Suzuki VL125 Service Manual

VL125

FOREWORD

This manual contains an introductory description on the SUZUKI VL125 and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

!

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

4

5

6

1

2

3

7

Motorcycle Service Department c COPYRIGHT SUZUKI MOTOR CORPORATION 1999

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE

LOOKING FOR:

1.The text of this manual is divided into sections.

2.The section titles are listed in the GROUP INDEX.

3.Holding the manual as shown at the right will allow you to find the first page of the section easily.

4.The contents are listed on the first page of each section to help find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

Left Right

"

ITEM

A

B

C

N.m

65

23

23 kgf.m

6.5

2.3

2.3

A Front axle

B Axle pinch bolt

C Brake disc bolt

SYMBOL

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

SYMBOL

"

DEFINITION

Torque control required

Data beside it indicates specified torque.

SYMBOL

,

DEFINITION

Apply THREAD LOCK SUPER

“1360”.

99000-32130

2 Apply oil. Use engine oil unless otherwise specified.

+

Apply or use brake fluid.

3

/

0

Apply *Molybdenum oil solution

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE “A”.

99000-25010

Apply SUZUKI SILICONE GREASE.

99000-25100

*

)

(

Measure in voltage range.

Measure in resistance range.

Measure in current range.

1 Apply SUZUKI MOLY PASTE.

99000-25140

'

Measure in diode test range.

6

4

Apply THERMO GREASE “G”.

99000-25300

&

%

Measure in continuity test range.

Use special tool.

5

.

-

Apply SUZUKI BOND “1215”.

99000-31110

Apply SUZUKI BOND “1216”.

99000-31160

Apply THREAD LOCK SUPER

“1303”.

99000-32030

Apply THREAD LOCK “1342”.

99000-32050

$

#

Use fork oil.

99000-99044-10G

Indication of service data.

* How to make Molybdenum oil : Pour an engine oil and SUZUKI MOLY PASTE in a ratio of 1:1 by volume into such as oiler, and stir well.

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE ............................................................... 1- 2

GENERAL PRECAUTIONS ................................................................ 1- 2

SUZUKI VL125Y (2000-MODEL) ........................................................ 1- 4

SERIAL NUMBER LOCATION ........................................................... 1- 4

FUEL AND OIL RECOMMENDATION ................................................ 1- 5

FUEL................................................................................................ 1- 5

ENGINE OIL .................................................................................... 1- 5

BRAKE FLUID ................................................................................. 1- 5

FRONT FORK OIL ........................................................................... 1- 5

BREAK-IN PROCEDURES ................................................................. 1- 5

CYLINDER IDENTIFICATION ............................................................. 1- 6

INFORMATION LABELS .................................................................... 1- 6

SPECIFICATIONS ............................................................................... 1- 7

COUNTRY AND AREA CODES ......................................................... 1- 9

1

1-2 GENERAL INFORMA TION

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.

!

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

7

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

!

* Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.

* When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil and exhaust system until they have cooled.

* After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks.

7

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery.

* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. A l ways tighten the bolts and nuts diagonally from the inside working out and to the speci fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMA TION

SUZUKI VL125Y (2000-MODEL)

LEFT SIDE

RIGHT SIDE

*Difference between photograph and actual motorcycle depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the frame tube. The engine serial number 2 is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.

ENGINE OIL

Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or

SG under the API service classification.

The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the following chart.

BRAKE FLUID

Specification and classification: DOT 4

!

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.

FRONT FORK OIL

Use fork oil #10.

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.

• Keep to these break-in procedures:

Initial 800 km : Less than 1/2 throttle

Up to 1 600 km : Less than 3/4 throttle

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation.

• Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.

1-6 GENERAL INFORMA TION

CYLINDER IDENTIFICATION

The two cylinders of this engine are identified as No. 1 and No. 2 cylinder, as counted from rear to front (as viewed by the rider on the seat).

INFORMATION LABELS

1 Noise label

2 Fuel caution label

3 Tire pressure label

4 Warning safety label

5 ID plate

6 ID plate

For E-34

For E-02

For E-18

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ....................................................... 2 240 mm

Overall width ........................................................ 880 mm

Overall height ....................................................... 1 110 mm

Wheelbase ........................................................... 1 520 mm

Ground clearance ................................................ 150 mm

Seat height ........................................................... 685 mm

Dry mass .............................................................. 140 kg

ENGINE

Type ...................................................................... Four-stroke, air-cooled, OHC, pent-roof, 65°V twin

Number of cylinders ............................................. 2

Bore ..................................................................... 44.0 mm

Stroke ................................................................... 40.9 mm

Displacement ....................................................... 124 cm 3

Compression ratio ................................................ 10.3 : 1

Carburetor ............................................................ MIKUNI BDS26, single

Air cleaner ............................................................ Polyurethane foam element

Starter system ...................................................... Electric

Lubrication system ............................................... Wet sump

TRANSMISSION

Clutch ................................................................... Wet multi-plate type

Transmission ........................................................ 5-speed constant mesh

Gearshift pattern .................................................. 1-down, 4-up

Primary reduction ratio ........................................ 3.173 (73/23)

Secondary reduction ratio ................................... 4.000 (56/14)

Gear ratios, Low ................................................. 2.636 (29/11)

2nd .................................................. 1.647 (28/17)

3rd ................................................... 1.217 (28/23)

4th ................................................... 0.952 (20/21)

Top .................................................. 0.818 (18/22)

Drive chain ........................................................... RK428H0, 142 links

1-8 GENERAL INFORMA TION

ELECTRICAL

Ignition type ......................................................... Electronic ignition (Transistorized)

Ignition timing ....................................................... 10° B.T.D.C. at 1 400 r/min

Spark plug ............................................................ NGK CR8E or DENSO U24ESR-N

Battery ................................................................. 12 V 21.6 kC (6 Ah)/10 HR

Generator ............................................................. Three-phase A.C. generator

Fuse ..................................................................... 20 A

Headlight .............................................................. 12 V 60/55 W

Position light ......................................................... 12 V 4 W

Brake light/Taillight ............................................... 12 V 21/5 W

Turn signal light .................................................... 12 V 21 W

Speedometer light ................................................ 12 V 1.7 W

Neutral indicator light ........................................... 12 V 1.7W

Turn signal indicator light ..................................... 12 V 1.7 W × 2

High beam indicator light ..................................... 12 V 1.7 W

CHASSIS

Front suspension ................................................. Telescopic, coil spring, oil damped

Rear suspension .................................................. Swingarm type, coil spring, oil damped, spring pre-load

5-way adjustable

Front fork stroke ................................................... 120 mm

Rear wheel travel ................................................. 90 mm

Steering angle ..................................................... 40° (right and left)

Caster .................................................................. 31° 42’

Trail ....................................................................... 120 mm

Turning radius ...................................................... 2.72 m

Front brake ........................................................... Disc brake

Rear brake ........................................................... Drum brake

Front tire size ....................................................... 90/90-18 51P

Rear tire size ........................................................ 130/90-15M/C 66P

CAPACITIES

Fuel tank, including reserve ................................ 12.0 L reserve ................................................ 3.0 L

Engine oil, oil change .......................................... 1 800 ml with filter change ............................... 1 900 ml overhaul ............................................. 2 100 ml

Front fork oil (each leg) ........................................ 406 ml

Specifications are subject to change without notice.

COUNTRY AND AREA CODES

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

CODE

E-02

E-04

E-17

E-22

E-34

E-18

COUNTRY or AREA

U.K.

France

Sweden, Finland (E-15), Norway (E-16), Denmark (E-26)

Germany

Italy, Belgium (E-21), Spain (E-53)

Switzerland, Austria (E-39)

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE

CONTENTS

PERIODIC MAINTENANCE SCHEDULE ............................................. 2- 2

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

LUBRICATION POINTS ................................................................. 2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ................................. 2- 4

VALVE CLEARANCE ..................................................................... 2- 4

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

EXHAUST PIPE BOLTS AND MUFFLER BOLTS .......................... 2- 7

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

CARBURETOR ............................................................................... 2- 9

FUEL HOSE.................................................................................... 2-10

CLUTCH ......................................................................................... 2-10

ENGINE OIL AND OIL FILTER ...................................................... 2-11

DRIVE CHAIN ................................................................................. 2-13

BRAKE SYSTEM ............................................................................ 2-15

STEERING ...................................................................................... 2-19

FRONT FORK ................................................................................. 2-19

REAR SUSPENSION ..................................................................... 2-19

TIRE ................................................................................................ 2-20

CHASSIS BOLTS AND NUTS ........................................................ 2-20

COMPRESSION PRESSURE CHECK ................................................. 2-21

OIL PRESSURE CHECK ...................................................................... 2-22

2

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers and months, and are dependant on whichever comes first.

NOTE:

More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

Interval

Item

Valve clearance

Spark plug

Exhaust pipe bolts and muffler bolts

Air cleaner element

Idle rpm (Carburetor)

Throttle cable km months

Fuel hose

Clutch

Engine oil

Engine oil filter

Drive chain

Brake

Brake hose

Brake fluid

Steering

Front forks

Rear suspension

Tires

Chassis bolts and nuts

–

I

I

–

T

1 000

5

I

–

4 000

20

I

C

I

I

T

–

–

T

C

I

I

R

I

I

R

I

Replace every 4 years.

I

R

I

–

I

I

Clean and lubricate every 1 000 km.

I I

I

Replace every 4 years.

I

R

I

I

R

I

I

T

C

I

I

8 000

40

I

R

I I

Replace every 2 years.

I

I

I

I

T

I

I

I

I

T

I: Inspection and adjust, clean, lubricate or replace as necessary

C: Clean R: Replace T: Tighten

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated below.

/8

Clutch lever holder

/8

Side-stand pivot

and spring hook

28

Drive chain

/

Throttle cable end and pully

/8

Brake lever holder

/8

Brake pedal pivot

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the motorcycle has been operated under wet or rainy condition.

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.

VALVE CLEARANCE

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months).

INSPECTION

NOTE:

The clearance specification is for COLD state.

The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing.

• Remove the spark plugs. (

9

2-6)

• Remove the right air cleaner box.

• Remove the fuel tank. (

9

4-3)

• Remove the cylinder head cover caps 1 and 2 .

• Remove the valve inspection caps.

"

Valve inspection cap bolt and nut (intake): 10 N.m

(1.0 kgf.m)

Valve inspection cap (exhaust): 18 N.m (1.8 kgf.m)

• Remove the generator cover plug 1 and the timing inspection plug 2 .

"

Generator cover plug: 15 N.m (1.5 kgf.m)

Timing inspection plug: 21 N.m (2.1 kgf.m)

NOTE:

To turn the crankshaft for clearance checking, and rotate in the normal running direction. The spark plug should be removed.

• Rotate the generator rotor to set the No.1 cylinder’s piston at

TDC of the compression stroke. (Rotate the rotor until the “ R” line on the rotor is aligned with the center of hole on the generator cover.)

• To inspect the No.1 cylinder’s valve clearance, insert the thickness gauge to the clearance between the valve stem end and the adjusting screw on the rocker arms.

#

Valve clearance (when cold):

IN. : 0.10 – 0.15 mm

EX.: 0.18 – 0.23 mm

%

09900-20806: Thickness gauge

• If the clearance is out of the specification, bring it into the specified range by using the special tool.

%

09917-10410: Valve adjust driver

7

Both right and left valve clearances should be as closely set as possible.

• Rotate the generator rotor 450 degrees (1-¼ turns) and align the “ F” line on the rotor with the center of hole on the generator cover.

• Inspect the No.2 cylinder’s valve clearance as the same manner above.

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

SPARK PLUG

Clean every 4 000 km (20 months) and replace every 8

000 km (40 months).

REMOVAL

• Disconnect the spark plug caps.

• Remove the spark plugs.

%

09930-10121: Spark plug socket wrench set

NGK

DENSO

Standard

CR8E

U24ESR-N

Cold type Hot type

CR9E CR7E

U27ESR-N U22ESR-N

CARBON DEPOSIT

Check to see the carbon deposit on the plug.

If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end.

SPARK PLUG GAP

Measure the plug gap with a thickness gauge if it is correct. If not, adjust it to the following gap.

#

Standard: Spark plug gap: 0.7– 0.8 mm

%

09900-20803: Thickness gauge

ELECTRODE’S CONDITION

Check to see the worn or burnt condition of the electrodes. If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, etc.

7

Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.

INSTALLATION

7

Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads.

• Install the spark plug to the cylinder head by finger tight, and then tighten it to the specified torque.

"

Spark plug: 11 N.m (1.1 kgf.m)

0.7 – 0.8 mm

EXHAUST PIPE BOLT AND MUFFLER BOLT

Tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

• Tighten the exhaust pipe bolts 1 , muffler connecting bolts 2 and muffler mounting bolts 3 to the specified torque with a torque wrench.

"

Exhaust pipe bolt & Muffler mounting bolt: 23 N.m

(2.3 kgf.m)

Muffler connecting bolt: 23 N.m (2.3 kgf.m)

PERIODIC MAINTENANCE 2-7

AIR CLEANER

Clean every 3 000 km.

REMOVAL

• Remove the air cleaner box cover 1 .

• With the hooks removed, remove the air cleaner cap 2 .

2-8 PERIODIC MAINTENANCE

• Remove the left air cleaner element 3 .

CLEANING

• Fill a washing pan of a proper size with a non-flammable cleaning solvent. Immerse the element in the cleaning solvent and wash it.

• Gently squeeze the element to remove the excess solvent: do not twist or wring the element or it will develop tears.

• Immerse the element in motor oil and squeeze out the excess oil. The element should be wet but not dripping.

• Reinstall the cleaned or new air cleaner element in the reverse order of removal.

7

* Inspect the air cleaner element for tears. A torn element must be replaced.

* If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component!

a Non-flammable cleaning solvent b Motor oil SAE #30 or SAE 10W/40

NOTE:

When cleaning the air cleaner element, drain water from the air cleaner box by removing the drain plug.

CARBURETOR

IDLE RPM (Idling adjustment)

Inspect initially at 1 000 km (5 month) and every 4 000 km

(20 months) thereafter.

NOTE:

Make this adjustment when the engine is hot.

• Connect an electric tachometer to the high-tension cord.

• Start up the engine and set its speed at anywhere between 1

500 and 1 700 r/min by turning throttle stop screw 1 .

#

Engine idle speed:

1 400 ± 50 r/min ... For E-18

1 400 ± 100 r/min ... For the others

%

09900-26006: Tachometer

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (5 month) and every 4 000 km

(20 months) thereafter.

Adjust the throttle cable play A as follows:

MINOR ADJUSTMENT

1st step:

• Loosen the lock nut 3 of the throttle returning cable 1 and turn in the adjuster 4 fully into the threads.

2nd step:

• Loosen the lock nut 5 of the throttle pulling cable 2 .

• Turn the adjuster 6 in or out until the throttle cable play should be 2.0 – 4.0 mm at the throttle grip.

• Tighten the lock nut 5 while holding the adjuster 6 .

3rd step:

• While holding the throttle grip at the fully closed position, slowly turn out the adjuster 4 of the throttle returning cable 1 to feel resistance.

• Tighten the lock nut 3 while holding the adjuster 4 .

#

Throttle cable play A : 2.0 – 4.0 mm

!

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

MAJOR ADJUSTMENT

• Loosen the lock nuts 1 of the throttle returning cable 2 .

• Turn the returning cable adjuster 3 to obtain proper cable play.

– Continued on next page –

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

• Loosen the lock nuts 4 of the throttle pulling cable 5 .

• Turn the pulling cable adjuster 6 in or out until the throttle cable play should be 2.0 – 4.0 mm at the throttle grip.

• Tighten the lock nuts 4 securely while holding the adjuster 6 .

• While holding the throttle grip at the fully closed position, slowly turn the returning cable adjuster 3 to obtain a cable slack B of

1.0 mm.

• Tighten the lock nuts 1 securely.

FUEL HOSE

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months).

Replace every 4 years.

• Remove the left frame cover. (

9

6-2)

Inspect the fuel hoses for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced.

FUEL FILTER

Visually check the fuel filter. If accumulation of sediment or clogging is found, replace the fuel filter with a new one. (

9

4-3)

CLUTCH

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

• Loosen the lock nut 1 and turn the adjuster 2 fully in.

• Loosen the lock nut 3 and turn the adjuster 4 until the clutch lever play A is within specificaton.

#

Clutch lever play A : 10 – 15 mm

• Tighten the lock nuts 1 and 3 .

GEARSHIFT LEVER HEIGHT ADJUSTMENT

• Loosen the lock nuts 1 .

• With the link rod 2 turned, adjust the gearshift lever height A .

#

Gearshift lever height: 65 – 75 mm

ENGINE OIL AND OIL FILTER

(ENGINE OIL)

Replace initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

(OIL FILTER)

Replace initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter.

#

NECESSARY AMOUNT OF ENGINE OIL

Oil change : 1 800 ml

Filter change : 1 900 ml

Overhaul engine : 2 100 ml

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

Oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

• Place an oil pan below the engine, and drain the oil by removing the filler cap 1 and drain plug 2 .

• Tighten the drain plug 2 to the specified torque, and pour fresh oil through the oil filler. Use an API classification of SF or SG oil with SAE 10W/40 viscosity.

"

Oil drain plug: 23 N.m (2.3 kgf.m)

• Start up the engine and allow it to run for several minutes at idling speed.

• Turn off the engine and wait about three minutes, then check the oil level through the inspection window. If the level is below mark “L”, add oil to “F” level. If the level is above mark “F”, drain oil to “F” level.

PERIODIC MAINTENANCE 2-11

2-12 PERIODIC MAINTENANCE

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil replacement procedure.

• Remove the oil filter cap 1 .

• Remove the oil filter.

• Install the new O-ring 2 .

• Install the new oil filter.

• Install the new O-ring 3 and spring 4 to the oil filter cap.

• Install the oil filter cap.

NOTE:

Before installing the oil filter cap, apply engine oil lightly to the new O-ring 3 .

• Add new engine oil and check the oil level as described in the engine oil replacement procedure.

7

Use SUZUKI MOTORCYCLE GENUINE OIL FILTER only, since the other make’s genuine filters and after-market parts may differ filtering performance and durability, which could cause engine damage or oil leaks. Suzuki automobile genuine oil filter is also not usable for the motorcycles.

DRIVE CHAIN

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

Clean and lubricate every 1 000 km.

Visually check the drive chain for the possible defects listed below. (Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to

Neutral.)

* Loose pins

* Damaged rollers

* Excessive wear

* Improper chain adjustment

* Dry or rusted links * Missing O-ring seals

* Kinked or binding links

If any defects are found, the drive chain must be replaced.

NOTE:

When replacing the drive chain, replace the drive chain and sprockets as a set.

CHECKING

• Loosen the axle nut.

• Loosen the front and rear torque link nuts.

PERIODIC MAINTENANCE 2-13

• Tense the drive chain fully by turning both chain adjusters 1 .

• Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

#

Drive chain 20-pitch length:

Service limit: 269.2 mm

2-14 PERIODIC MAINTENANCE

ADJUSTING

• Loosen or tighten both chain adjusters 1 until the chain has

20 – 30 mm of slack in the middle between the engine and rear sprockets. The marks 2 on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.

#

Drive chain slack: Standard: 20 – 30 mm

• Place the motorcycle on its side-stand for accurate adjustment.

• After adjusting the drive chain, tighten the axle nut and the torque link nuts to the specified torque.

• Tighten both chain adjusters 1 securely.

"

Rear axle nut: 65 N.m (6.5 kgf.m)

Torque link nut (Front) : 13 N.m (1.3 kgf.m)

Torque link nut (Rear) : 13 N.m (1.3 kgf.m)

• Recheck the drive chain slack after tightening the axle nut.

CLEANING AND LUBRICATING

• Wash the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

7

Do not use trichlene, gasoline or any similar fluids: These fluids have too great a dissolving power for this chain and, what is more important, they can damage the “O”rings (or seals) confining the grease in the bush to pin clearance. Remember high durability comes from the presence of grease in that clearance.

• After washing and drying the chain, oil it with a heavy-weight motor oil.

7

* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the “O”-rings (or seals).

* The standard drive chain is a RK428 H0 Suzuki recommends that this standard drive chain should be used for the replacement.

20 – 30 mm

BRAKE SYSTEM

(BRAKE)

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months). Replace hoses every 4 years.

Replace fluid every 2 years.

BRAKE FLUID LEVEL CHECK

• Keep the motorcycle upright and place the handlebars straight.

• Check the brake fluid level by observing the lower limit line on the front brake fluid reservoir.

• When the level is below the lower limit line, replenish with brake fluid that meets the following specification.

+

Specification and Classification: DOT 4

!

The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period.

!

Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

PERIODIC MAINTENANCE 2-15

BRAKE PAD WEAR

The extent of brake pad wear can be checked by observing the grooved limit A on the pad. When the wear exceeds the grooved limit, replace the pads with new ones.

7

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

2-16 PERIODIC MAINTENANCE

FRONT BRAKE PAD REPLACEMENT

• Remove the brake caliper and brake pad pin 1 .

• Remove the brake pads.

• To reassemble, reverse the above sequence.

"

Brake caliper mounting bolt: 39 N.m (3.9 kgf.m)

Brake pad pin: 18 N.m (1.8 kgf.m)

7

Be sure to install the shims 2 properly as shown in the photograph.

FRONT BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handlebars straight.

• Remove the master cylinder reservoir cap and diaphragm.

• Suck up the old brake fluid as much as possible.

• Fill the reservoir with new brake fluid.

+

Specification and classification: DOT 4

• Connect a clear hose 1 to the air bleeder valve and insert the other end of the hose into a receptacle.

• Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.

• Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper line.

"

Air bleeder valve: 7.5 N.m (0.75 kgf.m)

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

• Fill the master cylinder reservoir to top of the inspection window. Replace the reservoir cap to prevent dirt from entering.

• Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.

• Bleed air from the brake system.

• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it.

Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip.

Then, close the air bleeder valve, pump and squeeze the brake lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.

NOTE:

While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.

• Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the upper line.

"

Air bleeder valve: 7.5 N.m (0.75 kgf.m)

7

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

PERIODIC MAINTENANCE 2-17

2-18 PERIODIC MAINTENANCE

REAR BRAKE PEDAL HEIGHT

• Loosen the lock nut 1 .

• Adjust the brake pedal height A by turning the adjuster 2 .

#

Rear brake pedal height A : 50 – 60 mm

REAR BRAKE ADJUSTING

• Adjust the free travel B to 20 – 30 mm by turning the adjusting nut 3 .

#

Rear brake pedal free travel B : 20 – 30 mm

REAR BRAKE SHOE WEAR

This motorcycle is equipped with brake lining wear limit indicator on the rear brake.

To check brake lining wear, perform the following steps.

• Make sure that the rear brake is properly adjusted.

• Depress the rear brake pedal. Make sure that the index mark

4 is within the range 5 embossed on the brake panel.

• If the index mark goes beyond the range, the brake shoe assembly should be replaced with a new set of shoes. (

9

5-

42)

BRAKE LIGHT SWITCH

Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed.

STEERING

Inspect initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter.

Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, and pull forward. If play is found, perform steering bearing adjustment as described in page 5-33 of this manual.

PERIODIC MAINTENANCE 2-19

FRONT FORK

Inspect every 4 000 km (20 months).

Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (

9

5-22)

REAR SUSPENSION

Inspect every 4 000 km (20 months).

Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage. Replace any defective parts, if necessary. (

9

5-45)

2-20 PERIODIC MAINTENANCE

TIRE

Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

%

09900-20805: Tire depth gauge

#

Tire tread depth: Service limit: (FRONT) : 1.6 mm

(REAR) : 1.6 mm

TIRE PRESSURE

If the tire pressure is too higt or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result.

Cold inflation tire pressure is as follows.

COLD INFLATION

TIRE PRESSURE

SOLD RIDING kPa kgf/cm 2 psi

DUAL RIDING kPa kgf/cm 2 psi

175 1.75

25 175 1.75

25 FRONT

REAR 200 2.00

29 225 2.25

33

7

The standard tire fitted on this motorcycle is 90/90–18

51P for front and 130/90–15M/C 66P for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire.

TIRE TYPE

Front: IRC GS-21F

Rear: IRC NR31

CHASSIS BOLTS AND NUTS

Tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque. (

9

7-26)

COMPRESSION PRESSURE CHECK

The compression of a cylinder is a good indicator of its internal condition.

The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

COMPRESSION PRESSURE SPECIFICATION

Standard

1 100 – 1 500 kPa

(at about 600 rpm)

(11 – 15 kgf/cm 2 )

Low compression pressure can indicate any of the following conditions:

* Excessively worn cylinder wall

* Worn-down piston or piston rings

* Piston rings stuck in grooves

* Poor seating of valves

* Ruptured or otherwise defective cylinder head gasket

COMPRESSION TEST PROCEDURE

NOTE:

* Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted.

* Have the engine warmed up by idling before testing.

* Be sure that the battery used is in fully-charged condition.

Remove the parts concerned and test the compression pressure in the following manner.

• Remove all the spark plugs.

• Fit the compression gauge in one of the plug hole, while taking care that the connection tight.

• Keep the throttle grip in full-open position.

• While cranking the engine a few seconds with the starter, and record the maximum gauge reading as the compression of that cylinder.

%

09915-64510: Compression gauge

09915-63310: Adaptor

PERIODIC MAINTENANCE 2-21

2-22 PERIODIC MAINTENANCE

OIL PRESSURE CHECK

Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.

OIL PRESSURE SPECIFICATION

35 – 60 kPa (0.35 – 0.60 kgf/cm 2 ) at 3 000 r/min., Oil temp. at 60°C (140°F)

If the oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE

* Clogged oil filter

* Oil leakage from the oil passage

* Damaged O-ring

* Defective oil pump

* Combination of above items

HIGH OIL PRESSURE

* Engine oil viscosity is too high

* Clogged oil passage

* Combination of the above items

OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.

• Remove the main gallery plug 1 .

• Install the oil pressure gauge with adaptor in the position shown in the figure.

• Connect an electric tachometer.

• Warm up the engine as follows:

Summer 10 min. at 2 000 r/min.

Winter 20 min. at 2 000 r/min.

• After warming up, increase the engine speed to 3 000 r/min.

(with the electric tachometer), and read the oil pressure gauge.

%

09915-74510: Oil pressure gauge

09915-74560: Adaptor

09900-26006: Tachometer

ENGINE

CONTENTS

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ....

3- 2

ENGINE REMOVAL AND REINSTALLATION ................................. 3- 3

ENGINE REMOVAL ...................................................................... 3- 3

ENGINE REINSTALLATION ......................................................... 3- 8

ENGINE DISASSEMBLY.................................................................. 3-11

ENGINE COMPONENT INSPECTION AND SERVICE ................... 3-20

CYLINDER HEAD COVER ........................................................... 3-20

CAMSHAFT .................................................................................. 3-22

CAM CHAIN TENSION ADJUSTER ............................................. 3-23

CYLINDER HEAD ......................................................................... 3-24

CYLINDER .................................................................................... 3-33

PISTON .......................................................................................... 3-34

CONROD AND CRANKSHAFT ................................................... 3-37

GENERATOR COVER .................................................................. 3-38

STARTER CLUTCH...................................................................... 3-39

STARTER DRIVEN GEAR ........................................................... 3-40

CLUTH COVER ............................................................................. 3-41

CLUTCH ........................................................................................ 3-42

PRIMARY DRIVEN GEAR ............................................................ 3-43

OIL PUMP ...................................................................................... 3-43

GEAR SHIFT SHAFT .................................................................... 3-43

TRANSMISSION ........................................................................... 3-44

CRANKCASE ............................................................................... 3-46

ENGINE REASSEMBLY .................................................................. 3-49

7

* Mark an identification of assembly location on each removed part so that each will be restored to the original position during reassembly.

* Wash clean and dry the removed parts before inspecting and measuring.

* Oil the rotating or sliding parts before assembly.

* Make sure to use the correct type of lubricant where specified.

* Check that each rotating or sliding part moves or operates smoothly after assembly.

* Make sure to follow the bolt tightening order where specified.

* If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the bolts and check that the tightening margin is equal in each bolt.

ENGINE 3-1

3

3-2 ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions.

ENGINE CENTER

ITEM

Air cleaner box

Starter motor

Cylinder head cover

Camshaft

Intake pipe

Cylinder head (only No. 2)

REMOVAL INSPECTION REINSTALLATION

9

9

9

9

9

9

3-3

3-11

3-11

3-12

3-13

3-13

9

2-7

9

6-12

9

3-20

9

3-22

–––––

9

3-24

–––––

9

9

9

3-70

3-67

3-65

9

3-64

9

3-63

Cam chain tension adjuster

Cam chain guide

Cylinder (only No. 2)

Piston (only No. 2)

9

3-13

9

3-13

9

3-13

9

3-14

9

3-23

9

3-23

9

3-33

9

3-35

9

3-64

9

3-63

9

3-63

9

3-62

ENGINE RIGHT SIDE

ITEM

Clutch cable

Exhaust pipe and muffler

1

Speed sensor

Clutch cover

2

Clutch (plates)

3

Primary driven gear

4

Primary drive gear

REMOVAL INSPECTION REINSTALLATION

9

3-4

9

3-5

9

3-11

9

3-15

9

3-15

9

3-16

9

3-16

–––––

–––––

9

6-24

9

3-41

9

3-42

9

3-43

–––––

–––––

9

3-10

9

3-69

9

3-59

9

3-58

9

3-57

9

3-57

Rear cylinder cam chain and cam chain tensioner

5

Oil pump

6

Speed rotor

7

Gearshift shaft

9

3-16

9

3-17

9

3-17

9

3-18

9

3-24

9

3-43

–––––

9

3-43

9

3-57

9

3-56

9

3-56

9

3-56

ENGINE LEFT SIDE

2

3

4

5

6

ITEM

Engine sprocket

Gearshift pedal

Starter idle gear

Oil sump filter

Generator rotor

Starter clutch

Starter driven gear

REMOVAL INSPECTION REINSTALLATION

9

3-6

9

3-6

1

Gear position switch

9

3-11

Generator (cover)

9

3-14

9

3-14

9

3-14

9

3-14

9

3-39

9

3-15

9

5-37

–––––

9

9

6-15

6-8

–––––

–––––

–––––

9

9

3-39

3-30

9

9

9

9

9

3-9

3-9

3-69

3-61

3-61

9

3-61

9

3-61

9

3-39

9

3-61

Front cylinder cam chain and cam chain tensioner

9

3-15

9

3-24

9

3-60

ENGINE REMOVAL AND REINSTALLATION

ENGINE REMOVAL

NOTE:

If the engine is dirtied, wash the machine with a steam cleaner before removing the engine.

• Remove the front seat. (

9

5-2)

• Remove the luggage box. (

9

5-2)

• Remove the fuel tank. (

9

4-3)

• Drain the engine oil. (

9

2-11)

• Remove the right frame cover. (

9

5-3)

• Disconnect the battery lead wire.

AIR CLEANER

• With the clamp screw loosened, remove the right and left air cleaner boxes.

• Remove the air valve hose. (

9

7-18)

• Disconnect the breather hose.

ENGINE 3-3

3-4 ENGINE

• Loosen the clamp screw.

• With the bolts removed, take out the center air cleaner box.

CARBURETOR

• Remove the carburetor. (

9

4-12)

• Disconnect the vacuum hoses 1 and 2 from the intake pipe.

CLUTCH CABLE

• Disconnect the clutch cable end out of clutch lever.

• Disconnect the clutch cable end out of clutch release arm.

EXHAUST PIPE AND MUFFLER

• With the exhaust pipe bolts and muffler bolts removed, remove the exhaust pipes and mufflers.

ENGINE 3-5

ELECTRIC PARTS

• Remove the spark plug caps.

• Remove the starter motor lead wire.

• Remove the engine ground lead wire 1 .

• Disconnect the speed sensor coupler 2 .

3-6 ENGINE

• Disconnect the signal generator coupler 3 , generator coupler 4 and gear position switch coupler 5 .

ENGINE SPROCKET

• Remove the engine sprocket cover.

• Remove the breather hose.

• With the bolt removed, disconnect the gearshift arm.

• Remove the left footrest.

• Flatten the lock washer.

• Remove the engine sprocket nut 1 and washer.

NOTE:

When loosening the engine sprocket nut, depress the brake pedal.

• Remove the engine sprocket.

NOTE:

If it is difficult to remove the engine sprocket, loosen the rear axle nut, rear torque link nuts and chain adjusters to provide additional chain slack. (

9

2-13)

• Support the engine using an engine jack.

• Remove the engine mounting brackets 1 and 2 .

• Remove the engine mounting nuts and bolts.

• Remove the engine from the frame.

ENGINE 3-7

3-8 ENGINE

ENGINE REINSTALLATION

Reinstall the engine in the reverse order of engine removal.

• Install the engine mounting bolts and nuts as shown in the following illustration.

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

NOTE:

The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.

"

ITEM

A , C , D , E

B

F

N.m

40

40

23

BOLT LENGTH

1

2

3 , 4 , 5

67 mm

65 mm

102 mm kgf.m

4.0

4.0

2.3

ENGINE SPOCKET

• Loosen the rear axle nut, rear torque link nuts and chain adjusters.

• Install the engine sprocket.

• Tighten the engine sprocket nut 1 to the specified torque.

"

Engine sprocket nut: 90 N.m (9.0 kgf.m)

NOTE:

When tightening the engine sprocket nut, depress the rear brake pedal.

• Bend the lock washer securely.

• Tighten the left footrest bolts to the specified torque.

"

Footrest bolt: 23 N.m (2.3 kgf.m)

• Install the gearshift arm and adjust the gearshift lever hight.

(

9

2-10)

• Connect each electric part and its couplers. (

9

7-10 – 12)

ENGINE 3-9

3-10 ENGINE

• Install the exhaust pipes and mufflers as shown in the following illustration.

Apply PERMATEX 1372 to the inside and outside.

"

ITEM N.m

kgf.m

A 23 2.3

B 23 2.3

C 23 2.3

• Install the carburetor and air cleaner. (

9

4-6)

• After remounting the engine, the following adjustments are necessary.

* Engine idling speed ....................................

9

2-9

* Throttle cable play ......................................

9

2-9

* Clutch lever play .........................................

9

2-10

* Drive chain ..................................................

9

2-13

* Rear brake pedal height and free travel ....

9

2-18

* Gearshift lever height .................................

9

2-10

* Engine oil level ............................................

9

2-11

ENGINE DISASSEMBLY

STARTER MOTOR

• Remove the starter motor.

GEAR POSITION SWITCH

• Remove the gear position switch.

• Remove the contacts 1 , 2 and springs 3 , 4 .

SPEED SENSOR

• Remove the speed sensor.

CYLINDER HEAD COVER

• Remove the spark plugs. (

9

2-6)

• Remove the head cover caps.

ENGINE 3-11

3-12 ENGINE

• Remove the valve inspection caps.

• Remove the front cylinder head cover.

NOTE:

When removing the cylinder head covers, the piston must be at top dead center on the compression stroke. (

9

2-4)

No. 2 (FRONT)

• Remove the rear cylinder head cover.

No. 1 (REAR)

CAM SHAFT AND SPROCKET

• Remove the cam chain tension adjusters 1 and 2 .

• Remove the camshaft sprocket bolts 3 .

• Remove the camshafts and sprockets.

INTAKE PIPE

• Remove the intake pipe 1 .

CYLINDER HEAD AND CYLINDER

• With the cylinder head nuts removed, remove the No. 1 (Rear) cylinder.

• Remove the gasket 1 , cam chain guide 2 and cylinder.

• Remove the No. 2 (Front) cylinder head and cylinder in same manner of No. 1 (Rear) cylinder head and cylinder removal.

ENGINE 3-13

3-14 ENGINE

PISTON

• Place a clean rag over the cylinder base to prevent piston pin circlips from dropping into the crankcase. Remove the piston pin circlips with long-nose pliers.

• Drive out the piston pins by using proper drift.

NOTE:

Scribe the cylinder position on the head of the respective pistons.

GENERATOR COVER

• Remove the generator cover.

• Remove the starter idle gear 1 and shaft 2 .

• Remove the oil sump filter 3 .

GENERATOR ROTOR

NOTE:

When removing the primary drive gear nut (

9

3-17), do not remove the generator rotor. The generator rotor is used when removing the primary drive gear nut.

• With the rotor held immovable using the special tool, loosen the rotor bolt.

%

09930-44530: Rotor holder

• Remove the rotor by using the special tool.

%

09930-32610: Rotor remover

• Remove the key 1 .

• Remove the starter driven gear 2 .

• Remove the cam chain tensioner 3 and cam chain 4 .

CLUTCH COVER

• Remove the clutch release arm 1 .

• Remove the clutch cover bolts.

• Remove the clutch cover.

CLUTCH

• With the primary drive gear nut held immovable, remove the clutch spring mounting bolts diagonally.

• Remove the pressure plate 1 .

ENGINE 3-15

3-16 ENGINE

• Remove the clutch drive and driven plates.

• Flatten the lock washer 2 .

• With the clutch sleeve hub held immovable using special tool, remove the clutch sleeve hub nut.

%

09920-53740: Clutch sleeve hub holder

• Remove the clutch sleeve hub 3 and primary driven gear assembly 4 .

PRIMARY DRIVE GEAR

• With the generator rotor held immovable using special tool, remove the primary drive gear nut.

!

09930-44530: Rotor holder

"

This bolt has left-hand thread. Turning it counterclockwise, it may cause damage.

• Remove the key 1 , cam chain 2 and cam chain drive sprocket

3 .

• Remove the cam chain tensioner 4 .

OIL PUMP

• Remove the circlip 1 and oil pump drive gear.

!

09900-06107: Snap ring pliers

• Remove the pin 2 and the washer 3 .

• Remove the oil pump 4 .

SPEED ROTOR

• Remove the circlip 5 and speed rotor.

!

09900-06107: Snap ring pliers

ENGINE 3-17

Loosening direction

3-18 ENGINE

GEARSHIFT SHAFT

• With the circlip 1 removed, draw out the gearshift shaft.

• Remove the gearshift cam stopper plate 2 .

• Remove the gearshift cam stopper 3 with spring.

• Remove the gearshift arm stopper 4 .

• Remove the oil seal retainer and drive shaft spacer 5 .

• Remove the crankcase securing bolts.

• Separate the crankcase into 2 parts, right and left, with a crankcase separating tool.

!

09920-13120: Crankcase separator

NOTE:

Fit the crankcase separating tool, so that the tool arms parallel the side of the crankcase. The crankshaft and transmission components must remain in the left crankcase half.

• Remove the gearshift fork shafts 1 and gearshift forks 2 .

• Remove the gearshift cam 3 .

• Remove the driveshaft assembly 4 , countershaft assembly 5 .

• Remove the crankshaft by using the special tool.

!

09920-13120: Crankcase separator

ENGINE 3-19

3-20 ENGINE

ENGINE COMPONENT INSPECTION AND

SERVICE

"

Be sure to identify each removed part as to its location, and lay the parts out in groups designated as “No. 1 cylinder”, “No. 2 cylinder”, “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.

CYLINDER HEAD COVER

DISASSEMBLY

• Loosen the rocker arm shaft bolts.

• Draw out the rocker arm shaft 1 using 6 mm bolt.

• Remove the intake rocker arm 2 , exhaust rocker arm 3 and spring washers 4 .

INSPECTION

CYLINDER HEAD COVER DISTORTION

After removing sealant from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge.

#

Cylinder head cover distortion:

Service Limit: 0.05 mm

!

09900-20803: Thickness gauge

If the distortion exceeds the limit, replace the cylinder head cover.

ROCKER ARM SHAFT O.D.

Measure diameter of rocker arm shaft.

#

Rocker arm shaft O.D.:

Standard: 11.973 – 11.984 mm

!

09900-20205: Micrometer (0 – 25 mm)

ROCKER ARM I.D.

When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked.

#

Rocker arm I.D.: Standard: 12.000 – 12.018 mm

!

09900-20605: Dial calipers

REASSEMBLY

Reassemble the cylinder head cover in the reverse order of disassembly. Pay attention to the following points:

• Apply engine oil to the rocker arm shafts.

NOTE:

Align the cutaway

A

of rocker arm shaft with the hole of cylinder head cover bolt.

• After inserting the shafts, tighten the rocker arm shaft bolts.

$

Rocker arm shaft bolt: 28 N.m (2.8 kgf.m)

"

Use a new gasket B on the rocker arm shaft bolt to prevent oil leakage.

ENGINE 3-21

3-22 ENGINE

CAMSHAFT

CAM WEAR INSPECTION

Check for abnormal surface damage or wear on the cam face.

Measure the cam height H with a micrometer.

Replace the camshaft if found worn down to the service limit.

#

Cam height H : Service Limit: (IN) 32.57 mm

(EX) Front: 32.60 mm

Rear : 32.33 mm

CAMSHAFT JOURNAL WEAR INSPECTION

Place the Plastigauge 1 between the camshaft and cylinder head cover and tighten the cylinder head cover bolts to the speified torque.

!

09900-22302: Plastigauge

$

Cylinder head cover bolt: 10 N.m (1.0 kgf.m)

NOTE:

Do not rotate the camshaft after the cylinder head cover has been tightened with the Plastigauge in place.

• Remove the cylinder head cover and take the measurement at the widest part of the crashed Plastigauge.

#

Camshaft journal oil clearance: Service Limit: 0.150 mm

If the clearance exceeds the service limit, measure the inside diameter of camshaft journal holder using a cylinder gauge.

#

Camshaft journal holder I.D.:

Standard: 22.012 – 22.025 mm

!

09900-20602: Dial gauge (1/1000 mm)

09900-22403: Small bore gauge (18 – 35 mm)

Measure the outside diameter of camshaft journal using a micrometer.

#

Camshaft journal O.D.:

Standard: 21.959 – 21.980 mm

!

09900-20205: Micrometer (0 – 25 mm)

Calculate from the measurement to determine if the clearance falls within the standard range when the camshaft is replaced with a new one. If the clearance does not come to the standard range, replace both the camshaft and cylinder head with new ones.

CAMSHAFT RUNOUT

With the camshaft held on the V-blocks, measure the runout with a dial gauge. If the runout exceeds the service limit, replace the camshaft.

#

Camshaft runout: Service Limit: 0.10 mm

!

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

CAM CHAIN TENSION ADJUSTER

INSPECTION

Check that the push rod 1 slides smoothly with the lock A of the ratchet mechanism released. If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one.

CAM CHAIN TENSIONER

INSPECTION

Check the contacting surface of the cam chain tensioner.

If it is worn or damaged, replace it with a new one.

CAM CHAIN AND CAM CHAIN GUIDE

INSPECTION

Check the cam chain for wear, damage and kinked or binding links. If any defects are found, replace it with a new one.

Check the cam chain guide for wear and damage. If it is found to be damaged, replace it with a new one.

ENGINE 3-23

3-24 ENGINE

CYLINDER HEAD

DISASSEMBLY

• Remove the exhaust pipe and gasket.

• Compress the valve spring using the special tool.

!

09916-14510: Valve lifter

09916-14910: Attachment

09916-84511: Tweezers

• Remove the valve cotter halves 1 .

• Remove the valve spring retainer 2 .

• Remove the valve spring 3 .

• Remove the valve 4 from the other side.

• Remove the valve stem sea l 5 .

• Remove the spring seat

6

.

INSPECTION

CYLINDER HEAD DISTORTION

Check for distortion of the mating surface diagonally with a straightedge and thickness gauge as shown.

If distortion exceeds the service limit, repair or replace the cylinder head.

#

Cylinder head distortion: Service Limit: 0.05 mm

!

09900-20803: Thickness gauge

VALVE STEM RUNOUT

Check the valve stem for abnormal wear or bend.

Place the valve on V-blocks and measure runout.

If the service limit is exceeded or abnormal condition exists, replace the valve.

#

Valve stem runout: Service Limit: 0.05 mm

!

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

VALVE HEAD RADIAL RUNOUT

Place a dial gauge as shown and measure valve head radial runout.

If the service limit is exceeded, replace the valve.

#

Valve head radial runout: Service Limit: 0.03 mm

!

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

VALVE FACE WEAR

Visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve head T . If it is out of specification replace the valve with a new one.

#

Valve head thickness T : Service Limit: 0.5 mm

!

09900-20102: Vernier calipers

VALVE STEM END CONDITION

Inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. Make sure that the length 1 is not less than the service limit. If this length becomes less than the service limit, replace the valve.

#

Valve stem end length:

Service Limit (IN & EX): 2.2 mm

ENGINE 3-25

3-26 ENGINE

VALVE STEM DEFLECTION

With the valve inserted into the valve guide, lift the valve head 10 mm from the valve seat and measure the deflection in X and Y directions.

#

Valve stem deflection (IN & EX): Service Limit: 0.35 mm

!

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

VALVE STEM DIAMETER

If the valve stem deflection exceeds the service limit, measure the valve stem outside diameter. If the diameter measured is within the standard range, replace the valve guide. (

%

3-27)

For each of upper, middle and lower sections within the sliding range, two measurements, each in crosswise direction must be taken.

#

Valve stem O.D.: Standard (IN) : 4.475 – 4.490 mm

(EX): 4.455 – 4.470 mm

!

09900-20205: Micrometer (0 – 25 mm)

VALVE GUIDE SERVICING

• Using the valve guide remover 1 , drive the valve guide out toward the intake or exhaust camshaft side.

!

09916-43210: Valve guide remover/installer

NOTE:

* Discard the remove valve guide subassemblies.

* Only oversized valve guides are available as replacement parts.

(Part No. 11115-33D71)

• Re-finish the valve guide holes in the cylinder head using the reamer and handle.

!

09916-34580: Valve guide reamer

09916-34542: Valve guide reamer handle

• Apply engine oil to the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer.

A Valve guide

B Cylinder head

!

09916-43210: Valve guide remover/installer

"

Apply oil to the valve guide hole before driving the new guide into place may result in a damaged guide or head.

• After installing the valve guides, re-finish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming.

!

09916-33210: Valve guide reamer

09916-34542: Valve guide reamer handle

NOTE:

Insert the reamer from the combustion chamber and always turn the reamer handle clockwise.

ENGINE 3-27

3-28 ENGINE

VALVE SEAT WIDTH INSPECTION

Visually check for valve seat width on each valve face.

If the valve face has worn abnomally, replace the valve.

Coat the valve seat with Prussian Blue and set the valve in place.

Rotate the valve with light pressure. Check that the transferred blue on the valve face is uniform all around and in center of the valve face.

If the seat width W measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter.

#

Valve seat width W

Standard: 0.9 – 1.1 mm

Service Limit: Reface if measurement does not agree with standard value.

!

09916-10911: Valve lapper set

VALVE SEAT SERVICING

The valve seats 1 for both the intake and exhaust valves are machined to four different angles. The seat contact surface is cut at 45°.

45°

15°

32°

INTAKE

N-131

N-144

!

09916-21111: Valve seat cutter set

09916-24470: Valve seat cutter (N-131)

09916-24460: Valve seat cutter (N-130)

09916-22610: Valve seat cutter (N-144)

09916-20460: Solid pilot (N-100-4.5)

EXHAUST

N-131

N-130

NOTE:

Use the solid pilot along with the valve seat cutter.

"

The valve seat contact area must be inspected after each cut.

32°

15°

32˚

For intake

For exhaust

45°

• When installing the solid pilot 1 , rotate it slightly.

• Seat the pilot snugly. Install the 45° cutter 2 and T-handle 3 .

INITIAL SEAT CUT

• Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.

• Measure the valve seat width W after every cut.

• If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more.

NOTE:

Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle.

45°

ENGINE 3-29

3-30 ENGINE

TOP NARROWING CUT

• If the contact area is too high on the valve, or if it is too wide, use the 15° or 32° cutter to lower and narrow the contact area.

Contact area too high and too wide on face of valve

(Use the 32° cutter for intake.)

(Use the 15° cutter for exhaust.)

32°: For intake

15°: For exhaust

FINAL SEAT CUT

• If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area.

NOTE:

After cutting the 15° and 32° angles, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width.

• After the desired seat position and width is achieved, use the

45°cutter very lightly to clean up any burrs caused by the previous cutting operations.

"

Do not use lapping compound after the final cut is made.

The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation.

NOTE:

After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. (

%

2-4)

VALVE SEAT SEALING CONDITION INSPECTION

With the valve and valve spring assembled, pour a small quantity of gasoline into the intake or exhaust port.

Check that no gasoline leaks though the valve seat. If leakage is found, correct the sealing surface.

&

Always use extreme caution when handling gasoline.

Contact area too low and too narrow on face of valve

45°

ENGINE 3-31

VALVE SPRING INSPECTION

The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism.

Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace both the inner and outer springs as a set.

#

Valve spring free length (IN & EX)

Service Limit: 37.2 mm

!

09900-20102 : Vernier calipers

#

Valve spring tension (IN & EX)

Standard: 121 – 139 N (12.1 – 13.9 kgf) at length 33.7 mm 121 – 139 N

33.7 mm

3-32 ENGINE

REASSEMBLY

• Apply molybdenum oil on the stem seal 1 and install it onto the valve guide by hand.

"

Replace the stem seal with new one.

'

MOLYBDENUM OIL

• With the entire surface of the valve stem coated with molybdenum oil, insert the valve 2 into the valve guide.

"

When installing the valve, insert the stem slowly while rotating and taking care not to cause damage to the oil seal lip.

• Install the spring seat 3 , valve spring 4 and spring retainer 5 .

"

Install the valve spring with the small-pitch side down

(facing the cylinder head) and the large-pitch side

(painted side) up.

Painted

• Compress the valve spring using the valve lifter and the attachment.

!

09916-14510: Valve lifter

09916-14910: Attachment (

φ

22)

09916-84511: Tweezers

"

Compressing of the valve spring must be limited to the extent only necessary to prevent the spring from fatigue.

• Install the valve cotter halves 7 .

NOTE:

To facilitate assembly, apply a little grease to the valve cotter when fitting into the valve stem groove.

"

Check that the rounded lip A of the cotter is securely fitted in the groove B in the valve stem end.

Painted

EXAUST PIPE

• Fit the new exhaust pipe gasket A .

• When installing the exhaust pipe, apply the THREAD LOCK to the exhaust pipe bolts and tighten them.

!

99000-32050: THREAD LOCK “1342”

"

Exhaust pipe bolt: 23 N.m (2.3 kgf.m)

CYLINDER

CYLINDER DISTORTION

Measure the distortion in diagonal directions on the cylinder upper surface. If the distortion exceeds the service limit, replace the cylinder.

#

Cylinder distortion: Service limit: 0.05 mm

$

09900-20803: Thickness gauge

CYLINDER BORE DIAMETER INSPECTION

Check that there is not abnormal surface damage or wear on the cylinder wall.

At three positions, top, middle and bottom, measure the bore diameter. At each position, take two measurements, one parallel with and the other perpendicular to the crankshaft axis.

#

Cylinder bore:

Standard: 44.000 – 44.015 mm

Limit: 44.100 mm

$

09900-20508: Cylinder gauge set

ENGINE 3-33

3-34 ENGINE

PISTON

PISTON DIAMETER INSPECTION

Measure the piston outside diameter in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer.

If the measurement is found less than the service limit, replace the piston.

#

Piston diameter:

Standard: 43.965 – 43.980 mm

Service Limit: 43.880 mm

Piston oversize: 0.5, 1.0 mm

%

09900-20202: Micrometer (25 – 50 mm)

PISTON-TO-CYLINDER CLEARANCE

To determine the piston-to-cylinder clearance, calculate the difference between the cylinder bore and the piston outside diameter.

#

Piston-to-cylinder clearance

Standard: 0.03 – 0.04 mm

Service Limit: 0.120 mm

PISTON PIN BORE

Using a small bore dial gauge, measure the piston pin bore both in the vertical and horizontal directions.

If the measurement exceeds the service limit, replace the piston.

#

Piston pin bore:

Standard: 12.002 – 12.008 mm

Service Limit: 12.030 mm

%

09900-20605: Dial calipers

PISTON PIN DIAMETER INSPECTION

Using a micrometer, measure the piston pin outside diameter at three positions, both the ends and the center.

If any of the measurements is found less than the service limit, replace the pin.

#

Piston pin O.D.:

Standard: 11.996 – 12.000 mm

Service Limit: 11.980 mm

%

09900-20205: Micrometer (0 – 25 mm)

10 mm

PISTON RING

PISTON RING FREE END GAP INSPECTION

Before installing piston rings, measure the free end gap of each ring using vernier calipers. If the gap is less than the service limit, replace the ring.

#

Piston ring free end gap:

Standard: (1st) Approx. 4.3 mm

(2nd) Approx. 5.4 mm

Service Limit: (1st) 3.4 mm

(2nd) 4.3 mm

%

09900-20102: Vernier calipers

PISTON RING END GAP INSPECTION

Insert the piston ring squarely into the cylinder using the piston head.

Measure the end gap with a thickness gauge.

If the gap exceeds the service limit, replace the piston ring.

#

Piston ring end gap:

Standard: (1st) 0.10 – 0.25 mm

(2nd) 0.10 – 0.25 mm

Service Limit: (1st) 0.5 mm

(2nd) 0.5 mm

%

09900-20803: Thickness gauge

PISTON RING-TO-GROOVE CLEARANCE INSPECTION

Remove carbon deposit both from the piston ring and its groove.

Fit the piston ring into the groove. With the ring compressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.

#

Piston ring-to-Groove clearance:

Limit: (1st) 0.18 mm

(2nd) 0.15 mm

#

Piston ring groove width

Standard:(1st) 1.01 – 1.03 mm

(2nd) 1.01 – 1.03 mm

(Oil) 2.01 – 2.03 mm

#

Piston ring thickness

Standard:(1st) 0.97 – 0.99 mm

(2nd) 0.97 – 0.99 mm

%

09900-20803: Thickness gauge

09900-20205: Micrometer (0 – 25 mm)

ENGINE 3-35

3-36 ENGINE

OVERSIZE RINGS

• Oversize piston ring

The following two types of oversize piston ring are used.

They bear the following identification numbers.

Piston ring 1st and 2nd

0.5 mm: 50

1.0 mm: 100

• Oversize oil ring

The following two types of oversize oil ring are used. They bear the following identification marks.

Oil ring side rail

0.5 mm: Painted red

1.0 mm: Painted yellow

• Oil ring spacer

Just measure outside diameter to identify the oil ring spacer as there is no mark or numbers on it.

0.5 mm O.S.

1.0 mm O.S.

CONROD AND CRANKSHAFT

CONROD SMALL END INSIDE DIAMETER INSPECTION

Using a small bore dial gauge, measure the conrod small end inside diameter both in vertical and horizontal directions. If any of the measurements exceeds the service limit, replace the conrod.

#

Conrod small end I.D.:

Standard: 12.006 – 12.014 mm

Service Limit: 12.040 mm

%

09900-20605: Dial calipers

CONROD DEFLECTION INSPECTION

Move the small end sideways while holding the big end immovable in thrust direction.

Measure the amount of deflection.

Turn the conrod and see if it moves smoothly without play and noise.

This method can check the extent of wear on the parts of the conrod’s big end.

#

Conrod deflecition: Service Limit: 3.0 mm

%

09900-20701: Magnetic stand

09900-20606: Dial gauge (1/100 mm)

09900-21304: V-block

CONROD BIG END SIDE CLEARANCE INSPECTION

Using a thickness gauge, measure the side clearance at the conrod big end. If the measurement is out of standard value, measure the conrod big end and the crank pin widths individually to determine which one is to be replaced.

#

Conrod big end side clearance

Standard: 0.10 – 0.56 mm

Service Limit: 1.00 mm

%

09900-20803: Thickness gauge

CRANKSHAFT RUNOUT INSPECTION

With the right and left crank journals supported with V-block, turn the crankshaft slowly. At this time, measure the crankshaft end runout using a dial gauge. If the runout exceeds the service limit, replace the crankshaft.

#

Crankshaft runout: Service Limit: 0.08 mm

%

09900-20701: Magnetic stand

09900-20606: Dial gauge (1/100 mm)

09900-21304: V-block

ENGINE 3-37

3-38 ENGINE

CRANKSHAFT REASSEBLY

• Decide the width between the webs referring to the figure below when rebuilding the crankshaft.

#

STD width between webs: 66.9 – 67.1 mm

Conrod No.1

Conrod No.2

Washer

Crank pin

Bearing

66.9 – 67.1 mm

GENERATOR COVER

GENERATOR INSPECTION:

9

6-8

SIGNAL GENERATOR INSPECTION:

9

6-19

DISASSEMBLY

• Remove the generator 1 and signal generator 2 .

66.9 – 67.1 mm

STARTER CLUTCH

Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction). The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the defective part(-s).

DISASSEMBLY

• Hold the generator rotor with the rotor holder and remove the starter clutch bolts.

%

09930-44530: Rotor holder

REASSEMBLY

• Assemble the starter clutch with its stamp mark facing outside.

• Apply a small quantity of THREAD LOCK SUPER “1303” to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder.

-

99000-32050: THREAD LOCK “1342”

%

09930-44530: Rotor holder

"

Starter clutch bolt: 10 N.m (1.0 kgf.m)

ENGINE 3-39

3-40 ENGINE

STARTER DRIVEN GEAR

STARTER DRIVEN GEAR BEARING

Install the starter driven gear bearing 1 and gear 2 onto the crankshaft and turn the starter driven gear by hand. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it.

DISASSEMBLY

• Remove the bearing using the special tool.

%

09921-20220: Bearing remover set (

φ

20)

REASSEMBLY

• Press in the needle bearing using a vice and bearing installer.

%

09913-70210: Bearing installer set (

φ

30)

CLUTCH COVER

OIL FILTER REPIACEMENT:

9

2-12

DISASSEMBLY

• Remove the circlip and right crankshaft oil seal.

%

09913-50121: Oil seal remover

• Draw out the clutch release camshaft 1 , oil seal 2 and bearing 3 .

REASSEMBLY

• With the grease to the clutch release camshaft and bearing applied, install them.

/

99000-25010: SUZUKI SUPER GREASE “A”

ENGINE 3-41

• Drive in the oil seal using the special tool.

%

09913-70210: Bearing installer set

• Install the circlip.

3-42 ENGINE

CLUTCH

CLUTCH DRIVE PLATES

Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.

%

09900-20101: Vernier calipers

#

Thickness: Service Limit: No. 1 2.6 mm

No. 2 3.1 mm

Claw width: Service Limit: No. 1 15.1 mm

No. 2 15.1 mm

CLUTCH DRIVEN PLATES

Measure each clutch driven plates for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.

%

09900-20803: Thickness gauge

#

Clutch driven plate distortion:

Service Limit: 0.10 mm

CLUTCH SPRING FREE LENGTH

Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring.

%

09900-20101: Vernier calipers

#

Clutch spring free length:

Service Limit: 38.5 mm

CLUTCH RELEASE BEARING

Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.

Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

PRIMARY DRIVEN GEAR

DISASSEMBLY

• Remove the ring 1 and oil pump drive gear 2 .

INSPECTION

Inspect the primary driven gear bearing for any damage. If any abnormal condition are found, replace the primary driven gear.

REASSEMBLY

• Install the oil pump drive gear with its flanged side A facing inside.

OIL PUMP

7

Do not attempt to disassemble the oil pump assembly.

This oil pump is available only as an assembly.

INSPECTION

Turn the oil pump shaft and check that rotation is smooth. If any abnormal condition is found, replace the oil pump with a new one.

GEARSHIFT SHAFT

Disassemble and reassemble the gearshift shaft as shown in right picture.

ENGINE 3-43

3-44 ENGINE

TRANSMISSION

DISASSEMBLY

• Disassemble the transmission gears as shown in right pictures.

1 Drive shaft

2 2nd driven gear

3 4th driven gear

4 3rd driven gear

5 5th driven gear

6 1st driven gear

7 Countershaft

8 5th drive gear

9 3rd drive gear

0 4th drive gear

A 2nd drive gear

INSPECTION

GEAR-SHIFTING FORK

Using a thickness gauge, check the shifting fork clearance in the groove of its gear.

The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.

If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.

%

09900-20803: Thickness gauge

09900-20101: Vernier calipers

#

Shift fork – Groove clearance:

Standard: 0.20 – 0.40 mm

Service Limit: 0.60 mm

#

Shift fork groove width:

Standard: 4.25 – 4.35 mm

#

Shift fork thickness:

Standard: 3.95 – 4.05 mm

REASSEMBLY

Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to following points:

NOTE:

Always use new circlips.

NOTE:

Before installing the gears, coat lightly engine oil to the driveshaft and countershaft.

7

* Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.

* When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft.

* After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

• When installing a new circlip, pay attention to the direction of the circlip. Fit it to the side where the thrust is as shown in figure.

TRANSMISSION GEARS AND RELATED PARTS

ENGINE 3-45

3-46 ENGINE

CRANKCASE

BEARING INSPECTION

Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase.

Replace the bearing in the following procedure if there is anything unusual.

DISASSEMBLY

• Remove the oil nozzle 1 .

RIGHT CRANKCASE BEARING

• Remove the bearing retainer.

• Remove the bearings 1 , 2 and 3 .

%

09921-20220: Bearing remover set

( 1 :

φ

20, 2 :

φ

25, 3 :

φ

17)

• Remove the bearing 4 .

%

09913-75520: Bearing installer set (

φ

55)

NOTE:

If abnormal noise does not occur, it is not necessary to remove the bearing.

7

The removed bearing should be replaced with a new one.

LEFT CRANKCASE BEARING

• Remove the oil seals 1 and 2 .

%

09913-50121: Oil seal remover

• Remove the bearing retainer.

• Remove the bearings 3 , 4 and 5 .

%

09921-20220: Bearing remover set

( 3 :

φ

20, 4 :

φ

17, 5 :

φ

35)

REASSEMBLY

Assemble the crankcase in the reverse order of disassembly.

Pay attention to the following points:

RIGHT CRANKCASE BEARING

• Drive in the bearings 1 , 2 , 3 and 4 .

%

09913-70210: Bearing installer set

( 1 :

φ

68, 2 :

φ

55, 3 :

φ

42, 4 :

φ

42)

LEFT CRANKCASE BEARING

• Drive in the bearings 1 , 2 and 3 .

%

09913-70210: Bearing installer set

( 1 :

φ

72, 2 :

φ

40, 3 :

φ

55)

ENGINE 3-47

3-48 ENGINE

• Install the oil seals 1 and 2 .

• Apply grease on the lip of oil seal.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Apply the engine oil to the O-ring.

• Install the oil nozzle.

NOTE:

Before installing the oil nozzle, check or clean its oil passage.

• Install the oil jet 3 as shown in illustration.

• Depress the breather union pipe 4 as shown in illustration.

20 mm

ENGINE 3-49

ENGINE REASSEMBLY

The engine reassembly can be performed in the reverse order of disassembly procedures. However, the following points must be observed in the reassembly operation.

7

* Make sure to coat the rotating and sliding sections with engine oil.

* Care must be taken so that the drive belt, drive face and driven face are completely free from oil and grease.

Starter clutch

Generator

Piston No.1

Conrod No.1

Piston pin

Conrod No.2

Washer

Crank pin

Primary drive gear

Bearing

80 N.m

(8.0 kgf.m)

Generator rotor

10 N.m (1.0 kgf.m)

66.9 – 67.1 mm

70 N.m (7.0 kgf.m)

[Left hand threads]

The Convex side of the washer faces outside.

3-50 ENGINE

. m)

. m (1.0 kgf

. m)

. m (5.0 kgf

. m

. m)

. m)

. m (1.0 kgf

. m

. m)

. m

. m)

. m

. m)

. m

. m)

ENGINE 3-51

3-52 ENGINE

CRANKSHAFT

• Using the special tool, press in the crankshaft into the left crankcase.

NOTE:

Fit steel plates between the crankcase and the special tool when installing the crankshaft with the special tool.

%

09910-32812: Crankshaft installer

09910-11310: Crankshaft installer attachment

09910-20116: Conrod holder

7

* Do not hit the crankshaft with a plastic hammer or the like to install it into the crankcase.

* Do not contact the conrod holder with the crankshaft when installing the crankshaft.

* Align the conrods position before installing the crankshaft.

TRANSMISSION

• Install the transmission.

GEARSHIFT CAM AND GEARSHIFT FORKS

• Install the geashift forks No. 1 1 , No. 2 2 and No. 3 3 .

• Install the geashift cam 4 and gearshift fork shafts 5 , 6 .

• Install the dowel pins 1 .

• Before assembling the crankcase, apply the engine oil to each gears and bearings.

• Apply sealant to the right crankcase.

4

99000-31110: SUZUKI BOND “1215”

7

* Coat the sealant evenly without break.

* Application of sealant must be performed within a short period of time.

* Take extreme care not to let sealant enter into the oil hole or bearing.

Right crankcase

ENGINE 3-53

3-54 ENGINE

• Assemble the crankcases with in few minutes.

• Install the clamp A .

• Tighten the crankcase bolts.

"

Crankcase bolt: 11 N.m (1.1 kgf.m)

NOTE:

* After the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly.

* If these shafts do not rotate smoothly, try to free it by tapping with a plastic hammer.

• Apply the grease to the driveshaft O-ring and oil seal lip.

• Install the driveshaft spacer.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Install the oil seal retainer.

GEARSHIFT SHAFT

• Install the gearshift arm stopper 1 .

"

Gearshift arm stopper: 19 N.m (1.9 kgf.m)

• Install the washer 2 and gearshift cam stopper 3 , and tighten the gearshift cam stopper bolt 4 .

"

Gearshift cam stopper bolt: 10 N.m (1.0 kgf.m)

• Hook the gearshift cam stopper spring 5 .

• Install the washer 6 and nut 7 .

• Check the neutral position.

• Install the gearshift cam stopper plate after aligning the gearshift cam pins A with the gearshift cam stopper plate holes.

• Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the specified torque.

-

99000-32050: THREAD LOCK “1342”

"

Gearshift cam stopper plate bolt: 10 N.m (1.0 kgf.m)

• Install the gearshift shaft after aligning the return spring with the gearshift arm stopper B .

• Install the washer 8 and circlip 9 .

ENGINE 3-55

3-56 ENGINE

SPEED SENSOR ROTOR

• Install the speed sensor rotor 1 and circlip 2 .

OIL PUMP

• Install the oil pump.

• Install the washer 1 and pin 2 .

• Install the oil pump driven gear 3 and circlip 4 .

CAM CHAIN TENSIONER

• Install the washer 1 and cam chain tensioner 2 , and tighten the cam chain tensioner bolt.

"

Cam chain tensioner bolt: 10 N.m (1.0 kgf.m)

• Install the cam chain drive sprocket 3 , cam chain 4 and key

5 .

ENGINE 3-57

PRIMARY DRIVE GEAR

• Install the primary drive gear 1 , washer 2 and primary drive gear nut.

NOTE:

* The convex side of the washer 2 faces outside.

* The primary drive gear nut has left hand threads.

* When tightening the primary drive gear nut, install the key and generator rotor temporarily.

• With the generator rotor held immovable using special tool, tighten the primary drive gear nut.

%

09930-44530: Rotor holder

"

Primary drive gear nut: 70 N.m (7.0 kgf.m)

PRIMARY DRIVEN GEAR

• Install the washer 1 and spacer 2 onto the countershaft.

NOTE:

Apply engine oil to the inside surface of the primary driven gear bearing.

• Install the primary driven gear assembly 3 and thrust washer

4 .

CLUTCH

• Install the clutch sleeve hub 1 , lock washer 2 and clutch sleeve hub nut.

Tightening

Direction

3-58 ENGINE

• Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool.

%

09920-53740: Clutch sleeve hub holder

"

Clutch sleeve hub nut: 50 N.m (5.0 kgf.m)

• Bend the lock washer securely.

• Install the clutch drive plates and driven plates.

1 Clutch drive plate No. 2

2 Clutch drive plate No. 1 (×2)

3 Clutch driven plate (×3)

Inside Outside

• Install the clutch plate spacer 4 .

• Install the clutch release rack 5 , bearing 6 and washer 7 .

• Install the clutch pressure plate 8 , clutch springs and clutch spring mounting bolts.

• Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern.

NOTE:

Make sure that the clutch pressure plate is installed correctly.

"

Clutch spring mounting bolt: 10 N.m (1.0 kgf.m)

CLUTCH COVER

• Install the two dowel pins and new gasket 1 .

• Apply engine oil to each gears, bearings and clutch plates.

• Face the rack teeth A backward and align the clutch release rack with the pinion gear.

• Tighten the clutch cover bolts securely.

NOTE:

Install the new gasket washer to the bolt B .

• Install the clutch release arm as shown in right illustration.

ENGINE 3-59

3-60 ENGINE

• Install the washer 1 , cam chain tensioner 2 and cam chain tensioner bolt.

• Tighten the cam chain tensioner bolt to the specified torque.

"

Cam chain tensioner bolt: 10 N.m (1.0 kgf.m)

• Install the cam chain.

STARTER CLUTCH AND GENERATOR ROTOR

• Fit the key 3 in the slot on the crankshaft.

• Degrease the tapered portion of the rotor and also the crankshaft. Use nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry.

• Install the starter driven gear 4 to the starter clutch rotating the starter driven gear.

• Install the rotor with the starter driven gear onto the crankshaft securely.

• With the generator rotor held immovable using special tool, tighten the generator rotor nut to the specified torque.

"

Generator rotor nut: 80 N.m (8.0 kgf.m)

%

09930-44530: Rotor holder

STARTER IDLE GEAR

• Install the starter idle gear 1 and its shaft 2 .

OIL SUMP FILTER

• Before installing the oil sump filter, clean it.

NOTE:

* The thinner side of the oil sump filter should be positioned inside.

* The lip A of the oil sump filter should be faced down ward.

GENERATOR COVER

• Install the new gasket and dowel pins 1 .

• Apply oil to the each gears, bearing and starter clutch.

• Install the generator cover and tighten the generator cover bolts.

"

Generator cover bolt: 10 N.m (1.0 kgf.m)

NOTE:

Install the new gasket washer to the bolt A .

ENGINE 3-61

3-62 ENGINE

PISTON RING

• Install the piston rings in the order of oil ring, 2nd ring and top ring.

• To install the oil ring, fit the spacer 1 first and then the side rails 2 .

7

* When inserting the spacer, take care not to have the ends overlapped.

* The top and 2nd rings have a stamped mark on the side. Be sure to bring the stamped mark side to the top when assembling to the piston.

* Be careful not to cause scratch on the piston when inserting the piston ring to the piston. Also, do not expand the piston ring more than necessary as the ring can break.

2

1

2

1st

“R”

2nd

“RN”

1

EX.

120°

120° 120°

2

3

IN.

• When all the piston rings have been assembled, check that each can turn smoothly.

• To minimize compression and oil leaks, locate each piston ring end gap in the position as shown in the right illustration.

1 2nd ring/side rail (lower side)

2 Side rail (upper side)

3 Top ring/spacer

PISTON

• Apply MOLYBDENUM OIL to the piston pin.

3

MOLYBDENUM OIL

• When installing the piston, turn the mark A on the piston head to exhaust side.

• After the piston pin has been inserted through the conrod, install the circlip 1 .

7

* Replace the circlip with a new one.

* Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crankcase.

* The circlip end gap must be positioned so as not to coincide with the piston pin bore cutaway.

CYLINDER

• Apply sealant to parting line of crankcase.

4

99000-31110: SUZUKI BOND “1215”

• Place the dowel pins 1 and a new gasket 2 on the crankcase.

7

Make sure to replace the gasket with a new one.

• Apply the engine oil to the conrod big end, piston and the piston rings.

• Coat the cylinder wall with oil.

• Install the cylinder.

NOTE:

Rear (No. 1) cylinder has cam chain tension adjuster hole “F” side.

Front (No. 2) cylinder has cam chain tension adjuster hole “R” side.

7

When inserting the piston into the cylinder, use care not to break the piston ring.

CAM CHAIN GUIDE

• Install the cam chain guide 1 and dowel pins 2 .

7

When installing the cam chain guide, check that the chain is properly engaged with the crankshaft sprocket.

CYLINDER HEAD

• Place a new cylinder gasket 1 facing the mark A upward.

7

Make sure to replace the gasket with a new one.

• Install the cylinder head.

ENGINE 3-63

3-64 ENGINE

• Apply the engine oil to the copper washers.

• Install the copper washer and cylinder head nuts.

• Tighten the cylinder head nuts diagonally and evenly.

• The nuts tightening must be performed in two stages; initial and final tightening.

"

Cylinder head nut: 25 N.m (2.5 kgf.m)

• Install the front piston, cylinder and cylinder head in the same manner of rear ones installation.

INTAKE PIPE

• Fit the intake pipe as shown in right picture.

• Apply the THREAD LOCK to the bolts and tighten them.

-

99000-32050: THREAD LOCK “1342”

CAMSHAFT

• Turn the crankshaft counterclockwise with the box wrench and align “ R” line on the generator rotor with the index mark on the generator cover keeping the camshaft drive chain pulled upward.

7

If crankshaft is turned without drawing the camshaft drive chain upward, the chain will be caught between crankcase and cam chain drive sprocket.

• Install the cam shafts to each cylinder head.

NOTE:

The camshaft can be distinguished by the embossed-letters, “F” and “R”.

“F” : Front (No. 2) cylinder

“R”: Rear (No. 1) cylinder

• Apply MOLYBDENUM OIL to the camshaft journals and cam faces.

3

MOLYBDENUM OIL

• Install the C-ring 1 .

• Align the engraved lines A on the front and rear camshafts so they are parallel with the surface of the cylinder heads.

• Engage the chains on the cam sprockets with the locating pin holes B as shown in the photograph.

NOTE:

Do not rotate the generator rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket.

No. 1 (REAR) CYLINDER

ENGINE 3-65

No. 2 (FRONT) CYLINDER

3-66 ENGINE

• Apply THREAD LOCK SUPER “1303” to the bolts and tighten them to the specified torque.

"

Cam chain sprocket bolt: 15 N.m (1.5 kgf.m)

.

99000-32030: THREAD LOCK SUPER “1303”

CAM CHAIN TENSION ADJUSTER

• Remove the cam chain tension adjuster set bolt 1 .

• Compress the tensioner shaft by releasing ratchet.

• Install a new gasket and cam chain tension adjuster.

• Tighten the cam chain tension adjuster bolts.

"

Cam chain tension adjuster bolt: 10 N.m (1.0 kgf.m)

• Install the cam chain tension adjuster set bolt with spring 2 and O-ring 3 .

"

Cam chain tension adjuster set bolt: 7 N.m (0.7 kgf.m)

7

* When the cam chain tension adjuster has been installed, check for cam chain tension to determine if the tension adjuster is functioning properly.

* Turn the crankshaft and check that all the moving parts work properly.

CYLINDER HEAD COVER

• Apply engine oil to the valve springs and cam chain.

• Install the dowel pins 1 and caps 2 .

ENGINE 3-67

• Thoroughly wipe off oil from the mating surfaces of cylinder head and cover.

• Uniformly apply SUZUKI BOND to the cylinder head surfaces.

5

99000-31160: SUZUKI BOND “1216”

7

Do not apply SUZUKI BOND to the camshaft journals.

3-68 ENGINE

• Install the cylinder head cover

NOTE:

* When tightening the cylinder head cover bolts, the piston must be at top dead center on the compression stroke.

* Install the new gasket washer to the bolts A .

* Align the cutaway of rocker arm shaft with the bolts A .

• Tighten the cylinder head cover bolts diagonally, and then if everything is satisfactory, tighten securely with a torque wrench to the specified torque.

"

Cylinder head cover bolt: 10 N.m (1.0 kgf.m)

• Check and adjust the valve clearance. (

9

2-4)

• Apply grease to the new O-ring and install the valve inspection caps.

/

99000-25010: SUZUKI SUPER GREASE “A”

"

Valve inspection cap (EX side): 18 N.m (1.8 kgf.m)

Valve inspection cap bolt and nut: 10 N.m (1.0 kgf.m)

• Install the generator cover plug 1 and timing inspection plug

2 .

"

Generator cover plug: 15 N.m (1.5 kgf.m)

Timing inspection plug: 21 N.m (2.1 kgf.m)

• Install the cylinder head cover caps.

"

Cylinder head cover cap bolt: 10 N.m (1.0 kgf.m)

NOTE:

Install the clamp to the bolt A .

Rear (No.1)

Front (No.2)

SPEED SENSOR

• Apply the grease to the O-ring and install the speed sensor.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Apply the THREAD LOCK to the speed sensor bolt and tighten it.

-

99000-32050: THREAD LOCK “1342”

SPARK PLUG

• Install the spark plugs. (

9

2-6)

ENGINE 3-69

3-70 ENGINE

GEAR POSITION SWITCH

• Install the springs 1 and contacts 2 .

• Apply the grease to the O-ring and install the gear position switch.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Pass through the gear position switch wire harness into the guide A .

STARTER MOTOR

• Apply the grease to the O-ring.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Mount the starter motor on the engine.

NOTE:

Install the clamp to the bolt A .

ENGINE 3-71

FUEL AND LUBRICATION SYSTEM 4-1

FUEL AND LUBRICATION SYSTEM

CONTENTS

FUEL SYSTEM ................................................................................. 4- 2

FUEL PUMP .................................................................................. 4- 2

FUEL TANK/FUEL COCK ................................................................ 4- 3

REMOVAL ..................................................................................... 4- 3

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

REASSEMBLY .............................................................................. 4- 4

FUEL PUMP ..................................................................................... 4- 5

REMOVAL, INSPECTION AND REASSEMBLY........................... 4- 5

CARBURETOR ................................................................................ 4- 6

SPECIFICATIONS ......................................................................... 4- 6

AIR CONTROLE VALVE ............................................................... 4- 7

SLOW SYSTEM ............................................................................ 4- 8

MAIN SYSTEM .............................................................................. 4- 9

ACCELERATOR PUMP SYSTEM ................................................ 4-10

REMOVAL ..................................................................................... 4-11

DISASSEMBLY ............................................................................. 4-11

INSPECTION ................................................................................. 4-14

CARBURETOR CLEANING ......................................................... 4-14

CARBURETOR HEATER AND THERMO-SWITCH

INSPECTION ................................................................................. 4-15

FUEL LEVEL ADJUSTMENT....................................................... 4-16

FLOAT HEIGHT ADJUSTMENT ................................................... 4-17

REASSEMBLY AND REINSTALLATION ..................................... 4-18

LUBRICATION SYSTEM.................................................................. 4-21

!

Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.

4

4-2 FUEL AND LUBRICATION SYSTEM

FUEL SYSTEM

The fuel pump is operated by a vacuum force which is supplied from the carburetor intake pipe. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. When the needle valve closes, the pressure of the fuel in the hose connecting the carburetor and the fuel pump increases, and when the set pressure is reached, the operation of the fuel pump is stopped by the fuel pressure to prevent excessive supply.

FUEL PUMP

Vacuum pulsations from the carburetor intake pipe are used to operate the pump diaphragm A . When vacuum is applied to the diaphragm A , fuel is drawn from the tank into the diaphragm’s chamber B . As positive pressure is applied, the diaphragm backs, pushing the fuel through the outlet to the carburetor.

A series of check valves ( 1 and 2 ) is used in the fuel flow route to allow the fuel to move in only one direction, through the pump body.

To intake pipe

From fuel cock

To carburetor

FUEL

VACUUM

If the fuel pressure in the chamber of carburetor side is too high, the return valve 3 is opened so that the fuel pressure is released to the chamber of fuel cock side.

FUEL

FUEL TANK/FUEL COCK

REMOVAL

!

Gasoline is very explosive. Extreme care must be taken.

• Remove the front seat. (

9

5-2)

• Remove the frame head cover. (

9

5-3)

• Disconnect the speedometer couplers.

FUEL AND LUBRICATION SYSTEM 4-3

• Remove the fuel tank mounting nut and bolt.

• Turn the fuel cock to “ON” and disconnect the fuel hose 1 and vacuum hose 2 .

• Remove the fuel tank.

• Remove the fuel tank cap.

• Remove the speedometer.

4-4 FUEL AND LUBRICATION SYSTEM

• Remove the fuel cock.

INSPECTION

FUEL COCK

If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel cock for cracks.

REMOUNTING

• Remount the fuel tank and fuel cock in the reverse order of removal.

!

* Gaskets 1 and 2 must be replaced with new ones to prevent fuel leakage.

* Tighten the fuel cock bolts evenly.

Fuel tank

Adhere

Cushion

Clamp

Cushion

Fuel cock

4.5 N.m (0.45 kgf.m)

Molding

10 N.m (1.0 kgf.m)

Cut the clamp after assembly.

FUEL PUMP

REMOVAL

• Remove the left frame cover. (

9

5-3)

• Turn the fuel cock to “ON”

• Disconnect the fuel hoses 1 , 2 and vacuum hose 3 .

• Remove the fuel pump mounting bolts.

INSPECTION

!

Gasoline is very explosive. Extreme care must be taken.

• Disconnect the fuel hose 2 , connect the suitable hose and insert the free end of the hose into a receptacle.

Check the fuel flow when cranking the engine for few seconds by pressing the starter button.

If the fuel flow is not found, check the fuel cock. (

9

4-4)

If the fuel cock and hoses are not fault, replace the fuel pump.

FUEL AND LUBRICATION SYSTEM 4-5

REASSEMBLY

Carry out the assembly procedure in the reverse order of disassembly.

• Install the clamp to the bolt A and tighten the bolts.

• Connect the fuel hoses 1 , 2 and vacuum hose 3 securely.

FUEL HOSE ROUTING:

9

7-18

Fuel hose 1 (To fuel cock)

Fuel hose 2 (To carburetor)

Vacuum hose 3 (To intake pipe)

4-6 FUEL AND LUBRICATION SYSTEM

CARBURETOR

SPECIFICATIONS

Carburetor type

Bore size

I.D. No.

Idle r/min.

Fuel level

Float height

Main jet

Main air jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Pilot screw

ITEM

Throttle cable play

E-02, 04, 34

MIKUNI BDS26

(M.J.)

(M.A.J.)

26 mm

26F0

1 400 ± 100 r/min.

11 ± 1.0 mm

9.9

±

1.0 mm

#102.5

#35

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(P.S.)

4DM9-4

O-1

#140

# 20

PRE-SET

(3-

1

/

4

turns out)

2 – 4 mm

SPECIFICATIONS

E-17, 22

←

←

26F1

←

←

←

←

←

←

←

←

←

E-22 (U-type)

←

←

←

←

←

←

←

←

←

←

←

←

← ←

← ←

E-18

←

←

26F2

1 400 ± 50 r/min.

←

←

←

←

←

←

#145

#17.5

PRE-SET

(3 turns out)

←

LOCATION OF CARBURETOR I.D. NO.

The carburetor I.D. is stamped on the location 1 on the carburetor as shown in the right photo.

FUEL AND LUBRICATION SYSTEM 4-7

AIR CONTROLE VALVE

• The air control valve changes the valve opening area to adjust the air volume for slow system in accordance with temperature variation, thereby supplying the optimum air/fuel mixture for idling operation.

In this system, air is taken in from the clean side of air cleaner and guided into the slow system through the air control valve.

Air supplied both from the slow air jet and the air control valve is metered by the pilot screw to produce air/ fuel mixture most appropriate for the current atmospheric temperature, and then jetted into the main bore.

Left air cleaner box

Pilot screw

Air cleaner element

Air control valve

AIR

FUEL/AIR MIXTURE

FUEL

When temperature is low (air density being high):

• The thermo-wax inside the air control valve shrinks and the valve opening area is narrowed due to spring force.

When temperature is high (air density being low):

• The thermo-wax inside the air control valve expands causing the piston to push the valve resulting in widened opening area.

Spring

Slow jet

Slow air jet

Valve

Piston

Air density being low

Air density being high

4-8 FUEL AND LUBRICATION SYSTEM

SLOW SYSTEM

This system supplies fuel during engine operation when the throttle valve 1 is closed or slightly opened. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4 . This mixture, rich with fuel, then goes up through the pilot passage to the pilot screw 5 . Part of the mixture is discharged into the main bore through bypass ports 6 . The mixture is metered by the pilot screw

5 and sprayed into the main bore through the pilot outlet port 7 .

AIR

FUEL/AIR MIXTURE

FUEL

FUEL AND LUBRICATION SYSTEM 4-9

MAIN SYSTEM

As the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve 2 to move upward.

The fuel in the float chamber 3 is metered by the main jet 4 . The metered fuel enters the needle jet 5 , mixes with the air admitted through the main air jet 6 and forms an emulsion.

The emulsified fuel then passes through the clearance between the needle jet 5 and jet needle 7 and is discharged into the venturi A , where it meets the main air stream being drawn by the engine.

Mixture proportioning is accomplished in the needle jet 5 . The clearance through which the emulsified fuel must flow ultimately depends on throttle position.

AIR

FUEL/AIR MIXTURE

FUEL

4-10 FUEL AND LUBRICATION SYSTEM

ACCELERATOR PUMP SYSTEM

This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve) is slow and sucking volume of fuel is less.

The throttle valve lever 1 turns lever 2 , and lever 3 turns and pushes rod 4 . The rod 4 pushes plunger

5 . This plunger pushes out the fuel through outlet pipe 6 , spraying fuel into the main bore.

FUEL

REMOVAL

• Remove the fuel tank. (

9

4-3)

• Remove the air cleaner box. (

9

3-3)

• Remove the fuel hose 1 .

• Disconnect the throttle position sensor coupler 2 .

• Remove the throttle cables 3 and starter plunger 4 .

• Loosen the clamp screw and remove the carbureter.

DISASSEMBLY

• Remove the carburetor top cap 1 .

• Remove the spring 2 and piston valve 3 along with diaphragm

4 .

• Remove the jet needle cap 5 , spring 6 , retainer 7 and jet needle 8 .

FUEL AND LUBRICATION SYSTEM 4-11

4-12 FUEL AND LUBRICATION SYSTEM

• Remove the float chamber body 1 .

• Remove the accelerator pump plunger 2 .

• Remove the float assembly 3 along with the needle valve 4 by removing the pin.

7

Do not use a wire to clean the valve seat.

• Remove the valve seat 5 .

• Remove the main jet 6 , jet holder 7 and pilot jet 8 .

7

Do not use a wire to clean the passage and jets.

• Remove the throttle cable bracket.

FUEL AND LUBRICATION SYSTEM 4-13

• Remove the pilot screw 1 .

(Except for E-18.)

NOTE:

Before removing the pilot screw, determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw. This counted number is important when reassembling pilot screw to original position.

PILOT SCREW REMOVAL (Only for E-18)

Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be removed before cleaning.

• Use a 1/8” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug.

• Thread a self-tapping sheet metal screw into the plug. Pull on the screw head with pliers to remove the plug. Carefully clean any metal shavings from the area.

• Slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly after cleaning.

• Remove the pilot screw along with the spring, washer, and Oring.

• After cleaning, reinstall the pilot screw to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.

• Install a new plug by tapping it into place with a punch.

1 Drill-stop

2 Plug

3 Pilot screw

4 Carburetor body

4-14 FUEL AND LUBRICATION SYSTEM

INSPECTION

Check the following parts for damage and clogging.

* Pilot jet

* Main jet

* Main air jet

* Pilot air jet

* Needle jet holder

* Float

* Jet needle

* Piston valve

* Starter jet

* Gaskets and O-rings

* Pilot outlet and bypass

* Coasting enrichement valve

* Needle valve

* Valve seat

If any abnormal condition is found, wash the part clean. If damage or clogging is found, replace the part with a new one.

Check for stopped wear

Needle value

Foreign substance

CARBURETOR CLEANING

!

Some carburetor cleaning chemicals, especially diptype 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 circuits of the carburetor thoroughly-not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if necessary, to loosen dirt and varnish. Blow the body dry using compressed air.

7

Do not use a wire to clean the jets or passageways. A wire can damage the jets and passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the carburetor components.

• After cleaning, reassemble the carburetor with new seals and gaskets.

CARBURETOR HEATER

(Only for E-02)

• Disconnect the carburetor heater terminal lead wires.

• Connect the positive + terminal of a 12V battery to the terminal of the carburetor heater and the battery negative terminal to the terminal.

• Check that the heater section A is heated in 5 minutes after the battery has been connected.

• Measure the resistance between the terminals.

%

09900-25008: Multi-circuit tester

#

Carbaretor heater resistance: STD: 12 – 18

Ω

FUEL AND LUBRICATION SYSTEM 4-15

THERMO-SWITCH INSPECTION

(Only for E-02)

• Cool the thermo-switch 1 with ice water and check for continuity.

%

09900-25008: Multi-circuit tester

#

Thermo-switch continuity:

Below 8 – 14°C

Above 15 – 21°C

Yes

No

THROTTLE POSITION SENSOR

Measure the resistance between the terminals as shown in the illustration.

#

Throttle position sensor resistance: Approx. 5 k Ω

NOTE:

When performing this test, it is not necessary to remove the throttle position sensor.

4-16 FUEL AND LUBRICATION SYSTEM

FUEL LEVEL

!

This inspection must be performed in an area well ventilated, away from fire or sparks since gasoline, an explosive fluid, is used in this operation.

• Remove the carburetor.

• Install the special tool to the carburetor drain outlet.

• Loosen the drain bolt 1 .

%

09913-10760: Fuel level gauge

• Adjust the carburetor to the proper angle holding the body with a vice or the like.

Carburetor set position: Lateral direction : Horizontal

Longitudinal direction: 80°

• Fill gasoline in the carburetor.

• Remove air completely from the fuel level gauge.

• With the level gauge held vertical, lower the gauge slowly and align the datum point 2 with the gauge graduation.

• Wait until the fuel level stabilizes.

• Determine the zero point on the gauge graduation and after waiting again for level stabilization, measure the height from the datum point.

#

Fuel level: 11 ± 1 mm under from datum point

80°

NOTE:

The apparent fuel level measured in the level gauge is higher than the actual level in the float chamber because of meniscus effect. (Meniscus is approximately 1 mm.)

Fuel level in gauge

Fuel level in float

FLOAT HEIGHT ADJUSTMENT

To check the float height, turn the carburetor upside down. Measure the float height A while the float arm is just contacting the needle valve using vernier calipers.

%

09900-20102: Vernier calipers

#

Float height A : 9.9 ±±±±± 1.0 mm

• Bend the float arm 1 as necessary to bring the float height A to the specified level.

• After adjustment, check the float height and the fuel level again.

FUEL AND LUBRICATION SYSTEM 4-17

4-18 FUEL AND LUBRICATION SYSTEM

REASSEMBLY AND REINSTALLATION

Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions.

7

* Assemble the parts taking consideration of their function.

* Replace O-rings and seals with new ones.

• After cleaning, reinstall the pilot screw to the original setting by turning the screw in until it lightly seats, and then backing it out the same number of turns counted during disassembly.

7

Replace the O-ring A with a new one.

• Apply grease to the O-ring and install the accelerating plunger.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Fit the seal rings securely to the float chamber and install the float chamber to the throttle body.

• Install the clamp to the screw A and tighten the screws.

• Install the jet needle with the pin B on the spacer securely engaged with the hole C on the piston valve.

• Align the hole D of the diaphragm with the passage way on the carburetor body.

FUEL AND LUBRICATION SYSTEM 4-19

• Install the clamp to the screw E and tighten the screws.

• Apply thermo-grease to the threads and tighten the carburetor heater. (Only for E-02)

99000-59029: THERMO-GREASE

"

Carburetor heater: 3 N.m (0.3 kgf.m)

4-20 FUEL AND LUBRICATION SYSTEM

THROTTLE POSITION SENSOR POSITIONING

• Install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle position sensor.

sensor terminals as shown in the illustration.

#

Throttle position sensor resistance : Approx. 5 k Ω sensor terminals as shown in the illustration.

• Fully open the throttle valve with the throttle lever.

– 4.63 k

Ω

.

throttle position sensor mounting screws.

#

Throttle position sensor resistance :

3.09 – 4.63 k

Ω

• After the assembly and installation on the engine have been completed, perform the following adjustment.

* Throttle cable adjustment (

9

2-9)

* Idle speed adjustment (

9

2-9)

Ω

2

Ω

1

LUBRICATION SYSTEM

FRONT (No. 2) CYLINDER

FUEL AND LUBRICATION SYSTEM 4-21

REAR (No. 1) CYLINDER

CHASSIS

CONTENTS

EXTERIOR PARTS REMOVAL AND REMOUNTING ........................ 5- 2

FRONT FENDER ............................................................................ 5- 2

FRONT SEAT .................................................................................. 5- 2

REAR SEAT .................................................................................... 5- 2

LUGGAGE BOX .............................................................................. 5- 2

FRAME COVER .............................................................................. 5- 3

REAR FENDER .............................................................................. 5- 5

FRONT WHEEL .................................................................................. 5- 7

REMOVAL ....................................................................................... 5- 7

INSPECTION AND DISASSEMBLY ............................................... 5- 8

REASSEMBLY ................................................................................ 5-10

REMOUNTING ................................................................................ 5-12

FRONT BRAKE .................................................................................. 5-13

CALIPER REMOVAL AND DISASSEMBLY .................................. 5-13

CALIPER INSPECTION .................................................................. 5-14

CALIPER REASSEMBLY ............................................................... 5-14

CALIPER REMOUNTING ............................................................... 5-15

BRAKE DISC INSPECTION ........................................................... 5-16

MASTER CYLINDER REMOVAL AND DISASSEMBLY ............... 5-17

MASTER CYLINDER INSPECTION ............................................... 5-18

MASTER CYLINDER REASSEMBLY AND REMOUNTING ......... 5-18

HANDLEBARS .................................................................................. 5-20

REMOVAL ....................................................................................... 5-20

REMOUNTING ................................................................................ 5-21

FRONT FORK..................................................................................... 5-22

REMOVAL AND DISASSEMBLY ................................................... 5-22

INSPECTION ................................................................................... 5-25

REASSEMBLY AND REMOUNTING ............................................. 5-26

STEERING .......................................................................................... 5-30

REMOVAL AND DISASSEMBLY ................................................... 5-30

INSPECTION ................................................................................... 5-31

REASSEMBLY AND REMOUNTING ............................................. 5-32

REAR WHEEL .................................................................................... 5-35

REMOVAL ....................................................................................... 5-36

INSPECTION AND DISASSEMBLY ............................................... 5-37

REASSEMBLY AND REMOUNTING ............................................. 5-39

REAR BRAKE .................................................................................... 5-42

REMOVAL AND DISASSEMBLY ................................................... 5-42

INSPECTION ................................................................................... 5-43

REASSEMBLY AND REMOUNTING ............................................. 5-43

REAR SHOCK ABSORBER .............................................................. 5-45

REMOVAL ....................................................................................... 5-45

INSPECTION ................................................................................... 5-45

REMOUNTING ................................................................................ 5-45

SWINGARM ........................................................................................ 5-46

REMOVAL ....................................................................................... 5-46

INSPECTION AND DISASSEMBLY ............................................... 5-47

REASSEMBLY AND REMOUNTING ............................................. 5-48

CHASSIS 5-1

5

5-2 CHASSIS

EXTERIOR PARTS REMOVAL AND

REMOUNTING

FRONT FENDER

• With the bolts removed, remove the front fender.

FRONT SEAT

• Remove the front seat with the ignition key.

REAR SEAT

• Remove the front seat.

• With the bolts removed, remove the rear seat.

LUGGAGE BOX

• Remove the luggage box as shown in illustration.

Luggage box

Tool holder

CHASSIS 5-3

FRAME COVER

Frame head cover

RIGHT FRAME COVER

• Remove the bolt.

• With the hooks A removed, remove the right frame cover.

RIGHT REAR FRAME COVER

• Remove the right frame cover.

• With the screw and bolts removed, remove the right rear frame cover.

Rear frame cover

R & L

Upper frame cover R &L

Frame cover

R & L

Left side only

5-4 CHASSIS

LEFT FRAME COVER

• Remove the screw and bolts.

• Remove the hook A .

• With the seat lock cable disconnected, remove the left frame cover.

LEFT REAR FRAME COVER

• Remove the left frame cover

• With the screw and bolts removed, remove the left rear frame cover.

REAR FENDER

Rear fender front mud guard

Rear fender

Ignitor bracket

Rear frame brace

23 N.m (2.3 kgf.m)

• Remove the front and rear seats.

• Remove the frame covers and luggage box.

• Remove the ignitor unit 1 and turn signal relay assembly 2 .

• Disconnect the rear turn signal light couplers and rear combination light coupler.

CHASSIS 5-5

5-6 CHASSIS

• With the bolt removed, remove the rear fender.

FRONT WHEEL

Left Right

CHASSIS 5-7

"

ITEM

A

B

C

N.m

65

23

23 kgf.m

6.5

2.3

2.3

REMOVAL

• Loosen the axle pinch bolt 1 .

• Loosen the front axle 2 .

• Raise the front wheel off the ground with a jack.

• Remove the front wheel by removing the front axle 2 .

7

When using a jack, take care not to cause scratches on the chassis.

• Remove the brake disc.

A Front axle

B Axle pinch bolt

C Brake disc bolt

5-8 CHASSIS

INSPECTION AND DISASSEMBLY

TIRE

For inspection of the tire:

9

2-16

FRONT AXLE

Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle.

%

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block set (100 mm)

#

Front axle shaft runnout:

Service Limit: 0.25 mm

WHEEL

Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

#

Wheel runout:

Service Limit (axial and radial): 2.0 mm

SPOKE NIPPLE

Check to be sure that all nipples are tight, and retighten them as necessary using a spoke nipple wrench.

%

09940-60113: Spoke nipple wrench

"

Spoke nipple: 4.5 N.m (0.45 kgf.m)

WHEEL BEARINGS

Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation.

Replace the bearing in the following procedure if there is anything unusual.

WHEEL BEARINGS REMOVAL

• Remove the wheel bearings by using the special tool A or B .

%

09921-20220: A Bearing remover set or 09941-50111: B Wheel bearing remover

7

The removed bearings should be replaced with new ones.

CHASSIS 5-9

5-10 CHASSIS

REASSEMBLY

Reassemble the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:

Left Right

"

ITEM

A

B

C

N.m

65

23

23 kgf.m

6.5

2.3

2.3

A Front axle

B Axle pinch bolt

C Brake disc bolt

WHEEL BEARING

• Apply grease to the wheel bearings.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Install the wheel bearings as follows by using the special tools.

%

09941-34513: Bearing/Steering race installer A

09913-70210: Bearing installer set (

φ

40 mm) B

7

First install the right wheel bearing, then install the left wheel bearing.

The sealed cover of the bearing must face outside.

Left Right Left Right

CHASSIS 5-11

BRAKE DISC

Make sure that the brake disc is clean and free of any greasy matter.

• Apply THREAD LOCK SUPER “1360” to the disc mounting bolts and tighten them to the specified torque.

"

Brake disc bolt: 23 N.m (2.3 kgf.m)

,

99000-32130: THREAD LOCK SUPER “1360”

Clearance

5-12 CHASSIS

REMOUNTING

Remount the front wheel in the reverse order of removal. Pay attention to the following points:

• Set the wheel spacer and install the front wheel with the front axle.

Spacer A : Right side

Spacer B : Left side

• Tighten the front axle 1 to the specified torque.

"

Front axle: 65 N.m (6.5 kgf.m)

• Tighten the axle pinch bolt 2 to the specified torque.

"

Axle pinch bolt: 23 N.m (2.3 kgf.m)

CHASSIS 5-13

FRONT BRAKE

!

* Do not mix with brake fluid of different brand.

* Do not use a brake fluid kept in a open container or stored for long period of time.

* To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.

* When filling brake fluid, take care not to allow water or dirt to enter the system.

* To wash the brake system parts, use brake fluid and not any other material.

* Do not allow dirt and fluids to contact the brake disc or pad.

7

Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause discoloration or crack.

BRAKE FLUID REPLACEMENT

• For replacing procedure of brake fluid:

9

2-14

BRAKE PAD REPLACEMENT

• For replacing procedure of brake pad:

9

2-14

CALIPER REMOVAL AND DISASSEMBLY

• Drain brake fluid. (

9

2-14)

7

To prevent brake fluid from splashing on the parts nearby, cover the parts with cloth.

• Remove the union bolt 1 and caliper mounting bolts 2 .

• Remove the brake pad. (

9

2-14)

• Remove the brake caliper holder 3 .

5-14 CHASSIS

• Using an air blow gun, pressurize the caliper fluid chamber to push out the piston.

!

* Place a rag over the piston to prevent it from popping out and flying and keep hand off the piston.

* Be careful of brake fluid which can possibly splash.

* Do not use high pressure air but increase the pressure gradually.

• Remove the dust seal 1 and piston seal 2 .

7

* Use care not to cause scratch on the cylinder bore.

* Do not reuse the piston seal and dust seal that have been removed.

CALIPER INSPECTION

Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages.

If any abnormal condition is noted, replace the caliper.

CALIPER REASSEMBLY

Reassemble the caliper in the reverse order of disassembly procedures and observe the following points.

7

* Wash the caliper components with fresh brake fluid before reassembly. Do not wipe off brake fluid after washing the components.

* Replace the piston seal and dust seal with new ones with brake fluid applied.

+

Brake fluid specification and classification: DOT 4

Dust seal

Piston seal

Caliper body

• Install the brake pad spring.

• Apply grease to the brake caliper holder.

0

99000-25100: SUZUKI SILICONE GREASE

• Install the brake pads. (

9

2-14)

CALIPER REMOUNTING

• Tighten the caliper mounting bolts 1 .

• With the hose end seted to the stopper, tighten the union bolt

2 .

"

Caliper mounting bolt: 39 N.m (3.9 kgf.m)

Union bolt: 23 N.m (2.3 kgf.m)

• For assembly procedure of brake hose:

9

7-16

• Fill the system with brake fluid and bleed air. (

9

2-14)

INSPECTION AFTER REASSEMBLY

Brake (

9

2-13)

CHASSIS 5-15

5-16 CHASSIS

BRAKE DISC INSPECTION

Check the brake disc for damage or cracks. Measure the thickness using the micrometer.

Replace the brake disc (

9

5-7) if the thickness is less than the service limit or if damage is found.

%

09900-20205: Micrometer (0 – 25 mm)

#

Brake disc thickness: Service Limit: 4.5 mm

Measure the runout using the dial gauge.

Replace the brake disc if the runout exceeds the service limit.

%

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

#

Brake disc runout: Service Limit: 0.30 mm

• If either measurement exceeds the service limit, replace the brake disc. (

9

5-7)

MASTER CYLINDER REMOVAL AND

DISASSEMBLY

• Drain brake fluid from the front brake side reservoir. (

9

2-

14)

• Disconnect the brake light switch lead wire coupler.

• Remove the union bolt 1 .

7

Place a rag under the union bolt so that brake fluid may not contact the parts.

• Remove the master cylinder.

• Remove the brake light switch 1 and brake lever 2 .

• Remove the reservoir tank cap.

• Detach the dust seal boot 3 and remove the circlip.

• Pull out the piston/cup set 4 and spring 5 .

CHASSIS 5-17

5-18 CHASSIS

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other damage.

Inspect the piston surface for any scratches or other damage.

Inspect the primary cup, secondary cup and dust seal for wear or damage.

MASTER CYLINDER REASSEMBLY AND

REMOUNTING

Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points:

7

* Wash the master cylinder components with new brake fluid before reassembly.

* Do not wipe the brake fluid off after washing the components.

* When washing the components, use the specified brake fluid. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc.

* Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly.

+

Specification and Classification: DOT 4

NOTE:

When installing the circlip, make sure that the sharp edge of the circlip faces outside.

• When reinstalling the brake light switch, align the projection on the switch with the hole in the master cylinder.

• Apply the grease to the brake lever pivot.

/

99000-25010: SUZUKI SUPER GREASE “A”

• When remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface A with punch mark B on the handlebars and tighten the upper clamp bolt first.

"

Master cylinder bolt: 10 N.m (1.0 kgf.m)

• Install the brake hose union (

9

7-16), tighten the union bolt to the specified torque.

"

Brake hose union bolt: 23 N.m (2.3 kgf.m)

7

Bleed air from the brake system after reassembling the master cylinder. (

9

2-14)

Master cylinder

Upper clamp bolt

Handlebars

Clearance

CHASSIS 5-19

5-20 CHASSIS

HANDLEBARS

HANDLEBAR RIGHT SIDE PARTS REMOVAL

• Remove the right handlebar switches 1 .

• Disconnect the brake light switch lead wires and remove the master cylinder. (

9

5-17)

• Remove the handlebar balancer 2 and grip 3 .

HANDLEBAR LEFT SIDE PARTS REMOVAL

• Remove the left handlebar switches 1 .

• Remove the handlebar balancer 2 and grip 3 .

• Remove the clutch lever holder.

• Remove the clamp bolts and detach the handlebar holders.

• Remove the handlebars.

REMOUNTING

Perform the remounting work in the reverse order of the removal procedures while observing the following instructions.

• Install the handlebers with the punch mark A aligned with the handleber clamp as shown.

• Tighten the handlebar clamp bolts to the specified torque.

"

Handlebar clamp bolt: 23 N.m (2.3 kgf.m)

NOTE:

The convex side of the washer 1 faces downward.

NOTE:

The gap B between the handlebar clamp and holder should be even.

• With the stopper C engaged with the handlebar hole, assemble the handlebar switch.

• Align the mating face of clutch lever holders with the respective punch marks D and tighten the bolt.

• Install the brake master cylinder. (

9

5-18)

• Apply the grease to the throttle cables and assemble them to the pulley.

/

99000-25010: SUZUKI SUPER GREASE “A”

• With the stopper E engaged with the handlebar hole, assemble the handlebar switch.

CHASSIS 5-21

5-22 CHASSIS

FRONT FORK

"

ITEM

A

B

N.m

23

30 kgf.m

2.3

3.0

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (

9

5-7)

• Remove the brake caliper. (

9

5-13)

7

Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose.

• Remove the front fender. (

9

5-2)

1 O-ring

2 Spacer

3 Washer

4 Front fork spring

5 Damper rod ring

6 Damper rod

7 Rebound spring

8 Inner tube

9 Dust seal

0 Oil seal stopper ring

A Oil seal

B Oil seal retainer

C Slide metal

D Guide bushing

E Oil lock piece

F Outer tube

G Gasket

A Front fork cap bolt

B Damper rod bolt

• Remove the turn signal light.

• Remove the front fork after loosening the front fork upper and lower clamp bolts ( 1 , 2 )

NOTE:

Slightly loosen the front fork cap bolt 3 to facilitate later disassembly.

• Remove the front fork cap bolt 3 , spacer 4 , washer 5 and spring 6 .

• Invert the front fork and stroke it several times to drain out the fork oil.

• Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain.

• With the damper rod held immovable, remove the damper rod bolt.

%

09940-34520: “T” handle A

09940-34581: Attachment B

• Remove the damper rod 7 and rebound spring 8 from the inner tube.

CHASSIS 5-23

5-24 CHASSIS

• Remove the dust seal 1 and oil seal stopper ring 2 .

• Separate the inner tube from the outer tube.

• Remove the following parts.

3 Oil seal

4 Oil seal retainer

5 Slide metal

6 Guide bushing

7 Oil lock piece

7

The removed oil seal, slide metal and guide bushing should be replaced with new ones.

INSPECTION

FRONT FORK SPRING

Measure the free length of the front fork spring.

If the length is found shorter than the service limit, replace the spring.

#

Front fork spring free length: Limit: 284 mm

INNER TUBE AND OUTER TUBE

Check the sliding surface of the inner tube, outer tube and damper rod ring for scratch, wear, bending, or other abnormal condition.

CHASSIS 5-25

5-26 CHASSIS

REASSEMBLY AND REMOUNTING

Perform the reassembly and remounting work in the reverse order of the disassembly and removal procedures while observing the following instructions.

7

* Thoroughly wash all the component parts being assembled.

Insufficient washing can result in oil leakage or premature wear of the parts.

* When reassembling the front fork, use new fork oil.

* Use the specified fork oil for the front fork.

* When reassembling, replace the slide metals, oil seal, dust seal and damper rod bolt gasket with new ones.

* Use care not to cause damage to the slide metal surfaces since the surfaces are TEFLON coated.

• On the inner tube, assemble the following parts.

1 Dust seal

2 Oil seal stopper ring

3 Oil seal

4 Oil seal retainer

5 Slide metal

6 Guide bushing

7

To prevent the lip of oil seal 3 from being damaged, cover the inner tube with vinyl sheet A during installation.

• With the oil lock piece 7 fitted to the inner tube so that its taper side face upward, assemble the inner tube to the outer tube.

• Apply grease to the lip of the oil seal 3 and install it into the outer tube using the front fork oil seal installer.

/

99000-25010: SUZUKI SUPER GREASE “A”

%

09940-52861: Front fork oil seal installer set

7

Wash clean the front fork oil seal installer before using.

If dirt is on the installer, the inner tube may possibly be damaged during press-fitting work.

• Fit the stopper ring 2 and dust seal 1 .

7

Make sure that the stopper ring is securely fitted into the groove on the outer tube.

1 Dust seal

2 Oil seal stopper ring

3 Oil seal

4 Oil seal retainer

5 Slide metal

• Fit the rebound spring 7 on the damper rod 6 and install them together to the inner tube.

• Apply the thread lock to the damper rod bolt 9 .

• With the damper rod held immovable, with the gasket 8 fitted, tighten the damper rod bolt 9 .

"

Damper rod bolt: 30 N.m (3.0 kgf.m)

:

99000-32110: THREAD LOCK “1322”

%

09940-34520: “T” handle A

09940-34581: Attachment B

7

Replace the gasket with a new one.

CHASSIS 5-27

5-28 CHASSIS

FRONT FORK OIL

• With the inner tube in fully compressed position, pour the specified amount of fork oil and stroke the tube several times to expel air.

$

99000-99044-10G: FORK OIL #10

#

Front fork oil capacity (each leg): 406 ml

• With the front fork held in vertical position, compress the inner tube all the way.

• Wait until the fluid level stabilizes, measure and adjust the level to specification using the special tool.

#

Front fork oil level (without spring): 88 mm

%

09943-74111: Front fork oil level gauge

• When installing the front fork spring 1 , closed pitch end should position upside.

• Assemble the washer 2 and spacer 3 .

• Fit the O-ring to the front fork cap bolt and apply grease.

/

99000-25010: SUZUKI SUPER GREASE “A”

7

Use a new O-ring to prevent oil leakage.

• Install the front fork to the motorcycle.

• Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket.

• Tighten the front fork lower clamp bolts 1 and front fork cap bolts 2 to the specified torque.

• Tighten the front fork upper clamp bolts 3 to the specified torque.

"

Front fork upper clamp bolt: 23 N.m (2.3 kgf.m)

Front fork lower clamp bolt: 33 N.m (3.3 kgf.m)

Front fork cap bolt: 23 N.m (2.3 kgf.m)

• With the stopper nut installed to the stearing stem hole A , assemble the turn signal light.

• Install the front fender and tighten the mounting bolts temporarily.

• Install the front brake caliper. (

9

5-15)

• Install the front wheel. (

9

5-12)

• Move the front fork up and down several times.

• Tighten the front fender mounting bolts securely.

CHASSIS 5-29

5-30 CHASSIS

STEERING

REMOVAL AND DISASSEMBLY

• Remove the front wheel. (

9

5-7)

• Remove the front fork. (

9

5-22)

• Remove the cable guide.

• With the nuts removed, remove the headlight housing 1 .

• Remove the handlebars. (

9

5-20)

• Remove the brake hose clamp bolt.

• Remove the stearing stem head nut 2 .

• Remove the stearing stem upper bracket.

• Remove the steering stem nut 3 using the special tool.

%

09940-14911: Steering stem nut wrench

• Draw out the steering stem lower bracket.

NOTE:

Hold the steering stem lower bracket to prevent from falling.

• Remove the handlebar holders by removing the nuts.

• To remove the lower inner race, use a chisel like, plain head steel rod.

7

* Unless corrosion, damage or other abnormal condition is found, the bearing race need not be replaced.

* Once the lower inner race has been removed, replace it with a new one.

• Drive out the steering stem bearing outer races using the special tools 1 and a suitable wedge bar 2 .

%

09941-54911: Bearing outer race remover 1

INSPECTION

Check the steering stem and steering stem head for any damage.

Check the bearing and race for corrosion, nick or other damage.

CHASSIS 5-31

5-32 CHASSIS

REASSEMBLY AND REMOUNTING

Reassembly and reinstallation can be performed in the reverse order of removal and disassembly procedures. However, operate the work taking care for the following points.

• Press in the upper and lower outer race using the special tool.

%

09941-34513: Bearing/Steering race installer

• Press in the lower inner race 1 .

%

09941-74911: Steering bearing installer

• Apply grease to the upper bearing, lower bearing and outer races prior to installing the steering stem.

%

99000-25010: SUZUKI SUPER GREASE “A”

• Install the upper inner race 2 and dust cover 3 .

• Install the handlebar holders and tighten their nuts temporarily.

• Install the steering stem.

• Tighten the steering stem nut.

"

Steering stem nut: 45 N.m (4.5 kgf.m)

%

09940-14911: Steering socket wrench

• Turn the steering stem lower bracket about five or six times to the left and right.

• Loosen the steering stem nut ¼ – ½ of a turn A .

NOTE:

This adjustment will vary from motorcycle to motorcycle. Make sure that the steering turns smoothly and easily in both directions without play.

• Install the steering stem upper bracket 1 and washer 2 .

• Tighten the steering stem head nut temporarily.

• Install the handlebars. (

9

5-21)

• Tighten the handlebar holder nuts to the specified torque.

"

Handlebar holder nut: 45 N.m (4.5 kgf.m)

• Align the upper surface of the front fork inner tube with the upper surface of the steering stem upper bracket.

• Tighten the upper front fork clamp bolts to the specified torque.

"

Front fork upper clamp bolt: 23 N.m (2.3 kgf.m)

• Tighten the steering stem head nut to the specified torque.

"

Steering stem head nut: 65 N.m (6.5 kgf.m)

CHASSIS 5-33

5-34 CHASSIS

• Install the cable guide.

• Install the front forks. (

9

5-26)

• Install the front wheel. (

9

5-10)

NOTE:

Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

7

After performing the adjustment and installing the handlebars, “rock” the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. Finally, check to make sure that the steering stem moves freely from left to right with its own weight. If play or stiffeness is noticeable, readjust the steering stem nut.

REAR WHEEL

Left Right

CHASSIS 5-35

A Rear axle nut

B Rear brake cam lever nut

C Rear sprocket nut

D Rear torque link nut

"

ITEM

A

B

C

D

N.m

78

10

50

13 kgf.m

7.8

1.0

5.0

1.3

5-36 CHASSIS

REMOVAL

• Remove the drive chain cover.

• Remove the rear brake adjusting nut 1 , spring 2 and washer

3 .

• Remove the cotter pin, torque link nut 4 and bolt.

• Remove the rear axle nut 5 .

• Raise the rear wheel off the ground with a jack or wooden block.

• Loosen the drive chain adjusters 6 , left and right.

• Remove the rear axle.

• Disengage the drive chain from the rear sprocket.

• Remove the rear wheel.

• Remove the rear brake panel 7 .

(Rear brake:

9

5-42)

• Remove the spacer 8 .

• Remove the rear sprocket 9 with mounting drum from the rear wheel.

NOTE:

Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts.

• Remove the rear sprocket damper 0 .

CHASSIS 5-37

• Remove the rear sprocket 1 from the rear sprocket mounting drum.

• Remove the dust seal.

%

09913-50121: Oil seal remover

INSPECTION AND DISASSEMBLY

WHEEL AXLE:

9

5-8

WHEEL:

9

5-8

SPOKE NIPPLE:

9

5-8

WHEEL BEARING:

9

5-8

REAR SPOROCKET MOUNTING DRUM BEARING:

9

5-8

BRAKE DRUM:

9

5-43

REAR SPROCKET DAMPER

Inspect the rear sprocket dampers for wear and damage.

Replace the rear sprocket damper if there is anything unusual.

SPROCKET

Inspect the sprocket’s teeth for wear. If they are worn, replace the sprocket and drive chain as a set.

A Normal wear

B Excessive wear

A B

5-38 CHASSIS

WHEEL BEARING REMOVAL

• Remove the bearings by using the special tool A or B .

%

09921-20220: Bearing remover set A or 09941-50111: Wheel bearing remover B

7

The removed bearings should be replaced with new one.

REAR SPROCKET MOUNTING DRUM BEARING

• Remove the bearing by using special tool.

%

09921-20220: Bearing remover set

7

The removed bearings should be replaced with new one.

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points:

Left Right

CHASSIS 5-39

A Rear axle nut

B Rear brake cam lever nut

C Rear sprocket nut

D Rear torque link nut

"

ITEM

A

B

C

D

N.m

78

10

50

13 kgf.m

7.8

1.0

5.0

1.3

5-40 CHASSIS

WHEEL BEARING

• Apply SUZUKI SUPER GREASE “A” to the bearing before installation.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Press fit the bearing to the wheel using the special tools.

%

09941-34513: Bearing/steering race installer A

09913-70210: Bearing installer set (

φ

35 mm) B

7

* First install the right wheel bearing, then left wheel bearing.

* The sealed cover on the bearing must face out.

Left Right

REAR SPROCKET MOUNTING DRUM BEARING

• Install the rear sprocket mounting drum bearing and dust seal using the special tool.

%

09941-34513: Bearing/steering race installer

NOTE:

Apply grease to the bearing and dust seal lip before assembling the rear sprocket mounting drum.

/

99000-25010: SUZUKI SUPER GREASE “A”

Left Right

Clearance

Spacer

REAR SPROCKET

• Tighten the rear sprocket nuts to the specified torque.

"

Rear sprocket nut: 50 N.m (5.0 kgf.m)

NOTE:

The stamped mark A on the rear sprocket should face to the outside.

• Install the retainer to the mounting drum as shown.

REAR WHEEL

• Tighten the rear torque link nut 1 to the specified torque and install the new cotter pin.

"

Rear torque link nut: 13 N.m (1.3 kgf.m)

• Adjust the drive chain slack after installing the rear wheel.

(

9

2-13)

• Tighten the rear axle nut 2 to the specified torque.

"

Rear axle nut: 78 N.m (7.8 kgf.m)

• Tighten both chain adjusting nuts securely.

• Adjust the rear brake pedal free travel. (

9

2-18)

CHASSIS 5-41

5-42 CHASSIS

REAR BRAKE

REMOVAL AND DISASSEMBLY

• Remove the rear wheel. (

9

5-36)

• Remove the rear brake panel.

• Remove the brake shoes.

• Remove the rear brake cam lever 1 and rear brake cam 2 by removing nut.

• Remove the washer 3 and O-ring 4 .

INSPECTION

BRAKE DRUM

Inspect the brake drum and measure the brake drum I.D. to determine the extent of wear. Replace the brake drum if the measurement exceeds the service limit. The value of this limit is indicated inside the brake drum.

%

09900-20102: Vernier calipers

#

Brake drum I.D.: Service Limit: 130.7 mm

BRAKE SHOES

Check the brake shoe wear (

9

2-18) and decide whether it should be replaced or not.

7

Replace the brake shoes as a set, otherwise braking performance will be adversely affected.

REASSEMBLY AND REMOUNTING

BRAKE CAMSHAFT

• When installing the brake camshaft, apply SUZUKI SUPER

GREASE “A” to the camshaft and cam face.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Install the brake shoes with spring hooks faced inside.

7

Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result.

BRAKE CAM LEVER

• Install the new O-ring and washer.

• Install the brake cam lever to the brake camshaft as shown.

17°

CHASSIS 5-43

5-44 CHASSIS

• Tighten the brake cam lever nut to the specified torque.

"

Brake cam lever nut: 10 N.m (1.0 kgf.m)

• Install the rear wheel. (

9

5-39)

• Adjust the rear brake pedal free travel. (

9

2-18)

REAR SHOCK ABSORBER

REMOVAL

• Remove the right and left rear frame covers. (

9

5-3)

• Remove the right and left rear shock absorbers by removing their nuts.

Left Right

29 N.m (2.9 kgf.m)

CHASSIS 5-45

INSPECTION

Inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one.

7

Do not attempt to disassemble the rear shock absorber.

It is unserviceable.

REMOUNTING

• Install the rear shock absorber and tighten the nuts to the specified torque.

"

Shock absorber mounting nut: 29 N.m (2.9 kgf.m)

SPRING PRE-LOAD ADJUSTMENT

• Adjist the rear shock absorber spring pre-load.

#

Spring pre-load: Standard: 3 /

5

position

29 N.m (2.9 kgf.m)

5-46 CHASSIS

SWINGARM

REMOVAL

• Remove the rear wheel. (

9

5-36)

• Remove the exhaust pipes and mufflers. (

9

3-5)

• Remove the engine sprocket cover.

• Remove the rear shock absorber lower bolts and disconnect the rear shock absorber from swingarm.

• Remove the swingarm pivot nut and washer.

• Remove the swingarm by removing the pivot shaft.

• Remove the rear torque link 1 from the swingarm.

• Remove the dust covers 1 , washers 2 and spacers 3 .

• Remove the chain buffer 4 from the swingarm.

INSPECTION AND DISASSEMBLY

SWINGARM

Inspect the swingarm for damage.

If any defects are found, replace the swingarm with a new one.

CHAIN BUFFER

Inspect the chain buffer for wear and damage. If any defects are found, replace the chain buffer with a new one.

SWINGARM PIVOT SHAFT

Measure the pivot shaft runout using the dial gauge. If the pivot shaft exceeds the service limit, replace it with a new one.

%

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

09900-21304: V-block (100 mm)

#

Swingarm pivot shaft runout: Service Limit: 0.3 mm

CHASSIS 5-47

5-48 CHASSIS

SWINGARM PIVOT SPACERS AND DUST SEALS

Inspect the swingarm pivot spacers and dust seals for damage. If any defects are found, replace the spacer with a new one.

SWINGARM NEEDLE BEARINGS

Insert the spacers into the needle bearings, rotate the spacer and check for abnormal noise and smooth rotation.

If there is anything usual, replace the bearing(-s) with a new one.

• Remove the swingarm needle bearings using the special tool.

%

09921-20220: Bearing remover set (

φφφφφ

20 mm)

7

The removed bearings should be replaced with new ones.

REASSEMBLY AND REMOUNTING

Reassemble and remount the swingarm and rear shock absorber in the reverse order of removal and disassembly.

Pay attention to the following points:

Left Right

72 N.m

(7.2 kgf.m)

Spacer

• Press the needle bearings into the swingarm pivot using the special tool.

%

09941-34513: Bearing/Steering race installer

• Apply the grease to the needle bearings and spacers.

/

99000-25010: SUZUKI SUPER GREASE “A”

• Install the torque link and washer 1 , tighten the torque link nut to the specified torque.

"

Torque link nut (Front): 13 N.m (1.3 kgf.m)

• Install the new cotter pin 2 .

• Install the swingarm and tighten the swingarm pivot nut to the specified torque.

"

Swingarm pivot nut: 72 N.m (7.2 kgf.m)

• Install the rear shock absorber. (

9

5-45)

• Install the rear wheel. (

9

5-39)

• Adjust the following points:

Drive chain slack:

9

2-13

Rear brake pedal free travel:

9

2-18

CHASSIS 5-49

ELECTRICAL SYSTEM 6-1

ELECTRICAL SYSTEM

CONTENTS

CAUTIONS IN SERVICING ................................................................ 6- 2

LOCATION OF ELECTRICAL COMPONENTS ................................. 6- 4

CHARGING SYSTEM ......................................................................... 6- 6

DESCRIPTION ................................................................................ 6- 6

TROUBLESHOOTING .................................................................... 6- 7

INSPECTION ................................................................................... 6- 8

STARTER SYSTEM AND SIDE-STAND/IGNITION

INTERLOCK SYSTEM ....................................................................... 6-10

STARTER SYSTEM DESCRIPTION .............................................. 6-10

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION .. 6-10

TROUBLESHOOTING .................................................................... 6-11

STARTER MOTOR REMOVAL AND DISASSEMBLY .................... 6-12

STARTER MOTOR INSPECTION ................................................... 6-12

STARTER MOTOR REASSEMBLY ................................................ 6-13

STARTER RELAY INSPECTION .................................................... 6-14

SIDE-STAND/IGNITION INTERLOCK SYSTEM PART

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

IGNITION SYSTEM ............................................................................. 6-17

DESCRIPTION ................................................................................ 6-17

TROUBLESHOOTING .................................................................... 6-18

INSPECTION ................................................................................... 6-19

SPEEDOMETER ................................................................................ 6-23

REMOVAL AND DISASSEMBLY ................................................... 6-23

SPEED SENSOR INSPECTION ..................................................... 6-24

LAMPS................................................................................................ 6-25

HEADLIGHT AND POSITION LIGHT ............................................. 6-25

BRAKE LIGHT/TAILLIGHT ............................................................. 6-25

TURN SIGNAL LIGHT .................................................................... 6-25

SWITCHES ......................................................................................... 6-27

BATTERY ........................................................................................... 6-29

SPECIFICATIONS ........................................................................... 6-29

INITIAL CHARGING ........................................................................ 6-29

SERVICING ..................................................................................... 6-30

RECHARGING OPERATION .......................................................... 6-31

6

6-2 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 before disconnecting it and push it in fully till the lock works when connecting it.

• 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.

CLAMP

• Clamp the wire harness at such positions as indicated in “WIRE

HARNESS ROUTING”. (

!

7-10 – 12)

• Bend the clamp properly so that the wire harness is clamped securely.

• In clamping the wire harness, use care not to allow it to hang down.

• Do not use wire or any other substitute for the band type clamp.

FUSE

• When a fuse blows, always investigate the cause, correct it and then replace the fuse.

• Do not use a fuse of a different capacity.

• Do not use wire or any other substitute for the fuse.

SEMI-CONDUCTOR EQUIPPED PART

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

• When inspecting this part, follow inspection instruction strictly.

Neglecting proper procedure may cause damage to this part.

BATTERY

• The MF battery used in this vehicle does not require maintenance as inspection of electrolyte level and replenishment of water.

• No hydrogen gas is produced during normal charging of the battery, but such gas may be produced when it is overcharged. Therefore, do not bring fire near the battery while it is being charged.

• Note that the charging system for the MF battery is different from that of an ordinary battery. Do not replace with an ordinary battery.

CONNECTING BATTERY

• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the negative ( ) terminal first.

• When connecting terminals to the battery, be sure to connect the positive ( + ) terminal first.

• If the terminal is found corroded, remove the battery, pour warm water over it and clean with a wire brush.

• Upon completion of connection, apply grease lightly.

• Put a cover over the positive ( + ) terminal.

WIRING PROCEDURE

• Route the wire harness properly according to “WIRE HAR-

NESS ROUTING”. (

!

7-10)

USING MULTI CIRCUIT TESTER

• Use the Suzuki multi-circuit tester (09900-25008).

• Use well-charged batteries in the tester.

• Be sure to set the tester to the correct testing range.

Using the tester

• Incorrectly connecting the + and probes may cause the inside of the tester to burnout.

• If the voltage and current are not known, make measurements using the highest range.

• When measuring the resistance with the multi-circuit tester, also measure the resistance with no-load. Sub-tract that resistance from the resistance measured under load in order to get the true resistance.

[ Measured resistance

] [ No load resistance

]

=

[ True resistance

]

• When measuring the resistance with the multi-circuit tester,

∞ becomes 10.00 M

Ω

and “1” flashes in the display.

• Check that no voltage is applied before making the measurement. If voltage is applied, the tester may be damaged.

• After using the tester, turn the power off.

"

09900-25008: Multi-circuit tester

NOTE:

* When connecting the multi circuit tester, install fine copper wires

(O.D is below 0.5 mm) to the back side of the lead wire coupler and connect the probes of tester to them.

* Use a fine copper wire, the outer diameter being below 0.5

mm, to prevent the rubber of the water proof coupler from damage.

ELECTRICAL SYSTEM 6-3

6-4 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

1 Battery

2 Starter relay and fuse

3 Front brake light switch

6 Speed sensor

4 Ignition coil (No. 2)

5 Ignition coil (No. 1)

7 Starter motor

8 Rear brake light switch

1 Clutch position switch

ELECTRICAL SYSTEM 6-5

2 Ignitor

3 Turn signal/ side-stand relay

4 Generator

5 Signal generator

6 Gear position switch

7 Side-stand switch

8 Regulator/Rectifier

9 Ignition switch

6-6 ELECTRICAL SYSTEM

CHARGING SYSTEM

DESCRIPTION

The circuit of the charging system is indicated in the figure, which is composed of the generator, regulator/ rectifier unit and battery.

The AC current generated from the generator is rectified by the rectifier and is turned into DC current, then it charges the battery.

ELECTRICAL SYSTEM 6-7

TROUBLESHOOTING

Battery runs down quickly.

Check accessories which use excessive amounts of electricity.

No accessories

Check the battery for current leaks. (

!

6-8)

No current leaks

Measure the charging voltage between the battery terminals.

(

!

6-8)

Incorrect

Measure the continuity of the generator coil.

(

!

6-9)

Continuity

Measure the generator no-load voltage. (

!

6-9)

OK

Inspect the regulator/rectifier.

(

!

6-9)

OK

Inspect wirings.

OK

Accessories are installed

Current leaks

Correct

No continuity

No good

No good

No good

• Remove accessories.

• Short circuit of wire harness

• Loose or disconnected wires

• Faulty battery

• Faulty battery

• Abnormal driving condition

• Faulty generator coil or disconnected lead wires

• Faulty generator

• Faulty regulator/rectifier

• Short circuit of wire harness

• Poor contact of couplers

• Faulty battery

Others

Battery overcharge • Faulty regulator/rectifier

• Faulty battery

• Poor contact of generator lead wire coupler

6-8 ELECTRICAL SYSTEM

INSPECTION

BATTERY CURRENT LEAK INSPECTION

• Remove the right frame cover. (

!

5-3)

• Turn the ignition switch to the OFF position.

• Disconnect the battery lead wire.

• Connect the multi circuit tester between the terminal and

lead wire of the battery.

"

09900-25008: Multi circuit tester set

#

Battery current leak: Under 3 mA

$

Tester knob indication: Current (

%

, 20mA)

&

* Because the current leak might be large, turn the tester to high range first to avoid tester damage.

* Do not turn the ignition switch to the ON position when measuring current.

When leakage is found, look for the part where the tester reads under 3 mA through the couplers and connectors by removing them one by one.

+

DCmA

-

Battery

CHARGING OUTPUT INSPECTION

• Remove the right frame cover. (

!

5-3)

• Start the engine and keep it running at 5 000 r/min. with lighting switch turned ON and dimmer switch turned HI position.

Measure the DC voltage between the battery terminals + and

with the multi circuit tester. If the tester reads under 13.4 V or over 15.1 V, inspect the generator coil and regulator/rectifier.

NOTE:

When making this test, be sure that the battery is in fully-charged condition.

"

09900-25008: Multi circuit tester set

09900-25006: Engine tacho tester

#

Charging output (Regulated voltage):

13.5 – 15.0 V at 5 000 r/min.

'

Tester knob indication: Voltage (

%

)

-

Battery

+

DCV

GENERATOR COIL RESISTANCE INSPECTION

• Remove the luggage box. (

!

5-2)

• Disconnect the generator coupler.

Measure the resistance between the three lead wires.

Also check that the stator core is insulated.

If the resistance is not specified value, replace the stator with a new one.

"

09900-25008: Multi circuit tester set

(

Tester knob indication: Resistance (

Ω

)

#

Generator coil resistance: 0.3 – 1.1

Ω

NOTE:

When making above test, it is not necessary to remove the generator.

GENERATOR NO-LOAD PERFORMANCE INSPECTION

• Start the engine and keep it running at 5 000 r/min.

Using the multi circuit tester, measure the voltage between three lead wires.

If the tester reads under the specified value, replace the generator with a new one.

"

09900-25008: Multi circuit tester set

'

Tester knob indication: Voltage ( ~ )

#

Generator no-load performance:

More than 60 V at 5 000 r/min (When engine is cold)

REGULATOR/RECTIFIER INSPECTION

• Remove the left frame cover. (

!

5-3)

• Disconnect the regulator/rectifier couplers.

Using the multi circuit tester, measure the voltage between the lead wires in the following table.

If voltage is incorrect, replace the regulator/rectifier.

"

09900-25008: Multi circuit tester set

)

Tester knob indication: Diode test (

*

)

R

R

Unit: V

+ Probe of tester to:

Y1 Y2 Y3 B/W

0.4 – 0.7 0.4 – 0.7 0.4 – 0.7

0.5 – 1.2

Y1 Approx. 1.5

Y2 Approx. 1.5 Approx. 1.5

Approx. 1.5 Approx. 1.5 0.4 – 0.7

Approx. 1.5 0.4 – 0.7

Y3 Approx. 1.5 Approx. 1.5 Approx. 1.5

B/W Approx. 1.5 Approx. 1.5 Approx. 1.5 Approx. 1.5

0.4 – 0.7

Y: Yellow, R: Red, B/W: Black with White tracer

NOTE:

If the tester reads under 1.4 V when the tester probes are not connected, replace the battery of multi circuit tester.

ELECTRICAL SYSTEM 6-9

B/W

R

Y

1

Y

2

Y

3

6-10 ELECTRICAL SYSTEM

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK

SYSTEM

STARTER SYSTEM DESCRIPTION

The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, gear position switch, starter button, engine stop switch, ignition switch and battery. Pressing the starter button (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery. The starter motor draws about 80 amperes to start the engine.

Starter motor

Starter relay

To ignitor and

Ignition coil

O/W

Engine stop switch

Ignition switch

R

Fuse (20A)

B/W

O/B

Y/B

Y/G

Clutch lever position switch

Sterter button

Bl

Turn signal/ side-stand relay

G side-stand switch

Gear position switch

SIDE-STAND/IGNITION INTERLOCK SYSTEM DESCRIPTION

This side-stand/ignition interlock system prevents the motorcycle from being started with the side-stand down. The system is operated by an electric circuit provided between the battery and ignition coils.

Fuse

R

Ignition switch

O

Turn signal/ side-stand relay

O/B

Engine stop switch

O/W

To ignitor and ignition coils

R

Battery

Neutral indicator Light

BI/B

BI

Gear position switch

G

Side-stand switch

ELECTRICAL SYSTEM 6-11

TROUBLESHOOTING

Starter motor will not run.

The transmission is in neutral. Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and listen for a click from the starter relay when the starter button is pushed.

No click

Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W pushed.

) when the starter button is

Voltage

Clicks

No voltage

Check if the starter motor runs when its terminal is connected to the battery + terminal (Do not use thin “wire” because a large amount of current flows)

Runs Does not run

• Faulty starter motor

• Faulty starter relay

• Loose or disconnected starter motor lead wire

• Faulty ignition switch

• Faulty engine stop switch

• Faulty clutch lever position switch

• Faulty gear position switch

• Faulty turn signal/side-stand relay

• Faulty starter button

• Poor contact of connector

• Open circuit in wire harness

• Faulty starter relay

Check the starter relay.

(

!

6-14)

OK

No good

• Poor contact of the starter relay

The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.

Check the side-stand switch.

(

!

6-15)

OK

No good • Faulty side-stand switch

• Open circuit in wire harness

• Poor contact of connector

Others

Engine does not turn though the starter motor runs.

• Faulty starter clutch

6-12 ELECTRICAL SYSTEM

STARTER MOTOR REMOVAL AND

DISASSEMBLY

• Disconnect the starter motor lead wire. (

!

3-5)

• Remove the starter motor. (

!

3-11)

• Disassemble the starter motor.

STARTER MOTOR INSPECTION

CARBON BRUSH

Inspect the brushes for abnormal wear, crack or smoothness in the brush holder.

If the brush has failed, replace the brush sub assy.

COMMUTATOR

Inspect the commutator for discoloration, abnormal wear or undercut A .

If the commutator is abnormally worn, replace the armature.

When surface is discolored, polish it with #400 sand paper and clean it with dry cloth.

If there is no undercut, scrape out the insulator 1 with saw blade.

ARMATURE COIL INSPECTION

Check for continuity between each segment.

Check for continuity between each segment and the armature shaft.

If there is no continuity between the segments or there is continuity between the segments and shaft, replace the starter motor with a new one.

"

09900-25008: Multi circuit tester set

+

Tester knob indication: Continuity test (

,

)

OIL SEAL INSPECTION

Check the oil seal lip for damage or leakage.

If any damage is found, replace the housing end.

STARTER MOTOR REASSEMBLY

Reassemble the starter motor. Pay attention to the following points:

&

Replace the O-ring with a new one to prevent oil leakage and moisture.

• Reassemble the starter motor as shown in the illustration.

ELECTRICAL SYSTEM 6-13

• Align the mark A on the housing with the line B on the housing end.

• Apply grease to the O-ring, and remount the starter motor.

-

99000-25010: SUZUKI SUPER GREASE “A”

1 Starter motor case

2 O-ring

3 Housing end (inside)

4 O-ring

5 O-ring (2 pcs)

6 Housing end (Outside)

7 O-ring

8 Brush holder

9 Brush (4 pcs)

0 Brush spring (4 pcs)

A Armature

6-14 ELECTRICAL SYSTEM

STARTER RELAY INSPECTION

• Remove the right frame cover. (

!

5-3)

• Disconnect the battery lead wire 1 , and starter relay cover.

• Disconnect the starter motor lead wire 2 , and battery lead wire 3 and starter relay coupler 4 from the starter relay.

• Remove the starter relay.

Apply 12 volts to A and B terminals, inspect the continuity between the terminals, positive and negative.

If continuity is found, the starter relay is in sound condition.

"

09900-25008: Multi circuit tester set

+

Tester knob indication: Continuity test (

,

)

&

Do not apply a battery voltage more than 5 seconds to the starter relay as it may overheat and cause damage to the relay coil.

12 V

• Check the coil for “open”, “ground” and ohmic resistance. The coil is in good condition if the resistance is as follows.

"

09900-25008: Multi circuit tester set

#

Starter relay resistance: 3 – 5 Ω

SIDE-STAND/IGNITION INTERLOCK SYSTEM

PART INSPECTION

If the interlock system does not operate properly, check each component. If any abnormality is found, replace the component with a new one.

SIDE-STAND SWITCH

• Remove the luggage box. (

!

5-2)

• Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White lead wires.

"

09900-25008: Multi circuit tester set

)

Tester knob indication: Diode test (

*

)

Geen

( + Probe)

Black/White

( Probe)

ON

(Side-stand up)

OFF

(Side-stand down)

0.4 – 0.6 V

1.4 – 1.5 V

NOTE:

If the tester reads under 1.4 V when the tester probes are not connected, replace its battery.

GEAR POSITION SWITCH

• Remove the luggage box. (

!

5-2)

• Disconnect the gear position switch lead wire and check the continuity between Blue and Black/White with the transmission in “NEUTRAL”.

&

When disconnecting and connecting the gear position switch lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

ELECTRICAL SYSTEM 6-15

6-16 ELECTRICAL SYSTEM

TURN SIGNAL/SIDE-STAND RELAY REMOVAL

The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode.

• Remove the luggage box. (

!

5-2)

• Remove the turn signal/side-stand relay 1 .

SIDE-STAND RELAY INSPECTION

First check the insulation between D and E terminals with the tester. Then apply 12V to terminals D and C ( + to D and to C ) and check the continuity between D and E . If there is no continuity, replace the turn signal/side-stand relay with a new one.

DIODE INSPECTION

Measure the voltage between the terminals using the multi circuit tester. Refer to the following table.

Unit: V

"

09900-25008: Multi circuit tester set

)

Tester knob indication: Diode test (

*

)

NOTE:

If the multi circuit tester reads under 1.4 V when the tester probes are not connected, replace its battery.

ELECTRICAL SYSTEM 6-17

IGNITION SYSTEM

DESCRIPTION

The fully transistorized ignition system consists of the following components: a generator, ignitor, throttle position sensor, neutral switch, ignition coil and spark plug. The ignition timing is programmed and stored in the ignitor.

The pick-up coil is mounted in the generator. The induced signal in the pick-up coil is sent to the wave-form arrangement circuit and the CPU receives this signal and calculates the best ignition timing, throttle position sensed by throttle position sensor and data stored in the ROM. The CPU outputs the signal to the transistor of the ignition coil output circuit which is connected to the primary windings of the ignition coil which is turned

“off” and “on” accordingly. Thus, it induces the secondary current in the ignition coil’s secondary winding and produces the spark between the spark plug gap.

Signal generator

Ignitor

Power source circuit

Wave form arrangement circuit

CPU

(Central

Processing

Unit)

TPS

Gear position switch

Engine stop switch

Side-stand relay

Ignition coil F Ignition swich

Ignition coil R

Battery

6-18 ELECTRICAL SYSTEM

TROUBLESHOOTING

INSPECTION

IGNITION COIL PRIMARY PEAK VOLTAGE

• Remove the fuel tank. (

!

4-3)

• Remove the two spark plug caps.

• Connect new two spark plugs to the each spark plug cap and ground them.

NOTE:

Be sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition.

Inspect the No. 1 ignition coil primary peak voltage in the following procedure.

• Connect the multi circuit tester with peak voltage adaptor as follow.

No. 1 ignition coil: White terminal – Ground

( + Probe) ( Probe)

NOTE:

Do not disconnect the ignition coil primary wire.

"

09900-25008: Multi circuit tester set

&

When using the multi circuit tester and peak volt adaptor, follow the instruction manual.

• Shift the transmission into the neutral and turn ignition switch

“ON”.

• Crank the engine a few seconds with starter motor by depressing starter button and then check the ignition coil primary peak voltage.

• Repeat the above inspection a few times and measure the highest ignition coil primary peak voltage.

'

Tester knob indication: Voltage (

%

)

#

Ignition coil primary peak voltage: More than 250 V

.

Do not touch the tester probes and speak plugs to prevent an electric shock while testing.

ELECTRICAL SYSTEM 6-19

6-20 ELECTRICAL SYSTEM

Inspect No. 2 ignition coil primary peak voltage in the same manner of No. 1 ignition coil inspection.

No. 2 ignition coil: B/Y terminal – Ground

( + Probe) ( Probe)

B/Y: Black with Yellow tracer

NOTE:

Do not disconnect the ignition coil primary wire.

'

Tester knob indication: Voltage (

%

)

#

Ignition coil primary peak voltage: More than 250 V

If they are lower than the specified values, inspect the ignition coil, signal generator.

IGNITION COIL RESISTANCE

Measure the ignition coil resistance in both the primary and secondary windings. If the windings are in sound condition, their resistance should be close to the specified values.

#

Ignition coil resistance

Primary: 1.8 – 3.0 Ω ( + terminal – terminal)

Secondary: 18 – 28 k Ω ( + terminal – Spark plug cap)

ELECTRICAL SYSTEM 6-21

SIGNAL GENERATOR PEAK VOLTAGE

• Remove the luggage box. (

!

5-2)

NOTE:

Be sure that all couplers are connected properly and the battery used is in fully-charged condition.

• Connect the multi circuit tester with peak volt adaptor as follows.

• Measure the signal generator peak voltage between White and

Green lead wires at the ignitor coupler.

Bl/B ( + Probe) – Green ( Probe)

"

09900-25008: Multi circuit tester set

'

Tester knob indication: Voltage (

%

)

&

When using the multi circuit tester and peak volt adaptor, follow the instruction manual.

• Shift the transmission into the neutral and turn ignition switch

“ON”.

• Crank the engine a few seconds with the starter motor by depressing starter button and check the signal generator peak voltage.

• Repeat the above test procedure a few times and measure the highest peak voltage.

#

Signal generator peak voltage:

More than 4.5 V (Bl/B – Green)

If the peak voltage is lower than the standard range, check the peak voltage at the signal generator lead wire coupler.

• Remove the luggage box. (

!

5-2)

• Disconnect the signal generator lead wire coupler and connect the multi circuit tester with the peak volt adaptor.

Blue ( + Probe) – Green ( Probe)

• Measure the signal generator peak voltage at the signal generator lead wire coupler.

'

Tester knob indication: Voltage (

%

)

#

Signal generator peak voltage:

More than 4.5 V (Blue – Green)

If the peak voltage is lower than the standard range, check each coupler at both ends of the circuit or replace the signal generator and inspect it again.

Signal generator coupler

Ignitor coupler

Signal generator

Peak volt adaptor

Signal generator

Signal generator coupler

Peak volt adaptor

6-22 ELECTRICAL SYSTEM

SIGNAL GENERATOR RESISTANCE

• Measure the resistance between the lead wires and ground. If the resistance is not specified value, the signal generator must be replaced.

"

09900-25008: Multi circuit tester set

(

Tester knob indication: Resistance ( Ω )

#

Signal generator resistance

: 180 – 280

Ω

(Green – Blue)

:

∞Ω

(Green – Ground)

Signal generator

Signal generator coupler

SPEEDOMETER

REMOVAL AND DISASSEMBLY

• Remove the frame head pipe cover.

• Remove the speedometer couplers.

• Remove the speedometer bolts, and fuel tank cap 1 .

• Remove the speedometer cover.

• Remove the bulb socket and pick up the indicator bulbs.

• Remove the speedometer from speedometer cover by removing the screws.

SPEED SENSOR REMOVAL:

!

3-11

ELECTRICAL SYSTEM 6-23

6-24 ELECTRICAL SYSTEM

SPEED SENSOR INSPECTION

• Disconnect the speed sensor coupler, and connect the tester to the speed sensor lead wire coupler.

+ →

Pink

→

Pink/Black

'

Tester knob indication: Voltage ( ~ )

• Lift the rear wheel.

Check that voltage varies between about 0 – 2 V when turning the rear wheel by hand.

If any abnormal condition is noted, check each coupler at both end of circuit or replace the sensor or wiring harness.

LAMPS

HEADLIGHT AND POSITION LIGHT

HEADLIGHT BULB REPLACEMENT

• Remove the headlight.

• Disconnect the coupler.

• Remove the socket 1 .

• Remove the rubber boot 2 .

• Remove the bulb 3 by removing the bulb holder spring.

• Remove the position light bulb 4 .

• Reassemble the bulb in the reverse order of removal.

&

If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

Headlight: 12 V 60/55 W (H4)

Position light: 12 V 4 W

.

The headlight uses a halogen bulb which operates at a high temperature. Therefore, handle the bulb after sufficiently cooled.

&

* A fouled glass can cause damage to the bulb when lit. If the bulb is contacted with bare hand, wipe clean with a cloth damped with alcohol or detergent.

* Do not use the bulb of a wattage other than specification.

* When installing the rubber boot, turn its “TOP” mark pointing upward.

ELECTRICAL SYSTEM 6-25

6-26 ELECTRICAL SYSTEM

BRAKE LIGHT/TAILLIGHT

BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT

• Remove the lens by removing the screws.

• Push in on the bulb 1 , turn it counterclockwise, and pull it out.

&

If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

• Reassemble the bulb in the reverse order of removal.

Brake light/Taillight: 12 V 21/5 W

TURN SIGNAL LIGHT

TURN SIGNAL LIGHT BULB REPLACEMENT

• Remove the lens by removing the screws.

• Remove the bulb.

&

If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

• Reassemble the bulb in the reverse order of removal.

&

Do not overtighten the lens fitting screws.

TURN SIGNAL/SIDE-STAND RELAY

The turn signal/side-stand relay 1 is composed of the turn signal relay, side-stand relay and diode.

• Remove the luggage box. (

!

6-7)

INSPECTION

Before removing the turn signal/side-stand relay, check the operation of the turn signal light.

If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty; therefore, replace the turn signal/side-stand relay with a new one.

NOTE:

* Make sure that the battery is fully charged.

* Refer to the page 6-16 for the side-stand relay and diode inspection.

SWITCHES

IGNITION SWITCH REMOVAL

• Remove the left frame cover. (

!

5-3)

• Disconnect the coupler.

• Remmove the ignition switch by removing the bolt.

/

Ignition switch bolt: 10 N.m (1.0 kgf.m)

ELECTRICAL SYSTEM 6-27

6-28 ELECTRICAL SYSTEM

INSPECTION

Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones.

IGNITION SWITCH

Position

ON

OFF

LOCK

P

Color

R O O/Y B/W Gr Br

HORN BUTTON

Position

•

PUSH

Color

B/Bl B/W

LIGHTING SWITCH

Position

OFF ( )

Color

( )

ON ( )

O/Bl

DIMMER SWITCH

Color

Position

HI ( )

LO ( )

W

Gr

Y

O/R Y/W

Y/W

FRONT BRAKE LIGHT SWITCH

Position

OFF

ON

Color

B/R

REAR BRAKE LIGHT SWITCH

Position

OFF

ON

Color

O

B/Bl

W/B

CLUTCH LEVER POSITION SWITCH

Position

FREE

Color

•

B/Y B/Y

TURN SIGNAL SWITCH

Position

L ( )

Color

PUSH

R ( )

Lg Lbl B

ENGINE STOP SWITCH

Color

Position

OFF ( )

RUN ( )

O/B

STARTER BUTTON

Position

•

PUSH

Color

O/W

O/W

Y/G

WIRE COLOR

B

Br

Gr

: Black

: Brown

: Gray

O : Orange

R : Red

Y : Yellow

W : White Lbl : Light blue

Lg : Light green

B/Bl : Black with Blue tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

B/R : Black with Red tracer

O/B : Orange with Black tracer

O/Bl: Orange with Blue tracer

O/R : Orange with Red tracer

O/W : Orange with White tracer

O/Y : Orange with Yellow tracer

W/B : White with Black tracer

Y/W : Yellow with White tracer

Y/G : Yellow with Green tracer

BATTERY

SPECIFICATIONS

Type designation

Capacity

YTX7L-BS

12V, 21.6 kC (6 Ah)/10HR

INITIAL CHARGING

Filling electrolyte

• Remove the aluminum tape 1 sealing the battery electrolyte filler holes.

• Remove the caps 2 .

NOTE:

* After filling the electrolyte completely, use the removed cap

2

as the sealed caps of battery-filler holes.

* Do not remove or pierce the sealed areas

3

of the electrolyte container.

• Insert the nozzles of the electrolyte container into the battery’s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill.

• Make sure air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes.

ELECTRICAL SYSTEM 6-29

6-30 ELECTRICAL SYSTEM

NOTE:

If no air bubbles are coming up from a filler port, tap the bottom of the two or three times.

Never remove the container from the battery.

• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes.

• Insert the caps into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery’s top cover.

&

* Never use anything except the specified battery.

* Once install the caps to the battery; do not remove the caps.

CORRECT

• Using multi circuit tester, measure the battery voltage. The tester should indicate more than 12.5 – 12.6V (DC) as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery charger. (Refer to the recharging operation)

NOTE:

Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture.

SERVICING

Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.

INCORRECT

RECHARGING OPERATION

• Using the multi circuit tester, check the battery voltage. If the voltage reading is less than the 12.0 V (DC), recharge the battery with a battery charger.

&

When recharging the battery, remove the battery from the motorcycle.

NOTE:

Do not remove the caps on the battery top while recharging.

Recharging time: 3 A for one hour or 0.7 A for 5 to 10 hours

&

Be careful not to permit the charging current to exceed

5 A at any time.

• After recharging, wait for more than 30 minutes and check the battery voltage with a multi circuit tester.

• If the battery voltage is less than the 12.5 V, recharge the battery again.

• If battery voltage is still less than 12.5 V, after recharging, replace the battery with a new one.

• When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery discharge.

ELECTRICAL SYSTEM 6-31

SERVICING INFORMATION

SERVICING INFORMATION 9-1

CONTENTS

TROUBLESHOOTING ...................................................................... 9- 2

ENGINE ......................................................................................... 9- 2

CARBURETOR .............................................................................. 9- 5

SHAFT DRIVE ............................................................................... 9- 5

CHASSIS ....................................................................................... 9- 6

BRAKES ........................................................................................ 9- 7

ELECTRICAL ................................................................................ 9- 8

BATTERY ....................................................................................... 9- 9

WIRING DIAGRAM (FOR E-02, 19 / FOR E-03, 28, 33 / FOR E-24) .. 9-10

WIRE HARNESS, CABLE AND HOSE ROUTING ........................... 9-13

WIRE HARNESS ROUTING .......................................................... 9-13

CABLE ROUTING ......................................................................... 9-16

FUEL HOSE ROUTING ................................................................. 9-17

COOLING HOSE ROUTING .......................................................... 9-18

FRONT BRAKE HOSE ROUTING ................................................ 9-19

BATTERY PROTECTOR ................................................................ 9-20

SPEED SENSOR LEAD WIRE ROUTING .................................... 9-20

SPECIAL TOOLS .............................................................................. 9-21

TIGHTENING TORQUE .................................................................... 9-24

ENGINE ......................................................................................... 9-24

SECONDARY AND FINAL ............................................................ 9-25

CHASSIS ....................................................................................... 9-26

TIGHTENING TORQUE CHART .................................................... 9-27

SERVICE DATA ................................................................................. 9-28

9

9-2 SERVICING INFORMATION

TROUBLESHOOTING

ENGINE

Complaint

Engine will not start or is hard to start.

Engine stalls easily.

Symptom and possible causes

Compression too low

1. Worn cylinder.

2. Worn piston ring.

3. Worn valve guide or improper valve seating.

4. Loose spark plug.

5. Broken, cracked, or damaged piston.

6. Slow cranking starter motor.

7. Mistimed valves.

8. Valve clearance out of adjustment.

Spark plug not sparking

1. Damaged spark plug.

2. Damaged spark plug cap.

3. Fouled spark plug.

4. Wet spark plug.

5. Defective ignition coil.

6. Open or short in high-tension cord.

7. Defective pick-up coil or ignitor unit.

No fuel reaching the carburetor

1. Clogged hole in the fuel tank cap.

2. Defective fuel pump.

3. Clogged or defective fuel valve.

4. Defective carburetor needle valve.

5. Clogged fuel hose.

6. Clogged fuel filter.

1. Fouled spark plug.

2. Defective signal coil or ignitor unit.

3. Defective fuel pump.

4. Clogged or defective fuel valve.

5. Clogged carburetor jet.

6. Valve clearance out of adjustment.

Remedy

Replace.

Replace.

Repair or replace.

Tighten.

Replace.

See electrical section.

Adjust.

Adjust.

Replace.

Replace.

Clean or replace.

Clean and dry or replace.

Replace.

Replace.

Replace.

Clean or replace.

Replace.

Clean or replace.

Replace.

Clean or replace.

Clean or replace.

Clean or replace.

Replace.

Replace.

Clean or replace.

Clean.

Adjust.

SERVICING INFORMATION 9-3

Complaint

Engine is noisy.

Symptom and possible causes

Excessive valve chatter

1. Excessive valve clearance.

2. Weak or broken valve spring.

3. Worn camshaft.

4. Worn or burnt camshaft journal.

Noise seems to come from the piston

1. Worn piston.

2. Worn cylinder.

3. Carbon buildup in combustion chamber.

4. Worn piston pin or piston pin bore.

5. Worn piston ring or ring groove.

Noise seems to come from the cam chain

1. Stretched cam chain.

2. Worn cam chain sprocket.

Clutch drags.

Transmission will not shift.

Transmission will not shift back.

3. Improperly working cam chain tensioner.

Noise seems to come from the clutch

1. Worn countershaft spline.

2. Worn clutch hub spline.

3. Worn clutch plate teeth.

4. Distorted clutch plate.

5. Weak clutch damper.

6. Weak clutch spring.

Noise seems to come from the crankshaft

1. Rattling bearing.

2. Worn or burnt crank pin bearing.

3. Worn or burnt journal bearing.

4. Excessive thrust clearance.

Noise seems to come from the transmission

1. Worn or rubbing gear.

2. Worn countershaft spline.

3. Worn driveshaft spline.

4. Worn or rubbing primary gear.

5. Worn bearing.

1. Clutch out of adjustment.

2. Clutch release screw out of adjustment.

3. Some clutch springs are weak, while others are not.

4. Worn or distorted clutch pressure plate.

5. Distorted clutch plate.

1. Broken gearshift cam.

2. Distorted gearshift fork.

3. Worn gearshift pawl.

1. Broken gearshift shaft return spring.

2. Rubbing or stuck gearshift shaft.

3. Worn or distorted gearshift fork.

Adjust.

Replace.

Replace.

Replace.

Replace.

Replace.

Clean.

Replace.

Replace.

Remedy

Replace cam chain and sprockets.

Replace cam chain and sprockets.

Repair or replace.

Replace countershaft.

Replace clutch hub.

Replace clutch plate.

Replace.

Replace primary driven gear.

Replace.

Replace.

Replace.

Replace.

Replace thrust bearing.

Replace.

Replace countershaft.

Replace driveshaft.

Replace.

Replace.

Adjust.

Adjust.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Repair or replace.

Replace.

9-4 SERVICING INFORMATION

Complaint

Transmission jumps out of gear.

Engine idles poorly.

Engine runs poorly in high-speed range.

Exhaust smoke is dirty or thick.

Engine lacks power.

Symptom and possible causes

1. Worn gear.

2. Worn or distorted gearshift fork.

3. Weakened gearshift stopper spring.

4. Worn gearshift pawl.

1. Valve clearance out of adjustment.

2. Improper valve seating.

3. Worn valve guide.

4. Worn camshaft.

5. Excessive spark plug gap.

6. Defective ignition coil.

7. Defective generator.

8. Defective ignitor unit.

9. Incorrect float chamber fuel level.

10. Clogged carburetor jet.

1. Weak valve spring.

2. Worn camshaft.

3. Insufficient spark plug gap.

4. Mistimed valves.

5. Ignition not advanced sufficiently due to poorly working timing advance circuit.

6. Defective ignition coil.

7. Defective generator.

8. Defective ignitor unit.

9. Low float chamber fuel level.

10. Dirty air cleaner element.

11. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.

1. Excessive amount of engine oil.

2. Worn cylinder.

3. Worn piston ring.

4. Worn valve guide.

5. Scored or scuffed cylinder wall.

6. Worn valve stem.

7. Defective valve stem oil seal.

8. Worn oil ring side rail.

1. Insufficient valve clearance.

2. Weak valve spring.

3. Mistimed valves.

4. Worn cylinder.

5. Worn piston ring.

6. Improper valve seating.

7. Fouled spark plug.

8. Incorrect spark plug.

9. Clogged carburetor jet.

10. Incorrect float chamber fuel level.

11. Dirty air cleaner element.

12. Air leakage from intake pipe.

13. Excessive amount of engine oil.

Remedy

Replace.

Replace.

Replace.

Replace.

Adjust.

Repair or replace.

Replace.

Replace.

Adjust or replace.

Replace.

Replace.

Replace.

Adjust float height.

Clean.

Replace.

Replace.

Regap or replace.

Adjust.

Replace ignitor unit.

Replace.

Replace.

Replace.

Adjust float height.

Clean or replace.

Clean and prime.

Check level and drain.

Rebore or replace.

Replace.

Replace.

Replace.

Replace valve.

Replace.

Replace oil ring.

Adjust.

Replace.

Adjust.

Replace.

Replace.

Repair or replace.

Clean or replace.

Replace.

Clean.

Adjust float height.

Clean or replace.

Tighten or replace.

Check level and drain.

SERVICING INFORMATION 9-5

Complaint

Engine overheats.

Symptom and possible causes

1. Carbon buildup on piston crown.

2. Insufficient amount of engine oil.

3. Defective oil pump.

4. Clogged oil circuit.

5. Float chamber fuel level too low.

6. Air leakage from intake pipe.

7. Incorrect engine oil.

Remedy

Clean.

Check level and add.

Replace.

Clean.

Adjust float height.

Tighten or replace.

Change.

CARBURETOR

Complaint

Starting difficulty.

Idling or low-speed trouble.

Medium or highspeed trouble.

Overflow and fuel level fluctuations.

Symptom and possible causes

1. Clogged starter jet.

2. Clogged starter jet passage.

3. Air leaking from carburetor joint or vacuum hose joint.

4. Improperly working starter (enricher) plunger.

1. Clogged or loose pilot jet.

2. Clogged or loose pilot air jet.

3. Air leaking from carburetor joint, vacuum pipe joint, or starter.

4. Clogged pilot outlet port.

5. Clogged bypass port.

6. Starter (enricher) plunger not fully closed.

1. Clogged main jet.

2. Clogged main air jet.

3. Clogged needle jet.

4. Improperly working throttle valve.

5. Clogged fuel filter.

1. Worn or damaged needle valve.

2. Broken needle valve spring.

3. Improperly working float.

4. Foreign matter on the needle valve.

5. Incorrect float chamber fuel level.

Remedy

Clean.

Clean.

Tighten or replace defective part.

Adjust.

Clean or tighten.

Clean or tighten.

Tighten or replace defective part.

Clean.

Clean.

Adjust.

Clean.

Clean.

Clean.

Adjust.

Clean or replace.

Replace.

Replace.

Adjust or replace.

Clean or replace with needle valve seat.

Adjust float height.

SHAFT DRIVE

Complaint

Noisy shaft drive.

Symptom and possible causes

Noise seems to come from secondary bevel gear and final bevel gear assemblies.

1. Oil level too low.

2. Drive and driven bevel gears damaged or worn.

3. Excessive backlash.

4. Improper tooth contact.

5. Damage to bearings.

Noise seems to come from propeller shaft area.

1. Propeller shaft universal joint damaged.

2. Propeller shaft splines damaged or worn.

3. Insufficient lubricant.

4. Cam dog contacting surface damaged or worn.

Replace.

Replace.

Refill. (Replace oil seal)

Replace.

Remedy

Refill. (Check oil jet/replace oil seal)

Replace.

Adjust.

Adjust.

Replace.

9-6 SERVICING INFORMATION

CHASSIS

Complaint

Steering is heavy.

Handlebar wobbles.

Front wheel wobbles.

Front suspension too soft.

Front suspension too stiff.

Front suspension too noisy.

Rear wheel wobbles.

Rear suspension too soft.

Rear suspension too stiff.

Rear suspension too noisy.

Symptom and possible causes

1. Overtightened steering stem nut.

2. Broken bearing in steering stem.

3. Distorted steering stem.

4. Low tire pressure.

1. Loss of balance between right and left front forks.

2. Distorted front fork.

3. Distorted front axle.

4. Twisted tire.

1. Distorted wheel rim.

2. Worn front wheel bearing.

3. Defective or incorrect tire.

4. Loose front axle nut.

5. Incorrect fork oil level.

1. Weak spring.

2. Insufficient fork oil.

1. Excessively viscous fork oil.

2. Excessive fork oil.

1. Insufficient fork oil.

2. Loose front suspension fastener.

1. Distorted wheel rim.

2. Worn rear wheel bearing.

3. Defective or incorrect tire.

4. Worn swingarm bearing.

5. Loose rear axle nut.

6. Loose rear suspension fastener.

1. Weak rear shock absorber spring.

2. Rear shock absorber leaks oil.

3. Improper suspension setting.

1. Improper suspension setting.

2. Bent rear shock absorber shaft.

3. Worn swingarm bearing and rear suspension related bearing.

1. Loose rear suspension fastener.

2. Worn swingarm bearing and rear suspension related bearing.

Remedy

Adjust.

Replace.

Replace.

Regulate.

Adjust or replace.

Repair or replace.

Replace.

Replace.

Replace.

Replace.

Replace.

Tighten.

Adjust.

Replace.

Check level and add.

Replace.

Check level and drain.

Check level and add.

Tighten.

Replace.

Replace.

Replace.

Replace.

Tighten.

Tighten.

Replace.

Replace.

Adjust.

Adjust.

Replace.

Replace.

Tighten.

Replace.

SERVICING INFORMATION 9-7

BRAKES

Complaint

Brake power insufficient.

Brake squeaks.

Brake lever or pedal stroke excessive.

Brake fluid leaks.

Brake drags.

Symptom and possible causes

1. Leakage of brake fluid.

2. Worn brake pad/shoe.

3. Oil on brake pad surface.

4. Worn brake disc.

5. Air in hydraulic system.

1. Carbon adhesion on brake pad/shoe surface.

2. Tilted brake pad.

3. Damaged wheel bearing.

4. Worn brake pad/shoe.

5. Foreign material in brake fluid.

6. Clogged return port of master cylinder.

7. Loose front or rear axle nut.

1. Air in hydraulic system.

2. Insufficient brake fluid.

3. Incorrect brake fluid.

1. Loose connection joint.

2. Cracked hose.

3. Worn piston seal.

4. Worn secondary cup.

1. Rusty part.

2. Insufficient brake lever or brake pedal pivot lubrication.

Remedy

Repair or replace.

Replace.

Clean brake disc and brake pads.

Replace.

Bleed.

Clean surface with sandpaper.

Readjust brake pad position or replace.

Replace.

Replace.

Change brake fluid.

Disassemble and clean master cylinder.

Tighten.

Bleed.

Check level and add. Bleed any air.

Change.

Tighten.

Replace.

Replace.

Replace.

Clean and lubricate.

Lubricate.

9-8 SERVICING INFORMATION

ELECTRICAL

Complaint

No sparking or poor sparking.

Spark plug is wet or quickly becomes fouled with carbon.

Spark plug quickly becomes fouled with oil or carbon.

Spark plug electrodes overheat or burn.

Generator does not charge.

Generator charges but charging rate is below the specifications.

Generator overcharges.

Unstable charging.

Starter button does not work.

Symptom and possible causes

1. Defective ignition coil.

2. Defective spark plug.

3. Defective pick-up coil.

4. Defective ignitor unit.

1. Excessively rich air/fuel mixture.

2. Excessively high idling speed.

3. Incorrect gasoline.

4. Dirty air cleaner element.

5. Incorrect spark plug (cold type).

1. Worn piston ring.

2. Worn piston.

3. Worn cylinder.

4. Excessive valve-stem-to-valve-guide clearance.

5. Worn valve stem oil seal.

1. Incorrect spark plug (hot type).

2. Overheated engine.

3. Loose spark plug.

4. Excessively lean air/fuel mixture.

1. Open or short in lead wires, or loose lead connections.

Remedy

Replace.

Replace.

Replace.

Replace.

Adjust carburetor.

Adjust carburetor.

Change.

Clean or replace.

Change to hot type spark plug.

Replace.

Replace.

Replace.

Replace.

Replace.

Change to cold type spark plug.

Tune-up.

Tighten.

Adjust carburetor.

Repair, replace, or connect properly.

Replace.

Replace.

Repair or tighten.

2. Shorted, grounded, or open generator coil.

3. Shorted or punctured regulator/rectifier.

1. Lead wires tend to get shorted or open-circuited or loosely connected at terminal.

2. Grounded or open-circuited stator coils or generator.

3. Defective regulator/rectifier.

4. Defective battery cell plates.

1. Internal short-circuit in the battery.

2. Damaged or defective regulator/rectifier.

3. Poorly grounded regulator/rectifier.

1. Lead wire insulation frayed due to vibration, resulting in intermittent shorting.

2. Internally shorted generator.

3. Defective regulator/rectifier.

1. Run down battery.

2. Defective switch contact.

3. Brushes do not seat properly on the commutator in the starter motor.

4. Defective starter relay.

5. Defective turn signal/side stand relay.

6. Wiring connections loose or disconnected.

Replace.

Replace.

Replace battery.

Replace battery.

Replace.

Repair, replace, or connect properly.

Repair or replace.

Replace.

Replace.

Recharge or replace.

Replace.

Repair or replace.

Replace.

Replace.

Tighten or repair.

SERVICING INFORMATION 9-9

BATTERY

Complaint

Sulfation or spots on surfaces of cell plates.

Battery runs down quickly.

Battery sulfation.

Symptom and possible causes

1. Cracked battery case.

2. Battery has been left in a run-down condition for a long time.

1. Incorrect charging method.

Replace.

Replace.

Remedy

2. Battery cell plates have lost much of their active material as a result of overcharging.

3. Internally shorted battery.

4. Excessively low battery voltage.

5. Battery is too old.

6. Dirty container top and sides.

1. Incorrect charging rate.

(When not in use, the battery should be checked at least once a month and properly charged if necessary, to avoid sulfation.)

2. The battery was left unused in a cold climate for too long.

Check generator, regulator/ rectifier circuit connections, and make necessary adjustment to obtain specified charging operation.

Replace battery and correct charging system.

Replace.

Charge.

Replace.

Clean.

Replace.

Replace the battery if badly sulfated.

9-10 SERVICING INFORMATION

WIRING DIAGRAM

For E-03, -28, -33

O/R O/R O/R

B B

B/R B/R

Y/G Y/G

B/R

Y/G

O/W O/W O/W

O/B O/B O/B

O/Bl O/Bl O/Bl

Gr Gr Gr

O O

O/G O/G

Y/W Y/W

O/G

Y/W

O/B O/B O/B

O/W O/W O/W

O/G O/G O/G

W/B W/B W/B

Y/G Y/G Y/G

W W

O/W O/W O/W

B/W B/W B/W

B/G B/G B/G

B/W B/W B/W

Y/B Y/B Y/B

O O

W/B W/B W/B

B B

Y Y

Bl Bl Bl

G G

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

Bl/W Bl/W Bl/W

B/Y B/Y B/Y

B/W B/W B/W

R R

Y Y

B/Br B/Br B/Br

O/R O/R O/R

W W

O/W O/W O/W

B/W B/W B/W

B/G B/G B/G

B/W B/W B/W

Y/B Y/B Y/B

W/B W/B W/B

O/G O/G O/G

R R

Y Y

B/Br B/Br B/Br

O/W O/W O/W

B/Y B/Y B/Y

P P

O/R O/R O/R

B/W B/W B/W

P P

O/R O/R

B/W B/W

O/R

B/W

Bl/B Bl/B Bl/B

G/Y G/Y G/Y

B/W B/W B/W

Y Y

Y/B Y/B Y/B

Gr O/ O/

R R

B/G B/G B/G

O/G O/G O/G

Lg Lg Lg

B B

O/Bl O/Bl O/Bl

B/W B/W B/W

P P

O/R O/R O/R

B/W B/W B/W

R R

B/W B/W

R/W R/W

B/W

R/W

Y/B Y/B Y/B

B/W B/W

O/G O/G O/G

Lbl Lbl Lbl

O/B O/B O/B

Y Y

Y Y

Y Y

G G

Bl/W Bl/W Bl/W

O G

O/G O/G

O/Bl O/Bl

O/G

O/Bl

Bl/B Bl/B Bl/B

Bl Bl Bl

G G

O/Y O/Y O/Y

O/Y O/Y O/Y

R R

W W

W W

R R

Y Y

Y Y

Y Y

Y Y

Y Y

R/W R/W R/W

B/W B/W B/W

B B

B B

B B

R/W R/W B/R

B/W B/W B/W

Y Y

Y Y

Y Y

G G

Bl Bl Bl

B/W B/W B/W

B/R B/R B/R

O/Y O/Y O/Y

B/R B/R B/R

B/Bl B/Bl B/Bl

O/G O/G O/G

W W

Y Y

O O

B B

Sb Sb Lbl

Lg Lg Lg

Y/W Y/W Y/W

B/W B/W B/W

Y/G Y/G Y/G

Y/B Y/B Y/B

B/Bl B/Bl B/Bl

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

G/Y G/Y G/Y

O O

R R

O/R O/R O/R

B/W B/W B/W

Gr Gr Gr

Br Br Br

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

G/Y G/Y G/Y

O O

R R

O/Y O/R O/R

B/W B/W B/W

Gr Gr Gr

Br Br Br

Lbl Sb Sb

B B

Lg Lg Lg

B/W B/W B/W

B/Bl B/Bl B/Bl

W W

Y Y

Y/W Y/W Y/W

B/Y B/Y B/Y

B/Y B/Y B/Y

B/W B/W B/W

B/R B/R B/R

Bl Bl Bl

B B

G O

B/W B/W B/W

For E-02, -19

Bl

Bl

B B

B B

B/W B/W B/W

O O

W/B W/B W/B

B B

B/W B/W B/W

Y/B Y/B Y/B

B B

Y Y

Bl Bl Bl

B/W B/W B/W

B/G B/G B/G

R R

Y Y

B/Br B/Br B/Br

B B

B/W B/W B/W

B/W B/W B/W

Y/B Y/B Y/B

W/B W/B W/B

O/G O/G O/G

B/W B/W B/W

B/G B/G B/G

G G

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

Bl/W

B/Y B/Y B/Y

Bl/W Bl/W

B/W B/W B/W

R R

Y Y

B/Br B/Br B/Br

O/R O/R O/R

W W

O/W O/W O/W

O/W O/W O/W

B/Y B/Y B/Y

B B

O/Y O/Y O/Y

B B

B/R

Y/G

B/R B/R

Y/G Y/G

O/W O/W O/W

O/B O/B O/B

Y/W Y/W Y/W

Gr Gr Gr

O/R O/R O/R

O/Bl O/Bl O/Bl

Gr Gr Gr

O O

O/G O/G

Y/W Y/W

O/G

Y/W

O/B O/B O/B

O/W O/W O/W

O/G O/G O/G

W/B W/B W/B

Y/G Y/G Y/G

W W

O/W O/W O/W

P P

O/R O/R

B/W B/W

O/R

B/W

Y Y

Y/B Y/B

B/G B/G

Y/B

B/G

Gr O/ O/

R R

O/G O/G O/G

Lg Lg Lg

B B

B/W B/W B/W

P P

O/R O/R O/R

Bl/B Bl/B

B/W B/W

Bl/B

B/W

G/Y G/Y G/Y

B/W B/W B/W

O/Bl O/Bl O/Bl

P P

O/R O/R O/R

B/W B/W B/W

SERVICING INFORMATION 9-11

R R

B/W B/W

R/W R/W

B/W

R/W

Y/B Y/B Y/B

B/W B/W

O/Y O/Y O/Y

Y Y

Y Y

W W

W W

R R

R R

O/G O/G O/G

Lbl Lbl Lbl

O/B O/B O/B

Y Y

Y Y

Y Y

G G

Bl/W Bl/W Bl/W

O G

O/G O/G

O/Bl O/Bl

O/G

O/Bl

Bl/B Bl/B Bl/B

Bl Bl Bl

G G

O/Y O/Y O/Y

Y Y

Y Y

Y Y

R/W R/W R/W

B/W B/W B/W

B B

B B

B B

B/R R/W R/W

B/W B/W B/W

Y Y

Y Y

Y Y

G G

Bl Bl Bl

B/W B/W B/W

B/R B/R B/R

O/Y O/Y O/Y

B/R B/R B/R

B/Bl B/Bl B/Bl

O/G O/G O/G

Lbl Sb Sb

W W

Y Y

O O

B B

Lg Lg Lg

Y/W Y/W Y/W

Y/G Y/G Y/G

B/W B/W B/W

Y/B Y/B Y/B

B/Bl B/Bl B/Bl

O O

R R

O/R O/R O/R

B/W B/W B/W

Gr Gr Gr

Br Br Br

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

Bl Bl Bl

G/Y

R/B

G/Y G/Y

R/B R/B

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

Bl Bl Bl

G/Y

R/B

G/Y G/Y

R/B R/B

O O

R R

O/Y O/R O/R

B/W B/W B/W

Gr Gr Gr

Br Br Br

Lbl Sb Sb

B B

Lg Lg Lg

B/W B/W

O/R O/R

B/W

O/R

W W

Y Y

Y/W Y/W Y/W

B/Y B/Y B/Y

B/Bl B/Bl B/Bl

B/Y B/Y B/Y

B/W B/W B/W

B/R B/R B/R

Bl Bl Bl

B B

G O

B/W B/W B/W

9-12 SERVICING INFORMATION

For E-24

O/R O/R O/R

B B

B/R B/R

Y/G Y/G

B/R

Y/G

O/W O/W O/W

O/B O/B O/B

O/Bl O/Bl O/Bl

Gr Gr Gr

O O

Y/W Y/W Y/W

O/B O/B O/B

O/W O/W O/W

O/G O/G O/G

W/B W/B

O/G

W/B

O/G O/G

Y/G Y/G Y/G

W W

O/W O/W O/W

P P

O/R O/R O/R

B/W B/W B/W

P P

O/R O/R

B/W B/W

O/R

B/W

Bl/B Bl/B Bl/B

Y Y

Y/B Y/B Y/B

Gr O/ O/

R R

B/G B/G B/G

Lg Lg Lg

B B

O/G O/G

B/W B/W

O/G

B/W

G/Y G/Y G/Y

O/Bl O/Bl O/Bl

B/W B/W B/W

P P

O/R O/R O/R

B/W B/W B/W

B/W B/W B/W

B/G B/G B/G

B/W B/W B/W

Y/B Y/B Y/B

O O

W/B W/B W/B

B B

Y Y

Bl Bl Bl

G G

G/Bl G/Bl

R/B

G/Bl

R/B R/B

Bl Bl Bl

Bl/W Bl/W Bl/W

B/Y B/Y B/Y

B/W B/W B/W

R R

Y Y

B/Br B/Br B/Br

O/R O/R O/R

W W

O/W O/W O/W

B/W B/W B/W

B/G B/G B/G

B/W B/W B/W

Y/B Y/B Y/B

W/B W/B W/B

O/G O/G O/G

R R

Y Y

B/Br B/Br B/Br

O/W O/W O/W

B/Y B/Y B/Y

R R

B/W B/W

R/W R/W

B/W

R/W

Y/B Y/B Y/B

B/W B/W

O/G O/G O/G

Lbl Lbl Lbl

O/B O/B O/B

Y Y

Y Y

Y Y

G G

Bl/W Bl/W Bl/W

O/Y O/Y O/Y

W W

Y Y

Y Y

R R

W W

R R

O G

O/G O/G

O/Bl O/Bl

O/G

O/Bl

Bl/B Bl/B Bl/B

Bl Bl Bl

G G

O/Y O/Y O/Y

Y Y

Y Y

Y Y

R/W R/W R/W

B/W B/W B/W

B B

B B

B B

R/W R/W B/R

B/W B/W B/W

Y Y

Y Y

Y Y

G G

Bl Bl Bl

B/W B/W B/W

B/R B/R B/R

O/Y O/Y O/Y

B/R B/R B/R

B/Bl B/Bl B/Bl

O/G O/G O/G

Lbl Sb Sb

W W

Y Y

O O

B B

Lg Lg Lg

Y/W Y/W Y/W

Y/G Y/G Y/G

B/W B/W B/W

Y/B Y/B Y/B

B/Bl B/Bl B/Bl

O O

R R

O/R O/R O/R

B/W B/W B/W

Gr Gr Gr

Br Br Br

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

G/Y G/Y G/Y

G G

B/W B/W B/W

G/Bl G/Bl G/Bl

R/B R/B R/B

Bl Bl Bl

G/Y G/Y G/Y

O O

R R

O/Y O/R O/R

B/W B/W B/W

Gr Gr Gr

Lbl Sb Sb

B B

Lg Lg Lg

B/W B/W B/W

B/Bl B/Bl B/Bl

W W

Y Y

Y/W Y/W Y/W

B/Y B/Y B/Y

B/Y B/Y B/Y

B/W B/W B/W

B/R B/R B/R

Bl Bl Bl

B B

G O

B/W B/W B/W

SERVICING INFORMATION 9-13

WIRE HARNESS, CABLE AND HOSE ROUTING

WIRE HARNESS ROUTING

After clamping, cut the excessive end.

50 mm

200 mm

200 mm

After clamping, cut the excessive end.

Clamp

Handlebar switch (L & R)

Speed sensor

Wiring harness

Front turn signal light (L & R)

Clamp

Clamp

Clutch cable

Starter motor lead wire

Engine coolant temp. switch

C

Regulator/Rectifier

To generator

To wiring harness

Fuse

VIEW C

Electrical parts holder

9-14 SERVICING INFORMATION

Fuel level gauge lead wire

Install between wiring harness and fuel pump vacuum hose.

Pass the battery

+

-lead wire under the starter relay.

Clamp

TPS

Fuel pump & carburetor hose

Wiring harness

Fuel pump vacuum hose

To speedometer

Frame head cover (L & R)

Carburetor heater lead wire

Bend

To fuel level gauge

Wiring harness

Thermo-switch

Battery

-

-lead wire

VIEW D

D

A

B

Wiring harness

Frame Radiator

SECT B

VIEW A

30˚ –

60˚

100˚

80˚ –

SERVICING INFORMATION 9-15

. m

. m

45˚ – 25˚

9-16 SERVICING INFORMATION

CABLE ROUTING

cable

(pulling)

Throttle cable

(returning)

Brake hose

Throttle cable plate

Wiring harness cable

(pulling)

Guide

Throttle cable clip

1

–

2 mm

1

–

2 mm

Clamp

Reservoir hose

High-tension cord

Clutch cable

Starter cable

Fuel hose

Reservoir hose

Clutch cable

Clamp

Starter cable

Throttle cable

(returning)

Clutch cable

Clamp between the projections.

Throttle cable

(pulling)

Cable guide

Throttle cable

(returning)

Throttle cable

(pulling)

200 m m

40 mm

Clamp

Front

Clutch cable

Starter cable

Cable guide

Cable guide

Wiring harness

Clamp

Clutch cable Starter cable

Throttle cable plate

FUEL HOSE ROUTING

SERVICING INFORMATION 9-17

9-18 SERVICING INFORMATION

COOLING HOSE ROUTING

. m

. m,

FRONT BRAKE HOSE ROUTING

SERVICING INFORMATION 9-19

42

9-20 SERVICING INFORMATION

BATTERY PROTECTOR

60 mm

Battery protector

SPEED SENSOR LEAD WIRE ROUTING

65 mm

Battery protector

30 mm

Speed sensor lead wire clamp

Speed sensor guide hook

Speed sensor lead wire

SERVICING INFORMATION 9-21

SPECIAL TOOLS

09900-06107

Snap ring pliers

09900-06108

Snap ring pliers

09900-09004

Impact driver set

09900-18710

Hexagon socket

(12 mm)

09900-18720

Hexagon socket

(14 mm)

09900-20102

Vernier calipers

(200 mm)

09900-20202

Micrometer

(25 – 50 mm)

09900-20203

Micrometer

(50 – 75 mm)

09900-20204

Micrometer

(75 – 100 mm)

09900-20205

Micrometer

(0 – 25 mm)

09900-20508

Cylinder gauge set

09900-20602

Dial gauge

(1/1000 mm, 1 mm)

09900-20605

Dial calipers

(10 – 34 mm)

09900-20606

Dial gauge

(1/100, mm, 10 mm)

09900-20701

Magnetic stand

09900-20803

Thickness gauge

09900-20805

Tire depth gauge

09900-21304

V-block (100 mm)

09900-22302

Plastigauge

09900-22403

Small bore gauge

(18 – 35 mm)

09900-25008

Multi circuit tester set

09913-50121

Oil seal remover

09913-70210

Bearing installer set

09913-75821

Bearing installer

09913-84510

Bearing installer

09915-40610

Oil filter wrench

09915-63210

Adaptor

09915-77330

Compression gauge

09915-74510

Oil pressure gauge hose

09915-74532

Oil pressure gauge adaptor

9-22 SERVICING INFORMATION

09915-77330

Meter (For high pressure)

09916-10911

Valve lapper set

09916-14510

Valve lifter

09916-14910

Valve lifter attachment

09916-21111

Valve seat cutter set

09916-22430

Valve seat cutter

(N-128)

09916-34550

Valve guide reamer

(5.5 mm)

09916-34580

Valve guide reamer

(10.8 mm)

09916-44910

Valve guide remover/installer

09916-44920

Valve guide installer attachment

09916-84511

Tweezers

09917-47010

Vacuum pump gauge

09918-03810

Compression gauge adaptor

09918-53810

Chain tensioner lock tool

09920-13120

Crankcase & Shaft remover

09920-53740

Clutch sleeve hub holder

09921-20240

Bearing remover set

09921-21820

Bearing retainer wrench

09923-73210

Bearing remover

09924-34510

Backlash measuring tool (27 – 50)

09924-62410

Final drive gear bearing holder wrench

09924-62430

22 mm Long socket

09924-64510

Final drive gear coupring holder

09924-84521

Bearing installer

09930-10121

Spark plug wrench set

09930-11920

Torx bit JT40H

09930-11940

Bit holder

09930-30102

Sliding shaft

09930-33730

Rotor remover

09930-40113

Rotor holder

SERVICING INFORMATION 9-23

09940-14911

Steering stem nut wrench

09940-34520

T handle

09940-34531

Attachment “A”

09940-52861

Front fork oil seal installer

09940-92720

Spring scale

09941-34513

Steering outer race installer

09941-50111

Bearing remover set

09941-54911

Bearing outer race remover

09941-64511

Bearing remover

09941-74911

Steering bearing installer

09943-74111

Front fork oil level gauge

9-24 SERVICING INFORMATION

TIGHTENING TORQUE

ENGINE

ITEM

Rocker arm shaft

Cylinder head cover bolt

Cylinder head bolt and nut

8 mm

10 mm

6 mm

8 mm

Initial

Final

Initial

Final

Cam sprocket bolt

Cam chain tension adjuster mounting bolt

Cam chain tensioner bolt

Primary drive gear bolt

Clutch spring set bolt

Clutch sleeve hub nut

Driveshaft bolt

Secondary drive gear shaft nut

Secondary gear case bolt Initial

Final

Generator rotor bolt

Starter clutch allen bolt

Crankcase bolt

Conrod cap nut

6 mm

Initial

8 mm

Final

Initial

Final

Oil pressure regulator

Oil pump mounting bolt

Oil pressure switch

Oil drain plug

15

22

160

26

11

15

22

10

95

10

60

65

105

25

51

28

11

14

21

N.m

27

10

25

10

25

25

38

15

10

1.5

2.2

16.0

2.6

1.1

1.5

2.2

1.0

9.5

1.0

6.0

6.5

10.5

2.5

5.1

2.8

1.1

1.4

2.1

kgf.m

2.7

1.0

2.5

1.0

2.5

2.5

3.8

1.5

1.0

11.0

16.0

115.5

19.0

8.0

11.0

16.0

7.0

68.5

7.0

47.0

44.2

76.0

18.0

37.0

20.0

8.0

10.0

15.0

lb-ft

19.5

7.0

18.0

7.0

18.0

18.0

27.5

11.0

7.0

ITEM

Oil plug 6 mm

8 mm

10 mm

14 mm

16 mm

Engine mounting bolt

Engine mounting bracket bolt

Frame mounting bolt/nut

Exhaust pipe clamp bolt

Muffler mounting bolt

Speed sensor rotor bolt

Spark plug

8 mm

10 mm

SECONDARY AND FINAL

ITEM

Secondary drive bevel gear bearing retainer bolt

Secondary driven bevel gear bolt

Secondary driven bevel gear bearing stopper

Final gear case mounting nut

Final drive bevel gear coupling nut

Final drive bevel gear bearing stopper

Final gear case oil drain plug

Final gear case bolt 8 mm

10 mm

Final driven bevel gear bearing retainer screw

79

23

23

50

23

23

100

N.m

6

18

15

23

35

18

100

110

23

23

50

9

N.m

23

23

105

40 kgf.m

2.3

2.3

10.5

4.0

10.0

11.0

2.3

2.3

5.0

0.9

SERVICING INFORMATION 9-25 kgf.m

0.6

1.8

1.5

2.3

3.5

7.9

2.3

2.3

5.0

2.3

2.3

10.0

1.8

57.0

16.5

16.5

36.0

16.5

16.5

72.5

lb-ft

4.3

13.0

11.0

16.5

25.5

13.0

lb-ft

16.5

16.5

76.0

29.0

72.5

79.5

16.5

16.5

36.0

6.5

9-26 SERVICING INFORMATION

CHASSIS

ITEM

Front axle

Front axle pinch bolt

Brake disc bolt

Front fork cap bolt

Front fork spring stopper nut

Front fork damper rod bolt

Front fork lower clamp bolt

Steering stem head nut

Front master cylinder mounting bolt

Front brake caliper mounting bolt

Brake hose union bolt

Air bleeder valve

Handlebar set bolt

Handlebar holder nut

Front footrest bolt

Frame down tube mounting bolt (M8)

Frame down tube mounting bolt (M10)

Rear brake pedal bolt

Rear swingarm pivot bolt (Left)

Rear swingarm pivot bolt (Right)

Rear swingarm pivot bolt lock nut

Rear shock absorber mounting nut

(Upper and Lower)

Rear cushion lever/rod mounting nut

Rear axle nut

Rear torque link nut (front)

Rear torque link nut (rear)

Rear brake cam lever bolt

Driven joint stopper bolt

Frame handle grip mounting bolt

Fuel level gauge mounting bolt

(M10)

50

78

65

35

25

10

10

50

10

23

70

55

23

50

11

100

9.5

100

33

90

10

39

23

7.5

N.m

65

33

23

45

35

20

5.0

7.8

6.5

3.5

2.5

1.0

1.0

5.0

1.0

2.3

7.0

5.5

2.3

5.0

1.1

10.0

0.95

10.0

kgf.m

6.5

3.3

2.3

4.5

3.5

2.0

3.3

9.0

1.0

3.9

2.3

0.75

36.0

57.5

47.0

25.5

18.0

7.3

7.0

36.0

7.0

16.5

50.5

40.0

16.5

36.0

8.0

72.5

7.0

72.5

24.0

65.0

7.0

28.0

16.5

5.5

lb-ft

47.0

24.0

16.5

33.1

25.5

14.5

SERVICING INFORMATION 9-27

TIGHTENING TORQUE CHART

For other bolts and nuts listed previously, refer to this chart:

Bolt Diameter

A (mm)

4

5

6

8

10

12

14

16

18

29

45

65

105

160

Conventional or “4” marked bolt

N.m

kgf.m

lb-ft

1.5

0.15

1.0

3

5.5

13

0.3

0.55

1.3

2.0

4.0

9.5

2.9

4.5

6.5

10.5

16.0

21.0

32.5

47.0

76.0

115.5

50

85

135

210

240

N.m

2.3

4.5

10

23

“7” marked bolt kgf.m

0.23

0.45

1.0

2.3

5.0

8.5

13.5

21.0

24.0

36.0

61.5

97.5

152.0

173.5

lb-ft

1.5

3.0

7.0

16.5

Conventional bolt “4” marked bolt “7” marked bolt

9-28 SERVICING INFORMATION

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance

(when cold)

Valve guide to valve stem clearance

Valve stem deflection

Valve guide I.D.

Valve stem O.D.

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

IN.

EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

IN. & EX.

INNER

OUTER

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN. & EX.

INNER

OUTER

STANDARD

30

(1.18)

26

(1.02)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.007 – 0.009)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

———

5.500 – 5.512

(0.2165 – 0.2170)

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

(0.2148 – 0.2154)

———

———

———

0.9 – 1.1

(0.035 – 0.043)

———

———

———

6.51 – 7.49 kgf

(14.35 – 16.51 lbs) at length 32.5 mm (1.28 in)

12.09 – 13.91 kgf

(26.65 – 30.67 lbs) at length 36.0 mm (1.42 in)

Unit: mm (in)

LIMIT

———

———

———

———

———

———

0.35

(0.014)

———

———

———

0.05

(0.002)

0.5

(0.02)

3.1

(0.12)

———

0.03

(0.001)

38.3

(1.51)

40.1

(1.58)

———

———

SERVICING INFORMATION 9-29

CAMSHAFT + CYLINDER HEAD

Cam height

ITEM

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Front

IN.

STANDARD

35.95 – 35.99

(1.415 – 1.417)

EX.

IN.

36.92 – 36.96

(1.454 – 1.455)

35.50 – 35.54

(1.398 – 1.399)

Rear

No.1 Left side

No.2 Right side

No.1 Right side

No.2 Left side

EX.

36.58 – 36.62

(1.440 – 1.442)

0.032 – 0.066

(0.0013 – 0.0026)

20.012 – 20.025

(0.7879 – 0.7884)

25.012 – 25.025

(0.9847 – 0.9852)

No.1 Left side

No.2 Right side

No.1 Right side

No.2 Left side

19.959 – 19.980

(0.7858 – 0.7866)

24.959 – 24.980

(0.9826 – 0.9835)

Camshaft runout

———

Rocker arm I.D.

Rocker arm shaft O.D.

Cylinder head distortion

IN. & EX.

IN. & EX.

12.000 – 12.018

(0.4724 – 0.4731)

11.966 – 11.984

(0.4711 – 0.4718)

———

Cylinder head cover distortion

———

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

STANDARD

1 300 – 1 700 kPa

( 13 – 17 kgf/cm 2

185 – 242 psi

)

Compression pressure difference

———

Piston to cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

0.045 – 0.055

(0.0018 – 0.0022)

83.000 – 83.015

(3.2677 – 3.2683)

82.950 – 82.965

(3.2657 – 3.2663)

Measure at 15 mm (0.6 in) from the skirt end.

———

Unit: mm (in)

LIMIT

1 100 kPa

( 11 kgf/cm 2

156 psi

)

200 kPa

( 2 kgf/cm 2

28 psi

)

0.120

(0.0047)

83.085

(3.2711)

82.880

(3.2630)

0.05

(0.002)

———

0.10

(0.004)

———

———

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

35.65

(1.404)

36.62

(1.442)

35.20

(1.386)

36.28

(1.428)

0.150

(0.0059)

———

———

———

9-30 SERVICING INFORMATION

ITEM

Piston ring free end gap

Piston ring end gap

Piston ring groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod big end side clearance

Conrod big end width

Crank pin width

Conrod big end oil clearance

Crank pin O.D.

Crankshaft journal oil clearance

Crankshaft journal O.D.

Crankshaft thrust bearing thickness

Crankshaft thrust clearance

Crankshaft runout

1st

2nd R

1st

2nd

1st

2nd

1st

2nd

Oil

1st

2nd

STANDARD

20.010 – 20.018

(0.7878 – 0.7881)

0.10 – 0.20

(0.004 – 0.008)

21.95 – 22.00

(0.864 – 0.866)

22.10 – 22.15

(0.870 – 0.872)

0.024 – 0.042

(0.0009 – 0.0017)

40.982 – 41.000

(1.6135 – 1.6142)

0.020 – 0.050

(0.0008 – 0.0020)

47.965 – 47.980

(1.8884 – 1.8890)

1.925 – 2.175

(0.0758 – 0.0856)

0.05 – 0.10

(0.002 – 0.004)

———

STANDARD

Approx.

9.6

(0.38)

Approx.

11.8

(0.46)

0.20 – 0.35

(0.008 – 0.014)

0.20 – 0.35

(0.008 – 0.014)

———

———

1.01 – 1.03

(0.0398 – 0.0406)

1.21 – 1.23

(0.0476 – 0.0484)

2.51 – 2.53

(0.0988 – 0.0996)

0.970 – 0.990

(0.0382 – 0.0390)

1.170 – 1.190

(0.0461 – 0.0469)

20.002 – 20.008

(0.7875 – 0.7877)

19.992 – 20.000

(0.7871 – 0.7874)

LIMIT

7.7

(0.30)

9.4

(0.37)

0.70

(0.028)

0.70

(0.028)

0.180

(0.007)

0.150

(0.006)

———

———

———

———

———

20.030

(0.7886)

19.980

(0.7866)

Unit: mm (in)

LIMIT

20.040

(0.7890)

0.30

(0.012)

———

———

0.080

(0.0031)

———

0.080

(0.0031)

———

———

———

0.05

(0.002)

SERVICING INFORMATION 9-31

OIL PUMP

ITEM

Oil pressure (at 60°C,140°F)

CLUTCH

ITEM

Clutch cable play

Clutch release screw

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

TRANSMISSION

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios Low

2nd

3rd

4th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

No.1

No.2

No.1

No.2

No.1

No.2

No.1

No.2

STANDARD

Above 350 kPa (3.5 kgf/cm 2 , 50 psi)

Below 650 kPa (6.5 kgf/cm 2 , 92 psi) at 3 000 r/min.

LIMIT

———

STANDARD

10 – 15

(0.4 – 0.6)

1/4 turn back

2.92 – 3.08

(0.115 – 0.121)

3.42 – 3.58

(0.135 – 0.141)

15.9 – 16.0

(0.626 – 0.630)

———

49.2

(1.94)

STANDARD

1.690 (71/42)

1.133 (17/15)

3.090 (34/11)

2.461 (32/13)

1.631 (31/19)

1.227 (27/22)

1.000 (25/25)

0.814 (22/27)

0.10 – 0.30

(0.004 – 0.012)

0.10 – 0.30

(0.004 – 0.012)

5.50 – 5.60

(0.217 – 0.220)

4.50 – 4.60

(0.177 – 0.181)

5.30 – 5.40

(0.209 – 0.213)

4.30 – 4.40

(0.169 – 0.173)

Unit: mm (in)

LIMIT

———

2.62

(0.103)

3.12

(0.123)

15.1

(0.594)

0.10

(0.004)

46.8

(1.84)

Unit: mm (in) Except ratio

LIMIT

———

———

———

———

———

———

———

———

0.50

(0.020)

0.50

(0.020)

———

———

———

———

9-32 SERVICING INFORMATION

SHAFT DRIVE

ITEM

Secondary bevel gear backlash

Final bevel gear backlash

Damper spring free length

Drive side

STANDARD

0.05 – 0.32

(0.002 – 0.013)

0.03 – 0.064

(0.001 – 0.025)

———

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Idle r/min.

Fuel level

Float height

Main jet

Main air jet

Jet needle

Needle jet

Throttle valve

Pilot jet

Pilot screw

Throttle cable play

(M.J.)

(M.A.J.)

(J.N.)

(N.J.)

(Th.V.)

(P.J.)

(P.S.)

E-02, 19, 24

MIKUNI BDSR34

34 mm

41F1

1 100 ± 100 r/min.

—

7.0 ± 0.5 mm

(2.76 ± 0.02 in)

#132.5

φ

1.8

5E22-3

P-0M

#95

#27.5

PRE-SET

(3.0 turns back)

2 – 4 mm

(0.08 ± 0.16 in)

SPECIFICATION

E-03, 28

←

←

41F2

←

—

←

#

←

5E23

#

←

PRE-SET

←

THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT

ITEM

Thermostat valve opening temperature

Thermostat valve lift

Engine coolant temp. switch operating temperature

Radiator cap valve opening pressure

Cooling fan thermoswitch operating temperature

Engine coolant type

Engine coolant capacity

STANDARD/SPECIFICATION

Approximately 75 °C (167 °F)

Over 6 mm (0.24 in) at 90 °C (194 °F)

OFF → ON

ON

→

OFF

Approximately 120°C (248°F)

Approximately 113°C (235.4°F)

95 – 125 kPa

(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)

OFF → ON

ON

→

OFF

Approximately 105°C (221°F)

Approximately 100°C (212°F)

Use an antifreeze/coolant compatible with aluminum radiators, mixed with distilled water only, at the ratio of 50:50

1 500 ml

(1.6 US qt, 1.3 lmp qt)

LIMIT

———

———

———

———

———

———

———

———

E-33

←

←

41F3

←

—

←

←

←

←

←

←

←

←

←

Unit: mm (in)

LIMIT

———

———

58.5

(2.30)

———

SERVICING INFORMATION 9-33

ELECTRICAL

Firing order

Spark plug

ITEM

Spark performance

Ignition coil resistance

Type

Gap

Primary

SPECIFICATION

1.2

NGK: DPR7EA-9

DENSO: X22EPR-U9

0.8 – 0.9

(0.031 – 0.035)

Over 8 (0.3) at 1 atm.

2 – 6 Ω

Secondary 15 – 30 k

Ω

Ignition coil primary peak voltage

More than 200 V

Generator coil resistance Pickup coil

Charging coil

160 – 300 Ω

0.2 – 1.5

Ω

More than 1.5 V Pickup coil peak voltage

Generator no-load voltage

(When engine cold)

Regulated voltage

Generator maximum output

Starter relay resistance

Battery

Fuse size

More than 70 V (AC) at 5 000 r/min.

Headlight

Signal

Ignition

HI

LO

Meter

Main

Power source

14.0 – 15.5 V at 5 000 r/min.

375 W at 5 000 r/min.

3 – 7 Ω

Type designation FTX12-BS

Capacity 12 V 36 kC (10Ah)/10HR

10 A

10 A

15 A

15 A

10 A

30 A

10 A

WATTAGE

Headlight

ITEM

HI

LO

E-03, 28, 33

60

55

SPECIFICATION

E-24

←

←

Position/Parking light

Brake light/Taillight

Turn signal light

Speedometer light

Water temp. meter light

Turn signal indicator light

High beam indicator light

Neutral indicator light

Oil pressure indicator light

21/5

21/5 (Front), 21 (Rear)

LED

LED

LED

LED

LED

LED

←

21

←

←

←

←

←

←

Unit: mm (in)

NOTE

Terminal –

Terminal

Plug cap –

Terminal

#1 + :W, :Ground

#2 + :B/Y, :Ground

G – Bl

Y – Y

+ : Bl, : G

Y – Y

Unit: W

The others

←

←

4

←

←

←

←

←

←

←

←

9-34 SERVICING INFORMATION

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork oil level (without spring)

Front fork oil type

Front fork oil capacity

(each leg)

Front fork spring adjuster

Rear shock absorber spring adjuster

Rear wheel travel

Swingarm pivot shaft runout

BRAKE + WHEEL

ITEM

Rear brake pedal free travel

Rear brake pedal height

Brake drum I.D.

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Wheel rim runout

Wheel axle runout

Wheel rim size

STANDARD/SPECIFICATION

140

(5.51)

551.7

(21.73)

177

(6.96)

SUZUKI FORK OIL SS-08 or an equivalent fork oil

412 ml

(24.0 US oz, 25.0 lmp oz)

———

4

105

(4.13)

———

Rear

Front

Front

Front

Front

Front

Axial

Radial

Front

Rear

Front

Rear

STANDARD

20 – 30

(0.8 – 1.2)

75 – 85

(3.0 – 3.3)

———

5.0 ± 0.2

(0.20 ± 0.01)

———

12.700 – 12.743

(0.5000 – 0.5017)

12.657 – 12.684

(0.4983 – 0.4993)

30.230 – 30.306

(1.1901 – 1.1931)

30.150 – 30.200

(1.1870 – 1.1889)

———

———

———

———

J16

×

MT3.00 or J16M/C × MT3.00

J15 M/C

×

MT4.00

Unit: mm (in)

LIMIT

———

540.6

(21.29)

———

———

———

———

———

0.3

(0.01)

———

———

———

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

———

———

Unit: mm (in)

LIMIT

———

———

180.7

(7.11)

4.5

(0.18)

0.30

(0.012)

———

SERVICING INFORMATION 9-35

TIRE

ITEM

Cold inflation tire pressure

(Solo riding)

Cold inflation tire pressure

(Dual riding)

Tire size

Tire type

Tire tread depth

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD/SPECIFICATION

200 kPa

(2.00 kgf/cm 2 , 29 psi)

250 kPa

(2.50 kgf/cm 2 , 36 psi)

200 kPa

(2.00 kgf/cm 2 , 29 psi)

250 kPa

(2.50 kgf/cm 2 , 36 psi)

130/90-16 67H

170/80-15 M/C 77H

IRC GS-23F

IRC GS-23R

Front ———

Rear ———

FUEL + OIL + COOLANT

ITEM

Fuel type

Fuel tank including reserve

Engine oil type

Engine oil capacity reserve

(flicker)

Final bevel gear oil type

Final bevel gear oil capacity

Brake fluid type

Coolant capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane or 91 octane ( ) or higher rated by the

Research Method.

Gasoline containing MTBE (MethyI Tertiary ButyI

Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

17.0 L

(4.5/3.7 US/lmp gal)

1.5 L

(0.4/0.3 US/lmp gal)

Change

SAE 10W/40, API SF or SG

3 000 ml

(3.2/2.6 US/lmp qt)

Filter change

Overhaul

3 400 ml

(3.6/3.0 US/lmp qt)

3 700 ml

(3.9/3.3 US/lmp qt)

SAE 90 hypoid gear oil with GL-5 under API classification

200 – 220 ml

(6.8/7.0 – 7.4/7.7 US/lmp oz)

DOT 4

1 500 ml

(1.6/1.3 US/lmp qt)

NOTE

E-03, 28, 33

Other models

Unit: mm (in)

LIMIT

———

———

———

———

———

———

———

———

1.6

(0.06)

2.0

(0.08)