Suzuki RM250 Owner's Service Manual

RM250

OWNER’S SERVICE MANUAL

Part No. 99011-37F56-01A

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator.

The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

FOREWORD

This manual is presented as a means whereby you can maintain your RM250 in top working condition at all times. Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition.

We sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding.

All information, illustrations, photographs and specifications contained in the manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepancies in this manual.

Suzuki reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to vehicles previous built or sold.

Suzuki Motor Corporation believes in conservation and protection of Earth’s natural resources. To that end, we encourage every vehicle owner to recycle, trade in, or properly dispose of, as appropriate, used motor oil, engine coolant, and other fluid, and tires.

WARNING/CAUTION/NOTE

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



and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words:



WARNING

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

CAUTION

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

c COPYRIGHT SUZUKI MOTOR CORPORATION 2006

GENERAL CONSIDERATIONS

• Wear a helmet and goggles

A helmet is the most important piece of gear to wear. Helmets do not reduce essential vision or hearing. Generally, helmets do not cause or intensify injury if you crash. Helmets simply help your skull protect your intelligence, your memory, your personality, and your life.

Your eyesight is equally valuable. Wearing suitable eye protection can help keep your vision unblurred by the wind and help shield your eyes from branches and airborne matter like bugs, dirt, or pebbles kicked up by tires. Wear a helmet and eye protection every time you ride.

• Wear protective gear

Wear proper clothing when you ride. Avoid loose clothes or scarves, which could get caught in moving parts. Abrasion injuries can be minimized by wearing protective clothing including gloves, strong boots that fit over the ankle, long pants, and a long sleeve shirt or jackets. Experienced riders often wear a kidney belt and chest or back protector for additional comfort and protection.

• Inspect your machine before riding

Before each use, perform an inspection per “Periodic Inspection” section starting on page 2-3.

• No Passengers

Suzuki RMs are designed for the rider only.

• Practice on level ground

Before you begin riding, you should find a good place to practice the skills you need to ride safely. Find a flat, open area with enough space to maneuver. Check with your Suzuki dealer or call police department if you do not know where you can ride.

Review the controls on your motorcycle before riding.

• Know your limits

Always ride within the boundaries of your own skills. Knowing these limits and staying within them will help you avoid accidents. Ride only in events appropriate for your experience.

Safely competing on a motorcycle requires that your mental and physical skills are fully part of the experience. You should not attempt to operate a motor vehicle, especially one with two wheels, if you are tired or under the influence of alcohol or other drugs. Alcohol, illegal drugs, and even some prescription and over-the-counter drugs and cause drowsiness, loss of coordination, loss of balance, and loss of good judgement. If you are tired or under the influence of alcohol or other drugs, PLEASE DO NOT RIDE your motorcycle.

• Conclusion

The actions of other riders are unpredictable.

Your motorcyclee’s condition can change. These factors can best be dealt with by giving every ride your full attention.

Circumstances beyond your control could lead to an accident. You need to prepare for the unexpected by wearing a helmet and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine.

May all of your rides on your new Suzuki be winning rides!

SERIAL NUMBER LOCATION

The frame number 1 is stamped on the steering head as shown in the photograph. The engine serial number 2 is stamped on the right side of the crankcase assembly.

Write down the serial numbers here for your future reference.

Frame No.

Engine No.

WARNINGS FOR SERVICING



WARNING

Never run the engine indoors or in a garage. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.

Only run the engine outdoors where there is fresh air.



WARNING

Fuel can catch on fire if you do not handle it properly. Gasoline vapors can catch fire easily.

Do not smoke when servicing the machine.

Do not service the machine in an area where there are open flames or sparks.



WARNING

Hot engine and muffler can burn you.

Wait until the engine and muffler cools before servicing.



WARNING

Brake fluids and engine coolant can be hazardous to humans and pets. Brake fluid and engine coolant are harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid and engine coolant away from children. Call your doctor immediately if swallowed, and induce vomiting.

Flush eyes or skin with water if either brake fluid or engine coolant gets in eyes or comes in contact with skin.



WARNING

Servicing the machine with engine running can be hazardous. You can be caught in the moving parts such as the drive chain, sprockets etc.

Be sure to stop the engine when servicing the machine.



WARNING

Servicing the machine without proper clothes and protective gear can be hazardous. You can be injured if you do not wear proper clothes and protective gear.

Be sure to wear proper clothes and shoes for servicing and wear protective glasses, mask or gloves as necessary.

PRECAUTIONS FOR SERVIC-

ING

• Replace gaskets, snap rings, circlips, O-rings and cotter pins with new ones.

• Take care not to expand the end gap larger than required to slip the circlip over the shaft when installing a circlip.

• Use special tools where specified.

• Use genuine SUZUKI parts and recommended oil.

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

• After reassembly, inspect parts for tightness and operation.

REPLACEMENT PARTS

Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI vehicles.

NOTE:

Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each symbol is also included in the table.

SYMBOL

Torque control required.

Data beside it indicates specified torque.

DEFINITION

Apply oil. Use engine oil or transmission oil unless otherwise specified.

SYMBOL DEFINITION

Use SUZUKI FORK OIL SS-05 or equivalent fork oil.

99000-99001-SS5

Use SUZUKI REAR SUSPENSION OIL

SS-25 or equivalent rear suspension oil.

99000-99001-S25

Apply SUZUKI SUPER GREASE “A” or equivalent grease.

99000-25010

Use engine coolant.

Apply SUZUKI SILICONE GREASE.

99000-25100

Apply or use brake fluid. (DOT 4)

Apply SUZUKI BOND “1207B”.

99000-31140

1216

Apply SUZUKI BOND “1216B”.

99000-31230

Measure in voltage range.

Measure in resistance range.

Apply THREAD LOCK SUPER “1303”.

99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent thread lock.

99000-32110

Apply THREAD LOCK “1342”.

99000-32050

Apply THREAD LOCK SUPER “1360”.

99000-32130

Use special tool.

Indication of service data.

Replace a part with a new one when reassembling.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

TROUBLESHOOTING

MACHINE TUNING

ENGINE REMOVAL AND INSTALLATION

CYLINDER, PISTON AND EXHAUST VALVE

CLUTCH

KICK STARTER

GEARSHIFTING

TRANSMISSION AND CRANKSHAFT

FUEL SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

FRONT AND REAR WHEELS

FRONT AND REAR BRAKES

FRONT FORK AND STEERING

REAR SUSPENSION

SERVICING INFORMATION

7

8

9

5

6

10

11

1

2

3

4

15

16

17

18

12

13

14

GENERAL INFORMATION

GENERAL INFORMATION 1-1

1

CONTENTS

LOCATION OF PARTS ............................................................................... 1- 2

FUEL AND OIL RECOMMENDATION ........................................................ 1- 3

OPERATING INSTRUCTIONS .................................................................... 1- 4

STARTING THE ENGINE ...................................................................... 1- 4

STOPPING THE ENGINE ..................................................................... 1- 5

TRANSMISSION ................................................................................... 1- 5

BREAK-IN (RUNNING-IN) ........................................................................... 1- 5

WHEN THE MOTORCYCLE IS NEW ................................................... 1- 5

WHEN ENGINE PARTS ARE REPLACED ........................................... 1- 5

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE

000

E-03

E-19

E-28

COUNTRY or AREA

Japan

U. S. A.

E.U.

Canada

EFFECTIVE FRAME NO.

JS1RJ18A000 500001 –

JS1RJ18C 72 100001 –

JS1RJ18A000 500001 –

JS1RJ18C 72 100001 –

1-2 GENERAL INFORMATION

LOCATION OF PARTS

1 Clutch lever

2 Engine stop switch

3 Clutch cable adjuster

4 Throttle grip

5 Front brake lever

6 Fuel tank cap

7 Starter knob

8 Gearshift lever

9 Fuel valve

0 Kick starter lever

A Rear brake pedal

GENERAL INFORMATION 1-3

FUEL AND OIL RECOMMENDATION

This motorcycle is of the two-stroke design, which requires a premixture of gasoline and oil.

Gasoline: Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2 method). .... For

Canada

Use only unleaded gasoline of at least 95 octane (Research Method). .... For other countries

MOTUL 800 2T FACTORY LINE OFF

ROAD or equivalent Two Cycle Racing

Mixing ratio:

Lubricant.

30 : 1

Fuel tank capacity: 8.0 L (2.1/1.8 US/lmp gal)

CAUTION

A mixture containing too little oil will cause piston seizure. Too much oil will cause excessive carbon formation resulting in preignition, fouled spark plug and loss of engine power.

Mix fuel and the engine oil at the ratio of 30:1.

NOTE:

* Mix gasoline and the engine oil thoroughly when the temperature is below 0 °C (32 °F). Vegetable-based oils can separate easier than mineral oils.

* Use premixture oil as soon as possible after mixing, or lubrication performance of the engine oil can decrease.

* Do not mix vegetable-based oil and mineral oil.

Gasoline

(L)

5.0

10.0

15.0

20.0

Oil

(ml)

167

333

500

667

Gasoline

(US gal.)

1

2

3

4

Oil

(US oz)

4.3

8.6

12.8

17.1

Gasoline

(Imp gal.)

1

2

3

4

Oil

(Imp oz)

5.4

10.7

16.0

21.4

1-4 GENERAL INFORMATION

OPERATING INSTRUCTIONS

STARTING THE ENGINE

Inspect the transmission oil level, coolant level and air cleaner condition before starting the engine.

When the engine is cold:

1) Turn the fuel valve lever to the “ON” position.

2) Shift the transmission into neutral.

3) Pull the bypass (starter) knob 1 .

4) Close the throttle grip completely and depress the kick starter lever forcefully.

5) Return the bypass (starter) knob when the engine revs at steady speed.

CAUTION

Racing the engine in neutral will exceed the engine speed limit. Exceeding the engine speed limit can damage the engine moving parts.

Do not race the engine at high speed to avoid the engine damage.

When the engine is warm:

1) Turn the fuel valve lever to the “ON” position.

2) Shift the transmission into neutral.

3) Open the throttle 1/8 – 1/4 turn and depress the kick starter lever forcefully.

ON

To restart after the motorcycle has fallen:

1) Shift the transmission into neutral.

2) Open the throttle completely and depress the kick starter lever forcefully.

3) Close the throttle gradually as engine speed increases.

4) Wait until engine revs smoothly.

OFF

STOPPING THE ENGINE

1) Shift the transmission into neutral.

2) Turn the fuel valve lever to the “OFF” position.

3) Push the engine stop switch 1 to stop the engine.



WARNING

Leaving the fuel valve in the “ON” position may cause carburetor overflow. This can cause a fire or severe engine damage when you start the engine.

Always leave the fuel valve in the “OFF” position when the engine is not running.

TRANSMISSION

This motorcycle has a 5-speed transmission. Neutral is located between low and 2nd. Engage first gear by pressing the lever down from the neutral position. You can shift into higher gears by lifting on the shift lever once for each gear. When neutral is desired, press or lift the lever to the position halfway between low and 2nd gear.

BREAK-IN (RUNNING-IN)

WHEN THE MOTORCYCLE IS NEW

1) Warm up the engine before starting off.

2) Ride for 1 hour using less than 1/2 throttle opening with various throttle opening.

3) Ride for 1 hour using less than 3/4 throttle opening with various throttle opening.

NOTE:

* The break-in (running-in) period is the period of greatest wear.

* The bolts and nuts of the new machine can loosen quickly. Be sure to retighten the bolts and nuts during the break-in (running-in) period.

WHEN ENGINE PARTS ARE REPLACED

Follow the same procedure when any of the following parts are replaced:

Piston

Piston ring

Cylinder

Crankshaft

Crankshaft bearing

N

GENERAL INFORMATION 1-5

– MEMO –

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-1

CONTENTS

PERIODIC MAINTENANCE ........................................................................ 2- 3

PERIODIC MAINTENANCE CHART .................................................... 2- 3

INSPECTION BEFORE PRACTICE ...................................................... 2- 5

INSPECTION BEFORE RACE

(All items of inspection before practice above plus) ........................ 2- 5

SPARK PLUG .............................................................................................. 2- 6

AIR CLEANER ............................................................................................. 2- 7

AIR CLEANER ELEMENT REMOVAL ................................................. 2- 7

WASHING .............................................................................................. 2- 7

INSTALLATION ..................................................................................... 2- 7

TRANSMISSION OIL ................................................................................... 2- 9

TRANSMISSION OIL LEVEL INSPECTION

AND REPLENISHMENT ....................................................................... 2- 9

TRANSMISSION OIL CHANGE ............................................................ 2-10

ENGINE COOLANT ..................................................................................... 2-11

ENGINE COOLANT LEVEL CHECK .................................................... 2-11

ENGINE COOLANT REPLENISHMENT ............................................... 2-12

ENGINE COOLING SYSTEM INSPECTION ......................................... 2-12

CLUTCH ....................................................................................................... 2-13

MAJOR ADJUSTMENT ........................................................................ 2-13

MINOR ADJUSTMENT ......................................................................... 2-13

THROTTLE CABLE ..................................................................................... 2-13

FUEL HOSE ................................................................................................. 2-14

FUEL VALVE ............................................................................................... 2-14

CYLINDER HEAD, CYLINDER AND PISTON ............................................ 2-15

CYLINDER HEAD ................................................................................. 2-15

CYLINDER ............................................................................................. 2-15

PISTON .................................................................................................. 2-15

EXHAUST VALVE ....................................................................................... 2-15

EXHAUST SILENCER ................................................................................. 2-16

DRIVE CHAIN AND SPROCKETS .............................................................. 2-16

DRIVE CHAIN SLACK .......................................................................... 2-16

DRIVE CHAIN ADJUSTMENT .............................................................. 2-16

20TH PITCH LENGTH ........................................................................... 2-17

2

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

CONTENTS

DRIVE CHAIN LUBRICATION ............................................................. 2-17

SPROCKET INSPECTION ................................................................... 2-17

DRIVE CHAIN GUIDE, BUFFER, CONTROL ROLLER ............................. 2-18

DRIVE CHAIN GUIDE ........................................................................... 2-18

DRIVE CHAIN GUIDE BUFFER ........................................................... 2-18

DRIVE CHAIN CONTROL ROLLER .................................................... 2-18

BRAKES ...................................................................................................... 2-18

BRAKE FLUID LEVEL ......................................................................... 2-18

BRAKE PAD ......................................................................................... 2-19

FRONT BRAKE LEVER ADJUSTMENT .............................................. 2-19

BRAKE PEDAL HEIGHT ADJUSTMENT ............................................ 2-20

FRONT FORK ............................................................................................. 2-20

AIR PRESSURE ADJUSTMENT .......................................................... 2-20

STEERING .................................................................................................. 2-20

REAR SUSPENSION .................................................................................. 2-21

WHEELS AND TIRES ................................................................................. 2-21

TIRE PRESSURE ................................................................................. 2-21

WHEEL RIM .......................................................................................... 2-21

SPOKE NIPPLE .................................................................................... 2-21

LUBRICATION ............................................................................................ 2-23

PERIODIC MAINTENANCE 2-3

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE CHART

It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.

Interval races

Service

Item

Spark plug

Air cleaner

Transmission oil hours

Cooling-system

Clutch

Throttle and clutch cable

Carburetor

Fuel hose

Piston

Piston ring

Cylinder head, cylinder

Exhaust valve

Crankshaft and transmission bearing

Exhaust silencer

Drive chain

Engine sprocket

Rear sprocket

Drive chain buffer

Drive chain guide

Kick starter lever

Brake

Front fork oil

Front fork

Rear suspension system pivoting portion

Every race

Every

2 hours

I

C

—

I

I

I & L

I

I

—

—

—

—

Every

3 races

Every

6 hours

R

—

R

—

—

R

C

C

—

—

—

—

R

—

—

—

—

—

—

—

Every

5 races

Every

10 hours

—

—

—

—

Remarks

Replace air cleaner element as necessary.

Change after 1st initial break-in.

Replace radiator hose and engine coolant every year.

Flushing for overhaul or storage.

Replace clutch plates as necessary.

Replace every 4 years.

I

I & L

I

Inspect as required

—

R

—

—

—

—

Adjust slack every 30 minutes.

I — —

Check and retighten sprocket bolts at initial and subsequent 10 minutes of riding and each race thereafter.

—

—

I & L

I

—

I

I

R

R

—

—

R

—

—

—

—

—

—

—

—

—

Replace brake hose and fluid every year.

Change after 1st initial break-in.

Check front fork inner tube frequently for abnormality. Check the air pressure.

Check rear suspension system frequently and apply the grease to the pivoting portion as necessary.

2-4 PERIODIC MAINTENANCE

Service

Item

Tire

Interval races hours

Every race

Every

2 hours

I

Every

3 races

Every

6 hours

—

Every

5 races

Every

10 hours

—

Remarks

Spoke nipple I — —

Inspect every 20 min. up to initial 2 hours then check before each ride.

Steering

Bolts and nuts

I

T

—

—

—

— Retighten every 1 hour.

NOTE: R = Replace, C = Clean, T = Tighten, I = Inspect and clean, adjust lubricate or replace if necessary,

L = Lubricate.

PERIODIC MAINTENANCE 2-5

INSPECTION BEFORE PRACTICE

WHAT TO CHECK

Spark plug

Air cleaner element

Transmission oil

Coolant

Cooling system

Clutch

Throttle

Brake fluid

Brakes

Drive chain

Drive chain guide/buffer

Suspension

Wheels

Tires

Steering

Exhaust pipe

Bolts and nuts

CHECK FOR

• Heat range, fouled electrode, tightness

• Loose high-tension cord

Lubrication

Oil level

Coolant level

• Radiator hose damage

• Engine coolant leak

• Play

• Smooth operation

• Play

• Smooth operation

Fluid level

• Brake lever position

• Brake pedal height

• Operation

Slack, lubrication, chain joint clip condition

Wear, damage

• Smooth operation

• Front fork air pressure

• Spoke tension

• Rim lock tightness or damage

Tire pressure

Smoothness, play

Firm fixation

Tightening torque (



18-8)

INSPECTION BEFORE RACE

(All items of inspection before practice above plus)

WHAT TO CHECK

Air cleaner

Clutch

Brake pads

Sprockets

Fuel tank

Fuel hose

Exhaust pipe

Piston and Cylinder

CHECK FOR

Cleanliness

Clutch disc plates wear and distortion

Wear

Wear

• Leakage

• Fuel filter clogging

Damage

Damage

• Combustion Chamber carbon deposit

• Piston head carbon deposit

• Piston and cylinder wear

2-6 PERIODIC MAINTENANCE

SPARK PLUG

Inspect the spark plug condition, electrode color, carbon deposits, spark plug gap, and washer damage, after removing the spark plug.

NOTE:

Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion chamber.

Inspect the porcelain tip color.

Porcelain tip color

White (overheated)

Black (fouled)

Cause

• Hot type spark plug

• Advanced ignition timing

• Lean air/fuel mixture

• Deteriorated fuel

• Cold type spark plug

• Retarded ignition timing

• Rich air/fuel mixture

• Rich oil/gasoline mixture

CAUTION

Changing the spark plug heat range improperly can damage the engine.

Select the spark plug heat range only after adjusting the ignition timing, carburetor setting and oil/gasoline mixture.

Clean the spark plug and check the spark plug gap with the thickness gauge.



Standard Spark plug: NGK BR8EG

Spark plug gap: 0.5 – 0.6 mm (0.020 – 0.024 in)



09900-20803: Thickness gauge

Tighten the spark plug to the specified torque after tightening the spark plug temporarily by hand.



Spark plug: 20 N·m (2.0 kgf-m, 14.5 lb-ft)

0.5 – 0.6 mm

(0.020 – 0.024 in)

AIR CLEANER

AIR CLEANER ELEMENT REMOVAL

• Remove the seat. (



5-4)

• Remove the air cleaner box lid.

• Remove screw 1 .

• Remove the element 2 from the element holder.

WASHING

• Fill a washing pan that is large enough to hold the element with non-flammable cleaning solvent A . Immerse the element in the solvent and wash it.

A : MOTUL AIR FILTER CLEAN or equivalent cleaning solvent

• Squeeze the element by grasping it to remove excess solvent. Do not twist or wring the element, or it will develop cracks.

• Dry the element in a plastic bag, pour in some foam filter oil B and work the oil into the element.

B : MOTUL AIR FILTER OIL or equivalent filter oil

• Squeeze the element to remove excess oil.

INSTALLATION

• Apply grease to the element base where contacts the air cleaner box.

• Fit the element onto the element holder.

NOTE:

Fit the projection of the element holder in the hole of the element base.

• Install them in the air cleaner box by engaging the projection

A of the element holder with the hole B of the cleaner body.

CAUTION

Improper element installation allows dust and dirt to enter the combustion chamber. It can result in piston and cylinder wear.

Be sure to check the element seals properly after installing the elements.

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

• Install the air cleaner box lid properly as shown.

NOTE:

Running the engine without the air cleaner box lid can vary the carburetion. Do not run the engine without the air cleaner box lid.

NOTE:

Follow the instructions below to keep the air cleaner element dry when cleaning the motorcycle.

* Cover the element with a plastic bag.

* Install the seat.

* Cover the inlet holes on the frame covers to prevent water from coming into the air cleaner box.

* Do not spray high pressure water to the air cleaner box.

Cap to the front.

Lid

Air cleaner box front wall

TRANSMISSION OIL

TRANSMISSION OIL LEVEL INSPECTION

AND REPLENISHMENT



WARNING

Transmission oil and exhaust pipe can be hot enough to burn you.

Wait until the oil drain plug and exhaust pipe become cool enough to touch with bare hands before draining oil.



WARNING

New and used oil and solvent can be hazardous. Children and pets may be harmed by swallowing new or used oil or solvent. Repeated, prolonqed contact with used engine oil may cause skin cancer, Brief contact with used oil or solvent may irritate skin.

* Keep new and used oil and solvent away from children and pets.

* Wear a long-sleeve shirt and waterproof gloves.

* Wash with soap if oil or solvent contacts your skin.

NOTE:

Recycle or properly dispose of used oil and solvent.

• Place the motorcycle on level ground and hold the motorcycle vertically.

• Run the engine for a few minutes and stop it. Wait for 5 minutes.

• Remove the oil check bolt 1 . Check that oil comes out of the hole.

• If oil does not come out of the hole, open oil filler cap 2 and add the specified oil. Tighten the filler cap and oil check bolt and inspect again as above procedure.



Transmission oil type: SAE 10W-40, API SF/SG or

SH/SJ with JASO MA

• Tighten the filler cap firmly and tighten the oil level check bolt to the specified torque.



Oil level check bolt: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

TRANSMISSION OIL CHANGE

• Warm up the engine.

• Place the motorcycle on the level ground and hold the motorcycle vertically.

• Remove filler cap and drain plug 1 . Drain oil thoroughly.

• Tighten the drain plug firmly.



Oil drain plug: 21 N·m (2.1 kgf-m, 15.0 lb-ft)

• Pour specified amount of oil.



Oil change......... 750 ml (0.8/0.7 US/Imp qt)

Overhaul............ 850 ml (0.9/0.7 US/Imp qt)

• Tighten the filler cap.

• Run the engine for a few minutes and stop it. Wait for 5 minutes.

• Inspect the oil level. (



2-9)

PERIODIC MAINTENANCE 2-11

ENGINE COOLANT

ENGINE COOLANT LEVEL CHECK



WARNING

You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot.

Do not open the radiator cap when the engine is hot.

Wait until engine cools.

• Remove the radiator cap.

• Check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the radiator with specified engine coolant.

• Tighten the radiator cap securely.

CAUTION

Improperly tightening the radiator cap will prevent the cooling system from reaching the specified operating pressure and will cause coolant overflow.

Tighten the radiator cap until it locks firmly.

NOTE:

* This motorcycle does not have an overflow tank at the end of breather hose. Therefore, engine coolant level may decrease while riding. Check the engine coolant level every time before riding.

* When replenishing engine coolant, be sure to use engine coolant mixed with distilled water at the ratio of 50:50. Adding only water will dilute engine coolant and it may decrease cooling performance.

* If the motorcycle is to be exposed to temperatures below –31

°C (–24 °F), the percentage of antifreeze should be increased to 55% or 60%, according to figure 1.

Antifreeze density

50%

55%

60%

Freezing point

–31 °C (–24 °F)

–40 °C (–40 °F)

–55 °C (–67 °F)

Density (%)

Fig. 1 Engine coolant density-freezing

point curve

2-12 PERIODIC MAINTENANCE

ENGINE COOLANT REPLENISHMENT



WARNING

Engine coolant is harmful if swallowed or if it comes in contact with your skin or eyes.

Keep engine coolant away from children and pets. Call your doctor immediately if engine coolant is swallowed and induce vomiting. Flush eyes or skin with water if engine coolant gets in eyes or comes in contact with skin.

• Remove the radiator cap 1 .

• Remove the drain plug 2 and drain engine coolant.

• Tighten the drain plug 2 and pour specified engine coolant.



Radiator drain plug: 5.5 N·m (0.55 kgf-m, 4.0 lb-ft)



Engine coolant capacity: 1 100 ml (1.2/1.0 US/lmp qt)

Use an anti-freeze and Summer coolant which is compatible with aluminum radiator, mixed with distilled water at the ratio of

50 : 50.

NOTE:

The radiator, cylinder and cylinder head are made of aluminum alloy. Using non-recommended coolant may corrode aluminum alloy and may clog the coolant passageways.

• Bleed air from the cooling circuit.

ENGINE COOLING SYSTEM INSPECTION

Inspect the following items before practice and races.

• Engine coolant leakage

• Radiator hose cracks and deterioration

• Radiator mounting condition

• Radiator breather hose condition

• Radiator fin condition

CLUTCH

Adjust the clutch cable play as follows:

MAJOR ADJUSTMENT

• Loosen the lock-nut 1 .

• Turn the adjuster 2 so that the clutch lever obtains 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end.

• Tighten the lock-nut 1 .

MINOR ADJUSTMENT

• Turn the quick adjuster 3 so that the clutch lever obtains 10 –

15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt.



Clutch lever play: 10 – 15 mm (0.4 – 0.6 in)

PERIODIC MAINTENANCE 2-13

10 – 15 mm

(0.4 – 0.6 in)

THROTTLE CABLE



WARNING

Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of rider control.

Adjust the throttle cable play so that engine speed does not rise due to handlebar movement.

Adjust the throttle cable play as follows:

• Loosen the lock-nut 1 .

• Turn the adjuster 2 so that the throttle grip obtains 2.0 – 4.0

mm (0.08 – 0.16 in) play.



Throttle cable play: 2.0 – 4.0 mm (0.08 – 0.16 in)

• Tighten the lock-nut 1 .

2.0 – 4.0 mm

(0.08 – 0.16 in)

2-14 PERIODIC MAINTENANCE

• Remove the throttle housing cover.

• Apply oil to the throttle cable 3 . (



2-23)

• Apply oil to the throttle cable spool 4 . (



2-23)

FUEL HOSE

Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. Replace fuel hose every four years.

FUEL VALVE

• Drain fuel from the fuel tank.

• Remove the fuel valve.

• If the fuel filter is dirty with sediment or rust, clean it with compressed air.



WARNING

* Gasoline is very explosive. Extreme care must be taken.

* The O-ring 1 must be replaced with a new one to prevent fuel leakage.

CYLINDER HEAD, CYLINDER AND

PISTON

CYLINDER HEAD

• Remove the cylinder head. (



6-5)

• Remove carbon deposits from combustion chamber surface.

• Inspect for pinholes, cracks and other damage.

CYLINDER

• Remove the cylinder. (



6-6)

• Remove carbon deposits from the exhaust port and exhaust valve chamber.

• Check for scratches and wear on the cylinder sleeve.

PISTON

• Remove the piston. (



6-6)

• Remove carbon deposits from the top surface of the piston.

• Check for scratches, cracks, and wear around the piston bosses.

• Remove minor scuffs with #1 000 – #1 200 sand paper.

• Check piston ring wear. Remove carbon deposits from the piston ring grooves.

EXHAUST VALVE

• Remove the exhaust valve. (



6-13)

• Remove carbon deposits from the exhaust valve 1 , exhaust side valves 2 and exhaust valve cams 3 .

• Check for wear and damage.

NOTE:

If tar drops from the exhaust valve breather hose when the motorcycle is parked, change engine oil brand because some engine oil can accumulate tar in the exhaust valve chamber.

PERIODIC MAINTENANCE 2-15

2-16 PERIODIC MAINTENANCE

EXHAUST SILENCER

• Remove the seat and the right frame cover.

• Remove the silencer.

• Remove bolts and extract the black frontal part from the aluminum case.

• Check if the glasswool silencer is clogged with carbon deposit or tar.

• Replace the glasswool silencer with new one if necessary.

NOTE:

To seal between the frontal part and the aluminum case, apply

SUZUKI BOND to the contact area of the frontal part.



99000-31140: SUZUKI BOND “1207B”

DRIVE CHAIN AND SPROCKETS

DRIVE CHAIN SLACK

• Place the motorcycle on the side stand.

• Inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket.



Drive chain slack: 40 – 50 mm (1.6 – 2.0 in)

DRIVE CHAIN ADJUSTMENT

• Loosen axle nut 1 .

• Loosen lock-nut 2 and adjust the drive chain slack to the specification by turning adjuster 3 .

• Check that both right and left alignment marks 4 are at the same position.

• Tighten the lock-nut 2 securely.

• Tighten the axle nut 1 .



Axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

NOTE:

Pull the upper drive chain tight and lock it by placing a bar between the drive chain and rear sprocket while tightening the axle nut. This will help prevent the chain adjusters from loosening.

40 – 50 mm

(1.6 – 2.0 in)

PERIODIC MAINTENANCE 2-17

20TH PITCH LENGTH

Pull the drive chain tight and measure the 20th pitch length.



Drive chain 20th pitch length

Service limit: 323.8 mm (12.75 in)

DRIVE CHAIN LUBRICATION

• Remove the chain clip and master link from the drive chain and remove the drive chain.

NOTE:

Be careful not to bend the chain clip.

Inspect for wear and damage of the drive chain and replace it if necessary.

• Clean the drive chain with non-flammable cleaning solvent.

• Do not use gasoline to clean the drive chain.

• Dry the drive chain.

• Apply Suzuki Chain Lube or equivalent to the link plates and rollers.

• Reassemble the drive chain.

NOTE:

Reassemble the drive chain clip so the slit end faces opposite the direction of rotation.

• Adjust the drive chain slack. (



2-16)

SPROCKET INSPECTION

Inspect the engine sprocket and rear sprocket for wear and cracks. Replace the sprockets as necessary.

NOTE:

When replacing a worn sprocket, it is likely that the drive chain will need to be replaced as well.

Direction of travel

Normal wear Excessive wear

2-18 PERIODIC MAINTENANCE

DRIVE CHAIN GUIDE, BUFFER,

CONTROL ROLLER

DRIVE CHAIN GUIDE

Inspect the drive chain guide 1 for bends and damage.

NOTE:

The drive chain can hit a bent guide causing noise and drive chain wear.

Inspect the chain guide defense 2 for wear.

DRIVE CHAIN GUIDE BUFFER

Inspect the drive chain guide buffer 1 for wear and cracks.

NOTE:

The drive chain can touch the swingarm directly if the chain guide buffer is worn out. This will cause drive chain and swingarm damage.

DRIVE CHAIN CONTROL ROLLER

• Inspect the drive chain control rollers 2 for wear.

• Inspect the drive chain control roller bolts for tightness.



Drive chain control roller bolt:

31 N·m (3.1 kgf-m, 22.5 lb-ft)

BRAKES

BRAKE FLUID LEVEL

Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER mark, replenish the reservoir with the specified brake fluid to the UPPER level.

Inspect brake pad wear and brake fluid leakage if the brake fluid level decreases.



Brake fluid: DOT 4



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.



WARNING

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from a sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any fluid when filling the brake fluid reservoir. Wipe spilled fluid up immediately.

BRAKE PAD

Inspect the brake pads for wear by observing the groove limit line A . If the brake pads are worn, replace them with new ones.

(



15-2)

NOTE:

* Pump the brake lever/pedal several times to restore the brake pads after replacing the brake pads.

* Replace both right and left pads together when replacing the brake pads.

PERIODIC MAINTENANCE 2-19

FRONT BRAKE LEVER ADJUSTMENT

Adjust the brake lever position as follows:

• Loosen lock-nut 1 .

• Turn in or out adjuster 2 to obtain the proper brake lever position.

• The standard adjuster length A is 11 – 15 mm (0.43 – 0.59

in).

• Tighten the lock-nut 1 .

2-20 PERIODIC MAINTENANCE

BRAKE PEDAL HEIGHT ADJUSTMENT

Adjust the rear brake pedal height as follows:

• Loosen the lock-nut 1 .

• Adjust the brake pedal height by turning the adjuster 2 to locate the pedal 0 – 10 mm (0 – 0.39 in) below from the top face of the footrest.



Brake pedal height: 0 – 10 mm (0 – 0.39 in) below

FRONT FORK

• Move the front fork up and down several times and inspect for smooth movement.

• Inspect for damage and oil leaks.

• Inspect the bolts and nuts for tightness.

AIR PRESSURE ADJUSTMENT

• Place a stand under the chassis tube to lift the front wheel off the ground.

• Remove the air bleed screw 1 and equalize the air pressure in the front forks to atmospheric pressure.

• Refit the air bleed screw.

STEERING

• Inspect the steering by moving the front fork up and down, and right and left. If the steering has play or binds, inspect steering stem head nut tightness and steering bearings.

(



16-23)

REAR SUSPENSION

• Move the rear suspension up and down several times and inspect for smooth movement.

• Inspect for damage and oil leaks.

• Inspect the bolts and nuts for tightness.

• Inspect that the rear suspension has play or binds by moving the swingarm up and down, and right and left.

WHEELS AND TIRES

TIRE PRESSURE

• Inspect front and rear tire pressure.



Tire pressure (cold):

70 – 110 kPa (0.7 – 1.1 kgf/cm 2 , 10 – 16 psi)

WHEEL RIM

• Inspect the wheel and tires for damage.

• Inspect the wheel bearings for rattles. Replace the bearings if necessary. (



14-4)

• Measure the wheel rim runout with the dial gauge.



Service Limit: 2.0 mm (0.08 in) ... axial and radial



09900-20607: Dial gauge (1/100 mm)

SPOKE NIPPLE

• Inspect the spokes for tension by grasping the spoke nipples.

Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.



Spoke nipple: 4 N·m (0.4 kgf-m, 3.0 lb-ft)

PERIODIC MAINTENANCE 2-21

2-22 PERIODIC MAINTENANCE

CAUTION

Improperly tightening of the spoke nipples can damage the wheel.

Tighten the spoke nipples less than 1/2 turn at a time.

Inspect the spoke tension and then retighten the spoke nipple.

Tighten additionally the nipples after breaking-in runnning, until when initial looseness will eliminated.

For additional tightening, take care so that all nipples are tightened uniformly without concentrating force on one point.

Rim Lock

• Inspect the rim lock 1 for tightness, damage and bend.

PERIODIC MAINTENANCE 2-23

LUBRICATION

Apply grease or oil to the moving parts to increase durability and prevent wear.

No.

1

ITEM

Inner cable ends, lever

LUBRICANT

A

FREQUENCY

Pre-race and between every race

COMMENTS

Run oil through cables until it exits the lower end. Lube the cable ends where they pivot.

Lightly oil the inside of throttle spool.

Keep free from dirt.

2

3

4

Throttle grip, throttle housing, cable

Rear brake pedal

Swingarm

A

C

Pre-race

Pre-race Grease the brake pedal pivot.

5

6

8

Rear suspension linkage pivot points

Steering stem bearings

7 Starter shaft

Drive chain

C

C

C

A

B

Every 3 races/ More often according to conditions

Every 1 race/More often according to conditions

Clean and pack the bearings.

Keep seals fresh.

Clean and pack the bearings.

Keep seals fresh.

Every 5 races/More often according to conditions

Pre-race

Pre-race and between every practice

Clean and pack the bearings.

Keep seals fresh.

Lightly oil the plunger shaft.

Keep chain thoroughly lubed at all times.

Always check wear and alignment.

The following materials are necessary:

A. Lightweight oil such as WD-40 or penetrating oil.

B. Aerosol type Chain Lube.

C. SUZUKI SUPER GREASE “A” or water-proof wheel bearing grease.

Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it allows you to clean out the grit which otherwise cannot be gotten out.

– MEMO –

TROUBLESHOOTING 3-1

TROUBLESHOOTING

CONTENTS

TROUBLESHOOTING ................................................................................. 3- 2

ENGINE ................................................................................................. 3- 2

CHASSIS ............................................................................................... 3- 5

3

3-2 TROUBLESHOOTING

TROUBLESHOOTING

ENGINE

Complaint

Engine does not start or hard to start

Engine stalls

Insufficient power

Possible Cause

Fuel deterioration

No fuel flow to the carburetor

• Fuel valve clogged

• Fuel hose clogged

• Fuel tank cap breather hose clogged

• Carburetor float valve malfunction

Carburetor overflow pipe clogging

Carburetor air vent pipe clogging

Too rich air/fuel mixture in combustion chamber

Incorrect ignition timing

No spark at spark plug

Low compression

• Piston ring worn or stuck

• Cylinder worn

• Air leak from cylinder gasket

• Air leak from crankshaft oil seal

Fuel deterioration

Fouled spark plug

Fuel hose clogged

Air cleaner clogged

Carburetor jets clogged

Low compression

• Piston ring worn or stuck

• Cylinder worn

• Air leak from cylinder gasket

• Air leak from crankshaft oil seal

Incorrect ignition timing

Carburetor fuel level maladjustment

Fuel deterioration

Brake dragging

Exhaust pipe cracked or clogged with carbon

Exhaust valve maladjustment

Exhaust valve carbon deposits

Air cleaner element clogged

Carburetor jets clogged

Incorrect fuel level in carburetor

Incorrect spark plug gap

Cylinder or piston ring worn

Reed valve malfunction

Incorrect ignition timing

Remedy

Replace

Clean

Clean or replace

Clean

Replace

Clean

Clean

Scavenge

Adjust

Replace

Replace

Replace

Replace

Replace

Replace

Clean or replace

Clean or replace

Clean or replace

Clean

Replace

Replace

Replace

Replace

Adjust

Adjust

Replace

Adjust

Replace or clean

Adjust

Clean

Clean or replace

Clean or replace

Adjust

Adjust or replace

Replace

Replace

Adjust

Complaint

Engine runs poorly in low speed range

Engine runs poorly in high speed range

Possible Cause

Exhaust valve maladjustment

Wide spark plug gap

Carburetor air screw maladjustment

Incorrect carburetor fuel level

Improper jet needle size

Incorrect ignition timing

CDI unit malfunction

Throttle position sensor malfunction

Ignition coil damage

Magneto malfunction

Magneto short circuit

Exhaust valve breather hose clogged

Narrow spark plug gap

Incorrect carburetor fuel level

Incorrect main jet setting

Power jet solenoid malfunction

Retarded ignition timing

CDI unit malfunction

Ignition coil damage

Air cleaner element clogged

Magneto short circuit

Exhaust pipe cracked

Exhaust valve malfunction

Engine speed does not return smoothly

Exhaust valve does not work

Spark plug does not ignite

Carbon deposits on spark plug porcelain

Spark plug electrode damage

Piston ring stuck

Too high engine idle speed

Carbon deposits on exhaust valve

Exhaust valve damage

Governer damage

Exhaust valve shaft damage

Valve spring damage

Exhaust valve breather hose clogged

Ignition coil malfunction

Spark plug malfunction

Magneto malfunction

CDI unit malfunction

Wide spark plug gap

Engine kill switch malfunction

Too rich air/fuel mixture

Too rich oil/gasoline mixture

Improper spark plug heat range

Improper spark plug heat range

Overheating

Incorrect ignition timing

Loose spark plug

Too lean air/fuel mixture

TROUBLESHOOTING 3-3

Remedy

Adjust

Adjust or replace

Adjust

Adjust

Replace

Adjust

Replace

Replace

Replace

Replace

Replace

Clean

Adjust or replace

Adjust

Adjust

Replace

Adjust

Replace

Replace

Clean or replace

Replace

Replace

Clean, adjust or replace

Replace

Adjust

Clean

Replace

Replace

Replace

Replace

Clean

Replace

Replace

Replace

Replace

Adjust

Repair or replace

Adjust

Adjust

Replace

Replace



2-6

Adjust

Tighten

Adjust

3-4 TROUBLESHOOTING

Complaint

Overheating

Excessive coolant level decrease

Clutch does not disengage

Clutch slipping

Transmission does not shift

Transmission gears jump out

Gearshift lever does not return

Possible Cause

Low engine coolant level

Engine coolant leak

Too lean air/fuel mixture

Incorrect ignition timing

Water pump malfunction

Cylinder head carbon deposits

Exhaust pipe carbon deposits

Improper spark plug heat range

Fuel deterioration

Clutch slipping

Radiator cap loose

Radiator fins damaged

Radiator hose cracked or damaged

Loose radiator hose connection

Radiator cracked or damaged

Water pump cover mating surface damage

Water pump cover crack

Water pump cover gasket damage

Water seal wear or damage

Radiator cap seal damage

Incorrect radiator cap valve pressure

Cylinder or cylinder head cracked

Cylinder or cylinder head O-rings damage

Clutch lever play maladjustment

Clutch spring damage

Clutch plates distortion

Tip of clutch release camshaft worn

Clutch cable play maladjustment

Weakened clutch spring

Clutch pressure plate wear

Clutch plate distortion

Clutch plates worn

Tip of clutch release camshaft worn

Gearshift cam damage

Gearshift fork distortion

Gearshift pawl wear

Gearshift fork groove wear or damage

Gearshift fork distortion or wear

Gearshift cam stopper damage

Transmission gear claw damage

Weakened gearshift return spring

Gearshift lever sticking

Remedy

Replenish

Repair

Adjust

Adjust

Adjust or replace

Clean

Clean or replace

Replace

Replace

Adjust or replace

Tighten

Repair or replace

Replace

Repair

Repair or replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair or replace

CHASSIS

Complaint

Heavy handling

Possible Cause

Steering stem nut overtightened

Steering head bearings damaged or rusted

Steering stem distortion

Front wheel wobbling Loose spoke nipples

Wheel distortion

Front wheel bearing damage

Incorrect axle tightening torque

Rear wheel wobbling Loose spoke nipples

Wheel distortion

Rear wheel bearing damage

Swingarm pivot bearing damage

Incorrect axle tightening torque

Incorrect swingarm tightening torque

Soft front suspension Weakened spring

Low oil level

Low fork oil viscosity

Damping force maladjustment

Damping valve malfunction

Standard spring too soft

Hard front suspension High fork oil level

High fork oil viscosity

Damping force maladjustment

Damping valve malfunction

Inner tube distortion

Standard spring too hard

Soft rear suspension Weakened spring

Damping force maladjustment

Low gas pressure

Standard spring too soft

Hard rear suspension Damping force maladjustment

Damper rod distortion

Rear suspension pivoting portion out of grease

Standard spring too hard

Poor braking

Brake noise

Brake pads worn

Improper air bleeding

Dirty pads and disc

Brake fluid leak

Brake pads worn

Brake disc worn

Dirty brake pads and disc

* An optional spring is available at your SUZUKI dealer.

TROUBLESHOOTING 3-5

Remedy

Adjust

Replace

Replace

Adjust

Replace

Replace

Retighten

Adjust

Replace

Replace

Replace

Retighten

Retighten

Replace

Replenish

Replace

Adjust

Replace

* Use optional spring.

Adjust

Replace

Adjust

Replace

Replace

* Use optional spring.

Replace

Adjust

Adjust

* Use optional spring.

Adjust

Replace

Lubricate

* Use optional spring.

Replace

Bleed air

Clean

Repair

Replace

Replace

Clean

– MEMO –

MACHINE TUNING 4-1

MACHINE TUNING

CONTENTS

CARBURETOR TUNING ............................................................................. 4- 2

PRINCIPLES OF CARBURETOR TUNING .......................................... 4- 2

CARBURETOR TUNING IN PRACTICE ............................................... 4- 6

FRONT FORK TUNING ............................................................................... 4- 9

COMPRESSION DAMPING FORCE ADJUSTMENT ........................... 4- 9

REBOUND DAMPING FORCE ADJUSTMENT .................................... 4- 9

OIL QUANTITY MINOR ADJUSTMENT ............................................... 4-10

OIL CHANGE (Only for outer tube oil chamber) ............................... 4-11

SPRING CHANGE ................................................................................. 4-13

FRONT FORK TUNING PROCEDURE ................................................. 4-15

REAR SUSPENSION TUNING .................................................................... 4-16

COMPRESSION DAMPING FORCE ADJUSTMENT ........................... 4-16

REBOUND DAMPING FORCE ADJUSTMENT .................................... 4-16

SPRING PRE-LOAD ADJUSTMENT .................................................... 4-17

REAR SUSPENSION TUNING PROCEDURE ..................................... 4-18

SUSPENSION BALANCE ..................................................................... 4-20

4

4-2 MACHINE TUNING

CARBURETOR TUNING

The carburetion of your motorcycle is carefully selected after extensive testing. You will find that the carburetion will function smoothly under many varied operating conditions. For best results, we recommend that the adjustments and carburetion jetting should be left “as is” from the factory.

Some riders may operate their motorcycle under extreme operating conditions such as; very high altitudes or extreme cold and hot temperatures. In these circumstances the jetting of the carburetor or other adjustments may need to be altered slightly.

Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the following information and specifications.

Carburetor Specifications

Bore

Main jet

Jet needle

Cut-away

Slow jet

Air screw

Power jet

Float height

39 mm (1.54 in)

#172

NEDH-4th

#7

#50

1 turn out

#55

6.5 mm (0.26 in)

Setting parts

Main jet #168

Main jet #175

Jet needle NECH

Parts No.

09491-33010

09491-35009

13383-37FC0

PRINCIPLES OF CARBURETOR

TUNING

CARBURETOR COMPONENTS AND FUNC-

TIONS

The carburetor consists of a number of parts as shown below. The asterisk (*) marked parts are precisely machined, which meter the intake air (oxygen) and fuel so that the air/fuel mixture ratio is controlled accurately. They can be divided by three operation-related groups; slow (pilot) system, intermediate system and main system, and they achieve their functions in each corresponding throttle opening range. It is necessary to have a full understanding of them for proper carburetor tuning.

14

3

5

4

6

13

10

15

7

9

11

12

8

2

1

1.

2.

Top cap

Spring

3.

* Clip

4.

* Jet needle

5.

6.

Throttle valve

Starter knob

7.

Throttle stop screw

8.

* Air screw

9. * Main jet

10. * Slow jet

11.

Needle valve ass’y

12.

Float

13.

Power jet

14.

Solenoid

15.

Throttle position sensor

MACHINE TUNING 4-3

As shown below, each of the asterisk (*) marked parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the carburetor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.

THROTTLE VALVE OPENING TUNING PARTS

MAIN JET

JET NEEDLE CLIP POSITION

JET NEEDLE O.D.

SLOW JET AND AIR SCREW

POWER JET

THROTTLE OPENING

1 MAIN SYSTEM 2 INTERMEDIATE SYSTEM 3 SLOW SYSTEM

Air Screw When performing carburetor tuning first find out in what throttle opening range an improper air/fuel mixture is supplied, by checking the color of exhaust smoke, spark plug, throttle response, power, etc. Second, replace or adjust the part(s) related to the throttle opening range by referring to the following instructions. The sizes referred to in the illustrations are those of standard setting.

Slow Jet

1/2

Rich

3/4

Lean

50

The slow jet meters the fuel supplied to the slow system. Each jet size is indicated by a number.

Larger number means a larger bore diameter and fitting a larger numbered slow jet enriches the air/fuel mixture.

The air screw is located in the inlet air passage and meters the air for the slow system. As it has a right-hand thread, tightening it makes the passage narrower, allowing less amount of intake air to flow and resulting in richer air/fuel mixture. Air flow adjustment is effective within a range of 1/2 – 2 turns out.

Power Jet

The power jet supplies the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When engine speed is 2 000 to 3 000 r/min and 9 300 to 10 500 r/min, the passage is closed by solenoid valve. The solenoid valve closes the passage when the current flows from CDI unit.

4-4 MACHINE TUNING

Needle Clip Position

Lean

Rich

3

4

1

2

5

Needle clip

Jet Needle

O.D. of Needle

Clip

The jet needle is linked to the throttle valve by means of the needle clip. Its lower part is tapered and it has five grooves cut in the upper part where the needle clip fits.

To adjust the air/fuel mixture with the jet needle, change position of the needle clip which is set in the

3rd groove. The lower groove the clip is moved to, the higher the jet needle rises and the larger the clearance with the needle jet becomes, resulting in a richer air/fuel mixture ratio.

Air/fuel mixture Needle type and clip position

Lean NECH-1st

NEDH-1st

NECH-2nd

NEDH-2nd

NECH-3rd

NEDH-3rd

NECH-4th

Rich

NEDH-4th

NECH-5th

NEDH-5th

Needle number

NEDH

O.D.

Changing the needle itself controls air/fuel mixture ratio particulary on lower mid-throttle opening. The smaller the O.D., the richer the air/fuel mixture becomes.

Air/fuel mixture Needle Number

Lean NECL/NEDL

NECK/NEDK

NECJ/NEDJ

Rich

O.D.

2.765 mm

2.755 mm

2.745 mm

NECW/NEDW 2.735 mm

NECH 2.725 mm

NEDH

NECG/NEDG

NECF/NEDF

2.725 mm

2.715 mm

2.705 mm

Main Jet

172

The main jet, like the slow jet, meters fuel flow.

Each jet size is indicated by a number. Larger number means a larger bore diameter and fitting a larger numberd main jet enriches the air/fuel mixture.

Throttle stop screw

When the throttle stop screw is turned clockwise, the throttle valve is forced upward allowing the engine to continue idling.

Throttle valve opening

Standard

After touching the throttle stop screw to the throttle valve, turn in the stop screw five to six turns to raise the throttle valve.

CAUTION

Too high an engine idle may cause driveability failure such as lack of engine braking and poor deceleration during brake application.

MACHINE TUNING 4-5

4-6 MACHINE TUNING

CARBURETOR TUNING IN PRACTICE

In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration.

Variation in Air (Oxygen) Concentration and Carburetor Conditions

As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly. Each of these three factors affects the air in different ways, and the following graphs show their effects respectively in terms of the oxygen concentration.

[%]

100

90

80

100

90

80

-10

10

0

30

10

50

20

70

30

90

40 [˚C]

110 [˚F]

ATOMOSPHERIC TEMPERATURE

500 1000 1500 2000 2500[m]

1600 3200 5000 6500 8200 [ft]

ALTITUDE

20 40 60 80 100 [%]

HUMIDITY

In the above graphs, oxygen concentration is graduated on the vertical axis while the temperature, altitude and humidity are on the horizontal axis respectively. Oxygen concentration is set 100% under the conditions of 20 °C (68 °F), 0 m (0 ft) and 50% humidity. The standard carburetor setting is chosen to obtain the best engine performance under these conditions.

The graph at the left shows that the oxygen concentration changes about 10% in the 0 °C to 40 °C temperature difference, the one in the center shows about 20% change in the 0 to 2 000 m altitude difference and the one at the right shows about 5% change in the 0 to 100% humidity difference. As for humidity, its normal range is from 20 to 95%. Therefore the possible effect of humidity on the oxygen concentration is so little that it can be disregarded. Consequently, we can say that the oxygen concentration varies by as much as 20

% depending on the temperature and altitude under normal riding conditions. On the other hand, different from the air, the fuel (gasoline) hardly changes in volume even when such environmental conditions change.

Therefore, increase in oxygen concentration will make the air/fuel mixture richer and decrease will make it lean.

As the carburetor mixes gasoline and air, which are metered by each jet in varying proportions to suit throttle opening, the air/fuel mixture is affected if the air concentration itself varies as described above. Then proper engine power output can not be attained and, should the mixture become too lean, a piston seizure may result. To compensate for such change in the air concentration, it is required to carry out carburetor tuning beforehand. This requirement applies to all models of motorcycles and ATVs if they are used in areas where temperature and altitude range widely. The next section describes the procedure of the above tuning in detail.

MACHINE TUNING 4-7

Judging Air/Fuel Mixture

For proper carburetor tuning, it is necessary to know how to judge the air/fuel mixture made in the carburetor; whether too rich, too lean or properly mixed. Given below are the symptoms observed when the engine is not supplied with the proper air/fuel mixture ratio from the carburetor. Check each item as reference for judging the air/fuel mixture condition.

When air/fuel mixture is too rich

1) The engine noise is dull and intermittent.

2) The engine condition becomes worse when the choke is applied.

3) The engine condition becomes worse as it is warmed up.

4) The engine condition improves when the air cleaner is removed.

5) The spark plug is fouled with carbon (wet and oily).

6) The exhaust gas produces heavy smoke.

When air/fuel mixture is too lean

1) The engine overheats.

2) The engine condition improves when the choke is applied.

3) Acceleration is poor.

4) The spark plug is burned white.

5) The speed of the engine fluctuates and lack of power is noticed.

6) Detonation and pinging are experienced.

Tuning Procedure

The following indicates the correct tuning procedure for this motorcycle. Understand the procedure by first riding the motorcycle where it will be used and adjust the engine to the best condition after judging the air/fuel mixture.

Carburetor standard setting

Main jet: #172

Jet needle: NEDH-4th

Slow jet: #50

Air screw: 1 turn out

Cut-away: #7

Power jet: #55

Included Parts and Optional Parts

Main jet

Air/fuel mixture

Lean

SIZE

#170

#172

* #175

#178

#180

#185

#190

#195

#150

#152

#155

#158

#160

#162

#165

* #168

#200

#205

#210 Rich

Slow jet

Air/fuel mixture

Lean

P/NO.

09491-30018

09491-30019

09491-31012

09491-31013

09491-32010

09491-32011

09491-33009

09491-33010

09491-34010

09491-34011

09491-35009

09491-35010

09491-36008

09491-37008

09491-38011

09491-39001

09491-40013

09491-41001

09491-42006

Rich

SIZE

#35

#40

#42

#45

#48

#50

#52

#55

#58

#60

P/NO.

09492-35019

09492-40022

09492-42019

09492-45032

09492-48013

09492-50023

09492-52011

09492-55017

09492-58001

09492-60016

4-8 MACHINE TUNING

Jet needle

Air/fuel mixture

Lean

Rich

SIZE

NECL

NEDL

NECK

NEDK

NECJ

NEDJ

NECW

NEDW

* NECH

NEDH

NECG

NEDG

NECF

NEDF

P/NO.

13383-37FG0

13383-37FP0

13383-37FF0

13383-37FN0

13383-37FE0

13383-37FM0

13383-37FD0

13383-37FL0

13383-37FC0

13383-37FK0

13383-37FB0

13383-37FJ0

13383-37FA0

13383-37FH0

NOTE:

SHADED: STANDARD

*: INCLUDED ALTERNATE PARTS

NONE: OPTIONAL PARTS

1 Adjustment of slow system

1) Set the air screw as specified.

2) See if the selected slow jet is correct or not by judging the air/fuel mixture. If air/fuel mixture is rich, replace it with smaller one. If air/fuel mixture is lean, replace it with larger one.

Ex. Slow jet #50

If air/fuel mixture is rich, replace it with #48 slow jet. If air/fuel mixture is lean, replace it with #52 slow jet.

2 Adjustment of main system

With the throttle opened 3/4 to full, make main system adjustment monitoring the air/fuel mixture condition after completion of slow system settings.

* Make sure to adjust the main system before adjusting the intermediate system.

Ex. Main jet #172

If air/fuel mixture is rich, replace it with

#170 main jet. If air/fuel mixture is lean, replace it with #175 main jet.

3 Adjustment of intermediate system

3

4

5

1

2

Lean

STD

Rich

Monitor the air/fuel mixture condition and adjust the intermediate system by changing the needle clip position.

4 Final adjustment of slow system

After a proper standard setting has been obtained by the procedure 1 through 3 , fine tune the carburetor according to the actual race conditions.

1) Adjust the air/fuel mixture by turning the air screw within 1/2 – 2 turns out.

1/2 turn out

3/4 turn out

1 turn out .................STD

1 and 1/4 turns out

1 and 1/2 turns out

1 and 3/4 turns out

2 turns out

2) If the mixture can not be adjusted by the air screw within 1/2 – 2 turns out range, readjust the slow system 1 .

5 Final adjustment of intermediate system

Fine tune the intermediate system by changing the needle type and clip position.

FRONT FORK TUNING

The front fork compression and rebound damping force, and oil level are adjustable for rider’s preference, rider’s weight and course condition.

NOTE:

* Break-in new front forks before attempting adjustment.

* Be sure to adjust both right and left front forks equally.

* Inspect the following items before attempting adjustment.

* Front fork air pressure adjustment. (



2-20)

* Front fork damage and oil leakage. (



2-20)

* Tire pressure. (



2-21)

* Tire and wheel damage. (



2-21)

* Spoke nipple tension and rim lock tightness. (



2-21, -22)

* Steering movement. (



2-20)

COMPRESSION DAMPING FORCE

ADJUSTMENT

• Turn the adjuster screw clockwise until it stops (full hard position).

• Turn the adjuster screw counterclockwise. 8th position is the standard position.



Compression damping force adjuster

Standard setting: 8 clicks turn back

REBOUND DAMPING FORCE ADJUSTMENT

• Turn the adjuster screw clockwise until it stops (full hard position).

• Turn the adjuster screw counterclockwise. 11th position is the standard position.



Rebound damping force adjuster

Standard setting: 11 clicks turn back

Soft Hard

Hard

MACHINE TUNING 4-9

4-10 MACHINE TUNING

OIL QUANTITY MINOR ADJUSTMENT

ADDING THE FORK OIL

• Remove the air bleed screw 1 .

• Add the fork oil using a injector into the air bleed hole.

REDUCING THE FORK OIL

• Remove the front forks. (



16-3)

• Remove the air bleed screw.

• Leaning the front fork, reduce the fork oil from the air bleed hole.

NOTE:

If 1 ml (0.34/0.35 US/Imp oz) of fork oil is added/reduced, the oil level raises/falls approx. 1.8 mm (0.07 in). Measure the fork oil quantity added/reduced and record it to know the oil quantity after adjustment.

CAUTION

The fork oil quantity must be adjusted equally on both fork legs to provide equal performance.

Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability.

Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate.



Front fork oil quantity (With standard fork spring used)

Standard: 350 ml (11.83/12.32 US/lmp oz)

Oil quantity adjustable range:

305 – 400 ml (10.31/10.74 – 13.52/14.08 US/lmp oz)



99000-99001-SS5: SUZUKI FORK OIL SS-05

(or equivalent fork oil)

OIL CHANGE

(Only for outer tube oil chamber)

• Remove the front forks. (



16-3)

• Thoroughly clean the fork before disassembly.

CAUTION

The fork oil quantity must be adjusted equally on both fork legs to provide equal performance.

Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.

Avoid scratching or damaging the inner tube or the oil seal. Use a mild detergent or car wash soap and sponge out dirt with plenty of water.

• Clamp the outer tube with a vise. Be sure to protect the outer tube. (



16-4)

• Unscrew the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube. (



16-4)



09941-53630: Front fork top cap wrench

• Hold the front fork inverted position for move than 20 minutes to drain oil.

• Force out the remaining oil completely using compressed air.

MACHINE TUNING 4-11

4-12 MACHINE TUNING

• Slide down the outer tube.

• Pour the specified amount of fork oil into the outer tube.



99000-99001-SS5: SUZUKI FORK OIL SS-05

(or equivalent fork oil)

NOTE:

Be sure to adjust the fork oil quantity within the range below.

Parts No.

Spring rate

Soft 51171-37FD0 4.2 N/mm (0.42 kgf/mm)

STD 51171-37FC0 4.4 N/mm (0.44 kgf/mm)

Hard 51171-37FE0 4.6 N/mm (0.46 kgf/mm)

Identification

(Slit mark on the spring end)

I

III

II

STD

Oil quantity

355 ml

(12.00/12.50

US/lmp oz)

350 ml

(11.83/12.32

US/lmp oz)

345 ml

(11.66/12.15

US/lmp oz)

Oil quantity adjustable range

310 – 405 ml

(10.48/10.92 –

13.69/14.26

US/lmp oz)

305 – 400 ml

(10.31/10.74 –

13.52/14.08

US/lmp oz)

300 – 395 ml

(10.14/10.56 –

13.35/13.91

US/lmp oz)

• Raise the outer tube and temporarily tighten the fork cap bolt

(sub-tank). (



16-4)



09941-53630: Front fork top cap wrench

• Install the front forks. (



16-16)

• Install the handlebars. (



16-18)

SPRING CHANGE

• Remove the front forks. (



16-3)

• Thoroughly clean the fork before disassembly.

CAUTION

The fork oil quantity and spring rate must be adjusted equally on both fork legs to provide equal performance.

Scratches or other damage the on inner tube or on the oil seal lip will cause oil leak.

Avoid scratching or damaging the inner tube or the oil seal. Use a mild detergent or car wash soap and sponge out dirt with plenty of water.

• Remove the fork cap bolt and drain fork oil. (



16-4)

• Loosen the center bolt completely. (



16-5)

• Compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom 1 and lock-nut 2 . (



16-5)



09910-20115: Conrod holder

• Hold the lock-nut with a wrench and remove the center bolt.

(



16-5)

• Remove the push rod. (



16-5)

• Remove the damper rod assembly and fork spring.

(



16-6)

• Hold the front fork inverted position for move than 20 minutes to drain oil. (



4-11)

• Force out the remaining oil completely using compressed air.

(



4-11)

• Replace the spring.

SPRING/No.

SOFT

51171-37FD0

STD

51171-37FC0

HARD

51171-37FE0

SPRING RATE

4.2 N/mm

(0.42 kgf/mm)

4.4 N/mm

(0.44 kgf/mm)

4.6 N/mm

(0.46 kgf/mm)

• Install the damper rod assembly.

Identification

(Slit mark on the spring end)

I

III

II

MACHINE TUNING 4-13

4-14 MACHINE TUNING

• Make sure approx. 10 mm (0.39 in) of inner rod thread is exposed on the end. (



16-13)

Approx.10 mm

(0.39 in)

Lock-nut

• Insert the push rod into the inner rod.

• Insert the shaped projection of center bolt into the push rod. (



16-14)

• Check the clearance between the lock-nut and center bolt to provide 1 mm (0.04 in) and more. (



16-14)

• Tighten the lock-nut/center bolt to the specified torque.



Lock-nut/center bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft)

• Tighten the center bolt to the specified torque.



Center bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)

• Pour the specified amount fork oil into the outer tube in accordance with the following table.

SPRING

SOFT

STD

HARD

STD OIL QUANTITY

355 ml

(12.00/12.50 US/lmp oz)

350 ml

(11.83/12.32 US/lmp oz)

345 ml

(11.66/12.15 US/lmp oz)

OIL QUANTITY ADJ.

RANGE

310 – 405 ml

(10.48/10.92 –

13.69/14.26 US/lmp oz)

305 – 400 ml

(10.31/10.74 –

13.52/14.08 US/lmp oz)

300 – 395 ml

(10.14/10.56 –

13.35/13.91 US/lmp oz)



99000-99001-SS5: SUZUKI FORK OIL SS-05

(or equivalent fork oil)

MACHINE TUNING 4-15

FRONT FORK TUNING PROCEDURE

Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression/rebound damping following the instructions below.

bottoms

SYMPTOM

Feels too hard overall

Feels too soft overall and

SECTION

• Jump

• Large bumps

• Series of medium bumps

• Jump

• Large bump

• When braking

ADJUSTMENT PROCEDURE

1. Adjust both the compression and rebound damping to a softer setting.

2. Decrease fork oil capacity.

3. Replace the spring with an optional softer one.

1. Adjust the compression damping to a stiffer setting.

2. Increase fork oil capacity.

3. Replace the spring with an optional stiffer one.

1. Decrease fork oil capacity.

Feels too hard near end of travel

Feels too soft near end of travel and bottoms harshly

Feels too hard in the beginning of stroke

Feels too soft and unstable

Bounces

Bounces

• Jump

• Jump

• Large bump

• Jump

• Large bump

• Series of medium bumps

• Series of small bumps

• Series of medium bumps

• Series of small bumps

1. Adjust the compression damping to a stiffer setting.

2. Increase fork oil capacity.

1. Adjust the compression damping to a softer setting.

1. Adjust the rebound damping to a stiffer setting.

• Jump

• Large bump

1. Adjust the rebound damping to a stiffer setting.

• Series of small bumps 1. Adjust the rebound damping to a softer setting.

NOTE:

When adjusting the front fork oil capacity, make sure that the oil level is within the specified range. Also, the capacity should be increased or decreased by 1 ml (0.034/0.035 US/Imp oz) [Approx. 1.8 mm (0.07 in)] at a time.

When adjusting the damping setting, attempt turning the adjuster 1 to 2 click stops at a time for each adjustment.

4-16 MACHINE TUNING

REAR SUSPENSION TUNING

The rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition.

NOTE:

* Break-in the rear suspension when riding with a new rear cushion unit. (



1-5)

* Inspect the following items before attempting adjustment.

* Rear shock absorber damage and oil leakage. (



2-21)

* Swingarm and links tighteness. (



17-19, -20)

* Tire pressure. (



2-21)

* Tire and wheel damage. (



2-21)

* Spoke nipple tension and rim lock tightness. (



2-21, -22)

COMPRESSION DAMPING FORCE

ADJUSTMENT

Low-side

• Turn the adjuster screw 1 clockwise until it stops (full hard position).

• Turn the adjuster screw 1 counterclockwise about 9 clicks where the punch mark A aligns with C .



Low speed compression damping force adjuster

Standard setting: 9 clicks turn back

High-side

• Turn the adjuster bolt 2 clockwise until it stops (full hard position).

• Turn the adjuster bolt 2 counterclockwise about 2 turns where the punch mark B aligns with C .



High speed compression damping force adjuster

Standard setting: 2 turns back

REBOUND DAMPING FORCE ADJUSTMENT

• Turn the adjuster screw 1 clockwise until it stops (full hard position).

• Turn the adjuster screw 1 counterclockwise about 11 clicks where the punch mark A aligns with B .



Rebound damping force adjuster

Standard setting: 11 clicks turn back

SPRING PRE-LOAD ADJUSTMENT

• Place a block under chassis tubes.

• Remove the seat. (



5-4)

• Loosen the air cleaner clamp screw.

• Remove the right frame cover. (



5-2)

• Remove the silencer and rear frame assembly.

MACHINE TUNING 4-17

• Loosen the lock-nut 1 using the special tool.



09910-60611: Universal clamp wrench

• Turn the adjuster 2 clockwise or counterclockwise to change the spring pre-load.

• Tighten the lock-nut 1 .



Standard spring set length:

4.1 mm (0.161 in) copressed from spring free length

Spring set length adjustable range:

245 – 263 mm (9.646 –10.354 in)

NOTE:

Turning the adjuster 2 without loosening the lock-nut 1 can damage the rear suspension unit.



Shock absorber lock-nut: 43 N·m (4.3 kgf-m, 31.0 lb-ft)

4-18 MACHINE TUNING

REAR SUSPENSION TUNING PROCEDURE

• Select the rear suspension according to the rider’s weight and preference by referring to the table below.

Spring Set-length adjustable range

Soft

Standard

Hard

Part No.

62211-37FH0

62211-37FJ0

62211-37FK0

62211-37FL0

62211-37FM0

Spring rate

48 N/mm (4.8 kgf/mm)

51 N/mm (5.1 kgf/mm)

53 N/mm (5.3 kgf/mm)

55 N/mm (5.5 kgf/mm)

56 N/mm (5.6 kgf/mm)

245 – 263 mm

(9.646 –10.354 in)

• Measure the distance L1 from the seat bolt to the chain adjuster lock-nut with the motorcycle on the stand and the rear wheel lifted off the ground.

• Measure the distance L2 from the seat bolt to the chain adjuster lock-nut with the motorcycle off the stand and riding the motorcycle normally in full riding gear.

• Find the sag by subtracting L2 from L1. Standard sag range is

104 mm (4.09 in).

When the sag measured is:

Less than 104 mm

(4.09 in)

More than 104 mm

(4.09 in)

Adjustment procedure

Reduce spring pre-set length by turning the spring adjuster nut.

Increase spring pre-set length by turning the spring adjuster nut.

L2

MACHINE TUNING 4-19

After the sag measurement has been set in 104 mm (4.09 in), test ride the motorcycle and adjust the suspension for the rider and track conditions referring to the guide below.

SYMPTOM

Feels too hard overall

Kicks up

Bottom feeling or feels too soft and unstable

Feels harsh and hits bumps too harshly

Provides poor traction

Tends to sink front than rear

• Jump

SECTION

• Series of bumps

ADJUSTMENT PROCEDURE

1. Adjust the low speed compression damping to a softer setting. (See note below.)

2. Adjust the rebound damping to a softer setting.

(See note below.)

3. Replace the spring with an optional softer one.

(



4-18)

4. Adjust the high speed compression damping to a softer setting. (See note below.)

• Medium to large bumps 1. Adjust the low speed compression damping and rebound damping to a harder setting. (See note below.)

2. Adjust the high speed compression damping to a harder setting. (See note below.)

• Jump

• Large bump

• Series of bumps

1. Adjust the low speed compression damping to a harder setting. (See note below.)

2. Adjust the rebound damping to a harder setting. (See note below.)

3. Replace the spring with an optional stiffer one.

(



4-18)

• Jump

• Large bump

• Series of bumps

• Accelerating

• Series of small bumps

1. Adjust the low speed compression damping to a harder setting. (See note below.)

2. Adjust the rebound damping to a harder setting. (See note below.)

3. If bottom feeling become after adjusting above mentions, adjust the high speed compression damping to a harder setting. (See note below.)

1. Adjust the rebound damping to a harder setting.

(See note below.)

2. If traction feeling does not improve after adjusting above mention, adjust the low speed compression damping to a softer setting. (See note below.)

3. If bottom feeling become after adjusting above mentions, adjust the high speed compression damping to a harder setting. (See note below.)

• Decelerating or braking 1. Adjust the high speed compression damping to a softer setting. (See note below.)

2. Adjust the rebound damping to a harder setting. (See note below.)

NOTE:

* When adjusting the low speed compression damping and rebound damping setting, attempt turning the adjuster 1 to 2 click stops at a time for each adjustment.

* When adjusting the high speed compression damping setting, attempt turning the adjuster 1/4 turn at a time for each adjustment.

4-20 MACHINE TUNING

SUSPENSION BALANCE

Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps. This transfers more of the motorcycle and rider weight rearward, possibly causing the rear suspension to bottom, where as it felt fine before the front fork adjustment was made.

BALANCE TEST

Stand next to the motorcycle on level ground. Place one foot on the footrest closest to you. Sharply push down. The front and rear suspensions should both collapse equally.

BALANCING TIPS

• Check for air pressure build-up in front forks. Heat and altitude will increase air pressure in the front forks.

• Always stay within sag measurement limits, 104 mm (4.09 in), when using spring pre-set to stiffen or soften rear suspension. If this is not possible, the next stiffer or softer accessory spring is needed.

• The rear shock compression damping can be used to fine tune suspension balance and is easy to access.

ENGINE REMOVAL AND INSTALLATION 5-1

ENGINE REMOVAL AND INSTALLATION

CONTENTS

EXTERIOR PARTS ...................................................................................... 5- 2

CONSTRUCTION ........................................................................................ 5- 3

SEAT RAIL, DRIVE CHAIN CONTROL ROLLER ................................ 5- 3

ENGINE DISMOUNTING ............................................................................. 5- 4

ENGINE MOUNTING ................................................................................... 5- 8

INSPECTION AFTER ENGINE MOUNTING ......................................... 5-10

5

5-2 ENGINE REMOVAL AND INSTALLATION

EXTERIOR PARTS

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

FWD

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

10 N.m

1.0 kgf-m

7.0 lb-ft

5 N·m

(0.5 kgf-m, 3.5 lb-ft)

10 N.m

1.0 kgf-m

7.0 lb-ft 10 N.m

1.0 kgf-m

7.0 lb-ft

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

Seat

Seat rail

10 N.m

1.0 kgf-m

7.0 lb-ft

Washer

Frame

Frame cover

Bolt

10 N.m

1.0 kgf-m

7.0 lb-ft

CONSTRUCTION

SEAT RAIL, DRIVE CHAIN CONTROL ROLLER

ENGINE REMOVAL AND INSTALLATION 5-3

23 N·m

(2.3 kgf-m, 16.5 lb-ft)

43 N·m

(4.3 kgf-m,

31.0 lb-ft)

31 N·m

(3.1 kgf-m, 22.5 lb-ft)

23 N·m

(2.3 kgf-m, 16.5 lb-ft)

31 N·m

(3.1 kgf-m, 22.5 lb-ft)

5-4 ENGINE REMOVAL AND INSTALLATION

ENGINE DISMOUNTING

• Drain transmission oil. (



2-10)

• Drain engine coolant. (



2-12)

• Remove the seat 1 .

• Turn the fuel valve lever to the “OFF” position.

• Disconnect the fuel hose.

• Remove the fuel tank 2 with the radiator cover.

• Remove the carburetor. (



11-3)

• Remove the exhaust pipe fitting springs with the special tool.



09920-20310: Spring hook

• Remove the exhaust pipe 3 .

• Remove the exhaust pipe gasket 4 .

• Disconnect the radiator hoses 5 and 6 .

• Disconnect the spark plug cap 7 .

• Disconnect the magneto lead wire coupler 8 and clamp.

• Remove the drive chain clip and open the drive chain 9 .

ENGINE REMOVAL AND INSTALLATION 5-5

5-6 ENGINE REMOVAL AND INSTALLATION

• Remove the cotter pins and brake pedal 0 .

• Remove the magneto cover. (



13-10)

• Disconnect the clutch cable.

NOTE:

Loosen the clutch cable adjuster when disconnecting.

(



2-13)

• Extract the clutch cable A .

• Remove the sprocket cover B .

• Remove the engine mounting bolts and brackets.

• Remove the swingarm pivot shaft nut and washer.

• Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position.

NOTE:

The swingarm will come off when the swingarm pivot shaft is completely removed.

• Dismount the engine to the right side.

ENGINE REMOVAL AND INSTALLATION 5-7

5-8 ENGINE REMOVAL AND INSTALLATION

ENGINE MOUNTING

Reassemble the removed parts in the reverse order of removal. Pay attention to the following points:

• Mount the engine from the right side.

• Tighten the engine mounting bolts/nuts to the specified torque.

1 2

3 4

5

6

N·m

43

45

55

70 kgf-m

4.3

4.5

5.5

7.0

lb-ft

31.0

32.5

40.0

50.5

NOTE:

Replace the self-locking nuts with new ones.

Bolt Length

A 45 mm (1.8 in)

B 55 mm (2.2 in)

C 48 mm (1.9 in)

D 105 mm (4.1 in)

E 125 mm (4.6 in)

• Install the spring 1 as shown.

• Apply grease to the brake pedal pivot bolt.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

ENGINE REMOVAL AND INSTALLATION 5-9

A

SECT AA

A

• Tighten the brake pedal pivot bolt 2 .



Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)

CAUTION

Replace the cotter pins with new ones.

• Reassemble the drive chain clip so that the slit end faces opposit to the direction of rotation.

Direction of travel

• Install a new exhaust pipe gasket.

• Apply a small quantity of grease to the new O-ring before installing the exhaust pipe.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Fit the projection of the carburetor to the depression of the intake pipe.

5-10 ENGINE REMOVAL AND INSTALLATION

INSPECTION AFTER ENGINE MOUNTING

After mounting the engine, inspect the followings.

• Transmission oil level (



2-9)

• Engine coolant level (



2-11)

• Throttle cable play (



2-13)

• Clutch cable play (



2-13)

• Drive chain slack (



2-16)

• Brake pedal height (



2-20)

• Wire, cable and hose routing (



18-13 to -15)

CYLINDER, PISTON AND EXHAUST VALVE 6-1

CYLINDER, PISTON AND EXHAUST VALVE

CONTENTS

CONSTRUCTION ........................................................................................ 6- 2

CYLINDER, PISTON ............................................................................. 6- 2

EXHAUST PIPE, SILENCER ................................................................ 6- 3

EXHAUST VALVE ................................................................................. 6- 4

REMOVAL ................................................................................................... 6- 5

CYLINDER HEAD ................................................................................. 6- 5

CYLINDER ............................................................................................. 6- 5

PISTON AND PISTON RING ................................................................ 6- 6

INSPECTION ............................................................................................... 6- 7

CYLINDER HEAD ................................................................................. 6- 7

CYLINDER ............................................................................................. 6- 7

PISTON TO CYLINDER CLEARANCE ................................................. 6- 8

CONROD ............................................................................................... 6- 8

PISTON AND PISTON RING ................................................................ 6- 8

INSTALLATION ........................................................................................... 6-10

PISTON AND PISTON RING ................................................................ 6-10

CYLINDER ............................................................................................. 6-11

CYLINDER HEAD ................................................................................. 6-12

INSPECTION AFTER INSTALLATION ................................................. 6-12

EXHAUST VALVE ....................................................................................... 6-13

DISASSEMBLY ..................................................................................... 6-13

INSPECTION ......................................................................................... 6-15

REASSEMBLY ...................................................................................... 6-16

EXHAUST VALVE GOVERNER AND ACTUATOR .................................... 6-19

DISASSEMBLY ..................................................................................... 6-19

INSPECTION ......................................................................................... 6-20

REASSEMBLY ...................................................................................... 6-20

6

6-2 CYLINDER, PISTON AND EXHAUST VALVE

CONSTRUCTION

CYLINDER, PISTON

4.5 N.m

(0.45 kgf-m, 3.0 lb-ft)

1216

20 N.m

(2.0 kgf-m, 14.5 lb-ft)

45 N.m

(4.5 kgf-m, 32.5 lb-ft)

25 N.m

(2.5 kgf-m, 18.0 lb-ft)

38 N.m

(3.8 kgf-m, 27.5 lb-ft)

4.5 N.m

(0.45 kgf-m, 3.0 lb-ft)

4.5 N.m

(0.45 kgf-m,

3.0 lb-ft)

EXHAUST PIPE, SILENCER

10 N.m

(1.0 kgf-m, 7.0 lb-ft)

CYLINDER, PISTON AND EXHAUST VALVE 6-3

10 N.m

(1.0 kgf-m, 7.0 lb-ft)

10 N.m

(1.0 kgf-m, 7.0 lb-ft)

6-4 CYLINDER, PISTON AND EXHAUST VALVE

EXHAUST VALVE

4.5 N.m

(0.45 kgf-m, 3.0 lb-ft)

4.5 N.m

(0.45 kgf-m, 3.0 lb-ft)

10 N.m

(1.0 kgf-m,

7.0 lb-ft)

4 N.m

(0.4 kgf-m, 3.0 lb-ft)

4.5 N.m

(0.45 kgf-m, 3.0 lb-ft)

REMOVAL

CYLINDER HEAD

• Drain engine coolant. (



2-12)

• Remove the seat and fuel tank. (



5-4)

• Disconnect the radiator hose 1 .

• Disconnect the spark plug cap 2 and remove the spark plug

3 .

• Remove the engine mounting brackets 4 .

• Remove the cylinder head.

NOTE:

Loosen the cylinder head nuts diagonally to prevent cylinder head distortion.

CYLINDER, PISTON AND EXHAUST VALVE 6-5

CYLINDER

• Remove the cylinder head O-rings 1 and 2 .

• Remove the exhaust pipe. (



5-5)

• Remove the carburetor. (



11-3)

• Remove the exhaust side valve cover 3 .

6-6 CYLINDER, PISTON AND EXHAUST VALVE

• Remove the exhaust valve rod bolt 4 .

• Remove the radiator guards 5 . (left & right)

• Remove the radiator lower mounting bolts (left & right) and move the radiator forward.

• Remove the reed valve. (



11-11)

• Remove the cylinder nuts.

NOTE:

Loosen the cylinder nuts diagonally.

• Remove the cylinder.

NOTE:

Take care not to drop the exhaust side valve spacer 6 .

• Remove the gasket 7 and dowel pins.

PISTON AND PISTON RING

• Remove the piston pin circlip 1 .

NOTE:

Place cloth under the piston to prevent the piston pin circlip from dropping into the crankcase chamber.

• Remove the piston pin 2 .

• Remove the piston 3 .

NOTE:

Use the special tool if necessary.



09910-34510: Piston pin puller

• Remove the conrod small end bearing 4 .

CYLINDER, PISTON AND EXHAUST VALVE 6-7

INSPECTION

CYLINDER HEAD

• Remove carbon deposits from the cylinder head.

• Inspect the cylinder head for cracks around the spark plug hole.

• Inspect for cylinder head distortion with the thickness gauge.



Cylinder head distortion

Service limit: 0.05 mm (0.002 in)



09900-20803: Thickness gauge

CYLINDER

• Remove the exhaust valve assembly. (



6-13)

• Remove carbon deposits from the exhaust port.

• Inspect the cylinder for cracks and replace the cylinder if necessary.

• Inspect the cylinder bore for wear and scratches.

NOTE:

Chrome-plated cylinder bore can not be modified such as boring and honing.

6-8 CYLINDER, PISTON AND EXHAUST VALVE

• Inspect for cylinder distortion with the thickness gauge.



Cylinder distortion: Service limit: 0.05 mm (0.002 in)



09900-20803: Thickness gauge

• Measure the cylinder bore for wear with the cylinder gauge at

20 mm (0.79 in) from the top surface.

NOTE:

The cylinder bore must be measured perpendicular to the crankshaft axis direction.



Cylinder bore

Standard: 66.400 – 66.415 mm (2.6142 – 2.6148 in)



09900-20508: Cylinder gauge set

PISTON TO CYLINDER CLEARANCE



Piston to cylinder clearance:

Standard: 0.045 – 0.055 mm (0.0018 – 0.0022 in)

Service limit: 0.120 mm (0.0047 in)

CONROD

• Measure the conrod small end bore. (



10-8)

PISTON AND PISTON RING

• Remove carbon deposits from the piston.

• Inspect the piston for wear, scratches and damage.

• Measure the piston outer diameter at 19 mm (0.75 in) from the skirt end.



Piston diam

Service limit: 66.280 mm (2.6100 in)



09900-20203: Micrometer (50 – 75 mm)

• Measure the piston pin bore and piston pin diameter.



Piston pin bore

Service limit: 18.030 mm (0.7098 in)



Piston pin O.D

Service limit: 17.980 mm (0.7079 in)



09900-20605: Dial caliper

09900-20205: Micrometer

20 mm

(0.79 in)

19 mm

(0.75 in)

• Remove carbon deposits from piston ring and piston ring groove.

• Measure the clearances with the thickness gauge.



Piston ring to groove clearance

Standard: 0.02 – 0.06 mm (0.0008 – 0.0024 in)



09900-20803: Thickness gauge

• Remove the piston rings from the piston ring grooves.

• Fit the piston ring into the cylinder and measure the piston ring end gap with the thickness gauge.



Piston ring end gap

Service limit: 0.80 mm (0.031 in)



09900-20803: Thickness gauge

• Measure the piston ring free end gap.



Piston ring free end gap

Service limit: 6.6 mm (0.26 in)



09900-20101: Vernier calipers

CYLINDER, PISTON AND EXHAUST VALVE 6-9

6-10 CYLINDER, PISTON AND EXHAUST VALVE

INSTALLATION

PISTON AND PISTON RING

Install the piston and piston ring in the reverse order of removal.

Pay attention to the following points:

• Apply engine oil to the piston rings and piston ring grooves.

• Fit the piston rings into the piston ring grooves so that the each piston ring end comes to the piston ring locating pin.

CAUTION

Locate the piston ring end to the locating pin and insert the piston into the cylinder.

If the piston ring end is not at the proper position, you can not insert the piston into the cylinder properly and the piston ring will be damaged.

• Apply engine oil to the piston pin and bearing.

• Fit the bearing to the conrod small end.

OK NG

• Face the embossed mark A on the piston top to the exhaust port side.

• Install the piston pin and new piston pin circlips.

NOTE:

* Place cloth under the piston to prevent the piston pin circlip from dropping into the crankcase chamber.

* Piston pin circlip ends should face upside.

CYLINDER

Install the cylinder in the reverse order of removal. Pay attention to the following points:

• Fit a new gasket 1 and dowel pins.

• Apply engine oil to the cylinder bore.

CYLINDER, PISTON AND EXHAUST VALVE 6-11

• Tighten the cylinder nuts to the specified torque according to the specified tightening order as shown.



Cylinder nut: 38 N·m (3.8 kgf-m, 27.5 lb-ft)

• Install the read valve. (



11-12)

• Tighten the exhaust valve rod bolt using the pin 2 as a stopper.

NOTE:

The pin 2 is one of the included parts.



Exhaust valve rod bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Fit a new gasket and install the exhaust side valve cover 3 .



Exhaust side valve cover bolt:

4.5 N·m (0.45 kgf-m, 3.0 lb-ft)

• Install the caburetor. (



11-7)

• Install the exhaust pipe. (



5-9)

• Apply grease to the O-rings.

• Install new O-rings 4 and 5 .



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

NOTE:

Apply Bond to the stud bolt threads when assembling the removed stud bolts into the cylinder.



99000-31140: SUZUKI BOND “1207B”

6-12 CYLINDER, PISTON AND EXHAUST VALVE

CYLINDER HEAD

• Tighten the cylinder head nuts to the specified torque according to the specified tightening order as shown.



Cylinder head nut:

Initial:15 N·m (1.5 kgf-m, 11.0 lb-ft)

Final: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

• Tighten the engine mounting bracket bolts. (



5-8)

• Tighten the spark plug. (



2-6)

INSPECTION AFTER INSTALLATION

• Route the wires, cables and hoses properly. (



18-13 to -15)

• Pour engine coolant. (



2-12)

• Check the throttle cable play. (



2-13)

EXHAUST VALVE

DISASSEMBLY

• Remove the cylinder. (



6-6)

• Remove the cylinder breather hose 1 and exhaust valve breather hose 2 .

CYLINDER, PISTON AND EXHAUST VALVE 6-13

EXHAUST SIDE VALVE (RH)

• Remove the exhaust side valve spacer 3 .

• Remove the exhaust side valve cam 4 and pin 5 .

• Remove the exhaust valve cap bolt 6 , stopper pin 7 and gasket 8 .

• Remove the exhaust side valve 9 .

6-14 CYLINDER, PISTON AND EXHAUST VALVE

• Remove the exhaust valve shaft retainer 0 .

EXHAUST SIDE VALVE (LH)

• Remove the side valve cap 1 and gasket.

• Remove the spacer, exhaust valve cam and exhaust side valve in the same manner as the right side.

• Remove the spring cap 2 .

• Remove the gasket 3 and return spring 4 .

EXHAUST MAIN VALVE

• Remove the exhaust valve cover 1 and gasket.

• Remove the exhaust valve shaft arm bolts.

• Remove the exhaust valve shaft 2 .

• Remove the following parts.

3 Exhaust valve arm

4 Spring

5 Right exhaust side valve rod

6 Left exhaust side valve rod

• Remove the retainer 7 and the exhaust main valve 8 .

• Remove the jet 9 .

INSPECTION

• Remove carbon deposits from the exhaust valves and component parts.

• Inspect the exhaust valves for wear and scratches.

• Inspect the return spring for abnormal bend and spring tension.

• Inspect the jet for cloggy and damage.

CYLINDER, PISTON AND EXHAUST VALVE 6-15

6-16 CYLINDER, PISTON AND EXHAUST VALVE

REASSEMBLY

Reassemble the exhaust valve in the reverse order of disassembly. Pay attention to the following points:

• Apply engine oil to the exhaust side valve rods.

• Install the exhaust side valve rods into the cylinder.

NOTE:

Make sure that the yellow painted valve rod 1 is installed on the right (left side of body) and the white painted valve rod 2 is installed on the left (right side of body).

• Apply engine oil to the exhaust valve shaft.

• Install the springs 3 to the exhaust valve arm 4 .

• Insert the exhaust valve shaft 5 through the exhaust valve arm 4 with springs 3 .

Yellow

• Apply engine oil to the exhaust main valve.

• Pull up the exhaust valve arm 3 and install the exhaust main valve 6 to the cylinder.

CAUTION

Pinch the pin 7 of the exhaust main valve with the spring ends.

• Install the retainer 8 .

• Tighten the bolts 9 , 0 to the specified torque.



Retainer bolt 9 : 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)

Exhaust valve shaft arm bolt 0 :

4 N·m (0.40 kgf-m, 3.0 lb-ft)

• Fit the exhaust valve shaft retainer A to the groove of exhaust valve shaft.

• Tighten the bolt to the specified torque.



Exhaust valve shaft retainer bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Install a new gasket and exhaust valve cover.

White

• Install a new gasket.

• Install the return spring with its end engaged the groove of the exhaust valve shaft and the other side the spring cap.

CYLINDER, PISTON AND EXHAUST VALVE 6-17

• Temporarily tighten the bolts B .

• Turn the spring cap 180° clockwise and tighten the bolts B to the specified torque.



Return spring cap bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)

• Apply engine oil to the exhaust side valve.

• Install the exhaust side valve C , stopper pin D and new gasket E .

• Tighten the exhaust valve cap bolt F to the specified torque.



Exhaust valve cap bolt: 4.5 N·m (0.45 kgf-m, 3.0 lb-ft)

NOTE:

Make sure that the yellow painted side valve C is installed on the right and the white painted side valve is installed on the left.

• Install the pin G .

NOTE:

Move the exhaust side valve fully to outer side.

Yellow

Spring cap

6-18 CYLINDER, PISTON AND EXHAUST VALVE

• Install the exhaust side valve cam as following.

Right side : Yellow paint

Left side : White paint

Exhaust side valve cam

Approx. 35˚

Exhaust side valve

Install the exhaust side valve cam with aligning the emboss A with the pin of the exhaust side valve.

Turn the exhaust side valve cam approx.

35˚.

• Install the exhaust valve spacer H with the hollow faced outside.

• Install the left exhaust side valve in the same manner as the right exhaust side valve.

NOTE:

Make sure that the exhaust side valve spacer is the same level with the cylinder. If not so, the exhaust side valve cam isn’t installed correctly.

• Install a new gasket and side valve cap.



Exhaust side valve cap bolt:

4.5 N·m (0.45 kgf-m, 3.0 lb-ft)

In above position, the pin behind the exhaust side valve cam engages the groove B on the exhaust valve cam rod.

• After assembling the exhaust valve, inspect it for smoothness by rotating the exhaust valve shaft.

NOTE:

* Temporarily install the bolt to the exhaust valve shaft for above inspection.

* Hold the exhaust side valve in fear of dropping off.

• Install the cylinder. (



6-11)

EXHAUST VALVE GOVERNER AND

ACTUATOR

DISASSEMBLY

• Drain the transmission oil. (



2-10)

• Drain the engine coolant. (



2-12)

• Remove the exhaust pipe. (



5-5)

• Remove the exhaust side valve cover. (



6-5)

• Remove the right crankcase cover. (



8-3)

• Disconnect the exhaust valve governer rod bolt.

• Remove the exhaust governer assembly 1 .

CYLINDER, PISTON AND EXHAUST VALVE 6-19

• Remove the exhaust valve rod assembly 2 .

• Remove the pin 3 by pushing down the retainer 4 .

6-20 CYLINDER, PISTON AND EXHAUST VALVE

• Disassemble the following parts from governer.

4 Retainer 0 Washer

5 Spring

6 Retainer

A

B

Bearing

Stater

7

8

Bearing

Washer

9 Spacer

C Balls

D Governer

INSPECTION

• Inspect the governer for wear and damage.

• Inspect hte bearings for abnormal noise, wear and damage.

• Inspect the exhaust valve rod for abnormal bend and damage.

REASSEMBLY

Reassemble the exhaust valve governer and actuator in the reverse order of disassembly. Pay attention to the following points:

• Apply transmission oil to the bearings.

• Assemble the governer.

NOTE:

The covered side A of bearings should face governer side.

• Apply THREAD LOCK SUPER to the actuator screw and tighten the screws.



99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

• Install the governer with the actuator B engaged with the groove C of the governer.

CYLINDER, PISTON AND EXHAUST VALVE 6-21

• Connect the exhaust valve rod to the exhaust valve shaft and tighten the exhaust valve rod bolt using the pin 1 as a stopper.

NOTE:

The pin 1 is one of the included parts.



Exhaust valve rod bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Install the right crankcase cover. (



8-6)

• Install the exhaust side valve cover. (



6-11)

• Install the exhaust pipe. (



5-9)

INSPECTION AFTER INSTALLATION

After the installation, inspect the followings.

• Transmission oil level (



2-9)

• Engine coolant level (



2-11)

• Brake pedal heignt. (



2-20)

– MEMO –

CLUTCH

CONTENTS

CONSTRUCTION ........................................................................................ 7- 2

REMOVAL ................................................................................................... 7- 3

CLUTCH PLATE ................................................................................... 7- 3

PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB .................... 7- 4

CLUTCH RELEASE CAMSHAFT ......................................................... 7- 5

INSPECTION ............................................................................................... 7- 5

DRIVE PLATE ....................................................................................... 7- 5

DRIVEN PLATE ..................................................................................... 7- 5

CLUTCH SPRING ................................................................................. 7- 6

CLUTCH PUSH ROD AND PUSH PIECE ............................................. 7- 6

PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB .................... 7- 6

BEARING AND SPACER ...................................................................... 7- 6

CLUTCH RELEASE CAMSHAFT ......................................................... 7- 6

OIL SEAL AND BEARING .................................................................... 7- 7

INSTALLATION ........................................................................................... 7- 7

PRIMARY DRIVEN GEAR .................................................................... 7- 7

CLUTCH PLATE ................................................................................... 7- 8

CLUTCH COVER .................................................................................. 7- 9

CLUTCH RELEASE CAMSHAFT ......................................................... 7- 9

INSPECTION AFTER INSTALLATION ................................................. 7- 9

CLUTCH 7-1

7

7-2 CLUTCH

CONSTRUCTION

11 N·m

(1.1 kgf-m, 8.0 lb-ft)

5 N·m

(0.5 kgf-m, 3.5 lb-ft)

90 N·m

(9.0 kgf-m,

65.0 lb-ft)

REMOVAL

CLUTCH PLATE

• Drain transmission oil. (



2-10)

• Remove the rear brake pedal. (



5-6)

• Remove the clutch cover 1 .

• Loosen and remove the bolts diagonally.

• Remove the clutch springs.

• Remove the pressure plate 2 .

• Remove the bearing 3 , push piece 4 and push rod 5 .

• Remove the drive plates and driven plates.

CLUTCH 7-3

7-4 CLUTCH

PRIMARY DRIVEN GEAR AND

CLUTCH SLEEVE HUB

• Flatten the lock washer.

• Hold the clutch sleeve hub with the special tool and remove the clutch sleeve hub nut.



09920-53740: Clutch sleeve hub holder

• Remove the lock washer 1 and clutch sleeve hub 2 .

• Remove the washer 3 and primary driven gear assembly 4 .

• Remove the bearing 5 and spacer 6 .

CLUTCH RELEASE CAMSHAFT

• Remove the magneto cover, magneto rotor and stator.

(



13-10)

• Loosen the clutch cable adjuster and unhook the clutch cable.

(



2-13, 5-6)

• Remove the clutch release camshaft 1 .

INSPECTION

DRIVE PLATE

• Inspect the drive plates for wear, distortion and discoloration.

• Measure the drive plate thickness.



Drive plate thickness

Service limit: 2.77 mm (0.109 in)



09900-20101: Vernier calipers

• Measure the drive plate claw width.



Drive plate claw width

Service limit: 13.35 mm (0.514 in)



09900-20101: Vernier calipers

DRIVEN PLATE

• Inspect the driven plates for wear and discoloration.

• Measure the driven plate distortion.



Driven plate distortion

Service limit: 0.10 mm (0.004 in)



09900-20803: Thickness gauge

CLUTCH 7-5

7-6 CLUTCH

CLUTCH SPRING

• Measure the clutch spring free length.



Clutch spring free length

Service limit: 49.4 mm (1.94 in)



09900-20101: Vernier calipers

NOTE:

Replace six clutch springs together even if only one spring is beyond the service limit.

CLUTCH PUSH ROD AND PUSH PIECE

• Inspect the clutch push rod for abnormal deflection, cracks and damage.

• Inspect the clutch push piece for cracks, wear and damage.

• Inspect the bearing for abnormal noise, wear and damage.

PRIMARY DRIVEN GEAR AND

CLUTCH SLEEVE HUB

• Inspect the clutch sleeve hub and primary driven gear assembly for abnormal wear, cracks and damage.

BEARING AND SPACER

• Inspect the spacer for wear and damage.

• Inspect the needle bearing for abnormal noise, wear and damage.

CLUTCH RELEASE CAMSHAFT

• Inspect the clutch release camshaft for abnormal deflection and damage.

OIL SEAL AND BEARING

• Inspect the oil seal for damage and oil leakage.

• Inspect the bearings for abnormal noise, wear and damage.

OIL SEAL REMOVAL AND INSTALLATION (



10-9, -10)

BEARING REMOVAL AND INSTALLATION (



10-12, -13)

INSTALLATION

Install the clutch assembly in the reverse order of removal. Pay attention to the following points.

PRIMARY DRIVEN GEAR

• Apply transmission oil to the spacer 1 and needle bearing 2 .

• Fit the primary driven gear assembly 3 and washer 4 .

• Fit the clutch sleeve hub 5 , new lock washer 6 and clutch sleeve hub nut 7 .

NOTE:

The flat side of the nut 7 must face outside.

CLUTCH 7-7

7-8 CLUTCH

• Tighten the clutch sleeve hub nut with the special tool to the specified torque.



Clutch sleeve hub nut: 90 N·m (9.0 kgf-m, 65.0 lb-ft)



09920-53740: Clutch sleeve hub holder

• Bend the lock washer to secure the nut.

CLUTCH PLATE

• Apply transmission oil to the drive plates and driven plates.

• Install the clutch drive plates and driven plates.

• Apply transmission oil to the bearing.

• Insert the clutch push rod.

• Insert the clutch push piece and bearing. The covered side A of the bearing should face outside.

• Fit the pressure plate 1 .

• Insert the springs and tighten the bolts diagonally to the specified torque.



Clutch spring bolt: 5 N·m (0.5 kgf-m, 3.5 lb-ft)

Outside

CLUTCH COVER

• Replace the O-ring with a new one.

• Apply grease to the O-ring.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the clutch cover 1 .



Clutch cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

CLUTCH RELEASE CAMSHAFT

• Install the clutch release camshaft 1 .

• Install the stator and magneto rotor. (



13-11)

• Install a new gasket and magneto cover. (



13-12)

• Reinstall the brake pedal. (



5-9)

INSPECTION AFTER INSTALLATION

• Pour transmission oil. (



2-9)

• Adjust the clutch cable play. (



2-13)

• Adjust the brake pedal height. (



2-20)

CLUTCH 7-9

– MEMO –

KICK STARTER 8-1

KICK STARTER

CONTENTS

CONSTRUCTION ........................................................................................ 8- 2

REMOVAL ................................................................................................... 8- 3

INSPECTION ............................................................................................... 8- 4

OIL SEAL .............................................................................................. 8- 4

KICK STARTER .................................................................................... 8- 4

KICK STARTER IDLE GEAR ................................................................ 8- 4

REASSEMBLY ............................................................................................ 8- 5

INSPECTION AFTER REASSEMBLY .................................................. 8- 6

8

8-2 KICK STARTER

CONSTRUCTION

23 N·m

(2.3 kgf-m, 16.5 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

REMOVAL

• Drain transmission oil. (



2-10)

• Drain the engine coolant. (



2-12)

• Remove the brake pedal. (



5-6)

• Disconnect the radiator hose.

• Remove the kick starter lever.

• Remove the crankcase cover.

• Remove the clutch. (



7-3, -4)

• Remove the snap ring 1 washer 2 and kick starter idle gear

3 .



09900-06107: Snap ring pliers

• Unhook the kick return spring and remove the kick starter assembly 4 .

• Remove the kick starter guide 5 .

• Disassemble the following parts from the kick starter shaft.

Spring 6

Kick starter 7

Kick starter drive gear 8

Spring guide 9

Kick return spring 0

Kick starter shaft A



09900-06107: Snap ring pliers

KICK STARTER 8-3

8-4 KICK STARTER

INSPECTION

OIL SEAL

• Inspect the oil seal for oil leakage and oil seal lip damage.

• Remove the oil seal with the special tool.



09913-50121: Oil seal remover

• Install the oil seal with the special tool.



09913-70210: Bearing installer set

KICK STARTER

• Inspect the return spring for damage.

• Inspect the kick starter drive gear teeth for wear and damage.

• Inspect the kick starter drive gear ratchet part for wear and damage.

• Inspect the kick starter shaft and drive gear contact surface for wear and damage.

KICK STARTER IDLE GEAR

• Inspect the kick starter idle gear teeth for wear and damage.

• Inspect the kick starter idle gear and driveshaft contact surface for wear and damage.

REASSEMBLY

Reassemble the kick starter assembly in the reverse order of disassembly. Pay attention to the following points:

• Apply transmission oil to the kick starter shaft.

• Install the return spring 1 into the kick starter shaft hole A .

• Install the spring guide 2 with the groove B of the spring guide engaged with the return spring 1 .

• Install the kick starter drive gear 3 and washer 4 to the kick starter shaft.

• Install the new snap ring 5 firmly with snap ring pliers.



09900-06107: Snap ring pliers

• Install the kick starter assembly to the crankcase and hook the return spring.

• Install the kick starter idle gear washer and new snap ring.



09900-06107: Snap ring pliers

KICK STARTER 8-5

8-6 KICK STARTER

• Install the clutch. (



7-7, -8)

• Fit a new gasket 6 and dowel pins.

• Install the crankcase cover.



Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

• Install the kick starter lever.



Kick starter lever bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Install the brake pedal. (



5-9)

INSPECTION AFTER REASSEMBLY

After reinstalling the kick starter assembly, inspect the followings.

• Transmission oil level (



2-9)

• Engine coolant level (



2-11)

• Brake pedal height (



2-20)

GEARSHIFTING 9-1

GEARSHIFTING

CONTENTS

CONSTRUCTION ........................................................................................ 9- 2

REMOVAL ................................................................................................... 9- 3

INSPECTION ............................................................................................... 9- 5

REASSEMBLY ............................................................................................ 9- 6

9

9-2 GEARSHIFTING

CONSTRUCTION

20 N·m

(2.0 kgf-m, 14.5 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

23.5 N·m

(2.35 kgf-m, 17.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

REMOVAL

• Drain transmission oil. (



2-10)

• Drain engine coolant. (



2-12)

• Remove the drive chain clip and open the drive chain.

(



5-5)

• Remove the gearshift lever 1 .

NOTE:

Mark the gearshift shaft with slit position of the gearshift lever for right installation position.

• Remove the crankcase cover. (



8-3)

• Remove the clutch assembly. (



7-3, -4)

• Remove the gearshift shaft 2 and washer 3 .

• Remove the pawl lifter 4 .

• Remove the gearshift cam driven gear 5 .

NOTE:

Be careful not to drop the pins and springs when removing the gearshift cam driven gear.

• Remove the gearshift pawls 6 , pins 7 and springs 8 .

GEARSHIFTING 9-3

9-4 GEARSHIFTING

• Remove the gearshift cam bolt 9 and stopper plate 0 .

• Remove the gearshift arm stopper bolt A and washer B .

• Remove the gearshift cam stopper C .

• Remove the spring D .

• Remove the gearshift return spring E by removing the snap ring.



09900-06107: Snap ring pliers

INSPECTION

• Inspect the gearshift shaft 1 for bends and damage.

• Inspect the gearshift return spring 2 for damage.

• Inspect the pawls 3 , pins 4 and springs 5 for damage.

GEARSHIFTING 9-5

9-6 GEARSHIFTING

REASSEMBLY

• Temporarily install the spring 1 , washer 2 and gearshift cam stopper 3 .

• Hook the spring 1 to the projection A .

• Tighten the gearshift cam stopper bolt.

• Align the pin groove B with the pin C when installing the stopper plate 4 .

• Tighten the gearshift cam bolt 5 .



Gearshift cam bolt: 23.5 N·m (2.35 kgf-m, 17.0 lb-ft)

• Apply THREAD LOCK SUPER and tighten the gearshift arm stopper bolt 6 to the specified torque.



Gearshift arm stopper bolt: 20 N·m (2.0 kgf-m, 14.5 lb-ft)



99000-32030: THREAD LOCK SUPER “1303”

• Fit the springs 7 , pins 8 and pawls 9 to the gearshift cam driven gear 0 . Wider side D of pawl should be positioned outside.

GEARSHIFTING 9-7

• With the pawls held in pushed position, install the pawl lifter

A .

• Reassemble the gearshift cam driven gear and pawl lifter.

• Apply THREAD LOCK SUPER to the screws.

• Tighten the screws.



Retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft)



99000-32030: THREAD LOCK SUPER “1303”

• Reassemble the gearshift return spring B to the gearshift shaft C properly.

 09900-06107: Snap ring pliers

9-8 GEARSHIFTING

• Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam shifter.

• Reassemble the clutch and crankcase cover. (



7-8, 8-6)

• Install the gearshift lever.



Gearshift lever bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

• Reassemble the drive chain clip. (



5-9)

• Refill transmission oil. (



2-9)

• Refill engine coolant. (



2-12)

• Inspect the gearshift lever for smooth movement.

• Inspect the brake pedal height. (



2-20)

• Inspect the drive chain slack. (



2-16)

TRANSMISSION AND CRANKSHAFT 10-1

TRANSMISSION AND CRANKSHAFT

CONTENTS

CONSTRUCTION ...................................................................................... 10- 2

CRANKSHAFT AND CRANKCASE ................................................... 10- 2

TRANSMISSION ................................................................................. 10- 3

ENGINE BOTTOM SIDE ............................................................................ 10- 4

PRIMARY DRIVE GEAR REMOVAL .................................................. 10- 4

CRANKCASE SEPARATION ............................................................. 10- 5

TRANSMISSION REMOVAL .............................................................. 10- 6

CRANKSHAFT REMOVAL ................................................................. 10- 6

TRANSMISSION INSPECTION .......................................................... 10- 6

CRANKSHAFT INSPECTION ............................................................. 10- 8

OIL SEAL INSPECTION ..................................................................... 10- 9

OIL SEAL REMOVAL ......................................................................... 10- 9

OIL SEAL INSTALLATION ................................................................. 10-10

BEARING INSPECTION ..................................................................... 10-11

BEARING REMOVAL ......................................................................... 10-12

BEARING INSTALLATION ................................................................. 10-13

CRANKSHAFT INSTALLATION ......................................................... 10-13

TRANSMISSION REASSEMBLY ....................................................... 10-14

CRANKCASE REASSEMBLY ............................................................ 10-15

PRIMARY DRIVE GEAR REASSEMBLY ........................................... 10-16

INSPECTION AFTER INSTALLATION ............................................... 10-16

10

10-2 TRANSMISSION AND CRANKSHAFT

CONSTRUCTION

CRANKSHAFT AND CRANKCASE

70 N·m

(7.0 kgf-m, 50.5 lb-ft)

21 N·m

(2.1 kgf-m,

15.0 lb-ft)

5.5 N·m

(0.55 kgf-m,

4.0 lb-ft)

TRANSMISSION

10 N·m

(1.0 kgf-m,

7.0 lb-ft)

10 N·m

(1.0 kgf-m,

7.0 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

TRANSMISSION AND CRANKSHAFT 10-3

10-4 TRANSMISSION AND CRANKSHAFT

ENGINE BOTTOM SIDE

• Dismount the engine. (



5-4)

NOTE:

The following parts must be removed before disassembling the engine bottom side (crankcase).

• Remove the engine sprocket 1 .

• Remove the gearshift lever. (



9-3)

• Remove the kick starter lever. (



8-3)

• Remove the cylinder head, cylinder and piston. (



6-5)

• Remove the crankcase cover and clutch. (



8-3, 7-3, -4)

• Remove the kick starter idle gear and kick starter shaft.

(



8-3)

• Remove the gearshift linkage. (



9-3)

• Remove the exhaust valve governor. (



6-19)



09900-06107: Snap ring pliers

PRIMARY DRIVE GEAR REMOVAL

• Hold the crankshaft immovable with the special tool.



09930-40113: Rotor holder

• Remove the primary drive gear bolt 1 .

• Remove the washer 2 and primary drive gear 3 .

• Remove the magneto rotor, stator and key. (



13-10)

• Remove the clutch release camshaft. (



7-5)

CRANKCASE SEPARATION

• Remove the engine sprocket spacer 1 and two O-rings 2 .

TRANSMISSION AND CRANKSHAFT 10-5

• Remove the crankcase bolts.

• Separate the crankcase with the special tool.



09920-13120: Crankcase separating tool

NOTE:

* Set the crankcase separating tool to the clutch side of the crankcase.

* Keep all the tool arms parallel to the crankcase surface.

* Separate the crankcase gradually while hitting the crankcase boss and countershaft softly with a plastic hammer.

10-6 TRANSMISSION AND CRANKSHAFT

TRANSMISSION REMOVAL

• Remove the dowel pins 1 and gasket 2 .

• Remove the gearshift fork shafts 3 .

• Remove the gearshift cam 4 .

• Remove the gearshift forks 5 .

• Remove the driveshaft assembly 6 and countershaft assembly 7 .

CRANKSHAFT REMOVAL

• Remove the crankshaft with the special tool.



09920-13120: Crankcase separating tool

NOTE:

Keep all the tool arms parallel to the crankcase surface.

TRANSMISSION INSPECTION

• Inspect the gear teeth, dogs, gearshift grooves and splines for abnormal wear and damage.

• Inspect the gearshift cam groove for abnormal wear and damage.

TRANSMISSION AND CRANKSHAFT 10-7

• Inspect the gearshift forks and shafts for wear and damage.

• Measure the gearshift fork thickness with a vernier calipers.



Gearshift fork thickness

Standard: 4.6 – 4.7 mm (0.181 – 0.185 in)



09900-20101: Vernier calipers

• Measure the gearshift fork groove width with a vernier calipers.



Gearshift fork groove width

Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)



09900-20101: Vernier calipers

• Measure the gearshift fork to groove clearance with a thickness gauge.



Gearshift fork to groove clearance

Service Limit: 0.5 mm (0.020 in)



09900-20803: Thickness gauge

10-8 TRANSMISSION AND CRANKSHAFT

CRANKSHAFT INSPECTION

• Measure the conrod small end inside diameter with the small bore gauge.



Conrod small end I.D.

Service Limit: 23.040 mm (0.907 in)



09900-20605: Dial calipers (10 – 34 mm)

• Measure the conrod deflection with the special tools.



Conrod deflection

Service Limit: 3.0 mm (0.12 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block

• Measure the conrod big end side clearance with the thickness gauge.



Conrod big end side clearance

Service Limit: 1.0 mm (0.04 in)



09900-20803: Thickness gauge

• Measure the crankshaft runout with V-blocks and dial gauge.



Crankshaft runout

Service Limit: 0.05 mm (0.002 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block

NOTE:

* Place the crankshaft onto the V-blocks so that it becomes horizontally.

* Measure the runout from the tips of the crankshaft.

• Measure the crankshaft web to web width with a vernier calipers.



Crankshaft web to web width

Standard: 59.9 – 60.1 mm (2.358 – 2.366 in)



09900-20101: Vernier calipers

OIL SEAL INSPECTION

• Inspect each oil seal lip for wear and damage.

TRANSMISSION AND CRANKSHAFT 10-9

OIL SEAL REMOVAL

• Remove the each oil seal with the special tool.



09913-50121: Oil seal remover

10-10 TRANSMISSION AND CRANKSHAFT

OIL SEAL INSTALLATION

• Fit each new oil seal with the special tools.

• Apply grease to each oil seal lips.



09913-70210: Bearing installer set

Oil seal 1 :



25 Attachment

Oil seal 2 :



40 Attachment

Oil seal 3 :



37 Attachment

Oil seal 4 :



22 Attachment

Oil seal 5 :



42 Attachment



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

NOTE:

Be sure to check the direction of the crankshaft bearing oil seals before fitting them.

OUT

SIDE

Magneto side

Clutch side OUT

SIDE

BEARING INSPECTION

• Inspect the each bearings for play, discoloration, wear and seizure.

• Move the inner race by finger and inspect for smooth movement.

TRANSMISSION AND CRANKSHAFT 10-11

10-12 TRANSMISSION AND CRANKSHAFT

BEARING REMOVAL

• Remove the each bearing retainers.

• Remove the bearings with the special tools.

Bearing 1 , 2 , 3 , 4 , 5 , 6 :



35 Attachment



09913-70210: Bearing remover/installer set

• Remove the bearings 7 , 8 .



09921-20240: Bearing remover set

• Remove the bearing 9 .



09917-50410: Bearing remover

• Remove the bearings 0 , A .



09921-20210: Bearing remover

09930-30104: Sliding shaft

BEARING INSTALLATION

• Press the each bearings with the special tools.

Bearing 1 , 5 :



63 Attachment

Bearing 2 :



52 Attachment

Bearing 3 , 4 :



42 Attachment

Bearing 6 :



55 Attachment

Bearing 7 :



40 Attachment

Bearing 8 :



32 Attachment

Bearing 9 :



22 Attachment

Bearing 0 :



17 Attachment

Bearing A :



15 Attachment



09913-70210: Bearing remover/installer set

NOTE:

* When installing the bearings 1 , 2 , 5 , 6 , 7 , 0 , A the stamped mark on the bearing must face outside.

* When installing the bearings 3 , 4 , 8 , 9 the stamped mark on the bearing must face inside.

• Apply THREAD LOCK SUPER to the shift cam bearing retainer screws.



99000-32030: THREAD LOCK SUPER “1303”

• Tighten the each bearing retainer screws to the specified torque.



Bearing retainer screw: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

TRANSMISSION AND CRANKSHAFT 10-13

CRANKSHAFT INSTALLATION

• Fit the crankshaft into the left crankcase half with the special tool.



09910-32812: Crankshaft installer

09911-11310: Crankshaft installer attachment

NOTE:

Do not hit the crankshaft with a hammer for installation.

10-14 TRANSMISSION AND CRANKSHAFT

TRANSMISSION REASSEMBLY

Install the transmission in the reverse order of removal. Pay attention to the following points:

NOTE:

Seat the snap ring in the groove and locate its end as shown in the illustration.

Thrust

Sharp edge

• Insert the driveshaft and countershaft with gears installed.

• Apply transmission oil to the following parts:

Driveshaft

Transmission gears

Countershaft

Bearings

Gearshift forks

Gearshift cam

Gearshift shafts

• Install the gearshift cam and gearshift forks.

NOTE:

The shape of the gearshift fork for countershaft is different from the others. (



10-7)

• Apply MOLY PASTE to the 5th drive gear.



99000-25140: SUZUKI MOLY PASTE

• Install the gearshift cam 1 and gearshift shafts 2 , 3 .

NOTE:

Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance.

TRANSMISSION AND CRANKSHAFT 10-15

CRANKCASE REASSEMBLY

• Install the new gasket and dowel pins.

• Install the right crankcase half on the left crankcase half.

• Tighten the crankcase bolts.



Crankcase bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

NOTE:

Tighten the bolts gradually and diagonally to guide the crankshaft into the bearing. If it is hard to tighten the bolts, separate the crankcase and confirm that the transmission parts are assembled correctly.

• Inspect the crankshaft, countershaft and driveshaft for smooth movement.

• Apply grease to new O-rings 1 .

• Fit the O-rings 1 and spacer 2 to the driveshaft.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

10-16 TRANSMISSION AND CRANKSHAFT

PRIMARY DRIVE GEAR REASSEMBLY

• Reassemble the clutch release camshaft. (



7-9)

• Reassemble the stator and magneto rotor. (



13-11)

• Install the primary drive gear and washer.

NOTE:

The washer is directional. Assemble the washer 1 as shown in the illustration.

• Hold the magneto rotor with the special tool and tighten the primary drive gear bolt to the specified torque.



09930-40113: Rotor holder



Primary drive gear bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)

• Reassemble the gearshift linkage. (



9-6)

• Reassemble the kick idle gear and kick starter shaft. (



8-5)

• Reassemble the exhaust valve governor. (



6-20)

• Reassemble the clutch and crankcase cover. (



7-7, 8-6)

• Reassemble the piston, cylinder and cylinder head.

(



6-10)

• Reassemble the kick starter lever. (



8-6)

• Reassemble the gearshift lever. (



9-8)

• Reassemble the engine sprocket.

• Remount the engine. (



5-8)

INSPECTION AFTER INSTALLATION

After mounting the engine, inspect the followings.

• Transmission oil level (



2-9)

• Engine coolant level (



2-11)

• Clutch cable play (



2-13)

• Throttle cable play (



2-13)

• Drive chain slack (



2-16)

• Brake pedal height (



2-20)

• Wire harness, cable and hose routing (



18-13 to -16)

FUEL SYSTEM 11-1

FUEL SYSTEM

CONTENTS

CARBURETOR .......................................................................................... 11- 2

CONSTRUCTION ................................................................................ 11- 2

REMOVAL AND DISASSEMBLY ....................................................... 11- 3

CLEANING .......................................................................................... 11- 5

INSPECTION ....................................................................................... 11- 6

REASSEMBLY AND REMOUNTING .................................................. 11- 7

CARBURETOR SOLENOID ...................................................................... 11- 8

REMOVAL AND INSPECTION ........................................................... 11- 8

REASSEMBLY .................................................................................... 11- 8

THROTTLE POSITION SENSOR .............................................................. 11- 9

INSPECTION ....................................................................................... 11- 9

REMOVAL ........................................................................................... 11-10

REED VALVE ............................................................................................ 11-11

CONSTRUCTION ................................................................................ 11-11

REMOVAL ........................................................................................... 11-11

INSPECTION ....................................................................................... 11-12

REASSEMBLY .................................................................................... 11-12

11

11-2 FUEL SYSTEM

CARBURETOR

CONSTRUCTION

REMOVAL AND DISASSEMBLY

• Open the clamp 1 .

• Disconnect the throttle position sensor coupler 2 and carburetor solenoid coupler 3 .

• Turn the fuel cock to OFF and disconnect the fuel hose 4 .

• Loosen the carburetor clamp screws and remove the carburetor.

CAUTION

To prevent dirt from entering the engine, seal the intake pipe after removing the carburetor.

• Remove the carburetor top cap 5 along with the throttle valve assembly.

CAUTION

Do not bend the throttle cable and do not damage the throttle position sensor.

• Drain fuel by removing the drain plug 6 .

• Unhook the throttle cable from the cable holder 7 .

FUEL SYSTEM 11-3

11-4 FUEL SYSTEM

• Remove the cable holder 7 .

• Disassemble the throttle valve assembly as follows.

Carburetor top cap 5

Cable holder 7

Collar spring 8

Collar 9

Clip and jet needle 0

Throttle valve A

Throttle valve collar B

Throttle valve spring C

• Remove the fuel hose 4 .

• Disconnect the air vent hoses A .

• Remove the overflow hoses B and C .

• Remove the float chamber D and hose clamps.

• Remove the following parts.

Float pin E and float F

Needle valve assembly G

Main jet H

Slow jet I

Power jet J

Carburetor solenoid K

Throttle stop screw L and spring

Starter knob M

Air screw N , spring, washer and O-ring

NOTE:

Before removing the air screw N , Turn it clockwise until it lightly seats and record the number of turns.

FUEL SYSTEM 11-5

CLEANING



WARNING

Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage.

• Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

• Clean all passageways of the carburetor thoroughly – not just the perceived problem area. Clean the passageways in the carburetor body with a spray-type cleaner. If necessary, soak carburetor body in a dip-type cleaning solution to loosen dirt and varnish.

Dry the carburetor body using compressed air.

CAUTION

* Do not use a wire to clean the jets or passageways. If wire is used, the jets and passageways may become damaged.

* Replace the removed O-rings with new ones.

11-6 FUEL SYSTEM

INSPECTION

• Inspect the following parts for damage.

Jet needle Screws

Throttle valve

Float

Springs

• Inspect the following parts for clogging.

Main jet Power jet

Slow jet

Hoses

Starter jet

Carburetor body

NEEDLE VALVE

• Inspect the needle valve tip for wear.

• Inspect the needle valve rod for smooth movement.

Good Worn

FLOAT HEIGHT

• Tilt the carburetor until the float arm B just touches the needle valve rod.

• Measure the float height A .



Standard float height: 6.5 mm (0.26 in)



09900-20101: Vernier calipers

• If necessary, slightly bend the float arm B to change the float height.

FUEL SYSTEM 11-7

REASSEMBLY AND REMOUNTING

Reassembly and remounting is in the reverse order of removal and disassembly. Pay attention to the following points:

• Fit the projection of the throttle valve collar into the groove of cable holder.

• Set the throttle position sensor guide roller upon the throttle valve.

• Fit the projection on the carburetor body in the depression of the intake pipe.

• Position the carburetor clamps as shown.

• Rout the cable and hoses properly. (



18-14, -15)

Left Right Left Right

Engine side

45˚

Air cleaner side

11-8 FUEL SYSTEM

CARBURETOR SOLENOID

REMOVAL AND INSPECTION

• Remove the carburetor solenoid 1 . Make sure the coupler 2 is connected.

• Connect the tachometer sensor.

• Shift the transmission into neutral.

• Start the engine.

• Inspect if the solenoid valve switches according to the following engine RPM.

ON position: 2 000 – 3 000, 9 300 – 10 500 r/min

OFF position: Others

If the solenoid valve operation is not correct, inspect the solenoid valve by following procedure.

• Remove the carburetor sorenoid.

• Connect 12 V battery as shown.

• Check if the valve moves each time the circuit is opened and closed.

If the movement is not correct, replace the solenoid valve with a new one.

If the movement is correct, inspect or replace following parts.

CDI unit

Stator coil (



13-9)

Wiring harness for open circuit

Coupler connection

REASSEMBLY

Pay attention to the following point:

• Apply transmission oil to the cross thread of the solenoid and the new O-ring.

CAUTION

Replace the O-ring with a new one.

ON OFF

FUEL SYSTEM 11-9

THROTTLE POSITION SENSOR

INSPECTION

THROTTLE POSITION SENSOR INPUT VOLTAGE

• Disconnect the throttle position sensor coupler 1 .

• Shift the transmission into neutral.

• Start the engine.

• Measure the throttle position sensor input voltage with the multi-circuit tester.



09900-25008: Multi-circuit tester set



Tester knob indication: Voltage (



)



B/G ( + probe) – B/Br ( probe):

4 – 6 V (Over 3 000 r/min)

• If the voltage is not within the specified value, replace the CDI unit.

THROTTLE POSITION SENSOR COIL RESISTANCE

• Remove the seat and fuel tank. (



5-4)

• Measure the throttle position sensor coil resistance with the multi-circuit tester.



09900-25008: Multi-circuit tester set



Tester knob indication: Resistance (

Ω

)



Reference data

B/G ( + probe) – B/Br ( probe): 4 – 6 k

Ω



Reference data

B/Bl ( + probe) – B/Br ( probe):

When the throttle is full closed: 0.3 – 0.75 k

Ω

When the throttle is full opened: 2.5 – 5.0 k

Ω

• If the resistance is correct, it is not necessary to replace the throttle position sensor.

• If the resistance is not within the specified value, replace the throttle position sensor assembly.

B/Bl B/Br B/G

FWD

B/G B/Br B/Bl

11-10 FUEL SYSTEM

REMOVAL

• Remove the carburetor. (



11-3)

• Remove the throttle position sensor using the special tool.



09930-11960: Torx wrench, T20

CAUTION

Do not loosen the bolt A .

FUEL SYSTEM 11-11

REED VALVE

CONSTRUCTION

REMOVAL

• Remove the carburetor. (



11-3)

• Remove the intake pipe 1 .

• Remove the reed valve 2 , spacer 3 and gasket 4 .

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

11-12 FUEL SYSTEM

INSPECTION

• Inspect the reeds for damage.

• Inspect the reed stoppers for damage.

• Inspect the valve seat rubber for damage.

• Inspect the reed valve clearance.



Reed valve clearance

Service limit: 0.2 mm (0.008 in)



09900-20803: Thickness gauge

REASSEMBLY

Reverse the sequence of removal.

• Tighten the intake pipe bolts to the specified torque.



Intake pipe bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

COOLING SYSTEM 12-1

COOLING SYSTEM

CONTENTS

CONSTRUCTION ...................................................................................... 12- 2

COOLING CIRCUIT ................................................................................... 12- 3

INSPECTION ....................................................................................... 12- 3

RADIATOR ................................................................................................ 12- 4

REMOVAL ........................................................................................... 12- 4

INSPECTION ....................................................................................... 12- 4

INSTALLATION ................................................................................... 12- 4

WATER PUMP ........................................................................................... 12- 5

REMOVAL ........................................................................................... 12- 5

INSPECTION ....................................................................................... 12- 6

REASSEMBLY .................................................................................... 12- 7

12

12-2 COOLING SYSTEM

CONSTRUCTION

5.5 N.m

(0.55 kgf-m, 4.0 lb-ft)

10 N.m

(1.0 kgf-m, 7.0 lb-ft)

COOLING CIRCUIT

INSPECTION

• Remove the radiator cap.

• Connect the tester 1 to the filler.



WARNING

Do not remove the radiator cap when the engine is hot.

• Give a pressure of about 120 kPa (1.2 kgf/cm 2 , 17 psi) and see if the system holds this pressure for 10 seconds.

• If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part.



WARNING

When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant.

CAUTION

Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged.

COOLING SYSTEM 12-3

12-4 COOLING SYSTEM

RADIATOR

REMOVAL

• Remove the seat and fuel tank. (



5-4)

• Drain engine coolant. (



2-12)

• Remove the radiator covers 1 . (LH & RH)

• Remove the hoses.

• Remove the radiators.

INSPECTION

RADIATOR

• Visually inspect the radiator for damage.

• Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver.

RADIATOR CAP

• Inspect the radiator cap for function with a radiator cap pressure gauge.



Radiator cap valve release pressure:

95 – 125 kPa (0.95 – 1.25 kgf/cm 2 , 14 – 18 psi)

NOTE:

Apply water to radiator cap seal before fitting the radiator cap to the pressure gauge.

INSTALLATION

Reverse the sequence of removal.

• Rout the radiator hoses correctly. (



18-15, -16)

WATER PUMP

REMOVAL

• Drain engine coolant. (



2-12)

• Drain transmission oil. (



2-10)

• Remove the kick starter lever. (



8-3)

• Remove the brake pedal. (



5-6)

• Disconnect the radiator hose 1 .

• Remove the water pump cover 2 .

• Remove the right crankcase cover and clutch cover.



WARNING

* Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.

* The engine must be cool before servicing the cooling system.

* Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes. If engine coolant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately.

• With the water pump shaft 3 held immovable, remove the water pump impeller 4 .

CAUTION

The impeller has left-hand threads.

COOLING SYSTEM 12-5

12-6 COOLING SYSTEM

INSPECTION

IMPELLER AND GEAR SHAFT

• Inspect the impeller and gear shaft for damage.

WATER PUMP BEARING

Inspect the inner race play of the water pump bearing while it is in the water pump housing. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. If abnormal noise occurs or if rough movement is noted, replace the water pump bearing with a new one.

• Remove the water pump bearing with the special tool.



09921-20240: Bearing remover set

CAUTION

Replace the removed bearing with a new one.

OIL SEAL

Visually inspect the oil seal for damage. If any damages are found, replace the oil seal with a new one.

Play

Play

• Remove the oil seal with the suitable size socket wrench.

CAUTION

Replace the removed oil seal with a new one.

REASSEMBLY

Reassemble the water pump in the reverse order of removal.

Pay attention to the following points:

• Apply THREAD LOCK SUPER to the outer surface of the oil seal.



99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

• Press the oil seal with the suitable size socket wrench.

• Apply grease to the oil seal lip.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install a new bearing with the special tool.



09913-70210: Bearing installer set

NOTE:

When installing the bearing, the stamped mark on the bearing must face outside.

• Hold the water pump shaft with a wrench and tighten the impeller bolt to the specified torque.



Impeller: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

CAUTION

The impeller has left-hand threads.

COOLING SYSTEM 12-7

12-8 COOLING SYSTEM

Apply THREAD LOCK SUPER or equivalent thread lock to outside of the oil seal before installing it.

1

Washer

2

Water pump shaft

3

Water pump driven gear

4

Water pump case

5

Bearing

6

Oil seal

7

Impeller

8

Washer

.

• Install the dowel pins 1 and a new gasket 2 .

CAUTION

Use a new gasket to prevent engine coolant leakage.

• Tighten the crankcase cover bolts to the specified torque.



Crankcase cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

After reinstalling the water pump, check the followings.

• Kick starter lever (



8-6)

• Brake pedal (



2-20, 5-9)

• Transmission oil level (



2-9)

• Engine coolant level (



2-11)

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM 13-1

CONTENTS

CAUTIONS IN SERVICING ....................................................................... 13- 2

CONNECTOR ...................................................................................... 13- 2

COUPLER ........................................................................................... 13- 2

SEMI-CONDUCTOR EQUIPPED PART ............................................. 13- 2

USING THE MULTI-CIRCUIT TESTER .............................................. 13- 2

SWITCH ............................................................................................... 13- 2

LOCATION OF ELECTRICAL COMPONENTS ........................................ 13- 3

CONSTRUCTION ...................................................................................... 13- 4

MAGNETO ROTOR AND STATOR .................................................... 13- 4

ELECTRICAL CIRCUIT ............................................................................. 13- 5

TROUBLESHOOTING (No spark or poor spark) .................................... 13- 5

INSPECTION ............................................................................................. 13- 7

IGNITION SYSTEM PEAK VOLTAGE ................................................ 13- 7

IGNITION COIL ................................................................................... 13- 8

STATOR COIL ..................................................................................... 13- 9

MAGNETO ROTOR AND STATOR .......................................................... 13-10

REMOVAL ........................................................................................... 13-10

INSTALLATION ................................................................................... 13-11

13

13-2 ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTOR

• When connecting a connector, be sure to push it in until a click is felt.

• Inspect the connector for corrosion, contamination and breakage in its cover.

COUPLER

• With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.

• When disconnecting the coupler, be sure to hold the coupler 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.

SEMI-CONDUCTOR EQUIPPED PART

• Be careful not to drop the part with a semi-conductor built in such as a CDI.

• When inspecting this part, follow inspection instruction strictly.

Neglecting proper procedure may cause damage to this part.

USING THE MULTI-CIRCUIT TESTER

• Properly use the multi-circuit tester + and probes.

Improper use can cause damage to the motorcycle and tester.

• If the voltage and current values are not known, begin measuring in the highest range.

• When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.

• After using the tester, be sure to turn the switch to the OFF position.



09900-25008: Multi-circuit tester set



Multi-circuit tester set

Before using the multi-circuit tester, read its instruction manual.

SWITCH

• Never apply grease material to switch contact points to prevent damage.

Click

Click

LOCATION OF ELECTRICAL COMPONENTS

ELECTRICAL SYSTEM 13-3

1 Engine stop switch

2 Ignition coil

3 CDI unit

4 Magneto, pick-up coil

13-4 ELECTRICAL SYSTEM

CONSTRUCTION

MAGNETO ROTOR AND STATOR

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

55 N·m

(5.5 kgf-m, 40.0 lb-ft)

11 N·m

(1.1 kgf-m, 8.0 lb-ft)

ELECTRICAL SYSTEM 13-5

ELECTRICAL CIRCUIT

Magneto

Engine stop switch

Throttle position sensor

B/Br B/G

W/Bl

CDI unit

Ignition coil

Spark plug

Carburetor solenoid

COLOR CODE

B: Black

G: Green

R: Red

Y: Yellow

B/Bl: Black with Blue tracer

B/Br: Black with Brown tracer

B/G: Black with Green tracer

B/R: Black with Red tracer

B/W: Black with White tracer

B/Y: Black with Yellow tracer

Bl/B: Blue with Black tracer

R/W: Red with White tracer

W/Bl: White with Blue tracer

TROUBLESHOOTING (No spark or poor spark)

Step 1

1) Check the ignition system couplers for poor connections.

Is there connection in the ignition system couplers?

YES

NO

Go to Step 2.

Poor connection of couplers

Step 2

1) Measure the peak voltage of ignition coil. (



13-7)

Is the peak voltage OK?

YES

NO

Go to Step 3.

Go to Step 4.

13-6 ELECTRICAL SYSTEM

Step 3

1) Inspect the spark plug. (



2-6)

Is the spark plug OK?

YES

NO

• Poor connection of the spark plug

• Go to Step 4.

Faulty spark plug

Step 4

1) Measure the ignition coil resistanace. (



13-8)

Is the ignition coil resistanace OK?

YES

NO

Go to Step 5.

Faulty ignition coil

Step 5

1) Measure the pick-up coil peak voltage. (



13-7)

Is the peak voltage OK?

YES

NO

Go to Step 7.

Go to Step 6.

Step 6

1) Measure the pick-up coil resistance. (



13-9)

Is the resistance OK?

YES

NO

Go to Step 7.

• Faulty pick-up coil

• Metal particles or foreign material being stuck on the pick-up coil and rotor tip

Step 7

1) Measure the exciter coil and charge coil peak voltages. (



13-7)

Are the peak voltages OK?

YES

NO

• Faulty CDI

• Faulty wire harness

• Faulty engine stop switch

Go to Step 8.

Step 8

1) Measure the exciter coil and charge coil resistance. (



13-9)

Is the exciter coil and charge coil OK?

YES

NO

Faulty CDI

Faulty magneto

ELECTRICAL SYSTEM 13-7

INSPECTION

IGNITION SYSTEM PEAK VOLTAGE

• Remove the seat and fuel tank. (



5-4)

• Remove the spark plug.

• Disconnect the magneto lead wire coupler 1 .

Measure the ignition system peak voltage in the following procedure:

• Connect the multi-circuit tester with the peak volt adaptor as follows. (See table below.)

• Measure the highest peak voltage by depressing the kick starter lever several times forcefully.

Exciter + Black/Red – Red/White 25 V and more

Pick-up

Charge

+ Red – Green

+ Yellow – Black/White

2 V and more

8 V and more



Tester knob indication: Voltage (



)



09900-25008: Multi-circuit tester

• Connect the magneto lead wire coupler and disconnect the ignition coil lead wire coupler 2 .

R/W

G

Y

B/R

B/W R

13-8 ELECTRICAL SYSTEM

• Connect the multi-circuit tester with the peak volt adaptor between Black/White lead wire and White/Blue lead wire.

• Measure the highest peak voltage by depressing the kick starter lever several times forcefully.

Black/White – White/Blue 200 V and more

NOTE:

Be sure to connect the Red probe to the Black/White lead wire and the Black probe to the White/Blue lead wire.

IGNITION COIL

• Remove the seat and fuel tank. (



5-4)

• Remove the ignition coil 1 .

Measure the ignition coil electrical resistance.

Primary

Secondary

White/Blue –

Black/White

Plug cap –

White/Blue

Approx. 0.17 – 0.70

Approx. 13 – 20 k



09900-25008: Multi-circuit tester



Tester knob indication: Resistance ( Ω )

Ω

Ω

W/Bl B/W

ELECTRICAL SYSTEM 13-9

STATOR COIL

• Remove the seat and fuel tank. (



5-4)

• Disconnect the magnet lead wire coupler 1 .

Measure the stator coils electrical resistance with the multi-circuit tester.

Reference data [at 20 °C (68 °F)]

Exciter

Pick-up

Charge

Black/Red – Red/White

Red – Green

Yellow – Black/White

24 – 40 Ω

72 – 127

Ω

1.6 – 2.6 Ω

NOTE:

The resistance of stator varies depending on the temparatare

(stator and atmosphere).



Tester knob indication: Resistance ( Ω )



09900-25008: Multi-circuit tester

R/W

Y

G

B/R

B/W R

13-10 ELECTRICAL SYSTEM

MAGNETO ROTOR AND STATOR

REMOVAL

• Remove the seat. (



5-4)

• Remove the fuel tank. (



5-4)

• Disconnect the magneto lead wire coupler 1 and clamps.

• Remove the magneto cover.

• Remove the magneto rotor nut with the special tool.



09930-40113: Rotor holder

• Remove the magneto rotor with the special tool.



09930-30113: Flywheel rotor remover

NOTE:

Fold the gearshift lever head for turning the special tool handle.

• Remove the stator.

• Remove the key 2 .

INSTALLATION

Install the stator and magneto rotor in the reverse order of removal. Pay attention to the following points:

• Degrease the tapered portion of the crankshaft and magneto rotor.

• Fit the key 1 into the crankshaft.

• Align the line on the stator and line on the crankcase to set the ignition timing correctly.

• Install the stator.



Stator mounting bolts: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

ELECTRICAL SYSTEM 13-11

13-12 ELECTRICAL SYSTEM

• Tighten the magneto rotor nut to the specified torque with the special tool.



Magneto rotor nut: 55 N·m (5.5 kgf-m, 40.0 lb-ft)



09930-40113: Rotor holder

• Fit a new gasket.

• Install the magneto cover.



Magneto cover bolt: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

INSPECTION AFTER INSTALLATION

After installing the stator and magneto rotor, inspect the following.

• Wire harness routing (



18-13)

FRONT AND REAR WHEELS 14-1

FRONT AND REAR WHEELS

CONTENTS

FRONT WHEEL ......................................................................................... 14- 2

CONSTRUCTION ................................................................................ 14- 2

REMOVAL ........................................................................................... 14- 3

INSPECTION ....................................................................................... 14- 3

BEARING REPLACEMENT ................................................................ 14- 4

DISC PLATE REPLACEMENT ........................................................... 14- 5

INSTALLATION ................................................................................... 14- 5

REAR WHEEL ........................................................................................... 14- 6

CONSTRUCTION ................................................................................ 14- 6

REMOVAL ........................................................................................... 14- 7

INSPECTION ....................................................................................... 14- 7

BEARING REPLACEMENT ................................................................ 14- 8

DISC PLATE REPLACEMENT ........................................................... 14- 8

REAR SPROCKET REPLACEMENT ................................................. 14- 9

INSTALLATION ................................................................................... 14- 9

14

14-2 FRONT AND REAR WHEELS

FRONT WHEEL

CONSTRUCTION

35 N.m (3.5 kgf-m, 25.5 lb-ft)

10 N.m (1.0 kgf-m, 7.0 lb-ft)

REMOVAL

• Place the motorcycle on a block to lift front wheel off the ground.

• Remove the axle nut 1 .

• Loosen the left axle holder bolts 2 .

• Loosen the right axle holder bolts 3 .

• Remove the front axle shaft 4 .

• Remove the front wheel and spacers.

INSPECTION

SPACER AND DUST SEAL

• Inspect the left and right wheel spacers and dust seals for wear and cracks.

• If any damage is found, replace the spacer together with the dust seal.

NOTE:

Apply grease to the spacer and dust seal when reassembling.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

AXLE SHAFT

Support the axle shaft with V-blocks and measure the axle shaft runout.



Wheel axle runout

Service limit: 0.25 mm (0.010 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

WHEEL RIM (



2-21)



Wheel rim runout

Service limit: 2.0 mm (0.08 in) ... axial and radial

FRONT AND REAR WHEELS 14-3

14-4 FRONT AND REAR WHEELS

WHEEL BEARING

Inspect the inner race play of the bearings while it is in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. If abnormal noise occurs or if rough movement is noted, replace the bearing with a new one.

BEARING REPLACEMENT

• Remove the dust seals using the special tool.



09913-50121: Oil seal remover

CAUTION

Removed dust seal and bearing must be replaced with a new one.

• Remove the bearings with the special tool.



09921-20240: Bearing remover set

• Remove the spacer.

• Apply grease to the bearings.

• Reassemble the bearings and spacer with the special tool.

• Fit the dust seals and apply grease to their lips.



09924-84521: Bearing installer set



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

NOTE:

* Install the left side (disc side) bearing first and then the right side bearing.

* After installing the bearings, inspect the bearings for smooth movement.

* When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside.

Left

Left

Right

Right

DISC PLATE REPLACEMENT

• Remove the disc plate.

• Apply THREAD LOCK SUPER to the bolts.



99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

• Install a new disc plate and tighten the bolts to the specified torque.



Disc plate bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

INSTALLATION

• Hold the axle shaft with the special tool and tighten the axle nut temporarily.



09940-34581: Attachment (F)

• Remove the block from under the chassis tube and move the front forks up and down several times.

• Tighten the axle nut to the specified torque.



Axle nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft)

• Tighten the left and right axle holder bolts to the specified torque.



Axle holder bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

FRONT AND REAR WHEELS 14-5

14-6 FRONT AND REAR WHEELS

REAR WHEEL

CONSTRUCTION

100 N.m (10.0 kgf-m, 72.5 lb-ft)

10 N.m

1.0 kgf-m

7.0 lb-ft

30 N.m

(3.0 kgf-m, 21.5 lb-ft)

REMOVAL

• Place the motorcycle on a block to lift rear wheel off the ground.

• Remove axle nut 1 and washer 2 .

• Loosen the chain adjuster lock-nuts 3 and chain adjuster bolts 4 .

• Remove the rear axle shaft 5 and chain adjuster washers 6 .

• Remove the rear wheel.

FRONT AND REAR WHEELS 14-7

INSPECTION

SPACER AND DUST SEAL (



14-3)

AXLE SHAFT (



14-3)



Axleshaft runout

Service Limit: 0.25 mm (0.010 in)

WHEEL RIM (



2-21)



Service Limit: 2.0 mm (0.08 in) ... axial and radial

WHEEL BEARING (



14-4)

REAR SPROCKET (



2-17)

14-8 FRONT AND REAR WHEELS

BEARING REPLACEMENT

• Remove the dust seals using the special tool.



09913-50121: Oil seal remover

CAUTION

Removed dust seal and bearing must be replaced with a new one.

• Remove the bearings using the special tool.



09921-20240: Bearing remover set

• Remove the spacer.

• Apply grease to the bearings.

• Reassemble the bearings and spacer with the special tool.

• Fit the dust seals and apply grease to their lips.



09924-84521: Bearing installer set



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

NOTE:

* Install the right side (disc side) bearing first and then the left side bearing.

* After installing the bearings, inspect the bearings for smooth movement.

* When installing the dust seal, place the manufacturer’s code indicated side of the dust seal outside.

DISC PLATE REPLACEMENT

• Remove the disc plate.

• Apply THREAD LOCK SUPER to the bolts.



99000-32110: THREAD LOCK SUPER “1322”

(or equivalent thread lock)

• Tighten the bolts to the specified torque.



Disc plate bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

Left Right

REAR SPROCKET REPLACEMENT

• Remove the rear sprocket.

NOTE:

Install the rear sprocket so the letters on the sprocket surface face outside.

• Tighten the bolts/nuts to the specified torque.



Rear sprocket bolt/nut: 30 N·m (3.0 kgf-m, 21.5 lb-ft)

FRONT AND REAR WHEELS 14-9

INSTALLATION

• Install the chain adjuster washers as shown.

• Adjust the drive chain slack. (



2-16)

• Tighten the axle nut to the specified torque.



Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

Left

FWD

Right

Chain adjuster washer

– MEMO –

FRONT AND REAR BRAKES 15-1

FRONT AND REAR BRAKES

CONTENTS

BRAKE PAD REPLACEMENT .................................................................. 15- 2

FRONT BRAKE PADS ........................................................................ 15- 2

REAR BRAKE PADS .......................................................................... 15- 2

BRAKE FLUID REPLACEMENT ............................................................... 15- 4

BRAKE FLUID AIR BLEEDING ................................................................ 15- 5

BRAKE DISC INSPECTION ...................................................................... 15- 6

FRONT BRAKE ......................................................................................... 15- 7

CONSTRUCTION ................................................................................ 15- 7

CALIPER ............................................................................................. 15- 8

MASTER CYLINDER .......................................................................... 15-11

BRAKE LEVER ................................................................................... 15-13

REAR BRAKE ........................................................................................... 15-14

CONSTRUCTION ................................................................................ 15-14

CALIPER ............................................................................................. 15-15

MASTER CYLINDER .......................................................................... 15-18

BRAKE PEDAL ................................................................................... 15-20

15

15-2 FRONT AND REAR BRAKES

BRAKE PAD REPLACEMENT

FRONT BRAKE PADS

• Remove the plug 1 .

• Remove the pad mounting pin 2 behind the plug.

• Remove the front brake pads.

NOTE:

Replace two pads as a set.

• Fit new brake pads into the caliper and tighten the pad mounting pin to the specified torque.



Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

NOTE:

Pump the brake lever several times to seat the brake pads after reassembling.

REAR BRAKE PADS

• Remove the pad mounting pin 1 .

• Remove the rear brake pads.

NOTE:

Replace two pads as a set.

• Apply SUZUKI SILICONE GREASE to the O-ring.



99000-25100: SUZUKI SILICONE GREASE

• Fit new brake pads into the caliper and tighten the pad mounting pin to the specified torque.



Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

NOTE:

* Pump the brake pedal several times to seat the brake pads after reassembling.

* Inspect not to pinch the O-ring of brake pad pin.

FRONT AND REAR BRAKES 15-3

15-4 FRONT AND REAR BRAKES

BRAKE FLUID REPLACEMENT



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful if swallowed or if it comes in contact with skin or eyes.

Keep brake fluid away from children or pets. Call doctor immediately if brake fluid is swallowed and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any brake fluid when servicing brake fluid. Wipe spilled fluid up immediately.

• Suck up the old brake fluid as much as possible.

• Pour fresh brake fluid into the reservoir.



Specification and classification: DOT 4

NOTE:

Replenish brake fluid up to the UPPER line before the brake fluid level drops below LOWER line.

• Connect a transparent tube to the air bleeder valve and set the other end into a receptacle.

• Loosen the air bleeder valve and pump the brake lever

(pedal) until new brake fluid comes out from the air bleeder valve.

• Tighten the air bleeder valve.



Air bleeder valve: 6 N·m (0.6 kgf-m, 4.4 lb-ft)

• Bleed air from the brake system. (



15-5)

BRAKE FLUID AIR BLEEDING

• Connect a transparent tube to the air bleeder valve and set the other end into a receptacle.

• Pour brake fluid up to the UPPER line.



Specification and classification: DOT 4

• Pump the brake lever (pedal) several times.

FRONT AND REAR BRAKES 15-5

• Hold the brake lever (pedal) in squeezing position then open the air bleeder valve.

• Close the air bleeder valve and release the brake lever

(pedal).

NOTE:

* Do not release the brake lever (pedal) while the air bleeder valve is opened.

* Replenish brake fluid up to the UPPER line before the brake fluid level drops below LOWER line.

• Repeat this sequence until air bubble is no longer squeezed out from the brake system.

• Tighten the air bleeder valve.



Air bleeder valve: 6 N·m (0.6 kgf-m, 4.4 lb-ft)

• Pour brake fluid up to the UPPER line.

15-6 FRONT AND REAR BRAKES

BRAKE DISC INSPECTION

• Measure the front and rear brake disc thickness.



Brake disc thickness

Service limit (Front): 2.5 mm (0.10 in)

(Rear): 3.5 mm (0.14 in)



09900-20205: Micrometer (0 – 25 mm)

• Measure the front and rear brake disc runout.



Brake disc runout

Service limit: 0.3 mm (0.012 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

FRONT BRAKE

CONSTRUCTION

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

FRONT AND REAR BRAKES 15-7

23 N·m

(2.3 kgf-m,

16.5 lb-ft)

23 N·m

(2.3 kgf-m,

16.5 lb-ft)

26 N·m

(2.6 kgf-m, 19.0 lb-ft)

23 N·m (2.3 kgf-m, 16.5 lb-ft)

6 N·m

(0.6 kgf-m, 4.4 lb-ft)

18 N·m

(1.8 kgf-m, 13.0 lb-ft)

23 N·m

(2.3 kgf-m,

16.5 lb-ft)

15-8 FRONT AND REAR BRAKES

CALIPER



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any brake fluid when servicing brake fluid. Wipe spilled fluid up immediately.

REMOVAL AND DISASSEMBLY

• Drain brake fluid. (



15-4)

• Place a rag under the hose to catch spilled brake fluid.

• Remove the brake hose union bolt 1 .

• Remove the caliper mounting bolt 2 .

• Remove the brake pads. (



15-2)

• Remove the caliper bracket from the caliper.

• Remove the boots and spring.

• Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out.

• Apply low-pressure air into the caliper through the hole to remove the pistons.



WARNING

Fingers can get caught between piston and caliper body when removing the piston.

Do not place your fingers on the piston when removing the piston.

• Remove the pistons 3 , the dust seals 4 and piston seals 5 .

FRONT AND REAR BRAKES 15-9

INSPECTION

• Inspect the caliper cylinder for scuffing.

• Inspect the caliper piston for scuffing.

CLEANING

• Flush the caliper ports with pressurized air.

• Wash the caliper piston and cylinder with fresh brake fluid.



Specification and classification: DOT 4

NOTE:

Do not use gasoline or other cleaning solvents to wash the caliper parts.

15-10 FRONT AND REAR BRAKES

REASSEMBLY AND INSTALLATION

Reassemble and remount the brake caliper in the reverse order of removal. Pay attention to the following points:

• Replace the piston seals and dust seals with new ones.

• Apply brake fluid to the piston seals, dust seals and pistons.

• Apply SUZUKI SILICONE GREASE to the caliper axles.

• Fit the caliper bracket and pad springs.



99000-25100: SUZUKI SILICONE GREASE

• Fit the brake pads.

• Tighten the brake pad mounting bolt temporarily.

• Tighten the caliper mounting bolts 1 to the specified torque.



Brake caliper mounting bolt:

26 N·m (2.6 kgf-m, 19.0 lb-ft)

• Tighten the brake pad mounting pin 2 to the specified torque.



Brake pad mounting pin: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

• Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 3 to the specified torque.



Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Refill brake fluid and bleed air from the brake system.

(



15-5)

MASTER CYLINDER



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any brake fluid when servicing brake fluid. Wipe spilled fluid up immediately.

REMOVAL AND DISASSEMBLY

• Drain brake fluid.

• Place a rag under the hose to catch spilled brake fluid.

• Remove the brake hose union bolt 1 .

• Remove the master cylinder holder bolts.

NOTE:

Mark the paint mark to the matching surface of master cylinder holder and handlebars.

• Remove the boot.

• Remove the brake lever.

• Remove the reservoir cap and diaphragm.

FRONT AND REAR BRAKES 15-11

15-12 FRONT AND REAR BRAKES

• Remove the dust boot 2 .

• Remove the snap ring 3 using the snap ring pliers.

• Remove the washer 4 and piston/cup set 5 .



09900-06106: Snap ring pliers

INSPECTION

• Inspect the cylinder for scuffing.

• Inspect the piston/cup and spring for damage.

CLEANING

• Flush the master cylinder ports with pressurized air.

• Wash the master cylinder bore and piston with fresh brake fluid.



Specification and classification: DOT 4

NOTE:

Do not use gasoline or other cleaning solvents to wash the master cylinder parts.

REASSEMBLY AND INSTALLATION

Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points:

• Install the brake lever. (



15-13)

• Align the master cylinder holder mating surface A with the paint mark B on the handlebar.

• Tighten the master cylinder mounting bolts to the specified torque.



Master cylinder mounting bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

NOTE:

Tighten the upper bolt first.

Handlebars

Master cylinder holder

Clearance

Master cylinder

• Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 1 to the specified torque.



Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Refill brake fluid and bleed air from the brake system.

(



15-5)

BRAKE LEVER

REMOVAL

• Remove the brake lever.

• Remove the brake lever adjuster return spring 1 .



09930-11960: Torx wrench, T20

FRONT AND REAR BRAKES 15-13

INSTALLATION

• Apply grease to the brake lever adjuster return spring, pivot bolt and contact point between piston and brake lever.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Tighten the pivot bolt and pivot nut to the specified torque.



Pivot bolt: 6 N·m (0.6 kgf-m, 4.4 lb-ft)

Pivot nut: 6 N·m (0.6 kgf-m, 4.4 lb-ft)

15-14 FRONT AND REAR BRAKES

REAR BRAKE

CONSTRUCTION

29 N·m

(2.9 kgf-m, 21.0 lb-ft)

23 N·m

(2.3 kgf-m,

16.5 lb-ft)

23 N·m

(2.3 kgf-m,

16.5 lb-ft)

10 N·m

(1.0 kgf-m, 7.0 lb-ft)

28 N·m

(2.8 kgf-m,

20.0 lb-ft)

18 N·m

(1.8 kgf-m, 13.0 lb-ft)

18 N·m

(1.8 kgf-m,

13.0 lb-ft)

6 N·m

(0.6 kgf-m, 4.4 lb-ft)

13 N·m

(1.3 kgf-m, 9.5 lb-ft)

CALIPER



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any brake fluid when servicing brake fluid. Wipe spilled fluid up immediately.

REMOVAL AND DISASSEMBLY

• Place a block under the chassis tubes.

• Remove the rear wheel. (



14-7)

• Drain brake fluid.

• Remove the caliper protector 1 and disc cover 2 .

• Place a rag under the hose to catch spilled brake fluid.

• Remove the brake hose union bolt 3 .

• Remove the caliper.

FRONT AND REAR BRAKES 15-15

15-16 FRONT AND REAR BRAKES

• Remove the brake pads. (



15-2)

• Remove the caliper bracket from the caliper.

• Remove the boots and springs.

• Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out.

• Apply low-pressure air into the caliper through the hole to remove the piston.



WARNING

Fingers can get caught between piston and caliper body when removing the piston.

Do not place your fingers on the piston when removing the piston.

• Remove the piston, dust seal and piston seal.

INSPECTION

• Inspect the caliper cylinder for scuffing.

• Inspect the caliper piston for scuffing.

CLEANING

• Flush the caliper ports with pressurized air.

• Wash the caliper piston and cylinder with fresh brake fluid.



Specification and classification: DOT 4

NOTE:

Do not use gasoline or other cleaning solvents to wash the caliper parts.

REASSEMBLY AND INSTALLATION

Reassemble and remount the brake caliper in the reverse order of removal. Pay attention to the following points:

• Replace the piston seal and dust seal with new ones.

• Apply brake fluid to the piston seal, dust seal and piston.

• Apply SUZUKI SILICONE GREASE to the caliper axles.



99000-25100: SUZUKI SILICONE GREASE

• Fit the brake pads.

• Tighten the brake pad mounting bolt temporarily. (



15-3)

• Tighten the brake pad mounting bolt 1 to the specified torque.



Brake pad mounting bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

NOTE:

Inspect not to pinch the O-ring of brake pad pin.

• Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 2 to the specified torque.



Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Refill brake fluid and bleed air from the brake system.

(



15-5)

• Adjust the drive chain slack. (



2-16)

FRONT AND REAR BRAKES 15-17

15-18 FRONT AND REAR BRAKES

MASTER CYLINDER



WARNING

Brake fluid can be hazardous to humans and pets.

Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with your skin or eyes.

Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed and induce vomiting. Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin.

The use of any fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Use only DOT 4 brake fluid from sealed container.

Never use or mix different types of brake fluid.

CAUTION

Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any brake fluid when servicing brake fluid. Wipe spilled fluid up immediately.

REMOVAL AND DISASSEMBLY

• Drain brake fluid.

• Remove the master cylinder mounting bolts.

• Place a rag under the hose to catch spilled brake fluid.

• Remove the brake hose union bolt 1 .

• Remove the reservoir cap and diaphragm.

• Strip the dust seal boot 2 and unsnap the snap ring 3 .

• Remove the push rod assembly 4 .

• Remove the piston/cup set 5 .



09900-06106: Snap ring pliers

INSPECTION

• Inspect the cylinder for scuffing.

• Inspect the piston/cup and spring for damage.

CLEANING

• Flush the master cylinder ports with pressurized air.

• Wash the master cylinder bore and piston with fresh brake fluid.



Specification and classification: DOT 4

NOTE:

Do not use gasoline or other cleaning solvents to wash the master cylinder parts.

FRONT AND REAR BRAKES 15-19

15-20 FRONT AND REAR BRAKES

REASSEMBLY AND INSTALLATION

Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points:

• Set the brake hose end between the hose stopper, then tighten the brake hose union bolt 1 to the specified torque.



Brake hose union bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the master cylinder mounting bolts 2 to the specified torque.



Master cylinder mounting bolt:

10 N·m (1.0 kgf-m, 7.0 lb-ft)

CAUTION

Improper brake hose routing can damage the brake hose.

Set the brake hose so it touches the stopper then tighten the union bolt. Ensure the brake hose has enough clearance to the rear suspension spring.

• Refill brake fluid and bleed air from the brake system.

(



15-5)

• Check the brake pedal height. (



2-20)

BRAKE PEDAL

REMOVAL

• Remove the cotter pin 1 and brake pedal pivot bolt.

• Remove the return spring.

• Remove the cotter pin 2 , washer and pin.

INSTALLATION

• Fit the return spring properly. (



5-9)

• Apply grease to the brake pedal pivot bolt.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Tighten the brake pedal pivot bolt to the specified torque.



Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lb-ft)

• Install new cotter pins.

• Adjust the brake pedal height. (



2-20)

FRONT FORK AND STEERING 16-1

FRONT FORK AND STEERING

CONTENTS

FRONT FORK ............................................................................................ 16- 2

CONSTRUCTION ................................................................................ 16- 2

REMOVAL ........................................................................................... 16- 3

DISASSEMBLY ................................................................................... 16- 4

INSPECTION ....................................................................................... 16- 8

REASSEMBLY .................................................................................... 16-10

INSTALLATION ................................................................................... 16-16

HANDLEBAR CONTROLS ....................................................................... 16-17

CONSTRUCTION ................................................................................ 16-17

REMOVAL ........................................................................................... 16-17

REMOUNTING .................................................................................... 16-18

STEERING ................................................................................................. 16-21

CONSTRUCTION ................................................................................ 16-21

REMOVAL ........................................................................................... 16-22

INSPECTION ....................................................................................... 16-23

BEARING REPLACEMENT ................................................................ 16-23

INSTALLATION ................................................................................... 16-24

16

16-2 FRONT FORK AND STEERING

FRONT FORK

CONSTRUCTION

30 N.m (3.0 kgf-m, 21.5 lb-ft)

35 N.m (3.5 kgf-m, 25.5 lb-ft)

22 N.m

(2.2 kgf-m,

16.0 lb-ft)

18 N.m

(1.8 kgf-m,

13.0 lb-ft)

70 N.m

(7.0 kgf-m, 50.5 lb-ft)

REMOVAL

• Place a block under the chassis tubes.

• Remove the front wheel. (



14-3)

• Remove the handlebars. (



16-18)

• Remove the fork protectors, brake hose guide and brake hose clamp.

• Remove the front brake caliper. (



15-8)

• Loosen the front fork cap bolt 1 – 2 turns to facilitate later disassembly.



09941-53630: Front fork top cap wrench

• Loosen the front fork upper clamp bolts 1 .

• Hold the fork body and loosen the fork lower clamp bolts 2 .

• Remove the front fork.

FRONT FORK AND STEERING 16-3

16-4 FRONT FORK AND STEERING

DISASSEMBLY

• Set rebound and compression damper settings to the minimum settings (softest) before disassembling. Record the setting before turning the adjuster.

• Thoroughly clean the fork before disassembly.

CAUTION

Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.

Avoid scratching or damaging the inner tube or the oil seal. Use a mild detergent or car wash soap and sponge out dirt with plenty of water.

• Clamp the outer tube with a vise. Protect the outer tube surface using a rag.

• Loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube.



09941-53630: Front fork top cap wrench



WARNING

Clamping the outer tube too tight can damage it which will affect riding stability.

Do not clamp the outer tube too tight.

• Place a drain pan under the front fork and drain fork oil.

NOTE:

Face the oil hole A on the sub-tank downward.

• Raise the outer tube and temporarily tighten the fork cap bolt

1 (sub-tank) to the outer tube.

• Clamp the axle holder 2 with a vise. Protect the axle holder surface using a rag.

• Loosen the center bolt 3 completely with a 21 mm socket wrench.



WARNING

Clamping the axle holder too tight can damage it which will affect riding stability.

Do not clamp the axle holder too tight.

• Compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom 2 and lock-nut 4 .



09910-20115: Conrod holder

• Hold the lock-nut with a wrench and remove the center bolt.

FRONT FORK AND STEERING 16-5

• Remove the push rod.

16-6 FRONT FORK AND STEERING

• With the outer tube compressed by hands, remove the special tool.

CAUTION

Removing the lock-nut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal.

Do not remove the lock-nut 4 from the inner rod.

• Loosen the fork cap bolt 1 (sub-tank) and remove the subtank 5 along with the damper rod assembly 6 .

• Remove the fork spring 7 .

CAUTION

Disassembling the damper rod assembly can lead to trouble.

Do not disassemble the damper rod assembly.

Do not separate the sub-tank and damper rod assembly.

• Remove the dust seal 8 and the stopper ring 9 .

CAUTION

Scratches on the inner tube could cause oil leaks.

Avoid scratching when removing.

INNER TUBE

• Separate the inner tube out of the outer tube.

• Remove the slide bushing from the inner tube.

• Remove the following parts from the inner tube.

Guide bushing 1

Seal retainer 2

Oil seal 3

Stopper ring 4

Dust seal 5

• Clamp the bottom (flat part) of the sub-tank with a monkey wrench.

CAUTION

Do not clamp the sub-tank too tight.

• Loosen the compression damper unit.

FRONT FORK AND STEERING 16-7

16-8 FRONT FORK AND STEERING

• Remove the compression damper unit from the sub-tank.

NOTE:

Slowly compress the inner rod until it stops so that the compression damper unit can be removed easily.

• Drain the fork oil from the damper rod assembly by moving the inner rod several strokes.

INSPECTION

CENTER BOLT

• Inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one.

• Replace the O-ring with a new one.

COMPRESSION DAMPER UNIT

• Inspect the compression damper unit for damage. If it is damaged, replace it with a new one.

• Replace the O-ring with a new one.

CAUTION

Disassembling the compression damper unit can lead to trouble.

Do not disassemble the compression damper unit.

INNER TUBE AND OUTER TUBE

• Inspect the inner tube for scratches. If it has scratches, replace it with a new one.

• Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one.

• Measure the inner tube runout using the V-blocks and dial gauge.



Inner tube runout

Service Limit: 0.4 mm (0.02 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block

DAMPER ROD

• Inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one.

FORK SPRING

• Measure the free length of front fork spring.



Service Limit: 487 mm (19.17 in)

FRONT FORK AND STEERING 16-9

16-10 FRONT FORK AND STEERING

SLIDE BUSHING AND GUIDE BUSHING

Inspect the “teflon coating metals” (slide bushing and guide bushing) for wear or damage. If they are worn or damaged, replace them with new ones.

Inspect the metal particles on the “teflon coating metals”. If they are not clean, clean them with a nylon brush and fork oil.

REASSEMBLY

NOTE:

* Clean all fork parts before reassembling.

* Replace the O-rings, oil seal and dust seal with the new ones.

* Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and other sliding parts.

INNER TUBE

• Apply front fork oil to the oil seal lip and the dust seal.

• Cover the inner tube with a plastic film.

• Install the following parts to the inner tube:

New dust seal 1

Stopper ring 2

New oil seal 3

CAUTION

Scratches on the oil seal lip can cause oil leaks.

When installing the seals, place a plastic film over the bushing attachment groove and edges of the inner tube to avoid damaging the seals’ lip.

NOTE:

The side of the oil seal that has a mark should face the dust seal.

• Remove the plastic film and install the seal retainer 4 , guide bushing 5 and slide bushing 6 .

• Clean the parts and keep them free from dust.

NOTE:

Inspect the bushings for burrs. If there is a burr, remove it with a knife, taking care not to peel off the teflon coating. If the bushings have a large crack or excessive play after installing them, replace them with new ones.

• Insert the inner tube into the outer tube.

• Install the new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen.



09940-52861: Front fork oil seal installer set

• Attach the stopper ring securely to the stopper ring groove of the outer tube.

• Attach the dust seal 1 .

NOTE:

After attaching the dust seal, make sure that there are no cracks around the circumference of the seal. Cracks could allow water, mud and the like to enter and cause an oil leak.

CAUTION

Use of grease as a substitute fork oil when installing the oil seal can result in an oil leak. Applying grease to the dust seal and oil seal can cause dirt to accumulate and damage the dust seal lip and oil seal lip.

Use only a thin coat of fork oil on the oil seal.

COMPRESSION DAMPER UNIT

• Clean each threaded part before installing.

FRONT FORK AND STEERING 16-11

• With the damper rod in fully extended position, pour the specified amount of fork oil.



Fork oil quantity (Inside the damper rod):

193 ml (6.52/6.80 US/lmp oz)



99000-99001-SS5: SUZUKI FORK OIL SS-05

(or equivalent fork oil)

16-12 FRONT FORK AND STEERING

• Apply fork oil to the O-rings and bushing on the compression damper unit.

• With the damper rod held immovable in fully extended position, gently install the compression damper unit to the subtank.

• Clamp the bottom (flat part) of the sub-tank with a monkey wrench.

CAUTION

Do not clamp the sub-tank too tight.

• Tighten the compression damper unit 1 to the specified torque.



Compression damper unit: 30 N·m (3.0 kgf-m, 21.5 lb-ft)

• With the damper rod held in vertical position, slowly move the inner rod several strokes.

• Tighten the lock-nut by hand completely.

100 mm

(3.9 in)

• With the damper rod held in vertical position, compress the damper rod fully to discharge an excess of oil.

CAUTION

Protect the inner rod end with a rag when compressing the damper rod.

NOTE:

Set the compression damper setting to the softest.

• Force out the remaining oil (discharged oil) using compressed air completely.

FRONT FORK AND STEERING 16-13

• With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly.

If the inner rod is not extend, repeat the “COMPRESSION

DAMPER UNIT” procedures (Pour the specified amount fork oil and discharge an excess of oil). (



16-11)

• Make sure approx. 10 mm (0.39 in) of inner rod thread is exposed on the end.

100 mm

(3.9 in)

Approx.10 mm

(0.39 in)

Lock-nut

• Completely wipe off the fork oil from the spring and damper rod assembly.

• Insert the spring and damper rod assembly into the fork.

• Temporarily tighten the fork cap bolt (sub-tank).



09941-53630: Front fork top cap wrench

16-14 FRONT FORK AND STEERING

• Clamp the axle holder with a vise. Protect the axle holder with a rag when using a vise.



WARNING

Clamping the axle holder too tight can damage it which will affect riding stability.

Do not clamp the axle holder too tight.

• Compress the outer tube by hands and install the conrod holder (special tool) between the axle holder bottom and locknut.



09910-20115: Conrod holder

• Insert the push rod into the inner rod.

• Insert the rod.

shaped projection of center bolt into the push

• Slowly turn the center bolt clockwise until resistance is felt and check the clearance between the lock-nut and center bolt to provide 1 mm (0.04 in) and more.

• Turn the lock-nut counterclockwise until it contacts with the center bolt.

• With the lock-nut held immovable using a wrench, tighten the lock-nut/center bolt to the specified torque.



Lock-nut/center bolt: 22 N·m (2.2 kgf-m, 16.0 lb-ft)

• With the outer tube compressed by hands, remove the special tool.

• Tighten the center bolt to the specified torque.



Center bolt: 70 N·m (7.0 kgf-m, 50.5 lb-ft)

• Loosen and remove the fork cap bolt (sub-tank) from the outer tube and slowly slide down the outer tube.



09941-53630: Front fork top cap wrench

• Pour the specified amount of fork oil into the outer tube.



Oil quantity (When standard fork spring is used):

350 ml (11.83/12.32 US/lmp oz)



99000-99001-SS5: SUZUKI FORK OIL SS-05

(or equivalent fork oil)

• Raise the outer tube and temporarily tighten the fork cap bolt

(sub-tank).



09941-53630: Front fork top cap wrench

FRONT FORK AND STEERING 16-15

16-16 FRONT FORK AND STEERING

INSTALLATION

• Install the front fork with the line T aligned with the upper surface of the upper bracket.

• Check that the air valve A is positioned at the front.

• Tighten the fork lower clamp bolts to the specified torque.



Fork lower clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the fork upper clamp bolts to the specified torque.



Fork upper clamp bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)

• Tighten the fork cap bolt (sub-tank) to the specified torque.



09941-53630 : Front fork top cap wrench



Fork cap bolt: 35 N·m (3.5 kgf-m, 25.5 lb-ft)

• Install the handlebars. (



16-19)

• Install the front wheel. (



14-5)

• Install the brake caliper. (



15-10)

INSPECTION AFTER INSTALLATION

• Front fork (



2-20)

• Steering (



2-20)

• Wire, cable and hose routing (



18-13, -14)

FRONT FORK AND STEERING 16-17

HANDLEBAR CONTROLS

CONSTRUCTION

Adhesive agent

25 N·m

(2.5 kgf-m, 18.0 lb-ft)

Adhesive agent

6 N·m

(0.6 kgf-m, 4.4 lb-ft)

6 N·m

(0.6 kgf-m, 4.4 lb-ft)

REMOVAL

• Place the motorcycle on a block to lift front wheel off the ground.

• Remove the front number plate. (



5-2)

• Remove the protector 1 .

• Remove the clamps.

• Remove the clutch lever.

• Remove the engine stop switch 2 .

• Remove the left handle grip 3 .

NOTE:

Mark the paint mark to the matching surface of clutch lever holder and handlebars, left handle grip and handlebars before removing.

16-18 FRONT FORK AND STEERING

• Remove the front brake master cylinder.

NOTE:

Mark the paint mark to the matching surface of master cylinder holder and handlebars before removing.

• Remove the throttle assembly mounting bolts.

NOTE:

Mark the paint mark to the matching surface of throttle holder and handlebars before removing.

• Remove the handlebar holder bolts and remove the handlebars.

NOTE:

Mark the paint mark to the matching surface of handlebar holder and handlebars before removing.

REMOUNTING

Remounting is in the reverse order of removal. Pay attention to the following points:

• Apply adhesive agent to the handlebar left end and left grip inner wall.

HANDLE GRIP BOND (Commercial available)

Adhesive agent

Handlebars

Adhesive agent

• Align the “ ” mark on the left grip with the paint mark A on the handlebars.

FRONT FORK AND STEERING 16-19

• Set the “ ” mark B on the handlebar holder forward.

• Align the paint mark C on the handlebars with the matching surface of the handlebar holder.

• Tighten the handlebar holder bolts to the specified torque.



Handlebar holder bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

NOTE:

When tightening the handlebar holder bolts, first tighten the bolts

1 then bolts 2 .

Clearance

FWD

• Rout the cables and hose correctly. (



18-13, -14, -17)

• Apply grease to the throttle cable.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Install the throttle grip so the “ ” mark on it aligns with the hole throttle cable end hooked.

Throttle holder

Throttle spool

Throttle grip

• Align the throttle holder mating surface with the paint mark D on the handlebars.

16-20 FRONT FORK AND STEERING

• Align the master cylinder holder mating surface with the paint mark E on the handlebars.

• Align the clutch lever holder mating surface with the paint mark F on the handlebars.

STEERING

CONSTRUCTION

FRONT FORK AND STEERING 16-21

25 N.m

(2.5 kgf-m, 18.0 lb-ft)

100 N.m

(10.0 kgf-m, 72.5 lb-ft)

23 N.m (2.3 kgf-m, 16.5 lb-ft)

23 N.m (2.3 kgf-m, 16.5 lb-ft)

16-22 FRONT FORK AND STEERING

REMOVAL

• Place a block under the chassis tubes.

• Remove the front wheel. (



14-3)

• Remove the handlebars. (



16-18)

• Remove the fork protectors, brake hose guide and brake hose clamp.

• Remove the front brake caliper. (



15-8)

• Remove the front forks. (



16-3)

• Remove the front fender.

• Remove the steering stem head nut.

• Remove the steering stem upper bracket 1 .

• Remove the steering nut 2 with the special tools.



09940-14911: Steering nut wrench

09940-14960: Steering nut socket wrench

• Remove the steering stem lower bracket 3 .

• Remove the dust seal 4 .

• Remove the upper needle bearing 5 .

INSPECTION

STEERING STEM

• Inspect the needle bearings for wear.

• Inspect the steering stem for distortion.

BEARING OUTER RACES

• Inspect the bearing outer races for wear.

BEARING REPLACEMENT

• Remove the lower bearing.

NOTE:

Replace the outer race and bearing as a set.

• Fit the lower bearing with the special tools.



09925-18011: Steering bearing installer

FRONT FORK AND STEERING 16-23

16-24 FRONT FORK AND STEERING

• Remove the upper and lower outer races with the special tools.



09941-54911: Bearing outer race remover

09941-74911: Steering bearing installer

• Fit the upper and lower outer races with the special tools.



09941-34513: Steering race installer

09924-84510: Bearing installer set

INSTALLATION

Installation is in the reverse order of removal. Pay attention to the following points:

• Apply grease to the bearings.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Tighten the steering stem nut using the special tools.



09940-14911: Steering nut wrench

09940-14960: Steering nut socket wrench



Steering stem nut: 45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Move the steering stem right and left several times to seat the bearings.

• Turn back the steering stem nut by 1/4 to 1/2 turn.

• Fit the steering stem head nut and tighten it temporarily.

• Remount the front forks. (



16-16)

• Tighten the steering stem head nut to the specified torque.



Steering stem head nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

• Remount the handlebars. (



16-19)

INSPECTION AFTER INSTALLATION

• Front fork (



2-20)

• Steering (



2-20)

• Wire, cable and hose routing (



18-13, -14, -17)

FRONT FORK AND STEERING 16-25

– MEMO –

REAR SUSPENSION 17-1

REAR SUSPENSION

CONTENTS

REAR SHOCK ABSORBER ...................................................................... 17- 2

CONSTRUCTION ................................................................................ 17- 2

REMOVAL ........................................................................................... 17- 2

INSPECTION ....................................................................................... 17- 3

SPRING REPLACEMENT ................................................................... 17- 3

BEARING REPLACEMENT ................................................................ 17- 4

OIL REPLACEMENT ........................................................................... 17- 5

DISASSEMBLY AND INSPECTION ................................................... 17- 9

REASSEMBLY .................................................................................... 17-10

INSTALLATION ................................................................................... 17-11

DISPOSAL ........................................................................................... 17-11

SWINGARM ............................................................................................... 17-12

CONSTRUCTION ................................................................................ 17-12

REMOVAL AND DISASSEMBLY ....................................................... 17-12

INSPECTION ....................................................................................... 17-14

BEARING REPLACEMENT ................................................................ 17-15

INSTALLATION ................................................................................... 17-15

REAR SUSPENSION LINKAGE ............................................................... 17-16

CONSTRUCTION ................................................................................ 17-16

REMOVAL AND DISASSEMBLY ....................................................... 17-16

INSPECTION ....................................................................................... 17-17

BEARING REPLACEMENT ................................................................ 17-17

REASSEMBLY .................................................................................... 17-18

17

17-2 REAR SUSPENSION

REAR SHOCK ABSORBER

CONSTRUCTION

55 N.m

(5.5 kgf-m, 40.0 lb-ft)

REMOVAL

• Place a block under chassis tubes.

• Remove the silencer and rear frame assembly. (



4-17)

• Remove the rear shock absorber upper mounting bolt and nut.

• Remove the rear shock absorber lower mounting bolt and nut.

• Remove the rear shock absorber.

NOTE:

If necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal.

55 N.m

(5.5 kgf-m,

40.0 lb-ft)

INSPECTION

• Inspect the rear shock absorber for oil leakage.

• Inspect the damper rod for bends and smooth movement.

• Inspect the bump rubber for deterioration and damage.

• Inspect the spacers and dust seals for damage.

• Inspect the bearing for excessive play and smooth movement.

SPRING REPLACEMENT

• Loosen the lock-nut 1 using the special tool and turn it to the end of the thread.

• Turn the adjuster 2 as well as the lock-nut 1 .



09910-60611: Universal clamp wrench

• Depress the spring seat 3 and remove the stopper ring 4 .

• Remove the spring seat 3 and the spring 5 from the rear shock absorber.

NOTE:

Install the spring as painted side A or small diameter side is bottom.

• Fit the lock-nut, adjuster, spring, spring seat and stopper ring.

REAR SUSPENSION 17-3

17-4 REAR SUSPENSION

• Adjust the spring set length and tighten the lock-nut.



Standard spring set length:

4.1 mm (0.161 in) compressed from the free length

Spring set length adjustable range:

245 – 263 mm (9.646 –10.354 in) a : Standard spring set length b : Spring free length



Shock absorber lock-nut: 43 N·m (4.3 kgf-m, 31.0 lb-ft)

BEARING REPLACEMENT

• Remove the spacers.

• Remove the needle roller bearings 1 .

• Remove the dust seals 2 .

• Remove the needle roller bearing cage 3 with the special tool.



09921-20240: Bearing remover set

• Press the bearing cage with the special tool and suitable size socket wrench.

NOTE:

Position the bearing by refering to the illustration of page 17-19.



09924-84521: Bearing installer set

• Install the dust seals.

NOTE:

When installing the dust seal, the stamped mark on the dust seal must face inside.

• Apply grease to the needle roller bearings and install them.

• Apply grease to the dust seals and spacers.

• Install the spacers A and B .

A for right side

B for left side



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

OIL REPLACEMENT

TOOLS AND EQUIPMENT

• Following tools and equipment are required to perform oil replacement.

REAR SUSPENSION 17-5

250

1 Screwdriver or small punch

2 Vise*

3 Drain pan

4 Oil can

5 Beaker

6 Specified shock absorber oil

* Not Shown in the illustration

7 Rags

8 Nitrogen tank

9 Filler hose and nozzle

0 Regulator assembly

A Owner’s service manual

OIL REPLACEMENT PROCEDURE

• Remove the rear shock absorber unit from the frame (



17-2), clean and dry it.

• Remove the spring from the rear shock absorber unit.

(



17-3)

NOTE:

Inspect the rear shock absorber unit for oil leakage.

Turn the rebound damping force adjuster screw counterclockwise until it stops so that the rear suspension oil can be poured easily.

17-6 REAR SUSPENSION

• Remove the valve cap. Press the valve with a screwdriver to bleed out nitrogen gas.



WARNING

Releasing high pressure gas from the rear shock absorber unit can be hazardous.

Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit. When releasing the gas pressure, place a rag over the gas valve and use the tip of a screwdriver etc. to press the valve. Do not use your finger to depress the gas valve, and direct the valve away from your face and body.

• Remove the compression adjuster assembly 1 from the rear shock absorber.

• Place a drain pan under the rear shock absorber unit.

• Move the rod and drain the oil completely.

• Push the valve core again to equalize the bladder to atmospheric pressure.

• Pour the fresh specified rear suspension oil as shown while moving the rod.

NOTE:

Be sure to extend the rod after filling the oil.

99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25

(or equivalent rear suspension oil)

• Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank.

• Cover the compression adjuster hole with the root of thumb.

• Tilt and shake the rear shock absorber unit to fill the reservoir tank with the oil.

• Add the oil and repeat the above procedure until the reservoir tank is filled with the oil completely.



Oil capacity:

Approx. 380 ml (12.84/13.38 US/Imp oz)

• Replace the O-rings on the compression adjuster assembly with new ones.

REAR SUSPENSION 17-7

17-8 REAR SUSPENSION

• Reinstall the compression adjuster assembly 1 .



Compression adjuster assembly:

30 N·m (3.0 kgf-m, 21.5 lb-ft)

• Fill the rear shock absorber unit with nitrogen gas to 981 kPa

(9.8 kgf/cm 2 , 139.5 psi).

• Tighten the gas valve cap.

• Reinstall the spring. (



17-3)



WARNING

Use of flammable gas for pressuring the rear shock absorber unit can be hazardous. Flammable gas such as gas welding oxygen can cause a fire hazard.

Use nitrogen gas. If nitrogen gas is not available, compressed air free from water can be substituted.



WARNING

Applying too much pressure to the rear shock absorber unit may rupture the rear shock absorber unit.

Be sure to fill the rear shock absorber unit to the specified pressure.

CAUTION

Riding the motorcycle with abnormal gas pressure can damage the rear shock absorber unit. Low gas pressure can result in oil leakage. Abnormal gas pressure cannot provide normal rear shock absorber unit performance.

Be sure to fill the rear shock absorber unit to the specified pressure.

DISASSEMBLY AND INSPECTION

• Clean and dry the rear shock absorber.

• Remove the spring from the rear shock absorber. (



17-3)

• Turn the rebound damping force adjuster to the softest position.

• Bleed out nitrogen gas. (



17-6)

• Remove the compression adjuster assembly and drain oil.

(



17-6)

• Vise the rear shock absorber unit in inverted position.

• Depress the bump rubber fully to protect the damper rod.

• Evenly hammer the stopper 1 with a screwdriver or equivalent and remove it from the rear shock absorber body.

• Depress the seal case 2 with a screwdriver until the circlip 3 is fully exposed.

• Remove the circlip 4 .

NOTE:

Do not scratch the inner surface of the shock absorber body to avoid oil leaks.

REAR SUSPENSION 17-9

17-10 REAR SUSPENSION

• Extract the damper rod assembly from the shock absorber body.

• Inspect the oil seal and O-rings.

• Inspect the damper rod for bends and scratches.

• Inspect the “teflon coating metal” on the piston.

• Inspect the inner surface of the body for wear.

• Replace O-rings with new ones.

• Replace the “teflon coating metal” by cutting off the old one and putting a new one onto the piston if necessary.

REASSEMBLY

• Apply rear suspension oil to the O-rings and “teflon coating metal”.

• Insert the damper rod assembly 1 and fit a new circlip 2 .

• Pull up the damper rod assembly 1 until it is stopped by the circlip 2 .

• Fit the stopper to the shock absorber body.

• Fill the specified rear suspension oil in the rear shock absorber. (



17-6)

99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25

(or equivalent rear suspension oil)



Oil capacity:

Approx. 380 ml (12.84/13.38 US/Imp oz)

• Pressure the rear shock absorber unit with nitrogen gas to

981 kPa (9.8 kgf/cm 2 , 139.5 psi). (



17-8)

• Reassemble the spring and adjust the spring set length.

(



17-3)

INSTALLATION

Install the rear shock absorber in the reverse order of removal.

Pay attention to the following points:

• Tighten the rear shock absorber lower mounting bolt and nut to the specified torque.

NOTE:

If necessary, move the swingarm up or down to facilitate this mounting bolt/nut tightening.



Rear shock absorber lower mounting nut:

55 N·m (5.5 kgf-m, 40.0 lb-ft)

• Tighten the upper mounting bolt and nut to the specified torque.



Rear shock absorber upper mounting nut:

55 N·m (5.5 kgf-m, 40.0 lb-ft)

DISPOSAL

High pressure nitrogen gas is sealed in the rear shock absorber unit. Be sure to release gas before disposing the rear shock absorber unit.

• Remove the valve cap.

• Press the valve with a screwdriver.



WARNING

Releasing high pressure gas from the rear shock absorber unit can be hazardous.

Place a rag over the valve and push the valve with a screwdriver to release nitrogen gas. Do not use your finger to push the valve, and direct the valve away from your face and body.

REAR SUSPENSION 17-11

17-12 REAR SUSPENSION

SWINGARM

CONSTRUCTION

REMOVAL AND DISASSEMBLY

• Place a block under chassis tubes.

• Remove the rear wheel. (



14-7)

• Remove the chain guide.

• Remove the rear brake hose guide.

• Remove the rear brake caliper from the swingarm.

70 N.m

(7.0 kgf-m, 50.5 lb-ft)

• Remove the rear cushion lever bolt and nut.

• Remove the brake pedal. (



5-6)

• Remove the swingarm pivot nut and shaft.

• Remove the swingarm.

• Remove the chain buffer.

• Remove the following parts from the swingarm.

Spacer 1

Dust seal 2

Washer 3

Thrust bearing 4

Dust seal 5

Spacer 6

REAR SUSPENSION 17-13

17-14 REAR SUSPENSION

INSPECTION

PIVOT SHAFT

• Measure the pivot shaft runout with the dial gauge and Vblocks.



Swingarm pivot shaft runout

Service Limit: 0.3 mm (0.01 in)



09900-20607: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

CHAIN BUFFER AND CHAIN GUIDE

• Inspect the chain buffer and chain guide for damage and excessive wear.

SWINGARM

• Inspect the swingarm for cracks and damage.

BEARING, SPACER, DUST SEAL

• Inspect the bearings, spacers and dust seals for damage.

• Insert the spacers into the bearings and inspect them for play and smooth movement.

BEARING REPLACEMENT

• Remove the bearing using the special tool.



09921-20240: Bearing remover set

• Apply grease to new bearings.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Press the bearing with the special tool.



09924-84521: Bearing installer set

INSTALLATION

Reassemble and remount the swingarm in the reverse order of removal and disassembly. Pay attention to the following points:

• Apply grease to the spacers, dust seals and bearings.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Tighten the swingarm pivot shaft nut to the specified torque.



Swingarm pivot nut: 70 N·m (7.0 kgf-m, 50.5 lb-ft)

• Tighten the rear cushion lever nut to the specified torque.



Rear cushion lever nut: 80 N·m (8.0 kgf-m, 58.0 lb-ft)

• Install the brake pedal. (



5-9)

• Adjust the drive chain slack. (



2-16)

REAR SUSPENSION 17-15

17-16 REAR SUSPENSION

REAR SUSPENSION LINKAGE

CONSTRUCTION

80 N.m

(8.0 kgf-m,

58.0 lb-ft)

80 N.m

(8.0 kgf-m,

58.0 lb-ft)

80 N.m

(8.0 kgf-m,

58.0 lb-ft)

REMOVAL AND DISASSEMBLY

• Place a block under chassis tubes.

• Remove the lower drive chain control roller 1 .

• Remove the rear cushion rod bolt and nut.

• Remove the cushion lever bolt and nut.

• Remove the shock absorber lower bolt and nut.

• Remove the cushion rod from the cushion lever.

INSPECTION

• Inspect the cushion rod and cushion lever for damage.

• Inspect the dust seals and spacers for damage.

• Insert the spacers into the bearings and inspect them for excessive play and smooth movement.

BEARING REPLACEMENT

• Remove the spacers and dust seals.

• Remove the needle roller bearings.

REAR SUSPENSION 17-17

17-18 REAR SUSPENSION

• Remove the needle roller bearing cage 1 with the special tool.



09921-20240: Bearing remover set

• Apply grease to the bearings.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Press fit the bearing cage with the special tool.



09913-70210: Bearing installer set

• Apply grease to the bearings.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

• Press fit the bearing cage with the special tool and a suitable size socket wrench.



09924-84521: Bearing installer set

NOTE:

Position the bearings by refering to the illustration of page 17-

19.

REASSEMBLY

Reassemble and remount the rear suspension linkage in the reverse order of removal and disassembly. Pay attention to the following points:

• Position the dust seals 1 so that the manufacturer’s code indicated side of the seals face outside. ( 2 : inside)

• Apply grease to the spacers and dust seals.



99000-25010: SUZUKI SUPER GREASE “A”

(or equivalent grease)

REAR SUSPENSION 17-19

• Tighten the cushion lever, cushion rod and swingarm nuts to the specified torque.

Left

5 mm

Right



Tightening torque:

A : 55 N·m (5.5 kgf-m, 40.0 lb-ft)

B : 55 N·m (5.5 kgf-m, 40.0 lb-ft)

C : 80 N·m (8.0 kgf-m, 58.0 lb-ft)

D : 80 N·m (8.0 kgf-m, 58.0 lb-ft)

E : 80 N·m (8.0 kgf-m, 58.0 lb-ft)

F : 70 N·m (7.0 kgf-m, 50.5 lb-ft)

4 mm

4 mm

4 mm

17-20 REAR SUSPENSION

Left Right

CAUTION

Improperly reassembled rear suspension linkage bolts can interfere with suspension movement and damage the rear suspension linkage.

* Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side.

* Insert the rear suspension linkage bolt 1 from the left side. Make sure that the nut B is in the recess of the rear shock absorber bottom bracket.

• Install the lower drive chain roller. (



5-3)

SERVICING INFORMATION 18-1

SERVICING INFORMATION

CONTENTS

SERVICE DATA ......................................................................................... 18- 2

TIGHTENING TORQUE ............................................................................. 18- 8

SPECIAL TOOLS ...................................................................................... 18-10

WIRING DIAGRAM .................................................................................... 18-12

WIRE, CABLE AND HOSE ROUTING ...................................................... 18-13

WIRE HARNESS ROUTING ............................................................... 18-13

CABLE ROUTING ............................................................................... 18-14

CARBURETOR HOSE AND WATER HOSE ROUTING .................... 18-15

BRAKE PEDAL SET-UP ..................................................................... 18-16

FRONT BRAKE HOSE ROUTING ...................................................... 18-17

REAR BRAKE HOSE ROUTING ........................................................ 18-18

HANDLEBAR SET-UP .............................................................................. 18-19

MUFFLER SET-UP .................................................................................... 18-20

SPECIFICATIONS ..................................................................................... 18-21

SPARE PARTS .......................................................................................... 18-23

OPTIONAL PARTS .................................................................................... 18-23

SETTING DATA ......................................................................................... 18-24

18

18-2 SERVICING INFORMATION

SERVICE DATA

CYLINDER + PISTON + PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

Piston diam.

STD/SPEC.

0.045 – 0.055 mm

(0.0018 – 0.0022 in)

66.400 – 66.415 mm

(2.6142 – 2.6148 in)

Measure 20 mm (0.79 in) from the top surface.

66.350 – 66.365 mm

(2.6122 – 2.6128 in)

Measure 19 mm (0.75 in) from the skirt end.

Cylinder distortion

—

Cylinder head distortion

—

Piston ring free end gap

Piston ring end gap

1st & 2nd R Approx. 8.2 mm (0.32 in)

Piston ring to groove clearance

Piston pin bore

Piston pin O.D.

1st & 2nd

1st & 2nd

0.30 – 0.45 mm

(0.012 – 0.018 in)

0.02 – 0.06 mm

(0.0008 – 0.0024 in)

18.002 – 18.008 mm

(0.7087 – 0.7090 in)

17.995 – 18.000 mm

(0.7085 – 0.7087 in)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Crank web to web width

Crankshaft runout

STD/SPEC.

23.003 – 23.011 mm

(0.9056 – 0.9059 in)

—

0.1 – 0.8 mm

(0.0039 – 0.0315 in)

59.9 – 60.1 mm

(2.358 – 2.366 in)

—

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

STD/SPEC.

10 – 15 mm

(0.4 – 0.6 in)

3.07 – 3.23 mm

(0.121 – 0.127 in)

13.85 – 13.95 mm

(0.545 – 0.549 in)

—

51.94 mm

(2.04 in)

LIMIT

0.120 mm

(0.0047 in)

Nicks or scratches

66.280 mm

(2.6100 in)

0.05 mm

(0.002 in)

0.05 mm

(0.002 in)

6.6 mm

(0.26 in)

0.80 mm

(0.031 in)

—

18.030 mm

(0.7098 in)

17.980 mm

(0.7079 in)

LIMIT

23.040 mm

(0.9071 in)

3.0 mm

(0.12 in)

1.0 mm

(0.04 in)

—

0.05 mm

(0.002 in)

LIMIT

—

2.77 mm

(0.109 in)

13.35 mm

(0.514 in)

0.10 mm

(0.004 in)

49.4 mm

(1.94 in)

SERVICING INFORMATION 18-3

RADIATOR + COOLANT

ITEM

Radiator cap valve release pressure

Engine coolant type

Engine coolant capacity

STD/SPEC.

95 – 125 kPa

(0.95 – 1.25 kgf/cm 2 , 14 – 18 psi)

Use a anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: 50.

1 100 ml

(1.2/1.0 US/Imp qt)

LIMIT

—

—

—

TRANSMISSION + DRIVE CHAIN

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

No.1, 2 & 3

No.1, 2 & 3

Shift fork thickness

Drive chain

No.1, 2 & 3

Type

Links

20-pitch length

STD/SPEC.

3.000 (63/21)

3.846 (50/13)

1.800 (27/15)

1.470 (25/17)

1.210 (23/19)

1.000 (21/21)

0.869 (20/23)

0.1 – 0.3 mm

(0.004 – 0.012 in)

4.8 – 4.9 mm

(0.189 – 0.193 in)

4.6 – 4.7 mm

(0.181 – 0.185 in)

DID 520DMA2

114 links

—

Drive chain slack

Gearshift lever height

40 – 50 mm

(1.6 – 2.0 in)

0 – 5 mm below

(0 – 0.2 in)

CARBURETOR

Carburetor type

Bore size

ITEM

I.D. No.

Float height

Main jet

Jet needle

Cut-away

Slow jet

Air screw

Power jet

Throttle cable play

(M.J.)

(J.N.)

(C.A.)

(S.J.)

(A.S.)

(PW.J.)

STD/SPEC.

KEIHIN PWK38S

39 mm (1.54 in)

37FB

6.5 mm (0.26 in)

#172

NEDH-4th

#7

#50

1 turn out

#55

2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip

LIMIT

—

—

—

—

—

—

—

0.5 mm

(0.020 in)

—

—

—

—

323.8 mm

(12.75 in)

—

—

18-4 SERVICING INFORMATION

ELECTRICAL

Ignition timing

Spark plug

ITEM

Pick-up coil resistance

(Reference data)

Pick-up coil peak voltage

Exciter coil resistance

(Reference data)

Exciter coil peak voltage

Charge coil resistance

(Reference data)

Charge coil peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

BRAKE

ITEM

Rear brake pedal height

Brake disc thickness

Type

Gap

STD/SPEC.

BTDC 4.5° at 1 000 r/min

NGK: BR8EG

0.5 – 0.6 mm

(0.020 – 0.024 in)

72 – 127

Ω at 20 °C (68 °F)

2 V and more

24 – 40

Ω at 20 °C (68 °F)

Primary

Secondary

25 V and more

1.6 – 2.6 Ω at 20 °C (68 °F)

8 V and more

0.17 – 0.70

Ω

13 – 20 k Ω

200 V and more

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front &

Rear

Front

Rear

STD/SPEC.

0 – 10 mm below

(0 – 0.39 in)

2.8 – 3.2 mm

(0.11 – 0.13 in)

3.8 – 4.2 mm

(0.15 – 0.17 in)

—

11.000 – 11.043 mm

(0.4331 – 0.4348 in)

12.700 – 12.743 mm

(0.5000 – 0.5017 in)

10.957 – 10.984 mm

(0.4314 – 0.4324 in)

12.657 – 12.684 mm

(0.4983 – 0.4994 in)

27.000 – 27.050 mm

(1.0630 – 1.0650 in)

27.000 – 27.050 mm

(1.0630 – 1.0650 in)

26.930 – 26.950 mm

(1.0602 – 1.0610 in)

26.918 – 26.968 mm

(1.0598 – 1.0617 in)

DOT 4

NOTE

R – G

+ R – - G

B/R – R/W

+ B/R – - R/W

Y – B/W

+ Y – B/W

W/Bl – B/W

Plug cap – W/Bl

+ B/W – - W/Bl

LIMIT

—

2.5 mm

(0.10 in)

3.5 mm

(0.14 in)

0.3 mm

(0.012 in)

—

—

—

—

—

—

—

—

WHEEL

ITEM

Wheel rim runout

Wheel rim size

Wheel axle runout

TIRE

ITEM

Cold inflation tire pressure

Tire size

Tire type

Tire tread depth

(Recommend depth)

SERVICING INFORMATION 18-5

Axial

Radial

Front

Rear

Front

Rear

STD/SPEC.

—

—

21 × 1.60

19 × 2.15

—

—

LIMIT

2.0 mm

(0.08 in)

2.0 mm

(0.08 in)

—

—

0.25 mm

(0.010 in)

0.25 mm

(0.010 in)

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STD/SPEC.

70 – 110 kPa

(0.7 – 1.1 kgf/cm 2 , 10 – 16 psi)

70 – 110 kPa

(0.7 – 1.1 kgf/cm 2 , 10 – 16 psi)

80/100-21 51M

110/90-19 62M

BRIDGESTONE MOTOCROSS-M59

BRIDGESTONE MOTOCROSS-M70

—

—

LIMIT

—

—

—

—

—

—

4.0 mm (0.16 in)

4.0 mm (0.16 in)

18-6 SERVICING INFORMATION

SUSPENSION

ITEM

Front fork stroke

Inner tube outside diam.

Front fork spring free length

Front fork spring rate

Front fork oil type

Front fork oil capacity (each leg)

Front fork damping force adjuster

Front fork air pressure

Rear shock absorber gas pressure

Rear shock absorber oil type

Rear shock absorber oil capacity

Rear shock absorber spring set length

Rear shock absorber spring rate

Rear shock absorber damping force adjuster

Rear wheel travel

Swingarm pivot shaft runout

STD/SPEC.

310 mm

(12.2 in)

47 mm

(1.85 in)

494 mm

(19.45 in)

4.4 N/mm

(0.44 kgf/mm)

SUZUKI FORK OIL SS-05 or equivalent fork oil

OUTER: 350 ml (11.83/12.32 US/Imp oz)

INNER: 193 ml (6.52/6.80 US/Imp oz)

Compression

Rebound

8 clicks turn back

11 clicks turn back

0 kPa (0 kgf/cm 2 , 0 psi)

981 kPa

(9.8 kgf/cm 2 , 139.5 psi)

SUZUKI REAR SUSPENSION OIL SS-25 or equivalent rear suspension oil

380 ml (12.84/13.38 US/Imp oz)

4.1 mm (0.161 in) compressed from the free length

Rebound

Compression

(High speed)

53 N/mm

(5.3 kgf/mm)

11 clicks turn back

2 turns back

Compression

(Low speed)

9 clicks turn back

310 mm

(12.2 in)

—

—

—

—

—

—

—

LIMIT

—

—

487 mm

(19.17 in)

—

—

—

—

—

—

—

—

—

0.3 mm

(0.01 in)

SERVICING INFORMATION 18-7

FUEL + OIL

Fuel type

ITEM

Fuel tank capacity

Engine oil type

Air cleaner element oil type

Fuel and engine oil mixture ratio

Transmission oil type

Transmission oil capacity

STD/SPEC.

Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2 method).

Use only unleaded gasoline of at least 95 octane.

(Research method)

8.0 L

(2.1/1.8 US/Imp gal)

MOTUL 800 2T FACTORY LINE OFF ROAD or equivalent Two Cycle Racing Lubricant

MOTUL AIR FILTER OIL or equivalent filter oil

30:1

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change

Overhaul

750 ml

(0.8/0.7 US/Imp qt)

850 ml

(0.9/0.7 US/Imp qt)

NOTE

For Canada

For other countries

18-8 SERVICING INFORMATION

TIGHTENING TORQUE

ENGINE

PART

Cylinder head nuts

Magneto rotor nut

Cylinder nuts

Clutch sleeve hub nut

Crankcase bolt

Primary drive gear bolt

Gearshift cam bolt

Gearshift pawl lifter screw

Exhaust valve shaft arm bolt

Kick starter lever bolt

Spark plug

Oil level chek bolt

Oil drain plug

Water pump drain bolt

Engine mounting bracket nuts (front and upper)

Engine mounting nuts (front and upper)

Engine mounting nut (lower)

CHASSIS

PART

Handlebar holder set nut

Handlebar holder bolts

Front fork clamp bolts (upper and lower)

Steering stem head nut

Front fork cap bolts

Front fork center bolt

Compression damper unit

Master cylinder mounting bolt (front & rear)

Master cylinder rod lock-nut (rear)

Brake hose union bolts (front and rear)

Brake pad mounting pin (front and rear)

Brake caliper mounting bolts (front)

Brake caliper axle bolt (rear)

Brake bleeder bolt (front and rear)

Disc plate bolt (front and rear)

Brake pedal pivot bolt (rear)

Front axle holder bolts

Front axle nut

Rear axle nut

Rear sprocket nuts

Drive chain control roller bolt

Rear swingarm pivot nut (engine mounting)

Rear shock absorber mounting nuts (upper and lower)

Rear cushion lever nut (upper and lower)

30

31

70

55

80

28

6

10

29

18

35

100

18

23

18

26

35

70

30

10

N·m

15

25

23

100

70

23.5

10

4

23

20

5.5

N·m

25

55

38

90

11

21

5.5

43

45

55

20.0

4.4

7.0

21.0

13.0

25.5

72.5

21.5

22.5

50.5

40.0

58.0

lb-ft

11.0

18.0

16.5

72.5

25.5

50.5

21.5

7.0

13.0

16.5

13.0

19.0

50.5

17.0

7.0

3.0

16.5

14.5

4.0

lb-ft

18.0

40.0

27.5

65.0

8.0

15.0

4.0

31.0

32.5

40.0

3.0

3.1

7.0

5.5

8.0

2.8

0.6

1.0

2.9

1.8

3.5

10.0

kgf-m

1.5

2.5

2.3

10.0

1.8

2.3

1.8

2.6

3.5

7.0

3.0

1.0

kgf-m

2.5

5.5

3.8

9.0

1.1

7.0

2.35

1.0

0.4

2.3

2.0

0.55

2.1

0.55

4.3

4.5

5.5

SERVICING INFORMATION 18-9

Rear cushion rod nut

Spoke nipple

Seat rail nut (upper)

Seat rail bolt (lower)

Brake lever pivot bolt

Brake lever pivot nut

PART N·m

80

4

23

23

6

6 kgf-m

8.0

0.4

2.3

2.3

0.6

0.6

TIGHTENING TORQUE CHART

For other bolts and nuts not listed in the table, refer to this chart.

Conventional or “4” marked bolt Bolt

Diameter A

(mm)

4

5

6

8

10

12

14

16

18

N·m

1.5

3

5.5

13

29

45

65

105

160 kgf-m

0.15

0.3

0.55

1.3

2.9

4.5

6.5

10.5

16.0

lb-ft

1.0

2.0

4.0

9.5

21.0

32.5

47.0

76.0

115.5

“7” marked or crown headed bolt

N·m kgf-m lb-ft

2.3

4.5

10

23

50

85

135

210

240

0.23

0.45

1.0

2.3

5.0

8.5

13.5

21.0

24.0

1.5

3.0

7.0

16.5

36.0

61.5

97.5

152.0

173.5

lb-ft

58.0

3.0

16.5

16.5

4.4

4.4

Conventional bolt “4” marked bolt

“7” marked bolt

18-10 SERVICING INFORMATION

SPECIAL TOOLS

09900-06106

Snap ring plier

09900-06107

Snap ring plier

09900-20101

Vernier calipers

(150 mm)

09900-20203

Micrometer

(50 – 75 mm)

09900-20205

Micrometer

(0 – 25 mm)

09900-20508

Cylinder gauge set

09900-20602

Dial gauge

(1/1 000 mm)

09900-20605

Dial caliper (1/100 mm, 10 – 34 mm)

09900-20607

Dial gauge

(1/100 mm)

09900-20701

Magnetic stand

09900-20803

Thickness gauge

09900-21304

V-block set (100 mm)

09900-25008

Multi-circuit tester set

09910-20115

Conrod holder

09910-32812

Crankshaft installer

09911-11310

Attachment

09910-34510

Piston pin puller

09910-60611

Universal clamp wrench

09913-50121

Oil seal remover

09913-70210

Bearing remover/installer set

09917-50410

Bearing remover

09920-13120

Crankcase separating tool

09920-20310

Spring hook

09920-53740

Clutch sleeve hub holder

09921-20210

Bearing remover

09921-20240

Bearing remover set

SERVICING INFORMATION 18-11

09924-84510

Bearing installer set

09924-84521

Bearing installer set

09925-18011

Steering bearing installer

09930-11960

Torx wrench, T20

09930-30104

Sliding shfaft

09930-30113

Flywheel rotor remover

09930-40113

Rotor holder

09940-14911

Steering nut wrench

09940-14960

Steering nut socket wrench

09940-34581

Attachment F

09940-52861

Front fork oil seal installer set

09941-34513

Steering race installer

09941-53630

Front fork top cap wrench

09941-54911

Bearing outer race remover

09941-74911

Steering bearing installer

18-12 SERVICING INFORMATION

WIRING DIAGRAM

CDI UNIT

IGNITION COIL

CARBURETOR

SOLENOID

ENGINE

STOP

SWITCH

RUN

OFF

: Pickup

coil

MAGNETO

THROTTLE

POSITION

SENSOR

WIRE COLOR

B: Black

G: Green

O: Orange

R: Red

Y: Yellow

B/Bl: Black with Blue tracer

B/Br: Black with Brown tracer

B/R: Black with Red tracer

B/W: Black with White tracer

B/Y: Black with Yellow tracer

Bl/B: Blue with Black tracer

R/W: Red with White tracer

W/Bl: White with Blue tracer

WIRE, CABLE AND HOSE ROUTING

WIRE HARNESS ROUTING

FRONT

SERVICING INFORMATION 18-13

18-14 SERVICING INFORMATION

CABLE ROUTING

CARBURETOR HOSE AND WATER HOSE ROUTING

SERVICING INFORMATION 18-15

18-16 SERVICING INFORMATION

Avoid contact between the clamp and cables.

60

90

˚

0 90˚

BRAKE PEDAL SET-UP

A

A

SECT AA

Protector

10 mm

(0.4 in)

SERVICING INFORMATION 18-17

FRONT BRAKE HOSE ROUTING

Front brake master cylinder

Washer

Hose guide

Front brake hose

Set the brake hose end between the hose stopper, then tighten the brake hose union bolt to the specified torque.

Front brake hose

Clamp

Clamp the upper difference portion in brake hose diameter.

Front fork protector

Caliper Washer

After touching the brake hose union to the stopper, tighten the union bolt to the specified torque.

18-18 SERVICING INFORMATION

REAR BRAKE HOSE ROUTING

SERVICING INFORMATION 18-19

HANDLEBAR SET-UP

When the movement is felt heavier, clean this and apply grease.

Adjustable range

Quick adjuster

Install the throttle grip so the “ ”mark on it aligns with the hole throttle cable end hooked.

Upper side

15˚

Adjuster

Do not apply grease to the rubber covers.

Fit the cover positively.

Align the throttle holder mating surface with the paint mark on the handlebars.

30˚

Upper side

Align the “ ” mark on the left grip with the paint mark on the handlebars.

121 mm (4.8 in)

Apply adhesive to inner of grip and handlebars.

190 mm (7.5 in)

Upper side

Align the clutch lever holder mating surface with the paint mark on the handlebars.

Align the master cylinder holder mating surface with the paint mark on the handlebars.

36 mm (1.4 in)

175 mm (6.9 in)

Upper side

Position of magic tape : rearward

Align the paint mark on the handlebars with the mating surface of the left handlebar holder.

18-20 SERVICING INFORMATION

MUFFLER SET-UP

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................

2 170 mm (85.4 in)

Overall width........................................................

830 mm (32.7 in)

Overall height .....................................................

1 280 mm (50.4 in)

Wheelbase ..........................................................

1 465 mm (57.7 in)

Ground clearance................................................

350 mm (13.8 in)

Seat height ..........................................................

950 mm (37.4 in)

Dry mass .............................................................

96 kg (212 lbs)

ENGINE

Type.....................................................................

Two-stroke, liquid-cooled

Intake system ......................................................

Piston reed valve

Number of cylinders ............................................

1

Bore.....................................................................

66.4 mm (2.614 in)

Stroke ..................................................................

72.0 mm (2.834 in)

Piston displacement ............................................

249 cm 3 (15.2 cu. in)

Corrected compression ratio ...............................

8.6 : 1 (EX VALVE OPEN)

10.4 : 1 (EX VALVE CLOSE)

Carburetor ...........................................................

KEIHIN PWK38S, single

Air cleaner ...........................................................

Polyurethane foam element

Starter system .....................................................

Primary kick

Lubrication system ..............................................

Fuel/oil premixture of 30 : 1

TRANSMISSION

Clutch ..................................................................

Wet multi-plate type

Transmission .......................................................

5-speed constant mesh

Gearshift pattern .................................................

1-down, 4-up

Primary reduction ................................................

3.000 (63/21)

Final reduction.....................................................

3.846 (50/13)

Gear ratios, Low .................................................

1.800 (27/15)

2nd ..................................................

1.470 (25/17)

3rd...................................................

1.210 (23/19)

4th ...................................................

1.000 (21/21)

5th ...................................................

0.869 (20/23)

Drive chain ..........................................................

D.I.D. 520DMA2, 114 links

SERVICING INFORMATION 18-21

18-22 SERVICING INFORMATION

CHASSIS

Front suspension ................................................. Telescopic, pneumatic/coil spring, oil damped

Rear suspension .................................................. Link type

Steering angle...................................................... 45° (right & left)

Caster .................................................................. 27° 30’

Trail ...................................................................... 115 mm (4.53 in)

Turning radius ...................................................... 2.3 m (7.5 ft)

Front brake........................................................... Disc brake

Rear brake ........................................................... Disc brake

Front tire size ....................................................... 80/100-21 51M

Rear tire size........................................................ 110/90-19 62M

Front fork stroke ................................................... 310 mm (12.2 in)

Rear wheel travel ................................................. 310 mm (12.2 in)

ELECTRICAL

Ignition type.......................................................... Electronic Ignition (CDI)

Ignition timing....................................................... 4.5° B.T.D.C. at 1 000 r/min

Spark plug............................................................ NGK BR8EG

CAPACITIES

Fuel tank .............................................................. 8.0 L (2.1/1.8 US/Imp gal)

Transmission oil, oil change ................................ 750 ml (0.8/0.7 US/Imp qt) overhaul ................................... 850 ml (0.9/0.7 US/Imp qt)

Coolant................................................................. 1 100 ml (1.2/1.0 US/Imp qt)

SERVICING INFORMATION 18-23

SPARE PARTS

0

A

A -A

A -B

B

C

6

7

8

9

ITEM

1

1

2

3

4

5

G

H

I

D

E

F

PART NAME

PARTS SET, SPARE

O-RING, CYLINDER HEAD NO. 1

O-RING, CYLINDER HEAD NO. 2

GASKET, CYLINDER COVER, NO. 1

GASKET, CYLINDER COVER, NO. 2

GASKET, CYLINDER COVER, NO. 3

GASKET, CYLINDER

GASKET, CRANKCASE

GASKET, CLUTCH COVER

GASKET, MAGNETO COVER

O-RING, CLUTCH COVER OUTER

PISTON COMP

PISTON

PIN, KNOCK

RING, PISTON

PIN, PISTON

O-RING, EXHAUST PIPE

LEVER, BRAKE

LEVER, CLUTCH

BEARING, PISTON PIN

O-RING, SPROCKET SPACER

CIRCLIP, PISTON PIN

OPTIONAL PARTS

REAR SPROCKET

PARTS No.

64511-37E00

64511-28E00

64511-36E00

64511-40261

FRONT WHEEL RIM

FRONT WHEEL

SPOKE SET

FRONT BRAKE DISC

COVER

BEAD STOPPER

55311-37F00

55320-37F20

59231-36E20

65270-43D00

Carburetor:



4-6

Front fork spring:



4-13

Rear suspension spring:



4-18

NUMBER OF TEETH

48

49

50

51

—

—

—

—

PART NUMBER

19900-37F60

11147-37F00

11148-37F00

11233-37F20

11234-37F20

11238-37F20

11241-37F20

11481-37F20

11482-37F01

11483-37E02

11484-37E00

12110-37F30-0F0

12111-37F30

09207-02008

12141-37F00

12151-28C00

14171-28C30

57310-37F00

57621-28C40

09263-18031

09280-20006

09381-18002

COMMENTS

Standard

—

20 inch

20 inch

2

4

1

1

1

1

1

1

1

2

2

1

Q’TY

1

2

2

1

2

2

1

1

1

2

Replace the drive chain from

114 links to 112 links.

—

1.85

18-24 SERVICING INFORMATION

SETTING DATA

DATE

RACE/COURSE

TEMP./HUMIDITY

WHETHER

COURSE COUDITION

MAIN JET

JET NEEDLE

SLOW JET

AIR SCREW

FLOAT LEVEL

SPARK PLUG

OIL LEVEL

COMP. ADJ. POSITION

RE-BOUND ADJ. POSITION

SPRING

SPRING

SPRING SET LENGTH

SUG

COMP. ADJ. POSITION LOW

COMP. ADJ. POSITION HIGH

RE-BOUND ADJ. POSITION

FINAL REDUCTION RATIO

MAKER/SIZE

PRESSURE

MAKER/SIZE

PRESSURE

COMMENT:

/ /

/

/

/

/ mm mm mm kPa kPa

/ /

/

/

/

/ mm mm mm kPa kPa

/ /

/

/

/

/ mm mm mm kPa kPa

*MAKE COPIES.

Failure to follow these safety precautions may increase your risk of injury:

!

Wear a helmet, eye protection, and bright protective clothing.

!

Don’t ride after consuming alcohol or other drugs.

!

This owner’s service manual contains important safety information. Please read it carefully.

K7

300 TAKATSUKA, HAMAMATSU, JAPAN

Printed in Japan