 5-51 CHASSIS * Tighten the damper rod bolt to the specified torque with a 8 mm hexagon wrench and special tools. W Damper rod bolt: 30 N-m (3.0 kg-m, 21.5 Ib-ft) 09940-34520: ‘’T’’ handle 09940-34592: Attachment “'G”' e Pour specified fork oil into the inner tube. Fork oil type: Fork oil #10 99000-99044-10G: SUZUKI FORK OIL #10 Capacity (each leg): 563 ml (19.0/19.8 US/Imp oz) * Hold the front fork vertical and adjust the fork oil level with the special tool. 09943-74111: Fork oil level gauge Oil level: 150 mm (5.9 in) NOTE: When adjusting the oil level, remove the fork spring and com- press the inner tube fully. e Install the fork spring close pitch side up. * Install the washer and fork cap bolt, and tighten the cap bolt your hand. * When remounting the front fork, align the upper surface (1) of the inner tube with the upper surface 2) of the steer- ing stem upper bracket. ¢ Tighten the front fork lower clamp bolts and fork cap bolt to the specified torque. e Tighten the front fork upper clamp bolt to the specified torque. [®) Front fork cap bolt: 23 N-m (2.3 kg-m, 16.5 Ib-ft) Upper clamp bolt : 29 N-m (2.9 kg-m, 21.0 Ib-ft) Lower clamp bolt : 26 N-m (2.6 kg-m, 19.0 Ib-ft) o Install the brake hose clamp and speedometer cable guide correctly. * Tighten the front brake caliper mounting bolts to the speci- fied torque. [7] Brake caliper mounting bolt: 26 N-m (2.6 kg-m, 19.0 Ib-ft) * Align the drive lugs (1) with the recesses (2) of the wheel hub. e Before tightening the front axle, position the stopper (3) of the speedometer gearbox against stopper (4). e Tighten the front axle to the specified torque and then move the front fork up and down. * Tighten the upper axle holder nuts first and then lower nuts to the specified torque. [9] Front axle: 65 N-m (6.5 kg-m, 47.0 Ib-ft) Axle holder nut: 10 N-m (1.0 kg-m, 7.0 Ib-ft) CHASSIS 5-52 5-b3 CHASSIS REAR SHOCK ABSORBER (1) Rear shock absorber (2) Plate (Optional part) (3) Plug (Optional part) (4) Spring seat RITA rente sit me E Е Standard spring seat (4) and mounting Changed spring seat (4) and mounting position position. ITEM N-m kg-m Ib-ft ® 55 5.5 40.0 30 3.0 21.5 CHASSIS 5-54 REMOVAL AND DISASSEMBLY * Remove the right and left frame covers. * Remove the seat by removing mounting bolts. * Loosen the carburetor clamp screw (1). * Disconnect the crankcase breather hose (2). * Remove the air cleaner by removing mounting bolts (3). * Remove the rear shock absorber by removing mounting bolts (4), (5). 5-55 CHASSIS ® Loosen the spring pre-load adjuster lock ring and adjuster ring fully with the special tool. 09910-60611: Universal clamp wrench * Remove the spring seat (1) and plate (2) by moving the cushion (3) to the shock absorber cylinder side. NOTE: The removed plate (2) will not be used when reassembling the shock absorber. REASSEMBLY AND REMOUNTING Reassemble and remount the rear shock absorber and air cleaner in the reverse order of removal and disassembly. Pay attention to the following points: * When installing the spring seat (1) to the shock absorber, invert it from standard position. e Position the cushion (3) against washer 4). ¢ Tighten the spring adjuster ring and adjust the spring pre- load with the special tool. The standard set length is 247.5 mm. e After adjusting the pre-load, tighten the adjuster lock ring securely. 09910-60611: Universal clamp wrench SPRING SETTING TABLE Spring pre-set length Softest 253.5 mm (10.0 in) Standard 247.5 mm (9.7 in) Stiffest 238.5 mm (9.4 in) * Tighten the plug (1) (optional part) to the lower mounting part of shock absorber (2) to the specified torque. [®] Plug: 30 N'm (3.0 kg-m, 21.5 Ib-ft) e Install the shock absorber lower plate (3) (optional part) as shown in the illustration. e Install the rear shock absorber and tighten it to the speci- fied torque. [9] Mounting bolt : 55 N-m (5.5 kg-m, 40.0 Ib-ft) (Upper and lower) SIDE STAND CHASSIS 5-56 LH + —— RH T—T @ - a (© D (1) Side stand @) Inner spring (3) Outer spring © ITEM | N-m kg-m Ib-ft A 50 5.0 36.0 55 5.5 40.0 5-57 CHASSIS SIDE STAND REMOVAL AND INSTALLATION * Support the motorcycle with jack or wooden block. * Remove the original side stand by removing mounting nut and bolt. * Apply SUZUKI SUPER GREASE “A” to the side stand pivot portion and spring hooks. AMAN 99000-25030: SUZUKI SUPER GREASE “A e Install the optional shorter side stand (silver-colored) and springs correctly as shown in the illustration. * Tighten the side stand mounting bolt and nut to the speci- fied torque. [9] Bolt: 50 N-m (5.0 kg-m, 36.0 Ib-ft) Nut: 55 N-m (5.5 kg-m, 40.0 Ib-ft) A WARNING A new, shorter, silver-colored optional side stand must be installed for safe parking. NOTE: Make sure that the side stand switch operation after in- stalling the side stand. WARNING LABEL e Attach the warning label (optional part) to the swingarm as shown in the illustration. NOTE: Select the appropriate language label for your country. Warning label Tire pressure label Swingarm left side ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ===——..— 0 ..=oÑ "non 6- 1 LOCATION OF ELECTRICAL COMPONENTS ----------=.....200000000000 6- 3 CHARGING SYSTEM ----........-.2.x0000000000r00ric00 0 e DA 6- 4 DESCRIPTION +::==========21=0 01d 0ua20n000eren canadian NED 6- 4 TROUBLESHOOTING :======<==2=0======1022=00a=0 007100 A ia. 6- 5 INSPECTION =====>==c(20z2200=0200000000000 00 EII ANOTA aaa AED 6- 6 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK S YS TE M PE a EAN EA EEE TO EEE CUESTE DE E E 0- 9 STARTER SYSTEM DESCRIPTION -------------.===..2000000000000 00 6- 9 SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION ---- 6- 9 TROUBLESHOOTING --<…<<<<<<<<<<<<<++<crrrrrerrarrananenenan nan ana sera nn anna uen 6-11 STARTER MOTOR REMOVAL AND DISASSEMBLY -----.-.---.------ 6-12 STARTER MOTOR INSPECTION -----------.=.==.122000000000000 6-12 STARTER MOTOR REASSEMBLY ----------=--=.==.2.0000000000 6-13 STARTER RELAY INSPECTION ++++44444444444444 cena cannanese 6-14 SIDE-STAND/IGNITION INTERLOCK SYSTEM INSPECTION ------ 6-15 IGNITION SYSTEM «===. ooo TIRÓN wrasse 6-17 DESCRIPTION ---<---<<<<<<<<-<<<<<.<rrrrranraranararanenaacennananan enr ace na an ane nee 6-17 TROUBLESHOOTING --..............002200000000000ii0ic0 0er RDA 6-18 INSPECTION came ar ee to A Ban ih ai i hmmm ann don. 6-19 SPEEDOMETER AND PILOT INDICATOR ----------==-=========00000s 6-22 REMOVAL AND DISASSEMBLY ---------==-==.==.02.200000000000 0 6-22 INSPEC TION oovesrermenonenennnnmeen sara en ennemies 6-22 LAMPS TS 6-24 71-7:15]8/0]: | O na ane nanene naar aan nee can ana ane 0 6-24 TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT Tr AS Mia ala. 6-25 TURN SIGNAL RELA Y a EE E e 6-26 S WI TCHE. S NINA A AC RAE AE TE AAA TEE 6-26 B A TTE R Y EAN 6- 2 7 SPECIFICA TIONS OT I EE EE J A A ARE НОЕи 6-27 INITIAL CHARGING Ee RR ESA EE EE REWER REE ERE EE 6-27 SER VICING EA A a AAA Ad na 6-28 RECHARGING OPERATION wivivsssvsavscvmsnriissasiss sass sass sass sons 6-29 6-1 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR When connecting a connector, be sure to push it in untill a click is felt. Inspect the connector for corrosion, contamination and breakage In its cover. COUPLER С With a lock type coupler, be sure to release the lock be- fore disconnecting it and push it in fully till the lock works when connecting it. When disconnecting the coupler, be sure to hold the cou- pler itself and do not pull the lead wires. Inspect each terminal on the coupler for being loose or bent. Inspect each terminal for corrosion and contamination. LAMP Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING" (Refer to pages 7-12 and 13.). Bend the clamp properly so that the wire harness is clamped securely. In clamping the wire harness, use care not to allow it to hang down. Do not use wire or any other substitute for the band type clamp. FUSE When a fuse blows, always investigate the cause, cor- rect it and then replace the fuse. Do not use a fuse of a different capacity. Do not use wire or any other substitute for the fuse. SEMI-CONDUCTOR EQUIPPED PART Be careful not to drop the part with a semi-conductor built in such as a CDI unit and regulator/rectifier. When inspecting these parts, follow inspection instruc- tion strictly. Neglecting proper procedure may cause damage to these parts. CORRECT INCORRECT ELECTRICAL SYSTEM 6-2 BATTERY e The MF battery used in this vehicle does not require main- tenance as inspection of electrolyte level and replenish- ment of water. e No hydrogen gas is produced during normal charging of the battery, but such gas may be produced when it is over- charged. Therefore, do not bring fire near the battery while it is being charged. e Note that the charging system for the MF battery is differ- ent from that of an ordinary battery. Do not replace with an ordinary battery. CONNECTING BATTERY e When disconnecting terminals from the battery for dis- assembly or servicing, be sure to disconnect the nega- tive ( ©) ) terminal first. e When connecting terminals to the battery, be sure to con- nect the positive ( 4) ) terminal first. ® |f the terminal is found corroded, remove the battery, pour warm water over it and clean with a wire brush. * Upon completion of connection, apply grease lightly. * Put a cover over the positive ( 4) ) terminal. WIRING PROCEDURE * Route the wire harness properly according to “WIRE HAR- NESS ROUTING" (Refer to pages 7-12 and 13.). USING POCKET TESTER Be sure to use positive ( +) ) and negative ( © ) probes of the tester properly. Their false use may cause damage in the tester. * |f the voltage and current values are not known, start measuring in the higher range. e Before measuring the resistance and after changing the resistance range, always perform O Y adjustment. e Taking a measurement where voltage is applied in the resistance range may cause damage in the tester. When measuring resistance, check to make sure that no voltage Is applied there. e After using the tester, turn the switch to the OFF position. 6-3 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS (1) Battery (2) Fuse (3) Starter relay (4) Generator (5) Ignition coil (6) Starter motor (7) Horn CDI unit (9) Diode Turn signal relay (D Regulator/rectifier (2 Side-stand/ignition interlock relay (13 Side-stand switch ELECTRICAL SYSTEM 6-4 CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in the figure, which is composed of an AC generator, regulator/rectifier unit and battery. The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the battery. Ignitilon switch „о“ 1 I I i I 1 i i i i i a o SCR SCR [SCR ¡+ Battery < | — — I U | 1 J mm Emm Em ; © AC generator = Q | — Es IEE IE I IE SE TE TEE A TED ED НН EEE SEE AEE EDD EE TED EE EE. Regulator/rectifier 77 7 6-5 ELECTRICAL SYSTEM TROUBLESHOOTING ( Battery runs down quickly. ) waste electric power. Check accessories which excessively Not installed Y (Refer to page 6-6.) Inspect battery leak current. No leak Inspect charging voltage between battery terminals. (Refer to page 6-6.) Incorrect Y Inspect continuity generator coils. (Refer to page 6-7.) | Correct ' Inspect generator no-load voltage. (Refer to page 6-7.) Correct y Inspect regulator/rectifier. (Refer to page 6-8.) | Correct ' Inspect wirings. | Correct Correct — — ——>e No continuity —— ® |псоггес{ — — — —> ® Incorrect— > Incorrect— — — > ® — Installed ———> * Remove accessories. Leak ——» * Short circuit of wire harness. Loose or disconnected wires. Faulty battery. Faulty battery. Abnormal driving condition. Faulty generator coils or discon- nected lead wires. Faulty generator rotor. Faulty regulator/rectifier. Short circuit of wire harness. Poor contact of couplers. Faulty battery. Battery overcharge * Faulty regulator/rectifier * Faulty battery * Poor contact of generator lead wire coupler ELECTRICAL SYSTEM 6-6 INSPECTION BATTERY LEAK CURRENT INSPECTION e Remove the frame covers and seat. * Remove the battery holder plate (1) . Turn the ignition switch to the OFF position. e Disconnect the battery ©) lead wire. Note that leakage is indicated if the needle swings even a little when the milliampare meter of the pocket tester is con- nected between a ©) terminal and the lead wire of the bat- tery as shown. 09900-25002: Pocket tester | À CAUTION | e Because the leak current might be large, turn the tester to high range first when connecting an ammeter. * Do not turn the ignition switch to the ON position when measuring current. When leakage is found, look for the part where the needle does not swing through the couplers and connectors are re- moved one by one. CHARGING OUTPUT INSPECTION * Remove the frame covers and seat. * Remove the battery holder plate. * Start the engine and keep it running at 5 000 r/min. with lighting switch turned ON and dimmer switch turned HI position. Measure the DC voltage between the battery terminals +) and ©) with a pocket tester. If the tester reads under the specified value, inspect the generator coil and regula- tor/rectifier. A CAUTION | If the pocket tester is set to read current or resistance = Pattery : @ and a voltage is applied across the test probes, damage will result. Therefore, it is important that the tester knob on the pocket tester be set the proper position before making any measurements. (DCV) Tester NOTE: When making this test, be sure that the battery is fully- charged condition. 09900-25002: Pocket tester Uv]! Tester knob indication: DC 25V Charging output Standard: 13.0—16.0 at 5 000 r/min. 6-7 ELECTRICAL SYSTEM GENERATOR COIL CONTINUITY INSPECTION * Remove the frame covers and seat. *e Disconnect the generator lead wire coupler (1). Using a pocket tester, inspect the continuity between the three lead wires. If there is no continuity, replace the generator coil with a new one. 09900-25002: Pocket tester US]! Tester knob indication: X 10 range GENERATOR NO-LOAD PERFORMANCE INSPECTION * Remove the frame covers and seat. e Disconnect the generator lead wire coupler (1) . * Start the engine and keep it running at 5 000 r/min. Using a pocket tester, measure the voltage between the three lead wires. If the tester reads under the specified value, replace the generator coil with a new one. 09900-25002: Pocket tester UN)! Tester knob indication: AC250V Generator no-load performance: More than 75V/5 000 r/min (When engine is cold) ELECTRICAL SYSTEM 6-8 REGULATOR/RECTIFIER INSPECTION ENE =" * Remove the right frame cover. REE RTT * Disconnect the regulator/rectifier coupler (1). Using a pocket tester ( x 1kQ range), measure the resistance between the terminals in the following table. If resistance is incorrect, replace the regulator/rectifier. 09900-25002: Pocket tester ([2]} Tester knob indication: X 1kQ range Unit: kQ + Probe of tester to: 2 ® © Yi Y2 Y3 e @ 6 ® со 00 00 00 = 1—20 1—10 1—10 1—10 © Ya 1—10 00 00 со © | = Y2 1-10 со со че =m == © Y3 1—10 со со со a 4 co: Infinity Yı Ya Ys NOTE: As diodes, thyristors are used inside this regulator/rectifi- er, the resistance values will differ when an ohmmeter other than the SUZUKI pocket tester is used. 6-9 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, starter relay, side-stand relay, side-stand switch, neutral switch, clutch lever position switch, starter switch, engine stop switch, IG switch and battery. Depressing the starter switch (on the right handlebars switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about 70 amperes to start the engine. Starter relay о : Side-stand Clutch lever Starter Engine stop relay position switch switch switch —o Ignition switch {Oo ; Fuse Side-stand > switch e Neutral - 5 | i + 0% switch POE “am (0 77 7 | SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION This side-stand/ignition interlock system is to prevent starting the motorcycle with the side-stand left down. The system is operated by an electric circuit provided between the battery and ignition coll. To CDI and ignition cail Engine Starter Clutch lever stop switch position switch switch HA Ignition Side-stand relay Fuse switch | о NL fo ; a Starter relay Starter motor | J Neutral indicator light BI/B G / Y Diode YB Г С— — ® A Side-stand ? BI A Neutral switch I switch + WIRE COLOR R : Red B/W : Black with White tracer O : Orange G : Green BI/B : Blue with Black tracer Y/B : Yellow with Black tracer BI: Blue ELECTRICAL SYSTEM 6-10 The circuit consists of relay, lamp, diode and switches and decides to live the ignition coil depending on the position of the TRANSMISSION and SIDE-STAND with the neutral and side-stand switches working mutually. The ignition coil lives only in two situations as follows. 1. Transmission: “NEUTRAL (ON)” Side-stand: "DOWN (OFF)"’ The current flow @ turns ON” the relay and the ignition coil lives even the side-stand is kept down. This is or warming up the engine. To CDI and ignition coil Engine Starter Clutch lever stop switch position switch switch I, TL Side-stand relay EEE EE Ignition switch N << Neutral 3 O indiater | E e eE Diode N— E Mere A Side-stand Spal switch Ÿ Side-stand “DOWN POSITION” 2. Side-stand: “UP-RIGHT (ON)” The current flow B) turns “ON” the relay and the ignition coil lives. The engine can be easily started at any transmission position. To CDI and ignition coil Clutch lever Engine da g Starter position stop switch : Side-stand switch EL switch relay ос” = IS Ignition switch —5 | Oo ous -— 5 ~ Neutral (9) indicator Diode + | ® "Tr 1 “| A Neutral Side-stand switch switch OFF y Side-stand “UP-RIGHT POSITION” 6-11 ELECTRICAL SYSTEM TROUBLESHOOTING ( starter motor will not run. ) The transmission is in neutral. Turn on the ignition switch with the engine stop switch in “RUN” position. Check whether to hear the click noise from the starter relay when the starter button is pushed. Clicks — —» No click Check whether to run the starter motor when connect the starter motor terminal to the battery ©) terminal directly. (Do not use thin wire, because flows.) large amount of current Measure the starter relay voltage at the starter relay connectors (between Y/G $ and B/W O) when the starter button is pushed. — Not voltage ——>»e Voltage measured Check the starter relay. (Refer to page 6-14.) Incorrect -— —»* | Correct Mii = © | | Run Not run ® Faulty starter motor Faulty starter relay Loosen or disconnected starter motor lead wire Faulty ignition switch Faulty engine stop switch Faulty neutral switch Faulty diode Faulty side-stand relay Faulty starter button Faulty clutch lever position switch Poor contact of connector Open circuit in wiring harness Faulty starter relay Poor contact of the starter relay Starter motor runs when the transmission is in neutral, but does not run with the transmission in any position except neutral, with the side-stand up position. Check the side-stand switch. (Refer to page 6-16.) Incorrect—>e Correct Faulty side-stand switch »-e Open circuit in wiring harness * Poor contact of connector Engine does not turn though starter motor runs. ® Faulty starter clutch ELECTRICAL SYSTEM 6-12 STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the exhaust pipe. * Remove the cam drive chain tensioner. * Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts. (Refer to page 3-11.) e Disassemble the starter motor as shown in the illustration. (1) O-ring (2) Housing end (inside) (3) Washer set (4) O-ring (2 pcs) (5) Starter motor case (6) Armature (7) Washer set Brush holder (9) Brush spring (2 Housing end (outside) STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushed for abnormal wear, crack or smooth- ness in the brush holder. If the brush has failed, replace the brush sub assy. 6-13 ELECTRICAL SYSTEM COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut À). If the commutator is abnormally worn, replace the armature. When surface is descolored, polish it with #400 sand paper and clean it with dry cloth. If there is no undercut, scrape out the insulator (1) with saw blade. ARMATURE COIL INSPECTION Check for continuity between each segment. Check for continuity between each segment and the arma- ture shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the ar- mature with a new one. OIL SEAL INSPECTION Check the seal lip for damage or leakage. If any damage is found, replace the bracket. STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disas- sembly. Pay attention to the following points: | A CAUTION Replace the O-rings with new ones to prevent oil leak- age and moisture. * Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. MAH 99000-25030: SUZUKI SUPER GREASE “A” Segment © / ® — ELECTRICAL SYSTEM 6-14 * Apply a small quantity of MOLY PASTE to the armature shaft. ÆŸH 99000-25140: SUZUKI MOLY PASTE * Apply a small quantity of THREAD LOCK “1342” to the starter motor housing bolts. 99000-32050: THREAD LOCK “1342” STARTER RELAY INSPECTION e Remove the right frame cover. e Remove the starter relay cover. e Disconnect the starter motor lead wire and battery lead wire at the starter relay. e Disconnect the lead wire coupler from the starter relay. Apply 12 volts to (1) and (2) terminals, inspect the continui- ty between the terminals, positive and negative. pr If the starter relay is in sound condition, continuity is found. 09900-25002: Pocket tester D— EN —o \[9]) Tester knob indication: X 12 range A CAUTION | Do not apply a battery voltage more than 5 seconds | | to the starter relay as it may overheat and cause damage to the relay coil. rr fi Check the coil for ‘’open’’, “ground” and ohmic resistance. The coil is in good condition if the resistance is as follows. 09900-25002: Pocket tester Mol) Tester knob indication: X 10 range Starter relay resistance \ Standard: 3—50 | | 6-15 ELECTRICAL SYSTEM STARTER RELAY CIRCUIT DIAGRAM To starter motor © ® To battery O = A | | SIDE-STAND/IGNITION INTERLOCK SYSTEM INSPECTION If the interlock system does not operate properly, check each component. If any abnormality is found, replace the com- ponent with a new one. 09900-25002: Pocket tester DIODE The diode is located under the seat. The diode can pass current only in one direction. Check the continuity between (1) and (2) . If one way con- tinuity the diode is in good condition. Also check the continuity between (2) and (3) as required. ELECTRICAL SYSTEM 6-16 NEUTRAL SWITCH The neutral lead wire coupler is located behind the left frame cover. * Remove the frame covers and seat. * Disconnect the neutral switch lead and check the con- tinuity between Blue and Ground with the transmission in “NEUTRAL”. SIDE-STAND SWITCH Green Black/White (© Proboe) (@) Proboe) ON (UP-right position) оО = OFF (Down position) SIDE-STAND/IGNITION INTERLOCK RELAY The side-stand/ignition interlock relay is located under the seat. e Remove the frame covers and seat. First, check the insulation between (1) and (2) terminals with pocket tester. Then apply 12 volts to (3) and (4) terminals, ® to 3) and © to (4) , and check the continuity between (1) and 2) . If there is no continuity, replace it with a new one. (329 09900-25002: Pocket tester Hol) Tester knob indication: X 19 range CLUTCH LEVER POSITION SWITCH Y ellow/Green Y ellow/Green ON (Squeeze) O e OFF 6-17 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system, the electrical energy generated by the magneto charges the capacitor. This energy is released in a single surge at the specified ignition timing point, and current flows through the primary side of the ignition coil. A high voltage current is induced in the secondary windings of the ignition coil resulting in strong spark between the spark plug gap. Neutral indicator light B W Bl G Ignition . switch Engine stop switch 0— 0 0— — ——A—0/W— Lg R W/Bl— | BW— CD! unit @ Ignition coil Fuse | e Side-stand Battery ® switch © : Pick-up Coil Spark B/W (2) : Power source coil plugs (3) : Neutral switch 7 > >» » > 7 WIRE COLOR B Black O : Orange W : White R : Red G : Green Lg : Light green BI : Blue O/W: Orange with White tracer B/W : Black with White tracer W/BI: White with Blue tracer ELECTRICAL SYSTEM 6-18 TROUBLESHOOTING ( No spark at plugs ) * Check that the transmission is in neutral position and the engine stop switch is in the RUN position. Inspect that the fuse is not blown before the diagnosis. Check the CDI couplers for poor —— Looseness ——» * Poor contact of coupler contact. p Correct y Inspect the battery voltage between input lead wires (0/W and B/W) at the CDI unit with the ignition switch ON” position. — Incorrect — > Faulty ignition switch * Faulty side-stand relay ® Faulty engine stop switch | e Broken wire harness or poor Carreet contact of related circuit | connecters Inspect the resistance of pick-up coil (BI and G) and power source coil (B and Incorrect ——>* Faulty pick-up coil W). (Refer to page 6-20.) ® Faulty power source coil | Correct | »e Faulty CDI ¢ Faulty ignition coil * If only one spark plug does not spark, it is defective or high-tension cord is disconnected because one ig- nition coil furnishes two spark plugs. 6-19 ELECTRICAL SYSTEM INSPECTION IGNITION COIL (Checking with Electro Tester) e Remove the fuel tank. e Remove the ignition coil. NOTE: Make sure that the three-needle sparking distance of elec- tro tester is set at 8 mm (0.3 in). With the tester and jumper wire, test the ignition coil for sparking performance in accordance with the following two steps. STEP (1) : Connect the jumper wire to the spark plug cap and ignition coil ground. STEP (2) : Switch over the jumper wire to the other plug cap and ground. If no sparking or orange color sparking occures in the above conditions, it may be caused by defective coil. 09900-28107: Electro tester Spark performance: Over 8 mm (0.3 in) A WARNING Do not touch the wire clips to prevent an electric shock when testing. IGNITION COIL (Checking with Pocket Tester) A SUZUKI pocket tester or an ohm meter may be used, in- stead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secon- dary windings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values. 09900-25002: Pocket tester Ignition coil resistance Primary: 0.07 —0.12 9 (®) Black lead — ©) Black/white lead) Uo]) Tester knob indication: X 1% range Secondary: 23—25 kQ (Plug cap —Plug cap) US)) Tester knob indication: X 1 kQ range POWER SOURCE COIL AND PICK-UP COIL e Remove the frame covers and seat. e Disconnect the lead wire coupler (1) from the CDI unit. Measure each coil resistance between lead wires. If the resistance is infinity or less than the specifications, the power source coil and pick-up coil must be replaced. 09900-25002: Pocket tester Power source coil resistance: 0.1 —0.20 (Black — White) Lo)! Tester knob indication: X 12 range Pick-up coll resistance: 170 — 2562 (Blue — Green) US] Tester knob indication: X 100% range CDI UNIT e Remove the frame covers and seat. e Disconnect the lead wire couplers (2) from the CDI unit. Measure the CDI unit resistance between the terminals. If the resistance is incorrect, the CDI unit must be replaced. NOTE: As capacitor, thyristors, diodes, etc. are used inside this CDI unit, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used. 09900-25002: Pocket tester ELECTRICAL SYSTEM 6-20 Боб nd 1 2 NS)! Tester knob indication: X 1 kQ range + 198) [38 .- Unit: ka €) Probe of tester 1 3 4 5 6 7 8 9 10 11 12 1 0 6-26 | 12-50 |2.4-10|2.6-12| 0 0 |50—400| 200—c |35—400| 1.2—5 2 0 5.5—24| 12-50 [2.4—10|2.6—12] 0 0 |50—400| 200—x |35—500| 1.2—5 3 |5.5-24|5.5-24 20—90 | 8—35 | 8—35 | 5.5—24 |5.5— 24 |50—400| 200—œ |45—500| 7—28 „| 4 |15-70 | 15—70 |26—150 16—70 | 17—80 | 5.5—70 | 5.5—70 |80—500| 200—w | 80—c0 | 14—60 | 5 [2.2-95[2.2-9.5] 8-35 | 11-70 3—13 |2.2—9.5(2.2-9.5/50—400| 200—« [40-500] 1.4—6 | 6 |28-12|28-12| 8-35 |17-70| 3-13 2.8—12 [2.8—12 |50—400| 200—x |40—500| 1.8—8 e| 7 0 0 6—26 | 12—50 |2.2—9.5/2.6—11 0 |50—400| 200—æ |35—500|1.2—4.8 =| 8 0 о | 6-26 |12—-50|2.2-95/26—11| © 50—400| 200— | 70—500|3.6—4.8 DI 91 |1.8-7.5|1.8-7.5| 10-45 [24—200| 5—22 | 6-24 |1.8-7.5/1.8—7.5 200—со | 70-00 |3.6—11 10 | 11-50 | 11—50 |22—100|35—400| 17—70 | 17—70 | 11—50 | 12—50 [80—1000 200—w | 14—60 11 00 00 00 00 00 00 00 00 00 00 00 12 |1.2-5 | 1.2-5 | 7-28 | 14—60 | 1.4—6 | 1.8—8 | 1.2—5 | 1.2—5 |50—400| 200—x |35—500 NOTE: When the capacitor is discharged state, the needle of tester swings first a certain value. со : Infinity then return to 6-21 ELECTRICAL SYSTEM SPARK PLUG * Remove the spark plugs. 09930-10121: Spark plug socket wrench set Carbon Deposit Check to see the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. Spark Plug Gap Measure the plug gap with a thickness gauge if it is correct. If not, adjust it to the following gap. 09900-20803: Thickness gauge Standard: 0.7—0.8 mm (0.028 —-0.031 in) Electrode's Condition Check to see a worn or burnt condition of the electrode. If it is extremely worn or burnt, replace the plug. Also replace the plug if it has a broken insulator, damaged thread, etc. Heat Range NGK CR10E or NIPPONDENSO U31ESR-N should be used as the standard. However, the heat range of the spark plug should be selected to meet the requirements of speed, ac- tual load, fuel and etc. Proper heat range would be indicat- ed if all insulators were LIGHT BROWN in color. If they are blackened by carbon, they should be replaced with a hot type plug NGK CR9E or NIPPONDENSO U27ESR-N. —oo \ — 4 0.7—0.8 mm | (0.028-0.031 in) Standard Hot type NGK CR10E СВЭЕ NIPPONDENSO U31ESR-N U27ESR-N A CAUTION | Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result. SPEEDOMETER AND PILOT INDICATOR REMOVAL AND DISASSEMBLY * Remove the speedometer and pilot indicator. (Refer to page 5-4.) ®* Disassemble the speedometer and pilot indicator as follows. ELECTRICAL SYSTEM 6-22 4 / Qu 7 INSPECTION Using the pocket tester, check the continuity between lead wires in the diagram on next page. If the continuity measured is incorrect, replace the respec- tive parts. 09900-25002: Pocket tester US] Tester knob indication: X 1Q range NOTE: When making this test, it is not necessary to remove the speedometer and pilot indicator. 6-23 ELECTRICAL SYSTEM — B/W : ILLUMINATION © Gr : ILLUMINATION @ Pr f Pr f TEEN nar un ar a ILLUMI Gr B/W HIGH BEAM B/R B/W NEUTRAL B/O B/BI TURN (L) B B/Lg TURN (R) B/Lg B b B/W : HIGH BEAM O) B/R : HIGH BEAM $) B/O : NEUTRAL @ NE) \ B: TURN (L) @ B/Lg : TURN (R) ® В/В! : NEUTRAL © 7 B :Black Gr :Gray B/BI : Black with Blue tracer B/O :Black with Orange tracer B/R :Black with Red tracer B/Lg: Black with Light green tracer B/W : Black with White tracer ELECTRICAL SYSTEM 6-24 LAMPS HEADLIGHT N Headlight bulb: 12V 60/55W Position light bulb: 12V 4W (Except E-03,24,28,33) NOTE: Adjust the headlight, both vertical and horizontal, after reassembling. BULB REPLACEMENT e Remove the headlight. (Refer to page 5-21.) e Disconnect the socket (1) and remove the rubber cap 2). e Remove the bulb (3) by unlocking the bulb holder spring (4). e Reassemble the bulb in the reverse order of removal. A CAUTION | When replacing the headlight bulb, do not touch the glass. Grasp the new bulb with a clean cloth. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol or soapy water to prevent early failure. 6-25 ELECTRICAL SYSTEM TAIL/BRAKE LIGHT, TURN SIGNAL LIGHT AND LICENSE PLATE LIGHT Tail/Brake light bulb: 12V 5/21W Turn signal light bulb: 12V 21W License plate light bulb: 12V 5W BULB REPLACEMENT e Remove each light lens. * Push in on the bulb, turn it to the left, and pull it out. A CAUTION Do not overtighten the lens fitting screws. TURN SIGNAL RELAY The turn signal relay (1) is located under the seat. If the turn signal light does not light. Inspect the bulb or repair the circuit connection. If the bulb and circuit connection checked are correct, the turn signal relay may be faulty, replace it with a new one. NOTE: Be sure that the battery used is in full-charged condition. SWITCHES ELECTRICAL SYSTEM 6-26 Inspect each switch for continuity with the pocket tester. If any abnormality is found, replace the respective switch assemblies with new ones. 09900-25002: Pocket tester Uo)) Tester knob indication: X 11) range IGNITION SWITCH Color R O |0/Y |B/W| Gr | Br Position OFF ON LOCK P LIGHTING SWITCH Color Position O OFF ON DIMMER SWITCH Color Position Y/W HI LO TURN SIGNAL SWITCH Color | Position g L PUSH R PASSING LIGHT SWITCH or Position O/R PUSH ENGINE STOP SWITCH Color Position О OFF RUN STARTER BUTTON Color Position D PUSH HORN BUTTON olor Position ® PUSH FRONT BRAKE SWITCH Color О Position OFF ON REAR BRAKE SWITCH Color O Position OFF ON WIRE COLOR B : Black R : Red Y : Yellow W : White Lbl: Light blue Br: Brown Lg: Light green Gr: Gray O : Orange B/BI : Black with Blue tracer B/W: Black with White tracer O/BI: Orange with Blue tracer O/R : Orange with Red tracer O/W: Orange with White tracer O/Y : Orange with Yellow tracer W/B: White with Black tracer Y/G : Yeilow with Green tracer Y/W: Yellow with White tracer 6-27 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation YTX9-BS Capacity 12V, 28.8 kC (8 Ah)/10HR Standard electrolyte 1.320 at 20°C (68°F) S.G. INITIAL CHARGING Filling electrolyte * Remove the aluminum tape (1) sealing the battery elec- trolyte filler holes. e Remove the caps (2) . NOTE: * After filling the electrolyte completely, use the removed cap (2) as the sealed caps of battery-filler holes. * Do not remove or pierce the sealed areas (3) of the elec- trolyte container. e Insert the nozzles of the electrolyte container into the bat- tery's electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. * Make sure air bubbles are coming up each electrolyte con- tainer, and leave in this position for about more than 20 minutes, Separator (fiberglass plate) À Anode plates fety valve Yur? Filler holes Electroyte containers Insert in filler holes Fl 0 |] /%]|06! Air 00 a Qo bubbles 19 0° On 00 О 9 o O Oo © o 2 a No) PONEN Y [5] — | [Gl ELECTRICAL SYSTEM 6-28 NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the two or three times. Never remove the container from the battery. e After confirming that the electrolyte has entered the bat- tery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes. e Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery's top cover. | A CAUTION | * Never use anything except the specified battery. * Once install the caps to the battery; do not remove the caps. * Using SUZUKI pocket tester, measure the battery voltage. The tester should indicate more than 12.5—12.6V (DC) as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery charg- er. (Refer to the recharging operation.) NOTE: Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture. SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper. Wy (at 25°C) sir 30 seconds 12 11 10 2 4 6 8 10 (Minutes) Time 6-29 ELECTRICAL SYSTEM RECHARGING OPERATION * Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V (DC), recharge the battery with a battery charger. | À CAUTION When recharging the battery, remove the battery from the motorcycle. NOTE: Do not remove the caps on the battery top while recharging. Recharging time: 4A for one hour or 0.9A for 5 hours A CAUTION | (V) 17 16 14 13 12 Charging period Stop charging 10 20 30 40 50 60 Time (Minutes) Be careful not to permit the charging current to exceed 4A at any time. * After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester. * |f the battery voltage is less than the 12.5V, recharge the battery again. * |f battery voltage is still less than 12.5V, after recharg- ing, replace the battery with a new one. * When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery dis- charge. (М) (at 0°—40°C) 1 75 50 25 %) Battery charged condition SERVICING INFORMATION CONTENTS TROUBLESHOOTING: ========0=====202=a0e 20m Macari da .— 7- 1 WIRING DIAGRAM <.-<..…............icrrserrrnareranen nana nan en nana nana nana nan nee 7- 8 WIRE, CABLE AND HOSE ROUTING --—<"""00000 meme mere ce carence nes n canne 7-11 WIRE BOUTING -======—.—0]000000 00 ee AAA 7.12 CABLE ROUTINO =======v0mer nas aaa naaa E e —]]————— 7-15 CARBURETOR AND AIR CLEANER HOSE ROUTING ---------........ 7-17 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING -------=-====............. 7-18 FRONT BRAKE HOSE ROUTING +--+ rvveesreesssseeressiusiessinsesens 7-19 REAR BRAKE HOSE ROUTING «4440ER RER RER 7-20 HEAT SHIELD ADHERING «4000ER EEK EEE eee 7-21 SIDE STAND SPRING SET-UD ++ one er mea 7.54 SPECIAL TOOLS HECKE en ——o——— 7-22 TIGHTENING TORQUE ---.-.......e....000000000000000rerrerice ee e e ea 7-25 SERVICE DATA ------.--........000000000000iiierirerireen eee ee eee 7-28 7-1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start, or is hard to start. Compression too low 1. Out of adjustment valve clearance. . Worn valve guides or poor seating of valves. . Mistiming valves. . Excessively worn piston rings. . Worn-down cylinder bores. . Too slowly starter motor cranks. . Poor seating of spark plugs. < © C1 45 ON Plugs not sparking Adjust. Repair or replace. Adjust. Replace. Replace or rebore. See electrical section. Retighten. 3. Not working tension adjuster. Noise seems to come from clutch 1. Worn splines of countershaft or hub. 2. Worn teeth of clutch plates. 3. Distorted clutch plates, driven and drive. 4. Worn clutch release bearing. 5. Weakened clutch dampers. 1. Fouled spark plugs. Clean. 2. Wet spark plugs. Clean and dry. 3. Defective ignition coil. Replace. 4. Open or short in high-tension cords. Replace. 5. Defective generator or CDI unit. Replace. 6. Defective side stand switch or side stand relay. Replace. No fuel reaching the carburetor 1. Clogged fuel tank cap. Clean or replace. 2. Clogged or defective fuel valve. Clean or replace. 3. Defective carburetor needle valve. Replace. 4. Clogged fuel hose or vacuum hose. Clean or replace. 5. Clogged fuel filter. Clean or replace. Engine stalls easily. 1. Fouled spark plugs. Clean. 2. Defective signal generator or CDI unit. Replace. 3. Clogged fuel hose. Clean. 4. Clogged jets in carburetor. Clean. 5. Out of adjustment valve clearance. Adjust. Noisy engine. Excessive valve chatter 1. Too large valve clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn down rocker arm or rocker arm shaft. Replace. 4. Worn and burnt camshaft journal. Replace. Noise seems to come from piston 1. Worn down piston or cylinder. Replace. 2. Fouled with carbon combustion chamber. Clean. 3. Worn piston pins or piston pin bore. Replace. 4. Worn piston rings or ring grooves. Replace. Noise seems to come from timing chain 1. Stretched chain. Replace. 2. Worn sprocket. Replace. Repair or replace. Replace. Replace. Replace. Replace. Replace the primary driven gear. SERVICING INFORMATION 7-2 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from crankshaft 1. Due to wear rattling bearings. Replace. 2. Worn and burnt big-end bearings. Replace. 3. Too large thrust clearance. Noise seems to come from transmission Replace conrod. 1. Worn or rubbing gears. Replace. 2. Badly worn splines. Replace. 3. Worn or rubbing primary gears. Replace. 4. Badly worn bearings. Replace. Slipping clutch. 1. Out of adjustment or loss of play clutch control. Adjust. 2. Weakened clutch springs. Replace. 3. Worn or distorted pressure plate. Replace. 4. Distorted clutch plates, driven and drive. Replace. Dragging clutch. 1. Clutch control out of adjustment or loss of play. Adjust 2. Some clutch springs weakened while others are not.| Replace. 3. Distorted pressure plate or clutch plates. Replace. Transmission will 1. Broken gearshift cam. Replace. not shift. 2. Distorted gearshift forks. Replace. 3. Worn gearshift pawl. Replace. Transmission will 1. Broken return spring on shift shaft. Replace. not shift back. 2. Rubbing or stickly shift shaft. Repair or replace. 3. Distorted or worn gearshift forks. Replace. Transmission jumps 1. Worn shifting gears on driveshaft or countershaft. | Replace. out of gear. 2. Distorted or worn gearshift forks. Replace. 3. Weakened stopper spring on gearshift cam. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Out of adjustment valve clearance. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn rocker arms or arm shafts. Replace. 5. Too wide spark plug gaps. Adjust or replace. 6. Defective ignition coil. Replace. 7. Defective generator or CDI unit. Replace. 8. Out of adjustment in carburetor float-chamber Adjust. fuel level. 9. Clogged jets. Clean. 1-3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly 1. Weakened valve springs. Replace. in high speed range. 2. Worn camshafts. Replace. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Adjust. 5. Ignition not advanced sufficiently due to poorly Replace CDI unit. working timing advance circuit. 6. Defective ignition coil. Replace. 7. Defective generator or CDI unit. Replace. 8. Too low float-chamber fuel level. Adjust. 9. Clogged air cleaner element. Clean. 10. Clogged fuel hose, resulting in inadequate fuel Clean and prime. supply to carburetor. Dirty or heavy 1. Too much engine oil in the engine. Check with inspection exhaust smoke. window drain out excess oil. 2. Worn piston rings or cylinder. Replace. 3. Worn valve guides. Replace. 4. Scuffed cylinder wall. Replace. 5. Worn valves stems. Replace. 6. Defective stem seal. Replace. 7. Worn oil ring side rails. Replace. Engine lacks power. 1. Loss of valve clearance. Adjust. 2. Weakened valve springs. Replace. 3. Out of adjustment valve timing. Adjust. 4. Worn piston rings or cylinder. Replace. 5. Poor seating of valves. Repair. 6. Fouled spark plug. Clean or replace. 7. Incorrect spark plug. Adjust or replace. 8. Clogged jets in carburetor. Clean. 9. Out of adjustment float-chamber fuel level. Adjust. 10. Clogged air cleaner element. Clean. 11. Sucking air from intake pipe. Retighten or replace. 12. Too much engine oil. Drain out excess oil. 13. Diffective generator, CDI unit or ignition coil. Replace. Engine overheats. 1. Heavy carbon deposit on piston crown. Clean. 2. Not enough oil in the engine. Add oil. 3. Defective oil pump or clogged oil circuit. Replace or clean. 4. Too low in float chamber fuel level. Adjust. 5. Sucking air from intake pipes. Retighten or replace. 6. Use incorrect engine oil. Change. 7. Oil cooler. Clean. SERVICING INFORMATION 7-4 CARBURETOR Complaint Symptom and possible causes Remedy Trouble with starting. 1. Clogged starter jet. Clean. 2. Clogged starter pipe. Clean. 3. Air leaking from a joint between starter body and Check starter body and carburetor. carburetor for tightness, adjust and replace gasket. 4. Air leaking from carburetor’s joint or vacuum Check and adjust. gauge joint. 5. Not operation properly starter plunger. Check and adjust. Idling or low-speed 1. Clogged or loose pilot jet, pilot air jet. Check and clean. trouble. 2. Air leaking from carburetor’s joint, vacuum hose Check and adjust. joint, or starter. too stiff. MN — 3. Clogged pilot outlet or bypass. Check and clean. 4. Not fully closed starter plunger. Check and adjust. Medium-or high 1. Clogged main jet or main air jet. Check and clean. speed trouble. 2. Clogged needle jet. Check and clean. 3. Not operating properly throttle valve. Check throttle valve for operation. 4. Clogged fuel filter. Check and clean. Overflow and fuel 1. Worn or damaged needle valve. Replace. level fluctuations. 2. Broken spring in needle valve. Replace. 3. Not working properly float. Check and adjust. 4. Foreign matter has adhered to needle valve. Clean. 5. Too high or low fuel level. Adjust float height. CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. | Replace. 2. Distorted front fork. Repair or replace. 3. Distorted front axle or crooked tire. Replace. Wobby front wheel. 1. Distorted wheel rim. Replace. 2. Worn front wheel bearings. Replace. 3. Defective or incorrect tire. Replace. 4. Loose axle or axle holder nuts. Retighten. 5. Incorrect front fork oil level. Adjust. Front suspension 1. Weakened springs. Replace. too soft. 2. Not enough fork oil. Replenish. Front suspension . Too viscous fork oll. Replace. . Too much fork oil. Drain excess oil. Noisy front suspension. M — . Not enough fork oil. . Loose bolts and nuts on suspension. Replenish. Retighten. 7-5 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Wobbly rear wheel. 1. Distorted wheel rim. Replace. 2. Worn rear wheel bearings or swingarm bearings. Replace. 3. Defective or incorrect tire. Replace. 4. Worn swingarm and rear suspension related bearings.| Replace. 5. Loose nuts or bolts on rear suspensions. Retighten. Rear suspension 1. Weakened shock absorber spring. Replace. too soft. 2. Improperly set rear suspension adjuster. Adjust. 3. Leakage oil of shock absorber. Replace. Rear suspension 1. Improperly set rear suspension adjuster. Adjust. too stiff. 2. Bent shock absorber shaft. Replace. 3. Bent swingarm. Replace. 4. Worn swingarm and rear suspension related bearings.| Replace. Noisy rear 1. Loose nuts or bolts on rear suspension. Retighten. suspension. 2. Worn swingarm and rear suspension related bearings.| Replace. BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace. power. 2. Worn pads. Replace. 3. Oil adhesion of engaging surface of pads. Clean disc and pads. 4. Worn disc. Replace. 5. Air in hydraulic system. Bleed air. Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with sandpaper. 2. Tilted pad. Modify pad fitting or replace. 3. Damaged wheel bearing. Replace. 4, Loosen front-wheel axle or rear-wheel axle. Tighten to specified torque. 5. Worn pads. Replace. 6. Foreign material in brake fluid. Replace brake fluid. 7. Clogged return port of master cylinder. Disassemble and clean master cylinder, Excessive brake 1. Air in hydraulic system. Bleed air. lever or pedal stroke.| 2. Insufficient brake fluid. Replenish fluid to spe- cified level; bleed air. . Worn piston and/or cup. 3. Improper quality of brake fluid. Replace with correct fluid. Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified fluid. torque. 2. Cracked hose. Replace. Replace piston and/or cup. SERVICING INFORMATION 7-6 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plugs. Replace. 3. Defective generator or CDI unit. Replace. Spark plug soon 1. Mixture too rich. Adjust carburetor. become fouled with 2. Idling speed set too high. Adjust carburetor. carbon. 3. Incorrect gasoline. Change. 4. Dirty element in air cleaner. Clean. 5. Too cold spark plugs. Replace with hot type plugs. Spark plugs become 1. Worn piston rings. Replace. fouled too soon. 2. Worn piston or cylinder. Replace. 3. Excessive clearance of valve stems in valve Replace. guides. 4. Worn stem oil seal. Replace. Spark plug electrod- 1. Too hot spark plugs. Replace with cold type es overheat or burn. plugs. 2. Overheated the engine. Tune up. 3. Loose spark plugs. Retighten. 4. Too lean mixture. Adjust carburetor. Generator does not 1. Open or short lead wires, or loose lead Repair or replace or charge. connections. retighten. 2. Shorted, grounded or open generator coils. Replace. 3. Shorted or panctured regulator/rectifier. Replace. Generator does 1. Lead wires tend to get shorted or open-circuited Repair or retighten. charge, but charging or loosely connected at terminals. rate is below the 2. Grounded or open-circuited stator coils or Replace. specification. generator. 3. Defective regulator/rectifier. Replace. 4. Defective cell plates in the battery. Replace the battery. Generator 1. Internal short-circuit in the battery. Replace the battery. overcharges. 2. Damaged or defective regulator/rectifier. Replace. 3. Poorly grounded regulator/rectifier. Clean and tighten ground connection. Unstable charging. 1. Lead wire insulation frayed due to vibration, Repair or replace. resulting in intermittent shorting. 2. Internally shorted generator. Replace. 3. Defective regulator/rectifier. Replace. Starter button is not 1. Run down battery. Repair or replace. effective. 2. Defective switch contacts. Replace. 3. Not seating properly brushes on commutator in Repair or replace. starter motor. 4. Defective starter relay/starter interlock switch. Replace. 1-1 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy stance or spots on surfaces of cell plates. “Sulfation’’, acidic white powdery sub- M — . Cracked battery case. . Battery has been left in a run-down condition for a long time. Replace the battery. Replace the battery. Battery runs down quickly. . Not correct the charging system. . Cell plates have lost much of their active material as a result of overcharging. . A short-circuit condition exists within the battery. . Too low battery voltage. . Too old battery. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation. Replace the battery, and correct the charg- ing system. Replace the battery. Recharge the battery fully. Replace the battery. Battery ““sulfation””. F . Too low or too high charging rate. (When not in use batteries should be checked at least once a month to avoid sulfation.) . Left unused the battery for too long in cold climate. Replace the battery. Replace the battery, if badly sulfated. Battery discharges too rapidly. Dirty container top and sides. Clean. SERVICING INFORMATION 7-8 WIRING DIAGRAM 189384) SUUAA YA MOJSA +: ANA 199€] USSIO) UM MOJNSA : D/A 180811 YIEJ YI MOJNSA : g/A 183811 an|g yum alum - 19/M 18984) YIEJJ YA SUYM : 9/M 199824) Y22/9 UUM Pay : 9/Y 18981) MOINSA UNM SSUelg : AJO 18981) SUUM yum sBUEJIO : MVO 18981] aN]g Y]IM U9a1H : 19/5 1822) UU UIIM eng : M/IB 189841 {32/9 yum anjg : 9/9 19984] S11YM ULM ¥oB|g : AAS 189811 рен yum Yelg : Н/9 AHILLVS 18981] SbBuelg UJIM ЭВ: 0/9 18921] иаазб убил yum oeyg : 61/9 190841 8njg yim oejg + 19/9 HOLOW Y314Y15 ‘IN 3504 NIVYIA 4 HOLLMS “ NOILISOd dAldILDIH | HOLIMS WEHEN /HOLYIND3Y | 1YHINEN H3LN12 HILIMS LHDIT TYNDIS NYNL HILIMS NOILINDI HILIMS HIWWIO AV 13H Н31Н\15 HOLVHINID NOLLNS NHOH Ww 1HDINAvYaH 3) (IH) LHONaYyaH :1) MONZA: + — A X08 3ISN4 UUM : M pay : H sBuelg : o uaaib yb : 61 anıq 14617 : 197 Ae : 1g uasin : E) umoJg : 19 ng - 18 ÿselg : E HOT109 3HIM (1) LH917 1YN9IS NHNL HY3Y (7) LHD11 1YNDIS NHAL МОНЫ LHDIM 3SN39I1 LHO11 34 YYH9/11 91 LHSI10Y3H (4) LH9I1 TYNDIS NHMI Hvay (4) LHDIT 1YNDIS NHNL 1NOH4 {21 1109 NOLLINSI LHDIT HOLVIIANI TYNDIS NHNL +1 1HOIT HOLVIIANI T¥HLN3N -N LHDIT HOLVIIONI NV38 HDIH :H LINN 102 ONVLS LA NH АЭН TYNDIS NEAL 1H9I1 HOLVIIONI HILIMS 3}vyg Yvan + NOLLNAE HILIMS HOLIMS HJLHVLS 3}vug TNA 1NOH3 3NIDN3 H313WO0Qg33ds ONVLS 3015 FOR CANADA AND U.S.A. 7-9 SERVICING INFORMATION 18581) SUUM UI MOJNSA : MVA 19981) US9ID) UNAM MOINSA 1 D/A 13984) YIE|Q YM MONSA : E/A 18984) 8NIg UM SUUM © g/m 49084] HOBIE UMM BHUM + g/m 199224) YIB/g YM Pay : E/H 18981) MOINSA YM 9B6UEIO : A/D 18393811 SUUM UM SBUelO : AVO : . dOLOW Yalgdv.lLS IN 18281 @N1g YUM U8819 : 19/5 3SN4 NIVW :4 HOLIMS 19981) SUMUM Yim ang } Mila NOLLISOd NOLLNA HILIMS LHONM 13984) MOBIg Чи ang : 8/18 AYT3Y HIIJILIJH | HIOLIMS HIAIT HILIMS NOLLINSI HOLIMS 1HOIT TYNDIS NYANL 199841 SUUM YUM MIBIg | A/G YILHVLS VH3N3D /HOLYIND3Y [IVHINAN — HOINT9 U3IAWIO ONISSVd NOLLNE NHOH 19938.) sBUelg Ulm Yy2e/g : 0/9 169811 U9916 14617 YM Yoejg : 61/9 RO | NO 440 El To JHDINOYIH ‘© “(D 18981) anig yim ¥oe|g : (9/9 (IH) LHDITOVI3H MOJ[BA > A SHUM © M Pay : H abuelo : o uaaıß 14617 : 57 enig bm : 197 ABIC : 15 нае): 0 umMOIg : 19 eng - 18 4219 : a HO109 3HIM (1) LH5I1 1YN9IS NHAAL HYvay (1) LHOI1 TYNDIS NUNL 1NOY4S 1HDIT 3SN3911 JHDIT 3HVHE/T1VL JHDIT]VIH (4) LHDIT TYNDIS NHNI Yvay (4) LHDIT TVNDIS NHAL 1NOH34 JT 1109 NOLLINDI JLHDIT HOLVIIONI TVNDIS NHAL <1 JHDIT YHOLVIIONI TVHLNIN ‘М 1HOIT HOLVIIONI NYI9 HDIH -H LINA 102 ONVLS lL NH AY 134 TYNDIS NEAL LHDIT HOLVIIONI HILIMS 1XVvH9 HY3H NOLILNE HOLIMS HOLIMS ONYLS 3015 H31HV1S VLE TY 1NOH3 3NIDN3 YH313NOd33d5 For Australia SERVICING INFORMATION 7-10 1832) SUUAA HA MOJNSA : AMA 189811 U8815) VIA MOJNSA D/A заоел yOB|g YHAN MONSA : g/A 18981] SN UA SILA © 19/00 433841 YIB9 YUM SUUAN © gM 182811 agg yum psy : 9/4 180811 MO|I3A yim aBueig : A/0O 19281) SHUM UYlim SíBuelO : M/O 1892211 an IM Usalo : 19/ HOLOW d3LHVLS -W (OT) LHDITAY3H :() pe. a а а Ee 3504 NIVIA 4 (1H) LHODINOV3H :(1) HOLIMS AE XOg 3SN4 NOILISOd HOLIMS NOILINDI NOLLNS HOLIMS LHDIM 19281) Y2e|g UM anlg : 8/18 AVT13H 431411334 | HILIMS HIA31 HILIMS LH911 1YN91S NUNL 22751 SUYA UA 4989 +. AVE HILHVLS HOLVH3N35 /HOLVIND3Y |TVHLINAN — HOINIS USIAWIO DNISSVd NOLLNA NHOH IN 130811 Pay UM y0eig : Y/O ды мя 18381) s6uelO yliM Y2e|g : 0/9 180814] иээзб 14617 Wa Yyoejlg : 61/9 19921) NI YM Y2E/g : 19/9 MOJISA : A SUUM + M Pay : H abuein : O uSalB JUBII] : 6 aenig 34817 : 107 ABIE) ! 15 usaig : = umolg : 19 ang - 18 42elg : g HOT109 3IYIM (1! LHDIT TYNDIS NHAL YYvay (1) LHOI 19N9IS NHAMI 1NOHA 1H9I1 3SN39I1 1H911 NOLLISOd 1HDIT 3}VH9/T1W1 LHDITOdVIH (9) LIHOIT TYNDIS NYAL HYga (H) 1HDIT TVNDIS NHAL LNOH4 LHDIT HOLVIIONI TYVNDIS NEAL :1 LHDIT HOLYIIONI TYYLNAN N JHDIT HOLVOIIONI NYV39 HDIH -H 1109 NOILINII LINA 199 ONVLS 1 N H AV13d TYNDIS NHNL HOLIMS 3MVH9 HVIY JHDIT HOLVOIGNI NOLINE HOLIMS HILIMS HILIMS H31HY1S5 34 YY TIM INILHDI 1NOY3 3NIDN3 YILIWO33ds ONYLS 3015 For Austria and Switzerland 7-11 SERVICING INFORMATION 180811 811Y/V\ ULM MO|IBA : MA 19981) US319) YUM MOJNSA : D/A 19984) HHE|G UYNM MOINSA : 9/A 189811 anjg YA SUYM | 19924) Y22/g UTM SUYM : 8/M 189811 ADE/g UMA pay : g/d заем мод ил sbuesp : A/D 18981] S11YAA YUM abuesQ : WO с 2 19081} 8N|g Yum usalg : 1/9 CODE Se (O1! LHDITOVIH :© HOLIMS 189811 81 LM ana : ; (UH) LHDITOYH :(1) TYHLNIN HOLIMS 195811 a ven pl ; le 3804 NOILISOd HOLIMS NOILINDI NOLLNA HOLIMS LHOIT I" AEE 2 AVE 3141193 HIATT HOLIMS 1HDI1 TVNDIS NHNL 2 SUM WM ASE + M/E HJLHVLS HOLIMS 311104H1 /HOLVIND3H HO1N19 HIWMIO DNISSVd NOLLNA NYOH 189811 pay yum oe|g : H/8 AH3llvg и 18581) SSUelJO yum yoejg : 0/9 102€1] US9J6 JUBII yum Yyoejg : 61/9 18981] eNIg yum YyOejg : (9/9 МОЛ: А SUUM © M pag + d aBueip : 0 usal6 JUBII] : 61 anjg 14617 : 197 Ава): 1D useir : ©) имо : 18 ng: 18 49219 : g HO109 3HIM (1) LHDIT 1YNDIS NYNL YV3H (1) LHDIT TYNDIS NHAL 1NOY4 JHDIT 3SN39I1 LH911 NOILISOd LHDI7 3HVHa/11V1 JHDITOVIH (4) LH911 1YNDIS NULL HY3Y (4) LHOI7 19N9IS NHAL LNOH4 REN 1109 NOLLINDI LH9I7 HOLYIIANI TYNDIS NYANL *1- 1H917 HOLYVIIANI TYWYLNEN :N 1НЭП HOLVIIANI WY3E HOIH ‘H 30010 HOLSISIY LINN 199 ONVLS 1 H AVT3H TYNDIS NEnl HOLIMS 3XVYH9 HYV3Y 1HOIT HOLVYIIANI NOLLNE HILIMS HILIMS ONYLS 3015 HILIMS H31HY 15 IHVHE ТМ ONILHON LNOHA INIONA Y313N0033d5 For the others SERVICING INFORMATION 7-12 WIRE, CABLE AND HOSE ROUTING WIRE ROUTING Clamp Clamp Handlebar switch (L) Clutch lever position switch Handlebar switch R)| Speedometer Clamp Lead wire cover Wiring harness Clutch cable | A = ay | IZ— E CE =F) Wiring harness Clutch lever position switch Throttle cable Starter cable switch (L) Clutch lever position switch Front brake hose Lead wire cover Clamp Clamp Blue tape Blue tape Clamp Wiring harness laniti Е = gnition Throttle position switch switch (Except for E-03,18,28 and 33) me Wiring A AA harness es = Clamp Wiring harness Ignition switch | Battery © Gap Clamp Wiring harness Rear turn signal light (R) License light | — |= И | - Cs fa NS Voies) NA Faz Fuse box \ Y Y Starter relay A Wiring harness — Starter motor NN Wiring Ванегу |Narness Starter motor Clamp Clamp 7-13 SERVICING INFORMATION Clamp Wiring harness Clutch lever position switch Throttle cable Starter cable Clamp Wiring harness Clamp Wiring harness Generator Throttle position switch Neutral switch 33) Rear brake switch нео = 27777777772 | Neutral switch Rear brake switch Engine ground Clamp wire Clamp Rear turn signal light (L) Tail/Brake light (Except for E-03,18,28 and a | > 4 a 9 = Ire o "| a ' Horn У “оо \ \ White tape Starter motor В Clamp Clamp Wiring mess Tail/Brake light da brake Sen Rear turn signal light Side stand switch ea Wiring harness Generator ead. Wire Generator (CRE cn Rear brake mí: switch coupler ee Rear turn signal light (L) coupler Regulator/ A Rectifier o 4 X Side stand switch : д Rear turn p signal light (R) License light Side stand switch | Clamp Clamp (Right side) Clamp (Left side) SERVICING INFORMATION 7-14 Starter motor lead wire Starter motor Generator lead wire Generator cover Forward Generator stator 7 E O, F я o E == E =. ard Fo a TT a gf ed 2 ll Breather cover Ignition coil High-tension cord (short cord) High-tension cord (long cord) 7-15 SERVICING INFORMATION CABLE ROUTING Clamp 5) Fix the clutch cable with a clamp. Clutch cable Brake hose Clutch cable Spacer Frame Clutch cable Spacer— Fuel tank cover — + bracket (R) Throttle cables Starter cable EJ Clamp // Clutch cable NN Brake hose Clutch cable holder Throttle cable Brake hose Throttle cables Starter cable Clutch cable Clutch cable Clamp Starter cable — Starter cable £ Clamp_ \ \. Clamp Clamp “y M1 © Starter cable Throttle cable Throttle cable (return) (pull) Clutch cable SERVICING INFORMATION 7-16 Clutch cable A I Ignition switch 7 | lead wire Wiring harness Cable guide Speedometer cable Cable guide 7-17 SERVICING INFORMATION CARBURETOR AND AIR CLEANER HOSE ROUTING 10191NG1209 ayl ybnouyl sse q ЧЕ Ч Ч а ( <P © ‘aulel) рие эшбиэ 9U1 UeIMISqg 9S0Y MOJ|HIOAO 2SOY MOJJISAO 10181NG18 dwe|D you MS 9ye1q 189y YOIMS ¡eJINSN | [esoy 1ayiealq | j/eseoyue1n y a = ajgeo yond -asoU JIE 10181NgJ1eo 9U1 JO SPISUI 9SOY 4 MIA 10U1891q ese9yuelo au UBnoJUy) ssed e mb à -ajgeo yaInjo OUI o episul esoy 18U1891q 9U ybnoiyl ssed e HH- -H1 'ajgeo Yainj9 sul JO apisino asoy 1UeA 11e eUl UBNOJUI SSEd e 1addn asoy Molano 10jaINd.eJ 9souy 19u1e91d osea yuelg Ne = asoy lie 101aingie) NN No \ Y Y = - \ \ \ N A : | W NN \\ \ \ | | EOE LI] asoy |an4 asoy wnnoea N 3/Ge9 JOMEIS | aigeo 8110441 TN © =) ® oc OOO o B Ho == fede 7 Ny Ea Si = т N 7 uonisod dwe|d 10181NG127 и О 65 sequen al AL senjuel PA ий Ня + оэвоц диел лу due|7 SERVICING INFORMATION 7-18 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING (For Austria and Switzerland) Pass through the PAIR control valve vacuum hose and air supply hose between the engine mounting plates. Air supply hose Clamp UE e Ce hose PAIR control valve vacuum hose Fuel hose PAIR control valve PAIR air pipe FRONT BRAKE HOSE ROUTING 71-19 SERVICING INFORMATION - аще) = = | | \ layse ; USEM + ‘enb1o] paijiveds au] O1 1/0G uolun ayy uaybn ‘1addols ayl ol uolun asoy aeliq ay1 Buiyonol 1814 Y apinb asoH я + 10puljÁo 1891SEN A 9soUy ayelg e|geo 1811815 : opinB esoH 'J9puljÁo 191SeW 841 O3 UOIUN asou 9ye1q sul чо lew ayl ade} ‘asoy aye1q ay] Buljejsul USUM SERVICING INFORMATION 7-20 REAR BRAKE HOSE ROUTING Master cylinder Reservoir tank hose vi O Reservoir tank Reservoir tank hose Reservoir tank hose guide After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Set the brake hose to the hose guide. Pass through the reservoir tank hose between the frame and brake hose union. — Brake hose guide Brake hose VIEW B 7-21 SERVICING INFORMATION HEAT SHIELD ADHERING Right frame cover Heat shield SIDE STAND SPRING SET-UP ide stand 5 Inner spring Outer spring SPECIAL TOOLS SERVICING INFORMATION 7-22 09900-00401 “L” type hexagon wrench set 7 SS (a 09900-00410 Hexagon bit wrench set ji 09900-06107 Snap ring pliers 09900-06108 Snap ring pliers 09900-09003 Impact driver set 09900-20102 Vernier calipers 09900-20202 Micrometer (25—50 тт) 09900-20204 Micrometer (75— 100 mm) 09900-20205 Micrometer (0— 25 mm) 09900-20508 Cylinder bore gauge set 09900-20513 Gauge rod 94 mm 09900-20605 Dial calipers 09900-20606 Dial gauge (1/100) > 09900-20803 Thickness gauge 09900-21304 V-block (100 mm) 09900-22301 Plastigauge 09900-25002 Pocket tester 09900-28106 Electro tester 09910-20116 Conrod holder К 09910-32812 Crankshaft installer 09910-32830 Crankshaft installer attachment = 09910-32860 Crankshaft installer attachment 09910-33210 Attachment 09910-60611 Universal clamp wrench 09913-10720 Compression gauge attachment 09913-50121 Oil seal remover 09913-60910 Bearing/gear puller 09913-75810 Bearing installer 09913-75830 Bearing installer 09915-64510 Compression gauge 7-23 SERVICING INFORMATION 09915-74510 Oil pressure gauge 09916-14510 Valve spring compressor 09916-14910 Valve spring com- pressor attachment 09916-20610 Valve seat cutter head 15° (N-121) 09916-24210 Valve seat cutter head 45° (N-615) 09916-24900 09916-34550 5.5 mm reamer 09916-34580 10.8 mm reamer 09916-44910 Valve guide remover 09916-84511 Tweezers 09917-23711 Ring nut socket wrench 09920-13120 Crankcase separator/ crankshaft remover 09920-53740 Clutch sleeve hub holder 09923-73210 Bearing remover 09923-74510 Bearing remover 09924-84510 Bearing installer set 09924-84521 Bearing installer set 09925-18010 Steering bearing installer 09930-11920 Torx bit JT40H @ 09930-11940 Torx bit holder 09930-30102 Sliding shaft 09930-33720 Generator rotor remover 09930-73110 Starter torque limiter holder 09930-73120 Starter torque limiter socket Steering nut socket wrench 09940-14960 Steering nut wrench socket 09940-34520 “TT” handle 09940-34592 Attachment G 09940-52860 Front fork oil seal installer 09941-34513 Steering race and swingarm bearing installer SERVICING INFORMATION 7-24 09941-50111 Wheel bearing remover 09941-54911 Bearing outer race remover 09941-74910 Steering bearing remover 09943-74111 Front fork oil level gauge 1-25 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N-m kg-m Ib-ft Cylinder head cover bolt 10 1.0 7.0 Camshaft sprocket bolt 15 1.5 11.0 Cylinder head bolt 38 3.8 27.5 Cylinder head nut 25 2.5 18.0 Cylinder base nut 10 1.0 7.0 Cam drive chain tensioner fitting bolt 13 1.3 9.5 Generator rotor bolt 160 16.0 115.5 Can drive chain adjuster mounting bolt 10 1.0 7.0 Spark plug 11 1.1 8.0 Crankcase bolt 11 1.1 8.0 T.D.C. plug 23 2.3 16.5 Oil gallery 23 2.3 16.5 Oil nozzle bolt 10 1.0 7.0 Generator cover plug 15 1.5 11.0 Starter clutch bolt 25 2.5 18.0 Primary drive gear nut 100 10.0 12.5 Clutch spring mounting bolt 10 1.0 7.0 Clutch sleeve hub nut 50 5.0 36.0 Gearshift arm stopper 19 1.9 13.5 Engine oil drain plug 23 2.3 16.5 Engine sprocket bolt 6 0.6 4.5 Engine mounting bolt 8 mm Diam. 40 4.0 29.0 Engine mounting bolt 10 mm Diam. 65 6.5 47.0 Engine mounting bracket bolt Me and 40 4.0 29.0 ront) (Rear) 23 2.3 16.5 Exhaust pipe bolt 26 2.6 19.0 Muffler mounting bolt 26 2.6 19.0 Crankshaft bearing ring nut 80 8.0 58.0 Engine oil pipe union bolt (Cylinder head) 23 2.3 16.5 (Crankcase) 20 2.0 14.5 Engine oil cooler hose bolt 10 1.0 7.0 Cam drive chain adjuster cap bolt 6 0.6 4.5 SERVICING INFORMATION 7-26 CHASSIS ITEM N-m kg-m Ib-ft Front axle 65 6.5 47.0 Front axle holder nut 10 1.0 7.0 Front fork damper rod bolt 30 3.0 21.5 Front fork lower clamp bolt 26 2.6 19.0 Front fork upper clamp bolt 29 2.9 21.0 Front fork cap bolt 23 2.3 16.5 Steering stem head nut 90 9.0 65.0 Handlebar clamp bolt 23 2.3 16.5 Handlebar holder nut 25 2:5 18.0 Front brake master cylinder mounting bolt 10 1.0 7.0 Front brake caliper mounting bolt 26 2.6 19.0 Brake caliper axle bolt (Front & Rear) 23 2.3 16.5 13 1:3 9.5 Brake hose union bolt (Front & Rear) 23 2:3 16.5 Brake pad mounting pin (Front & Rear) 18 1.8 13.0 Front brake pad mounting pin plug 2.5 0.25 1.8 Brake air bleeder valve (Front & Rear) 8 0.8 6.0 Brake disc mounting bolt (Front & Rear) 23 2.3 16.5 Swingarm pivot nut 77 7.7 55.5 Front footrest bolt 39 3.9 28.0 Chain roller mounting bolt (Upper & Lower) 40 4.0 29.0 Rear brake master cylinder mounting bolt 10 1.0 7.0 Rear brake rod lock nut 18 1.8 13.0 Rear shock absorber bolt (Upper & Lower) 55 5.5 40.0 Rear cushion lever nut (Front) 80 8.0 58.0 Rear cushion lever nut (Center) 100 10.0 72.5 Rear cushion rod nut 100 10.0 12:5 Rear axle nut For Canada and U.S.A. 100 10.0 72.5 For the others 110 11.0 79.5 Rear sprocket mounting nut 27 2.7 19.5 Spoke nipple (Front & Rear) 4.5 0.45 3.0 7-27 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt 7 marked bolt @ (mm) N-m kg-m Ib-ft N-m kg-m Ib-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1.0 7.0 8 13 1:3 9.5 23 2:3 16.5 10 29 2.9 21.0 50 5.0 36.0 12 45 4.5 32.5 85 8.5 61.5 14 65 6.5 47.0 135 13.5 97.5 16 105 10.5 76.0 210 21.0 152.0 18 160 16.0 115.5 240 24.0 173.5 ® Conventional bolt “4” marked bolt “7” marked bolt SERVICE DATA VALVE + GUIDE SERVICING INFORMATION 7-28 Unit: mm (in) at length 31.0 mm (1.2 in) ITEM STANDARD LIMIT Valve diam. IN 33 : (1.3) 28 Valve clearance IN 0.08—0.13 (when engine is cold) (0.003— 0.005) EX 0.17—0.22 E. (0.0067—0.0087) Valve guide to valve stem IN 0.010—0.037 clearance (0.0004—0.0015) EX 0.030—0.057 (0.0012—0.0022) Valve stem deflection 0.35 МЫ 61, BX (0.014) Valve guide |.D. 5.500—5.512 US. EA, (0.2165—0.2170) Valve stem O.D. IN 5.475—5.490 (0.2156—0.2161) EX 5,.455— 5.470 (0.2148—0.2154) Valve stem runout 0.05 N. 8 EX. (0.002) Valve head thickness 0.5 IN. & EX. ее (0.02) Valve stem end length 2.7 Valve seat width 0.9—1.1 № & БА. (0.035—0.043) Valve head radial runout 0.03 Valve spring free length 34.4 (IN. & EX.) INNER (1.35) 38.1 OUTER (1.50) Valve spring tension 5.9—6.7 kg (IN. & EX.) INNER (13.0— 14.8 Ibs) — at length 27.5 mm (1.1 in) 13.8— 15.8 kg OUTER (30.4— 34.8 lbs) — 7-29 SERVICING INFORMATION CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height IN 33.710—33.750 33.410 (1.3272—1.3287) (1.3154) EX 33.700—33.740 33.400 (1.3268—1.3283) (1.3150) Camshaft journal oil clearance | Right & 0.032—0.066 0.150 Center (0.0013—0.0026) (0.0059) Left 0.028—0.059 0.150 © (0.0011 —0.0023) (0.0059) Camshaft journal holder I.D. Right & 22.012—22.025 Center (0.8666—0.8671) Lef 17.512—17.525 en (0.6894—0.6900) Camshaft journal O.D. Right & 21.959—21.980 Center (0.8645—0.8654) Left 17.466 — 17.484 © (0.6877 —0.6883) Camshaft runout 0.10 (0.004) Rocker arm |.D. 12.000—12.018 М & ЕЖ. (0.4724—0.4731) — Rocker arm shaft O.D. 11.973—11.984 "Na Se Ex (0.4714—0.4718) Cylinder head distortion 0.05 (0.002) Cylinder head cover distortion 0.05 (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.020—0.030 0.120 (0.0008 — 0.0012) (0.0047) Cylinder bore 100.000— 100.015 Nicks or (3.937 — 3.9376) Scratches Piston diam. 99.975—99.990 (3.9360 — 3.9366) Ea Measure at 21 mm (0.8 in) from the skirt end. Cylinder distortion 0.05 (0.002) Piston ring free end gap 13,6 10.8 1st R Approx. (0.53) (0.43) 11.4 9.1 ева. | В Apprex. 19,45) (0.36) Piston ring end gap 1st 0.30—0.45 0.50 2 (0.012—0.018) (0.020) ond 0.45— 0.60 1.00 A (0.018—0.024) (0.039) Compression pressure (Automatic decomp. actuated) 850 kPa Approx. (5 er 120 psi SERVICING INFORMATION 7-30 ITEM STANDARD LIMIT Piston ring to groove clearance 1st 0.180 > (0.0071) 0.150 2nd (0.0059) Piston ring groove width 1st 1.230—1.250 > (0.048—0.049) Ind 1.210—1.230 A (0.047—0.048) oi 2.810— 2.830 (0.110—0.111) Piston ring thickness 1st 1.170— 1.190 5 (0.0461 —0.0469) 1.150—1.170 end (0.0453—0.0461) Piston pin bore 23.002—23.008 23.030 (0.9056 — 0.9058) (0.9067) Piston pin O.D. 22.996—23.000 22.980 (0.9054—0.9055) (0.9047) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end |.D. 23.006— 23.014 23.040 (0.9057—0.9061) (0.9071) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10—0.65 1.00 (0.004 — 0.026) (0.039) Conrod big end width 24.95— 25.00 (0.982 —0.984) Crankshaft runout 0.05 (0.002) Crank web to web width 71.0 + 0.1 (2.795 + 0.004) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.033 (61/28 x 30/20 x 15/30) Oil pressure (at 60°C,140°F) Above 30 kPa (0.3 kg/cm?, 4.3 psi) Below 70 kPa (0.7 kg/cm?, 10.0 psi) at 3 000 r/min. 7-31 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10—15 (0.4—0.6) Drive plate thickness No.1 & 2.9—3.1 2.6 No.2 (0.11—0.12) (0.10) Driven plate distortion 0.10 (0.004) Clutch spring free length 33.0 (1.30) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.178 (61/28) E — Final reduction E-03,28,33 2.800 (42/15) 2. ratio The others 2.733 (41/15) — Gear ratios Low 2.416 (29/12) >" 2nd 1.625 (26/16) es 3rd 1.238 (26/21) — 4th 1.000 (21/21) — Top 0.826 (19/23) — Shift fork to groove clearance 0.10—0.30 0.50 (0.004—0.012) (0.020) Shift fork groove width 5.0—5.1 (0.197—0.200) Shift fork thickness 4.8—4.9 (0.189—0.193) Drive chain Type DAIDO:DID525V9 тт Links 110 — 20-pitch length — MN Drive chain slack 30—45 (1.2—1.8) SERVICING INFORMATION 7-32 CARBURETOR SPECIFICATION ITEM E-03 E-33 E-28 E-18 Carburetor type MIKUNI И — - BST40SS Bore size 40 mm — — E |.D. No. 32ET 32E6 32E5 32E2 Idle r/min. 1 500 + 100 — _ 1 500 + 50 r/min. r/min. Float height 14.7 1.0 тт de — _ (0.58 + 0.04 in) Main jet (M.J.) #140 Te # 140 # 137.5 Jet needle (J.N.) 6F23 = 6F19-3rd 6H21-4th Needle jet (№...) Y-5M Y-5 + Throttle valve (Th.V.) #95 = Are = Pilot jet (P.J.) # 42.5 = #42.5 = Starter jet | (G.S.) #40 + em = Pilot screw (PS) PRE-SET PRE-SET PRE-SET — (172 turns (1.0 turn back) back) Throttle cable play 0.5—1.0 mm а E (pulling cable) (0.02—0.04 in) Starter cable play 0.5—1.0 mm _ _ — (0.02—0.04 in) CARBURETOR ITEM SPECIFICATION E-02,04,34 E-37 E-17,22,24 | U-type E-22 Carburetor type MIKUNI — — — BST40SS Bore size 40 mm € — — |.D. No. З2ЕО 32E8 32E3 32E4 Idle r/min. 1 500+ & ds _ 100 r/min. Float height 14.7+1.0 mn — - — (0.58 + 0.04 in) Main jet (M.J.) # 140 € — — Jet needie (J.N.) 6F19-3rd — — + Needle jet (N.J.) Y-5 < € — Throttle valve (Th.V.) #95 € ee + Pilot jet (P.J.) # 42.5 — — + Starter jet (G.S.) # 40 & + E Pilot screw (P.S.) PRE-SET és PRE-SET PRE-SET (1 turns back) (1.0 turn back)|(17%s turns back) Throttle cable play 0.5—1.0 mm - и è (pulling cable) (0.02—0.04 in) Starter cable play 0.5—1.0 mm _ _ — (0.02—0.04 in) 7-33 SERVICING INFORMATION ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 10° B.T.D.C. at 1 500 r/min. rk plu ND.: U31ESR-N E Type N.G.K.: CR10E Gap 0.7—0.8 (0.028—0.031) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Primary 0.07—0.12 Q B—B/W Secondary 23—25 kQ CEE Generator coil resistance Charging 0.5—0.9 Q Y — Y Power source 0.1—0.2 Q B—W Pick-up 170—256 Q BI—G Generator no-load voltage More than 75 V(AC) at 5 000 r/min. Generator Max. output Approx. 200W at 5 000 r/min. Regulated voltage 13.0—16.0 V at 5 000 r/min. Starter relay resistance 3—5 Battery Type designation YTX9-BS Capacity 12V 28.8 kC (8Ah)/10 HR В 1.320 at 20°C (68°F) Fuse size Main 30 A Headlight (H) 10 A Headlight (L) 10 A WATTAGE Unit: W ITEM SPECIFICATION E-03,24,28,33 The others Headlight HI 60 — LO 55 — Parking or position light o see 4 Tail/Brake light 5/21 = Turn signal light 21 e Speedometer light 3 > Turn signal indicator light 2 <— High beam indicator light 2 — Neutral indicator light 2 = License light 5 — BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height D (0.2) Brake disc thickness Front 4.0 + 0.2 3.5 (0.157 £ 0.008) (0.14) Rear 4.5 + 0.2 4.0 (0.177 + 0.008) (0.16) Brake disc runout 0.30 ( 0.012) SERVICING INFORMATION 7-34 ITEM STANDARD LIMIT Master cylinder bore isnt 12.700—12.743 ron (0.5000—0.5017) R 12.700—12.743 car (0.5000—0.5017) Master cylinder piston diam. Fránt 12.657—12.684 ron (0.4983—0.4994) R 12.657— 12.684 car (0.4983 — 0.4994) Brake caliper cylinder bore Frañt 27.000—27.050 ron (1.0630— 1.0650) R 30.23—30.28 car (1.1902—1.1921) Brake caliper piston diam. Front 26.90— 26.95 ron (1.0591— 1.0610) R 30.16—30.18 car (1.1874—1.1882) Wheel rim runout Axial 2.0 “a (0.08) 2.0 Radial —— (0.08) Wheel axle runout 0.25 Front «== == (0.010) 0.25 Rear (0.010) Tire rim size Front 21x 1.85 Ss Rear 17xMT2.50 — Tire size Front 90/90-21 545 — Rear 120/90-17 64S = Tire tread depth 3.0 Front (0.12) oo 3.0 Rear (0.12) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke 260 (10.2) a mr Low seat Front fork spring free length 548 (21.6) Front fork oil level 164 (6.5) 150 = Low seat (5.9) 7-35 SERVICING INFORMATION ITEM STANDARD LIMIT NOTE Rear shock absorber spring 247.5 pre-set length (9.74) Rear wheel travel 260 (10.2) or — Low seat Swingarm pivot shaft runout 0.3 (0.01) TIRE PRESSURE COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kg/cm?! psi | kPa |kg/cm? psi FRONT 150 | 1.50 22 175 | 1.75 25 REAR 175 | 1.75 25 200 | 2.00 29 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (83M) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or E-03,33 less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Use only unleaded gasoline of at least 87 pump octane ( 22M method) or 91 octane E-28 or higher rated by the Research Method. Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is The others recommended. Fuel tank including reserve 12 L E-33 (3.2/2.6 US/Imp gal) - 13L (3.4/2.9 US/Imp gal) The others reserve 3.0L (0.8/0.7 US/Imp gal) Engine oil type SAE 10W/40, API SE, SF or SG Engine oil capacity 2 300 ml Change (2.4/2.0 US/Imp qt) Filter change 2. 404) ml (2.5/2.1 US/Imp qt) Overhaul 2. 500 ml (2.7/2.3 US/Imp qt) Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 565 ml (19.1/19.9 US/Imp oz) 563 ml (19.0/19.8 US/Imp 02) E seat Brake fluid type DOT 4 IMPORTANT NOTICE ! If this manual was not purchased from manualcd then you will be missing important pages and also have some features locked. To insure you have the complete manual only buy from manualcd If this manual was not purchased from manualcd please contact us and we will inform you of what pages are missing and which features are locked. [email protected] EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL CARBURETOR COMPONENTS ----------------=-- 8- 1 EVAPORATIVE EMISSION CONTROL SYSTEM -----==========e=m=n=ne=—.- 8- 2 CANISTER HOSE ROUTING ea RR ee a ee ee ee 8- 3 8-1 EMISSION CONTROL INFORMATION EMISSION CONTROL CARBURETOR COMPONENTS DR650SE motorcycles are equipped with precision, manufactured carburetors for emission level con- trol. These carburetors require special mixture control components and other precision adjustments to function properly. There are several carburetor mixture control components in each carburetor assembly. Three (3) of these components are machined to much closer tolerances than standard machined carburetor jets. These three (3) particular jets —MAIN JET, NEEDLE JET, PILOT JET —must not be replaced by stan- dard jets. To aid in identifying these three (3) jets a different design of letter and number are used. If replacement of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below. The jet needle is also of special manufacture. Only one clip position is provided on the jet needle. If replacement becomes necessary the jet needle may only be replaced with an equivalent perform- ing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability. Conventional Figures Used on Standard Tolerance Jet 1 2 3 4 b G / 8 9 О Components Emission Type Figures Usedon Close Tolerance | | J 3 4 56656 1H § [] Jet Components The carburetor specifications for the emission-controlled DR650SE are as follows. Carburetor Main Needle Jet Pilot Pilot D. No. Jet Jet Needle Jet Screw 32E6 (California model only) #140 TE 6F23 % 40.5 PRE-SET 32E1 Adjusting, interferring with, improper replacement, or resetting of any of the carburetor components may adversely affect carburetor performance and cause the motorcycle to exceed the exhaust emission level limits. If unable to effect repairs, contact the distributors representative for further technical information and assistance. EMISSION CONTROL INFORMATION 8-2 EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) Fuel tank Fuel filler pipe Fuel filler cap \ Fuel-vapor separator UT CJ Breather pipe Fuel valve Vacuum hose Roll-over valve Fuel hose Carburetor Air vent hose | <——— (Canister a Purge port <—— HC VAPOR sem FUEL æ=--- FRESH AIR 8-3 EMISSION CONTROL INFORMATION CANISTER HOSE ROUTING (California model only) А asoy Jie abing [| | RRA | dwe|n 9sou aBind asoy abing (edulis pay) О asoy abing esouy abind a1siue) (ed113s pay) asoy abing Jap|oy anjea 1109 19n0-||0y 19AO-|JOH 199eds i= due” asoy abund asoy abing yuel [an DR650SEV/W/X/Y (°97/°98/°99/°00-MODEL) CONTENTS SPECIFICATIONS ---.----..------:---.000000000000000000er re e re 9- 1 SERVICE DATA EEK EEE CI RD As 9. 3 WIRING DIA GRAM a DS CA EA 9-1 1 9-1 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height "= ® 4 8 ® ® 8 ® # 8 8 FB 8 8 0 HE BE mE NE ® EN W mw om mE B oN NE OW m Wheelbase ........... ce, = m= "ww... ES ® ® ® # Si ENGINE Тур rea sa ve mana y mea ae ARE a E FUGA E $ CEPA NY NI Valve clearance (IN) (EX) Number of cylinders BOF can y 4 e ques ÿ à © om à à USE à à PRIT à € MENT ЕК ИФ Stroke Piston displacement Compression ratio Carburetor Air cleaner ...........eeeeeccaaneeeonooneno Starter system Lubrication system в в ия HE вен ини ни нии нии нии ни = = = = = ® = =: =" = = = = ® + = + + = © + E AE EEE = = ® 1 = вши ван ни вн ини #6 d BH ни и пи ни нии RB BEN WEN N N NN BUS 8 0 5 & ® ни ни ни ини нии 5 # ип ® ® = N ® ® N ® ® = 5 WW N ES ® ® ® ® H ® à т + я и и + и и пи Ши нии вин + 8 N ® & = = um TRANSMISSION Clutch = ® & 4 «=: ES вия ® и ши ви ® 4 ни ® 4 ни ни ни нии нии нина нии HW Gearshift pattern Primary reduction ratio Gear ratios, Low 2nd ТОВ) вая иен в р В mamen ae MN y & Beal a . ® § 4 ини ви нии ви и mF & #4 ® FB ян ини ни ви нити ® 2 345 mm (92.3 in) ..... E-17, 18, 22 2325 mm (91.5 in) ..... E-17, 18, 22 (Low seat) 2 255 mm (88.8 in) ..... Others 2 235 mm (88.0 in) ..... Others (Low seat) 365 mm (34.1 in) 1205 mm (47.4 in) 1165 mm (45.9 in) ..... (Low seat) 1490 mm (58.7 in) 1475 mm (58.1 in) ..... (Low seat) 265 mm (10.4 in) 225 mm ( 8.9 in) ..... (Low seat) 885 mm (34.8 in) 845 mm (33 in) ..... (Low seat) 147 kg (324 Ibs) Four-stroke, air-cooled, with SACS, OHC 0.08-0.13 mm (0.003-0.005 in) 0.17-0.22 mm (0.007-0.009 in) 1 100 mm (3.937 in) 82 mm (3.228 in) 644 cm? (39.3 cu. in) 9.5: 1 BST40, single Polyurethane foam element Electric Wet sump Wet multi-plate type 5-speed constant mesh 1-down, 4-up 2.178 (61/28) 2.416 (29/12) 1.625 (26/16) 1.238 (26/21) 1.000 (21/21) 0.826 (19/23) 2.800 (42/15) E-03, 28, 33 2.733 (41/15) Others DID525 V9, 110 links CHASSIS Front suspension Rear suspension « "="... mw Front fork stroke : ® ® N ® ® & = ® #8 ® ® #6 & 1 = Ww ини ни ни ими НВеаг \уПпее! {гаме! ........................., Steering angle Caster Trail Turning radius Front brake Rear brake т и в «€ : =: т и = N WN = = = 6 ® 1 = W N SS ® 5 ® & = = = ни & # ® a ® ® ® 1 1 = WN = ® NW и ® WH 6 ® ®E ®E ®W = N N N ® ниве ни нии "= 8 ии ни ни ни ни нии и ® 3 ® 8 EE. . ® ® # ® ® # 1 = = N = = H ® # ®§ EE . = =: = = = EE ®§ & HE ве в ити и ти на ни F хин ®E mE ES. = a) = ® ® & a 8 #8 ® 4 S FW WE EN N WN EE & = ® ®E ™W EN NR ниве ни ини uw и и 8 #4 ® нение вии ванн ини тии нивы ниве вин E 4 = ® ®§ ® 4 ® ¥ 4 ® 6 ®# ® ®E EF a ви ® 8 ® вия ни ии ива ELECTRICAL Ignition type Ignition timing Spark plug Battery Generator = = ® ® =m = > & & ® # ни в ни ина F ® ® EW ® ®W нивы и. и ини и «+ 4 8 6 + ® 1 1 = нии ви 5 § 5 a ни ни в = = = 5 8 8 SB § 4 1 = = = = = = ниве нии нии ини EE @# 88 B® ® =m я п пин неа 8 § # 4 ®w Ww ®W Ww N N U WW ¥ ® ® ® ® mH W WN = ® mE ® ® нии Headlight Parking or city light Turn signal light Brake light/Taillight License plate light Speedometer light Neutral indicator light High beam indicator light Turn signal indicator light : « =: =: =: = = = AE SS 8 m и = ® ии наи н вне нии ни ии вин ве т и и ни и = à 4 в ве w = и пи и ван не ини ии ни 6 + = ® шин « ве и = = нии 5 #6 ® ® Ww = = = 1 = 5 + 5 = = = = = =: = 5 § 1 EE ен ини ине 88 1 ® = = ®w ® HEH NE 0 « 8 ® a = EF & 4 E EA в ея ини нии вине тиви вая . и и +5 = =: «: = = = = = = = + = =: = CAPACITIES Fuel tank, including reserve ................ reserve Engine oil, oil change with filter change overhaul « ее чтении ии вине вен ии ви вые 9-2 Telescopic, coil spring, oil damped Link type, coil spring, gas/oil damped, spring pre-load fully adjustable, compression damping force adjustable 260 mm (10.2 in) 220 mm ( 8.7 in) 260 mm (10.2 in) 220 mm ( 8.7 in) ..... (Low seat) 43° 28° 30’ 111 mm (4.37 in) 2.5 m (8.2 Tt) Disc brake Disc brake 90/90-21 54S, tube type 120/90-17 64S, tube type (Low seat) Electronic ignition (CDI) 10° B.T.D.C. at 1500 rpm NGK CR10E or DENSO U31ESR-N 12V 28.8 kC (8 Ah)/10 HR Three-phase A.C. generator 30/10/10A 12V 60/55W 12V 4W 12V 21W 12V 21/5W 12V 5W 12V 3W 12V 2W 12V 2W 12V 2W except E-03, 24, 28, 33 E-33 Others 12.0 L (3.2/2.6 US/Imp gal) 13.0 L (3.4/2.9 US/Imp gal) 3.0 L (0.8/0.7 US/Imp gal) 2300 ml (2.4/2.0 US/Imp at) 2 400 ml (2.5/2.1 US/Imp qt) 2 600 ml (2.7/2.3 US/Imp at) 565 ml (19.1/19.9 US/Imp oz) 563 ml (19.0/19.8 US/Imp oz) .... (Low seat) 9-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN 33 (1.3) 28 EX. (1.1) Valve clearance IN 0.08—0.13 (when engine is cold) (0.003— 0.005) EX 0.17—0.22 (0.0067 —0.0087) Valve guide to valve stem IN 0.010—0.037 clearance ; (0.0004 —0.0015) EX 0.030 —0.057 (0.0012—0.0022) Valve stem deflection 0.35 IN. & EX. (0.014) Valve guide |.D. 5.500—5.512 МЫ. Si E (0.2165—0.2170) Valve stem O.D. IN 5.475—5.490 ` (0.2156—0.2161) EX 5.455 —5.470 (0.2148—0.2154) Valve stem runout 0.05 IN. & EX. (0.002) Valve head thickness 0.5 Valve stem end length 2.7 IN. & EX. (0.1 1) Valve seat width 0.9—1.1 НШ. в EX (0.035—0.043) Valve head radial runout 0.03 Valve spring free length 34.4 (IN. & EX.) INNER (1.35) 38.1 OUTER — (1.50) Valve spring tension (IN. & EX.) 5.9—6.7 kg INNER (13.0— 14.8 165) тени at length 27.5 mm (1.1 in) 13.8 — 15.8 Ка OUTER (30.4— 34.8 165) — at length 31.0 mm (1.2 in) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height IN 33.710—33.750 33.410 (1.3272—1.3287) (1.3154) EX 33.700—33.740 33.400 (1.3268 — 1.3283) (1.3150) Camshaft journal oil clearance | Right & 0.032—0.066 0.150 Center (0.0013—0.0026) (0.0059) Left 0.028—0.059 0.150 = (0.0011—0.0023) (0.0059) Camshaft journal holder I.D. Right & 22.012—22.025 Center (0.8666 —0.8671) Lef 17.512—17.525 a (0.6894 —0.6900) Camshaft journal O.D. Right & 21.959—21.980 Center (0.8645—0.8654) Left 17.466 — 17.484 © (0.6877 —0.6883) Camshaft runout | 0.10 (0.004) Rocker arm 1.D. 12.000—12.018 Ne El EA (0.4724—0.4731) Rocker arm shaft O.D. 11.973—11.984 IN, Ea BA, (0.4714—0.4718) Cylinder head distortion o 0.05 (0.002) Cylinder head cover distortion _ 0.05 (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.020— 0.030 0.120 (0.0008 — 0.0012) (0.0047) Cylinder bore 100.000 — 100.015 Nicks or (3.937—3.9376) Scratches Piston diam. 99.975— 99.990 99 880 (3.9360— 3.9366) (3.9323) Measure at 21 mm (0.8 in) from the skirt end. - Cylinder distortion o 0.05 (0.002) Piston ring free end gap 1st R Approx. DE Тя 11.4 Zia | в APProx. (0.45) (0.36) Piston ring end gap ler 0.30—0.45 0.50 : (0.012—0.018) (0.020) 2nd 0.45—0.60 1.00 n (0.018 —0.024) (0.039) Compression pressure Approx. 850 kPa (Automatic decomp. actuated) ES kg/cm?) — 120 psi 9-5 ITEM STANDARD LIMIT Piston ring to groove clearance 1st 0.180 > (0.0071) 0.150 2nd (0.0059) Piston ring groove width 1st 1.230—1.250 (0.048—0.049) 2nd 1.210— 1.230 (0.047—0.048) oi 2.810— 2.830 | (0.110—0.111) Piston ring thickness 1st 1.170—1.190 ® (0.0461 —0.0469) 2nd 1.150— 1.170 (0.0453 —0.0461) Piston pin bore 23.002 — 23.008 23.030 (0.9056 — 0.9058) (0.9067) Piston pin O.D. 22.996 — 23.000 22.980 (0.9054 —0.9055) (0.9047) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end |.D. 23.006 — 23.014 23.040 (0.9057 — 0.9061) (0.9071) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10—0.65 1.00 (0.004 — 0.026) (0.039) Conrod big end width 24.95— 25.00 (0.982 — 0.984) Crankshaft runout 0.05 (0.002) Crank web to web width 71.0 + 0.1 (2.795 + 0.004) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.633 (61/28 x 30/20 x 15/30) Oil pressure (at 60°C,140°F) Above 30 kPa (0.3 kg/cm?2, 4.3 psi) Below 70 kPa (0.7 kg/cm?, 10.0 psi) at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10—15 (0.4—0.6) Drive plate thickness No.1 & 2.9—3.1 2.6 No.2 (0.11—0.12) (0.10) Driven plate distortion 0.10 (0.004) Clutch spring free length 33.0 (1.30) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.178 (61/28) o Final reduction E-03,28,33 2.800 (42/15) === ratio The others 2.733 (41/15) =n Gear ratios Low 2.416 (29/12) Sees 2nd 1.625 (26/16) — 3rd 1.238 (26/21) — 4th 1.000 (21/21) — Top 0.826 (19/23) т Shift fork to groove clearance 0.10—0.30 0.50 (0.004 — 0.012) (0.020) Shift fork groove width 5.0—5.1 (0.197—0.200) Shift fork thickness 4.8—4.9 | (0.189—0.193) Drive chain Type DAIDO:DID525V9 — Links 110 envers ; 319.4 20-pitch length — (12.57) Drive chain slack 30—45 (1.2—1.8) 9-7 CARBURETOR TEM SPECIFICATION E-03 E-33 E-28 E-18 Carburetor type MIKUNI а =. _ BST40SS Bore size 40 mm — — < |.D. No. 32E1 32E6 32E1 32E2 Idle r/min. 1 500+ 100 2. a 1 500+ 50 r/min. r/min. Float height 14.7+1.0 mm (0.58 + 0.04 in) Main jet (M.J.) # 140 € — % 137.5 Jet needle (J.N.) 6F23 = = 6H21-4th Needle jet (N.J.) Y-5M — + «+ Throttle valve (ТЫ. У.) # 95 = + < Pilot jet (P.J.) Же. — — *— Starter jet (С.5.) # 40 = < = Pilot screw (P.S.) PRE-SET PRE-SET = € (1.0 turn back) Throttle cable play 0.5—1.0 mm — _ _ (pulling cable) (0.02 — 0.04 in) Starter cable play 0.5— 1.0 mm “ an г (0.02—0.04 in) CARBURETOR ITEM SPECIFICATION E-02,04,34 P-37 E-17,22,24 U-type E-22 Carburetor type MIKUNI = i г BST40SS Bore size 40 mm + + foes |.D. No. З2ЕО 32E8 32E3 32E4 ldle r/min. 1 500 + — — — 100 r/min. Float height 14.7 + 1.0 тт = г (0.58 + 0.04 in) Main jet (М...) # 140 = #— — Jet needle (J.N.) 6F19-3rd — = — Needle jet (N.J.) Y-b 7 € <— Throttle valve (Th.V.) #95 — — + Pilot jet (P.J.) #42.5 = + + Starter jet (G.S.) # 40 — — — Pilot screw (P.S.) PRE-SET — PRE-SET PRE-SET (11% turns back) (1.0 turn back) (1 turns back) Throttle cable play 0.5— 1.0 mm — _ _ (pulling cable) (0.02 — 0.04 in) Starter cable play 0.5— 1.0 mm è_ e - (0.02—0.04 in) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 10° B.T.D.C. at 1 500 r/min. ND.: U31ESR-N Ps Jie Type N.G.K.: CR10E Gap 0.7—0.8 (0.028—0.031) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Primary 0.07—0.12 Q B—B/W Secondary 23—25 kQ Pine Generator coil resistance Charging 0.5—0.9 Q Y — Y Power source 0.1—0.2 Q B—W Pick-up 170—256 Q BIG Generator no-load voltage More than 75 V(AC) at 5 000 r/min. Generator Max. output Approx. 200W at 5 000 r/min. Regulated voltage 13.0— 16.0 V at 5 000 r/min. Starter relay resistance 3—5 Q Battery Type designation YTX9-BS Capacity 12V 28.8 kC (8Ah)/10 HR pee e e 1.320 at 20°C (68°F) Fuse size Main 30 A Headlight (H) 10 A Headlight (L) 10 A WATTAGE Unit:W ITEM SPECIFICATION E-03,24,28,33 Other markets Headlight HI 60 + LO 55 += Parking or position light ea BA TS 4 Tail/Brake light 5/21 + Turn signal light 21 — Speedometer light 3 = Turn signal indicator light 2 = High beam indicator light 2 = Neutral indicator light 2 — License light 5 — BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 5 (0.2) Brake disc thickness Front 4.0 + 0.2 3.5 (0.157 + 0.008) (0.14) 4.5 + 0.2 4, Nest (0.177 + 0.008) (0.16) Brake disc runout 0.30 ( 0.012) ITEM STANDARD LIMIT Master cylinder bore Bost 12.700—12.743 "E (0.5000—0.5017) 12.700—12.743 Rear (0.5000—0.5017) Master cylinder piston diam. Front 12.657—12.684 9 (0.4983—0.4994) 12.657 — 12.684 near (0.4983—0.4994) Brake caliper cylinder bore Front 27.000— 27.050 en (1.0630—1.0650) 30.23— 30.28 car (1.1902—1.1921) — Brake caliper piston diam. Front 26.90— 26.95 a (1.0591—1.0610) 30.16—30.18 Hear (1.1874—1.1882) Wheel rim runout ; 2.0 Axial = (0.08) 2.0 Radial Ce 8 (0.08) Wheel axle runout Front 0.25 ron a (0.010) Rear ZZ 0.25 (0.010) Tire rim size Front J21 x 1.85 — Rear J17x MT2.50 — Tire size Front 90/90-21 545 San Rear 120/90-17 64S ——— Tire tread depth 3.0 Front — (0.12) 3.0 Rear — (0.12) SUSPENSIÓN Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke 260 о (10.2) E = Low seat Front fork spring free length 548 (21.6) Front fork oil level 164 (6.5) 150 HS Low seat (5.9) 9-10 ITEM STANDARD LIMIT NOTE Rear shock absorber spring 247.5 pre-set length (9.74) Rear wheel travel 260 (10.2) a теснее Low seat Swingarm pivot shaft runout 0.3 (0.01) TIRE PRESSURE COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa |kg/cm?| psi | kPa _|kg/cm?| psi FRONT 150 | 1.50 22 175 | 1.75 25 REAR 175 | 1.75 25 200 | 2.00 29 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (557) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary £.03 33 Butyl Ether), less than 10% ethanol, or TM less than 5% methanol with appropriate cosolvents and corrosion inhibitor 15 permissible. Use only unleaded gasoline of at least 87 pump octane ( ==" method) or 91 octane or E-28 higher rated by the Research Method. Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is recommended. Other markets Fuel tank capacity 12 L E-33 Including (3.2/2.6 US/Imp gal) reserve 13 L (3.4/2.9 US/Imp gal) Other markets Only 3.0L reserve (0.8/0.7 US/Imp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity Oil 2 300 ml change (2.4/2.0 US/Imp qt) Oil and 2 400 ml filter change (2.5/2.1 US/Imp at) Engine 2 600 ml overhaul (2.7/2.3 US/Imp at) Front fork oil type Fork oil #10 Front fork oil capacity (each leg) 565 ml (19.1/19.9 US/Imp oz) 563 ml (19.0/19.8 US/Imp 02) Low seat Brake fluid type DOT 4 9-11 WIRING DIAGRAM 182811 SUYMA YUM MOJSA $ АМА 13281] USSIO) YIIAA MOISA : D/A 18381) YIE YM MOJSA : E/A 189811 anjg YM SUMUM + [9/MA 19924) YSEJg ULA SUUM : /M 199811 зов YIM Pay : g/y 18981) MOJSA YUM SUBIO : AJO 193811 SHUM цим sbuesg : MO 18981) NI Чим Las) : 19/5 180811 SUUM UUM aNIg : MIS 193814) YIEIg YUM anlg : g/g 195841 SUUA UMM YOEIg : Mg 19281) Pay yum ое : yg 189841 3BUBIO YM Yoejg : 0/9 18081] U881B 14617 YUM yoejg : 61/9 180811 8nNIg yum зов : 19/9 (ON AND AFTER '98-MODEL PRODUCTION) MOJSA : E UUM © M pag : y abuesp : 0 usaib yb : 67 aniq 14617 : 197 Ав) 15 Usalo) : ©) имо : 19 snig : 19 42219 : g HO109 34YIM (1! LH9I1 TYNDIS NHAL HYay LHS17 35N3911 1H911 3449/11 1 (4H) IHDIT TYNDIS NHNL HVIH AHILLVS HOLOW HIlHVLS WA 3504 NIVIA 4 AY 13H TYNDIS МНП AV13d H31lHV1S ONVLS IN HILIMS 3x4 vH9 HYv3Y 1H5DI10YAaH + €: (IH) LHOINAV3H : | X04 3snd aNYLS 30IS 31411234 lHOLVINDIÿ [TVYHLNIN 1INM 19D HILIMS HOL1N12 HILIMS NOILISOd 83A31 L 105 NOILINDI NOLLNE HILHVLS HILIMS NOLLINDI HILIMS З\Ч 1NOYJ HILIMS H43WWIa HILIMS Тя INION3 HILIMS LH91 TYNOIS NHNL NOLLAB NHOH (1) LHDIT TYNDIS NHAL 1NOH4 LHDITOVIH (4) 1HDIT TYNDIS NHAL LNOYJ 1HDIT HOLVOIONI TYNDIS NHAL ‘1 LHDIT HOLVIIONI TYHLNIN IN LHDIT HOLVIIQNI NV39 HOIH ен 1 N OH LHOIT HOLVOIONI H313WO033d5 DR650SEK1 (°01-MODEL) SPECIFICATIONS SERVICE DATA... LIQUID GASKET .. CONTENTS FEF FANE RFA FERRE FN NNR RENNER FENN FEN FF FANE FEF AEF FF FEF E нии нити FEF TE) AEF FERN SRNR NE FR FRE NNN FANN FRR NER NR FANN NRA N EN FFF RFR FFF ANN FPA ENN FASE EEN EAN EREEREN 10-1 DR650SEK1 ('01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall Engl == ARA vera WI aa Aaa Омега" ПОЮТ conan sucreries VEE DASE eit ete sera rene ea ae ee neue nee nee a aa aa ana ea ae ae Ground CIAO an TAREA NA pa a CC cnn oon om sim se srs SANT ARO HRA DEV PASS re A Тао Наор сни ENGINE Te race sta ae DEI AA ere Valve clearance (IN) o.oo eee (EX) Louvovssoenrauramenensaatesmeseraneenaemaea ca meamepancamamees Number of cyInderS (AAA N BOLO comonomer a ER RE EE TEE CNE ee RC on nca ana SB ESR Displacement.................rm..m.. eee ee Compression Tate Eee CarBuretor cuss ss ms ma Ren aR Ba A RE Starter SYSIEM ae RER RR ee Lubrication SYSTEM as ree eee RA Idle seed rer ER TR tT WE TRANSMISSION Gearshift pattern conan anise rusian Primary reduction ratios assassins imitates COSTAS. LOW 2 LOTE TUN re ra serre a(S 2/1 ........e.enincececezeerenereeneeneneen ace reer eme reeeeeceoneeeececee. “A pan Mas TOD agas NAAA UR OEA Eig REE IEE TBE srs coms someon ons mosses ane pe een Bo 31 || a NASA Ty cuca in кана CHASSIS PONE SUSPENSIÓN ===. 00 aa arte Rear suspension ...................ee.escieriiecrcec re II III IRIRIIRIIRIRIIRIIIIA EERE Tor SHORE. iia sm ss oh EHE SEEN Rear wheel travel o.oo eee eee eee eee eee eee eee eee eae stesring aidé uisamsssui o CEsSter mua mur css Sti ra ae AA TEA nom mn sms aa ENANA us TUFNING FAQUUS …............crrecccrrrerrere ren enne rer ecer cer are amer nee carence Front brake ……....…........rrersrsnrene nan ren renr sara n ann ana ren sen ne na nan ere reee. Beal Drak cess srr SR аиооосолеа ао оао нае Eront Ue SIZÓ --=====0= == sais sissies i es es assy Rear tire SIZE wen eee Rea RER EEE ELECTRICAL НИНОЙ ME N [gan BG ee ER SE ei EEE A RII so casa er ren ea A SE A TE IIA UTE Generator .............. MENE Sp cane ELSE rana ME HEART woarmsmmumnsmmm assess ieee sia isis sane ys ais Parking or city light... eerenaooor Terreno ТЫВА Sicinal NONE «aaa aa Brake: light/ Taillight EEE License plate OAt numanana nu” o Speedometer light iss essa ER ASMA Neutral indicator light... e eee Fligh bear indicator ПОП? === == aaa Tar sidnal. indicator HONt :==0=====—— CN CAPACITIES Fuel tank, including reserve ................eem.reeeimecieree eE (SEE BMA Engine ol oll Change 0 ME EEE EEE with filter change ...................=.. eee KK rene overhauul .......................xrenrierierenec recerca reee ss Front fork:0il (each 160) ss ere 2 345 mm (92.3 in) ..... E-17, 28, 22 2 325 mm (91.5 in) ..... E-17, 28, 22 (Low seat) 2 255 mm (86.8 in) ..... Others 2 235 mm (88.0 in) ..... Others (Low seat) 865 mm (34.1 in) 1 205 mm (47.4 in) 1 165 mm (45.9 in) ..... (Low seat) 1 490 mm (58.7 in) 1475 mm (58.1 in) ..... (Low seat) 265 mm (10.4 in) 225 mm ( 8.9 in) ..... (Low seat) 885 mm (34.8 in) 845 mm (33 in) ..... (Low seat) 147 kg (324 №5) Four-stroke, air-cooled, OHC 0.08 — 0.13 mm (0.003 — 0.005 in) 0.17 — 0.22 mm (0.007 — 0.009 in) 1 100 mm (3.937 in) 82 mm (3.228 in) 644 cm“ (39.3 cu. in) 95:1 MIKUNI BST40SS, single Polyurethane foam element Electric Wet sump 1 500 £ 100 r/min Wet multi-plate type 5-speed constant mesh 1-down, 4-up 2.178 (61/28) 2.416 (29/12) 1.625 (26/16) 1.238 (26/21) 1.000 (21/21) 0.826 (19/23) 2.800 (42/15) ..... E-03, 28, 33 2.733 (41/15) ..... Others DID 525 V8, 110 links Telescopic, coll spring, oil damped Link type, coil spring, oil damped, spring preload fully adjustable, compression damping force adjustable 260 mm (10.2 in) 220 mm ( 8.7 in) ..... (Low seat) 260 mm (10.2 in) 220mm ( 8.7 in) ..... (Low seat) 43° 28° 30’ 111 mm (4.37 in) 2.5 m (8.2 ft) Disc brake Disc brake 90/90-21 545, tube type 120/90-17 645, tube type Electronic ignition (CDI) 10° B.T.D.C. at 1 500 rpm NGK CR10E or DENSO U31ESR-N 12V 28.8 kC (8 Ah)/10HR Three-phase A.C. generator 30A 10/10A 12V 60/55W 12V 4W ..... Except E-03, 24, 28, 33 12V 21W 12V 21/5W 12V 5W 12V 1.7W 12V 2W 12V 2W 12V 2W 12.0 L (3.2/2.6 US/Imp gal) ..... E-33 13.0 L (3.4/2.9 US/Imp gal) ..... Others 3.0 L (0.8/0.7 US/Imp gal) 2 300 ml (2.4/2.0 US/Imp qt) 2400 ml (2.5/2.1 US/Imp qt) 2600 ml (2.7/2.3 US/Imp qt) 565 ml (19.1/19.9 US/Imp oz) 563 ml (19.0/19.8 US/Imp oz) ..... (Low seat) DR650SEK1 ('01-MODEL) 10-2 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. a) 28 oe EX. (1.1) Valve clearance IN 0.08 — 0.13 (when engine is cold) (0.003 — 0.005) 0.17 — 0.22 = (0.0067 — 0.0087) Valve guide to valve stem IN 0.010 — 0.037 clearance ; (0.0004 = 0.0015) 0.030 — 0.057 EX. (0.0012 — 0.0022) Valve stem deflection IN. & EX. 00 Valve guide |.D. IN. & EX. (0.2185 = 02170 Valve stem O.D. 5.475 — 5.490 IN. (0.2156 — 0.2161) EX 5.455 — 5.470 (0.2148 — 0.2154) Valve stem runout IN. & EX. D162) Valve head thickness IN. & EX. OIEA) Valve stem end length IN. & EX in Valve seat width IN. & EX. 0 jo Valve head radial runout IN. & EX. Don Valve spring free length INNER 34.4 (IN. & EX.) (1.35) OUTER _ RO Valve spring tension (IN. & EX.) NED — an ; INNER .0— 14.8 Ibs — at length 27.5 mm (1.1 in) 13.8 — 15.8 kg OUTER (30.4 — 34.8 Ibs) — at length 31.0 mm (1.2 in) 10-3 DR650SEK1 ('01-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height IN 33.710 — 33.750 33.410 (1.3272 — 1.3287) (1.3154) EX 33.700 — 33.740 33.400 (1.3268 — 1.3283) (1.3150) Camshaft journal oil clearance Right & 0.032 — 0.066 0.150 Center (0.0013 — 0.0026) (0.0059) Left 0.028 — 0.059 0.150 (0.0011 — 0.0023) (0.0059) Camshaft journal holder |.D. Right & 22.012 — 22.025 Center (0.8666 — 0.8671) 17.512 — 17.525 Left (0.6894 — 0.6900) Camshaft journal O.D. Right & 21.959 — 21.980 Center (0.8645 — 0.8654) 17.466 — 17.484 Left (0.6877 — 0.6883) Camshaft runout 0.10 (0.004) Rocker arm |.D. 12.000 — 12.018 ВЫ. AER (0.4724 — 0.4731) Rocker arm shaft O.D. 11.973 — 11.984 _ IN. & EX. (0.4714 — 0.4718) Cylinder head distortion 0.05 (0.002) Cylinder head cover distortion 0.05 (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.020 — 0.030 0.120 (0.0008 — 0.0012) (0.0047) Cylinder bore 100.000 — 100.015 Nicks or (3.9371 — 3.9376) Scratches Piston diam. 99.975 — 99.990 (3.9360 — 3.9366) (0929) Measure at 21 mm (0.8 in) from the skirt end. Cylinder distortion 0.05 (0.002) Piston ring free end gap 13.5 10.8 1st | В Арргох. (0.53) (0.43) 11.4 9.1 2nd | R Approx. (0.45) (0.36) Piston ring end gap {st 0.30 — 0.45 0.50 (0.012 — 0.018) (0.020) ña 0.45 — 0.60 1.00 (0.018 — 0.024) (0.039) Compression pressure 850 kPa (Automatic decomp. actuated) Approx. (SS Em 120 psi DR650SEK1 ('01-MODEL) 10-4 ITEM STANDARD LIMIT Piston ring to groove clearance ist 0.180 (0.0071) 0.150 2nd — (0.0059) Piston ring groove width {st 1.230 — 1.250 (0.048 — 0.049) 1.210 — 1.230 2nd (0.047 — 0.048) oil 2.810 — 2.830 (0.110 — 0.111) Piston ring thickness {st 1.170 — 1.190 (0.0461 — 0.0469) 1.150 — 1.170 end (0.0453 — 0.0461) Piston pin bore 23.002 — 23.008 23.030 (0.9056 — 0.9058) (0.9067) Piston pin O.D. 22.996 — 23.000 22.980 (0.9054 — 0.9055) (0.9047) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end |.D. 23.006 — 23.014 23.040 (0.9057 — 0.9061) (0.9071) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10 — 0.65 1.00 (0.004 — 0.026) (0.039) Conrod big end width 24.95 — 25.00 (0.982 — 0.984) Crankshaft runout 0.05 (0.002) Crank web to web width 71.0 + 0.1 (2.795 + 0.004) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.633 (61/28 x 30/20 x 15/30) Oil pressure (at 60°C,140°F) Above 30 kPa (0.3 kg/cm?, 4.3 psi) Below 70 kPa (0.7 kg/cm?, 10.0 psi) at 3 000 r/min. 10-5 DR650SEK1 ('01-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10-15 (0.4 — 0.6) Drive plate thickness No.1 8 2.9 — 3.1 2.6 No.2 (0.11 — 0.12) (0.10) Driven plate distortion 0.10 (0.004) Clutch spring free length 33.0 (1.30) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.178 (61/28) Final reduction E-03,28,33 2.800 (42/15) — ratio The others 2.733 (41/15) ——— Gear ratios Low 2.416 (29/12) —— 2nd 1.625 (26/16) ——— 3rd 1.238 (26/21) — 4th 1.000 (21/21) — Top 0.826 (19/23) Shift fork to groove clearance 0.10 — 0.30 0.50 (0.004 — 0.012) (0.020) Shift fork groove width 5.0 — 5.1 (0.197 — 0.200) Shift fork thickness 4.8 — 4.9 (0.189 — 0.193) Drive chain Type DAIDO:DID525V9 — Links 110 319.4 Drive chain slack 30 — 45 (1.2 — 1.8) (0.02 — 0.04 in) DR650SEK1 ('01-MODEL) 10-6 CARBURETOR SPECIFICATION TEN E-03, 28 E-33 E-18 Carburetor type MIKUNI BST40SS Ne x Bore size 40 mm — — |.D. No. 32E1 32E6 32E2 Idle r/min. 1 500 + 100 r/min. 1 500 + 50 r/min. Float height 14.7 + 1.0 MM (0.58 + 0.04in) — — Main jet (M.J.) #140 — #137.5 Jet needle (J.N.) 6F23 — 6H21-4th Needle jet (N.J.) Y 5M — Y5 Throttle valve (Th.V.) #95 — Co Pilot jet (PJ.) #42 8 — — Starter jet (G.S.) #40 &— Pilot screw (PS.) PRE-SET PRE-SET < (1.0 turn back) Throttle cable play 0.5-1.0 mm (pulling cable) (0.02 — 0.04 in) к — Starter cable play 0.5- 1.0 mm (0.02 — 0.04 in) = = CARBURETOR ITEM SPECIFICATION E-04, 34, 54 E-17, 22, 24 U-type E-22 Carburetor type MIKUNI BST40SS — — Bore size 40 mm — — [.D. No. 32E0 32E3 32E4 Idie r/min. 1 500 + 100 r/min. — — Float height 14.7 £ 1.0 mm (0.58 + 0.04 in) — Main jet (M.J.) #140 — — Jet needle (J.N.) 6F19-3rd &— — Needle jet (N.J.) Y-5 — — Throttle valve (Th.V.) #95 — Pilot jet (PJ.) #42.5 — — Starter jet (G.S.) #40 — — Pilot screw (P.S.) PRE-SET PRE-SET PRE-SET (1% turns back) (1.0 turn back) (1/5 turns back) Throttle cable play 0.5-1.0 mm (pulling cable) (0.02 — 0.04 in) — — Starter cable play 0.5- 1.0 mm — — 10-7 DR650SEK1 (01-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 10% B.T.D.C. at 1 500 r/min. Spark plug ND.: U31ESR-N Type N.G.K.: CR10E 0.7 — 0.8 Gap (0.028 — 0.031) Spark performance Over 8 (0.3) at 1 atm. Ignition coll resistance Primary 0.07 — 0.120 B — B/W _ Plug cap — Secondary 23 — 25 kQ Plug cap Generator coil resistance Charging 0.5 — 0.9 © Y —Y Power source 0.1 — 0.2 © B-W Pick-up 170 — 256 Q Bl -G Generator no-load voltage More than 75 V (AC) at 5 000 r/min. Generator Max. output Approx. 200 W at 5 000 r/min. Regulated voltage 13.0 — 16.0 V at 5 000 r/min. Starter relay resistance 3-50 Battery Type designation Y TX9-BS Capacity 12V 28.8 kC (8Ah)/10 HR Standard electrolyte S.G. 1.320 at 20°C (68°F) Fuse size Main 30 A Headlight (H) 10 A Headlight (L) 10 A WATTAGE Unit: W ITEM SPECIFICATION E-03, 24, 28, 33 Other markets Headlight HI 60 <= LO 55 — Parking or position light EE EEE 4 Brake light/Taillight 5/21 — Turn signal light 21 — Speedometer light 3 е— Turn signal indicator light 2 — High beam indicator light 2 «= Neutral indicator light 2 — License light 5 — BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height 5 (0.2) Brake disc thickness Bit 4.0 + 0.2 3.5 (0.157 + 0.008) (0.14) 4.5 + 0.2 4.0 ВОГ (0.177 + 0.008) (0.16) Brake disc runout 0.30 (0.012) DR650SEK1 ('01-MODEL) 10-8 ITEM STANDARD LIMIT Master cylinder bore 12.700 — 12.743 Front (0.5000 — 0.5017) R 12.700 — 12.743 wal (0.5000 — 0.5017) Master cylinder piston diam. Eri 12.657 — 12.684 (0.4983 — 0.4994) 12.657 — 12.684 Rear (0.4983 — 0.4994) Brake caliper cylinder bore ot 27.000 — 27.050 (1.0630 — 1.0650) 30.23 — 30.28 Rear (1.1902 — 1.1921) Brake caliper piston diam. Front 26.90 — 26.95 (1.0591 — 1.0610) Rear 30.16 — 30.18 ча (1.1874 — 1.1882) Wheel rim runout ; 2.0 Axial — (0.08) 2.0 Radial — (0.08) Wheel axle runout 0.25 Front — (0.010) 0.25 aca — (0.010) Tire rim size Front J21 x 1.85 Rear J17 x MT2.50 —— Tire size Front 90/90-21 545 —— Rear 120/90-17 64S Tire tread depth 3.0 Front — (0.12) 3.0 Rear — (0.12) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke 260 (10.2) * 220 (8.7) 0 Low seat Front fork spring free length 548 (21.6) Front fork oil level 164 (6.5) 150 (5.9) — Low seat Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible. 10-9 DR650SEK1 ('01-MODEL) ITEM STANDARD LIMIT NOTE Rear shock absorber spring 247.5 pre-set length (9.74) Rear wheel travel 260 (10.2) 220 (8.7) — Low seat Swingarm pivot shaft runout 0.3 (0.01) TIRE PRESSURE COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE | kPa |kg/cm?| psi | kPa |kg/cm?| psi FRONT 150 | 1.50 22 175 | 1.75 25 REAR 175 | 1.75 25 200 | 2.00 29 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (BM) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is recommended. Other markets Fuel tank cap acity 12 L Including (3.2/2.6 US/Imp gal) E-33 reserve 13 L (3.4/2.9 US/Imp gal) Other markets Only 3.0L reserve (0.8/0.7 US/Imp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity Oil 2 300 ml change (2.4/2.0 US/Imp qt) Oil and 2 400 ml filter change (2.5/2.1 US/Imp qt) Engine 2 600 ml overhaul (2.7/2.3 US/Imp at) Front fork oil type Fork oil +10 Front fork oil capacity (each leg) 565 ml (19.1/19.9 US/Imp 02) 563 ml (19.0/19.8 US/Imp 02) Low seat Brake fluid type DOT 4 DR650SEK1 ('01-MODEL) 10-10 LIQUID GASKET CYLINDER HEAD COVER NOTE: SUZUKI BOND NO.1215 or NO. 1207B has to be applied to the cylinder head cover and cylinder head. a E: se ЗЕ E Us 3 1 * 3 Sa CYLINDER HEAD LS IMPORTANT NOTICE ! 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Key features
- 644cc
- air-cooled
- single-cylinder
- DOHC engine
- electric starter
- 5-speed transmission
- chain drive
- front and rear disc brakes
- 21-inch front wheel
- 17-inch rear wheel
Frequently asked questions
The Suzuki DR650SE has a 644cc, air-cooled, single-cylinder, DOHC engine.
The Suzuki DR650SE has a 5-speed transmission.
The Suzuki DR650SE has front and rear disc brakes.
The Suzuki DR650SE has a 21-inch front wheel.
The Suzuki DR650SE has a 17-inch rear wheel.
Yes, the Suzuki DR650SE is easy to maintain.